Dokumen Meja Tender

KERAJAAN MALAYSIA
JABATAN KERJA RA YA MALAYSIA
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DOKUMEN-DOKUMEN YANG DISERTAKAN BERSAMA
DOKUMEN PRA-BIDA
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UNTUK
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MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA
SEPULOH, PERLIS
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(REKA & BINA)

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NO. TENDER: JKRlCKUB/22648/2023

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1. SENARAI SEMAKAN MENGEMUKAKAN TENDER

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- Senarai Semakan Mengemukakan Tender Panduan kepada Petender

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- Senarai Semakan Kandungan Dokumen Pra-Bida

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2. BORANG-BORANG MAKLUMAT YANG PERLU DILENGKAPKAN OLEH

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PETENDER
KETUA PENGARAH KERJA RAYA

JABATAN KERJA RAYA MALAYSIA
JALAN SULTAN SALAHUDDIN
50582 KUALA LUMPUR
DISEMBER 2023
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SENARAI SEMAKAN MENGEMUKAKAN
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TENDER
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SENARAI SEMAKAN MENGEMUKAKAN TENDER
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PANDUAN KEPADA PETENDER
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JABATANKERJARAYA
SENARAI SEMAKAN MENGEMUKAKAN TENDER

PANDUAN KEPADA PETENDER
PROJEK: MEMBINA JALAN DAR! BEHOR MALI KE KAMPUNG KEPALA

SEPULOH, PERLIS
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NOTA
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a) Senarai semakan ini adalah bertujuan bagi menolong petender mengemukakan satu
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( tender yang lengkap dan tanpa sebarang kesilapan. Semua petender adalah
dinasihatkan supaya menggunakan senarai semakan ini bagi menyemak tender
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mereka sebelum menyerahkan tender masing-masing.
b) Segala usaha telah diambil untuk menyenaraikan perkara-perkara yang lazimnya

perlu diambil tindakan oleh seorang petender dalam mengemukakan tendemya.
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Walaupun begitu, adalah menjadi tanggungjawab Petender sepenuhoya bagi
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menentukan lengkapnya sesuatu tender yang dikemukakannya itu.
c) Petender adalah digalakkan menggunakan senarai semakan ini sebagai panduan

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bahawa sesuatu tindakan perlu diambil atau peringatan bahawa tindakan telah
diambil untuk mempastikan kesempumaan tender yang dikemukakan.
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d) Petender adalah bertanggungjawab sepenuhoya bagi memastikan setiap dokumen

pra-bida yang dibelinya adalah lengkap danjika terdapat apa-apa ketidaksempumaan
pada dokumen atau muka surat di dalam dokumen pra-bida berkenaan, adalah
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menjadi tanggungjawab petender untuk merujuk kepada pejabat ini supaya

( ) pembetulan kepada ketidaksempumaan tersebut dapat dibuat.
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e) Petender hendaklah merujuk kepada Senarai Semakan Kandungan Dokumen

Pra-Bida untuk memastikan semua dokumen yang berkenaan dimuat turun.
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TANDAKAN - / JIKA
BIL. PERKARA TINDAKAN TELAH
DIAMBIL
1. PENGISIAN DOKUMEN
1.1. JANGAN gunakan dakwat mudah luntur,

pemadam getah atau kimia cecair dan betulkan
kesilapan dengan memotong kesilapan tersebut
dengan satu gan san bersih melintang dan D
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ditandatangani ringkas oleh petender dan saksinya.
1.2. JANGAN buat apa-apa perubahan atau tambahan
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kepada Borang Tender/mana-mana dokumen lain
dalam Dokumen Pra-bida yang boleh dianggap
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( mengenakan had, syarat atau perj anji an tambahan
kepada syarat-syarat yang telah ditetapkan oleh D
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Kerajaan dalam Dokumen Pra-bida.
2. Instructions to Tenderers
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Appendix A - List of Proposed Consultants (S ila
lengkapkan - selaraskan dengan mukasurat 4 & 5 kepada
Borang Tender)
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Appendix D Lampiran AI,Surat Akuan Pembida

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Tandatangan hendaklah seorang ya ng dibenarkan

menandatangani kontrak bagi pihak Syari kat petender menurut
pendaftaran LPIPM iaitu Pegawai Syarikat Yang Ditauliahkan
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(Penama yang tereatat di dalam sijil).
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Appendix F - Surat Akuan Pembida Untuk Tujuan

Melaksanakan Program Professional Training and
Education for Growing Entrepreneurs-Ready To Work
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(PROTEGE-RTW)
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Tandatangan hendaklah seorang ya ng dibenarkan

menandatangani kontrak bagi pihak Sya rikat petender menurut
pendaftaran LPIPM iaitu Pegawai Syarikat Yang Ditauliahkan
(Penama yang tereatat di dalam sijil).
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TANDAKAN...! JIKA
SIL. PERKARA TlNDAKAN TELAH
DIAMSIL
2. Form of Tender (PWD Form DB/T-A2002)
2.l. Muka surat No . 1
a) Perenggan 1
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lsi dengan perkataan dan juga angka, amaun
tender (hendaklah sarna dengan jumlah di
' Tender Sum Analysis' di 'Appendix 4'
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kepada Syarat-syarat Kontrak.
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( Harga Indikatif Jabatan boleh dirujuk dalam
Arahan Kepada Petender (Item 41.0)
b) Perenggan 2
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lsi tempoh menyiapkan kerja mengikut unit
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bulan
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Tempoh Siap Kerja Maksimum boleh dirujuk

dalam Arahan Kepada Petender (Item 27.0)
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2.2. Muka surat No. 2

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a) Perenggan 3
'Performance Bond' - Batalkan bentuk gerenti
bon pelaksanaan yang tidak menjadi pilihan D
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( Petender
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b) Perenggan 7
Addenda - Lengkapkan jika berkaitan
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TANDAKAN / JIKA
SIL. PERKARA TINDAKAN TELAH
DIAMSIL
2. Form of Tender (PWD Form DB/T-A2002)
2.3 Muka surat No.3
a) lsi tarikh
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b) Turunkan tandatangan (hendaklah seorang
yang dibenarkan menandatangani kontrak bagi
pihak Syarikat petender menurut pendaftaran
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LPIPM - Penama yang tercatat di dalam
sijiJ).
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c) Turunkan Cop Syarikat
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d) Turunkan tandatangan saksi dan isi makl umat
saksi.
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2.4 Muka surat NO.4 & 5
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'List of Consultants' - Senaraikan nama dan alamat

perunding-perunding yang dicadang dilantik
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(selaraskan dengan Appendix A kepada Arahan

Kepada Petender)
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3. Lampiran-lampiran kepada Syarat-syarat Kontrak di

Dokumen Pra-Bida - Kemukakan dokumen-dokumen
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berikut:-
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a) Appendix 4 - Tender Sum Analysis
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Pastikan bahawajumlah di ' Tender Sum Analysis'
dipindah ke Borang Tender.
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Harga bagi kerja-kerja elektrik hendaklah di bawa dari

Schedule A: Summary of Price For Electrical
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Services, Appendix Al2 - Electrical Works (Rujuk

Jilid II - Technical Requirement)
b) Appendix 5B - Oaywork Rates for Labour and Plant

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TANDAKAN.J JIKA
SIL. PERKARA TINDAKAN TELAH
DIAMSIL
4. Borang-borang maklumat yang perlu diJengkapi oleh

petender
lsi semua butir di borang-borang ini (6 muka surat

kesemuanya) dengan betul dan lengkap. Kegagalan mengisi
maklumat atau memberi maklumat palsu, jika dapat dikesan
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akan mengakibatkan tender ditolak atauldan tindakan
tatatertib diambil terhadap petender berkenaan.
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a) BorangA
Surat pengakuan kebenaran maklumat dan kesahihan
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( dokumen yang dikemukakan oleh petender
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b) Borang B
Maklumat am dan latar belakang petender D
c) Borang G
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Senarai kerja kontrak semasa.
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d) Borang GA
Laporan Penyelia Projek Atas Prestasi Kerja Semasa
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Petender
5.0 Borang-Borang Piawai

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5.1 Borang laminaR
a) Borang laminan Bank / Jaminan Syarikat Kewangan /

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Jaminan lnsurans Untuk Bon Pelaksanaan (Kontrak

Kerja) - Appendix 6
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b) Bank Guarantee for Design Guarantee - Appendix

6A
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c) Borang laminan Bank / laminan Syarikat Kewangan /

Jaminan Insurans Untuk Bayaran Pendahuluan
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(Kontrak Bekalan / Kerja) - Appendix 6B
Borang-borang ini adalah untuk makluman sahaja.

Borang-borang ini tidak perlu diambil tindakan atau
diisi pada peringkat tender.
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TANDAKAN _I JIKA
DIAMBIL
5.2 Bon Pelaksanaan
Sebagaimana yang dinyatakan dalam Syarat-syarat Kontrak,

Petender boleh memilih untuk mengambil Bon Pelaksanaan
dalam bentuk berikut :
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a) Jaminan Bank / Jaminan Syarikat Kewangan /
Jaminan Insurans, atau
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b) Wang Jaminan Pelaksanaan yang dikenakan potongan
sebanyak sepuluh peratus (10%) daripada setiap
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bayaran interim sehingga mencapai jumlah lima
( peratus (5%) daripada Harga Kontrak.
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Petender dikehendaki memilih bentuk Bon Pelaksanaan
yang akan diambil pad a Para 3, Borang Tender
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6.0 Dokumen-dokumen yang perlu dijilid dan dikemukakan
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dalam bentuk salinan keras (hardcopv)
6.1 Dokumen-dokumen wajib

dinyatakan di para 2 hingga 4.
sepertimana yang
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6.2 Dokumen-dokumen lain yang perlu dikemukakan

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a) Senarai Semakan Kandungan Dokumen Pra-Bida

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b) Programme of Works
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c) Tender' s Key Personnel
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d) Tender's Organisation Chart

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e) List of Works to be sublet to Bumiputera

Contractors/Suppliers/Organisation
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6.3 Cadangan Teknikal
a)
b)
Civil & Structural Works
Electrical Works
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TANDAKAN / JIKA
DIAMBIL
7. KEMUKA TENDER
7.1 Cara Mengemukakan Tender
Asingkan dokumen-dokumen dalam dua (2) sampul

berasingan seperti berikut :
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a) Masukkan dokumen-dokumen seperti di 6. 1
dan 6.2 dalam sampul yang berlabel sebagai
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'DOKUMEN WAJIB DAN SOKONGAN'
dan berlakri.
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( b) Masukkan Dokumen Pra-Bida dan Cadangan
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Teknikal Petender ke dalam sampul lain dan
dilakri.
Masukkan kedua-dua sampul ini dalam satu sampul

besar dan dilakri. Nama projek yang ditender
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hendaklah ditulis dengan terang pad a sampul ini.
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7.2 Masukkan sampul surat ini di tempat dan pada tarikh

seperti yang ditetapkan dalam surat Pelawaan
Tender. D
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SENARAI SEMAKAN KANDUNGAN DOKUMEN
PRA-BIDA
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SENARAI SEMAKAN KANDUNGAN DOKUMEN PRA-BIDA
NAMA PROJEK: MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH, PERLIS
JILID 1/11 - CONTRACTUAL AND GENERAL REOUIREMENTS
PART DESCRIPTIONS PAGE NO
A INSTRUCTION TO TENDERERS I to 23 D
Appendices
Appendi x 'A' - Li st of Proposed Consultants A- I D
Appendix '8' ~ General Guidelines for the Preparation of the Environmental Management 8-1 10 8-6 D
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Appendi x 'C' _ Dasar Pengagihan Kerj a Kcpada Kontraktor Bumiputera Gred G2 Dan G 1 C- I 10 C- II D
Appendi x 'D' - Kaedah Pelaksanaan Integrity Pact D- \ 10 0-5 D
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Appendix 'E' - Reference lnfonnation E-I D
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Appendix 'F' - Program pro resional Training And Education For Growing
Entrepreneurs - Ready To Work (PR OTEGE -RTW)
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B GOVERNMENT'S REQUIREMENTS (NE ED STATEMENT)
GENERAL AND CONTRACTUAL REQUIREMENTS
I. Contractual and General Requirements CGRlI 10 CGRl33 D

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2. Appendices
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Appendix A I-A - Location Plan for the Work s AI-A D

Appendix A 1-8 - Proposed Alignment Plan of the Proj ect A I-8 D
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Appendix A 1~C - Typical Cross-Section At Bridge A I-C

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Appendi x A2a - List ofContraclor 's Consultant ' s Supervision Personnel A2-A D
Appendi x A2b - List of Contractor' s Supervision Personnel A2-8 D
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Appendix A3 - Fac iliti es for the Proj ect Director A3- 1 to A3 -\ II I

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Appendix A4 - JKR Green Mi ssion 2.0 N/A D
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C FORM OF TENDER - (P.W.D. FORM DBrr-A2002) I to 5 D

D LETT E R OF ACCEPTANCE OF TENDER (I PP PK4.2) 1 to 13 D
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E CONDITIONS OF CONTRACT AND ADDENDUM

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I. Table of Contents ito iv D

2. Conditions of Contract (P.W.D. Fonn DB Rev . 1120 10) I to 62 D
3. Addendum 10 the Conditions of Contract
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Add endum No . I
Addendum No. 3
Addendum No.5 I to 2
Addendum No. 6 I to 2
Addendum No.8 I
SENARA I SEMAKAN KANDUNGAN DOKUMEN PRA-BIDA
JILID 1/11- CONTRACTUAL AND GENERAL REOUIR EMEN TS
DESCRIPTION S PAG E NO
F APPENDI CES TO THE COND ITIO NS OF CONTRACT
1. List of Appendices 0
2. Appendix 1 Appendix to the Conditions of Contract 63 to 65 0
3. Appendix 2 Govemment's Requirements A2- 1 0
4. Appendi x 3 Contractor's Proposal A3 -1 0
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5. Appendix 4 Tender Sum Analysis A4- 1 to BQI S-I II
6. Appendix 5 Contract Schedule of Rates AS- I 0

7. Appendi x SA - Preambles to Contrac t Sum Analysis and Contract Schedule of Rates ASA- I to ASA-6
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- Method of Measurement and Pricing ASA-7 to ASA-26
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( 8. Appendix 58 - Preambles to Oaywork Rales
- Daywork Rates for Labour and Plant
ASB- I to ASB-2
ASB-3 to AS B-7 B
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9. Append ix 6 - Borang l aminan Bank/laminan
- Syarikat Kewangan/l aminan
A6- 1 to A6-2 0
- Insurans untuk 80n Pelaksanaan
(Kontrak Kerj a yang Bemilai lebih RM I 0 juta )
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10. Appendix 6A - Bank Guarantee For Design Guarantee AM- I to A6A-2 0
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11. Appendix 68 - S arang laminan Bank/l ami nan A6B- 1 to A6B-2 0

- Syarikat KcwanganlJaminan
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- Insurans untuk Bayaran Pcndahuluan

(Kontrak BckalanlPcrkhidmatanlKcrja)
12. Appendix 7 - Government Multimodal Transport Operators A7-1 0

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13. Appendix 8 - Detai led Design and Spec ifications AS- I 0

14. Append ix 9-Non-Compl iance Schedul e - NCS A9 -I - A9 -2 0
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JILID 11/11 (BOOK I Of 2) TECHNICAL REOUIREMENTS
A TECHN ICAL REQU IREMENT TRi I to TRi ll

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APPEND ICES
I. Appendix AS - J KR Design Standard and Guidelines AS - 1/6 to AS-6/6

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2. Appendix A 6 - Tenns of Re ference for Traffic Study I to 9 0
3. Appendix A 7 - Tenns o f Reference for Bridge and Viaducts Structures
Structure for Design And Build Proj ect
J to 9 0
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- Tenns o f Reference fo r Independent Structural
Checker
10 to 14
0
- Tenns of Reference fo r Bridge Assessment I S to 19 0
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Procedure
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( 4. Appendi x AS - Geotec hnical Design Requirements 1 10 6 0
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- Tenns o f Reference for Independent Geotechnical Chec ker I to 6
5. Appendix A9 - Tenns o f Re ference for RSA

Appendix I to Append ix 7
A I to 9 0
6. Appendix AID - Not Applicable N/A 0
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7. Appendix A II - Tenns of Re ference for Topographical Survey Works 1\0 S6 0
- Tenns of Reference for Underground Utility Survey Work I to 10 0
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8. Appendix A 12 - Electrical Works Page I o f 60 to

Page 60 0[ 60
0
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9. Appendix A 13 Environmental Protection and Enhancement Requirements A I3 - 1 tOA 13-3 1

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10. Appendix A 14 Road Design Requirements A 14- 114 to A 14-4/4 0
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II . Appendix A 15 Tenns o f Re ference for Pavement Evaluation 1/6 to 6/6 0
12. Appendi x A 16 - OS HA I to 19
0
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13. Appendix A 17 - Tenn of Reference for Hydrographical Survey Works N/A 0

14. Appendix A 18 - pH JKR I to 6
0
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15. Appendix A 19 - J KR Acceptance Criteria 110 Page 3 of 3

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16. Appendix A20 - Building Infonnation Modelling (BIM) Requirements A20- 1 to A20-3: II I
0
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JILID 11111 ( BOOK 2 OF 2) - ST ANDA R D SPEC I FICATIONS
PART DESC RI PTIONS PAGE NO
A STANDA RD SPEC I FICATIONS
A.I ROADWORKS
I. Section 1 General (JKRlS PJ/20 15-S I)

Appendix 1A - IN
S I-i toS I-32
S IA- I to S IN- I
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2. Section 2 Eanhwork s (JKRlSPJl2020-S2) S2-i to S2·27 D
3. Section 3 Drainage Works (J KRiSP J120 13-S3) S3-i to S3-2 1
B
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Addendum No.1 AS3-i to AS3( I )-4/4
§
4. Section 4 Aexible Pavement (JKRlS PJI2008-54) S4-i to 54-X IX
Addendum No. J & 2 i to 54.17-46
Addendum (item 4.5) AS4-i to AS4( I )-212
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5. Section 5 Concrete Pavemenl (JKRlS PJ /2020·SS) 1 to 69
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( 6. Section 6 Road Furniture (JKRlSPJI2017-S6) S6-i to S6-33
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Addelldllm No.1 AS6( 1)-1I 1
7. Section 7 Road Lighting(JKRlSPJ/20 11-S7) S7-i to 57- 1 D

8. Sec tion 8 Traflie Signals System (JKRlSPJI2008-S8 ) S8- i to S8-29 D
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9. Section 9 Concrete (JKRlS PJ/20 18-S9) S9-i to S9-63
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10. Section 10 Foundation Works (JKRJSPJ/20 19-S I 0) S IO-i toS 10-73 D

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11 . Section 11 Prestressing for Structures (JKRlSPJ /20 16-S 11) S II-i to S 11 -35
12. Section 12 Structural Steelwork (JKRlS PJI2022-S 12) S I2-itoSI2-63 D

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13. Section 13 Bridge Bearings (J KRlS PJI20 13-S13) S J3-i to S 13-24 D

14. Section 14 Expansion Joints (JKRlS PJI20 \ 3-5 14 ) S 14- i to 5 14-8
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15. Sec tion 15 Parapets (JKRlSPJl2013-S 15) S 15- i to S IS- IS D
A.2. 1 ADDENDUM TO STANDARD SPEC IFICAT ION FO R BR IDGE W OR KS
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Addendum No. 1 General Items for Bridge Works ABI-i to AB I-2 D

Addendum No.2 Launching for Precast Element AB2-i to AB2-2 D
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Addendum No.3 Precasl Concrete Segmental Works AB3-i to AB3-8 D

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Addendum No.4 Blended Shredded Tires AB4- i to AB4-4 D

Addendum No.5 Miscellaneous for Bridge Works AB5-i to A B5-4
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16. Sect ion 16 Slope Stabi lisation (JKRlSPJ/20 13-S 16) S16-i to S 16·107 D
17. Section 17 Site Investigation (JKRlSPJ/20 13-S 17) S 17-i to S 17-45 D
18. Section 18 Soil Stab ili sat ion (JKRlSPJ/20 18-S 18) S 18- i to S 18-2 1 D
19. Sec tion 19 Traffic Management at Work Zone
(JKRlS PJ/20 17·S 19)
S 19-i toS 19-43
D
20. Section 20 Ground Improvement
(J KRiS PJ12020-S20)
S20-i to S20-64 D
iv
SENARA I SEMAKAN KA NDUNGAN DOKUMEN PRA-B IDA
JILID 1111 1 (BOOK 2 OF 2) - STANDARD SPECIFI CAT IONS
DESC RIPTIONS PAGE NO
2 1. The Responsibi lities and Scope of works of Traffic Management Officer and
Road Safety Auditor
1104
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B S PECIAL PROVISION TO THE STANDA RD SPEC IFICATION FOR ROAD WORKS
I. Work Programme Specification (Collventional) 1 10 14 D

2. Environmental Protection and Enhancement ito C-2 D
3. Specification for Occupational Safety and Health in Engineering Contruclion ito 19 D
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Works (20 19)
4. Quality Assurance and Control (QAfQc) ito 9 D

5. Proof Rolling Test ito 8 D
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6. Post Mounted Delineators & Rai sed Pavement Markers ito 1
D
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( 7. Pile Testing i to 15 D
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8. Waterproofing and Damp Proofing for Structures ito 5 D
9. Joint Filler Testing ito 2 D
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10. Rain Gauge and SMS Remote Tcnninal Unit (S MS RTU) ito 5 D
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II. Spec ial Requirement In Relation to Dra inage and Irri gation Department i to I
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12. General Requirement fo r Utiliti es and Services Relocation i 10 8 D
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13. Landscape Works i 102 1 D

14. Hydromulching i 103 D
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BORANG-BORANG MAKLUMAT YANG PERLU
DILENGKAPKAN OLEH PETENDER
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BORANG A - SURAT PENGAKUAN KEBENARAN MAKLUMAT DAN KESAHIHAN
DOKUMEN YANG DIKEMUKAKAN OLEH PETENDER
Nama Petender : .. . .. .. .... . .. . ...... ..... ... ... .. ..... .

Alamat : ................. . .... .... . ........ .. ... .. ....... .. .
Kepada ,
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Pengarah Pengarah Kanan,
Cawangan Kontrak & Ukur Bahan
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Ibu Pejabat JKR Malaysia
Tingkat 17, Menara Tun Ismail Mohamed Ali
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( 50582 KUALA LUMPUR
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Tuan,
MAKLUMAT LATAR BELAKANG, KEWANGAN DAN TEKNIKAL PETENDER

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1. Kami telah membaca dengan teliti semua arahan-arahan yang terkandung dalam
Arahan Kepada Petender termasuk arahan yang menghendakkan kami
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mengemukakan maklumat-maklumat dan dokumen-dokumen mengenai perkara di

atas bersama-sama dokumen tender kami semasa mengemukakan Tender ini untuk
membolehkan agensi tuan menilai keupayaan kami untuk melaksanakan kerja yang
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ditender semasa Penilaian Tender.
2. Kami faham dan mengambil maklum bahawa Penilaian Tender ini akan
mengambilkira dan mementingkan keupayaan kami melaksanakan kerja yang
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( ditender. Justeru itu Tender kami akan hanya dipertimbang untuk diperakukan
kepada Lembaga Tender untuk disetuju terima sekiranya kami didapati
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berkeupayaan untuk melaksanakan projek yang ditender, mengikut kaedah penilaian

yang ditetapkan berasaskan maklumat-maklumat dan dokumen-dokumen yang kami
kemukakan.
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3. Kami juga mengambil maklum bahawa kami dikehendaki mengemukakan semua

maklumat dan dokumen yang diminta bersama-sama Tender kami sebelum Tender
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ditutup dan maklumat atau dokumen yang dikemukakan kemudian daripada itu tidak
akan diterima untuk diambilkira dalam penilaian keupayaan kami.
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PROJEK: MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH, PERLIS
DOKUMEN YANG DIKEMUKAKAN OLEH PETENDER (samb)
4. Kami mengaku bahawa semua maklumat dan data yang kami berikan bersama-sama
ini di Borang B, C, CA, D, E, G & GA * dan dokumen-dokumen yang kami sertakan
bersamanya setahu kami adalah semuanya benar dan sah pada semua segi dan
kami telah mengambil maklum dan sedar akan tindakan yang boleh diambil oleh
Kerajaan terhadap kami dan/atau Tender kami , sekiranya mana-mana maklumat,
data dan dokumen yang kami berikan itu didapati tidak benar dan palsu.
5. Kami juga mengambil maklum dan sedar bahawa Tender kami akan ditolak
(disqualified) dan tidak akan dipertimbangkan sekiranya maklumat-maklumat yang
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kami berikan tidak mencukupi atau sekiranya kami gaga I untuk memberikan
bersama-sama ini mana-mana maklumat dan/atau menyertakan mana-mana
dokumen penting yang sangat diperlukan untuk membolehkan agensi tuan menilai
keupayaan kami, terutamanya dokumen-dokumen berhubung dengan kedudukan
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kewangan dan prestasi kerja semasa kami sebagaimana yang dinyatakan dalam
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Arahan Kepada Petender seperti berikut:
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tB
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Penyata Kewan§an Syarikat
~ Penyata BlJlanan Bank
~ ba~9ran Bank IlnstitlJsi Kewan§an Men§enai KeR'llJElahan KraElit
A
~ De~9sit Teta~ (sekiranya aEla)
(5) Laporan Prestasi Kerja Semasa
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6. Kami dengan ini memberi kuasa kepada mana-mana pegawai kerajaan , jurutera-
jurutera projek, juruaudit, pegawai bank dan mana-mana pihak yang berkenaan
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untuk memberikan maklumat-maklumat yang dianggap perlu dan diminta oleh pihak
Kerajaan untuk mengesahkan maklumat-maklumat yang kami berikan di perenggan
4 dan 5 atau untuk mendapatkan maklumat tambahan . Kami dengan ini juga
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memberi kebenaran kepada pihak Kerajaan untuk merujuk apa-apa maklumat yang
kami kemukakan kepada mana-mana pihak termasuk Lembaga Hasil Dalam Negeri.
Walau bagaimanapun kami tetap bertanggungjawab di atas maklumat-maklumat
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dan dokumen-dokumen yang kami berikan bersama-sama ini.

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7. Kami juga dengan ini mengakui dan mengesahkan bahawa pihak kami tidak ada
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membuat sebarang pakatan atau apa-apa bentuk am alan sepadu dengan mana-
mana petender lain bagi mempengaruhi kemunasabahan harga tender dan apa-apa
tindakan yang boleh menjejaskan atau yang mempunyai kesan menghalang,
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menyekat atau menggangu persaingan yang sihat bagi membolehkan tender kami
atau petender lain di pertimbangkan . Kami akur pihak Jabatan boleh menolak
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tawaran kami sekiranya pihak Jabatan mengesyaki sebarang pakatan harga dan
pihak kami juga boleh diambil tindakan di bawah Akta Persaingan 2010 (Akta 712).
' Sila pastikan rujukan borang adalah betul oleh Pegawai Mengurus Tender.
PROJEK : MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH, PERLIS
DOKUMEN YANG DIKEMUKAKAN OLEH PETENDER (samb)
8. Kami maklum bahawa sekiranya pihak yang dihubungi tidak memberi

pengesahan dalam tempoh yang ditetapkan akan menyebabkan tender kami
tidak dipertimbangkan untuk disetuju terima.
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Yang benar,
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Tarikh : .. ...... . .. . ..... . ... ... .
(Tandatangan Petender)
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Nama Penuh : ......... .... ... ..... ...... ..... ... . .
No. Kad Pengenalan : ... ..... •............. .....
Atas Sifat : .... ...... ................ ............... .
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yang diberikuasa dengan sempurnanya untuk
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menandatangani Tender ini Untuk Dan Bagi
Pihak :
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(Meteri atau Cap Petender)

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Tarikh : .... ......... ........... .

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(Tandatangan Saksi)
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Nama Penuh : ..... .................. . ........ ...... .

No. Kad Pengenalan: ... ....... ..... ...... ... .... .
Pekerjaan : ......................... ................. .
Alamat : ............... .... . ........ ..... .... .. .
PROJEK: MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH , PERLIS
BORANG B - MAKLUMAT AM DAN LATAR BELAKANG PENTENDER
1. Nama
2. Alamat
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No. Telefon No. Faks
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Email
N
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3.
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Pendaftaran Cukai Barangan dan Perkhidmatan (CBP) dengan Jabatan Kastam
Diraja Malaysia Uika berdaftar dan sertakan salinan pendaftaran)
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(i) No. Pendaftaran :
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(ii) Tarikh Kuat kuasa

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EN
4. Perniagaan Utama lain, jika ada
(a) sejak
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( (b) sejak
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4
PROJEK : MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH , PERLIS
I'" ~
BORANG G - SENARAI KERJA KONTRAK SEMASA

(Senarai sernua kerja di dalarn tangan/sedang berjalan dan bel urn siap terrnasuk kontrak yang baru diawad)
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Bil. Nama Nilai Nilai Tempoh TarikhH Tarikh Kemajuan Kerja + Nama Dan Nama Dan
KontraklProjek + Kontrak Petender Kontrak Milik Siap Alamat Jurutera Alamat Majikan
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(RM) Bertanggung- ** Tapak Kontrak Projek
Jawab * Ikut Sebenar
N
Jadual Dicapai
(%) (%)
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A
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M
EN
M
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* Hanya perlu diisi sekiranya pentender melaksanakan kerja sebagai ahli syarikat gabungan.
*. Tempoh kontrak hendaklah termasuk lanjutan masa yang di luluskan .
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D
5
SULIT
BORANG GA - LAPORAN PENYELIA PROJEK ATAS PRESTASI KERJA SEMASA
PETENDER
(Borang ini hendakla h dilengkapkan oleh Penyelia Projek atau Pembantu Kanannya yang
mengawasi projek dan diserahkan kepada Kontraktor dalam satu sampul berlakri untuk
disertakan bersama-sama tendernya).
Kepada : Pengarah Kanan

Cawangan Kontrak Dan Ukur Bahan,
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Ibu Pejabat JKR Malaysia,
Tingkat 17, Menara Tun Ismail Muhamad Ali ,
No. 25, Jalan Raja Laut, 50582 Kuala Lumpur.
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(u.p : Juruukur Bahan Penguasa Kanan
(Bahagian Jalan)
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( Nama Kontraktor : .......................................... ................... .......... ...... ..... . .... .. .
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Nama Projek Yang Di Laksanakan : ...... ... .. ....... .... . ..... .......... ..... ........ ...... ........ .
No. Kontrak :
Harga Kontrak (termasuk anggaran nilai kerja perubahan) : RM
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Wang Kos Prima dan Peruntukan Sementara : RM
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Nilai Kerja Pembina: RM
Tarikh Milik Tapak : Tempoh Kontrak : minggu
Tarikh Penyiapa n Asal :
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Lanjutan Masa Yang Telah Diluluskan : hari

Lanjutan Masa Seterusnya ;
Yang difikir / dijangka layak diperakukan : hari
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Atas Sebab-sebab : (i) ................................................................. .

(ii) ........................................................ ..... .. ..
Kemajuan Kerja (berdasarkan nilaian kerja yang telah dilaksanakan) :
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Pencapaian sebenar : % Mengikut Jadual : %

Tarikh Kerja dijangka akan dapat disiapkan :
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Nilai Bahagian Kerja Yang Telah Siap : RM .... .. .. ..... ....................... .. ..

Nilai Baki Kerja Yang Belum Siap : RM ................. .. .. .. ..... ... .... ..
Ulasan-ulasan mengenai Prestasi Kontraktor :
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(Nyatakan apa-apa kepujian dan / atau kelemahan Kontraktor dan juga apa-apa tindakan /
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perakuan yang diambil / dipertimbang berhubung dengan prestasi Kontraktor melaksanakan

Kontrak)
Tandatangan Penyelia Projek

Nama
Jawatan : Tarikh
6
PROJEK : MEMBINA JALAN DAR I BEHOR MALI KE KAMPUNG KEPALA SEPULOH, PERLIS
ER
D
N
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EVALUATION CRITERIA
A
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MEMBINAJALAN DARI BEHOR
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MALI KE KG KEPALA SEPULOH,
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PERLIS
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KRITERIA DAN SUB KRITERIA
EN
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---- •. "..~-. -,---

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~ ITERIA UTAMA ?ENILAIAN

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- -- KRITERIA
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1. UMUM
N
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2. JALAN
3. JAMBATAN
A
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4. GEOTEKNIKAL
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5.
EN ALAM SEKITAR
6. ELEKTRI KAL
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1. Contractor
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(Personnel & Experience)
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2. Consultant
(Background company, Personnel & Experience)
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3. Work Program
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(Software, Task, Duration & Sequence)
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4. Qualification/ Accreditation
5.
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Building Information Modelling
- BIM Execution Plan
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- BIM Model
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BIL. SUBKRITERIA
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1. General Road Design
N
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2. Report
3. Geometric
A
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4. Pavement
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5. Drainage
6.
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Road Furniture
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7. Junction
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8. Traffic Management Plan & Maintenance

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D
~UB KRITERIA JANlBATAN
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SUBKRITERIA
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1. Scope
N
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2. Design Requirement
3.
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Constructability
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4. Design Compliance
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5. Maintainability
6.
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Aesthetic
M
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O
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1 UB KRITERIA G~TEKNIK
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BIL. SUBKRITERIA
-
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1.
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Contractor/Consultant
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2. Constructability
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3. Site Investigation
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4. Retaining Wall/ Bridge Approaches
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5. Soft Ground Treatment
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6. Slope Stabilization
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7. Instrumentation
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1. Scope Of Works
N
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2. Special Requirements
3. Legal Requirements
A
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4. Environmental Management Plan (EMP)
5.
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Environmental Officer (EO)
6.
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Erosion And Sediment Control Plan (ESCP)
7. Environmental Monitoring
M
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8. Environmental Audit
9. Penarafan Hijau (pH)
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D
t;UB KRITERIA EL~KTRIKAL
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BIL. SUBKRITERIA
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1. Design Criteria dan Concept Design
N
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2. Road Lighting Design
3. Traffic Light
A
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4. Pedestrian Bridge / Bus Stop
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5. Builder Works In Connection (BWIC)
6.
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Catalogue & Manufacturer Brand
7.
M
Consultant Capability
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O
D
D
O
KU
M
EN
M
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A
TE
N
D
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KERAJAAN MALAYSIA
ER
D
DOKUMEN PRA BIDA
N
TE
UNTUK
A
MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG
EJ
KEPALA SEPULOH, PERLIS

M
(REKA & BINA)

EN

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JILID 1111
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CONTRACTUAL AND GENERAL REQUIREMENTS

O
D
KETUA PENGARAH KERJA RA YA

mu PEJABA T JKR MALAYSIA
JALAN SULTAN SALAH UDDIN
50582 KUALA LUMPUR
DISEMBER 2023
SEPULOH, PERLIS.
TABLE OF CONTENT
JILID lIII - CONTRACTUAL AND GENERAL REOUIREMENTS
PART DESCRIPTIONS PAGE. NO
A INSTRUCTIONS TO TENDERER
ER
1. Instructions to Tenderers I to 23
2. Appendices
D
Appendix A - List of Proposed Consultants A-I
N
( Appendix B - General Guidelines For The Preparation
TE
Of The Environmental Management
Plan (EMP) - By The Contractor B-1 to 8-6
Appendix C - Dasar Pengagihan Kerja Kepada Kontraktor C-I to C-ll

A
Bumiputera Gred G2 dan Gl
EJ
Appendix D - Kaedah Pelaksanaan Integrity Pact D-I to D-5
Appendix E - Reference Information E-I

M
Appendix F - Program Profesional Training And Education F-I

For Growing Entrepreneurs - Ready To Work
EN
(PROTEGE-RTW)
M
( B GOVERNMENT'S REQUIREMENTS (NEED STATEMENT)

GENERAL AND CONTRACTUAL REQUIREMENTS
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1. Contractual and General Requirements CGRlI to CGRl33

O
2. Appendices
D
Appendix Al-A - Location Plan for the Works AI-A
Appendix Al-B - Alignment Plan of The Project AI-B
Appendix Al-C - Typical Bridge Cross Section AI-C

SEPULOH, PERLIS.
TABLE OF CONTENT
JILID 1111 - CONTRACTUAL AND GENERAL REOUIREMENTS
Appendix A2 - List of Contractor' s Consultant's A2-A
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Supervision Personnel
- List of Contractor' s Supervision A2-B

Personnel
D
Appendix A3 - Facilities for the Project Director A3-1 to A3-1: 11l
N
(
Appendix A4 - Sustainability and Green Mission 2.0 N /A
C FORM OF TENDER (P.W.D. FORM DB/T-A2002)

TE I to 5
A
D LETTER OF ACCEPTANCE (IPP PK4.2) I to 13
EJ
E CONDITIONS OF CONTRACT AND ADDENDUM

M
I. Table of Contents i to iv
2. Conditions of Contract (P.W.D. Form DB Rev. 11201 0) I to 62

EN
3. Addendum to the Conditions of Contract

Addendum No . I
M
Addendum NO . 3
( Addendum No.5 I to 2
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Addendum No.6 I to 2
Addendum No.8 I
O
F APPENDICES TO THE CONDITIONS OF CONTRACT

D
I. List of Appendices
2. Appendix I Appendix to Conditions of Contract 63 to 65
3. Appendix 2 Government's Requirements A2-1
4. Appendix 3 Contractor's Proposal A3-1
5. Appendix 4 Tender Sum Analysis A4-1 to BQ15-1I1
6. Appendix 5 Contract Schedule of Rates A5-1
11
MEMBINA JALAN DAR! BEHOR MALI KE KAMPUNG KEPALA
SEPULOH, PERLIS.
TABLE OF CONTENT
JILID 1111 - CONTRACTUAL AND GENERAL REOUIREMENTS
F APPENDICES TO THE CONDITIONS OF CONTRACT (CONT'D)
ER
7. Appendix 5A - Preambles to Contract Sum Analysis and
Contract Schedule of Rates A5A-1 to A5A-6
Method of Measurement and Pricing
D
Factors A5A-7 to A5A-26
N
( 8. Appendix 5B - Preambles to Daywork Rates A5B-I to A5B-2
TE
Daywork Rates for Labour and Plant A5B-3 to A5B-7
9. Appendix 6 Borang Jaminan Bank/Jaminan A6-1 to A6-2

Syarikat KewanganlJ aminan
A
Insurans untuk Bon Pe1aksanaan
(Kontrak Kerja yang Bemilai lebih RM I 0 juta )
EJ
10. Appendix 6A - Bank Guarantee For Design Guarantee A6A-I to A6A-2

M
II. Appendix 6B Borang Jaminan BanklJaminan

Syarikat KewanganlJaminan
Insurans untuk Bayaran
EN
Pendahuluan (Kontrak Bekalanl

PerkhidmataniKerja) A6B-I to A6B -2
M
12. Appendix 7 Government Multimodal

( Transport Operators A7-1
KU
13. Appendix 8 Detailed Design and Specifications A8-1

O
14. Appendix 9 Non-Compliance Schedule (NCS) A9-1 to A9-2

D
111
SEPULOH, PERLIS.
TABLE OF CONTENT
JILID II III ( BOOK I OF 2) - TECHNICAL REOUIREMENTS

A TECHNICAL REQUIREMENT TRiI to TRill
ER
APPENDICES ;-
Appendix A5 JKR Design Standard and Guidelines A5-1 /6 to A5-6/6
D
Appendix A6 Tenn of Reference Traffic Study I to 9
N
( Appendix A7 Tenns of Reference for Bridge and Viaducts I to 9
TE
Structures for Design and Built Project
Tenns of Reference for Independent Structural 10 to 14

Checker
A
Tenns of Reference for Bridge Assessment 15 to 19
EJ
Procedure
Appendix A8 Geotechnical Design Requirements I to 6

M
Tenns of Reference for Independent I to 6

EN
Geoteclmical Checker
Appendix A9 Tenns of Reference for RSA I to 9

M
Appendix I to Appendix 7
<-
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Appendix AIO Not Applicable N /A

O
D
IV
SEPULOH, PERLIS.
TABLE OF CONTENT
JILID II III (BOOK 1 OF 2) - TECHNICAL REOUIREMENTS

A TECHNICAL REQUIREMENT (CONT'D)
ER
APPENDICES :-
Appendix A II Tenn Of Reference For Topographical ito 56
D
Survey Works
Tenns of Reference for Underground Utility I to 10
N
( Survey Works
TE
Appendix A 12 Electrical Works Page I of 60 to
Page 60 of60
A
Appendix A 13 Environmental Protection and Enhancement A13-1 to A13-31
Requirements
EJ
Appendix AI4 Road Design Requirements A14-1/4 to A14-4/4

M
Appendix A IS Tenns of Reference for Pavement Evaluation 1/6 to 6/6

EN
Appendix A 16 OSHA I to 19
Appendix Al7 Hydrographic Survey N /A

M
( Appendix A 18 pHJKR I to 6
KU
Appendix AI9 JKR Acceptance Criteria I to Page 3 00
Appendix A20 B1M A20/ 1 to A20-3: III

O
D
v
SEPULOH, PERLIS
TABLE OF CONTENT
JILID IIIII (BOOK 2 OF 2) - STANDARD SPECIFICATIONS
A STANDARD SPECIFICATIONS
ER
1. Section I General (JKRlSP J/20 15-S I) SI-i to SI-32
Appendix IA - IN SIA-I to S IN-I
D
2. Section 2 Earthworks
N
(JKRlSP J/2020-S2) S2-i to S2-27
(
TE
3. Section 3 Drainage Works S3-i to S3-21
(JKRlSPJ/2013-S3)
Addendum No. J AS3-i to AS3(J)-414
A
4. Section 4 Flexible Pavement S4-i to S4-XIX
(JKRlSP J/2008-S4)
EJ
- Addendum No. J & 2 ito S4.J7- 46

- Addendum (item4.5) AS4-i to AS4(J)-212
M
5. Section 5 Concrete Pavement I to 69

(JKRlSPJ/2020-S5)
EN
6. Section 6 Road Furniture S6-i to S6-33

(JKRlSPJ/2017-S6)
- Addendum No. J AS6(J)-JIJ
M
<- 7. Section 7 Road Lighting (JKRlSPJ/2011 -S7) S7-i to S7-1

KU
8. Section 8 Traffic Signal System (JKRlSPJ /2008-S8) S8-i to S8-29

O
9. Section 9 Concrete S9-i to S9-63

(JKRlSP J/20 18-S9)
D
10. Section 10 Foundation Works S 10-i to S 10-73

(JKRlSPJ/2019-S I 0)
VI
SEPULOH, PERLIS
T ABLE OF CONTENT
ER
A STANDARD SPECIFICATIONS (CONT'D)
II. Section II Prestressing for Structures SII-i to SII-35

(JKRlSPJ/2016-SII)
D
N
12. Section 12 Structural Steelwork S12-i to S12-63
(
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13. Section 13 Bridge Bearings S13-i to S13-24
(JKRlSPJ/2013-S 13)
14. Section 14 Expansion Joints S14-i to S14-8

A
(JKRlSPJI2013 -S 14)
EJ
IS . Section IS Parapets S 15-i to SIS-IS

(JKRlSPJ /2013-S IS)
M
ADDENDUM TO STANDARD SPECIFICATION FOR BRIDGE WORKS

EN
Addendum No.1 General Items for Bridge Works ABI-i to ABI-2
Addendum No.2 Launching for Precast Element AB2-i to AB2-2

M
(
Addendum No.3 Precast Concrete Segmental Works AB3-i to AB3-8
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Addendum No.4 Blended Shredded Tires AB4-i to AB4-4

O
Addendum NO.5 Miscellaneous for Bridge Works AB5-i to AB5-4

D
VII
SEPULOH, PERLIS
TABLE OF CONTENT
ER
16. Section 16 Slope Stabilisation S16-i to S16-107
(JKRlSP J/20 13-S 16)
D
17. Section 17 Site Investigation S17-i to S17-45
N
( (JKRlSP J/2013-S 17)
TE
18. Section 18 Soil Stabilisation S18-i to S18-21
(JKRlSPJ /20 18-S 18)
19. Section 19 Traffic Management At Work Zone

A
S19-i to S19-43
(JKRlSPJ /2017-S 19)
EJ
20. Section 20 Ground Improvement S20-i to S20-64

(JKRlSP J120 19-520)
M
21. The Responsibilities and Scope of works of Traffic

Management Officer and Road Safety Auditor I to 4
EN
M
(
KU
O
D
Vlll
SEPULOH, PERLIS
T ABLE OF CONTENT
JILID mIl (BOOK 2 OF 2) - STANDARD SPECIFICATIONS
B SPECIAL PROVISION TO THE STANDARD SPECIFICATION
ER
FOR ROAD WORKS
I. Work Programme Specification (Design & Build) I to 14
D
2. Environmental Protection and Enhancement i to C-2
N
( 3. Specification for Occupational Safety and Health in Engineering
Construction Works (2019) to 19
TE
4. Quality Assurance and Control (QAlQC)A to 9
5. Proof Rolling Test i to 8

EJ
6. Post Mounted Delineators & Raised Pavement Markers i to I
7. Pile Testing to 15
M
8. Waterproofing and Damp Proofing for Structures to 5

EN
9. Joints Filler Testing to 2
10. Rain Gauge and SMS Remote Tenninal Unit (SMS RTU) i to 5
M
( II. Special Requirements In Relation to Drainage and

KU
Irrigation Department i to I
12. General Requirements for Utilities and Services Relocation i to 8

O
13 . Landscape Works i to 21
D
14. Hydromulching i to 3
IX
ER
D
N
(
TE
A. INSTRUCTIONS TO TENDERERS
A
EJ
M
EN
M
(
KU
O
D
MEMBINA JALAN DARI DARI BEHOR MALI KE KAMPUNG KEPALA
SEPULOH, PERLIS
INSTRUCTIONS TO THE TENDERERS
1.0 GENERAL
This document shall be deemed to form and be read and construed as part
of the Contract Documents. The Tenderer shall be deemed to have read
ER
this document thoroughly as failure to comply with the instructions
contained herein may disqualify the Tenderer's submission for this project.
D
2.0 SCOPE OF TENDER
N
( The Government of Malaysia (hereinafter referred to as 'the Government')
TE
intends to carry out the project for "MEMBINA JALAN DARI DARI BEHOR
MALI KE KAMPUNG KEPALA SEPULOH, PERLlS" .
A
The scope of works shall include the planning , design, construction,
equipping , testing , commissioning and maintenance of "MEMBINA JALAN
EJ
DARI DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH, PERLlS"

M
The Works shall be carried out complete with relevant appurtenance and
ancillary works, services and equipment a" in strict accordance to the
Government's Requirements as specified in the Pre-Bid Documents.
EN
The design of the scope of works shall comply with the need statements
and the requirements and guidelines of the Government. The Government
M
<- gives no warranty in any manner whatsoever for any information provided
KU
by the Government in the Contract as to their accuracy of sufficiency or as

to how the same shall be interpreted and the Government shall not be
liable if such information is inaccurate or insufficient. The Contractor shall
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not be relieved from the obligations to ensure that such information is

accurate and sufficient for the purpose of this Contract.
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The project is to be executed on a design and build basis.
MEMBINA JALAN DARI BEHOR MALI KE KAM PUNG KEPALA SEPULOH, PERLIS
3.0 SCOPE OF WORKS
The scope of works consists of planning , design , construction , equipping ,

testing , commissioning and maintenance for the project all in accordance
with Governrnent's Requirement. The scope of works shall include but not
limited to the following :
A General Items & Design and Build Elements

B Demolition Works and Site Clearance
C Earthworks
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D Drainage Works
E Pavement Works
F Road Furniture
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G Geotechnical Works
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H Structures Works
( Traffic Management and Control
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J Environmental Protection Works
K Routine Maintenance Works
L Electrical Works
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M Occupational Safety And Health
N Provisional Sum
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The Works covered in this tender comprise the provision by the tenderer at
his own risk including but not limited to cost of all materials, scaffolding ,
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tools, plants, professional services, labour, transport, water, electricity,

other temporary works, and everything else necessary for the execution of
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the Works.
4.0 PRE-BID DOCUMENTS

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Tenderers should note that the Pre -Bid Document for this project will be
distributed in softcopy with J-Cloud method.
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The Tenderer must refer to the checklist of documents to be downloaded

by the Tenderer to ensure that all relevant documents are downloaded . The
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Government will not be responsible if the Tenderer is negligent in ensuring

the completeness of the documents that need to be downloaded and any
complaints related to this matter will not be entertained.
The documents issued to the Tenderers by the Government comprising of

two (2) sections will be referred to as Pre-bid Documents.
MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH, PERLI S

The Pre-bid Documents comprises the following :-
Contractual And General Requirements

Jilid 1111 Instructions to Tenderers
Government's Requirements - Contractual and
General Requirements
Form of Tender
Letter of Acceptance
Conditions of Contract
Addendum to the Conditions of Contract
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Appendices to Conditions of Contract
Jilid 11111 Technical Requirements (Book 1 of 2)
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Specifications (Book 2 of 2)
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( 5.0 TENDER TABLE DOCUMENT
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Tender Table Document will be displayed and distributed in softcopy with J-
Cloud method.
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In the event of a discrepancy between the downloaded tender document
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and the Tender Table Document displayed online, the information
contained in the Tender Table Document will be used and an addendum
will be distributed to the Tenderer.
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6.0 EXPLANATION OF THE PRE-BID DOCUMENT

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If the Tenderer requires further clarification on the Pre-Bid document, the

Tenderer are required to write officially to :-
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(
Juruukur Bahan Penguasa Kanan
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Cawangan Kontrak dan Ukur Bahan

Tingkat 17, Menara Tun Ismail Mohamed Ali
No.25, Jalan Raja Laut
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50582, Kuala Lumpur

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(u.p: Bahagian Jalan)
Any request for clarification shall be submitted officially seven (7) days
before tender closing date.
During the tender period , the Government may issue further instructions or
information. Any such instruction , information or clarification will be given
to the Tenderers as written Addenda to the Pre-bid Documents and such
Addenda will be deemed to be part of the Pre-bid Documents.
MEMBINA JALAN DARI BEH OR MALI KE KAM PUNG KEPALA SEPU LOH, PERLI S
7.0 COST OF TENDERING
The Government shall not be liable to reimburse any costs, expenses or

losses incurred by the Tenderer in the preparation and submission of his
tender.
8.0 CONTRACTUAL AND GENERAL REQUIREMENTS
The Tenderer shall fully comply with the Contractual and General
Requirements as contained in the Pre-Bid Documents.
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9.0 ADHERING TO CONDITIONS OF CONTRACT AND INSTRUCTIONS TO
TENDERERS
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The Tenderer's attention is drawn to the Instructions to Tenderers and the
( Conditions of Contract and the Tenderer shall adhere strictly to the same.
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All expenses which may arise due to compliance with such instructions or
conditions shall be deemed to have been reflected and included in the
Tender Sum Analysis.
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10.0 TENDERER'S LOCAL CONSULTANTS
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The Tenderer shall submit a complete list of local Consultants to be

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employed for the project stating their job category and their obligations. The
non in - house and independent local Consultants shall be qualified and
competent and shall be registered with the Ministry of Finance and their
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respective Boards in Malaysia. The Tenderer's attention is also drawn to

the fact that the Consultants shall be retained throughout the Contract
Period including Defects Liability Period and shall not be discharged
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( without the consent of the Project Director. Consultants shall also be

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involved in the supervision of the Works in order to certify the 'As-Built

Drawings'.
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The Consultants shall have adequate and qualified personnel to provide

professional services during design, construction and certification of Work
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phases as specified in Government's Requirements.
10.1 Appointment of Consultants for Tenderer's Proposal Submission .

a) It is mandatory for the tenderer to engage the following
consultants for their submission of technical proposal:
a) Civil and Structural Engineer

b) Electrical Engineer
c) Quantity Surveyor
d) (Other consultants/independent checker if applicable)
MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH, PERLIS

b) The Tenderer shall also engage other relevant consultants
required for the Works as detailed out in the respective
Government Technical Requirements (needs statement).
c) The criteria and qualification / experience required for each

consultant discipline is detailed out in the respective
Govemment's Requirements. Failure to comply with the required
criteria may result in the Technical Proposal not considered for
technical evaluation.
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10.2 Submission of Consultant Profile.
a) It is compulsory for the Tenderer to submit the list of consultants
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attached in Appendix A with all relevant documents including
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Curriculum Vitae (C.V.), the relevant documentary proof of
( experience and Consultant's registration.
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b) The Consultant's C.V. and registration above must be submit
under the Contractual General Requirement and will be
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considered as a master list. The same documents of individual
discipline shall attached in the Government Requirements on
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Technical Works.
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11.0 THE TENDERER'S ORGANISATIONAL PLANNING
The Tenderer shall submit an outline of their organisation for planning and
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design works and for construction works in their tender.
12.0 INSPECTION OF SITE

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(
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The Tenderer is required to visit the sites and shall have inspected and
examined the same as well as its surroundings and obtained information in
connection therewith and have satisfied himself before submitting his
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Proposal , as to the form and nature thereof including the subsurface

conditions, the hydrological and climatic conditions, existing services , the
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requirements of authorities such as Jabatan Alam Sekitar, the relevant

planning approval and local authorities having jurisdiction over the Works,
the extent and nature of work and materials necessary for the completion of
the works, the means of access to the sites and the accommodation he
may require and, in general, shall have obtained all necessary information ,
as to risks , contingencies and all other circumstances which may influence
or affect his Proposal.
MEMBINA JALAN DARI BEH OR MALI KE KAMPUNG KEPALA SEPULOH, PERLIS

Any such information forwarded by the Government shall not relieve the
Tenderer of his obligations under the provisions of this Clause . The
Government gives no guarantee for the information either, as to the
accuracy or sufficiency, or as to how the same should be interpreted or
otherwise howsoever and the Tenderer shall make use of and interpret the
same entirely at his own risk.
13.0 SUFFICIENCY OF PROPOSAL
The Tenderer shall have satisfied himself before submitting his Proposal as
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to the correctness and sufficiency of his Proposal for the Works and the
Contract Sum Analysis, except in so far as is otherwise provided in the
Contract, shall cover all his obligations under the Contract and all matters
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and things necessary for the proper planning , design , construction ,
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supervision , completion , maintenance and guarantee of the works.
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14.0 DESIGN CONCEPT
The Conceptual Design Drawings are as attached in Government's

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Requirements on Technical Works (if applicable). The Tenderer shall take
note that the layout plan given are meant to serve a guide only. The
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Tenderer shall check the conceptual design & accept responsibility for it. In
the event that the Government Conceptual Design Drawings is deficient in
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the aspect of suitability, functionality and safety, the Tenderer shall modify
so as to rectify the same and shall be liable and guarantee that the
proposed design is independent of fault pursuant to the Government
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Requirements.
The Tenderer is deemed to have assumed full and total responsibility for
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( adopting the Government Conceptual Design Drawings as though they

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were his own and for evolving and developing his detailed design from
these drawings.
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The Tenderer hereby warrants that the said designs are in all respects
adequate , accurate , sufficient and fit for their purposes and that the said
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designs when developed by him will meet the Government's Requirements.
The Tenderer shall develop the aforementioned designs so as to procure a

complete detailed Final Design of the Works. Each and every part thereof
will when completed jointly and severally be in all respects fit for its or their
purpose and in particular without limiting the generality of the foregoing ,
such that the Works as a whole and as appropriate part thereof shall meet
the Government's Requirements.
MEMBINA JALAN DARI BEHOR MALI KE KAM PUNG KEPALA SEPULOH, PERLI S
15.0 DRAWINGS, SPECIFICATIONS AND GOVERNMENT REQUIREMENTS
The Tenderer shall take note that the drawings, specifications, and
Government's Requirements issued are meant to serve as a guide only and
the Tenderer shall submit their own proposal for the evaluation and
consideration by the Government. The specifications proposed shall not be
inferior to those described in the Government's Requirements.
16.0 CONTRACTOR'S DESIGN, MATERIALS, GOODS AND WORKMANSHIP
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The Design and Specifications proposed by the Contractor shall not be
inferior to those described in the Government Requirements where
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applicable.
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16.1 Design, Execution, Completion and Maintenance*
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Notwithstanding to the provisions of Clause 14.0 of the Conditions of
Contract, the Tenderer shall be fully responsible for the design,
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execution, completion and maintenance* of the Works which have been
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accepted by the Government and shall take full and unequivocal

responsibility for the functionality, suitability, compatibility and safety of
the design and the adequacy, stability and safety of all site operation
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and methods of construction.

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The approval or acceptance of the design by the Government shall not

absolve the Tenderer from its responsibility. The Tenderer shall be
liable and keep the Government indemnified for any design defects,
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( damage, inadequacies, or insufficiency of such design.

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16.2 Materials, Goods and Workmanship
All materials, goods and workmanship shall comply to the respective

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kinds and standard described in the Government's Requirements or if

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not therein, as specifically described in the Tenderer's Proposals or

specifications it shall not be substituted to anything else without the
consent of the p.o.
17.0 CURRENCY TO BE USED IN THE TENDER
The total of the Tender Sum shall be quoted in Malaysian currency that is
in Malaysian Ringgit.
MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH. PERLIS

18.0 METRIC SYSTEM
All plans and specifications submitted by the Tenderer shall be in the

International System of Units (S .I) of measurement, commonly known as
the metric system .
19.0 MATERIALS, EQUIPMENTS AND MACHINERIES
Before the issuance of the Certificate of Practical Completion for the whole
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of the Works under this contract, the Tenderer is required to have satisfied
the Project Director that all materials and equipment supplied and
incorporated into the Works are new and unused and are of the best quality
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with regard to the design , manufacture and performance.
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( All equipment and machineries which is to be installed and incorporated as
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part of the permanent works shall be manufactured by companies having
agents in Malaysia for the subsequent maintenance and repair of the
equipment and machinery.
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20.0 LANGUAGE
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For the purpose of this tender the language used shall be English. All
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submissions including plans, specifications, etc. forming the Tenderer's

tender document shall accordingly be in English. Provided that nothing in
this Contract shall invalidate any instruction or notice or certificate given to
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the Contractor or his authorised representative in Bahasa Malaysia or

English.
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<- 21.0 REGISTRATION AS A GOVERNMENT CONTRACTOR

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Tenderers are required to be registered and obtained Perakuan

Pendaftaran Kontraktor (PPK) and Sijil Perolehan Kerja Kerajaan (SPKK)
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with Construction Industry Development Board (CIDB) or Perakuan

Pendaftaran Kontraktor (PPK) and Unit Pendaftaran Kontraktor dan
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Juruperunding (UPKJ) Negeri Sarawak or Perakuan Pendaftaran

Kontraktor (PPK) and Pusat Pendaftaran Kontraktor-Kontraktor Kerja,
Bekalan Dan Pekhidmatan Negeri Sabah (PUKONSA) as shown in Table
1.
MEMBINA JALA N DARI BEHOR MALI KE KAMPU NG KEPALA SEPULOH, PERLI S

Tender Procurement in
Contractor's
Registration Peninsular
Sabah Sarawak
Malaysia
PPK & SPKK
" " "
PPK & PUKONSA
" " X
PPK & UPKJ

" X
"
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Table 1
Tenderers must obtain Siji/ Taraf Bumiputera from relevant authority if and
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when required . Tenderers shall submit the current registration certificate
issued by the said authority together with his Proposal.
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(
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The Tenderer shall ensure that his registration is valid throughout the
execution of the said Contract. The Tenderer shall ensure that all his Sub-
Contractors/Suppliers are registered with relevant authorities.
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22.0 ACCEPTANCE OF TENDER

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The Government reserves the right to accept any tender or to reject all the
tenders or to accept in whole or in part, a particular tender.
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The final decision of the Agency Tender Board / Ministry of Finance (MOF)
on the award of the Contract will be made available for public viewing at the
agency's notice board . The public will be able to view the name of the
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( successful Tenderer, Contract Amount and the Date for Completion as

soon as practically possible after the Letter of Acceptance is duly signed by
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both parties concerned .
23.0 ADVERTISEMENT
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Tenderers are not allowed to publish any information regarding the tender
in any form of media .
24.0 PERIOD OF VALIDITY OF TENDER
Tenders shall remain valid for a period of up to 180 days from the date of
Closing of the Tender. However, the Government reserves the right to
extend the validity of the said period .
MEMBINA JALAN OARI BEHOR MALI KE KAMP UNG KEPALA SEPULOH , PER LIS
25.0 TENDERER'S INFORMATION
The Tenderers are required to submit the following documents with the
tender for evaluation of the tender:
Surat Pengakuan Kebenaran Maklumat dan

a) BORANG A
Kesahihan Dokumen Yang Dikemukakan Oleh
Petender
b) BORANG B Maklumat Am dan Latar Belakang Petender
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c) BORANG G Senarai Kontrak Kerja Semasa
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d) BORANG Laporan Penyelia Projek Atas Prestasi Kerja
GA Semasa Petender
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(
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The Tenderer MUST fill in, sign and submit a completed Borang A.
Failure to submit a completed Borang A will result in Tenderer not
being eligible for evaluation .
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The Tenderer shall list down their current project in Borang G. Submit
a copy of Letter of Acceptance (LA) for each works for each current job
listed in Borang G. For the Tenderers who do not have a current job,
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please note "No Current Job" in Borang G.

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Sealed original report(s) from the Project Supervisor on the current

performance of the tenderer, for each current job listed in Borang G, in
a format as Borang GA. The report must be signed by the
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Superintendent / Deputy Superintendent / Professional Officer who

( supervise the listed project.The tenderer MUST complete the Borang
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GA and submit the form with the prescribed supporting documents.

Failure of the Tenderer to declare current employment will result in the
tender being rejected.
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For joint venture or joint tender tenderers between two or more

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contractors, each member of the joint venture must each complete the
forms and enclose the above documents described above separately.
All information and documents mentioned above must be submitted by

the Tenderer together with his tender before the Tender Closing Date.
Any information or any such documents received after the tender is
closed will not be taken into account in the Tenderer's assessment.
If the Tenderer is found to provide false information or deliberately

withhold or not provide any information that has a negative impact on
MEMBINA JALAN DARI BEHOR MALI KE KAM PUNG KEPALA SEPULOH , PERLI S
its ability, his tender will be rejected and disciplinary action will be taken
against Tenderer's.
26.0 TENDERER'S PROPOSAL
The tenderer shall take note the following conditions:
26.1 Design
All design by the tenderer shall be carried out in accordance to the
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latest standard engineering practice and shall be approved by local
and central authorities if required .
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26.2 Quantity
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(
Any quantities and figures as indicated in the tenderer's proposal for
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any system or portion of work shall be taken as purely indicative
only. No extra cost shall be entertained if such increase is an
essential part of the completion of the whole works or systems.
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26.3 Discrepancy
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Where there is any discrepancy within the Tenderer's Proposal, the

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Project Director shall have the right to decide between the discrepant
items and the Contractor shall comply with the decision without any
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cost incurred to the Government.
26.4 Detailed Drawings

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<- Any drawings shown in the Tenderer's Proposal are considered as the
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complete working drawings to be used for the completion of the whole

of the works. Any necessary updating/modification or enhancement to
design subsequently made in order to suit the final accepted layout
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shall not be treated as variation to the contract.

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26.5 All temporary, protection and other works need to be carried out during
construction must be submitted in proposal.
MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH , PERLIS

27.0 PERIOD OF COMPLETION
The completion of this project not more than 4.~ ..m9.!,)~!'!~. from the date of
possession as stated in the Letter of Acceptance. Tenderer are advised to
offer a suitable and reasonable completion period in the Tender Form of
the Pre-bid Documents but shall not be more than the period stated above.
28.0 MAINTENANCE OF WORKS
The Tenderer's attention is drawn to Clause 52 of the Conditions of
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Contract whereby the successful tenderer will be required to maintain the
whole of the Works contained in the Government's Requirements for a
period of Twenty Four (24) months from the date of Practical Completion of
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the works.
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( 29.0 PARTICIPATION PROGRAMME OF GRADE 'G1' AND 'G2'
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BUMIPUTERA CONTRACTORS (FOR PROJECT ~ RM10 MILLION
ONLY) A
The Tenderers are required to sub-contract part of the work to Bumiputera
subcontractor(s) Grade G2 and Grade G1 in accordance to Surat Arahan
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KPKR Bil. 2/2010 for the sum allocated as Provisional Sum (PS) for
Bumiputera Contractor Grade G2 and Grade G1 in the Contract Sum
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Analysis (Appendix 4 of the Condition Of Contract).
The Contractor will be paid Profit and Attendance for the execution of the
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subcontract work(s). The implementation of this policy shall be in

accordance to Appendix C.
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( 30.0 IMPLEMENTATION OF INTEGRITY PACT

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Tenderers must submit a Letter of Integrity Pact (Bidder's Declaration) as

shown in "Appendix D", together with the Tender Document in which it
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covenants not to offer or give bribes to any other individual as a bribe to be

selected in the bid. Company representatives who signed the Letter of
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Integrity Pact shall also attach a Letter of Power Delegation on behalf of the
Company.
That Letter of Integrity Pact is one of the documents required for the
assessment of quotation/first stage tender evaluation. If the tenderer fails to
submit the Letter of Integrity Pact signed by the qualified officers, the
tenderer will be assessed as FAILED in the first stage of evaluation (failure
to submit required documents) and no further assessment will be
conducted .
MEMBI NA JALAN DARI BEH OR MALI KE KAMPU NG KEPALA SEPULOH , PERLI S

The successful Tenderer must submit the 'Letter of Integrity Pact
(Successful Bidder's Declaration) as shown in "Appendix D", together with
a Letter of Acceptance, which were signed in which it covenants not to give
bribes in return for obtaining contracts. Company representatives who
signed that Letter of Integrity Pact for Successful Bidder also need to attach
a Letter of Power Delegation on behalf of the Company. This Letter of
Integrity Pact for Successful Bidder will be part of Contract Documents.
31.0 CONSTRUCTION INDUSTRY DEVELOPMENT BOARD (CIDB) SCORE

CERTIFICATION
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The Tenderer is required to submit a valid SCORE Certificate with a
minimum rating of three (3) stars from the CIDB .
D
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32.0 ENVIRONMENTAL MANAGEMENT PLAN (EMP)
(
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As stated in the Contract Specification issued by JKR on behalf of the
Government of Malaysia, the tenderer shall comply with all legal duties and
obligations regarding the protection of environment as laid in the
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Environmental Quality Act 1974 (Act 127). Before the commencement of
works, Tenderer shall submit to the Project Director (P.D), an
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Environmental Management Plan (EMP), detailing the Tenderers proposed

arrangement for the abatement and mitigation measures for environmental
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protection , environmental monitoring , testing programmed and reporting,

and his organisation chart.
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32 .1 Condition of Contract
The Tenderer shall submit for the S.O.' approval an Environmental

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( Management Plan (EMP) as specified in Appendix A13 before

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commencement of site clearing and earthwork activities on site. In

the event if the Tenderer fail to submit such plan, then the
Government deserve that right to prepare such plan and the cost
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incurred shall be deducted from the contract sum . The cost of

preparing the EMP shall include the cost involved in obtaining the
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services of Registered Environmental Consultant as is deemed to be

borne by the tenderer.
32.2 The Environmental Impact Assessment (EIA) report and the

Condition Condition of Approval given by the Department of
Environmental (DOE), where possible, will be made available by the
Government to assist the Tenderer and Environmental Consultant in
preparing the EMP.
MEMBINA JALAN DARI BEH OR MALI KE KAMPUNG KEPALA SEPULOH, PERLI S

33.0 GREEN RATING IMPLEMENTATION·
Penarafan Hijau JKR Manual - Road Sector (RS)
This project uses the pH of JKR Road Sector to measure the level of
sustainability to be achieved . This certification is for encourage the
development of sustainable projects so that it can reduce operating costs,
maintenance costs and minimizing the impact on the environment. This
project shall meet the green requirements stipulated in the Government
Need Statement.
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34.0 PARTICIPATION IN PROFESSIONAL TRAINING AND EDUCATION FOR
GROWING ENTREPRENEURS - READY TO WORK (PROTEGE - RTW)
D
Contractor shall comply and follow strictly all requirement as per
Government's Professional Training and Education For Growing
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( Entrepreneurs (PROTEGE - RTW) programme . The implementation of this
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policy shall be in accordance to as detailed out in Appendix F.
35.0 UTILITIES SERVICES

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Tenderer shall take note of utility services such as water pipes, cables and
other utility services along the road alignment and shall arrange their work
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accordingly and take into account the protection/ removal and relocation of
the utility services.
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The protection, removal and re-installation of assets of utility services

permanently will be carried out by Asset Owner/ The Utility Company. All
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relocation works related to utilities and services shall be carried out

accordance to 'Garis Panduan Perlindungan, Pengalihan Dan
Pemasangan Semula Utiliti dalam Perlaksanaan Program Dan Projek
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<. Kerajaan RMKe -12', 'Nota Panduan Perlindungan, Penga/ihan Dan

Pemasangan Semula Utiliti dalam Perlaksanaan Program Dan Projek
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Kerajaan RMKe-12' (Pindaan 2022) and 'Surat Arahan KPKR Bil.13/2023 '.
For water supply and sewerage system for public purposes, the application
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of above guidelines is excluded and the works will be carried out by the
main contractor without attendance fee . Attendance fee will only be paid to
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the main contractor if relocation and protection of uti lies services works
carried out by the asset owner or utility company.
In the circumstances which the Project Director (PO) decided the works
(except for public related utility services i.e water supply and sewerage) to
be carried out by asset owners/utility companies, deduction and adjustment
to the Contract shall be made accordingly. The contractor shall not ceased
his obligation to provide attendance for the work carried out by the asset
owners/utility companies as stated in the guidelines.
MEMBINA JALAN DA RI BEHOR MALI KE KAM PUNG KEPALA SEPU LOH . PERLI S
36.0 BUILDING INFORMATION MODELLING (BIM) REQUIREMENTS
This project will be using the BIM technology and BIM tools to execute BIM
related activities in the project's planning , design , construction , equipping ,
supervision , testing , commissioning and maintenance phases to enhance
the performance of the project delivery and to improve the overall quality of
the project.
For this purposes, the Tenderer will not be reimbursed for any expenses
incurred in the preparation and submission of his proposal.
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The Tenderer is required to submit his proposal for this project using BIM
tools as specified in the Government's Requirements . The requirements
shall include the modelling , visualization , analysis and design
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documentation of the building's design and shall assist in validating the
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( scope of the project. The principal objective of incorporating BIM is to
improve the quality of design solutions and the exchange of information
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between the relevant stakeholders. This requires cooperation among the
Contractor's project team. The use of BIM in this project shall involve the
processes of creating BIM models, build the required Models, analyses and
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produce design documentation from the Models.
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BIM shall be used for the roads design which include but not limited to the
civil works and structural, geotechnical works, electrical works and others
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work including specialty equipment. During design development phase,

BIM technology shall be used to develop and establish the basis of design
in accordance with the Government's Requirements. The model shall
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include all geometry, physical characteristics, materials, specifications and

product data needed to describe the design , construction and as-built work
towards the asset life cycle. The Tenderer shall comply with the
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( Government's Requirements for all BIM related works.

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37.0 REMINDER PERTAINING TO THE OFFENCE OF CORRUPTION

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All tenderers are reminded not to be involved in the criminal activities of

corruption in relation to this procurement. Therefore all tenderers are
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reminded as follows:
(i) Any act or attempt to corruptly offer or give, solicit or receive any
gratification to and from any person in connection with this
procurement is a criminal offence under th e Malaysian Anti-
Corruption Act 2009 (Act 694).
(ii) If any person offers or gives any gratification to any member of the
public service, the latter shall at the earliest opportunity thereafter
MEMBI NA JALAN DAR I BEH OR MALI KE KAMPUNG KEPALA SEPULOH, PE RLI S

lodge a report at the nearest office of the Malaysian Anti-Corruption
Commission or police station . Failure to do so is an offence under
the Malaysian Anti-Corruption Act 2009 (Act 694).
(iii) Without prejudice to any other actions, disciplinary action against a

member of the public service and blacklisting of the contractor or
supplier may be taken if the parties involved with any act of
corruption under the Malaysian Anti-Corruption Act 2009 (Act 694).
(iv) Any contractor or supplier who makes a carried out or no goods
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were supplied or no services rendered in accordance with the
specifications and any member of the public service who certifies the
claim commits an offence under the Malaysian Anti-Corruption Act
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2009 (Act 694).
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( 38.0 PROHIBITION OF COMPANY EQUITY TRANSFER DURING THE
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CONTRACT PERIOD
The Successful Tenderer for this project is prohibited to transfer equity

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owned by the company during the contract period unless approval is
obtained in writing the GOVERNMENT of MALAYSIA in advance.
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39.0 COMPLIANCE WITH ACT 342 AND NEW NORMS IN THE

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CONSTRUCTION SECTOR AND IN HANDLING EPIDEMICS AND

PANDEMIC COVID-19
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Successful tenderer are required to comply with the prevention and Control
of Infectious Diseases Act 1988 (Act 342) and all relevant standard
operating guidelines and procedures in dealing with epidemics and
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( pandemic outbreak such as Covid-19 issued by Ministry of Health

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Malaysia, CIDB and Public Works Department Malaysia . The Tenderer

must take into consideration the compliance in the tender price.
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Failure to comply with the said standard operating guidelines and

procedures may cause action to be taken by the relevant agencies and any
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claims arising from this action will not be considered .
MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH . PERLIS
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40.0 CONSTRUCTION INDUSTRY DEVELOPMENT BOARD (CIDB) LEVY
All tenderers are reminded that they are subjected to a levy of 0.25% of the
contract price value for the work more than RM500 ,000 .00 as stipulated
under Section 34(2) of the Construction Industry Development Board
(CIDB) Act 1994 (Act 520). The said amount should be borne by the
Tenderer.
41.0 DEPARTMENT INDICATIVE PRICE
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The Department's Indicative Price for this tender is Ringgit Malaysia :
SEVENTY EIGHT MILLION SIX HUNDRED TOUSAND ONLY
(RM78,600,OOO.00).
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This Department Indicative Price is an estimate only and the amount is not
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binding on the Government or any other party also for the purpose of
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avoiding confusion that may arise.
The Government does not warrant that the company will be selected or
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able to complete the work based on the Department's Indicative Price.
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42.0 TENDER SUM ANALYSIS
Tenderer shall require to price based on Tender Sum Analysis. The

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tenderer is required to complete the Tender Sum Analysis as shown in

Appendix 4.
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( Upon acceptance of tender the Tender Sum Analysis shall be the Contract
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Sum Analysis.
The Tenderer shall submit together with his tender, an adequate

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breakdown of the tender prices for different portions of the Works where
appropriate such as the Design and Built Element, Preliminaries and
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General Conditions, and all the related works etc., as shown in the form for
Contract Sum Analysis in Government's Requirement Appendix 4.
Upon acceptance of his tender by the Government, the tenderer shall

submit within three (3) weeks of the said acceptance, a make-up of tender
prices which shall be sufficiently detailed and in a format acceptable to the
p.o. showing a breakdown of the different portions of the Works as
MEMBINA JALAN DARI BEH OR MALI KE KAMPUNG KEPALA SEPULOH, PERLI S

aforesaid including the Design and Build Element and Preliminary Items so
as to enable the P.O. or his representative to efficiently carry out valuations
for the purpose of interim valuations under Clause 53.
The Tenderer's attention is drawn to Clause 52 of the Condition of Contract

whereby the successful tenderer will be required to maintain the whole
Works contained in the Government's requirements for a period of Twenty-
Four (24) months from the date of Practical Completion of the Works
43.0 COST OF TENDERING
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The Tenderer will not be reimbursed for any expenses incurred in the
preparation and submission of their proposals.
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( 44.0 TENDERER'S PROPOSAL ON PRODUCTS
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The Tenderer is required to state in his proposal the exact brand names,
models, grades and other relevant particulars and prices of all equipment
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and other products offered .
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45.0 GENERAL DEFINITIONS

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The word "Project Director" and "Superintending Officer (S.O.)" and

"Pengarah Projek" (P.P)" and/or "Engineer" where appears in the Pre-bid
Document shall be synonymous.
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46.0 DESIGN FEE

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( The Tenderer shall design for works under Lump Sum Component,
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Provisional Quantities Component (if applicable) and Provisional Sum

items executed by Grade G1 and G2 Bumiputera Contractors only. The
Tenderer is not required to design for other items (if any) covered under
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Provisional Sum Component in Appendix 4 to the Conditions of Contract.

As such the Tenderer is to ensure the amount priced as the design fee is
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only for the applicable works indicated above.
If the Contractor is instructed by Project Director to prepare design for

works under the Provisional Sum Items EXCEPT works executed by Grade
G1 and G2 Bumiputera Contractors, the design fee shall be valued and
paid together with the said works. The Contract Sum shall be adjusted in
accordance with the expressed provisions of the Conditions of Contract.
MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH. PER LI S
•
47.0 NO ALTERNATIVE DESIGN
The Tenderer is to note that alternative proposals will not be allowed either
at the tender stage or during the construction stage. Any submissions
based on alternative proposal shall be disregarded and not considered.
However variations can be effected to the Works or design if it is

considered necessary for the purpose of suitability, functionality and safety
of the Works and any cost arising therefrom shall be dealt with in
accordance with the provisions of the Clause 23 and 24 of the Conditions
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of Contract.
48.0 POSSESSION OF SITE
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The Tenderer is to note that this project involves the acquisition of some
( private land and properties along the stretches of the project. However this
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possession of site may not be for the complete works as the process of
land acquisition is still expected to continue. The Tenderer is required to
commence work on whatever portion of land that is made available by the
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Date of Possession of Site stipulated in the Letter of Acceptance of Tender
and shall plan and sequence his works accordingly and reflect this in his
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works programme.
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The tenderer is expected to take into account this delayed commencement

of work as no claim for additional payment or extension of the completion
time on the ground of ignorance of this requirement will be entertained ,
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should possession of site be given by the date stipulated in the Letter of

Acceptance of Tender.
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(, This provision shall however in no way waive the right the Government has,
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to revise the date of possession of site in accordance with Clause 12 of the

Conditions of Contract.
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49.0 REFERENCE INFORMATION

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The results of subsurface exploration and topographical, hydrographic and

land surveys already carried out by the Government are shown in
Appendix 'E'.
The Tenderer is to note that the data shown in Appendix 'E' to these
Instructions DOES NOT FORM PART OF THE CONTRACT but is only
given for information to assist the Tenderer in their preliminary design only.
The giving of this information shall not relieve the Tenderer of his
obligations under the provisions of this contract. The Government gives no
MEMBINA JALAN DARI BEHOR MALI KE KAM PUNG KEPALA SEPULOH. PERLI S
warranty for the information or document either as to the accuracy or
sufficiency or as to how the same should be interpreted or otherwise
howsoever and the Tenderer shall make use of and interpret the same
entirely on his own risk.
The Tenderer shall undertake additional soil investigation, surveys and

other works in order to ascertain and confirm information already given and
satisfy himself fully as to the true nature and extent of the works required
such that the design and construction of this project will be completed fit for
its intended purpose .
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50.0 TRAFFIC MANAGEMENT AT CONSTRUCTION WORK ZONES
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As stated in the contract specification issued by JKR on behalf the
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Government of Malaysia , the tenderer shall comply with all legal duties and
( obligations regarding Traffic Management at Work Zones as laid in the
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latest Arahan Teknik (Jalan).
Before the commencement of works, Tenderer shall submit to the p.o. for
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approval the Traffic Management Plans (TMP), Standard Operating
Procedure, Daily Records Format and appointed qualified Traffic
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Management Officer responsible for the operations and maintenance of the

traffic control of the work zones.
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51.0 STANDARDS
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All workmanship , materials and components throughout shall comply with

either:
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( (a) Malaysia Standards or Codes of Practice current at the date of

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closing of Tender, or if not available;
(b) British Standard or Code of Practise shall apply; or

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(c) Other Standards or Codes of practice proposed by the Tenderer

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provided that these Standards or Codes of Practice are equivalent or

superior to the relevant Standards or Codes of Practice previously
mentioned and shall be provided by the Tenderer with the Tender.
If the Tenderer wishes to propose alternative Standard or Codes different

from those stipulated in the Specification, then such Standards or Codes of
Practice proposed must be equivalent or superior to the relevant Standard
or Codes of Practice stipulated in the Specification.
MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH, PERLI S

Acceptance of such alternative Standards or Codes of Practice at the
acceptance of Tender shall only be acceptance in principle. The successful
Tenderer shall be required to comply with the specified Standards or Codes
of Practice if any deviations are found between the specified and the
alternative Standards or Codes of Practic
52.0 QUALITY CONTROL
All quality control tests specified and directed by the P.D. shall be
witnessed and certified by a Professional Engineer (P.Eng .) registered with
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the Board of Engineers Malaysia.
53.0 PERFOMANCE BOND 1 PERFOMANCE GUARANTEE SUM
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The Tenderer are strictly subjected to all requirement as per "Surat Arahan
( KPKR Bil. 4/2018 - JKR.KPKR:121 .0101051 Jld.12 (8) dated 15 February
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2018.
The Contractor shall , on the date of the possession of Site, provide a

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Performance Bond or Performance Guarantee Sum as the case may be
substantially in the form as in Appendix issued by an approved licensed
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bank or financial institution incorporated in Malaysia in favour of the

Government for a sum equivalent to five percent (5%) of the total Contract
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Sum as specified to secure the due performance of the obligations under

this Contract by the Contractor.
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The Performance Bond shall remain valid and effective until twenty four
(24) months after the expiry of the Defect Liability Period or the issuance of
the Certificate of Completion of Making Good Defects, whichever is the
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54.0 SUBMISSION OF TENDER

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The Tenderer shall submit a proposal containing all information and

particulars called for in the Pre-bid Documents. Any tenderer who submit
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more than one (1) proposal will be disqualified . In the submission of his
Tender, the Tenderer is required to submit the Pre-bid Documents, filled in
and complete in all respects , properly sealed and marked in the following
manner:
MEMBINA JALAN DARI BEH OR MALI KE KAMPUNG KE PALA SEPULOH. PERLIS

SECTION I - GENERAL AND CONTRACTUAL PROPOSAL
(i) Instructions to the Tenderers including Appendix;

(ii) General & Contractual Requirement
(iii) Form of Tender
(iv) Letter of Acceptance
(v) General Conditions of Contract and Addendum to the Conditions of
Contract
(vi) Tender Sum Analysis (marked as Appendix 4 in the Conditions of
Contract) and the priced Bills Quantities
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(vii) Programme of Works
(viii) Tenderer's key personnel
(ix) Tenderer's organisation chart showing the personnel involved in the
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planning , design and the construction of the Works
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(x) List of Consultants approved by the Department
( (xi) List of Works, Supply and Services to be sublet to Bumiputera
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Organisations and Professionals
(xii) Other documents for Tender Evaluation.
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SECTION" - TECHNICAL PROPOSAL
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Technical proposals containing all the technical details of the project

including preliminary design and report , specification and relevant
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standards and drawings and marked in the following manner:-
Part 1 - Civil & Structural Works

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Part 2 - Electrical Works
The Tenderer shall be required to submit eight (8) sets in two (2) sections
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( of the Pre-bid Document together with drawings and specifications

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including one original copy. The tenderer also shall submit the softcopy of
design proposal drawings in respective technical volume.
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The original copy of th e Pre-bid Document shall be properly signed,

witnessed and dated and shall be marked 'ORIGINAL'.
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All the above mentioned documents, must be wrapped and sealed as one
whole bundle/bundles. The bundles must be written the project title as
below :
M.!;.M~!NA ... }A.I,..AN ... 'p'.~g.l.....~.~HQ.I:L . M.Aq ....K!;.....MM.P..\,I.NG ....~.!~:.r:~A.I,..A

.~~. P.V ~Q.I:! J•• p..!; g.!,,!~.
MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH. PERLIS

All tenders shall be submitted so as to arrive at the office of the
UNIT TAWARAN PUSAT,

CAWANGAN PENGURUSAN PEROLEHAN DAN HARTA,
TINGKAT BAWAH, BLOK A
KOMPLEKS KEMENTERIAN KERJA RAYA,
JALAN SULTAN SALAHUDDIN,
50582 KUALA LUMPUR.
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not later than 12:00 noon as stipulated in Surat Pelawaan
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If the Tenderer chooses to submit the Pre-Bid Document by using the
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courier service, the tenderer must ensure that the document arrives safely
( at the designated place before or on the Tender Closing Date no later than
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12.00 pm.
Any delay arising in the matter will not be entertained . Proof of delivery
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between the Tenderer and the courier company is not considered as proof
of receipt by the tender closing office. All costs to submit the Pre -Bid
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Document using the courier service are fully borne by the Tenderer.
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MEMBINA JALAN DARI BEHOR MALI KE KAM PU NG KEPALA SEPULOH. PERLI S

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( APPENDIX A
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LIST OF PROPOSED CONSULTANTS
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...I ' ~ APPENDIX " A'
LIST OF PROPOSED CONSULTANTS
PROJECT MEMBINA JALAN DARI BEHOR MALI KE KAM PUNG KEPALA SEPULOH, PERLI S
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CONTRACTOR :
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CONSULTANT 'Architect! Civil & Stru ctural Eng ineerl Mechanical Eng ineerl Electrical Engineerl Quantitiy Surveyorl
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. .. . .... (others please sta te)
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NO. NAME & ADDRESS OF FIRM EQUITY NO. OF PROFESSIONAL EXPERIENCE
Bumiputera Non-Bum iputera STAFF (List Projects)
(state discipline)
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, Delete whichever is not relevant. The contractor is required to submit the company profile including curriculum vitae of all professional staff
of the consultant proposed to enable the Government to make an assessment
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( APPENDIXB
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GENERAL GUIDELINES FOR THE
PREPARATION OF THE ENVIRONMENTAL
MANAGEMENT PLAN (EMP) - BY THE
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CONTRACTOR
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APPENDIX B
ENVIRONMENTAL MANAGEMENT PLAN (EMF) STANDARD REPORT

FORMAT FOR JKR PROJECTS
1.0 Definition of EMP
An EMP is basically a documentation of administrative environmental management

and coordination procedures for onside management in order to ensure that all
development activities complies with the EIA approval conditions as stipulated by
DOE. It must show the commitment of the project proponent in terms of
accountability and availability of resources. An EMP should be improved and adapted
throughout the life of the project to reflect changing conditions. It must also be
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subjected to periodic review to ensure it' s continues relevance and validity.
2.0 Objectives of EMP
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The main objectives of the Environmental Management Plan (EMP) is to set out a
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( comprehensive programme which will form the basis for implementing environmental
mitigation measures, environmental monitoring and environmental auditing of the
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construction works by the Contractor as listed below:
(a) To set out various environmental protection / conservation measures that

conform to the environmental conditions stipulated in the Specifications, EIA
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report and by other relevant authorities (e.g. the Department of Environment
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(DOE);
(b) To ensure that the Contractor comply with all applicable environmental
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standards and guidelines, legislative requirements and other relevant

conditions related to the environment;
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(c) To specify a detailed environmental monitoring and auditing programme to

ensure that the Contractor and all his Sub-contractors comply with all
stipulated requirements throughout the duration of the project; and
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(d) To streamline the different functions of various sections and authorities related
<- to the environmental matters during the construction.
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3.0 General Information about the Project

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The following details are needed to help commence the preparation ofthe EM P:-
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(i) Project Contractor

(ii) Project Title
(iii) Condition of Contract
(iv) Project Cost
(v) Duration 0 f Contract
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APPENDIXB
4.0 Information on EMP
The type of EMP that is being prepared can be divided into:-
(i) Compliance to EQA 1974

(ii) Compliance to JKR MS ISO 14001
5.0 Cover Page Information
The cover has to include the following information:-
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(i) Project & Document Title
(i i) JKR Logo
(iii) Contractor's Logo
(iv) Contractor' s Registration
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(v) DOE Approval Reference (if applicable);
(vi) Insertion page for document verification
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6.0 Executive Summary
The executive summary must manage to summarise the key elements of the project:-
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(i) Site Features
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(ii) Project Description
(iii) Identified Impacts
(iv) Proposed Mitigation
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(v) Conclusion
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7.0 Chapter I: Introduction
Key information needed to be detailed in Chapter I is:-

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( (i) Project Title

(ii) Details of Project Proponent
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(iii) Site Description

• Topography
• Drainage
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• Flora
• Fauna
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• Land use
• Geology & Soils
• Socio Economy
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APPENDIX B
(iv) Project Description

• Concept
• Components
• Activities
• Scheduling
8.0 Chapter 2: Environmenta l Requirement
This chapter has to outline the need for the EMP and has to detail the following:-
( i) Listing of all Environm enta l Requirements including any approval obta ined
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for the ESCP, MASMA, disposal site etc.
(ii) EIA ap proval conditions (if applicab le)
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9.0 Chapter 3: Environmental Policy
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( Chapter 3 has to state in the Policy in relation to Environment of the Project
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Proponent and elaborate on the objectives of the EMP:-
(i) Objectives of the EMP

(ii) Environmental Policy of the PP
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10.0 Chapter 4: Organisation Chart and Budget
Chapter 4 has to detail the aspects related to the Environmental Management Unit
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(EMU) and the allocations provided for Envi ronmental Protection:-
(i) Organisation chart of EMU

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(ii) Contact detail s of EMU

(iii) Job description of EMU
(iv) Training proposed
(v) Budget for EMP imp lementation
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I 1.0 C hapter 5: Mon itoring Program
Detailing of the env ironmental monitoring proposal for the project:-

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(i) Baseline in formation

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• Monitoring locations and justification of locations

• Validity of data
• Verification of data
• Frequency of mon itoring
• Sampling methodology and Accreditation of laboratory
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APPENDIXB
(ii) Proposed monitoring programme
• Monitoring locations and justification of locations

• Frequency of monitoring
• Accred itation oflaboratory to be used for sampling
• Report to be subm itted
12.0 Chapter 6: Auditing Programme
This chapter has to detail the auditing programme for the project:-
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(i) Audit elements
(ii) Frequency of audit
(iii) Reports to be submitted
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(iv) Types offorms used
(v) Registration detai ls of auditor
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(vi) Follow up action on audit
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13.0 Chapter 7: Identification of Aspect. Impact and Recommended Mitigation
Measures A
This chapter has to detail the identified significant aspects, impacts and their
corresponding site specific mitigation measllres:-
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(i) Site Cleaning and Biomass Management

(i i) Wildlife Protection Plan
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(iii) Social Acceptance Plan

(iv) Earthworks Description
(v) ESCP Description
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• Elements
• Staging
• Plans
• Implementation Schedule
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'- (v i) Stockpile Management

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(vi i) Slope Protection

(viii) Drainage
(ix) Logistics
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(x) Site Facilities

(xi) Solid Waste Management
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(xii) Schedu led Wastes Management

• Type of waste generated
• Estimated volume
• Storage, Collection and Disposal Plan
(xiii) Safety
(xiv) Traffic Control
(xv) Site Abandonment/Closing Plan
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APPENDIXB
14.0 Chapter 8: Environmental Contingency Plan
This chapter has to detail the contingencies related to the project:-
(i) Issued identified

• Flooding
• Landslide
• Fire
• Medical Emergencies
• Spillages
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(i i) Action Plan and Line of Communication
(iii) Contact Numbers of relevant Agencies
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15.0 C hapter 9: Performance Evaluation and Project Review
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( This chapter has to detail the analysis used to determine performance of the
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environmental Protection Measures and the recommendations for improvement:-
(i) Description of Analytical Methodology Used

(i i) Forms Used
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(iii) Recommendations for Improvement
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16.0 C hapter 10: Conclusion

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This chapter has to conclude the findings of the EMP:-
(i) Concluding Statements on site related issues and their corresponding

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mitigation measures.
17.0 Appendices
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Items to include in the appendix are:-
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(i) Data sources

(i i) Consultations held
(iii) Approvals obtained
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(i v) References
(v) Calculations
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(vi) Plans
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APPENDIXB
18.0 Figu res
The following figures a re mandatory to be included in the EMP: -
(i) Location plan

(i i) Layout of site and faci lities
(i ii) Organi sation chart of EMU
(iv) Location of water, ai r and noise monitoring stations (baseline)
(v) Location of water, air and noise monitoring stations (proposed)
(vi) ESCP
• Earth drain network
• Diversion channels
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• Silt traps/sediment basins locat ions
• Final discharge outlets
• Si lt fence
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• Gabions
• Check dams
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( (v ii) Overa ll Mitigation Plan
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• Location of sol id waste storage
• Location of schedu led wastes storage
• Toilets
• Stockpi le area
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• Boundary of site clearing
• Septic tanks
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• Grease traps
• Wash trough
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(vii i) Emergency Response chart for any Non-compl iances observed/identified

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( APPENDIXC
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DASAR PENGAGllIAN KERJA KEPADA
KONTRAKTOR BUMIPUTERA
GRED Gl DAN G2
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APPENDIX 'C'
ARAHAN KEPADA PETENDER
DASAR PENGAGIHAN KERJA KEPADA KONTRAKTOR BUMIPUTERA

GRED G1 DAN G2
(BAGI PROJEK BERNILAI RM10 JUTA KE ATAS SAHAJA)
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1.0 Am
1.1 Petender yang disetujuterima dikehendaki mengsubkontrakkan sebahagian

daripada kerja-kerja kepada Subkontraktor Bumiputera Gred G1 dan G2
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melalui Wang Peruntukan Sementara (WPS) yang diperuntukkan dalam
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( Senarai Kuantiti/Contract Sum Analysis.
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1.2 Kontraktor Utama akan dibayar Keuntungan dan Layanan (Profit &
Attendance) seperti yang telah dihargakan oleh kontraktor.
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2 .0 Perolehan Kerja Subkontrak dan Syarat-syarat Pelantikan
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2.1 Perolehan kerja subkontrak akan dibuat oleh Pegawai Penguasa/Pengarah

Projek (P.P) melalui Sebut harga, dan kontraktor perlu membuat perlantikan
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rasmi dan menandatangani satu perjanjian subkontrak dengan

Subkontraktor yang dilantik.
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2.2 Bagi projek Reka dan Bina, Skop kerja , rekabentuk, spesifikasi dan Senarai
Kuantiti hendaklah disediakan oleh kontraktor dan diserahkan kepada
P.PlWakil P.P. untuk tujuan pemanggilan Sebut harga.
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3.0 Kaedah Pembayaran
3.1 Semua bayaran bagi kerja-kerja subkontrak akan dibuat secara terus oleh
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Kerajaan kepada Subkontraktor yang dilantik. Bagi tujuan ini , satu Surat
Ikatan Penyerahan Hak dari Kontraktor Utama kepada Subkontraktor yang
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dilantik hendaklah dilaksanakan. Format Surat Ikatan Penyerahan Hak

adalah seperti di Lampiran H. Penyerahan Hak hendaklah mendapat
persetujuan P.P. seperti di Lampiran J terlebih dahulu .
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3.2 Sekiranya Kontraktor berhasrat untuk menyerahhakkan faedah kepada
bank/institusi kewangan , pihak Kerajaan hanya boleh membenarkan
penyerahanhak tersebut bagi nilai yang tidak melebihi 80% daripada
Harga Kerja Pembina. Ini adalah bagi menjamin kelangsungan bayaran
kepada Subkontraktor yang dilantik.
3.3 Kontraktor juga hendaklah mendapatkan daripada Subkontraktor yang

dilantik, 'Surat Jaminan Tanggung Rugi dari Subkontraktor kepada
Kerajaan ' seperti di Lampiran K dan hendaklah dikemukakan kepada P.P.
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4.0 Pelaksanaan Kerja Subkontraktor
4.1 Kontraktor Utama hendaklah mengawasi sepenuhnya pelaksanaan kerja-
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kerja Subkontraktor dari segi kualiti dan kemajuan kerja serta memberi
layanan (attendance) sewajarnya bagi membolehkan Subkontraktor
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( menjalankan kerja masing-masing .
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4.2 8agi Subkontraktor Gred G1 , kerja-kerja subkontrak adalah tertakluk
kepada peruntukan Tanggungan Kecacatan sebagaimana yang termaktub
dalam Perjanjian Subkontrak masing-masing. 8agi kerja yang dilaksanakan
oleh Subkontraktor Gred G2 pula , Wang Tahanan sebanyak sepuluh
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peratus (10%) hendaklah dipotong dari setiap bayaran interim sehingga
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mencapai jumlah maksimum lima peratus (5%) dari nilai subkontrak.
4.3 Kontraktor Utama hendaklah memastikan Subkontraktor memperbaiki

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semua kecacatan dan kerosakan dalam tempoh 6 bulan selepas kerja-

kerja subkontrak disiapkan. Sekiranya Subkontraktor gagal memperbaiki
kecacatan dalam tempoh tersebut, Kontraktor Utama adalah
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bertanggungjawab untuk memperbaikinya dan kos akan diambil dari Wang

Tahanan tersebut. Wang Tahanan atau bakinya Uika ada) akan
dikembalikan kepada Subkontraktor setelah semua kecacatan atau
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kerosakan diperbaiki dengan sempurna .

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4.4 Kontraktor Utama boleh menamatkan pengambilan kerja Subkontraktor

yang dilantik sekiranya didapati memungkiri tanggungjawab subkontraknya
dan seterusnya memaklumkan penamatan tersebut kepada P.P.
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LAMPIRAN H
CONTOH
DEED OF ASSIGNMENT
(Security for direct payments to third party)
THIS DEED OF ASSIGNMENT is made the ..... ... .. day of

.................... 20 ......... between ...... .... ................................................. .
having its registered office at ..... ..... ............ .. ... ...................................... .
(hereinafter referred to as "the Assignor") of the one part and
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... ... ... ... .. . ... ... ... .. . ... . ... .. . ... ... ... ... ... ... ... (hereinafter referred to as "the
Assignee") of the other part.
WHEREAS-
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1. The Assignor has been awarded by the Government of Malaysia
( (hereinafter referred to as "the Government") a contract numbered
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... .. . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. . .. . ... ... ... ... ... ... ... (hereinafter
referred to as "the Contract") for the
... ... ... ... .. . ... ... ... .. . ... ... ... (hereinafter referred to as "the Works") for the
A
sum of Ringgit ........ .................. .. ................. .. ................ ..... . ... .
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(RM .. ... ..... ..... ... .. ........... .) (hereinafter referred to as "the Contract Sum").
2. The Assignor has caused work to be executed and/or is desirous of causing

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' work /supply to be executed and the Assignee has agreed to execute
certain 'work/supply namely .... .... ....................................... .
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(hereinafter referred to as '''the Subcontract Work"/ the Subcontract Supply)

for the Assignor in the fulfillment of his obligations under the Contract.
3. The Assignor is desirous of assigning to the Assignee moneys due and

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( payable to the Assignor under the Contract as payment for the 'Sub-
contract Work! Subcontract Supply, up to a maximum value of
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Ringgit... ............. ... ........ . .... .. .. .. ........................ (RM .......... ......... .

(hereinafter referred to as the "Assigned Sum").
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4. The Government has through its authorized representative in a letter

... ... ... ... .. . .. . ... .. . ... ... ... ... ... ... ... .. . ... ... ... .. . ....... dated .................... .
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(attached herewith as Appendix A) given its approval for the assignment by

the Assignor to the Assignee moneys due and payable to the Assignor
under the Contract.
• Delete whichever is not applicable
C-3
NOW THIS DEED WITNESS as follows :
1. The terms of this Deed of Assignment shall be subject to the terms and
conditions imposed by the Government or its authorized representative in
granting its consent to this Assignment.
2. In consideration of the Assignee having executed and/or agreeing to

execute the ' Subcontract Work/Subcontract Supply, the Assignor hereby
absolutely assigns to the Assignee moneys payable now or hereinafter due
and payable to the Assignor under the Contract, not exceeding the
Assigned Sum .
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3. This assignment shall be irrevocable and shall remain in force for so long as
moneys due and payable to the Assignor under the Contract shall remain
unpaid by the Government.
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4. For the purposes of this Assignment, moneys due and payable to the
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( Assignor under the Contract shall be deemed to exclude moneys due and
payable to nominated subcontractors and nominated suppliers who, in
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accordance with the terms and conditions of the Contract shall be paid
direct by the Government to the nominated subcontractors and nominated
suppliers.
A
5. The Assignee shall be paid the value of the ' Subcontract Work/Subcontract
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Supply executed out of moneys due and payable to the Assignor under the
Contract in interim payments and the final payment shall be made in
accordance with the terms and conditions of the Contract.
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6. The amount to be paid to the Assignee in each interim payment shall be

ascertained based on claims certified by the Assignor or his authorized
EN
representative and submitted by the Assignee to the Superintending Office r

named in the Contract or his authorized representative not later than 3 days
before the date of interim valuation .
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7. In the event of the money due and payable to the Assignor in an interim
KU
payment is insufficient to pay the amount due to the Assignee in respect of

the ' Subcontract Work/Subcontract Supply executed , the deficiency shall be
paid to the Assignee in the next and subsequent interim payment(s) .
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8. If upon final payment under the Contract no money is received by the

Assignee or the amount received by the Assignee is less than the total
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value of the ' Subcontract Work/ Subcontract executed , the value of the
' Subcontract Work/ Subcontract Supply that remain unpaid shall be a debt
due from the Assignor to the Assignee .
C-4
9. The Assignor shall do all things and acts necessary to ensure that the
Government pays to the Assignee moneys otherwise due and payable to
the Assignor under the Contract in respect of the ' Subcontract
Work/Subcontract Supply executed by the Assignee.
10. The Assignor shall notify the Government of the execution of this Deed of
Assignment by lodging a stamped copy thereof with the Government or its
authorised representative.
11. Any charge to this Deed of Assignment and the stamp duty thereof shall be
borne by the Assignor.
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12. This Deed of Assignment shall be binding upon the successors in title of the
parties hereto and , if the party is an individual, upon his heirs, executors and
personal representatives.
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(
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A
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M
EN
M
(
KU
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D
• Delete w hichever is not applicable
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IN WITNESS WH EREOF the Parties hereto have hereunto set their hands
and seals on the day and year first above written.
SIGNED by )
)
Name: )
)
Capacity )
)
for and on beha lf of (Signature of Ass ignor)
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(Seal or chop of Assignor)
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in the presence of
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( Name: )
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)
NRIC No.: ) (Signature of Witness)
)
Address: )
A
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SIGNED by )
)
Name: )
EN
)
Capacity )
)
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for and on behalf of ) (Signature of Assignee)

)
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)
(Seal or chop of Assignee)
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in the presence of
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Name )
)
NRIC No. ) (Signature of Witness)
)
Address: )
C-6
LAMPIRAN J
KERAJAAN MALAYSIA
CONSENT BY GOVERNMENT FOR DIRECT PAYMENT TO THIRD PARTY

THROUGH DEED OF ASSIGNMENT
Reference: ... .. . .... .. .... .... . .. ..... .. ....... Office of: .... .. .. .... .... .. ... ...... ... ..... .
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Date: ..... .... ..... .. .. .... ..... ........ . .
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To: (Contractor)
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A
CONTRACT NO.: ... ..... . ..... . .... ... ... ... .. .... ... .. ... .... .
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WORK ..... ..... ...... ....... .... ... ..... .. ... ........ ...... ... .... .. ............. ..... ......... ...
I refer to your application ..... ......... ....... ... ... .... .... .... .......... ......... .. ... ...... ... .
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dated .. ... .... .. ... ... ... .. .... .. seeking the consent of the Governrnent to your
proposal to assign part of the Contract Sum by a Deed of Assignment to
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................................. , the Assignee.
2. Please be informed that the Government has consented to the said

assignment as contained in the Deed of Assignment, subject to the terms as
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( follows:
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a. Any obligation imposed upon the Government by the Deed of

Assignment shall not in any way prejudice or affect the rights of the
Government or the powers of the Superintending Officer under the
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terms and conditions of the Contract, including those relating to direct

payments to nominated subcontractors and nominated suppliers and
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deductions from any money otherwise due to you under the Contract.
b. Any payment made to the Assignee shall be deemed to be a

payment as if the same is paid to you under the terms and conditions
of the Contract and shall constitute a sufficient and valid discharge of
C-7
the obligations of the Government under the Contract to the extent of
such payment.
c. No terms of payment including any term for the payment of interest

for delayed payments which the Assignee may impose upon you
shall be imposed upon the Government by the Deed of Assignment.
d. You shall be liable and shall indemnify the Government against any
damage, expense, liability, loss whatsoever suffered by the
Government in the event of any claim or action taken by the
Assignee arising from the assignment.
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3. Kindly acknowledge receipt of this letter and confirm acceptance by the
Assignee and yourself of the terms stipulated above by appending your signature
and returning the same to me.
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Yours faithfully ,
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A (Superintending Officer)
l!We acknowledge receipt of the above Consent of the Government and confirm
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my/our acceptance of the terms imposed.

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EN
Signature of Assignor Signature of Assignee
Name: Name :
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Capacity: Capacity:
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for and on behalf of for and on behalf of

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(Seal or chop of Assignor) (Seal or chop of Assignee)
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LAMPIRAN K
(JKR 203Sub7 Pind.2010)
CONTOH
SURAT JAMINAN TANGGUNG RUG I

DARI SUBKONTRAKTOR KEPADA KERAJAAN
Surat Tanggung Rugi ini diberi pada ............... .. haribulan ........ ....... ......... 20 ...... .. .
oleh Kami ,
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yang beralamat (atau pejabat berdaftar yang terletak
di)
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kepada Kerajaan ................ .. .................. .. ..... (kemudian dari ini disebut "Kerajaan").
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( (2) Kerajaan telah melalui Kontrak No .............. .. ..................................... yang diikat
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pad a .......... . haribulan .......... .. .... .. ....... 20 ......... (kemudian dari ini disebut "Kontrak
Utama") di antara KerajaanA bagi satu pihak dan
(kemudian dari ini disebut "Kontraktor") sebagai pihak yang satu lagi, mengambil kerja
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Kontraktor bagi melaksana dan menyiapkan

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(kemudian dari ini disebut "Kerja Kontrak Utama").

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(3) Kami telah mengemukakan Sebut harga bagi

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(kemudian dari ini disebut "Kerja Subkontrak"), yang berkenaan dengan Wang Peruntukan
( Sementara terdapat dalam dan menjadi sebahagian dari Kontrak Utama .
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(4) Menurut peruntukan berkaitan dalam Kontrak Utama, kami telah dinamakan untuk
menjalankan dan menyiapkan Kerja Subkontrak ini di atas terma dan Syarat-syarat
Subkontrak (kemudian dari ini disebut "Kerja Subkontrak") yang akan diikat di antara
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Kontraktor dan Kam i.

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(5) Sebagai balasan ke atas pengakuanjanji Kerajaan untuk membayar terus kepada
Kami amaun yang disahkan sebagai kena dibayar kepada Kami dalam Perakuan-
perakuan Interim atau Perakuan Muktamad menurut dan tertakluk kepada peruntukan
yang berkenaan dalam Kontrak Utama dan Subkontrak ini, Kami dengan ini membuat
pengakuanjanji yang tidak boleh terbatal untuk melindungi dan menanggung rugi Kerajaan
terhadap dan dari :
C-9
(i) sebarang tanggungan Kerajaan kepada Kontraktor berpunca dari apa jua
disebabkan oleh Kerajaan membuat bayaran terus kepada kami; dan
(ii) sebarang tanggungan Kerajaan kepada Kontraktor berpunca dari apa jua
disebabkan oleh sebarang tindakan , kecuaian atau ketinggalan , atau sebarang
pecah kontrak, tidak mematuhi atau tidak melaksanakan peruntukan Syarat-syarat
Subkontrak oleh Kami , pengkhidmat atau ejen Kami ; dan
(iii) sebarang kerugian dan /atau perbelanjaan yang ditanggung oleh Kerajaan berpunca
dari apa jua disebabkan oleh sebarang tindakan , kecuaian atau ketinggalan , atau
sebarang pecah kontrak , tidak mematuhi atau tidak melaksanakan peruntukan
Syarat-syarat Subkontrak oleh Kami , pengkhidmat atau ejen kami.
ER
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Ditandatangani oleh Dihadapan
(
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(Tandatangan Subkontraktor) A (Tandatangan Saksi)
Nama Penuh ............... .... ..... .... ..... ..... . Nama Penuh ................ .... .... .... .
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No. Kad Pengenalan ..... . .... .. ... .... ....... . No Kad Pengenalan ............... .... .
Atas sifat .......... . Pekerjaan .. . .. ..... ... .

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Yang diberi kuasa menandatangani untuk Alamat ....... ..... .... ..... .... ...... .
dan bagi pihak
EN
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Meteri atau Cap Subkontraktor

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ER
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( APPENDIXD
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KAEDAH PERLAKANAAN INTEGRITY PACT
A
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EN
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APPENDIX '0'
KAEDAH PELAKSANAAN INTEGRITY PACT
Peringkat Pertama - Semasa penghantaran dokumen tawaran oleh petender/penyebut

harga
Kesemua petender/penyebut harga yang menghantar dokumen tender/ sebut harga hendaklah
menandatangani Surat Akuan Pembida bahawa ia tidak akan menawar atau memberi rasuah
sebagi sogokan untuk mendapatkan kontrak . Wakil syarikat yang menandatangani Surat Akuan
ER
Pembida hendaklah juga melampirkan Surat Perwakilan Kuasa menandatangani bagi pihak
syarikat.
Format Surat Akuan Pembida adalah seperti di Lampiran A1. Agensi hendaklah memastikan
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Surat Akuan Pembida juga dijadikan sebagai dokumen wajib yang perlu disertakan bersama
dokumen tawaran petender/penyebut harga.
N
(
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Peringkat Kedua - Semasa mengembalikan Surat Setuju Terima oleh petender I penyebut
harga berjaya
Petender I penyebut harga yang berjaya dikehendaki menandatangani Surat Akuan Pembida
A
Berjaya bahawa ia tidak akan memberi rasuah sebagai ganjaran kerana mendapatkan kontrak.
Wakil syarikat yang menandatangani Surat Akuan Pembida Berjaya hendaklah juga melampirkan
EJ
Surat Perwakilan Kuasa menandatangani bagi pihak syarikat.
Format Surat Akuan Pembida Berjaya adalah seperti di Lampiran A2, Agensi hendaklah
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memastikan Surat Akuan Pembida Berjaya juga dijadikan sebagai dokumen wajib yang perlu
disertakan bersama Surat Setuju Terima .
EN
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0-1
LAMPIRAN A1
SURAT AKUAN PEMBIDA
Saya, ..... ... No. Kad Pengenalan Yang mewakili

nombor Pendaftaran ... dengan ini
mengisytiharkan bahawa saya atau mana-mana orang yang mewakili syarikat ini:
ER
i. tidak akan menawarkan, menjanjikan atau memberikan apa - apa suapan kepada mana-
mana orang dalam mana-mana Kementerian/Agensi atau mana-mana orang lain , sebagai
suapan untuk dipilih dalam mana-mana perolehan; dan
ii. tidak akan melakukan atau terlibat dengan tipuan bida dalam mana-mana perolehan .
D
N
Bersama ini dilampirkan Surat Perwakilan Kuasa bagi saya mewakili syarikat seperti tercatat di atas untuk
( membuat pengisytiharan ini.
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2. Sekiranya saya, atau mana-mana individu yang mewakili syarikat ini didapati terlibat dalam
pakatan tipuan bida dengan syarikat lain berkenaan perolehan di atas atau menawarkan, menjanjikan atau
memberikan apa-apa suapan kepada mana-mana orang dalam .K.eJ)).en!erj<!!! . !<:.erj;:'--'~<!y.?i~<!R<!!<!8.
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!<:.e!i.?__R<!i'? atau mana-mana orang lain sebagai dorongan untuk dipilih dalam perolehan seperti di atas,
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maka saya sebagai wakil syarikat bersetuju tindakan-tindakan berikut boleh diambil:
2.1 Hilang kelayakan untuk dinilai dan dilantik bagi perolehan di atas ; dan
2.2 Lain-lain tindakan undang-undang/tatatertib mengikut undang-undang/peraturan
M
perolehan Kerajaan yang berkuat-kuasa .

EN
3. Saya sesungguhnya faham bahawa :

3.1 saya atau mana-mana orang yang berkaitan dengan syarikat boleh didakwa bagi
kesalahan* di bawah Akta Suruhanjaya Pencegahan Rasuah Malaysia 2009 [Akta 694]
dan Kanun Keseksaan [Akta 574] serta boleh dihukum di bawah undang-undang
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masing-masing atas kegagalan saya atau mana-mana orang yang mewakili syarikat ini
( untuk mematuhi perkara (i) dalam surat akaun ini; atau
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3.2 tindakan boleh dikenakan ke atas syarikat di bawah Akta Persaingan 2010 [Akta 712]
atas kegagalan saya atau mana-mana orang yang mewakili syarikat ini untuk mematuhi
O
perkara (ii) dalam surat akuan ini. Sekiranya syarikat didapati melanggar peruntukan
seksyen 4(2)(d) Akta 712, syarikat boleh didenda tidak melebihi sepuluh peratus (10%)
D
daripada pusing ganti (turn over) seluruh dunia sepanjang tempoh suatu pelanggaran itu
berlaku .
4. Sekiranya terdapat mana-mana orang cuba memperolehi atau meminta apa-apa suapan daripada
saya atau mana-mana orang yang berkaitan dengan syarikat ini sebagai dorongan untuk dipilih dalam
perolehan seperti di atas, maka saya berjanji akan dengan segera melaporkan perbuatan tersebut kepada
pejabat Suruhanjaya Pencegahan Rasuah Malaysia (SPRM) atau balai polis yang berhampiran. Saya
sedar bahawa kegagalan saya berbuat demikian adalah merupakan suatu kesalahan di bawah seksyen
25 (1) Akta Suruhanjaya Pencegahan Rasuah Malaysia 2009 [Akta 694] dan boleh dihukum di bawah
0-2
seksyen 25 (2) akta yang sama, apabila disabitkan boleh didenda tidak melebihi RM100,000 atau penjara
selama tempoh tidak melebihi sepuluh tahun atau kedua-duanya.
5. Saya sesungguhnya faham bahawa syarikat melakukan kesalahan jika seseorang yang bersekutu
dengan syarikat" memberikan, menjanjikan atau menawarkan suapan untuk memperoleh atau
mengekalkan perniagaan atau faedah dalam menjalankan perniagaan di bawah Seksyen 17A, Akta
Suruhanjaya Pencegahan Rasuah Malaysia 2009 [Akta 694], apabila disabitkan kesalahan boleh didenda
tidak kurang daripada sepuluh kali ganda jumlah atau nilai suapan, atau RM1 juta, atau dipenjarakan
selama tempoh tidak melebihi dua puluh tahun atau kedua-duanya.
ER
Yang benar,
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Tandatangan
N
Nama
(
TE
No.KP
Tarikh
Cop Syarikat
A
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Catatan:
(i) • termasuk kesalahan ditetapkan dalam Jadual (Perenggan 3 (a), takrif "kesalahan ditetapkan") Akta
Suruhanjaya Pencegahan Rasuah Malaysia 2009 [Akta 694) yang boleh dihukum di bawah Kanun Keseksaan.
M
(ii) •• seseorang yang bersekutu dengan syarikat merujuk kepada seksyen 17A (6) Akta Suruhanjaya
Pencegahan Rasuah Malaysia 2009 [Akta 694), iaitu seseorang itu bersekutu dengan organisasi komersial
jika dia seorang pengarah, pekongsi atau pekerja organisasi komersial itu atau dia ialah orang yang
EN
melaksanakan perkhidmatan untuk atau bagi pihak organisasi komersial itu.

(iii) Surat Akuan ini hendaklah dikemukakan bersama surat perwakilan kuasa.
(iv) Takrifan perusahaan di bawah Akta 712 merangkumi syarikat yang tertibat dengan perolehan Kerajaan.
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Pihak Syarikat : Penama pada sijil pendaftaran untuk menandatangani Surat ini.
Pihak Kerajaan : Pegawai yang diberi kuasa oleh Menteri di bawah Seksyen 2 Akta Kontra Kerajaan 1949 untuk
menandatangani kontrak .
D-3
LAMPIRAN A2
SURAT AKUAN PEMBIDA BERJAYA
Saya , .. .... (Nama Wakil Syarikat) .. No. Kad Pengenalan ........ .............. ..... . . yang mewakili
...... (Nama Syarikat) ...... nombor Pendaftaran .... (MOF/PKKlCIDB/ROS/ROC/ROB) . dengan ini
mengisytiharkan bahawa saya atau mana-mana orang yang mewakili syarikat ini:
i. tidak akan menawarkan, menjanjikan atau memberikan apa- apa suapan kepada mana-
ER
mana orang dalam mana-mana Kementerian/Agensi atau mana-mana orang lain, sebagai
suapan untuk dipilih dalam mana-mana perolehan; dan
ii. tidak akan melakukan atau terlibat dengan tipuan bida dalam mana-mana perolehan.
D
Bersama ini dilampirkan Surat Perwakilan Kuasa bagi saya mewakili syarikat seperti tercatat di atas untuk
N
( membuat pengisytiharan ini.
TE
2. Sekiranya saya , atau mana-mana individu yang mewakili syarikat ini didapati terlibat dalam
membuat pakatan harga dengan syarikat lain atau apa-apa pakatan sepanjang proses perolehan atau
menawarkan , menjanjikan atau memberikan apa-apa suapan kepada mana-mana orang dalam
A
...... (Nama Kementerian/Agensi) ...... atau mana-mana orang lain sebagai dorongan untuk dipilih dalam
perolehan seperti di atas , maka saya sebagai wakil syarikat bersetuju tindakan-tindakan boleh berikut
EJ
diambill:
2.1 Penarikan balik tawaran kontrak bagi perolehan di atas di atas; atau
M
2.2 Penamatan kontrak bagi perolehan di atas; dan

2.3 Lain-lain tindakan undang-undang/tatatertib mengikut undang-undang/peraturan
perolehan Kerajaan yang berkuat-kuasa .
EN
3. Sesungguhnya saya faham bahawa:

3.1 saya atau mana-mana orang yang berkaitan dengan syarikat boleh didakwa bagi
M
kesalahan* di bawah Akta Suruhanjaya Pencegahan Rasuah Malaysia 2009 [Akta 694]
( dan Kanun Keseksaan [Akta 574] serta boleh dihukum di bawah undang-undang masing-
KU
masing atas kegagalan saya atau mana-mana orang yang mewakili syarikat ini untuk
mematuhi perkara (i) dalam surat akuan ini ; atau
3.2 tindakan boleh dikenakan ke atas syarikat di bawah Akta Persaingan 2010 [Akta 712] atas
O
kegagalan saya atau mana-mana orang yang mewakili syarikat ini untuk mematuhi perkara
(ii) . Sekiranya syarikat didapati melanggar peruntukan seksyen 4(2)(d) Akta 712, syarikat
D
boleh didenda tidak melebihi sepuluh peratus (10%) daripada pusing ganti (turn over)
seluruh dunia sepanjang tempoh suatu pelanggaran itu berlaku.
4. Sekiranya terdapat mana-mana orang cuba memperolehi atau meminta apa-apa suapan daripada
saya atau mana-mana orang yang berkaitan dengan syarikat in i sebagai dorongan untuk dipil ih dalam
perolehan seperti di atas, maka saya berjanji akan dengan segera melaporkan perbuatan tersebut kepada
pejabat Suruhanjaya Pencegahan Rasuah Malaysia (SPRM) atau balai polis yang berhampiran . Saya
sedar bahawa kegagalan saya berbuat demikian adalah merupakan suatu kesalahan di bawah seksyen
25 (1) Akta Suruhanjaya Pencegahan Rasuah Malaysia 2009 [Akta 694] dan boleh dihukum di bawah
D-4
seksyen 25 (2) akta yang sama, apabila disabitkan boleh didenda tidak melebihi RM1 00 ,000 atau penjara
selama tempoh tid ak melebihi sepuluh tahun atau kedu a-duanya .
5. Saya sesungguhnya faham bahawa syarikat melakukan kesalahan jika seseorang yang bersekutu
dengan syarikat" memberikan, menjanjikan atau menawarkan suapan untuk memperoleh atau
mengekalkan perniagaan atau faedah dalam menjalankan perniagaan di bawah seksyen 17A Akta
Suruhanjaya Pencegahan Rasuah Malaysia 2009 [Akta 694], apabila disabitkan kesalahan boleh didenda
tidak kurang daripada sepuluh kali ganda jumlah atau nilai suapan, atau RM1 juta , atau dipenjarakan
selama tempoh tidak melebihi dua puluh tahun atau kedua-duanya.
ER
Yang benar,
Tandatangan
D
Nama
N
( No .KP
TE
Tarikh
Cop Syarikat A
Catatan :
(i) termasuk kesalahan ditetapkan dalam Jadual (Perenggan 3 (a), takrif "kesalahan ditetapkan") Akta
EJ
Suruh anjaya Pencegahan Rasuah Malaysia 2009 [Akta 694] yang boleh dihukum di bawah Kanun Keseksaan.
(ii) •• seseorang yang bersekutu dengan syarikat merujuk kepada seksyen 17A (6) Akta Suruhanjaya
Pencegahan Rasuah Malaysia 2009 [Akta 694], iaitu seseorang itu bersekutu dengan organisasi komersial
M
jika dia seorang pengarah, pekongsi atau pekerja organisasi komersial itu atau dia ialah orang yang
melaksanakan perkhidm atan untuk atau bagi pihak organisasi komersial itu .
(iii) Surat Akuan ini hendaklah dikemukakan bersama surat perwakilan kuasa.
EN
(iv) Takefan perusahaan di bawah Akta 712 merangkumi syarikat yang terlibat dengan perolehan Kerajaan.
M
(
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D
N
( APPENDIXE
TE
REFERENCEINFO~ATION
A
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M
EN
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APPENDIX E
REFERENCE INFORMATION
Refer to Technical Requirement
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APPENDIXF
PROGRAM PROFESSIONAL TRAINING AND
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EDUCATION FOR GROWING
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ENTERPRENEURS - READY TO WORK

(PROTEGE-RTW)
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lAMPIRAN F
SURAT AKUAN PEMBIDA UNTUK MElAKSANAKAN

PROGRAM PROFESSIONAL TRAINING AND EDUCA TlON FOR GROWING
ENTREPRENEURS - READY TO WORK (PROTEGE-RTW)
Kepada (Agensi)
Cawangan Kontrak Dan Ukur Bahan,
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Ibu Pejabat JKR Malaysia,
Tingkat 17, Menara Tun Ismail Mohamad Ali,
No. 25, Jalan Raja laut,
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50582 Kuala lumpur
(u.p.: Bahagian Jalan)
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Tender :
MEMBINA JALAN DAR] BEHOR MALI KE KAMPUNG KEPALA SEPULOH,
PERLIS
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Saya ...... ..... ".............. .......... .. .... ................. .. .... ... nombor kad pengenalan
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............ .. ......... . ..... .... ...... ... .. .. .... . ..................... ......... yang mewakili syarikat
. .. ................... . .. .... .. .. .. ...... ............ ....................... nombor Pendaftaran
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.......................... .. .. .. .................... .. . (CIOB) dengan ini mengisy1iharkan bahawa

saya akan melaksanakan program PROTEGE-RTW jika dipilih untuk tender ini mengikut
had nilai am bang (threshold value) dan bilangan minimum peserta program PROTEGE-
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RTW seperti yang ditetapkan di dalam syarat tender.
2. Sekiranya, saya tidak melaksanakan program PROTEGE-RTW mengikut had

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nilai ambang (threshold value) dan bilangan minimum peserta setelah dipilih untuk
( tender ini, maka Kerajaan boleh mengambil tindakan ke atas syarikat saya berdasarkan
syaratlklausa kontrak dan syarikat saya mungkin tidak akan dipertimbangkan untuk
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tender perolehan kerajaan pada masa yang akan datang.
Yang Benar,
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(Nama dan No. Kad Pengenalan)
Cap Syarikat:
Catatan: i) Surat Akuan ini hendaklah ditandatangani oleh hanya

penama di sijil pendaftaran CIOB.
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CONTRACTUAL AND
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GENERAL
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REQUIREMENTS
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JKR/CJ /MC /NS /2022·3
CONTRACTUAL AND GENERAL REQUIRE MENTS
ROADWORK D&B (BIM 51) - 2022
TABLE OF CONTENTS
GENERAL CONDITION & REQUIREMENT PAGE
1. General 1
2. Scope of Work 1
3. Survey Works and Utility Mapping 7
4. Contractor's Local Consultants 8
5. Contractor's Organization Chart 9
6. Contractor's Project Manager and Personnel 9
7. Contractor's Proposal 9
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8. Bumiputera Contractors Participation 12
9. Design Guarantee Bond 12
10. Compliance with Local Authorities Requirements 12
Sufficient Notice to Local Authorities/Utility Providers/Regulatory Bodies 12
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11.
12. Joint Venture Requirements 13
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13. Materials of Malaysian Origin 13
( 14. Imported Materials, Goods, Constructional Plant, Equipment, Vehicles 14
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and Machineries
15. Government's Procurement Policy on Imported Goods and Foreign 14
Services
16. Patent Rights 14
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17. Performance Bond and Insurances 15
18. Quality Assurance Plan 15
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19. Programme of Works 17

20 . Bills of Quantities 19
21. Contract Documents 19
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22. Monthly Progress Report and Supervision Report 20

23. Progress Photographs 20
24. Site Diary 20
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25. Temporary Facilities and Services 21

26. Permanent and Temporary Relocation Works Related to Utilities and 23
Services
27. Maintaining The Site In Clean And Sanitary Conditions and Compliance 24
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( The Statutory Requirements

28. Clearing and Making Good on Completion 24
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29. Access and Temporary Roads 25

30. Care and Protection of Materials and Works 25
31. Contractor's Safety and Health Plan 25
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32. Protection of the Environment 27

33. As Built Models, Drawings and Documents 27
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34. Certification of Works before Testing and Commissioning and Final 29

Inspection
35. Asset Registration ans Laselling 29
36. Green Rating Implementation 29
37. Testing and Commissioning 30
38. Building Information Modelling (BIM) Requirements 31
39. 'J'Jerks Unser Water 32
40. Logging 32
41. Land Acquisition 32
JKR/CJ/MC /N5/2022·3
ROADWORK D&B (BIM 51) • 2022
1. General
1.1 . All works with respect to investigation, design, construction , maintenance, etc.
shall comply with the Government's Requirements.
1.2. All designs must optimally satisfy the requirements of visual elegance,
functional adequacy, safety, suitability, and robustness, ease of maintenance
and cost effectiveness.
1.3. The location and alignment plan of the project is as shown in Appendix A1-A,
and Appendix A1-B.
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2. Scope of Work
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The scope of works shall include the planning , design, construction , equipping,
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( testing , commissioning and maintenance of MEMBINA JALAN DARI BEHOR MALI
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KE KAMPUNG KEPALA SEPULOH, PERLIS.
The Works shall be carried out complete with relevant appurtenance and ancillary
works, services and equipment all in strict accordance to the Government's
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Requirements as specified in the Pre-bid Documents.
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The design of the scope of works shall comply to the need statements and the
requirements and guidelines of the Government. The Government gives no warranty
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in any manner whatsoever for any information provided by the Government in the
Contract as to their accuracy of sufficiency or as to how the same shall be interpreted
and the Government shall not be liable if such information is inaccurate or insufficient.
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The Contractor shall not be relieved from the obligations to ensure that such
information is accurate and sufficient for the purpose of this Contract.
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The scope of work shall comprise but not limited to the following :
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a) Design and construction of new/upgrading road of two (2) Lane Single

Carriageway for Jalan Kampung Mengkuang Layar from Jalan Utama
Kangar - Alor Setar (Laluan 7) to Jalan Kampung Surau (R159) to Jalan
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Jejawi - Tambun Tulang (R175) at approximately total 5.5 km at-grade

road complying with JKR R2 Standard as specified in latest Arahan
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Teknik Jalan (ATJ) with compliance to road safety requirement.
b) Design and construction of new bridges over MADAlJPS stream/irrigation

channel/waterways where neccessary complying with latest JKR R2
Standard as shown in Appendix A1-C .
c) Design and construction of Vehicular Box Culvert (VBC) and culvert

where required.
d) Design and construction of intersection, service road and u-turn where
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JKR/CJ/MC/NS/2022-3
required based on traffic study done by the registered traffic consultant /

projected traffic volume.
e) Design and construct of new access roads and/or upgrading existing

access roads to any affected residential area, residential houses, shop
area, adjacent lots where required .
f) The design of road alignment shall not disturb tHe cemetery and also the
existing development along the road segment if any within the road
corridor.
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g) Demolition of existing bus stops, design and construction of new bus
stops and bus lay-by where required by local authorities.
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h) Provision of signa Ii sed pedestrian crossings push button system complete
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with countdown display and buzzer, pedestrian bridge / pedestrian bridge
( with motorcycle ramp, pedestrian crossing with kerb ramps, pedestrian
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crossing with kerb ramps and tactile / paving block, and sidewalk at
school area and others area shall comply with MS1184:2014 Universal
Design and Accessibility in The Built Environment - Code of Practise
when necessary and appropriate as deemed by the Governement. It shall
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be designed with facilities for disable people's usage.
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i) Provison and construction of all necessary temporary river crossing, road

diversion, where required by Jabatan Pengairan dan Saliran (JPS) and
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tempoary access road for the proper and expeditious execution of the
Contract;
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j) Protection And Temporary Relocation Of Existing Utilities and Services,

where required
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( k) Permanent Relocation Of Utilities And Services, if necessary.

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2.2 The proposed works shall include Design and Construction of the
following major components but not limited to:
a) Site Clearance and Demolition Works
i) Site clearing including demolition of existing structures and culverts.

grubbing and stripping of the topsoil;
ii) Cutting of trees, shrubs and
iii) Demolish and replace (Including design & Construct) Government
structures affected along the proposed alignment (if required).
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b) Earthwork
i) Earthworks
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Preparation of road structure till formation level as designed,
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inclusive of importing suitable material, exporting unsuitable
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ii) Turfing
Turfing in Earthwork Embankment
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c) Drainage
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i) Drainage works including study, evaluate and proposed drainage

system to conform to JPS requirements (culverts, sumps, diversion
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drains, interceptor drains, roadside drains, toe drains, subsoil

drains, berm drains, shoulder drains, other drainage structures)
where necessary; and
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ii) Design and construction of drainage system including culverts,

subsoil drainage and other related drainage structures;
iii) Lean concrete to be provided as foundation for all type of precast
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( concrete drain to prevent erosion at the surrounding of the drain

due to the water seepage, and
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iv) Box culvert size more than 1.5m (width and height) and
embankment fill height more than 3.0m shall be design and
construct as concrete cast in-situ.
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d) Pavement
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i) Evaluate existing pavement condition and pavement rehabilitation

at Junctions / interfacing with existing road if necessary;
ii) Design and construction of pavement works along the road ; and
iii) Design, construct and maintain of new access roads or upgrading
existing access roads to any affected residential area, residential
houses, shop area where required.
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e) Road Furniture
i) Design and Construction of road furniture and traffic control devices

including road signs, retroreflective thermoplastic pavement marking
paint, guardrails;
ii) Traffic control devices shall also include crush cushion, warning and
destination signboard and provision of gantries (if required); and
iii) Relocation of existing billboard and advertisement board where and
when necessary and liaison with all the relevant government
agencies.
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f) Geotechnical Works
Design and construction of
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i) Foundation to structures
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ii) Ground treatment/improvement
( iii) Geotechnical instrumentation and monitoring
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iv) Slope stabilisation; e.g. : soil nailing, rock bolt, rock shed etc.
v) Slope surface protection
vi) Retaining structures
vii) Others that relevant to foundation works and geotechnical works.
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g) Structure
1. The new bridges/structure over MADAlJPS streamlirrigation

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channel/waterways (where necessary)
i) The new bridges inclusive of approach road at both bounds

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shall be two (2) lanes single carriageway in accordance to JKR

R2 Standard as specified in latest Arahan Teknik Jalan (ATJ)
with compliance to road safety requirement; and
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ii) The bridge/structure design and construction shall comply with

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JKR Terms of Reference for Bridges and Viaducts Structures

(Rev 2018) as stated in Appendix A7;
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iii) The existing bridge/structure shall be demolished including the

foundation ; and
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iv) Temporary crossing and road diversion and access for public
use shall be provided throughout the construction period; and
v) The bridge/structure shall be designed with aesthetical pleasant

that is in harmony and blend in with surrounding and localities;
vi) The Contractor is required to propose detail / exact

configuration and position of the bridge. The proposed
configuration and position of the bridge shall pose minimum
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JKR/CJ/MC/NSI2022-3
impact to the environments, acquisitions of private lands,

impact to the existing utility networks, minimum disturbance to
the public and existing structures during constructions, ease of
construction, care for geotechnical problematic area and all
related issues. The Contactor must seek relevant documents
and information from related local authorities to ensure the
above issues are kept at minimum level;
vii) Design and construction of box culvert size 3m and above in

height and/or width including foundation as in Appendix A7.
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viii) The contractor is required to design and construct protection
works for the existing bridge if required; and
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ix) The contractor must seek approved clearance i.e the highest
recorded flood level, minimum vertical clearance required from
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( any other related authorities. Contractor shall finalize the
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propose soffit level with respect to the flood level and shall be
indicated in drawings;
h) Electrical
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i) Design and Construction of road lighting (energy efficient lighting)
and traffic light at junction, intersections, u-turns, bridges, bus stop
(if required) and pedestrian bridges (if required). Phasing time for
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traffic light shall be based on traffic analysis done by registered by

traffic consultants; and
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ii) Relocate if necessary (transfer back road lighting/traffic light to

owner asset), provide temporary road lighting & traffic light during
construction and maintain existing road lighting & traffic light to
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function / operate throughout the construction period;

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i) Traffic Management at Works Zones
Design and Construction of Traffic Management at Works Zones and

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i) Provision and construction of all necessary temporary river/stream

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crossing, temporary road diversion and temporary access roads,

including necessary signages and safety measures for the proper
and expeditious execution of the contract.
ii) Provision and construction of all necessary temporary road lighting

and traffic signal light at the strategic location e.g. conflict area, road
diversion and slip road which in line with Traffic Management Plan
requirement. Electricity bill throughout the construction period shall
be priced in the Contract.
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iii) Construction of all temporary works with proper traffic management

includingthe preparation of traffic management plans and the
provision of any necessary road diversion and crossing.
iv) The contractor shall appoint a qualified Traffic Management Officer

(TMO). The contractor shall also carry out monitoring, auditing and
maintaining of the above if required.
j) Environmental
i) Environmental Impact Assessment (EIA) Study, Social Impact
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Assessment (SIA) Study and Approval where is required;
ii) Design and Implementation of mitigation works for EIA, SIA and
Environmental Protection and Enhancement Works (EPW) where is
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required;
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iii) Flora and Fauna Study and Approval where is required;
( iv) Implementation of mitigation measures for flora and fauna where is
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required; and
v) Design and Implementation of Penarafan Hijau (pH) JKR.
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k) Routine Maintenance
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Provision and routine maintenance of all road and access affected by

the construction in motorable condition at all time including Defect
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Liability Period (DLP).
I) OSHA
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i) Planning for Safety & Health Management System:

a) To provide Site Occupational Safety and Health Plan (S-Plan)
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b) To provide hazard identification risk assessment and risk

l control (HIRARC)
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c) Safety & Health report

ii) To provide resources for site safety
iii) To provide personal protective equipment
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m) Building Information Modelling (BIM)

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Execute BIM methodology relevant to the engineering professional

services throughout the project life cycles until handing over of project
for asset maintenance.
n) Road Safety Audit (RSA)
i) Upon the acceptance of tender by the Government, the Contractor

shall appoint independent Road Safety Auditor, subjected to the
approval of the Government. All fees to be borne by the Contractor;
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ii) Road Safety Audit to be carried out by independent accredited

auditors approved by JKR. The cost of any corrective action as the
result of the audits shall be borne by the Contractor;
iii) All other works to be in compliance with Road Safety Audits' needs
pertaining to safety of road users and pedestrians, e.g. provision of
pedestrian facilities.
0) Miscellaneous
i) Carry out Land Survey Works (including reimbursable), Utility

Underground Mapping Survey, l=lyElregraphis :i>urvey and Utilities
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Protection & Relocation Works;
ii) Carry out, analysis and reports of Site Investigation Works including
Geological Study, Soil Investigation and others relevant to Site
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Investigation;
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iii) Prepare Land Acquisition Plans and carry out Road Boundary
( Marking (ROW) including helping the government in preparation of
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any drawings and documentation related to ex-gratia payment by
the government. Wherever required the contractor shall get the
approval of Development Order from Local Authority;
iv) Carry out detail traffic study and approval;
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v) Carry out temporary utilities protection, relocation, diversion and
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reconnection works (including telecommunication lines, water
supply, electricity supply, gas supply and etc) where and when
necessary and liaison with all the relevant government and utilities
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agencies;
vi) Carry out Risk Management Plan, analysis and reports;
vii) The design shall where appropriate incorporate new technologies
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and innovation.
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3. Survey Works and Utility Mapping

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The Contractor shall employ at his own registered licensed land surveyor who shall
undertake surveys of the site boundaries, spot levels, and topographical features, etc
as per stated in Appendix A11 (as a reference only) within the site and the areas
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adjacent to the boundaries. The survey works shall also include the setting out and
preparation of precomputation plans for the projects.
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The Contractor shall provide to the P.O. six (6) hardcopies and one (1) set of
readable or editable softcopy of the duly certified survey plans of all survey
undertaken within six (6) months from the issuance of the Certificate of Practical
Completion of the project. Editable softcopy shall also provide in AutoCAD format.
The Contractor shall carry out utility mapping as per stated in Need of Statement for
Utility Mapping and submit the said utility mapping for the approval of the p.o.
The Contractor shall disclose all the utility survey data information to the Utility
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Company or Agency for verification of the relocation and protection of the utility scope
involved.
4. Contractor's Local Consultants
4.1. Generally
The Contractor shall submit a complete list of consultants to be employed for

the project stating their job category and their obligations. The Consultant shall
be suitably qualified and competent and shall be registered with their respective
professional bodies in Malaysia and the Ministry of Finance (MOF).
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4.2. Appointment of Consultants
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The Contractor shall appoint the consultants for their submission of technical
proposal for approval of the P.D. and shall be submitted to the Local Authorities
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( for approval.
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4.3. Agreement
The Contractor shall enter into an Agreement with all the relevant consultants.
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The Contractor is required to submit organization charts for all the consultants
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employed for this project.
It shall be a condition precedent to the first interim payment, for the Contractor
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to submit to the Government copies of the Consultancy Agreement as provided

under clause 35.1 to Condition of Contract.
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Pursuant to Clause 35.4 Condition of Contract, The Contractor shall not employ
any consultants (other than those named in his proposal) without the prior
consent of the Project Director (p.o.). The Contractor is also required to retain
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the said Consultants throughout the Contract Period and they shall not be
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discharged without the consent of the Project Director.
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All construction drawings shall be recorded, monitored and amended

accordingly throughout construction period in relation thereto, upon completion
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of works and As-Built Drawings shall be prepared and submitted to the p.o. for
approval.
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4.4. Consultancy Fees
a) Consultancy Fees shall include all fees for the Consultants engaged by the
Contractor which include among other the design, certification and obtaining
approval from Local Authorities.
b) The Consultancy Fees shall also include fees for Supervision and
Reimbursable.
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c) Requirements for BIM Project
Consultancy Fees shall include all fees inclusive of services in relation to

BIM for the Consultants engaged by the Contractor including but not limited
to design, certification and obtaining approval from the Local Authorities. The
consultancy fee for design services inclusive providing and submitting
hardcopy and softcopy BIM deliverables.
4.5. Supervision during Construction Period
The Contractor shall engage sufficient number of personnel for standing
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supervision during construction period. Supervision of the Works by employing
suitably qualified personnel as Appendix A2·A and Appendix A2·B.
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5.
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Contractor'S Organization Chart
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The Contractor shall submit together with his Proposal an organisation chart showing
the personnel (names and designations) involved in the planning, design, supervision
and construction of the Works. During construction, the Contractor shall also submit
to p.o. resume of proposed key personnel to be involved in this Works.
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6. Contractor's Project Manager and Personnel

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The Contractor shall at all times retain at the Site a competent, efficient, suitably
qualified, and experienced Project Manager who must be of good character and
capable of receiving instructions and communicating in Bahasa Malaysia and English.
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Any instructions given to such Project Manager by the p.o. shall be deemed to have
been given to the Contractor.
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The Contractor shall engage a full·time supervisory team on site during the whole
duration of the Contract, headed by the Project Manager.
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7. Contractor's Proposal
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The Contractor shall have satisfied himself before submitting his Proposal as to the
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correctness and sufficiency of his Proposal for the Works and the Contract Price,
except in so far as is otherwise provided in the Contract, shall cover all his obligations
under the Contract and matters and things necessary for the proper design ,
construction, completion and guarantee of the Works.
The Contractor shall take note the following conditions and shall read in conjunction
with the Instructions to Tenderer and Conditions of Contract PWD Form DB (Rev.
1/2010):
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7.1 . Mandatory Compliance for Contractor's Proposal
7.1.1. Design
a) Information in the Pre-bid Document such as layout etc. are

intended to assist the Design and Build Contractor in the design
and shall not be regarded as the only features or facilities required
or constraint to the design. The DeSign and Build Contractor shall
understand the responsible to provide complete Design and Build
facilities for the proper function of each area. The failure of the
Design and Build Contractor to comply with the said design
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requirement shall not entitle him to any additional costs whenever
he is instructed to build or install such facilities .
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b) Design shall include the following features, but not limited :
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( i. Features the state of the art technology
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ii. Safety
iii. Constructability
iv. Functionality
v. Economic
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vi. Mobility
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vii. Accessibility
viii. Maintainability
ix. Sustainability
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c) All design work by the Contractor shall be carried out in

accordance with all the relevant standard engineering practice and
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standards and shall be approved by Local and Central Authorities if

required .
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d) Any quantities and figures as indicated in the Contractor's Proposal

for any system or portion of work shall be taken as purely indicative
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only. No claims for extra cost shall be entertained if such increase

is an essential part of the completion of the whole of the Works.
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7.1.2 Drawings - The layout drawings shall consist (types, descriptions,

specifications, exact dimensions, locations, and numbers etc. of all the
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items as outlined in a Schedule) of the followings, but not limited to:
a) Key Plan
b) Location Plan
c) Abbreviation, Symbol and Legend Plan
d) Elements of Curve Plan
e) Superelevation Detail Plan
f) Typical Road Cross Section and Pavement Details Plan
g) Alignment Control Plan
h) Plan and Longitudinal Profile Plan
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i) Cross Section Plan

j) Junction Detail Plan
k) Road Marking Plan
I) Traffic, Guide and Temporary Sign Plan
m) Drainage Plan , including
i) Culvert and sump Schedule,
ii) Inlet and outlet invert level stated in each culvert schedule
n) Traffic Management Plan
0) Structure Plan
p) Temporary and Permanent Protection and Relocation of Utilities
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and Services Plan
q) Electrical Plan
r) Environmental Protection and Enhancement Works Plan
s) Geotechnical Plan
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( 7.1.2. Quantities and Figures
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Any quantities and figures as indicated in the Contractor's Proposal for
any system or portion or mark shall be taken as purely indicative only.
No claims for extra cost shall be entertained if such increase is an
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essential part of the completion of the whole of the Works.
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7.1.4 The Contractor shall take note that, all drawings used for his own
proposal for the scope of BIM Works as specified in the Needs
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Statement, shall be generated from the BIM models. Any information

provided by the Government are meant to serve as a guide only,
whereby the Contractor shall submit his own BIM model proposal
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including drawings for the evaluation and acceptance by the

Government. The design and specification proposed shall not be
inferior to those described in the Government's Requirements .
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7.2. Discrepancy
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Where there is any discrepancy within the Contractor's Proposal, the Project
Director shall have the right to decide between the discrepant items and the
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Contractor shall comply with the decision without any cost incurred to the
Government. Generally, the Technical Brief shall take precedence in the event
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of any discrepancies that appear in the Pre-bid Documents.
The Contractor's attention is further drawn to Clause 7.2, 7.3, 7.4 and 7.5 of the
Conditions of Contract where there is any discrepancy within the Contract
Documents.
7.3. Detailed Drawings
Any drawings shown in the Contractor's Proposal are considered as the

complete working drawings to be used for the completion of the whole of the
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Works . Any necessary updating/modification subsequently made in order to suit

the final accepted layout shall not be treated as variation to the Contract.
8. Bumiputera Contractors Participation
The Contractor shall engage Bumiputera Contractors or other Bumiputera

Organizations to carry out specific portions of the Works on a sub-contract basis. The
overall amount of the G2 (Class E) and G1 (Class F) participation is flexible (no
minimum amount) but maximum value is not exceeding fifteen (15) percent of the
builder's work (exclude Electrical Services), whereby the overall amount of
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Bumiputera G2 (Class E) and G1 (Class F)/Organizations shall be at least thirty (30)
percent of the Contract Sum. The Bumiputera Contractors shall be from the
registered list approved by the 'Pusat Khidmat Kontraktor' and the Construction
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Industry Development Board (CIDB) in the relevant Grade and Category.
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9. Design Guarantee Bond
Notwithstanding the provisions of Clause 14.0 of the Conditions of Contract, the

Contractor shall take note that the design (including any further design), materials
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and workmanship, supervision, construction and maintenance of the Works are
included within the scope of the Contract.
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Pursuant to the Conditions of Contract whereby the Contractor will be required to

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deposit with the Government a DeSign Guarantee in form of banker's guarantee in

the sum of five (5) percent of the Contract Sum as a security to the Contractor's
obligations under this Contract. The said bond shall be worded strictly in accordance
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with Appendix 6A and shall be issued by an approved bank operating in Malaysia.

The Design Guarantee Bond shall be issued upon or before the issuance of the
Certificate of Practical Completion.
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10. Compliance with Local Authorities Requirements
Notwithstanding the provisions of Clause 5.0 of the Conditions of Contract, the

Contractor is also required to seek the approval of the various relevant authorities
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concerned with the Works and to submit evidence of such approval to the p.o.
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11. Sufficient Notice to Local Authorities/Utility Providers/Regulatory Bodies
11.1. The Contractor shall give sufficient notice to the relevant Local Authorities/Utility
Providers/Regulatory Bodies before commencing or to inspect any Works in
relation to their scope of services. Failure to give sufficient notice shall not
entitle the Contractor to extension of time due to any subsequent delays in
connection with the Works.
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11 .2. Any notice given to the above mentioned authorities shall also be copied to the
p.o ..
12. Joint Venture Requirements
Any Proposal submitted by a legally constituted joint venture shall comply with the
following:
12.1. The Contractor's Proposal shall be Signed by the authorised signatories of all
the partners to the Joint Venture so as to be legally binding upon each partner.
ER
12.2. A copy of the Joint Venture agreement shall be attached to Volume 1 of the
Proposal for the perusal and approval of the Government.
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12.3. The Joint Venture agreement signed by the authorized signatories shall include
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( an undertaking by all partners to the joint venture and that they remain liable
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jointly and severally to the Government for the execution and completion of the
whole of the Works in full accordance with the terms contained in the
Government's Requirements .
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12.4. The Contractor's Proposal shall include:
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a) A description of the proposed participation and responsibilities of each

partner.
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b) A statement of proposed capital contribution of each partner and the sharing

out of profits and losses among the parties.
c) The Contractor's Proposal shall include the official correspondence address
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for service of all letters, written notices and instructions to the Joint Venture
including the leading partner to be designated.
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( 13. Materials of Malaysian Origin

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The Contractor shall only use local good/materials materials and goods as listed in
the 'Senarai Bahan/Barangan Binaan Tempatan' issued by IKRAM QA Services Sdn.
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Bhd . and/or 'Senarai Bahan/Barangan Buatan Tempatan ' issued by SIRIM QAS
International Sdn. Bhd., and no other, whichever is relevant. If the Contractor fails to
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comply with this requirement, a penalty shall be imposed and/or the materials
supplied shall be rejected.
The locally manufactured materials and goods which are not listed aforesaid, may be
permitted if the materials have been tested and certified by IKRAM QA Services Sdn.
Bhd. and/or SIRIM QAS International Sdn. Bhd. whichever is relevant. If the testing
cannot be carried out by IKRAM QA Services Sdn. Bhd . and/or SIRIM QAS
International Sdn. Bhd., the Contractor may apply and, subject to the approval of the
P.O., carry out the testing by other agencies .
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JKR/CJ/MC/NS/2022-3
14. Imported Materials, Goods, Constructional Plant, Equipment, Vehicles and

Machineries
Subject to the requirements on the use of materials of Malaysian origin, importation

and procurement of imported materials, plant, equipment and vehicles forming part of
the scope of works shall be in accordance with Clause 16.0 and 17.0 of the
15. Government's Procurement Policy on Imported Goods and Foreign Services
ER
In line with Government's Procurement Policy on Imported Goods and Foreign
Services, the Contractor shall deemed to have allowed in his Tender all cost and time
necessary for full compliance with Clause 16 and 35 of the Conditions of the
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Contract.
N
( For the purpose of compliance with Clause 16 of the Conditions of The Contract:
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Restriction and Procedure on Use of Imported Goods, the Contractor whose Tender
has been recommended and considered for acceptance will be required to submit to
the p.o. to secure the Government's approval, the list and particulars of any material,
plant, equipment, vehicles or other goods which are not locally available and
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proposed to be imported, prior to the acceptance of his Tender.
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For the purpose of compliance with Clause 35 of the Conditions of Contract on the
employment of foreign consultants, the Contractor shall submit together with his
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Tender the list and particulars of any foreign consultant whose expertise required for
the implementation of the Works cannot be obtained locally. The Contractor will be
required to replace any proposed foreign consultant that has not been approved by
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the Government with suitably qualified/experienced local consultants approved by

the p.o. before his tender can be considered for acceptance.
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( 16. Patent Rights

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16.1. The Contractor shall deem to be include from his price fully indemnify the
Government against any action, claims or demands, costs or expenses arising
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from or incurred by reason of infringement of letters, patent rights and design,

trademark or name, copyright of other protected means in respect of any
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machine, plant, work, materials or things, systems, method of using, fixing,

working or arrangement used, fixed or supplied by him .
16.2. All payments of royalty payable in one sum or by installments of otherwise shall
be included by the Contractor in his Tender and shall be paid by him to whom
they may be due or payable.
16.3. In the event of any claims being made or action brought against the
Government in respect of such matters aforesaid, the Contractor shall
immediately be notified thereof, and he shall at his sole expense, conduct all
CGRl14
JKR fCJfMCINSI2022·3
negotiation for the settlement of the same or any litigation that may arise
therefore .
17. Performance Bond and Insurances
17.1. Performance Bond
The Contractor's attention is drawn to Clause 10.0 of the Conditions of Contract

whereby the Contractor will be required to deposit with the Government, a
Performance Bond equal to five (5) percent of the Contract Sum for the due
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observance and due performance of the Contract. The said bond shall be
worded strictly in accordance with Appendix 6 and shall be issued by an
approved bank in Malaysia.
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17.2. Insurances
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(
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The Contractor's attention is drawn to Clause 11 .0, 38.0 and 39.0 of the
Conditions of Contract whereby the Contractor shall be required to indemnify
the Government in respect of injury to persons and damage to property and to
ensure the Works as required by said clauses.
A
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18. Quality Assurance Plan

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18.1. The Contractor shall submit to the p.o. an outline Quality Assurance Plan for
comment within fourteen (14) days of the date of Letter of Acceptance . Within
twenty-eight (28) days thereafter the Contractor shall submit to the p.o. for
EN
approval a properly documented Quality Assurance Plan that shall take proper
account of the P.D.'s comment on the outline Quality Assurance Plan. The
approval by the p.o. of such plan shall not relieve the Contractor of any of his
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obligations under the Contract. The Contractor shall update and revise the said
( Quality Assurance Plan during the progress of the work in order to comply with
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the Contract, all to the approval of the P.O.
18.2. Details of all procedures and compliance documents shall be submitted to the
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p.o. for information before each design for temporary works and execution
stage of the Works is commenced . When any document of a technical nature
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is issued to the p.o., evidence of the prior approval by the Contractor himself
shall be apparent on the document itself.
18.3. Quality Assurance Plan shall set out the specific quality procedures, practices,
resources and sequence of activities to meet the requirements of the Contract
and Specifications and shall include the proposed organization structure of
the Contractor including quality assurance team , quality procedures,
Contractor's plant, construction programme, method statements, environmental
management, health and safety, selection and testing of materials, placement,
installation, site operational control, Non-Conformance Report (NCR), closing
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ROADWORK 0&8 (81M 51) . 2022
out NCR for the taking over, coordination with local and statutory authorities,
internal quality audit control , remedying of defects, commissioning and
maintenance.
18.4. All Quality Assurance Plan submitted by the Contractor to the p.o. shall
conform to the relevant standards set out by the International Standards
Organization (ISO) and in conjunction with the Public Works Department
Quality Management System .
18.5. The Contractor shall implement the quality assurance procedures in the
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approved Quality Assurance Plan and shall submit a monthly quality assurance
report to be endorsed by a Quality Assurance Officer incorporating all test
results, test certificates, photographs and lab reports relating to the quality of
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materials and workmanship .
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18.6. The Contractor shall appoint a suitably qualified and experienced person to act
( solely as Quality Assurance Officer full time on Site to lead the Quality
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Assurance Team. The Quality Assurance Officer shall meet the following
requirements:
a) Possess a relevant technical Degree from a university recognized by the

A
Government of Malaysia, and
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b) Possess not less than 5 years' experience in the construction industry,
and
c) Possess a Construction Industry Development Board (CIDB) Green Card ,
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d) Has anyone of the following;

i. Minimum two (2) years relevant experience in the implementation of
MS ISO 9001 in the construction industry, or
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ii. Has attended field internal audit activities for MS ISO 9001 , or
iii. Possess Internal Auditor Certificate from agency or body recognized
by MAMPU.
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18.7. The Contractor shall provide a Quality Assurance Team and resources that are
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required to ensure the effective operation of the Quality Assurance Plan.
18.8. The Contractor shall at his own cost provide all access, assistance and facilities
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to enable the p.o.'s Representative to audit/verify the implementation of the

Quality Assurance Plan and adherence thereto.
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18.9. The P.D.'s Representative may, at his discretion, reject any of the Works which
in his opinion have not been executed in accordance with the Quality
Assurance Plan and which ultimately does not conform with the specification , or
the resultant execution of the work was not done in a good and workmanlike
manner and to the accepted standard and good practice. The Contractor shall
re-execute at his own cost and without any entitlement to any extension of time
all such parts of the Works so rejected .
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JKRICJIMCINS I2022-3
19. Programme of Works
The Contractor shall submit to the p.o. for his approval a detailed work programme
using Critical Path Method (CPM) including electron ic and printed copies of all data.
The work programme shall be prepared and maintained throughout the Contract
Period by trained and qualified personnel. The work programme shall be:
i. presented in the form of Gantt Chart and network diagram indicating, among
others the critical activities, interface dates and resources required to complete the
Works within the Contract Period .
ER
ii. financially loaded as per the tender items and cost. In the event the tender is of
lump sum in nature, the Contractor will need to disperse their tender cost across
the work programme, task and activities, the values to be rationalized and
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approved by the Government or its authorized representatives .
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iii. presented in a Works Breakdown Structure (WBS) format, using codes approved
( by the Government or its representatives .
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The Contractor is required to submit to the Government a soft copy of the work
programme in any removeable storage device. The said device must be submitted in
a completely sealed and labeled in format approved by p.o ..
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The Contractor is required to submit a coloured printout copy of the work programme,
all related schedule of works progress including preparation of drawing , site
preparation, throughout construction period , maintenance period and defect liability
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period inclusive of all activities prior to design approval up to certification of As-Built

Drawing for the approval of the P.D.. It shall be bound into a presentable format and
labeled accordingly.
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The Software acceptable for use in the creation of the work programme is either:
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a) Microsoft Office Project 2016 or later version, or

<- b) Primavera Project Planner P3W or later version
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The Contractor shall provide a Legal and original copy of either one of the above
software to JKR or its representatives for use during the duration of the project.
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Construction Simutation
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The contractor shall update the BIM model progressively and provide construction
simulation as per work programme. The construction simulation shall reflect the
planning and actual work progress on site and may be used for verification and
monitoring of physical works virtually .
19.1. Programme to be submitted after Award
The Contractor shall submit to the P.D.'s within twenty-one (21) days of the
Commencement Date, in accordance with the Government's Requirements and
CORl l 7
in a form acceptable to and for approval by the P.O., and in addition to any
further requirements set out in the Government's Requirements , the following
documents:
a) An overall execution programme covering the whole of the period for

activities.
b) A detailed programme covering the activities for the first six (6) months of
the period for Execution of the Works and including manufacture,
procurement and other off-site activities.
ER
c) A detailed method statement setting out the method and manner in which
the Contractor intends to execute the Works.
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d) A detailed cash flow forecast, in quarterly periods, of all payments to which
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the Contractor will be entitled under the Contract, and showing the
( relationship between expenditure and the progress of the Execution of the
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Works, with the aim of synchronising cash flow to performance.
19.2. Revised Programme

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The Contractor shall supply to the p.o. at such times as the p.o. may direct
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during the progress of the Execution of the Works, such further or special
written particulars and information and shall attend all meetings as are required
by the p.o. to enable a progress record to be maintained in respect of the
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Works.
If at any time it should appear to the p.o. that the actual progress of the Works
EN
does not conform to the programme to which approval has been given under
Clause 13.5 (c) or Clause 13.5 (d) of the Conditions of Contract, the Contractor
shall produce, at the request of the P.O. for approval, a revised programme
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( showing the modifications to such programme necessary to ensure completion

of the Works by the Date for Substantial Completion and to take account of any
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extensions of time granted pursuant to Clause 49.
19.3. Cash Flow Estimates to be Revised

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The Contractor shall, if and when required to do so by the p.o., supply revised
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cash flow estimates amended where necessary to reflect the actual progress of
the execution of the Works and the programmed future progress.
19.4. Contractor not Relieved of Duties or Responsibilities
Upon approval by the p.o., the overall execution programme referred to in

Clause 13.5 (b) of the Conditions of Contract, shall become the Programme for
the Works, including without limitation thereto for the purposes of Clause 49 of
the Conditions of Contract. Such approval by the P.O. shall not relieve the
Contractor of any of his obligations under the Contract. No such approval shall
COR/ I 8
create any obligation or liability on the part of the Employer nor shall any
approval of the Programme by the P. D. establish the Programme as part of the
Contract.
Unless expressly stipulated or described in the Contract, the choice of methods

of working and Temporary Works , programming of the Works and deployment
of the Contractor's resources on the Site shall be the sole responsibility of the
Contractor. The approval of the Programme and of any other document
submitted to the p.o. pursuant to this Clause 13.5 (b) of the Conditions of
Contract, signifies merely the P.D.'s understanding of the proposed order,
sequence and method of working but shall not relieve the Contractor from any
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of his obligations under the Contract.
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20. Bills of Quantities
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( 20 .1. The Contractor shall submit to the p.o. three (3) sets of Bills of Quantities (hard
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and soft copy) prepared by the Consulting Quantity Surveyor based on the
Contractor's Proposal as part of consulting fee services as described in item 4.0
Contractor's Local Consultant. The Bills of Quantities shall be priced by the
Contractor and submit not later than three (3) months from date of site
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possession.
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20.2. The Bills of Quantities shall have various sections based on the scope of works
of the Government Requirements as summarised in Contract Sum Analysis in
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Appendix 4.
20 .3. The Bills of Quantities shall not form part of the Contract and used solely for the
EN
purpose of Interim Valuation as a guide.

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21. Contract Documents

(
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Pursuant to the Clause 6.0 of Conditions of Contract, Contract Documents shall be

prepared in two (2) original copies. The original copies of the Contract Documents
shall remain in the custody of the P.D. and the Contractor.
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Immediately after the execution of this Contract, the Contractor shall furnish without
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charge to the Government eighteen (18) certified true copies.
The Contract Documents shall be prepared and certified by the project consultants
appointed by the Contractor and shall be completed within four (4) months from the
date of the Letter of Acceptance.
CGRJ19
22. Monthly Progress Report and Supervision Report
The Contractor shall be required to submit to the Government ten (10) copies of the
Monthly Progress Report complete with aerial photos and videos of the project using
camera to build 3D model to be within ± 8cm using drone / Unmanned Aerial Vehicle
(UAV) including power point presentation showing the progress of works carried out
each month of the Contract by the first week of every month to the p.o.
As for supervision report, the Contractor shall submit to P.O. each month or any other
time as required by the P.O. supervision reports on the following:
ER
i) Works properly on site
ii) Progress of the works
iii) Any tests done on the site
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iv) Safety measures at the site
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v) Environmental impact assessment of works; and
( vi) Any another matter as required by the Government
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The Report shall contain all the relevant information pertaining to contract
management, extent of work done, the labour force employed, at least four (4)
illustrative photographs at every level of construction for each site and problems
encountered. A set of photographic slides showing the progress and stage of
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construction of each part of the Works and where possible an overall view of the
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Works shall also be submitted together with the aforesaid monthly progress report.
All such reports which are to be submitted by the Contractor shall be duly verified and
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certified by the Consultants of the Contractor.

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23. Progress Photographs
23.1. The Contractor shall take progress photographs at monthly intervals or more
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frequent as directed by the p.o. The photographs to be taken from different

( angles as approved by the P.O. and the average number of photographs shall
KU
be sufficient enough to show the progress of the Works.
23.2 . The Contractor shall supply six (6) sets of bound printed copies of the approved
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photographs, all properly titled and dated . The photographs shall also be
provided in .jpeg or other approved format with each image set at minimum size
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of 1280 x 1080 pixels and submitted to the p.o. monthly, in removable storage
device.
24. Site Diary
The Contractor shall provide and maintain a site diary which shall comply with the
standard JKR format at each site office. It shall be kept up to date at all times and
shall be regularly certified by the Contractor's Site Supervisory Team and the
Consultant's Supervision Team . The site, work done during each day, etc. and shall
be made available at the site to the P.O. and his representatives whenever required .
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ROADWORK 0&8 (81M 51) . 2022
All site diaries shall be kept in a reasonably tidy condition and shall be handed over to
the p.o. upon completion of the Works.
25. Temporary Facilities and Services
The Contractor shall provide and maintain the following facilities and services for the
entire duration of this Contract.
25.1. For the Works
ER
The Contractor shall provide and maintain in good condition all the necessary
temporary facilities and services during the duration of the Works, to include,
but not limited to , the following :
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a) Project Signboards (minimum 2 numbers) complete with structure and panel
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( with project title, name and address of the employer, contractor and
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consultants, date of site possession and date for completion and other
relevant information and all in accordance to the JKR Standard design;
b) Maintain, repair and reinstate existing roads, culvert and other related
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services including outside limit of work if necessary ;
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c) Storage place for keeping all building material such as cements , chemicals ,
tools and machineries to keep from weather;
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d) Provide water and power throughout the construction period and during
testing and commissioning and permanent connection for the services on
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behalf of the Government. The Contractor must pay all the bill and expenses
and shall provide alternative or substitute whenever power failure or shortage
by providing standby genset and sufficient water tank. The Contractor shall
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allow in the Contract Sum for the permanent connection to public services
( company;
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e) Sanitation with proper building and proper temporary manhole or waste

container;
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f) Provide sufficient personnel protective equipment for site staff;

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g) Survey instruments such as theodolite with tripods, leveling staff, etc;
h) Security Guard to lookout the site and make sure only permitted staff or
workers can enter the site.
i) Provision of Laboratory and testing services when necessary
j) Site office for contractor and consultants complete with office furniture and
other office facilities with proper air conditioning and ventilation
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JKRfCJIMC/NS/2022-3
k) Temporary accommodation or shelter for workers and it shall complete with

facilities and proper sanitation system
I) Plant and machineries whenever necessary
m) Mosquito prevention
n) Telephone
ER
0) First aid kit for emergency or accident which shall be kept and properly
maintained in the Contractor's Site Office
p) Diversion of existing services, pipes, etc
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q) Traffic Control Devices for Traffic Management at Work Zones
(
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r) Traffic Control Devices for utility works including by others
s) Scaffolding, staging, nets, ladders and catwalk whenever necessary

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t) Hoarding
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u) Safe Access and temporary roads and crossing to all works and public use
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v) Drainage, removal of surface water and all necessary physical works for
Environment Protection and Enhancement Works, etc
EN
w) Provision of lighting for works as per OSHA requirement
Before handing over of the Works to the Government, the Contractor shall
M
( remove all temporary buildings, temporary works and temporary installation to

the satisfactory of p.o.
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ROADWORK D&B (BIM 51)·2022
25.2. For the Project Director
The Contractor shall provide for the Project Director or his representatives, the
following :
a) The Contractor shall provide and maintain a site office for the use of the
Project Director or his representatives all in accordance with JKR design
type as shown in the relevant drawings inclusive all fittings and furniture
as stated therein and as mentioned in specifications.
ER
b) Transport services for the P.O.
The Contractor shall provide suitable and reliable transport facilities

service by means brand new vehicle(s) including licensed and competent
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driver(s) for the p.o. and his representatives to attend site meetings, site
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visits, progress evaluation visits, project meetings and briefings and any
( events held in connection with the project. The number and specification
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of the vehicle to be provided by Contractor shall accordance to Appendix
A3.
c) Equipments and Facilities for the P.O.

A
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The Contractor shall provide to the Project Director's or his representative
the equipment and facilities during Contract Period as per list and
specification in Appendix A3.
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26. Permanent and Temporary Relocation Works Related to Utilities and

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Services
The Contractor shall inspect the site and carry out utility mapping or other methods
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approved by the Utilities Company or Agency to identify any existing utilities and
( services within the surrounding of site to discover the needs for temporary dan
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perrnanent relocation and protection of utilities and services.
The Contractor shall establish the proposal for the temporary relocation and
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protection of utilities and services to the approval and satisfaction of the P.O. and
Utilities Company or Agency if necessary for the execution of the Works.
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The Contractor shall make all arrangement and obtain all necessary approvals and
permission required in execution of the temporary relocation and protection of
utilities and services.
The contractor shall liaise with the Utility Company or Agency to determine the new
location, duration and any necessary requirements for the execution of permanent
utility relocation and protection work by the Utility Company or Agency. The
Contractor shall include and coordinate the utility company's or agency's work
programme in the Contractor's work programme.
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ROADWORK D&B (BIM 51)·2022
The permanent utility relocation and protection work shall be carried out or execute
in accordance to ' Garis Panduan Perlindungan, Pengalihan Dan Pemasangan
Semula Utiliti dalam Perlaksanaan Program Dan Projek Kerajaan RMKe-12'.
27. Maintaining the Site in Clean and Sanitary Conditions and Compliance the
Statutory Requirements
The Contractor shall clear and remove from the site at adjacent site (if any) and
dispose off at his own dump, all rubbish, waste and superfluous materials arising from
ER
the Works and leave the site in clean state acceptable to the p.o. during the progress
of the Works throughout the construction period and must ensure all safety
requirement are followed in full compliance with the statutory requirement. All building
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materials, tools, plants and machinery shall be arranged properly as per logistic
arrangement and logistic plan must be approved by the Consultant. All debris,
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( construction wastage , unused material shall be collected and removed from site. No
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site burning will be allowed .
27.1 . Keeping Site Dry

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The Contractor shall be responsible for keeping the whole of the Works well
drained. The Contractor shall ensure that the water drained from the site shall
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be kept reasonably free from earth, debris, etc. He shall be responsible for
finding outlets for the discharge of the water drained from site and if the water is
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drained from the site to the public drains, he shall be responsible for making
arrangements with the Authorities to do so including playing all necessary fees
and making good damages to the roads , drains etc.
EN
The Contractor shall be held solely responsible for the sufficiency of the
arrangement made for the Execution of the Works and shall be held
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responsible for keeping the works safe and dry at all times including periods of
( heavy rainfall and for any loss or damage which may result from the
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Contractor's neglect of his obligations.
27.2. Dust Prevention

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The Contractor shall made adequate provision by spraying water, erecting

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screens or the suitable methods against any nuisance or damage by dust to all
existing properties and their occupants in the vicinity and he will be held
responsible for any complaints , damage or claims in this connection .
28. Clearing and Making Good on Completion
The Contractor shall from time to time on the completion of any part of the Works or
where directed by the p.o., remove and clear away all rubbish, surplus materials or
any other construction debris and cut shorts grass within the site. Before handing
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ROADWORK D&B (BIM 51)- 2022
over of the works to the p.o., The Contractors shall leave the whole site in clean,
sound and tidy condition to the approval of the p.o.
Ensure all existing drains are clear of any road debris, earth etc. at all times. Remove
and clear away from site all temporary buildings, temporary works and temporary
installation, upon completion or as and when directed by the p.o.
Gather up and clean away all rubbish as it accumulated during the progress of the
Works and leave the site clean and tidy upon completion.
ER
29_ Access and Temporary Roads
29.1. The Contractor shall provide and maintain, to the approval and satisfaction of
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the p.o., all necessary temporary culverts, roads, tracks, bridges, material etc.
for access to and within the site (or sites) as long as required for the Execution
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( of the Works. The positions where the site access is to be made shall be clearly
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indicated on the site plans submitted by the Contractor as part of the Proposals.
The Contractor shall make all arrangements and obtain all necessary approvals
and permission required in connection thereto.
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29.2 . Access roads from the site (or sites) leading to public roads shall be properly
maintained at all times and shall only be removed by the Contractor when
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instructed to do so by the P.O.

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30. Care and Protection of Materials and Works

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The Contractor shall provide and maintain everything necessary for proper protection
of materials and Works from any damage by weather especially reinforcement iron
fully covered, carelessness or otherwise. Any damage caused shall be made good at
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the Contractor's own costlo the approval of the P.O.

(
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31. Contractor's Safety and Health Plan
31 .1. Contractor to establish Safety and Health Plan

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The Contractor shall establish a Safety and Health Plan to ensure that all
activities required to facilitate execution of the Works are carried out in a
hygienic and safe manner, consistent with proven good practice, and comply
with all laws, regulations, codes of practice and other things relevant to health
and safety which may from time to time apply to the Works.
31.2. Contractor to submit a Safety and Health Plan
Within thirty (30) days of the date of the Letter of Acceptance, the Contractor
shall submit to the p.o. an outline of the Safety and Health Plan. Within twenty-
CORI2S
ROADWORK D&B (BIM SI) . 2022
eight (28) days of such submittal the Contractor shall submit for approval its
detailed Safety and Health Plan which shall take proper account of all
comments made by the Employees Representative and any and all
submissions to the Employees Representative of supplemental parts of the
Safety and Health Plan shall be made as appropriate or upon the request of
the p.o. but in any event not less than twenty eight (28) days before
commencement of any work which is the subject of any such submission. The
submission and approval by the Employees Representative of Safety and
Health Plan and any supplement thereto shall not relieve the Contractor of any
of his obligations under the Contract.
ER
31 .3. Safety and Health Plan to be in accordance with the requirements of the p.o.
The form and content of the initial submission of the Safety and Health Plan
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and of all supplemental parts thereof shall be in accordance with the
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requirements prescribed by the Employees Representative.
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31.4. Contractor to adhere to the Safety and Health Plan
Upon the P.O. notifying his approval to the Safety and Health Plan, or any
supplemental part thereof, and without limiting his obligations under the
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Contract, the Contractor shall implement and adhere to the principles and
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procedures contained in such document.
31.5. Appointment of Safety Officer and Other Personnel

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The Contractor shall appoint a suitably qualified and experienced person as

safety officer to act as manager of the Safety and Health Plan and to be
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responsible for all safety matters related to the Works. The Contractor shall
from time to time provide such other personnel and resources including but not
limited to a deputy to the Safety and Health Officer who can act in the absence
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( of the Safety and Health Officer, as may be required to ensure the effective
implementation and operation of the Safety and Health Plan. The said Safety
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and Health Officer shall submit regular safety reports to the Employees
Representative in accordance with the requirements of the p.o.
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31.6 . Contractor to provide access

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The Contractor shall provide all access, assistance and facilities to enable the
p.o. to carry out surveillance visits both on and off the Site to verify that Safety
and Health Plan is being implemented and adhered to.
31.7. Requirement to Comply the JKR Specification for Occupational Safety & Health
for Engineering Construction Works
The contractor shall comply requirement of OSHA as well as with the JKR
Specification for Occupational Safety and Health for Engineering Construction
CGRl26
JKR/CJ /MC /NSI2022·3
ROADWORK D&B (81M 51) - 2022
Works 2019 as per attached in ADDendix A16 including the provision of

Personnel Protective Equipment (PPE).
31.8. Pandemics, Epidemics and Medical Attendance
The Contactor shall maintain the Site in clean and sanitary condition and shall
comply with all requirements of the Government Health and Sanitary
Authorities . In the event of any outbreak of illness of an epidemic and pandemic
nature such as Covid 19, the Contractor shall comply with and carry out such
regulations , order and requirements as in Prevention and Control of Infectious
Diseases Act 1988 (Act 342) and related Standard Operation Procedure issued
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by Ministry of Health Malaysia, CIDB and Public Works Department of
Malaysia.
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32. Protection of the Environment
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(
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32.1. The Contractor shall take necessary precautions to prevent the deposition of
any debris, rubbish , silt, waste materials, foul water, chemicals, etc. arising from
the execution of the Works into existing streams/ waterways.
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32.2. The Contractor shall divert existing drains, waterways, etc. encountered during
the progress of the Works without disrupting their flow system and if such
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diversion is temporary, he shall subsequently reinstate the same subject to the

p.o.'s approval.
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32.3. The Contractor shall take necessary precautions to ensure that the tires of all
vehicles leaving the site are free of mud.
EN
32.4. The Contractor shall not carry out any open burning on the site (or sites)
without the written approval of the P.O ..
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32.5. The Contractor shall be held solely responsible for the sufficiency of
( precautions taken by him to protect the environment and shall comply with
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requirements imposed by the relevant authorities.

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33. As-Built Models, Drawings and Documents

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33.1 Submission during Construction
For the purpose of BIM implementation for this project, the Contractor shall
be required to submit the As-Built Documents in the form of As-built Model
and drawings to the p.o. progressively as the relevant portions of work are
completed or as and when required by the p.o. All drawings shall be
generated from the As-built Model.
CGRl27
JKR/CJ/MCINS/2022-3
ROADWORK D&B (BIM 51)· 2022
33.2 Submission after Practical Completion
33.2.1 Within three (3) months from the date of practical completion, the
Contractor shall submit to the P.O. for his concurrence a full set of
As-built Model and two (2) sets of as-built drawings and other details
and information to show the final construction and form of the Works
as completed and stamp on every sheet of drawing as "As-built
drawing". All drawings shall be generated from the As-built Model.
33.2.2 Upon concurrence of the p.o., the Contractor shall prepare and
submit for each drawing as per below:-
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(a) Six (6) non-fade prints (A1 size); and
(b) Ten (10) removable storage devices for all information models
and as-built drawings in their native formats and pdf format.
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33.2.3 Failure of the Contractor to submit the As-built Model and drawings
( within the stipulated period will entitle the Project Director to have
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such model and drawings prepared by others at the expense of the
Contractor.
33.3 Documents Ownership and Use of Electronic Files

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33.3.1 It is expressly agreed within the parties that all BIM models, BIM
components, BIM Project and Family Templates, BIM deliverables
including but not limited to drawings, reports, specifications,
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materials, calculations , design and all other relevant documents

including other electronic files pertaining to this Contract shall be the
absolute property of the Government and not to be utilized or
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retained by the Contractor for any purpose other than with the
permission of the Government.
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( 33.3.2 The Contractor is responsible to check, verify, and otherwise confirm

the accuracy of data in the model and other related electronic files
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including but not limited to drawings, reports, specifications,

materials, calculations, design and all other relevant documents
produced from the model.
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33.3.3 The Contractor shall not make any claims and hereby waives to the
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fullest extent permitted by law, any claims or causes of action of any

nature against the Government, which may arise out of, or in
connection with the use of the BIM and its deliverables including but
not limited to Project and Family Templates , reports, specifications,
materials, calculations, design and all other relevant documents
including other electronic files.
33.3.4 For the purpose of payment under clause 53 of the Condition of

Contract, the Contractor shall submit the above documents
mentioned progressively.
CGR128
ROADWORK O&B (BIM 51) - 2022
33.3.5 Upon payment the said design in the form of hardcopy and softcopy
and shall belong to Government inclusive of the copyright.
34. Certification of Works before Testing and Commissioning and Final Inspection
All works claimed to be completed works shall be certified by the Contractor's

Consultants in each respective discipline, as complete, functional and safe for use
before a request is made for the P.O. or his representatives to witness or carry out
any testing, commissioning and final inspection prior to the issuance of the Certificate
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of Practical Completion .
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35. Asset Registration
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( If the Contractor is appointed by the P.D. to implement the Works under the
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Provisional Sum, the Contractor shall fulfill the entire requirement for the scope of
works, latest related manual/ guideline mentioned about Garis Panduan
Pengumpulan Data & Pelabelan Aset Tak Alih (PeDATA).
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36. Penarafan Hijau JKR
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36.1. Penarafan Hijau JKR -Road Sector Green rating for road works project.
36.1.1. This project shall adopt Penarafan Hijau JKR- Road Sector to measure
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the level of sustainability to be achieved. This certification is to

promote sustainable project development as well as to minimize the
impact on the environment.
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( 36.1 .2. This project shall be evaluated as at least ** ... 3 ... . Star (Certificate of
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Participation/Potential Recognition /Best Management

Practices/National Excellence/Global Excellence). This project is
designed according to the following main criteria:
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Bil Criteria
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i. Sustainable Site Planning and Management

ii. Pavement Technologies
iii. Environment and Water
iv. Access and Equity
v. Construction Activities
vi. Material and Resources
vii. Innovations
36.1.3. Penarafan Hijau JKR - Road Sector can be implemented for all project
of new roads or upgrading roads .
CGRJ29
JKR/C J/MC/N 5 /2022·3
36.1.4. The rating score is as described in pH JKR Manual for Road. This
document can be downloaded from JKR's official website .
36.1.5. There will be no fees or charges imposed for the registration and
evaluation using Penarafan Hijau JKR -Road Sector.
36.1.6. This project shall also adopt JKRlSIRIM STANDARD - JKRlSIRIM

1:2017 Manual for Green Product Scoring System (GPSS) to measure
the percentage of green product use in a building or road project.
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36.1.7. Tenderer shall comply with the Design and Construction Stage Scoring
Plan for GPSS rating.
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36.1.8. Rating scores are as described in JKRlSIRIM STANDARD -
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( JKRlSIRIM 1:2017, a document published by the Malaysian Public
Work Department with SIRIM STS. This document can be obtained at
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the SIRIM Berhad document purchase counter.
36.1.9. There will be no fees or charges imposed for the registration and
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evaluation using JKRISIRIM STANDARD - JKRlSIRIM 1:2017.
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37. Testing and Commissioning

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37.1. All equipment after installation shall be properly tested and commissioned. The
Contractor shall carry out test on all individual section of the system to prove
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that the individual capacities specified for all equipment can be produced and
maintained. He shall also carry out test as a whole to prove that the equipment
has been properly adjusted and calibrated to produce the required guaranteed
performance as offered.
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(
37.2. The testing and commissioning shall be carried out endorsed by qualified and
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competent persons. The Contractor shall also notify the p.o. where and when
these tests are to be conducted so that a representative(s) may be present for
observation and satisfaction.
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37.3. Prior to the actual testing and commissioning carried out, the Contractor shall
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put forward testing format with all information on make, type, model , serial nos. ,
etc. already printed in and a list of test to be performed and empty column or
spaces for results when actual test has been carried out. A copy of each testing
format shall be viewed and modified to p.o.'s acceptance and satisfaction .
37.4. Further adjustments to the controls shall also be made whilst the building is
occupied and the installation is in use during the defects liability period . No
additional cost shall be charged in carrying out these adjustments.
CGRl30
JKR/CJ /MC /NS/2022·3
ROADWORK D&B (BIM 51).2022
37.5. The Contractor shall also perform all other commissioning tests that may be
specified elsewhere in the Tender.
37.6. A complete record of the tests and results of such tests (whether successful or
otherwise) shall be kept up to date by the Contractor. At the conclusion of all
the tests, these records shall be collected and two (2) bound sets provided to
the P.D.
38. Building Information Modelling (BIM) Requirements
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38.1. General
Implementation of BIM is a strategic initiative for improving the delivery system
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in Government's projects. The common objectives of BIM implementation are to
improve the quality and productivity in project delivery and communication
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( among relevant stakeholders in relation to project's information dissemination
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as well as to develop structured information to facilitate rational decision making
throughout the project phases.
The Government intends to use BIM in conjunction with planning, design,

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coordination , construction and maintenance with all design and engineering
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processes being provided using BIM methodology.
38.2. Access to Electronic and Digital Files

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The P.D. shall have the non-limited rights to access all the BIM models,
analysis reports and the associated data (including drawings) stored and
EN
shared in the BIM data center. The P.O. may extend the authorization of
accessibility to his representatives and project team, as and when required
throughout the contract period at his own discretion.
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( 38.3. It is expressly agreed within the parties that all BIM models, BIM components,
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BIM Project and Family templates, BIM deliverables including but not limited to
drawings, reports, speCifications, materials, calculations, design and all other
relevant documents including other electronic and digital files pertaining to this
O
Contract shall be the absolute property of the Government and not to be

utilized or retained by the Contractor for any purpose other than with the
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permission of the Government.
None of the documents in this BIM Requirements shall be used by the

Contractor for any purpose other than this Contract. The Contractor alone is
responsible to check, verify, and otherwise confirm the accuracy of data in the
model and other related electronic and digital files including but not limited to
drawings, reports, speCifications, materials, calculations , design and all other
relevant documents produced from the model.
CGRl31
JKR/CJ/MC/NS/2022-3
The Contractor shall not make any claims and hereby waives, to the fullest
extent permitted by law, any claims or causes of action of any nature against
the Government, which may arise out of, or in connection with, the use of the
BIM and its deliverables including but not limited to Project and Family
templates reports, specifications, materials, calculations, design and all other
relevant documents including other electronic and digital files.
The Contractor shall be liable for any electronic file corruption or unintended
amendment, modification or alteration of data available in the BIM deliverables
during the transmission and/or submission process. The Contractor shall
ensure that the BIM deliverables are protected from any threat during
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transmission via folders/devices/web/internet by providing comprehensive
maintenance, routine scanning and back-up programs throughout the contract
period until the issuance of Certificate of Practical Completion, all at the
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expenses of the Contractor. The maintenance shall include all necessary
periodic servicing and renewal of licenses, fees and charges for the usage of
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( the BIM deliverables.
39. Logging
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39.1 The Contractor shall note that there may be trees of commercial value within
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the Right of Way of the road that requires to be cleared. The Contractor shall
liaise with the Jabatan Perhutanan Negeri Perlis, the State Government and
other statutory bodies before the site clearing activities.
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39.2 The Contractor is to submit all alignments to Jabatan Perhutanan Negeri

Perlis for approval and ascertain if the alignment traverses into any Pelan
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Induk Central Forest Spine (CFS), Permanent Reserved Forest (PRFs) or

Permanent Forest Estate (PFE). Any incursion into these areas the
contractor shall notify and obtain approval from Jabatan Perhutanan Negeri
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<. Perlis. Construction of signages are required as specified by Jabatan

Perhutanan Negeri Perlis.
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39.3 The Contractor shall comply to Akta Perhutanan Negara 1984 and shall
submit request for permission in writing through P.O. to the Director of Forest
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for any acts done within Permanent Reserved Forest (PRFs).

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40.0 Land Acquisition
The Contractor shall follow land acquisition process as per Land Acquisition Act
1960 (Act 486) as Amended. Under Section 4 on Gazette Notification, the Land
Acquisition Act 1960 (as Amended) that land is likely to be acquired. Gazette
Notification under Section 8 of the Land Acquisition Act 1960 (as Amended) is to
declare that land is to be acquired.
CGRl32
JKRICJ /M C/NS/2022·3
ROADWORK D&9 (91M 51) - 2022
The Contractor shall identify all land requirements for the Works, and prepare Land
Acquisition Plans, right-of-way (RoW) markings, liaising with local authorities and
including title search to enable the Government to acquire the necessary RoW . The
land Acquisition plans shall be finalized and submitted to the appropriate scales and
requirements of the Land Officel JUPEMI JKPTG. All costs for land compensation
are to be borne by the Government. The land acquisition plans shall be subjected to
the Government's approval. In respect of land acquisition and environmental
protection, the Contractor, where applicable and practical, shall satisfy the
requirement of Department of Environment unless otherwise approved by the p.o.
The contractor shall allocate sufficient time (maximum 12 months) for Land
ER
Acquisition process in the programme of works.
In the event the Contractor's design and construction of the Works requires
additional land to the above due to any error or misjudgment on the part of the
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Contractor in making due allowance for land requirements for the Works, all the cost
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of such further land acquisition and including title searched shall be borne by the
( Contractor.
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CGRl33
ER
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Appendix AI-A
N
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(Location Plan for the Works)
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Appendix AI-B
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(Alignment Plan of the Projects)
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Appendix AI-C
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(Typical Cross Section at Bridge)
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EN
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APPENDIX A1-C
PROJEK MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG

KUALA SEPULOH, PERLIS
ER
11 00
2000 3000 3000 2000 00

SHOULDER CARRIAGEWAY CARRIAGEWAY SHOULDER
D
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ASPHALTIC CONCRETE WEARING COURSE
( ACW 14
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DECK SLAB
~SLOPE
-
2.5% SLOPE
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TYPICAL BRIDGE CROSS SECTION FOR R2

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(
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AppendixA2
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(
(List of Contractor's Consultant's
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Supervision Personnel)
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(List of Contractor's Supervision
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Personnel)
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(
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APPENDIX A2-A
1.0 LIST OF CONTRACTOR'S CONSULTANT'S SUPERVISION PERSONNEL
Pursuant to Clause 1.0 of the Contractual Requirements, the works must be

supervised by the consultant engaged for the design.
The minimum requirement (but not limited to) for the personnel proposed for the
standing supervision of the Works is indicated below and as detai led out in the
Consultant's Site Supervision Organ isation Chart:
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1. Resident Engineer Civil (R .E.) with P.E - 1 no.
(mi n 10 years work experience)
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2. Assistant Resident Engineer Civil (A.R.E.) - C&S - 1 no.
(min 5 years work experience)
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3. Inspector of Works - Civil - 1 no.
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4. Inspector of Works - Electrical - 1 no.

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A2-A
APPENDIX A2-B
1.0 LIST OF CONTRACTOR'S SUPERVISION PERSONNEL
Pursuant to Clause 2.0 of the Contraclual Requirements, the works must be supervised
by the contractor's supervision team.
The personnel proposed for the standing supervision of the Works is indicated below
and as detailed out in the Contractor's Site Supervision Organisation Chart :
1. Project Manager with P.E - 1 no.
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(min 15 years work experience in related field works)
2. Site Engineer - 2 nos.

(min 10 years work experience in related field works)
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3. Safety and Health Officer - 1 no.
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( (min 5 years site work experience in related field works)
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4. Environmental Officer - 1 no.
(min 3 years site work experience in related field works)
5. Traffic Management Officer - 1 no.

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(min 5 years work experience in civil works)
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6. Site Supervisor - 2 nos.

(min 5 years work experience in civil/electrical works)
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7. Other as per requirement by the Contractor to carry out the works

(contractor to list down the requirement)
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A2-B
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Appendix A3
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(Facilities for the Project Director)
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APPENDIXA3
FACILITIES FOR THE PROJECT DIRECTOR
1.0 TRANSPORT SERVICES FOR THE PROJECT DIRECTOR AND HIS STAFF
1.1 General
(a) The Contractor shall provide suitable transportation services as specified in

Standard Specification for Road Works Section 1: General (Appendix 1C) by
means of:
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(i) 3 nos locally new assembled Completely Knocked Down (CKD) four (4) wheel
drive vehicle(s) complete with competent driver(s) for the p.o. and his staff or
any persons permitted by the P.O. for the supervision of the Works and
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administration of the Contract as and when required by the P.O. or his staff at
all times from the commencement of the Contract until the issuance of the
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Certificate of Practical Completion.
(
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(b) The Contractor shall ensure that the vehicle(s) are accident free and are in a
well maintained condition subject to certification from Puspakom at every six (6)
months.
(c) The vehicle(s) shall be in the custody of the Contractor at all times.
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(d) The Contractor shall provide comprehensive insurances to cover all drivers and
passengers, and ensure that all road tax is valid throughout the Contract Period.
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1.2 Arrangement for Transport and Failure to provide Transport
(a) The Contractor shall provide the necessary transport from the office(s) of the
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p.o. or his staff or from designated pick-up points to the Site and vice versa as
request by the P.O. or his staff. The transport shall at all times be readily
available for the use of the p.o. and his staff.
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(b) The Contractor shall notify the relevant officer should there be any delay in the
pick-up times. If the Contractor fails to notify of the delay or fails to provide the
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required transport, the officer shall have the option to arrange alternative
transport and the Contractor shall bear the expenses and an appropriate
adjustment shall be made to the Contract Sum.
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Note:
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a. All vehicles shall be assigned to and for the sole use of P.O. and his staff
b. The Contractor is assumed to provide vehicles for his Construction and
Supervising Team inclusive of the Consultants
2.0 EQUIPMENT AND FACILITIES
2.1 The Contractor shall provide the following facilities listed hereunder for the use of the
P.O. and/or his staff. All equipment(s) provided for the facilities shall be new, local
A3-J
APPENDIXA3
products as specified in Standard Specification for Road Works Section 1: General

(Appendix 1E) and shall be delivered, tested and installed within a month of the
issuance of the Letter of Acceptance. The place of delivery and installation shall be as
directed by the P.O. The facilities provided shall be maintained by the Contractor or
his appointed agent throughout the contract period until the issuance of the
Certificate of Practical Completion. Maintenance shall include all necessary monthly
servicing according to manufacturer's specification and supply of accessories and
consumables.
2.2 The equipment(s) and facilities shall be in the custody of the Contractor at all times.
Upon issuance of the Certificate of Practical Completion, the Contractor shall remove
all equipment and facilities from its location.
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2.3 If the Contractor fails to provide or maintain any equipment(s) for the facilities as listed
hereunder the Government shall have the right to procure the equipment(s) from
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other sources or maintain it and all expenses arising shall be borne by the Contractor
and an appropriate adjustment shall be made to the Contract Sum.
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(
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(a) 3 sets workstation desktop
(b) 1 sets high end specification workstation desktop with BIM Software (Refer
Appendix A3-A)
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(c) 1 sets Mobile Workstation Laptop
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(d) 5 sets printers

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(e) 1 no. Copier Machine
(f) 1 no. Projector

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(g) 1 no. Digital Camera
Notes:
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All Equipment supplied to the Project shall be reverted to the Contractor at the
( end of the Contract Period
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3.0 BIM FACILITIES

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The Contractor shall provide the following facilities for the use of the p.o. and his
project team. All equipment and facilities provided shall be genuine, new, delivered,
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installed and tested within one (1) month of the issuance of Letter of Acceptance. The
location of delivery and installation shall be as instructed by the p.o. The facilities
provided shall be maintained by the Contractor or his appointed agent throughout the
contract period until the issuance of the Certificate of Practical Completion.
Maintenance shall include all necessary monthly servicing according to
manufacturer's/system provider's specification.
If the Contractor fails to provide or maintain any facilities and equipment as specified
below, the Government shall have the right to procure the facilities/equipment from
A3-2
APPENDIXA3
other source or maintain it and all expenses arising shall be borne by the Contractor
and an appropriate adjustment shall be made to the Contract Sum.
Upon the issuance of the Certificate of Practical Completion, the Contractor shall
remove all equipment and facilities from its location.
3.1 BIM Hardware and Software (BIM Workstation)
The BIM workstation shall comprise of and be supplied with the following
requirements as listed below:
3.1.1 BIM Hardware (Computer):
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Please refer to 'Appendix A3·A.
The system should include monitor, keyboard , mouse, audio and speakers,
network interface and uninterruptible power supply.
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3.1.2 Software:
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( Please refer to 'Appendix A3·A.
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All software to be supplied under this Contract shall be original and legal
copies. The software shall be registered under the name of the Contractor.
The Contractor shall submit all documentation evidence of the originality and
legality of the software.
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The Contractor shall pay all related license renewal fees and charges,
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warranty, maintain functionality of operations for all software provided

throughout the contract period until the issuance of the Certificate of Practical
Completion.
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Upon issuance of the Certificate of Practical Completion, all equipment and

the relevant inventory shall be endorsed by the p.o. before handing over to
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the Contractor.
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A3·3
APPENDIX A3-A
Item Komputer Berspesifikasi Tinggi Berserta Perisian

BIM
Workstation Desktop I General
Brand I Model I To be proposed bv the Contractor
Function I Functional as Workstation and Local Data Storage
Hardware Specification
Chassis Micro Tower
Processor Intel Xeon Processor E3 - 1226 V3 3.30GHz or
equivalent
Clock Speed Minimum 3.20GHz
Chipset Intel C216
Cache 8MBL2
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Memory 32 GB (4x8GB) 1600MHz DDR3
Slot 4 DIMM slots
Hard Drives 1 TB 2.5 inch SSD
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Partition Configuration Windows OS (Active), Data, Recovery Image & Boot
Manager
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( Optical Drive 16x DVD +I-RW
Optical Drives 16x DVD +I-RW Drive
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Network Integrated Intel 82579 Gigabit LAN (Ethernet)
1. Integrated Intel HD Graphics 2000
Video Card
2. 4GB NVIDIA
Monitor 22" Wide Screen Monitor
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Front: 2-USB 2.0, 2-USB 3.0, 1 Microphone, 1
Headphone
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Internal: 1-USB 2.0, 2-SATA 6.0 Gbls, 2-SATA 3.0

110 Ports Gbls
Rear: 4-USB 2.0, 2-USB 3.0, 2-PS2, 2-displayport, 1-
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VGA , 1RJ45, 1-serial, 1-Audio line-in microchip, 1-

audio line-out
Kevboard Wired Business Multimedia USB Kevboard
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Software Installed
Operating System Microsoft Windows Latest Version (Pro 64-bit)
Office Suite Microsoft Office 365 Business latest version
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Microsoft Project Professional latest version

Anti Virus Kapersky or equivalent
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Others Manage Engine Desktop

BIM Software Installed (Ori~inal)
BIM software Latest version of Revit (Architecture, Structure, MEP)
Latest version of AutoCAD Civil 3D
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Latest version of Navisworks Manage

Accessories (Others)
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Cables Cables
Helpdesk Stickers Helpdesk Stickers
Utility CD Utility CD
Mouse Mouse
A3-1: 1/1
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AppendixA4
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r (JKR Green Mission 2.0)
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Not applicable
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FORM OF TENDER
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(P.W.D FORM DB/T-A2002)
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(P.W.D. Fonn DB/T-A2002)
FORM OF TENDER
(This/orm to be used/or Design & Build or Turnkey Contracts)
TENDER FOR The Design, Construction and Maintenance of
MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH,

PERLIS.
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To:
Ketua Pengarah Kerja Raya
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Ibu Pejabat JKR Malaysia
Jalan Sultan Salahuddin
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( 50582 Kuala Lumpur
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Dear Sir,
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Having examined the Govemment's Requirements including Instructions to Tenderer
and the Conditions of Contract and the Appendices annexed thereto (hereinafter referred to as
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the Pre-bid Documents) we, the undersigned, offer to design, construct and complete the said
Works in confonnity with the said Pre-bid Documents for the lump sum of Malaysian
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Ringgit ................................................................................................. .. .... .

............................ ........... (RM .......................... ) or such other sum as may be
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ascertained in accordance with the said Conditions of Contract.
2 'We undertake, if our Tender is accepted, to commence the Works on the Date of
Possession stated in the Letter of Acceptance of Tender and to complete and deliver the whole
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of the Works in confonnity with the Contract Documents within .................. ...... .... ...... .
month calculated from the said Date of Possession.
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"We undertake, if our Tender is accepted, to commence the Works on the Dates of
Possession stated in the Letter of Acceptance of Tender and to complete and deliver sections of
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the Works in confonnity with the Contract Documents by the date/period as stated in the
Govemment's Requirements.
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• Delete if sectional completion is required

•• Delete if sectional completion is not required
3. We intend, in the event of acceptance of this Tender, to choose one of the following
1
form of Performance Bond:
*i) Bank Guarantee

*ii) Finance Company Guarantee
*iii) Insurance Guarantee
*iv) Bank Islam Guarantee
*v) Bank Pembangunan & Infrastruktur Guarantee
*vi) Takaful Guarantee
*vii) Performance Guarantee Sum whereby ten percent (10%) of each interim
payment shall be deducted until the total amount deducted aggregate to a sum
equivalent to five percent (5%) of the original Contract Sum.
4. This tender shall remain valid for the period of 180 days from the date fixed for
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receiving the same and it shall remain binding upon us and may be accepted at any time before
the expiration of that period or within any extended period subsequently agreed by us.
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5. Unless and until a formal Agreement is prepared and executed, this Tender, together
with your written acceptance thereof, shall constitute a binding contract between the
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( Government and ourselves.
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6. We agree that if we withdraw our tender anytime during the tender validity period as
mentioned in paragraph 4 above or if we repudiate the Contract when the tender is awarded to
us or if we fail to provide the Performance Bond or if we fail to execute the Contract Agreement,
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the Government reserves the right to take disciplinary action against the undersigned or to
cancel the registration of the undersigned as a Government Contractor as the Government
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deems fit.
7. We acknowledge receipt of the following Addenda to the Pre-bid Document:

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Addendum No. Date

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8. We understand that you are not bound to accept the lowest or any tender you may
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receive.
9. The undersigned confirms after a personal scrutiny, that the documents used by the
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undersigned in compiling this Proposal are true copies ofthe documents included in the
Pre-bid Table Documents.
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10. We propose to engage the Consultants as listed in the List of Consultants attached.
* The tenderer to delete wh ichever is not applicable
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Dated this ...... .... .. ... .
Signature of Tenderer
Name in full
NRICNo. :
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in the capacity of
(State position held in Company)
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( du ly authorised to sign this Tender
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for and on behal f of:
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(Tenderer's seal or chop)
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Witness:
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Name:
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NRIC No.:
Occupation:
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Address
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3
List of Consultants
No. Description Name and Address
-h Arefiiteet
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2. Engineer
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(i.e. Civil & Structure) and
M&E
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3. Quantity Surveyor
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4. Independent Checkers
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( a) Structural
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No. Description Name and Address
4. Independent Checkers
b) Road safety
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( c) Geotechnical
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EN
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D.
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LETTER OF ACCEPTANCE
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(SURA T SETUJU TERIMA)
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EN
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No. T ender/Kontrak: . PK 4.2
KERAJAAN MALAYSIA
JABAT AN KERJA RA YA
SURAT SETUJU TERIMA TENDER

(Bagi Tender Kerja)
Untu k Perolehan Bagi Kerja Pembinaan
Rujukan Kami: ...... ....... .. ........... ... .

Tarikh: ..... ... .. ...... .. ...... .. . ..
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Tuan,
Tender Untuk: MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG

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SEPULOH, PERLIS
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No. Tender I Kontrak: ........ .. ..... .. ... .. ...... .. ...

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Dengan ini dimaklumkan bahawa Kerajaan telah bersetuju menerima tawaran tender tuan
dengan harga sebanyak Ringgit Malaysia: ................................... (RM ........ .. ...... ) yang
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merupakan harga kontrak bagi tempoh kontrak selama .. ............ .. . Hari/Minggu/Bulan/Tahun

tertakluk kepada dokumen tender menjadi sebahagian daripada perolehan ini dan Surat Setuju
Terima ini berserta dengan Lampiran A kepada Surat Setuju Terima iaitu maklumat terperinci
kontrak (selepas ini disebut sebagai "Surat ini").
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( 2. Dengan pengakuan penerimaan Surat ini berserta lampiran berkaitan, suatu kontrak yang
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mengikat terbentuk di antara Kerajaan dengan syarikat tuan . Satu dokumen kontrak hendaklah
ditandatangani dalam kadar segera dengan memasukkan semua terma sebagaimana dokumen
tender serta semua terma dalam Lampiran A. Sehingga dokumen kontrak tersebut
ditandatangani , Surat ini hendaklah terus mengikat kedua-dua pihak.
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3. Harga kontrak adalah tid ak termasuk cukai jualan selaras dengan pengecualian yang
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diberikan di bawah Perintah Cukai Jualan (Orang Yang Dikecualikan Daripada Pembayaran
Cukai) 2018 yang dengannya Sijil Di Bawah Perintah Cukai Jualan (Orang Yang Dikecualikan
Daripada Pembayaran Cukai) 2018 akan dikeluarkan sebelum sebarang pembayaran dibuat.
Tandatangan & Cop (Kerajaan): Tandatanga n & cop (Syarikat):
1 daripada 13
No. Tender/Kontrak: .. PK 4.2
4. Pelarasan harga dan kadar harga dalam *Jadual Kadar Harga dan /atau Ringkasan
Tender atau Senarai Kuantiti, mengikut yang mana berkenaan setelah diteliti dan diselaraskan
oleh Kerajaan tentang kemunasabahannya , yang mana akan menjadi sebahagian daripada
terma-terma kontrak. Walau bagaimanapun, Jumlah Harga Kontrak seperti di atas adalah kekal
tidak berubah.
5. Tarikh milik tapak, seperti yang disebutkan dalam Syarat-Syarat Kontrak ialah pada
........... .. ............. .... Walau bagaimanapun, tuan adalah diingatkan bahawa tiada kerja boleh
dibuat melainkan jika tuan telah mengemukakan kepada Kerajaan dokumen-dokumen berikut:
*(a) suatu bon pelaksanaan yang tidak boleh dibatalkan yang berjumlah Ringgit
Malaysia: .. .. .... ...... ...... ............ ........ .. (RM .... ................. ) dan jikalau Bon
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Pelaksanaan gaga I dikemukakan pada tarikh milik tapak, Kerajaan berhak untuk
melaksanakan kaedah Wang Jaminan Pelaksanaan;
*(b) suatu polisi Insurans Tanggungan Awam (iaitu insurans terhadap bencana kepada
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orang-orang dan kerosakan kepada harta) nilai insurans tidak kurang daripada
Ringgit Malaysia: ........................ (RM ..................... );
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*(c) suatu polisi Insurans Kerja yang berjumlah: Ringgit Malaysia:
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. (RM ............ ....... .. );
(d) nom bar Kod Majikan di bawah Skim PERKESO dan/atau Polisi Pampasan Pekerja,
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(e) Nombor Pendaftaran Kumpulan Wang Simpanan Pekerja (KWSP),
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mengikut ketetapan seperti di Lampiran A. Walau bagaimanapun, bagi memulakan kerja-kerja

dan bukan maksud lain, tuan boleh menyerahkan Nota-nota Liputan bagi maksud polisi-polisi
insurans tersebut dan resit-resit premium yang telah dibayar itu kepada Pegawai Penguasa.
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Tuan dikehendaki menyerahkan Polisi-polisi Insurans yang berkenaan Uika belum diserahkan)
menurut perenggan ini, dalam tempoh tidak lewat 30 hari daripada tarikh penyerahan Nota-nota
Liputan. Apa-apa kegagalan dalam mematuhi kehendak di perenggan ini dalam tempoh masa
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yang ditetapkan, boleh mengakibatkan Surat ini terbatal dan Kerajaan tidaklah dengan apa-apa
cara jua bertanggungan terhadap tuan melainkan jika penepian bertulis diberikan oleh orang
yang diberi kuasa , bagi kerja yang perlu dibuat dengan segera atau serta-merta apabila
kelewatan itu akan memudarat dan menjejaskan perkhidmatan dan kepentingan awam.
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6. Setelah arahan dikeluarkan oleh Kerajaan, tuan dikehendaki melaksanakan kerja dalam
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tempoh yang ditetapkan dan kualiti kerja tersebut hendaklah memuaskan hati serta memenuhi
kehendak Kerajaan . Sekiranya tuan gaga I melaksanakan kerja dalam tempoh yang ditetapkan,
Kerajaan berhak membatalkan arahan yang dikeluarkan dan/atau mengenakan Liquidated &
Ascertained Damages (LAD) seperti yang ditetapkan dalam Lampiran A.
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7. Syarikat tuan juga adalah dikehendaki melaksanakan program Professional Training And
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Education For Growing Entrepreneurs-Ready To Work (PROTEGE-RTW) seperti yang

ditetapkan oleh Kerajaan berdasarkan harga kontrak dengan bilangan minimum peserta
PROTEGE-RTW sebanyak ............ orang tanpa sebarang kos kepada Kerajaan. Bilangan
minimum peserta yang diperlukan hendaklah dikira berdasarkan formula di bawah:
Tandatangan & Cop (Kerajaan): Tandatangan & Cop (Syarika t):
2 daripada 13
No. Tender/Kontrak: PK4 .2
1% X Harga Kontrak
RM24,OOO.OO **
• Bagi tujuan pengiraan PROTEGE-RTW, Harga Kontrak ad alah harga kerja pembina ta npa cuka i
•• Elaun PROTEGE (RM 2,OOO seorang x 12 bulan)
8. Bagi tujuan program PROTEGE-RTW ini, syarikat tuan adalah dikehendaki untuk:
(a) mengemukakan Jadual Pelaksanaan Program PROTEGE-RTW berdasarkan

tempoh kontrak kepada Sekretariat PROTEGE untuk kelulusan dalam tempoh dua
(2) minggu selepas tarikh pengakuan penerimaan Surat ini oleh syarikat tuan;
(b) melaksanakan program ini mengikut Jadual Pelaksanaan Program PROTEGE-
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RTW yang diluluskan oleh Sekretariat PROTEGE;
(c) mengemaskini maklumat berkaitan pengalaman syarikat melaksanakan program

PROTEGE-RTW dalam sistem ePerolehan di Kementerian Kewangan atau sistem
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di Lembaga Pembangunan Industri Pembinaan Malaysia (CIOB), mengikut mana
yang berkaitan ;
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(d ) mengemukakan sijil atau surat pengesahan oleh Sekretariat PROTEGE kepada
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Agensi sebaik sahaja pelaksanaan program PROTEGE-RTW selesai ; dan
(e) mengemukakan laporan berkaitan pelaksanaan program PROTEGE-RTW kepada

Sekretariat PROTEGE.
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9. Se kiranya syarikat tuan gaga I mematuhi mana-mana terma di perenggan 7 dan 8 atau
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arahan oleh Kerajaan, Kerajaan berhak untuk tidak mempertimbangkan sebarang tawaran
kontrak baharu atau pelanjutan kontrak pad a masa hadapan kepada syarikat tuan.
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10. Syarikat tuan juga adalah diingatkan bahawa Kerajaan berhak untuk membatalkan Surat
ini sekiranya:
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(a ) syari kat tuan gagal mematuhi mana-mana terma di perenggan 5 dalam tempoh
masa yang ditetapkan;
(b) syarikat tuan gagal mematuhi mana-mana terma yang dinyatakan dalam Surat
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( Akuan Pembida Berjaya;

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(c) syarikat tuan gaga I memulakan kerja dalam tempoh dua (2) minggu dari tarikh milik
tapak;
(d) syarikat tuan telah membuat salah nyataan (misrepresentation) atau

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mengemukakan maklumat palsu semasa berurusan dengan Kerajaan bagi

perolehan ini atau melaku kan apa-apa perbuatan lain, seperti memalsukan
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maklumat dalam Sijil Akuan Pendaftaran Syarikat, mengemukakan bon

pelaksanaan atau dokumen lain yang palsu atau yang telah diubah suai;
(e ) syarikat tuan membenarkan Sijil Akuan Pendaftaran Syarikat disalahgunakan oleh

individu/syarikat lain;
Tandatangan & Cop (Kerajaan): Tandatangan & Cop (Syarikat):
3 daMpada 13
No. Tender/Kontrak : . PK 4.2
(f) syarikal luan lerlibal dalam membual pakalan harga dengan syarikal-syarikal lain
alau apa-apa pakalan sepanjang proses lender sehingga dokumen konlrak
dilandalangani;
(g) syarikal luan lelah memberikan subkonlrak sama ada sepenuhnya alau
sebahagiannya perkhidmalan lanpa kelulusan Kerajaan lerlebih dahulu. Sekiranya
Kerajaan meluluskan permohonan syarikal luan unluk memberikan subkonlrak
sebahagian kerja alau keseluruhan kerja , kelulusan lersebul adalah lertakluk
kepada syarikal luan mengikal perjanjian hak (Deed Of Assignment) dengan
Subkonlraklor lerlebih dahulu ;
(h) syarikal gagal menyempurnakan kerja dalam lempoh yang dilelapkan seperti di
Lampiran A;
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(i) syarikal luan gaga I memaluhi mana-mana lerma/arahan di dalam dokumen lender;
U) syarikal luan/pemiliklrakan kongsi/pengarah lelah disabilkan alas kesalahan
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jenayah di dalam alau luar Malaysia;
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( (k) syarikal luan digulungkan;
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(I) syarikal luan membekal barang-barang yang lidak lulen, bukan baharu alau yang
lerpakai;
(m) konlraklor gagal/mungkir dalam melaksanakan langgung jawabnya sepertimana

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dilelapkan dalam Syaral-syaral Konlrak;
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(n) syarikal luan lidak mendapal kelulusan daripada Kerajaan lerlebih dahulu bagi apa-
apa penjualan alau pemindahan ekuili sepanjang tempoh konlrak ini berkual kuasa;
alau
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(0) lerdapat perkara yang melibatkan kepenlingan awam atau keselamalan dan
kepentingan negara.
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11 . Sekiranya Sural ini dibalalkan atas alasan seperti yang ditetapkan di perenggan 10,
Kerajaan lidak akan bertanggungan terhadap apa-apa kerugian syarikat luan lermasuk
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kerugian masa hadapan.

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12. Bersama-sama Sural ini disertakan Sural Akuan Pembida Berjaya dan Surat Akuan
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Sumpah Syarikal seperti di Lampiran B dan Lampiran C unluk dilandalangani oleh syarikal
luan dan dikembalikan bersama-sama dengan Sural ini.
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13. Syarikal luan juga adalah dikehendaki untuk mengemukakan dokumen berikul bersama-
sama dengan Sural ini yang lelah dilandatangan balas oleh luan, unluk kelulusan Pegawai
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Penguasa sebelum memulakan kerja di lapak bina:
(a) Senarai nama subkontraklor berserta pengalamannya dengan menyalakan

bahagian kerja yang terlibat; dan
(b) Program Kerja bagi pelaksanaan projek ini.
Tandata ngan & Cop (Kerajaan): Tandatangan & Cop (Syarikat):
4 danpada 13
No. T ender/Kontrak : .. PK 4.2
14. Berdasarkan kepada Tempoh Siap Kerja yang ditenderkan selama

......... harilminggu/bulan. Tarikh Siap untuk seluruh kerja-kerja di bawah kontrak ini ialah
pada .... .. ................ ..
15. Surat ini dihantar kepada syarikat tuan dalam tiga (3) salinan. Sila kembalikan ke pejabat
ini salinan asal dan kedua beserta lampiran yang berkaitan yang telah ditandatangani dengan
sempurna oleh syarikat tuan dan saksi syarikat tuan tidak melebihi *3/7/14 hari dari tarikh Surat
ini diterima untuk tindakan kami selanjutnya. Apa-apa kegagalan dalam mematuhi kehendak di
perenggan ini dalam tempoh masa yang ditetapkan boleh mengakibatkan Surat ini terbatal dan
Kerajaan tidaklah dengan apa-apa jua bertanggungan terhadap syarikat tuan .
Sekian. terima kasih .
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"MALAYSIA MADANI"
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"BERKHIDMAT UNTUK NEGARA"
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( Saya yang menjalankan amanah .
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(Nama Penuh Pegawai)
Jawatan Pegawai
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Tandatanga n & Cop (Kerajaa n): Tandata ngan & Cop (Syarikat):
5 daripada 13
No . T ender/Kontrak : PK 4.2
PENGAKUAN PENERIMAAN SURAT SETUJU TERIMA DAN

LAMPIRAN YANG BERKAITAN OLEH SYARIKAT
Dengan ini disahkan bahawa yang bertandalangan di bawah ini mengakui penerimaan Sural ini
dan lampiran yang berkailan yang rujukannya ialah " ........ " " .. "...... ........... bertarikh
" ........ " " .......... " .. ,," dan berseluju dengan lerma dan syaral yang lerkandung dalam Sural
ini lanpa syaral yang mana salinan kepada Sural ini lelah pun disimpan, dan selanjulnya
disahkan bahawa liada apa-apa lerma, syaral alau slipulasi lambahan kepada yang lerkandung
dalam dokumen lender dan Sural ini lelah dikenakan .
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( Nama Penuh: Nama Penuh :
No. Kad Pengenalan : No. Kad Pengenalan :
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Alamal: Alamal :
Tarikh: Tarikh :
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Melerai alau Cop Syarikal

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Tandatanga n & Cop (Kerajaan): Tandatangan & Cop (Syarikat):
6 da ripada 13
No . Tender/Kontrak: . PK 4.2
LAMPIRANA
BUTIRAN KONTRAK
1. Pendaftaran Syarikat Oengan Suruhanjaya Syarikat Malaysia (SSM) Atau Pendaftaran

Koperasi Oengan Suruhanjaya Koperasi Malaysia (SKM) (jika berkaitan)
1.1 No. Pendaftaran
1.2 Tempoh Sah Laku
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2. Pendaftaran dengan Lembaga Pembangunan Industri Pembinaan Malaysia (CIOB) Oi Bawah
Perakuan Pendaftaran Kontraktor
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2.1 No. Pendaftaran
N
Tem poh Sah Laku
( 2.2
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2.3 Gred
2.4 Kategori
2. 5 Pengkhususan
A
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3. Pendaftaran dengan Lembaga Pembangunan Industri Pembinaan Malaysia (CIOB) Oi Bawah

Sijil Perolehan Kerja Kerajaan (jika berdaftar)
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3.1 No. Pendaftaran
3.2 Tempoh Sah Laku

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3.3 Gred
3.4 Kategori
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( 3. 5 Pengkh ususan
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4. Pendaftaran dengan Pusat Khidmat Kontraktor (PKK) (Sijil Taraf Bumiputera) (jika
berdaftar)
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4.1 No. Pend aftaran

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4.2 Tempoh Sah Laku
4.3 Gred Kontraktor
Tandatangan & cop (Kerajaan): Tandatangan & c op (Syarikat):
7 daripada 13
No. Tender/Kontrak: PK4 .2
LAMPIRAN A
5. Pendaftaran dengan Pusat Pendaftaran Kontraktor Keria. Bekatan Perkhidmatan Negeri

Sabah (PUKONSA) Oika berdaftar)
5.1 No. Pendaftaran
5.2 Tempoh Sah Laku
5.3 Gred Kontraktor
5.4 Kepala
5.5 Sub Kepala
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6. Pendaftaran dengan Unit Pendaftaran Kontraktor dan Juruperunding. Peiabat Setiausaha
Kewangan Negeri Sarawak (UPKJ) Oika berdaftar)
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6.1 No. Pendaftaran
N
6.2 Tempoh Sah Laku
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6.3 Gred Kontraktor
6.4 Kod Bidang
7. Harga dan Tempoh Kontrak

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7.1 Harga Tender (butiran : RM ....... . ...... .
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harga seperti di Lampiran A 1)

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7.2 Harga Kontrak :RM ............. . .. . .... .
7.3 Tem poh Kontrak

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7.4 Tarikh Mil ik Tapak
7.5 Tarikh Siap Kerja

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8. *Bon Petaksanaan
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8.1 Kadar Bon 5%

Pelaksanaan
8.2 Formula Bon ~xR M ...... . . . . . .. .. .... . . . . . ... ... . . . ..... ..... .
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Pelaksanaan
8.3 Nilai Bon RM ............. .... ...... . .. . ............................. ... ... ... .. . ...... .
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Pelaksanaan
8.4 Bentuk Bon Jaminan Bank! Bank Islaml Bank Pembangunan Malaysia
Pela ksanaan Berhad ; atau Jam inan Syarikat Kewangan ; atau Jaminan
Insuransl Takaful.
Jikalau Bon Pelaksanaan gagal dikemukakan pada tarikh

milik tapak. Kerajaan berhak untuk melaksanakan kaedah
Wang Jaminan Pelaksanaan.
Tandatangan & cop (Kerajaan): Tandatangan & cop (Syarikat):
8 daripada 13
No. Tender/Kontrak : . PK4.2
LAMPIRANA
8.5 Tempoh Sah Laku 'Dari tarikh kuat kuasa kontrak sehingga 12 bulan selepas
tamat Tempoh Tanggungan Kecacatan (DLP) - bagi projek
bernilai sehingga RM10 juta; atau
'Dari tarikh kuat kuasa kontrak sehingga 24 bulan selepas

tamat Tempoh Tanggungan Kecacatan (DLP) - bagi projek
bernilai melebihi RM10 juta.
Mengikut format yang ditetapkan oleh Kerajaan seperti di Lampiran A4
9. No. Kod Majikan PERKESO/No. Pendaftaran KWSP/'Polisi Insurans Kerja
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9.1 No. Kod Majikan
PERKESO
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9.2 No. Pendaftaran
KWSP
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( '9.3 Nilai Polisi RM .... ...... . .... ...... .. .. .. .. . ......... .
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'9.4 Tempoh Perlindungan Meliputi tempoh kontrak
10. 'Polisi Insurans Tanggungan Awam

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10.1 Nilai Polisi RM ..
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10.2 Tempoh Perlindungan Meliputi tempoh kontrak, tempoh tanggungan kecacatan dan
14 hari dan 3 bulan
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11. Kenaan Liguidated & Ascertained Damages (LAD)

(Lewat menyiapkan kerja mengikut jadual yang ditetapkan)
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11 .1 Formula
11.2 Kadar sehari :RM ..

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12. 'Professional Training And Education For Growing Entrepreneurs - Ready To Work
(PROTEGE-RTW) Wka berkaitan)
(Bagi perolehan yang telah melebihi nilai am bang berdasarkan PP/PK1.2)
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12.1 Tertakluk kepada Ya I Tidak

pelaksanaan Program
PROTEGE-RTW
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12.2 Bilangan minimum .............. peserta

peserta Program
Tandatangan & cop (Kerajaan): Tandatangan & cop (Syarikat):
9 daripada 13
No. Tender/Kontrak: PK 4.2
LAMPIRAN A
Salinan Kepada:
1. Ketua Setiausaha Kementerian Kerja Raya

Aras 6, Kompleks Kerja Raya
Jalan Sultan Salah uddin
50580 KUALA LUMPUR
2. Pejabat Ketua Pegawai Eksekutif
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Ibu Pejabat Lembaga Hasil Dalam Negeri Malaysia
Menara Hasil, Aras 18, Persiaran Rimba Permai , Cyber 8
63000 CYBERJAYA
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3. Ketua Eksekutif
Lembaga Pembangunan Industri Pembinaan Malaysia
N
Tingkat 10, No. 45, Menara Dato' Onn , Pusat Dagangan Dunia Putra , Jalan Tun Ismail
( 50480 KUALA LUMPUR
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4. Ketua Setiausaha
Kementerian Pembangunan Usahawan dan Koperasi
Pusat Khidmat Kontraktor, Aras 5, Siok Menara, Menara Usahawan
A
No. 18, Persiaran Perdana Presint 2
62652 PUTRAJAYA
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(u .p: Pengarah Pusat Khidmat Kontraktor)
5. Sekretariat
Majlis Perundingan Gaji Negara , Kementerian Sumber Manusia
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Aras 7, Siok D3, Kompleks D

62530 PUTRAJAYA
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6. Profesional Training & Education For Growing Entrepreneurs (PROTEGE)

Aras 2 Siok E4/5 Parcel E
Kementerian Pembangunan Usahawan dan Koperasi
Pusat Pentadbiran Kerajaan Persekutuan
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<. 62668 PUTRAJAYA

(u .p: Ketua Sekretariat PROTEGE)
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7. Ketua Pegawai Eksekutif

Kumpulan Wang Simpanan Pekerja , Jabatan Penguatkuasaan
Tingkat 13, Sangunan KWSP, Jalan Raja Laut
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50350 KUALA LUMPUR

(u .p: Ketua Unit Forensik Majikan dan Hubungan Luar, Seksyen Operasi)
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8. Lembaga Perolehan Kementerian Kerja Raya

(u .p: Urusetia Tender, Kementerian Kerja Raya)
Tandatanga n & Cop (Kerajaan): Tandatangan & Cop (Syarikat):
10 daripada 13
No. Tender/Kontrak : .......... .. . . PK 4.2
LAMPIRAN B
SURAT AKUAN PEMBIDA BERJAYA
Saya ......... .... .. ...... ............... ........... ......... .... ....... .. ........ . nombor Kad Pengenalan .................. .
yang mewakili ....... ..... ..... ............. ........................... nombor Pendaftaran .... .... .... ...... ,............. .
dengan ini mengisytiharkan bahawa saya atau mana-mana orang yang mewakili syarikat ini:
tidak akan menawarkan, menjanjikan atau memberikan apa-apa suapan kepada mana-mana
orang dalam mana-mana Kementerian/Agensi atau mana-mana orang lain, sebagai sua pan
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untuk dipilih dalam mana-mana perolehan; dan
tidak akan melakukan atau terlibat dengan tipuan bida dalam mana-mana perolehan .
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Bersama ini dilampirkan Surat Perwakilan Kuasa bagi saya mewakili syarikat seperti tercatat
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di atas untuk membuat pengisytiharan ini.
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2. Sekiranya saya, atau mana-mana individu yang mewakili syarikat ini didapati terlibat
dalam membuat pakatan harga dengan syarikat lain atau apa-apa pakatan sepanjang proses
perolehan atau menawarkan , menjanjikan atau memberikan apa-apa suapan kepada mana-
mana orang dalam Kementerianl Jabatan Keria Raya atau mana-mana orang lain sebagai
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dorongan untuk dipilih dalam perolehan seperti di atas, maka saya sebagai wakil syarikat
bersetuju tindakan-tindakan boleh berikut diambil:
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2.1 Penarikan balik tawaran kontrak bagi perolehan di atas; atau

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2.2 Penamatan kontrak bagi perolehan di atas; dan
2.3 Lain-lain tindakan undang-undang/tatatertib mengikut undang-

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undang/peraturan perolehan Kerajaan yang berkuat-kuasa.
3. Saya sesungguhnya faham bahawa:

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3.1 saya atau mana-mana orang yang berkaitan dengan syarikat boleh didakwa
( bagi kesalahan** di bawah Akta Suruhanjaya Pencegahan Rasuah Malaysia
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2009 [Akta 694] dan Kanun Keseksaan [Akta 574] serta boleh dihukum di
bawah undang-undang masing-masing atas kegagalan saya atau mana-mana
orang yang mewakili syarikat ini untuk mematuhi perkara (i) dalam surat akuan
ini; atau
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3. 2 tindakan boleh dikenakan ke atas syarikat di bawah Akta Persaingan 2010

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[Akta 712] atas kegagalan saya atau mana-mana orang yang mewakili syarikat
ini untuk mematuhi perkara (ii). Sekiranya syarikat didapati melanggar
peruntukan seksyen 4(2 )(d) Akta 712, syarikat boleh didenda tidak melebihi
sepuluh peratus (10%) daripada pusing ganti (turn over) seluruh dunia
sepanjang tempoh suatu pelanggaran itu berlaku.
Tandatangan & Cop (Kerajaan): Tandatangan & Cop (Sya rikat):
11 danpada 13
No . Tender/Kontrak: . PK 4.2
4. Sekiranya lerdapal mana-mana orang cuba memperolehi alau meminla apa-apa

sua pan daripada saya alau mana-mana orang yang berkailan dengan syarikal ini sebagai
dorongan unluk dipilih dalam perolehan seperti di alas, maka saya berjanji akan dengan
segera melaporkan perbualan lersebul kepada pejabal Suruhanjaya Pencega han Rasuah
Malaysia (SPRM) alau balai polis yang berhampiran. Saya sedar bahawa kegagalan saya
berbual demikian adalah merupakan sualu kesalahan di bawah seksyen 25 (1) Akla
Suruhanjaya Pencegahan Rasuah Malaysia 2009 [Akta 694) dan boleh dihukum di bawah
seksyen 25 (2) akla yang sama, apabila disabilkan boleh didenda lidak melebihi RM100,OOO
alau penjara selama lempoh lidak melebihi sepu luh lahun alau kedua-duanya.
5. Saya sesungguhnya faham bahawa syarikal melakukan kesalahan jika seseorang yang
bersekulu dengan syarikal*** memberikan, menjanjikan alau menawarkan sua pan unluk
memperoleh alau mengekalkan perniagaan alau faedah dalam menjalankan perniagaan di
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bawah seksyen 17A Akla Suruhanjaya Pencegahan Rasuah Malaysia 2009 [Akta 694],
apabila disabilkan kesalahan boleh didenda lidak kura ng daripada sepuluh kali ganda jumlah
alau nilai suapan , atau RM1 juta, atau dipenjarakan selama tempoh tidak melebihi dua puluh
tahun atau kedua-duanya
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Yang benar,
Tandatangan
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No.KP
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Tarikh
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Cop Syarikat
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<. Catatan :
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• poto ng mana tidak berkenaan
•• termasuk kesalahan ditetapkan dalam Jadual (Perenggan 3 (a), takrif "kesalahan ditetapkan") Akta Suruhanjaya Pencegahan
Rasuah Malaysia 2009 (Akta 694) yang boleh dihukum di bawah Kanun Keseksaan .
... seseorang yang bersekutu dengan syarikat merujuk kepada seksyen 17A (6) Akta Suruhanjaya Pencegahan Rasuah
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Malaysia 2009 (Akta 694), iaitu seseorang itu bersekutu dengan organisasi komersial jika dia seorang pengarah , pekongsi atau
pekerja organisasi komersial itu atau dia ialah orang yang melaksanakan perkhidmatan untuk atau bagi pihak organisasi
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komersial itu .
Surat akuan ini hendaklah dikemukakan bersama surat perwakilan kuasa
T andatangan & Cop (Kerajaan): Tandatangan & Cop (Syarikat):
12 danpada 13
No . T ender/Kontrak: ....... .. ... .. . PK 4.2
LAMPIRAN C
SURAT AKUAN SUMPAH SYARIKAT
Saya ..... ... .......... .... .. .............. .... . ..... ..... ... nombor kad pengenalan ........... 0 0 .. ... 0 • •• • •
yang mewakili syarikat ............................ nombor pendaftaran ........... .. 0 ••• 0 ••••••
(*MOF/CIDB/SSM) dengan sesungguhnya dan sebenarnya mengaku bahawa:
(a) syarikat TIDAK membuat salah nyataan (misrepresentation) atau

mengemukakan maklumat palsu semasa berurusan dengan Kerajaan bagi
perolehan ini atau melakukan apa-apa perbuatan lain, seperti memalsukan
maklumat dalam Sijil Akuan Pendaftaran Syarikat, mengemukakan bon
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pelaksanaan atau dokumen lain yang palsu atau yang telah diu bah suai;
(b) syarikat TIDAK membenarkan Sijil Akuan Pendaftaran Syarikat disalahgunakan
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oleh individu/syarikat lain;
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(c) syarikat TIDAK terlibat dalam membuat pakatan harga dengan syarikat-syarikat
( lain atau apaapa pakatan sepanjang proses *seslJt haF§a/tender sehingga
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dokumen kontrak ditandatangani;
(d) syarikat/pemilik/rakan kongsi/pengarah TIDAK disabitkan atas kesalahan

jenayah di dalam atau luar Malaysia; dan
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(e) syarikat TIDAK digulungkan.
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Sekiranya pada bila-bila masa, dibuktikan bahawa pengisytiharan perenggan di atas adalah
tidak benar, Kerajaan berhak menarik balik tawaran kontrak atau menamatkan perkhidmatan
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syarikat bagi projek ini.
Dan saya membuat Surat Akuan Bersumpah ini dengan kepercayaan bahawa apa-apa yang
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tersebut di dalamnya adalah benar serta menurut Akta Akuan Berkanun 1960.
Diperbuat dan dengan

sebenar-benarnya diakui oleh
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Tandatangan ........ .. ... ..... 0 • • •••••• 0 ••

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di
pada
Di hadapan saya,
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Pesuruhjaya Sumpah
Catatan:
i. · Potong ma na yang tidak berkenaan.
ii. Su rat akuan ini hendaklah ditandatangani oleh hanya penama di sijil pendaftaran MO F/CI DB
Tandatanga n & Cop (Kerajaan): Tanda tangan & Cop (Syarikat):
13 danpada 13
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CONDITION OF CONTRACT
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GOVERN MENT OF MALAYSIA
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STANDARD FORM OF DESIGN AND BUILD CONTRACT
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PWD FORM DB (Rev. 1/2010)
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Hak Cipta Terpelihara Kerajaan Malaysia

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CONDITION OF CONTRACT
FOR DESIGN AND BUILD CONTRACT

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PWD FORM DB (Rev, 112010)
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Th'is form has been approved 'by Attorney General's Chamber'

TABLE OF CONTENTS
Clause Page
1.0 DEF INITIONS AND INTERPRETATIONS 2

2.0 CONSIDERATION 4
3.0 SCOPE OF CONTRACT 4
4.0 REPRESENTATIONS , WARRANTI ES AN D UN DERTAKINGS OF T HE 5
CONTRACTOR
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5.0 COMPLIANCE WITH THE LAW IN PERFORMING TH E WORKS 6
6.0 CUSTODY AND SUPPLY OF CONTRACT 7
7.0 SUFFICIENCY OF CONTRACT DOCUMENTS 8
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8.0 RI GHTS OF p.o . 9
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9.0 CONTRACTOR'S PROJ ECT MANAGER 10
( 10.0 PERFORMANCE BOND 10
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11 .0 INSURANC E OF WORKS 11
12.0 POSSESSION OF SITE 12
13.0 PERFORMANCE OF TH E WORKS 13
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14.0 DESIGN 16
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15.0 MATERIALS , GOODS AND WORKMANSHIP 19
16.0 RESTRICTION AND PROCEDURE ON USE OF IMPORT ED MAT ERIALS AND 20
GOODS
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17.0 CONSTRUCT IONAL PLANT, EQU IP MENT , VEHICLES AND MACHI NERI ES 21
18.0 NON-REMOVAL OF MATERIALS AND GOODS ON SIT E 21
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19.0 SITE BOUNDARI ES AND SETTI NG OUT 22

20.0 ANTIQUIT IES 23
21 .0 INSPECTION OF SITE 23
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23.0 VARIATIONS 24
24.0 VALUAT ION OF VARI ATIONS 25
25.0 PROVISIONAL SUMS 25
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26.0 EMPLOYMENT OF WORKM EN 26

27.0 COMPLIANCE WITH EMPL YMENT ACT 1955, ETC 26
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28.0 EPIDEMICS AND MED ICAL ATTENDANCE 26

29.0 DAYS AND HOURS OF WORKING 27
30.0 WAGES, BOOKS AND TIME SH EETS 27
31.0 DEFAULT IN PAYMENT OF WAGES 28
32.0 DISCHARGE OF WORKMEN 28
33 .0 EMPL YEESS' SOCIAL SECURITY ACT 1969 28
34 .0 INDEMNITIES TO GOVERNMENT IN RESPECT OF CLAIMS BY WORKMEN 29
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Clause Page
35.0 CONSU LTANTS 29

36.0 DIRECT PAYMENTS TO CONTRACTOR'S CONSULTANTS 30
37.0 SUB-CONTRACTTING AND ASSIGNM ENT OF CONSULTANT'S 32
RESPONSIBILITY
38 .0 GOVERNMENT'S INDEMNITY IN RESPECT OF INJURY TO PERSONS AND 32
DAMAG E TO PROPERTY
39.0 INSURANCE AGAINST INJURY TO PERSONS AND DAMAG E TO 33
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PROP ERTY
40.0 SUB-CONTRACTING AND ASSIGNM ENT 34
41.0 BUMIPUTERA PARTICIPATION 35
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42 .0 TESTING AND COMMISSIONING OF MECHANICAL, ELECTRICAL AND 36
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( OTH ER SERVIC ES
43.0 SECTIONAL COMPLETION 36
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44 .0 COMPLET ION OF THE WORKS 37
45.0 DAMAG ES FOR NON-COMPLETION 38
46 .0 PARTIAL OCCU PATION I TAKI NG OVER BY GOVERNMENT 39
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47 .0 DEFECTS AFTER COMPLETION 39
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48.0 UNFU LF ILLED OBLIGATIONS 40
49.0 DELAY AND EXTENSION OF TIME 41
50.0 PROCEDURE FO R CLAIMS 42
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51.0 INTELLECTUAL PROPERTY RIGHTS, RO YALTUIES, E TC. 42

52.0 MAINTENANCE OF WORKS AND SERVICES 43
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53.0 INTERIM PAYM ENTS 44

54.0 FINAL ACCOUNT AND FINAL CERTIFICATE 45
55.0 EFF ECT OF P.D'S CERTIFICATES AN D PAYME NT BY GOVERNMENT 46
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56.0 DEDUCTION FROM MONEY DUE TO CONTRACTOR 46

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57.0 ADVANCE PAYMENT 46

58 .0 PROVISIONAL BILLS OF QUANTITI ES 47
59.0 SUSPENS ION 48
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60.0 EVENTS AN D CO NSEQUENC ES OF DEFAULT BY THE CONTRACTOR 49

61 .0 TERMINATION ON CORRUPTION, UNLAWFUL OR ILLEGAL ACTIVITIES 52
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62.0 TERMINATION ON NATIONAL INTEREST 52

63.0 PAYM ENTS UPON SUSPENSION OR TERMINATION ON NATIONAL 53
INTEREST
64.0 EVENTS AND CONS EQUENC ES OF DEFAULT BY THE GOVERNMENT 53
65.0 CERTI FICATE OF TERMINATION COSTS 54
66.0 SURVIVING RIGHTS 55
67.0 FORCE MAJEURE 55
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Clause Page
68 .0 ARBI TRATION 56
69 .0 SAFETY AT SITE 57
70 .0 TECHN OLOGY TRANSFER 58
71.0 ENVIRONMENTAL MATTERS 58
72.0 LAW GOVERNING THIS CONTRACT 59
73 .0 COMPLIANC E WITH THE LAW 59
74.0 AMEN DMENT 59
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75.0 CONF IDENTIALI TY 59
76 .0 STAMP DUTY 60
77.0 NOTICES 60
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78 .0 TIM E 61
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79 .0 SEVERAB ILITY 61
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LIST OF APPENDICES
AP PENDIX 1 AP PENDIX TO THE CONDITION OF CONTRACT

APPEND IX 2 GOVERNMENT'S REQUIREM ENTS
APPENDIX 3 CONTRACTOR'S PROPOSAL
AP PENDIX 4 CONTRACT SUM ANALYSIS
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AP PENDIX 5 CONTRACT SCHEDULE OF RATES
APPENDIX 6 CERTIFIED COPY OF BANK GUARANTEE FOR PERFORMANCE BOND
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APPENDIX 7 LIST OF GOVERNMENT MULTI MODAL TRANSPORT OPERATORS
AP PENDIX 8 DETAILED DESIGN AND SPECIF ICATIONS
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iv
CONTRACT NO: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Of 20 _ __
EXPENDITURE to be met from Head _ _ _ _ _ _ _ _ Year of _ _ _ _ __
Sub-head _ _ _ _ _ _ __
THIS CONTRACT is made on the _ _ _ day of _ _ _ _ _ _ _ _ 20 _ _ __
BETWEEN
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THE GOVERNMENT OF MALAYSIA (hereinafter referred to as "the Government") of the one part;
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AND
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(
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ (hereinafter referred to as "the Contractor"), [a
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company incorporated in Malaysia under the Companies Act 1965 (Com . No . ) J with its
registered office at of
the other part.
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(The Government and the Contractor shall hereinafter individually be referred to "Party" or collectively as the
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"Parties")
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WHEREAS
A. The Government is desirous of obtaining the design , construction , equipping' and maintenance'
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of MEMBINA JALAN DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH, PERLIS

(hereinafter referred to as the 'Works') at PERLIS for which Works the Government has
issued to the Contractor its requirements and instructed the Contractor to design Ihe
Works and to submit proposals including drawings and specification for carrying out the
Works .
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( The Contractor has examined the site and has submitted proposals including drawings and
B.
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specification for carrying out the Works .
C. The Contractor has made an estimate of Ihe sum which he will require for carrying out that which
is necessary for completing all the Works in accordance with the Conditions of Contract and has
submitted an analysis of that sum (hereinafter referred to as 'the Contract Sum Analysis').
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D. The Government has examined the Contractor's Proposals and the Contract Sum Analysis and
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subject to the Conditions of Contract, is satisfied that they appear to meet the Government's
Requirement. +
, Delete if not applicable

# State the title of intended works .
+ \M)ere the Government has accepted a divergence in the Proposals submitted by the Contractor from the Government's
Requirements, the divergence should be effected by deletion or substitution in the Government's Requirements before the
contract documents are signed.
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NOW IT IS HEREBY AGREED AS FOLLOWS:
1.0 DEFINITIONS AND INTERPRETATIONS
1.1 Definitions
In this Contract. unless the context otherwise requ ires , the following words and phrases in this
Contract and the Appendices shall have the meaning given below:
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(a) "Append ices" means Appendix 1, 2, 3, 4, 5" , SA , SB, 6. 6A, 66 , 7, and 8 to
this Contract;
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(b) "Contract" means this Contract includ ing all the appendices and special
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( provisions attached hereto ;
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(c) "Contractor" means the person or persons , sole proprietor, partnership , firm
or company whose tender for the Work s has been accepted
and who has or have signed this Contract and includes Ihe
Contractor's personal representatives, heirs , successors ,
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executors, administrators , servant and agent;
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(d) "Contractor's Proposals" means the proposals submitted by the Contractor for carrying
out the Works , including all drawi ngs which comprises of
preliminary design and specifications as appended herewith
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and Detailed Design and Specifications as submitted by the

Contractor from time to time;
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(e) "Contract Period" means the contra ct period specified in the Letter of
Acceptance;
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( (I) "Contract Sum" means the sum stipulated in clause 2.2 of this Contra ct;
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(g) "Contract Sum Analysis " means the sum stated in Appendix 4 which is prepared by the
Contractor as the estimate which he will require for carrying
out that which is necessary for completing all the Works in
accordance with this Contract;
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(h) " "Contract Schedule of Rates" means the schedule of rates agreed between the Contractor
and the Government prior to the execution of the Contract,
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for the purpose of valuation of variations under the Contract;
.. Delete if Contract Schedule of Rates is not applicable
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(i) "Date for Completion" means the date fixed and stated in Appendix 1 or any date
fixed under clause 49 as provided under clause 44 .1;
"Date for Possession" means the date stated in Appendix 1;
(k) "Date of Tender" means the date fixed for submission of Tender as stated in
Appendix 1;
(I) "Day work" means the Day work price as specified in Appendi x ( 56 ];
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(m) "Defects Liability Period" means the period stated in Appendix 1 or if none stated the
period is twenty four (24 ) months from the date of practical
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completion certified by the P.D as provided under clause 44 .2;
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( (n) Government's Requirements means in structions given by the Government to the Contractor
which contain information relating to the criteria, performance
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specification and outcome expected of the Works in order for
the Contractor to prepare its proposals ;
(0)
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"On-cost Charges" means the cost and expense reasonably incurred by the
Government to perform the Contractor's obligations which the
Contractor has fai led to perform and is calculated by applying
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the percentage for On-cost Charges as stated in Appendix 1 to

the amount incurred ;
(p) "Site" means the land and other places on , above , under, in or
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through which the Works are to be executed and any other

lands or places provided or approved by the Government for
working space or any other purpose as may be specifically
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deSignated under this Contract or subsequently agreed by the

P.D as forming part of the Site ;
(q) 'Project Director or P.D" means ' Rujuk Kepada Surat Arahan KPKR Bit. 16/2018 and
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( his successors in office;

(r) "P.D's Representative" means any person delegated by the P.D to perform any or all
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of the duties of the P.D ;
(s) "Variation Order" means an instruction issued by the P.D in the fo rm as set out
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in Appendix (to refer to PWD DG's Circutar] pursuant to

clause 23 .2; and
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(t) "Works" means the works briefly described in Recital A and referred to
in the Government Requirements and the Contractor's
Proposals and shall include both permanent and temporary
works .
State the official designation of the officer responsible for the overall supervision and direction of the Works.
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1.2 Interpretation
<a) Unless otherwise specifically stated . any refe rence to Clauses and Appendices in this
Contract and the Appendices to any clause means that clause of this Contra ct.
(b) This Contract and the Appendices are to be rea d as a whole and the effect or operation
of any clause in this Contra ct or item in or entry in the Appendices shall . unless otherwise
specifically stated . be rea d subject to any rel evant qualification or modification in an y
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other clauses in this Contract or item or entry in the Appendices.
(c) The terms "concurrence " and "approval" wherever used in this Contract means written
consent or approval by the Government or the P 0 as the ca se may be , pursuant to a
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written request or submission made by the Contractor;
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( (d) The term "instructed" wherever used in this Contract means instructed in writing by the
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P.D (including subsequent confirmation of previous verbal instruction by the P.O).
(e) Words importing the singular shall also include the plural and vice versa.
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(f) The headings are for convenience of reference only and shall not be deemed to be part
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of this Contract or be taken into consideration in the interpretation or construction of this
Contract.
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(g) The English text of this Contract shall be the authentic text and prevail over any
translations made on thi s Contract.
2.0 CONSIDERATION
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2.1 For the consideration mentioned in clause 2.2, the Contractor shall upon and subject to the
clauses of this Contract both complete the design for the Works and carry out construction and
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l completion of th e Works .
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2.2 The Government hereby covenants to pay to the Contractor the sum of Malaysian Ringgit:
=""7-:-;-;:;_-;;--:--:-:::-.,-;;.,---,-,i.e. RM (hereinafter referred to as ·the

Contract Sum') or such other sum as shall become payable hereunder at the times and in the
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manner specified in the Conditions of Contract.

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3.0 SCOPE OF CONTRACT
3.1 The Contractor shall subject to the provisions of the Contract and save in so far as it is legally or
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physically impossible, -
(a) plan, design , cons truct, complete, test and comm iss ion the Works in accordance wi th
the Contract; and
(b) provide all design, service s, labou r, materials , Contractor's equipment, temporary works ,
transport to and from and in or abo ut the Site and everything wheth er of a temporary or
permanent nature required in and for such planning, design , construction , completion,
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testing and commissioning so far as the necessity for providing the same is specified in
or reasonably to be inferred from the Contract.
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3.2 The Contractor shall design, construct and complete the Works in accordance with th e Contract
and where not expressly provided otherwise in the Contract, to the best advantage of the
Government and in accordance with good management and best industry practice, as
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( determined by the Government.
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3.3 The Contractor shall take all appropriate measures expected of a comp etent con tractor using due
care and skills of a professional person providing sim ilar service or works to ensure that the
Works comply with th e terms and conditions of this Contract.
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3.4 The Contractor shall at all times perform its obligations specified in cl ause 3.1 in such manner as
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will always safeguard and protect the Government's interest and take all necessary and proper
steps to prevent abuse and in accordance with the provisions of this Contract.
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4.0 REPRESENTATIONS, WARRANTIES AND UNDERTAKINGS OF THE CONTRACTOR

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4.1 Representations and Warranties
The Contractor rep resents and warrants to the Government that as at the execution date and
through out the Contract Period- .
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(a) the Contractor is a corporation validly existing under the laws of Malaysia' ;
(b) the Contractor has obtained a valid regi stration with the Constru ction Industry
Development Board;
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(c) the Contractor has the corporate power to enter into and perform his obligations under
this Contract and to carry out the transactions and to carryon his business as
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contemplated by this Contract';
(d) the Contractor has taken all necessary corporate actions to authorize the entry into and
performance of this Contract and to carry out the transactions contemplated by this
Contract' ;
• applicable onfy if the Contractor is a company registered under the Companies Act 1965.
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(e) neither the execution nor performance by it of this Contract nor any transactions
contemplated by this Con tract will viola te in any re spect any provision of-
(i) its Memorandum and Articles of Association; or
(ii) any other document or agreement which is binding upon it or its asset' ;
(f) no litigation , arbitration, tax claim, dispute or administrative proceeding is presently

current or pending or, to its knowledge, threatened , which is likely to have a material
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adverse effect upon it or its ability to perform its fi nancial or oth er obligations under this
Contract;
(g) this Contract cons titutes a legal, valid and binding obligation of the Contractor and is
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enforceable in accordance with its terms and conditions; and
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(h) it has necessary financial and technical capability, skills and expertise to undertake Ihe
( Works,
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and the Con traclor acknowledges Ihal the Government has enlered into this Contract in reliance
on its representations and warranlies as aforesaid .
4.2 Undertakings of the Contractor'

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The Contractor undertakes that -
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(a) it shall comply with all requirements, statutory or othelWise, regu lating or relating to the
conduct, trade, business or profession of a contractor, and the Contractor shall be fully
and solely liable for all costs incurred thereby;
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(b) it shall pay all taxes Ihal may be imposed on the profits made in respect of this Contract
in accordance with the applicable laws; and
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(c) it shall ensure that all his employees, including non-Malaysian personnel, comply with all
relevant laws to which they are subject to, including payment of income tax, which in
respeci thereto the Contractor shall make such deductions from Ihe salaries of his
employees as may be lawfully imposed by Ihe relevanl authority.
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5,0 COMPLIANCE WITH THE LAW IN PERFORMING THE WORKS

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5.1 The Contraclor shall comply with all respects (including the giving of all notices and the paying of
all fees req uired) with any law, regulation or by-law, or any order or directive issued by any public
authority or public service company (hereinafter referred to as "Statutory Requirements"), relating
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to the Works or, in the case of a public authority or public service company, with whose syslems
the same are or will be connected . The Contractor shall keep the Governm ent indemnified
against all penalties and liability of every kind of breach of any such Statutory Requirements The
Contractor shall submit to Ihe P.D all documentation received by the Contractor in complying with
the Statutory Requirements.
~ applicable only if the Contractor is a company registered under the Companies Act 1965.
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5.2 If the Conlraclor or the P.D finds any divergence belween the Statutory Requ irements and either
the Government's Requirements (including any Variation), or the Contractor's Proposals , he shall
imm ediately give to the other written notice specifying the divergence . In either case, the
Contractor shall inform the P.D in writing of his proposed amendment for removing th e
divergence, and with the P.D's consent (which shall not be unreasonably delayed or withheld) the
Contractor shall entirely at his own cost save as provided in clause 5.5 and clause 5.6 complete
th e design and construction of the Works in accordance with the arnendment and the P.D shall
note the amendment on the Contract Documents.
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5.3 If in any emergency, compliance with clause 5.1 requ ires the Contractor to supply materials or
execute work before receiving th e P.D's consent under clause 5.2, the Contractor shall supply
such materials and execute such works as are reasonably necessary to secure immediate
compliance with the Statutory Requirements . The Contractor shall forthwith inform the P.D of the
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emergency and of the steps that he IS taking under this clause.
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( 5.4 The Contractor shall pay and indemnify the Government against liability in respect of any fees,
levy, charges, rates or taxes (excluding capital contribution) legally demandable under any written
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law, regulation or by-law of any local authority or of any statutory undertaker in respect of the
Works. No adjustment shall be made to the Contract Sum in res pect of the amount of any such
fees, levy, charges, rates or taxes .
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5.5 If after the Date of Tender, there is a variation in the Statutory Requirements affecting the Works
which necessitates some amendment to the Contractor's Proposals, such amendments shall be
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treated as if it were an instruction of the P.D under clause 23.2 affecting a Variation.
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5.6 If after the date of Tender, there is a decision made by a relevant authority which necessitates
any amendment to the Contractor's Proposals, such amendment shall be treated as if it were an
instruction of the P.D under clause 23.2 affecting a Variation to this Contract, PROVI DED THAT
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such amendment is not precluded in the Govemment's Requirements .
6.0 CUSTODY AND SUPPLY OF CONTRACT

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6.1 The Contract shall be prepared in two (2) original copies . The original copies of the Contract shall
remain in the custody of the P.D and the Contractor.
6.2 Immediately after the execution of this Contact th e Contractor shall furnish without charge to the
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Government, unless the Government shall have been previously so provided, with at least ten
(10) certified true copies.
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6.3 The Contractor shall , without further charge to the Governmen t, provide the P.D with two copies
of the construction drawings, specifications, details, levels and setting out dimension which the
Contractor prepares or uses for the purposes of the Works .
6.4 The Contractor shall keep one certified true copy of the Contract and other documents referred to
in clause 6.3 at the Site so as to be available to the P.D at all reasonable times.
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6.5 After the practical completion of the Works but within three (3) months after that date the
Contracto r shall without further charge to the Government supply for the retention and use of the
P.D two (2) sets of drawi ngs stored in CD-ROMs and four (4) sets of such drawings, documents,
information and manuals showing or deSCrIb ing tne Works as built, and concerning the
maintenance and operation of the Works, including any installations comprised in the Works, as
may be specified in the Contract.
6.6 It is expressly agreed between parties that all maps, drawings , reports, specifications,
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calculations , designs, and all other relevant documents pertain ing to this Contract shall be the
absolute property of the Government and shall not be Stilized or reta ined by the Contractor for
any purpose other than with the permission of the Government.
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6.7 The Contractor's pla ns and specifications shall use th e S.1. Units (System International D'Unites )
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of measurement, commonly known as the metric system as this is th e requirement of all
( approving authorities in Malaysia.
7.0 SUFFICIENCY OF CONTRACT DOCUMENTS

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7.1 The Contractor shall provide everyth ing necessary fo r the proper execution of the Works until its
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completion according to the true intent and meaning of the Contract taken together whether the
same mayor may not be particularly shown or described provided the same can be reasonably
inferred therefrom .
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7.2 The Appendices are to be taken as mutually explanatory of one another but in the event of any
ambiguity or discrepancy the same shall be expla ined by the P.D to the Contractor who shall
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rectify the discrepancy at his own cost and expense.
7.3 If there remain ambiguities or discrepancies between the Government's Requirements and the
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Contractor's Proposal, the Government's Requ irements shall prevail without adjustment of the
( Contract Sum . Provided that if in th e opinion of the P.D the Contractor's Proposal is beUer than
the Government's ReqUirements in terms of grade, technical specifications and materials the
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Contractor's Proposal and drawings shall prevail.
7.4 Any ambiguities or discrepancies within the Government's Requirements shall be explained and
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resolved by the P.D who shall thereupon issue to the Contractor appropriate instructions .
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7.5 Where there is a discrepancy within the Contractor's Proposals or drawings, the Contractor shall
inform the P.D in writing of his proposed amendment to remove the discrepancy and (subject
always to compliance with Statutory Requirements) the P.D shall decide between the discrepant
items or otherwise may accept the Contractor's proposed amendment and the Contractor shall
be obliged to comply with the decision or acceptance by the P.D without cost to the
. Government.
7.6 The Government gives no warranty in any manner whatsoever for any information provided by
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the Government in the Contract as to their accuracy or sufficiency or as to how th e same shall be
interpreted-and the Govern ment shall not be liable if such information is inaccurate or insuffici ent.
The Contractor shall not be relieved from its obligations to ensure that such information is
accurate and sufficient for the purpo ses of this Contract.
8.0 RIG HTS OF P.D
8.1 The Contractor shall , subject to clauses 8.4 and 23 .2 , forthwith comply with all instructions issued
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to him by the p.o in regard to any matter in respect of which the P.D is expressly empowered by
this Contract to issue instructions.
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8.2 All instructions, notifications , consent or approvals issued by the P.D shall be in writing.
However, the P.D may, where necessary, issue oral instructions , notifications, consent or
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approvals and such ora l instructions , notifications , consent or approvals shall be followed in
( writing not later than seven (7) days thereafter.
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8.3 Such written instructions, notifications , consent or approval shall be left at the office of the
Contractor at the Site or sent to th e Contractor's principal place of business .
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8.4 If within seven (7) days after receipt of a written notice from the P.D requi ring compliance with an
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instruction the Contractor does not comply therewith , then the P.D may employ and pay other
persons to execute any work whatsoever which may be necessary to give effect to such
instruction and all costs incurred in connection with such employment inctuding On-cost Charges
shall be deducted by him from any monies due or to become due to the Contractor under this
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Contract, failing which such deductions sha ll be recovered from the Performance Bond or as a
debt due from the Contractor.
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8.5 In the event there is any change in the person who is named as P.D during the con tinuance of
this Contract, such successor shall not disregard or overrule any decision, approval. concurrence
or direction given to the Contractor in writing by his predecessor unless he is satisfied that such
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action will not cause any pecuniary loss to the Contractor.

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8.6 Notwithstanding any provision in th is Contact, it is hereby agreed that:
(a) the power of the P.D to issue instructions requiring a variation under clause 23.2 shall be
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subject to the financial limits as set out in Appendi x 1 hereto. If the instruction 'for a
variation under clause 23.2 is more than th e fin ancial limits as set ou t in Appendix 1, the
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P.D shall obtain the prior written approval of the relevant authorities of the Government;
and
(b) th e right to take action andlor initiate proceedings on behalf of the Government in respect
of any matter which arises out of the provisions of Clauses, 60, 61, 62, 67 or 68 shall be
exercised by the Officer named in Appendix 1.
8.7 If any of the p.o's instruction s which is issued pursuant to this clause 8 require the Contractor to
make any changes to the design in order to ens ure that the Government's Requirements are
fulfilled, such changes shall not constitute a variation within the meaning bf clause 23.
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8.8 The Contractor shall not be entitled to claim for extension of time or any extra cost or expense or
whatsoever arising from compliance with th e provisions of clause 8.
9.0 CONTRACTOR'S PROJECT MANAGER
9.1 The Contractor shall at all times retain at the Site a competent, efficient, suitably qualified, and
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experienced Project Manager who must be of good character and capable of receiving
instructions and commun icating in Bahasa Malaysia and English.
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9.2 An y ins truction given to such Project Manager re ferred to in clause 9. 1 by the P.D shall be
deemed to have been given to the Contractor.
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10.0 PERFORMANCE BOND
10.1 The Contractor shall , as a condition preceden t to the commencement of any work deposit with
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the Govemment a Performance Bond substantially in th e form as set out in Appendix [ 1issued by
an appro ved licensed bank or financial institution incorpora ted in Malaysia in favour of the
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Government fo r a sum equivalent to five percent (5%) of the Contract Sum to secure the due
performance of the Contractor's obligations under this Contract. The Performance Bond shall
remain valid and effective from th e date of issuance until twelve (12) months after th e expiry of
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the Defect Liability Period or the issuance of the Certificate of Completion of Making Good
Defects, whichever is the later.
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10.2 If the Contractor fails to submit the said Perform ance Bond in the fo rm as specified under clause
10.1 by the Date for PosseSSion, the Contractor shall be deemed to have opted for a
Performance Bond in the form of a performance guarantee sum instead whereby deduction s of
ten percent (10%) shall be made from every interim payments until the total amount deducted is
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equ ivalent to a five percent (5%) of the Contract Sum. The amount deducted shall be retained by
( the Government up to twelve (12) months after the expiry of the Defect Liability Period or the
issuance of the Certificate of Completion of Making Good Defects, wh ichever is the later.
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10.3 Notwithstanding clause 10.2, the Contractor may subm it a Performance Bond in the manner
specified in clause 10.1 at any time after deductions of the interim paymen ts are made pursuant
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to clause 10.2. In such an event the Government shall refund the Contractor the amount wh ich
has been deducted up to the date of submission of the Performance Bond.
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10.4 NotWithstanding anything contained in this Contract, if the Contractor fails to perform any of his
obligations under the Contract and such failure is not remedied in accordance with this Contract,
the Government shall be entitled to call upon the Performan ce Bond, wholly or partially.
10.5 If a payment is made to the Government pursuant to any claim .under the Performance Bond, -
(a) in the case of a Performance Bond in the form specified under clause 10.1, tfie
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Contractor shall issue to the Government further security in the form of add itional
. Performance Bond, or
(b) in the case of a Performance Bond in the form of a perfomnance guarantee sum under
clause 10.2, the Government may further deduct from any monies due by th e
Government to the Contractor,
an amount not less than the amount so paid to the Government on or prior to the date of such
payment so that the total sum of the Performance Bond shall be maintained at all times at the
value specified in clause 10.1 or clause 10.2, whichever is applicable.
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10.6 The Performan ce Bond (or any balance thereof remaining for the credit of the Contractor) may be
released or refunded to the Contractor on the completion of making good of all defects,
shrinkages or other faults which may appear during the Defects liability Period and upon the
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issuance of the Certificate of Completion of Making Good Defects for the whote of the Works
under clause 47 .
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10.7 Notwithstanding clauses 10.2 and 10.4, in the event this Contract is terminated under clauses 60
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and 61 the said Performance Bond or any balance thereo f shall be forfeited.
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11 .0 INSURANCE OF WORKS
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11 .1 The Contractor shall, in th e joint names of the Government and Contractor, insure against loss
and damage by fire, lightning, explosion, storm, tempest, flood, ground subSidence, bursting or
overflowing of water tanks , apparatus or pipes, aircraft and other aerial devices or articles
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dropped therefrom, riot and civil commotion, all works executed and all unfixed materials and
goods delivered to, placed on or adjacent to the Works and intended thereof (but excluding
temporary buildings, plant, tools and equipment owned or hired by the Contractor or any sub-
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contractor) to the full value thereof together with the cost of the design work of the Contractor
(plus any amount wh ich may be specifically stated in Appendix 1) and shall keep such works,
materials and goods so insured until the practical completion of the whole of the Works but
subject to any partial termination of insurance permitted under this Contract in cases of sectional
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completion or Partial Occupation by the Government. Such insurance policy or policies shall
( provide expressly for payment in the first place to the Government of any insurance monies due
under the policy or policies.
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11.2 The said insurance with or without an excess clause as specified in Appendix 1 shall be effected
with an insurance company approved by th e P.D and the Contractor shall deposit with the P.D
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the pol icy or pOlicies and the receipts for the premium paid for such insurance. Where an excess
clause is specified in Appendix 1, th e Contractor shall bear the amount of such excess.
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11.3 In the event the Contractor fails to ren ew such insurance as are necessary under this clause, th e
Government or th e P.D on its behalf may renew such insurance and pay the premium in respect
thereof and deduct the amount so expended including On-cost Charges from any money due or
to become due to th e Contractor under this Contract, and failing which such premium shall be
recovered from the Performance Bond or as a debt due from th e Contractor.
11.4 Upon the occurrence of any loss or damage to the Works or unfixed materials or 990ds prior to
the completion of the Works from any cause wh atsoever, the Contractor shall notwithsta·nding
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that settlement of any insu rance claim has not been completed, with due diligence restore,
replace or repair the same, remove and dispose of any debris and proceed with the carrying out
and completion of the Works. All money if and when received from the insurance under th is
clause shall be paid in the first place to the Government and then (l ess only such amounts as are
specifically required in Appendix 1 or elsewhere in th e Contract Documents) be released to the
Contractor by installments on the certificate for payment issued by the p .o., calculated as from
the date of receipt of the money in proportion to Ihe extent of the work of restoration, replacement
or repair and the removal and disposal of debris previously carried out by the Contractor. The
Contractor shall not be entitled to any payment in respect of the work of restoration, replacement
or repair and the removal and disposal of debris other than the money received under the said
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insurance.
11 .5 The Contractor shall ensure that any insurance policy effected hereto shall only be cancelled by
the insurer after the expiry of thirty (30) days from the date of receip t by the Government of a
written notice from the insurer advising of such impending cancellation PROVIDED THAT the
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Contractor has been issued with the Certificate of Completion of Making Good Defects in
accordance with clause 47.
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may result in any insurance effected by virtue of th is Contract being vitiated or rendered void or
voidable or whereby the rate of the premium on any insurance effected shall be liable to be
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12.0 POSSESSION OF SITE
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12.1 No work on this Conlract shall commence unless and until the Performance Bond stipulated
under clause 10.1 and such insurance policies as specified under clause 39 shall have been
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deposited with the Government. Provided thai for the purposes of this clause only (but for no
other), if the Contractor shall produce to the Government or the p.o the Perfomnance Bond, if
opted for by the Contractor, and the original cover notes of the said insurance policies and the
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receipts of premiums paid, it shall be sufficient discharge of his obligations under this clause.
12.2 Unless the Contract Documents provide otherwise, the Contractor shall be entitled on or before
the Date for Possession to access to and possession of the Site or such part of the Site to enable
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<- the Contractor to commence Works . The Contractor's access to and possession of the Site or
such part of the Site shall not be exclusive but shall be subject to the Government's rights. The
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Contractor shall thereupon forthwith commence the Works (but subject to clause 12.1) and
regularly and diligently proceed with and complete the Works on or before the Date for
Completion. The Date for Completion of the Works as referred to under clause 44 shall be
calculated from the said Date for Possession .
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12.3 Notwithstanding clause 12.2, possession of Site may be given in sections or in parts and may be
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imposed with any restriction as specified in the Appendices or in this Contract.
12.4 In the event of any delay in giving possession of the Site or in giving any section or part of the
Site, wheth er or not provided in Appendix 1, th e p.o may issue instructions to revise th e 'Date
for Possession', and th e 'Date for Completion' shall be accordingly revised under clause 49 .1(g).
The Contractor however shall not be entitled to claim for any loss , expense or damage caused by
such delay nor shall he be entitled to terminate th is Contract.
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12.5 Notwithstanding clause 12.4, should the delay in giving possession of the whole Site exceed
ninety (90) -days from the Date for Possession, the PD shall notify the Contractor of the causes
of such delay. Within fourteen (14) days of receipt of such notification , the Contractor may inform
the PD in writing of his decision which is either-
(a) agree to procee d wi th the Works wh en the whole Site is made ava ilable, in wh ich case
sub-d ause 1i4 shall apply and the Contractor shall not claim any loss or damage
caused by such delay; or
(b) terminate this Contract, without prejudice to any other rights or remedies that the
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Government and the Contractor may have as a resul t of the termination.
12.6 Notwithstanding clause 12.4, should the delay in giving possession of any section or part of the
Site (whether or not provided in clause 12.3) exceeds ninety (90) days from th e Date of
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Possession or the date the Contractor is scheduled to commence work on that section or part of
the Works in accordance with the approved programme of Works referred to in clause 13.5. as
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( the case may be, the P.D shall notify th e Contraclor of the causes of such delay . Within fourteen
(1 4) days of receipt of such notification, the Contractor may inform th e PD in writing of his
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decision which is either-
(a) agree to proceed with the Works when the section or part of th e Works is made available ,
in which case clause 12.4 shall apply and th e Contractor shall not be entitled to cla im any
loss or damage caused by the delay; or
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(b) request for the relevant section or part of the Works to be omitted from the Contract. If
the P.D. agrees to such request then the relevant section or part shall be duly omitted
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and deemed to be a variation to the Contract. Such variation shall not vitiate th e Contract.
If the P.D does not agree to such request then the Contractor shall be entitled to claim for
any loss or expense caused by the delay which exceeds ninety (90) days .
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13.0 PERFORMANCE OF THE WORKS
13.1 Submission of Supervision Reports

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(a) The Contractor shall submit supervision reports on the following:

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(i) works properly done on Site;

(i i) progress of the Works;
(iii) any tests done on the Site;
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(iv) safety measures at the Site;

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(v) environmental impact assessment of the Works; and

(vi) any other matter as required by the Government,
to the P.D each month, or at any other time as required by the PD .
(b) All such reports wh ich are to be submitted by the Contractor shall be duty verified and
certified by the Consultants of the Contractor.
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(c) The submission of such reports under this clause shall be a condition precedent to any
interim payment tha t the Contractor shall be entitled under clause 53 of this Contract. In
the event that the Contractor fa ils to comply wi th the req y irement of this clause, the
Government shall be entitled to withhold the interim payment that the Contra ctor would
otherwise be entitled to.
(d ) The submission of reports by the Contractor pursuan t to this clause shall not in any way
absol ve th e Contractor of any of its liabi lity under thi s Contract.
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13.2 Quality Assura nce Syste m
(a) To the extent req uired by the Contract the Con tractor shall institute a quality assurance
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system, and for this purpose the Contractor shall submit to the P.D the Contractor's plan
for the quality assurance systems for his approval before the comm encemen t of the
Works.
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(b) The parties hereby agree th at compliance with such approved quality assurance system
shall not relieve the Contractor from any of his other duties , obligations or liabilities under
the Con tract and neither shall the P.D or th e Government be liable in any manner
whatsoever notwithstanding the approval by th e P.D of th e said system .
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13.3 Contractor to be Responsible for the Works, Materials, etc.
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(a) From the commencement of the Works to the date of the issuance of the Certificate of
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Practical Completion for the whole of the Works the Contractor shall , save as in clau se
13.3(b), take full responsibility for the care of the Works and for rnaterials, plant and
equipment for incorporation therein and shall at his own cost replace, repair and make
good any damage , loss or injury to the same so that at completion the W orks shall be in
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good order and condition and in conform ity in every respect with the requirements of the
Contract and the P.D's instructions. The Contractor shall also be liable for any damage to
the Works occasioned by him in the course of any operation s carried out by him for the
purpose of complying with his obligations under clause 47 hereof.
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(b) If the P.D issues a Certificate of Practical Completion or Certi ficate of Parti al Occupation
fo r any Section or part of the perm anent works the Contractor shall cease to be
respon sible for the care of that Section or part from the date of issuance of that
Certificate of Practical Completion or Certificate of Partial Occupati on when the
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responsibility for the care of that Section or part shall pass to the Governmen t. Provided
always that the Contractor shall remain responsible for any damage to such completed
work caused by or as a result of his other activities on the Site .
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(c) The Contractor shall take full responsibility for the care of any outstanding work and
materials, plant and equ ipment for incorporation therein which he undertakes to fin ish
durin g the Defects Liability Period until such outstanding work has been completed .
13.4 Accident, failure , etc., to the Works
(a) If any accident, failu re or other event occurs due to any caus e w hatsoever to, or in
14
connection with the Works or any part thereof either during the execution of the Works or
during the Defects Liability Period, the Contractor shall immediately report the accident, '
fai lure or event to the P.D. Unless otherwise directed by the P.D generally or in any
particular respect conduct a full investigation into the said accident, failure or event in
order to determine the cause or reason fo r the accident, failure or event and submit a
report to the Government and the P.D together with his proposals for remedial works in
respect thereof.
(b) The Contractor shall not, however, cause remedial work to be carried out in respect
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thereof until directed to do so by the P.D in writing. And upon being so directed the
Contractor shall proceed with the remed ial works within fourteen (14) days from the date
of such direction.
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(c) Where the Government, its employee or any person or body appointed or 15 authorised
by it carried out any investigation in relation to any accident. failure or other event which
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( has occurred to. in or in connection with the Works or any part thereof for the purpose of
determining the cause or reason for the said accident, failure or event, the Contractor
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shall render all such necessary assistance and facilities as may be required by the
Government, its employee or such person or body including the giving of access to all
specification. designs, records or other available information relating to th e Works.
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(d) If by reason of any accident, or failure, or other event occurring to in or in connection with
the Works, or any part thereof either during the execution of the Works or during the
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Defects Liability Period, any remedial or other work or repa ir shall, in the opinion of the
PD be urgently necessary for the safety of the Works or the public and the Contractor
fai ls to immediately do such work or repair, the Government may employ and pay other
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persons to carry out such work or repair as the PD may consider necessary. If the work
or repair so done by the Government is work wh ich, in the opinion of the PD , the
Contractor was liable to do at his own expense under the Contract, all costs and charges
properl y incurred by the Government in so doing shall be recoverable from the Contractor
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by th e Government. or may be deducted by the Government from any monies due or

which may become due to the Contractor. Provided always that the PD shall, as soon
after the occurrence of any such emergency as may be reasonably practicable, notify the
Contractor thereof in writing.
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13.5 Programme of Works
(a) Within fourteen (14) days from the receipt of the Letter of Acceptance the Contractor shall
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submit to the PD for his approval -

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(i) a programme showing the order in which he proposes to carry out the Works
having regard to the provisions of clause 12.3; and
(ii) a general description in writing, of the arrangements and methods of construction
which the Contractor proposes to adopt for the carrying out of the Works .'
(b) The PD shall within twenty-one (21) days after receipt of the Contractor's programme:
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(i) approve the programme in writing; or
(ii ) reject the programme in writing with reason s and/or request modifications ; and/or
(iii) request the Contra ctor to supply further information to clarify or substantiate the
programme or to satisfy the P.D as to its reasonableness having regard to the
Con tractor's obligations under the Contract,
PRO VID ED THAT if none of the above actions is taken within the said period of twenty-
on e (21) days the p.o shall be deemed to have approved the programme as submitted.
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(c) The Contra ctor shall upon receipt from the P.D any request under clause 13.5(b)(ii) or (iii)
resubmit a modified programme or provide further information as requ ested .
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(d) If at any time it should appear to the P.D that the actual progress of Works does not
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( conform to the approved programme referred to hereinbefore th e Contractor shall
produce, at th e request of the p.o ., a revised programme showing the modifications to
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the approved programme necessary to ensure completion of the whole Works within the
time fo r completion provided for in clause 44 hereof or extended tim e granted pursuant to
clause 49 hereof.
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(e) The submission to and approval by the P.D or the p.o's representative of such
programme or the furn ish ing of such particulars shall not relieve the Contractor of any of
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his duties or responsibilities under this Contract.

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14.0 DESIGN
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14.1 Design
(a) The Contractor shall be fully responsible for the design , execution and maintenance of
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the Works/portion of the Works fo r wh ich his design/alternative design have been
accepted by the Government. The Contractor further guarantees to the Government that
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the design, materials and workmanship of the Works or portion of the Works complies
with the Government's Requirements as well as are su itable and fit for purpose and
independent of fault.
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(b) Any reference to the design which the Contractor has prepared or shall prepare or issue
for the Works shall include the reference to any design which the Contractor has caused
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or shall cause to be prepared or issued by others.
(c) Where an y part of the Warks has been designed by or an behalf af the Gavernm ent, and
that design has been included in the Government's Requirements, the Cantractar shall
check the design and accept respansibility far it, and shall ensure that such design shall
be suitable, functianal, safe and campatible with the design and specificatians af the
Warks, having first abtained the approval af the P.D far any madificatio,ns which the
Cantractar cansiders to be necessary. Natwiihstanding thereta, ' the Cantractar shall
remain liable far the Warks.
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(d) Where the Contractor has to integrate its des ign and Works to the existing structure , the
Contractor shall ensure that design and works shall be suitable, functional , safe, and
compatible with the existing structure and fit for the purpose and meet the Government's
Requirements.
(e) The Contractor shall take full and unequivocal responsibility for the safety of the design
and for the adequacy , stability and safety of all site operations and methods of
construction .
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(f) Where any Act of Parl iament, Regulation or Bye-law requires that a separate check of the
design or a test shall be carried out prior to the construction of any permanent and
temporary Works . The Contractor shall arrange and carry out such check or test at his
own costs .
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(g) The approval or acceptance of the Contractor's design by the Government under this
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Contract shall not absolve the Contractor from Its re sp00slbllity and the Contractor shall
be liable and shall fully Indemnify and keep the Government Indemnified for any deSign
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defects, damage, inadequacies or InsuffiCiency of such deSign
(h) The Contractor warrants to the Government that the Works shall be carried oul In
accordance with -
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(i) the terms and conditions of this Contract;
(ii) the specifications and standards as approved by the Government,

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(iii) all by-laws and local authority building regulations ;

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(iv) sound engineering practice or other relevant best industry practice,
and that such deSign shall In all respects fits and conforms With the purposes of the
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( Works as described in the Government's ReqUIrements.

[Note' Please substitute where appropriate: building , road, structure , and services]
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14.2 Design Guarantee

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(a) The Contractor shall deposit to the Government a Des ign Guarantee as per Appendix SA as
a security to the Contractor's obligations under this Contract. The DeSign Guarantee shall be
effective for the duration of five (5) years commencing from the date of practical completion
("the Design Guarantee Period").
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(b) If any defect or damage shall occur to the Works or any part thereof as a result of any
defect, fault, insufficiency or inadequacy in the design including workmanship, material
or equipment arising from design default during the Design Guarantee Period, the
Government shall issue to the Contractor a notice specifying the default and requiring
the Contractor to remedy the same within the period specified at the Contractor's own
cost and expense. If the same is not remedied, the Government shall be entitled, without
prejudice to any other rights or remedies it may possess against the Contractor under
this Contract or at law, to claim and recover from the Contractor any payment for any
loss and/or damages suffered or any other expenses incurred as a result thereof.
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(c) Notwithstanding the above , the Government may elect to remedy the defect,
insufficiency or inadequacy in the design as at the time such defect, fault, insufficiency,
inadequacy is established and the Government shall be entitled to deduct the amount
up to the limit of sum certified by the P.D to be the sum required to remedy the same
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from any money due or to become due to the Contractor under this Contract, and failing
which such sum shall be recovered from the Performance Bond or as a debt due from
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( the Contractor.
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14.3 Design Guarantee Bond A
a) The Contractor shall provide to the Government a banker's guarantee issued by an approved
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licensed bank/financial institution of the sum of Ringgit ... ... . ..... ... ... .. . ..... ...... ... .
(RM ................ ...... ...... ....... ........... .. .. .... ..... ....... ........ )(hereinafter referred to as
"the Design Guarantee Bond") substantially in the form as in Appendi x upon or before the issuance
of the Certificate of Practical Completion of the Works as a security for the Contractor's obligations
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and warranties under clause 14. Such Design Guarantee Bond shall remain valid for a period of
five (5) years from the date of practical completion of the Works .
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b) If any defect or damage shall occur to the Works or any part thereof as a result of any defect,
fault, insufficiency, imperfection, shrinkages or inadequacy in the designs including
workmanship, materials or equipment which has become defective then the approved licensed
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bank / financial institution issuing the Design Guarantee Bond pursuant to clause (a) above shall
( pay to the Government, on demand by the Government in writing and notwithstanding any
objection by the Contractor or any other third party, the sum of
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...... .... ..... ....... ........... being equal to 5% of the cost of the Works or such part
thereof as may be demanded.
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c) If the Design Guarantee Bond is not deposited with the Government in accordance with clause (a)
above , the Government shall have the right to claim from the Performance Bond the sum of RM
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.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ... ... .... being equal to 5% of the cost of
the Works or such part thereof as may be demanded .
d) If a payment is made to the Government pursuant to clause (b), the Contractor shall ensure that
further security in the form of an additional Design Guarantee Bond for an amount no less than the
amount so paid to the Government shall be issued to the Government prior to or upon the date of
such payment. If any of the issued Design Guarantee Bond were to expire prior to the validity period ,
a replacement Design Guarantee Bond shall be issued to the Government on or prior to the date of
expiry of the first mentioned Design Guarantee Bond in an amount not less than the amount of
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Design Guarantee Bond.
15.0 MATERIALS, GOODS AND WORKMANSHIP
15.1 Compliance with Government's Requirements
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(a) All materials, goods and workman ship shall, so far as procurable, be of the respective
kinds and standards described in the Government's Requirements, or, if not th erein, as
specifically described in the Contractor's Proposals or specifications referred to in clause
6.3: PROVIDED THAT th e Contractor shall not substitute anything so described without
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the P.D's consent in writing, which consent shall not be unreasonably delayed or
withheld. No such consent shall relieve the Contractor of his other obligations .
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(b) The Contractor shall upon the requ est of the P.D provide him with the relevant certificates
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or vouchers to prove that th e materials and goods comply with clause 15.1 .
15.2 Inspecti on and Testing of Materials, Goods and Workma nsh ip

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(a) Further to the Contractor's obligations under clause 14.1(e), the Contractor shall submit
to the P.D for his approval proposals fo r inspecting the design and setting out of the
Works and testing the materials and workmanship to ensure that the Contractor's
obligations under the Contract are fulfilled.
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(b) The Contractor shall carry out the inspection and tests approved under clause 15.2(a) or
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elsewhere in the Contract and such further tests as th e P.D may rea sonably requi re,
including to open up for inspection any work covered up or to carry out any test of any
materials or goods (whether or not already incorporated in the Works or any executed
Works).
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(c) The P.D may issue instructions to the Contractor to remove from the Site or rectify any
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work, goods which are not in accord ance with this Contract at his own cost.
(d) The Contractor shall , as may be required by the P.D from time to time , provide such
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assistance, instruments, machines, labour and materials as are normally required for the
purpose of examining, measuring and testin g of any work, as well as the quality, weight
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or quantity of the materials used; and shall supply samples of materials before
incorporation in the Works for testing .
(e) Unless the Contract otherwise provides, the cost of making any test shall be born e by the
Contractor if such test is:
(i) proposed by the Contractor under clause 14.1(e) 'or clause 15.2(a); or
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(ii) clearly intended by or provided fo r in the Contract.
(f) Notwithstanding anything in clause 15.2(e), if the Contractor carries out any furthe r test
as required by the P.D pursuant to clause 15.2(b) and the resu lt of such test shows the
workmanship or materials is not in accordance with the provisions of th e Contract, then
the cost of such test shall be borne by the Contractor. But if the res ult of such tes t shows
the workmanship or materials comply with the provisions of the Contract, then the cost of
such test shall be borne by the Government.
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16.0 RESTRICTION AND PROCEDURE ON USE OF IMPORTED MATERIALS AND GOODS
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( 16.1 The Contractor shall use local goods/materials as listed in the 'Senarai Bahan/Barangan Buatan
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Tempatan' issued by IKRAM QA Services Sdn . Bhd . And/or issued by SIRIM QA Services Sd n.
Bhd ., whichever is relevant. If the Contractor fails to comply with this requi rement, the
Government may reject the goods/materials which are found to be not in compliance with this
requirement.
16.2 For local goods/materials not listed as aforesa id, such goods/materials may be allowed if prior
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testing and certification from IKRAM QA Services Sd n. Bhd. Or SIRIM QA Services Sdn . Bhd.,
whichever is relevant, has been obtained. Where such testing cannot be carried out by IKRAM
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QA Services Sdn . Bhd . Or SIRIM QA Services Sdn . Bhd. The Contractor may, with the P.D's
prior appro val, have the testing done by another agency.
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16.3 Under no circumstances shall the Contractor be permitted to incorporate or supply imported
materials , plant, equipment, vehicles or other goods into the Works or forming part of the scope
of the Works except those approved by the Government. prior to the execution of the Contract.
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The Contractor shall at his own cost entirely substitute any materials , plant, equipment, vehicles
or other goods proposed to be imported but not approved by the Government, with suitab le local
materials, plant, equipment, vehicles or other goods, including making any necessary
subsequential changes or adjustment to the design of the Works to accommodate such
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( substitution, all to the concurrence of the P.D Such substitution, any necessary subsequential
ch anges to the design of the Works and the P.D's concurrence thereto shall not prejudice or
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affect the Contractor's obligation and liability to guarantee the design under clause 14.
16.4 The Contractor shall ensure that the procurement of approved imported materia ls, plant,
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equipment, veh icles or other goods are obtained directly from the country of origin based on
F.O. B. or other similar basis . The transportation and insurance of such imported materia ls, plant,
equipment, veh icles or other goods from the country of origin to the Site shall be arranged by the
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Contractor throug h the Government's Multi Modal T rans port Operators (hereinafter referred to as
MTO) as listed in Appendix 7. The Contractor shall allow in his tender all costs and time required
in complying with the requirements of this clause including the cost requi red for the services
provided by the MTO.
16.5 The Contractor shall submit documentary evidence of compliance with this clause to the P.D
within one (1) month from the date of each delivery to the Site of such materials, plant,
eqUipment, vehicles or other goods.
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17.0 CONSTRUCTIONAL PLANT, EQUIPMENT, VEHICLES AND MACHINERIES
17.1 The Contractor shall pay all port dues including (but not by way of limitation) wharfage dues,
pilotage fees, anchorage. berth age and mooring fees, quarantine dues. loading porterage and
overtime fees for constructional plant, equipment, vehicles and machineries for use directly in
connection with the construction, completion of the works brought into and 21 ispatched from
Malaysia by the Contractor (or in his name by agents).
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17.2 The Contractor shall furnis h to the P.D all such shipp ing documents, invoices and other
documentation as may be required by the Customs Authorities in connection wi th the importation
of goods , materials, cons tructional plant, equip ment, vehicles and machineries.
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17.3 In the case of constructiona l plant. equ ipment, vehicles , and machineries imported on the
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Contractor's behalf by importing agents and the like both the shipping documents and th e
( invoices of th e original suppliers or manufacturers must indica te cl early that the consignment is
for the Contractor's accou nt.
17.4
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The procedure in respect of th e requirements of the foregoing shall be determined by the
Customs Authorities . The Contractor shall make written appl ication to the p.o and shall provide
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the relevant documentation of all constructional plan t, equipm ent, vehicles and machineries to be
imported into Malaysia not less than forty-five (45) days before the arrival of the said
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constructional plant, equipment, vehicles and machineries .
17.5 The Contractor shall pay all charges and other expenses in connection with the landing and
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shipment of all con struction al plant materials and other things of whatsoever nature brought into
or 21 ispatched from Malaysia fo r the purpose of the Contract.
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17.6 The Contractor shall make his own arrangement in obtaining clearance through the Customs of
constructional plant. equipment, vehicles and mach ineries. However, if required , the p.o's
assistance may be sought.
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'- 17.7 Under this Contract the Contractor shall be requ ired to furnish all lists of constructional plant,
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equipm ent, vehicles and machineries to the p.o whether the constructional plant, equipment,
veh icles and machineries are hired or acq uired.
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18.0 NON· REMOVAL OF MATERIALS AND GOODS ON SITE

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18.1 Exclusive Use for the Works
(a) All equipment, temporary works, materials for temporary works or other goods or
materials provided by the Contractor shall, when brought onto the Site, be deemed· to be
exclusively intended for the execution of the Works.
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(b) The Contractor shall not without the written consent of the P.D (wh ich consent shall not
unreasonably be withheld wh ere the items in question are no longer immediately requ ired
for the purposes of the completion of the Works) remove such equ ipment, temporary
works, materials for temporary works or other goods or materials or any part of the same
except for the purpose of moving it within the Site .
18.2 Passing of Proprietary Rights and Vesting
Proprietary rights and ownership in goods or materials which form part of the Works, equipment,
temporary works and materials for temporary works , shall pass to the Government when payment
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is made for the same in accordance with clause 53 and such property shall be deemed to be the
property of the Government.
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18.3 Governmen t not liable for Dama ge
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The Government shall not at any time be liable for loss or damage to any of the equ ipment,
( temporary works, materials for temporary works or other goods or materials nor fo r any loss,
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expense, costs, damages , liabil ity or claim arising from the presence of use of the equ ipment,
temporary works , materials for temporary works or other goods or materials except and to the
extent that the same is due to any act or neglect of the Government or of any person for whom
the Government is responsible .
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18.4 Incorporation of clause in sub-contract
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The Contractor shall , when entering into any sub-contract for the execution of any part of the
Works, incorporate in such sub-contract (by reference or otherwise) the provisions of this clause
in relation 10 equipment, temporary works, materials for tempora ry works or olher goods or
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materials brought onto the Site by the sub-contractor.

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19.0 SITE BOUNDARIES AND SETIING OUT
19.1 The P.D shall define the boundaries of the Site and shall determine any levels, boundary stones
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and any other points of reference which may be required by the Contractor for the execution of
( the Works. The P.D shall also furnish the Contractor such inform ation to enable the Contractor to
set out the Works at ground level.
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19.2 Notwithstanding clause 19.1 , the Government gives no warranty in any manner whatsoever for
the information either as to their accuracy or sufficiency or as to how the same shall be
interpreted and the Contractor, when he makes use of and interprets the same shall do so at his
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own risk and the Government shall not be liable if such information is inaccurate or insufficient.
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19.3 The Contractor shall use and interpret the information at his own risk and shall be responsible for
the true and proper setting out of the Works and for the correctness of the positions, tevels,
dimensions and alignments of all parts of the Works and for the provisions of all necessary
instruments, appliances and labour in connection therewith.
19.4 If at any time during the progress of the Works any error in the position, levels, dimensions or
alignments of any part of the Works is discovered, the Contractor shall, at his own expense,
rectify suc~ error notwithstanding thai the error arises from inaccurate or insufficient information
given by the Government. .
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19,5 The Contractor shall provide the P.D at no cost such information relating to the setti ng out as may
be required by th e P.D from time to time,
20,0 ANTIQUITIES
20 ,1 All fossils, coins , antiquities and other objects of interest or value which may be found on the Site
or in excavating the same during the progress of the Works shall become the absolute property of
the Government and upon discovery of such an object the Contractor shall forthwith -
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(a) not disturb th e object and shall cease work if and in so far as the continuance of the work
would endanger the object or prevent or impede its excavation or its removal ;
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(b) take all steps which may be necessary to preserve the object in the exact position and
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( condition in which it was found; and
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(c) inform the P.D of the discovery and precise location of the object.
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20,2 The P ,0 shall issue instructions in regard to what is to be done concerning the object reported by
the Contractor under clause 20,1 and (without prejudice to the generality of his power) such
instructions may require the Contractor to perm it the examination, excavation or removal of the
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object by a third party, Any such third party shall for the purpose of clause 39 be deemed to be a
person fo r whom the Government is responsible and not to be a sub-contractor.
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20.3 If compliance with the provisions of clause 20. 1 or with an in struction issued under clause 20.2
has involved the Contractor in direct loss andlo r expense for wh ich he would not be reimbursed
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by a payment made under any other provisions of this Contract then the amou nt of such loss
andl or expense shall be added to th e Contract Sum.
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( 21 .0 INSPECTION OF SITE
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21.1 The Contractor shall be deemed 10 have inspected and examined th e Site and its surroundings
and to have satisfied himself and allowed in the Contract Sum as to th e following :
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(a) the nature of the ground and subsoil;

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(b) the form and nalure of the Site;
(c) the extent and nature of the work, materials an d goods necessary for the completion of
the Works;
(d) the means of communica tion with and access to the Site;
(e) the accommodation he may requ ire; and
(f) in general to have obtained for himself all necessary information as to risks,
23
contingencies and all circumstances infiuencing and affecting his tender.
21.2 An y information or documen t forwa rded by th e Government to the Contractor shall not relieve the
Contractor of his obligations under the provi sions of this cl ause.
22.0 ACCESS TO THE SITE
22 .1 The P.D, and any person 24authorized in writing by him shall be entitled at all times to enter and
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inspect the Site, factories, workshops or other places of th e Contractor or any sub-contractor or
supplier where any equipment, materials, goods or work are being manufactured, fabricated,
assembled , prepared or stored for this Contract.
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22 .2 Where any such equipment, materials, goods or works are being prepared or stored in the
factories, workshops or other places of a sub-contractor or supplier, the Contractor sha !l, by a
term in the sub-contract, so far as possible secure a sim ilar ri ght of access to those factories,
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( workshops or other places for the P.D and any person 24authorized by him, and shall take all
reasonable steps required of him by the P.D to enforce or assist in enforcing such right.
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22.3 The Contractor shall, in accordance with the requirements of the P.D, afford all reasonable
access and facil ities to any person engaged by the Government for purposes of executing any
work on or near the Site.
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23.0 VARIATIONS
23.1 The term 'variation' means a change in th e Governmen t's Requirements which makes necessary
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the alteration or modification of the design, quality or quantity of the Works as described by or
referred to therein and affects the Contract Sum, including:
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(a) the addition, omission or substitution of any work,

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(b) the alteration of the kind or standard of any of the materials, goods to be used in the
( Works; and
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(c) the removal from the Site of any work executed or materials or goods brought thereon by
the Contractor for the purposes of the Works oth er than work, materials or goods which
are not in accordance with this Contract.
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23.2 The P.D may issue instructions effecting a variation by way of a Variation Order. The Contractor
shall forthwith comply with the Variation Order. No variation instructed by the P.D under this
clause shall in any way vitiate or invalidate the Contract but the fair and reasonable value (if any)
of all such variations shall be taken into account in ascertaining the amount of the Contract Sum,
unless such variation is necessitated by the Contractor's default. PROVIDED THAT any variation
which alters or modifies the design of the Works shall be with the consent of the Contractor,
whose consent shall not be unreasonably delayed or withheld .
23.3 Notwithstanding clause 23.2, if in the opinion of the P.D the variation is necessary fo r the purpose
24
of suitability, functionality and safety of the Works, the Contractor shall effect the variations. For
the purpose of this clause, what constitutes "suitability, functionality and safety of th e Works" shall
be solely determined by the p.o and such determination shall for all intents and purposes be final
and conclusive. Notwithstanding thereto the Contractor shall remain respons ibl e for the design of
the works as provided under clause 14.
23.4 Where a variation under clause 23 .3 results in extra cost, the said exira cost shall be borne by
the Contractor. However, if the variation results in a reduction in cost, the Contract Sum shall be
accordingly reduced.
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23.5 Any variations made under this clause shall not relieve the Contractor of his obligations under
clause 14.1(a).
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( 24.0 VALUATION OF VARIATIONS
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24.1 The valuation of additional or substituted work shall be consistent with the valu e of works of
similar character set out in the Contact Sum Analysis or Contract Schedule of Rates, making due
allowance for any change in the conditions under which the work is carried out or any significant
change in the quantity of the work so set out. Where there is no work of a similar character set
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out in the Contract Sum Analysis or Contract Schedule of Rates a valuation shall be made by the
p.o.
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24.2 The valuation of the omission of work shall be in accordance with the values in the Contract Sum
Analysis or Contract Schedule of Rates.
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24.3 Any valuation of work under clause 24.1 and 24 .2 shall include allowance for any necessary
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addition to or reduction of the Site administration, Site facilities and temporary works .
24 .4 Where an appropriate basis of a valuation of additional or substituted work is Day work, the
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valuation shall comprise the prime cost of such work plus 15% which shall include the provision
of Site administration, Site facilities and temporary works and fo r profit. PROVIDED THAT as a
condition precedent to any right to any payment the Contractor shall produce vouchers specifying
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the time daily spent upon the work, the workmen's names, the plant and the materials employed
to the p.o for verification not exceeding seven (7) days after the work has been executed.
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24.5 The valuation made under this clause shall not include any claims for direct loss or expense
notwithstanding that such variation affects the regular progress of the Works.
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24.6 Upon determ ination of the valuation of the variation, the Contract Sum shall be rev ised
accordingly by way of addition or deduction.
25.0 PROVISIONAL SUMS
25. 1 The term Provisional Sum included in th e Contract Docum ents means a sum for work to be
25
executed or th e supply of materials or goods wh ich cannot be entirely foreseen, defined or
detailed be fore the Date df Tender and the P.D shall issue in struction to the Contractor in regard
to the expend iture of such Provisionat Sum .
25.2 The value of works which are executed by the Contractor in respect of a Provisional Sum shall be
ascertained in accordance with clause 24. At the settlement of the accou nts the value of such
work executed by the Contractor shall be set against the Provisional Sum and th e balance shall
be added to or deducted from the Contract Sum. If the Provisional Sum is not used either wholly
or partly, the unused amount shall be deducted from the Contract Sum.
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26.0 EMPLOYMENT OF WORKMEN
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26.1 The Contractor shall employ in the execution of the Contract only Malaysian citizens as workmen .
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If in any particular trade or skill required to complete this Contract, th e Contractor can show to the
( satisfaction of the PD that Malaysian citizens are not available, then the Contractor may employ
non-Malaysian citizens subject to the approval of the relevant authorities .
26.2
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The Contractor shall on the commencement of the Works furnish to the Jabatan Tenaga Kerja of
the state in which this Contract is performed all particulars connected with this Contract and such
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returns as may be called for from tim e to time in respect of labour employed by him and his sub-
contractors (including 'labour only' sub-contractors) on the execution of this Contact in
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accordance with the requirements of the Employment Act 1955, Employment (Restriction) Act
1968, and Internal Security (Registration Of Labour) Regulation 1960 or any subsequent
modification or re-enactment thereof. The Contractor shall maintain on the Site at all times during
the progress of the Works an up-to-date register containing particulars of all workers employed by
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him .
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26.3 The Contractor shall cause his sub-contractors including 'labour-only' sub-contractors to comply
with clause 26.
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27.0 COMPLIANCE WtTH EMPLOYMENT ACT 1955, ETC.

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The Contractor shall comply and shall cause his sub-contractors including 'labour only' sub-contractors to
com pl y with all the req uirements of the Employment Act 1955, Employment (Restriction) Act 1968,
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Employees Provident Fund Act 199 1, the Industrial Relations Act 1967 and any other law relating to the
employment of workmen, or any subsequent modification or re-ena ctm ent thereof. PROVIDED THAT the
Contractor shall not be entitled to any claim for additional costs and payments wh atsoever in respect of
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his compliance with this clause.
28.0 EPtDEMICS AND MEDICAL ATTENDANCE
28 .1 The Contractor shall maintain the Site in clean and sanitary condition and shall comply with the
requirements of al l relevant laws and with any instructions and requirements issued by the
26
relevant authorities. In the event of any outbreak of illness of an epidem ic nature, the Contractor
shall comply With and carry out such regulations, orders and requirements as may be made by
the Governm ent or the local medical or health authorities for the purpose of dealing with and
overcoming the same.
28.2 The Con tractor shall ensure that sufficient first aid kits are made available at suitable locations on
the Site and shall instruct an adequate number of person in their use. The names of the persons
so instructed shall be made known to all em ployees of the Contractor.
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29.0 DAYS AND HOURS OF WORKtNG
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29 .1 No work shall be done on :
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( (a) the weekly day of rest;
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(b) any public holiday which is recognized in th e state where this Contract is being carried
out; or
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(c) between the hours of six in the evening and six in the following morning ,
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without th e prior written consent of the P.0 and such consent shall not be unreasonably withheld
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or delayed.
29.2 In the event that the written application of the Contractor is approved by th e p.o under clause
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29.1, the Contractor shall comply with all requirements of the Employment Act 1955 in regard
thereto and shall bear all cost for compliance therewith including payment of wages.
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<.
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30.0 WAGES, BOOKS AND TIME SHEETS
30 .1 The Contractor shall keep and shall cause his sub-contractors (including 'labour only' sub-
contractors) to keep proper wages books and time sheets showing the amount of wages paid to
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and the number of hours worked by every workman employed by him and his sub-contractors
as aforesaid in and for the performance of this Contract.
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30 .2 The Contractor shall produce such wages books and time sheets on demand for inspection by
any persons duly 27uthorized by the p.o.
30.3 The Contractor shall furnish the P.D or his duly 27uthorized representative such information
relating to the wages and conditions of employment of such workmen as the p.o may from ljme'
to time require.
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31 .0 DEFAULT IN PAYM ENT OF WAGES
31 .1 In the event of default being made in the paymen t of-
(a ) wages; andlor
(b) Employees Provident Fund Contributions,
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of any workman employed by the Contractor or his sub-contractors, including 'labour only' sub-
contractors in and for the perfomnance of this Contract then the P.D shall make payment to the
Director General of Labour andlor Employees Provident Fund Board , as the case may be .
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( 31 .2 Such payment made by the P.D under clause 31 .1 and On-cost Charges shall be deducted from
any money due or to become due to the Contractor under th is Contract, and failing which such
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payment shall be recovered from th e Performance Bond.
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32.0 DISCHARGE OF WORKME N
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32.1 The Contractor shall employ in and about the execution of the Works only such persons as are of
good character, careful, skilled and experience d in th eir respective vocations and trades.
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32.2 The P.D shall be at liberty to object to and requ ire the Contractor to remove immediately from the
Site any person employed by the Contractor in or about the execution of the Works who in th e
opinion of the P.D misconducts himself or is incompetent or negligent in the proper performance
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of his duties and whose continued presence is undesirable or unacceptable . Such person shall
not again be employed upon the Works without the prior written permission of the P.O.
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32.3 Any person so removed from the Works shall be rep laced wi th out delay by a substitute approved
( by the P.D; PROVIDED THAT the Contractor shall not be entitl ed to any cla im for any expense
whatsoever incurred by him in respect of any direction given by the P.D under this clause.
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33.0 EMPLOYEES ' SOCIAL SECURITY ACT 1969

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33 .1 Without prejudice to his liability to indemnify the Governm ent under clause 14, the Contractor
shall reg ister or cause to register all local workmen employed in the executi on of the Works and
wh o are subject to registration under the Employees' Social Security Scheme ("the SOCSO
Scheme") in accordance with the Employees' Social Security Act 1969 or any subsequent
modification or re-enactment of the said Act. For the purpose of this clause , the term "local
workmen" shall include workmen wh o are Malaysian citizen s and those who have permanent
resident status.
33 .2 The Contractor shall subm it his Code Number and Social Security Numbers of all workers on the
Site req uired to be covered under the Employees' Social Security Act 1969 to the P.D for
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checking.
33.3 The Contractor shall make payment of all contributions from time to time on the first day on which
the same ought to be paid and until the end of the Defects liability Period and it shall be the duty
of the Contractor to produce to the PD con tribution cards or stamp vouchers as evidence of
paymen t of such contribution, whether demanded or not.
33 .4 If the Contractor fails to comply with the terms of this clause , the Government or the P.D on its
behalf may without prejudice to any other remedy available to Government for breach of any of
the terms of th is Contract:
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(a) withhold an amount from any money which wou ld otherwise be due to the Contractor
under this Contract and wh ich in the opinion of the PD will satisfy any claim s for
compen sa tion by workmen that would have been borne by SOCSO had th e Contractor
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not made defau lt in maintaining the contribution; andlor
(b) pay such contributions as have become due and remain unpaid and deduct the amount
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( of such contributions including On-Cost Charges from any money due or become due to
the Contractor under this Contract, and failing which such contributions shall be
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recovered from the Performance Bond or as a debt due from the Contractor.
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34.0 tNDEMNITIES TO GOVERNMENT tN RESPECT OF CLAIMS BY WORKMEN
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34.1 The Contractor shall be liable fo r and shall indemnify and keep indemnified the Government and
its officers or servants from all liabilities arising out of claims by any and every workmen
employed in and for the performance of this Contract for payment of compensation under or by
virtue of the Workmen's Compensation Act 1952 and the Employees' Social Security Act, 1969 or
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any other law amending or replacing such law and from all costs and expenses incidental and
consequential thereto.
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34.2 The Contractor shall effect and maintain throughout the Contract Period an Employer's liability
Insurance or Workmen Compensation Insurance or any other applicable insurance for its
personnel, servants, agents or employees required under the laws of Malaysia.
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35.0 CONSULTANTS
35.1 The Contractor shall enter into an agreement with each consultan t and shall deposit eight (8)
copies of the Contract entered to the P D as a condition precedent before the P D approve the
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first interim payment.

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35.2 The Contractor shall only employ local consultants for the design and supervision of the Works
and the management of the Project. Under no circumstances will the Contractor be permitted to
employ foreign consultants except where there are no local consultan ts with the required
expertise and special exemption had been obtained from the Government, prior to the execution
of the Contract.
35.3 The Contractor shall submit a complete list of consultants to be employed for the Works sta ting
their job and their obligations. The Contractor shall ensure that the consultants are efficient,
29
suitably qualified and experienced and are registered with their respective professional Boards .
35.4 The Contractor shall not employ any other professionals (other than those nam ed in his proposal)
without the prior consent of the PD The Con tractor's attention is also drawn to the fact that the
said consultants shall be retained throughout the Contract Period for the supervision of the Works
and they shall not be discharged without the consent of the P.O. All as-built drawings required for
the Works shall be certified by th e relevant consul tan t.
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35.5 Any action , decision, instruction or consen t taken, made or given by the Government or th e PD
as the case may be under this clause shall not in any way whatsoever relieve the Contractor of
any of his obligations under thi s Contract.
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36.0 DIRECT PAYMENTS TO CONTRACTOR'S CONSULTANTS
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36.1 Payment to Consu ltants
(a ) For purposes of payment to the consultant, the Contractor and the ConSUltant shall enter
into an Irrevocable Deed of As signment fo r th e assignmen t of any money due to the
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Consultant to be paid directly by the Government. The Irrevocable Deed of Assignment
shall provide for an escrow account to be opened jointly by the Contractor and consultant
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at a bank licensed in Mala ysia.

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(b) The Contractor shall subm it to the Government the escrow accoun t number and th e
Government shall pay the amount recommended by the consultan t to the PD as th e
amount payable to the consultants directly into the said escrow account. Any payment
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made by the Government into the escrow account shall be deemed to be a payment
under this Contract. Any dispute between the Contractor and the consultant in relation to
the amount due to the escrow account shall not affect the continuous payment by the
Government into the escrow account pursua nt to this Contract and the Government shall
not be a party to any such dispute.
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(c) The Contractor shall recommend to the PD the amount payable to the consu ltants. The
PD in issuing Interim Certificates under clause 53 or the Final Certificate under clause 54
of the Contract shall state separately the amount of interim or final payment due to each
consultant which amount subject to clause 36.1 (d), shall be paid by the Government
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direct to the consultant. The amount paid by the Government direct to the consultant shall
be deemed to be a payment to the Contractor by the Government under and by virtue of
this Contract, provided that if the P.D received written notice of dissatisfaction from the
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consultant not later than two (2) weeks before the issuance of the next interim certificate
or final certificate regarding the amount certified by the Contractor then the PD may
certify and the Government may make direct payment to the consultant in accordance
with the clause 36 .1.
(d) The amount payable to the consultant by the P.D shall include fees for basic services and
supervision as specified in the Consultancy Agreement. Supervision fees shall be paid for
supervision of Works carried out during the Contract Period and approved extended
period subject to clause 50. Any additional costs for supervision of Works beyond the
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approved period shall be borne by the Contractor.
(e) Subject to the relevant provisions in the Consultancy Agreem ent, the Contractor shal l be
entitled to be paid and the Government may pay to the Contractor out of any money
otherwise due to a Consultant:
(i) any amount wh ich the Government or th e P. D on its behalf in exercise of any
ri ght under this Contract has deducted from any money due to the Contractor
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and such deduction is in re spect of some act or default solely of the Consultant,
his servants or agents;
(ii) any amount agreed by the Consultant as due to the Contractor, or any amount
awarded in arbitration or litigation in favou r of the Contractor wh ich arises out of
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or under the Consultancy Agreement; and
(iii) th e amount of any claim for loss andlor expense actually incurred by the
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( Contractor by reason of any breach or failure to observe the provisions of the
Consultancy Agreement by the Consultant.
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An y amount pa id to the Contractor in accorda nce with this clause shall be deemed to be
a payment to the Consultant under the Consultancy Agreement.
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(f) Nothing in this clause nor anything else contained in this Contract shall render the
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Government in any way liable to any Consultant nor relieve the Contractor from his
obligations and liabilities under the Contract.
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36.2 Responsibilities of Contractor to Consultants

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(a) In and for the purpose of this Contract, the Contra ctor shall be full y responsible to ensure
that the Consultants shall confo rm with the terms and conditions of this Contract and
shall be fu lly responsible for the acts, defaults or breach of any terms andlor conditions of
this Contract by the Consultants on their part in the same way as for his own or those of
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( other sub-contractors or suppliers engaged by himself, and the Government shall in no

circumstances be liable to the Contractor for the default of any Consultant.
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(b) In the event of repudiation or abandonment of his consu ltancy services by any
Consultant, or the determ ination by the Contractor of the employmen t of the Consultant
for any reason whatsoever under the Consultancy Agreement or as directed by the P .0,
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the Contractor shall with the consent of the P.D (such consent shall not be unreasonably
withheld) employ another competent consultant to complete the consultancy services.
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Provided that in any of such events the Contractor is entitled to be paid the same sum for
the services to be executed, as would have been payable had the original Consultant
completed the consultancy services without any default on his part.
(c) All notices with regard to termination of the Consultancy Agreement shall not be issued
without the prior consent of the PD. Where in the opinion of the PD the Consultant has
defaulted due to any reason as provided for under the Consultancy Agreement, the P.D
may instruct the Contractor to determine the employment of the Consultant, and the
31
Contractor shall forthwith determine the employment of the Consultant.
37 .0 SUB-CONTRACTTING AND ASS IGNM ENT OF COUNSULTANT'S RESPONSI BILIT Y
37.1 The Contractor shall ensu re that the Con sultant employed for the design and supervisio n of the
Works shall not assign or sub-contract the said design and supervision respo nsibil ity to other
Consultant without prior wri tten consent of the p.o.
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37 .2 Any such consent. if given . shall not relieve the Contractor from any liability or obligation under
this Contract and he shall be respo nsible for the due observance by such sub-consultant. of all
th e terms. stipulations and conditions under this Contract.
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37.3 Notwithstanding any sub-contract or assignment made pursuant to this clause . the Contractor
shall be fully responSible fo r the acts , defaults or neglects of any sub-consultant, his agents.
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servants or workmen as if they were the acts, defaults or neglects of the Contractor.
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37.4 It shall be a condition in any sub-contract or assignment which has been consented to by the p.o
that upon termination of the Consultant's employment by the Contractor, the employment of th e
sub-consultant under the sub-contract or assignment shall terminate immediately. No claim
whatsoever shall be made by the Consultant andlor sub-consultant against the Government for
any work done.
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38.0 GOVERN MENT'S INDEM NITY IN RESPECT OF INJ URY TO PERSONS AND DAMAGE TO
PROPERTY
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38 .1 The Contractor shall perform all of its obligations under th is Contract at its own risk and re leases,
to the fullest extent permitted by law. the Government and their agents and servants from all
claims and demands of every kind resulting from any accident, damage, injury or death arising
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from the carrying out of the Works. except where such aCCident, damage, injury or death is
caused or contributed to by any act or omission or negligence of the Government or its agents
and servants. The Contractor expressly agrees that in the absence of any such act, omission or
negligence as aforesaid, the Government shall have no respon sibility or liability whatsoever in
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( relation to such aCCident, damage, injury or death.

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38 .2 The Contractor shall indem nify and keep indem nified the Government from and against all
actions, suits, claims or demands . proceedings, losses , damages, compen sation, costs (including
legal cost), charges and expenses whatsoever to which the Government shall or may be or
become liable in respect of or arising from-
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(a) the negligent use, misuse or abuse by the Contractor or its personnel, servan ts, agents
or employees appointed by the Contractor;
(b) any loss or damage to property or injury of whatsoever nature or kind and howsoever or
wherever sustained or caused or contribu ted to by carrying out of the Works by the
Contractor !o any person and not caused by the negligence or willful act, default or
omission o(the Government, its agents or servants; or
32
(c) any loss , damage or injury from any cause whatsoever to property or persons affected by
the Works to the extent to which the same is occasioned or contributed to by the act,
omission, neglect, breach or default of the Contractor or personnel , servants, agents or
employees.
38 .3 The Contractor agrees that the obligations under this clause shall continue after the expiry or
earlier termination of this Contract in respect of any act, deed, matter or thing happening before
such expiration or termination of this Con tract.
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38.4 The Contractor shall indemnify, protect and defend, at its own cos t and expen se, the Government
and its agents and servants from and against all actions, claims and liabitities arising out of acts
done by the Contractor in the performance of this Contract.
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( 39.0 INS URANCE AGAINST INJURY TO PERSONS AND DAMAGE TO PROPERTY
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39 .1 Without prejudice to his liability to indemnify the Govern ment under cl ause 38 , the Contractor
shall as a condition precedent to the commencement of any work under th is Contract, effect and
maintain such insurances whe ther with or without an excess amount as specified in Append ix 1
as are necessary to cover the liability of the Contractor and all sub-contractors .
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39.2 Such insurance shall be in respect of personal injuries or death , damage or loss to property,
movable or immovable, arising out of or in th e course of or by reason of the execution of th e
Works and caused by any negligence , omission, breach of contract or default of the Contractor or
any sub-contractor, or of any servants or agents of the Contractor or of any such sub-contractor.
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Where an excess amount is specified in Append ix 1 the Contractor shall bear the amount of such
excess. The policy or policies of insurance shall con tain a cross liability clause indemnifying each
of the jOintly insured against claims made on him by the other jointly insu red.
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39.3 The Contractor shall effect and maintain insurances during th e executi on of the Works as well as
during the Defects Liability Period for such amount of indemn ity as may be specified in Appendix
1 in respect of any expense, liability, loss, claim or proceedings which the Government may incur
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( or sustain by reason of damage to any property (includin g the Works and any other property of
the Government) cau sed by collapse, subsidence, vibration , weakening or removal of support or
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lowering of ground water arising out of or in the course of or by reason of the carrying out of the
Works except damage arising from an Event of Force Majeure under clause 66.2.
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39.4 Such insurance as referred to under clause 39.1 and 39.2 shall be effected with an insurance
company approved by the Government and maintained in the joint names of the Government and
Contractor, from the period of the date of possession of site until the date of issuance of
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Certificate of Completion of Making Good Defects. The Contractor shall ensure that such
insurance shall also cover the Government, the Contractor and all sub-contractors, for any claim
occasioned by the Contractor or any sub-contractor in the course of any operations carried out by
him or any sub-contractor for the purpose of complying with his obligations under clause 47
hereof. It shall be the duty of the Contractor to produce the relevant policy or policies of the
insurance together with receipts in respect of premiums paid to the p.o, whether demanded or
not.
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39.5 If the Contractor or any sub-contractor fa ils to renew such insurance as are necessary under this
clause , the Government or·the P.D on its behalf may renew such insurance as aforesaid and may
deduct a sum equivalent to the amount in respect of prem ium s paid including On-cost Charges
from any money due or to becom e due to the Contractor under this Contract, failing which such
prem iums shall be recovered from th e Performance Bond or as a debt due from the Contractor.
39.6 The Contractor shall ensure that any insurance polic y effected shall only be cancelled by the
insurer after the expiry of thirty (30) days from the date of receip t by the Government of a written
notice from the insurer advising of such impending cancellation PROVID ED THAT the Contractor
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has been issued with a Certificate of Completion of Making Good Defects in accordance with
clause 47.
39 .7 The Contractor shall not at any time permit or cause to be done any act, matter or thin g which
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may result in any insurance effected by virtue of this Contract being vitiated or rendered void or
voidable or whereby th e rate of th e premium on any insurance effected shail be liabie to be
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increased.
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40 .0 SUB-CONTRACTING AND ASSIGNMENT A
40.1 The Contractor sha ll not without the prior written consent of the P.D (which consent shall not be
unreasonably delayed or withheld) subcontract the design for all or an y portion of the W orks .
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Where the P.D consents to any sub- con tract under this clause, such consent shall not in any
way absolve the obligations of the Contractor under clause 14.1 (a).
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40 .2 The Contractor shall not sub-contract the whole or any substantial part of the Works with ou t the
prior written consen t of the P.D (which consent shall not be unreasonably delayed or withheld).
Any such consent, if given , shall not relieve the Contractor from any liability or obligation under
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this Contract and he shall be responsible for the due observance by such sub-contractors, of all
the terms, stipulations and conditions under this Contract.
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40 .3 Notwithstanding any sub-contract made pursuant to clauses 40.1 and 40.2, the Contractor shall
( be full y responsible fo r the acts, defaults or neglects of any sub-contractor, including 'labour only'
sub-contractors , his agents , servants or work men as if they were the acts, defaults or neglects of
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the Con tractor; PROVIDED THAT the provision of labou r on a piecework bas is shall not be
deemed to be a subcontract under this clause .
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40.4 It shall be a condition in any subcontract which has been consented to by the Government that
upon termination of the Contractor's employment under the Contract, the employment of the sub-
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contractor under th e sub-contract shall terminate immediately. No claim whatsoever shall be

made by the Contractor andlor sub-contractor against the Government for any work done or
materials or goods supplied .
40.5 If the Contractor sub-contracts the Works, in whole or in part, to any person without getting prior
written consent of the PD as provided under this clause, the P.D shall have the right to instruct .
the Contractor to forthwith terminate such sub-contract and the Contractor shall be liable for all
costs and expense relating to such termination .
34
40.6 The Con tractor shall not assign the Contract or any part th ereof; or any benefit or interest th erein
o( thereunder without the prior written consent of the p.o.
41.0 BUMIPUTERA PARTIC IPATION
41.1 The Contractor shall employ Bumip utera organ ization s or professionals to carry out specific
portion of the Works on a sub-contract basis as defin ed under clau se 40 and th e amount of all
these participation shall be at least 30% of the total Contra ct Sum.
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4 '1.2 It is also required that:
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(a) the Bumiputera organisations shall be from the list of registered contractors maintained
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( by the Contractors Service Centre of th e Ministry of Entrepreneurial Developm ent
Malaysia or the list of registered suppl iers and professional fi rms maintained by the
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Ministry of Finance Malaysia, whichever is applica ble;
(b) within fo urteen (14) days from the receipt of the Letter of Acceptan ce, th e Contractor
shall subm it to th e P.D for his approval a list of works, supply or services wh ich he
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proposes to sub-con tract to Bumiputera organisation s in accordance w ith th is clause.
The P.D shall, within twenty-one (2 1) days after receipt of this list, -
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(i) approve the list in writing ; or

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(ii) reject the list in writing, with reasons andlor request m odifications ; andlor
(iii) request the Contractor to supply furt her inform ation to clarify or substantiate the
list;
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PROVIDED THAT if none of the above actions is taken within the said period of twenty-
one (21 ) days the P.D shall be deemed to have approved the list as subm itted .
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41 .3 If the Contractor fails to fulfi ll th e requ irements of this cl ause, the Govern ment reserves the right
to -
(a) reallocate any portion of the Work s to Bumiputera organisations for which th e Contractor
sh all remain fully responsible for any delay or fai lure on the part of the Bumiputera
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organisations; or
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(b) take action against the Contractor by suspension or cancellati on of the Contractor's
reg istration as a "Governme nt Contractor" .
41 .4 Any action, decision , instruction or consen t taken, made or given by the Govern m ent or the P .D,
as the case may be, under this clause shall not in any way whatsoever rel ieve the Contractor of
any of his obligations under th is Contract.
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42.0 . TESTING AND COMMISSIONING OF MECHANICAL , ELECTRICAL AND OTHER SERVICES
42.1 Where the Works require the installation of any mechanical, electrical and other systems , the
Contractor shall carry out testing and commissioning of the installation to prove that the
equipment has been properly adjusted and calibrated to produce the required guaranteed
performance and that the system as a whole conforms to the specifications .
42 .2 Upon completion of the installation work at th e Site the Contractor shall arrange fo r all necessary
tests to be carried out on the equipment and installa tion as requ ired by applicable laws .. The
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Contractor shall also perform all other tes ts which may be specified elsewhere in this Contract.
The costs of all tests including the provision of necessary equipment, lools, materials, labour and
all other expen ses shall be deemed to be included in Ihe Contract Sum.
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42.3 In the event the equ ipmenl or system fails to ach ieve th e requ ired guaranteed performance or
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does not conform to the specifications, Ihe Contractor shall take all necessary measures to
(" ensure that the equipmenl or system installed pass all the necessary te sts . The installation work
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shall not be considered as complele until the equipment or syslems have achieved the requi red
guaranteed performance and have conformed to the specifications.
42.4 The Contractor shall submit a test programme to and notify the P.D when these tests are to be
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conducted so that the P.D or his representatives may be present to witness such tests.
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42.5 The Contractor shall also carry out further adjustments to the controls whilst the building is
occupied and the installation is in use, during the Defects Liability Period . No additional cost shall
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be charged in carrying ou t these adjustments.
42.6 A complete record of the tests and results of such tests (whether successful or otherwise) shall
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be kept up-to-date by the Contractor. At the conclusion of all the tests, these records shall be
collated and two bound sets are to be provided to the P.O.
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42.7 On successful testing of the complete installation, the Contractor shall arrange to commission the
( equipment in the presence of the P.D or his rep resentatives. The Contractor shall demonstrate
the correct operation of all mechanical and electrical aspects of the equipment, the correct
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operations of all controls and prove that the installation is complete.

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43.0 SECTIONAL COMPLETION

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Where different completion dates for different sections or parts of the Work s are stated and identified in
Appendix 1 or elsewhere in the Contract Documents and different and separate Liquidated and
Ascertained Damages are provided for each section or part of the Works, the pro visions of this Contract
in regard to -
(a) clause 44 (Completion of the Works);
36
(b) clause 45 (Damages for Non-completion);
(c) clause 47 (Defects After Completion); and
(d) clause 49 (Delay and Extension of Time),
but not clause 10, clause 11 and clause 54 shall , in the absence of any express provision to the contrary
elsewhere in the Contract Documents apply mutatis mutandis as if each such section or part was the
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subject of a separate and distinct contract between the Government and the Contractor.
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44.0 COMPLETION OF THE WORKS
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( 44.1 Subject to any requirement as to the completion of any section or part of the Works under
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clauses 12.3 and 43 before the completion of the whole of the Works, the Contractor shall
complete the whole of the Works on or before the Date for Completion or such extended time as
may be allowed under clause 49. A
44 .2 When the whole of the Works have reached practical completion accordi ng to the provis ions of
this Contract and to the satisfaction of the p.o , and the Contractor has obtained a temporary
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certificate of fitness for occupation / certificate of completion and compliance , wherever
applicable, the date of such completion shall be certified by the P.D and such date shall be the
date of the commencement of the Defects liabil ity Period as provided in clause 47. The
certificate issued under this clause shall be referred to as the 'Certificate of Practical Completion' .
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44.3 If the Contractor considers that the Works have achieved practical completion, the Contractor
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shall notify the P.D in writing to that effect.
44.4 W ithin 14 days of receipt of such notice, the p.o shall carry out testing / inspection of the Works.
Pursuant to such inspection/testing, the p.o shall - .
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( (a) issue the Certificate of Practical Completion to the Contractor if in his opinion the whole
Works have reached practical completion and have satisfactorily passed any
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inspection/test carried out by the p.o subject to the Contractor giving a written
undertaking to complete any outstanding work during the Defects Liability Period . The
date of such completion shall be certified by the p.o and such date shall be the date of
the commencement of the Defects Liability Period as provided in clause 47.2 hereof; or
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(b) give instruction to the Contractor specifying all defective works which are required to be
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completed by the Contractor before the issuance of the Certificate of Practical

Completion.
44.5 If the p.o has given instruction pursuant to clause 44.4(b), no Certificate of Practical Completion
shall be issued to the Contractor until the Contractor has effectively carried out the remedial
work within reasonable period to the satisfaction of the p.o.
44.6 The Works' shall only be regarded as practically complete if-
37
(a) the Works have been completed in accordance with the terms and conditions of this
Contract;
(b) th e Governmen t can have full , proper and beneficial use of the Works for their intended
purpo se, notwithstanding that there may be works of a very minor nature still to be fully
executed provided that such works do not prevent or diminish the full, proper and
beneficial use as aforesaid;
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(c) th e Contractor has given to the P.D an undertaking to compl ete any outstanding work of
a very minor nature;
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(d ) the Works have passed any commissioning tests required in this Contract;
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( (e) the Works shall be made available to the Government in a condition which is fit for
occupation; and
(f)
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all the essential services, including access roads, landscape (if applicable), car parks (if
applicable), drains , sanitary, water and electricity installation, fire hydrant, sewerage and
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refuse disposal equipment and , fire lifts where requi red. have been provided .
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44.7 Notwithstanding the provision of clauses 45 and 49, time shal l be the essence of this Contract.
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45.0 DAMAGES FOR NON-COMPLETION

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45.1 If the Contractor fails to complete the Works by the Date for Completion or within any extended
time granted pursuant to clause 49, the P.D shall forthwith issue a Certificate of Non-Completion
to the Contractor.
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( 45 .2 Without prejudice to the Government's right to terminate this Contract, when the P.O. issues the
Certificate of Non-Completion , th e Government shall be enti tled to recover from the Contractor.
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Liquidated and Ascertained Damages calculated at the rate stated in Appendix 1 from the period
of issuance of the Certificate of Non-Completion to the date of issuance of Certificate of Practical
Completion or the date of termination of this Contract. The P.D may ded uct such damages from
any money due or to become due to the Contractor, failing which such damages shall be
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recovered from the Performance Bond or as a debt due from the Contractor. The P.D shall inform
the Contractor of such deduction .
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45.3 The Liquidated and Ascertained Damages stated in Append ix 1 shall be deemed to be a
rea sonable amount of loss which the Government will suffer in the event that the Contractor is in
breach of this clause . The Contractor by entering into this Contract agrees to pay to the
Government the said amount(s) if the same become due without the need of the Government to
prove his actual damage or loss.
45.4 The payment or d.eduction of such Liq uidated and Ascertained Dam ages shall not relieve the
Contractor from its obligation to complete the Works or its obligations and liabilities under the
Contract.
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46.0 PARTIAL OCCUPATION I TAKING OVER BY GOVERNMENT
46.1 If at any time or times before the whole of the Works have reached practical completion , the
Government with the consent of the Contractor sha ll take possession of and occupy any part or
parts of the same (any such part being hereinafter in this clause referred to as 'the releva nt part'),
then notwithstanding anything expressed or implied elsewhere in this Contract-
(a) within seven (7) days from the date on which the Government shall have taken
possession of the relevant part the P.D shall issue a Certificate of Partial Occupation in
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respect of th e relevant part stating the estimated value of the said relevant part, and for
all the purposes of this clause (but for no other) the value so stated shall be deemed to
be th e total valu e of the said rel evant part;
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(b) for the purposes of clauses 44 and 47 hereof. the rele vant part shall be deemed to have
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reached practical completion and the Defects Liability Period in respect of the releva nt
( part shall be deem ed to have comm enced on the date on which the Government sha ll
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have taken possession and occupied thereof;
(c) at the end of the Defects Liability Period of the re levant part and if in the opinion of the
P.D any defect, imperiection, shrin kage or any other fault whatsoever in respect of the
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relevant part which he may have req uired to be made good under clause 47, shall have
been made good by the Contractor, the P.D shall issue a certi ficate to that effect;
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(d) the Contractor shall insure and keep insured the Works in the manner as stipulated under
clause 11 and the Contractor shall give notice to the insurer of such partial occupation
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notwithstanding the partial occupation by the Government of the relevant part; and
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(e) the Liquidated and Ascertained Damages specified under clause 45 for any period of
delay after such certification of the practica l completion of the relevant part 'under clause
44 .1, shall be reduced in the proportion which the total value of the relevant part bear to
the Contract Sum .
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46 .2 It is expressly agreed that nothing contained in the preceding paragraphs shall entitle the
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Contractor to the release of the Periormance Bond or any part thereof; the intention being that the
said Periormance Bond or any part thereof shall be relea sed or refunded only upon the
completion of making good all defects, imperiections , shrinkages or other faults which may
appear during the Defects Liability Period and upon the giving of the Certifi cate of Completion of
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Making Good Defects for the whole of th e Works under clause 47 hereof.
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47.0 DEFECTS AFTER COMPLETION
47 .1 The Contractor shall, during the Defects Liability Peri od com plete with due expedition or wi thin
such time as may be specified by the P.D , any work outstanding at the Date of Practical
Com pletion (whether or not the Contractor has undertaken to do so).
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47.2 The Contractor' shall , at any time during the Defects liability Period as stated in Appendix 1
hereto (or if none stated the period is twenty-four (24) months from the date of practical
completion of the Works) make good any defect, imperfec tion, shrinkage or any other fault
whatsoever which may appear and which are due to design , materia ls, goods, workmanship or
equipment not in accordance with this Contract, as specified by the P.D in a written instruction to
the Contractor.
47.3 Notwithstanding sub-clause 47 .1 above, any defect, imperfection , shrinkage or any other fault
whatsoever which may appear during th e Defects liabil ity Period to be made good by the
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Con tractor, shall be specified by the P.D in the Schedules of Defects of which the first schedule
shall be delivered to the Contractor within fourteen (14) days and the fina l schedule shall be
delivered not later than twenty-eight (28) days after the expiration of the Defects liability Period .
The defects, imperfections, shrinkages or any other fault whatsoever specified in the Schedules
of Defects shall be made good by the Contractor at his own costs and to be completed within a
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reasonable time but in any case not later than three (3) months after the receipt of the final
schedule. Provided that the P.D shall not be allowed to issue any further instruction requiring the
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( Contractor to make good any defect, imperfection , shrinkage or any other fault whatsoever after
the issuance of the said Schedu le of Defects or after twenty eight (28) days from the expiration
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of the said Defects Liability Period, whichever is the later.
47 .4 If the Contractor shall fail to comply with either clause 47 .1 or clause 47.2 or both within the time
so specified, th e materials or works so affected may be made good in such manner as the P.D
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may think fit, in which case the costs incurred including On-cost Charges shall be deducted from
any money due or to become due to the Contractor under this Contract and failing which such
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costs shall be recovered from the Performance Bond or as a debt due from the Contractor.
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47.5 If any defect, imperfection , shrinkage or any other fau lt whatsoever is such that, in the opinion of
the PD, it shall be impracticable or inconvenient to the Government to have the Contractor to
remedy th e same, the PD shall ascertain the diminution in the value of the Works due to the
existence of such defects , imperfections, shrinkages or any other fault whatsoever. The amount
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of such diminution shall be recoverable by the Government from the Contractor as a debt due to
the Government under this Contract, and failin g which such diminution shall be recovered from
the Performance Bond .
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47.6 When in the opinion of the PD the Contractor has made good tile defects, imperfections,
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shrinkages or any other fault whatsoever which he is required to make good under clau ses 47.1
or 47.2, or both, the PD shall issue a certificate to that effect, and the date stated in such
certificate shall be the date on which the Contractor has completed making good such defects,
imperfections , shrinkages or any other fault whatsoever. The said Certificate shall be referred to
as the 'Certificate of Completion of Making Good Defects '.
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48.0 UNFULFILLED OBLIGATIONS
Notwithstanding the issue of the Certificate of Completion of Making Good Defects under clause 47.6,
the Contractor and the Government shall remain liable for the fulfillment of any obligation arising under
the provisions of the Contract, prior to the issuance of the said certificate, which remains unfulfilled at the
time such certificate is issued . For the purpose of determining the nature and extent of any such
obligation, the Contract shall be deemed to remain in force between the Parties.
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49.0 DELAY AND EXTENSION OF TIME
49. 1 Upon it becoming reasonably apparent that the progress of th e Works is delayed , the Contra ctor
shall forthwith give written notice to the p.o. as to the cause s of delay and rele vant information
with supporting documents enabling the said officer to form an opinion as to the cause and the
length of delay. If in the opinion of the P.D. the completion of the Works is likely to be delayed or
has been dela yed beyond th e Date for Completion stated in Appendix 1 or beyond any extended
Date for Completion previously fixed under th is clause -
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(a) by an occurrence of an Even t of Force Majeure as provided under clause 66;
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(b) by reason of directions given by the P .D, consequential upon disputes wi th neighbouring
owners provided the same is not due to any act, negligence or default of the Contractor
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( or an y sub-contractor;
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(c) by reason of exceptionally inclement weather conditions;
(d) by reason of PD 's instructions issued under clauses 7.5, 15.2(b), 20 .2 or 23.2 provided
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that such instructions are not issued due to any act, negligence, defa ult or breach of this
contract by the Contractor or an y sub contractor;
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(e) by reason of the Contractor not having received in due time necessary instructions ,
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decisions, information, concurrence or consent from the PD which the P.D is obliged to
provide or give under the Contract for which the Contractor shall have specifically applied
in writing on a date which having rega rd to the Date fo r Completion stated in Appendix 1
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or to any extension of tim e then fixed under this clause , wa s nei ther unreasonably distant
from nor unreasonably close to the date on which it was necessary for the Con tractor to
receive the same; or
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( (f) by delay in receipt of any necessary permission or approval of an y statutory body or local
au th ority which the Contractor has taken all practicable steps to avoid or reduce; or
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(g) by reason of delay in giving possession of the Site as provided under clause 12.4 and/or
12.5; or
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(h) by delay on the part of artists , tradesmen or others engaged by the Governm en t in
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execu ting work not formi ng part of this Con tract;
(i) by the Contractor's inability for reason be yond his control and which he could not
reasonably have foreseen at the date of closing of tender of th is Contract to secu re such
goods , materials and/or services as are essen tial to the proper carryin g out of th e Works;
or
41
OJ by reason of suspension of the Works as pro vided under clause 59,
then the P.O. may, if he is of the opin ion tha t an extension of time should be granted , so soon as
he is able to estimate the length of the delay beyond the date or time aforesaid issue a Certificate
of Delay and Extension of Time giving a fai r and reasonable extension of time for completion of
the Works.
PROVIDED THAT the Contractor has taken all reasonable steps to avoid or reduce such delay
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and shall do all th at may reasonably be required to the satisfaction of the P.D to proceed with the
Works.
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PROVID ED FURTHER THAT the Contractor shall not be entitled to any extension of time where
the instructions or acts of the Government or the P.D are necessitated by or intended to cure any
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default of or breach of contract by the Contractor.
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49.2 If during the regular progress of the Works or any part thereof has been materially affected by
reason of delays as stated under clause 49.1(b), (d), (e), (h) and U) hereof (and no other), and
the Contractor has incurred or is likely to incur direct loss andlor expense beyond that reasonably
contempla ted and for which the Contractor would not be reimbursed by a payment made under
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any other provision in this Contract, then the Contractor shall be entitled to claim fo r such direct
loss andlor expense incurred, subject always to clause 50 .
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50.0 PROC EDURE FOR CLAIMS
50 .1 Notwithstanding any other provision of the Contract, if the Contractor intends to claim any
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additional payment pursuant to any clause of th is Contrac t, the Contractor shall within sixty (60)
days of the occurrence of such event or circumstances or instructions give notice in writing to the
p.o of his intention for such claim.
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<. 50.2 As soon as is practicable but not later than ninety (90) days after practical completion of the
Works, the Contractor shall submit full particulars of the claims under clause 50 .1 together with
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all supporting documents, vouchers, explanations , calculations, records and receipts for payment
made which may be necessary to enable the claim s to be ascertained by the p.o . Upon expirY of
the ninety (90) days period , the P.D shall proceed to ascertain the claims based on such
documents subm itted by the Contractor. The amount of such claims ascertained by the p .o shall
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be added to the Contract Sum .

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50.3 If the Contractor fails to comply with clause 50.1 and clause 50.2, he shall not be entitled to such
claim and the Government shall be discharged from all liability in connection with the claim.
51.0 INTELLECTUAL PROPERTY RIGHTS , ROYALTIES , ETC.
51 .1 Any intellectual property rights arising out of design, plans, calculations, drawings, developed or
used for or incorporated in the Works shall vest in and become the sole property of the
Government free and clear of all liens, claims and encumbrances. The Contractor shall not
42
during or at any time after completion on the Work s or after the expiry or termination of this
Contract, in any way, question or dispute the ownership of the Government.
51 .2 The Contractor agrees to grant to the Government free from all royalties, fees and other
charges , all licenses in respect of intellectual property rights now or here.,fter owned or
controlled by the Contractor or in respect of which the Contractor has or will have the right to
grant licenses of any design, plans, calculations , drawings, developed or used for or
incorporated in th e Works or any part thereof.
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51 .3 All royalties or other sums payable in respect of the design, plans, calculations, drawings which
are subject to copyright (o ther th an the design, plans, calculations or drawings provided by the
P.D ) which are used in the Works shall be deemed to have been included in the Contract Sum .
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51.4 The Contractor shall defend and indemnify the Government from and against all claims, costs,
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damages, charges and proceedings whatsoever for or on account of infringement of any
( intellectual property rights in resp ect of any design , plans , calculations, drawings , docu ments,
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pla nt, equipment, machinery, material, methods or processes developed or used for or
incorporated in the Works except where such infringement results from compliance with the P.D's
instructions pursuant to clause 23. A
51 .5 Where any infringement results from compliance with the P .D's instructions pursuant to clause
23, any royalties, damages or other mon ies which the Contractor may be liable to pay to the
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persons entitled to such intellectual property rights shall be reimbursed by the Government.
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51.6 The Contractor shall indemnify the Government from and against all claims , proceedings,
damages, costs and expense which may be brought or made against the Government as a result
of the use of such intellectual property rights or infringement by the Contractor of the same.
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51 .7 Except where otherwise specified , the Contractor shall pay all tonnage and other royalties, rent
fees and other payments or compensation (if any) fo r getting stone, sand, gravel, clay or other
materials required for the Works.
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52.0 MAINTENANCE OF WORKS AND SERVICES

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52 .1 The Contractor shall maintain the whole of th e Works and Services as listed in the scope of
maintenance of works contained in the Government's Requireme nts for a period of twenty-four
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(24) months from the date of the Practical Completion of the Works (hereinafter referred to as the
"Maintenance Period") and guarantee the same to be in good working conditions at all times. This ·
maintenance shall include services and equipment provided by the manufacturer of the
equipment installed and all materials and workmanship supplied by the Contractor.
52.2 The Contractor hereby expressly undertakes to rem edy and supply/repla ce all defective parts or
items caused by normal wear and tear, inclusive of all consumable items at his own cost during
the said twenty-fou r (24) mon th s so that the whole of the Works and Services is maintained in the
43
best efficient working order. This maintenance shall include regular and systematic checking,
cleaning, servicing, testin'g , calibration an'd services as recommended by' the
manufa cturer/supplier as required by the relevant authorities and necessary adjustment to the
equipment. The Contra<;:tor shall also provide alternative/temporary subs titutes to the eq uipment
and services as requ ired in the event of a breakdown of the plant. An y spare parts required fo r
replacem ent shall be made readily available during the Mai ntenance Period .
52 .3 Replacem ent made or requi red to be made du ring the Main tenance Period shall be subjected to
a si milar Maintenance Period from the date of repla cem ent, provided that such Maintenance
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Period shall not exceed 24 months from th e expiry date of the first Maintenance Period as
aforesaid.
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52.4 When in the op inion of the P.D the Contractor has satisfactorily compl eted the maintenance of
the Works and Services as requ ire d under this clause, the p .o shall issue a certificate to th at
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effect, and the date named in such certificate shall be th e date on which the Con tractor has
( completed th e same. The said Certificate shall be referred to as the "Certificate of Completion of
Maintenance".
53 .0 INTERIM PAYMENTS
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53.1 Interim payments shall be made by the Government based on the p.o's mon thly valuation of the
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Works done and properly executed and of any goods or unfixed materials del ivered to or adjacent
to the Site intended for use or to be incorporated into the Works PROVI DED THAT it shall be a
condition precedent to the fi rst interim payment, fo r the Contra ctor to submit to th e Government
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copies of the Consultancy Agreement as provided under clause 35 .1.
53 .2 The Contractor shall subm it to the p.o, at such times and in such fo rm as the p.o may prescribe,
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written application for Interim Payments showing the amounts wh ich in the Contractor's opinion
are due under the Contract Payments. The submission shall include the following:
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( (a) the value of Works done and properly executed;

(b) the amount of any valuation of variations or of the instructions by the p.o (clause 24);
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(c) the amount in rega rd to the expenditure of Provis ional Sums executed or expend ed
(clause 25);
(d) th e value of any goods or unfixed materials delivered to or adjacent to the Site intended
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for use or to be incorporated into the Works; and

(e) the supervision reports as required by the p.o under clause 1 3.1 .
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53.3 The P.D shall within twenty-eight (28) days from the date of receipt of the application for Interim
Payments, inspect and verify the Works, and make a valuation of the same and issue an Int<;lrim
Payment Certificate stating the amount due to the Contractor from the Government PROVIDED
THAT the total value in each monthly valuation shall not be less than the sum referred to in
Appendix 1.
53.4 The amount stated as due in an Interim Payment Certificate shall be the estimated total value of
the Works done and properly executed and up to ninety (90) percent of the value of any goods or
44
unfixed materials delivered to or adjacent to the Site inten ded for use or to be incorporated into
the Works up to and incliJding th e date the valuation was made, less any payments (including
Advance Payment) previously paid under this Contract. PROVI DED THAT such Certificate shall
only inctude th e value of th e said goods or unfixed materials as and from such time as they are
reasonably and properly and not prem aturely delivered to or adjacent to the Site and adequately
protected against weather, damage or deterioration.
53 .5 Within a number of days as stated in Appendix 1 (or if none stated then within thirty (30) days of
the issuance of any such Interim Payment Certificate) the Government shall pay the Contractor
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the amount certified as due to the Contractor in the said Certificate .
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54.0 FtNAl ACCOUNT AND FINAL CERTtFtCATE
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( 54 .1 Within th ree (3) months after issuance of the Certificate of Completion of Making Good Defects or
the Certificate of Completion of Maintenance (i f any) whichever is the later, the Contractor shall
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submit to the p.o a statement of the final account showing in detail the value in accordance with
the Contract, of the Works carried out together with all further sums which the Contractor
considers to be due to him after giving cred it to the Government fo r all amounts previously paid
by the Government and for all sums to which the Government is entitled under the Contract up to
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the date of the Certificate of Completion of Making Good Defects or the Certificate of Completion
of Maintenance, as the case may be. The Final Account shall be supported by all documentation
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substantiating the value of the same.
54.2 Upon expiry of the three (3) months period as specified in clause 54.1 , the P.D shall proceed to
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verify the Final Account based on such documents submitted by the Contractor. The p.o shall
issue a certificate (hereinafter referred to as "the Final Certificate") stating the amount which in
his opinion is finally due under the Contract from the Government to the Contractor or from the
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Contractor to the Government, as the case may be, after giving credit to the Government for all
amounts previously paid by the Government and for all sums to which the Government is entitled
under the Contract not later than three (3) months thereafter.
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54 .3 tf the Contractor does not submit the final account within the three (3) months referred to in
clause 54. 1 the P.D may on the expiry of th e said three (3) months give notice in writing to the
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Contractor that if the final account is not submitted by the Contractor within two (2) months from
the date of the written notice the p.o may himself prepare the Final Accoun t.
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54.4 Subject to any deductions authorized by th e Contract any balance properly stated in th e Final
Certificate shall as from the 30th day after the issuance of the same become conclusive as to the
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balance due between th e parties and be a debt payable as the case may be by the Government
to the Contractor or by the Contractor to the Government.
54.5 Where the Government exercises any right of deduction fro m monies due or to become due to
the Contractor, the p.o shall inform the Contractor in writing the reason of that deduction .
. 54.6 No final payment dU!3 to the Contractor shall be made unless and until the Contractor shall have
satisfied the P.D by means of a Statutory Declaration made by or on behalf of the Contractor that
45
th e workmen who have been employed by the Contractor on the Works , including workm en
eimployed By sub-contraCtors, whether nominated or otherwise (inciudiiig 'la bour only' sub-
contractors ) have received all wa ges due to them in connection with such employm en t, and that
all dues or contributions under the Employment Act 1955, the Employee's Social Secu ri ty Act
1969 , the Employee's Provident Fund Act 1991 and any oth er laws relevant to th e employment of
workm en , have been paid .
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55 .0 EFFECT OF P.D'S CERTIFICATES AND PAYMENT BY GOVERNME NT
No certificate of the P.D or any approval, written or otherwise, by th e P.D or the Government or payment
by the Government under any prov ision of this Contract shall be considered as conclu sive evidence as to
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the sufficiency of any deSign, works, materials or goods to which it relates, nor shall it relieve the
Contractor from any or all of his obl igations under th is Contract and/or his liability to amend and make
good all defects , imperfections, shrinkages, or any other faults whatsoever as provided by thiS Contract.
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( In any case, no certificate of the P.D shall be final and binding in any dispute be~Neen th e Government
and the Contractor if the dispute is brought whether before an arbitrator or in the Courts.
56 .0 DEDUCTtON FROM MONEY DUE TO CONTRACTOR

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The Government or th e P.D on its behalf shall be entitled to deduct any money owing from the Contractor
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to the Government under thi s Contract from any sum which may become due or is payable to the
Contractor under this Contract or any other contracts to which the Govern ment and Contractor are parties
thereto. The P.D in issuing any certificate under clauses 53 and 54, shall have regard to any such sum so
chargeable against the Contractor, PROVI DED T HAT this provision shall not affect any other remedy to
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which the Government may be entitled for the recovery of such sums.
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57.0 ADVANCE PAYMENT

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57.1 The Contractor shall be entitled to an advance payment on the Contract amounting to 25% of the
'- value of the Contract Sum less Provisiona l Sums (hereinafter referred to as the "Builder's Work')
but subject to a maximum of RM 10 million on comp liance with the following conditions:
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(a) on return of the Letter of Acceptance duly Signed by the Contractor together with the
Performan ce Bond (if any), insurance policies, confirmation from SOCSO Authorities and
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the receipts for all premium paid;

(b) production of a Banker'sllnsurance/Finance Com pany Guarantee in the approved format
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equal in value to the advance proposed to be paid ;

(c) Submission of the Banker's Guarantee I Insurance Guarantee I Financial Company
Guarantee not later th an 3 months from the date of possession of Site.
57.2. The advance paym ent shall be recouped when the cumulative total value of the Builder'S Work
execu ted and certified (including the amount certified for materials on site) reaches (25%) twenty
five percent of the total contract value of Builder'S Work, by way of a fixed percentage deduction
from the total certified value of the Builder's Work executed (includ ing the amount certified for
46
materials on site) during the period covered by an Interim Payment Certificate, in all the
subsequent Interim Payment Certificates on ihe basis that the advance payment made shall be
fully recovered in the Interim Payment Certificate in which the cum ulative to tal certified value of
th e Builder's Work executed (including the amount certified for ma terials on site) reaches
seventy-five (75) percent of the total contract value of the Buil der's Work>. The deduction shall be
calculated as follows: .
$0 = 200 r:, percent of $P

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Where $ 0 = cum ulative deduction to be made in Interim
Payment Certificate,
$A = tota l amount of ad vance pa id,
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$B = total contract value of Builder's Work
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$P = gross certified value of Builder' s Work executed
( (including the amount certified for materials on site)
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or agreed cumulative scheduled payments in
excess of 25% of $ B
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57. 3 The liability under th e advance guarantee shall be terminated upon rea liza tion by the
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Government of the full sum of advance paid . However if the full sum of th e advance paid cannot
be re alized before th e completion date of the contract or any authorised extension thereof or the
case of the contract been determined before the date of the determination, then the balance of
th e advance repayable to the Government shall be recovered from the advance guarantee.
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58.0 PROVISIONAL BillS OF QUANTITIES
(a) Where the Contract includes any Bills of Quantities, which is stated as "provisional", it
shall fu lly describe the qualities of Works tha t need to be executed in respect of any
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specified items . Where quantities are stated as "provisional" such quanti ties are the
( estimated quantities of the Works but they are not to be taken as the actu al and correct
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quantities of the Works to be executed by the Contractor in fu lfil lment of his obligations
under the Contract.
(b) Where the quantities of any part of the Works are stated as "provisional" in the Bills of
Quantities the amount to be paid to the Contractor in respect of the said part of the Works
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upon completion of this contract shall be ascertained by re measurem ent as th ey are

actuall y execu ted. Provided Always that if the remeasuremen t resu lted in an increase in
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costs, then the Governmen t shall not be liable for such increase in cos ts if it is due to the
fau lt, error, omission or negligence of th e Contractor or his Consultants in preparing the
said "pro visional" Bills of Quantities. Such costs shall be fully borne by the Contractor.
However, if the re measurement of the said "provisional" quantities results in a reduction
in cost the Contra ct Sum shall be accordingly reduced .
(c) The rates in the "provisional" in th e Bills of Quantities shall determine the valuation of the
Works' of similar character and executed under sim ilar condi tions as work priced therein .
The said rates, where work is not of similar character or executed under similar
con ditions as aforesaid, shall be the basis of rates for the same so far as maybe
47
reasonable, failing which a fair valuation thereof shall be made by the PD.
59.0 SUSPENSION
59.1 Suspension and Resumption of Works
(a) The PD . may at any time instruct the Contractor to suspend part or all of the Works .
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(b) Upon receipt of such written instruction, the Contractor shall suspend part or all of th e
Works for such time and in such manner as specified in the instruction and shall duly
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protect, store and secure the Works or such part of the Works against any deterioration ,
loss or damage .
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(c) During the suspension period, the Contractor shall continue to perform his obligations
under this Contract which are not affected by th e instruction to suspend, including the
obligation to effect and maintain insurances and performance bond .
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(d) The P.D may instruct the Contractor to resume the Works at any time thereafter. Upon
receipt of such instruction the Contractor shall resume the Works and the parties shall
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jointly examine the Works affected by the suspension . The Contractor shall make good
any deterioration or defect in or loss of the Works which has occurred during the
suspension .. The Contractor shall also take all necessary actions to mitigate the
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expenses incurred .
59.2 Extension of time

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(a) If the Contractor suffers delay andlo r incurs expenses in complying with the instruction
under clause 59.1(a), and in resumption of the Works, and if such delay andlor expenses
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was not foreseeable by the Contractor, the Contractor shall give notice for extension of
time under clause 49 and the provis ions thereof shall apply accordingly. PROVID ED
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THAT the Contractor shall not be entitled to such extension if the suspension is due to a
cause attributable to the Contractor and th e Contractor shall not be entitled to payment of
loss and expense if he -
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(i) fa ils to take measures specified in clause 59. 1 (b); and

(ii) fa ils to take all necessary action to mitigate the expenses incurred.
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(b) In the event such suspension shall continue for a period exceed ing 12 months, the
parties shall then discuss whether to mutuall y terminate the Contract or suspend the
Works for a further period.
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59.3 Consequences of mutual termination
If this Contract is mutually terminated under this clause-
(a) clause 60.1 (c)(i) shall apply ; and
(b) payment obligations including all costs and expenditure incurred by the Government and
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the Contractor shall be ascertained in accordance with clause 63.
60.0 EVENTS AND CONSEQUENCES OF DEFAULT BY THE CONTRACTOR
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60.1 Default of Obligations
(
(a) Events of Default
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In the event the Contractor-
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(i) fails to commence Works at the Site within two (2) weeks after the Date for
Possession ;
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(ii) suspends or abandons the carrying out of the Works or any part thereof for a
continuous period of .... .( ... ) days ;
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(iii) fails to proceed regularly and diligently with the performance of his obligations
under the Contract;
(iv) fails to execute the Works in accordance with the Contract;
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(v) perSistently neglects to carry out his obligations under the Contract;
(vi) refuses or persistently neglects to comply with a written notice from the P.D in
relation to any defective work or equipment, materials or goods which do not
meet the requirements of the Contract;
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( (vii) fails to comply with the provisions of clause 4;

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(viii) fai ls to obtain the prior written consent of the P.D required under clause 40 ; or
(ix) fails to comply with any terms and conditions of this Contract,
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then the Government may give written notice to the Contractor specifying the default, and
requiring the Contractor to remedy such default within fou rteen (140 days of the receipt of
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the default notice or any period determined by the Government.
(b) Termination
If the Contractor fails to remedy the breach within such period, the Government shall
have the right to forthwith terminate this Contract by giving a written notice to that effect.
49
(e) Consequences of Termination
If this Contract is terminated under clause 60.1 (b),
(i) the Contractor shall -
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(A) forthwith cease all opera tio ns on the Works;
(8) carry out any protection works so as to secure the Site, equipment,
goods and materials therein against any deteriora tion, loss or damage
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and to do all things necessary so as to leave the Site in a clean and ti dy
condition ;
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( (C) remove its personnel and workmen from the Site ;
(D ) vacate the Site with in the time specified by the P.D and remove all
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temporary buildings , plant, tools . equ ipment, goods and unfixed
materials which have not been paid by the Government, as specified by
the p.o . Failing wh ich , the Government may (but without being
responsible for any loss or damage) remove and sell any such property
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belong ing to the Contractor, holding the proceeds , less all cost incurred ,
to the credit of the Contractor;
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(E) either-
(aa) terminate all third party contracts entered into by the Contractor
for the pu rposes of this Contract;
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(bb) assign to the Government, if so requ ired by the Government, at

no cost or expense to the Government, the benefit of any
agreement fo r the supply of materials or goods andlo r for the
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execution of any work for the purposes of this Contract; or

(cc) allow such third party to enter into a contract with the
Government or any other person deemed necessary by th e
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Government for th e purpose of completing the Works,

( PROVID ED THAT the Government shall not be obliged to pay any third
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party for any materials or goods delivered or any work executed or

services for the purposes of this Contract (whether before or after the
date of termination) for which the Government has paid but the
Contractor has failed to make payment to the third party;
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(F) at no cost to the Government, hand over to the Govern ment all plans,
designs, drawings, specifications and other relevant docu ments relat ing
to the Works;
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(G) pay to the Government any losses and damages suffered as a result of
the termination of this Contract in the manner provided under clause 64;
and
(H) not be released from any of its obligations or liabilities under this
Contract.
(ii) the Government shall -
50
(A) call upon the Performance Bond or forieit the performance guarantee
sum, andlor call upon the Design Guarantee Bond ;
(B) enter and repossess the Site;
(C) be entitled to carry out and complete the Works on its own or employ
any other person to carry ou t and complete the Works; and
(D) be entitled to claim against the Contractor for any losses and damages
suffered as a result of th e termination of this Contract in the manner
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provided under clause 64 .
(iii) For the avoidance of doubt, the Parties hereby agree that the Contractor shall not
be entitled to any form of losses including loss of profit, damages, claims or
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whatsoever upon termination of this Contract under this clause.
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( 60.2 General Default
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If at any time during the con tract period -
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(i) the Contractor becomes bankrupt;

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(ii) the Contractor becomes insolvent or compounds with or enters into an

arrangement or compositions with its creditors ;
(iii) an order is made or resolution is effectively passed for the winding-up of the
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Contractor (except for th e purpose of restructuring or amalgamation with the

written consent of the Government, which consent shall not be unreasonably
withheld);
(iv) a provisional liquidator, receiver or manager of its business or undertaking duly
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appointed, or possession taken by or on behalf of creditors or debenture holders

secured by a floating charge of any property comprised in or subject of the said
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floating charge; or
(v) execution is levied against a substantial portion of the Contractor's assets,
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then the Government shall have the right to terminate this Con tract forthwith by giving
notice to that effect
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(b) Consequences of Termination
(i) In the event of termination of this Contract under clause 60.2, clause 60.1 1(i) and
(ii) shall apply.
(ii) For the avoidance of doubt, the Parties hereby agree that the Contractor shall not
be entitled to any form of losses including loss of profit, damages, claims or
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wh~ts oever upon termination of this Contract under this clause .
61 .0 TERMINATION ON CORRUPTION , UNLAWFUL OR ILLEGA L ACTIVITIES
61 .1 Termination
Without prejudice to any other rig hts of the Government, if the Com pany, its personnel , servants
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or emp loyees is convicted by a court of law for corru ption or unlawful or illegal activities in re lati on
to this Contract or any oth er contract that the Contractor may have with the Government , the
Governmen t shall be entitled to terminate this Contract at any time, by giving imm ediate wri tten
notice to that effect to the Contractor.
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61.2 Conseq uences of Termination
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( I Upon such termination und er clause 61.1 -
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(a) the Governme nt shall be entitled to all losses , costs, damages and exp en ses including
any incidental costs and exp enses incurred by the Government arising from such
termination;
(b) clause 60. 1(c)(i) and (ii) shall apply; and

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(c) For the avoidance of doubt, the Parties hereby agree that th e Contractor shall not be
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entitled to any form of losses includ ing loss of profit, damages , claims or whatsoever
upon term ination of th is Contract.
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62.0 TERMINATION ON NATIONAL INTEREST

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62.1 Termination
(a) Notwithstanding any provision of this Contract, the Governrnent may terminate this
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Contract by giving not less than thirty (30) days written notice to that effect to the
( I Contractor (without any obligation to give any reason thereof) if the Govern men t
considers that such termination is necessary for national interest, national policy or
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national security.
(b) For the purposes of this clause, wha t constitutes "national interesf', "national policy" and "
national security", shall be solely made and determined by the Government and such
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determination shall for all inten t and purposes be final and conclusive and shall not be
open to any chal lenge whatsoever.
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62.2 Consequences of Termination
Upon such termination under clause 62.1 -
(a) payment obligations including all costs and expenditure incurred by the Government and
the Contractor shall be ascertained in accordance with clause 63; and
(b) clause 60. 1(c )(i) and clause 60.1 (c)(ii)(8 ) and (C) shall apply.
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63. 0 PAYMENTS UPON SUSPEN SION OR TERMINATI ON ON NATIONAL INTEREST
63.1 If this Contract is terminated under clause 59 or clause 62, the amount to be paid (in so far as.
such amounts or items have not already been covered by payments on account made to the
Contractor) shall be the following:
(a) the value of all works carried out up to the date of termination;
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(b) the amounls payable in resp ect of any preliminary items so far as Ihe Work or service
comprised Iherein has been carried out or performed and a proper prop ortion of any such
items which have been partially carried ou t or performed;
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(c) the cost of materials or goods reasonably ordered fo r the Works wh ich have been
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delivered to the Contractor or of which the Contracto r is legally liable to accepl delivery
( (such malerials or goods becoming th e property of Ih e Government upon such payment
being made to the Conlractor);
(d)
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a sum being Ihe amount of any exp enditure reasonably incurred by the Co ntractor in so
far as such expenditure has not been recovered by any other payments referred to in this
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sub-clause; and
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(e ) the reasonable cost of any protection works and removal of equipment and site facilities
pursuant to termination as provided under Ihis Contract,
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PROVIDED THAT such amount to be paid by the Government shall be confined only to those
items as are clearly and expressly stated in paragraphs (i )-(v) above .
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63 .2 For the avoidance of doubt, the Parties hereby agree that the Contractor shall not be entitled to
any form of losses including loss of profit, damages , claims or whatsoever other than stipulated
under clause 63 .1(a)-(e) . The Parties further agree that the amount agreed above by the
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Government shall constitute as a full and final settlement between the Parties.
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64.0 EVENTS AND CONSEQUENC ES OF DEFAULT BY THE GOVERNMENT
Default of Obligations
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If the Government without any reasonable Cause fails to perform of fulfill any of its obligation
which adversely affects the Works,
then the Contractor may issue a notice specifying the default by the Government and requiring
Ihe Government to remedy the same within the period specified therein taking into account the
nature of the remedy to be carried out by the Government or such other period as m ay be agreed
by both Parties from the dale of receipt of such notice.
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(b) Termination
If th e Government fails to remedy the default period specified in such notice issued under Clause
64.0 (a) within the stipulated period time therein, the Contractor shall have the right to forthwith
terminate th is Contract by giving a writte n notice to that effect.
(c) Consequences of Term inatio n
If this Contract is terminated under Clause 64 .0(b ) -
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(i) the Governmen t shall pay to th e Contractor -
(a) the value of th e Works carried out up to the date of termination;
(b) th e amounts payable in respect of any preliminary items so far as the Work or
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service comprised therein has been carried out or performed and a proper
proportion of any such items wh ich have been partially carried out or performed;
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( (c) the cost of materials or goods reasonably ordered for the Works which have
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been delivere d to the Con tractor or of which th e Contractor is legally liable to
accept delivery (such materials or goods becoming the property of the
Government upon such payment being made to the Contractor); and
(d) a sum be ing the amount of any expenditu re reasonably incurred by the
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Contractor in so far as such expenditure has not been recovered by any other
payments referred to in this sub-clause.
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(ii) For the avoidance of doubt, the Parties hereby agree that the Contractor shall not be
entitled to any other form of losses including loss of profit, damages, claims or
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whatsoever upon termination of this Contract.

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65.0 CERTIFICATE OF TERMINATION COSTS
65.1 As soon as the arrangements for the completion of the Works made by the Government enable
Ihe P.D to make a reasonably accurate assessment of the ultimate cost 10 the Government of
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completing the Works following the termin ation of the Contractor's employment and the
( engagement of other contractors or persons, and the amount of direct loss andlor damage
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caused to the Government due to the termination has been ascertained by the P.D then the P.D
may issue a certificate (hereinafter referred to as the "Certificate of Termination Costs") stating
the Completion Cost (hereinafter defined) and the Final Contract Sum (hereinafter defined).
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65.2 The Completion Cost comprises the following sums, cosls or expenditu re:
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(a) the sums previously paid to the Contractor by th e Government;

(b) the sums paid or payable to other contractors or persons engaged by the Government to
complete the Works;
(c) any sums paid to sub-con tractors or suppliers under clause 60 .1(c)(i)( E);
(d) any costs or expenditure incurred or to be incurred including On-cost Charges incurred
by the Government in completing the Works; and
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(e) the amount of direct loss andlor damage caus ed to the Government due to the
termi nation.
65.3 The Final Contract Sum comprises the following amounts or sums:
(a) th e amount which would have been payable under the Contra ct on completion in
accordance with the Contract, allowing fo r any variations or other matters whic h would
have resulted in an adjustment of the original Con tract Sum; and
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(b) any other sums which the Government might be entitled under the terms of th e Contract
to deduct from the original Contract Sum,
had the Contractor's employment not been term inated.
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65.4 The Certificate of Term ination Costs shall state the difference between the Final Contract Sum
( and the Complelion Cost. If the Final Contract Sum is less than the Completion Cost, the
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difference shall be a debt payable by the Contractor to the Government and if greater the
difference shall be a debt payable by the Government to the Contractor.
65.5 The Certificate of Termination Costs shal l be binding and conclusive on the Contractor as to the
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amount of such loss or damage specified therein; and
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65.6 In the event of the completion of the Works being undertaken departmentally, allowance shall be
made, when ascertaining the amount to be certifi ed as costs or expense incurred by th e
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Governmen t, for cost of supervision, interest and depreciation on plant and all other usual
overhead ch arges and profi t as would be incurred if the Works were compl eted by other
con tractors or persons .
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66.0 SURVIVING RIGHTS

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Any termination under th is Contract shall not affect the liability of either party hereto for any of its acts or
( omissions during the period of the Contract and both parties shall th ereafter continue to be so liable and
shall keep the other party hereto indemnified and hold harm less in respect of any claims arising
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th erefrom.
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67.0 FORCE MAJ EURE

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67 .1 Neither th e Government nor the Contractor shall be in b r~ach of its obligations under this
Contract if it is unable to perform its obligation und er this Contract ( or any part of thereof), other
than the payment obligation s as a result of the occurrence of an Event of Force Majeure.
67.2 An "Event of Force Majeu re" is an event beyond the control of both parties which are:
(a) war (whether declared or not), hostilities, invasion, act of fo reign enemies;
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(b) insurrection, revolution, rebellion, military or usurped power, civil war, terrorism;
(c) natural cata strophe including but not lim ited to earthq uakes, floods, subterranean
spontaneous combustion or any operation of the forces of nature against which an
exp erienced contractor could not reasonably have been expected to take precautions;
(d) nuclear explosion , radioactive or chemical contamination or radiati on (unless caus ed by

the negligence act, omission or default of the Contractor, its agents or personnel );
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(e) pressure waves caus ed by aircraft or other aerial devices traveling at sonic or supersonic
speeds ; and
(I) riot, commotion or disorder, unless solely restricted to employees of the Contractor or its
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personnel , servants or agents.
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PROVIDED THAT an Event of Force Majeure shall not include financial inability on the part of the
( Contractor to perform his obligations under this Contract.
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67.3 If an Event of Force Majeure occurs by reason of which either party is unable to perform any of its
obligation under this Contract (or any part thereof), the party shall inform the other party
immediately of the occurrence of that Event of Force Majeure with fu ll particulars thereof and the
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consequences thereof.
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67.4 If either party considers the Event of Force Majeure to be of such severity or to be continuing for
such period of time that it effectively frustrates the original intention of this Contract, then the
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parties may agree that this Contract be terminated upon mutual agreement of the parties.
67.5 If this Contract is term inated by an Event of Force Majeure pursuant to the above clause, all
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rights and obligations of the parties under this Contract shall forthwith terminate and neither party
shall have any claim against the other party and neither party shall be liable to each other save
for any rights and liabil ities accruing prior to the occurrence of th e Event of Force Majeure.
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( 67.6 Neither party shall be entitled to rely upon the provisions above if both parties reasonably
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determine tha t an Event of Force Majeu re has not occurred .
67.7 For avoidance of doubt, the parties shall continue to perform those parts of those obligations not
affected, delayed or interrupted by an Event of Force Majeure and such obligations shall , pending
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the outcome of this clause continue in full force and effect.

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68.0 ARBITRATION
68.1 If any dispute or difference shall arise between the Government and the Contractor out of or in
connection with the contract, then parties shall refer such matter, dispute or difference to the officer
named in Appendix for a decision.
68.2 The officer named in Appendix's decision shall be in writing and shall subject to clause 68.4 hereof,
56
be binding on the Parties until the completion of the Works and shall forthwith be given effect to by
the Contrador who shall proceed with the Works with all due diligence whether or not notice of
dissatisfaction is given by him .
68.3 If the Parties -
(a) fails to rece ive a decision from the officer named in the Appendix within forty-five (4S) days
after being requested to do so; or
(b) is dissatisfied with any decision of the officer named in th e Appendix,
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then such dispute or difference shall be referred to arbitration within forty-five (4S) days to an
arbitra tor to be agreed between th e Parties and failing such agreement, to be appointed by the
Director of the Regional Centre fo r arbitration in Kual a Lumpur on the applica tion of either Party
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hereto. Such arbitration shall be heard at the Kuala Lumpur Regional Centre for Arbitration and shall
be conducted in accordance with the rules fo r arbitration of the Kuala Lumpur Regional Centre for
Arbitra tion using the facilities and the system available at th e Centre .
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( 68.4 Such reference, except on any difference or dispute under clause 60 hereof shall not be
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commenced until after the completion or alleged completion of the Work s or determination or alleged
determination of the Contractor's em ployment under this Co ntract, or abandonment of the Works,
unless with the written consent of the Government and th e Contractor.
68.S In the event that such consent has been obtained in accordance with clause 68.4, the reference of
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any ma lter, dispute or difference to arbitrati on pursuant to this cl ause and/or the continuance of any
arbitration proceedings consequent thereto shall in no way operate as a wai ver of the obligation s of
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the parties to perfomn their respective obligations under this Contract.
68 .6 In any arbitration proceedings conducted pursuant to clause 68 .3, the Parties may make any counter
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claim in relation to any dispute or difference arising from the Contract.
68.7 Upon every or any such reference the costs of such incidental to the reference and award shall be in
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the discretion of the Arbitrator who may determine the amount thereof, or direct the amount to be
taxed as between solicitor and client or as between party and party, and shall direct by whom and to
whom and in what manner the same be borne, award and paid .
68.8 The award of the Arbitrator shall be final and binding on the Parties .
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( 68.9 In the event of the death of the arbitrator or his unwillingness or inability to act, then the Government
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and the Contractor upon agreement shall appoint another person to act as the arbitrator, and in the
event the Government and the Contractor fail to agree on the appointment of an arb itrator, an
arbitrator shall be appointed by the Director of the Regional Centre for Arbitra tion in Kuala Lumpur.
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68.10 In th is clause, "reference" shall be deemed to be reference to arbitration within the meaning of the
Arbitration Act 200S.
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68.11 The arbitration shall be govern ed by the Arbitration Act 200S and the laws of Malays ia.
69.0 SAFETY AT THE SITE
69.1 Compliance wi th Safety Requirem ents
The Contractor shall comply with all relevant laws , regulations, rules , by-laws, directive or order by the
57
relevant authorities on the req uirements of safety:at-work ("Safety Requirements") and shall ensure its
"personnel, workmen and sub-contractors at all times during the execution of Works comply with such
Safety Requirements.
69.2 Submission of Safety Programme
(a) Within 14 days from the receipt of the Letter of Acceptance by the Government, the
Contractor shall submit to the p .o a safety programme to ensure that all construction
activities required for the execution of th e Works are carried out in a safe manner and in
compliance with Safety Requirements.
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(b) The safety programme shall be subject to th e approval of the p.o . The subm ission to and
approval by the P.O of the safety programme shall not relieve the Contractor of any of its
obligations and liabilities pertaining to th e safety requirement under the Contract.
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69.3 Safety Officer and Personnet
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(a) The Contractor shall appoint a suitably qualified and experienced person as safety officer
( who shall be responsible for compliance with Safety Requirements and all safety matters
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rel ating to the Works . The Contractors shall , from tim e to time. provide such other
personnel and resou rces as may be required to ensure the effective implem entation of
the safety programme on Site .
(b) The Contractor shall conduct training programmes for all workm en including workmen of
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its sub-contractors for compl iance with the Safety Requirements.
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69.4 Safety Measures
(a) The Contractor shall ensure that the constructional plant together with all other tools and
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equipment and other items used in the execution of the Works are in a safe, sound and
good condition and capable of performing th e functions for which they are intended.
(b) The Contractor is responsible for instituting a safe method of construction on site for all of
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the workers and shall ensure that its subcontractors whether nominated or otherwise
institute the same method of construction for their workers.
(c) Without limiting its liability under the Contract, the Contractor shall provide all workmen
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on Site with the necessary safety equipment including but not limited to safety boots ,
( safety helmets and protective clothing .
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70.0 TECHNOLOGY TRANSFER

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If the Contractor appoints foreign professionals , the Contractor shall endeavour to ensure that the
employees of the Government are trained or exposed to the expertise of such foreign professionals
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pursuant to a programme for technology transfer.
71.0 ENVIRONMENTAL MATTERS
If the Contractor is required under the Environ mental Quality Act 1974 to carry out an environmental
impaCt assessment report ("EIA Report") in relation to the Works, the Contractor shall -
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(a) comply with all relevan l laws, in particular the Environmen tal Quality Act 1974 and the
Govemment policies as set out in the approval condition s of th e Elk Report. '[he
Government acknowle dges that compliance with the approva l condition s of the EIA
Report shall satisfy the noise, visual impact, aerial pollution and vibrati on parameters
required in respect of the Works;
(b) ' ensure the incorporation of appropriate mitiga tive, reh abilitative, restorative and
enhancement measures in the planning, des ign and implementation works;
(c) give due consideration to the preservation and social implications of the water and air
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quality, soil , fiora and fauna within the site of the Works.
PROVIDED THAT the Government reserves the right to determine the cutting, felling or preservation of
trees or the replanting thereof on the Site and the Contractor shall comply with any direction of the
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Government in this respect.
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( 72.0 LAW GOVERNING THIS CONTRACT
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This Contract shal l be governed by and construed according to the laws of Malaysia and the parties
irrevocably submit to the exclusive jurisdiction of the courts of Malaysia.
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73.0 COMPLIANCE WITH THE LAW
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The Contractor shall comply with all applicable laws and with all gu idelines, instruction, directions, orders,
requ irements and instructions issued to the Contractor by any authority comp etent to do so under any
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applicable law.
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74.0 AMENDMENT
No modification, amendment or waiver of any of the provisions of this Contract shall be effective unless made
by mutu al consent and made in writing by way of supplementary agreement specifically referrin g to th is
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Contract and duly signed by th e Parties. The provisions in respect of such amendmen t, variation or
modification thereof shall be supplemental to and be read as integral part of thi s Contract which shall rema in
in full force and effect as between both Parties.
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75.0 CONFIDENilALlTY
75.1 This Contract and all such drawings, records , data, books, reports and all matters pertaining hereto
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shall be considered as confidential matter and shall not be disclosed to an y th ird party without prior
written mutual agreement, save and except where-
(a) disclosure of such information is necessary for the purposes of raising finance to undertake
the obligations of the Contractor under th is Contract;
(b) disclosure of such information is made to the Contractor's consultants, auditors or advisers;
59
(c) disclosure of such information is req uired by law or by any government agency or for the
performance of any obligations under thi s Contract; or
(d) the information has entered public domain.
75.2 Wh ere information has been disclosed to third parties pursuant to clause 68 .1, th e Contractor
undertake to ensure that such third parties shall not disclose th e information to any other third
party.
75.3 The restrictions contained in this clause shall survive the termin ation of this Contract and shall
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continue to bind both Parties without limit in point of time.
76.0 STAMP DUTY
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All costs ior the preparation of this Contract Including the stamp duty , If any shall be borne by the
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Contractor
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77.0 NOTICES
77 1 Any notice, approval, consent, request or other communication reqUIred or permitted to be given
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or made under this Contract shall be In writing In Bahasa MalaYSia or English language .
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77 2 Such notice shall be effected by

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(a) hand delivery or courier and an acknowledgement of receipt obtained ,

(b) leaving the notice at the registered office or site office of the Contractor in which case it
shall be deemed to have been duly delivered; or
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(c) registered post in which case it shall be deemed to have been rece ived seven (7) days
after the date of posting .
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75 .3 The address of the Government and the Contractor is as shown below or such other address as
( either party may have notified the sender:
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to the Government:
Address :
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to the Contractor:
Address:
75.4 It shall be the duty of the parties to notify the other if there is a change of address or entity by
giving a written notice within fourteen (14) days . In the event of the Contractor failing to notify the
PD of such an address or any change in his address, such written notices and instructions shall
be deemed to have been served upon the Contractor if they are sent in the manner stated above
60
to the address stated in this Contract or to the Contractor's site office.
78.0 TIME
Time whenever mentioned shall be of the essence of this Contract.
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79 .0 SEVE RABILITY
If any provision of this Contract is held to be illegal or invalid under present or future laws or regulations
effective and applicable du ring the term of this Contract, such provision shall be fu lly severable and this
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Contract shall be construed as if such Illegal or invalid provision had never comprised as part of this
Contract and the remaining provisions of this Contract shall remain in full force and effect and shall not be
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affected by the illegal or invalid provision or by its severance from this Contract.
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IN WITNESS WHEREOF Th is Contract has been executed by the duly authorised rep resentative of the
parties on the day and year first above written.
Signed for and on behal f of

THE GOVERNMENT OF MALAYSIA
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In th e presence of
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Witn ess
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Signed for and on behalf of
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In the presence of
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Witness
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CONDITIONS OF CONTRACT
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(P.W.D. FORM DB Rev.1I2010)
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WITH
ADDENDUM TO THE CONDITION OF
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CONTRACT
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This Addendum No.1, No.3, No.5, NO.6 and NO.8 to the Conditions of Contract PWD FORM
DB (Rev. 1/20 10) consists of 8 pages (including this page) which are and shall be read and
construed as part of the said Contract.
Signature of Contractor Signature of Officer
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(Name in full ....................... .... .............. ) (Name in full ............................................. )
I.C. No ......................... .. ... ................ .. I.C. No ............. ............ .. .. ................ .. ... ..
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In the capacity of ........... .. ...... .. ......... .. .. .. In the capacity of .. ....... ... .. .... .... ............ ... ..
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Duly authorized to sign for and on behalf of
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Duly authorized to sign for and on behalf
of the Government
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Contractor's Chop or Seal Official Chop

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Witness .................... .... ...... ...... ....... ... .. Witness ............ .. ..... ...... .... ... ................ .
(Name in full ............ ............... .... .... ..... .. ) (Name in full .. ...... .. ....... .. ........... ... .. ........ )
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( : I.C. No ..... ........... .. .. ............................ . I.C. No . ... .. .. .... .......... .... .. .. ....... .. .. .. ........ .
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Occupation .............. ............. .. ......... .... . Designation ... ............... ... ........... ....... ... .. .
Address Address
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ADDENDUM NO.1 TO THE CONDITIONS OF CONTRACT
NO. AMENDMENTS
1. Page 38, Clause 45.0
1.1 Substituta clause 45.1 with tha new clause 45.1 as follows:
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45.1 " the Contractor fails to complela the Works by the Dale for Completion or within
any extended tima granted pursuant to clause 49, the P.D shall issua a
Certificate of Non-Completion to the Contractor.
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1.2 Substitute clause 45.2 with the new clause 45.2 as follows:
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( 45.2 Without prejudice to the Government"s right to terminate this Contract. when the
P.O. issues the Certilicate of Non-Completion, the Government shall be entilled to
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recover from the Contractor. Liquidated and Ascertained Damages calculated at
the rate stated in Appendix 1 from the date of the failure to complete the work
pursuant to clause 45.1 to the date of lhe Practical Completion or the date of
termination of this Contract. The P.O. may deduct such Liquidated and
Ascertained Damages from any money due or to become due to the Contrector.
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failing which such damages shall be recovered from the Performance Bond or as
a debt due from the Contractor. The P.O. shall inform the Contractor in writing of
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such deduction.
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PWD FORM DB (Rev. 112010)
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NO., AMENDMENTS
1. Page 10, Clause 10
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10.0 PERFORMANCE BOND
1.1 Substitute the Clause 10.1 with the new Clause 10.1 as follows:
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J 10.1 The Contractor shall. as a condition precedent to the commencement of any
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( work deposit with the Government a Performance Bond substantially in the
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form as set out in Appendix [ J issued by an approved licensed bank or
financial institution incorporated in Malaysia in favour of Ihe Government for a
sum equivalent to five percent (5%) of the Contract Sum to secure the due
performance of the Contractor's obligations under this Conlract. The
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Performance Bond shall remain valid and effective from the date of issuance
until "twelve (12) I twenty four (24) months after the expiry of the Defect
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Liability Period or the issuance of the Certificate of Completion of Making
Good Defects, whichever is the later.
1.2 Substitute the Clause 10.2 with the new Clause 10.2 as follows:
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10.2 If the Contractor fails to submit the said Performance Bond in Ihe form as
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specified under clause 10 .1 by the Date for Possession , the Contractor shall
be deemed to have opted for a Performance Bond in the form of a
Performance Guarantee Sum instead whereby deductions of ten percent
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(10%) shall be made from every interim payments until the total amounl
( deducted is equivalent to a five percent (5%) of the Contract Sum. The
amount deducted shall be retained by the Government up to "twelve (12) I
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twenty four (24) months after the expiry of the Defect Liability Period or the
issuance of the Certificate of Completion of Making Good Defects, whichever
is the later.
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"Delete whichever is not applicable

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Contract sum up to RM10 million : twelve (12) months.
Contract sum more than RM10 million : twenty four (24) months
NO. AMENDMENTS
Substitute the whole of Clause 67.0 with the new Clause 67.0 as follows:
67.0 EFFECTS OF FORCE MAJEURE
67.1 Events of Force Majeure
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Neither the Government nor the Contractor shall be in breach of its obligations
under this Contract if it is unable to perform of fulfil any of its obligations under
this Contract (or any part of them) as a result of the occurrence of an Event of
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Force Majeure. An event of "force majeure" shall mean an event, not within the
control of the Party affected, which that party is unable to prevent , avoid or
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remove, shall mean -
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(a) war (whether declared or not). Hostilities, invasion, act of foreign enemies ,
rebellion , revolution , insurrection , military or usurped power, civil war, or acts of
terrorism ;
(b) ionizing radiation or contamination by radioactivity from any nuclear waste , from
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the combustion of nuclear fuel , radioactive toxic explosive, or other hazardous
properties of any explosive, nuclear assembly or nuclear component thereof;
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(c) pressure waves cause by aircraft or other aerial devices travelling at son ic or
supersonic speeds;
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(d) natural catastrophe including but not limited to earthquakes, floods, subsidence ,
and subterranean spontaneous combustion or any operation of the force of
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nature, lightning and exceptionally inclement weather;
(e) riot, commotion and disorders, criminal damage, sabotage, strike, lock out ,
labour unrest or other industrial disturbance (affecting the performance of this
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Contract) which are not the fault of the Contractor or its personnel, servants or
( agents or the Government which causes , or can reasonably be expected to
cause any party to fail to comply with its obligations;
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(f) pandemic or epidemic; or

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(g) any other unforeseeable event which fulfils the criteria as set forth below:
(i) which beyond the reasonable control of the Party affected by such event,
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circumstance or combination of events or circumstances;
(ii) which was not foreseeable or, if foreseeable, could not have been
prevented or avoided or overcome by the affected Party having taken all
reasonable precautions and due care ;
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NO. AMENDMENTS
(iii) which directly causes the effected Party to be unable to comply with all
or a material part of its obligations under this Contract; and
(iv) which is not the direct result of a breach by the affected Party of its
obligations under this Contract.
PROVIDED THAT an Event of Force Majeure shall not include economic downturn ,
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non-availability of or insufficient of funds or lack of financing on the part of the
Contractor to perform its obligations under this Contract.
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67.2 If an Event of Force Majeure occurs by reason of which either party is unable to
perform any of its obligation under this Contract (or for any part thereof) , the
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Party shall inform the other Party immediately of the occurrence of that Event of
( Force Majeure with full particulars thereof and the consequences thereof.
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67.3 If either Party considers the Event of Force Majeure to be of such severity or to
be continuing for such period of time that it effectively frustrates the original
intention of this Contract, then the Parties may agree that this Contract may be
terminated upon mutual agreement of the Parties.
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67.4 If this Contract is terminated by an Event of Force Majeure pursuant to the
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above clause, all rights and obligations of the Parties under this Contract shall
forthwith terminate and neither Party shall have any claim against the other
Party and neither Party shall be liable to each other save for any rights and
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liabilities accruing prior to the occurrence of the Event of Force Majeure.
67.5 Neither Party shall be entitled to rely upon the provisions above if both Parties
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reasonably determine that an Event of Force Majeure has not occurred .
67.6 For avoidance of doubt, the Parties shall continue to perform those parts of
those obligations not affected, delayed or interrupted by an Event of Force
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Majeure and such obligations shall , pending the outcome of this clause continue
<- in full force and effect.
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NO. AMENDMENTS
Substitute the whole of Clause 77.0 with the new Clause 77.0 as follows:
77.0 NOTICE
(a) Any notice, approval, consent, request, requirement, permission or other
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communication required , authorized, permitted or contemplated to be
given or made under this Agreement shall be writing in bahasa Melayu or
the English language and delivered by registered post or by personal
service to the address, transmitted to the facsimile number or to the e-
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mail address, of the Parties, as the case may be, specified below or to
such other address, facsimile number or e-mail address as either Party
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may have notified the sender. The proof of service of the same shall be
deemed to be duly given or made -
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(i) in the case of delivery by registered post, on the third day it is
posted to such address;
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(ii) in the case of delivery in person, when delivered to the reCipient
at such address and an acknowledgement of receipt obtained;
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(iii) in the case of facsimile transmission, when the recipient's

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facsimile number is shown on the sender's print-out for the

transmission regarding the date, time and transmission of all
pages; or
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(iv) in the case of e-mail, when it is transmitted without any error

message.
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( To the Government:
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Address
Tel
Fax No
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E-mail Address
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To the Company:
Address
Tel
Fax No
E-mail Address
(b) It shall be the duty of the Parties, to notify the other, if there is a change
of address, facsimile number or e-mail address by giving a written notice
within fourteen (14) days from the change.
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(c) For the avoidance of doubt, the mode of delivery of notice stipulated in
the Clause herein shall not apply to notices required to be given under
any applicable laws relating to this Agreement.
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NO. AMENDMENTS
Clause
8.6(a) Officer empowered to approve instructed

variations according to the limits
as set out In Treasury Circullar as amended
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Financial Limit Officer
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8.6(b) Officer (s) empowered to take Action on
Behalf of the Government in respect of :
Clause 49
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Clause 60, 61, 62, 67 and 68
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5.5 Date of Tender ................................. ..

5.6
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25.1
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10 Performance Bond
Arnount of Guarantee ......... RM

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Guarantee Bank / Insurance Company

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Guarantee No ....... .. .... . ...... .
11 Amount to the added to full

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Value of Contract Sum as the

Insured sum ...................................... ... . . RM
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Total Amount Insured ...... .. .. RM

Policy No ...................... .. ..
Period of Insurance ....... .. .. ..
11 .2 Amount of excess ........ ........... ........... .. .. . RM
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APPENDICES TO THE CONDITIONS OF
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CONTRACT
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LIST OF APPENDICES
APPENDIX I Appendix to Conditions of Contract
APPENDIX 2 Government's Requirements
APPENDIX 3 Contractor's Proposal
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APPENDIX 4 Tender Sum Analysis
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APPENDIX 5 Contract Schedule of Rates
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APPENDIX SA Preambles to Contract Sum Analysis and
Schedule of Contract Rates
Preamble of General Items
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APPENDIXSB Preambles to Daywork Rates

Daywork Rates for Labour and Plant
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APPENDIX 6 Certified Copy of Bank/Finance Company/

lnsurance* Guarantee for Performance Bond
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APPENDIX6A Design Guarantee Bond

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( Borang Jaminan Bank/Jaminan

APPENDIX6B
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Syarikat KewanganlJaminan
Insurans untuk Bayaran
Pendahuluan (Kontrak Bekalanl
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PerkhidmataniKerja
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APPENDIX? List of Government Multimodal Transport

Operators
APPENDIX 8 Detailed Design and Specifications
APPENDIX 9 Non-Compliance Schedule (NCS)

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APPENDIX!
APPENDIX TO THE CONDITIONS OF
CONTRACT
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APPENDIX 1
APPENDIX TO THE CONDITIONS OF CONTRACT
Clause
8.6(a) Officer empowered to approve

instructed variations according
to the limits as set out in
Treasury's Instructions No. 202
as amended
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Financial limits Officer
(a) If the original Contract Sum is less than A Committee chaired by the Superintending
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RM10 million and the cumulative value of the Officer as named in the contract.
proposed variation works is less than 10% of
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( the Contract Sum OR if the original Contract
Sum exceeds RM 10 million and the
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cumulative value of the proposed variation
works is less than RM1 million.
(b) If the original Contract Sum is less than A Committee chaired by the Deputy Director
RM10 million and the cumulative value of the General of Public Works Malaysia.
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proposed variation works is less than 20%
OR if the original Contract Sum exceeds
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RM10 million and the cumulative value of the

proposed variation works is less than RM2
million.
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(c) If the original Contract Sum is less than A Committee chaired by the Director General
RM20 million and the cumulative value of the of Public Works Malaysia.
proposed variation works is less than 30%
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OR if the original Contract Sum exceeds

RM20 million and the cumulative value of the
proposed variation works is less than RM6
million.
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( (d) In all other cases. Secretary General of Finance Ministry.

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8.6(b) Officer( s) empowered to take

action on behalf of the
Government in respect of:
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Clause 49 LII..Lli!!lS. Mpw!Q. SWlil.QJ:Ql!Ii11 .Kf.XR

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fjjJ, .I. (i/lQ.I. 8. .a!Ii!l. l iJ:fl.i1,q n.Kf.XR

Y.f!(!g .tl?!./s/nil
Clauses 60, 61,62,67 and 68 LJI..LJ.i!!k.kmlirl.a.S~!ml.g!:gl!!1n.Kf.XR
IN.I.(iNQ.I.8..q!Ii~!.A.mil!1!!.Kf.XR
Y.f!(!9.t1?!i</nil
5.5 Date of Tender
5.6
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APPENDIX 1
Clause
10 Performance Bond
Amount of Guarantee . RM ;;'% .Qf.c;.Q!l!m~(.S!!m
Guarantor Bank/Insurance Company r~.Q.~.~HQ!!!iM4./J.Y.!Mr;gmm.9./.Q!:!f
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!?9.(P~!fQ!m(l}I.c;~J;Hgrfl}J!~f?SWJl
Guarantee No. ... ... ...... r~ .Q.~.~HQm!!!~"h.rI!~.r;gm!J!9!.Q!:!f

n9_(_f~!fQ!mR~I.c;~.q~~(l}:fl-'.l!~~. SEI!1
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11 Amoun t to be added to full
value of Contract Sum
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( as the insured sum RM ....... Nil .... .... ..... ..
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Total Amount Insured RM yq!H?fJJ. (;(.W.']:«f!.$.Wn. .±~W.Y
_A nl.Q.rmt.9i.f4;r.C;'f.s.$
Policy No ..
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Peri od of insurance ...
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11 .2 Amount of excess RM A~ _S!m'f4_ in/~lJ~)~I/il:l}·9..1J.C;~

fg!i9X
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12 . Date for Possession' of the Site ......... .

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33 SOCSO Scheme registration number
39 Minimum insurance cover for anyone

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accident or series of accidents

( arising out of one event RM 2,000,000.00
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Policy No ...
Period of insurance ... [;Q n!U!~( ~~rjgd.:I: I)U..T. .~Ii .if.QY~ . ±

J .~1JmHb.s.
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39.2 Am ount of excess RM A~.sUH?4. in .(~I.f4)H.fHnW.C;~

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f~!i9X
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Membina lalan Dari Behor Mali Ke Kamptmg Kepa/a Sepuloh, Perlis

APPENDIX 1
Clause
43 Sectional Completion:
Identification of Date for Date for Liquidated and

Sections or parts Possession Completion Ascertained Damages
[Clause 39.3] (Clause41.1) (Clause 42.1)
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44 . Date for Completion' for whole of
the Works ................................ . .'[Q _l}_~ .9..~9.I?!:(q j n?.cJ./J.f1_~ ?.cf.Qn p~U9.cJ.
pi t;.Q!r/pl.€lti9.1J. !?v.cJ{!:[f3A
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45 Liquidated and Ascertained Damages
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at the rate of ....................... .. RM 0.0185 % of Contract Sum ...
per day
47 Defects Liability Period (if none stated,

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then the period is twenty four (24)

months) ........................ ..... . Twenty Four (24) months
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53.3 Value of work to be executed including

materials and goods to be delivered before
I nterim Certificate will be issued .................... . Not less than RM1,OOO.00
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53.5 Period for honouring payment

( certificate (if none stated, then
within thirty (30) days of the issue
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of the Certificate) Thirty (30) days of the issue

of the certificate
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84, Percentage of on-cost charges 5%

11.3,
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31.2,
334(b),
39.5.
474 Percentage of on-cost charges 10%

64.2(d)
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Membina Jalan Dari Behor Mali Ke Kampung Kepa/a Sepli/olz, Perlis

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APPENDIX 2
GOVERNMENT'S REQllREMENTS
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APPENDIX 2
GOVERNMENT'S REQUIREMENTS
The Government's Requirement are comprised in the following documents:
(a) General and Contractual Requirements -
As in Jilid I, Part B of the Pre-Bid Document
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(b) Technical Requirements -
As in Jilid \I (Book I of2), Part A of the Pre-Bid Document

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(c) Standard Spesification -
As in Jilid \I (Book 2 of2), Part B of the Pre-Bid Document

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APPENDIX 3
CONTRACTOR'S PROPOSAL
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APPENDIX 3
CONTRACTOR'S PROPOSAL
The Contractor's Proposal are comprised in the following documents (including

any drawings):
a)
b)
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c)
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APPENDIX 4
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TENDER SUM ANALYSIS
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APPENDIX 4
(REKA DAN BINA)
TENDER SUM ANALYSIS
ITEM DESCRIPTION FROM AMOUNT (RM)

PAGE
A LUMP SUM COMPONENT
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GENERAL ITEMS AND DESIGN & BUILD ELEMENTS BQI-6/6
2 SITE CLEARANCE AND DEMOLITION WORKS
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3 EARTHWORKS (Please Itemised)
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( 3.1 ..... .............. .......... .. .. ... .. .. ....... ................................. ..
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3.2 ... ............................................................................. ..
3.3 ... ............................................................................. ..

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4 CULVERT & DRAINAGE WORKS (Please Itemised)
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4.1 .... ............................................................................ ..
4.2 ............. ......................... .......................................... ..

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4.3 ......... ... .................................................................... ..
5 PAVEMENT WORKS (Please Itemised)

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5.1 ... ........................................................................... .. ..
5.2 ................................................................................ ..
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( 5.3 .............................................................. ...... .. .. ........ ..

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6 ROAD FURNITURE (Please Itemised)
6.1 ................................................................................ ..
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6.2 .. .......................................................................... .... ..

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6.3 .. ........... .. ...................................................... .. ........ . ..
7 GEOTECHNICAL WORKS (Please Itemised)
7.1 . ................................................... .. .......................... ..
7.2 . .. ........................................................................... .. ..
7.3 .......... .. ........................ ..................... ....................... ..
Note: This Tender Sum Analysis shall be guide only. The tenderer may add, omit or vary the content as the case may be.
A4-1
(REKA DAN BINA)
TENDER SUM ANALYSIS
ITEM DESCRIPTION FROM AMOUNT (RM)

PAGE
A LUMP SUM COMPONENT (CONT'D)
8 STRUCTURES (Please Itemised)
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8.1 ... ............................ ..................... ..............................
8.2 .. ............. ..................................... .. ... .... .................... .
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8.3 .. ...... ............................................ .. .............. ... .......... .
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( 9 TRAFFIC MANAGEMENT AND CONTROL (Please Itemised)
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9.1 .. ........... ................................................................... ..
9.2 ...... .. ................................ .. .. ........ .............. .. ............. .
9.3 ... ... .. ............... ...... ........... ............. .. .. ........................ .

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10 ENVIROMENTAL PROTECTION WORKS (Please Itemised)
10.1
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10.2
10.3
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II ROUTINE MAINTENANCE WORKS (Please Itemised)
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1l.3
12 OCCUPATIONAL SAFETY AND HEALTH (Please Itemised)

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12.1
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12.2
12.3
13 ELECTRICAL WORKS (Please Itemised)
13.1
13.2
13.3
Note: This Tender Sum Analysis shall be guide only. The tenderer may add, omit or vary the content as the case may be.
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(REKA DAN BINA)
TENDER SUM ANALYSIS
ITEM DESCRIPTION FROM AMOUNT(RM)

PAGE
B PROVISONAL SUM
14 RELOCATION AND PROTECTION OF UTILITY BQ I4-I /J 4,000,000.00
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SERVICES
i. SY ARIKA T AIR PERLIS (SAP)
ii. TENAGA NASIONAL BERHAD (TNB)
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iii. TELEKOM MALAYS IA (TM)
iii. TELCO (MAXIS, TIME)
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( ATTANDANCE FEE FOR RELOCATION AND 60,000.00
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PROTECTION OF UTILITY SERVICES
15 ALLOCATION FOR WORKS TO BE EXECUTED BY BQI5- 1/ 1

GRADE G2/G I BUMIPUTERA CONTRACTORS·
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15. I SIGN AGE
15.2 ROADLlNE MARKING

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TOTAL AMOUNT CARRIED TO FORM OF TENDER

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Contractor Witness
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Signature: Signature:
Name: Name:
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NRICNo. :
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Date:
Company
Stamp :
Date:
Note: This Tender Sum Analysis shall be guide only. The tenderer may add, omit or vary the content as the case may be,
A4-3
APPENDIX 4
MEMBINA JALAN DAR I BEHOR MALI KE KAMPUNG KEPALA SEPULOH, PERLIS
GENERAL ITEMS AND DESIGN & BUILD ElEMENTS
No. Code No. Description Unit Amount (RM)
A100 CONTRACTUAL REQUIREMENTS
Bond
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A A111 Performance Bond; Banker's/lnsurance/Financiallnstitution Guarantee'" sum
B A1 12 Design Guarantee Bond sum
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Insurances
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( A121 Insurance of the Works .
C sum
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D A122 Public Liability Insurance. sum
E A123 SOCSOfWorkmen Compensation Insu rance. sum

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PO'S REQUIREMENTS
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Facilities
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F A2 11 Establishment and maintenance of office including fittings and furnitures sum

as listed in APPENDIX 1F of the Specification and Contractual and
General Requirements;
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JKR Design (Kalegori 3) / Relocatable Type (New/Yse<l) / Rent Shoplot""
G A2 13 Establishment and maintenance of laboratories including equipments, sum

fittings and furnitures as identified in APPENDIX 10 of the Specification
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Equipment
A221 Provision and maintenance of office equipment as per APPENDIX 1 E of

the Specification and Appendix A3 of the Contractual and General
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Requirements .
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H A221.1 3 Nos. computers sum
J A221.2 1 Sets Mobile Workstation Laptop sum
K A221 .3 1 Nos . of high end specification workstation desktop with 81M sum
software
Amount for General Items Carried to Collection
D o not price if tenderer opt for Performance Guarantee Sum

Choose one option and delete where not applicable
BQ1- 1/6
A PPENDI X 4
GENERAL ITEMS AND DESIGN & BUILD ELEMENTS
N o. Cod e No. D escriptio n Unit A mount (R M)
PO'S REQUIREMENTS (Conl'dl
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Equipment (c onl'dl
A221 Provision and maintenance of office equ ipment as per APPENOIX IE of

the Specification and Appendi x A3 of the Co ntractual and General
Requ irements.
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A A221.3 1 No. Copier machine sum
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C A221 .5 1 No. digital camera A sum
0 A221.6 1 No. projector sum

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Services for the PO/PO's Representative
Provision of suitable transport services as listed in APPENDIX 1C of the

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Specification and Appendix A3 of the Contractual and General

Requ ireme nts for the duration of contract period;
E A23 1 3 nos of four wheel drive (4WD) vehicle sum
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F A232 Operation and Maintenance of 3 nos of of four wheel drive (4W O) vehicle sum
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Attend ance for PO/PO's Representative

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G A24 1 Provide 3 nos. of driver sum
H A245 Provide licensed security services sum

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Submissio n of Documents
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J A251 BIM Execution Plan as specified in Appendix A20 of Technical su m

Requ irement and Contractual And General Req uirements
K A254 Works programme; To provide and update 'NOrks programme using sum
Microsoft Project to produce Critical Path Method (CPM) and Works
Breakdown Structure (WBS) etc. by the planner including provid ing
supply of (1 copy) Microsoft project software (latest version) as specified
in Specia l Provision to the Standard Specification for Road Works: Work
Programme Specification and item 19 in Contractual and General
Requirements, to be submitted for consent before commencement of
works.
Amount for Gen eral Item s Carried to Colle ction
6Q1- 2/6
APPENDIX 4
PO'S REQUIREMENTS (Cont'd)
Miscellaneous
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A A262 Project signboard (2 nos) sum
B A263 As built Drawings and Documents as specified in APPENOIX 1H of the sum
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Specification, item 33 in Contractua l and General Requirements and item
10 in Technical Requirements including assets inventory data.
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C A269 Project report in 10 sets comprising of progress report and quality control sum
report. All the reports to be converted/scanned to a digital copy (in pdf
format or equiva lent and stored in CO) and to be enclosed with each set
of the Project Report including compilation of:
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Progress photographs and Video recording;
(i) Photographic and Video capture of work progress on ground using
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camera .
(ii) Aerial Photog raphy and Aerial Video capture of work progress using
Drone or Unmanned Aerial Vehicle I UAV
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PROJECT REqUIREMENTS
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Qualitv Assurance/Quality Control (QAlQC)
0 A321 QA/QC Plan as per Specification and item 18 in Contractual and General sum
Requirements.
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<- Clearance of site upon completion

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E A360 Clearance of site upon completion as per Specification. sum
Temporary Works
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F A379 Provision for locating, temporary protection and temporary relocation of sum
Pu blic Utility installations and other services and related works
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Amount for General Items Carried to Collection
601- 3/6
APPEND IX 4
No. Code No. Description Unit Amount (RM )
CONTRACTOR'S REQUIREMENTS
Facilities
Establishment, maintenance and removal of accommodation and
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buildings
A A511 Office sum
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B A516 Stores and workshops sum
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C A517 Workmen accomodations sum
Temporary works·
Construct, maintain and remove temporary works j

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0 A52 1 Access and haul roads· sum
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E A529 Temporary drainage· sum

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F A544 Hoardings· sum

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Site management
G A559 Provide site management tea m for the duration of contract period as per sum
Appendix A2-B of the Contractual and General Requirements
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( H A560 Mobilisation and demobilisation of construction plants and equipments sum

excluding piling and specialise plants
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Amount for Design and Build Elements Carried to Collection
• Delete whichever is not applicable or insert if not fisted
BQl - 4/6
APPENDIX 4
N o. Code No. Description Unit Amount (RM)
A600 DESIGN AND BUILD ELEMENTS
A A630 UTILITIES DETECTION WORKS sum
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Covering:
i) Detection, Survey and Mapping (Level A) of existing above

ground and underground services and utilities
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ii) Mobilsation and demobilsation of equipment, temporary
works and traffic management, etc
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( iii) Preparation of reports , programme and traffic management plan
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iv) Preparation of 5 sets of Utilities and services mapping full
colour hard copy drawings A 1 size
v) Preparation of 2 sets digital data on CD-ROM in AUTOCAD

format
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vi) Liason with relevant utilities and services provider
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vii) Consultancy services onsite during design and construction
PREPARATION AND DATA COLLECTION

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B A620 Preparatory and liaison works for submission of Contractor's Proposal sum
including data collection (soi l investigation, detailed engineering survey,
traffic survey, 'title sea rch' for land acqu isition, etc.
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CONTRACTOR'S CONSULTANTS
A651 Consultancy Services as specified in the respective Memorandum
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Agreement as per Appendix A of the Instruction to Tenderers (Please

( itemised, add or delete where applicable)
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C A65 1.1 i) Civil & Structural Engi neer sum
D A65 1.2 ii) Quantity Surveyor sum
E A65 1.3 iii) Electrical Engineer sum

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F A65 1.4 iv) ... ... ..... sum

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G A652 Supervision Team as per Appendix A2-A of the Contractual and General sum
Requirements
INDEPENDENT CHECKERS
A660 Professional services as List Of Consultant in Form of Tender (Add if any)
H A66 1 i) Structural sum
J A662 ii) Geotechnical sum
K A663 iii) Road Safety sum
Amount for Design and Build Elements Carried to Collection
6Q1- 5/6
APPEND IX 4
COLLECTION
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GENERAL ITEMS
From Page BQ1 • 1/6
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From Page BQ1 ·2/6
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DESIGN AND BUILD ELEMENTS
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AMOUNT CARRIED TO TENDER SUM ANALYSIS
BQ1· 6/6
APPENDIX 4
PROVISIONAL SUM
ITEM AMOUNT
DESCRIPTION OF WORKS
NO. (RM)
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PROVISIONAL SUM
RELOCATION AND PROTECTION OF UTILITY SERVICES WORKS
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A Allow a Provisional Sum for the relocati on andlor protecti on of the existing utilities 4.000.000.00
services as listed below to be expended as directed by the Project Director or
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deducted in whole or in part if not expended.
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i) SYARIKAT AIR PERLIS (SAP)
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ii) TENAGA NASIONAL BERHAD (TNB)
iii) TELEKOM MALAYS IA (TM)

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iv) TELCO (MAXIS, TIME)
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ATTENDANCE FEES FOR RELOCATION OF UTILITY SERVICES WORKS

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B Allow a Provisional Sum of Ringgit Malaysia : Sixty Thousand Only (RM 60.000.00
60,000.00) for Attend ance Fee for Relocati on and Protection of Utility Services as
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directed by the Project Director or deducted in whole or in part if not expended.

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AMOUNT CARRIED TO TENDER SUM ANALYSIS : 4,060,000.00
BQ 14-1 /1
APPENDIX 4
MEMBINA JALAN DAR I BEHOR MALI KE KAMPUNG KEPALA SEPULOH , PERLIS
PROVISIONAL SUM FOR WORKS TO BE EXECUTE BY CLASS G2 & G1 'BUMIPUTERA' CONTRACTORS
ITEM AMOUNT
DESCRIPTION OF WORKS
NO. IRM\
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PROVISIONAL SUM FOR WORKS TO BE EXECUTED BY CLASS G2 & G1
'BUMIPUTERA' CONTRACTORS
A Allow a Provisional to be execuled by Grade G1 "Bumiputera" Contractor and to be
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expended as directed by the Project Director or deducted in whole or in part if not
expended .
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( Scope of works and Amount: ............ .. S I ~I'!AG~ ..... .... .... . . . ..... 190,000.00
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Allow for Profit .... .. .. .. .... %
Allow for Attendance

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B Allow a Provisional to be executed by Grade G2 "Bumiputera" Contractor and to be

expended as directed by the Project Director or deducted in whole or in part if not
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expended.
Scope of works and Amou nt: ...................R.()A.D.LII'!Py11\.R .KII'!~ ....... .. . 410,000.00

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Allow for Profit .............. %
Allow for Attendance

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Notes:
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The description of the Provisional Sum Works must clearly indicate scope of works, location and amount
allowed
A mount of works for G1 "Bumiputera" Contra ctor : up to RM200,OOO.OO
Amoun t of works for G2 "Bumiputera" Contractor: RM200,OOO.OO to RM 500,OOO.OO
AMOUNT CARRIED TO TENDER SUM ANALYSIS:
BQ15-1 /1
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APPENDIX 5
CONTRACT SCHEDULE OF RATES
(TO BE SUBMITTED BY THE CONTRACTOR, IF APLLICABLE,
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AFTER AWARD TENDER)
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APPENDIX 5
CONTRACT SCHEDULE OF RATES
To be finalli sed and insert before issuance Letter of Award
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APPENDIX5A
-PREAMBLE TO CONTRACT SUM ANALYSIS
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AND CONTRACT SCHEDULE OF RATES
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-PREAMBLE TO GENERAL ITEMS

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APPENDIX SA
PREAMBLES TO CONTRACT SUM ANALYSIS AND CONTRACT SCHEDULE

OF RATES
I. GENERAL DIRECTIONS
1.1 The Contract comprises the design, construction, completion and maintenance of
the said Works, The Works shall include the provision of all labour, materials,
constructional plant, temporary or permanent works as required in the Contract.
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1.2 The Contract Sum Analysis in Appendix 4 to this Contract comprises three
components of price i.e. the Lump Sum Component, the Provisional Quantities
Components (if applicable) and the Provisional Sum Component.
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1.3 The Contract Schedule of Rates in Appendix 5 to this Contract is the rates which
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forms the basis of cost for the Lump Sum Component and is included only for (and
no other) the purpose of evaluating Variation Order works and Progress Payments.
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1.4 General directions and descriptions of work and materials are not necessarily
repeated in the Contract Sum Analysis (in particular the Provisional Quantities
Bills), and reference shall be made to the Conditions of Contract and Specification.
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The prices and rates inserted shall be the full inclusive cost of the works described
and of all general liabilities and obligations set forth or implied in the Contract
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Documents for the completion of the Works.

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1.5 The Contract Sum Analysis shall be read in conjunction with the other Contract
Documents in particular the Conditions of Contract, the Specification and the
Drawings.
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1.6 The quantities in the Provisional Quantities Component (if applicable) of the
Contract Sum Analysis shall not be taken to be the actual and correct quantities to
be executed. The basis of payment will be the actual quantity of works ordered and
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( carried out and shall be ascertained by joint measurement as stated in the

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1.7 In the Provisional Quantities Components (if applicable) of the Contract Sum
Analysis and Contract Schedule of Rates, The headings, sub-headings and item
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descriptions in the Bill of Quantities identify the works covered. However the
exact nature and extent of the work to be carried out shall be ascertained by
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reference to the Contract as a whole, in particular the Conditions of Contract, the

Specification and the Drawings. It shall be read together with the relevant "Item
Coverage" in the "Method of Measurement".
A5A-1
1.8 Except where expressly shown to the contrary, item descriptions generally are in
respect of components of the Pennanent Works and not of the operations involved
in constructing them .
1.9 The rates and prices entered in the Provisional Quantities Components (if
applicable) of the Contract Sum Analysis and Contract Schedule of Rates shall
include cost of the works described, all risks, liabilities and obligations set forth or
implied in the Contract Document and shall be deemed to include the following,
unless expressly stated otherwise:
(a) the provision oflabour and all costs in connection therewith;
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(b) the supply of materials, goods, equipment and storage thereof including
delivery to site and all costs in connection therewith;
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(c) taking delivery of materials, goods and equipments necessary for the Works
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and including those supplied by others, loading and unloading, storage and
( all costs in connection therewith;
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(d) the provision of plants and machineries and all costs In connection
therewith;
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(e) the fixing, erecting and installing or placing in position of materials, goods
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and equipment including around obstruction, tolerances, penetration,
working space, over-breaks etc. and all costs in connection therewith;
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(f) the provision of all temporary works and all costs in connection therewith
unless separately provided for;
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(g) the phasing requirements of the Works including the effect on the
programming of the Works of all traffic and drainage diversions, special
structural requirements, earthwork restrictions, alterations to services and
street lighting (executed under the Contract or in conjunction with it) and
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( all other requirements of the Contract and all costs in connection therewith;
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(h) all costs of complying with all clauses of the Condition of Contract and
Specification whether such clauses and items have or have not been
particularized in the Specification and in the Contract Sum Analysis and
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such costs shall be deemed to be included in the rates and prices tendered;
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(i) all cost of testing to show proof of compliance with the Specification on
materials and workmanship inclusive of samples of materials and
submission of tests results. Should the frequency of testing and sampling be
not specified, then it shall be in accordance with the relevant
Malaysian/British Standards and Codes of Practice. Where there is no such
relevant Standards and Codes of Practice for reference, it shall then be as
instructed by the P.O.;
(j) all royalties and dues which the Contractor may be required to pay;
(k) wastages;
A5A-2
(I) water and electricity for the Works;
(m) establishment charges, overheads and profit;
(n) whatsoever method of construction the Contractor may adopt.
2. MEASUREMENT
2.1 Notwithstanding any customs to the contrary or any other Civil Engineering
Standard Method of Measurement (MyCESMM2) principles, the works as
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described in the Contract Sum Analysis shall be measured in accordance with this
Preamble, the Method of Measurement and the items in the Contract Sum Analysis
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2.2 The measurement of work shall be computed net from the Drawings unless stated
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otherwise in the Method of Measurement.
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2.3 Certain items in the Contract Sum Analysis (in particular the Provisional
Quantities Component, if applicable) represent composite construction works
involving several classes of materials and workmanship which may not be
described in the item, Preambles or Specifications. The Contractor shall ascertain
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the quantities of the component works involved in the items and price them
accordingly.
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3. UNPRICED ITEMS
3.1 Items against which no price or rate is entered will not be paid for when executed
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and shall be deemed to be covered in other prices or rates in the Contract Sum
Analysis.
3.2 All cost not included elsewhere but necessary for compliance with each and every
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( tenn in the Conditions of Contract shall be deemed to have been covered by the
rates and prices in the Contract Sum Analysis.
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4. GENERAL ATTENDANCE
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General attendance on Nominated Sub-contractors shall include:

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(a) in the case of works or services executed: for allowing the use of existing
working space, access, temporary roads, erected scaffolding, sanitary,
messing, welfare and other facilities existing on Site and the provision of
protection, water, electricity for lighting and clearing away rubbish and
debris arising from the work;
(b) in the case of goods, materials or services supplied: for taking delivery,
unloading, storing, protection and returning crates, cartons and packing
materials.
A5A-3
5. PHASING SEQUENCE OF OPERATIONS AND METHODS OF
CONSTRUCION
The rates and prices shall, unless otherwise stated, include for the costs of
compliance with any restrictions imposed on the programming of the Works by the
Government and Local Authorities and other relevant authorities dealing with
phasing sequence of operations, method of construction, safety and health and
liaison and access.
6. TRIALS, SAMPLES, TESTS AND INSPECTION
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The rates and prices shall incl ude for tests and the effects on the progress of the
Works for the carrying out of all trials, sampling and tests whether specified in the
Contract Documents or otherwise in order to ensure compliance with the
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requirements of the Specification except where separately itemised in the Contract
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Sum Analysis.
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7. EXISTING SERVICES AND MAINS
The Contractor shall include in his rates and prices for taking measures to locate
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the actual position and provide support and full protection of existing services and
mains and other equipment and machineries during the progress of the Works. The
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Contractor shall infonn the P.D of all arrangements with the Statutory Undertakers
and Public Utility Authorities.
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8. WORK UNDER WATER AND FLOOD CONDITIONS

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The rates shall include any costs arising from executing work under water
wherever required unless otherwise stated.
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9. PHRASEOLOGY
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Differences in the method of billing and in phraseology used in various parts of the
Contract Sum Analysis and Contract Schedule of Rates shall not be a basis of any
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claim for an increase in the rates and prices.

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10. PROVISIONAL SUMS
All provisional sums included in the Contract Sum Analysis are intended to be
approximate indications only of the amounts to be expended in respect of the work
described and may be omitted entirely or substantially varied without entitling the
Contractor to any claim for compensation. No part of the Contractor's overhead,
expenses or profit should be included in these sums when the bill is priced unless
items for profit and attendance are specifically allowed for.
A5A-4
11. CURRENCY OF PAYMENT
Pricing of the Contract shall be in Malaysian Ringgit to two decimal place.

Payment to the Contractor under the Contract shall be in Malaysian Ringgit.
12. TEMPORARY DIVERSIONS
Work in connection with the temporary diversion of roads, accesses, drainage and
services, whether detailed in the Contract or not shall be covered by the
appropriate Items in Bill No. I of the Lump Sum Component (unless separately
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measured in other parts of the Contract Sum Analysis.
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13 . MAINTENANCE OF TRAFFIC FLOWS ON EXISTING ROADS
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Unless otherwise provided and paid for separately in the Contract Sum Analysis,
( the Contractor is deemed to have allowed in his rates and prices for the costs of
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maintaining traffic flows on any existing roads until the completion of the Works.
14. ABBREVIATIONS
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The following unit of measurement and abbreviations are used:
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Units Abbreviation
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Millimetre mm
Linear Metre m
Square Metre m2
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Hectare ha.
Cubic Metre m3
Kilogramme kg
Tonne t
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( Number nr
Month mth
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Man-month man-mth
Kilometre month Ian mth
Cycle cycle
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Hour hr
Week wk
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Degree deg
Provisional Sum ProvoSum
Lump Sum sum
Prime Cost P.C.
A5A-5
15. All units shall be in metric and for all units in imperial the following conversion
shall be used, unless otherwise stated
I inch = 25.4 mm
I foot = 304.8mm
I Ib = 0.45 kg
I cwt = 50.91 kg
I ton = 1.018 tonnes
I Ib/in 2 = 0.0069 N/mm 2
I ftl = 0.0283 m l
I gallon = 4.545 litres
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I gallonlyd 2 = 5.44litres/m 2
In case where it is difficult to apply the metric units, the PD can use his di scretion
to use the original names stated in imperial units.
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A5A-6
PREAMBLES
BILL 1 - GENERAL ITEMS
A100 CONTRACTUAL REQUIREMENTS
A 111 Performance Bond
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Lump Sum (sum).
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Measurement
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( The payment shall be made in full after verifying authenticity of the Bankl
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Insurance Guarantee and upon submission of receipt of the premium paid from
the company! authorized agent.
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A 112 Design Guarantee Bond
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Lump Sum (sum).

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Measurement
The payment shall be made in full after verifying authenticity of the Bank!
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Insurance Guarantee and upon submission of receipt of the premium paid from
( the company! authorized agent.
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A 5A-7
A120 Insurances
A121 Insurance of Works
Lump Sum (sum).
Measurement
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The payment shall be made in full after receiving the insurance policy and upon
submission of receipt of the premium paid from the insurance company/
authorized agent.
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A122 Public Liability Insurance
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Lump Sum (sum).
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Measurement
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authorized agent.
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A5A-8
A123 SOCSO !Workmen Compensation Insurance
Lump Sum (sum).
Measurement
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authorized agent.
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A200 PO'S REQUIREMENTS
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A210 Facilities
A211 Establishment, Maintenance and Removal of Office

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A213 Establishment, Maintenance and Removal of Laboratories
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Lump Sum (sum).
Measurement
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The payment shall be made as follows:

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(a) 60% on completion of the facilities as specified;

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(b) 20% for maintenance which shall be made in each interim payment in
proportion of the total period lapsed to the Contract Period (excluding
Defects Liability Period);
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(c) 20% on removal.

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A5A-9
Item Coverage
The item shall be deemed to include the PD's requirements, as per General
Preambles and Preambles to Bill of Quantities and shall include:
(a) Provision and preparation of site;
(b) Foundations and bases;
(c) Fences, hoarding , notice and direction boards;
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(d) Vehicle access, hard standing, parking area and foot paths;
(e) Office furnishing, fittings, supplies and initial consumable stores as
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specified in Appendix '1F' ;
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( (f) Laboratories equipments, furnishing, fittings , supplies and initial
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consumable stores as specified in Appendix '1D';
(g) Provision of telephones, internet lines and extension as specified (where

applicable );
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(h) Water, sanitation, power, air conditioning and lighting services;
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(i) Compliance with local building by-laws;

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Ul Depreciation of buildings, furnishings and fittings;

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(k) Receiving back from the SO/PD and removing buildings, furniture, fittings
and supplies off site;
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(I) Disconnecting and removing services and sealing off disused services;
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(m) Demolishing and removing off site temporary accommodation, vehicle

access, hard standing, parking areas, footpath , fences , notices and
direction boards;
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(n) Disposal of surplus materials;

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(0) Reinstatement of the site;
(p) Removal and disconnecting of telephone (where applicable).
A5A-IO
A212 The item maintenance as per General Preambles and Preambles to Bill
A214 of Quantities and shall include:
(a) Rental charges including land and telephone rental and charges on
telephone calis and internet access;
(b) Fees and charges levied by the respective authorities and maintenance
of power, lighting, water, sanitation, air conditioning and sewerage
disposal;
(c) Maintenance of buildings, services, fences, hoarding, notice and direction
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boards, vehicle access, parking areas, hard standing and footpaths;
(d) Maintenance of furnishings and fittings and supplies;
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(e) Maintenance of telephone (where applicable);
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(f) Cleaning accommodation including pest control;
(g) Moving and re-establishing portable office accommodation as required up

to a maximum of 3 moves;
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(h) Replenishment of consumable stores;
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(i) Maintenance of ali access for use under all weather conditions.
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A220 EQUIPMENT
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A221 Establishment and Removal of Office Equipment

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(a) Computer
( (b) Photocopy machine
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(c) DigitalNideo camera

(d) Facsimile machine
(e) Printer
(f) Scanner
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(g) LCD projector & screen

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(h) Any other equipment not listed above
Lump Sum (sum).
Measurement
(a) 60% upon the complete delivery and commissioning of the equipment
as specified;
A5A-l1
(b) 40% for maintenance of the equipment which shall be made in each
interim payment in proportion of the total period lapsed to the Contract
Period (excluding Defects Liability Period).
Item Coverage
The item for provision of office equipment shall in accordance with the General
Preambles and Preambles to Bill of Quantities and shall include:
(a) Provision, delivery to PO's office and commissioning of equipment and
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accessories/peripherals as listed in Appendix ' 1E' of the Specification;
(b) In the case of computers, the provision of internet connection and the
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original and legal copies of software as specified;
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( (c) In the case of facsimile machine, the provision of telephone line and
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connection;
(d) Depreciation;
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(e) Removal from the PO's office and revert back to the Contractor upon
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issuance of the certificate of practical Completion.
A222 The item for maintenance of office equipment shall in accordance with the
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General Preambles and Preambles to Bill of Quantities and shall include:
(a) Maintenance of all equipment and accessories;

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(b) Rental charges (where applicable);

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(c) Repair cost and cost of replacement in case of breakdown;

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(d) Regular servicing of all equipment, with suitable replacement when the
regular equipment is not available for more than 24 hours;
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(e) Provision and replenishment of consumable items.

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A5A-1 2
A230 SERVICES FOR THE ENGINEERISO/PD/ER
A231 Provision of Transport Services
Lump Sum (sum).
Measurement
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The payment shall be made in each interim payment commencing upon when
the transport service is made available.
Item Coverage
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The item shall in accordance with the General Preambles and Preambles to
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( Bill of Quantities and shall include:
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(a) Provision of the vehicle type as specified in Appendix '1C' of Standard
Spesification - Section 1 and specification as stipulated in Pekeliling
Perbendaharaan Malaysia PK 4.6 or the latest
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Vehicle Specification
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(a) For the used on (i) Up to 2000 c.c

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paved road (ii) Petrol with Electronic

4WD Fuel Injection 4WD
Completely Knocked (iii) Standard Accessories
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Down (CDK) only
(b) For the used on (i) Up to 2500 c.c

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unpaved road (ii) Diesel with

( turbocharged 4WD
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(iii) Standard Accessories

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Motorcycle Up to 150 c.c

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(b) Vehicle/s is/are accident free;
(c) Certification from Puspakom at every six months;
(d) Transport is readily available for the use of PD or PD's staff;
(e) Depreciation.
A5A-1 3
A232 Operation and maintenance of Vehicle
Lump Sum (sum).
Measurement
the transport service is made available.
Item Coverage
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Bill of Quantities and shall include:
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(a) Taxing for use on public highway and for carriage of goods and samples;
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(b) Comprehensive insurance to cover all drivers and passengers and the
carriage of goods and sample throughout the Contract Period (excluding
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(c) Provision of suitable replacement including equipment when regular
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vehicle is not available or unserviceable for more than 24 hours;
(d) Maintenance in a roadworthy condition and in conformity with the vehicle

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manufacturer's recommendations ;
(e) Toll charges, fuel , oil , lubricant and parking fees (where applicable);
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(f) Validity of road tax throughout Contract Period (excluding Defects Liability
Period);
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( (g) Keeping the vehicles clean inside and out.

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A5A-14
A240 ATTENDANCE FOR THE ENGINEER/SO/PD/ER'S REPRESENTATIVE
A241 Driver
A243 Laboratory assistant/technician
A245 Licensed Security Services
Lump Sum (sum).
Measurement
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the attendance is made available.
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Item Coverage
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Bill of Quantities and shall include:-
(a) The wages and other emoluments paid to the operative including
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payment for overtime;
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(b) Working outside the Contractor's normal working hours if so required by

the SO/PO;
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(c) Cost and expenses incurred consequent upon the employment or hiring
of the operative including payment of Employee Provident Fund,
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insurance, medical and hospitalization;
(d) Replacement of unsuitable personnel.

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A250 SUBMISSION OF DOCUMENTS

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A251 BIM Execution Plan (BEP)

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Lump Sum (sum).
Measurement
The payment shall be made upon submission and approval by the PO or in

each interim payment in proportion of the total period lapsed to the Contract
Period (excluding Defects Liability Period).
A5A-15
Item Coverage
The item shall be in accordance with the General Preambles, Preambles to Bill
of Quantities and BIM Specification and shall include:-
(a) Information gathering and processing of BIM Execution Plan;
(b) Provision of BIM hardware, software and ICT (if not provided under office
equipment);
(c) Qualified BIM personnel;
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(d) BIM deliverables base on Level Of Developement (LOD);
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(e) Periodic updating as work progress
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A254 Works Programme
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Lump Sum (sum).
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Measurement
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The payment shall be made in interim payment in proportion of the total period
lapsed to the Contract Period (excluding Defects Liability Period).
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Item Coverage
The item shall be in accordance with the General Preambles and Preambles to
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Bill of Quantities and shall include:-

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(a) Item on implementing the CPM programme for planning of resources and
progress of work as specified in Appendix ' 1G' of the Specification and
Works Programme Specification (Design and Build) and should include:
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(i) Trained and qualified personnel to maintain and update the

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programme;
(ii) Planning using the CPM programme;
(iii) Integrate Work Programme with Construction Model to generate 40

simulation;
(iv) Providing software for JKR, which is to be retained by JKR after the
completion of the project. The software to be utilized is:
A5A-16
the latest version of Microsoft Project or equivalent for projects
costing less than RM50 million;
the latest version of Primavera Project Planning or equivalent
for projects costing more than RM50 million or projects which
incorporate a lot of scopes and milestones.
(b) Carry out regular check of progress including updating all information and
maintain the planned programme periodically or as and when instructed
by the SO/PD;
(c) Submission of the reports to JKR on computer medium and printed hard
copies periodically or as and when instructed by the SO/PD;
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(d) Identification of critical path for the timely execution of the work to
completion;
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(e) A detailed programme which would identify the requirements of every
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( possible resources for the successful implementation of at least six (6)
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months of work for assisting everyone concern in planning their
associated activities. A
A260 MISCELLANEOUS
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A262 Project Signboard

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Lump Sum (sum).

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Measurement
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The payment shall be made as follows :

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(a) 60% on completion of installation;
(b) 20% on maintenance;

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(c) 20% on removal.

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Item Coverage
(a) Excavation in any material including rock and reinforced concrete and
loading into transport, upholding the sides and keep the earthworks free
of water;
A5A-17
(b) Backfilling and compaction;
(c) Support;
(d) Formwork;
(e) In-situ concrete;
(f) Disposal of surplus material;
(g) Painting, high intensity reflectorize aluminum sheeting and illumination;
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(h) Cleaning, maintaining and repairing;
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(i) Erection, dismantling and removing from site;
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( (j) Reinstatement of surfaces;
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(k) Payment of all charges including obtaining permission, licenses and fees
etc;
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A263 As-built Drawings and Documents
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Lump Sum (sum).

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Measurement
The payment shall be made upon submission (progressively) and approval by

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the PD.
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Item Coverage
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(a) Preparation and submission of As-built Drawings for approval by the PO

and final ROW surveyed drawing by an approved licensed Land Surveyor
in tracing, print, CAD in digital format as detailed in Appendix '1H' of the
Specification;
(b) Integrate As-built Drawings with AS-built Model
(c) Providing labor, tools and equipment necessary to take measurement

and obtaining such information on site as are required by the SO/PO for
the preparation of as-built drawings;
A5A-18
(d) Confirming correctness of as-built drawings;
(e) Preparation of monthly periodic updating as work progress for inspection

by PD;
(f) Preparation and submission of road asset inventory comprising culvert
and bridges, slope protection and road furniture in the number of set
specified.
A269 Progress Report Including Progress Photographic and Video
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Lump Sum (sum).
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Measurement
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The payment shall be made in interim payment in proportion of the total period
lapsed to the Contract Period (excluding Defects Liability Period).
Item Coverage
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i. Taking measures and computation;

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ii. Keeping of records;

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iii. Compilation of;
a. Report (Physical and Financial progress, QAlQC, Risk

Management and others as required)
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b. Photographic and Video capture of work progress on ground

l using camera
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c. Aerial Photography and Aerial Video capture of work progress

using Drone or Unmanned Aerial Vehicle/UAV
iv. Processing and writing of report inclusive of identification marking on the

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prints and slides;

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v. Printing and binding;
vi. Dispatching;
vii. Submission of monthly performance reports (print and digital format) to

the p.o.
A5A-19
A300 PROJECT REQUIREMENTS
A321 Quality Assurance/Quality Control Plan (QAlQC)
The unit shall be in Lump Sum (sum).
Measurement
The payment for QA/QC plan shall be made upon submission (progressively)
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and approval by the p.o.
Item Coverage
D
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( Bill of Quantities and shall include:-
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(a) Costs and expenses incurred consequent upon the employment or hiring
of the trained and qualified personnel including payment of Employee
Provident Fund, insurance, medical and hospitalization;
A
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(b) Preparation and submission to the p.o. properly documented QA/QC
plan according to work procedures set in the current JKR ISO 9001 and
in accordance to JKR Guidelines for Inspection & Testing.
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(c) Submission of monthly reports incorporating all test results, test

certificates, photographs and lab report for testing of material (incoming
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inspection).
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A360 Clearance of Site Upon Completion

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Measurement
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The payment shall be made in the last interim payment upon clearing up of Site
to the satisfaction of the S.O.lP.o.
Item Coverage
The item for clearing up of site on completion shall in accordance with the
General Preambles and Preambles to Bill of Quantities and shall include:
A5A-20
(a) Reinstatement of damaged area due to any work and temporary work
carried by the Contractor to its original condition ;
(b) Disposal of surplus material, waste etc;
(c) Clearing of the drainage system.
A379 Temporary Protection and Temporary Relocation of Public Utility

Installations and Other Services and Related works
ER
Lump Sum (sum).
D
N
Measurement
(
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The payment shall be made in each interim payment in proportion of the total
period lapsed to the Contract Period (excluding Defects Liability Period).
Pricing Factors
A
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The item for temporary protection of Public Utility installations and other
services shall in accordance with the Preambles to Bill of Quantities General
Direction include:
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(a) locating the positions of the utilities including excavating trial holes of all
services (measured separately under Utilities Detection);
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(b) making good any damage caused to the approval of the appropriate
Service Authority or owner (measured separately under Utilities
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Detection);
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(c) arranging with the appropriate Service Authority or owner for all temporary
diversions required in connection with the works and keeping the p.o.
fully informed of all such negotiations;
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(d) providing all labour, materials and plant to expeditiously execute the
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works;
(e) protecting utilities to the requirements of the appropriate Service Authority
The item for temporary relocation or diversion of Public Utility installations and
other services shall in accordance with the Preambles to Bill of Quantities
General Direction include:
(a) arranging and liaising with appropriate service Authorities or owner for all
temporary diversion and all related works ;
A5A-21
(b) complying with requirements of respective Service Authorities;
(c) making good of any damage caused to the approval of the appropriate
Service Authority;
(d) providing all plants, labour and materials;
(e) cutting off and disposal of redundant mains pipes, cables, chambers,
covers, etc.;
ER
(f) the credit value of disposed materials as stated in (e) above;
(g) provision of a competent and experienced person to liaise and coordinate
D
the services operations with the works;
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( (h) reinstate connection to properties and make good of all services;
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(i) allowing for inspection by the respective Service Authorities.
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A500 CONTRACTOR'S REQUIREMENT
Contractor's Facilities
M
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A511 Office
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A512 Office Equipment

l A513 Laboratory
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A514 Laboratory Equipment

A515 Stores
A516 Workshop
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A517 Workman 's accommodations

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Measurement
The payment for establishment, maintenance and removal contractor's

facilities shall be made as follows:
(a) 60% on completion of the facilities as specified;
A5A-22
(c) 20% on removal
Item Coverage
The item for establishment and removal of Contractor's facilities shall in

accordance with the General Preambles and Preambles to Bill of Quantities
and shall include:
(a) Preparation of site, foundations , bases, hard standings;
ER
(b) Water, sanitation, power, lighting and communication systems;
(c) Fences, notices and direction boards, vehicle access, parking areas and
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footpaths;
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( (d) Buildings and accommodation including payment of fees and other
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charges;
(e) Depreciation of buildings and accommodation, office equipment,

laboratory equipment, furniture and fittings;
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(f) Medical and first aid facilities;
(g) Safety equipment and clothing;

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(h) Telephone line/extension and switchboard/Private Automatic Branch

Exchange (PABX), radio communication and others (if related);
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(i) Layout drawings for the approval of the S.O/P.O.;

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(j) Getting approval from the relevant statutory authority;

<-
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(k) Dismantling and removal of all buildings, fences , notices and direction
boards, office equipment, etc.;
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(I) Disconnection and removal of services and sealing-off disused services;

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(m) Disposal of surplus materials and reinstatement of site to its original

condition.
The item for maintenance of Contractor's facilities shall in accordance with the
General Preambles and Preambles to Bill of Quantities include:
(a) Any costs incurred in the use of the land;
(b) Rental charges (where applicable);
A5A-23
(c) Fees and charges for water, power, sewage disposal and communication
systems (inclusive internet charges);
(d) Maintenance of all buildings, vehicle access, parking areas, hard

standings and footpaths;
(f) Cleaning;
(f) Replenishment of consumables stores.
ER
Temporary Works
D
A521 Access and haul road
A529 Temporary drainage
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( A544 Hoardings
Lump Sum (sum).

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A
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Measurement
The payment for temporary works shall be made as follows:

M
(a) 60% on completion of the design and construction of the temporary

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works;
M

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(c) 20% on removal

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Item Coverage
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The item for all access temporary works shall in accordance with the General
Preambles and Preambles to Bill of Quantities and shall include:-
(a) Obtaining license, permission from owners of road and relevant

authorities and complying with conditions imposed thereto;
(b) Making arrangements with owners and occupiers of land temporarily

acquired and costs arising therefrom;
A5A-24
(c) Preparing design, amending and submitting to the S.O'/P.D. and other
interested bodies, approved subcontractors for all temporary works;
(d) Construction;
(e) Maintenance of temporary works;
(f) Removal;
(g) Reinstatement of site to its original condition.
ER
A550 SITE MANAGEMENT
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A559 Site Management /inclusive all staffi
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( (a) Supervision
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(b) Administration
A
Lump Sum (sum).
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Measurement
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The payment shall be made in each interim payment in proportion of the total
period lapsed to the Contract Period (excluding Defects Liability Period).
EN
Item Coverage
M

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(a) The wages and other emoluments paid to the site agent and other
personnel necessary for the Works;
(b) Working outside the Contractor's normal working hours if so required by
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the p.o.;
(c) Costs and expenses incurred consequent upon the employment or hiring
D
of the site agent and all other personnel including payment of Employee
Provident Fund, insurance, medical and hospitalization;
(d) Replacement of unsuitable site agent and other personnel ;
(e) Substitution of superintendent when the appointed site agent is absent or

on leave for more than three (3) consecutive days.
A5A-25
A560 Mobilisation and Demobilisation
Lump Sum (sum).
Measurement
The payment shall be made as follows:
(i) 60% on completion of mobilisation;
ER
(ii) 40% on completion of demobilisation
D
Pricing Factors
N
( The item for mobilisation of construction plant and equipment shall be in
TE
accordance with the Preambles to Bill of Quantities General Direction and shall
include:
(a) transport to site including loading and unloading at ports and site, places
A
of assembly in Malaysia or other sites to the sites where they are to be
EJ
used on the works;
(b) obtaining any import licenses/permits;

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(c) all taxes, import duties and other fees;

EN
(d) assembling, erection and installation.
The item for demobilisation of construction plant and equipment shall be in

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accordance with the Preambles to Bill of Quantities General Direction and shall
include:-
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(a) dismantling;
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(b) transport from site including loading and unloading at ports and site;
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(c) obtaining any export licenses/permits.
A5A-26
ER
D
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( APPENDIX5B
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-PREAMBLE TO DAY WORK RATES
-DAYWORK RATES FOR LABOUR AND PLANT
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APPENDIX5B
PREAMBLE TO DAY WORK RATES
Any work ordered by the P.O. to be carried out by day work shall be paid for at the rates
entered hereunder subject to the following conditions:-
I. The rates entered for labour shall be deemed to include all on-costs associated with
the employment of such labour including (inter alia), head office charges, overhead
charges, profit, site expenses, subsistence allowances, time lost due to inclement
weather, bonus, holiday and sick pay and any other employee's fringe benefit(s),
small tools and consumable stores, temporary equipment such as wedges,
temporary tracks, ladders, staging, scaffolding and all items of a si milar nature
ER
unless these are provided or set up exclusively for day work.
2. The wages of gangers and leading hands working with their gangs shall be paid for
D
at the appropriate rates, but the time of walking gangers, sub-foremen and foremen
will not be included and shall be deemed to be included in the rates entered for
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labour under site supervi sion and staff.
(
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3. Payment for overtime work, if chargeable and approved by the P.O. shall be made
at the rates entered herein, but the time so worked as overtime shall be adjusted in
the same proportion as that used for the paying the normal workmen on the site and
approved by the P.O .. Thus if a man works I hour overtime for which the rate
A
payable is double time, payment shall be made for 2 hours at the rate entered in the
day works schedule.
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NOTE: Overtime is working time over and above 8 hours per working day
including Saturday or 48 hours per week.
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4. The cost of special watching and lighting necessitated by day works shall be
included in the rates.
EN
5. The rates entered for plant shall apply only to plant which the Contractor has
available on the site. Such rates shall be deemed to include all overhead charges,
profit, site supervision and staff, hire charges, fuel, maintenance, consumable
M
( stores, spare parts, insurances, depreciation etc. but shall exclude the cost of wages
for drivers and operators which shall be payable separately as dealt with under
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paragraph I above.
6. Payment for mechanically operated plant shall be made only at such times as the
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plant is engaged in day work and shall exclude all standing, idle or down time.
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7. If any workmen or items of plant on day work do not readily belong to any
class ification included in the schedule or inserted by the Contractor at the time of
tendering, the P.O. shall determine the equivalent classification to be adopted for
such workmen or items or plant, and payment for such will be made accordingly.
A5B-1
8. The rates inserted by the Contractor shall be realistic rates in conformity with those
on which his tender has been based and shall be based on conditions prevailing at
the time of tender but bearing in mind that claims for escalation will not be
entertained.
9. The rates inserted shall be subjected to agreement with the P.O. as to their
reasonableness and subject to such agreement shall be used as day work rates.
10. The day works rates entered hereunder and agreed by the P .O. shall be deemed to
include the fifteen per cent (15%) addition as stipu lated in C lause 28.4 of the
Cond itions of Contract.
II . The Contractor shall produce for verification to the P.O. vouchers specifying the
ER
time and materials employed on the work. If required, the Contractor shall also
produce his receipted bills and wages books in support of his accounts.
D
12. Where special mechan ica l plant is requ ired for use on day works, the cost to be
pa id to the Contractor shall be subject to the agreement by the P.O.
N
( 13. Only time on work actually done wi ll be allowed. A ' day ' is considered to be
TE
normal work ing day of 8 hours. Fraction of a day wi ll be paid for pro-rata.
14. Rates for power driven tools are not included in the labour rates but charges for
hand too ls shall be deemed to be included.
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A5B -2
DAY WORK RATES
I. LABOUR
Only time on work will allowed . A ' DAY ' is considered to be a normal working day of
eight (8) hours. Fractions ofa day will be paid for ' pro-rata' .
Item Description Unit Rate

(exclude 15%
0 & 1')
I General Labour (Male) Manday
ER
2 General Labour (Female) Manday
3 Mason Manday
D
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4 Carpenter and Joiner Manday
(
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5 Concretor Manday
6 Steel Bar Bender & Fixer A Manday
7 Steel and Iron Worker Manday

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8 Painter Manday
9 Plasterer Manday
M
10 Bricklayer Manday
EN
\I Drain Layer Manday
12 We lder Manday
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( 13 Charge Hand/Ganger Manday

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14 Plant Operator Manday
15 Fitter Manday
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16 Pneumatic Tool Operator Manday

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17 Lorry Driver Manday
18 Blasting Operator Manday
AS B-3
I. LABOUR (cont'd)
Item Description Unit Rate

(exclude 15%
0&1')
19 Blasting Labourer Manday
20 Bitumen Worker Manday
21 Watchman Manday
ER
22 Pi li ng Labourer Manday
23 Pi li ng Serang Manday
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24 Pi ling Rigger Manday
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(
2. PLANT
TE
(Person s te ndering are to enter the s ize or capacity of plant they propose to have on
A
site, where not stated)
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Item Description Capacity Unit Rate

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(exclude 15%
0&1')
I
EN
(a) Bu lldozer - - HP Day

(b) - ditto -
- - HP Day
(c) - ditto - --
HP Day
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2 (a) Bu lldozer with ripper HP Day

( (b) - ditto -
--
--
HP Day
KU
3 (a) Motor - grader --

HP Day
(b) - ditto - -- HP Day
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4 (a) Fu lly hydrau lic excavator --

HP Day
(b) - ditto - - - HP Day
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5 Hydraulic rock breaker --

HP Day
A5B-4
2. PLANT (cont'd)

(exclude 15%
O&Pt
6 Tractors
(a) - craw ler type with bull or angle
dozer blade and/or ripper Day
- - HP
(b) - ditto - - - HP Day
(c) - whee l - - HP Day
(d) - shove l - - cu.m Day
ER
(e) - agricultu re - - cu.m Day
7 (a) Wheeled hydraulic shove l - - cu .m Day

(b) - ditto - - - cu.m Day
D
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8 (a) Tracked hydraulic shovel - - ell .m Day
( (b) - ditto - - - cu .m Day
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9 Backhoe excavator/loader - - cu.m Day
10 Wheel loader - - cu.m Day

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II (a) Dragline excavator - - cu.m Day
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12 (a) Scrapper - - cu.m Day

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13 (a) Clamshell excavator - - eU.m Day

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14 Bucket - wheeled excavator

- - cu.m Day
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( 15 (a) Asphalt Paver - - cu.m Day

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16 (a) Dump-truck (d umper) - - eu.m Day

(b) - ditto - Day
- - cu.m
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17 (a) Mobile crane - - tonne Day

(b) - ditto - - - tonne Day
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18 (a) Self propell ed sing le vibrating

roller - - tonne Day
(b) - d itto - - - tonne Day
A5B-5
2. PLANT (cont' d)

(excl ude 15%
O&P)
19 (a) Se lf - pro pelled tandem vi brating - - tonne Day

roller Day
- - tonne
(b) - ditto -
- - tonne Day
20 (a) Pneumatic tyred ro lle r - - tonne Day
ER
(b) - ditto -
- - tonne Day
21 (a) Sheepfoot ro ller - - tonne Day
(b) - ditto -
D
- - tonne Day
N
22 (a) Steel wheeled ro ller - - tonne Day
( (b) - ditto -
TE
--
tonne Day
23 (a) Towed vibrati ng ro ller - - tonne Day
(b) - ditto -
kg Day
A
24 (a) Ramm er kg Day
(b) - ditto -
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kg Day
25 (a) Tamper kg Day
(b) - ditto -
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kg Day
26 Concrete/Asphalt cutter
EN
27 Lorries
(a) ord inary - - tonne Day
(b) heavy haulage - - tonne Day
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<. 28 Water truck .................... (type)

including spray ing equipment _ _ ga ls Day
KU
29 (a) Pile driving machine _ _ pile Day

(b) - ditto - pile Day
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30 (a) Concrete mixer - - ell.m Day

(b) - d itto - Day
D
- - e U. ITI
(c) - ditto - (open drum) - - ell.m Day
(d) - ditto - (weigh batcher)
- - cU.m Day
A5B-6
2. PLANT (cont'd)

(exclude 15%
O&P)
31 Pumps
(a) portable (including foot valve,
suction hose up to 60ft of
delivery hose and all fittings) - - c.c Day
(b) - ditto - (diesel or petrol driven) - - c.c Day
(c) - ditto - --
c.c Day
ER
32 Generating sets - - KYA Day
33 Compressors
D
(a) portable (including tools and
hose) c.f.m Day
N
--
( (b) - ditto - --
c.f.m Day
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(c) - ditto - mobile (including tools
and hose --
c.f.m Day
34 Welding and cutting set

(a) Oxyacetylene inclusive of
A
oxygen and acetylene) --
each Day
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(b) - ditto -Electric arc --
each Day
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35 Any item not included above:
(a) ..... .. ............... .. .................

EN
(b) ............... .. ...... . .......... .. .....
(c) .........................................
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( (d) ............... .. ....... .. ...............

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(e) ............ .. ...........................

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(Contractor) (Witness)
Date ........ .. ...... .. Date ........ .. ...... ..
A5B-7
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( ) APPENDIX 6
TE
BORANG JAMINAN BANK / JAMINAN
SYARIKA T KEWANGAN / JAMINAN INSURAN
UNTUKBONPERLAKSANAAN
A
(KONTRAK KERJA)
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APPENDIX 6
BORANG JAMINAN BANKlJAMINAN SYARIKAT KEWANGANI JAMINAN

INSURANS UNTUK BON PELAKSANAAN
(KONTRAK KERJA YANG BERNILAI MELEBIHI RM10 JUTA)
Sebagai balasan kepada Kontrak No ........... ... .. ............. yang dibuat antara Kerajaan
Malaysia , (kemudian daripada ini dirujuk sebagai "Kerajaan") dan
................ ... ..... ... . .... , (kemudian daripada ini dirujuk sebagai "Kontraktor") bagi
.. ........ ... ... ... ............. (namakan projek) , (kemudian daripada ini dirujuk sebagai
ER
"Kontrak") kami yang bertandatangan di bawah, (kemudian daripada ini dirujuk
sebagai "Penjamin") atas permohonan Kontraktor, mengaku janji yang tak boleh
batal untuk memberi Jaminan kepada Kerajaan ke atas pelaksanaan yang
D
sepatutnya Kontrak terse but mengikut cara sebagaimana yang terdapat kemudian
daripada ini.
N
(
MAKA Penjamin dengan ini bersetuju dengan Kerajaan seperti berikut:
TE
1. Apabila sahaja Kerajaan membuat tuntutan bertulis, maka Penjamin
hendaklah dengan serta merta membayar kepada Kerajaan nilai yang ditentukan
dalam tuntutan tersebut tanpa mengira sama ada terdapat apa-apa bantahan atau
A
tentangan daripada Kontraktor atau Penjamin atau mana-mana pihak ketiga yang
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lain dan tanpa bukti atau bersyarat. Dengan syarat sentiasanya bahawa jumlah
tuntutan yang dibuat tidak melebihi sebanyak Ringgit ................................. .
(nyatakan nilai jaminan dalam perkataan) (RM .................. ) dan bahawa tanggungan
M
Penjamin untuk membayar kepada Kerajaan di bawah Perjanjian ini tidak melebihi
nilai tersebut di atas.
EN
2. Kerajaan berhak untuk membuat apa-apa tuntutan sebahagian jika

dikehendakinya dan jumlah kesemua tuntutan sebahagian itu hendaklah tidak
melebihi nilai Ringgit .................. .......................... (nyatakan nilai jaminan dalam
perkataan) (RM .. ... .... .) dan liabiliti Penjamin untuk membayar kepada Kerajaan
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jumlah yang disebutkan terdahulu hendaklah dikurangkan dengan perkadaran yang

( bersamaan dengan apa-apa bayaran sebahagian yang telah dibuat oleh Penjamin .
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3. Penjamin tidak boleh dibebaskan atau dilepaskan dari Jaminan ini oleh
sebarang perkiraan yang dibuat antara Kontraktor dan Kerajaan sama ada dengan
atau tanpa persetujuan Penjamin atau oleh sebarang perubahan tentang kewajipan
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yang diaku janji oleh Kontraktor atau oleh sebarang penangguhan sama ada dari
segi pelaksanaan , masa , pembayaran atau sebaliknya.
D
4. Jaminan ini adalah Jaminan yang berterusan dan tak boleh batal dan
hendaklah berkuat kuasa sehingga ........ .. (kemudian daripada ini disebut
("Tarikh Mati Asal") (Initial Expiry Date) iaitu dua puluh empat (24) bulan selepas
tarikh tamat tempoh kecacatan atau dalam keadaan di mana kontrak dibatalkan ,
satu (1) tahun selepas tarikh kontrak dibatalkan . Penjamin hendaklah melanjutkan
A6-1
Tarikh Mati Asal (Initial Expiry Date) Jaminan ini untuk tempoh tambahan selama
tidak melebihi satu (1) tahun daripada Tarikh Mati Asal (Initial Expiry Date)
(kemudian daripada ini disebut "Tarikh Mati Lanjutan") (Extended Expiry Date)
apabila diminta oleh Kerajaan dan Jaminan ini adalah dengan ini dilanjutkan . Jumlah
agregat maksimum yang Kerajaan berhak di bawah Perjanjian ini mestilah sentiasa
dipastikan tidak melebihi jumlah Ringgit ........................ ..... (nyatakan nilai Jaminan
dalam perkataan) (RM .... ... ... ).
5. Apa-apa tanggungjawab dan tanggungan Penjamin di bawah Perjanjian ini

hendaklah luput apabila Perjanjian ini tamat pada Tarikh Mati Asal (Initial Expiry
Date) atau Tarikh Mati Lanjutan (Extended Expiry Date) melainkan jika sebelumnya
Kerajaan telah meminta secara bertulis kepada Penjamin untuk membayar sejumlah
wang tertentu yang masih belum dijelaskan mengikut peruntukan kontrak.
ER
6. SEMUA TUNTUTAN BERKAITAN DENGAN JAMINAN INI , JIKA ADA,
MESTILAH DITERIMA OLEH PIHAK BANKlSYARIKAT KEWANGANI SYARIKAT
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INSURANS DALAM TEMPOH SAH LAKU JAMINAN INI ATAUPUN DALAM MASA
EMPAT (4) MINGGU DARI TAMATNYA TARIKH JAMINAN INI , MENGIKUT MANA
N
YANG LEBIH KEMUDIAN.
(
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PADA MENYAKSIKAN HAL DI ATAS pihak-pihak kepada Perjanjian ini telah
menurunkan tandatangan dan meteri mereka pada hari dan tahun yang mula-mula
tertulis di atas.
A
Ditandatangani untuk dan
bagi pihak Penjamin di Nama : .............................. .
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hadapan Jawatan : .......................... .

Cop BanklSyarikat Kewanganl
Syarikat Insurans:
M
(Saksi)
EN
Nama : .................................................. .
Jawatan : ..................................... .. ....... .
Cop Bank/Syarikat Kewangan/Syarikat Insurans :
M
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A6-2
APPENDIX 6
BANK/FINANCE COMPANY'S/INSURANCE GUARANTEE FORM FOR

PERFORMANCE BOND
(WORKS MORE THAN RM10 MILLION)
In consideration of the Government Of Malaysia (hereinafter referred to as the

"Government") allowing ............................... (hereinafter referred to as the
"Contractor") to ... ... .. .. .................. ........ .. (state title of the project) for a contract sum
of ............................... (RM ............ ). WE. the undersigned at the request of the
Contractor irrevocably undertake a guarantee to the Government that:
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The Guarantor has agreed to guarantee the due performance of the Contract in the
manner hereinafter appearing .
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Now the Guarantor hereby agrees with the Government as follows:
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( 1. On the Government's first written demand , the Guarantor shall forthwith pay to
the Government the amount speCified in such demands not withstanding any
TE
contestation or protest by the Contractor or Guarantor or by any other third party and
without proof or conditions. Provided always that the total of all demand so made
shall not exceed the sum of Ringgit Malaysia
....... ..... ..................... .................. .................... ................... .... (state the amount of
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bond in words) (RM ... .... ... ....... .... ..) and the total amount recoverable against the
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Guarantor under this Agreement shall not exceed the said sum.
2. The Government reserves the right to make any partial demands if it shall so
desire and the total of all such partial demands so made shall not exceed the sum of
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Ringgit Malaysia ............ ... .... .......... ..... .. ... (state the amount of bond in words) (RM
................ ) and our liability of the Guarantor to pay the Government the aforesaid
EN
shall correspondingly be reduced proportionate to any payment of partial demands

having been made by the Guarantor.
3. The Guarantor shall not be discharged or released from this Guarantee by

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any arrangement between the Contractor and the Government with or without the
( consent of the Guarantor or by any alteration in the obligations undertaken by the
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Contractor or by any forbearance . whether as to payment. time. performance or

otherwise.
4. The Guarantee given by the Guarantor is a continuing guarantee. This

O
Agreement shall be irrevocable and shall initially remain in force and effect until
.......... (hereinafter referred to as the "Initial Expiry Date") being the end of a period of
D
twenty four (24) calendar months after the expiry date of the defects liability period
as stated in the Contract or in the case of the Contract being determined . one (1)
calendar year after the date of determination . The Guarantor shall. upon the request
of the Government. extend the Initial Expiry Date of this guarantee for a further
period of one (1) calendar year from the Initial Expiry Date (hereinafter referred to as
the "Extended Expiry Date") and the Guarantee shall be so extended . The maximum
aggregate amount that the Government shall be entitled to under this Agreement
A6-1
shall not exceed the said Sum of Ringgit ............... ........... (state the amount of bond
in words) (RM ..................... )
5. All whatsoever obligation and liabilities of the Guarantor under this Agreement
shall cease upon the determination of this Agreement on the Initial Expiry Date or the
Extended Expiry Date as the case may be said to the extent that the Government
shall previously have called upon the Guarantor in writing to pay specified moneys
payable under the Contract then remaining outstanding .
6. ALL CLAIMS, IF ANY, IN RESPECT OF THIS GUARANTEE MUST BE

RECEIVED BY THE BANK/FINANCE COMPANYIINSURANCE COMPANY
DURING THE VALIDITY PERIOD OF THIS GUARANTEE OR WITHIN FOUR (4)
WEEKS FROM THE EXPIRY DATE OF THIS GUARANTEE WHICHEVER IS THE
ER
LATER
IN WITNESS WHEREOF the parties hereto have hereunto set their hands the day
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and year first abovewritten.
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Signed for and on behalf of the ) ..................... .
( said Guarantor in the presence of ) Name : . . . . . . . ... .
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) Designation: ..... ............ .
) Bank/Finance Company/
Insurance Company Seal:
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(Witness)
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Name : .................................................. .
Designation: ................................. .
Bank/Finance Company/Insurance Company Seal:
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BANK GUARANTEE FOR DESIGN
GUARANTEE
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APPENDIX 6A
(PWD DGB 1/2011 )
BANK GUARANTEE FOR DESIGN GUARANTEE
Bond No: .... .... ..... .. ...... .
By: (Banker} ............... , ... , ... , , ... , .. .. ,. , ., .. ... ... (hereinafter referred as 'the Guarantor")
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To: (Government} ..... ..... . , ... ........... . .. . .... .. (hereinafter referred as 'the Government")
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WHEREAS
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(
A. The Government has entered into a written contract no ..... . ... ...... .. . ..... .. ... .. .. .
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dated .... .. ... ..... ... .. .. .... .. with (Contractor) .... .. ..... . ..... .. .. ... .... (hereinafter
referred as "Contractor") for .. ...... . .... ... .. ..... .... .. .. .. .. ... . .... (hereinafter referred
as "the Works').
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B. At the request of the Contractor and in the consideration of the Government
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accepting this Bank Guarantee for Design Guarantee Bond (hereinafter referred
as "Design Guarantee Bond") in relation to the obligation of the Contractor to
provide to the Government security for the purpose of ensuring the design ,
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workmanship , materials or equipment of the Works against any defect, fault,

insufficiency, imperfection , shrinkages or inadequacy, the Guarantor
unconditionally and irrevocably undertakes to pay on demand any sum which
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may from time to time be demanded by the Government.

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Now the Guarantor hereby agrees with the Government as follows :

(
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(1) The Guarantor shall within fourteen (14) Business Days after receiving notice of
demand pay to Government the sum so demanded not withstanding any
contestation or protest by the Contractor or any other third party and without
proof or conditions Provided that the total of all demands so made shall not
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exceed the sum of Ringgit ........ .. .. ..... . ..... ...... ... . (RM ... ... .......) (hereinafter
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referred as 'the said sum ') and the total amount recoverable against guarantor
under this guarantee shall not exceed the said sum. 'Business Days' means the
days which commercial banks are open for business in Malaysia and other than
Saturday or Sunday.
A6A-l
(2) The Government reserves the right to make any partial demands if it shall so
desire and the total of such partial demands so made shall not exceed the sum
as stated in paragraph (1) above and as the liability of the Guarantor to the
Government shall correspondingly be reduced proportionate to any payment of
partial demands having been made.
(3) The Design Guarantee Bond given by the Guarantor is a continuing Design
Guarantee Bond and the Guarantor shall not be discharged or released from this
Design Guarantee Bond by any arrangement between the Contractor and the
Government.
(4) This Guarantee given by the Guarantor is irrevocable and shall remain in force
ER
until .. ... ... . ... ... ..... .. .. ... .. . that is for a period of five (5) years six (6) months
after the completion of the works.
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Given under our hand this .. . ... ... Day of .... .. ... ... .. 20 .
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( Signed for and on behalf }
of the said Guarantor in }
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the presence of }
Name: .. ... ... ...... .... ... .. . .. .. ... .. .. .. .. ........ ..... ........... ... .... ... .
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Designation : ..... ...... .. ...... .. ... .... .. .... .. ... .. ...... .... .... ... .. ..... .. .. .. ..
Banker's Seals : .. . .... .... . ... ... ... ... ..... . .... .. ... .. .... .... .... . ....... ..
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Witness
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( Name: ......... ... ... .... .. ... ... .... .... ...
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Designation : ... ..... . .. .. .... .... ... ... .. .
Banker's Seal : .. . .. .. ... .. ..... ... . ... ... .

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BORANG JAMINAN BANK / JAMINAN
SYARIKA T KEWANGAN / JAMINAN INSURAN
UNTUKBAYARANPENDAHULUAN
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(KONTRAK BE KALAN / PERKHIDMATAN / KERJA)
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APPENDIX6B
BORANG JAMINAN BANKfJAMlNAN SYARIKAT KEWANGAN!JAMINAN

INSURANS UNTUK BAYARAN PENDAIDJLUAN (KONTRAK BEKALAN!
PERKHIDMA T AN! KERJA)
Sebagai balasan Kerajaan Malaysia (kemudian daripada ini disebut sebagai "Kerajaan")
bersetuju membuat bayaran pendahuluan selaras dengan terma dan syarat-syarat Kontrak
yang dibuat se laras dengan iklan tender!pelawaan oleh Kerajaan bertarikh ............ dan
tawaran o leh .................. ..... (kemudian daripada ini disebut sebagai "Kontraktor")
bertarikh ............ dan persetujuan daripada itu melalui Surat Setujuterima oleh Kerajaan
bi!. ........ ... . ... bertarikh ............ dan tertakluk kepada apa-apa term a dan syarat baru
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Uika ada), dibuat oleh Kerajaan dan diterima oleh Kontraktor pad a ............ dengan
syarat jika kontrak rasmi disediakan berikutnya, selaras dengan terma-terma dan syarat
kontrak rasmi tersebut, untuk ...... ..... ... . ......... .. (sebutkan nama perolehan) (kemudian
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daripada ini disebut "Bekalan"!"Perkhimatan"!"Kerja") kami, yang bertandatangan di
bawah ini, atas permintaan Kontraktor, mengaku janji (iaitu aku janji yang tak boleh batal)
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satu Jaminan kepada Kerajaan bahawa :
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I. Kami hendaklah membayar kepada Kerajaan tanpa faedah, jumlah wang sebanyak
Ringgit Malaysia .................................. .. (RM ..... .. .... ......... ) sebagai
wang pendahuluan seperti yang terse but di atas atau sebahagian daripada itu yang
belu m lagi didapatkan kembali oleh Kerajaan selaras dengan perenggan 3 atau 4
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yang berkenaan dan jumlah harga itu hendaklah dibayar apabila sahaja Kerajaan
membuat tuntutan tanpa mengira apa-apa tentangan atau bantahan daripada
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Kontraktor atau daripada kami atau daripada mana-mana pihak ketiga yang lain.
Sekiranya dalam apa-apa keadaan kami melengah-Iengahkan membuat
pembayaran dan seumpamanya setelah menerima tuntutan daripada Kerajaan,
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maka pihak Kerajaan berhak menuntut dan berhak dibayar apa-apa kos tambahan
sebagai ganti rugi akibat keengganan kami mematuhi syarat-syarat Jaminan ini.
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2. Apa-apa konsesi atau tolak ansur yang diberi o leh Kerajaan kepada Kontraktor
atau apa-apa persetujuan antara Kerajaan dan Kontraktor atau apa-apa
pengekangan!penahanan yang dibuat oleh Kerajaan kepada Kontraktor sam a ada
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berkenaan dengan bayaran, tempoh, prestasi atau se lainnya tidak akan melepaskan
( kami daripada jaminan ini tetapi kami adalah berhak untuk diberitahu akan
persetujuan atau peru bah an tersebut.
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3. Tertakluk kepada perenggan 4, tanggungjawab kami untuk membayar jumlah yang

tersebut sebanyak RM ................. . ... hendaklah secara automatik dikurangkan
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daripada amaun atau amaun-amaun pembayaran yang dibuat oleh kami kepada
kerajaan berhubung dengan Jaminan ini.
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4. Jumlah wang tersebut yang dijamin oleh kami untuk dibayar kepada Kerajaan
hendaklah dikurangkan secara automatik mengikut kadar potongan yang dibuat
oleh Kerajaan daripada bayaran kemajuan yang layak dibayar kepada Kontraktor
sebaga i pembayaran balik wang pendahuluan yang telah dibuat. Jaminan ini
terbatal dan hendaklah dikembalikan dengan serta-merta setelah kesemua wang
A6B-I
pendahuluan dijelaskan melalui potongan daripada bayaran kemajuan yang layak
dibayar kepada Kontraktor, atau selepas semua bekalan telah
dihantar/perkhidmatan telah disiapkan/ kerja telah diksanakan dengan memuaskan
oleh Kontraktor kepada Kerajaan se laras dengan term a dan syarat-syarat kontrak
mengikut mana yang terda hulu.
5. Jaminan ini adalah Jaminan yang berterusan dan tak bo leh batal dan hendaklah
berkuat kuasa sehingga ....... .. ..... . (kemudian daripada ini disebut sebagai
"Tarikh Mati Asal") iaitu meliputi tempoh kontrak. Penjamin hendaklah
melanjutkan Tarikh Luput Asal Jaminan ini untuk tempoh tambahan se lama tiga
(3) bu lan daripada Tarikh Mati Asa l (kemudian daripada in i di sebut sebaga i
"Tarikh Mati Lanjutan") apabila diminta o leh Kerajaan dan Jami nan ini ada lah
dengan ini dilanjutkan .
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Ditu runkan tandangan kami pada hari II1J . . ...•..•••.. untuk dan bagi pihak Penjamin di
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atas.
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Nama: ...... . ........... ... .. .... . .
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Jawatan: ............. .. ... ..... .. ..

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Cop BanklSyarikat Kewa ngan/Syarikat Insurans :

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Nama
Jawatan
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GOVERNMENT MULTIMODAL TRANSPORT
OPERATORS
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APPENDIX 7
GOVERNMENT MULTIMODAL TRANSPORT OPERATORS
In compliance with the Clause 16 to the Conditions of Contract, the Contractor shall refer
to the latest Treasury Instruction Letter for the appointment of Government' s Multi Modal
Transport Operators.
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DETAILED DESIGN AND SPECIFICATIONS
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APPENDIX 8
DETAILED DESIGN AND SPECIFICATIONS
To refer to Contractor' s Proposal
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APPENDIX 9
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NON-COMPLIANCE SCHEDULE (NCS)
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r-
""" LAMPIRANA
JADUAL KETIDAKPATUHAN (NON-COMPLIANCE SCHEDULE) KEPERLUAN TEKNIKAL
ER
KONTRAKTOR: ... ......... ....... ...... .... ... ... ..... ... .... ... ...... .. ... .. ....... .. .... .... ... ........ ..... ... .
SKOP
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NO TECHNICAL
SPECIFICATION CONTRACTOR'S OFFER JKR'S COMMENTS
REQUIREMENTS
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Tandatangan Ringkas (Syarikat) : ... ... ..... ........ ... ...... ... ..... . .
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LAMPIRAN B
JADUAL KETIDAKPATUHAN (NON-COMPLIANCE SCHEDULE) KEPERLUAN KONTRAK DAN KEPERLUAN AM
ER
KONTRAKTOR: ........ ......... .. ... .................. ... ... ... ...................... ... .......... ...... ... ... .... .
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CONTRACTUAL CONTRACTOR'S OFFER JKR'S COMMENTS
REQUIREMENTS
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Tandatangan Ringkas (Syarikat) : ...................................... .

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AppendixA5
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(JKR Design Standard and Guidelines)
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APPENDIX AS
Garis Panduan dan Arahan Teknik (Jalan) yang telah diterbitkan oleh Bahagian
Pembangunan Inovasi & Standard, Cawangan Jalan, Jabatan Kerja Raya boleh dibeli
daripada:
Unit Tawaran Pusat

Bahagian Kewangan dan Akaun
Cawangan Pengurusan Perolehan dan Harta
Blok A , Tingkat Bawah , Kementerian Kerja Raya
Jalan Sultan Salahuddin , 50582 Kuala Lumpur
No. Tel: 03-27714096 (En . Tarmizi & Pn . Latifah)
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Pembayaran hendaklah dibuat dengan menggunakan Bank Draf I Kiriman Wang (money
order) atas nama AKAUNTAN NEGARA MALAYSIA-KKR-T.
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Sumber Rujukan : https://www.jkr.gov.my/my/page/arahan-teknik-cawangan-jalan
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( JKR DESIGN STANDARD AND GUIDELINES
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1. Arahan Teknik (Jalan) 1/2020
Guidelines on Design & Selection of Traffic Restraint System
2. Arahan Teknik (Jalan) 2A/85 (Pindaan 2019)

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Manual on Traffic Control Devices: Standard Traffic Signs
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3. Arahan Teknik (Jalan) 2B/85 (Pindaan 2019)

Manual on Traffic Control Devices: Standard Sign Applications
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4. Arahan Teknik (Jalan) 2C/85 (Pindaan 2017)

Manual on Traffic Control Devices: Temporary Sign and Work Zones Control
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5. Arahan Teknik (Jalan) 20/85 (Pindaan 2019)

Manual On Traffic Control Devices: Road Marking And Delineation
6. Arahan Teknik (Jalan) 2E/87 (Pindaan 2015)

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( Manual on Traffic Control Devices : Guide Signs Design and Applications

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7. Arahan Teknik (Jalan) 3/2021 (Pindaan 3/85)

Garis Panduan Untuk Memproses Permohonan Pembangunan Tepi Jalan Persekutuan
+ Addendum SAKPKR 32/2017 Penggantian Klausa 2.1.21 - Penambahbaikan kepada
Keperluan Pengurusan Pegawai Trafik (TMO)
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Application For The Installation Of Public Utility Services Within The Road Reserve :
First Schedule: Guide For JKR Engineers
Second Schedule: Instruction to Applicants

Manual for the Structural Design of Flexible Pavement
+ Addendum SAKPKR 28/2017 - Penambahbaikan kepada perenggan 2.3 (perkara e, f
dan g) berdasarkan had kenaikan berat kenderaan

Guidelines for Presentation of Engineering Drawings
A 5-1 /6
APPENDIX AS
11 . Arahan Teknik (Jalan) 7/85 (Pindaan 2014)

Garispanduan Untuk Penyediaan Pelan Pengambilan Balik Tanah Bagi Projek Jalan
Persekutuan

A Guide On Geometric Design of Roads
13. Arahan Teknik (Jalan) 9/86 (2022)

Guidelines For The Installation Of Kilometre Post
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A Guide to the Design of Cycle Track

A Guide to the Design of At-Grade Intersections
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( A Guide to the Design of Interchanges
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A Guide to the Design of Traffic Signals

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Model Terms of Reference for Detailed Ground Survey and Engineering Design of Roads
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19. Arahan Teknik (Jalan) 24/05 (2021)
A Practical Guide for Environmental Protection & Enhancement Works
20 . Arahan Teknik (Jalan) 28/2013

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Design Checklist For Road Projects

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Geometric Guideline For Exclusive Motorcycle Lane

Guidelines For Traffic Impact Assessment
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(
23 . JKRISPJ/2015-S1
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Standard Specification For Road Works Section 1: General
Standard Specification For Road Works Section 2 : Earthworks
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25. JKRISPJ/2013-S3
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Standard Specification For Road Works Section 3 : Drainage Works
26. JKRISPJ/2008-S4
Standard Specification For Road Works Section 4 : Flexible Pavement
+ Addendum SAKPKR BIL. 1/2017 Bitumen Penetration Grade 60-70
+ Addendum SAKPKR BIL. 11/2019 Clause 4.16 Natural Rubber Modified Asphalt &
Clause 4 .17 Crumb Rubber Modified Asphalt
27. JKRISPJ/2020-S5
Standard Specification For Road Works Section 5 : Concrete Pavement
AS-2/6
APPENDIX AS
28. JKRISPJ/2017-S6
Standard Specification For Road Works Section 6 : Road Furniture
+ Addendum SAKPKR Bil. 15/2019 Clause 6.3.9 Retrorefiectivity Requirements
+ SAKPKR BIL. 2/2021, arahan penggunaan Standard Specification For Road Works
Section 6: Road Furniture (JKRISPJ/2017-S6) termasuk kerja mengecat semula garisan
jalan di atas jalan sedia ada
29. JKRISPJ/2011-S7
Standard Specification For Road Works Section 7 : Road Lighting
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30. JKRISPJ/2008-S8
Standard Specification For Road Works Section 8 : Traffic Signal System
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Standard Specification For Road Works Section 9 : Concrete
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( 32. JKRISPJ/2019-S10
Standard Specification For Road Works Section 10 : Foundation Works
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33. JKRISPJ/2016-S11
Standard Specification For Road Works Section 11 : Prestressing for Structures
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34 . JKRISPJ/2022-S12
Standard Specification For Road Works Section 12 : Structural Steelwork
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Standard Specification For Road Works Section 13 : Bridge Bearings
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Standard Specification For Road Works Section 14 : Expansion Joints
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37 . JKRISPJ/2013-S15
Standard Specification For Road Works Section 15 : Parapets
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( Standard Specification For Road Works Section 16 : Slope Stabilisation

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Standard Specification For Road Works Section 17 : Site Investigation
40 . JKRISPJ/2018-S18
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Standard Specification For Road Works Section 18 : Soil Stabilisation

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Standard Specification For Road Works Section 19 : Traffic Management At Work Zones
42 . JKRISPJ/2020-S20
Standard Specification For Road Works Section 20 : Ground Improvement
43 . Nota Teknik (J) 14/87 (Pindaan 2020)

Model Terms Of Reference For Detailed Ground Survey And Engineering Design Of
Roads
44 . Nota Teknik Jalan (NTJ) 18/97

Basic Guidelines On Pedestrian Facilities
AS-3/6
APPENDIXA5
45 . NTJ 19/97 (Pindaan 2019)

Intermediate Guidleines to Road Reserve Landscaping
46. NTJ 26/08 (Pindaan 2016)

An Interim Guide On Standard Bill Of Quantities
Section 1: Road Works
Section 2: Bridge Works
47 . NTJ 27/2012
Terminologi Jalan
48 . NTJ 29/2015
Guidelines for The Provision Of Road Lighting
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49. NTJ 30/2015
Design Guidelines On Safety Facilities for Schools
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50 . NTJ31/2015
Design Guidelines for Emergency Escape Ramp
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( 51 . NT J 32/2015
Performance Guidelines for Hybrid Ground Anchor
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52 . NTJ 33/20 15
Guidelines For Motorcycle Facilities
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53. NTJ 34/20 16
Guidelines for Selection of Speed Limit
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54. Nota Teknik (J) 36/2020

Panduan Sistem Penomboran Jalan
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55. NTJ 39/2019

Manual For Bridge Approach Differential Settlement Improvement
EN
56 . NTJ 40/2020
Manual For Precast Beam Installation And Launching
57. Standard Drawings For Road Works (Pindaan 2021)

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( 58 . Construction Supervision Manual For Contract Road Works

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59. Guidelines For Inspection And Testing of Road Works
60. A Guide To The Visual Assessment of Flexible Pavement Surface Condition

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61. Interim Guide To Evaluation And Rehabilition of Flexible Road Pavement

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62. Interim Guide On Identifying, Prioritising And Treating Hazardous Locations On Roads In
Malaysia
63. Guidelines For The Environmental Impact Assessment of Highwayl Road Projects
64. Road Safety Audit - Guidelines For The Safety Audit Of Roads And Road Project In
Malaysia
A5-4/6
APPENDIX AS
65 . Design Guide For Alternative Pavenment Structures Low Volume Roads
66. A Guide To The Visual Assessment Of Concrete Pavement
€l7 . StaneaFG Speci~cation For Asphaltic Concrete For Roae Pavement For B~ileing IJVorks
€l8. StaneaFG Speci~cation For Bit~mino~s Macaeam For Roae Pavement For B~ileing
WeFks
69. Manual Fasiliti Keselamatan Jalan
70. Manual Penarafan Hijau JKR (pH JKR) 3.0

httpsJ/www.jkr.gov.my/page/manual-1
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71. Highway Capacity Manual 2011 published by Highway Planning Unit Ministry of Works
Malaysia
httpJ/www.kkr.gov.my/en/node/2350
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72. Garis Panduan Pengurusan Risiko Projek Bagi Projek Kerajaan JKR29300-0033-17
httpsJ/www.jkrgov.my/page/garis-panduan
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( 73 . Garis Panduan Pengalihan dan Pemasangan Semula Utiliti Dalam Pelaksanaan Program
dan Projek Kerajaan RMKe-12
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74 . Latest Road Traffic Volume Malaysia
httpJ/rtvm.kkr.gov.my/
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OTHER DESIGN STANDARD AND GUIDELINES
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- Garis panduan yang lain boleh dibeli atau dirujuk seperti dibawah
Sumber rujukan : httpsJ/www.ream.org.my/?q=node/4

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75. REAM - GL 1/1999

Guidelines on Bridge Aesthetics
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76. REAM - GL 3/2004

Guidelines for Road Drainage Design . Volume 1: Hydrological Analysis - Estimation of
Design Floods
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( 77. REAM - GL 3/2002

Guidelines for Road Drainage Design. Volume 2 - Hydraulic Design of Culverts
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78 . REAM - GL 3/2002
Guidelines for Road Drainage Design . Volume 3 - Hydraulics Consideration in Bridge
Design
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79 . REAM - GL 3/2002
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Guidelines for Road Drainage Design . Volume 4 - Surface Drainage
80. REAM - GL 3/2002

Guidelines for Road Drainage Design . Volume 5 - Subsoil Drainage
81 . REAM - GL 4/2002
Guidelines for Works Related to Public Utilities Installation within the Road Reserve
A5-5/6
APPENDIX AS
82. REAM - GL 5/2004

A Guide For Bridge Inspection
83. REAM - GL 6/2004

Guidelines for Planning Scope of Site Investigation Works for Road Projects
84. Manual Saliran Mesra Alam Malaysia (MASMA) Edisi Ke-2

https:llwww.water.gov.my/jpslresourcesIPDFIMSMA2ndEdition_ augusC 20 12. pdf
85. Malaysian Civil Engineering Standard Method of Measurement (MyCESMM) 2.0

https:llwww.cidb.gov.mylindex.phplenlabout-uslpubficationlmafaysia-civif-engineering-
standard-method-measurement-2-mycesmm2
86. Environment Impact Assessment Guidelines in Malaysia
ER
https:llenviro2.doe.gov.mylekmcldigitaf-contentlenvironmentaf-impact-assessment-
guidefine-in-mafaysial
87 . JKRISIRIM 3:2020 - JKR Standard 2020 Environmental Protection and Enhancement
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Works for Projects
https:llstandards.sirimsts.mylcatafog.php
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AppendixA6
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(Terms of Reference Traffic Study)
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GOVERNMENT OF MALAYSIA
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TERMS OF REFERENCE
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TRAFFIC STUDY
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MEMBINA JALAN DARI BEHOR MALI

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KE KAMPUNG KEPALA SEPULOH, PERLIS

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THE STATE OF PERLIS

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TERMS OF REFERENCE OF TRAFFIC STUDY
Contents
1.0 Background of Traffic Study ....... ............. .................. .. .. .. ................ .. ..... ...... ................... 3
2. 0 Objective of Traffic Study ................... .. ............... .. .. .. .......... ............................. ............... 3
3.0 Study Area ............................................ ............ ... .. .... ..................................... ..... ...... ...4
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4.0 Scope of Works ... .............................................. ............................. ................. .............. 4
4. 1 Traffic Studies .............. ......... ..... ..... ......... ...... ........... .. ................................. ..... .......... 4
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4.1.1 Road Network Analyses .............................................. ......................................... 4
4. 1.2 Traffic Surveys ............................. ....... ........ .. ................. ................................ . 4
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( 4.1.3 Traffic Projections ....... ................... ...... ........ .. .................................................. 4
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4. 1.4 Analysis ................. ................... ........... .. ..................................................... 5
4.1.5 Fi ndings ..................................................... .. .... ........ .. ....... ...... ...... ...... ..... ...... ........ 5
5.0 Roles and Qualification of The Consultant ....................................... .. .... ....... ....... .... ........ 5
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6. 0 Deliverables by The Consultant to JKR ................ .. .... .. .......................... ........... ............... 6
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7. 0 Methodology and Output of Traffic Study ............. .. .... ..... ................. .. ... .. ....... .. ................ 6
8. 0 Validity Period of Traffic study .......... .. ........................ ............................................... 7
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9. 0 Approval Process and Consu ltant Responsibi lity ............ ................................................. 7

10.0 Government Indemnity ........................................................... ........................................ 7
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11.0 Ownership of Documents & Data ....................... .. .. .......... ..... .. ......................................... 7

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MEMBINA JALAN DARI BEHOR MALI
KE KAMPUNG KEPALA SEPULOH, PERLIS
1.0 Background of Traffic Study
The Government of Malaysia is desirous to carry out the project Membina Jalan Dari
Behor Mali Ke Kampung Kepala Sepuloh, Perlis.
As such , a detailed Traffic Study has to be carried out to analyse the road and intersection
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Level of Service (LOS) , analyse and estimate future growth in traffic demand , and
propose optimum mitigation to cater for the future traffic demand. It also serves to
determine the capacity of traffic, analyse the existing and future road and intersections'
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performance (whichever relevant), propose U-turn, suitable traffic IighUtraffic signal
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( phasing and intersections' configuration for the intersections involved , if necessary.
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The exact locations of the proposed intersections are to be identified based on their
connections to the existing road network and at appropriate distances from each other.
The study also needs to identify possible alternative existing routes to disperse the current
traffic load and allow for a smoother flow of traffic within affected area.
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2.0 Objective of Traffic Study

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The Traffic Study shall be carried out with the following objectives;
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a) To analyse existing traffic condition on midblocks (including weaving sections, if

any) and all intersections involve in the study area, with particular reference to
the performance of the road network in the study area ;
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( b) To forecast the potential future traffic demand resulting from the proposed project
and to assess its impacts on the road network;
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c) To analyse future traffic impacts upon project completion year and forecasting
years ;
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d) To propose mitigation measures for all negative impacts on LOS, safety aspects
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and others to curb possible future traffic-congestion in the transportation system

within the vicinity of the proposed project; and
e) To recommend the most economically feasible new alignment for the project.
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3.0 Study Area
The area of study covers part of Federal Route (FT7) across Jalan Kampung
Mengkuang Layar to Jalan Kampung Surau (R159) and Jalan Jejawi - Tambun
Tulang (R175) and within its vicinity corridor. The proposed traffic study location is shown
in Figure 1. However, the Consultant shall ascertain for himself the extent of the study
area so that its coverage is sufficient for the Consultant to get required data for the proper
completion of the Study (to consult and obtain approval from JKR).
4.0 Scope of Works
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4.1 Traffic Studies
4.1.1 Road Network Analyses
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regard to the traffic capacity in the Study Area by conducting traffic surveys
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and making use of all available data.
4.1 .2 Traffic Surveys

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Th e Consultant shall obtain and study all available traffic data and all
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available public transport data for the Study Area and conduct appropriate
field surveys at selected locations to determine the traffic data and travel
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characteristics in the Study Area. The traffic surveys , when carried out, shall
be consistent with the methodology that is currently being adopted in the
country.
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4.1.3 Traffic Projections

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( The traffic projections shall cover future traffic demand upon project
completion , 10 and 20 years, starting from the completion year of the
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project. The latest version of Road Traffic Volume Malaysia (RTVM)

coordinated by Highway Planning Division , Ministry of Works shall be
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utilised in order to obtain the traffic growth rate.

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The Consultant shall assess the adequacy of the existing road network, in
terms of the road hierarchy and traffic capacity in the Study Area in catering
for the forecasted travel demand .
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4.1.4 Analysis
Based on the roads and intersections analysis software such as SIDRA or

its equivalent, the Consultant shall develop, validate and calibrate existing
roads and intersections for the study.
Consultant shall carry out traffic modelling for the study area using
modelling software such as EMME, PTV Visum or its equivalent as
approved by JKR. Validation shall be undertaken to ensure that the traffic
model will reproduce the observed traffic demands in the existing road
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system in the study area. The time horizon for traffic projection traffic
projection shall cover 10 and 20 years from the projected completion year
of the project.
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The cost of purchasing all software shall be borne by the Consultant. All
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( databases and models developed and utilized in the Study shall be handed
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over to the Government at the end of the Study.
4.1.5 Findings
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In consultation with the relevant government authorities and in accordance
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with the latest Highway Capacity Manual Malaysia, Arahan Teknik (Jalan)
JKR and relevant international guidelines, the Consultant shall recommend
the number of lanes required , the layout of intersections, U-turns and the
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time phasing for existing traffic light, or if necessary, propose new traffic
light and the optimum mitigation to cater for the future traffic demand where
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the exact locations of the proposed intersections are to be identified based

on their connections to the existing road network at appropriate distances
from each other, in accordance to the projected traffic, function and
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hierarchy of the proposed roads and bridges.

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5.0 Roles and Qualification of The Consultant

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Role of the The Consultant:
a) Consultant can be a Professional Engineer with Practicing Certificate (PEPC)

or a team of specialists in a firm led by a qualified PEPC .
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b) Consultant who has been commissioned by the Client to carry out the Traffic
Study shall act independently and professionally, without interference or
influence from any party. Consultant shall directly or indirectly look after the
interests of the general public and the local community.
c) Communicate and liaise with the Approving Authority to demonstrate the traffic
planning and proposal for the development/redevelopment project and identify
any possible adverse traffic impacts.
The Consultant Firm must be registered with the Ministry of Finance (MOF) under the
Traffic Study (Kajian Trafik) Code 340202 or the Transport Network (Kajian Rangkaian
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Pengangkutan) Code 340201 whichever is applicable or whatever relevant to traffic
engineering study as required by MOF.
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6.0 Deliverables by The Consultant to JKR
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The deliverables of the Traffic Study by the Consultant and how they are to be managed
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are as follows:
i. Final Traffic Study Report

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Final deliverables produced by the Consultant and to be submitted to JKR at the
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end of the study period .

Submission is:
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- five (5) hard copies and two (2) soft copies (including traffic model and
simulation) to JKR, unless requested otherwise.
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All reports submitted shall be duly signed by the Consultant and shall be.ar the
professional stamp and company seal.
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c.
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7.0 Methodology and Output of Traffic Study

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The Traffic Study methodology and expected output resulting from the proposed
mitigation measures shall comply with the requirements of the latest Highway Capacity
Manual Malaysia and Arahan Teknik (Jalan) JKR, or relevant international guidelines
approved by JKR (Refer Attachment A).
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8.0 Validity Period of Traffic study
If the time lapse between the dates of a Traffic Study undertaken and its submission is
more than two (2) years, the Traffic Study must be updated to reflect the current traffic
conditions of the locality. Notwithstanding the abovementioned time lapse, JKR may ask
for an updated Traffic Study as deemed necessary.
9.0 Approval Process and Consultant Responsibility
Notwithstanding the validity period of the Traffic Study as per Clause 9.0 of the TOR , the
Consultant is still responsible in discharging his duty and obligations until approval of the
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Traffic Study Final Report is obtained from Approving Authority.
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10.0 Government Indemnity
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( The Consultant shall take all necessary measures and be responsible for any damages
to life and property that may arise out of their works and shall take all necessary insurance
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cover to indemnify the Government from any claims for compensation that may occur due
to their negligence. A
11.0 Ownership of Documents & Data
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On completion of the Study, the Consultant shall hand over to JKR all relevant data
collected, and other related documents prepared and such materials in softcopies and
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hardcopies shall become the property of JKR.

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All traffic data collected including traffic model and simulation developed during the Study
shall be handed to JKR and become its property.
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Membina Jalan Dari Behor Mali Ke Kampung Kepala Sepuloh, Perl is. (Coordinate 6.380214,100.183198)
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- RUJUK LAMPlRAN Al -
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Figure 1: Proposed Study Area

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ATTACHMENT A
1. Highway Capacity Manual Malaysia 2006
2. Highway Capacity Manual Malaysia 2011
3. ATJ 38/2018 - Guidelines for Traffic Impact Assessment
4. ATJ 8/86 (Pindaan 2015) - A Guide on Geometric Design of Roads
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5. ATJ 11/87 (Pindaan 2017) - A Guide to The Design of At-Grade Intersections
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6. ATJ 12/87 - A Guide to The Design of Interchanges
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7. ATJ 13/87 (Pindaan 2017) - A Guide to The Design ofTraffic Signal
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AppendixA7
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(Terms of Reference for Bridge and
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Viaducts Structures For Design And
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Built Projects)
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REV: NOV 2018
TERMS OF REFERENCE FOR BRIDGES AND VIADUCTS STRUCTURES
1.0 General
This term of reference shall apply to the design and construction of all bridges and
viaduct structures or parts of structures to be undertaken for Malaysian Government
Projects. This term of reference shall be read in conjunction with latest version of JKR
Arahan Teknik, Nota Teknik, Specifications for roadworks and any other documents
approved by JKR. Any digression of stipulated herewith or reference documents in
the design or construction shall seek the approval from JKR.
1.1 Geometric Standards
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The bridge geometric standards shall conform to JKR R2 Arahan Tekn ik (Jalan)
8/86 (Pindaan 2015) : A Guide On Geometric Design Of Road and sha ll be read
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together with the Project Brief or Government Need of Statements .
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1.2 Materials
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1.2.1 The bridge and viaduct structures shall be of steel or concrete construction . The
Contractor shall use local materials, particularly locally produced steel. Other
materials can be only be used upon approval from JKR. Designer and contractor
are also highly recommended to use sustainable material in the design and
construction .
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1.2.2 Materials used shall be in compliance with related specifications approved by
JKR and shall possess adequate durability and protection against environmental
deterioration . Minimum grade of concrete allowable is Grade 40 N/mm2 of cube
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strength. Where the bridge structures or elements of the structure are subjected
or prone to chlorides, sulphate or to any other detrimental effects that may cause
durability issue , high performance concrete or any other type as approved by
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JKR shall be used.
1.3 Design Requirements and Considerations

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1.3.1 The design and construction of the bridge and viaduct structure must adhere to
( the following requirements and considerations:
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(i) Functionality: The bridge and viaduct structure must be fully functional
for its intended use, connecting way from one point to the other, allowing
passage for traffics under the required serviceability limit state condition
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throughout its design life as given by the approved standards.

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(ii) Safety: The bridge and viaduct structure must be designed with adequate
factor of safety in compliance with approved code of practices, design
standard and specifications during construction and at service condition.
(iii) Robustness: The bridge and viaduct structure must be designed with
adequate robustness at ultimate limit state condition. The structures
should be desig ned so that they are not reasonably damaged or sudden
collapse to the effects of accidents. In particular, situations should be
avoided where damage to small areas of a structure or failure of single
elements may lead to collapse of major parts of the structure. The design
must also allow for adequate redundancy to avoid any sudden failure.
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(iv) Durability: The bridge and viaduct structures shall be designed with
adequate durability to withstand the service conditions for which it was
intended use over a prolonged period without significant deterioration and
major maintenance.
(v) Maintenance: The bridge and viaduct structures shall be designed for
ease of inspections, maintenance and replacements of the various parts,.
such as bearings, expansion joints, stay cables and others. Suitable
access facilities shall be provided and incorporated in the bridge structure
where access is not possible by normal means.
(vi) Aesthetic: The bridge and viaduct structures shall be designed with
aesthetically pleasant that is in harmony and blend in with surrounding
and localities. The structure must also have a right geometrical
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proportionality in span length and expressively form of structural anatomy
where necessary.
(vii) Economics: The cost of design and construction of the structure must be
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cost-effective and well-proportioned to its functional requ irements. The
consultant must provide a value for money in selecting materials and
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( method of construction of the bridge.
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1.3.2 The design of bridge and viaduct structure component must endure to
utilize the Industrial Building System (IBS) as follows:
(i) Minimum percentage of IBS component utilization calculated based on

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cost of structural works shall be fixed at 70%;
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(ii) Foundation works shall not be included in accounting for percentage of
IBS used in the structure.
(iii) For cast in-situ construction that deploys repetitive method or procedure
such as balanced cantilever, movable scaffolding system or other labour
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saving method, the maximum score for reusable formwork allowed is only
50%.
(iv) All reinforcement for the precast reinforced concrete structure shall be cut
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and bent off-site with the compliance to MS 146 as well as BS 4466 and
BS 5400.
(v) The Consultant Engineer (CE) or Contractor must submit calculation for
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percentage of IBS content when submitting structural drawing for

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1.3.3 Appropriate investigations and data collection shall be carried out to determine
the best design. The investigations shall include at least the followings:
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(i) Hydraulic and hydrological data

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Hydraulic and hydrological data are required to determine the soffit and
deck finished levels, river training geometry, scour depth estimation,
scour protection, drainage networks and other related measures.
Investigation and evaluation of the complete hydraulic and hydrological

data shall be carried out to determine the design flood flow capacity, tidal
effects/water tide, flood level, flow velocity, rainfall, waterway width,
catchment area, river slope and other measures.
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The return period or annual recurrence interval (ARI) to determine the
design discharge of the waterway or loca l drainage shall be in accordance
to DJ 1/2001: Design of Highway Bridges for Hydraulic Action .
All design data used in the design calculations shall be submitted to JKR.
(ii) Weather and climatic data
Weather and/or climatic data shall be obtained in the case where it has
significant impact to the bridge structure. Where it is envisaged that wind
loadings may have a significant effect on the stability and serviceability
design of the structure, appropriate wind tunnel testing shall be carried
out.
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(iii) Seismic Consideration
Seismic consideration must be accounted for in the design of long-span

lifeline structure or depending on the nature of the project as directed by
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JKR. The seismic considerations shall follow the relevant Malaysian
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guideline where appl icable or other related codes. The guideline or code
( used shall be subject to approval of JKR.
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(iv) Navigational requirements for navigable bridge
The navigational requirements of the bridge shall be confirmed with the

relevant authorities to determine soffit levels, minimum navigational
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spans, protection against vessel impact, appropriate navigational lighting,
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maritime/aviation navigational aids etc.
1.3.4 Bridges of total length not exceeding 60.0 meters with skews not exceeding 30 °
shall be designed as an integral bridge.
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1.3.5 For multi-span bridge, the superstructure shall be structurally continuous with the
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minimum use of expansion jOints as possible . Continuity connection by using the

tied deck slab only is not allowed. Whenever pOSSible, the abutment shall be
designed as a semi-integral type without the needs of having the expansion
joints.
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( 1.3.6 Where the substructures are slender and flexible enough to abridge the bending
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moments at the superstructure, the bridge shall be designed with integral pier
crosshead between the superstructure and substructure without the needs of
having any form of bearings.
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1.3.7 Beam of less than 30.0 m span shall be designed and constructed by using the
JKR standard Beam Sections where applicable. Other types of beam may be
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used subjected to the approval of JKR. The contractor and consultant are
responsible to undertake and carried out the stability calculation and checking
during the launching and positioning of beam prior to deck slab and diaphragm
casting. The contractor and consultant must also ascertain that adequate braCing
system is properly designed and placed onto the correct positions and subject to
approval of JKR
1.3.8 A single pier cross head that is carrying a 6-lane carriageway on a single deck
shall be designed and constructed as a precast prestressed element members.
The construction of the crosshead shall be in the form of segmental construction.
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1.3.9 Public utility services
Where applicable, the bridge shall be designed to cater for water pipe
(approximate size 600mm diameter) under full service load
conditions, telecommunications and/or other utility services cables or
ducting. Details of the utility services cables or ducting shall be obtained from
relevant agencies or authorities by the Consultants. High tension or high
voltage cables or ducting shall not be permitted at anywhere on the bridge.
1.3.10 Bridge Parapets

Bridge parapets shall be precast and of New Jersey Barrier type. Bridge parapets
shall be design and construct with decorative facade and subject to approval of
JKR. Cast in-situ parapets shall use formworks (Type F3 - smooth surface). All
parapet bridge shall be applied with aesthetical surface coating on inner and
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outer side of the parapet. Parapet on the bridges that are located in the area
subjected to environmental conditions of chloride and sulphate attack shall be
coated in accordance to clause 1.4.14.
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Bridge parapet shall be installed with reflector plate at minimum interval of 1.5m
spacing . The reflector plate shall also be installed at the guardrail on both
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( approaches towards the bridge.
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1.3.11 Pier protection system
Any pier structures that are located in the major river or within the navigable
channel shall be provided with pier protection system in the form of fenders ,
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dolphin, etc. Data for riverine traffics, vessel or laden weight shall be obtained
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from relevant agencies.
Erosion protection measures to the approach embankments, abutments, piers

and/or riverbed/riverbank shall be provided where necessary.
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1.3.12 Surface Coating

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Protective surface coating shall be applied to the structures that are exposed to
environmental condition of chloride or sulphate attacks. The coating shall be
applied to all exposed members of the superstructure and substructure and/or to
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the area deemed to be subjected to environmental condition attacks or to a

( specific area as directed by JKR.
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Surface coating for aesthetical purpose without the needs of protective surface
coating shall be applied in case where the structures located in the major town,
or as an iconic monumental structures at which the area is not prone to
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environmental condition attacks .The surface coated area shall be determined by

JKR.
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Surface coating to serve as the function of protective as well as for aesthetical

purpose shall be applied where the structures are located in major town and also
subjected to environmental condition attacks. The surface coating shall be mixed
and combined in a single application and shall not be applied in layer on top of
the other.
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1.3.13 Lighting
All bridges/viaducts/elevated structures shall be provided with road lighting

including the suitable lighting post, supports and cabling . The spacing of the
post shall be based on the illumination requirements. For bridge span less
than 20m, the lighting shall be provided at both approach part of the bridge
inclusive of supports, post, cabling and all related items to the completeness of
road lighting.
Bridge lighting shall be of linear lighting system fixed to the bridge. The light
fixture shall be of appropriate brightness aimed at the roadway and shielded
to prevent glares to motorists. The used of facade, spotlight and ftoodlight
lighting at the bridge shall be testing and commissioning as approved by JKR.
Where required by the navigational authorities, appropriate navigational
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lighting aids shall be provided .
1.3.14 Outlet drain pipe or rain water down pipe shall be provided on the deck at suitable
position as to collect the surface runoff from the deck and discharge to the nearest
discharging point inclusive of all collector pipes. The minimum size of outlet pipe
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shall be 150mm depending on the amount of surface runoff and spacing of the
outlet pipe. Scupper drain on the deck may be provided as appropriate.
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1.3.15 Access for inspection under the bridge in the form of staircase or platforms must
be incorporated in the design . Adequate height clearance at the abutment area
must be provided for the bearing inspection .
1.3.16 Cast in-situ box culvert:

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Box culvert of size 1.5 m and above in height and/or width shall be designed as
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cast in-situ type including the approach slab. Culverts with the height of
embankment or fill is more than 3m shall be designed and constructed as cast
in-situ box shaped type. The foundation of the culvert shall be based on-site soil
bearing pressure. Sand bedding layer shall not be used as the base layer of the
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culvert.
1.3.17 Precast box culvert and precast arch bridge shall be properly designed to satisfy
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the following conditions:
(i) The segments must be analysed and designed as rigid frames ;

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(ii) Minimum top and bottom slab thickness is 200 mm;

( (iii) Minimum wall thickness is 200 mm;
(iv) All joints between precast section shall be provided with tongue, groove
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and lifting hooks to pick up sections;

(v) Water proofing, geotextile fabric or wrap shall be placed over joints;
(vi) The joint exterior shall be covered with a minimum of 225 mm wide wrap
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centre on the joints;

(vii) To prevent precast section from pulling apart during or after construction,
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minimum four (4) longitudinal 12.7 mm diameter low relaxation

polypropylene sheathed prestressing strands with corrosion inhibitor or
other approved post-tensioning device, shall be placed in position
through preformed holes in the corners of the precast units;
(viii) Prestressing strand with minimum 183 kN breaking load shall be
provided. Each strand shall be stressed to 137 kN or equivalent to 75%
ULS;
(ix) These end anchorage forces must be considered in the box culvert
design;
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(x) The exposed end of the sheathed prestressing strand shall be removed
after post-tensioning. No part of the strand or the end fittings shall extend
beyond 50mm inside the hand-hold pocket. The pocket shall then be filled
with non-shrink grout;
(xi) Recommended allowable weight of precast section is below 18 metric
tonnes.
1.3.18 Retaining structures at approach embankment
The maximum height of any type of retaining structure at approach embankment

shall be maximum of 6.0m unless approved otherwise by JKR.
1.3.19 Stringent measures shall be taken to prevent long-term discontinuities and

unacceptable driving condition as a result of differential settlement between the
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bridge and the approach embankments.
1.3.20 Footbridges
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Footbridges shall be designed in compliance to BD 29/17 or as approved
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otherwise by JKR. For dual carriageway with permitted speeds in excess of 50
( kml h, a single span shall be provided spanning both carriageways to avoid the
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need for support in the central reserve. Both ramps and staircases shall be
provided for access.
The staircase of the footbridge shall have minimum tread width of 260mm and a
maximum riser of 180mm. The inclination angle of the steps shall be maximum
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of 34°.
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1.4 Design Criteria and Parameters

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1.4.1 Latest Malaysian, British Standards, Eurocode and Codes of Practice shall be
adopted for design of structures. The principal standards but not limited to are as
the following :
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(i) The latest version of British Standard Institution BS 5400: Steel, Concrete
and Composite Bridges, BS EN 1990, BS EN 1991 , BS EN 1992, BS EN
1993 and BS EN 1994.
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( (ii) Bridge loading shall follow The Highways Agency, UK BD 37/01: Loads
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for Highway Bridges, BS EN 1992-2. Prestressed member should be

design for Class1 under Load Combination 1 with HA and HA+30 units
HB. Load Combinations 2 to 5 is designed for Class 2 with HA and HA+45
units HB.
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(iii) Integral bridges shall follow BA 42/96 Amendment No. 1: The Design of
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Integral Bridges.
(iv) Foundations, Retaining wall structures and Reinforced Earth shall follow
BS 8004: Foundation, BS 8002 : Code of Practice for Earth Retaining
Structures , BD 3/78: Reinforced and Anchored Earth Retaining Walls
and Bridge Abutments for Embankments [Rev. 1987], BS EN 1997 :
Geotechnical Design.
(v) Vehicle Impact shall follow BD 60104: Design of Highway Bridges for
Vehicle Collision Loads or BS EN 1991 :Part 2 :Traffic Loads On Bridges.
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(vi) Vessel impact
Shall establish appropriate ship collision forces and follow the latest
version of AASHTO Guide Specification And Commentary For Vessel
Collision Design of Highway Bridges, Second Edition (2009) , BS EN
1991:1-7: Accidental Action .
(vii) Expansion Joints in Bridge Decks

Shall follow BD 33/94 and BA 26/94 . Expansion Joints for Use in Highway
Bridge Decks. The expansion joints shall be guaranteed by the
manufacturer to have a minimum effective live of 10 years in the
prevailing ciimate and traffic condition.
(vii) Parapet shall be in accordance to BD 52193: The Design of Highway

Bridge Parapets and in compliance to Arahan Teknik (Jalan) 1/85
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(Pindaan 1/89) Manual on Design Guidelines of Longitudinal Traffic
Barrier and REAM GL- 9/2006 :Guidelines on Design and Selection of
Long itudinal Traffic Safety Barrier.
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(viii) The bridge and viaduct structures shall be designed to satisfy for
aesthetics requirement by following REAM - GL 1/1999: Guidelines on
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( Bridge Aesthetics.
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(ix) Footbridge design shall follow BD 29/04 : Design Criteria for Footbridges
1.4.2 Durability
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The bridge and viaduct structural elements shall be designed for enhance
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durability (if applicable) in accordance to The Highways Agency, UK BA 57/01 :
Design For Durability. Reinforcement cover: in designing concrete members,
nominal cover derived from BS5400: Part 4 Table 13, shall be increased by
1Omm in accordance to BD 57/01 in the case of the bridge or structural elements
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of the bridge are subjected to abrasive chloride attack.
1.4.3 Design crack widths for reinforced concrete shall be in accordance to BS5400
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part 4 andlor EN 1992-2 or as directed by JKR.
1.4.4 Earthquake loading

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( Earthquake loading for long-span lifeline bridges or bridges that required to be

designed with seismic loading as directed by JKR, shall be taken as 1.0 in ULS
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and in Load Combination 4 only. The Peak Ground Acceleration (PGA) value
depends on the project location and shall be taken as follow:
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a) Peninsular Malaysia and Sarawak: 0.08g

b) Sabah : 0.17g
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In considering earthquake loading no relieving effects from bearing friction will be

considered .
1.4.5 Drainage: drainage facility for the bridge deck shall be suitably provided and the
bridge deck shall have a minimum cross fall of 2.5% .
1.4.6 Reinforced earth wall shall be designed to Department of Transport Highways

and Traffic Departmental Standard BD 3/78 (Revised 1987) Reinforced and
Anchored Earth Retaining Walls and Bridge Abutments for Embankments.
Reinforced earth structures shall have a design life of 120 years.
71 Page
1.4.7 Approach embankment
Approach embankment for viaducts and structures shall conform to Geotechnical

Design Criteria for Road Work to minimize any differential settlement at
abutments.
Embankment must be designed with zero differential settlement at the connecting

pOint to the bridge abutment and gradual settlement of 1 in 500 within 50m away
from the abutment towards the toe of the approach embankment. Appropriate
soil treatment must be provided in the case of SPT of the underlying soil is less
than 5. Consultant must provide detail calculation of expected differential
settlement with respect to the proposed type of soil improvement at the
embankment area.
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1.4.8 Differential Settlement
Where differential settlement is likely to affect the structure in whole or in part,
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the effects of this parameter should be taken into account.
(i) When designing a structure, the value of differential settlement shall be
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taken as 12.5 mm at serviceability limit state (SLS).
( (ii) The structure shall be checked for differential settlement of 38.0 mm at
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ultimate limit state (ULS).
1.4.9 Surface finishes : the surfacing designed thickness shall be taken as 100 mm thick
asphaltic concrete .
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1.4.10 Bridge Clearances
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(i) For bridge over river the freeboard and horizontal clearance shall be
in accordance to Sarawak River Board (SRB) or relevant authorities;
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(ii) For bridge over road the vertical and horizontal clearance shall
be approved by the relevant Road Authority.
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1.4.11 Prestressing anchorages shall not be located at top flange face of T-beams or
any other beams.
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( 1.4.12 Half joint shall only be allowed as the temporary seating of precast beams onto
the integral in situ crossheads .
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1.4.13 Elastomeric bridge bearings shall be of natural rubber and shall be in accordance
with the specification proposed by the Committee on Natural Rubber in
Construction, Rubber Research Institute, Malaysia. Bridge bearing shall be
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designed with adequate stability in all directions during the beam launching and
placement prior to deck slab casting .
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81 Page
1.4.14 Coating
The detail mix design and application of protective surface coating system for
exposed concrete surfaces or areas where it deemed to be subjected to
environmental condition attacks shall be in accordance to Section 9 (Concrete)
Specification for Roadworks. Similar condition apply in the case of protective
surface coating in combination with aesthetical surface coating. The minimum
effective life of both protective systems shall be in excess of 20 years.
Compulsory sample testing of paints is required.
1.4.15 Anti-corrosion protective system
The steel materials used for the bridge structures shall follow BS 5400: Part 6. A
comprehensive anti-corrosion protective system in accordance with BS 5493 or
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equivalent shall be submitted and approval by JKR. The minimum effective life
of such protective system shall be in excess of 20 years . Compulsory sample
testing of pa ints is required .
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1.4.16 Launching of precast elements
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( Utmost precautions shall be taken to eliminate any danger to workers and
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general public while launching precast elements. All lifting equipment shall be
designed, such that if the primary lifting mechanism fails , a secondary
mechanism will ensure that the precast element does not fall.
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Upon erection , a fail-save method shall be used to temporarily secure the precast
unit until the permanent fixing arrangements are implemented .
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All precast unit must be braced adequately and maintained stable at all time.
Bracing system must be designed to ensure stability of the precast unit prior to
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the fixed arrangement of the unit or structural members.
1.4.17 Temporary works

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The risks for each case shall have to be considered and appropriate safety
factors allowed in the design. The minimum safety factor at ULS shall be taken
as 1.5 if the safety of the general public is at risk.
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1.4.18 Bridge furniture and traffic signs on the bridge or at approaches shall be in
( accordance to that specified separately in the relevant sections of roadwork .
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1.4.19 A plaque shall be fixed on the inner face of the parapet or wingwall of each bridge.
The shape and dimension of the plaque shall be as approved by the PD or S.O
and shall be of yellow brass with bold face alphabets.
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The wordings on the brass plaques shall be as follows: -

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JAMBATAN Name of bridge

TARIKH Month and year of completion of bridge
PEREKABENTUK Name of Designer
KONTRAKTOR Name of Contractor
BEBAN Design loading
RENTANG Bridge spans, type of beam and bridge system
(semi integral/fully integral)
ASAS Type , size, and length of pile
91 Page
TERMS OF REFERENCE FOR INDEPENDENT STRUCTURAL CHECKER
2.0 Introduction
All structural design shall be independently checked by expert, to be appointed by the

Contractor and the prior appointment of which is subjected to the approval of the Project
Director (PO) and advice from Bahagian Rekabentuk Jambatan.
The Independent Checking Engineer (referred to as the checker herein after) shall take
full responsibility, integrity, thoroughness and competence of his report and
recommendatio n that it has been adequately carried out in accordance with accepted
best engineering practice , as well as to ensure the structural integrity and stab ility of
the proposed design and con struction by the contractor's co nsultants.
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The type of works that req ui red the involvement of The Checker shall be as follow:
(a) Any sing le project that has more tha n three (3) numbers of bridges or a project
that has one or two numbers of si ngle span bridge structure other than RC
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Beam and Slab type that has skew angle more than 30 deg ree with structural
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form of monolith ic integral or frame type ;
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(b) A multiple spa n bridg e and skew angle with or without precast prestressed
elements;
(c) Bridge structures that use box-shape type of structure as the main carrying
member;
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(d) S pecial bridge structures such as cable stayed bridg e, suspension bridge,
extradosed bridge or any type of ico nic bridge that possess complex structure
behaviour and interactions ;
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(e ) Any bridge project which , in the opinion of the approving authority, requires
safety check.
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2.1 The Checkers
The Contractor shall subm it and propose a min imum of 3 names of experts for the field
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of structural discipline to JKR for approval.

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The Checker shall fulfil the following requirements :
(a) Is a Professional Engineer with Practicing Certificate or P.E.P.C.s' registered

with a Board Of Engineers Malaysia for a minimum of 5 years or Professional
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Engineer registered with a Board Of Engineers Malaysia for a minimum of 10

years and majority of the tenure must be involved with bridge design and
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construction;
(b) The experts shall have at least 10 years of working experiences at the
professional level in the bridge design and construction field; or have published
several technical papers in their specialized fields (not less than 5 technical
papers in national/international seminar, conferences or journals); QLQualified
as an accredited checker in structural engineering field (bridge structures) with
the Board of Engineer Malaysia (BEM).
The Checker is not allowed to have a financial or professional interest in the project he
is undertaking.
10l Page
2.2 Scope of Services
A certificate of approval by the Checker in respect of the consultants design calculation,

engineering plans relating to the bridge and associated structures works including
critical temporary works stating that, to best of his knowledge and belief, the design
and all related engineering plans are checked and fit for construction and serviceable
during its design life cycle.
The Checker shall evaluate, analyse and review the structural design and details in the
plan and perform such independent calculations with a view to determine the adequacy
of key elements. The Checker shall also verify that the key elements designed are
consistent with general layout shown and in any amendments thereto .
The contractor must ensure sufficient working drawing details and specifications shall
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be made available to the Checker. A reasonable time frame must be given to the
Checker in carryi ng out his/her duty as a Checker.
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The checker in carrying out this is required to:
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(a) Determine and use of the Code of Practice and Design Standards in the plans;
( (b) Check the standards and specifications of materials to be used;
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(c) Ascertain the structural design concept used and identify the key structural
elements;
(d ) Analyse all key structural elements of the bridge and associated structure to be
built;
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(e ) Determine the stability of the structural frame ;
(f) Check structural detailing of the key structural elements;
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(g) Check the method of construction that is viable and pose no detrimental effect
to the public safety including all related temporary works ;
(h) Checking construction sequence and constructability of the structure;
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(i) Determine the adequacy of other aspects of the design which are peculiar to
the bridge and associated structures to be built and which are essential to the
structural integrity of the works .
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Note:
Key elements is define as those parts of elements of a bridge and associated structure
which resist forces and moments and include pile caps , and walls beams, beams, deck
slabs and all other elements designed to resist forces and moments.
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( 2.3 Reporting Of The Independent Check

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The checker's report shall be submitted to JKR within 2 weeks from the data received
complete working drawings from the contractor or otherwise agreed in writing by JKR.
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The report should specifically describe the deficiencies, potential or real, which have
been identified along with the relevant references to accepted standards, practices and
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design principles. The point should be illustrated wherever practicable by marking-up

the plans or with sketches, drawings and such related materials.
The report may include the checkers suggestion, amendments, alternative solutions
and designs for amendments and or alternative solutions. A tabulated summary of all
the checkers and designers comment with or without their agreement shall be included
as per Appendix A.
111 Page
APPENDIX A
FORMAT FOR INDEPENDENT STRUCTURAL CHECKER'S REPORT

(To be prepared by the Independent Structural Checker - here called as Checker)
1. TITLE PAGE
(Title Page of the Report should contain the following information)
Name of the project:
Name of the client:
Name and Address of the contractor's consultant:
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BEM registration No . of the contractor's consultant:
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Name and address of the Checker:
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BEM Reg istration No. of the Ch ecker:
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Endorsement of PE/ PEPC by ICE
Date of report: A
2. CONTENTS PAGE
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(The contents page should have the following information)
(i) Introduction
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(i i) Desig n information submitted by the contractor's consultant.

(This section should mention the key elements that are to be checked)
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(iii) Scope of Work of the Independent Structural Checker

(As per TOR ICE and any addition scope of work required)
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(iv) List of reviewed drawings submitted by the con tractor's consultant.

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(v) Detailed Design Check
(a) Geotech nical design for the foundation system

(b) Structural Engineering Design for the Superstructure and the
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Substructure
(i) Code of Practices
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(ii) Materials and its Specifications

(iii) Design Parameters
(iv) Check on design concept used and identify the key structural
elements
(v) Vertical and lateral loadings
(vi) Engineering software's used (analysis of key structural element)
(vii) Check on the stability of the structural frame
(viii) Structural detailing of the key structural elements including
substructures and foundation
(ix) Construction methods and the needs for public safety
(x) Temporary work
121 Page
(vi) Discussion and findings on the existing design as per Table 1.
(vii) Suggestion and recommendation
(viii) Conclusion
3. APPENDICES
(This section should contain all the drawings and independent design check
calculations and analysis of the Independent checker)
Note: Every page of the ICE REVIEW SHEET need to be cop and sign by the checker and
engineer.
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131 P a 9 e
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ICE REVIEW SHEET
PROJECT (NAME OF PROJECT)
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Name Contractor's Consultant: Name of Independent Checker:
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Bridge Name: Date :
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No. DrawinCl title I No. ICE Comment Designer's Response Final ICE Response Status
1 Accepted, drawing has
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been amended
2
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3
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----
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Note: Status of Approval
1. Approved
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2. Revise and Resubmit

3. Rejected
Table 1
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141 Page
TERMS OF REFERENCE FOR BRIDGE ASSESSMENT PROCEDURE
3.0 Introduction
This bridge assessment procedure shall be adopted if the Need Statement requires
rehabilitation, upgrading works and replacement. It involves careful consideration for
the treatment of the existing stock of structures (bridges and culverts) to attain the
desired objectives of ensuring structural safety, quality, serviceability, durability and
economy.
3.1 Bridge Replacement Policy
The general policy is to save existing structures. The Contractor shall follow this Bridge
Assessment Procedure and prepare a report to cover the assessment of existing
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structures.
The objective of th is report is to access: .
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(a ) The conditions of the existing bridge based on visual inspection ,
(b) The hydraulic capacity of an existing structure based on site investigation and
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discharge capacity
( (c) The existing structures capacity based on theoretical calculation .
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If one or all the criteria given above are not satisfied, the existing structure will either
be replaced , upgraded or rehabilitated as deemed necessary.
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3.2 Bridge Assessment Procedure
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The Bridge Assessment Procedure is a nine (9) steps procedure as shown in Figure 1
The three types of assessment to be carried out are explained below:
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(a) Visual Assessment
The conditio n of the existing structures to be inspected by checking defects of

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each structure through visual inspection, giving particular attention to primary

members such as longitudinal beams, cross heads and abutments. The
inspections condition existing structures can be referring JKR Annual Bridge
Inspection Manual as a guidance . The defects shall be divided to :
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( (i) Material defects

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These includes spalling of concrete, corrosive of steel reinforcement and

abrasion of piers and abutments.
(ii) Structural Defects

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Structural defects are caused by the inability of the structural member to

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resist the load imposed on it and can be in the form of cracks, settlement or
deformation
(iii) Hydrological Defects
This includes silting and erosion due to fluctuation of water level and
inadequate discharge capacity of the existing section.
151 Page
(b) Hydrological Assessment
The aim of this assessment is to ensure that the existing structure provides
adequate opening for the designed flood frequency discharge. Also the
foundation structure is to be checked for scouring effects.
(c) Analytical Assessment
The loading shall be JKR Specification for Bridge Live Loads

(i) Long Term Axle Loads (LTAL) combined with KEL
(ii) Special Vehicle (SV20) loading
Method of analysis should ideally consider of all the significant aspects of

behaviour of a structure governing its response to loads and imposed
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deformations.
(d) Structu ral Member Resistance
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(i) Evaluation Code shall follow :
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( • BD 21 /01 : The Assessment of Highway Bridges And Structure,
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Department of Transport UK.
• BD 44/95 : The Assessment of Concrete Highway Bridges and
Structures, Department Of Transport UK.
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(ii) Partial ILoad Factors
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Dead Load 1,15

Superimposed Dead Load = 1,75
If premix was measured = 1.25
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Live Load LTAL = 1.5

Live Load SV = 1.3
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(iii) For material Strength Without Drawings (Unknown)
fy = 230 N/mm2 = y ms 1.10

fyv = 230 N/mm2 = Y mv = 1.15
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( feu = 20 N/mm2 = Y me = 1.20

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(iv) Calculation of Member Resistance by Statistical Method

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This method shall be used to obtain percentage of steel for reinforced

concrete bridges without flexural reinforcement details. The use of
this method is restricted to :
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1) Simply supported reinforced concrete bridges

2) Bridges in Peninsular Malaysia
3) Bridges constructed between 1950 and 1972
4) Bridges spanning between 6 -15 metres.
The Formula is:

% steel = 0.015 x Rcindex - 0.2
Rcindex = 100 x S.L 1.326V
W.D 2
161 Page
S = The girder spacing(mm);
L = Span length (mm);
W = The girder width (mm);
D = The effective depth (mm) - 0.9 of the total depth
(e) Rating System
The load carrying capacity of a bridge is assessed based on the ratio of the
available resistance of a member to the effective of live load
Rating = <t:>R-aD
aL
<t:>R = Factored resistance of a member
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aD = Effect of the factored dead load on a member
aL = Effect of the factored live load for LTAL
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SV Rating = 20 . <t:>R-aD
aLsv
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( where aLsv = effect of the factored SV20 loading on the member
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(f) Decision Making
W iden when Rating> 0.8 LTAL

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Replace when rating < 0.8 LTAL
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3.3 Reporting On the Bridge Assessment

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The detail report shall be submitted in writing to JKR within 2 weeks of the assessment
being done or otherwise as agreed in writing .
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It shall include a summary of the consultant's recommendation as shown in Figure 2

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17I Page
FIGURE 1: BRIDGE ASSESSMENT PROCEDURE
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Desk Study
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SIRl
Categorised bridges imo
a. Bridges with ndequmc dl"llwing.s
b. Bridges without druwings
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\. isual mspcctionand condi[i~)11 a... ,;c!).~mcnt
'. m~dl'1<h ""pr, \
, iiI: h II 1\,11,
h r~u ..·r1 ,IL';'
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II) JI4ulil. <I!'.,c... ~mcnt
lltm. ..I<r...r.I'!J,;.[j
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( 1011111 .\
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I )" .. u ;,,11 UlJ ,.:..:"
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• iurlh':l .d' 1<.:<.: "',1,
1f.,,1{
'\lrul:!ur.J1 ,m,II:. ;I~
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Ih·hlllli, h.II'I... I~1 ,I.
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1<..:.. 111'lle.. d 1\'1'
_ _I \c~":I>I,IH
lo,;rLJ<..cm,11l
STEPbA
lIT.Ef..§.
Idcntitkllllon ofbridgc~ suiwble for usIng the lKR
Structural capacily detcrmlntttioo
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Stalhil.u:al method
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STEI' 7A. 8A.9A

RI r \[\,J
Di:\clls..'iion <lnd ~«k further ndvlSt; Ii'Pm
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D~lcrmln,· malcllwl pnJflC111L-
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"tr~n&1h n
STJ(I'R . - - -..... -...... Adequate '? Ill,).d I.
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Rephn:C!rnbl t
R~~ Strul,;lUral capaclly
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181 Page
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FIGURE 2 : SUMMARY OF CONTRACTOR'S RECOMMENDATION
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No. Structure
No/River
Name
Bridge
Type
Span
Length(m)
Carriageway
Width(m)
Year Built
Hydraulic 1 Consultant's R~rt
Condition J Analytical 1
Recommendation Opinion 1
JKR Comments
Consultant's
Action
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19 1Page
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AppendixA8
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(Geotechnical Design Requirements)
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APPENDIX A8
REV. 112022
KERAJAAN MALAYSIA
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GEOTECHNICAL DESIGN REQUIREMENT FOR
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KPLB(R1&R2) PROJECT
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( DESIGN & BUILD)

(REVISION 1/2022 )
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CAWANGAN KEJURUTERAAN GEOTEKNIK
IBU PEJABAT JKR
APPENDIX AS
REV. 1 / 2022
1.1 GEOTECHNICAL DESIGN REOUIREMENT !Design & Build)
1.2 General
The Contractor shall study and search all reports on geotechnical conditions
and engineering carried out. The Contractor shall undertake soil
investigations and material surveys for the purpose of engineering design and
construction of the works.
1.3 Independent Check on Geotechnical Designs
All geotechnical design shall be independently checked by experts, to be
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appointed by the Contractor and the prior appointment of which is subjected
to the approval of the P.D. : as per Term of Reference of Independent
Geotechnical Checker (IGC) .
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1 .4 Earthwork
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1.4. 1 Fill Material
Materials used in the construction of fill slopes and embankments shall, as

far as possible be those excavated from adjacent cuts. Rock excavated from
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the cuts may be used as material for fills if they are crushed to acceptable
grading envelopes, with maximum size of individual pieces not greater than
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150mm. Drying out of the fill material during hauling and handling from cut
to position of placing shall have to be allowed for.
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1.5 Ground Treatment

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The design of ground treatment for fill slopes or embankment shall comply
with Geotechnical Design Criteria in TABLE 1. Settlement and stability
analysis shall be carried out for the fill slopes and embankments depending
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'- on the subsoil conditions encountered. The contractor shall take extra
consideration to make sure that smooth transition is designed at approach
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structure, transition between existing and widening alignment, transition

between different types of ground treatment and in between cut area and
fill embankment.
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Ground improvement methods shall enable the works to be carried out in the
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time frame provided and cost effective .
1.5.1 Settlement Analysis
Settlement analysis shall be carried out for the fill slopes and embankments
depending on the subsoil conditions encountered. Design of fill slopes or
embankment shall be based on 90% settlement during construction unless
otherwise agreed by JKR.
- I -
APPENDIX A8
REV. 1 / 2022
Ground improvement methods are used to reduce or accelerate settlement.

Some typical methods are vertical drains, stone columns, etc.
During construction, the degree of consolidation and rate of settlement shall

be verified on site using field measurement of pore water pressure and
settlement. Asaoka's Method (1978), Hyperbolic Methods or etc. is used to
measure settlement and evaluate the settlement rate.
Total post construction settlement within the first five years of service shall
not exceed 350mm.
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The differential settlement shall be gradual settlement of ratio 1 in 300
within the structure zone.
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The differentia l settlement shall be gradual settlement of ratio 1 in 300 away
structure zone.
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Structure zone is defi ned as a length not less than 50m within the approach
to any structure (bridge, culverts, non -floating pile embankment, etc).
1.6 Stability Design of Slopes

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1.6.1 Rock Slopes
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Rock slopes shall be designed and cut in a safe and stable condition.
Preliminary consideration can be used using cut to 4: 1 (vertical: horizontal)
for weathering grade I and 3V:1H for weathering grade II. The rock slope
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stability analysis shall be carried out to confirm the slope cutting gradient
proposed . This analysis shall take into consideration a weathering grade,
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hydrological, discontinuity, relic t structure and other related factor

according to engineering geological report endorsed by professional
geologist. If analysis indicates that it is unstable, it shall be designed to a
better gradient and / or requiring extensive stabilization measures. The t ype
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( of stabilization measures to be used but not limited to the following:

permanent rock anchors
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rock dowels
rock bolting
buttress walls
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counter forts
relieve drains
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gunite protective surface seal

wire netting
1.6.2 Cut Slopes
All cut slopes shall be analyzed and designed . This includes cut slopes in
residual soils and in completely decomposed rock. All untreated slopes shall
be designed to 1: 1.5 to 1: 2 with 2m berm width and 6m height with a
-2-
APPENDIX A8
REV. 1 / 2022
Factor of Safety greater than 1.3 . For steeper slopes, stabilization measures
are to be provided such as: -
soil nailing with slope surface protection / guniting

permanent ground anchors
retaining walls, etc.
The Minimum Factor of Safety for treated slopes shall be 1.5
Generally, the maximum number of berms in a cut slope is restricted to six

berms unless there is difficulty to construct it due to the terrain
encountered.
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1.6.3 Fill Slopes and Embankments
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Fil l slopes and embankments shall be constructed to a gradient of 1:2 with
2m berm width and 6m height with a Factor of Safety as per Table 1. For
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( steeper slopes, stabilization measures shall be provi ded such as:
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geogrid / geotextiles reinforcement
reinforced concrete retaining structure
reinforced fill structure
replacing the fills with elevated structures
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1.6.4 Typical Slope Construction
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Some typical slope construction criteria adopted are illustrated in Table A.

However, the design and gradient of the slope adopted shall be verified
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with stability analysis.

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· lSI OJe Cons t ruc t"JOn C"t·

Tabl e AT yplCa n ena
Existing
No . of
Slope Typical Construction
Berms
Angle
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( < 3 ~ 35°
Normal Slopes 1: 2
(Vertical: Horizontal)
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Side-Long Fill on Reinforced Slopes 4: 1

> 3 ~ 35°
Slope (Vertical: Horizontal)
> 6 ~ 35° Replace with Retaining Structure
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Normal Slope 1:2

< 6 ~ 35°
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Embankment
Reinforced Slope 4: 1
> 6 ~ 35°
Reinforced 6
> ~ 35° Replace with Elevated Structure
Embankment
Normal Slopes 1:1.5 to 1:2 with

Cut Slopes < 6 -
surface drains and 2.0m berms
-3-
APPENDIX AS
REV. 1 / 2022
1.6.5 Slope Drainage System
(a) Berm Drain/ Interceptor Drain
Berm drain shall be designed to have sufficient capacity to undertake the

surface runoff based upon 10 years return period rainfall. Function of berm
drain is to minimize water infiltration, surface erosion and design to provide
self-cleansing velocity (eg. V-shape cast in situ concrete drain). Precast drain
is not allowed to be used in a slope drainage system.
(b) Cascading Drains
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Cascading drains in slope faces shall be provided in addition to normal cut
off drains at the top of slope and berm drains . Cascading drains shall be
provided for all 1: 1 cut slope surface and all fill slope surfaces which have
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1: 1. 5 or steeper gradient .
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( (c) Subsurface Drains
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Subsurface drains such as horizontal drains or drainage blankets shall be
provided for cut and fill slopes and for areas where the groundwater / perched
water table is found to be high.
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1.6.6 Retaining Structures
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Any proposed system of retaining structure shall be technically appropriate,

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cost -effective and aesthetically pleasing. The system shall have been
successfully implemented in similar accepted conditions wi th proven case
history
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Reinforced structures shall be design according to BS 8006: 1994. The types

of foundation for the reinforced structures shall be design based on the
subsoil profile and geotechnical properties of the subsoil at each location.
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( Typical foundations are driven piles and micro piles.

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Load or bearing tests can also be carried out to assess the foundation
capacity.
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1.7 Intrumentation
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The Contractor shall also be responsible to provide ground monitoring

instrumentation during construction such as piezometer, settlement markers
and plates and inclinometers etc. in order to facilitate the monitoring
reporting phase of any ground improvement methods / slope stabilization
method:
- 4-
APPENDIX AS
REV. 112022
i. To provide sufficient quantities of instrumentations and equipments

required.
ii. To provide planning and monitoring instrumentation schedule.
iii. To analysis and interpret instrument data
iv. To review the design in case monitoring result show noncompliance
assumptions made during design stage.
1.8 Foundation
The selection of suitable foundation types shall be chosen to suit the actual
conditions with regard to the type of structures to be constructed. All timber
piles and bakau piles shall not be used in any foundation works in line with
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government's environmental pol icy.
Piles with size less than 200mm shall not be used for foundation .
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All foundation shall be designed to provide sufficient factor of safety to
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( support the design loads as described in Geotechnical Design Criteria shown
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in Table 1.
Pile selection and installation method shall take into consideration the
environmental constraints such as effecting to adjacent structures, build up
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areas etc .
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Reinforced Concrete Piles must be in accordance to JKR Standard

Specifications or equivalents. Commercial grade piles i.e MS1314: 2004 Class
S shall not be used.
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Prestressed Spun Concrete Piles used must be in accordance with JKR

EN
Standard Specification or MS 1314:2004 Part 4 or equivalent. Minimum Grade

80 Class B shall be used except for marine environment: Class C shall be used .
1.9 Effect of Earthquake

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The Contractor shall carry out sufficient ground investigations and / or
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geological studies to determine the seismic action in areas that areas that
are prone to earthquakes in order to incorporate the seismic factor into
design.
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The Contractor shall carry out assessment of potential liquefaction or

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densification hazard of the site and take into consideration in their design,
the effect of liquefaction or densification that may lead to risk of ground
rupture, slope instability and permanent settlement in the event of an
earthquake.
The Contractor shall ensure that the foundation elements and any earth
retaining structure elements provided have sufficient stiffness, stability and
strength to resist the effects resulting
-5-
A PPENDIX A8
REV. 1/ 2022
1.10 Design Consideration in Aggressive Subsurface Environments
Consideration shall be given to the possible deterioration of all geotechnical

elements including pile over its design life due to the surrounding
environment where corrosion, chemical attack, abrasion , and other factors
can adversely affect the durability after installation, fill materials, and
groundwater properties is necessary to completely categorize an aggressive
subsurface condition .
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1.11 Typical Geotechnical Design Criteria
Typical geotechnical design criteria to be complied with are shown in Table

1•
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1.12 Detailed Design Report. Bill of Quantity. Drawings and Specifications
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The Con tractor shall carry out and prepare detailed analysis, design,
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drawi ngs and specifications following the approval of the preliminary design
by the Govern men t and upon acceptance of his tender. This shall include the
following :
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(Q The detailed design report consists of executive summary, design
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crite ria , area / site geology, description of soil condition with soil
profile , soil parameters, ground treatm en t conce pt, justification and
geotechnical analysis.
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(iJ) Detailed analysis and design of the geotechnical works in accordance

with Geotechnical Design Requirement.
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(iii) Monitoring of geotechnical works and Instrumentations .

(rv) Proposed sufficient numbers of test on pile for the verification of pile
capacity and integrity.
(v) Geotechnical drawin gs showing the location and result of soil
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( investigation in layou t plans.

(vi) Geotechnical drawings for the geotechnical treatments and
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instrumentation shall be included showing details as location , type,

size, length , dimensions and other requirement in layout plan and
specifications.
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(vii) Bill of Quantities and Taking Off for the e xecution of the geotechnical
works.
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(viii) Curriculum Vitae of the geotechnical designer and checker.
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TABLE I i TYPICAL GEOTECH N ICAL DESIGN CRITERIA
"""
DESIGN LI FE
MINIMUM f .O.5/SmLEMENT
N, DESIGN COMPONENT DESIGN CRITERIA (Durability of REMARK
(mm)
1.1 Local & Global Stability 1.3
M" "I:" I) 90% of pri mary consolidation shall be achieved during construction unless otherwise agreed by JKR.
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Unreinforced
1.2 Bearing (Fill) 2.0
Not on soft II) Fo r Item 1.10 & 1. 11
Ground 1.3 local & Globa l Stability 1.5 Structure Zone IS defined as a length not less than 30m within the approach to.my
ReinfOf"ced
1.' Bearins (Fill) 2.0 structure (bridges, culverts, non·floating piled embankment, elc).
1.5 local & Global Stability (Shon term) 1.3 Immedia te settlement aft er strlJoCture should be allowed up to maximum lSmm.
,, ,,
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1.6 Local & Global Stability (long Term) 1.5
1.7 Bearing (Short term) 1.4
,, ,,
SETTLEMENT(mm) 75 YeOirs ,,, ...
, ,,"""
,,,
1 Embilnkment
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STRlJCTURE ztH: I STRl.Cl\,I!EZO!'£
I<PLB(Rl&R2) BUILDING PROJECT
SIROCTlIIE I
PROJECT
Soft Ground
.'Ii -.... --.~ ···-··-···--t~::-·;;.::::-~:·: ;.-

< 10% o f pnmilry conso lidation or
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1.8 5 Yeus Post Construction Settlement <350
maxlOOmm
1.9 ITotal post const ruction settlement <2 5(1
if
DIFFERENTIAL SETILEMENT RAno
1.10 With in the structure zone 1:300
I 1:500
,, ,
l.11 Away Structure Zone 1:300
I 1:300 ,
I) Ana lySIS sh all always con sider tl(lnsientcondi t ion.
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Unreinforced / Natural Slope 2.1 LOCi l & Globil Stability 1.3
II) For Item 2 2, prOject With a complete geological data se t & 10 years rainlall data, minimum F.O.Slor
2 Cut Slope 75 Years
reinforced cut slo pe can be cons idered as 1.4.
Reinforced 22 Local & Global Stability 1.5
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H " ", ,,"n
Periodic Insl!ection
3.1 Tensile Resistence 2.0
I) Monllonn g and malO ten an ce shall be conducted once a years lor the first 3 years after i nst allation. After
3 yea rs, It shall be conducted In ellery 3 -5years.
3.2 Resistance at soil grout 3.0 II) For extremely ImpOrl ant i nchon ind old type of anchOfS, inspection shalt be conducted every lZmonths.
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3 Anchors /Soil Nail 75 Yeilrs
Intel:rit'llnvest iga tion
I) Shall be conducted once wl\hin 5 years ofinstallalion.
3.3 Interfice creep/ cOfrosi on 3.0 11) For e ~tremely Important inchors, it sh all be conducted once in every 2-3years.
Inspe£tlon & Mainte nance Minuill lor Ground Anchors (English Version), June 2015
, Rigid Retaining St ructures

4.1
4.2
Overturnins
Sliding
EN 2.0
1.6
75 YeOirs
i) Hong Kong Geogulde 1 upda t ed e-version, June 2020
,.•
'.3 Overall Stability 1.5 II) as EN 1997· 1-2004, Eurocode7
Bearing 2.0
5.1 Internil Jstabi lity BS8006 I) BS8006
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5 Mechanically Stabilized Earth 120 Years n) BS EN 1997: 1-2004, Eurocode 7
5.2 ExternOiI Stability B58006 / as For 4. 1,4.2,4.3 & 4.4
Allowable settlem ent :
I) 12.501m along alliS of pile head at design load.
6.1 Shaft Resistance 2.0
III 3Bmm or 10% pde Slle at pile head at twice design load whichever is the lowervalue.
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Indivi dual Foundiltion Piles (ma i nly under axial 1111 ReSi dual settlement not exceed (diameter 01 pile or diagonal width lor non-circlar pile /120)+4
6 75 Veirs •
load) )m m OR 12.5mm whi chever is the lo wer value.
6.2 Base Resistance 3.0 IY) For pile >30m maximum allowable settlement (i ) & (ii) above Cin be increased by 2.2%forevery meter
length of pile be yond 30me te r
Allowable senlement· M all. permi ssible Iiltera l mo vem ent ·
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Individual Foundation Piles (ma i nly under 100terai As 6 above for mdlvldual l%of pile diameter or ISmm perpendiculilr to a~ isof pile at design load
7 7.1 Ultimate lateral Resi stan ce 2.5 75Yeilrs'
&bending loads perpendiculu to alli s pile) foundation plies (ma inly under whichever is higher. (Japanese Specification of Highway Bridges)
."
Differential settlement be tween adjilcent group of pile < I :S00
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8 Pile Group 8.1 Block Beiring Capa ci ty 2.0 75 Yeitn ·

:BJerru m l. 1963. Allo wable settlement of structures)
Max. I!ermissible lal eral mo ve ment:
• Pile as retaining structure or guide pile '.1 As lor 4.3, 6 & 7 above As for 4.3, 6 & 7 above 7S Years '
1% of retitln height (Geoguide 1 2020)
·DeI. " life for pile foundotion for bJld,,, Ihill be 120yean
Reference.:
I. GeolechniCJI Manual For '>lape5econd Edilion Fiflh rep lin!, Jan 2011 6. >a panese Speclfic. uon of H.h .... l1 ~ 8rr d.tl
2 Hang Konl GeospK I SKond [dillon fim rep"nl, Jlln 1997 7 IIJeffum. t. . 1961.Allowab le >eUl"".nl 01 ' '' uetu re, Proceed,,,. of £u,o~ un Conf. , en,. on S",I Mechanics and Found. lion [n . ,neering.
J Hon, Kanl Geotulde 1 updated ...-.nion , June 2020 W,e.boden, Germ any. 1. 1 3~U 1
, . 8S EN 1997: 1·2004, [urocode1
5. 8S 1006
KERAJAAN MALAYSIA
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TERMS OF REFERENCE FOR
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INDEPENDENT GEOTECHNICAL CHECKER
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(REVISION 112022)
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CAWANGAN KEJURUTERAAN GEOTEKNIK
IBU PEJABAT JKR
I -
APPENDIX AS
REV. 112022
1.1 TERMS OF REFERENCE FOR INDEPENDENT GEOTECHNICAL CHECKER
1.2 Introduction
In general, the Independent Geotechnical Checker (referred to as IGC herein after) will
check on technical suitability and reliability of the consultant's design system with
particular reference to cost effectiveness, constructability and compliance to
acceptable code of practices and standards as well as fully comply with JKR's Need
Statement for the projects.
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2.1 ThelGC
All geotechnical designs shall be independently checked by IGC. The IGC is t o be
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appointed by the Contractors and the prior appointment is subjected to the approval of
the P.D. The IGC shall have working experience in the geotechnical design work at
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( least: -
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i) PHD 10 years; OR
ii) Master 15 years; OR

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iii) Bachelor 20 years; OR
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iv) Published technical papers in their specialized fields of not less than 20 papers
in International Conference .
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2.2 Scope of Services

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The IGC shall check on the adequacy of the consultant's design on all geotechnical
engineering works with particulars reference to the technical adequacy, cost
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( effectiveness, constructability, short term and long term safety including that of the
adjacent properties, serviceability, and compliance to the relevant legislation,
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acceptable codes of practice , standards and guidelines. It should also include

independent interpretations and calculations for critical elements of the projects. The
tasks IGC shall include, but not limited to the following:
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a. Check the site mapping and topography, geomorphology of the site and adjacent
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areas.
b. Check the geological implication on the design .
c. Check on the adequacy of the subsurface investigation (5.1.) and laboratory tests
carried out for the proposed development.
d. Check the interpretation of subsurface investigation (5.1) and subsoil profiles and
layering.
-2-
APPENDIX AS
REV. 112022
e. Check on all the assumptions, interpreted and selected design soil/rock

parameters and groundwater conditions.
f. Check on geotechnical analyses and designs of the slopes:
i. Slope terrain classification
ii. Zoning of the slopes at the site and adjacent sites (if there is an influence on
the site) into different class in accordance to DOE requirements.
iii. Slope stability analyses of existing, natural and engineered cut & fill slopes.
Various failure modes shall be checked including relevant surcharge loads
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and etc .
iv. Exposed rock slopes should include detailed rock mapping and kinema tics
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analysis.
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( v. Detailed analyses and design of strengthening works for soil and rock slopes
with regular maintenance (e.g. soil nails, rock bolt, dowel , etc.
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vi. Effect of surface and ground wa ter and the provision of adequate drainage
measures .
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vii. Effect to the adjacent properties if the proposed works have influence on
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the safety and serviceability of the adjacent properties (e .g. dewatering,

exaction , rock blasting, etc . ) Check on the proposed mit igating measures .
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g. Check on the geotechnical analyses and designs of the foundations :
i) Suitability of the t ypes of foundations systems proposed .

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ii) Detailed analyses and designs of the foundation including bearing capacity
and deformation predictions .
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( iii) Proposed testing programme.

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h. Check on the geotechnical analyses and design of retaining Walls:
i) Suitability of the type of retaining walls systems proposed.

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ii) Detailed analyses and designs of the retaining walls including internal and
external stability of the wall.
iii) Deformation predictions and its influence to the surrounding structures,

services and slopes.
i. Check and verify all taking off and quantity calculation as per BQ for the item
related to the geotechnical works.
j. Check on Specifications for all the geotechnical works.
-3-
APPENDIX A8
REV. 112022
k. Check on the construction control measures to be implemented at site (e.g.

monitoring scheme, turfing, etc)
l. Check on the adequacy of the superV1Slon programme proposed by the

Consultant for works such as subsurface investigations (5.1), earthworks and al
geotechnical works.
m. Check on long·term maintenance programme of the slopes and retaining walls

(such as the maintenance of slopes permanent ground anchors, drainage and
weep holes).
n. Check on the adequacy on instrumentation and monitoring program and
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emergency response time .
o. Check on constructions method in relation to the design assumptions and
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approaches.
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( p. Check the design risks , factor of safety and unsatisfying measures.
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2.3 Reporting Of The Independent Check
The IGC's report shall be submitted in writing to JKR within 2 weeks of the
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Independent Check being done or otherwise as agreed in writing.
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The report should specifically describe the deficiencies, potential or real , which have
been identified along with the relevant refere nces to accepted stand ards, practices,
design principles and requirement to the JKR needs statement and design criteria. The
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point should be illustrated wherever practicable by marking-up the plans or with

sketches, drawings and such related materials . The report may include the checkers
suggestion , amendments, alternative solutions and designs for amendments and or
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alternative solutions.
The IGC should provide Independent Geotec hnical Design Review Report and the report
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( should include but not limited to the following information :

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(a) Site history
(b) Geology which includes general geology, structural geology

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(discontinuities) 8: hydrogeology
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(c) Subsurface investigation (5.1.) results and subsoil profile plotted in cross-sections
for different area of the sites. They are to be superimposed on proposed roads
network, and platforms.
(d) Slope terrain classification with zoning of the slopes at the site and adjacent
areas (if there is an influence on the site) into different class in accordance with
DOE requirements.
(e) Design soil parameters (shall be plotted in figures together with selected values
where relevant) and may include :
-4-
APPENDIX A8
REV. 112022
i) Basic soil properties, e.g., unit weight, soil classifications and etc.
ii) Chemical properties of subsoil and its effect to the foundation and structures
iii) Consolidation parameters include OCR profile, compression and

recompression indices, drainage path , coefficient of consolidation (C y and Ch)
of subsoil and etc.
iv) Shear strength parameters include effective (c and 0) and total stress
strength (Su).
v) Groundwater level / regime and prediction after excavation or filling of
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slopes.
vi ) Stiffness of soil (for prediction of def ormation of the wa lls and piles )
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(f) Slope stability analyses of existing, natural and engineered cut & fill slopes.
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( Various failure modes (both circular and non-circular or wedge ) shall be chec ked
including relevant surcharge , loads and forces.
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(g) Analyses & designs of retaining works including the options considered and the
various stability checks such as global, external & internal stabilities .
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(h) Settlement analyses including assessments of total and differential set tlements
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of the proposed fill , and ot her buildings imposed loads.
(i) For exposed rock slopes, detailed rock mapping and kinematics analyses shall be
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carried out.
(j) Analyses and designs of slope strengthening and stabilization ifused.

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(k) Ground treatment measures including its analyses and designs as well as
summaries. This should include design of temporary surcharge if required .
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( (I) Foundation designs for walls, structures, bridges and culverts should include the
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following calculations and designs (both piers and abutments) , where applicable:
i) Assessment of bearing capacity of piles (both single and group)

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ii) Prediction of settlements

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iii) Assessment of negative skin friction on piles and prediction of down drag.
iv) Pile group analyses shall include checking on combined bending moment and
axial load on piles.
v) Detailing of pile head to pile cap for the assumption of free head or fixed
head analyses.
(m) Analyses on the influence of the proposed development on the safety and
serviceability of the adjacent properties and services including movements and
-5-
APPEND IX A8
REV. ' 12022
induced structural forces (e.g. dewatering, excavation, rock blasting, etc.). If

there are potential impacts, mitigation measures shall be proposed.
(n) Analyses Ei: Designs of both the surface Ei: subsurface drainage.
(0) Design/construction drawings related to drainage Ei: geotechnical works .
(p) Construction sequence for the geotechnical works.
(q) Specifications for all geotechnical works including construction control

measures . Recommendations on instrumentations monitoring and validation
tests.
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(r) Propose supervision programme including organization chart, number of fulltime
supervising staff, supervising staff' s qualif ications and experiences .
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(s) Long -term maintenance programme for the slopes, retaining walls and etc.
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( (t ) Engineering software used for the analyses and design.
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TABLE 1 ; TYPICAL GEOTECHNICAL DESIGN CR ITERIA
DESIGN UfE
MINIMUM F.O.SI SffiUMENT
No DESIGN COMPONENT DESIGN CRITERIA
(mml
(Dura bility of REMARK
M. ",.11
1.1 Local & Global Stabl1ity 1.3 ,) 90% of pnmil!"'f consolidation shall be achieved during construction unless otherwise agreed by JKR.
ER
Unreinfarced
Not on soft 1.2 Bearing (FiliI 2.0
10) For item 1. 10&1. 11
Ground 1.3 local & Global Stability I .' Structure Zone IS defined ilS.iiI length not less than 30m within the approach tcallY
Reinforced
1.4 Bearing IFill) 2.0 structure (bndges, culverts, non-floating piled embankment,e IC).
I.' local & Global Stabili ty (Short term) 1.3 Immed,il te settlement after structu re should be allowed up to mnimum lSmm.
I.' ,, ,
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,,,
1.6 local & Global Stability (long Term)
1.7 Bearing (Short term) 1.4 ,,
SffilEM ENTlmm) ,, , ,..,-
Embankment 75 Years
, ,,
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1 I STRUCT\JtE lOtE
KPl8(RI&R2) 8UILDING PROJECT ST'''':ME ZOI£
STRlCTlRE I,
- f·: · · · · · : :
PROJECT
Soft Ground
< HI% of primary consolidation or
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1.8 5 Years Post Construction Settlement <350
maK lOOmm
.~- ------- : .:
------_+-_.-:----2.....-· ~o
I:
1.9 Total post construction settlement <250 .11 [
DIFFERENTIAL SmlEMENT RATIO ! --.~-.--- .. -(
1.10 Wi thin the strUClUre zone 1:300 I 1:500
1.11 Away Structure Zone 1:300
I 1:300 ,' "
I) AnalYSIS shal! always conSider tranSient condition.
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Unreinforced / Natural Slope 2.1 local & Global Stability 1.3
II) For Item Z.2, project With a com plete geological data set & lOyears rainfal! da t a, minimum F.O.Slor
2 Cut Slope 75 Years
".
reinforced cut slope can be conS idered as 1.4.
Reinforced 2.2 local & Global Stability 1.5
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P~( lodi c insgection
3.1 Tensile Resistence 2.0
I) Monltonng and main tenance shall be conducted once a years for the first 3 years after i nstallil tion. After
3 yeilrs, It shall be conducted in every 3 -5y ears.
II) For eKtremely Importiln t ilnchors and old type 01 anchors, inspection shall be conducted every 12months.
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Anchors / Soil Nail
3.2 Res istance at soil grout 3.0 75 Years
3
I ntegri t ~
Investisatio n
I) Shall be condlJCted once w it hin 5 yeus of installation.
3.3 Interface creep/ corrosion 3.0 II ) For eKlfemely Important anchors, it shall be conducted once in every 2-3years.
Inspeclton & M aintenance Manual lor Ground Anchors (En,lish Version). June 2015
4.1
4.2
Overturnin,
Sliding
EN 2.0
I.' i) Hong Kong Geogulde 1 updated e-verSlon, June 20 20

4 Rigid Ret aining Structures
4.3
4.4
Overall Stability
Searing
I.'
20
7S Years
ii) SS EN 1997· 1-2004, Eurocode7
, 5. 1 Intemill stability 858006 ,) BS8006

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Mechanically Stabilized E,lfth 120 Yeilrs ,;)B5 EN 1997: 1-2004, Eurocode 7
'.2 External Stilbility 858006/ as FOl"" 4. 1,4.2.4.3 & 4.4
Al lowabl e settlement:
i ) 125mm along aKlS 01 plie head at designioad.
6.1 Shaft Resistance 2.0
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11138mm or 10% pile size at pile head at twice design IOild wh ichever is th el owervalue.
Individu~1 Foundation Piles (mil inly under aKial III) ReSidua l settlement not eKceed (diameter of pile or diagonal wid l h for non-circ1ar pile /120)+4
6 7S Years·
load) lmm OR 12 .5mm w hichever is the lower value.
6.2 Base Resistance 3.0 IV) For pile >30m ma~lmum allowable se tt lement (il & (ii) above can be increased by 2.2% for every meter
length of pile beyond 30meter
Allowable settlem ent: Max. permissible lateral movement :
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Individual Foundation Piles (mainly under la t eral As 6 above for IndiVidual 1%01 pile diameter o r 15mm perpendicular to ilK;S 01 pile at design load
7 7.1 Ultimilte Lilteral Resistance 2.' 75 Years '
&bendin8loads perpendicular to aKis pile) f oundallon piles (mamly under w hichever is higher. (Japanese Specifica t ion of HighwilY Bridges)
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Di fferential settlement between adjilcent group of pile < 1;500

8 Pile Group 8.1 Block Bearing Capacity 2.0 7S Yeirs •
B errum L 1963. Allo wa ble settlemen t of st ructures
MaK. Qermissible laleral m ovem ent:
9 Pile as ret~jning structure or guide pile 9.1 A5 f~4.3, 6 & 7 above A5 for 4.3, 6 & 7 above 75 Years •
1% 01 retalll hel ht Gee Ulde 12020
°De'II n IiI, 10' pUt I""ndltion lot btidle shIll be t2D ~u ..

Reler.nc• • :
I G...,technlnl Mlnull For Slope Second Edition fi lt h 'tprinl. Jln 2011 6. Jopln e.e Sp"" fie'lIon 01Hllhw l V8""11.
1 Honi Konl GtO<Pec 1 Second Edition Jirlt 'ep,in t, JLln 1'.197 1 . 8j.",um , L . 1963. A~ow.ble .tllitone ni 01.\!uel,,'h Proceed,nl oJ[",o pun Con ftren ct on Soil Mechanics Ind Found.lion Engintt ,in l-
3 Honl koni GtOlu,de I upd.ted e· ve'llon. June 2020 Wltsb.den. G" many, 1, 135- 13 7
4. BS EN 1997: 1·2004. [",oeode1
S. 8S 8006
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AppendixA9
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(Terms of Reference for RSA)
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TERMS OF REFERENCE
FOR
ROAD SAFETY AUDIT
1.0 Objectives of Road Safety Audit
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The objective of Road Safety Auditing is to identify road safety
deficiencies at various stages in the development of road
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projects / network so that they can be eliminated or mitigated at
the most opportune time to reduce costs and minimize disruption
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to planning, design , construction and operation , and ultimately to
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enhance the safety of the road environment.
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2.0 Scope of Work
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Road Safety Aud it shall be carried out in accordance with the

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Guideline For The Safety Audit Or Roads And Road Projects In

Malaysia prepared by JKR and shall include audits at the following
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stages of the project:
Stage 1 Audit - Planning and Feasibility Stage of the

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(. Project Development.
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The Stage 1 Audit will be carried out during the Planning

phase, where a number of alternative proposals are being
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considered for the project. Audit is to be made of each

alternative, the results of which (to the extent relevant)
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should be included in the evaluation process .
TOR Oktober 2006 (Pindaan Mei 2018)

Stage 2 Audit - Preliminary Design Stage
The Stage 2 Audit will be carried out at the end of the

preliminary design phase where the Functional Layout has
been prepared and land acquisition requirements are being
determined.
Stage 3 Audit - Detailed Design Stage
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This audit must be done at an appropriate stage towards
the end (but not at the end) of the detailed deSign , or as
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soon as it is possible to determine the safety implications
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of the design and when changes can be made at the most
( opportune time to avoid costly redesign . This may
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necessitate separate audit checks as various elements of
the project reach the desired stage of design .
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The audit work at this stage includes auditing the
suitability and workability of the proposed traffic
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management that will be carried out during the

construction . The Guidelines on the Estimation Procedures
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for Traffic Management prepared by JKR will be used as a

basis for the traffic management procedures.
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Stage 4 Audit - At the Construction/Pre-Opening

Stage
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Road Safety Audit Stage 4 shall include two distinct aspects

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as follows:
Audit of the compliance of the works to the Stage 3

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Audit ( Detail Design ) to ensure that the decisions of

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JKR with regards to the Stage 3 Audit are 'carried

through' in the construction. In particular the audit
TOR Oktober 2006 (Pindaan Mei 2018) 2

shall include a final detailed check of the project just
prior to it being 'opened to traffic ' .
Audit of Traffic Management through and in the vicinity

of the project during the construction phase .
This includes the observation of the effectiveness of
the Traffic Management Plans (TMPs) prepared by
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the contractor / consultant and the devices employed
during the night. The scope of work shall include:
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i) Auditing the TMPs during the Design Phase
(
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ii) Auditing the changes to the TMPs and Work Zones
during the Construction Phase. This is to be
carried out at every Stage 4 audit and additional
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every three (3) months or as required by the
Supervision Officer. The audit shall be carried out
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based on the latest Traffic Management Safety

Reports prepared by the Traffic Management
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Officer from the contractor's counterpart.

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The audit at this stage will be carried out three (3) times
during the construction duration:
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• RSA Stage 4 (Part 1) or Verification Audit to be

carried out after the issuance construction and
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traffic management drawings.

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TOR Oktober 2006 (Pindaa n Mei 2018) 3

• RSA Stage 4 (Part 2) to be carried out when the
construction work's progress is about 50%.
• RSA Stage 4 (Part 3) to be carried out during the

pre-opening of the project. Both day and night audit
will be required
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Should the Supervision Officer requires additional audit, he
shall ask the Road Safety Auditor to carry out the additional
audit and the additional fees shall be agreed upon by the
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Supervision Officer and the Road Safety Auditor.
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Stage 5 Audit - Operational Stage
There are two types of Stage 5 audit:

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i) On new road projects
ii) On existing road
EJ
The audit at this stage is to ensure that the roads are safe
M
for public use.
The Stage 5 audit for new projects shall be carried out

EN
within three (3) to six (6) months after the opening of the
project to the public.
M
(,
The project development shall not proceed into the next stage of
KU
audit before resolution of each of the road safety items identified

from the previous audit.
O
D
JKR reserved the right to commence the audit at the appropriate

stages in the development of the road projects.
TOR Oktober 2006 (Pindaan Mel 2018) 4

3.0 Use of Road Safety Audit Check Lists
The Road Safety Audit Guidelines issued by JKR detailed 'Check

Lists' for each of the above stages of Audit. These Check Lists
should be used as a guide and •reminder' of the items to be
considered and it needs to be recognised that they do not
necessarily provide a complete list of the issues or pOints to be
ER
checked. It is the auditor's responsibility to critically examine all
aspects of the project which may have adverse safety
implications, considering carefully the need of all road user
D
groups.
N
(
TE
4.0 Management of Road Safety Audit
The process flowchart in Appendix 1, 2, 3, 4, 5, 6 and 7 shall be

used as a guide in the management of road safety audit.
A
EJ
5.0 Road Safety Auditors

M
5. 1 Roles of Auditor
EN
The principal role of the Auditor is to ensure that safety

deficiencies/problems/hazard are identified before they are
locked into the design and / or become a safety problem. The
M
Auditor is expected to highlight all the safety deficiencies in a

( design/existing road.
KU
The Auditor will look into:

O
a. Adoption of appropriate standards

b. Compliance and non-compliance of standards that will have
D
road safety implications
TOR Oktober 2006 (Pindaan Me; 2018) 5

The Auditor's primary role is to look into the safety repercussion
of compliance to standard or otherwise and highlight the possible
consequences wherever possible of major road safety
deficiencies. The Auditor is expected to use his/her experience
and wisdom in dealing with the design checkers in these
overlapped areas.
The following flowchart indicates the position of the Auditor in
ER
relationship with other parties:
D
Flowchart
N
(
TE
Designer I
Design Checker
t
A
.. Submit Plan
EJ
To redesign
Road Safety
if req uired
Auditor
M
EN
Road Authority
(JKR MALAYSIA)
M
(
KU
5.2 Independence of Auditors
The auditors must be independent of project planners, designers

O
and construction companies involved in the project and have no

D
business or other company associations with them.
TOR Okto ber 2006 ( Pindaan Mei 2018) 6

6.0 Qualification of Road Safety Auditor
A qualified Road Safety Auditor shall be an engineer that have a

good understanding of the Driver/Vehicle/Road Environment
interaction and have experience in accident investigation and
countermeasures. The auditor shall also fulfill the following
requirements:
ER
a) Minimum ten (10) years working experience as Civil Engineer or
eight (8) years working experience as Civil Engineer with
Masters' Degree qualification in road engineering areas or six
D
(6) years working experience as Civil Engineer with Doctorate
N
qualification in road engineering areas; and
(
TE
b) Minimum of six (6) years experience in roads area that is
minimum three (3) years experience in road design and
minimum three (3) years experience in road safety; and
A
c) Is a professional engineer registered with the Board of
EJ
Engineers Malaysia for a minimum of two (2) years .

M
d) Attended and obtained a certificate in Road Safety Audit

course from Stage 1 to Stage 5 that is recognized by JKR
Malaysia.
EN
Notwithstanding the above, the auditor needs to be accredited

with JKR Malaysia and any other requirements stipulated in the
M
( agreement.
KU
7.0 Reporting of the Road Safety Audit

O
Each stage of the Road Safety Audit shall be reported, in writing,

D
generally as set out in the JKR Guidelines and shall be submitted

to the Client within 2 weeks of the audit being done or otherwise
as agreed in writing.

The report should specifically describe the safety deficiencies,
potential or real, which have been identified along with the
relevant references to accepted standards, practices and road
safety principles. The points should be illustrated wherever
practicable by 'marking-up' on the plans or other relevant
drawings and / or by colour photographs of the items concerned .
ER
The report may include the auditors' suggestions for eliminating
or otherwise treating the safety problem identified, but this is not
an essential requirement.
D
N
( The report should not be simply a copy of the 'Check List'
TE
annotated with 'ticks' or 'crosses' or 'yes' / 'no' answers, or in
any other way submitted as the Safety Audit Report.
A
A summary of audit of the audited items shall be prepared by the
EJ
Auditor together with the audit report.

M
8.0 Handli ng of Road Safety Audit Report

EN
8.1 Response Report
A Response Report will be prepared by designer before any

M
completion meeting at any stage of audit. This report is based on

the Summary of Audit by the Road Safety Auditor. A Response
KU
Report is a document that allows the designer to respond the

Road Safety Auditor's comments or recommendations.
O
D
TOR Oktober 2006 (Pindaan Mei 20 18) 8

8.2 Completion Meeting
Within 2 weeks of receipt of the Road Safety Audit Report in every

stage, JKR / Client shall conduct a completion meeting. In this
meeting, the findings are presented by the Road Safety Auditor
and discussed. Decisions on actions are to be agreed upon and
ER
formally documented.
8.3 Compliance Report
D
N
A compliance report will then be prepared by the designer based
( on the Summary of Audit f rom the Stage 3 Road Safety Audit
TE
Report. The Compliance Report is a document indicating
designer's declaration that matters agreed upon in the Road
Safety Audit Stage 3 completion meeting has been incorporated in
A
the revised detailed design engineering drawings.
EJ
8.4 Compliance Audit

M
Compliance Audit needs to be carried out by the Road Safety

Auditor after receiving the Compliance Report from the designer.
This audit produces the Compliance Audit Report which confirms
EN
all matters agreed upon in the Road Safety Audit Stage 3

completion meeting has been incorporated by the designer in
their detailed design engineering drawings .
M
8.5 Verification Audit

KU
A Verification Audit (Road Safety Audit Stage 4 Part 1) is to be

carried out by the Road Safety Auditor to ensure that all decisions
O
during design stage are implemented in the construction drawings.

D
This audit produces the Verification Audit Report which verifies all
matters agreed upon in the completion meeting of the previous
Audits have been incorporated in the construction drawings.

RSA STAGE 1 PROCESS
APPENDIX 1
COMMENCEMENT MEETING (')

- Called & chaired by HOPT/PD/SO
- Discuss scope of audit and schedule
CONCEPTUAL DESIGN
- Prepared by designer
- Designer subm it Conceptual Drawing and
other relevant infonnation to Road Safety
Auditor. Extend copy to JKR
ER
D
ROAD SAFETY AUDIT
~_ _ _ _ _ _ _ _~ • Road Safety Auditor prepare RSA Stage 1 1- - - - - - - - - - - ,
N
report
( - Submit Report to HOPTIPD/SO &
Designer
TE
RESPONSE REPORT
- Designer prepare response report
Refinement and submit to Road Safety Auditor.
Required Extend copy to HOPT/PD/SO
A
ASSESSMENT OF AUDITOR'S
REPORT
EJ
- BAPKJ assess auditor's report
Refinement Not Required

M
EN
RSASTAGE 1
COMPLETION MEETING
- Called & chaired by HOPT/PO/SO
-Road Safety Auditor to present finding s
- Designer present response
M
'-
- Decisions are made & minut
KU
Design Concept Not Acceptable I Partially Acceptable
Notes:
Design Concept
O
i) HOPT - Bahagian Pengurusan Projek REVIEW DESIGN CONCEPT Acceptable

(Cawanga n Jalan) • Designer make amendments based on
decision of RSA meeting
D
Ii) P.D - Project Director
iii) S.O - Superintending Officer
Iv) BAPKJ - Bahagian Audit & Program

Keselamatan Ja lan (Cawangan Jalan)
PRELIMINARY DESIGN
. Prepare by designer
v) (*)Commencement meeting can be
cond ucted at other stages (if necessary)
vi) A ll copies of audit reports to be extended to

BAPKJ for monitoring and record purposes
Next stage of audit
RSA STAGE 2 PROCESS
APPENDIX 2
COMMENCEMENT MEETING (*J

- Called & chaired by HOPT IPO/SO
PRELIMINARY DESIGN
- Designer submit Preliminary Design and
other relevant information to Road Safety
Aud itor. Extend copy to JKR
ER
D
ROAD SAFETY AUDIT
_ _ _ _ _ _ _.~ - Road Safety Auditor prepare RSA Stage 2 1-- - - -- - - - - - - ,
N
report
( - Submit Report to HOPTIPD/SQ &
Designer
TE
RESPONSE REPORT
Refinement - Designer prepare response report
and submit to Road Safety Auditor.
Required Extend copy to HOPT IPO/SO
A
ASSESSMENT OF AUDITOR'S
EJ
REPORT
- BAPKJ assess auditor's report
M

EN
RSASTAGE2
COMPLETION MEETING
-Road Safety Auditor to present findings
M
- Desig ner present response

- Decisions are made & minuted
KU
Preliminary Design Not Acceptable I Partially Acceptable
Notes:
REVIEW PRELIMINARY DESIGN Preliminary
O
i) HOPT - Bahagian Pengurusan Projek

(Cawangan Jalan) - Designer make amendments based on Design Acceptable
decision of RSA meeting
D
ii) P.D - Project Director
iii) S.O - Superintend ing Officer
iv) BAPKJ - Sahagian Audit & Program DETAIL DESIGN

Keselamatan Jalan (Cawangan Jalan) - Prepare by designer
v) (")Commencement meeting can be

conducted at other stages (if necessary)
Next sta e of audit
vi) All copies of audit reports to be extended to
!
RSA STAGE 3 PROCESS
- APPENDIX 3
COMMENCEMENT MEETING (*J

-<: - Called & chaired by HOPT IPD/SO =-
I
DETAIL DESIGN
- Designer submit Detail Design and other relevant infonnalion
to Road Safety Auditor. Extend copy to JKR
+
ROAD SAFETY AUDIT
ER
- Road Safety Aud itor prepare RSA Stage 3 report
- Submit Report to HOPT/PO/SO, BAPKJ &
Designer
RESPONSE REPORT
Refinement
D
- Designer prepares response report and submit
Required
- to Road Safety Auditor. Extend copy to HOPTI
POISO
N
( ASSESSMENT OF AUDITOR'S
REPORT
TE
- BAPKJ assess aud itor's report

A
-
EJ
RSA STAGE 3
COMPLETION MEETING
M
- Designer present response

EN
Detail Design Not Acceptable I Partially Acceptable
REVIEW DETAIL DESIGN

- Designer makes amendment based on decision of RSA meeting
M
'-
KU
DESIGNER COMPLIANCE REPORT

Notes:
- Designer prepares compliance report Detail Design
i) HOPT - Sahagia n Pengurusan Projek Acceptable
O
(Cawangan Jalan)
AUDITOR COMPLIANCE AUDIT REPORT

D

• Road Safety Auditor prepares Compliance Audit
iii) S.O - Superintending Officer Report & submit to HOPT/PD/SO
iv) BAPKJ - Sahagian Audit & Program

Keselamatan Jalan (Cawangan Jalan)
..
NEGOTIATION /TENDER PROCESS
(*)Commencement meeting can be . Design & Built - Negotiation
v)
conducted at other stages (if necessary) Conventional· Tender
vi) All copies of audit reports to be extended to

BAPKJ for monitoring and record purposes Next staJe of audit
+
RSA STAGE 4 (PART 1) PROCESS
APPENDIX 4
COMMENCEMENT MEETING (*)

- Called & chaired by SOIPD
CONSTRUCTION & TRAFFIC

MANAGEMENT DRAWING
ER
-s.O I P.D submit drawings to Road Safety
Auditor
D
VERIFICATION AUDIT
STAGE 4 (PART 1)
N
- Road Safety Auditor prepare RSA Stage 4
( (Part 1) report & sent to S.O I P.D and
Contractor. Extend copy to HOPT
TE
RESPONSE REPORT
- Contractor prepare response
- - - ----1 report and submit to Road Safety
Auditor. Extend copy to S .O I P.D
A
and HOPT
EJ
RSA STAGE 4 (PART 1)

COM PLETION MEETING
- Called & chaired by S.O I P.D
M

- Contractor present response
EN
Correcti ve Actio n Required

M
( CORRECTIVE ACTION
KU
- By contractor
No Corrective Act ion
Required
No
O
Notes: WORK APPROVAL (*)

i) S .O - Superintending Officer
D
Ii) P.D - Project Director
iii) HOPT - Sahagian Pengurusan Projek Yes

(Cawangan Jalan)
iv) (*)Supervision Team need to ensure comments I ...

recommendations by Road Safety Auditor is Next Stage Of Audit ..-------~
adhered by contractor
II) All copies of audit reports to be extended to

APPENDIX 5
DIRECTIVE TO DO RSA
STAGE 4 (PART 2)
- S.O I P.D instruct Road Safety A uditor
to do RSA Stage 4 (Part 2)
ROAD SAFETY AUDIT

- Road Safety A udito r prepare RSA Stage 4
(Part 2) report & send to S.O I P.D &
ER
RESPONSE
REPORT
D
- Contractor prepare response
r report and submit to Road

Safety Auditor. Extend copy to
N
S.O I P.D and HOPT
TE
COMPLETION MEETING
- Called & chaired by S.O I P .D
A
-Road Safety A uditor to present findings
EJ
Corrective Action Required

M
EN
CORRECTIVE ACTION
- By Contractor
M
( 1 No
KU
No Corrective Action
Required
O
Notes:
i) S.O - Superi ntend ing Officer
D
iii) HOPT - Sahagian Penguru san Projek

(Cawangan Jalan)
Yes
iv) (·)Supervision Team need to ensu re comments J

recommendations by Road Safety Auditor is
adhered by contractor T
Next Stage Of Audit ,,"- -
v) All copies of aud it reports to be extended to
APPENDIX 6
DIRECTIVE TO DO RSA
STAGE 4 (PART 3)
- S.O I P.D instruct Road Safety Auditor
to do RSA Stage 4 (Part 3)
ROAD SAFETY AUDIT

- Road Safety Auditor prepare RSA Stage 4
(Part 3) report & sent to 5.0 I P.D &
ER
RESPONSE
REPORT
D
101- - - - - - - - - - - - -1 - Contractor prepare response
report and submit to Road
N
8.0 I P.D and HOPT
(
TE
COMPLETION MEETING
- Called & chaired by S.O I P.D
A
EJ

M
EN
CORRECTIVE ACTION
- By Contractor
M
( No No Corrective Act ion

KU
Required
O
Notes:
i) S.O - Superintending Officer
D
iii) HOPT - Sahagian Pengurusan Projek

(Cawangan Jalan) Yes
iv) (*)Supervision Team need to ensure comments I
l' .
Next Stage Of A udit ..---------~
v) All copies of audit reports to be extended to
BAPKJ for monitoring
RSA STAGE 5 PROCESS
APPENDIX 7
DIRECTIVE TO DO RSA
STAGE 5
- S.O I P,D instruct Road Safety Auditor
to do RSA Stage 5 within 3-6 months
from issuance of CPC
ROAD SAFETY AUDIT

- Road Safety Auditor prepare RSA Stage 5 1- - - - - - - - - - - - - - ,
report & sent to HOPT, S.O I P.O, &
ER
Contractor
RESPONSE
REPORT
D
10- - - - - - - -- - - - -1 -Contractor prepare response
report and submit to Road
N
HOPT and S.O I P.D
( /
TE
RSASTAGE5
COMPLETION MEETING
- Called & chaired by HOPT I SO I PO
A
EJ

M
EN
CORRECTIVE ACTION
- By Contractor
M
l . No
No Corrective Action
KU
Required
WORK APPROVAL (*)

O
Notes:
i) S.O - Superintending Officer
D
iii) HOPT - Bahagian Pengu rusan Projek

(Cawangan Jalan)
Yes
iv) (*)Supervision Team need to ensure comments I
v) All copies of audit reports to be extended to PROJECT

BAPKJ for monitoring and record purposes COMPLETION
ER
Appendix AIO
D
N
(
(Available Data Provided)
TE
A
EJ
M
EN
M
<-
KU
O
D
t(
D
O
KU
M
EN
M
EJ
A
NOT APPLICABLE
TE
N
D
ER
ER
D
N
(
Appendix A 11
TE
(Terms of Reference for Topographical
A
Survey Works and Underground Utility
EJ
Survey Works)
M
EN
M
L
KU
O
D
TERM OF REFERENCE
ER
FOR
D
N
TOPOGRAPHICAL
TE
SURVEY WORKS
A
ONPRO]ECT
EJ

M

EN
M
(
KU
O
D
TOR TOPOGRAPHI CAL SURVEY WORKS
CONTENTS
1.0 Background And Objective ......... ..... .. ......... .. ....... .. ... .............. ...... ..... ..... .......... 1
2.0 Scope Of Works .. ... ... ........... .... ................... .... ............. ..... ........... ..... .. ... .......... 1
3.0 Licensed Land Surveyor (LLS) Service Period ........ .. .... ........ .. ............... .......... 1
ER
Services Specifications For Survey Of Road Details .............................. ............... ..... 2
Services Specifications For Topographical Survey Works .................................... ... 22
Services Specifications For Bridge Works ......................... ...... .... .......... ....... ............ 35
D
N
(
TE
APPENDIX
A
Appendix A1 Location Plan for The Works & Road Corridor Survey
EJ
Appendix A2 Ground Markers On Hard Surface
Appendix A3 Ground Markers On Normal Surface

M
Appendix A4 Certified by Licensed Land Surveyor (LLS)

EN
Appendix A5 Schedule of Service Period Licensed Land Surveyor (LLS)

M
(
KU
O
D
TOR TOPOGRAPHICAL SURVEY WORKS
1.0 Background And Objective
The purpose of the detailed ground survey is to provide all the necessary data and information
MEMBINA JALAN
required for undertaking the engineering design review for project
DARI BEHOR MALI KE KAMPUNG KEPALA SEPULOH, PERLIS and also for
the necessary land acquisition and application
2.0 Scope Of Works
2.1 Survey Length/Area
ER
The details of the extent of the works to be surveyed are given in the attached plan of
Appendix A 1.
2.2 Survey Width
D
The proposed road alignment corridor to be fully located and surveyed. The corridor
N
( width is to be appropriately increased where relevant to cover existing road reserves
and also major details like rivers, railway line, lot boundaries, interchange site, new
TE
alignment routes and or as decided by the Government.
The exact location of the alignment of the corridor is subject to changes on Site by the
Government's Representative.
A
EJ
3.0 Licensed Land Surveyor (LLS) Service Period
The determination of the LLS Service Period is based on project implementation schedule
M
which is shown in Appendix AS.
This schedule should be a reference to the LLS to prepare a proposed work execution schedule
EN
in the Technical Proposal (Cadangan Teknika~ .
The Final Account Claim and consultant declaration on the total payment received must be
finalized within 4 months before the end of services .
M
l
KU
O
D
SERVICES SPECIFICATIONS FOR SURVEY OF ROAD DETAILS
1. Basic Professional Land Surveying Services for survey of road details
The Services to be rendered by the LLS in this paragraph include the provis ion of all expert
technica l advice and skills , which are normally required for the Works for which the LLS
has been engaged .
1.1 General
ER
The Serv ices to be provided by the LLS as listed herein and as deta iled in subseq uent
sections : -
D
1.1.1 Prior discussion with relevant authorities such as JKR, PDRM , land office and local
N
( authorities before the physical commencement of work on site .
TE
1.1.2 Study all relevant information and maps provided and obtain add itiona l da ta if
necessary for the proper execution of the works .
A
1.1.3 Consultation with the GR and setting out.
EJ
1.1.4 Setting out of survey alignment.

M
1.1.5 Field survey and picking up of mapping details for subsequent submission of 3
dimensional digital data in DWG (Autocad) format. (Refer to SPECIAL
EN
INSTRUCTIONS to the LLS)
1.1.6 Establishment of Permanent Ground Markers for survey control such as Survey
M
Markers, Bench Marks , and Temporary Bench Marks .

KU
1.1.7 Preparation of land acqu isition base plans in accordance to JKR guidelines as
contained in latest Arahan Teknik Jalan 7185 (Garis Panduan Untuk Penyediaan
Pelan Pengambilan Balik Tanah bagi Projek Jalan Persekutuan) and as specified
O
in Sub-paragraph 1.5.7 below .

D
1.1.8 Preparation of plans in accordance to latest Arahan Teknik (Jalan) No. 6/85
(Guidelines for Presentation of Engineering Drawings) or as specifi ed in the Terms
of Reference .
1.1.9 Compilation, processing and preparation of data in accordance to 3D DWG format

(Autocad).
2
1.1.10 Pegging of centre line for Design Road Alignment and establishment of Permanent
Ground Markers fo r Design Road Alignment Centreline such as IPs, RMs , and
TBMs .
1.1.1 1 Provide services for data verification in the event of any discrepancy in survey data
during construction .
1.1.12 Provide aerial photos of the survey corrid ors .
1.2 Accuracies. Tolerances. Errors and Corrections
ER
Wherever accuracies or lolerances are specified herein, they are defined as Maximum
Errors or statistically based root mean square errors (r.m.s .e.) as follows : -
D
N
1.2.1 Maximum Errors
(
TE
Maximum errors are only used for fieldwork misclosures [sub-paragraphs 1.3.1
and 1.3.2J and plotting of map grids and control points [sub-paragraph 1.4.3J . All
errors exceeding the maximum allowable tolerance including co nsequential errors
A
shall be corrected by Ihe LLS at his own expense.
EJ
1.2.2 Root Mean Square Errors

M
The root mean square errors (r.m.s .e.) are related to checks on representative
dimensions or levels and the following conditions have to be satisfied : -
EN
(a) At least 67% of all readings must be correct to or better than the r.m.s .e.
M
(b) At least 90% of all readings must be correct to or better than 1.65 times the
r.m.s .e.
KU
(c) All readings must be correct to or better than 3 times the r.m.s.e.
O
All readings not complying with the above 3 conditions including consequential
errors shall be corrected by the LLS at his own expense.
D
1.2.3 Method and Location of Corrections
The LLS shall agree with the Government the method , location and extent of the
work to be corrected.
3
1.3 Fieldwork
1.3.1 Grid and Planimetric Control Accuracies
(a) For Peninsular Malaysia , planimetric control shall be ca lculated based on the
relevant State Cassin i-Soldner Grid lines projection as agreed by the
Government. Where necessary, the State origin shall be transform ed into the
equivalent Rectified Skewed Orthomorphic Projection (Malaya) point and all
coordinates sha ll follow the same transforma tion factor.
ER
(b) Azimuths shall be checked by solar observations at appropriate intervals and
the survey traverses shall be tied up to any nearby trigonometrical points or
D
standard traverse points or permanent GPS points or Boundary Mark. The
closing error of the traverse shall be 1:4000 or better.
N
(
TE
(c) The LLS shall determine the grid coordinates of all junctions and intersection
points so marked , and the bearings and distances of all straight sections of
the rou te s relative to the specified grid system .
A
1.3.2 Height Datum and Vertical Accuracies
EJ
All heights supplied by the LLS shall be related to the latest published values of
M
JUP EM Bench Marks at the time of survey .
All Temporary Bench Marks shall be connected by a closed levelling net which
EN
shall be tied to a minimum of two JUPEM Bench Marks unless otherwise agreed
by the Government.
M
'- Vertical misclosures within the levelling net and between JUPEM bench marks
shall not exceed the lesser of the fo llowing: -
KU
(a) ± 16 mm
O
(b) ± (20 -vf<) mm where K is the sum of the distances levelled in

kilometers .
D
JU PEM Bench Marks which exceed these tolerances shall be omitted from the
adjustment. The LLS shall inform the GR and JUPEM whenever the JUPEM Bench
Marks are found to be damaged or in error.
All levelling shall be done in sections of approximately 1 km. in length.
4
1.3.3 Permanent Ground Markers
Permanent Ground Markers shall include the following : -
(a) Intersection Points (IPs )

(b) Reference Marks (RMs)
(c) Survey Markers (SMs)
(d) Temporary Bench Marks (TBMs)
(e) Pegging
(f) Tangent Points (TPs)
ER
The LLS shall construct, coordinate and height of Permanent Ground Markers to
the satisfaction of the Government at the location where points are required to form
D
a reference system for future setting out of the Works at the approximate locations
N
indicated on the Drawings , clear of future construction works and as agreed with
(
the Government.
TE
The types of marker which will be considered acceptable for the appropriate
general ground surface conditions are shown in Appendix A2 and
A
Appendix A3 . Alternative forms of marker submitted by the LLS may however be
EJ
considered .
The Government will indicate on the Drawings the likely types of the Permanent
M
Ground Markers to be installed within the Site . The final locations and types of
markers shall be agreed with the Government before emplacement. All Permanent
EN
Ground Markers shall be clearly and legibly inscribed to distingu ish between IP,
RM, SM , TP and TBM .
M
There shal l be a joint inspection and handling over of all Permanent Ground
l Markers to the GR.
KU
1.3.3.1 Intersection Points

O
The LLS shal l establish Intersection Points along the proposed road alignment and
shall be numbered in accordance to the plan given by the Government.
D
1.3.3.2 Reference Marks
The LLS shall erect at least two (2) RMs for each IP. To ensure accuracy, RMs
sha ll be placed at least 25 m away from the IP. and the base of the triangle which
they fo rm wi th the apex shou ld be at least 15m. apart. Each point of this triangle
shall be visible from the two other points.
5
1.3.3.3 Survey Markers
Whe never required by the Government, the LLS shall erect permanent Survey
Markers at locations indicated in the Drawings or as agreed by the Government.
1.3.3.4 Temporary Bench Marks
The LLS shall establish Temporary Bench Marks at approximately 1 km. intervals
and reference it to the JUPEM Datum . Reduced levels of these temporary bench
marks shall be clearly and legibly inscribed and referenced for identification for the
ER
subsequent construction stage .
1.3.3.5 Pegging
D
The surveyor shall be using suitable type of wood for all pegs . At least 1Ocm of the
N
( peg should be visible above ground level and painted with red colour.
TE
1.3.4 Deliverables
A
The LLS shal l supply two copies of the fo llowing to the Government on completion
EJ
of fieldwork and survey adjustment: -
(a) Schedules of all Permanent Ground Markers (IPs, RMs , SMs , TBMs) giving
M
the reference numbers, coord inates and heights above JUPEM's datum.
EN
(b) Descriptions of Permanent Ground Markers and JUPEM Bench Marks giving
the types of marker constructed and location sketches .
M
(c) Copies of the most recently available JUPEM Triangulation Station

( descriptions for each station used for the Works, giving the reference
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number, coordinates, height above JUPEM's Datum , and description of

position .
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(d) Copies of the most recently available JUPEM Bench Mark lists used for the
Works, indicating Bench Marks used, Bench Marks found to be damaged or
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destroyed and the readjusted heights of any JUPEM Bench Marks found to
be out of tolerance.
(e) Diagrams of the plan control net showi ng the connections between
Permanent Ground Markers and JUPEM Triangulation Stations, and with
loop closures or re siduals .
6
(f) Diagrams of the levelling net indicating the connections between Permanent
Ground Markers, Temporary Bench Marks and JUPEM Bench Marks with
misclosures.
(g) Where applicable , description of the Local or State grid giving the origin ,
scale factor, and parameters used for transformation from the Local Grid to
the National Grid .
The LLS shall supply to the Government immediately after initial completion,
advance copies of the above results in order for the Government to carry out a
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check survey.
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1.3.5 Survey of Watercourses
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( 1.3.5.1 Streams and Rivers
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The LLS shall survey all streams , rivers and watercourses crossing the line of the
routes . These include all watercourses whether there is water or no water flow at
the time of surveying . The survey shall extend to the following minimum distances
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on either side of the route centre lines (distances measured along the channels) ,
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or up to the edge of the Survey corridor, whichever is the greater:
Major Rivers exceeding 10m width 250 m.

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Rivers/Streams between 5 -10m width 150 m.

Watercourse less than 5 m width 50 m.
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The locations of channel edges and other significant features shall be recorded
and levels shall be taken along the bank slopes and channel inverts at intervals of
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not more than 20m or 10m at anticipated sites for bridges and culverts (cross-
section points shall not exceed 5m .).
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Details of existing adjacent bridges shall be recorded as described in Sub-

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paragraph 1.4.7.
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1.3.5.2 Urban Drainage
The LLS shall survey all top and bottom edges and invert levels of urban drains
at intervals not exceeding 10m, showing all significant changes of level and
direction of flow. The type, width and depth of each section of different drainage
system (including sumps) shall be recorded.
7
1.3.5.3 Culverts
All the relevant details of the culvert as described in Sub-paragraph 1.4.8 shall be
recorded .
1.3.5.4 Flood Information
The LLS shall record the maximum flood level at each river crossing. Existing
water surface at suitable poi nts shall be taken along the channel. Each reading
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shall be taken at intervals not exceeding one hour and the mean , maximum and
minimum of 12 hour readings shal l be recorded .
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In areas where tidal effects are significant, the LLS shall gather al l the necessary
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information as an appendix to the mapping in a form agreed by the Government.
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1.3.6 Details of Junctions and Existing Roads
The LLS shall survey all junctions to enable the designer to design the junction
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properly .
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A corridor width of min m shall be taken for a distance of not less than
metres up and down the proposed intersection of the road as required by
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Government.
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All metalled roads , ma in roads and footpaths or tracks having the width greater
than 2 m shall have a minimum of two (2) points defining both edges of the
carriageways . Consecutive points along the road fea ture shall not exceed 20 m in
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<-, rura l areas and 10m in urban or built-up areas . More points are generally needed
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to define curved features such as slip roads, islands, etc.
Levels of the road centre line shall be record ed for metalled / paved roads having
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widths greater than 6.0 metres. The main destination of the road from the junction
shall be recorded by the LLS .
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1.3.7 Strip Survey
The LLS shall carry out a strip survey contours at 1 meter wi thin 20 metres interval
together with the detail of the strip . The width / area of the strip is as ind ica ted in
the Terms of Referen ce.
The LLS shall carry out all field work necessary to accurate at the specified
interva ls and detailed physical features of the terrain. Sufficient control height
points and spot heights shall be taken to ensure accu ra cy of the contour lines.
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The LLS shall carry out all fiel dwork suitable fo r the digital data requ ired for Autocad
program .
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1.3.8 Setting-out of Survey and Road Alignment
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( 1.3.8.1 Consultation with GR before Setting -out of Survey Alignmen t
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Before setting out. proposals for the detailed survey should be submitted to the
Government before the work is being carried out. The LLS has to consult and
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follow the Government's instructions either verbally on site or in plans on the
locations of all Permanent Ground Markers and other aspects of setting out of the
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Survey Alignment. If instructed by the Government, the LLS shall submit fie ld
survey plans showing the sufficient detai ls as described in Sub-paragraph 1.5.2 so
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as to enable the Government to make the decisions in choosing the best alignment
of the road. The LLS sha ll make any minor adjustment on the setting out of the
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Survey Alig nment when req uested by the Government provided such request is
made before all the plans are submitted.
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1.3.8.2 Setting out of Design Road Alignment

.(
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The LLS has to set out the centre line of the proposed road alignment essentially
in two (2) stages as follows: -
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Stage 1 - Setting out of survey align ment and monumenting of SMs and
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TBMs based initially on drawings supplied as stated in Sub-

paragraph 1.3.3 and modified appropri ately to su it site
conditions and/or as directed by the Government.
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Stage 2 - a) Final Setting Out and Monumenting

The LLS shall carry out works for the Final Setting Out and
pegging of the Centre Line including Tangent Points (TPs)
and horizontal curves and monumentation of all
Intersection Points (IPs), Reference Marks (RMs) and
TBMs of from the Approved Final Design Road Alignment
based on the design from the earlier surveyed data .
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b) Setting Out of Reserve Boundaries (Road Reserve)
The LLS shall demarcate along both sides the Road
Reserve with hard wood pegs painted in red such that the
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pegs are intervisible between each other or at all points
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where the Road Reserve is crossing the affected land
( boundaries , where it is required by the PTGILand Office .
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The LLS shall provide at least one senior survey technician and other supporting
staff to pick up the line to set out, giving bearings and distances. The LLS when
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requested by the Government shall provide all the assistance and necessary
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information regarding the survey and show the Government's representative on the
ground the whole setting out whenever required to do so .
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1.3.8.3 Cross -Sections along the Road Alignment

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Cross sections shall be taken along the cen treline of the proposed road alignment
at the interval of 25m and up to the corridor width . Adjacent points along the cross-
sections shall not exceed 10m. Levels are to be taken at the road edges (levels to
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( be taken on adjacent shoulders if level difference are significant) and centreline ,

top and bottom of kerbs , invert levels of drains and at any change in gradient.
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1.3.8.4 Longitudinal Profile along the Road Alignment

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Carry out longitudinal profiling with levels to be taken at every 25 metres or

less to indicate change in terrain .
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1.4 Plan Drawing
1.4.1 Unit of Measurement
Metric units shall be used throughout.
1.4.2 Scale
Mapping on final drawings shall be plotted to a scale of 1:1000 or as specified in

latest Arahan Teknik (Ja/an) 6/85) or as agreed by the Government.
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1.4.3 Grid and Detail Accuracy
Mapping shall be based on the Grid System as defined in Sub-paragraph
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1.3.1. Grid lines and Permanent Ground Markers shall be drawn to an accuracy of
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±0 .3 mm maximum tolerance .
(
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Well defined points of detail shall be plotted in their true positions at map scale to
±0 .3 mm root mean square error when coordinated scaled off the map from the
nearest grid line are compared with coordinates determined by measurement on
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the ground from the neares t Permanent Ground Marker. (90% of a representative
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sample of well defined pOints shall be within ± 0.5 mm) .
Master transparencies shall be permitted to have an additional tolerance for

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shrinkage of their stable based material not exceeding ±0.3 mm per metre.
1.4.4 Features To Be Shown :

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1.4.4.1 Buildings/Structures
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(. (a) The plinth line of all permanent bui ldings.

(b) Construction type of building, whether Wooden (W) , Semi Concrete
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(SC) , Concrete (C), Double Storey (D) , and etc .

(c) Ruins or partially demolished buildings or foundations by the walls and
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masonry visible at the time of the survey .

(d) Names and type of usage of all buildings , schools, and etc.
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(e) Buildings under construction.
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TOR TOPOGRAPHICAL SU RVEY WORKS
1.4.4.2 Boundary Features
(a) Fences and gates

(b) Boundary stones located/used for fie ldwork
(c) La nd parcels and their lot numbers
(d) Walls
(e) Burial grounds (Ind icate whether Muslim , Chinese , Christian, Hindu, and
etc.)
(f) Historical sites
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1.4.4.3 Railways
(a) Gauge faces of railway running rails
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(b) Level crossings
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(c) Platforms
( (d) Bridges (over roads , river, etc.)
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(e ) Station buildings
(f) Telegraph poles (indicate the reference numbers)
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1.4.4.4 Roads, Tracks and Footpat hs
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(a) Kerb line or edge of surfacing to carriageways .

(b) Tracks
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(c) Pedestrian bridges and footpaths

(d) Traffic islands (similar to kerb line) .
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(e) Destination of road from junction level

(f) Bridges (over Railway, rivers , etc.)
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1.4.4.5 Road Furniture

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(a) Kilometer post (value to be noted)

(b) Bus stop faci lities
(c) Traffic signal posts and controllers
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(d) Guardrails
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(e) Road signs
1.4.4.6 Industrial
(a) Tanks (indicate type of material stored e.g. fue l, gas, water, and etc.)
(b) Sewage disposal works details
(c) Chimneys (substantial)
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1.4.4.7 Slopes and Earthworks
(a) Cutting and Embankments

(b) Terraced slopes
(c) Borrow pits I Quarries
(d) Retaining walls
(e) Rock outcrops
(f) Mining tips
(g) Indicate date of survey if on-going earthworks are present and mark the
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affected area .
1.4.4.8 Services and Utilities
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(a) Transformers (boundary fence s only)
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(b) Electri city SU b-Stations and switch boxes (bound ary fen ces only)
( (c) Pylon lines (indicate levels at lowest point at sag and at pylon towers) .
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(d) Pylon bases
(e ) Pylon reference numbers and voltage of transmission .
(f) Radio , TV station masts or towers
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(g) Telecom poles
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(h) Electricity po les

(i) Fire hydrants
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U) Water Mains pipes and Stop valves (Indicate diameter of pipe)

(k) Manholes (circular and square )
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1.4.4.9 Survey Controls
(a) JUPEM 's Trigonometrical Stations

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<. (b)
(c)
Permanent GPS points
Permanent Ground Markers (IPs, RMs, TBMs , etc .)
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(d) JUPEM Bench Marks used (Indicate reference number and height level )
1.4.4.10 Woods, Trees & Recreation Areas

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(a) Playing fields

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(b) Prominent trees

(c) Land-use and vegetation , and etc.
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TOR TOPOGRA PHI CAL SURVEY WORKS
1.4.4.11 Water, Drainage and Coastal Features
(a) Lakes
(b) Ponds or mining pools
(c) Reservoirs
(d) Rivers (Name to be indica ted)
(e) Streams
(I) Ditches. (width and depth to be indicated )
(g) Cana ls
Wells . (Diameter or width to be indicated )
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(h)
(i) Swamps
Ul Lined drains (width , depth and type to be indicated )
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(k) Water towers
(I) Culverts
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( (m) Waterfalls
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(n ) Jetties
(0) The top of banks of all water featu res over 1.0 metre wide shall be
detailed and the bottom of banks as ind icated by the water level at the
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time of the survey . The direction of fl ow of all rivers , streams and
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watercourses shall be indicated .
(p) Slopes with a heig ht greater than 1.0 metre of too sharp a gradient to be
shown by contou rs, includ ing river and stream banks are to be shown
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on conventional markings and the top and bottom of slopes are to be

shown as dotted lines .
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(q) Slope conven tions sha ll be drawn as near as possible to indicate the
actual shape of the slope face , i.e . all berms and terraces shall be
detailed .
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Any other features not listed, which are requested by the Government
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shall also be shown .
1.4.5 Contours
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Where required , contours shall be shown at vertical intervals as described in

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Sub-para graph 1.3. 7 and shall be correct to within the tolerances given below when
a representati ve sa mple of points on contour lines is checked by measurement
from the nearest JUPEM Bench Mark or height control point.
Contour Interval r.m.s.e. 90% Tolerance

O.50m +O. 15m +0. 25m
1.0m ±O.30m ±O.50m
2.0m +O.60m +1.00m
3.0m +O.90m +1 .50m
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Where steep slopes are encountered and it is not practicable on the plan to
represent each contour fully throughout, its length , the LLS may with the
Government's approval terminate certain intermediate contours.
Any contour which can be brought within this vertical tolerance by moving its plotted
position in any direction by not more than 0.5 mm or one-tenth of the horizontal
distance between contours, whichever is the greater, shall be considered
acceptable .
ER
Index contours shall be shown using continuous thick lines . Contour and spot
heights shall be differentiated from other deta ils. The value of each contour shall
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be indicated along the contours at interva ls not exceeding 200 mm and/or the
edges of the Mapping Area .
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(
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Where because of undergrowth, on-going earthworks , swampy areas , or other
obstructions, the ground surface is obscured , or access is restricted , and provided
the Governments prior agreement is obta ined , contours can be shown by broken
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lines to indicate that their accuracy cannot be guaranteed .
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1.4.6 Spot Heights
Spot heights shall be shown on the Final Drawings at spacing not exceeding 20 m.
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at the following locations : -

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(a) at salient points such as hilltops , bottoms of depressions and saddles .
(b) along the centre and edges of all roads and public accesses, at road
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intersections and significant changes of gradient.

(
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(c) at water level at the time of survey along rivers , streams , major
watercourses and ditches .
(d) on bed levels of rivers , streams , canals and other watercourses .

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In flat areas, where the horizontal distance between contours generally exceeds
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40 m . Supplementary spot heights shall be shown at intervals not exceeding 20 m.

parallel to the contours.
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Spot heights shall be correct to within the tolerances given below when a
representative sample is checked by measurement from the nearest JUPEM
Bench Mark; or
Map Scale r.m.s.e. 90% Tolerance

1:500 + 0.06m ± 0.10m
1:1000 + 0.12m + 0.20m
1:2500 + 0.30m + 0.50m
1:10000 + 1.00m ± 1.60m
1.4.7 Bridge Details
ER
Where required the bridge details shall be shown on a separate drawing for each
bridge (see Sub-paragraph 1.5.4) in a form agreed by the Government. They shall
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not be shown on the map .
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The bridge details shall includ e:
(
TE
(a) The coordina tes and levels of the four corners of the bridge (points shall
be are on the adjacent road surface), the two edges of the piers ,
abutment and wing walls .
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(b) The coordinates and levels of the bridge deck on the intermediate piers
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(if any) of the bridge .
(c) Length , width and type of construction of bridge.

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(d) The type and location of services adjacent to the bridge .

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(e) The co-ordinates and levels of the centre line and the two edges of the
road on the bridge at approximate intervals of 5 metres.
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( (f) The cross-sectional clearance envelope at the two sides of an overpass

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bridge (with respect to the road centre line passing underneath) showing
all the relevant levels , offsets and skew angle.
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1.4.8 Culvert Details

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Details of each culvert are to be shown on the Survey plans and a separate
tabulation of the following information is to be submitted with the plans: -
(a) Type of culvert and diameter;

(b) Chainage of culvert at the road centre line;
(c) Skew angle of the culvert from the centre line ;
(d) Length of culvert from each side of the centre line ;
(e) Invert levels of the inlet and outlet;
16
(f) A sketch of the inlet and outlet structures including all visible dimensions
to a scale of 1:200.
For major cu lverts (dia meter 2: 2.0m) the outlet structures are to be properly
measured and modelled as 3D strings as described in Sub-paragraph 3.3.2 .
1.5 Preparation and Submission of Plans and Data
The LLS shall provide the Government with two sets of prints together with one set of
Master transparency for all drawings prepa red . The drawings required are as follows:-
ER
1.5.1 Location Plan and Alignment Control Plan
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Location plan of the proposed roads (inclusive aeri al photos ) to a suitable scale
such that the area under study can be put into a single standard A 1 size sheet .
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( The ch ainage of the survey alignment shall be indicated for ease of reference to
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the detail plans .
Alignment control plan shall be prepared as described in latest Arahan Teknik

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(Ja/an) 6/85) .
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1.5.2 Preliminary Survey Plans and Data
The plans and data shall contain all the essential details so as to enable the
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Government to make decisions in choosing the best alignment of the proposed

road.
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The details may include the following: -

(a) Contours
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'- (b)
(c)
Grid Lines
Structures , buildi ngs or any obstru ctions
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(d) River crossi ngs

(e) Rock outcrops
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(f) Swampy areas

(g) Existing roads, tracks, railways, etc.
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(h) Transmission lines
The LLS shall provide other additional details and data wherever instructed
by the Government.
17
1.5.3 Final Survey Plans
The plans shall be shown in a scale of 1:1000. These shall show the Alignment,
Perm anent Ground Markers, chainage and all other features as described in
Paragraph 1.4.
1.5.4 Detail Plans for Bridges and Culvert Sites
The sites shall be produced in a scale of 1:500 showing features and levels as
detailed in Sub-paragraphs 1.3.5.1 and 1.3.5.3.
ER
Details of any adjacent existing bridges as described in Sub-paragraph 1.4.7 as
well as culverts in Sub-paragraph 1.4.8 shall be shown as a separate figure with
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all the relevant dimensions in a suitable scale.
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( 1.5.5 Ptans for Junction or Site Details
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Wherever shown on the drawings or as instructed by the Government , the LLS
shall provide plans that show details of Junctions or Site to a scale of 1:500 . These
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details shall be as described in Paragra ph 1.4 and any other additional details as
instructed by the Government.
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1.5.6 Land Acquisition Plans

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The LLS sha ll compi le and prepare precomputed plans fo r property , land
acquisition and applications purposes from the JU PEM's Cadastral Standard
EN
Sheets and the latest Revenue Sheets ; Litho-Sheets ; from the Land Office and
other relevant Government agencies to the same scale where applicable all in
accordance with JKR guidelines as described in latest Arahan Teknik (Jafan) 7/85 .
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(
The drawing shall show the following :
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(a) Lot boundaries

(b) Lot numbers
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(c) Existing total lot areas computed based on coordinates (Determination

of areas by measurement is not permitted).
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(d) Land use indicating type of cultivation , etc.

(e) Types of buildings indicating perm anent or semi-permanent and usage
(f) The existence of burial ground if any fall s within the survey corridor.
(g) Other rel evant deta ils as instructed by the Government
Land lots that are partially within the mapping area shall be presented showing the
whole area of that lot.
18
All coordinates shall be computed and all calcu lations shall be presented as an
appendix in a neat and clean form as agreed by the Government. Coordinates shall
be presented based on the transformation factor as described in
Sub-paragraph 1.3.1.
The drawing of this plan shall include the preparation of the final land acquisition
plan nor the computation of the area to be acquired d.
1.5.7 Format of Drawings to Be Submitted
ER
1.5.7.1 Format for Presentation
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Unless otherwise specified in Ihe Terms of Reference , all formats of drawings
submitted including the title block shall conform to JKR Guidelines as contained in
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( latest Arahan Teknik (Ja/an) 6/85 (Guidelines For Presentation of Engineering
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Drawings ). All drawings shall be to A 1 size unless otherwise specified .
Unless otherwise specified all text and annotations sha ll be in English .

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All legends any symbols used in the drawings shall be those currently used by JKR
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for the standard MOSS drawing output and approval must be obtained for any
departure from accepted practice .
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RSO (Malaya) grid lines shall be shown by symmetrical lines at 100 mm . intervals
for Peninsular Malaysia; while RSO (Borneo) Grid lines shall be shown by
EN
symmetrical lines at 100 mm. intervals for Sabah , Sarawak and FT of Labuan .
For Peninsular Malaysia, State Cassin i-Soldner grid lines (if so required by the
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Government) shall be shown at 100 mm intervals by symmetrical crosses (10mm .

<- North-South and 10mm East-West) . Coordinates shall be shown outside the band
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of detail, or at the sheet edges at 100m interval.
1.5.7.2 Preliminary Copies

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Preliminary copies shall be submitted in the form of stable based paper printed
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by diazo process. Every sheet of the drawings shall be marked as Preliminary

copy.
19
1.5.7.3 Final Drawings
All Final Drawings shall bear the name , signature and qualification of the LLS as
wel l as the name and address of his company.
Final Drawings shall consist of two (2) set of paper prints and if necessary further
copies until approved . One (1) set of readable I editable softcopy plans on USB
Flash Drive or Digital Versatile Disc (DVDs) shall also be provided in Autocad 2014
format.
ER
1.5.8 Format of Data to be Submitted
The LLS shall submil the survey data in USB Flash Drive or DVD-ROM in .DWG
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(Autocad 3-D ) format.
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( 1.6 Date of Submission of Drawings and Data
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1.6.1 Survey Drawings and Data for Preliminary Design
Drawings and data listed under Sub-paragraph 1.5.2 are to be prepared and
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submitted to the Government within 2 weeks after completion of the relevant
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field works and prior to the preparation of other drawings.
Whenever necessary the plans and data may be delivered in stages as instructed
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by the Government.
1.6.2 Completed Survey Drawings and Data

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All survey drawings and data are to be prepared and submitted to the Government
within 4 weeks or as instructed by the GR , whichever is earlier, after completion of
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<- the relevant field works . All services to be performed under the Terms of Reference
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shall be completed within the duration of Services as stipulated in Clause 3.1 of

this Agreement.
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1.7 Field Books and Final Survey Report
All fie ld books and computer data must be properly kept and shall record truthfully all the
survey work carried out and verified by JUPEM . The LLS shall do all workings in proper
books . adequately in good style and according to best practice. All field books shall be
done in ink. Unsatisfactory works and errors shall be struck off and there shall be no
su peri mposed writing or erasure .
ER
The GR may check the field books now and then to ensure that a high standard of work is
maintained . He may request the LLS to carry out some spot checks if he has reasonable
doubt on the accuracy of the survey work . The LLS shall comply with such requests unless
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he can prove to the Government·s representative's satisfaction that such checks are
unnecessary .
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(
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The LLS may propose the use of electronic equipment for the purpose of booking . The
type of equipment is subject to the Government's approval.
A
On completion of survey work . all field books and computer data shall be properly labelled
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and compiled and submitted to JKR and shall remain the property of the Government
All field books and survey data , plans and drawings shall be duly certified by the LLS in a
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format as shown in Append ix A4.

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<-
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21
TOR TOPOGRAPH ICAL SURVEY WORKS
SERVICES SPEC IFICA TIO NS FOR TO POGRAPHI CAL SURVEY WO RKS
2.0 Scope of Works
2.0.1 Survey Area
The details of the extent of the works to be surveyed is given in the attached plan .
2. Basic Professional Land Surveying Services fo r topographical survey works
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The Services to be rend ered by the LLS in this paragraph include the provision of all expert
technical advice and skills , which are normally required for the Works for which the LLS
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has been engaged .
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( 2.1 General
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The Services to be provided by the LLS as listed herein and as detailed in subsequent
sections : -
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2.1.1 Prior discussion with relevant authorities such as JKR, PDRM, land office and local
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authorities before the physical commencement of work on site.

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2.1.2 Study all releva nt info rmation and maps provided and obta in additional data if
necessary for the proper execution of the works .
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2. 1.3 Field survey and picking up of mapping details fo r subseq uent submissio n of digital
data in DWG (Autocad ) fo rmat.
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( 2.1.4 Estab lishment of Permanent Ground Markers for survey control such as Survey
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Ma rkers (S Ms) and Temporary Bench Marks (TBMs) .
2.1.5 Compi lation, processing and preparation of data in accord ance to DWG format
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(Autocad) .
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2.2 Accuracies, Tolerances, Errors and Corrections
Wherever accuracies or tolerances are specified herein, they are defined as Maximum
Errors or statistical ly based root mean square errors (r.m .s.e.) as follows : -
2.2.1 Maximum Errors

Maximum errors are on ly used for fieldw ork misclos ures [sub-paragraphs 2.3. 1 and
2.3.2] and plotting of map grids and control poi nts [sub-paragraph 2.4 .3]. All errors
exceeding the maximum al lowa ble tolerance including consequential errors shall
ER
be corrected by the LLS at his own expense .
2.2.2 Method and Location of Corrections
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The LLS shall agree with the Government the method , location and extent of the
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work to be corrected .
(
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2.3 Fieldwork
2.3.1 Planimetric Control

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For Peninsular Malaysia , planimetric control shall be calculated based on the
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relevant State Cassin i-Soldner Grid lines projections as agreed by the

Government. For Sabah , Sarawak and the Federal Territory of Labuan , planimetric
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control shall be calculated based on the relevant Rectified Skew Orthomorphic

(Borneo) Grid as agreed by the Government.
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Azimuths sha ll be checked by solar observations at appropriate intervals and the

survey traverses shall be tied up to any nearby trigonometrical points or standard
traverse points or permanent GPS points or Bou ndary Mark. The maximum closing
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<. error of the traverse sha ll be 1:4000 .

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Survey should be started from the Local Survey Datu m.
Existing boundary marks within and adjacent to the Work site shall be located.
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Replacement with temporary markers shall be done when the boundary marks are
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found to be missing or out of positions.
2.3.2 Height Control and Connection
All heights supplied by the LLS shall be related to the latest published values of
JUPEM Bench Marks at th e time of survey. Where possible , the Height Control
shall be based on JUPEM Bench Mark proven in its height accuracy. However
where the JUPEM Bench Mark is not ava ilable within 5km radius from the site, an
23
Assumed Height of the TBM may be adopted with the approva l of the Government.
TBM shall be established not more than 1 km interval.
JUPEM Bench Marks which exceed these tolerances shall be omitted from the
adjustment. The LLS shall inform the GR and JUPEM whenever the JUPEM Bench
Marks are found to be damaged or in error.
At least three (3) Temporary Bench Marks (TBMs) shall be established at the Work
site and indicated the same on pla n. The TBM shall be of solid construction and
ER
shall be of concrete .
All Temporary Bench Marks shall be connected by a closed levelling net which
D
shall be tied to a minimum of two JUPEM Bench Marks unless otherwise agreed
N
by the Government.
(
TE
All level ling shall be done in sections of approximately 1 km . in length.
Vertical misclosures within the levelling net and between JUPEM bench marks
A
shall not exceed the lesser of the following : -
EJ
(a) ± 16 mm
M
(b) ± (20 ,,1<) mm where K is the sum of the distances levelled in kilometres.
Levelling shall be carried out with spot height at 10m. interval & contour lines
EN
should cover the whole of site and 20 meters beyond the boundaries and any other
areas indicated in red in the attached Requisition Plan.
M
2.3 .3 Permanent Ground Markers

KU
Permanent Ground Markers shall include the following : -

(a) Survey Markers (SMs)
O
(b) Temporary Bench Marks (TBMs)

D
The LLS shall construct, provide coordinates and heights Permanent Ground
Markers to the satisfaction of the Government at the location where points are
required to form a reference system for future setting out of the Works at the
approximate locations indicated on the Drawings, clear of future construction works
and as agreed with the Government.
24
The types of marker which will be considered acceptable for the appropriate
general ground surface conditions are shown in Appendix A2 and
Appendix A3 . Alternative forms of marker subm itted by the LLS may however be
considered .
The Government will indicate on the Drawings the likely types of the Permanent
Ground Markers to be installed within the Site. The final locations and types of
markers shall be agreed with the Government before emplacement. All Perman ent
Ground Markers shall be clearly and legibly inscribed to distinguish between SM
ER
and TBM .
There shall be a joint inspection and handling over of all Permanent Ground
Markers to the GR.
D
N
2.3.3.1 Survey Markers
(
TE
Whenever required by the Government , the LLS shall erect permanent Survey
Markers at locations indica ted in the Drawings or as agreed by the Government.
A
2.3.3.2 Temporary Bench Marks
EJ
The LLS shall establish Temporary Bench Marks at approximately 1 km intervals

or a minimum 3 TBMI Site or 1 TBM/ 10ha and reference it to the JUPEM Datum .
M
Reduced levels of these temporary bench marks shall be clearly and legibly
inscribed and referenced for identification for the subsequent construction stage .
EN
The LLS shall supply two copies of diagrams of the levelling net indicating the
connections between Permanent Ground Markers , Temporary Bench Marks and
M
( JUPEM Bench Marks with misclosures. to the Government on comp letion of

fi eldwork and survey adjustment.
KU
O
D
25
1. Pilip berkonk rit
ER
Pecahan bahagian konkrit:
D
, b,h:;>g ian s;m.n . 2 b'llh'gl;an pnlr 4 b~h"'ilI .. n b"ru b"ur
N
( 2.3.4 Topographic Detail Survey
TE
All details and up the full width of the approach road fronting the land shall be
picked up , inclusive of the following : -
A
(a) North Point;
EJ
(b) All boundary marks ;

(c) Road names , pavement, side tables , road islands , meridian and
M
intersections ;
(d) Visible manhole, inspection cover , sump and their invert levels, if
EN
necessary ;
(e) Water supply pipes and water mains-water pressure ;
(f) Drain , culvert and invert levels - direction of flow ;
M
(g) Electricity and telegraph poles and pylon ;

(h) Existing temporary and permanent buildings in and around sites ;
KU
(i) Fencing - types and wei ght;

U) River, stream , inverts and fl ood levels;
(k) All others visible obstacles for future construction, e.g . flood levels , and
O
etc;
D
(I) Prominent trees 0.3 metre in circu mference and bigger; and
(m) Railway track, rock, outcrops and etc .
26
TOR TOPOGRAPH ICAL SU RVEY WORKS
2.3.4.1 Survey of Watercourses
(a) Streams and Rivers

The LLS sha ll survey all streams, rivers and watercourses crossing or
located adjacent to the Work site. These include all watercourses
whether there is water or no water flow at the time of surveying.
(b) Urban Drainage

The LLS shall survey all top and bottom edges and invert levels of urban
drains at intervals not exceed ing 10 m, showing all significa nt changes
ER
of level and direction of flow . The type , width and depth of each section
of different drainage system (including sumps) shall be recorded .
D
(c) Culverts
N
All the relevant details of the culvert as described in Sub-paragraph
( 2.4 .7 shall be recorded .
TE
(d) Ftood Inf ormation
The LLS shall record the highest flood level! water level at each river
A
crossing . Such information shall include date, year and time . Existing
EJ
water surface at suitable points shall be taken along the channel.
In areas where tidal effects are significant , the LLS shall gather all the
M
necessary information as an appendix to the mapping in a form agreed

by the Government.
EN
2.4 Mapping
M
2.4.1 Unit of Measu rement

l Metric units shal l be used throughout.
KU
2.4.2 Scale
Mapping on fina l drawings shall be plotted to a scale of 1:1000.
O
2.4.3 Control and Detail Accuracy

D
Mapping shall be based on the Planimetric Control as defined in Sub-parag raph

2.3.1. Permanent Grou nd Markers shall be drawn to an accuracy of ±0.3 mm
maximu m tolera nce .
Well defined points of detail shall be plotted in their true positions at map scale to
±0.3 mm root mea n sq uare error when coordin ated scaled off the map are
compared wi th coordinates determi ned by meas urement on the ground from the
27
nearest Permanent Ground Marker. (90% of a representative sample of well

defined points shall be within ± 0.5 mm).
2.4.4 Features To Be Shown:
2.4.4.1 Buildings/ Structures
(a) The plinth line of all permanent build ings .

(b) Constru ction type of building, whether Wooden (W) , Semi-Conc. (SC) ,
Concrete (C), Double-Storey (D), and etc.
ER
(c) Ruins or partially demolished bu ildings or foundations - by the walls and
masonry visible at the time of the survey.
(d) Names and type of usage of all buildings , schools , and etc .
D
(e) Buildings under construction .
N
( 2.4.4.2 Boundary Features
TE
(a) Fences and gates
(b) Boundary marks located/used for fieldwork
A
(c) Land parcels and their lot numbers
(d) Walls
EJ
(e) Burial grounds (I ndicate whether Muslim , Chinese , Christian , Hindu , and
etc.)
M
(f) Historical sites
2.4.4. 3 Railways
EN
(a) Gauge faces of railway running rails

(b) Level crossings
M
( (c) Platform s
KU
(d) Bridges (over roads , river, etc.)

(e) Station buildings
(f) Telegraph poles (ind icate the referen ce numbers)
O
2.4.4.4 Roads, Tracks and Footpaths

D
(a) Kerb line or edge of surfacing to carriageways.

(b) Tracks
(c) Pedestrian bridges and footpaths
(d) Traffi c islands (similar to kerb li ne).
(e) Destination of road from junction leve l
(f) Bridges (over Railway, rivers, etc .)
28
2.4.4.5 Road Furniture
(a) Kilometer post (value to be noted)

(b) Bus stop facilities
(c) Traffic signal posts and con trollers
(d) Guardrails
(e) Road signs
2.4.4.6 Industrial
ER
(a) Ta nks (indicate type of materia l stored e.g. fue l, gas , water, and etc .)
(b) Sewage disposal works details
(c) Chimneys (substantial )
D
N
2.4.4.7 Slopes and Earthworks
(
TE
(a) Cutting and Embankments
(b) Terraced slopes
(c) Borrow pits I Quarries
A
(d) Retaining wal ls
EJ
(e) Rock outcrops

(f) Mining lips
M
(g) Indicate date of survey if on-going earthworks are present and mark the
affected area .
EN
2.4.4.8 Services and Utilities
(a) Transformers (boundary fences only)

M
(b) Electricity SUb-Stations and switch boxes (boundary fences only )

(c) Pylon lines (indicate levels at lowest point at sag and at pylon towers ).
KU
(d) Pylon bases

(e) Pylon reference numbers and vol tage of transmission .
O
(f) Radio , TV station masts or towers

(g) Telecom poles
D
(h) Electricity poles

(i) Fire hydrants
U) Water Mains pipes and Stop valves (Ind icate diameter of pipe)
(k) Manholes (circular and square)
2.4.4.9 Survey Controls
(a) JUPEM 's Trigonometrical Stations

(b) Permanent GPS points
29
(c) Permanent Ground Markers (TBMs, etc.)

(d) JUPEM Bench Marks used (Indicate reference number and height level)
2.4.4.10 Woods , Trees & Recreation Areas
(a) Playing fields

(b) Prominent trees
(c) Land-use and vegetation , and etc .
2.4.4.11 Water, Drainage and Coastal Features
ER
(a) Lakes
(b) Ponds or min ing pools
D
(c) Reservoirs
(d ) Rivers (Name to be indicated )
N
( (e) Streams
TE
(f) Ditches . (width and depth to be indicated)
(g) Canals
(h) Wells. (Diameter or width to be indicated)
A
(i) Swamps
U)
EJ
Lined drains (width, depth and type to be ind icated )
(k) Water towers
(I) Culverts
M
(m) Waterfalls
(n) Jetties
EN
The top of banks of all water features over 1.0 metre wide shall be detai led and the
bottom of banks as indicated by the water level at the time of the survey . The
M
direction of flow of all rivers , streams and watercourses shall be indicated.

KU
Slopes with a height greater than 1.0 metre of too sharp a gradient to be shown by
contours , including river and stream banks are to be shown on conventional
markings and the top and bottom of slopes are to be shown as dotted lines.
O
Slope conventions sha ll be drawn as near as possible to indicate the actual shape
D
of the slope face, i.e. all berms and terraces shall be detailed.
Any other features not listed , which are requested by the Government shall
also be shown.
30
2.4.5 Contours
Where required, contours shall be shown at vertica l intervals as described in Sub-

paragraph 1.3.7 and sha ll be correct to with in the tolerances given below when a
representative sample of points on contour lines is checked by measurement from
the nearest JUPEM Bench Mark or height control point.
Contour Interval r.m.s.e. 90% Tolerance

1.0m +0 .30m ±0.50m
2.0m ±0.60m +1 .00m
ER
3.0m +0 .90m +1 .50m
Where steep slopes are encountered and it is not practicable on the plan to
D
represent each contour fully throughout . its length , the LLS may with the
Government's approval lerminate certain intermediate contours .
N
(
Any contour which can be brought within Ihis vertical tolerance by moving its plotted
TE
position in any direction by not more than 0.5 mm or one-tenth of the horizontal
distance between contours , whichever is the greater, shall be considered
acceptable .
A
EJ
Index contours shall be shown using continuous thick lines. Contour and spot
heights shall be differentiated from other details. The value of each contour shall
M
be indicated along the contours at intervals not exceeding 200 mm and I or the
edges of the Mapping Area.
EN
Where because of underg rowth , on-going earthworks , swampy areas , or other

obstruclions , the ground surface is obscured, or access is restricted, and provided
Ihe Governments prior agreement is obtained , contours can be shown by broken
M
lines to indicate that their accuracy cannot be guaranteed .

KU
2.4. 6 Spot Heights
Spot heights shall be shown on the Final Drawings at spacing not exceeding 20 m.
O
at the following locations : -

D
(a) at salient points such as hilltops , bottoms of depressions and sadd les.
(b) along the centre and edges of al l roads and public accesses, at road
intersections and significant cha nges of gradient.
(c) at water level at the time of survey along rivers, streams, major
watercourses and ditches.
31
(d) on bed levels of rivers, streams , cana ls and other watercourses.
In flat areas, where the horizontal distance between contours generally exceeds
40 m. Supplementary spot heights shall be shown at intervals not exceeding 20 m.
parallel to the contours .
Spot heights shal l be correct to within the tolerances given below whe n a
representative sample is checked by measurement from the nearest JUPEM
Bench Mark ; or
ER
Map Scal e r. m .s.e. 90% Tolerance
1:500 ± 0.06m ± 0.10m
1: 1000 + 0.12m + 0.20m
1:2500 + 0.30m + 0.50m
D
1:10000 + 1.00m ± 1.60m
N
( 2.4. 7 Culvert Details
TE
Details of each culvert are to be shown on the Survey plans and a separate
tabu lation of the following information is to be submitted with the plans :
A
(a) Type of culvert and diameter;
EJ
(b) Chainage of culvert at the road centre line ;

(c) Skew angle of the culvert from the centre line ;
M
(d) Length of culvert from each side of the centre line ;

(e) Invert levels of the in let and ou tlet;
EN
(f) A sketch of the inlet and outlet structures including all visible dimensions .
2.5 Preparation and Subm ission of Plans and Data

M
(
The LLS sha ll prepare site plan with bou ndary dimensions and bearings to sca le of 1:000
KU
or as agreed the GR covering the whole site and including the area up to the fu ll width of
approach road adjacent to the site and indicate on it all the details as listed in Sub-
O
paragraph 2.4.4.
D
The LLS shall state whether site is liable to flood ing, and if it is, state the highest water
levels experienced or like ly to experi ence.
2.5.1 Key Plan and Location Plan
Key Pla n and Location Plan of the proposed site shall be shown to a su ita ble small
scale such that the area under study ca n be included into a single standard A 1 size
sheet as part of the Final Survey Plan.
32
2.5.2 Final Survey Plan
The plan shall consists of site plan , Key Plan and Loca tion Plan .
2.5.3 Detail Plans for Culvert Sites
Details of any adjacent existing culverts in Sub-paragraph 2.4.7 shall be shown as

a separate figure with all the releva nt dimensions in a suitable scale .
2.5.4 Format of Drawings to Be Submitted
ER
2.5.4.1 Format for Presentation
All drawings shall be to A 1 size unless otherwise specified .
D
All legends and symbols used in the drawings shall be those currently used by JKR
N
( for the standard MOSS drawing output and approval must be obtained for any
TE
departure from accepted practice .
For Peninsular Malaysia , State Cassini-Soldner grid lines (if so required by the
A
Government) shall be shown at 100 mm . intervals by symmetrical crosses (10mm.
North-South and 10mm East-West). Coord inates shal l be shown outside the band
EJ
of detai l, or at the sheet edges at 100m. interva l.

M
2.5 .4.2 Final Drawings
Approved Final Drawing shall be plotted on suitable paper material.

EN
The LLS shall submit one (1) set of hardcopy plans on tracing paper, two (2)
sets of paper prints and one (1) set of readable I editable softcopy plans on
M
( US B Flash Drive or DVD-ROM in AutoCAD 2014 format.

KU
All Final Drawings sha ll bear the name, signature and qualification of the LLS
as well as the name and address of his compa ny.
O
D
33
TOR TOPOGRAPHI CAL SURVEY WO RKS
2.5.4.2 Computer Input Requirement
The LLS sha ll supply the digital data ground model data suitable for input to the
Government computer as specified below :
Government Computer
Ma ke: DELL
Model Number : OPTIPLEX 990
Operating System : Windows 7
ER
Main Software : AutoCad Civil 3D 2014
The data shall be supplied as spsecied below in order of preference :
D
a) USB Flash Drive
N
Format : Windows 7
( Capacity : 4 Gigabyte and above
TE
b) Dig ital Versatile! Video Disc
Format : Windows 7
A
Capacity : 4.7 Gigabyte
EJ
The data shall be supplied with an index scheduling the contents and
M
referencing and shall rema in the property of the Government.
2.6 Date of Subm ission of Drawings and Data

EN
All survey drawings and data are to be prepared and submitted to the Government within
the duration of Services as stipulated in Clause 3.1 of this Agreement.
M
(.
KU
O
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34
SERVICES SPECIFICATIONS FOR BRIDGE WORKS
3.0 SCOPE OF SERVICES
3.1 General
The scope of survey services to be provided by the Surveyor shall be as listed herein under and
as detailed in subsequent paragraphs:-
(a) Prior discussion with releva nt authorities such as JKR, JPS, Police and Land Offices
before the physical commencement of work on site .
ER
(b) Study of all relevant information and maps provided and obta in additiona l data if
necessary for the proper execution of the proposed works .
D
(c) Field survey and picking up details.
N
(d) Consultation with the Engineer and Setting Out.
(
(e) Levelling and establishment of Temporary Bench Marks (TBM )
TE
(f) Preparation of plans and data suitable for bridge/culvert design .
(g) Pegging of centre line and cross-sectioni ng .

A
(h) Pegging of right-of-way (if required )
EJ
3.2 Field Survey and Setting Out

M
3.2 .1 General
EN
The surveyor shall perform all field survey work necessary to locate accurately the locations and
dimensions of the following features within the corrid or of the existing structure at every location
for survey of:-
M
(
KU
(a) Existing roads , tracks and paths , JPS reserve and ROW li ne .
(b) Existing structures above and below the ground level indicating whether temporary ,
semi-permanent or permanent and whether dwelling , industrial of other use , type of
construction and any other relevant particulars .
O
(c) Existing drains including their type of construction .

D
(d) Natural vegetation and type of plantation .
(e) Existing water main, TNB and Telecom overhead lines and underground cables,
Telecom manholes, fire hydrants, pylons etc.
(f) Highest known flood levels .
35
3.2.2 Consultation with Client before Setting Out
Before setting out, proposals for the detailed survey should be submitted to th e Government
before the work is being carried out.
3.2.3 Monumenting of Existing Bridge/ Culvert and Road
The Surveyor has to set out and peg th e centreline of the existing bridge/cu lvert and the right-of-
way limit where appropriate .
ER
The Surveyor when requested by the Government shall provide all the assistance and necessary
information regarding the survey and show the Government's representative on the ground the
whole setting out whenever required to do so.
D
N
For setting out of the centre-line on existing bridge/culvert and roads , steel rod pins or spikes
( must be used . These spikes shall be permanent in nature.
TE
There shall be a joint inspection and handing over of all BM's and TBM 's to the Government's
representative after pegging out or setting out have been completed .
A
EJ
3.3 Levelling
3.3.1 Levelling to Establish Temporary Bench Marks

M
The Surveyor shall establish temporary bench mark(s) and relate it to Survey Department Datum
(Ordinance Datum ). Reduced Level of this temporary bench mark(s) shall be clea rly and legibly
EN
inscribed on the mark(s) and referenced for identification for the subsequent constru ction stage .
The location of bench mark(s) must be clearly described and indica ted on the plans to be
M
submitted . This TBM(s ) shall be located well away from the construction limits . The maximum
( error in spot levels sha ll not both exceed +,Jl .02K metres where K is the horizontal distance in
KU
kilometres from the nearest Permanent Bench Mark.
3.3.2 Surveys at Bridge/Culvert Sites

O
The Surveyor shall survey to the distances as shown in Figure (i) on either side of the road and
D
bridge centre-line . The Govern ment may request the Surveyor to extend these distances where
it is required.
The locations of channel edges and other significant fea tures shall be recorded and levels shall
be taken along the bank slopes and channel inverts at interval of 3m. A minimum of 3 cross-
sections showing all significant changes of level are required at both sides of the channel. The
cross-sections , one of which shall be taken along the existing structure ce ntre-lin e shall extend
to a distance not less than ---1!l from one bank tops on either side of the strea m.
36
The Surveyor shall record the maximum flood level at each river crossing. Existing water surface
at suitable points shall be taken along the channel. Each re ading shall be taken at interva ls not
exceedi ng one hour. The Surveyor shall indicate on the Plan and Longitudi nal Profile the
chainage and redu ced level of the lowest point of all depressions along the route including
direction of flow.
3.4 Booking For Survey
The Surveyor shall do all workings in proper books , adeq uately in good style and according to
ER
best practice . All fields shall be done in ink . Unsatisfactory works and errors shall be struck off
and there shall be no superimposed writing or erasure . The field books must be kept properly .
On completion of the survey works , all field books shall be properly labelled , certified and
D
submitted to the Government and will remain the property of the Government.
N
( 3.5 Reference Markers (TBM)
TE
To ensure accuracy , reference markers shall be placed at least 25m away from the mark (i. e.
IP's or TBM's ). There shall be at least 2 TBMs and the base of the triangle which they form with
the apex should be at least 15m apart.
A
EJ
1. Pai p be rkonkrit
M
~cm
!Scmt
EN
30 0m
M
<-
KU
Pecah.n b.h,glln konkrtt :

I bo~a gl~ n limen 1 tHo~~ gl.n p.oll • • Dahl"." b,I,,, b.oll.
O
D
37
3.6 Colour Codes For Pegs.
All pegs should be colour-coded with paint on site to indicate their purpose . A consis ten t colour
code as specified below must be retained throug hout the survey.
PEG COLOUR CODE
PEG FUNCTION COLOUR
Centre Line pegs for all work Red
ER
Off-set pegs from centre line White
Right of Wa y (RO W) (Specified Design )
D
N
4.0 PREPARATION AND SUBMISSION OF PLANS AND DATA
(
TE
4 .1 The Surveyor shall provide the Government with soft and hard copies for all the drawings
prepared . All soft copies submitted must be in AutoCAD 2014 or .dxf format. The hard copies
submitted shall comprise of one set of tracings wi th 2 sets of prints. The drawings requ ired are
A
as follows :-
EJ
(a) Key Plan
The key plan shall be indicated with Longitude and Latitude reference to the proposed
M
site .
EN
(b) Site Plan
i) The site plan is required in 1/8 inch to a chain scale or a preferred scale used
for land acquisition in the district.
M
l ii) Each lot shall be provided with the coverage of land area with C.P. references
KU
(if any) and the name of Mukim , District and reference of sheet number has to
be given.
O
D
38
(c) The Survey Plan and Longitudinal Profile
The plan view and the longitudi nal profile should be shown in the same plan and shall
be as follows :- Refer to Figure (i)
(i) Top Section of Plan-View (With Spot Levels)
These shall show the existing road and structure centre-line , chainages of
centre-line markers, locations and levels of Temporary Bench Marks , contou rs
of corridor surveyed, channel profile (100 meters upstream and downstream) ,
direction of water flow, existing structure, existing roads (100 meters of both
ER
side of structure) , Reference markers and other features that may be required
for design considerations .
D
Scale : Horizontal (1 : 300 preferred)
N
( (ii) Bottom Section of Pla n-Long itud inal Profi le
TE
These shall show the longitudinal profile of the road and structure centre-line,
cross-section of the rivers , position of existing structure , highest know fl ood
level (if any) , water level during surveying (time and date shall be stated) and
A
other features needed for design considerations for a distance 100 meter on
both side of the existing structure .
EJ
Scale : Horizontal (1 : 300 preferred)

Vertical (1 : 100)
M
(d) Cross-Sections
EN
(i) Cross-section s of channelsl rivers
Drawings of all the cross-sections across the cha nnel/river shall be plotted in
M
consecutive order to a scale of 1 : 200 for horizontal and 1 : 100 fo r vertical.

( The drawings shall show details of ground levels , invert levels and chainage
KU
as regu ired . Refer to Figure (ii) .
Cross-sections along the centre line of the existing roadl Bridge

O
(ii)
Drawings of all the cross-sections along the centre line of the existing road,
D
shall be plotted in consecutive order, to a scale of 1 : 200 fo r horizontal and

1 : 100 for verti cal. The drawings shall show details of ground levels and
distances from the centreline of the existing road. Refer to Figure (iii) and
Figure (iv) .
39
4.2 Format of the Plans and Drawings
All formats of plans submitted including the title block shall conform to JKR Guidelines as
contained in latest Arahan Teknik (Jalan) 6/85 (Guidelines For Presenta tion of Engineering
Drawings) . All drawings shall be to A1 size unless othelWise specified.
All legends and symbols used in the plans shall be those currently used by the J KR and approva l
must be obtained for any departure from accepted practice.
For the preparation of drawings , the followings format is preferred : -
ER
Colour Pen Size Layers
White 0.18 Public Services ; Existing Slope
D
Cyan 0.18 River & Drain ; Contours & Spot Level
N
( Green 0.25 Road
TE
Yellow 0.35 Lettering ; Existing Bridge
Magenta 0.50 Lot Boundaries and Road Reserve

A
4.3 Date of Submission of Plans and Data
EJ
All survey plans and data are to be prepared and submitted to the Government within 2 weeks
after completion of the each site . However, all services to be performed under the Terms of
M
Reference shal l be completed within 4 weeks of the date of appointment. The surveyor is to
submit his time schedu le showing each item of work and the time required to the Government for
EN
approval.
M
5.0 FIELD BOOK

KU
Al l fi eld books must be properly kept and shall record truthfully all the survey work carried out.
The Government's repres entative may check the field books now and then to ensure that a high
standard of work is maintained. He may request the Surveyor to carry out some spot checks if
O
he has reasonable doubt on the accuracy of the survey work. The Surveyor shall comply with
D
such requests unless he can prove to the Government's representative's satisfaction that such
checks are unnecessary. On completion of su rvey work, all field books shall be properly labelled
and submitted to JKR and shall remain the property of the Government.
All fi eld books and survey data , plans and drawings shall be du ly certified by the LLS in a format
as shown in Appendix A4.
40
6.0 SURVEY STAFF ETC .
The Surveyor shall provide such staff, instruments and equipment, tools, materia ls , tentage,
transport, etc, and will ensure the completion of the work to the standards and within the ti me
sched ules specified . All technical staff employed by the Surveyor for the execution of the works
shall be suitably qualified and experienced in route location work. Party leaders sha ll possess
the minimum qualification of technician surveyor.
A professionally qualified surveyor shall be provid ed to ta ke charge of the survey parties and
provide day-to-d ay lia ison with the Government's representative.
ER
7.0 GOVERNMENT INDEMNITY
D
The Surveyor shall be responsi ble for any da mage to life and property tha t may arise out of his
N
work and he sha ll take ou t all necessary insurance cover to indemnify the Government from any
( claims of compensation that may arise out of his work .
TE
8.0 REMUNERATI ON
The fees payable to the Surveyor firm shall follow the approved Treasury's rates of payment
A
(Jadual Fee Ukur Kejuruteraan 2001)
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The Surveyor's fees for the rendering of service s mentioned under the Scope of Work and
elsewhere in the Terms of Reference, shall be deemed to cover all materials , services , wages ,
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allowances , investigations, fie ld surveys , equ ipment, transport, computations, preparation of

plans , overheads , profits and other fees and expenses as stated in the Memorandum of
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Agreement between Government and consulting Surveyor for Professional Serv ices .
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PELAN DAN KERATAN MEMANJANG JAMBATAN

PLAN AND LONGITUDINAL PROFILE FOR BRIDGES
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_ _.-1--
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PLAN
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Proposed
m m
/1 '" )" Bridge
,f , /
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'---- /1
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ARAS , I I
RAN TA IAN I I
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KERA TAN MEMANJANG JALAN SED IADA

Figure (i)
42
KERATAN LlNTANG SUNGAI

CROSS - SECTION OF RIVER
Sejauh _ m dari kedua -dua belah tebi ng sunga i.

A distance of m from the river bank at both sides.
(i) Dari garis tengah jalan sed iada.

At centreline of existing carriageway.
(i i) _ m da ri garis tenga h jala n sediada - di hulu sunga i.

At _ m from centreline of existing carriageway - upstream.
(iii ) _ m dari garis tenga h jala n sed iada di hilir sungai.
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At _ m from centreline of carriageway - downstrea m.
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m / SUNGA I m /
/ / / /
/
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ARAS
RANTAIAN
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JUMLAH - 3 KERATAN
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KERATAN LlNTANG SUNGAI

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Figur e (ii)
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TOR TOPOGRAP HICAL SURVEY WORKS
KERATAN LlNTANG JALAN SEDIADA

CROSS - SECTION OF EXISTING ROAD
(i) _ m dari garis tengah jalan di kedua-dua belah jalan.

_ m corridor from centreline of carriageway, on both sides of road.
(ii) Kedudukan tembok-tembok landas jambatan sediada.

Position of existing abutments.
(iii) Keratan lintang pad a setiap jarak sepanjang _ m dari kedua-dua tembok landas jambatan
sediada .
Cross section of _ m inteNals from existing abutments at both approaches.
ER
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m m
~
CARR , AGEWA Y
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( 1/ 1/
r---:: /
----r--------/
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ARAS
RANTAIAN
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KERATAN LlNTANG JALAN SED IADA

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Figure (iii)
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KERATAN LlNTANG JAMBATAN SEDIADA

CROSS - SECTION OF EXIS TING BRIDGE
Sejauh 30 m dari garis tengah jambatan sedia ada dengan mengambil kira semua kedudukan dan
jarak kemudahan awam yang ada di kedua-dua sisi jambatan.
Up to a distance of 30m from centerline of existing bridge showing all the location and distance of
existing public services on both sides of the bridge.
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Clli:SS S[cnON Q f EX S~"G 8'" DGE
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r PI .. m D' $ m
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Figure (iv)
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SPECIAL INSTRUCTIONS TO THE LLS
ACAD Drawing
All layer in ACAD drawing shal l foll owing as below :
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No. Definition Layer' s name Colour
1. Contour Contour Red

2 Lot Boundary Lot Brown
D
3. Lot No. Lotno Brown
4. Road Road Green
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Text Text Wh ite
( 5.
6. Public Services PUS Magenta
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7. Building/Fence Bid Red
8. Slope/CuUFili Slope Cyan
9. Culvert Culvert Blue
10 . Drain/Invert Level Drain Blue
11. Bridge Bridge Blue
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12 . River River Blue
13 . Spot Height Text Spotht White
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14. Spot Height Point (3D x,y,z) Point Yellow

15. Traffic Sign Sign White
16. Railway Track Railway Red
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17 . Detail/TBM /Travers Station Deta il White

18. Grid/Utara Grid White
19. Vegetation Veg Green
20 . Title Block/Frame Tblock Whi te
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21 . Others Others White

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ACAD 3D Format
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Surveyor was required to provide ACAD 3D for all 3 dimensional string .

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Filing Conventions
The following shall be the conventions used for this project:

a. Restrict the filename length to eight characters
b. The filename extension shall be as follows:
Survey data fil es .SUR

Dig it files .DIG
MOSS Input files .MOS
MOSS Draw files .DRW
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MOSS macro input files .MCR
MOSS Genio input data .DAT
ACAD 3D .DWG
Data Exchange File .DXF
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Any additional extensions may be used with prior approval from the
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( Government.
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Work Directory
Main Directory Pathname fo r working area is :

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Data Tapes
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For MOSS Users in Windows 7 operating environment

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The LLS shall submit the data in two set of Compact Disc containing :
Tape 1- Only worki ng fi les (i.e . MODEL.FIL and MACRO.FIL

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containing the complete and error free digital models plus other
relevant MOSS fi les).
Tape 2 All input data from the Survey work.

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For other Users
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The LLS shall submit the data in Compact Disc or in USB Flash
Drive in GENIO format as defined in the MOSS manual. For Apollo
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DOS emu lation software requirement all filenames have to be with

.DAT extensions.
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47
DIGITAL GROUND MODELS (DGM's)
METHODS
The data shall be presented by the LLS in a form suitable for input to the MOSS String Dig ital
Grou nd Model program, and as defined in the MOSS User Manual which is available from the
Government or the local agent for the software.
GRID
The coordinates of the DGM shall be referred to the grid system .
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STRING LABELLI NG
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All strings shall be labeled as requested . Any additional labels may be considered and the LLS
shall submit the list for approval prior to their usage in the DGM .
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MODE LS
The DGM shal l incorporate two (2) types of digital models as follow:-
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a) Ground Model
b) Property Model
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Ground Model
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The ground surface over the required area shall be simulated by strings of coordinated
information along characteristic lines on the terrain . The model shall consist of a
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combination of three dimensiona l (3 D) and contour (2 0 ) strings .
The existing road surface over the required area shall be simulated by 3D strings of
coordina ted information along characteristic lines on the existing carriageway . Any
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other strings that do not affect the accuracy of the ground surface may be assigned a
( nu ll level. The LLS shall obtain prior approval by the Government for any strings that
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are to be digitized but that does not absolve the LLS fro m the subsequent accuracy
and defin ition of the model. The features to be included in the Ground Model shall be
as requested .
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Property Model
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This model shall be stimulated by a series of 3D null level strings and text strings and
include the following:-
a) Strings of land lots (nu ll level strings)

b) Lot numbers (Text strings)
c) Reference no . fo r certified plan no. (Text Strings).
Coordin ate of each lot shall be computed and stored as separate strings according to
the MOSS GENI O string form at. All boundary coordin ates shall be ca lculated based
from known information on the Certified Plans.
48
Any land lot that is partia lly within the mapping area shall be computed and stored
containing the information of the complete lot. No scaling or digitizing work is allowed
unless there is no proper lot information and with prior written approval from the
Government.
THREE (3) DIMENSIONAL STRINGS
These strings represent man made and angu lar features or break lines in the terrain. Each 3D
string shall be recorded as a series of three dime nsional points (easting , northing and level).
Features recorded shall include tops and toes of embankmen ts, brows of hills and dips of
hollows , highway boundaries, channels , lines of carriageway, footpaths , banks or rivers and
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streams , railway lines etc .
The general shape in plan of individual traffic islands sha ll be represented by separate 3D
strings with points at sharp changes of direction , levels being given for the adjacent carriageway
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surface . Supplementary strings sufficient to indicate the approximate vertical profile of paved
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islands shall be provided . These will also be required on grassed islands where there are
( insufficient contours (20 strings ) to describe their surface shape .
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If the highway is kerbed the edges of carriageway are to be defined immediately adjacent to
the kerb face except where the kerbs divide a difference in levels (eg. central medians ), the top
of the kerbs are to be outlined .
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Where there are auxiliary traffic lanes , lay-bys , junctions or breaks in the central reservation
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additiona l strings will be required along the edge of the carriageway which carries the through
traffic.
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3D strings sha ll also be used to define the ground where 20 strings are inadequate . Closer
spaced points to define curved 3D strings are required unless special survey options in MOSS
to define curves are used .
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TWO (2) DIMENSIONAL STRINGS

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<- These are con tour strings and sha ll be recorded as a series of two dimensional points (easting
and northing) together with the associated string level.
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In models conSisting of 20 and 3D strings the 20 strings shall be recorded throughout the area
of the model except in the fo llowing instances: -
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a. Highways: Upon carriageway, the features are to be represen ted by 3D

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strings only.
b. Flat Areas : In flat areas where the horizontal distance between contours
exceeds 40m, the contours shall be supplemented by a series of 3D strings so
tha t the distance between adjacent strings and also between adjacent points
on the strings shal l not exceed 20 m.
c. Steep Areas : Where steep slopes are encountered and it is not practical on
the plan to represent each contour fully throughout its length , the LLS may with
the Government's approva l adopt a 3D string representa tion. In such instances
49
the slope sha ll be bounded by a 3D string and any changes of slope or berms
within this area shall also be depicted by 3D strings.
d. Densely vegetated areas or rock outcrop areas : Where vegetation is

so dense that the ground is completely obscured , contour strings may be
repla ced by 3D point strings the spaci ng of which shall be agreed with the
Government.
e. Temporary feature s : Where features appear to be temporary such as

stockpiles and spoil heaps , they should be represented by contour stri ngs as
if permanent unless directed otherwise by the Government.
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ACCURACY AND DEFINITION
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a. 3D Strings
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The levels and co-ord inates of recorded point shall be correct to within the r.m.s.e.
( tolerances stated in Table 1. 90% of these must be within 1.65 times the values stated ,
TE
when a representative sample of points is checked by measurement from the nearest
Survey Department Bench Mark or height control point.
Table 1: Tolerances of levels and co-ordinates of directly recorded points on strings

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Carriageways & Other Surfaces Major Bridge Decks

Hard Surfaces
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Vertical Horizontal Vertical Horizontal Vertical Horizontal

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± 0.06m ±0 .15m ± 0.10m ± 0.30m ± 0.01m ±0.10m
The spacing of points along 3D strings shall be such that the maximum vertica l and
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( horizontal errors of interpolated points shall not exceed those given in Table 2.
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Table 2: Total error of interpolated pOints on strings
Carriageways and Hard Other Surfaces Major Bridge Decks

Surfaces
Vertical Horizontal Vertical Horizontal Vertical Horizontal
± 0.12m ± 0.30m ± 0.20m ± 0.60m ± 0.02m ± 0.20m
b. 2D Strings
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Sufficient points shall be recorded on the contours so tha t the digital representati on of
the contour shall conform to the standards specified .
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c. Strings formed of Spot Heights
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( Strings formed of Spot Heights shall be accurate to the Accuracy Level as stated in
Table 1 above.
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GENERAL STRING DETAILS
A string may start or finish at any point providing it is not more than 10m outside the boundary
A
of the block for which the data is being recorded .
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Continuity between blocks shall be provided either by mathematically precise matching at break
boundaries or in the form of a short overlap between the end of one string (e.g. in Block 1) and
the start of another string (e .g. in Block 2) . Where a string stops at another string boundary
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there must not be any gap between the two strings .

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If a string passes outside a block by more than 10m then loops back into the block , another
string must be started prior to re-entry into the block, and the loop section recorded with the
data for the adjoining block. Short overlaps shall be provided to maintain continuity.
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( If a string is a closed loop within the block, or within 10m of the block boundary , then it shall be
closed with mathematical precision or by means of a short overlap at the start .
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Survey Station Strings
These (40) strings consist of points with Easting , Northing, Levels and the four
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character station number or name. MOSS default string labeling to store all main stations is
PSSA.
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Null Level Strings
These strings consist of points with Easting and Northing coordinates and assigned
levels of -999 .0. They are generally additional information so as to complete the
definition of the ground model. MOSS program does not include them when performing
the analysis functions (e.g. SECTION).
These null level stri ngs may include the following : -
51
a. Cartographic features such as tadpole symbol for slopes, vegetation symbols,

etc.
b. Land lot strings in the Property Model.
c. Additional stru ctures or buildings (with prior approval from the Government).
Text Strings
These strings form a group of information data (usua lly digitized or interactive ly added)
in the Ground Model that may include the following :-
a. Cartographic information such as vegetation type , land use , lot numbers, etc.
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b. Names and/or usage of prominent buildings and structures .
c. Destination of road leading to and fro the existing main road and where there
are discontinuities of the road within the Mapping Area .
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Unless otherwise stated all text shall be in ENGLISH and the following text shall the
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precise real world bearing :-
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1. Road destination / type
2. River name / type
All other text may optionally have zero bearing .

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Point Strings
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These strings (with suffix 'P' for the labeling) could be either with or without levels and
may include the following :-
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a. Spot level strings

b. Utilities such as telecom or electrical poles
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c. Survey Station Strings (MOSS default label PSSA)

MOSS program does not include these strings when doing the analysis SECTION but
include them when doing the CONTOUR and TRIANGLE except those with null levels
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MOSS STRING DATA FORMAT SAMPLE
20 strings fo rmat for con tour lines
MOSS
GEN IO,G ROU ND MOD EL
001FO RMAT(6F1 2.3,A4)
080 ,ZX,4=120.000 ,0.0,0.0, 7=2
34006 .109 93790.720
34001.339 93790.243
33996.896 93790.714
0 .000 0 .000
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080,ZI,4= 122.000,0 .0,0.0,7=2
33792.611 93639 .062
33792 .824 93635.4 14
33791.057 93630 .116
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33791.529 936 18.834
33791.095 93610.991
N
33791.514 93605 .465
( 0.000 0 .000
TE
999
FINISH
Fo rm at for 3D feature strings with levels

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MOSS
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GENIO,GROUND MODEL
00lFOR MAT(6F 12.3 )
080,LO,S=0.0,0.0,7=3
33870 .994 93599.374 120.360
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33860.906 93587.641 120.190

33837 .023 93570.033 120.120
0.000 0.000 120. 120
EN
999
FIN ISH
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Format for 3D null level strings (e.g. Boundary. ca rtogra phic symbol strings)
(
MOSS
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GENIO,G ROUN D MODEL

001FOR MAT(6F 12.3,A4 )
080,0 L,5=0.0 ,0 .0,7=3
34084 .613 93755 .397 -999 .000
O
34050.003 93732.622 -999 .000

33997 .803 93697.40 1 -999 .000
D
29431.640 92471.117 -999 .000

0 .000 0.000 -999.000
080,V,S=0.0,0.0,7=3
34050.993 93805.595 -999.000
33989.360 93763.940 -999.000
33953.750 93740.073 -999.000
33863 .065 93678.688 -999.000
0 .000 0 .000 -999.000
999
FINISH
53
Format for 4D Survey station s pOints
MOSS
GENIO,GROUND MODEl
001FORMAT(4F12.3,A4)
003,ORDR,4=1,1,2,3,4
080,PST ,7=4
34039.010 93797.000 120.170 STN1
33244.500 93054.700 125.310 STN2
32620.110 92486.380 132.950 IP01
28894 .260 92060.400 155.150 TBM2
26413.500 86520.370 141.930 RM10
26249 .490 85565.320 124.870 SM23
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0.0 0 .0 0.0
999
FINISH
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Format for text I annotation strings
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( . MOSS
GENIO,GROUND MODEL
TE
OOlFORMA T(4F12.3,/, 11A4 )
080, *T,5=0 .0,6=0.0, 7=12
34039.010 93797 .000 0.200 90.000
SCH
A
33244 .500 93054.700 0.200 93 .340
KE KUALA LUMPUR
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32620.110 92486.380 0.200 90.000

8M NO . 214
28894.260 92060.400 0.200 90.000
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SG. HUSNI
26413.500 86520.370 0.200 90.000
BOX CULVERT
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26249.490 85565 .320 0.250 90.000

MUSLIM CEM .
0 .0 0 .0
999
M
FINISH
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Format for cross-sections along master alignment

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MOSS
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GENIO,CROSS-SECTION MODEL,ROAD MODEL

082,MS01"G
1000.000 12
-30.020126.810 -23.960 126.590 -20.550 126.350 -16.370 126.410
-8.980126.120 0.000126.230 6.200126.490 13.460127.790
19.210 129.770 24.670132.090 28.860133.800 32.100134.180
1025.000 11
-35.270 124.510 -27.980 124.740 -22.400 124.830 -17.600 124.990
-16.380126.470 -8.400125.990 0.000125.950 6.000125.470
11.590 125.240 25.980 126.410 36.340127.030
1050.000 11
-37.290130.560 -31.460129.560 -25.140129.110 -18.350 125.610
54
-9.300125.4 10 0.000125.300 6.000124.800 11.790 124.670

17.990124.550 23.990124.410 30.100124.390
1075.000 11
-3 1.400124.320 -23.000 124.430 -18.260 124.380 -12.370 124.540
-6.390124.540 0.000124.730 9.000124.620 17.990 124.590
23.980124.730 31.940125.180 37.960125.780
999999.9
FINISH
6D Master Al ignment String
MOSS
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GENIO,ROAD
00lFORMAT(6F12.3,A4)
080,MS01,5=0.0,0.0,7=6
34067 .410 93780.900 120.658 0.000 4.118 999999 .900
D
33984.543 93724.926 120.314 100.000 4 .118 999999.900
33901.676 93668.952 120.264 200.000 4.118 999999.900
N
( 33818.809 93612.978 120.802 300.000 4.118 999999.900
33735.942 93557 .005 121.633 400.000 4.118 999999.900
TE
33653.075 93501.031 122.465 500.000 4.118 999999.900
33570.208 93445.057 123 .297 600.000 4.118 999999.900
33487.341 93389.083 124.129 700.000 4.118 999999.900
33464.351 93373.554 124.359 727 .744 4.118 999999.900
A
33449.862 93363.739 124.505 745 .244 4.114 -2200 .000
33435.452 93353.809 124.650 762.744 4.102 -1100.000
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33421.202 93343.652 124.796 780.244 4 .083 -733.333

33407.198 93333.158 124.942 797 .744 4.055 -550.000
33405.416 93331.775 124.960 800.000 4.051 -550.000
M
33332.533 93263.507 125.758 900.000 3.869 -550.000

33273.196 93183.185 126.441 1000.000 3.687 -550.000
33270.057 93177.947 126.478 1006.106 3 .676 -550.000
EN
33261.367 93162.758 126.584 1023.606 3.648 -733 .333

33253 .042 93147.365 126.688 1041.106 3.628 -1100.000
33244.962 93131.842 126.792 1058.606 3.616 -2200.000
33237 .007 93116.255 126.895 1076.106 3.612 999999.900
M
33226.172 93094 .959 127.037 1100.000 3.612 999999.900

33180.829 93005.830 127.630 1200.000 3.612 999999.900
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33170.867 92986 .248 127.760 1221.970 3.612 999999.900

33159.495 92963.985 127.908 1246.970 3.617 2550.000
33147.905 92941.834 128.056 1271.970 3.632 1275.000
33135 .883 92919.915 128.204 1296.970 3.656 850.000
O
33134.387 92917.280 128.222 1300.000 3.660 850.000

33079.857 92833.524 128.815 1400.000 3.778 850.000
D
33015.874 92756.748 129.407 1500.000 3.895 850.000

32943.321 92688.013 130.170 1600.000 4.013 850.000
32863.201 92628.269 131.273 1700.000 4.130 850.000
32776.623 92578.342 132.545 1800.000 4.248 850.000
32684.783 92538.922 133.818 1900.000 4.366 850.000
32666.254 92532.470 134.068 1919.621 4.389 850.000
32642.450 92524.833 134.386 1944.621 4.413 1275.000
32618.500 92517.664 134.704 1969.621 4.428 2550.000
32594.481 92510.730 135.Q22 1994.621 4.433 999999.900
32589.310 92509.246 135.091 2000.000 4.433 999999.900
32521.669 92489.838 135.987 2070.370 4.433 999999.900
32493.184 92481.683 136.364 2100.000 4.435 8437.454
55
32459.319 92472.137 136.811 2135 .185 4.441 3857 .138

32425.368 92462.901 137.259 2170.370 4.453 2500.000
32396.685 92455.470 137.636 2200.000 4.465 2500.000
32299 .270 92432.911 138.905 2300.000 4.505 2500.000
32102 .124 92399.563 141.112 2500.000 4.585 2500.000
0 .000 0 .000 141.112 2500.000 4.585 2500.000
999
FINISH
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APPENDICES
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"...., ~
TOR TOPOG RAPH ICAL SURVEY WOR KS
APPENDIX A1
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LOCATION PLAN FOR THE WORKS
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- REFER TO LOCATION PLAN APPENDIX A1 -
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2
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APPENDIX A2
'5 "' TMI ex '-:"'l"AHll€ D

STEEL ~ TE
so
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, .
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t:so-.
( .. /'ClIO:
STEEL *tLS ~I~ I NTO
G.AJ..'>'M IZEO
TE
CIJfO'€TE c¥> KAro SlPF>£E
(El<CS'T P'V9<EN1)
A
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T BNl 1S ------,, I
M
10 11m I ~IVET
J KRoJ LN '-'--I----i~~+_-
EN
EN3RA '/EQ
NAME CF F IGLl<ES
SuRVEYCA
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GROUND MARKERS ON HARD SURFACE
NOT TO SCALE (ALL DIMENSIONS IN MILIMETER)
( I)
APPENDIXA3
Srrm d Q~ r LJ_EO C:;:: . . ,-CH
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0--
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oOmm c/ G , PIPE;
EN
Sr"r r/ OR I LLEO CENiE::)
I P. 28
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/ F I GURES ENGRAVED
J~1i JLN
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ON CONCRETE
/ -~
~ME OF
SURVEYOR
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GROUND MARKERS ON NORMAL SURFACE
NOT TO SCALE (ALL DIMENSIONS IN MILIMETER)
(2)
APPENDIXA4
CERTIFIED BY LICENSED lAND SURVEYOR (llS)
I certify that these fi eld notes consisting of ..... ..... pages are a correct and complete record of the
observations and measurements made by or under the immediate personal direction and supervision
in the fie ld of .... (1)... tha t the survey was effected in strict conformity with the Licensed land Surveyors
ER
Regulations , that the standard of accuracy of the survey is ... .... .... .. .. ..... class as defined in those
Regulations and that the survey was completed on the . da y of ........ .. ... ..... .. ..
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I underta ke to accept full responsibility for the correctness of the survey .
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.. ... .. (2) ....... . Surveyor, Licensed under Ordinance No. 11 of 1958.
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NOTE:-
(1) Name , signature and qua lification of the Qual ified Surveyor in charg e of the survey parties .
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(2) Name, signature and qualifications of the Licensed Surveyor.

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(3)
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APPENDIX AS
Schedule of Service Period Licensed Land Surveyor (LLS).
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(4)
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CADANGAN TEMPLAT NORMA TEMPOH PERKHIOMATAN PERUNDING UKUR TANAH UNTUK KOS PROJEK < RMSOJ
CAOANGAN NORMA TEMPOH PERKHJOMATAN PERUNDING UKUR: 32 aUIAN.
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(f)
GOVERNMENT OF MALAYSIA
TERM OF REFERENCE
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FOR
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UNDERGROUND UTILITY
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SURVEY WORKS
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ON PROJECT
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1.0 BACKGROUNO AND OBJECTIVE
The Government of Malaysia intends to carry out detailed engineering survey -

Underground Utility Survey Works in the State of P.!;R!,~$..
The purpose of the detailed ground survey is to provide all the necessary data and
information required for undertaking the engineering design for MEMBINA JALAN DARI
BEHOR MALI KE KAMPUNG KEPALA SEPULOH, PERLIS - (Underground
Utility Survey Works).
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1.1 SCOPE OF WORKS
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( 1.1.1 Survey Area
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The details of the extent of the works to be surveyed is given in the
attached plan of Appendi x A.
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( 1)
SPECIFICATIONS
1. SCOPE OF WORKS
The scope of works shall include the supply of all labour and use of machineries,
equipment and materials required for the complete sub-surface detection, investigation
and mapping of underground utilities for the above project inclusive of the followings:
» construction of survey reference grid with Global Positioning System (GPS).
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» surface reference line survey.
» complete underground utilities detection including but not limited to the markings
of power and telecommunication cables, sewer, water and gas pipes.
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a) The LLS is to use GPS and electronic survey total station to construct a survey
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( control point network, coordinate, in which the position of all survey works and
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detected services will relate.
b) All survey results will be in State's Cassini Soldner coordinate system.

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c) Survey plan shall indicate layer but not limited to pavement edges, kerb lines, road
edges, traffic dividers and valve/manhole covers.
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d) All existing utilities shall be detected /surveyed within the specified area as in
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Appendix A.
e) The conductive services such as cables & pipes is to be located, pin pOinted and
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( traced using electromagnetic cable and pipe detection instruments and these
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positions are recorded in X, Y and Z coordinates on to a field data logger before

transferring to the computerized utility information database.
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f) Non-metallic services to be detected using Ground Penetrating Radar (GPR)

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whenever soil conditions allow.
(2)
g) Relating attribute data to the service, i.e. materials, diameters, type, ways and
voltages to be logged and retained wherever and whenever possible.
h) The LLS is to provide digital plans to the client, containing information on all
underground services within the project area.
i) The LLS is to maintain an estimated accuracy level of +/- 10 cm horizontally and

+/- 10 % from the actual depth vertically of all buried services located up to 3
meters deep.
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j) Wherever pOSSible, the works are to be carried out during the daytime. However,
due to traffic conditions, the detection and survey works, where necessary can
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be conducted at night till 6.00 a.m.
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k) The LLS using available electromagnetic techniques and equipment
(electromagnetiC cable locator, pipe detectors and GPR) at its disposal is to locate
all buried PVC, asbestos, concrete and other non-metallic service. The LLS will
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undertake to advise the client of any problems it experiences or potential hazards
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it antici pates.
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I) As a general practice, the LLS will be liable to any damages to underground

utilities due to the negligence of LLS staff. In this respect, the LLS is to detect
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and locate all metallic and accessible non-metallic services.
" Electromagnetic cable locator and pipe detectors can be used to

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detect metallic/conductive services such as iron and steel pipes for

( water, gas, sewer, oil, electric cables, copper telecommunication and
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control cables.
" Ground Penetrating Radar (GPR) can be used to detect non-metallic

services such as sewer, water and drain pipes, accessible ducts (i.e.
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empty protection pipes for optic fiber and other cables) and other
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accessible nonconductive underground objects, if the soil contents

and conditions permit.
(3)
2. SUBMISSION OF SURVEY PLANS, UTIUTIES, DIGITAL DATA AND
RECORDS
Upon the satisfactory completion of the whole works, the LLS shall submit the survey
results as follows:-
i. Hardcopy Requirements
Paper Quality Minimum 80 GSM ink-jet media paper.

Printing Quality Full standard colour coding
Utilities
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Individual colour coding .
Electric (red), Telecommunication (green), Water and Raw
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water (blue), Sewer and Force Sewer (brown), Gas
(magenta), Drainage (grey) & Others (black).
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( Non-Utilities
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Individual symbol.
Traverse point, GPS point, chainage symbol, kilometre post,
street name, edge of street, wall line, fence, bush, leaf tree,
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fountain, statue, palm tree, river bank, shore line, rail road,
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shelter roof, pillar, traffic signage, boundary stone & others.

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JUPEM standard coding: Full compliance with MS 1759:2015.

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Submit two (2) copies of report consist of i.e. Introduction,

Objective, Methodology, Findings on Every Plan and
Summary
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( Submittals Three (3) complete sets of colour coded maps.

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Scale Metric scale: 1:100 ~ 1:1000

Paper size ISO A3 ~ AO size
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(4)
ii. Softcopy Requirements
File System 3D (* .xy), AutoCAD (* .dwg) & type of files as requested
Media type DVD-R ; USB - Flash Drive
Submittals One (1) set of storage media (DVD, USB Media & etc.)
iii. Detection and Survey Requirements
System State Cassini Coordinates System (GPS)

i) State Cassini Coordinates System
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ii ) Malaysian Rectified Skew Orthomorphic (RSO)
where required
Underground Utility i) Electromagnetic Field/ Electromagnetic Locator
Technologies/ Devices ii) Magnetic Field/ Magnetometer
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iii) Radar/ Ground Penetrating Radar (GPR)
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iv) Electronic Distance Measuring Device (EDM)/ Total
( Station
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v) Real Time Kinematic (RTK) GPS/ Aplikasi MyRTKNet
vi) Latest technology/ device where required
Electromagnetic Site
Investigation Full detection / survey of the area required.
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(Full Detection/Survey)
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Attributes Information • Comply with latest MS 1759
• Physical characteristic (size, material type, PVC, etc.)
• Depth of network
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• Number of ways (Telecommunication / TN B)
If any related information

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• Contractor's name
• Historical data of utility laid
• When laid
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<- Nevertheless, the LLS shall liaise with relevant agencies to verified on the utilities information
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gathered and issue to Jabatan Kerja Raya (JKR) / contractor part of any of the above items
as and when required by JKR. All data and drawing shall be recorded and plotted in a format
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required and approved by JKR. All the above mentioned items submitted shall become the
properties to JKR.
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(5)
3. PRECAUTIONS TO BE TAKEN
The LLS shall observe and comply with the following procedures to ensure that the
Detection Works carried out are not injurious to other parties: -
i. The LLS shall provide proper traffic management systems and schemes during
the course of the Detection Works. Traffic control devices (including temporary
Signs/roadside furniture) shall be provided in accordance with the relevant JKR
Arahan Teknik (Jalan) publications or other relevant local authorities standards
and guidelines.
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ii. The LLS shall not cause the Detection Works to disrupt the normal functioning
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of existing services and utilities and shall not disconnect any of the services
and utilities without the written approval from the relevant authorities and
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companies. The Contractor shall make good, at his own expense, any damage
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whatsoever to existing services and utilities in accordance with the instructions
and to the complete satisfaction of the relevant authorities and companies
concerned, and shall keep JKR indemnified at all times from all claims, costs
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and expenses which may be brought against or incurred by JKR for or in
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account of any damage to the said services and utilities.

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iii. The LLS shall be responsible for clearing any site obstructions and obtaining
any permit that may be necessary for the carrying out of the Detection Works.
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iv. All personnel shall be equipped with Personal Protection Equipment (PPE) such
as reflective clothing either yellow or orange florescent in the compliance/
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requirement of Department of Safety & Health (DOSH) and Team Leader is

l provided telecommunication tools for field communication.
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(Subject to compliance with JKR traffic management requirements)

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(6)
4. ATTRIBUTES
4.1 Quality Level Attributes
4.1.1 General
The quality level attribute of an underground utility feature is the most
important information aside from its alignment or presence in a utility
map. As such due care should be given to precisely indicate the quality
level of an underground feature especially in hardcopy maps given the
fact that in any congested corridor, the horizontal and vertical separation
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between utility features could be reduced to several decimeters, and at
plotting scale such separation may be difficult to discern. Careful usage
of the following cartographic elements can help in ensuring a reliable
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indication of the quality level of underground features.
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4.1.2 Labelling
This is also one of the methods of differentiating between the quality
levels, utility type, ownership, date of depiction, accuracy of surveyed
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appurtenances, end pOints of any utility data, active, abandoned, or out-
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of-service status, size, condition, number of jointly buried cables and
encasement.
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4.1.3 Symbol Embedding

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Symbol embedding can also be used to indicate the different quality levels
of underground utility data.
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4.1.4 Colour
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Colour is frequently used to indicate type which can be used in

conjunction with other methods.
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4.1.5 Line Weight

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Line weight can be used at actual scale to depict the size of the utility.
However, it has the effect of obscuring other data if the line size is large.
(7)
4.1.6 Layer
Occasionally layers are used to portray various attributes. For example,
quality level 'N data could be on one layer, quality level 'B' data on
another, and etc. All layers must be turned be on to present the complete
utility information particularly in a geographic information system.
4.1.7 Annotation
Annotation should be used with care as to ensure that it does not obscure
other util ity data.
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4.2 Utility Depiction Legend
In most cases, an underground utility map should be provided with a separate
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utility legend to clearly indicate the methods of quality level differentiation and
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( other utility attributes.
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4.3 Parcel Boundaries
Parcel boundaries shown shall be derived from the National Digital Cadastral
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Database (NDCDB) currently maintained by JUPEM.
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4.4 Lot Numbers

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Lot numbers of all parcels as depicted in the NDCDB shall be shown whenever
possible.
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4.S Names of Building, Street, Road and River

Official names of buildings as well as names of streets, roads and rivers shall be
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( shown.
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4.6 North Arrow

An arrow-like symbol indicating the direction of the grid north and the true north
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shall be shown.
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(8)
4.7 Scale Representation
Since maps must necessarily be smaller than the areas mapped, their use requires
that the ratio or proportion between comparable measurements be expressed on
the map. This is called map scale and should be the first thing which the map user
becomes aware. Scale should be expressed as a statement of map distance in
relation to earth distance or a graphic (or bar) scale or both.
4.8 Plan Date

The date of the plan should be prominently displayed.
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4.9 Marginal Information
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Marginal information may include such items as section, town, city and state
names, scale, north arrow, legend and disclaimer, among others .
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4.10 Disclaimer
Disclaimers are used to limit and define the map author's responsibility for the
content, accuracy and currency of the map. Although some maps may require
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specialized disclaimers, the following disclaimer represents one suggestion:
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''Not to be treated as a map depicting property boundaries"

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5. METADATA
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Metadata are commonly defined as the data about data or the data about the processes
performed on the data. The major uses of the metadata are:
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i. To maintain an organization's internal investment in geospatial data;

ii. To provide information about an organization's data holdings to data
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catalogues, clearing houses and brokerages; and

iii. To provide information needed to process and interpret data to be received
through a transfer from an external source.
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Thus, in order to facilitate their use, underground utility maps produced shall be
accompanied with appropriate metadata which complies with Malaysian Standard for
Geographic Information - Metadata.
(9)
6. COLOUR CODE
The color code and utilities marking procedure shall follow "PEKELILING KETUA
PENGARAH UKUR DAN PEMETAAN BILANGAN 1 TAHUN 2016" for "GARIS PANDUAN
KOD WARNA DAN PENANDAAN BAGI PEMETAAN UTILm BAWAH TANAH" and
"PEKELILING KETUA PENGARAH UKUR DAN PEMETAAN BILANGAN 2 TAHUN 2016" for
"GARIS PANDUAN PENERIMAAN DATA DIGITAL DAN PELAN UTILm DARI JURUUKUR
TANAH BERTAULIAH (JTB) OLEH JABATAN UKUR DAN PEMETAAN MALAYSIA (JUPEM)"
see attached. The utility code according to MS1759: 2015 is automatically amended by
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following JUPEM utility code circular. The LLS shall follow general colour code according
to MS1759: 2015. Refer figure below.
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( 10)
Append ix A ("- ~
LUAS KAWASAN
BIL PROJEK UNDERGROUND UTILITY GAMBA RAJAH SKEMA
SURVEY WORKS
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PROJEK
I' ~ JALAN SEDIA
l.
••• Ko ridor survey untuk underground
utility survey works pada persimpangan 3 ~ ADA
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di sepanjang jajaran ja lan sedia ada.
Lekasi kerider ada lah tertakluk kepada r-------------------------------]
131
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peruba han di tapak oleh Wakil Kerajaan.
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PETUNJUK:
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KAWASAN UNDERGROUND UTILITY SURVEY WORKS

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Appendix AI3
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(Environmental Protection and
A
Enhancement Requirements)
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APPENDIX A13
GOVERNMENT REQUIREMENTS
(NEEDS STATEMENT) (TERMS OF REFERENCE)
ENVIRONMENTAL PROTECTION AND ENHANCEMENT REQUIREMENTS

(FOR DESIGN AND BUILD PROJECTS)
MEMBINA JALAN DARI BEHOR MALI KE

KAMPUNG KEPALA SEPULOH, PERLIS
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CONTENTS
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1.0 Scope of Works
2.0 Special Requirements
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3.0 Legal Req uirements
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3.1 Compliance with the Legal Req uirements
3.2 En vironme ntal Impact Assessment (EIA)/Proposa l Mitigation Measures
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(PMM )
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3.3 Social Impact Assessment (SIA)
3.4 Other Management Plans
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3.5 Environmental Protection Works

3.6 Preservation of Flora and Fauna (Wildlife)
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4 .0 Safety and Health Requirements

5.0 Waste Management and Disposal System
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6.0 Stormwater Management

<- 7.0 Environmental Management Plan
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7.1 Erosion and Sediment Control Plan (ESCP)

8.0 Environmental Monitoring, Auditing and Training
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8.1 Monitoring
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8.2 Auditing
8.3 Reports
8.4 Training
Annex A - Standard Report Format for EMP, EMR, EAR, ECAR and
CSWMP
Annex B - Schedule 1: Summary of documents to be enclosed with
submission
A13 - 1
APPENDIX A13
GENERAL
1.0 Scope of Works
1.1 The works shall cover planning, design, construction, monitoring,

auditing, reporting, training and maintenance of environmental
protection and enhancement work.
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1.2 The contractor is deemed to have visited the site to familiarise himself
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with site and loca l conditions that pertain to the necessary programme ,
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( design and execution of this work. The co ntractor shall take all
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necessary actions and precautions during construction and maintenance
works so as not to affect the surrounding environment.
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2.0 Special Requirements
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2.1 During the tender submission, the tenderer should submit their proposal
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regarding the en vironmental requirement to protect site condition

including drawings and the breakdown of prices and all necessary as per
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Annex B - Schedule 1: Summary of documents to be enclosed with

submission.
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2.2 An EMP report should be submitted by the contractor to the P.O . and
shall be approved prior to commencement of any works on site. For
projects subjected to EIA requirements, the EMP shall be submitted after
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the approval of the EIA. No site clearing and earthworks shall be carried
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out prior to EMP approval by relevant parties/authorities.
2.3 The contractor shall need to include the environmental activities in the
work programme to be submitted to the p.o. These activities shall
contain all the necessary actions and interactions in detail.
A13 -2
APPENDIX A13
2.4 The onus of obtaining timely approval from each relevant Local
Approving Authority on environment shall be the contractor's
responsibility . Untimely receipt of approvals which may affect the
contractor's design/construction programme shall not in any way be a
basis/cause for consideration of time extension or variation to the
contract.
2.5 The contractor shall take serious and urgent actions on all find ings and
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recommendations toward protecting the environment as in the report
or/and as instructed by the p.o . Fail ure to do so , the p.o . shall appoint
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other party and all costs will be borne by the contractor.
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2.6 The contractor shall provide rain gauge to determine rain fall intensity
and turbidity measuring equipment to determine direct in-situ
measurement on water quality for immediate rectification action should
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pollution occur.
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3.0 Legal Requirements

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3.1 Compliance with the Legal Requirements

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Prior to the execution of the project, the project proponent/contractor shall

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( comply with all related federal and state legislations such as, but not limited to ,
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the following :
a) En viron mental Quality Act 1974 (Act 127)
b) Environmental Quality (Scheduled Wastes) Regulations 2005
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c) Environmental Quality (Sewage) Regulations 2009

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d) Environmental Quality (Clean Air) Regulations 2014

e) Environment Quality (Prescribed Activities) (Environmental Impact
Assessment) Order 2015
f) Federal Territory (Planning) Act 1982 (Act 267)
g) Fisheries Act 1985 (Act 317)
h) National Forestry Act 1984 (Act 313)
A13 - 3 .
, .
APPENDIX A13
i) Land Conservation Act 1960 (Act 385)

j) Local Government Act 1976 (Act 171)
k) National Land Code 1965 (Act 56)
I) Occupational Safety and Health Act 1994 (Act 514)
m) Solid Waste and Public Cleansing Management Act 2007 (Act 672)
n) Street, Drainage and Building Act, 1974: Act 133 and Amendment, 1978
0) Town and Country Planning Act 1976 (Act 172)
p) Wi ldlife Conservation Act 20 10 (Act 716) Amend ment 201 2
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q) Workers Minimum Am enities Act 1990 (Act 446)
r) Akta Pen yiasatan Kajib umi 1974 (Akta 129)
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s) Akta Air 1920 or an y enactments re lated to water as enforced by states
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( t) National Heritage Act 2005 (Act 645 )
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u) Town & Country Planning (Amendment) Act 2017 [A1522]
3. 2 Enviro nmental Impact Assessment (EIA)/Proposa l fo r Mit igati on

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Measures (PMM)
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Whe re EIAlPMM is requ ired by the said Act, the co ntractor sh all prepare ,
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su bmit and obtai n approval from th e DOEm REB/EPD . The co ntractor

shall also inco rporate in his works all th e abatement and mitigation
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measures for environmental protection and enhancement incl udi ng

monitoring and auditing.
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3.3 Social Impact Assessment (SIA)
Where Social Impact Assessment (SIA) is required by the said Act, the
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contractor shall prepare, submit and obtain approval from the

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PLAN Malaysia I Local Authority. A Social Impact Management Plan

(SIMP) shall be developed for the Project as part of the SIA report for
approval. The contractor shall also incorporate in his works all the
abatement and mitigation measures required to address the predicted
social impacts .
---------------------------------------------- A13 '-4'"

APPENDIX A13
3.4 Other management plans
Where required by the said Act, the contractor shall prepare, submit and
obtain approval from the relevan t approving authorities for other
management plans, if applicable , such as:
a) Construction Solid Waste Ma nagement Plan;
b) Flora Management Plan , incl uding Site Inventory An alys is and
Penilaian isi hutan;
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c) Wi ldlife/Fauna Managem ent Plan ;
d) Coral Reef and Marine Ecosystem Management Plan ;
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e) Conservation Management Plan ; and
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( f) Any other plans required .
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3.5 Environme ntal Protecti on Wo rks
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The contractor shall identify the significant environmental aspects and
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impacts of the projects and execu te all mitigating measures proposed in

the Conditions of Approval by the Approving Authority and in the
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EMP/ECR. Reference shall be made to the JKR Standard on

Environ mental Protection and Enhancement Works for Projects (EPW),
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for a more compre hensive understan ding of the scope of works. The
contractor shall also observe/carry out the following.
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a) Limit and co ntro l site clearing works to co nstruction areas only.

Existing trees of 80 cm girth at breast height are to be retained as
much as possible and only minimum tree cutting is allowed unless
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they impose danger to the public and traffic after completion of

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the project.
b) Transport and stockpile topsoil to designated areas approved by

the P.O . for reuse during turfing , hydroseeding and landscaping.
=- .-.
APPENDIX A13
c) Turf or hydroseed slopes immediately upon reaching their

formation levels. For cut slopes, hydroseeding shall be carried out
together with supportive materials. Landscaping works shall
commence early as directed by the P.O.
d) Take necessary precautions to prevent deposition of debris,

rubbish, silt, waste materials, polluted water, chemicals, etc.
during execution of the works from entering existing
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strea ms/waterways.
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e) Constru ct berm/bench drains , interceptor drainage and other
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( related drainage works to slopes which have reached the required
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formation levels. Provide temporary cover, for example , erosion
control blanket to the exposed slopes .
f) Provide and maintain sediment control measures namely silt
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fences , silt traps , sediment basins , gabion walls , check dams , silt
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curtains, etc. Upon completion , reinstate site including

landscaping where sediment basins were located and remove
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other measures which are not required as directed by the P.O.

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g) Take necessary precautions to ensure that tyres of all vehicles

leaving the site are free of mud .
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h) Not to carry out open burning on site.
i) Supply and lay immediately at least to binder course layer on

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roads which have reached the required formation levels including

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the required drainage system.
j) Prohibit activities such as hunting/trapping of wildlife.

Fines/penalties imposed by the relevant Government
Departments due to such activities shall be borne by the
contractor.
A13-6 .
APPENDIX A13
k) Preserve mangrove areas on site unless deemed necessary for

construction. However, the clearing of mangroves shall be limited
to the construction infrastructural area only and with approval
from the relevant authorities.
3.6 Preservation of Flora and Fauna (Wildlife)
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3.6.1 Flora
Where preservation of flora is required by the said Act, the Contractor
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shall prepare , submit and obtain approval from the State Authority / other
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approving authorities. The Contractor shall incorporate in his Works all
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the mitigation measures for the preservation , conservation or relocation
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of any trees / species in site.
3.6.2 Fauna (Wildlife)

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Where preservation of fauna (wildlife) is required by the said Act, the
Contractor shall prepare , submit and obtain approval from the State
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Authority / other approving authorities. The Contractor shall incorporate

in his Works all the mitigation measures for the protection , relocation or
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rehabilitation of the fauna species and their habitat.

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( 4.0 Safety and Health Requirements

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The contractor shall provide and maintain suitable accommodation for

workers as follows :
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a) Location to be agreed by the P.O.

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b) Sufficient toilet facilities to the satisfaction of the P.O.

c) Facilities for the proper disposal of waste and refuse.
d) Adequate supply of clean water for washing, cooking and drinking.
The contractor shall maintain the site in a clean and sanitary condition that
complies with all requirements of government, health and sanitary authorities.
----~.-----------------------, ..-...--------------------------...------..
APPENDIX A13
5.0 Waste Management and Disposal System
5.1 All types of waste i.e. solid waste and scheduled wastes are to be
segregated, stored and disposed in accordance with the DOE
requirements and other approving authority requirements (e.g. the local
authority).
5.2 Wastes with sharp edges are to be stored in specially designed
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containers and specially manufactured for that purpose .
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5.3 Scheduled wastes storage is to be handled according to DOE's
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( Guidelines for Packaging , Labelling and Storage of Scheduled Wastes
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in Malaysia. A licensed contractor with DOE shall be appointed for the
disposal of scheduled waste to a licensed facility .
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5.4 The disposal of solid waste and scheduled wastes shall be properly
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designed and programmed to abide with the relevant authorities'

requirements .
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6.0 Stormwater Management

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Stormwater management design and construction works shall comply with the
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( requirements of JKR Malaysia , 'Erosion and Sedimentation Control Plan

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(ESCP), Jabatan Pengairan dan Saliran's latest edition of Manual Saliran

Mesra Alam (MSMA) and other relevant local authority requirement.
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Stormwater drainage shall be designed for least maintenance cost, effective

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initial cost and serves its function. There shall be no flooding, ponding/silting up
and erosion during construction and after completion of the works.
- · A1'3-8 :·
APPENDIX A13
7.0 Environmental Management Plan (EMP)
The contractor shall submit for prior approval by the Government,

Environmental Consultant registered with DOE/~JREB or other approving
authorities for preparation of site-specific EMP. The EMP shall be submitted to
p.o. for endorsement before site possession, site clearing and commencement
of earthwork in compliance with the Conditions of Contract and/or in compliance
with the requirements of the conditions of approval of the EIA report by the
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DOE/ ~JREB or other approving authorities . The earthwork can only be
commenced after EMP is approved by P.D .lDOE/NREB or other approvi ng
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authorities .
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The EMP shall make reference to the following but not limited to :
a) DOE/ ~JREB format for the preparation of EMPs ;
b )the approved EIA reports , if applicable ; and
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c) EIA Approval Conditions from DOE/ ~JREB (if any).
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It should be clearly noted that the EMP is a document for practical use on site
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by nominated personnel and thus should be concise, up to date and site

specific.
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The contractor shall engage the following qualified personnel on site :

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<. a) Environmental Officer (full time);

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• E.O. shall have a degree in Civil Engineering or Environmental

Management/Science/ Engineering or diploma in
Environmental Management/Science/ Engineering with
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minimum three (3) year experience and be certified to

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CISEC/CESSWIlCePSWaM/LDP2M2 or equivalent.
b) horticulturist/plant/tree expert (part time), if required;

c) fauna/wildlife/coral expert (part time), if required; and
d) registered conservator, if required.
-
APPENDIX A13
7.1 Erosion and Sediment Control Plan (ESCP)
The contractor shall prepare an ESCP certified by a Professional Engineer and

submit the ESCP to the Drainage and Irrigation Department (JPS ) or relevant
local authority for acceptance .
The approved ESCP shall be submitted to the P.O . 30 days prior to

commencement of any earthwork activity at project site. For Sabah , ESCP shall
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be approved as subm itting document for EIA approval cond ition . For Sarawak,
submission of ESCP can be done either post-EIA in compliance to the Terms
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and Conditions of the EIA approval or prior to EIA approval if time permits .
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The following items apply to an ESCP document.
a) The document shall be prepared in accordance with the Manual Saliran

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Mesra Alam (MSMA) or Sarawak Urban Stormwater Management
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(SUS toM) or MS 2526 .

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b) It sha ll be amended wheneve r a cha nge in the design, constructio n,

operation or maintenance at the co nstruction site has a significant effect
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on the discharg e of pollutants to the wate rs at project site not previously

addressed in the document.
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c) It shall be amended if discharges are ca using wate r-quality deterioration

or the Best Management Practice (BMPs ) are ineffective in minimising
pollutants in storm water discharging from the construction site.
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d) The document shall be revised within seven calendar days following an

inspection when additions and/or modifications to BMPs are necessary
to correct observed problems.
________________- ___________________=-_____n_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____
';4.'13 - 10
APPENDIX A13
8.0 Environmental Monitoring, Auditing and Training
8.1 Monitoring
The contractor shall monitor monthly water quality, quarterly ambient air
quality and noise; and vibration, if required , or as specified by the
relevant authorities . All samples taken shall be tested by an accred ited
laboratory. Th e contractor sh all produce and submit environm ental
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monitoring reports cons isting in-situ and laboratory resu lts , sampling
photographs with weather charts and analyses of the monitoring data in
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terms of en vironmental performance , month ly or as specified by the
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( relevant authorities . Reference to the contents of the reports can be
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made to the Standard Report Format attached in Ann ex A.
8.2 Auditi ng
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The contracto r shall engage a third-party DOE-registered/NREB-
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reg istered/EP D-registered Environmental Auditor to audit all activities on

site as required by the relevant authorities. The tasks of the Auditor
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among others are:

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a) to ca rry out enviro nmental co mpliance to EIA approva l cond iti ons
or contractua l req uirements quarterly or as specified by the
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relevant authorities ;
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b) to interp ret monitoring data in terms of environmental

performa nce;
c) to verify effectiveness of co rrective and preventive action
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implemented;
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d) to recommend requirement and improvement of mitigating

measures; and
e) to produce and submit a comprehensive environmental auditing
report.
------------,--_._----,-------------------------'g A1-3 - 11.'

,-,iJ.t;:r~:27$ .
APPENDIX A13
8.3 Reports
The submission of monitoring and audit reports shall follow the

requirements given in Table 8 of JKR Standard on Environmental
Protection and Enhancement Works for Projects (EPW). The contents
of the report shall be in accordance with the Standard Report Format as
attached in Annex A.
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8.4 Training
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The contractor shall provide yearly training by competent trainers in
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( environment for the project team in the field of environment. This training
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shall include environmental law and regulations , en vironmental
management and conservation, post EIA and environmental monitoring ,
emergency response preparedness, waste management and any
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competency training approved by DOE/NREB/EPD . The contractor's
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E.O. shall also provide regular training/awareness briefing for site

personnel involved in works that have impact on the environment.
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Training conducted shall be in accordance with latest Govemment's

requirement.
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, ,A13 - .12 l,
- , , t, .:.. (~.;,~ J
APPENDIX A13
Annex A
(normative)
Standard report format for Environmental Management Plan (EMP),

Environmental Monitoring Report (EMR), Environmental Audit Report (EAR),
Environmental Close Audit Report (ECAR) and Construction Solid Waste
Management Plan (CSWMP)
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E.1 Format for Environmental Management Plan (EMP)
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E.1.1 For EIA project and non-EIA project
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Chapter 1: Introduction
Key information needed to be detailed in this chapter is as follows :

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a) Project layout as approved in the Development Order by Local Authority.

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b) Project implementation schedule.

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c) Name of the EMP preparer and his consulting firm .

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(. Chapter 2: Policy
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This chapter should provide the information on :

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a) Company's corporate policy statement on environmental management and

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protection .
b) Commitment by the top management on the mainstreaming of environmental

agenda and instilling self-regulation in the development project and on ensuring
continuous compliance with the environmental regulatory requirements.
--------------=----------------.,---------------~.---------------------
A13'£' 13
APPENDIX A13
Chapter 3: Organisational structure
This chapter should detail the aspects related to the Environmental Management Unit
(EMU) and the allocations provided for Environmental Protection as follows :
a) Organisation chart of the company's top management with responsibilities for

environmental management and protection (provide names, positions, mobile phone
contact numbers and e-mail addresses).
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b) Name, mobile phone contact number and e-mail address of envi ronm ental
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manager, environmental officer (EO ), engineering consultant, contractor, site
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( supervisor and competent person (wherever relevant and available).
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c) Name of environmental consultant and accred ited laboratory conducting
environmental monitoring , analysis of environmental samples and submitting reports
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to the DOE .
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Chapter 4: Training requirement

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This chapter should provide information on plan for staff training to develop
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competency to discharge responsibiliti es on environmental requirements and

compl iance. The train ing areas shall include maintenance and performance
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monitoring of all P2M2 (L D-P2M2 , lETS , APeS, STS , management of scheduled

(
waste) , wherever relevant.
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Chapter 5: Environmental Requirement

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This cha pter should outline the need for the EMP and detail the following:
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a) EIA approval conditions (applicable for EIA projects only).
b) LD-P2M2 document (applicable for EIA projects only).

c) Pollution Prevention and Mitigation Measures (P2M2) to be implemented as in Table
A below:
- ",.
. "A13 -' 14 '

APPENDIX A13
Table A. Pollution Prevention and Mitigation Measures (P2M2) to be

implemented (Example)
Project activities Impacts P2M2 P2M2 to be

and recommended in implemented
environmental EIA Report
issues concerned
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NOTES:
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1. The contents of the above table are to be derived from "Summary of Impacts and
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pollution prevention and mitigation measures" recommended in the EIA Report and
additional requirements stipulated in the EIA approval conditions (COAs).
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2. P2M2 are those which can be described as "state of the art technologies" or
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"industry best practices".
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d) Water pollution control :

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i) Water pollution control monitoring .

ii) Effuent treatment.
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iii) Temporary sullage and sewage treatment.

iv) Permanent sullage and sewage treatment.
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v) Control of oil and grease, concrete wash , etc.

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e) Control of air pollution and noise:

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i) Air pollution control monitoring .

ii) Air pollution control.
A13-15
APPENDIX A13
f) Materials and waste management:

i) Raw materials and stockpiles.
ii) Solid waste .
iii) Biomass.
iv) Spoils/dredge materials/construction solid waste .
v) Open buming.
vi) Housekeeping .
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g) Scheduled waste management
The following information shall be provided : Proposal for the management of
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scheduled waste to comply with Environmental Quality (Scheduled Waste)
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( Regulations 2005 generated during construction and post construction stages.
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h) Emergency Response Plan (ERP)
The following information shall be provided : name and contact details (mobile phone
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number, e-mail address) of the professional who has been tasked to prepare the ERP
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and the schedule for its preparation and submission to DOE.

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i) Abandonment and closure plan

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In a particular case where the project proponent intends to abandon a project whether
it is in the construction stage or after it has started operation, an abandonment and
closure plan shall be prepared .
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j) Declaration and checklist
The project proponent is required to make a declaration (Example of format in the

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Table B) that all the actions/measures/plans outlined in the EMP will be implemented.
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The form is required to be filled out and submitted to the DOE together with the EMP
document.
A checklist to assist the Consultant in the EMP preparation and to summarise the EMP
actionable items is given in Table C.
A13 - 16
APPENDIX A13
Table B. Declaration by Project Proponent/Authorised Person (Example)
DECLARATION BY PROJECT PROPONENT/AUTHORISED PERSON
I certify that the Environmental Management Plan (EMP) has been prepared with my knowledge
and I shall undertake the responsibility to ensure the actions plans/pollution prevention and
mitigation measures (P2M2) stated in the EMP will be implemented. I have provided sufficient
allocation for the implementation of th e EMP and P2M2 .
PROJECT TITLE: .......................................... .
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PROJECT ADDRESS/LOCATION:
Name of Project ProponenUAuthorised Person
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Date: .
Table C. Environmental Management Plan Preparation Checklist (Example)

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PROJECT TITLE:
NAME OF PROJECT PROPONENT:

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NAME OF CONSULTANT:
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RECOMMENDED POLLUTION PREVENTION AND MITIGATION MEASURES (P2M2) AND EIA

APPROVAL CONDITIONS (COAS) COMPLIANC E CH ECKLIST
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<- P2M2 RECOMMENDED OR

COA NUMBER ....
ACTtONABLE ITEM IN EMP
ON PAGE .....
NOTES
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Name of Project Proponent

. .... .. ............. . ....... ............. .........
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Signature: . ... . ... .. .... ... .. ... ....

Date: . . . . . . . . . . . . . . . . . . ..... .. . . .
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APPENDIX A13
E.2 Format for Environmental Monitoring Report (EMR)
E.2.1 EMR for EIA and non-EIA projects
TABLE OF CONTENTS
EXECUTIVE SUMMARY
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1.0 INTRODUCTION
1.1 Introduction to Project
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1.2 Progress of works to date (EIA 1-18)
1.3 Pematuhan syarat ketutusan EtA (EIA 2-1 8)
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2.0 WATER QUALITY MONITORING
2.1 Sampling and analysis procedures
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2.2 Results
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2.3 Comparison with baseline and previous results

2.4 Discussion on water quality results
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2.5 Conclusion of findings on water quality

2.6 Photos
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3.0 SILT TRAP/SEDIMENT BASIN MONITORING

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3.2 Results
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3.4 Discussion on results
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3. 5 Conclusion of findings on discharge quality

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3. 6 Photos
4.0 CORAL REEF MONITORING (IF REQUIRED)

4.1 Sampling and analYSis procedures
4.2 Results
A13 -18
APPENDIX A13

4.4 Discussion on results
4.5 Conclusion of findings on life coral cover and indicator species
4.6 Photos
5.0 AMBIENT AIR QUALITY MONITORING

5.2 Results
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5.4 Discussion on ambient air quality results
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5.5 Conclusion of findings on ambient air quality
5.6 Photos
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6.0 NOISE QUALITY MONITORING
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6.2 Results
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6.4 Discussion on noise quality results
6.5 Conclusion of findings on noise quality
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6.6 Photos
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7.0 SITE OBSERVATION DETAILS
Photos to verify site observations. For EIA project, aerial view photos or videos are
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8.0 CONCLUSION
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APPENDIX A13
E.2.2 EMR fer projects IlRder the ceRtrel ef NRE8
Chapter 1: GeRerallRfermatieR
Key iRrormation nee€le€l to be €Ietaile€l in this chapter is as follows :

a) Project title.
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b) Oate of commencement.
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c) Physical proQress of construction.
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€I) Oate of submission of the previous Environmental MonilorinQ Report.
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Chapter 2: '.'\later quality sampliR!J aRd eR'IireRmeRtal mORiteriR!J
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Item 2.1: Particulars of water an€l ambient air quality monitorinQ
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I nclu€le the roliowinQ items:

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a) Frequency.
b) Oate of samplinQimonitorinQ.
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c) \'\leather an€l ti€lal con€litions €IurinQ an€l prior to samplinQ .
€I) GeoQraphical coor€linates of the water samplinQ point.

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Item 2.2: Environmental monitorinQ
This chapter shoul€l inclu€le compliance to the Terms an€l Con€litions of the Ell'.
approval an€l implementation of the prescribe€l mitiQatinQ measures on:
A13 - 20
APPENDIX A13
a) Control of air an9 water pollution;
b) Control of soil erosion an9 se9imentation ;
c) Control of noise an9 vibration ;
9) VVaste !leneration an9 mana!lement;
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e) Traffic 9isruption an9 hazares;
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f) Public an9 occupational safety an9 health issues; an9
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( !l) Public complaints, etc.
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Chapter 3: Result and discussion
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Itemd.1: Water an9 ambient air Eluality
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Incluge the followin!l items:

a) Collation an9 evaluation of €lata (attach Laboratory
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Analysis Report) .
b) Interpretation of €lata with comparison to the baseline an9
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the previous monitorin!l €lata .

c) Discussion .
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9) Recommen9ation(s) .
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Item d.2: Other environmental parameters

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I ncluge the followin!l items:

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a) Various environmental components as state9 in Item 2.2.

b) Status of implementation of the recommenge9 miti!latin!l
measures.
c) Propose9 reme9ial action(s) .
A13-21
APPENDIX A13
Itell1 d.d: COll1ll1ents or recoll1ll1enElationiall1enElll1ent to the prescribeEl

ll1iti§atin§ ll1eaSlJres
IncllJEle the followin§ itell1s:

a) Ill1ll1eEliate rell1eElial actions to be taKen .
b) AElElitionalll1iti§atin§ ll1eaSlJFOS reqlJireEl .
Chapter 4: Appendices
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This chapter sholJlEl contain relevant plates anEl ll1aps.
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APPENDIX A13
E.3 Format for Environmental Audit Report (EAR)
E.3.1 For EIA projects
A AUDIT SITE ADMINISTRATIVE DETAILS

Information including :
I. DOE Audit Tracking Number:
ii. Organisation name
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iii. Audit Location/Address
iv. Organisation representative
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v. Audit scope/area
Audit criteria
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VI.
( VII . Audit site visit date
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viii . Date of report
ix. Name of lead auditor and auditors
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B REGULATORY COMPLIANCE SUMMARY
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Information including:
i. Regulation or COA Title/Reference
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ii. Regulation or COA Number

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iii. Number of non-compliances
C MAIN REPORT
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Information including:
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i. Audit Finding Summary Sheet presented at the closing meeting and

signed by the organization.
ii . Environmental control equipment compliances such as valid licenses,
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conditions that are conformed with , etc.

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iii. Environmental Sampling Results (if any was done during the audit).
IV. Additional non-compliances (if any) for the Environmental Sampling
Results .
v. Additional notations/explanations on the audit findings if pertinent and
of material value .
A13 - 23
APPENDIX A13
vi. Recommendations for the non-compliances found .

vii. A statement of the confidential nature of the contents of the audit
report.
D ATTACHMENTS
i. Updated site layout plan showing key activities/processes, pollution
control equipment, sewage discharge points, etc.
ii. Attendance list - audit opening and closing meeting .
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iii. Photos of observable non-compliances at the site .
iv. Laboratory results of environmental sampling .
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v. Any other pertinent information.
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vi. Confidentiality Statement.
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APPENDIX A13
E.3.2 For non-EIA projects
TABLE OF CONTENTS
EXECUTIVE SUMMARY
1.0 INTRODUCTION
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1.1 Introduction to Project
1.2 Project Development Concept
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1.3 Project Environmental Management Unit
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1.5 Auditing Period
2.0 STATUS OF COMPLIANCE

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2.1 Regulation of Earthworks
2.2
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Drainage and Surface runoff control
2.3 Slope Protection
2.4 Air Pollution Control
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2.5 Noise Pollution control

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2.6 Biomass Management

2.7 Sewage Management
2.8 Solid Waste Management
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2. 10 Coral Reef Management (If required)

2. 11 Contingency and Emergency Response Plan
2.12 Housekeeping
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3.0 RECOMMENDATIONS
3.1 NCR Issued/Closed Out
3.2 Action Plan for Rectification/Improvement works
3.3 Recommendations for Identified/Predicted Issues
A13 - 25
APPENDIX A13
4 .0 CONCLUSION
APPENDIX:
• PROJECT PHOTOGRAPHS
• ENVIRONMENTAL PROTECTION AND ENHANCEMENT MONITORING

CHECKLIST DURING CONSTRUCTION
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APPENDIX A13
E,3.3 Far NREB projects
I. Title Page
Title of Projeot
Perio9 of A1I9it
~Jame an9 a99ress of flrojeGt flroflonent
Name of A1I9it Team
Configentiality ~Jote
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II. Table of Content
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List of Tables
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List of f'igllres
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List of Aflflen9iGes
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List of Abbreviations
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III. ExeGlitive Slimmary
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IV. Main Reflort

Chaflter 1: Intro911Gtion
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1. 1 Projeot Baokgrolln9
1.2 Legal ReElllirement for Ingeflengent Environmental A1I9it
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1.J A1I9it ObjeGtives

1.4 A1I9it Soofle
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1.5 A1I9it Metho90logy

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1.8 A1I9it Team
Chaflter 2: '/Vorking COflY

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Comfllete9 a1l9it Cheoklists/Criteria

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Fin9ings from Interviewing A1I9itee's Reflresentative

EvigenGe of DOGliment Review
Chaflter J : A1I9it A otivities an9 Fin9ings
A13 - 27
APPENDIX A13
3.1 Results of Verifiaation Interviews Inalude questions asked , responses

received and analysis of the responses
3.2 Findin§s frorn Site Inspeation photographs with olear aaptions and
cornrnents
3.2.1 Noteworthy Efforts
3. 2.2 Areas for Irnprovernent
3.3 Correative Aation ! Preventive Measures
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Chapter 4: Status of NCRs Raised in Previous Audit (not appliaable for the fi rst
audit report)
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Chapter 5: Reaornrnendations
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Chapter 6 : Conalusion
Chapter 7: Disalairner
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Appendices :
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Attendanae Lists of Openin§ and Closin§ Meetin§s

Presaribed Criteria or Approval Doaurnent
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Correative and Preventive Action Report (CAR)

Relevant Docurnent
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APPENDIX A13
E.4 Format for Environmental Close Audit Report (ECAR)
TABLE OF CONTENTS
EXECUTIVE SUMMARY
10 INTRODUCTION
1.1 Background details of Project
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1.2 Project Description
1.3 Any changes to Project Activities throughout duration of Contract
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1.4 Summary of Monitoring Programme
1.5 Summary of Audit Programme
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2.0 EVALUATION OF PROJECT PERFORMANCE
2.1 Description and evaluation of environmental monitoring results
2.2 Description and evaluation of mitigating measures
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2.3 Achievement of environmental performance as compared to JKR
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Corporate Objectives
2.4 Achievement of environmental performance compared against JKR ISO
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14001 EMS, the EMP and other environmental requirements

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3.0 LESSONS LEARNED AND RECOMMENDATIONS

3.1 Detailing of any problems encountered on-site
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3.2 Suggestions for improvement

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APPENDIX :
• PROJECT PHOTOGRAPHS
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• HANDING OVER AUDITING CHECKLIST
A13 - 29
APPENDIX A13
E.5 Construction Solid Waste Management Plan (CSWMP)
The CSWMP shall include the following:

a) detailed information on the project initiator or proponent (company or
personal details, contact information , etc.);
b) detailed descriptions on the project location, expected activities to be

carried out and expected duration of the activities;
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c) estimated quantity and types of C&D waste to be generated from the
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project activities at different stages of the activities;
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( d) proposed on-site management plan for the C&D waste (such as specific
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area for C&D waste segregation and storage, specifications of waste bins
to be used , methods of on-site recycling or reuse, etc.);
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e) detailed information on the licensed C&D waste contractors engaged and
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the expected collection frequency;

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f) proposed plan of the destinations of C&D waste, either to recyclable

buyers, treatment facilities or authorised disposal site; and
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g) Emergency Response Plan (ERP) in relation to possible incidents caused

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by C&D waste handling .

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APPENDIX A13
ANNEX B
SCHEDULE 1: SUMMARY OF DOCUMENTS TO BE ENCLOSED WITH SUBMISS ION
ITEM DESCRIPTION OF DOCUMENTS Yes/No
1. Environmental Protection Works (EPW) Proposal contains;
(a) EPW activities in work program
(b) Environmental Impact Assessment (EIA) - letter to/from DOEI
NReB for legal requirement
(c) Social Impact Assessme nt (SIA) -letter to/from PLAN Malaysia or

other approving authorities for legal requirement
(d) Preservation of Flora and Fauna (Wildlife) - letter to/from Forestry
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Department or other approving authorities for legal requirement
(e) Erosion and Sediment Control Plan (ESCP)
i. Layout Plan
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ii. Concept Drawing
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iii . Name of ESCP Preparer
( iv. Drawing certified by Professional Engineer
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(f) Dust & Mud Control
(g) Environmental Monitoring

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(h) Environmental Auditing
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(i) Fuel Spillage Management
OJ Waste Management & Disposal System - Scheduled Waste &
Construction and Domestic Waste
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(k) Catalog for rain gauge and turbidity measuring equipment

(I) Schedule of prices for the works
2. Name of Environmental Consultant and company profile, Curriculum Vitae
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of Registered Environmental Consultant for preparation of EMP including

copy of related certificate (Registered with DOEl NR!;Ell!;PD/other
aoorovina authorities)
3. Name of Independent Environmental Auditor including copy of related
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certificate (Registered with DOE/NReBI€PG/other approving authorities)

4. Name of Accredited Laboratories including copy of related certificate
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(Certified with Skim Akreditasi Makmal Malaysia from Department of

Standard Malaysia)
5. Name of Environmental Officer including copy of related certificate (Degree
in Civil Engineering or Environmental Management/Sciencel Engineering or
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diploma in Environmental Management/Sciencel Engineering with minimum

three (3) year experience and be certified to CePSWaM , and CISEC/CESSWII
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ILDP2M2 or equivalent.
Signature of Tenderer
Name of Authorized Personnel
Official Stamp of Tenderer
Date
A13 - 31
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Appendix A 14
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(Road Design Requirements)
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APPENDIX A14
ROAD DESIGN REQUIREMENT (R2)
1.0 Road Geometric
The geometric design of the road shall satisfy the criteria 's specified in Arahan
Teknik (Jalan) 8/86 (Pindaan 2015) - A Guide On Geometric Design of Roads, for
JKR R2 standard (2 lanes, single carriageway). This shall include horizontal
alignment, vertical alignment, superelevation etc. The design of works, where
possible, should involve minimum land acquisition and demolition of structures
and shop houses.
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The proposed upgrading design shall follow the existing alignment, unless there is
a need for the alignment to be changed to suit the special conditions of the site.
2.0 Lane Width
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Lane width shall be 3.00 m and Marginal Strip width shall be 0.25m
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3.0 Centre Median
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Centre Mesian shall ee as states in ATd gigs (pinsaan 2Q15) A Guise On
GeorretriG Desi§n of Roass, for dKR R2 stansars.
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4.0 Road Shoulders
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Useable road shoulders shall be 2.0 m wide
5.0 Climbing Lane / Passing Lane

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Climbing lane/passing lane shall be provided as per the requirements stipulated in

the ATJ 8/86 (Pindaan 2015) - A Guide On Geometric Design of Roads.
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6.0 Road Drainage
Surface runoff, stream and river flow in the vicinity of the roadway shall be
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'- computed and from such computation design shall be made for drainage system
of the road which includes culverts, roadside drains, subsoil drains, toe drains,
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berm drains, shoulder drains, interceptor drains, etc. All drainage design shall be
in accordance with the guidelines and criteria established by JKR as well as
procedures published by Jabatan Pengairan dan Saliran (MASMA), Arahan
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Teknik (Jalan) 8/86 (Pindaan 2015) and REAM. The structural design of
reinforced box culverts shall be in accordance with BS 8110 and the loading shall
be in designed to resist the worst traffic load in the same way as bridge structure.
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For precast reinforced concrete pipe culvert, it shall be designed in accordance to

MS881 : 1991.
7.0 Design Flood Levels
The following criteria for estimation of design flood levels shall be adopted: -
(a) For embankments in areas subjected to flooding , the subgrade level (after
total settlement in soft ground areas) shall be designed to be at least 300
mm above the 25-year flood level.
A14-l /4
APPENDIX A14
(b) Culverts shall be designed for a return period of 50 years with a headwater
depth not exceeding two times the diameter/height of the culvert.
(c) Surface drains shall be designed for a 10-year return period and shall
cater for efficient removal of storm water from road surface, erosion
protection and slope stabilization.
8.0 Pavement
i) New Pavement/New Alignment
The pavement for roadwork shall be of the flexible type and designed in
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accordance with the Standard Specification for Roadworks
(JKRlSPJ/2008-S4), Arahan Teknik (Jalan) 5/85 (Pindaan 2013) and
Addendum ATJ 5/85 (Pindaan 2013): Manual for the Structural DeSign of
Flexible Pavement (Surat Arahan KPKR Bi1.28/2017 dated 28 November
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2017), as followed.
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( a) Execute mechanistic design of pavement structure using axle load
survey.
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b) The contractor shall do the axle load study around the vicinity of the
area to determine the mixed traffic, axle load spectrum and axle load
configuration.
c) Arahan Teknik (Jalan) 5/85 (Pindaan 2013) is only for guideline but the
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designer shall use the mechanistic design using axle load and
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equivalent factor.
The minimum design life of the flexible pavement is to be for duration of

twenty (20) years.
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ii) For Existing Pavement / Upgrading Alignment

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Pavement evaluation shall be carried out prior to proposal of the most

suitable rehabilitation works, together with the design calculation .
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9.0 Cross-Section
All normal cut and embankment slopes shall be designed with a factor of safety of
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not less than 1.25 based on realistic shear strength against all modes of failure
(global). For stabilised slopes (cut & fill), the minimum factor of safety shall be 1.5
based on the realistic shear strength against all modes of failure (global).
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Preliminary slope in earth cuts are designed to 1:1.5 to 1:2 with 2.0m bench width
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and 6.0m height.
Preliminary slope in earth fills are designed to 1:2 with 2.0m berm width and 6.0m
height.
Other important geotechnical design requirements are as described in Appendix

A8.
A14-2/4
APPENDIX A14
10.0 Intersection and Access
Traffic analysis study and traffic impact shall be carried out when deem
necessary. The layout, design and type of control at intersections shall be
prepared to suit the traffic volume.
11.0 Temporary Control Devices and Signs
Temporary control devices and signs during construction shall be compliance with
the latest Arahan Teknik (Jalan) 2C/85 with respect to traffic control devices,
temporary signs and work zone control.
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12.0 Traffic Management Plan
The Contractor must prepare traffic management plan for the implementation of
the project.
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13.0 Traffic Control Devices
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Adequate traffic control devices and roadside furniture such as directional signs
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and pavement/carriageway markings shall be provided all in accordance with the
latest Arahan Teknik (Jalan) 2AJ85, 2B/85, 20/85, 2E/87, 9186.
14.0 Barriers
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Contractor to proposed the su itable barriers (if needed) and shall generally follow
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the Arahan Teknik (Jalan) 1/2020: Guidelines On Design & Selection Of Traffic
Restraint System.
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15.0 Road Lighting
All intersections, interchanges, U-turns, roundabouts, elevated structures, bridges

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and road shall be lighted where required and the Contractor shall include detail of
lighting performance in his technical proposal.
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16.0 Landscaping
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The whole sestion of the roaEl shall be suitably lanElssapeEl in assorElanse '/lith the
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following guiElelines:
(a) 'GarispanEluan bansl<ap ~Jegara' published by Jabatan Peransang Bandar

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dan Desa ~emenanjung Malaysia, and
(b) Nota Te,lmik (Ja,laR) 19/97 (pindaan 2Q1 g) Intermediate Guidelines To

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Road Reserve bandssaping published by JKR Roads Braneh.
The lands saping proposals shall be presented in the normal standard engineering
fermat indieating its relative loeations with respeet to other road furniture and
signages. This proposal shall be subjested to Road ~afety Audit ~tago d, to
evaluato its road safety potentials.
A14-3/4
APPENDIX A14
17.0 Retaining Wall
Retaining wall shall be designed and constructed by the contractor where

required.
18.0 U-Turns
U-turns, where needed, shall be designed and constructed by the contractor.
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Appendix A 15
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(Terms of Reference for Pavement
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Evaluation)
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TERMS OF REFERENCE
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PAVEMENT EVALUATION
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CAWANGAN JALAN
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IBU PEJABAT JKR MALAYSIA

50400 KUALA LUMPUR
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Table of Contents
1.0 INTRODUCTION ............................................................ ... ....... ...... .............. ............. ............. ... ... .. 2
2.0 OBJECTIV E ......... ....................... ... .... ........................................................................... ................... 2
3.0 SCOPE OF WORKS ... .... ... ... ...................... ..................................................... ........................ ... ... ... 2
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4.0 METHODOLOGy ....................................................... ...................... Error! Bookmark not defined.
4. 1 Falling Weight Detlectometer (FWD) .......................................................................................... 2
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4.2 V isual Condition Survey (VCS) .......................................................... ....................... ............ ...... 3
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( 4.3 Coring and Dynamic Cone Penetrometer (DC P) ............ ............. ................................................. 3
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4.4 Material Testing ................................................. ....... ..... ............................................ ................... 4
5.0 TRAFFIC CONTROL ......................... ... ......... ............. .... ............. .............. ........ .. .. ........ .... ............. 6
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6.0 PERJOD OF COMPLETION ................................ ............... ............ ......... ...................................... . 6
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7.0 DOCUMENTS TO BE SUB MI TTED ................................ ........... ......... ........... .. .... .. .. ... .... ....... .. ..... 6
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1/6
1.0 INTRODUCTION
The total length of upgrading road for project MEMBINA JALAN DARI BEHOR MALI
KE KAMPUNG KEPALA SEPULOH, PERLIS is approximately _ km . The scope of work
for this project does involve upgrading the existing road of two (2) lanes siRgle earriagev.,ay to
fololf (4) laRes 810lal earriageway to JKR R2 Standard and rehabilitation works. The contractor needs
to carry out the pavement evaluation and propose the most suitable and most cost-effective
rehabilitation design.
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2.0 OBJECTIVE
The objective of pavement evaluation is to collect the surface and structural condition data using
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Falling Weight Deflectometer (FWD), Coring and Dynamic Cone Penetrometer (DCP). The
information collected shall be used to produce more effective rehabilitation treatment and cost for
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the rehabilitation works.
3.0 SCOPE OF WORKS

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The scope of works shall include, but not limited to the following:
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• To prepare and submit propose work progranune.

• To mobilise all personnel and equipment necessary.
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• To carry out the data collection as follows:

o Falling Weight Deflectometer (FWD) Test
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o Visual Condition Survery (VCS)

o Coring and Dynamic Cone Penetrometer (DCP) analysis
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( o Material Testing
• To prepare detail report on pavement analysis and to propose Rehabilitation Design.
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4.0 METHODOLOGY
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4.1 Falling Weight Deflectometer (FWD)

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• A Dynatest FWD machine or approved equivalent should be used for the measurement of
the deflections.
• The FWD machine shall be calibrated according to manufacturer's specification.
2/6
• FWD measurements shall be taken at every 100m intervals according to the number given
in Bill of Quantities and/or Drawings
• Readings from at least 7 geophones including the one located at the centre of the loading
plate shall be recorded.
• The distance of the geophones from the loading plate should be: Omm, 300mm, 600mm,
750nun, 1050mm, 1350mm and 1650mm.
• Three (3) load pulses (drops) of the FWD load shall be applied at each position. Data from
all 3 drops should be recorded and reported in the same file.
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• The load level used for the FWD drops shall be 50kN, which corresponds to a load pressure
of approximately 700kPa.
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• Pavement temperatures shall be taken at the location of the test at every 30mins.
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( • Analysis and reporting shall include the following:
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o Layer Moduli derived from the third (3rd) drop
o Tables and summary of the FWD analysis
• The Contractor shall be responsible for arranging necessary traffic control in order to
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ensure the safety of the road users and FWD Operator.
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4.2 Visual Condition Survey (YCS)

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• A visual condition survey ofthe bituminous pavements shall be carried out. The areas with
different types of surface distress shall be identified and recorded following the procedures
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given in the JKR Guide, A Guide to the Visual Assessment of Flexible Pavement SUlfilce
Conditions (JKR 20709-2060-92).
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• The results shall be presented in a tabular form of 100m block intervals for each lane.
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• The defects shall be characterized in terms of type, severity and intensity.
4.3 Coring and Dynamic Cone Penetrometer (DCP)

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• Coring shall be performed in the left wheel path of each lane at selected locations.
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• 100mm diameter core samples of bituminous pavements shall be taken.

• DCP test will be carried out through the coring locations and up to a depth of 1.2m from
the pavement surface with minimum 6 Nos. per direction.
• Where possible, core samples shall be take where the surface is visibly cracked.
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• Each core shall be described to identify the bituminous layer thickness, crack depth and
crack propagation (if any).
• DCP Analysis and reporting shall include the following:
o Graphical results of the DCP analysis
o Layer thicknesses of all layers at each location
4.4 Material Testing
• Aggregate Gradation
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Gradation test are used by aggregate producers for quality control purposes and by users
for checking compliance with specification. In the case of course (retained on a 3.35 mm
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sieve) and fine (passing 3.35 and retained on the 75 micron sieves) particles, these
quantities are determined by sieve analysis, i.e. by allowing the aggregate sample to fall
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through a stack of standard sieves of diminishing mesh size that separate the particles into
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p0l1ions retained on each sieve. The percent passing of the aggregate through the selected
sieves is determined by taking weights retained on individual sieves. The percent passing
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is then plotted on a 0.45 power gradation chart.
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• Binder Content Test (ASTM 02172)

The test is carried out for quantitative determination of bitumen in hot-mixed mixtures for
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specification acceptance, service evaluation, control and research.

The sample with determined moisture content is place in the bowl. The sample is covered
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with methylene chloride and allows sufficient time for the solvent to disintegrate. The
centrifuge start to resolve the speed to a maximum 3600 r/min until the solvent ceases to
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flow. The content from the bowl is removed and dry in an oven with constant temperature
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110 ± 5°C. The mass of extracted aggregate is determined.
• Penetration Test (ASTM OS)

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The penetration test measures the depth which a standard needle will penetrate a bitumen
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under standard conditions of temperature (25°C), load (lOOg) and time (5s). The result
obtained is expressed in penetration units, where one unit equals Idmm (O.lmm).
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The penetration test on its own simply a classification test, and is not directly related to
binder quality. Nonetheless, the penetration grade of bitumen is inextricably linked to the
composition and use of a bituminous material. For example, higher penetration bitumen is
preferred for use in pavements in cooler climates (to reduce cracking problems) whilst
lower penetration ones have preference in hot climates.
• Softening Point Test ( ASTM D36)

The softening point test determines the temperatures at which bitumen changes from semi-
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solid to fluid. There is a rule-of-thumb to the effect that the mixing temperature of
penetration-grade bitumen is 110 °C above its softening point, thus, for example nominal
50 pen and 100 pen bitumen are often mixed at about 162 °C and 156 °C respectively.
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( The test involves placing a 3.5g steel ball on a disc of bitumen that is supported by a brass
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ring, and immersing it in water. The water is heated uniformly at the rate of 50 C/min until
the di sc is sufficiently soft for the ball, enveloped in bitumen, to fall 25mm through the
ring onto the base plate. The water temperature at which the binder touches the base plate
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is recorded as the softening point of the bitumen.
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• Determination of Indirect Tensile Strength Test (ITS)

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The standard ITS test is used to test the briquettes under both dry and soaked conditions.
The ITS is determined by measuring the ultimate load to failure of a specimen which is
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subjected to a constant deformation rate 50.8 mrnIminutes on its diametrical axi s. Check
the density for all the samples using standard ASTM D 2724. In order to determine the ITS
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soaked samples, place the cured specimen in a vacuum desiccators and cover with water at
25 °C ± I 0c. Apply a vacuum of mercury for 60 ± 1 minutes, and if no vacuum desiccator
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is available, soak for 24 hours at 25 °C ± 1 °C. Remove the specimen, surface dry and test
for the ultimate tensile load. Calculate the ITS for each specimen to the nearest 1 kPa using
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the following formula:

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ITS = 2xP
1t x LxD
Where: ITS = indirect tensile strength in kPa
P = maximum applied load in kN
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L = average height of the specimen in m
D = diameter of the specimen in m.
5.0 TRAFFIC CONTROL

The contractor shall provide traffic management equipment and personnel to implement proper
traffic management system in accordance to the requirements of JKR while carrying out the
pavement evaluation works.
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6.0 PERIOD OF COMPLETION
The completion of the above works including FWD test, visual condition survey and coring and
DCP test and rehabilitation design ii'om the date of possession of site is three (3) months.
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( 7.0 DOCUMENTS TO BE SUBMITTED
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The contractor shall submit the following documents together with:
i) Company profile
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ii) Certificate of MOF Registration
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iii) Proposed detailed work programmed

iv) Pavement Detail Analysis Report with all relevant data and recommendations
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v) Pavement Rehabilitation Design

vi) A Compact disc containing electronic copies of the above-mentioned reports
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Appendix A 16
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(OSHA)
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SPECIFICATIONS FOR OCCUPATIONAL
SAFETY AND HEALTH
IN ENGINEERING CONSTRUCTION WORKS
2019
TABLE OF CONTENT PAGE

FOREWORD
ACKNOWLEDGEMENTS ii
ABBREVIATIONS iii
REGULATION & LEGISLATION iv
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1.0 GENERAL
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1.1 General Requirements
1.2 Safety and Health Plan (S-Plan) 2
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( 1.3 Safety and Health Committee (SHC) 2
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1.4 Competent Person And Designated Person 2
1.5 Medical Check-up I Health Surveillance 3
1.6 Personal Protective Equipment (PPE) 4
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1.7 Safety And Health Programme 4
1.8 Monthly Safety and Health Report 4
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1.9 Inspection Report 5

1.10 Hazards Identification Risk Assessment Determining Control (HIRADC) 5
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1.11 Site Safety Signage and Information Board 5

1.12 Emergency Response Plan (ERP) 6
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1.13 Notification of Accident. Dangerous Occurrence, Occupational Poisoning and 6

Occupational Disease (NADOPOD)
1.14 Fire Fighting Equipment 6
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1.15 Traffic Movement Management 7

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2.0 HEALTH AND WELFARE 7
3.0 PLANT AND MACHINERIES 7

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3.1 Registration Certification 7

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3.2 Valid Certification Period 7

3.3 Renewal of Certification 8
3.4 Operation of Plant and Machinery 8
3.5 Machinery In stalled On Any Floor Above The Ground Floor 8
4.0 SAFE WORKING AREA 8
4.1 Catch Platform 8
4.2 Scaffolding 9
4.3 Floor Opening/Manholes/Open Edges 9
4.4 Working at Height 9
4.5 Access to Workplace 10
4.6 Excavation and Shoring 10
4.7 Formwork and Concreting 10
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4.8 Piling Works 11
4.9 Lifting Works 11
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5.0 MECHANICAL AND ELECTRICAL EQUIPMENTS AND TOOLS 11
5. 1 General Requirement 11
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( 5.2 Hand Tools and Power Tools 12
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5.3 Electric Power-Operated Tools 13
5.4 Pneumatic Power Tools 13
5.5 Fuel-Powered Tools 13
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5.6 Hydrau lic-Powered Tools 14
5.7 Power-Actuated Tools 14
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5.8 Wiring/Cabling/Switching 15
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6.0 HAZARDOUS CHEMICALS AND MATERIALS 15

6.1 Storage 15
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6.2 Handling and Labelling 15
7.0 SPECIAL SAFE WORKING CONDITION 15

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7.1 Confined Space 15

7.2 Hot Works 16
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7.3 Blasting and Demolition Works 16

7.4 Working At Night 16
7.5 Working over/ near water 17
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Appendix A
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Appendix B
FOREWORD
J ;rJ.
To trigger further im in the safew and health pelformance, it is imperative for
Jabatan Kerja Raya (JKR) continuouslp upd'att! and improve their OSH specifications.
These new specifications are not only aimed/at/keeping abreast with current regulations,
guidelines and practices but also to help imp' ~ove the OSH performances based on contract
requirement and also latest KPKR instructio~ . Consequently, these new specifications will
ultimately have a significant positive impactlon /t'he construction works especially with the
incorporation of new products and tecl].nologips1)
The JKR Specifications for (!)ccupational s afilty a d Health in Engineering Construction
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Works 2019 is an essential compor,e.n t ;in' the construction of JKR's project. This
Specification provides an improved guiCiance and reference in implementation of OSH
monitoring and hazard control based i e,h4:Jcurrent best practices. The purpose of the
Specifications for Occupational Safety and 'Health in Engineering Construction Works 2019
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is to establish uniformity with latest revision of JKR Standard Specification for Building
Works and JKR Standard Specification for Road Works :/
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This particular document, the "Specifications for oc~ u ~ational Safety and Health in
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Engineering Construction Works 2019", is an improved sRecifications ofthe Specifications
for Occupational Safety and Health for Engineeringl Construction Works 2011. The
compilation of this document was carried ,out through many discussions and deliberations
that had been held by the technical committee. The ci~aft had also been presented and
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discussed at length in a specially held workshop ~o get feedback and comments from
relevant parties involved, which were then carefully considered and incorporated into the
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Specification wherever appropriate or necessar;y.
The Specifications has also gone through the ifferent phases of vetting and approval
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before the production of its final draft and printed copy. It will be reviewed and updated
from time I to time to cater for any changes in policies and the inclusion of current
require e ts, if necessary. Any feedback or improvement to be considered for fut re
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revisions should be forwarded to Baha ian Pengurusah Kualiti, Cawangan Dasar dan
pengurusi n Korporat, JKR Malaysia. I- .
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Publishea li>y: -
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Cawangan Dasar dan Pengurusan Ko'rp.or<lt";-=~l.'i:!~Gt

Bahagian Pengurusan Kualiti
Tingkat 31 Blok G, Menara erja Raya
Ibu Pejaba~ JKR Malaysia __
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Jalan Sult~n Salahuddin, 50~80 Kuala Lumpur

Email: kualiti@jkr.gov.my ~
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First Edition 2011

Second Edition 2019
ACKNOWLEDGEMENTS
This "Specification for Occupational Safety and Health in Engineering Construction Works
2019" has been prepared by a technical committee comprising of the following members;
Committee Members:
Ir. Wan Abdul Rahman bin Wan Hassan Cawangan Jalan

Ir. Anisah binti Saim Cawangan Dasar dan Pengurusan Korporat
Ir. Maslinda binti Mohamed Cawangan Kejuruteraan Mekanikal
Ir. Rosilawati binti Mazlan JKR Negeri Sembilan
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Ir. Siti Nurilam binti Abu Mansor Cawangan Jalan
Pn . Kueh Hiong Mui JKR Melaka
En . Hasrudin bin Mohd Fadzali Cawangan Kejuruteraan Elektrik
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Ir. Nurmawaddah binti Mohd Idris JKR Kelantan
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Ts . Bakori bin Ahmad Cawangan Kerja Bangunan Am 1
( Pn . Siti Nurhani binti Ahmad Ridzuan Cawangan Dasar dan Pengurusan Korporat
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Ir. Raja Rusdy Irwan bin Raja Hussin JKR Tumpat
Ir. Mohd Nor Hakim bin Mohd Taib JKR Johor
Pn . Illyani binti Ariffin Cawangan Kerja Pendidikan
En. Maizali Halil bin Ghazali Cawangan Kontrak dan Ukur Bahan
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Sr. Hafez Fadzli bin Arshad Cawangan Kontrak dan Ukur Bahan
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En . Shuhaimi bin Abdul Rahim JKR Johor

Ir. Ak htar Nurfitri bin Mat Zain Cawangan Kejuruteraan Awam Struktur
En . Muhamad Shukry bin M. Nor JKR Terengganu
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Secretariats (Cawangan Dasar dan Pengurusan Korporat) :
Pn. Ai'nun Bashirah binti Hamid

En . Mohd Izzham bin Ismail
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En. Mohd Rusydan Syahir bin Shaharuddin

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En. Shahrom Darmawan bin Mohd Yunus
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Pn . Nor Fazilawati binti Che Ramli

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Finally, the publisher would like to express its gratitude to the above committee members, and
also all those who were involved, directl y or indirectly, but their names missed out from being
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mentioned above, for their undying effort and substantial contribution towards the successful
completion of this document.
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ABBREVIATIONS
The following abbreviations appearing in these specifications have their meanings as assigned
against them :
(i) . S.O - Superintending Officer

(ii) . PD - Project Director
(iii) . SHO - Safety and Health Officer
(iv). PEPC - Professional Engineer with Practicing Certification
(v). CP - Competent Person registered with DOSH
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(vi) . DP - Designated Person appointed by Employer
(vii) . CIDB - Construction Industry Development Board
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(viii) . DOSH - Department of Occupational Safety and Health
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(ix). MOH - Ministry of Health
( (x). SPJ - Standard Specification For Road Works
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(xi). ATJ - Arahan Teknik Jalan
(xii) . CLASS - Classification , Labelling and Safety Data Sheet of Hazardous
Chemicals
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(xiii). USECHH - Use and Standard of Exposure of Chemical Hazardous to
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Health
(xiv). BOWEC - Building Operations And Works Of Engineering Construction .
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(xv). SPB - Sistem Pengurusan Bersepadu

(xvi). PTW - Permit to Work
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REGULATIONS AND LEGISLATIONS
List of Related Acts, By-Laws, Regulations, Codes of Practice, Standards, and Guidelines
Referred To In This Specification:
1. Occupational Safety And Health Act (OSHA), 1994 and Regulations under the act
2. Factory And Machinery Act (FMA) , 1967 and Regulations under the act
3. Uniform Building By-Law (UBBL), 1984
4. Environmental Quality Act (EQA), 1974
5. Construction Industry Development Board Act, 1994
6. Local Government Act, 1976
7. Street, Drainage and Building Act, 1974
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8. Electricity Supply Act, 1990
9. Electricity Regulations, 1994
10. Fire Services Act, 1988
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11 . Explosives Act, 1957
12. Irrigation Areas Act, 1953
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( 13. The Radiation Protection (Basic Safety Standards) Regulations 1987
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14. MS 2318: Code of Practice for Demolition of Buildings, 2010
15. MS 2558 : Safety and Health Signage Used In The Workplace
16. BS 5228 Code of Practice for Noise control on Construction and Demolition
Site
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17. Code of Practice for Safe Working In A Confined Space, 2001 , DOSH
18. Guidelines For Hazard Identification, Risk Assessment And Risk Control, 2008, DOSH
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19. Guidelines For Public Safety And Health At Construction Sites, 2007, DOSH
20. Guidelines For The Prevention of Falls At Workplaces , 2007, DOSH
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21. Guidelines on Occupational Vibration, 2003, DOSH

22. Guidelines On Occupational Safety And Health In Tunnel Construction,1998, DOSH
23. Standard OHSAS 18001 and ISO 45001 : Occupational Safety and Health
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Management System
24. Guidelines For Approval of Design Scaffolding 2016
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Note : The contractor at all times need to comply with the provisions of all legislation , regulations
{ and by-laws currently in force with regard and related to the construction works , the environment,
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safety and health. The relevant legislation , regulations and by-laws including any revisions
thereto are as listed in but not limited in regulation and legislation stated in this specification .
Compliance with this Specification does not of itself confer immunity from legal obligations.
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SPECIFICATIONS FOR OCCUPATIONAL SAFETY AND HEALTH IN ENGINEERING
CONSTRUCTION WORKS
1. GENERAL
1.1 General Requirements

1.1.1 Specifications for Occupational Safety and Health in Engineering Construction
Works 2019 cover the requirement regarding occupational safety and health
that all JKR Malaysia projects need to comply with .
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1.1.2 This Specification shall be read in conjunction with latest version of Standard
Specifications for Building Works, Standard Specifications for Road Works and
Bill of Quantities for Occupational Safety and Health in Engineering
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Construction Works .
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1.1.3 Construction works with contract period more than Six (6) weeks or involve the
( use of machinery shall register with DOSH by Contractor within Seven (7) days
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from the date of site possession as comply with Section 35, Factory And
Machinery Act.
1.1.4 Comply with Section 15: Occupational Safety And Health Act
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(i). The Contractor shall ensure, so far as is practicable, the safety, health
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and welfare at work of all his workmen (employees) .
(ii). WIThout prejudice to the generality of item (i) , the matters to which the
duty extends, so far as is practicable, include in particular:
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a) The provision and maintenance of plant and system of work

with safe and without risks to health;
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b) The making of arrangements for ensuring safety and absence

of risks to health in connection with the use or operation ,
handling , storage and transport of plant and substances;
c) The provision for such information , instruction, training
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( and supervision as is necessary to ensure the safety and health

at work of his workmen
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d) The maintenance of place of work condition , the provision and

maintenance of the means of access to and egress from place
of work that are safe and without risks.
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e) The provision and maintenance of a working environment for his

workmen that is safe without risks to health , and adequate as
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regards facilities for their welfare at work.
1.1.5 Comply with Construction Industry Development Board (CIDB) Malaysia Act
and/or Regulations under the act
(i) . Ensure all workmen at Works and before entering the Construction Site
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must be owned with a valid CIDB Green Card.
1.2 Safety and Health Plan (S-Plan)

1.2.1 The Contractor shall submit S-Plan to the S.O 1 p.o, within one (1) month after
the receipt of Letter of Acceptance. It shall include the following :
(i). The Contractor shall submit in writing to the S.OI P.D, The Hazard
Identification, Risk Assessment and Determining Control (H IRADC)
before commencement of each activity throughout the contract period.
(ii) . S-Plan shall be endorsed by the Owner/Director of the company with the
date and version on the cover page.
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1.2.2 The contractor shall provide a complete S-Plan as stated in Appendix A.
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1.2.3 The S-Plan shall be monitored and reviewed when 1 after an incident (accident
or illness) occurred including changes to the project organization chart or
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( changes to the regulations and scope of project. S-Plan shall be revised
periodically as requested by S.O/P.o.
1.3 Safety And Health Committee (SHC)

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1.3.1 The Contractor shall form a Safety and Health Committee to be complied with
Occupational Safety and Health (Safety and Health Committee) Regulations
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and organise meetings at minimum once in every three (3) months as required .
1.3.2 The Contractor shall provide Contractor's Organization Chart and Safety and
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Health Committee (SHC) Chart which shall describing the staff involved
including list of duties and responsibilities .
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1.4 Competent Person (CP) And Designated Person (DP)

1.4.1 The Contractor shall employ throughout the entire contract period a competent
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and qualified person as the Safety and Health Practitioner as below:

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(i) . Safety and Health Officer (SHO) to be stationed full time for all projects
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with cost of contract more than RM20 million or high risk workplace as
directed by S.O/P.DIDOSH.
(ii) . Site Safety Supervisor (SSS) to be stationed minimum 15 hours a week
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for all projects.

(iii). The Contractor shall comply with Occupational Safety And Health
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(Safety and Health Officer) Order 1997, Order I and II in any contract
price of the project exceeds RM20 million or high risk . As stipulated in
this Order, the main Contractor shall ensure their sub-Contractor(s)
employ SHO o
(iv) . Every Contractor other than main Contractor in charge of worksite who
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employs more than 20 persons shall appoint their own Contractor Safety
Supervisor (CSS) to be stationed minimum 5 hours a week .
1.4.2 If the Safety and Health Practitioner absent from Works , Contractor shall get the
permission from DOSH to operate the Works without Safety and Health
Practitioner or Contractor may require to (temporarily) appoint another Safety
and Health Practitioner.
1.4.3 The Contractor shall employ Competent Person(s) (CP) in charge of handling
high risk Works that defined by DOSH and CIDB.
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1.4.4 The Contractor shall conduct Health Measurements (if necessary) by
designated/ competent person (example: Occupational Health Doctor/ Medical
Practitioner).
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1.4.5 The Contractor shall employ DeSignated Person(s) (DP) for the following
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( works:
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1.4.5.1 Public vehicular traffic
1.4.5.2 Protection of the public
1.4.5.3 Inspection of Formwork
1.4.5.4 Inspection of Safety harness
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1.4.5.5 Inspection of Safety nets
1.4.5.6 Demolition
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1.4.5.7 Excavation work

1.4.5.8 Piling work
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1.4.5.9 Pile testing

1.4.5.10 Handling of explosive
1.4.5.11 Other works as necessary
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1.5 Medical Check-up! Health Surveillance

1.5.1 Medical Report (Health Surveillance) of workmen to be recorded by the
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( Contractor (employer! self-employed person) for the Works exposed to

chemicals and hazardous working area as listed in Occupational Safety and
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Health (Use and Standards of Exposure of Chemicals Hazardous to Health)

Regulations 2000 or latest version . Medical Report (Health Surveillance) shall
be conducted by Occupational Health Doctor! Medical Practitioner.
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1.6 Personal Protective Equipment (PPE)
1.6.1 Provision and maintenance of Personal Protective Equipment to S.O/P.o staffs
at site of adequate quantity and of approved quality as instructed by S.O/P.o.
The equipment shall include but not be limited to the following :
(i) . Safety boots
(ii). Safety helmets
(ii i). Safety harness and life lines (for workmen who work at heights more
than 3 m above ground level)
(iv). Protective gloves
(v). Safety goggles
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(vi). Safety jackets of refiective type
(vii). Ear plugs and muffs
(viii). Gas masks
(ix). Dust masks
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(x). Head lamp
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(xi). Life jacket
( (xii) . Others as necessary
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1.6.2 Provision and maintenance on the site during the entire contract period, of the
adequate safety equipment to be approved by the S.O/P.o:
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(i). Gas detectors
(ii) . Breathing apparatus
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(iii). Air ventilation pumps

(iv). Adequate lighting and warning lamps
(v) . Hazard tape
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(vi). Safety barriers

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1.7 Safety and Health Programme

1.7.1 The Contractor shall conduct OSH related training and programme for the
workmen including sub-Contractor for the successful implementation of the
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project as following below. All costs shall be borne by the Contractor.

(i). OSH related Best Practise and Awareness Course
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(ii). First Aid Training to be trained by a certified trainer.

(iii) . CIDB Green Card.
(iv). Toolbox /Induction / Evacuation Drill/ Housekeeping Programme
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1.8 Monthly Safety and Health Report

1.8.1 The Contractor shall submit monthly safety and health reports to the S.O / P.o,
in accordance with Appendi x B.
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1.9 Inspection Report
1.9.1 The Contractor shall conduct inspection at the place of work at least once in
every three (3) months to ascertain if there is anything prejudicial to the safety
and health of persons employed therein :
Provided that the committee may, at any time, make further inspections of any
plant therein or any part of the place of work to check on the effectiveness of the
measures taken to the safety and health of persons at the place of work .
1.10 Hazards Identification Risk and Determining Control (HIRADC)
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1.10.1 The Contractor shall identify potential hazards to employees or, assess their
risk, or likelihood of happening and the effects they would have, and the taking
of necessary control measures for such hazards.
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1.10.2 Records of HIRAOC shall be kept, maintained and submitted to the S.O/PO prior
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to commencement of the work . HIRAOC may be reviewed during the course of
( work as required .
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1.11 Site Safety Signage and Information Board
1.11 .1 The Contractor shall do provision and maintenance of safety and health
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statistic scoreboard at the entrance of site office I workplace as approved by
S.O I PO
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1.11 .2 The Contractor shall provide and maintain adequate safety and health signage,
warning signs and warning lights or as instructed by S.O I p.o . Minimum
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requirements of signage:
(i) . Sign Plate
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Sign plate shall be made of aluminium composite material with total

minimum thickness of 4mm with aluminium thickness of 0.2mm for both
sides .
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( (ii) . Sign Face

The sign face shall comply with the Malaysian Standard Specification for
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Reflective Sign Faces Materials (MS 1216 or ASTM 04956).
(iii) . Colour code usage

a) Red : Prohibition , danger alarm , fire protection equipment, high risk
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of injury or death , emergency stops and alarms

b) Yellow :Warning, caution statements , minor risk of injury , materials
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handling equipment
c) Blue : Mandatory , no immediate hazard
d) Green: Emergency escape , safety equipment or information , first
aid equipment or location , no danger
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1.12 Emergency Response Plan (ERP)
1.12.1 The contractor shall establish a written Emergency Response Plan and shall
cover those designated actions employers and employees must take to ensure
employee safety from fire and other emergencies.
1.12.2 The plan shall be reviewed and communicated to all employees at the following
time :
(i). initially when the plan is developed
(ii) . Whenever the employees' responsibilities or designated actions under
the plan change; and
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(iii) . Whenever the plan is changed .
1 12.3 Before implementing the Emergency Response Plan, sufficient number of
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persons shall be designated and trained to assist for safe and orderly
emergency evacuation .
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( 1.12.4 Emergency drill for testing the plan shall be conducted.
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1.13 Notification of Accident, Dangerous Occurrence, Occupational Poisoning and
Occupational Disease (NADOPOD)
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1.13.1 Notification and record keeping :
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(i) . Notification
Accident, dangerous occurrence, occupational pOisoning and
occupational disease that occur at the workplace shall be notified to
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relevant authorities
(ii) . Record keeping
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Records of all accident, dangerous occurrence, occupational poisoning

and occupational disease that occur at the workplace shall be
maintained.
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( 1.13. 2 Deciding whether a case should be notified and recorded

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(i) . In determining whether a case should be notified and recorded ,

contractor should follow the "Guidelines on Occupational Safety and
Health (Notification of Accident, Dangerous Occurrence, Occupational
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Poisoning and Occupational Disease) Regulations [NADOPOD]".

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1.14 Fire Fighting Equipment

1.14.1 Suitable types of fire fighting equipment shall be installed and maintained at
required locations on the Site throughout the Contract period.
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1.15 Traffic Movement Management
1.15.1 The Contractor shall provide and maintain adequate safety including traffic
warning signs and warning lights at place of works and close proximity of public.
1.15.2 The Contractor shall provide and maintain traffic control and signage by
competent persons including provision of flagmen ; where Works is in close
proximity of public road and reporting to S.OI P.O. (refer Standard Specification
For Road Works Section 19 (SPJ Section 19) and latest version of Arahan
Teknik Jalan 2C/S5) .
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2. HEALTH AND WELFARE
The Contractor shall provide and maintain at his own risk adequate water supply, power
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supply, sanitary system , lighting , temporary rest area , first aid facilities and ventilation where
required for use in the Works and shall pay all costs, fees and charges and comply with all
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safety regulations , requirements and by-laws in connection therewith .
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3. PLANT AND MACHINERIES
The Contractor shall taking measures to ensure that all equipment, machinery and place of
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Works are in proper working condition so as to minimize the amount of noise generated and
dust suppression. All Work shall be carried out without unreasonable noise and dust
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suppression The S.OI P.D may require the Contractor to replace any machinery and
equipment as well as method of statements that to his discretion, is emitting excessive noise
and dust.
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3.1 Registration Certification

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3.1.1 All plant and machineries shall have valid certification under Factories and
Machinery Act, Section 19.
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3.1.2 All machineries specified in the schedule as stated at the Factories and
( Machinery (Exemption of Certificate of Fitness for Hoisting Machine) Order 2015
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are exempted from statement 3.1.1 .
3.2 Valid Certification Period

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3.2.1 The contractor must ensure that the Certificate of Fitness of the plant and
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machinery used throughout the contract period is still valid
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3.3 Renewal of Certification
3.3.1 The Contractor shall ensure that renewal of certification should refer Factories
and Machinery (Notification , Certificate of Fitness and Inspection) Regulations.
3.3.2 The contractor shall have the plant registration and renew its certification as
required by the Department of Occupational Safety and Health.
3.4 Operation of Plant and Machinery

3.4.1 The Contractor shall ensure that operation of Plant and Machinery should refer
to the Factories and Machinery (Fencing of Machinery and Safety) and
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(BOWEC) Regulations.
3.4.2 Unless otherwise provided , all the provisions of the Factories and Machinery
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(Fencing of Machinery and Safety) Regulations shall apply to every machinery
used in connection with or for the purpose of building operations and works of
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( engineering construction .
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3.5 Machinery Installed On Any Floor Above The Ground Floor
3.5.1 The Contractor shall ensure that machinery installed on any floor above the
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ground floor need to refer to Factories and Machinery (BOWEC) Regulations .
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3.5.2 No machinery shall be used or caused to be used on any floor above the ground
floor of any building or structure unless such floor or structure has been so
designed and constructed as to support the load imposed by the machinery or
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alternatively strengthened for the purpose.

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3.5.3 Any floor or working level surrounding any machinery shall be maintained in
good and safe condition and shall , as is practicable, be free from any loose
material and in non-slippery condition .
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( 4. SAFE WORKING AREA

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4.1 Catch Platform

4.1.1 Erection , maintains and dismantling of catch platform during demolition of
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structure or other related exterior works at more than 12m height; and shall be
constructed and maintained not more than 6m below from which the exterior
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works. Such platform shall be designed by a Professional Engineer with

Practising Certificate (PEPC) and certified for safety prior to erection under
Factory and Machinery (BOWEC) Regulations. Catch platform shall not be used
for storage of material or be used as working platforms or walkways.
8
4.2 Scaffolding
4.2.1 Erection, maintenance, and dismantling of scaffolding , working platform with
safety nettings by Competent Person(s) under the direct supervision of a
Designated Person under Factory and Machinery (BOWEC) Regulations.
4.2.2 Every metal tube scaffold exceeding 40m in height and every other scaffold
exceeding 15m in height shall be constructed in accordance with the design and
drawings of a Professional Engineer with Practising Certificate (PEPC). All other
metal tube scaffolds shall have their designs and drawings approved by the
DOSH . (refer to the Guidelines For Approval of Design Scaffolding 2016)
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4.2.3 No scaffold shall be used unless:
(i) . It has been inspected by a Designated Person (DP) within the preceding
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seven days;
(ii). It has been inspected by a Designated Person (DP) since its exposure
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( to weather conditions is likely to have affected its strength or stability or
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to have displaced any part; and
(iii). The result of such inspection are entered by the Designated Person (DP)
into a register which is to be kept at the worksite
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4.3 Floor Opening! Manholes! Open Edges
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4.3.1 Erection , maintenance and removal of safety barricades! fencing! railing!

screen! wire netting! toe board for maintaining safe working environment during
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the Works.
4.3.2 Provision , maintenance and removal of guardrails or board fences and

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temporary foot walks with adequate overhead protection for public walkways
and thoroughfares during the Works.
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4.4 Working At Height

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4.4.1 Construction Works above 3 m

(i) . Submission of scaffolding design and working platform certified by a
Professional Engineer with Practising Certificate (PEPC) for the
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approval from DOSH. The copy of the approval must be submitted to

S.O!P.D .
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(ii) . Fall arrest equipment shall be provided by the contractor and be used in
accordance with the manufacturer's instruction.
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4.5 Access to Workplace
4 .5.1 Stairways, ramps or runways shall be provided as the means of access to
working levels above or below ground except where the nature of progress of
work prevent their installation in which case ladders or other safe means shall
be provided .
4.5.2 All buildings under construction of more than two storeys high shall be provided
with well-defined access at the ground floor with adequate overhead protective
cover for person entering or leaving the building.
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4.6 Excavation and Shoring
4.6.1 No employee shall be permitted to enter any excavated area unless sheet piling,
shoring or other safeguards that may be necessary for his protection are
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provided .
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after every rainstorm or other hazard-increasing occurrence and the protection
against slides and cave-ins shall be increased , if necessary.
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4.6.3 Excavated materials and other superimposed loads shall be placed at least
600mm from the edge of open excavation and trenches , and shall be so piled
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or retained that no part thereof can fall into excavation , or cause the banks to
slip or cause the upheaval of the excavation bed .
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4.6.4 Open sides of excavations where a person may fall more than 3m shall be
guarded by adequate barricades and suitable warning sign .
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4.7 Formwork and Concreting

4.7.1 Formwork and shores shall be certified structu rally safe by a Professional
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( Engineer with Practicing Certificate (PEPC) and shall be properly braced or tied
together.
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4.7.2 A Designated Person (OP) shall supervise the erection of the formwork including
the shores , braces and other support and to do inspection regularly during
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placing of concrete . All records of such inspection shall be kept at worksite .

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4.7.3 Where the floor to ceiling height exceeds 9.14m or where the formwork deck is
supported by shores constructed in two or more tiers, or where the dead , live
and impact loads on the formwork exceed 732 .2kgf/m2 , the formwork structure
shall be designated by Professional Engineer with Practicing Certificate (PEPC)
10
and a copy of the specification and drawings shall be submitted to DOSH before
work commences.
4 .7.4 Where the formwork structure is designed by a Professional Engineer with

Practicing Certificate (PEPC), he shall be responsible for the supervision of the
construction and stability of such structure.
4.7.5 Where the formwork structure is of two or more tiers, it shall have sufficient cat-
walks and other secure access for inspection.
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4.8 Piling Works
4 .8.1 Where there is any question of stability of structures adjoining area to be piled ,
such structures shall be supported where necessary by underpinning , sheet
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piling , shoring , bracing or other means in accordance with the design of a
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Professional Engineer with Practicing Certificate (PEPC) to prevent injury to any
( person
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4.8.2 All pile-driving equipment shall be inspected daily by a Designated Person (DP)
before the start of work. Every piling frame shall be thoroughly examined by an
approved person at least once in every twelve months.
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4.9 Lifting Works

4 .9.1 Cordoning off working area and provision of public control and safety measures
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where lifting operations, moving, shifting , transferring works are carried out
outside the hoarded up area of the worksite .
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5. MECHANICAL AND ELECTRICAL EQUIPMENT AND TOOLS

The Contractor shall ensure that mechanical and electrical equipment and tools should refer
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to the Factories and Machinery (BOWEC) Regulations .

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5.1 General Requirement

5.1.1 All hand and power tools and similar equipment, whether furnished by the
employer or the employee, shall be maintained in a safe condition .
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5.1.2 When power-operated tools are designed to accommodate guards, they shall
be equipped with such guards when in use.
5.1.3 Belts, gears, shafts, pulleys , sprockets , spindles , drum, fly wheels, chains , or
other reciprocating rotating or moving parts of the equipment shall be guarded
if such parts are exposed to contact by employees or otherwise create a hazard
11
in accordance with the requirements of the Factories and Machinery (Fencing
of Machinery and Safety) Regulations.
5.1.4 Employees using hand and power tools and exposed to the hazard of falling ,
flying, abrasive, and splashing objects, or exposed to harmful dusts, fumes,
mists, vapours or gases shall be provided with the necessary personal
protective equipment to protect them from hazards.
5.1.5 Hand-held powered requirement:

(i). All hand-held powered platen sanders, grinders with wheels 51
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millimetres in diameter or less, routers , planers, laminate trimers,
nibblers, shears, scroll saws, and jigsaws with blade shanks 6
millimetres wide or less may be equipped with only a positive "on-off'
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control.
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(ii). All hand-held powered drills, tappers , fastener, drivers, horizontal,
( vertical , and angle grinder with wheels greater than 51 millimetres in
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diameter, disc sanders, belt sanders , reciprocating saws and other
similar operating powered tools, shall be equipped with a momentary
contact "on-off' control and may have a "lock-on" control provided that
turnoff can be accomplished by a single motion of the same finger or
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fingers that turn it on .
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(iii). All other hand-held powered tools, such as circular saws , chain saws ,
and percussion tools without positive accessory holding means, shall be
equipped with a content pressure switch that will shut off the power when
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the pressure is released .

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5.2 Hand Tools and Power Tools

5.2.1 The Contractor shall ensure that all electrical and mechanical tools and
equipment is inspected by a deSignated person (DP) where relevant and in
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proper working condition .

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5.2.2 Employers shall not issue, suffer or permit the use of unsafe hand tools .
5.2.3 Wrench , including adjustable pipe ends and socket wrenches shall not be used
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when jaws are sprung to the point that slippage occurs.

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5.2.4 Impact tools , such as drift pins, wedges, and chisels , shall be kept free of
mushroomed head .
5.2.5 The wooden handles of tools shall be kept free of splinters or cracks and shall
be kept tight in the cool.
12
5.3 Electric Power-Operated Tools
5.3.1 Electric power-operated tools shall be insulated in accordance with the
requirement of Electrical Inspectorate Regulations .
5.3.2 The use of electric cords for hoisting or lowering tools shall not be permitted.
5.4 Pneumatic Power Tools

5.4.1 Pneumatic-power tools shall be secured to the hose or whip by some positive
means to prevent the tool from becoming accidentally disconnected .
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5.4.2 Safety clips or retainers shall be securely installed and maintained on pneumatic
impact (percussion) tools to prevent attachments from being accidentally
expelled .
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5.4.3 All pneumatically-driven nails, staplers, and other similar equipment provided
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( with automatic fastener feed , which operate at more than 7 bars pressure at the
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tool shall have a safety device on the muzzle to prevent the tool from ejecting
fasteners , unless the muzzle is in contact with the work surface.
5.4.4 Compressed air shall not be used for cleaning clothing or parts of the body.
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5.4.5 The manufacturer's safe operating pressure specification for hoses, pipes,
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valves , filters and other fittings shall not be exceeded .

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5.4.6 The use of hoses for hoisting or lowering tools shall not be permitted .
5.4.7 All hoses whose inside diameter exceed 13 millimetres shall have a safety
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device at the source of supply or branch line to reduce pressure in case of hose
failure .
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5.4.8 Airless spray guns of the type which atomize paints and fluids at a pressure
( greater than 70 bars shall be equipped with automatic or visible manual safety
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devices which will prevent pulling of the trigger to prevent release of the paint or
fluid until the safety device is manually released or alternatively, a diffuser which
will prevent high pressure or high velocity release, while the nozzle tip is
removed , plus a nozzle tip guard which will prevent the tip from coming into
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contact with the operator, or their equivalent protection, shall be provided .

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5.5 Fuel -Powered Tools

5.5.1 All fuel-powered tools shall be stopped while being refuelled , serviced , or
maintained , and fuel shall be transported , handled , and stored safely.
13
5.5.2 When fuel-powered tools are used in enclosed spaces, the applicable provisions
in respect of concentrations of toxic gases and the use of personal protective
equipment must be followed .
5.6 Hydraulic-Powered Tools

5.6.1 The fluid used in hydraulic-powered tools shall be fire-resistant fluids, and shall
retain its operating characteristics at the most extreme temperatures to which it
may be exposed.
5.6.2 The manufacturer's safe operating pressure specifications for hoses, pipes,
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valves, filters and other fittings shall not be exceeded .
5.7 Power-Actuated Tools
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5.7.1 Only employees who have been trained in the operation of the particular tool in
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use shall be allowed to operate a power-actuated tool.
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5.7.2 The tool shall be tested each day before loading to see that safety devices are
in proper working condition . The method of testing shall be in accordance with
the manufacturer's recommended procedure.
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5.7.3 Any tool found not in proper working order, or that develops a defect during use,
shall be immediately removed from use and shall not be used until it is properly
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repaired .
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5.7.4 Tools shall only be loaded within a reasonable period prior to the intended firing
time. Neither loaded nor empty tools shall be pointed at any employees. Hands
shall be kept clear of the open barrel end.
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5.7.5 Loaded tools shall not be left unattended .

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5.7.6 Fasteners shall not be driven into very hard or brittle materials including, but not
( limited to, cast iron , glazed tile , surface-hardened steel, glass block , live rock ,
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face brick, or hollow tile .
5.7.7 Driving into materials easily penetrated shall be avoided unless such materials
are backed by a substance that will prevent the pins or fastener from passing
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completely through to the other side.

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5.7.8 No fastener shall be driven into a spalled area caused by an unsatisfactory

fastening .
5.7. 9 Tools shall not be used in an explosive or flammable atmosphere.
14
5.8 Wiring/Cabling/Switching
5.8.1 The Contractor shall ensure that wiring/cabling/switching should be refer to the
Factories and Machinery (BOWEC) Regulations & (Fencing of Machinery and
Safety) Regulations .
5.8.2 All electrical equipment and installations shall be of such construction and so
installed and maintained as to prevent fire hazard and danger from contact with
moving parts and live parts. Such electrical equipment and installations shall
conform to all the requirements prescribed in any written law relating to electrical
equipment and installations and shall have been approved by the authorities
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appointed by the said law.
5.8.3 The Contractor shall ensure that the electrical safety condition as stated in
Factories and Machinery Act & Factories and Machinery (BOWEC) Regulation
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is adhered by the employee where the electric power circuit is exposed .
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6. HAZARDOUS CHEMICALS AND MATERIALS
6.1 Storage
The Contractor shall ensure that chemicals to be stored should be classified refer to the
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Guidelines on Storage of Hazardous Chemicals: A Guide for Safe Warehousing of
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Packaged Hazardous Chemicals , DOSH.
6.2 Handling and Labelling

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The Contractor shall ensure that chemicals are to be handled, labelled and/or relabelled
as per to The Occupational Safety & Health (USECHH) Regulations 2000 and/or The
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Occupational Safety and Health (CLASS) Regulations , and/or The Pesticides Act 1974
(Latest amendment) and/or The Environmental Quality (Scheduled Wastes)
Regulations 2005 (Latest amendments) .
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7. SPECIAL SAFE WORKING CONDITION

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7.1 Confined Space

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7.1.1 Including excavations works, underground works , foundation works, caisson

piling works, tunnelling works , underwater diving , demolition works, and places
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of work as defined in the Code of Practice for Safe Working in a Confined Space,
2001 , DOSH .
(i). The Contractor shall comply with Occupational Safety and Health
requirements as listed in Regulation and Legislation .
15
(ii) . The Contractor shall ensure that closed tanks with restricted means of
entry and exit, open manholes, trenches, pipes, flues, ducts, ceiling
voids, enclosed rooms such as basements and other places where there
is inadequate ventilation and/ or the air is either contaminated or oxygen
deficient, be tested by a Competent Person before entry to determine
that there are adequate levels of oxygen present, and that dangerous
amounts of flammable and or poisonous gases are not present.
(iii). The Contractor shall establish a safe work system for workers who will
be carrying out their work in confined spaces.
(iv) . The Contractor shall adopt an entry permit system, so as to ensure that
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employees and others are aware of the location of anyone required to
enter confined spaces.
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7.2 Hot Works
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7.2.1 Hot Work includes flame cutting , welding , heat treatment, metal spraying,
( forging , grinding and any similar work that generates heat, flame or sparks. The
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Contractor shall appoint a Competent Person (CP) to be responsible for any hot
works. The Contractor must ensure there is at least one trained person can use
the fire fighting equipment when performing any hot works .
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7.2.2 Hot work shall not be performed in a confined space until a Designated Person
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(DP) has tested the atmosphere and determined that it is not hazardou s.
7.3 Blasting and Demolition Works

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7.3.1 Danger signs shall be conspicuously posted around workplace and all doorways
or thorough fares giving access to the property shall be barricaded except when
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being used as a passage for men or equipment.
7.3.2 Explosives shall not be handled or used except in accordance with the
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manufacturer's instructions, if any, and under the immediate control of a

Designated Person (DP) who has the training, knowledge , or experience in the
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field of transporting, storing, handling and use of explosives.
7.4 Working At Night

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7.4.1 Prior to the start of work, the Contractor shall submit a detailed work plan for
review and approval by the SO/P.O. The plan shall be updated by the Contractor
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as operations require. The plan shall include, but may not be limited to :
(i). Traffic control ;
(ii). Lighting plan ; and
(iii). Special safety elements.
16
7.5 Working overt near water
7.5.1 The Contractor shall provide approved life jacket or buoyant work vests when
working over or near water, where the danger of drowning exists. Prior to and
after each use, the buoyant work vests or life preservers shall be inspected for
defects which would alter their strength or buoyancy. Defective units shall not
be used.
7.5.2 A lifebuoy with sufficient lifeline (not less than 30m) should be provided and the
locations of the lifebuoys should be at less than 50m intervals along the edges
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of places where work is being carried out over side or in an exposed position on
vessels where there is a reasonably foreseeable risk of falling or being washed
overboard. To avoid any delays to rescue operations, lifebuoys should not be
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tightly tied to posts.
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APPENDIX A
REQUIREMENTS OF SAFETY AND HEALTH PLAN (S-PLAN)
1. Project Introductions
2. Management Responsibility
3. OSH Programme
4. Hazard Identification, Risk Assessment And Determining Control (HIRADC)
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5. Safety And Health Control Form
6. Permit To Work (PTW)
7. Fire Precaution And Protection And Emergency Respond
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8. Safety Operation Procedure
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9. Investigation And Incident Report
( 10. Occupational Safety And Health Statistics And Record
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11 . Employee Health Examination
12. Safety, Health And Welfare
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13. List Of Machines, Equipment And Plant
14. Traffic Control At Construction Site
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15. Personnel Protective Equipment (PPE)

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Whenever there is any dispute arise, item listed as per Prosedur Kawalan Keselamatan
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dan Kesihatan Pekerjaan JKR.PK(O).04B (Format Pelan Keselamatan dan Kesihatan

Pekerjaan , S-PLAN) under the latest version of Sistem Pengurusan Bersepadu (SPB),
JKR shall be referred .
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APPENDIXB
REQUIREMENTS OF SAFETY AND HEALTH REPORT
1. Introductions
2. OSH Programme
3. OSH Statistics And Record
4. OSH Complaints and Notices
5. Status of S-Plan
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6. Status of HIRADC
7. Employee and Worker's Registrations
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8. Registration of Machineries, Equipment and Plants
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9. Traffic and safety controls
( 10. Occupational Safety and Health Committee
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Whenever there is any dispute arises , item listed as per Prosedur Kawalan Keselamatan
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dan Kesihatan Pekerjaan JKR.PK(O).04B (Format Laporan Keselamatan Dan Kesihatan
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Pekerjaan) , under the latest version of Sistem Pengurusan Bersepadu (SPB) , JKR shall be
referred .
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Item Description Unit Qty Rate Amount
1 Prepare and submit safety and health plan (S- No

Plan) as per Specifications For
Occupational Safety And Health In
Engineering Construction Works .
2 Prepare and submit monthly safety & health No

report as per Specifications For
Occupational Safety And Health In
Engineering Construction Works.
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3 Employment of a Safety & Health Officer Manl
(SHO) registered with DOSH and to the Month
satisfaction of the S.OI P.D for the entire
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contract period to be stationed fulltime at the
site. (For works exceeding RM20 millions
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contract value or high risk workplace as
directed by S.OI P.DI DOS H)
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4 Employment of a Site Safety Supervisor (SSS) Manl
and to the satisfaction of the S.OI P.D for the Month
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entire duration of the construction period to be
stationed minimum 15 hours a week at the
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site.
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5 Provision and maintenance of Personal

Protective Equipment to S.OI P.D staffs at
site of adequate quantity and of approved
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quality. The equipment shall include but not

be limited to the following :
• Safety boots No
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• Safety helmets No
• Full Body Harness clw Hook and Lanyard No
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for workmen who work at heights more

than 3m above ground level
• Safety I life lines for workmen who work at m
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heights more than 3m above ground level

• Protective gloves No
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• Safety goggles No
• Safety jackets of reflective type No
• Ear plugs and muffs No
• Gas masks No
• Dust masks No
• Head lamp No
• Life jacket No
• Others as necessary No
6 Provision and maintenance on the Site during
the duration of the Works, of the adequate
safety equipment to be approved by the
S.O/P.D as follows:
Gas detectors No
Breathing apparatus No
Air ventilation pumps No
Warning lights No
Fire extinguishers No
Hazard tape rn
Safety barriers No
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7 Traffic Management LS
(Please delete this item if Traffic
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Management Plan is already existed in the
contract)
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r Provision and maintenance of adequate
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safety, traffic and warning signs and warning
lights including traffic control and signage by
cornpetent persons where site is in close
proximity of public road as stipulated in
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Standard Specification For Road Works
Section 19 (SPJ Section 19) and latest version
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of Arahan Teknik Jalan 2C/85.

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Appendix A17
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(Terms of Reference for Hydrographical
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Survey Works)
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NOT APPLICABLE
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Appendix A 19
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(JKR Acceptance Criteria)
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JABATAN KERJA RAVA MALAYSIA
PE1ABAT KETUA PENGARAH KERJA RAYA _ , (03) 26929011
mUPE1ABATJKR.MALAYSJA, T_ ' lCRTr,fA3041S
JALAN SUI.: 'n. KaWOl ,M1IIWORK.XUAU. UJMPIJR
:r"", SALAHUDDIN, Pax , (03)26921202
50582 KUALA LUMPUR. LInD ""., .""''-JIr....''''''
Rujukan : ( 39 )d1m.JKR.KPKR020.050/03 Kit 8

Tarikh : 1,5' Jolai 2009
Semua Pengarah Cawangan Ibu Pejabat JKR

Semua Pengarah Kerj a Raya Negeri/Wilayah
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Semua I'engarah 1 Pengurus Pembinaan
Pengarah JKR Unit Khas KESEDAR
Semua Jurutera Daerah
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SURAT ARABAN KPKR BU, 3/Z009
KRITERlA PENERIMAAN PROJEK JALAN SlAP
BAGIPENGURUSANPENYENGGARAAN
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1.0 Pendahuluan
1.1 Kebelakangan ini, proj ek-projek ' pembinaan j alan tidak dilaksanakan dengan
sempuma sehingga menimbul rungutan daripada orang rarnai khususnya berkaitan
permukaanj alan yang beralun.
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1.2 Sehubungan dengan itu, p ihak HO PT dan S.O . seharusnya memastikan kerja-
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kerja pembinaan jalan di laksanakan dengan sempuma dan semua spesifikasi
terpakai dipatuhi sepenuhnya.
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1.3 Sural Arahan ini bertujuan bagi mcnetapkan satu garis panduan bagi penyerahan
projek jalan yang mengand ungi K rilcria Penerimaan ke alas projek-projek
pembinaan jalan yang lelah ' s iap dibina dan yang akan diserahkan kepada
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Cawangan Kej uruteraan Senggara bagi pengurusan penyenggaraan.
Z.O Kriterls Pencrimaan
2. 1 Bagi melanearkan proses penyerahan projek pem bina.an j ala n yang lelah siap
M
( d ibina kepada Cawangan Kej urute'raan 8eoggara letapi pada masa yang sarna
me ma~l ikan ti ada kompromi ke atas kualiti pembinaan, garis panduan penyerahan
KU
dan Krite r a Pencrima' D seharusnya dipatuhi sepenuhnya.
2.2 Bagi Projek pembinaan jalan yang menggunakan JKRl8PJ/ 1988, Kriteria
Penerimaan seperti di Lampiran 1 seharusnya dipatuhi sepenuhnya.
O
D
Rujukan ( )JKR.KPKR.020.050/03 kit 8
Tarikh ,5" Julai 2009
SURAT ARABAN KPKR BIL 2/2009

KRITERIA PENERIMAAN PROJEK JALAN SlAP
ER
2.3 Bagi projek pembinaan jalan yang menggunakan JKR/SPJI2008-S4, Kriteria
Pcnerimaan seperti di Lampiran 2 seharusnya dipatuhi sepenuhnya. Rujuk sural
(35) dlm.JKR.KPKR 020.050/03 kIt 8 bertarikh J6 April 2009 mengenai araban
penggunaan 'Standard Specification For Road Works' JKRlSPJI2008-S4: Flexible
D
Pavement.
N
2.4 Kriteria Penerimaan ini merangkumi semua sl<op kerja pembinaan jnJan
( termasuk kerja-kerja jambatan (rujuk Lampiran 3) dan elektrik (rujuk
TE
Lampiran 4).
2.5 Segala kecacatan iaitu hasil kerja pemasangan atau pembinaan yang tidak
mematuhi Kriteria Penerimaan tersebul seharusnya dibaiki dengan sempurna
sebelum Tempoh Tanggungan Kecacatan lamat.
A
3.0 Penguatkuasaan
EJ
3.1 Sural Araban ini berkuatkuasa dengan serta-merta.

M
Sekian,
"BERKHIDMAT UNTUK NEGARA"

EN
~."""" ~
M
(DATO' .....BDUL KARJMl

Ketua Pengarah Kerja Raya Malaysia ~
KU
Sk.
I. Timbalan Ketua Pengarah Kerja Raya (Scktor Bisness)
2. TimbaJan Ketua Pengarah Kerja Raya (Sektor Pengurusan)
3. TimbnJan Ketua Pengarah Kerja Raya (Scktor Pakar)
O
D
lAMPIRAN 1

BAGI PENGURUSAN PENYENGGARAAN
A. Before CPC
1. Pavement
• Longitudinal Irregularity (shall comply with sub-section 4.4.3
ER
JKRlSPJ/1988)
• Transverse irregularity (rut depth) S 4 mm
• No crack
D
• No pothole
• No bleeding
N
( 2. Shoulder
• Flush and proper gradient from edge of pavement to RSD
TE
• Pavement/shoulder difference S 25 mm 2
• Irregularities (depression more than 150 mm) s 1 m
3. Culvert
A
Major
• All culverts constructed as per drawings (no .• size. type)
=
EJ
• Water flowing 100%
• Subsidence of adjacent pavement S 10 mm
Minor
• Debris in culvert s 10 mm
M
• Water pondlng inside culvert s 10 mm

• Gap between joints s 6 mm
EN
4. DraInage
Major
• All drains constructed as per drawings (length, size, type)
• Water flowing = 100%
M
Minor
<- • Debris In drain S 10 mm
KU
• Water ponding in drain S 10 mm

• Gap between Joints s 6 mm
5. Slope
O
• No slope failure
D
6. Bridge
• Condition Rating for each component/member = 1 or 2
7. Mechanical & Electrical

• Acceptance of testing & commissioning, witnessed by HOMT
3
LAMPIRAN ,

8. Roadllide Furniture
• Constructed as per drawing and in accordance with Arahan Teknik
ER
9. Road Safety Audit
• RSA Stage 4 Part 3 has been carried out and action on all comments has
been taken
D
B. Before CMGD
N
( 1. Pavement
TE
• longitudinal irregularity (shall comply with sub-section 4.4.3
JKRlSPJ/19B8)
• Transverse Irregularity (rut depth) S 4 mm
• No crack
• No pothole
A
• No bleeding
EJ
2. Shoulder
• Pavement/shoulder difference s 50 mm 2
M
• Irregularities (depression more than 150 mm) :S 1 m
3. Culvert
EN
Major
=
• Subsidence of adjacent pavement S 10 mm
Minor
M
• Water ponding inside culvert s 10 mm
• Gap between joints :S 6 mm
KU
4. Drainage
Major
O
Minor
• Debris in drain :S 10 mm
D

4
lAMPIRAN 1

5. Slope
ER
6. Bridge
• Subsidence of adjacent pavement s 20 mm
D
• In wor1<ing condition
N
( 8. Roadside Furniture
TE
• No fading/blemishes

• RSA Stage 5 has been carried out and action on all comments has been
taken
A
EJ
M
EN
M
KU
O
D
LAMPlRAN2

A. Before CPC
1. Pavement
• The lane International Roughness Index (IRI) measured for the whole
ER
length and each 100 meter section shall be less than 2.0 mlkm as per
Bub-section 4.5.3 JKRlSPJ/2008-S4)
• No crack
• No pothole
D
• No bleeding
N
( 2. Shoulder
TE
• Pavement/shoulder difference :s 25 mm
2
• Irregularities (depression more than 150 mm) :s 1 m
3. Culvert
Major
A
• All culverts constructed as per drawings (no., size, type)
EJ
• Subsidence of adjacent pavements 10 mm

Minor
M
• Water ponding inside culvert s 10 mm

EN
4. Drainage
Major
• All drains constructed as per drawings (length, size, type)
M
Minor
( • Debris in drain s 10 mm
• Water pending in drains 10 mm
KU
5. Slope
O
6. Bridge
D

• Acceptance of testing & commissioning, witnessed by HOMT
6
lAMPlRAN2

8. Roadside Furniture
• Constructed as per drawing and in accordance with Arahan Teknlk
ER
• RSA Stage 4 Part 3 has been carried out and action on all comments has
been taken
D
B. Before CMGD
N
( 1. Pavement
TE
• The lane International Roughness Index (IRI) measured for the whole
length and each 100 meter section shall be less than 2.0 m/km as per
sub-section 4.5.3 JKRlSPJ/2008-S4)
• No crack
• No pothole
A
• No bleeding
EJ
2. Shoulder
• Pavement/shoulder difference S 50 mm
M
• Irregularities (depression more than 150 mm) S 1 m2
3. Culvert
EN
Major
=
• SubSidence of adjacent pavement s 10 mm
Minor
M
( • Water ponding Inside culvert s 10 mm
KU
4. Drainage
Major
O
Minor
• Debris in drain s 10 mm
D

7
LAMPlRAN2

5. Slope
ER
6. Bridge
• Subsidence of adjacent pavement s 20 mm
D
• In working condition
N
c' B. Roadside Furniture
TE
• No fading/blemishes

• RSA Stage 5 has been carried out and action on all comments has been
taken
A
EJ
M
EN
M
KU
O
D
8
lAMPIRAN 3
SENARAI SEMAK KRITERIA PENERIMAAN PROJEK JAMBATAN SlAP '3AGI

PENGURUSANPENYENGGARAAN
Nama Projek
1) Reka &8!n. I I
ER
KMdah Pelakun.an 2) Konven-'onal Dalaman I I
3) Konven~lP1wun~ng I I
D
1) Pengul\ll Program.f"PIPD:
--
P-sl1WII1 Yang
N
2) HOPT IWPPIWPD :
( BcrtanggllngJawab
3) HOOT I WPP (Ey#PO (E) :
TE
Kontraldor 1) Kontraktor Ulama :
POflJOding 1) PerunCllng Utama :

A
Tempoh KontJak
EJ
PERKARA Stotua nnd.un I Cltatan

. _nLo"~
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12; "~~: UKur Id'n~~ :~lting our u"""
'IBU I ,••,:';:;~:d ""Y

EN
, .aru
I' ;::::;~'
16. Ookum,,"
, 'e;•. . .......
' ,'
..l "penl 01,,,,,,,, "nO'
, bearing, noioa _ dl
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( 16. M.klum" pcnting'ontra'''perIJ al.mal l I

(OlP) ~. tarikh slap. tlrikh tamat tanggungan
KU
Tandatangan.
O
Nam. Pegawal BSFJ:

Tarikh:
D
r"'< ~
Borang Kriteria Penerimaan Projek Jambatan Siap Bagi Pengurusan Penyenggaraan
ER
:,f>',;.;." . "" :. , ,,' .
''=Ng: :I'~'- C<>riI~nt ". >:;. {);ji'n~l!e , D9•.crtptlo n Ai:tlo"" J RBmaifts
; -":'~;i}' .: :.~ " . .
-~:'. ~., .",. -. "~.,. ': .j""
D
1.0 I BrIdge Surfoco 1.01 IPotholes 23
(Pavement) 1.02 IWheel Track Rutting 24
N
1.03 Iloss of Bond and Delamination 25
1.04 IRippiing 26
TE
1.05 IPavement Crad<ing 27
1.06 IPonding Wafs 18
1.07 IOthers
1.1 I Approaches 1.11 IDlffo"mC8 in Level a1 Bridge Approaches 30
1.12 IOthers
A
2.0 I Expansion Joln1s 2.01 IWater Leak 14
(Asphaltic Plug 2.02 ICrad<ing at Elcpansjon Joint 28
EJ
Expansion Joint) 2.03 IAbnormal Spacing at Bndge Joint 29
2.04 ITotally Damaged lJ<Je to Road Aeddent
2.1 I Expansion Jotnta 2.11 IWater Leok 14
M
(Reinforced Elastomeric 2.12 IAbnorm", Noise 31
Expansion Joint) 2.13 IRupture of Bridge Joint 32
2.14 IAbnormal Spadng at Bridge Joint
EN 29
2.15 IEpoxy Nosing Crad<ing 26
2.16 ISpalied & Delomina\iOn of Epoxy Nosing 25
2.17 ITo1a11y Damaged Due to Road Accident
2.2 I Expanolon Join" 2.21 IWater Leak 14
M
(Comp!9ssion Seal 2.22 IRupture of Bridge Joint 32
Expansion Joint) 2.23 IAbnormal Spacing at Bndge Joint 29
KU
2.24 I Epoxy NOSing Crad<ing 28

2.25 ISpelied & Delamination of Epoxy Nosing 25
2.26 I Detachment J Lost of Compression Seal Joint
2.27 ITotajly Damaged nue to Road Accident
O
2.3 I expansion Jolnl1l 2. 31 ICorrosion

(Steel Cantilever Comb 2.32 IFracture at Steel 2
D
or Tooth Joint) 2.33 I Loose Connection 3

2.34 IPermanent Deformations 4
.--'. 2.35 IWater ._- -.. _ _ , - -14
L ~ -.l..- ... . __ . _ _ . - - -Leak
_. --L. __ • ___ • _ _ _ _ _ ____ • • •
-
Page 1
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,,·r _....; .; '.: Defect ** .' -:
·f'~ ·!lOf.~: ~!.9bo.rved "
-- 'f:.:;1 ':'" -~ r'" "
li;~~P'~;;' "
r -
No. Comp'o~ent :"'1'

".'1' ,;"'\,<~ Damag e Descriptio,n . , Gondltl'!"Raung Actions J Rem""arlta .... <-!I,
.•~~ ~-"~~ i /. ,',
-: l:>~' :' ,;}~),},":-.' :.'.",-'
/.e!i('4:'.rifC>,,' ~ .,:·
"' :o<J:". • •
.' ~ ; :,~ .. -',. ~ .. "":, ,;~'+
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2.36 IAb",,"",,1 Spacing at Bridge Joinl 29
2.31 IAbnormal Noise 31
N
2.38 INo Provision of Gutter
2.39 I No Provision of UPVt: Rain Water Down Pipe
TE
3.0 I Plropot 3,01 ICorrosion
(Steel) 3.02 IFracture at Steel 2
3.03 ILoose Connection 3
3.04 IPermanent Deformetions 4
3.05 IPalnt Detarioralioo on Steel Surfaces 5
A
3.06 !Impact Damage 22
EJ
3.07 IStalning and Dirty
3.1 I P .... pol 3.11 ICraci<s in Concrete 6
(Concrete) 3.12 ISoailing
3.13 ISurfaoa 00_ 7
11
M
3.14 IDelamination 12
3.15 !lmpadDamage 22
4.0
4.1
I SIdewalk I Median
(Concrete)
I Kerb
4.01 ICracks in Conaste
4.02 ISurfaoa
4.11 ISpalling
00_ EN 6
11
7
(Conerate) 4.12 /Impact Damage 22
5.0 I O..lnlll_ Pipe 5.01 1000nage BIod<ed 20
M
5.02 INo Pipe or InadequaJe Pipe Lengtfl 21
5.03 IWater Loa!< 14
KU
5.04 IConoded and Section Lost 1

6.0 I Slopes 6.01 IScouring 17
6.02 IErosion 35
1.03 IMalsnal Loss I Disintegration 36
O
D
Page 2
r" ~
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.. ,
No,
:>-'~ . . ._
. <}:,
. Componeltt:· ,. '"n:
".~ .. ' " ., . .
·~;~ f <: ::~··::;\;,~!.

. t)1In!1IiII'DHcrlptl~
. . . . ..
. ,:,'~,''''' . " ';:'1'I,".~ct.'
.
'~"."'-l.
. . .. ; r
. ! ', ~~ :t:ii;~,}.~?
!','.- ' ~
,,~~:~':;_ '~
!
.•.~
,'
DOfGel
Ob,elVed
No ~ con'dIlf~~tiridl ~~tabIG
! :.: :::i;.t.i'~:, '!": ~;~~~: ~' .No .
'
ACfloml'R.~~!'" ";<. ·l..

..--./J: ~.F:;:-~:;' ~·7~~.~~
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7.0 Wtngwllil 7.01 Cra""" In Concrete 6
(Concrete) 7.02 Spalling 7
N
7.03 Surface Defects 11
7.04 Wear and Abrasion 9
TE
7.05 Material De1e<ioraOOn 10
7.06 Delamination 12
7.07 Scouring 17
7.06 Impac1 Damage 22
TIlt I Sot1Ioment 15
A
7.09
7.1 I Retatntng Wall 7.11 Cracks in Concrete 6
EJ
(Concrete) 7.12 Spatting 7
7.14 'Wear and Abrasion 9
7.15 Material Deterioration 10
M
7.17 Scouring 17
7.16 Impac1 Damage EN 22
7.19 TIlt I Settlement IS
7.2 I Retaining Wall 7.21 Corrosion I
(Steel) 7.22 Fracture at Steel 2
7.23 loose Connection 3
M
7.24 Permanent Deformations 4
7.25 Paint Deterioration on Steel Surfaces 5
KU
7.28 Scouring 17
7.27 IIl1"ICI Damage 22
7.28 Tilt I Settlement 15
7.3 I Retaining Will 7.31 SUrtaceo._ 11
O
(Masonry) 7.32 Cracks in Masonry Jointing Works 6

7.33 Scouring 17
D

7.36 Material Loss I Disintegration 36
7.36 Tilt I Settlement 15
Page 3
I"" ~
ER
I"~ D.• fect ',' "1'- •.
Dam.gl[.o~¥~~~ • .'. :.
;{', ':r'" .' .:'
-: 0efKt
"-Nb. . ;'dOt\;AAii~~t . . 06~er.v'd ~. . ·~ ·Ci>n~tiioll'f!j "c((OMJ.R'~
,...;,.
,}~ '~.-,
" .':' ;':./:!t';:: ... ;. ,". ·Coda . )i.e: I Ni> . - ~~~.:." ' ".(:!:?~' ·s :"',f.JT':·.~'.~··~':·\~1 '.'
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7.4 I curtain W.II 7.41 Cracks in Concrete 6
(Concrele) 7.42 Spalling 7
N
TE
7.46 Oelamlnotlon 12
7.47 Impact Damage 22
8.0 I Foundation 8 .01 CIlId<s In Concrets 8
A
8.03 Surface Defec1s 11
EJ
8.04 Wear and AbraBion 9
8.05 Ma18ri.1 Deb!rioration 10
8.07 Scouring 17
M
8.08 Tin, S.lIIemenl 15
9.D I Abutment 9.01 Cracks in Concrete 6
(Concrate) 9.02 Spalling 7
9.03 Surface De_
EN II
9.06 Tilt I SettSement 15
M
9.08 Scouring 17
KU
9.1 I Abutment 9.11 Surface De_ II

(Masorvy) 9.12 CIlId<s In Masonry Jointing Wo.... 6
9.13 Scouring 17
O
9.15 Ma1Bri.1 Loso' Oisln1egration 36

9.16 Tilt' settlement 15
D
Page 4
I""
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ER
No. ·le. ~ C'oniliOnont .. : ';;::j~~~'1leSCriPIiOn ~Plllble: f:. ;:.. - • ''lotions, Ram,,"",
~;"·I: .. '·-;· ". ~:.' y"" I No ·. , ...... ,:",
D
10.0 I Plar 10.01 ICracks in Conaele 6
(Concrete) 10.02 ISpalling 7
N
10.03 ISurface DeIac1s 11
10.04 IWear and Abrasion 9
TE
10.05 IMlllanal De1erioration 10
10.06 IDelaminallon 12
10.07 IScouring 17
10.06 ITiltJ Settlement 15
A
10.11 PIer 10.IIISurface De_ 11
(Masonry) 10.12 ICracks In Masonry JoinUng Wor1<s 6
EJ
10.131 Scounng 17
10.1 4 IWaar and Abrasion 9
10.15 lMa1erial Loss'
Disinlegration 36
10.16 Intt , Sotllemont 15
M
11 .0 I Beartng 11.01 ICOrrosion
(Steer-Mecl1anlcal) 11.02 ILoose Connection 3
11 .03 IDebris and Vegetation
EN 19
11 .04 IAboonnai Displacement 34
11 .11 Bea,lng 11.11 I Debris and Vegetation 19
(Rubber) 11.121Abnannal Displacement 34
11.13 iAbnormal Bulging 33
M
11.2 Bea~ng Shalf 11 .21 Debris and Vegetation 19
11.22 Ponding Wlllar 18
KU
12.0 Deck Slab 12.01 Crack8 in Concrete 6

(Concrete) 12.02 Spoiling 7
12.03 Surface Defeda 11
12.04 ~ Delamination 12
O
12.05 IWaier Leak 14

12.06 IAbnormal Displacement 34
D
12.07 ICorrosion of Reinforcement 8
Page 5
r- ~
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.. ,.
..;, ::-.-.:. ,. Defect
"
oefoct · ;W~~tab~" " ..' ',~..:
No. Component
.: .:. '~::~:':~ .
Oamag.8 Descrfptlo'" .-, .....
:i .~
,,', ,... c~cii.'

~
. Obs~ri&d ** Cono'ltlorf Rating· ::i,':;'. '" .... ".~ ',.
,
Action l / · R.em.~
'!.';~ ~ :;~~;;
. ' - ::~··f' .,y.. !IO
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. . . :··."e~...· '*{~ ' ..
.;0'
.~,.. " . .t', . .. " .,..
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12.1 Deck Slob 12.11 Corrosion 1
(Steel) 12.12 Paint Deterioration on Sleel Surfaces 5
N
12.13 Fracture at SleeI 2
12.14 Loose Connection 3
TE
12.15 PennanentDe~ations 4
12.16 Abnormal Displacement 34
12.17 Abnormal Noisa 31
12.18 Wa1er Leak 14
A
13.0 Glrd... lBeams 13.01 Cracks In Concra1s 6
EJ
13.03 Surface Defec1s 11
13.05 CorrosIon of Reinforcement 8
13.06 Abnonnat Vibration I Deflec1ion 13
M
13.07 Abnormal Noise 31
13.1 Glrde ... Jgeama 13.11 Corrosion 1
(Steel) 13.12 Paint Deterioration on Steel Surfaces 5
13.13 Fracture at Steel
EN 2
13.14 Loose Connection 3
13.15 Pennanent Deformations 4
13.18 Ahnonnal Vibration I De1leclion 13
M
13.17 Abnormal Norse 31
14.0 Riverbed 14.01 Scouring 17
KU
14.02 Silting 37
14.03 Debris Depositing 19
15.0 O1har Elementa 15.01 Scouring 17
(Items Re12ted to General 15.02 TI~ I setIIemer t 1~
O
Detects of Culvert) 15.03 SIlting at Culvert 37

15.04 Inadequate Size 36
D
15.1 CUlvort Body 15.11 Corrosion 1

(Steel) 15.12 PaInt Deterioration on Steel Surfaces 5
-. - ~- ... - - _. 15.13 Fractu<. al Steel

-- --_ .. .... - - ---- .- . --. 2 ._- _ .. _-- '- . - - ._-- - - -_ . ._-
Page 6
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- .. ., ' .' '. ", ," ~
~oj~,:~,nt '::<~' '.

.:~ Ot>fe~t . ..._.::;1'" "• r '"'
.. COrldlllon:R.iilng .:. ~cceptabl~
~.'
• Dtf8¢t .' ' I ' .... : .1
, Damage Dose.npl/olt -' , ; Ob8Q~.D.d .. :. Actlon.;~~~" ..' .,',
N...•· COdit ' -
•..):~::. - . - :-. ' .. v.. - ~ . . -..:,
'.
,::V" No ..··:··.t::·,, ·~:;: . ~·: .
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15.14 Loose COnnedion 3
15.15 Permanent Deformatlons
•
N
15.16 Water leak 14
15.2 Culvert Body 15.21 Cracks in Concrete 6
TE
; 15.24 Wear and AbrasIon 3
A
15.27 Water leak 14
EJ
15.28 Ti~ I Set1!ement 15
15.3 Culvert Body 15.31 Surface Defects 11
(Masonry) 15.32 Wear and AbraSion 9
15.33 Cracks in Masonry Jointing Works 6
M
15.35 Tilt / SetUemant 15
15.4 Headwall/Wlngwoll 15.41 Cracks in Concrete
EN 6
(Concrete) 15.42 Spoiling 7
15.43 Surface Defacls 11
M
15.5 Headwall rWlngwoH 15.51 Surface DefacIs 11
KU
(Masonry) 15.52 Cracks In Masonry Jointing Work:s 6

! 15.53 Wear and Abrasion 9
15.54 Material Deter1oration 10
O
15.6 Apron 15.61 Cracks in Concrete 6

D

-- - - _.._ - -15.65
._.,
Material Deterioration
._ .-- - _ . -- - - ._-10 - -. - - - - _.- '- ._...- - - - .- - _.
Page 7
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","' 'i...'.'::', ,
~l:{'(;,'-,: ·Co;nponanf l~;i~.~ ~gG 9.~s~npf1on
., .' oefiet" ".~. ,- r
* ~f8et. o~~Oi'ea :-;.: ~:t·ondltton .~tfrfg
t'
Acceitab~ ·1· :, .i.J;;.~'". AcUomi'/Remarl".

\r~r.' (,':\(.... .'.. . . . ir,;:::\ ,_
:;' , ~.-f . Code. : :~~.~ "l:'~'~O ~- ':~:;y'.' ,Vft ' ~ '. '~1 ~;i~r;'~::~: ,'-, :':.
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15.66 IScouring 17
15.67 ITiiti Se\1Iement 15
N
16.0 I Brtdge Panel ~.;:16:::.0=1:-1IES~Ia;::in:::.lng
~an~d;,:D:::I:.:.rty!.....-_ _ _ _ _ __ _ -4_ "":"'- -,I-_+_--1
16.02 Collapsed I S10ien
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17.0 I 801d90 Structu ... Numbor ~::17;::.0=1:-1IES1a=.;::in:::.
ing ~ond::::D;::i?rty!.....-_ _ _ _ _ _ _ _-4_ "":"'_I-_+_--1
17 .02 Collapsed I Stolen
Verified by:
A
Cheeked by:
EJ
Name: Name:
M
Designation: Designation:
Date: Date:
EN
~
• Defect Code" Refer 10 Table 4.2" Criteria For ClassifICation Of Severity Of Damage (Chapter 4), Annual Bridge Inspection Manual (JKR 20416-001H)1), OkIober 2003
.. Condition Rating
M
Bm!ng General Definition
1 No damage found and no maintenance required as a resuH of the inspection.
2 Damage detected and ~ is necessary to record Ihe condition for observation purposes.
KU
3 Damage detected are slightly critical and thus it is necessary to Implement routine maintenance work.
4 Damage detected is critical and thus il Is necessary 10 implement repair work or to carry out a detailed inspection to delenmine whelher any rehabilitation
works ana required not.
S Being heavily and critically damaged and possibly affecting the safety 01 traffic, it is necessary to implement emergency temporary repeirwork immediately
O
or rehabilitation work wijhout delay after the provision 01 a load lim~elion tratIIc sign.
D
PageS
LAMPIRAN 4a
rr';:;;';n'j LAMPIRAN 1 : SENARAI KRITERIA PENERIMAAN SEBELUM CPC

-.. -.::. -~., .
Lampu Jalan Lampu Isyarat

PERKARA Tindakan I Catatan
VA TIDAK VA TlDAK
TESTING ::
"
· Earthing Test DO DO
· Conlinul/y lost DD DD
ER
· Insulation Tost DD DD
· PoI.tity Tost DO DO
· Luminance Test DO DO
DO DO
D
· I/Jurmnance Tost
N
2, IlAItJI.A/~BIt.JTY :•
• Poi8 serVk. Door DO DO
TE
: .: ~o~ Door at-Para",,1 DO DO
.- ~ . AnIl· Varidafis-m ( e_Q. Fiber
,-... . . DO DO
' , Sorvic8;DoOr) DO DO
DD DD
A
• Cable Ril
EJ
TERIMA I TIDAK TERIMA
DISEMAK OLEH : DISAHKAN OLEH :

M
Tandatangan : Tandatangan :
EN
Nama pegawal : Nama Pegawal :

M
(
Tarikh: Tarikh:
KU
ULASAN:
O
D
LAMPlRAN4b
rj.rKn·, LAMPIRAN 2 ; SENARAI KRITERIA PENERIMAAN SELEPAS CPC

---..:-- ..
Lampu Jalan Lampu Isyarat
PERKARA Tindakan / Catatan
YA TIDAK YA TIDAK
1. FUNCTIONAL ,.
· Load Bslancing DO DO
· ELCB Trip DO DO
ER
· Timer I Photocefl DO DO
• .TN8 M.t.r (Digna/) DO DO
· Filings (Lamp, Switch Socket DO DO
DO DO
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Outlel, Hest.r efc )
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( 2" ·VlSUAL:.
< TiiIJ9;fI(J IlAbe"ing I Slicker DO DO
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.;. Pai>an I~nda Ad~an ~roSakan DO DO
. ' Log:!look DO DO
• ,Lock & 2 S"ts Of Kay DO DO
!iPsa.; Tool (IfAny) DO DO
A
;~ ;
-
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TERIMA I TIDAK TERIMA
DISEMAK OLEH : DISAHKAN OLEH :

M
Tandatangan : Tandatangan :
EN
Nama Pegawal ; Nama Pegawai :

M
( Tarikh: Tarikh:
KU
ULASAN :
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PEIABAT KETUA PENGARAH KERIA RAYA
\BU PEIABAT JKR MALAYSIA,
Thief...
lCler..
(OJ) 26967001
KRTMAJ041S i JJIftm
lALAN SULrAN SALAHUDDIN,
50582 KUALA LUMPUR.
K.....
Fa
MlNWOJU:. XUALA LUMPUR
(0)26911117 ~. %=-'"
l.amen Web htzp:llwww.jkq•.OV.ru1
Rujukan : ( 3 )dlm.JKR.KPKR 020.050103 kit 9

Tarikh : 30 Disember 2009
ER
Semua Pengarah Cawangan Ibu Pejabat JKR
Semua Pengarah Kerja Raya NegerilWilayah Persekutuan
Semua Pengarah/Pengurus Pembina an
D
Pengarah JKR Unit Khas KESEDAR
Semua Jurutera Daerah
N
( SURAT ARAHAN KPKR BIL. 8/2009
TE
PENYEDIAAN DAN PENYERAHAN DOKUMEN
BAGI TUJUAN PENYERAHAN PROJEK JALAN SlAP
A
1.0 Pimdahuluan
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1.1 Sebaik sesuatu projek pembinaan jalan disiapkan, dan segala kecacatan
yang dikenalpasti dalam Tempoh Tanggungan Kecacatan dibaiki dengan
sempurna dan mematuhi Kriteria Penerimaan seperti yang telah
ditetapkan, projek tersebut seharusnya dlserahkan kepada Bahagian
M
Senggara Fasiliti Jalan (BSFJ), Cawangan Kejuruteraan Senggara bagi

pengurusan penyenggaraan.
EN
1.2 Peoyerahan projek bagi pengurusan penyenggaraan seharusnya

dikemukakan bersama dengan dokumen seperti Sijil Siap Secara
Praktikal (CPC), Sijil Siap Baiki Kecacatan (CMGD), Lukisan Siap Bina
(As-Built Drawings), Sijil Jaminan, Maklumat Inventorisasi dan lain-lain.
M
(
1.3 Lukisan Siap Bina khususnya adalah amat penting bagi membolehkan
KU
aset negara disenggara dengan sempurna. Dengan berpandukan kepada

lukisan tersebut, struktur binaan jalan dapat dirujuk dan ditelill dalam
mengenalpasli punca dan lokasl sesuatu kerosakan atau kecacatan,
sekiranya ada, selepas infrastruktur tersebut dibuka kepada pengguna
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jalanraya. Di sam ping itu, lukisan tersebui juga amat berg una untuk
dirujuk apabila jalan tersebut dinaiktaraf di masa akan datang.
D
1.4 Sural Arahan ini bertujuan bagi menetapkan dokumen yang perlu
dikemukakan bersama oleh pihak S.D. semasa penyerahan projek jalan
yang telah siap dibina kepada BSF J bagl pengurusan penyenggaraan.
Rujukan : ("3 )dlm.JKR.KPKR 020.050103 kit 9
Tarikh : 30 Disember 2009
, SURAT ARAHAN KPKR BIL.9/2009

PENYEDIAAN DAN PENYERAHAN DOKUMEN
BAGI TUJUAN PENYERAHAN PROJEK JALAN SlAP
ER
2.0 Dokumen Penyerahan
D
2.1 Senarai dokumen yang seharusnya diserahkan adalah merangkuml
samua skop karja 'pembinaan jalan termasuk kerja-kerja jambatan, eleklrlk
N
( dan mekanikal. Rujuk Lampiran.
TE
2.2 Penyerahan dokumen ini adalah mandatori sebelum BSFJ dapat
mengambil alih sepenuhnya projek jalan tersebut bagl pengurusan
.... penyenggaraan. A
3.0 Penguatkuasaan
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3.1 Sural Arahan ini berkuatkuasa dengan serta merta.
Sekian.
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'BERKHIDMAT UNTUK NEGARA'

EN
M
(
KU
s.k.
1. Timbalan Ketua Pengarah Kerja Raya (Sektor Bisnes)
O
2. Timbalan Ketua Pengarah Kerja Raya (Sektor Pengurusan)

3. Timbalan Ketua Pengarah Kerja Raya (Sektor Pakar)
D
2
[Borang JKR.PK(O).05-1 Plndaan 2009]
SENARAI SEMAKAN PRA-PENYERAHAN KEPADA BSFJ

(Un/uk disediakan sa/spas Sljil S;sp SeCSfS PrsktlkBI dlkeluarken)
Nama Projek :
--------------------------------------------
Ada Tiada TB
1. Sijil Slap Seeara Praklikal (CPC)

,------,I L-I---,I L-I---'
ER
2. Borang A - Perakuan Sera han Kerja Siap (Selepas CPC)
Kepada BSFJ ,------,I L-I---,I L-I---'
D
N
3. Borang A mengandungi lampiran berikut;
(
• Senarai baki kerja belum siap
BBB
TE
• Senarai kerja cacat
4. BII TNB yang lerkini

,---,I <--I---,I L-I---'
A
5 Kerja-kerja Penyenggaraan Rutin dalam Tempoh
,---,I '<-----,I <--I---'
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Tanggungan Keeaeatan di dalam Skop Kontrak

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6. Tindakan mewartakan jalan sebagai Jalan Persekutuan

telah diambil ,---,I '<-----,I <--I---'
EN
Nota ,' 1.BSFJ -Sahagian SenggarB FasifiU Jelen

2. TB· Tidak Berkaitan
3. Jika "Ada", sile sertakan befsama sese/men dokumen
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Calalan :
(
KU
O
(Wakil Pegawai Penguasa)

D
Nama :
Jawatan :
Tarikh:
Page 1 of 1
BORANGA
JABATAN KERJA RAYA

PERAKUAN SERAHAN KERJA SlAP (SELEPAS CPC)
KEPADA BAHAGIAN SENGGARA FASILITI JALAN
Ruj Fail :
Tarikh :
Tajuk Kontrak
ER
No. Kontrak
Kerja di alas lelah disiapkan dan Sijil Siap Secara Prakllkal (CPC) lelah dikeluarkan. Kerja telah diperiksa
D
oleh:
N
(
TE
mewakili
(Nama Pegawai) (Kemenlerian/Jabalan Pelanggan)
dan
A
mewakili
EJ
(Nama Pegawai) (Pegawai Penguasa)
Kami yang menandatangani di bawah ini mengakui bahawa Kerja tersebul lelah diserahkan oleh
Pegawai Penguasa kepad a Pengarah Bahagian Senggara Fasiliti Jalan. Baki kerja yang masih belum
M
disiapkan dan/alau kerja cacat adalah seperti disenaraikan di Lampiran.

EN
Tandalangan Tandalangan
M
Wakil Kemenlerian/Jabalan Pelanggan Wakil Pegawai Penguasa

(
Nama : Nama :
KU
Jawatan : Jawatan:
O
D
Tarikh: Tarikh :
Nola: Aduan terhadap kerja cacal hendaklah dibuat secara bertulis kepada Pegawai Penguasa lidak
lewat dari tarikh lamatnya Tempoh Tanggungan Kecacatan iaitu pada _ _ _ __ _ __
[Borang JKR.PK(O).05-2 Plndaan 2009]
SENARAI SEMAKAN PENYERAHAN KEPADA BSFJ

(Untuk disediak8n se/epas Slji/ Slap Baiki Kecacatsn dike/u8l'kan)
Nama Projek :
Va Tiada TB
ER
1. Sijil Siap Baiki Kecacatan
L----,I ,-I--,I ,-I----'
2. Borang B - Perakuan Sera han Siap Ke~a (Selepas
L----,I ,-I--,I 1,----,
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CMGD) Kepada BSFJ
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( 3. Pelan Lukisan Siap Bina
TE
(Softcopy, 2 salin an - 1 lonmat dwg autoCAD yang boleh diedit dan
1 fonmat pdf dengan cop dan tandatangan Jurutera Profesional)
Pel an Lokasi
A
Pel an Had Laluan (ROW)
Pel an Longitudinal Profile
EJ
Pelan Soil Investigation

Pelan Alignment Control
M
Pelan Drainage Layout

Pelan Geotechnical - Ground Treatment Layout
EN
Pelan Road Furnitura Layout

Pelan Traffic Control Layout
Pelan Utilities Layout
M
Telekom
<- TNB
KU
Bekalan Air
Lain-lain (nyatakan, _ _ _ _ _ _ _ __ .
Pelan Kerja Jambatan/JejambatiJejantas/Pembetung

(layout, structure, drainege, furniture & utilities)
O
BBB
• Pelan Ke~a Elektrik
D
• Pelan Ke~a Mekanikal
Page 1 of 3
[Borang JKR.PK[O).OS.2 Pindaan 2009)
Va TIada TB
4. Sijil Jaminan
Sijil Jaminan Kerja Awam
Sijil Jaminan Kerja Jambatan
Sijil Jaminan Kerja Arkitek
Sijil Jaminan Kerja Elektrik
• Sijil Jaminan Kerja Mekanikal
ER
5. Kerja Elektrikal (Lampu Jalan/Lampu Isyarat)
Surat Perlantikan Kontraktor/Perunding
L---!I ,-I_I ,-I ----.-.J
D
Elektrik (untuk Projek Reka dan Bina)
• Manual Operasi & Penyelenggaraan (OMM)
BBB
N
( • Kepulusan Pemeriksaan Pengujian
(Ujian Earthing, Continuity, Insulation, Polarity - untuk
TE
seliap feeder pillar)
(Ujian Luminance dan fffuminance - unluk seliap
lampu jalan)
§§§
Latihan Penggunaan Sistem
A
Jadual Kerja-Kerja Penyenggaraan
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Katalog Produk
6. Kerja Mekanikal
M
• Surat Perlantikan KontraktorlPerunding

Mekanikal (untuk Projek Reka dan Bina)
,-----,I IL--.....JI ,-I----'
EN
Manual Operasi & Penyelenggaraan (OMM)

Keputusan Pemeriksaan Pengujian
• Latihan Penggunaan Sistem
M
Jadual Kerja-Kerja Penyenggaraan

( Katalog Produk
KU
7. Maklumat Inventorisasl
JejambaUJejantas
O
Jambatan & Pembetung

Perabot Jalan
D
• Lampu Jalanllsyarat dan Feeder Pillar
Page 2 of 3
[Borong JKR.PK(O).05-2 Pindaan 2009]
Va Tlada TB
B. Laporan Penutupan NCR

• Kerosakan/Kecacatan yang dikenalpastl oleh Wakil
Pegawai Penguasa L......--->I I I <-I----'
BBB
• Audit Kriteria Penerimaan
• Teguran Road Safety Auditor
ER
9. Audit Keselamatan Jalan
• Compliance Report
,----,I c::J <-I----'
D
N
Nota: 1. BSFJ - Sahagian Senggara Fasilili Jelen
( 2. TB - Tidak Berk8itan
J. Jika -Ad8 ~. si/a seriskan berssms sesoJinan dokumsn
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Cataton: A
EJ
M
(Wakil Pegawai Penguasa)
Nama:
EN
Jawatan :
Tarikh :
M
( UNTUK KEGUNAAN BAHAGIAN SENGGARA FASIUTI JALAN

KU
(Wakil KPPK Zon)

O
Nama:
D
Tarikh terima dokumen:
Page 3 of 3
BORANG B
JABATAN KERJA RAYA

PERAKUAN SERAHAN KERJA SlAP (SELEPAS CMGD)
KEPADA BAHAGIAN SENGGARA FASILITI JALAN
Ruj Fail :
Tarikh :
Tajuk Kontrak
ER
No. Kontrak
Kerja di atas telah disiapkan sepenuhnya dan Sijil Siap Baiki Kecacatan (CMGD) telah dikeluarkan. Kerja
D
telah diperiksa oleh:
N
(
TE
mewakili
(Nama Pegawai) (Kementerian/Jabatan Pelanggan)
dan
A
mewakili
EJ
(Nama Pegawai) (Pegawai Penguasa)
Kami yang menandatangani di bawah ini mengakui bahawa Kerja tersebut telah diserahkan oleh Pegawai
M
Penguasa kepada Pengarah Bahagian Senggara Fasiliti Jalan.

EN
Tandatangan
_ __ __ _-_ _._--_ _----
.... ... ...
Tandatangan
.. ..
M
Wakil Kementerian/Jabatan Pelanggan Wakil Pegawai Penguasa
<- Nama: Nama:

KU
O
Jawatan : Jawatan :
D
Tarikh : Tarikh :
CARTA AliR PROSES KERJA
AKTlVfTI TANGGUNGJAWAB RUJUKAN
Rajah 1
Projek slap dan (PC pp
telah dikeluarkan
,
Maklumkan dan kemukakan k~p~a BSFJ
ER
I) Sorang A Pegawal Penguasa
il)Borang JKR.PK.{O)05-1 Plndaan 2009
D
I Pel.ksan•• n
Audtt Krlterla Penerlmaan
Sahagian Senggara
Fasiliti Jaran
RuJuk Proses Kerja Audit Kriterla
Penerimaan
N
( ~
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Penyedlaan d.an penyer.han
dokumen kepada BSFJ
e
~
i) Borang
Pegawal Penguasa
iiJ Borang JKR.PK.(O)05-2 Plndaan
2009
A
Tidak
lengkap
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Semakan Dokumen Sahagian Senggara

Fasiliti Jalan
M
Penyerahan
EN
B
M
(
KU
O
I Penyerahan sepenuhnya kepada BSFJ I Pegawai Penguasa

D
ER
Appendix A20
D
N
(
(BIM Requirements)
TE
A
EJ
M
EN
M
{
KU
O
D
APPENDIX A20
BUILDING INFORMATION MODELLING (BIM) REQUIREMENTS
1.0 GENERAL
This Building Information Modelling (BIM) Requirements forms part of the Contract for
Malaysia Government project, and must be read in conjunction with the overall
Government Requirements including all Appendix A20.
The purpose of this document is to define the minimum requirements for the use of BIM
in the project and shall include the generation of information rich-model , model reviSion ,
visualization and analysis, and collaborative use of BIM throughout the project duration
as defined in the document.
ER
2.0 PLATFORM AND SOFTWARE
D
The BIM platform used in JKR is Autodesk and the software used are as specified in
N
Appendix A20-1.
(
TE
3.0 BIM DELIVERABLES A
3. 1 The Contractor shall develop model for road works , structural, geotechnical ,
electrical works, and other services (also known as Information Model) . The
EJ
development of the models shall be in accordance to Appendix A20-2. All

drawings submitted shall be generated from the model where necessary or
required by the Government.
M
3.2 The BIM Deliverables shall be produced , updated , submitted and shared in
accordance to the requirements as specified in Appendix A20-1.
EN
a) BIM Project Execution Plan (BEP)
The Contractor shall submit an outline of BIM Execution Plan (BPEP) in the
M
( Proposal for tender bidding purposes. The successful Contractor then shall
update the BEP based on the acceptance from the P.O..
KU
The contents of BEP shall be inclusive of the followings (but not limited to) :
O
(i) Project information ;

(ii) Project's BIM objectives;
(iii) List of BIM personnel ;
D
(iv) Roles and responsibilities ;

(v) BIM deliverables;
(vi) BIM data requirements ;
(vii) BIM work process;
(viii) BIM information exchanges ;
(ix) Collaboration and coordination procedures;
(x) Quality control ;
A2011 I P age
APPENDIX A20
(xi) Technological infrastructure needs; and
(xii) Model structure
The contents of the BEP shall be updated progressively by the Contractor

in relation to any changes that may occur throughout the project life cycle.
For monitoring purpose, the Contractor shall mandatorily submit the
progressively updated BEP to the p.o. at preliminary, construction and
close out phase. Nevertheless, the Contractor shall also able to provide the
updated BEP whenever required by the P.O..
The acceptance by the P.O. of such plan shall not relieve the Contractor of
any of his obligations under the Contract. The Contractor shall update and
revise the said BEP during the progress of the work when necessary in
order to comply with the Contract, all to the acceptance of the P.O..
ER
The Contractor shall maintain records of development of all the information
models (BIM) in each project phases involved according to their respective
purposes as stated in the BPEP.
D
N
In the event of any disagreement on the terms or modifications to the BEP,
( the Contractor must seek for the P.D.'s acceptance and such decision by
TE
the P.O. shall be final and conclusive.
The BPEP should be considered as a living document and the Contractor

shall continually develop and refined the document throughout the project
A
development life cycle as required to ensure the project remains on
schedule and meets the Government's Requirements.
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The Contractor shall at his own cost provide all access, assistance and
facilities to enable the P.D.'s Representative to verify the implementation
M
of the BEP and adherence thereto.

EN
b) Road Works Model
Model the following Road Works element as per designed to a level that
defines the design intent and accurately represents the detailed design
M
( solution.
KU
Model of Earthwork elements shall be fully developed by using 'AutoCAD

Civil 3D tools' which consist of entire site formation level including grading
(slopes) , road-subgrade and any elements that modified and reshaping the
original ground level due to design requirement.
O
Model of other Road Works element can be developed partly by using

D
'AutoCAD Civil 3D tools' combined with 'Drafting and Annotation tools'

and/or '3D Modelling tools' available in the AutoCAD Civil 3D software. The
other Road Works element shall consist of but not limited to the following :
• Drainage system
(e.g. earth drain, roadside drain, monsoon drain);
• Road Works
(e.g. road alignment, road profile, pavement structure) ;
A20/2 1 P age
APPENDIX A20
Road Furnitures;
(e.g. road line marking , signages, guardrail , etc);
• Traffic Management Plan
(e.g. traffic management control devices, traffic management
at work zone);
The layout, cross-section, plan profiles and longitudinal section shall be

generated from the Road Works Model. The Contractor is required to
produce reports generated from the Road Works Model where applicable
which consist but not limited to the followings :
Site Analysis Report comprised of elevation , slope and
water flow analysis;
• Cut and Fill Volume Report; and
• Quantity take-off Report.
ER
c) Structural Model
D
Model the following structural elements as per designed to a level that
N
( solution . Structural elements are to be modeled for within structural
TE
discipline and interdisciplinary coordination as follows (but not limited to):
• Abutment, Beam , Slab, Pier, Pierhead , Staircase, Ramp,
Foundations, Stiffener, and Other structural components.
A
Detailed drawings including key plan and detailing shall be generated from
the model where necessary. However, the following details are not required
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to be modeled but shall be incorporated/linked (CADlink) into the model for

references:
Concrete reinforcement details (rebar), Connection details
M
of structural members; and Base plates, clip hangers, fixing

etc.
EN
The following details and information whichever appropriate shall be

included in the model.
• Design criteria such as material properties and
design characteristic; and
M
( • Design Standards / Code of Practices.

KU
d) Electrical Model
O
Model the electrical elements as per designed to a level that defines the
design intent and accurately represents the detailed design solution.
D
Electrical elements are to be modeled for within the discipline and

interdisciplinary coordination as follows (but not limited to):
Electrical component schedules shall be generated from the

model to indicate all the symbols, descriptions and quantities.
A20/3 I P age
APPENDIX A20
e) Geotechnical Model
Model the following geotechnical elements as per designed to a level that

solution . Geotechnical elements are to be modeled for within the discipline
and interdisciplinary coordination as follows (but not limited to):
Retaining Wall , foundations, and other geotechnical
components;
Demarcation of boreholes and soil treatments/improvements
(if any) .
Detailed drawings including key plan and detailing shall be generated from
the model where necessary. However, the following details are not required
to be modeled but shall be incorporated/linked (CADlink) into the model for
ER
references :
Concrete reinforcement details (rebar) , connection details of
structural members; and base plates, clip hangers, fi xing etc.
D
The following details and information whichever appropriate shall be
included in the model.
N
( • Design criteria such as material properties and design
TE
characteristic; and
• Design Standards / Code of Practices.
A
f) Clash Analysis
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Clash Analysis shall be carried out prior to the commencement of
construction phase and in the event where design/work changes occurred
during the construction phase to identify interferences of components
M
within each discipline and among disciplines. Clashes need to be resolved

upfront to reduce conflicts that may have cost implication and cause delay
in project completion. Throughout the modeling process, any design
EN
conflict or clash or interference shall be identified and properly

documented .
In the event where design/work changes occurred during construction

M
( phase upon PD.'s instructions and require coordination to be done , the

Contractor shall carry out Clash Analysis for that particular part(s) involved .
KU
The Contractor shall fulfil the followings:

The Clash Analysis Reports shall be submitted for reference
as and when requested by the P.D.; and
O
Every clash identified in Clash Analysis Reports must be

resolved before construction works begin on site. No claims
D
for extra cost shall be entertained for any essential part of the
clash resolution in order to suit the accepted design .
A20!4 I P age
APPENDIX A20
g) Design Coordination
The Contractor shall carry out design coordination to check on the integrity
of all the detailed Design Model. The aim of the design coordination is to
resolve discrepancies in drawings and design documentation, lack of
design information and constructability issues before the commencement
of works on site and in the event where design/work changes occurred
during the construction phase. The Contractor shall fulfil the followings:
Carry out visual demonstration on the coordinated detailed
Design Models upon stakeholders request in Technical and
Site Meeting throughout the whole project duration; and
The Design Review Reports shall be submitted for reference
as and when requested by the P.O.
ER
h) Coordinated Model
The Contractor shall submit Coordinated Model consists of the combination
D
of the completed final design and clash-free of Road Works , Structural ,
N
Geotechnical and Electrical models before the commencement of the
( works on site. This Coordinated Model shall be ready to be used as a
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Construction Model and to be updated in the event where design/work
changes occurred during the construction phase.
A
i) Construction Model
EJ
The Contractor shall continue to develop, maintain and update the
information model (i.e. Construction Model) progressively to include any
changes that may occur during construction period.
M
The model shall reflect the latest technical requirements approved by the
P.O. The Construction Model shall be used for construction simulation , site
EN
coordination and construction administration documents.
The Contractor shall able to submit the updated models whenever required
by the P.O. The final submission of the Construction Model shall lead to the
M
( production of the As-Built Model.

KU
j) Construction Simulation Model
The Contractor shall carry out Construction Simulation as a reference to

O
verify work program in terms of the sequencing of actual construction

works .
D
The Contractor shall fulfil the followings :

• The Construction Simulation Model shall be submitted
in .nwf/.nwd format and be used as a work program verification tool
during work program acceptance meeting; and
Construction Simulation Video shall be submitted for
reference as and when requested by the P.O.
A20/5 I P age
APPENDIX A20
k) As-Built Drawings
a. The Contractor shall provide and deliver to the P.O. approved As-
built models in latest software version and drawings after completion
of each section of the Works in the form of:
(i) Four (4) sets of as-built drawings (generated from the models)
as actually constructed pertaining to the Works including all
services and facilities systems and all supporting documents
such as Operation and Maintenance Manual , Testing and
Commissioning Certificates. All As-built Drawings for building
Works provided shall be compatible with the "Immovable
Asset Code System " (Sistem Kod Aset Tak Alih - SKATA) .
(ii) Four (4) sets of Digital Copies in Revit (.rvt and .dwfx),
ER
Navisworks (.nwc and .nwd), Civil 3D (.dwg , dwfx, .pkt, pipes
catalog and pressure pipes catalog), Infraworks (.sqlite) and
other related format to be stored in compact discs or
D
removable storage.
(ii i) Four (4) sets of Digital Copies in Acrobat (.pdf) format to be
N
stored in compact disc or removable storage.
( (iv) Two (2) sets A 1 size and Three (3) sets A2 size of Hardcopy
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Copies drawing generated from the As-Built Models
b. The As-built drawings shall be endorsed by a Professional Architect!

Engineer! Surveyor registered with the respective Professional
A
Boards! Bodies in Malaysia .
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I) Model Quality
The model quality shall include but not limited to :

M
a. Components with accurate geometry, function , type , coding ,

specification , material, graphic and associated parameters
EN
according to LaD requirements ;
b. Materials with coding , specification, graphic and rendered properties

according to LaD requirements;
M
(
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c. An efficient, consistent and accurate modelling practice with

acceptable related wamings : e.g. eliminate object overlap, incorrect
close wall intersections, etc;
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d. Parametric models and components with dimension accuracy

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according to design intent, analysis and construction ;
e. Models with correct application of material and functionality;
f. The use of correct component classification for modelling : e.g. the

use of road furniture ;
A20/6 1P age
APPENDIX A20
g. The maintenance of parametric linkages within the model at all times
to enable automatic generation of all plans, sections, elevations,
custom details and schedules as well as 3D views ;
h. The use of appropriate and interoperable viewing , checking , and

output file formats such as .dwfx, .nwd , etc. ;
i. The use of model checking tools (e.g. Navisworks Manage) to

confirm the validity and accuracy of files/models and adherence to
design requirement/needs statement; and
J. If the exact component specification is not available for tender

submission purposes, the component shall be modeled accordingly
as conceptual basis.
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APPENDIX A20-1
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BIM: PROJECT BRIEF
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A20-1: till
APPENDIX A20-1
TABLE OF CONTENT
1 INTRODUCTION ......................... ..... .. ...... .. ... ...... .. ... ...... .... ..... ..... ..... .. 3
2 PROJECT INFORMATION .... ........... ... ......................................... .. .... 4
3 PROJECT SCOPES, OBJECTIVES, USES AND DELIVERABLES ..... 5
3. 1 SCOPES OF BIM WORK ... ... . ..... ................................ .... .... .. .. ... . 5
3.2 BIM OBJECTIVES, USES AND DELIVERABLES ..... ... .... ... .. . 5
3. 2.1 BIM OBJECTIVES AND USES. . . . .......... ..... ........... 5
3.2.2 BIM DELIVERABLES .. ... ... ........ ... ............ ..... ..... ..... .......... ..7
4 BIM TECHNICAL REQUIREMENT. . ...... ................ .............. .. . .. .. 10
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4.1 COMMON DATA ENVIRONMENT (CDE) / SHARING
PLATFORM ......................... .. .. .... ... ................................. ... ... .. ... ...... . 10
4.2 BIM SOFTWARE . . . . . . . ............................ .... . ... .. ... 10
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4.3 INFORMATION EXCHANGE FORMAT ... .. ..... .. .. . ...... 11
5 REFERENCES ...... .. ............ ...... ......................... ...... .. ....... . . ..... 12
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LIST OF TABLE
Table 1: Scopes of BIM Work ............. .... .... ... ............................ ........... 5
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Table 2: BIM Objectives, BIM Uses and BIM Deliverables .................... 6
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Table 3: BIM Deliverables ................... ....... ............. ................... ........... 9

Table 4 : BIM Software ............... . ....... .. ...... ..... ..... ..... ................... 10
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Table 5: Information Exchange Format ... .. ...... ................ ..... ..... ......... 11
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APPENDIX A20-1
1 INTRODUCTION
BIM: PROJECT BRIEF (BPB) is a document that line up the needs

statement of BIM project. This document outlines the scopes, objectives,
uses, deliverables, technical needs and roles of each stakeholder.
BPB needs to be developed during the project planning phase to ensure

its effectiveness. This document describes the JKR's needs and will be
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included in the Tender Document.
BIM Execution Plan (BEP) will be developed based on this document
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and will be used throughout the project life cycle.
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APPENDIX A20-1
2 PROJECT INFORMATION
Project Title MEMBINA JALAN DARI BEHOR MALI KE

KAMPUNG KEPALA SEPULOH, PERLIS
Client KEMENTERIAN PEMBANGUNAN LUAR

BAN DAR (KPLB)
Program BAHAGIAN PENGURUSAN PROJEK ZON LUAR
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Manager BAN DAR
Procurement DESIGN & BUILD
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Method
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APPENDIX A20-1
3 PROJECT SCOPES, OBJECTIVES, USES AND

DELIVERABLES
3.1 SCOPES OF BIM WORK

The scopes of BIM work for this project are as the followings:
NO. SCOPES OF BIM WORK

1. Earthwork
2. Drainage and Culvert
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3. Pavement Works
4. Bridge ! Structure Works
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5. Geotechnical Works
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6. Electrical Work (Road lighting, traffic light and etc)
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7. Road Furniture
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8. Traffic Management Plan
9. Relocation of Utilities and Sevices
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10. Land Acquisition
Note: This list IS not exhaustive and other Item may be Included
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Table 1: Scopes of BIM Work

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3.2 BIM OBJECTIVES, USES AND DELIVERABLES

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3.2.1 BIM OBJECTIVES AND USES
'- The BIM objectives are aligned with BIM uses and BIM deliverables as
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follows:
PHASES BIM BIM BIM

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OBJECTIVE USES DELIVERABLE

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1. Planning Optimise I. Existing i. Existing

design Condition Condition
options Modelling Model
II. Site Analysis II. Site Analysis
Manage Report
iii. Engineering
client's iii. Concept
Ana lysis
expectation! Design Model
iv. Design
design intent
Authoring
A20-J: 5111
APPENDIX A20-1
PHASES BIM BIM BIM

OBJECTIVE USES DELIVERABLE
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through 3D
visualisation
2. Design Facilitate i. Existing i. Detailed
design Condition Design Model
process Modelling ii. Coordinated
(including II. Site Analysis Model
design iii. Design
review Authoring
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process) iv. Engineering
Analysis
v. Design review
vi. 3D Design
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Coordination
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Minimize i. Design i. Clash Analysis
( design Review Report
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conflicts ii. 3D Design ii. 'Design
Coordination Review Report
Generate i. Design I. Tender
drawings/ Authoring Drawings

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documentatio ii. Design II. Construction
ns using Review Drawings

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models iii. 3D Design

Coordination
i. Coordinated
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3. Construction Verify Work i. Phase

Program Planning Model
submitted via ii. 40
construction
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40 simulation
simulation
incorporated
with Work
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Program
( I. As-built Model
4. Hand-over Facilitate i. Record
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facility Modelling ii. As-built

management Drawings
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Table 2: BIM Objectives, BIM Uses and BIM Deliverables

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APPENDIX A20-1
3.2.2 BIM DELIVERABLES
Project's BIM Deliverables are as follows :
NO. BIM DELIVERABLES

A) TENDER PROPOSAL PHASE:
1. BIM Execution Plan (BEP)
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2. Concept Design Model
Submission in *.sqlite format (including all associate files)
and fly through video consisting of all related works in item
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table 1: Scopes of BIM Work and as specified in Pre-bid
Document.
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( B) DESIGN AND CONSTRUCTION PHASE:
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1. Updated BEP as required
2. Preliminary Design Model
a) Structural Works (*. rvt)
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b) Road Works (*. dwg C3D)
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c) Electrical Works (*.rvt) ;

d) Coordinated Model (*.nwc, *.nwf and *.nwd) ;
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e) Preliminary Site Analysis Report (*.pdf)

i.e. Elevation , Earthwork, Land Acquisition , Final
Discharge Analysis , Road Safety Audit, etc.
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3. Detailed Design Model

f) Structural Works (*. rvt)
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( g) Road Works (*. dwg C3D)

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h) Geotechnical Works (*. rvt) :

Including location of boreholes and ground treatment
(if any)
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i) Electrical Works (*.rvt) ;

j) Site Analysis Report (*. pdf)
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i.e. Elevation, Slope, Water flow analysis, Road Safety

Audit etc.
k) Coordinated Model (*.nwc, *.nwf and *.nwd)
I) Clash Analysis Template and Report (*.xml and *. pdf)
A20-1 :711 1
APPENDIX A20-1
NO. BIM OELIVERABLES

4. Coordinated (Construction) Model (*.nwc, *.nwf and
*.nwd)
a) Structural Works;
b) Road Works;
c) Geotechnical Works;
d) Electrical Works.
5. Construction 40 Simulation Model ('.nwc, *.nwf and
*.nwd)
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Not less than LOD 400, combination of:
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b) Road Works ;
c) Geotechnical Works ;
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( d) Electrical Works ;
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6. Construction Drawing Documentation in Softcopy (* .dwg
& * .pdf) and Hardcopy
a) Structural Works ;
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b) Road Works ;
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C) HANDING OVER PHASE:
1. Updated BEP as required

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2. As-Built Model (* .nwc and * .nwd)

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( b) Road Works ;
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3. As-Built Drawings Documentation in Softcopy (*.dwg &
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* .pdf) and Hardcopy

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b) Road Works ;
A20-1: 8111
APPENDIX A20-1
NO. BIM DELIVERABLES

4. Family Creations in Softcopy (Native Format)
Not less than LOD 300, related to the Scopes of Work but not
limited to:
b) Road Works;
c) Geotechnical Works;
Note. ThIs list IS not exhaustIve and other Item may be Included
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Table 3: BIM Deliverables
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APPENDIX A20-1
4 81M TECHNICAL REQUIREMENT
4.1 COMMON DATA ENVIRONMENT (CDE) I SHARING PLATFORM

BIM data sharing platform should be provided as a data storage centre
and BIM data sharing medium. The coordination and operation of data
storage centre must take into account several aspects, such as security
contro l, sharing, transmission , security, accessibility and ICT security
aspects which comply with Dasar dan Garis Panduan Keselamatan ICT
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JKR and Dasar Keselamatan Teknologi Maklumat dan Komunikasi (lCT)
Kementerian Komunikasi dan Multimedia Malaysia (KKMM). The BIM
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Data Center must be maintained accordingly throughout the project life
cycle.
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4.2 BIM SOFTWARE
The BIM software used in this project are as follows :
APPLICA TION AREA SOFTWARE VERSION

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NO.
Design Authoring and
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I.
Modelling Infraworks,
Revit & 2022
Drawing Production and Civil 3D
II.
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Documentation
Visualization and Design
iii. Coordination including Clash Navisworks 2022
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Analysis
iv. Construction Simulation Navisworks 2022
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Revit &
v. Record Modelling (As-Built) 2022
( Civil 3D
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Note. ThIS list IS not exhaustJve and other Item may be Included
Table 4: BIM Software

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APPENDIX A20-1
4.3 INFORMATION EXCHANGE FORMAT

The preparation and exchange of data model is shown as fo llows:
Exchange Model Preparation Model Exchange

Purpose Software Format Software Format
Design Revit .rvt Revit .dwg
authoring - .rfa .dwfx
Drawing
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production
Civi l 3D .dwg AutoCAD .dwg
.pkt .dwfx
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Design Infraworks .sqlite Navisworks .nwc
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( authoring - .nwf
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Revit .rvt .nwd
coordination!
design review .rfa
Civi l 3D .dwg
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.pkt
Design Revit .rvt Navisworks .nwc
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authoring - .rfa .nwf

construction .nwd
phase!4D Civil 3D .dwg
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simulation .pkt
MS Project .mpp
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Reports MS Exce l .x/s Adobe .pdf

Reader
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( MS Word .doc Adobe .pdf

Reader
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Note: ThiS /1st IS not exhaustive and other Item may be Included
Table 5: Information Exchange Format

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APPENDIX A20-1
5 REFERENCES
i. 81M : Garis Panduan JKR
ii. 81M : Piawaian JKR
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Appendix A20-2
Level of Development, 81M Uses and Level of Information Need
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'Optlonal
The model elem ent is The model eleme nt is The m odel element is The model element is The model elem ent is
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only graphica lly graphically graphical ly graphically a field verified

represented in t he represented within t he represented withi n r epresented within the r epresentation in
Model with a symbol Model as a generic Model as a specific Model as a specific terms of quantities,
or other generic system, object, or system, object, or system, object, or size, shape,
representation, but assembly with assembly in terms assembly in terms location, and
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does not sat isfy the approximate of quantities, size, of quantities, size, orientation . Non -
needs for LOD 200. geometric shape, location, shape, location, and geometric information
information of orientation . Non- orientation with shall be attached to
quantities, size, geometric information detailing, the model elem ent .
shape, location, and shall be attached to fabrication,
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orientation . Non- the m odel element. assembly, and

( geometric information
may also be attached
installation
information . Non-
to t he m odel element. geometric information
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shall be attached to
the m odel element.
Element s are not Elem ents may be Elements (as Elements are modeled Elements are modeled
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geometric recognizable as t he designed) can be wit h sufficient deta ils with sufficient details
represent ations. The components they measured directly and accuracy for and accuracy with
symbol and other represent but its from t he model fabrication and respect to field
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generic representation geometric in formation without refer ring to construction. Elements verification for
in the model only shall be considered non-modeled (as designed) can be modeL It is not an
show the existence of approximate. information such as measured di rectly indication of higher
a component but its notes or 20 drawings. from the model model development
geometric information The project origin wit hout referring to element geometric or
shall be considered (coordinates) is non-modeled non-geometric
approximate. defined and the infor mation such as in form ation.
elements is located notes or 20 drawings.
accurately with
respect to the project
origi n .
A16-2: 1/2
Appendix A20-2
Level of Development, BIM Uses and Level of Information Need
-,-----------,-----------,-------
Dimensions (approx.) Dimensions (approx.) Dimensions Dimensions Dimensions
Location/Orientation Coordinates Coord inat es Coordinates
Quantity (approx.) Quantity Quantity
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Technical
Specification: e.g.
• Material
• Grade/Strength
• Finish ing
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Code
( Model/Code
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Capacity
Cost
As- built Model

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Existing Condition: Desig n element l :
• Topog raphy Earthwork
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Contour Road
Drai nage Drainage
Road furniture Road furniture
• Utility services Utility Ut il ity
• Bridge/Structural Bridge/Structural Bridge/Structural
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components components components

Geot echnical • Geotech nical
components components
Electrica l • Electrica l
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components components
Informat ion Model: Infor~ion ~odel: I nformation Model: I nfor mation Model 2 : I nformation Model 2 :
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Proposed road • Earthwork volume Mater ia l QTO • Material quantity • Mater ial quantit y
platform level • EartHwor profi le Material • Material • Material
Proposed road • Proposed road level specification specifi cation speci fication
alignment including ~ a li gnment
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• Asset information • Asset information

junction/ • Proposed invert
interchange level
• Proposed bridge Bridge/Structural
components
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Drawing Production: Drawing Production: Drawing Production:

• Tender drawings • Construction • As-built drawings
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l Design element development shall be updated accordingly

2 Information model shall be updated accordingly
A16- 2 : 2/ 2
Appendix A20-3
~3:::ol BIM Rotes & Respons ibilities
BIM ROLES AND RESPONSIBILITIES
BIM ROLES RESPONSIBILITIES
• Manage, monitor and update BIM Execution Plan (BEP);

BIM Manager • Execute the model coordination process among disciplines;
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• Identify and solve problems to I and
• Manage BIM data storage
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• Coordinate with
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• Manage the preparation of COll1'pon,enlAamilies and models;
( • Ensure the integrity of the model ng project implementation;
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BIM Coordinator • Identify problems among disciplines;
• nalnlrl~ convention;
I coordination process within each discipline; and
data storage and sharing.
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• Assist BIM Coordinator to coordinate with project team members;

• Create the information model and/or design authoring for each
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BIM Modeller
""-(ienler;,te drawing aocumentation from such models; and
• upaal:e the models to fulfill the information required in related phase s.
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KERAJAAN MALAYSIA
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DOKUMEN PRA BIDA
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UNTUK
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KEP ALA SEPULOH, PERLIS

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(REKA & BINA)

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nLIDIIIII
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(BOOK 2 OF 2)
STANDARD SPECIFICATIONS
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iii JKR KETUA PENGARAH KERJA RA YA

.....
• •
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IBU PEJABA T JKR MALA YSlA
JALAN SULTAN SALAHUDDIN
50582 KUALA LUMPUR
DISEMBER 2023
SEPULOH, PERLIS
TABLE OF CONTENT
A STANDARD SPECIFICATIONS
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1. Section I General (JKRJSP J/20 15-S I) SI -i to SI-32
Appendix I A - IN SIA-I to SIN-I
2. Section 2 Earthworks
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(JKRJSPJ/2020-S2) S2-i to S2-27
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( 3. Section 3 Drainage Works S3-i to S3-21
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(JKRJSPJ/2013-S3)
- Addendum No.1 AS3-i to AS3(J)-414
4. Section 4 Flexible Pavement S4-i to S4-X IX

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(JKRJSP J/200S -S4)
- Addendum No.1 & 2 ito S4.17- 46
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- Addendum (item4.5) AS4-i to AS4(J)-212
5. Section 5 Concrete Pavement I to 69

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(JKRJSP J/2020-S5)
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6. Section 6 Road Furniture S6-i to S6-33

(JKRJSPJ/2017-S6)
- Addendum No. 1 AS6(J)-111
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( 7. Section 7 Road Lighting (JKRJSP J/20 II-S7) S7-i to S7-1

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S. Section S Traffic Signal System (JKRJSPJ/200S-SS) SS-i to SS-29
9. Section 9 Concrete S9-i to S9-63

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(JKRJSPJ /20IS-S9)
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10. Section 10 Foundation Works S I O-i to S10-73

(JKRJSPJ/2019-S I 0)
SEPULOH, PERLIS
TABLE OF CONTENT
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II. Section II Prestressing for Structures SII-i to SII-3S
(JKRJSPJ/2016-SII)
12. Section 12 Structural Steelwork S12-i to S12-63
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13. Section 13 Bridge Bearings S 13-i to S 13-24
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( (JKRJSPJ/2013-S 13)
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14. Section 14 Expansion Joints S14-i to S14-8
(JKRJSPJ/2013-S 14) A
IS . Section IS Parapets SIS-i to SIS-IS
(JKRJSPJ/2013-S IS)
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ADDENDUM TO STANDARD SPECIFICATION FOR BRIDGE WORKS

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Addendum No.1 General Items for Bridge Works ABI-i to ABI-2

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Addendum No.2 Launching for Precast Element AB2-i to AB2-2
Addendum No.3 Precast Concrete Segmental Works A83-i to AB3-8

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Addendum No.4 Blended Shredded Tires AB4-i to AB4-4
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Addendwn No.S Miscellaneous for Bridge Works ABS-i to ABS-4

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SEPULOH, PERLIS
TABLE OF CONTENT
JILID 11111 (BOOK 2 OF 2) - STANDARD SPECIFICATIONS
16. Section 16 Slope Stabilisation S 16-i to S 16-1 07
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(JKRJSPJ/2013-S 16)
17 . Section 17 Site Investigation S17-i to S17-45
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(JKRJSPJ/2013 -S 17)
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( 18. Section 18 Soil Stabilisation S 18-i to S 18-21
(JKRJSPJ/2018-S 18)
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19. Section 19 Traffic Management At Work Zone S19-i to S19-43
(JKRJSPJ/2017-S 19)
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20. Section 20 Ground Improvement S20-i to S20-64
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(J KRJSP J120 19-520)
21. The Responsibilities and Scope of works of Traffic

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Management Officer and Road Safety Auditor 1 to 4

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SEPULOH, PERLIS
TABLE OF CONTENT
B SPECIAL PROVISION TO THE STANDARD SPECIFICATION

FOR ROAD WORKS
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1. Work Programme Specification (Design & Build) I to 14
2. Environmental Protection and Enhancement i to C-2
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3. Specification for Occupational Safety and Health in Engineering
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( Construction Works (2019) i to 19
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4. Quality Assurance and Control (QAlQC) i to 9
5. Proof Rolling Test i to 8

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6. Post Mounted Delineators & Raised Pavement Markers i to I
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7. Pile Testing i to 15
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8. Waterproofing and Damp Proofing for Structures i to 5
9. Joints Filler Testing i to 2

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10. Rain Gauge and SMS Remote Tenninal Unit (SMS RTU) i to 5
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II. Special Requirements In Relation to Drainage and

( Irrigation Department ito 1
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12. General Requirements for Utilities and Services Relocation i to 8
13 . Landscape Works i to 21
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14. Hydromu1ching i to 3
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JILIDll-PARTA A
STANDARD SPECIFICATION
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A.1 ROADWORKS
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1. Section 1 General (JKRISPJ/2015-S1)
Appendix lA - IN
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2. Section 2 Earthworks (JKRISPJ/2020-S2)
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3. Section 3 Drainage Works (JKR/SPJ/2013-S3)
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Addendum No.1
4. Section 4 Flexible Pavement (JKRtSPJ/200S-S4)

Addendum No.1 & No.2 (clause 4.16 &4.17)
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Addendum (item 4.5)
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5. Section 5 Concrete Pavement (JKRlSPJ/2020-S5)

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6. Section 6 Road Furniture (JKRlSPJ/2017-S6)

Addendum No.1
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7. Section 7 Road Lighting (JKR/SPJ/2011-S7)

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S. Section S Traffic Signal System (JKRlSPJ/200S-SS)

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9. Section 9 Concrete (JKRlSPJ/201S-S9)
10. Section 10 Foundation Works (JKRlSPJ/2019-S10)

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Section 1-
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General (JKRlSPJ/2015-S1)
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JKRISPJ /2015-S1
JKR 20401-0051-15
KERAJAAN MALAYSIA
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FOR ROAD WORKS
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JABATAN KERJA RAY A MALAYSIA
50582 KUALA LUMPUR.
FOREWORD
As practices in road construction change over time, it is imperative for Jabatan Kerja
Raya (JKR) to continuously update and improve their standard specifications. These
new specifications are not only aimed at keeping abreast with current technologies but
also to help improve the quality of construction works and its final product.
Consequently, these new specifications will ultimately have a significant positive impact
on the construction industry especially with the incorporation of new products and
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technologies .
The JKR Standard Specification for Road Works is an essential component in the road
infrastructure construction industry. This Specification provides an improved guidance in
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the material selection and quality control of workmanship and products, based on
current best practices. The purpose of the JKR Standard Specification is to establish
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uniformity in road construction to be used by road designers, road authorities, 0
manufacturers and suppliers of road related products.
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This particular document, the "Standard Specification for Road Works - Section 1:
General", is a part of a series of improved specifications in the JKR Standard
Specification for Road Works. The compilation of this document was carried out through
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many discussions that had been held by the technical committee. The draft had also
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been presented and discussed at length in a specially held workshop to get feedback
and comments from relevant parties involved, which were then carefully considered and
incorporated into the Specification wherever appropriate or necessary.
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The Specification has also gone through the different phases of vetting and approval
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from time to time to cater for any changes in policies and the inclusion of current
requirements, if necessary. Any feedback or improvement to be considered for future
revisions should be forwarded to Sahagian Pembangunan Inovasi & Standard,
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Cawangan Jalan, JKR Malaysia.

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Published by: -
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Cawangan Jalan
Ibu Pejabat Jabatan Ke~a Raya
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Tingkat 21, Menara PJD,

No. 50, Jalan Tun Razak,
50400 Kuala Lumpur.
Email: ussj@jkr.gov.my
Oktober 2015
S1-i
(JKRISPJ/2015-S 1)
ACKNOWLEDGMENT
This "Standard Specification for Road Works - Section 1: General " has been
prepared by a technical committee comprising of the following members;
Committee Members:
Ir. Mohd. Azahar bin Don (Chairman)
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Sr. Paul Leow
Ir. Cheng Chin Tai
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Ir. Norsahrizal bin Mohammed Sharuni
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Ir. Shafawati binti Asmawi
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Special thanks and appreciation to the following proof reader: -
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Ir. Abdul Mutalif Bin Abdul Hameed

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Finally, the publisher would like to express its gratitude to the above committee
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members, and also all those who were involved, directly or indirectly, but their names
missed out from being mentioned above, for their undying effort and substantial
contribution towards the successful completion of this document.
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(J Appreciation is alsa accorded to Ir. Hj. Manan bin Embong, the Director of Pakar
Kejuruteraan "alan & Jambatan, Cawangan Jalan and Ir. Dr. Mohamad Nor bin Omar,
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previously the Director of Cawangan Kejuruteraan Jalan & Geoteknik, Jabatan Kerja Raya
Malaysia for their full support and cooperation throughout the preparation and compilation
of the document.
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Not forgetting, a special word of thanks also goes to Ir. Kamil Puat bin Nil, the first Director
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of Cawangan Kejuruteraan Jalan & Geoteknik, JKR for leading the committee during its
inception stage, without whom the Chairman could not have possibly taken over the rein of
accomplishing the task in good stead.
S1 -ii
(JKRlSPJ/2015-51 )
CONTENT
SECTION 1 - GENERAL PAGE
1.1 GENERAL DESCRIPTION OF THE PROJECT 51-1
1.2 SCOPE OF WORKS 51-1
1.3 NOTES, ABBREVIATIONS AND UNITS OF MEASUREMENT 51-1
1.3.1 Notes 51-1
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1.3.2 Abbreviations 51-2
1.3.3 Units of Measurement 51-2
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1.4 PROGRAMME OF WORKS 51-3
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1.4.1 Method 5tatement S1-3
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1.5 LIMITATION OF SITE 51-3
1.6 SUPPLY OF MATERIALS (Goods, Materials & Workmanship) 51-4

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1.6.1 5upplyof Materials by Contractor 51-4
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1.6.2 5upply of Materials by Government 51-4
1.7 USE OF LOCAL MATERIALS 51-5

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1.8 SETTING OUT 51-6

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1.9 DIMENSIONS, LEVELS AND COORDINATES Sl-6
1.10 PROTECTION OF WORKS 51-7

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1.10.1 Bridge Loading Restriction During Construction 51 -7

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1.11 DESIGN OF TEMPORARY WORKS BY THE CONTRACTOR 51-7
1.12 CONTRACTOR'S SUPERINTENDENCE 51-7

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1.13 INSPECTION AND TESTS 51 -8
51-8
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1.14 COVERING UP OF WORKS
1.15 OFFICE ACCOMODATION FOR S.O AND HIS STAFF 51-8
1.16 TRANSPORT SERVICE FOR S.O AND HIS STAFF 51 -11
1.16.1 Arrangement for Transport and Failure to Provide Transport 51 -11
1.17 CONTRACTOR'S OFFICE AND ACCOMODATION 51 -11
Sl-iii
(JKRlSPJI2015-S1 )
PAGE
1.18 MATERIAL TESTING LABORATORY AND STAFF S1 -12
1.19 PROVISION FOR SURVEY INSTRUMENTS, EQUIPMENT S1 -13

AND PERSONNEL
1.20 MAINTENANCE OF EXISTING ROADS AND PROTECTION OF 51-14

TRAFFIC
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1.20.1 Maintenance of Existing Roads, Bridges, Culverts, etc. 51 -14
1.20.2 Temporary Diversions S1 -14
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1.20.3 Half-width Construction and Traffic Control S1 -16
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1.20.4 Temporary Traffic Signs 51-17
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1.20.5 Temporary Works S1-17
1.21 RELOCATION, TEMPORARY PROTECTION AND TEMPORARY S1-18

DIVERSION OF PUBLIC UTILITY INSTALLAl'!ONS AND
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OTHER SERVICES
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1.22 WATER AND ELECTRICITY SUPPL-Y 51-19
1.23 PROJECT SIGN BOARD 51 -19

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1.24 PHOTOGRAPHIC RECORD OF WORKS S1-19

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1.25 AS BUILT DRAWINGS 51-20
1.26 CLEARING THE SITE UPON COMPLETION 51 -20

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1.27 ACCESSIBILITY TO THE SITE FOR OTHER CONTRACTORS S1-20

\)
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1.28 QUALITY ASSURANCE PLAN 51-20
1.28.1 Contractor to Submit Quality Assurance Plan S1-20

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1.28.2 Contractor to Adhere to Quality Assurance Plan S1 -21
1.28.3 Quality Assurance Team

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S1-21
1.28.4 Verification of Implementation 51-22
1.29 NOTICE OF COMMENCEMENT OF PERMANENT WORK(S) S1 -22
1.30 CONTRACTOR'S RESPONSIBILTY FOR WORKS S1-23
1.31 AVOIDANCE OF NUISANCE AND DAMAGES S1-23
1.32 PROHIBITION OF ADVERTISING S1-23
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(JKRlSPJ/2015-S1 )
PAGE
1.33 UNAUTHORIZED USAGE 51-23
1.34 ACCESS TO SITE 51-23
1.35 MOBILISATION AND DEMOBILISATION 51-24
1.35.1 Mobilisation 51 -24
1.35.2 Demobilisation 51-24
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1.36 SAFETY, HEALTH AND WELFARE 51-24
1.37 SANITATION 51-26
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1.38 WASTE MANAGEMENT 51-26
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1.39 ENVIRONMENTAL PROTECTION WORKS 51-26
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1.39.1 Environmental Management Plan (EMP) 51-26
1.39.2 Environmental Officer (E.O) 51-27

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1.40 WATER AND AIR QUALITY, NOISE AND VIBRATION CONTROL 51-27
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1.40.1 MonitOring Water and Air Quality, Noise and 51-27

Vibration Control
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1.40.2 Air Quality 51-28
1.40.3 Noise and Vibration Control 51-28

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1.41 NOMINATED SUB·CONTRACTORS 51·29
NOMINATED SUPPLIERS 51 -30

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1.42
1.43 COORDINATION OF MECHANICAL AND ELECTRICAL SERVICES 51·31

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1.43.1 General 51-31
1.43.2 5cope of Works 51-31

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1.44 MINIMUM REQUIREMENT OF M & E SERVICES COORDINATOR

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BASED ON PROJECT COST 51·31
1.45 QUALIFICATION AND COMPETENCY OF M & E COORDINATORS 51-31
1.45.1 Engineer 51·31
1.45.2 Clerk of Works (CoW) 51-31
1.46 RESPONSIBILITIES OF M & E SERVICES COORDINATOR 51 -32
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(JKRlSPJ/2015-S1 )
APPENDICES
PAGE
APPENDIX 1A : GENERAL DESCRIPTION OF PROJECT S1A-1
APPENDIX 1B : SCOPE OF WORKS S1B-1 to S1B-2
APPENDIX 1C : TRANSPORT SERVICES FOR THE S.O. AND HIS STAFF S1C-1
APPENDIX 10: LIST OF LABORATORY EQUIPMENT
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(a) Soil Testing Equipment SlO-1 to SlO-2
(b) Concrete Testing Equipment S1D-3 to SlO-3
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(c) Flexible Pavement Testing Equipment SlO-3 to SlO-5
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APPENDIX 1E: EQUIPMENT AND FACILITIES S1E-1 to S1E-3
APPENDIX 1F: FITTINGS AND FURNITURE FOR s.e:s OFFICES S1F-1 to S1F-4
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APPENDIX 1G : PROGRAMME USING CRITICAL.: PATH METHOD S1G-1
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(CPM)
APPENDIX 1H : AS-BUILT DRAWINGS AND ROAD ASSETS INVENTORY S1H-1

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APPENDIX 1J : ENVIRONMENTAL QUALITY STANDARDS (TABLE A2) S1J-1
APPENDIX 1K: CONSULTANT'S SUBMISSIONS AND DECLARATION S1K-1

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FORM (SCHEDULE A)
APPENDIX 1L: LAMPI RAN 1 - FORMAT PELAN KESELAMATAN DAN

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) KESIHATAN PEKERJA (S-PLAN) S1L-1

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APPENDIX 1M: LAMPIRAN 4- FORMAT PELAN KUALITI PROJEK (Q-PLAN) S1M-1
APPENDIX 1N: LAMPIRAN 5- FORMAT LAPORAN KESELAMATAN DAN

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KESIHATAN PEKERJA S1N-1

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S1-vi
(JKRlSPJ/2015-S1 )
SECTION 1 - GENERAL
1.1 GENERAL DESCRIPTION OF THE PROJECT
The general description of the project is as given in Appendix 1A - (General

Description of Project).
1.2 SCOPE OF WORKS
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The Works covered in this Contract comprise the provision by the Contractor at
his own risk and cost of all materials, tools, plants, labour. transport and
everything else necessary for the construction and completion of the Works as
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given in Appendix 1B - (Scope of Works). all to the approval of the S.O.
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The Standard Form of Contract (PWD Form 203/203A) shall be read in
conjunction with this Specification. A copy of the Standard Form of Contract is
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available for inspection in the Tender Table Document on any working day up to
the time the tender closes. If the tenderer considers that any of the clauses of the
Contract involves expenses, it shall be deemed to have been priced in his Tender.
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1.3 NOTES, ABBREVIATIONS AND UNITS OF MEASUREMENT
1.3.1 Notes
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Any clause in this Specification which relates to work or materials not

included in the Works shall be deemed not applicable.
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Unless stated to the contrary. any dimension of material described means

the finished or fully compacted dimension.
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The requirements for tolerance where necessary are incorporated in the

specification notes shown on the Drawings and by references to the
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relevant Malaysian Standard, British Standard, Eurocode and/or other

equivalent international standard approved by the S.O.
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All Standards and Codes of Practice referred to in this Specification

together with any addenda issued shall be deemed to be the current
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editions at the time of Tender. If the Malaysian Standard (MS) exists,

which is equivalent to other standards specified, then the Malaysian
Standard shall prevail.
In the event of any discrepancy between the provisions of this Specification

and the provisions within the relevant Standards or Codes of Practice as
mentioned in this Specification. then the provision of this Specification shall
take precedence.
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(JKRlSPJ/2015-S1 )
The terms 'Engineer', 'Superintending Officer' and 'Project Director' shall

be synonymous.
Unless specifically defined otherwise, the definition of terms used in this

Specification are those stated in the BS 6100 Glossary of Building and Civil
Engineering Terms. All abbreviations in this Specification is in accordance
with the recommendations given in BS 5775.
1.3.2 Abbreviations
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M.S Malaysian Standards published by the Scientific and
Industrial Research Institute of Malaysia (SIRIM).
B.S British Standards published by the British Standard
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Institution
AAS .H.T.O The American Association of State Highway and
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Transportation Officials
AS.T.M. The American Society for Testing and Materials
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M.D.D. Maximum Dry Density
O.M.C. Optimum Moisture Content
C.B.R. California Bearing ~a io
S.O. Superintending Officer
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B.Q. Bill of Quantities
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R.OW. Right Of Way

P. Eng. Profes5'ional Engineer
S.O.R. Superintending Officer Representative
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CIDB CQnstruction Industry Development Board

DOE Department of Environment
DOSH Department of Occupational Safety and Health
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EMP Environmental Management Plan

JKR Jabatan Kerja Raya
JPS Jabatan Pengairan dan Saliran
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Manual Saliran Mesra Alam

() MASMA
PSM Department of Standards Malaysia
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BSEN British Standard Euro Norm

SPB Sistem Pengurusan Bersepadu
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1.3.3 Units of Measurement

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All units of measurement used in this Specification and in the Bill of

Quantities shall be in accordance with the metric system unless stated
otherwise.
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(JKRlSPJ/2015-S1 )
1.4 PROGRAMME OF WORKS
Within fourteen (14) days from the receipt of the Letter of Acceptance of Tender,
the Contractor shall submit to the S.O. for approval a detailed works programme
using the Critical Path Method (CPM) as per Appendix 1G - (Programme Using
Critical Path Method (CPM), showing his proposals and the periods for carrying
out the various sections of the Works in order to complete the whole works within
the specified completion time. The proposal shall be supported by schedule of
construction plant, resources mobilization schedule, such as estimated work
production rates and manpower mobilization plan for the various sections/activities
of the Works. The approved CPM shall be submitted in both hard copies and soft
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copies as required by the S.O.
If at any time should it appear to the S.O. that the actual progress of the Works
does not conform to the approved programme referred therein, the S.O shall
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instruct the Contractor to submit a revised works programme for his approval,
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showing the revised programme and additional resources necessary to ensure
that the whole of the Works can be completed within the stipulated time for
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completion.
The Contractor shall employ trained and qualified planner/scheduler for this
purpose. Where required elsewhere in the Contract Documents, the Contractor
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shall provide the original programme software and appropriate training for the
proper operation of the CPM programme in monitoring the physical progress of
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the Works.
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1.4.1 Method Statements

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The Contractor shall also furnish in writing to the S.O., particulars of the
Contractor's method statements for carrying out such works and of the
construction plant and temporary works if any, which the Contractor
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intends to supply, use or construct as the case may be.
The submission to and approval by the S.O. of such programme or the

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furnishing of such particulars shall not relieve the contractor of any of his
duties or responsibilities under the Contract. For the purpose of monitoring
the work progress effectively, the Contractor shall carry out regular
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progress tracking against the planned progress.

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1.5 LIMITATION OF SITE
The Contractor shall ensure that all his plants, materials, temporary workshops,
stores and offices are kept within the Site at locations approved by the S.O.
Any approval given by the S.O. for the location of his temporary workshops,
stores and offices shall not absolve the Contractor from his responsibility to
ensure that the same will not affect the progress of works. Notwithstanding the
above, should such land being used by the Contractor for temporary workshops,
S1-3
(JKRlSPJI2015-S1)
stores for materials, offices, etc. are required to be relocated, the Contractor shall
clear the site and re-erect his offices, stores, temporary workshops etc. elsewhere
immediately.
Should the Contractor require land outside the site for his work yard , stores,
offices, temporary haul roads or any other temporary structures, he shall on his
own, purchase or rent any land area he may require. Area or areas to be rendered
as part of the Site shall be subject to the S.O.'s approval.
The Contractor shall obtain written approval prior to removal of plants, materials,
temporary workshops, stores and offices from the Works site.
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1.6 SUPPLY OF MATERIALS
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Goods, Materials and Workmanship
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Materials and workmanship throughout the Works shall be in accordance with the
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Drawings and Specifications and to the approval of the S.O.
Only if necessary, and under unavoidable circumstances, any alternative to the

goods or materials specified may be considered fo), acceptance provided that they
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comply in all respect with regards to appearance, quality and performance, and
shall be approved by the S.O. subject to the provision relating to Variations in the
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Conditions of Contract. •
1.6.1 Supply of Materials by Co ~ractor

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The Contractor shall suBmit samples of materials or execute samples of

workmanship for the S.O. approval, and for further sampling as may be
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required, until the sample submitted or work executed are in accordance

with the Speeification. Samples, after approval, shall indicate the standard
of materials and workmanship to be maintained in the execution of the
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Works .
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If",hoWever, the Contractor has shown beyond reasonable doubt that the
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specified goods or materials cannot be obtained and the S.O. is satisfied

with regards to its non-availability, the benefit of cost savings, if any,
resulting from the Contractor's proposal for the alternative goods or
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materials as approved by the S.O., shall be deducted from the Contract

Sum.
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1.6.2 Supply of Materials by Government
If the Contractor fails for any reason to supply any materials or goods,
which he has contracted to supply, or if he fails to supply any such
materials in sufficient time to enable the Contract to be completed by the
agreed date for completion, the Government may supply any portion, or all
of such materials.
If the Government supplies such material or goods, the cost in respect

thereof to be borne by the Contractor shall be either the current market
S1 -4
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(JKRlSPJ/2015-S1 )
rates or the actual cost to the Government, whichever is greater, plus 5%

on-cost charges.
The cost to be borne by the Contractor, as detailed above, shall be

deducted from any monies due or to become due to the Contractor under
this Contract and failing which, such costs shall be recovered from the
Performance Bond or as a debt due from the Contractor.
No action by the S.O. under this clause shall be deemed in any way to
affect or modify the right of the Government to claim for damages in the
event of the Contractor's failure to complete the Works by the agreed date
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of completion .
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1.7 USE OF LOCAL MATERIALS
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The Contractor shall use locally manufactured materials and goods as listed in the
'Senarai Bahan! Barangan Binaan Buatan Tempatan' issued by IKRAM QA ()
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Services Sdn. Bhd. and! or 'Senarai Bahan! Barangan Buatan Tempatan' issued
by SIRIM QA Services Sdn. Bhd .• whichever is relevant. If the Contractor fails to
comply with this requirement, such materials supplied shall be rejected .
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The locally manufactured materials and goods which are not listed aforesaid may
be permitted if the materials have been tested and certified by IKRAM QA
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Services Sdn.Bhd. or SIRIM QA Services Sdn.Bhd., whichever is applicable. If the

testing cannot be carried out by IKRAM QA Services Sdn.Bhd or SIRIM QA
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Services Sdn.Bhd., the Contractor may apply for the goods and materials to be
tested by other agencies as approved by the S. O.
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The Contractor shall place his orders for specified materials at the earliest
possible date after notification of acceptance of tender or at such times as may be
specifically stated for any particular material.
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Under no circumstances will the Contractor be permitted to incorporate or supply

imported materials, plants, equipment, or other goods into the Works or forming
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part of the Scope of Works except those approved by the Government, prior to the
execution of the Contract. The Contractor shall substitute any materials, plants,
equipment, or other goods proposed to be imported but not approved by the
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Government, with suitable local materials, plants, equipment, or other goods,

including making any necessary subsequential changes or adjustments to the
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design of the Works to accommodate such substitution, all to the concurrence of

the S.O.
The Contractor shall ensure that the procurement of approved imported materials,
plant, equipment, or other goods are obtained directly from the country of origin
based on Free-On-Board (F.O.B) or other similar basis. The transportation and
insurance of such imported materials, plants, equipment, or other goods from the
country of origin to the Site shall be arranged by the Contractor through approved
Government's Multi Modal Transport Operators (MTO). The Contractor shall
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(JKRISPJ/2015-S1 )
allow in his tender all costs and time required in complying with the requirements
of this clause including the cost required for the services provided by the MTO.
The Contractor shall submit documentary evidence of compliance with this clause
to the S.O within one (1) month from the date of each delivery to the Site of such
materials, plant, equipment, vehicles or other goods.
1.8 SETTING OUT
Before commencing the Works at any location, the Contractor shall provide and
install precast concrete reference beacons on both sides of the road centre-line at
a spacing of 250 metres. The beacons shall be firmly sited at right angles to the
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center-line at a distance from the centre line of 15metres or such other distance as
directed by the S.O. The beacons shall be not less than 75 mm square in plan
and shall project at least 600mm above the surrounding ground. Each beacon
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shall be clearly marked with its chainage and elevation above datum. The
Contractor shall take all practicable steps to safeguard the beacons and shall
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immediately replace any damaged beacons. The Contractor shaD give the S.O. not
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less than 24 hours' notice of his intention to set out or give levels for any part of
the Works in order that arrangements may be made for checking.
All temporary bench marks, reference markers, levels and coordinates as shown
in Drawings shall be checked on the Site by the Contractor at his own expense
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and agreed upon by the S.O. prior to the commencement of clearing works.
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The Contractor shall carry out the setting out of coordinates and levels for such
control points as shown in the Drawings, as the established reference markers and
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bench marks. These may be distrihuted during the progress of the Works. The
Contractor shall also carry'out regular checks to ensure their accuracy,
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To ensure a continuous and proper execution of the_Works, the Contractor shall

provide a Licensed Surveyor to carry out these survey works and the cost of this
provision shall be deemed to have been included in the Contract price.
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The Contractor-,shall provide all instruments and attendants required by the S.O.
\) for checking tlie Works , Notwithstanding the provision, the Contractor shall not be
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relieved of his responsibility for the accuracy of the setting out of coordinates and
levels, The Contractor shall remedy, at his own cost, any works wrongly
constructed as a result of incorrect setting out, levels or coordinates,
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1.9 DIMENSIONS, LEVELS AND COORDINATES
All temporary benchmarks, reference markers, dimensions, levels and coordinates

as shown in the Drawings shall be checked on the Site by the Contractor at his
own expense and to be confirmed by the S.O.
Before commencement of the Works or any part thereof, the S.O. and the
Contractor shall, by means of a joint survey, carry out the original ground level
survey to verify the levels of the existing ground surface within areas where
earthworks are to be performed and bed levels of water courses ,These may differ
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(JKRlSPJ/2015-S1 )
from the locations and levels shown on the Drawings, owing to changes which
could have taken place during the interval between the original survey and
construction .
The levels, dimensions and coordinates taken by the Contractor jointly with the
S.O. shall form the basis of measurement for the relevant work quantities.
1.10 PROTECTION OF WORKS
From the commencement of the Works to the date the Works are taken over by
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the Government, the Contractor shall be fully responsible for the care of the Works
including all temporary works. In the event of any damage or loss to the Works
and any part thereof or to any temporary works, the Contractor shall, at his own
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cost, repair and make good the same so that upon completion, the Works shall be
in good order and in conformity with the requirements of the Contract. The
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Contractor shall also be liable for any damage to the Works caused by him in the
course of any remedial works carried out during the Defects Liability Period.
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1.10.1 Bridge Loading Restriction During Construction
The Contractor shall note that the bridge has been designed according to
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the loading laid down in the General Layout Drawings. At the time during
construction, the Contractor is to ensure that the bridge is not overloaded
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such that the prestressed beams have tensile stresses at their soffits or in-
situ deck slab is loaded before having attained sufficient strength.
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1.11 DESIGN OF TEMPORARY WORKS BY THE CONTRACTOR

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Unless otherwise provided in the Contract, the Contractor shall submit to the S.O.
tor his approval, working or shop drawings produced by him and endorsed by a P.
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Eng., including all drawings made by his approved sub-contractors/suppliers

before commencement of the temporary works. Notwithstanding the approval by
the S.O., the Contractor is solely responsible for the adequacy and safety of his
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temporary works and for any necessary modification or addition whenever found
necessary by the S.O.
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1.12 CONTRACTOR'S SUPERINTENDENCE
The Contractor shall submit to the S.O. an Organization Chart showing all his
employees involved in the superintendence of the Works for approval and provide
the same during the execution of the Works and for as long thereafter as the S.O.
may consider necessary for the proper fulfillment of the Contractor's obligations
under the Contract.
A competent Site Agent, whose appointment shall be approved by the S.O., shall
be employed by the Contractor for management on Site. The Site Agent shall
have the authority to receive instructions from the S.O. and to act on behalf of the
S1 -7
(JKRlSPJ/2015-S1)
Contractor. The Site Agent shall be stationed on Site for the whole duration of the
Contract and shall not be replaced without the approval of the S.O.
If the Site Agent needs to be absent from the Site, the Contractor shall appoint
another temporary site agent and notify the S.O. accordingly.
1.13 INSPECTION AND TESTS
The S.O. may, at any stage of the Works, carry out inspection, measurement and
tests on any part of the Works to ensure compliance with the requirements of this
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Specification and of the Drawings. The Contractor shall provide the necessary
attendance whenever required by the S.O. or his representative.
Notwithstanding any tests which may have been carried out, the S.O. shall be
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empowered to order further tests of any materials or goods to be made on the site
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and to reject such materials or goods should they fail to pass such tests on site.
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The Contractor shall submit periodically and, when requireCl, a copy of the result of
any quality control test carried out by the Contractor on his own accord during the
progress of the Works.
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Where independent sampling and testing is re!luired by the S.O., the Contractor
shall grant the use of laboratory facilities, equipments, instruments and free
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access to mixing plants and storage depots, supply materials and provide all
facilities for the S.O. or his representative to sample and carry out tests as
instructed ..
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1.1 4 COVERING UP OF WORK
Before any part of the Works is permanently covered up, the Contractor shall give
due notice to the S.O. for the inspection and measurement of dimensions and/or
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( ) confirmation of levels. The S.O. shall attend without unreasonable delay for the
purpose of examination and measurement unless he considers it unnecessary and
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advises the Contractor accordingly.

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1.15 OFFICE ACCOMMODATION FOR S.O. AND HIS STAFF

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The Contractor shall provide and maintain a site office for the use of the S.O. and
his supervisory staff, all in accordance with the relevant Drawings, inclusive of all
fittings and furniture as in Appendix 1F - (Fittings and Furniture for S.O.'s
Offices) and Appendix 1E - (Equipment and Facilities) of this Specification. The
Contractor shall provide/supply the land, free of all charges and encumbrances for
the construction of the S.O. office(s).
In the event that the Contractor is unable to provide a site office of the JKR design
type as shown in the relevant drawings, for the use of the S.O. and his supervisory
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(JKRlSPJ/2015-S1)
staff, then, subject to the S.O .'s approval, the Contractor shall propose an
altemative site office as follows, i.e. either:
i) Relocatable site office of equivalent floor area and standard not inferior to the
JKR design type and equipped with similar furniture, fittings and equipment.
Where a relocatable site office is to be provided, the Contractor shall submit
details of the relocatable site office, which shall include floor area and layout, list of
furniture, fittings, and brochures if available. The Contactor shall provide a new
relocatable office, the quality of which is equivalent but not inferior to the JKR
design type, and to be approved by the S.O., or
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ii) Rented shop lot, office space of equivalent floor area and standard not inferior
to the JKR design type and equipped with similar furniture, fittings and equipment.
Where a rented shop lot site office is to be provided , the Contractor shall submit
details of the shop lot which shall include the layout and a list of furniture and
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fittings to be provided, to the S.O. for approval.
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Unless otherwise shown on the Drawings, the location and construction of the site 0
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office as proposed by the Contractor shall be approved by the S.O., with the
condition that in the event if there arises any necessity for relocation in the future,
the Contractor shall do so immediately.
The Contractor shall make proper arrangements for, and pay, all charges in
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connection with conservancy. The site office shall comply with local Building By-
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laws. Within two (2) weeks of the acceptance of his tender, the Contractor shall
submit full details of his proposed layout and construction for the offices, including
surface drainage and other related works, to the S.O. for approval. All offices shall
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be erected or provided by the Contractor, fully furnished as specified and ready for
occupation within four (4) weeks from the date of possession of Site.
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Where electricity and piped water are available from public utility authorities, the
Contractor shall arrange for the site office to be connected to the electrical and
water supplies. Otherwise, the Contractor shall supply the site office with electric
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power from generator set(s) and shall provide adequate supply of water from an
approved alternative source for in-house use including washing and potable
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filtered water for drinking purpose. Sanitary facilities with disposal to septic tanks
located not nearer than 5m from the building shall be provided to the approval of
the S.O. and the appropriate Authority.
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All offices shall be illuminated by fluorescent fittings giving a general level of

illumination of at least 215 lumens/sq.m. Additional lightings shall be provided
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where required by the S.O. Air-conditioners capable of maintaining a temperature

below 23· Celsius in the office shall be provided .
The Contractor shall arrange for the installation of two (2) permanent telephone
lines including provision of internet access or, as per preliminary requirement in
the BQ for the exclusive use of the S.O. at all times. The Contractor shall be
responsible for the payment of the purchase/rental of the telephone and internet
services provided including pay all call charges and disconnection.
S1-9
(JKRl8PJ/2015-S1 )
Where a telephone exchange is not within practical distance, an automatic mobile

telephone such as the ATUR (Automatic Telephone Using Radio) or other
alternative provider's service shall be made available.
Suitable external lighting shall be provided at the entrance to all buildings and in
the parking areas. Adequate provisions for fire prevention as per Fire & Rescue
Department Of Malaysia guideline shall be provided.
The Contractor shall construct suitable entry and exit roads from the nearest
public road to the site office and shall provide a covered hard standing parking
area in addition to that indicated in the JKR site office drawing for the exclusive
ER
use of the S.O. vehicles with additional allowance for parking bays.
All offices and laboratory shall be surrounded by a chain link security fence
1800mm high and steel gates with locks provided at entry and exit points where
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applicable.
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The Contractor shall keep the offices accessible at all times, maintained in good
condition and habitable for working purposes for as long as they are in use. All
TE
offices shall be properly cleaned each day and arrangements shall be made for
the proper disposal of all waste material. The Contractor shall also provide such
labour and cleaning materials as required in order to maintain the office in a
thoroughly clean condition.
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One full-time attendant shall be provided at the office compound whose services
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shall be available during normal working hours and outside of normal working
hours if so required by the S.O.
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The Contractor shall provide adequate first aid facilities throughout the duration of
Contract for the offices and laboratory.
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The Contractor shall provide, install and maintain throughout the Contract Period
and six (6) months after the date of the Certificate of Practical Completion or, on
closing of the Final Account as directed by the S.O, all the furniture, fittings,
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equipment and consumables as described in the Appendix 1F- (Fittings and

\ )
Furniture for 5.0.'s Office) and Appendix 1E - (Equipment and Facilities) of
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this Specification, all for the exclusive use of the S.O. and his representatives.
In the event of failure on the Contractor to provide or maintain any equipment or

facilities as per requirement, the Government shall have the right to procure or
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maintain them from other sources, all expenses arising therefrom shall be borne
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by the Contractor and an appropriate adjustment be made to the Contract Sum.
Safety facilities to be provided for the use of the S.O and his supervisory staff and
to comply with DOSH requirements should include safety boots, safety helmets,
safety harness and life lines, protective gloves, safety goggles and safety jackets
of the reflective type.
On completion of the Works, the Contractor shall further maintain the site office
including its contents, access roads and hard standings as listed in the Contract
throughout the contract period until six (6) months after the date of the Certificate
81-10
,/
I
(JKRlSPJ/2015-S1 )
of Practical Completion (CPC) or, on closing of the Final Account as directed by

the 5 .0 .
The Contractor shall then dismantle and remove from site, the site office with all
fumiture, fittings and equipment which shall become the property of the Contractor
and reinstate the site to the satisfaction of the 5.0., or as directed by the 5.0.
1.16 TRANSPORT SERVICES FOR THE S.O. AND HIS STAFF
The Contractor shall, within two (2) weeks of the date of site possession and on
ER
approval of the 5 .0, provide suitable transportation service by means of vehicle as
listed in the B. Q . and stipulated in Appendix 1C - (Transport Services for the
S.O. and His Staff).
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The Contractor shall provide comprehensive insurances including cover for all
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drivers and passengers, for the purpose of site supervision and transport and shall
ensure that road tax is valid throughout the Contract period. All costs incurred and ()
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pertaining to the vehicle(s) transportation service, inclusive of the operating and
maintenance costs shall be borne by the Contractor.
The Contractor shall ensure that the vehicle{s) is/are in a good and well-
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maintained condition subject to certification from PUSPAKOM at every six (6)
months interval. The Contractor shall provide the vehicle{ s) throughout the
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Contract Period until six (6) months after the date of the Certificate of Practical
Completion or, on closing of the Final Account as directed by the 5.0.
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1.16.1 Arrangement for Transport and Failure to Provide Transport
The Contractor shall notify the 5 .0 or S.O.R. should there be any delay in
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the delivery of vehicle{s). If the Contractor fails to provide the required

transport, the Contractor shall arrange for an equivalent alternative
vehicle{s). The Contractor shall bear all necessary expenses and an
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appropriate adjustment shall be made accordingly in the event an

equivalent vehicle(s) cannot be provided.
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1.17 CONTRACTOR'S OFFICE AND ACCOMMODATION

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The Contractor shall provide and maintain a suitable office for himself and his staff
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at a location (s) in a position or positions to be approved by the 5.0.
The Contractor shall submit full details of his proposed layout to the 5.0. for
approval and finish construction for the site office(s), plant yards and workshops in
the shortest possible time after the date of possession of site or as directed and
approved by the 5.0.
In addition, the Contractor shall provide and maintain temporary accommodation,

stores, workshops, etc., including all necessary facilities and services for water
supply, drainage, sanitation and lighting for his staff. Before any works can
commence the Contractor shall submit to the 5.0., details of the proposed
Sl-ll
(JKRlSPJ/2015-S1 )
buildings and services and shall obtain the S.O.'s approval together with any other
necessary approvals in writing from the relevant Authorities.
The Contractor shall be responsible for all fees and other charges or expenses
incurred in connection with such office and housing and shall keep the whole area
in a clean , tidy and well-maintained condition . The Contractor shall provide
adequate first aid facilities appropriate to the size and composition of his staff and
labour force.
The Contractor shall be responsible for controlling all persons under his
employment and those employed by his sub-contractors at the work site and shall
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take all necessary precautions to prevent damage and nuisance of any kind and
shall indemnify the Government against any claim arising therefrom .
When instructed by the S.O. upon completion of the project, the Contractor shall
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remove all such buildings and appurtenant works from the site, clean up the area
and restore it to the satisfaction of the S.O.
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()
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1.18 MATERIAL TESTING LABORATORY AND STAFF
The Contractor shall provide land area free of all charges to the Government for
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the construction of testing laboratory. The Contractor shall provide and maintain a
laboratory at the Site at the location of S.O. office throughout the duration of the
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Contract and shall be equipped with the necessary laboratory equipments only, i.e.
equipments for all tests required to be carried out for the project. Details of
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equipment, if required and necessary, are as detailed in Appendix 10 - (List of

Laboratory Equipment) of this Specification. The minimum floor area for the
laboratory shall be 20'x60', or as stipulated in the latest site office drawings,
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whichever is bigger.
Alternatively, the Contractor can propose an accredited laboratory approved by

SIRIM, for the approval of the S.O. All works subject to laboratory tests such as
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\ ) earthworks and concreting works, shall not be permitted to commence until the
laboratory and all necessary equipment have been provided.
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The said laboratory shall be constructed of durable weatherproof materials suitably

treated and painted for weather resistance. Roofing shall be of approved suitable
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material which shall be leak-proof lapped. The roof shall overhang the verandah
by at least 1m and the floors shall be raised a minimum of 150mm above the
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existing ground level. The laboratory shall be painted internally and externally,
according to the colour scheme approved by the S.O. The false ceiling shall span
the full length and width of the laboratory space to provide a headroom of 3m
above floor level. The window area at the testing area of the laboratory shall be a
minimum of 35% of the floor area. The Contractor shall submit full details of his
proposed layout and construction of the laboratory, including surface drainage,
and certified by a P.Eng., to the S.O. for approval and completion of its
construction within three (3) weeks of the possession of Site.
S1-12
(JKRlSPJ/2015-S1 )
The Contractor shall arrange for, provide and maintain water and electricity
supplies to the laboratory. The Contractor shall be responsible throughout the
Contract period to provide and maintain all such equipment and instruments
deemed necessary only, for laboratory tests to be carried out for the project,
details of which as listed in Appendix 1D - (List of Laboratory Equipment) of
this Specification.
The Contractor shall also provide a lockable weatherproof storage shed, with a
concrete floor, for the storage of soil samples and concrete cubes and cylinders
adjacent to the laboratory.
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Waste materials from the laboratory shall be disposed of by the Contractor who
shall provide a tip area to be approved by the S.O., and shall clear the tip area at
intervals as required .
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The laboratory, is to be jointly used by the S.O. and the Contractor for this project
only, to carry out any test(s) as required under the Contract or as instructed by the
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S.O. However, the Contractor shall provide suitable laboratory assistant I
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technician who shall carry out the necessary laboratory tests and shall be
witnessed by the S.O.
On completion of the Works, all laboratory equipment shall become the property of
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the Contractor and the building including its contents, access roads and hard
standing shall be removed from the Site, which shall then be restored to the
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satisfaction of the S.O.

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1.19 PROVISION FOR SURVEY INSTRUMENTS, EQUIPMENTS AND PERSONNEL

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The Contractor shall provide for the use of the S.O. and his staff all such
instruments, equipment and survey personnel as the S.O. may require until six (6)
months after the date of Certificate of Practical Completion or, on closing of the
Final Account as directed by the S.O, so as to enable him to check and confirm
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the accuracy of measurements taken. The survey personnel shall have knowledge
of Bahasa Malaysia or English and, as far as possible, the same men shall be J
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provided and maintained throughout the Contract period.
The Contractors shall be responsible throughout the Contract period for all such
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instruments, equipment and personnel, and shall ensure that the instruments and
equipment are at all times in good working condition and calibrated in accordance
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to the manufacturer's instruction. All instruments and equipment shall remain the
property of the Contractor upon completion of the Works or on closing of the Final
Account as directed by the S.O.
S1-13
(JKRlSPJ/2015-S1)
1.20 MAINTENANCE OF EXISTING ROADS AND PROTECTION OF TRAFFIC
1.20.1 Maintenance of Existing Roads, Bridges, Culverts,etc.
The Contractor shall maintain all sections of existing and access roads,
bridges, drains and culverts included therein within the Site to the condition
as existing at the time of possession of Site for the full duration of the
Contract. Such maintenance shall include routine activities such as grass
cutting, clearing of drains, patching of potholes, etc. He shall also be
responsible for maintaining the free flow of traffic on these sections of
existing road.
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The Contractor shall arrange for the conveyance of materials and plants so
as to cause minimum damage to existing roads and installations and the
least inconvenience to the public. He shall not deposit any earth, rubbish
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or materials on any road, street, pavement or footway so as to cause
hindrance or obstruction to vehicles or pedestrians.
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The Contractor shall be responsible for any d~mage caused by any works
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carried out by him and his construction vehicles to any existing roads or
installations and shall repair, maintain and reinstate the same to their
original condition to the satisfaction of t)1e S.D. The Contractor shall also
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keep such roads clear of slurry, boulders and loose earth which may be
caused by construction vehicles during the transportation process.
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Upon failure on the part of the l tntractor to fulfill his obligations under this
Section, the S.D. may take whatever action and means necessary to
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satisfy the requirements of the Contract, and all costs incurred by the S.D.
shall be deducted from any amount of monies due or to become due to the
Contractor under this Contract.
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1.20.2 Temporary Dil&rsions
Temporary diversions shall be constructed wherever the Site is intersected

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( ) by existing roads, footpaths, cycle tracks, access to properties, etc.

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SUCh diversions shall be of a standard of construction at least equivalent to

that of the original road, path, track or access. They shall be constructed in
advance of the closure of the existing passage and regularly maintained,
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for as long as required, in a satisfactory condition. On completion of the

Works, the existing passages shall be reinstated to their original condition
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to the satisfaction of the S.D. At least fourteen (14) days notice in writing
of any proposed temporary diversion of traffic shall be given to the S.D. for
his approval.
Where access roads are to be permanently closed due to the construction

of the permanent works, as shown on the Drawings, such closures shall
not be effected until a specified permanent access has been provided and
only with the written approval of the S.D.
The Contractor shall maintain reasonable access to all properties adjoining

the Works where such access exists during construction, and shall ensure
S1 - 14
(JKRlSPJ/2015-S 1 )
that all the necessary fences, planking and gangways are adequately lit for
public safety, to the satisfaction of the S.O.
Where the Contractor proposes to use existing local passageways as

temporary diversions, he shall give at least fourteen (14) days notice in
writing of his proposal to the S.O. for his approval. The Contractor shall
maintain and/or reinstate these temporary diversions to their original
condition throughout the entire duration of the temporary diversion, all to
the satisfaction of the S.D. If the Contractor fails to maintain and/or
reinstate these temporary diversions to the satisfaction of the S.O., the
S.O. shall have the right to carry out these works and all costs incurred
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shall be deducted from any amount of monies due or to become due to the
Contractor under this Contract.
Where, in the opinion of the S.O., a detour is not feasible, construction on
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existing public roads shall be undertaken only half of the full width of the
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roadway at any time . The length of such half-width construction shall be as
short as is practicable. For all temporary diversions, the Contractor shall
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provide, install and maintain adequate temporary construction signs in
accordance with Sub-section 1.20.4.
1.20.2.1 Demolition of Existing Structure And Construction Of

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Temporary Road Diversion And River Crossing
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Before the demolition of the existing bridge, the Contractor shall

construct the temporary road diversion and temporary river
crossing at the position as approved by the S.O. for the
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maintenance of the existing traffic flows and pedestrian

movement.
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Where the Contractor is required to propose a suitable

temporary crossing, the following conditions shall be met;
As soon as possible after the acceptance of the Tender, detailed

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drawings of the temporary crossing as specified in the Scope of

Works required for the execution and maintenance of the work
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shall be submitted by the Contractor to the S.O. for approval

prior to the commencement of the demolition of the existing
bridge.
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The drawings shall be submitted with the calculation and

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description as necessary, in such order as will enable the S.O. to

consider simultaneously related portions of the Works. A
Professional Engineer shall sign all submissions inclusive of
declaration form as shown in Schedule A as per Appendix 1K -
(Consultant's Submissions And Declaration Form (Schedule
A) of the Specification.
The design of the temporary river crOSSing shall comply with the
requirements of Jabatan Pengairan dan Saliran (JPS) Malaysia
and other relevant Authorities.
S1 -15
(JKRlSPJ/2015-S1)
All drawings shall be in metric A 1 size. Any works contained therein

the drawings shall not proceed until the drawings have been
approved by the S.O. No deviation from the construction procedure
of temporary works, which the drawings have been approved by the
S.O., shall be permitted.
Approval by the S.O. of the Contractor's proposed drawings or

documents shall not in any way relieve the Contractor of any of his
duties or responsibilities under the Contract. The Contractor shall
be and remain entirely responsible for the proper execution,
completion and maintenance of the Works in accordance with the
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provisions of the Contract.
The Contract Sum shall be deemed to include the cost of

preparation, supply, delivery of all drawings, information, and
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copies thereof, which the Contractor is required to provide under
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the terms of the Contract.
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The temporary river crossing shall have a carriageway of 7.5m
width with a 1.5m pedestrian sidewalk on both side of the crossings
or as required by the JPS. It shall be capable of carrying all classes
of traffic loads using the existing road.
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Detailed drawings accomllanied by design calculations shall be
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submitted to the S.O. for his approval prior to the commencement

of demolition of the eJ:(isting bridge. The design of the temporary
river crossings shall be in compliance with the requirements of the
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JPS and other relevant Authorities
The temporary road diversions and temporary river crossing shall

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be regulafly maintained in a satisfactory condition during the full

duration of construction of the new bridge. On completion of the
Works, the temporary road diversions and river crossings shall be
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removed and the materials disposed of the site and the ground
reinstated to its original condition, all to the approval of the S.D.
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1.20.3 Half-width Construction and Traffic Control
Where half-width construction is necessary, work on culverts shall be

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completed and the embankment adjacent to them must be reinstated to a

satisfactory condition so that at least half the carriageway shall be available
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for use by the public at all times.
Where one-way traffic becomes necessary on any particular length of the

Works, or on the entire stretch of the Works, or on the approaches to the
Works, the Contractor shall maintain through traffic routes by providing a
width of at least 3.5 meters for a single-way traffic. The Contractor shall
also provide prior approved, electrically operated signals for traffic control
on the affected lengths and any additional traffic signs as may be required .
The electrical signal lights shall be automatic in operation, but the S.D.
S1 - 16
(JKRlSPJ/2015-S1)
may, however, at any time, require them to be hand operated by competent

operators, if necessary.
The Contractor shall make suitable arrangements for emergency servicing

of the electrically operated traffic signals to be available at all times.
Manually operated "Stop/Go" signs shall only be used with the prior
approval of the S.O. and shall be of the size, colour and type as shown on
the Drawings and complying with the requirements of the latest ARAHAN
TEKNIK (JALAN) 2C/85 - (Manual on Traffic Control Devices for
Temporary Signs and Work Zones Control), published by Ibu Pejabat
JKR, Kuala Lumpur.
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At least fourteen (14) days notice in writing of any proposed one-way traffic
system shall be given to the S.O. for his approval before such a system
can be implemented.
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1.20.4 Temporary Traffic Signs
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The Contractor shall at all times assume full responsibility and take all
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necessary precautions to ensure the safety of all traffic through and around
the Work Site and of traffic that is diverted owing to the Works.
To this end, the Contractor shall erect and maintain on the Site and at
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prescribed points on the approaches to the Site, all traffic signs, signals
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and warning lights necessary for the direction and control of traffic. The
sizes of all such signs and the lettering and wording shall be as shown on
the Drawings. Construction and excavation shall be sign posted and shall,
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during periods of darkness, be lit up as required, to the approval of the

S.O.
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Temporary traffic Signals and signages shall comply with the requirements
of the latest ARAHAN TEKNIK (JALAN) 2C/85 published by Ibu Pejabat
JKR, Kuala Lumpur and shall be reflectorized and kept clean and legible at
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all times.
The Contractor shall position, cover or remove these signs as necessary

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and/or when directed by the S.O.
1.20. 5 Temporary Works

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The Contractor shall provide, maintain and remove on completion of the

Works, all temporary works including diversion ways, tracks, staging,
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bridging, etc., and shall make them safe and suitable for carrying all
plants and materials and for all purposes related to the Works.
S l -17
(JKRlSPJ/2015-S1)
1.21 RELOCATION, TEMPORARY PROTECTION AND TEMPORARY DIVERSION

OF PUBLIC UTILITY INSTALLATIONS AND OTHER SERVICES
The Contractor shall be responsible for locating the positions of all public utility
installations, including water mains, overhead and underground cables, pipes,
sewers and drains and all service connections to buildings, and where necessary,
shall adopt such methods of excavation as may be required by the appropriate
Approving Authorities or service owners to ensure that no damage is caused to
them.
The Contractor shall make good, at his own expense, any damage caused by him
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to the existing services to the approval of and in accordance with the instruction of
the appropriate Service Authority or owner concerned, and shall keep the
Government indemnified at all times from all claims, costs and expenses which
may arise due to any damages (whether permanent, temporary or recurring) to the
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said services, failing which the S.O. reserves the right to settle the incurred costs
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and expenses by way of deduction of monies due or may become due to the
Contractor. This shall in no way relieve the responsibilities of the Contractor under
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this clause.
All such installations which are encountered in the course of the Works shall be
adequately supported, Slung-up, strutted or otherwise protected from injury, to the
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satisfaction of the respective Service Authority.
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The temporary diversion or relocation of any service within or outside the Works to
permit the construction of the Works shall be the responsibility of the Contractor.
,
The Contractor shall be responsible for arranging with the appropriate Authorities
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for all temporary diversions required in connection with the Works. The Contractor
shall keep the S.O. fully informed of his liaison with the relevant Service
Authorities.
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During the execution of the Works, the S.O. may coordinate all services
operations in clOSE! liaison with the appropriate Authorities involved to ensure
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expeditious progress of the Works. The Contractor shall make such necessary
( ) adjustme ts to his programme from time to time to accommodate the actual
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progress achieved as a result of temporary diversions undertaken by whomsoever.

Where temporary diversions of services are required in connection with the
Works, they shall be carried out as agreed with the appropriate Service
Authorities .
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All temporary diversions shall be subjected to the approval of the S.O. The cost of
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all temporary diversions whether undertaken by the Contractor, or the relevant

Service Authorities or their contractors shall be borne or paid by the Contractor.
Temporary diversion shall mean works involved in the diversion of services that
will be reinstated to their original position and condition on completion of the works
in the affected areas. In planning his work for the diversion or relocation of
services, the Contractor shall make reasonable allowance for the time duration
necessary to obtain the S.O.'s and the relevant Service Authorities' approvals of
the works to be carried out.
S1-18
(JKRlSPJ/2015-S1)
1.22 WATER AND ELECTRICITY SUPPLY
The Contractor shall provide at his own risk and cost. all water, lighting and
electric power where required for use in the Works and shall pay all costs, fees
and charges and comply with all safety regulations, requirements and by-laws in
connection therewith.
The Contractor shall also provide and maintain temporary water storage together
with any plumbing works associated with it in the case of non-availability of water
or water supply disruption and ensure its removal on completion of the Works.
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Where electricity cannot be obtained from Tenaga Nasional Berhad (TNB) or local
electricity supply company, generator set(s) may be used but with safety
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precautions as outlined by TNB or the relevant Authority, strictly adhered to .
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1.23 PROJECT SIGNBOARDS
The Contractor shall provide, erect and maintain signboards at locations to be

decided by the S.O. throughout the duration of the construction period, and pay all
A
charges and fees in connection therewith, including obtaining pennission, etc.
Each sign board shall comply with the design and specification as shown on the
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Drawings. On completion of the project, the Contractor shall dismantle and

remove the signboards from the project site.
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1.24 PHOTOGRAPHIC RECORD OF WORKS

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The Contractor shall provide a new camera of reasonably good quality as

specified in the Appendix 1E - (Equipment and Facilities) for the sole use of the
S.O.
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The Contractor shall arrange to have the monthly progress photographs and
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slides (both to be in color) of the Works taken from time to time and to cover such
extent and interval of the Works as instructed by the S.O. The Contractor shall
record the photographs taken, duly dated and captioned with a brief description of
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the work including chainage reference and direction of view, in a proper hard
cover photograph album for safe keeping . One set of the photographs, stored in
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CD-ROM, shall be attached together with the photograph album.
The photographs shall be the sole property of the Government and no print or
softcopy of these photographs shall be utilized by any other person(s) or party,
other than for the purpose of the project only except with the consent of the S.O.
S1 -19
(JKRlSPJ/2015-S1)
1.25 AS-BUILT DRAWINGS
The as-built drawings, as per requirement in Appendix 1H - (As-built Drawings

And Road Assets Inventory), of the Works shall be prepared by the Contractor,
and endorsed by the Consultant with a P.Eng. chop stamped on them. The
drawings, in digital format and the required number of hard copies in A 1 size
(838mm x 584mm) duly signed and stamped with a P. Eng. chop, unless
otherwise approved by the S.O., shall be supplied by the Contractor to the S.O.
progressively as each section of the Works is completed .
All drawings shall be prepared and complete within one (1) month from the
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completion of the respective section of the Works or, the whole of the works,
failing which , a reasonably substantial amount of remaining balance of payment or
monies due to the Contractor shall be withheld by the S.O. until the Contractor
fulfills his obligation under the Contract. In default of this, the S.O. reserves the
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right to appoint a third party to get the drawings completed and only on completion
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of the full set of as-built drawings as required under the Contract shall the balance
of payment or monies due to the Contractor be released to him.
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1.26 CLEARING THE SITE UPON COMPLETION
The Contractor shall make every effort to keep ~he Site in a reasonably clean and
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tidy condition for the duration of the Works. He shall, in addition, from time to time
and on the completion of any area of tfle Works or where directed by the S.O.,
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remove rubbish, surplus materials, or any other construction debris from such
areas as may be attributable to his work under this Contract and leave the Site in
a satisfactory condition, to the a~pr9val of the S.O.
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The Contractor shall remove from the Site all such waste and surplus materials
that are no longer required for the execution of the Works, at his own expense and
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to the satisfaction of the S.O. and shall indemnify the Govemment against any
claims arising from tile disposal of such waste and surplus materials.
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\ ) 1.27 ACCESSIBILITY TO THE SITE FOR OTHER CONTRACTORS

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The Contractor shall, when required by the S.O., allow reasonable access to the
Site to any other contractor(s) employed by the Government, their workmen, the
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workmen of the Government and other duly constituted authorities who may be
employed in the execution on or near the Site of any other works not included in
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the Contract.
1.28 QUALITY ASSURANCE PLAN
1.28.1 Contractor to Submit Quality Assurance Plan
i. The Contractor shall submit to the S.O. an outline Quality

Assurance Plan for comment within fourteen (14) days of the date
of Letter of Acceptance. Within twenty eight (28) days thereafter the
S1 -20
(JKRlSPJ/2015-S1)
Contractor shall submit to the S.O. for approval a properly

documented Quality Assurance Plan that shall take proper account
of the S.O.'s comment on the outline Quality Assurance Plan. The
approval by the S.O. of such plan shall not relieve the Contractor of
any of his obligations under the Contract. The Contractor shall
update and revise the said Quality Assurance Plan during the
progress of the Works in order to comply with the Contract, all to
the approval of the S.O.
ii. Details of all procedures and compliance documents shall be

submitted to the S.O for information before each design for
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temporary works and execution stage of the Works is commenced.
When any document of a technical nature is issued to the S.O,
evidence of the prior approval by the Contractor himself shall be
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apparent on the document itself.
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iii. Quality Assurance Plan shall set out the specific quality procedures,
practices, resources and sequence of activities to meet the
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requirements of the Contract and Specifications and shall include
the proposed organization structure of the Contractor including
quality assurance team, quality procedures, Contractor's plants,
construction programme, method statements, environmental
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management, health and safety, selection and testing of materials,
placement, installation, site operational control, non-conformance
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reporting (NCR), closing out NCR for the taking over, coordination
with local and statutory authorities, internal quality audit control,
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remedying of defects, commissioning and maintenance (if any).
iv. All Quality Assurance Plan submitted by the Contractor to the S.O.
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shall conform to the relevant standards set out by the International

Standards Organization (ISO) and in conjunction with the latest
Public Works Department Quality Management System or known
as the Sistem Pengurusan Bersepadu (SPB), JKR.
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1.28.2 Contractor to Adhere to Quality Assurance Plan

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The Contractor shall implement the quality assurance procedures in the

approved Quality Assurance Plan and shall submit a monthly quality
assurance report to be endorsed by a Quality Assurance Officer
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incorporating all test results, test certificates, photographs and lab reports
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relating to the quality of materials and workmanship.
1.28.3 Quality Assurance Team
i. The Contractor shall appoint a suitably qualified and experience

person to act solely as Quality Assurance Officer full time on Site to
lead the Quality Assurance Team . The Quality Assurance Officer
shall meet all the following requirements:
Sl -21
(JKRlSPJ/2015-S1 )
a) Possesses a relevant technical Degree from a university

recognized by the Government of Malaysia.,
b) Possesses not less than 5 years experience in the construction

industry,
c) Possesses a Construction Industry Development Board (CIDB)

Green Card, and
d) Has anyone of the following;
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• Minimum 2 years relevant experience in the implementation of
MS ISO 9001 in the construction industry, or
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• Has attended field internal audit activities for MS ISO 9001, or
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• Possesses Internal Auditor Certificate from agency or body
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recognized by MAMPU
ii. The Contractor shall provide a Quality Assurance Team and

resources that are required to ensure the effective operation of the
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Quality Assurance Plan.
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1.28.4 Verification of Implementation
i. The Contractor shall, at his own cost, provide all access,

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assistance and facilities to enable the S.O.'s Representative to

audit/verify the implementation of the Quality Assurance Plan
according to ttie Prosedur Perancangan Pelaksanaan Projek
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unde~ the latest Sistem Pengurusan Bersepadu (SPB), JKR -

LAMPIRAN 4 (Pelan Kualiti Projek - Q.Plan) and adherence
thereto.
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ii. The S.O.'s Representative may, at his discretion, reject any of the
Works which in his opinion have not been executed in accordance
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with the Quality Assurance Plan and which ultimately does not
conform with the Specification, or the resultant execution of the
work was not done in a good and workmanlike manner and to the
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accepted standards and good practice. The Contractor shall re-

execute, at his own cost and without any entitlement to any
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extension of time, all such parts of the Works so rejected.
1.29 NOTICE OF COMMENCEMENT OF PERMANENT WORK(S)
No permanent works shall be undertaken without the S.O.'s approval and the
Contractor shall give a minimum of 24 hours' notice prior to the commencement of
any part of the Works so that the S.O. may make whatever arrangements
necessary for the inspection thereof.
S1-22
(JKRlSPJ/2015-S1 )
1.30 CONTRACTOR'S RESPONSIBILITY FOR WORKS
Where the S.O.'s approval is required prior to the commencement of work, the
issue of such approval shall not relieve the Contractor of any of his liabilities,
responsibilities or obligations as described in the Contract.
1.31 AVOIDANCE OF NUISANCE AND DAMAGES
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The Contractor shall consider the close proximity of the Works to residential,
commercial and industrial property and shall take full responsibility for and all
reasonable precautions to avoid damage, as well as minimize all inconvenience
and nuisance such as dust, noise and vibrations arising from his operations. In
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relation to this, the Contractor shall compile a dilapidation survey baseline record
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before, during and after construction.
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1.32 PROHIBITION OF ADVERTISING
The Contractor shall treat the Contract Documents as private and confidential. In
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particular, the Contractor shall not publish any information, drawings or
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photographs related to the Works and shall not use the project Site for advertising
purposes, except with the consent of the S.O. and subject to such conditions as
the S.O. may prescribe.
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1.33 UNAUTHORISED USAGE
The Contractor shall ensure that there is no unauthorized usage of the Site, and
make good at his own expense any damage caused by his failure to prevent such
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unauthorized usage of the Site.

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1.34 ACCESS TO SITE

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Each tenderer shall, before submitting his Tender, satisfy himself regarding the
existing access to the Site and shall include in his Tender, the cost of any
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additional works, improvements, extensions and maintenance works which may be

required to enable him to perform his obligations under the Contract or which may
be required by any regulation or requirement of any Authority, unless otherwise
stated in the Contract.
81-23
(JKRlSPJ/2015-S1 )
1.35 MOBILISATION AND DEMOBILISATION
The item for mobilization and demobilisation in the Bill of Quantities shall include
the supply of all labour, materials, tools, equipment and incidentals necessary for
moving into the Site and out of it on completion, and shall deem to include:
1.35.1 Mobilisation
The transportation and installation of any construction plant necessary to

complete the Works from the ports of unloading, places of assembly in
Malaysia or 'other locations to the Site where they are to be used for the
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Works.
1.35.2 Demobilisation
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On completion of the Works and before the S.O. issues the Certificate of
Practical Completion (CPC) in accordance with the Conditions of the
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Contract, the Contractor shall, with the approval of the S.O. , dismantle and
n remove from the Site, all plants, temporary staging, traffic signs, project
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signboard and anything else not included in the Permanent Works.
1.36 SAFETY, HEALTH AND WELFARE

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The Contractor shall be required to provide a complete First Aid Kit as stated
under the Factory and Machinery (Safety. Health And Welfare) Regulation
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1970 which shall be kept and properly maintained in the Contractor's site office.
The kit shall be in the charge of either tRe Contractor's site representative or some
other responsible person who shall be on the Site during all working hours to
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ensure that the first aid facilities are available without delay at all times when
Works is in progress. At least one (1) designated person of the Contractor's staff
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shall be trained in first aid duties.
The Contractor shall refrain from dumping and/or depositing any form of materials
that are capable of collecting water which can afford breeding places for
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mosquitoes, rodents, insects and vermins of any kind . All excavation and any
\ )
portion of the site where water stagnates or accumulates shall be kept dry by
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pumping, bailing or other operations. The Contractor shall pay all charges as may
be required by the Ministry of Health and/or Local Authority and employ whatever
destructive measures as are necessary in order to rid of them .
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All Works shall be carried out under controlled conditions of acceptable noise and
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dust emission levels. The Contractor shall take measures to ensure that all
equipment and machinery are in proper working condition so as to minimize the
amount of noise and dust generated. The S.O. may require the Contractor to
submit a proposal on how to reduce excessive noise and dust, to which the
Contractor has to respond in an efficient and fast manner.
The Contractor is prohibited from discharging oil and grease to any water course.
Storage tanks for oil and grease shall be placed on concrete base with upstand
edges to contain any spillage. Any spilled oil and grease shall be promptly
removed by the Contractor. The Contractor shall collect and store used oil, grease
81-24
(JKRlSPJ/2015-S1)
and other scheduled wastes and dispose these according to methods approved by
DOE.
Where the Contract Period is more than six weeks, the Contractor shall register
with DOSH within seven (7) days after commencement of Works.
All safety measures shall be carried out in accordance with Occupational Safety
and Health Act (OSHA) 1994 or its latest version, JKR Specifications For
Occupational Safety and Health (OSH) for Engineering Construction Works
2011 (items 4, 5, 6, 7.1 and 9, where applicable, for projects below RM20 million
or project cost based on prevalent policy and guideline) or its latest version and
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relevant local by-laws. The Contractor shall be held solely responsible for all
accidents arising from any negligence in this respect. The Contractor shall employ
throughout the entire Contract period a competent and qualified person as the
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Safety and Health Practitioner as below:
(i) Site Safety Supervisor (SSS) to be stationed minimum 15 hours a week

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b~~~.
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(ii) Safety and Health Officer (SHO) to be stationed full time for contracts
worth more than RM20 million or that based on prevalent policy and
guideline
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The Contractor shall ensure all sub-contractors who employ more than 20 persons
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shall appoint a Contractor Safety Supervisor (CSS) to be stationed minimum 5
hours a week.
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The Contractor shall submit Safety and Health Plan (S-Plan) in writing duly signed
by the Director of the company to the S.O. within one (1) month after the receipt of
the Letter of Acceptance. The S-Plan shall be as per Prosedur Kawalan
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Keselamatan dan Keslhatan Pekerjaan, under the latest Sistem Pengurusan

Bersepadu (SPB), JKR - (LAMPIRAN 1 - Format Pelan Keselamatan dan
Kesihatan Pekerjaan, S-PLAN). The Contractor shall submit the revised S-Plan
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whenever required .
The Contractor shall form a Safety and Health Committee in accordance with the
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Occupational Safety and Health Regulations 1996 and organise meetings at

minimum once in every three (3) months.
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The Contractor shall conduct Occupational Safety and Health (OSH) related
training and programmes for the workmen including sub-contractors.
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The Contractor shall carry out site safety and health inspections and submit
monthly safety and health reports to the S.O. in accordance with Prosedur
Kawalan Keselamatan dan Kesihatan Pekerjaan under the latest Sistem
Pengurusan Bersepadu (SPB), JKR - (LAMPIRAN 5 - Format Laporan
Keselamatan dan Kesihatan Pekerjaan).
The Contractor shall provide and maintain safety and health statistic scoreboard at
the entrance of site office and workplace.
The Contractor shall provide and maintain adequate traffic safety signage,
S1 -25
(JKRl8PJ/2015-81 )
warning signs and warning lights at place of Works and close proximity to public.
The Contractor shall provide and maintain traffic control by competent persons
including provision of flagmen where Works is in close proximity to public roads
and accesses.
The Contractor shall carry out site safety and health audits as per DOSH
requirements and/or as instructed by the S.O.
1.37 SANITATION
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The Contractor shall provide and maintain sufficient temporary toilets at
appropriate locations on site as approved by the S.O. Toilets shall be complete
with adequate water closets, urinals, hand-basins with proper sanitary system and
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maintained in a clean and sanitary condition in accordance with the requirements
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of the Ministry of Health. All wastewater must be treated sljGh that its discharged
effluent meets the requirements of all existing legislation and reg lations.
1.38 WASTE MANAGEMENT

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The Contractor shall ensure that all waste generated on site shall be managed in
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accordance with the Solid Waste And ~ul'llic Cleansing Management Act 2007 .
and Environmental Quality Act 1974 as follows:
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(i) The Contractor shall $ybmit in the approved format the Construction
Waste Management Plan (CWMP) to the S.O. for approval within
fourteen (14) days from the date of site possession.
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"",
(ii) The Contractor shall provide Roll-On Roll Off (RORO) for construction
waste and Mobile Garbage Bin (MGB) for domestic waste
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(iii) The Contractor shall provide a minimum of one (1) location on site for
( ) segregation and collection of construction and domestic waste.
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(iv) The Contractor shall appoint a licensed contractor(s) to collect the

construction waste, scheduled waste and domestic waste from the site
to approved locations for disposal or to recycle the waste.
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1.39 ENVIRONMENTAL PROTECTION WORKS
1.39.1 Environmental Management Plan (EMP)
The Contractor shall prepare the Environmental Management Plan (EMP)

for the following situations:
i. Projects worth more than RM20 Million including earthworks.
ii. Project sites located in Environmental Sensitive Area (ESA) as
81 -26
(JKRlSPJ/2015-S1 )
defined in the National Physical Plan by Jabatan Perancangan

Bandar dan Desa (JPBD).
iii. Projects where Environmental Impact Assessment (EIA) has

been carried out.
The EMP shall be prepared by a registered Environmental Consu ltant and

submitted to the S.O for approval within 14 days from the date of
possession of Site. The EMP shall be concise, up to date and site specific.
The EMP shall make reference to the following, but not limited to :
i. Department of Environment (DOE) format for the preparation of
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EMPs
ii. The approved EIA report and conditions imposed ( if any)
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The Contractor shall submit the following documents as per TABLE 1 to
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the S.O. for approval:
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TABLE 1 : PERIOD FOR SUBMISSION OF DOCUMENTS
No. Of Reporting
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Documents Timing
Copies Fre~uency
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Once only ( to
be updated Within 14 days from the date
EMP 5
when of Possession of site
necessary)
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Environmental
Quality Report 5 Monthly 14 days after monitoring
.
(EQR)
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Environmental
Monitoring And
5 Quarterly 14 days after audit"
Audit Report
(EMAR)
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14 days prior to issuance of

Closure Audit
5 Once Only Certificate of Practical
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Report ( CAR)
Completion (CPC)"
Note" to be carried out by registered environmental consultant
1.39.2 Environmental Officer (E.O.)

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The Contractor shall appoint a person to be responsible to ensure the

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implementation of the EMP and to monitor and report on the site

compliance on a daily basis.
1.40 WATER AND AIR QUALITY, NOISE AND VIBRATION CONTROL
1.40.1 Monitoring Water and Air Quality, Noise and Vibration Control
The Contractor shall carry out monitoring of water and air quality, noise
and vibration as indicated in the EMP and tests to be carried out by
Sl-27
(JKRlSPJ/2015-S1)
accredited laboratories. Parameters to be tested are as specified in

Appendix 1J - Environmental Quality Standards (Table A2) to be
complied with by the Contractor.
1.40.2 Air Quality
The Contractor is not allowed to carry out open burning of cleared

vegetation, debris and construction waste, etc. and shall not be allowed
ER
unless prior approval is obtained from the Director General of the
Department of Environment.
The Contractor shall provide suitable spraying equipment for regular
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spraying of water over the existing roads, tracks and access roads, near
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settlements, completed as well as incomplete road and other barren areas
() of the site used by the Contractor, especially duriQg the dry season or as
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and when directed by the S.O.
When the Contractor's trucks or equillment utilizes public or private

roadways, all dirt and materials shall be removed from the trucks!
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equipments by means of hosing, lorry wash-trough, etc. before leaving the
site.
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The Contractor shall provide for. the prompt removal of all dirt and other
materials spilled from his or his sub-contractor's vehicles on public or
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private roadways.
For Contractor's---trucks carrying sand, aggregates, earth and other loose

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construction ,rTiaterials liable to spillage, tarpaulin must be used to cover

such open trucks when passing through villages or settlements and on all
roadways.
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\ ) The Contractor shall also ensure dust control at quarry I batching plant (if
allY) complies with the environmental requirements as stipulated in the
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Environmental Quality (Clean Air) Regulations, 2014
1.40.3 Noise And Vibration Control

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The Contractor shall ensure that at any time, the vibration levels resulting
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from his works at or across real property boundary should not exceed the
Recommended Limit as specified in Table A2 (Appendix 1J). No person,
unless duly authorized by law or carrying our legitimate duties, shall use
explosives or that which results in explosions that create a vibration
disturbance across a real property boundary or on a public space or right
of way.
The Contractor shall comply with the general recommendations set out in
DOE Interim Planning Guidelines for Vibration Limits and Control in
Sl -28
(JKRlSPJ/2015-S1 )
the Environment together with any specific requirements described in the

Contract.
The Contractor shall indemnify and keep indemnified the Govemment,

S.O. and the S.O.'s Representatives against any liability for damages on
account of vibration disturbance created while or in carrying out of the
Works and from and against all claims, demands, proceedings, damages,
costs charges and expenses whatever with regard to or in relation to such
liability.
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1.41 NOMINATED SUB-CONTRACTORS
The Contractor shall allow in his tender price, for attendance and facilities, upon
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all nominated sub-contractors, if any. such attendance and facilities shall include
the following :
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i. Making good of roadworks, related structures, etc. and finishes thereto
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including touching up of all completed works necessitated, damaged or
disturbed by the Nominated Sub-contractor's work.
ii. Supplying all setting out infonmation.

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iii. Giving all necessary dimensions and taking responsibility for their
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accuracy.
iv. Affording free and full use of standing scaffolding or other temporary
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structures whilst it remains erected on the Site.
v. Affording free and full use of storage accommodation for materials,

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equipment and plant which are for incorporation into the Works and/or
which require protection against weather and deterioration, messrooms,
sanitary and welfare facilities.
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vi. Providing site space only for Nominated Sub-contractor's temporary office,
workshops, workmen's accommodation and storage of materials, tools,
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plant and equipment which are not for incorporation into the Works and not
requiring protection against weather or deterioration.
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vii. Providing temporary water supply, electric power supply, artificial lighting
and paying all fees and charges for fuel, water and electricity consumed,
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including for testing and commissioning of the whole NSC works.
viii. Liaising with the relevant service/utility authorities for the expeditious
installation of the connections for permanent water and electricity supplies
in the Works making available such supplies to the Nominated Sub-
contractors; and paying all fees and charges for such installation, deposits
for such supplies/services on behalf of the Government. All such payments
made, shall be reimbursed to the Contractor on production of receipted
bills.
Sl-29
(JKRl8PJ/2015-81 )
ix. Providing competent personnel in compliance with the latest Electricity

Regulations to take responsibility for the operation of the electrical
installation from the time the permanent electricity supply is made available
until testing , commissioning and handing over of the Works.
x. Protecting, watching and taking full responsibility for all Nominated Sub-
contractor's work and unfixed materials and goods intended for use
thereon .
xi . Removing rubbish and debris off the Site and cleaning the Works internally
and externally.
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It is deemed that the Nominated Sub-contractor shall include in the Sub-
contract Sum, inter alia, the costs in connection with the following :
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i. Unloading, getting in, storing and all handling and hOisting of these
materials, plant and tools into required positions.
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n ii. Providing, erecting, maintaining and removing of all his temporary
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office, workshops and workmen's accomrpodation including paying all
assessment and other charges.
iii. Connecting to temporary water and power supplies made available by

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the Contractor for the execution of the Works, supplying and running
distribution pipes, hoses, cables, leads, electrical gear, etc. but
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excluding payment for water ana electricity consumed.
iv. Provision of fuel, gas, steam, oil lubricants, chemicals and everything
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else necessary (other than water and electricity) for the test running
and commissioning of the Sub-contract Works.
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v. Any scaffolding, staging, etc. that are required for the Sub-contract
Works but not covered in the relevant paragraph.
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1.42 NOMINATED SUPPLIERS

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The Contractor shall allow in his tender, price for attendance upon all nominated
suppliers which is to include taking delivery, unloading, setting in, checking and
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accepting delivery, returning empties, handling, storing and hoisting of the

materials/goods supplied by the nominated suppliers. Packing and carriage to site
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shall be bome by the nominated supplier unless specifically stated to the

contrary.
81-30
(JKRlSPJ/2015-S1 )
1.43 COORDINATION OF MECHANICAL AND ELECTRICAL SERVICES
1.43.1 General
This section shall describe the scope of works, qualifications, competency,

roles and responsibilities of the mechanical and electrical (m&e) services
coordination team.
1.43.2 Scope Of Work
The Contractor shall be responsible for coordinating the implementation of
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all M&E works and related activities within the project scope. For this
purpose the Contractor shall appoint M&E services coordinators full-time
on Site during the whole duration of the Works. The appointment shall be
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approved by the S.O.
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The Contractor shall ensure all M&E requirements are implemented in a
timely manner and adequately integrated with all other services involved ()
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such as architectural, structural and other related services.
The Contractor shall conduct regular coordination meetings among all sub-
contractors, nominated or otherwise, from all related disciplines to
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evaluate and resolve all issues or problems regarding the integration
and coordination of all services involved.
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1.44 MINIMUM REQUIREMENT OF M & E SERVICES COORDINATOR BASED ON

PROJECT COST
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Project Cost (RM) Minimum Requirement of M & E Coordinator
Between 10 - 50 million 1 Engineer & 1 CoW

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> 50 million 1 Engineer & 2 CoW

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1.45 QUALIFICATION AND COMPETENCY OF M & E COORDINATORS

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1.45.1 Engineer
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Possesses a Degree in related engineering field with minimum 3 years of

working experience in Building Construction.
1.45.2 Clerk of Works (CoW)
Possesses a Diploma in related engineering field with minimum 5 years of

working experience in Building Construction.
Sl -31
(JKRl8PJ/2015-81)
1.46 RESPONSIBILITIES OF M & E SERVICES COORDINATOR
The M&E Services Coordinator shall be responsible, on behalf of the contractor

for :
i. Guiding the overall M&E works and implementation of related activities

within the project scope and providing timely and relevant information.
ii. Ensuring that all layout, schematic, detail and Suilder's-Work-in-

Connection (SWIC) drawings (for architectural, structural, mechanical and
electrical works) are received from the S.O.
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iii. Supervising all the installation and construction works to ensure the works
are sufficiently coordinated.
iv. Identifying and resolving issues or problems related to integration and
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coordination of services.
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()
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81-32
(JKRlSPJ/2015-S1 )
APPENDIX 1A
GENERAL DESCRIPTION OF THE PROJECT
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S1A-1
(JKRlSPJI2015-S1)
APPENDIX1B
SCOPE OF WORKS
The Scope of Works may include all or part thereof (as mentioned clearly andlor inferred
indirectly in the Bill-of-Quantities andlor Drawings), but not necessarily limited to the
following :-
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ROADWORKS
1. Site clearing of the required width of the right-way as shown on the drawing of all
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trees, shrubs and undergrowth, grubbing up of roots, and demolition of buildings,
structures and superficial obstructions on the site in the way of or otherwise
N
affected by the works.
n
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2. Provision and subsequent removal of all necessary temporary river crossings.
Road diversions, an access roads, etc. for the necessary execution of the
construction works.
3. Earthworks and rock excavation to formation level including excavation of any

A
unsuitable material and the formation of slope on the approaches to the level
shown in the drawings. Where necessary, the Contractor shall provide his own
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source of fill material, transport it to the site, compact and consolidate it as his
own expense and settle all the necessary royalties required on the earth
transported by him.
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4. Turfing and soiling of the embankments, cut slopes, benches and rounding off
portions.
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5. Traffic diversion works as per required of relevant authorities and S.O ..
6. Maintenance of all roads and any access affected by construction in a safe and
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motor able eondition at all times.

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7. Flexible pavement works.
8. Demolition of existing bridge I culvert and construction of new culverts .

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9. Provision and subsequent removal of all temporary staging necessary for the
proper construction of box culverts.
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10. Construction of retaining walls comprising rubble or reinforced concrete.
11. Supply, drive and test piles for box culverts.
12. Drainage works including culverts, sumps, interceptor drains, cascading drains
and sub soil drains where necessary.
S18-1
(JKRlSPJ/2015-S1)
APPENDIX 1B
13. Protection of existing or new services such as water supply, electricity supply
telephone lines and to maintain the services to the local population whist resiting
works are carried out.
14. Installation of guardrails, traffic signs and signals, kerbs, road pavement markings,
interlocking pavers for footpaths, hoardings, fencing, site offices I temporary
buildings.
15. Associated M & E Works associated with street lighting and traffic signalization as
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well as electrical ducting and cabling etc.
16. Miscellaneous works and all other works incidental to the Project including any
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modifications and variations carried out within the terms of the Contract.
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BRIDGE WORKS
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The contractor shall provide all labour, materials, plants and everything necessary for the
proper execution and completion of the works in accordance with the condition of
Contract, the Specification and the Drawing.
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1. All preliminary items and works described in the general items.
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2. Demolition of existing bridge
3. All piling works including testing

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4. Excavation and replacing with specified material as foundation.

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5. Construction of bridge abutments and wing walls in reinforced concrete.
6. Installation of laminated elastomeric bearings pads including epoxy mortar

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7. Placing of prestressed beams.

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8. Construction of diaphragms, deck slabs, parapets and approach slabs in

reinforced concrete.
9. Construction of the proposed approach road works.

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10. All other miscellaneous.

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818-2
(JKRlSPJ/2015-S1)
APPENDIX 1C
TRANSPORT SERVICES FOR S.O. AND HIS STAFF
1.0 General
1.1 The Contractor shall provide suitable transportation service by means of:
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a) * locally assembled motorcycles
b) * locally assembled air-conditioned four (4) wheel drive vehicle(s)

complete with competent driver(s) for the 5.0. and his staff or any
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other persons permitted by the 5 .0. for the supervision of the Works
and administration of the Contract as and when required by the 5 .0 . or
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his staff at all times from the commencement of the Contract until the
issuance of the Certificate of Practical Completion. The JKR logo and
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the name of the project shall be printed on tii e left and right front doors
1.2
of the vehicles( s).
.,.
The Contractor shall ensure that the vl!hiGle(s) are accident free and are in
a well maintained condition subject to certification from PUSPAKOM at
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every six (6) months.
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1.3 The vehicle(s) shall be in the custody of the Contractor at all times.
1.4 The Contractor shall provide comprehensive insurances to cover all drivers
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and passengers and ensure that all road tax are valid throughout the
contract period.
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2.0 Arrangement. for Ttansport and Failure to Provide Transport
2.1 The Cdntractor shall provide the necessary transport from the office(s) of
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the 5 .0. or his staff or from deSignated pick-up pOints to the Site and vice
( ) versa as requested by the 5 .0 . or his staff. The transport shall at all times
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be readily available for the sole use of the 5 .0. and his staff. Replacement
vehicles shall be provided when the normal vehicle is not available such as
during periods of servicing, maintenance or repair.
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2.2 The Contractor shall notify the relevant officer should there be any delay in
the pick-up times. If the Contractor fails to notify of the delay or fails to
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provide the required transport, the officer shall have the option to arrange
alternative transport and the Contractor shall bear the expenses and an
appropriate adjustment shall be made to the Contract Sum.
S1C-1
(JKRlSPJ/2015-S1 )
APPENDIX 10
LIST OF LABORATORY EQUIPMENT
The Contractor shall provide and maintain the following testing laboratory equipment,
those which are deemed necessary only for the project, and shall become the property of
the Contractor at the end of the Contract:-
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No.
(a) Soil Testing Equipment
1. Moisture content tins - 76mm x 25mm with lids. 25
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2. Electric balance of 1 kg capacity, accurate to 0.1g
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with a tare correction of not less than 1~Og. 1
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3. Electric forced draught oven, capacity of 0.08 cU .m. 1
4. Atterberg limit machine calibrated with a grooving

device as specified in B.S. 1377. 1
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5. Glass plates - 457mm x 609mm x 6mm 2
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6. Linear shrinkage moulds - 254mm 5
7. Spatulas - 152mm 2
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8. 203mm diameter B.S . sieves - 75mm, 63mm,

50mm, 37.5mm, 28mm, 25mm, 20mm, 14mm,
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12.5mm, 10mm, 9.5mm, 6 .3mm, 5mm, 4.75mm,

3.35mm, 2.36mm, 2mm, 1.18mm, 60um ,
425um, 300um, g12um, 150um, 75um,
lid and pan together with vibrating machine. 1 of each
M
9. 203mm diameter B.S. sieves - 75um, 425um, 2 of each

KU
10. Wash sieves - 75um . 2
11. Sample splitter - 50mm 2

O
12. Sample splitter - 12mm 2

D
13. Balance of 10kg capacity, accurate to 19 1
14. Standard compaction hammer, electric motor

operated, as specified in B .S. 1377. 1
15. Standard compaction mould as specified in

B.S. 1377. 1
510-1
(JKRlSP J/2015-S 1 )
APPENDIX 1D
No.
16. Compaction mould extruder as specified in

B.S. 1377. 1
ER
17. Steel scoop 1
18. Rubber mallet 1
D
19. Measuring flasks - 1000c.c 1
N
20. Vernier calipers - 152mm 1
TE
21 . Steel rule - 305mm. 1
22. Compression machine suitable for laboratory and

field C.B.R.s with all fittings necessary for
A
field and laboratory operation as specified in
B.S. 1377. 1
EJ
23. C.B.R. moulds fitted with collars and base plates for
compaction and soaking and tripods for small
measurement fitted with dial gauges having 0.01mm
M
divisions and 25mm travel as specified in B.S. 1377 10
24. 2.26kg surcharge weights - ring type 6

EN
25. 2.26kg surcharge weights - horseshoe type 9
26. Complete field density kit, sand replacement type

M
\
suitable for volume measurement of 0.005cu.m
J to an accuracy of not less than 0.0001 cU.m as
KU
specified in B.S. 1377. 2
27. Hand auger suitable for boring to depths of 5m

and supplied with 100mm diameter heads suitable
O
boring in cohesive and cohesion's soils. 1

D
28. Crowbar, pick and spade. 1 of each
29. Drying pans - 406mm x 406mm x 76mm 6
30. British Standard 1377 - "Method of Test for Soils

for Civil Engineering Purposes" , latest edition . 1
31 . Mackintosh I JKR Probe 1
SlO-2
(JKRlSPJ/201 5 -S1 )
APPENDIX 1D
(b) Concrete Testing Equipment.
1. 152mm x 152mm 152mm standard concrete test

cube steel moulds as specified in B.S. 1881 . 6
ER
2. Slump cones with tamping rods as specified in B.S.
1881. 2
D
3. Compacting factor apparatus as specified in B.S.
1881 . 1
N
4. Tank for curing of concrete specimens to
TE
accommodate 50 Nos. x 152mm cubes in layers not
more than 50mm deep. 1
(c) Flexible Pavement Testing Equipment

A
1. Metal tray, 0.6m square or similar suitable for
EJ
measuring spray rates of bituminous materials and
spread rates of cover aggregates for surfaces dressing. 4
2. Metal thickness gauge (or set of slotted sleeves)

M
as specified in M.S. 30 for determination of aggregates

flakiness index. 1
EN
Additional items required for asphaltic concrete and/or bituminous Macadam :-
3. Balance of 2kg capacity, accurate to 0 .1g suitable

for weighing samples suspended in liquid. 1
M
4. Steel moulds for Marshall test specimens (100mm

KU
diameter) with base, extension collar, extraction

collar and extraction plate as specified in B.S.598. 6
5. Extractor for removing Marshall test specimens

O
from moulds without distortion or shock as

specified in B.S. 598. 1
D
6. Compaction hammer and automatic compactor for

Marshall test specimens as specified in B.S. 598. 1 of each
7. Compaction pedestal and mould holder for Marshall

test as specified in B.S. 598. 1
8. Thermostatically controlled hot plate 1
SlO-3
(JKRlSPJ/2015-S1 )
APPENDIX 1D
No.
9. Thermometers for use in laboratory and in asphaltic

mixes for Marshall test as specified in B.S. 598. 2 of each
10. Rubber and heat resistant gloves. 2 pairs of each
ER
11 . Filter papers - 100mm diameter. As needed
12. Containers for heating aggregates and

bituminous materials. As needed
D
13. Pavement coring machine of the thin-walled
N
diamond bit type for obtaining 100mm diameter
() samples of bituminous surfacing. 1
TE
14. 100mm diameter thin-walled diamond bit for
use with pavement coring machine.
A As needed
15. Tools for cutting and trimming paveme1'ft cores As needed

EJ
16. Metal bottles of suitable capacity or bitumen
extraction, by direct determination as specified in
B.S. 598. As needed
M
17. Machine to rotate the bottles about their

longitudinal axes at a speed of between 10 rev/min
to 30 rev/min as speCified in B.S. 598. 1
EN
18. Volumetric flasks of suitable capacity. As needed
19. Centrifuge capable of developing an acceleration of

M
() 25,QOOm/sq second as speCified in B.S. 598. 1

KU
20. Filtration apparatus for extraction of bitumen by

direct determination as specified in B.S. 598. 1
21 . Recovery apparatus for extraction of bitumen by

O
direct determined as specified in B.S. 598. 1

D
22. Pressure filter of appropriate size, air pump and

funnel for extraction of bitumen by direct
determination as speCified in B.S. 598. 1 of each
Further items required for asphaltic concrete :-
23. Wire basket of 6.5mm or smaller mesh with wire

hanger as specified in M.S. 30, for determination
of specific gravity and water absorption of aggregates. 1
S1D-4
(JKRlSPJ/2015-S1)
APPENDIX 10
24. Airtight container of similar capacity as wire basket

above . 1
25. Gas jar - 1.5 litre 1
ER
26. Pyconometer - 1 litre 1
27. Warm air blower 1
D
28. Mechanical mixer of 2kg capacity, for preparation
of asphaltic concrete mixtures . 1
N
29. Thermostatically controller water bath for Marshall
TE
test specimens as specified in B.S. 598. 1
30. Steel Marshall testing head as specified in B.S. 598. 1
31. Compression testing machine with proving ring, capable

A
of applying loads of up to at least 22kN at a constant rate
of stain of 50mm :t 3mm per minute and recording the
EJ
maximum load achieved as specified in B.S. 598. 1
32. Dial gauge and mounting assembly for measuring

M
Marshall test flows of up to 10mm with accuracy

of:t 0.1 mm as specified in B.S. 598. 1
EN
Testing which is specifically required in the Contract and any test defined in quoted British
Standard Specifications which are required to ensure compliance with the Contract but
cannot be done in the Site Testing laboratory shall be carried out at approved laboratories
M
off the Site. These tests shall be carried out as directed by the S.O.. The cost incurred
by the Contractor shall be deemed to have been included in the tendered rates. u
KU
O
D
SlO-5
(JKRlSPJ/2015-S1)
APPENDIX 1E
EQUIPMENT AND FACILITIES
The Contractor shall provide the following equipment and facilities for the use
of the Superintending Officer (S.O) and/or his staff. All equipment provided
shall be new, and shall be delivered, tested and installed within a month of
the issuance 0f the Letter of Acceptance. The place of delivery and
ER
installation shall be as directed by the S.O. The facilities provided shall be
maintained by the Contractor or his appointed agent throughout the contract
period until the issuance of the Certificate of Practical Completion.
Maintenance shall include all necessary monthly servicing according to
D
manufacturer's specification and supply of accessories and consumables.
N
Upon the issuance of the Certificate of Practical Completion, the Contractor
TE
shall remove all equipment and facilities from its location.
If the Contractor fails to provide or maintain any equipments as specified

below, the Government shall have the right to procure the equipment(s) from
A
other sources or maintain it and all expenses arising shall be borne by the
Contractor and an appropriate adjustment shall be made to the Contract Sum.
EJ
1. COMPUTER SYSTEM AND OTHER REQUIREMENT

M
1.1 Each set of microcemputer system shall comprise of and be

supplied complete with the following minimum requirements as the
EN
table below :-
r.l>r 4 <
-""'i{---- -\ ~--,-
,' ..
L
',-'"
- .
."':"f,j+.
~ -.: . "' ,t'-'<T ~i~.. (
·
~X1;'1.Ii~~~m;')·".~.
~~p ~ tot ~Ft'":~
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t\ .. , 1 ~.t
~.1 ':'"r"}~, "" •. t ,..-I;r.,,;
~·,\>.l'k:·;.
t,.
\'l~~,
',"
,' ..• ~. \ '>;.;
"'<Jr,.", ,.t ',.
;.·Jd.fl;,<:.~_~t;~~ '~
i!!i~ . . ,"t••.
() ; .
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. .mI.U. . .1 .~ ..,
Brand / Model To be proposed by the Contractor
O
Function Functional as Workstation & local Data Storage

D
HARDWARE ~'I.f:lfglft1M '~" • ,.

OPERATING SYSTEM Windows 10 Pro/Home, 64-bit.
CHASIS AII-in-One Desktop
PROCESSOR (11th Generation) Intel'" Core'· i7-1165G7 Processor
ASlE- I
(JKRlSPJ/2015-S1)
A PPENDIX 1E
MEMORY 16GB (16GBxl) DDR4, 2666MH
VIDEDCARD NVIDIA"' GeForce"' MX330 with 2GB GDDR5
HARD DRIVE MAIN (Boot) 512 GB M.2 SOLID STATE DRIVE (Boot)
HARD DRIVE SECONDARY Optional : 1 TB Hard Drive (Secondary Storage)
ER
Screen Size: 27-inch FHD
Display TYpe: ToucnlJlspiay with WiCie Viewmg Angie
MONITOR Resolution : 1920 x 1080
Screen Mode: Full HD
D
Touchscreen: YES
N
Wi-Fi: Intel"' Wi-Fi 6 2x2 (Gig+)
WIRELESS
- Bluetooth: 5.1 -
TE
HDMlln-Out: Yes
USB 3.1 Gen 2 Type-C
INTERFACE/PORTS USB 3.1 Type A
A
Network (RJ-45): Yes
IVilCropnune/1 LJdC~ : .es
EJ
KEYBOARD & MOUSE Wireless Keyboard & Mouse

M
COMMUNICATION DEVICE Bluetooth Headphone/Mic

EN
SOn1MARI' INSTIIU. It ACTIVATION
I
OPERA nNG SYSTEM I Windows 10 Home, 64-bit.
Office Home & Business 2019
M
OFFICE (Word, Excel, PowerPuinl & Outlook) ,J -

,r-UIIY Ar:<IIIO(eol
KU
PDf HANlJLER Latest Version of Acrobat Pro DC iFuii Activated;
ACCESSORIES (Others)
O
HEADSET Bluetooth Headphone & Mic

D
PORTABLE STORAGE 32GB USB 3.1 Pen Drive
Table 1: Computer Speclficalions
ASIE-2
(JKRlSPJ/2015-S1)
APPENDIX 1E
KOMPUTER BERSPESIFIKASI TINGGI BERSERTA PERISIAN BIM
~M KOMPImi 8IRiPll5lFIkASi TINIS.I UIBlIBTA PiRl8lAN 81M

Wericstation ~5ktoe LGen.eral
".. • ,-'C-·.c
Brand / Model To be proposed by the Contractor
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Function Functional as Workstation and local Data Storage
HrHdwgre le.ecification
~.
,~, :t' ~
Chassis Micro Tower
D
Processor Intel Xeon Processor E3 -1226 V3 3.30GHz or equivalent
N
Clock Speed Minimum 3.20GHz
() Chipset Intel C216
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Cache 8MBl2
Memory 32 GB (4x8GB) 1600MHz DDR3
Slot 4 DIMM slots
A
256 GB Solid State Drille (Boot)
Hard Drives
EJ
1 TB Hard Drive (Secondary Storage)
Partition Configuration Windows OS (Active), Data, Recovery Image & Boot Manager
Optical Drive 16x DVD +/-RW
M
Optical Drives 16x DVD +/-RW Drive

Network Integrated Intel 82579 Gigabit LAN (Ethernet)
EN
Integrated Intel HD Graphics 2000

Video Card
4GB Nvidia
Monitor 24" Wide Screen Monitor
M
Front: 2-USB 2.0, 2-USB 3.0, 1 Microphone, 1 Headphone

() Internal: 1-USB 2.0, 2-SATA 6.0 Gb/s, 2-SATA 3.0 Gb/s
KU
I/O Ports
Rear: 4-USB 2.0, 2-USB 3.0, 2-PS2, 2-displayport, 1-VGA,1R145, 1-
serial, 1-Audio line-in microchip, 1-audio line-out.
Keyboard Wireless Keyboard & Mouse
O
Sof1lt!!.are installed
D
Microsoft Windows latest Version (Pro 64-bit) (Fully Activated

Operating System
Latest Version)
Office Suite Microsoft Office 36S Business (Fully Activated Latest Version)
Microsoft Project Professional (Fully Activated Latest Version)
Anti Virus Kapersky or Equivalent (Fully Activated Latest Version)
Others Manage Engine Desktop
ASIE-3
(JKRlSPJ/2015-S1 )
APPENDIX 1E
c-
81M Soflware Installed (OriQina/) , 1: ~
Revit {Architecture, St ructure, MEPJ - {Fully Activated La test

BIM Software (min Versian)
2021J AutoCAD Civil 3D - (Fully Activated Latest Versian)
Navisworks Manage - (Fully Activated Latest Version)
Accessories (Others) ;;
ER
Cables Cables
Helpdesk St ickers HelPdesk~ficke rs
Utility CD Utility CD
D
Table 2; BIM Computer Specifications
N
TE
A
EJ
M
EN
M
KU
O
D
AS IE-4
(JKRlSPJ/2015-S1 )
APPENDIX1E
"l ~,~ " C' ',T
'~~lit:"}i~·. "'~ONC_ _
,
,'! I ~,' ~. ;;,
LAPTOP (lSNHRAL " jl

.c., , ~ ., ~,
Bfand / Madel To be proposed by the Contractor.
ER
Function Functiona l as Mobile Workstation & Loca l Data Storage
-
HARDWARE SPBCIFICAl'lON
l"-- -~.~ ,~
D
CHASIS A / C / D Aluminum alloy, B Mylar.
N
PROCESSOR AMD Ryzen 7 3700U
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MEMORY 16GB DDR4
VIDEO CARD Radeon~ RX Vega 10 Graphics
HARD DRIVE MAIN (Boot) SSD 512GB

A
EJ
Screen Size: 15.6 inches
Screen Type: IPS
Resolution: 1920 x 10S0
M
Screen-To-Body Ratio: S7%

MONITOR
Contrast Ratio: SOO:l
Brightness: 250 nits
EN
Viewing Angle: 17S· degrees

Aspect Ratio: 16:9
Wi-Fi: IEEE S02.11a/b/g/n/ac, 2.4 GHz and 5 GHz, 2 x 2

M
MIMO
WIRELESS
Bluetooth 5.0, compatible with Bluetooth 4.2,
KU
Bluetooth 2.1 + EDR
USB-A 3.0x 1
USB-A 2.0x 2
O
PORTS USB-C x 1
HDMlxl
D
3.5 mm headset and microphone 2-in-l jack x 1

Chiclet keyboard, Full-size keyboard
KEYBOARD & MOUSE
Support touch pad
Bluetooth Headphone/ Mic
COMMUNICATION DEVICE
ASI E-5
(JKRlSPJ/2015-S1)
A PPENDIX 1E
SOFTWARE INSTALL & f!.CTlVATION

; " -
,., ..l.. •.. , j . ..i•.
OPERATING SYSTEM Windows 10 Prof Home, 64- bit.
Office Home & Business 2019

OFFICE (Word, Excel, PowerPoint & Outlook)
(Fully Activated)
Latest Version of Atrobat Pro DC (Full Version Fully
ER
PDF HANDLER
.. .. - Activateg)
'ir'~"
ACCES$ORIES (Others)
c •. ' . "'. • • . .• . 'd . .. : ,
D
PORTABLE STORAGE 32.GB USB 3.0 Pen Drive
N
Table 3: Laptop SpeCifications
TE
Printer
• Speed : (min) 22 pages per minute (A4)

A
• Memory : 265 MB
• Resolution : 1200 x 1200 dpi
EJ
• Print Technology: Laser

• Duty Cycle : 10,000 pages per month
• Media: Input - Single sheet multipurpose input slot, 2 x 250
M
sheet input tray

• Size : A4 and A3
EN
• Duolex orintina - automatic (standard)

° Connectivity: Parallel, USB and 10/100 base Tx Ethernet
Cgnsumable Items
M
_ __ __ __ _ _ _ _ _ __ "-0~Pem!J:i\tea:J:ItJmbd!lve_:_1.Q..N.QS (USS : 3..O...high-s~B)I---''''''''

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• A4 Paper : 120 Reams

° A3 Paper : 40 Reams
° Toner :...1Q...Nos Each Colour
° External Hard Disc:..i..Nos (USB 3.0 high speed - 2TB)
O
D
1.2 All software to be supplied under this contract shall be original and
legal. Copies of the software shall be registered in the name of the
contractor. The contractor shall submit all the documentary
evidence of the originality and legality of the software.
ASl E-6
(JKRlSPJ/2015~1)
APPENDlX1E
1.3 Upon issuance of the Certificate of the Practical Completion, all

equipments and the relevant inventory shall be handed over to the
contractor.
2. COPIER MACHINE (3 in 1 - COPY/SCAN/FAX)
ER
The copier machine shall be of the following minimum requirements as
listed below:-
• Automatic document feeder
D
• Minimum 10 numbers of sorter bins
• Engine speed up to 25/13 pages per minute A4/A3 in colour and
N
n b/w ,with added features oUeducing and enlar!!ling copy from 25
TE
- 400 % ,in 1 % steps, autani;;ltic' copyihglTom one page.tI() 2, 2
pages to 2 and 2 pages to one and scan speed 100 images per
mindtein b/w and OOIour (A4, 300 dpI, dupl~x'With (')1"-772)
A
Upon the issuance of the Certificate of PraGtjcal Completion, the
copier machine shall be reverted to the Contractor.
EJ
3. PReJECTOR
M
One (1) number of projector with the fallowing requirement

EN
• Up to WXGA 1280 x 800 pixel

• Up to 3000 lumens
• HOM I Videa/Audio Input
M
• 15-pinVGA
(J
KU
4. DIGITAL CAMERA
One (1) number of digital camera with the following requirement

O
• Up to 16.1 megapi){el
D
Up to 16 GB Memory card
• Up to 5){ optical zoom
• Built-in WIFI
Full HD video
ASlE-7
(JKRJSPJ/2015-S1)
APPENDIX1F
FITTINGS AND FURNITURE FOR 5.0.'5 OFFICES
The Schedule lists aut the minimum fittings and furniture to be supplied and installed for
each room. The fittings and furniture shall be suitable for its intended use in each room
and shall be approved by the S.O . before ordering and installation. The items supplied
shall become the property of the Contractor at the end of the Contract or such extended
time required by the S.O. until formally vacated .
List of Consumable Stores
ER
Provide each of the ofllces and the Testing laboratory with an a 'equate suppiy for ine
duration of the works of all necessary consumable stores, ~ ~quired by the S.O.
including the items scheduled here. All items shall be new. .:
o
D
•'\
Office stationery •
N
Soap, toilet rolls and hand towels
wa-stiingoupliquiO, diSh aotn ~ .- 'l....' o
TE
\ •• ~ .t
Torch lights and batteries .. \.
Replacementfor first aid boxes '-. ....".
Toilet brushes, brooms, mop .' '}."'"
Polythene bags, 760mm x 510m!lt<;<)
..
A
.{'\,
. ,r··, ..
~
~ .(~...:.~,
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List of Protection Clothing

\"
30 no. Safety hel~ •
M
15 pairs safety~f1~(PVC)
15 pairs safe ' ,
15no.sets PV similar waterproof outfits
EN
:t ...,
san~Orfci""'SitU dry density tests

Sol , fer'determination of binder
Contil t - 8 drums (50 gal per drum)
M
KU
O
D
S1F-1
(JKRlSPJf2015-S1 )
APPENDIX1F
Schedule of Fittings and Furnishing for S.O.'s Offices
The schedule Lists out the minimum fittings and furnishings to be supplied and installed
for each room . The Fittings and Furnishings shall be new be and suitable for its intended
use in each room and shall be approved by the S.O. before ordering and installation. The
items supplied shall become the property of the Contractor at the end of the Contract or
such extended time required by the S.O. until formally vacated .
ER
1 2 3 4 5 6 7 8
Item Description Chief Employer's Resident Assistant General Conference Drawing Laboratory
D
Resident Represen- Engineer Resident Office Room Office & Survey
Engineer tative Engineer Clerkl Supervisor Store
(Engineer) Recep.
N
'.
() (1.82 x 1.22 x 1 1
TE
0.76)m high table
with
drawers
Lockable
together
,,'
with suitable
reclining chairs
A
(1 .22 x 0.91 x
,. 1
EJ
0 .76)m high table
with Lockable ~,
drawers together
with suitable chairs
M
(1.22 x 0.91 x 1
0.76)m high table
for typist with
EN
adjustable height V
type chair
Stand size drawing 1

M
tables with
( ) drawings boards
tee square together
KU
with sitting stool
Steel cabinets with 1 1 1

4 drawers file
O
Steel cabinets with 1 1 1

D
2 drawers file
SlF-2
(JKRlSPJ/2015-S1)
APPENDIX 1F
1 2 3 4 5 6 7 8
Item Description Chief Employer's Resident Assistant General Conference Drawing Laboratory
Resident Represen- Engineer Resident Office Room Office & Survey
(Engineer) Recep.
ER
Conference Table 1
for 15 persons with
suitable arm rest
chairs
D
Plan file - 6 2
drawers horizontal
N
125w x 8900 x
430c/w 3 shelves
10
TE
Full height storage 1 1
cupboard 180QH x
900 x 150 slw 3
shelves
A
Soft board wall 1 1
paneling 2100 x
EJ
1200
Soft board wall 1

M
paneling 1200 x
900
EN
White board 1 1 1 1
(Procelain Magnetic
Surface stand type
2100 x 1200
(double surface)
M
White board
(Procelain Magnetic
1 1 1 4 U
KU
Surface Wall 1200

x 900
T-square 1
O
Set Square 1 3 1
D
Waste paper 1 2 2 2
basket
S1F-3
(JKRlSPJ/2015-S1 )
APPENDIX1F
1 2 3 4 5 6 7 8
Item Description Chief Employe~ s Resident Assistant General Conference Drawing Laboratory
Resident Represen~ Engineer Resident Office Room Office & Survey
(Engineer) Recap.
ER
Electronic 1
Typewriter
Heavy duty hole 1 1 1 1 1

puncher and heavy
D
duty stapler
N
~
n Fire extinguisher 1 1
TE
First Aid Kit 1 1 1
Additional 13 amp 2 4 2 2 1 2
A
socket outlets
EJ
Electric Kettle 1 1
Handheld 1 1 1 1
M
Calculators HP41CV HP41CV Casie Gaslo

with card with card
reader reader
EN
Shelving 300mm 2
wide x 25mm thick
M
Camera with zoom

( ) lens 20 degree to
105 degree
KU
Furniture setting 1
O
D
S1F-4
(JKRlSPJ/2015-S1 )
APPENDIX 1G
PROGRAMME USING CRITICAL PATH METHOD (CPM)
Programme
Within 14 days after the receipt of the letter of Acceptance, the Contractor shall submit to
the 5 .0 . for approval a detailed work programme using the Critical Path Method ( CPM )
ER
showing his proposals and the periods for carrying out the various sections of the works
in order to complete the whole works within the completion time specified. The proposal
must be together with schedule of construction plant and labour strength plan for the
various periods and section of the works.
D
This programme must be presented in Gantt chart form and network diagrams indicating
N
the critical activities and non-critical activities complete with all interface dates (Early
Start, Late Start, Early Finish, Late Finish and Float I Slack times). This programme is 0
TE
inclusive of copies of all data on computer medium and printed hard copies together with
the software and manuals.
The Contractor shall also fumish in writing to the 5.0. or S.O.'s Representative
particulars of the contractors method statements (method and sequence) for carT)'ing out
A
such works and of the construction plants and temporary works if any which the
contractor intends to supply, use or construct as the case may be. The submission to
EJ
and approval by the 5.0. or S.O.'s Representative of such programme or the fumishing of
such particulars shall not relieve the contractor of any of his duties or responsibilities
under the contract.
M
For the purpose of monitoring the work progress effectively, the contractor shall carT)' out
regular check on progress achieved against the planned progress. The contractor shall
EN
be required to update all information and maintained the planned programme using CPM
periodically by trained and qualified personnel or as when instructed by the 5 .0.
For any Projects in which JKR furnish the Work programme, the Contractor shall
M
provide all the necessary resources required as specified in the programme, or the
Contractor may propose an improved programme which shall not exceed the contract
KU
period stipulated, in which case, the CPM must also be used, denoting all the critical
milestones for the successful implementation and completion of the project.
Notwithstanding the above, the Contractor shall submit method statements for carrying
out such works and temporary works, if any, which the Contractor intends to supply, use
O
or construct as the case may be.

D
If anytime it should appear to the 5.0. that the actual progress of the Works does not
conform to the approved programme referred to herein before, the Contractor shall
submit for approval, a revised programme showing the modifications to the previously
approved programme and additional resources necessary to ensure the completion of the
whole works within the time set for completion.
S1G-1
(JKRlSPJ/2015-S1 )
APPENDIX 1H
AS-BUILT DRAWINGS AND ROAD ASSETS INVENTORY
The Contractor shall prepare and submit as-built drawings, final Right of Way surveyed
drawing in tracing , print, CAD format in computer CD as follows :-
ER
1. All as-built construction drawing and final Right of Way 2 Sets
Surveyed drawings in tracing (A1)
D
Surveyed drawings in prints (A3)
N
() Surveyed drawings in CAD format in computer CD Rom
TE
•
As-built construction drawings are to be approved by the S.Q.
A
Final Right-of-Way surveyed drawings are to be prepared and certified by an approved
licensed Land Surveyor. ~
EJ
"
As-built construction drawings shall be~ supplied by the Contractor to the S.O.
M
progressively as sections of the works are completed within one month after the
completion of the respective section.
EN
The Contractor shall prepare and submit road asset inventory consist of the following:-
1. Inventory for culvert and bridges 2 Sets

M
() 2. InventorYfor. slope protection 2 Sets

KU
3. Inventory for road furniture 2 sets
Inventory for road assets shall follow the latest format as per JKR requirement, with
O
sufficient details as required and instructed by the S.O.

D
S1H-1
(JKRlSPJ/2015-S1)
APPENDIX 1J
ENVIRONMENTAL QUALITY STANDARD (TABLE A2)
TABLE A2 : ENVIRONMENTAL QUALITY STANDARDS TO BE COMPLIED WITH BY THE

CONTRACTOR
Environment Quality National Water
JKR EMS Set (Sewage) Regulations. Quality Standards
Aspects Parameter 2009 (NWQS)
Target
ER
Standard A Standard B Class IIA Class liB
Minimum earthwork
Phase construction
Soil Soil loss S 6 bermslbenches
for slopes (S 6m per
D
benm) ·Reuse topsoil
Turbiditv s 200 NTU - - S 50 NTU
N
Suspended Solid s 100 mgn S 50 mgn s 100 mgn s 50 mg/l
Biochemical Oxygen
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Demand 5@ 20"C s 50 mgn S20 mgn S 50 mgll S 3 mgn
(BOD).
Chemical Oxygen
S 100 mgn S 120 mgll S 200 mgn S25 mgn
Demand (COD)
pH 5.5 9 6-9 5.5-9 6-9
Water 12
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S 100 s400
S 400 counts I
E-Coli
100ml - - counts I
100ml
counts I
100ml
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Dissolved Oxygen
(DO)
;,4mgn - - 5-7 mg/l
Oil and Grease S 10 mgn S 5mg/l s 10 mgn S40 ~gn. N
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Ammoniacal Nitrogen
(river)
- s 10 mgn S 20 mgn S 0.3 mg/l
Total Suspended Particulate (TSP) (24hr) S 250 ~g/m'/day

Air 3
S 150 ~g/m3/day
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Particulate Matter (PM10)(24hr)

Receiving Land Use (residential)
Day time (7.00 am - 7.00 pm)
L.. S 60dBA; L,. S 75dBA; L~ S 90dBA;
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Evening (7.00 pm - 10.00 pm)
Noise Equivalent Noise Level (t...). L, •• L.. L.. S 55dBA; LIO S 70dBA; L~ S 85dBA;
Night time (10.00 pm - 7.00 am) IJ
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Noise Sensitive Areas : LA S40dBA

Suburban Areas : L... S 45dBA
Urban Areas : L...., S 50dBA
Not more than 3 mmls at receiver location or across
Vibration 5 Vertical Vibration Peak Velocity (mm/s)
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real property boundary
Reference :
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1) 2nd Schedule (Regulation 7), Environmental Quality (Sewage) Regulations 2009, Environmental Quality Act 1974.
I. Standard A : For location with downstream water intake
II. Standard B : For location with no downstream water intake
2) National Water Quality Standard for Malaysia
I. Class IIA : Water Supply 11- conventional treatment required
a) Fishery II - sensitive aquatic species
II. Class liB : Recreational use with body contact
3) Recommended Malaysian Guidelines on Ambient Air Quality
4) Schedule 1 & Schedule 5, Planning Guidelines for Environmental Noise limits & Control , (OOE,2004)
5) Planning Guidelines for Vibration limits and Control of the Environment (DOE, 2004)
Note: N - No visible floatable materials or debris or no objectionable odour, or no objectionable taste
S1J-1
(JKRlSPJ/2015-S1)
APPENDIX 1K
CONSULTANT'S SUBMISSIONS AND DECLARATION FORM (SCHEDULE A)
Schedule A
Temporary Crossing
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Declaration by the Professional Engineer
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I hereby certify that I have designed and supervised the construction of the temporary
crossing for bridge across
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in accordance with the required load and in compliance with all existing statutory
n requirements and JKR Specifications.
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Engineer's Signature Contractor's Signature
(with official stamp or seal) (with official stamp or seal)
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(Full name) (Full name)

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(Address) (Address) : .... .... .... ....... .... ...... .. ... .

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(Date) (Date)
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S1K-1
(JKRlSPJ/2015-S1 )
APPENDIX1L
(LAMPIRAN 1)
FORMAT PELAN KESELAMATAN DAN KESIHATAN PEKERJA (S·PLAN)
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REFER TO LATEST JKR.PK(O).04B-1
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(please refer to S.O/S.O.R. for latest version of document)

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S1L-1
(J KRISPJ/201S-S1)
APPENDIX 1M
(LAMPI RAN 4)
FORMAT PELAN KUALITI PROJEK (Q-PLAN)
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REFER TO LATEST JKR.PK(O).01-4
(please refer to S .O/S.O.R. for latest version of document)

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S1M-1
(JKRlSPJ/201S·S1)
APPENDIX 1N
(LAMPIRAN 5)
FORMAT LAPORAN KESELAMATAN DAN KESIHATAN PEKERJA
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REFER TO LATEST JKR.PK(O).04B·S
(please refer to S.O/S.O.R. for latest version of document)

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S1N· 1
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Section 2 - Earthworks (JKR/SPJ/2020-S2)
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J KR/SP J/2020-S2
KERAJAAN MALAYSIA
JABATANKERJARAYA MALAYSIA
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FOR ROAD WORKS
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Section 2: Earth\Norks TE
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50582 KUALA LUMPUR.
(JKRlSPJ/2020-52)
FOREWORD
As practices in road construction change over time, it is imperative for Jabatan Ke~a Raya
(JKR) to continuously update and improve their standard specifications. These new
specifications not only aimed at keeping abreast with current technologies but also helping in
improving the quality of constructed product. In unison, these new specifications have
significant positive impact on the construction industry especially with the incorporation of
new products and technologies.
Standard Specification for Road Works is an essential component in the road infrastructure
construction industry. This specification provides an improved guidance in the material
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selection and the production of good quality workmanship and products based on current
best practices. The purpose of this standard specification is to establish uniformity in road
works to be used by road designers, road authorities, manufacturers and suppliers of road
related products.
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This document "Standard Specification for Road Works - Section 2: Earthworks
(JKRlSPJ/2020-S2)" is a part of series of improved specifications in the Standard
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many discussions by the technical committee members. Additionally, it has been presented
at a technical workshop held on February 2019. Feedbacks and comments received had
been carefully considered and incorporated in the Specification where appropriate as well as
considering the ambiguities and difficulties that arise in the previous version .
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In the new version of this Specification, it has also considered the use of two newly
introduced Specifications, namely "Standard Specification for Road Works - Section 18: Soil
Stabilisation (JKRlSPJ/2018-S18)" and "Standard Specification for Road Works - Section 20:
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Ground Improvement (JKRlSPJ/2020-S20)", where both should be read together with this
Specification where applicable.
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This Specification also had been presented in the Mesyuarat Jawatankuasa Spesifikasi
Piawai JKR bagi Kerja-kerja Jalan Bil. 212012 on 12th July 2020, Mesyuarat Teknikal
Cawangan Jalan on 14", August 2020 and finally approved in the Mesyuarat Pengarah-
Pengarah Bil. 0412020 on 17", August 2020.
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This document will be reviewed and updated from time to time to cater for any changes on
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policies and current requirements. In this respect, any comments and feedback regarding to
this specification should be forwarded to Sahagian Pembangunan, Inovasi & Standard,
Cawangan Jalan.
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Published by: -
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Cawangan Jalan,
Ibu Pejabat Jabatan Ke~a Raya Malaysia
50400 Kuala Lumpur.
Email: ussj.jkr@1govuc.gov.my
August 2020
S2-i
(JKRlSPJ/2020-S2)
ACKNOWLEDGEMENT
This "Standard Specification for Road Works - Section 2: Earthworks" has been
prepared by a technical committee comprising of the following members:
Committee Members:
Ir. Ismail Bin Mohamad (Chairman) Caw. Kejuruteraan Geoteknik, JKR

Ir. Edayu Binti Saleh @ Aman Caw. Kejuruteraan Geoteknik, JKR
Ir. Som Pong all Pichan Caw. Kejuruteraan Geoteknik, JKR
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Ir. Eng Boon Cheng Caw. Kejuruteraan Geoteknik, JKR
En. Zulkifli Bin Ismail Caw. Kejuruteraan Geoteknik, JKR
Ir. Eow Thien Ewe Caw. Jalan, JKR
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Ir. Eka Kusmawati Binti Suparmanto Caw. Kejuruteraan Geoteknik, JKR
En. Hisham Bin Ahmad Caw. Kejuruteraan Geoteknik, JKR
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Prof. Emeritus Dato' Dr. Ibrahim Bin Komoo Universiti Kebangsaan Malaysia (UKM)
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Prof. Dr. Hj. Edy Tonnizam Bin Mohamad Universiti Teknologi Malaysia (UTM)
Prof. Madya Dr. Rosli Bin Saad Universiti Sains Malaysia (USM)
Dato' Ir. Prof. Dr. Dr. Gue See Sew G & P Professionals Sdn. Bhd.
Ir. Neoh Cheng Aik E-Geo Consultant Sdn. Bhd.
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Ir. Amir Hamzah Bin Mustapha lR Two Consult Sdn. Bhd.
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Tn. Hj. Abdul Rahman bin Abdul Aziz JKR (Retiree)
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Special thanks and appreCiation to proof reader Mrs. Zamzarina Binti Mohd. Sarin from
Cawangan Jalan, JKR. Appreciation also to Secretariat, Research and Development
Department of Cawangan Kejuruteraan Geoteknik throughout the preparation and
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compilation of the document.
Finally, the publisher would like to express its gratitude to the above committee members,
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and all those who were involved, directly or indirectly, for their tireless effort and contribution
() towards the successful completion of this document.
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Appreciation also goes to Ir. Abdul Hadi Bin Abdul Aziz (Director of Caw. Kej . Geoteknik
(Oct. 2017 - Sept. 2019», Ir. Razali Bin Che Embi (Director of Caw. Kej. Geoteknik (Sept.
2019 - Aug. 2020», Dato' Ir. Haji Che Noor Azeman Bin Yusoff (Director of Road & Bridge
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Engineering Specialist, Caw. Jalan (Jan. 2017 - July 2020) the for their full support and
cooperation.
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This Specification is specially dedicated to:
Ir. Ismail Bin Mohamad (Chairman)
" He passed away in the preparation of this Specification. May the effort to publish this speCificatiOdbe
accepted by Allah as his charity and may Allah place him among the believers and pious deeds. "
S2- ii
(JKRlSPJ/2020·S2)
Previous Committee Members for Standard Specification for Road Works . Section 2:
Earthworks (JKRlSPJ/S2·2013):
Ir. Dr. Mohamad Nor bin Omar (Chairman) Caw. Kej. Jalan & Geoteknik, JKR
Ir. Ramie bin Othman Caw. Kej. Jalan & Geoteknik, JKR
Ir. Abdul Hadi bin Abdul Aziz Caw. Kej . Jalan & Geoteknik, JKR
Ir. Edayu bt Salleh @ Aman Caw. Kej . Jalan & Geoteknik, JKR
Ir. Norhazamawati bt Md Desa Caw. Kej. Jalan & Geoteknik, JKR
Ir. Som Pong all Pichan Caw. Kej. Jalan & Geoteknik, JKR
Ir. Zaiton bt Zainal Badri Caw. Kej . Jalan & Geoteknik, JKR
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A special thanks to the Committee that prepared the "Research Report Guidelines and
Improvement of JKR Specification for Earth Works" who chaired by Ir. N. Selvanayagam ,
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fonmer Deputy Director General Public Works Department.
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82· iii
(JKRlSPJ/2020-52)
SECTION 2 - EARTHWORKS
2.1 GENERAL REQUIREMENT ................................................................................................. S2-1
2.2 METHOD OF CONSTRUCTION •..•.......•.•..••.......•••.......•..•.......•••..•...••••••••..........•••..•.•••......•• S2-2
2.3 SITE CLEARING, GRUBBING AND STRIPPING TOPSOIL. .....•.......................................• S2-3

2 .3.1 DESCRIPTION .................... ............. ......... ..... .. ............. ........... .......... ......... ... .... .... ........ ......• 52-3
2.3.1.1 Site Clearing ..................................................................... .................... .................... S2-3
2.3.1.2 Grubbing ............................. .. ... ... ....................... ....................................................... S2-4
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2.3.1.3 Stripping topsoil .. ...... ...... .. ............................... ......................................................... S2-4
2.3. 1.4 Topsoil ...... ........................................................................................ ........................ S2-4
2.3.1.5 Timber ...................................................................................................................... S2-4
2.3.1.6 Structures .............................................................................................................. ... S2-5
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2.3.1.7 Disposal and Dumping ............................................................................................. S2-5
2.4 EARTHWORKS .................................................................................................................... S2-6
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() 2.4.1 DEFINITIONS ... .. .... .. .. ... ............ ...... ... ...... ....... ... ............ ........ ..... ........ ...... ......... ..... ....... ...... 52-6
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2.4.2 CONFIRMATION OF HARD MASS OR ROCK MASS EXCAVATION .... ... ............. ... .. ........ ... ........... 52-8
2.4.3 ROADWAY EXCAVATION ..... .... ...... ... ....................... .......... ........................... .....•.. ................. 52-9
2.4.3.1 General ..................................................................................................................... S2-9
2.4.3.2 Dimensional Tolerances ........................................................................................... S2-9
2.4.3.3 Separation and Stockpiling of Suitable Material ...................................................... S2-9 '
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2.4.3.4 Removal of Excavated Material from Site ................................................................ S2-9
2.4.3.5 Removal of Unsuitable Material and/or Soft Soil Layer ......................................... S2-10
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2.4.3.6 Replacement of Excavated Material Under standing Water............ ... ................... S2-10
2.4.3.7 Sides of Excavation .. ................................... ................................................... ... ..... S2-11
2.4.3.8 Widening Cuts ............................................... ......................................................... S2-11
2.4.3.9 Excavation of Rock Mass ....................................................................................... S2-11
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2.4.3.10 storage and Handling of Explosives ...................................................................... S2-12

2.4.3.11 Blasting ........................ ........................................................................................... S2-12
2.4.3.12 Safety Measures .................................................................................................... S2-12
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2.4.3.13 Insecure Material ....... .............. ...... ......................................................................... S2-13

2.4.4 FILLING WORKS ........... ............... ....... .... .. ....... ........... .. ... ... .... ................... ..... .. .•......... .... .. 52-13
2.4.4. 1 Material .. ......... ........................................................................................................ S2-13
2.4.4.2 Borrow Pits ............................................................................................................. S2-14
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2.4.4.3 Placement of Fill Materials ..................................................................................... S2-14

() 2.4.4.4 Compaction ............................................................................................................ S2-14
2.4.4.5 Control Tests .................. .......... .... .......................................................................... S2-16
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2 .4.5 ROCK FILL EMBANKMENT ..... ...... ......... .... ..... ..... ....... ... ............ ......... ... ............................... 52- 17
2.4.6 FILLING ON THE 50FT GROUND ................................................... ........... .... ... ... ....... .. .... .... 52-18
2.4.6.1 General .... ................... ............................................................................................ S2-18
2.4.6.2 Foundation treatment ............................................................................................. S2-18
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2.4.6.3 Surcharge and Staged Construction ................ ...................................................... S2-18

2.4.6.4 Geotechnical Instrumentation ...................................................... ........ ..... ... .. ... ..... S2-18
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2.4.6.5 Monitoring Records ................................................................................................ S2-19

2.4.7 5UBGRADE .... ......................................... ... ....... ... .... ..... ... .......... ... ...... ........ ....... ....... ... ...... 52-19
2 .4 .8 PROTECTION AND MAINTENANCE FOR EROSION CONTROL ............ ... .............. ..•.................. 52-20
2.4.8.1 Topsoil ................. ....... ........... ................................................................................. S2-20
2.4.8.2 Turfing ..................................................... ............................................................... S2-20
2.4.8.3 Hydroseeding ......................................................................................................... S2-21
2.4.8.4 Creepers ........ ... ........... ..................... ...................................................................... S2-21
2.4.8.5 Temporary Slope Protection ... .................................. ...... ........................................ S2-22
2.4.8.6 Failure to Comply to Specification .................... ... .. ................................................. S2-22
52- iv
(JKRlSPJ/2020-S2)
TABLE
Table 2.1: Category of Excavalion Based on Corrected Poi nt Load S2-8

Test Index I.(so}
Table 2.2: Grading Limits of Materials for Replacement of Excavated S2-10

Material
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Table 2.3: Frequency of Control Test for Earth Embankment S2-17
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APPENDIX A
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Table 2.4: Equivalent production rate of hard mass based on types S2-23 n
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of excavators
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Table 2.5: Equivalent production rate of rock mass based on types S2-23
of track-type tractors with ripping equipment (bulldozer ripper)
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APPENDIXB
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Table 2.6: Example form for Point Load Test (PLT) S2-24
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APPENDIXC
Photo 2.1: Portable Hydraulic Point Load Tester with a stain-gauged S2-25
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load cell and digital readout for load monitoring.

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Photo 2.2: Portable Hydraulic Point Load Tester with a pressure-gauged S2-25
readout for load monitoring.
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Photo 2.3: Excavator (Series 400) of 41.4 tonnes and 321 BHP S2-26
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Photo 2.4: Track-type of tractor (08 Dozer) of 37 tonnes and 303 BHP S2-26
Photo 2.5: Ripper unit I ripping equipment S2-27
Photo 2.6: Track-type of tractor (Dozer) attached with single shank ripping S2-27
equipment (Bulldozer ripper)
S2- v
(JKRlSPJf2020-52)
SECTION 2 - EARTHWORKS
2.1 GENERAL REQUIREMENT
This specification covers the construction of the earthworks including the clearing and
removing of all obstacles within the limits of the earthworks; the excavation of all cuts,
including excavation below the final subgrade surface; the excavation of borrow areas,
benches and surface drainage facilities; the transport of the excavated material to fill or
waste; and construction of the fills and subgrade; shaping , trimming, turfing and
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maintaining of the works, in conformity with the Drawings and in accordance to the
Specifications.
The excavation and earthworks shall be executed in such a manner and order as
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approved by the S.O. The Contractor shall be responsible for compliance with any by-
laws and regulations relating to earthworks.
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n Excavation in rock mass andlor hard mass shall respectively be measured and paid for
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as extra over to excavation of earthworks and in accordance with the Provisional Bill of
Quantities (B.Q.). The Contractor shall give reasonable notice to the S.O. to examine,
classify the excavation and to take measurement prior to breaking up.
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For contract based on Specifications and Drawings, unless otherwise provided in the
Contract for the purpose of pricing the excavation and earthworks, the whole excavation
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shall be assumed to be without rock mass andlor hard mass as defined hereafter.
For contract based on Quantities, the pricing shall be in accordance with the B.Q and
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deem to include all testing required by this specification.
Computation of volume for rock mass excavation for the purpose of payment shall be
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based on nett volume excavated.
The Contractor shall comply with all statutory requirements and regulations such as
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payment of royalties and environmental protection for removal of unsuitable material and
C) borrow materials.
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The Contractor shall provide where necessary temporary water courses, ditches, drains,
pumping or other means of maintaining the earthworks free from water. Such provision
shall include carrying out the work of forming the cuttings and embankments in such a
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manner that their surfaces at all times are at sufficient gradient to enable them to shed
water and prevent water ponding.
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In pumping water out from excavation and in the lowering of water table, the Contractor
shall pay due regard to the stability and settlement of all structures.
Adequate means for trapping silt shall be provided on all temporary drainage systems.
Similar arrangements shall be made for all earthworks including excavation whether for
pile trenches, foundations or cuttings.
Should the surface of completed areas be damaged by erosion or by any other causes,
the Contractor at his own cost shall make good such areas to the approval of the S.O.
82-1
(JKRlSPJ/2020-S2)
The Contractor shall exercise care in preventing wastage of suitable material needed for
embankment or fill construction .
2.2 METHOD OF CONSTRUCTION
The Contractor shall submit to the S.O. detailed method statement for earthworks. For
the purpose of this clause, the method statement shall contain :
(a) Detailed construction sequences.
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(b) Shop drawings showing details of all special requirements for the construction
activities.
(c) Design calculation of key temporary works endorsed by Professional Engineer.
(d) Materials, plants, machineries and labour requirements at each construction
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stages.
(e) Rate of production output based on resources allocations.
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(f) Other relevant information .
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If requested by S.O, the Contractor shall submit additional information pertaining to the
method of construction.
The contractor's method of construction shall comply with stringent of either the statutory
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limits imposed on lateral and vertical ground movements, construction noise, vibration
and air pollution levels, or such limits necessary for the adequate protection and proper
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functioning of neighbouring roadways, buildings and their facilities as agreed with the
S.O. The Contractor's compliance with these limits shall not relieve him of his sole
responsibility for all consequential damages to adjoining structures, roads and other
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properties caused by excavation work.
The Contractor shall conduct condition survey prior to excavation at nearby existing
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structures within 500 m away of the proposed excavation works. The Contractor shall
submit Environmental Management Plan (EMP) to the S.O for further confirmation and
execution of the paid works.
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The Contractor shall not change the methods that had been approved by the S.O.
Approval by the S.O. of the Contractor's proposed methods of construction in J
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accordance with the clause shall not in any way relieve the Contractor of any of his
duties or responsibilities under the Contract.
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82-2
(JKRlSPJ/2020-S2)
2.3 SITE CLEARING, GRUBBING AND STRIPPING TOPSOIL
2.3.1 Description
This work shall consist of clearing, grubbing and stripping topsoil in the areas
within the limits of Works designated hereunder andlor shown on the
Drawings, and of clearing only in other areas designated hereunder andlor
shown on the Drawings all as specified herein and as required by the S.D.
The work shall also include the demolition and disposal of structures in the
said areas, except where otherwise provided for in the Contract, as specified
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herein and as required by the S.D.
2.3 .1.1 Site Clearing
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The areas where the Works are to be carried out shall be cleared as
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described in Sub-Section 2.3.1, unless otherwise shown on the Drawings
() andlor directed by the S.D.
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Clearing shall be carried out to the extents deemed necessary and
approved or directed by the S.O. in areas outside the road reserve where
channel excavation or other wor!< is required.
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In areas which are to be cleared only, and in which grubbing and stripping
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topsoil are not required, method of wor!<s shall be such as will not unduly
damage the surface vegetation and topsoil, and care shall be taken not to
disturb the topsoil and the root systems of grasses and other surface
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vegetation. No topsoil shall be removed from such areas, except as

directed by the S.O., and any topsoil, grasses and other surface
vegetation otherwise removed or disturbed shall be replaced and made
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good at the Contractor's own expense, with the agreement of the S.D.
Unless otherwise shown on the Drawings andlor directed by the S.O.,

clearing, grubbing and stripping of topsoil shall be carried out in all areas
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of roadway excavation and in all areas where embankment is to be

() constructed, except that grubbing and stripping topsoil shall not be carried
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out in those areas where embankment is to be constructed on ground

identified as swamp or soft ground.
Clearing shall consist of cutting andlor taking down, removing and

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disposing of everything above ground level, including objects such as

walls, fences, drains and other obstructions, except specific trees,
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vegetation's, structures or parts of structures and other things which are

designated in the Contract to remain, or well be removed by others, or
which the S.O. directs to be left undisturbed. The material to be cleared
shall include but not necessarily limited to trees, stumps (parts above
ground), logs, brushwood, undergrowth , long grasses, crops, loose
vegetable matter and structures (except those structures whose removal
or clearance is otherwise provided for in the Contract). Clearing shall also
include levelling of obsolete dikes, terraces, ditches, etc., unless
otherwise stated and directed by the S.D.
All holes and cavities on the ground surface after clearing , grubbing and
S2-3
(JKRlSPJ/2020-S2)
stripping topsoil shall be filled with materials similar to the adjacent

ground, and such fill shall be compacted to a dry density as specified by
Sub-Section 2.4.4.4 (c), with the agreement and approval of S.O.
This work shall be considered incidental to the work of clearing, grubbing

and striping topsoil, and shall not be measured for payment.
2.3.1.2 Grubbing
Grubbing shall consist of removing and disposing of surface vegetation,

bases of stumps, roots , underground parts of structures, and other
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obstructions to a depth of at least 500 mm below ground level, with the
agreement of the S.O.
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2.3.1 .3 Stripping topsoil
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Stripping topsoil shall consist of the removing of topsoil to an average
depth of at least 100 mm below ground level, and its stockpiling for use in
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the Works, andlor its disposal, as directed by the S.O.
2.3.1.4 Topsoil
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Topsoil to be stockpiled for the Works shall be sufficiently fertile to
promote and support the growth of vegetation , and shall be taken from
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such areas where clearing, grubbing and stripping topsoil is required as
approved or directed by the S.O. Before stockpiling, topsoil shall be
separated from objectionable materials as defined in Sub-Section 2.3.1.7,
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with the agreement of the S.O. The Contractor shall arrange for stockpile
sites either within or outside the road reserve, at his own expense, and
with the agreement of the S.O. or as required by the relevant laws and
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regulations.
Otherwise, topsoil removed during grubbing and stripping operations shall

be separated from objectionable materials and spread within the road
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reserve or borrow areas, or otherwise disposed of, as approved or

directed by the S.O.
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2.3.1.5
The ownership of timber is vested in the Government.

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Saleable timber shall be trimmed and stacked in accordance with the

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requirements of the appropriate Government agency, in accessible places

within the road reserve as approved or directed by the S.O.
The Contractor shall have the right to use unsaleable timber {or saleable
timber when permission is granted in writing by the appropriate
Government agency or authority} for his own purposes in connection with
the Contract provided that he shall comply with the requirements and
approval of the S.O.
82-4
(JKRlSPJ/2020-S2)
2.3.1 .6 Structures
Major structures are those which cannot practicably be cleared by

bulldozer andlor hydraulic excavator, whose demolition requires
pneumatic tools, explosives andlor other specialised equipment. A brief
description of each major structure (if any) and depth to which extent it
shall be demolished is given in the Bill of Quantities (B.Q.).
All fences, buildings, structures, and encumbrances of any character

within the limits of the Works, except those to be removed by others or
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designated to remain, shall be demolished and removed by the
Contractor.
Materials designated in the Contract or directed by the 5.0. to be
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salvaged, shall be carefully removed and stored , and shall be the property
of the Government.
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n 2.3.1.7 Disposal and Dumping
TE
All materials resulted from site clearing shall be dumped to the
Contractor's dump site as approved by the 5 .0 . The contractor at his own
expenses shall be responsible for the removing and dumping of all
A
materials in accordance with Environmental Quality Act 1974 and Solid
Waste and Public Cleansing Management Act 2007.
EJ
Objectionable material such as combustible material including all timber

(except timber to be salvaged or used), all brushwood, stumps, roots,
M
vegetation from clearing, grubbing and stripping topsoil (including the

demolition of structures) shall be disposed as approved or directed by the
5.0.
EN
M
()
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O
D
82-5
(JKRlSPJ/2020-S2)
2.4 EARTHWORKS
2.4.1 Definitions
(a) Formation level
Formation level means the top surface of the sub-grade.
(b) Sub-grade
ER
Sub-grade means part of the embankment or existing ground in cutting
which is immediately below the sub-base or lower sub-base of the road
pavement and shoulders.
D
(c) Common excavation
N
Common excavation means excavation in any materials which exclude
hard mass or rock mass as defined in Sub-Section 2.4.1 (f) and Sub- o
TE
Section 2.4.1 (g).
(d) Unsuitable materials

A
Unsuitable materials shall include:
EJ
(i) Running silt, peat, logs, stumps, roots, grass and other
vegetable matter, perishable or toxic material, slurry or mud; or
M
(ii) Organic clay and organic silt; or
(iii) Any material

EN
which is susceptible to spontaneous combustion; and/or

M
which is clay having a liquid limit exceeding 80% and/or

plasticity index exceeding 55%; and/or
J
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which has a loss of weight greater than 2.5% on ignition;

and/or
O
which has a volumetric change greater than 3% in

California Bearing Ratio (CBR) test under 4 days-soaked
condition (for the top 300 mm of subgrade only).
D
Materials that are soft or unstable merely because they are highly
saturated or too dry for effective compaction are not classified as
unsuitable material, unless otherwise classified or stated by the S.O.
(e) Suitable materials
Suitable materials shall mean those materials other than the unsuitable
materials defined in Sub-Section 2.4.1 (d).
82-6
(JKRlSPJ/2020-S2)
General fill shall generally comprise of suitable materials made up of

either cohesive soil or cohesionless soil or mixture of both . The
classification of cohesive and cohesion less soil shall be based on Soil
Classification System set out in the MS 1056: Method of Test for Soil for
Civil Engineering Purposes.
Special fill shall comprise of material, which would otherwise be

classified as general fill but contains durable well-graded natural sand
and gravel or crushed rock, other than argillaceous rock (e.g. mudstone,
shale), or durable clean crushed demolition rubble of similar particle
ER
size and free from any contaminants.
(f) Hard mass
D
Hard mass could be termed as semi cemented sediments, weathered
rock mass and- highly fractured rock mass where the excavation work
N
depends on the machinery and production rate as specified below:
()
TE
Excavator (Series 400) with minimum weight of 41 .4 tonnes and
nett horsepower rating of 321 brake horsepower (BHP) with a
production rate not exceeding 50 m3 / hour.
Hard mass shall exclude individual masses less than 0.5 m 3 that shall
A
be considered as common excavation .
EJ
(g) Rock Mass

M
Rock mass shall mean fresh to moderately weathered rock found in

ledges or masses where the excavation work depends on the
EN
machinery, equipment and production rate as specified below:
Bulldozer ripper: Track-type tractor (08 Dozer) with mInimum

weight 37 tonnes and nett horsepower rating of 303 brake
M
horsepower (BHP) or more and attached with ripping equipment

with a production rate less than 20 m3/hour. The ripping
equipment to be attached shall have a single shank in good
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working condition with sharpened cutting point with a minimum

penetration force of 120 kN .
O
Boulders or detached pieces shall only be regarded as rock if they

individually exceed 0.5 m3. For boulders or detached pieces
D
individually measuring less than 0.5 m3, it shall be considered as

common excavation.
For determination of the volume of individual boulder, diameters of the

boulder in three (3) orthogonal directions shall be taken. The average
of the three (3) dimensions shall be used to calculate the volume of
boulder. Records of measurements and photographs shall be taken
and recorded kept supporting the calculation of the volume of boulder.
52-7
(JKRlSPJ/2020-S2)
2.4.2 Confirmation of Hard Mass or Rock Mass Excavation
Confirmation of hard mass or rock mass excavation shall be verified by direct

method and indirect method as described below:
(a) Direct Method by Trial Excavation
Trial excavation shall be carried out using the machineries and equipment as
specified in Sub-Section 2.4.1 (f) and Sub-Section 2.4.1 (g) to confirm that
the excavated material is categorized under hard mass or rock mass
excavation based on its hourly production rate. The trial excavation shall be
carried out on a flat platform (as much as possible) in order to develop the
ER
rated horsepower at maximum efficiency. All machineries shall be run in
good condition and operated by skilled personnel approved by the S.O.
D
In the event where the Contractor unable to provide the machineries as
stated in Sub-Sections 2.4.1 (f) and Sub-Sections 2.4.1 (g), the Contractor
N
may propose similar machine that can be used at site for the purpose of trial
excavation for the S.O. approval. The equivalent production rate of the
TE
machine can be calculated by referring to the table as shown in Appendix A.
The ripper unit shall be used in excavation of hard mass and rock mass only
and shall not be used in common excavation.
A
(b) Indirect Method by Point Load Test
EJ
Point load test shall be carried out on excavated material for this purpose by
using portable point load tester apparatus. Minimum ten (10) rock samples
from the excavated material resulted from the direct method by trial
M
excavation {as described in (a)) shall be tested and the results interpretation
are shown in Table 2.1. Sample to be tested shall have size not less than
30mm and not more than 85mm with the preferred dimension about 50mm
EN
according to ASTM 05731 (see Appendix B).

M
Table 2.1 : Category of excavation based on Corrected Point Load Test Index, I,(so)
J
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I~
Type of excavation Corrected Point Load Test Index, 10(50)
O
Not applicable
Common Excavation (no solid sample can be tested)
D
< 80% of the samples

Hard Mass obtain result < 2MPa
~80% of the samples
Rock Mass obtain result ~ 2MPa
The provision of point load test equipment at site for the above-mentioned
testing shall be at Contractor's own cost and time. The point load test
apparatus shall be calibrated and a valid calibration certificate shall make
available to the S.O. upon request.
S2-8
(JKRlSPJ/2020-S2j
Both criteria (i.e. direct method and indirect method) shall be fulfilled in order
for the material to be classified as hard mass or rock mass. Confirmation test
shall be carried out again when in S.O.'s opinion if the materials excavated
are different from the trial excavation before.
2.4.3 Roadwav Excavation
2.4.3 .1 General
ER
Wherever applicable, this Section shall be read together with JKR
Standard Specification for Roadworks, Section 20: Ground Improvement.
The work involves removal of unsuitable material andlor soft soil layer and
D
replaced with suitable material as shown in the Drawings.
N
2.4.3.2 Dimensional Tolerances
TE
Slopes in cutting shall be trimmed mechanically to get neat and even
surfaces and shall have gradients not steeper than shown in the
Drawings. Widths of excavations shall not exceed the dimensions shown
in the Drawings by more than 300 mm with encumbrance free to complete
A
the Work, unless otherwise approved by the S.D.
EJ
2.4.3.3 Separation and Stockpiling of Suitable Material
Where excavation reveals a combination of suitable and unsuitable

M
materials, the Contractor shall, wherever the S.D. considers it practicable,

carry out the excavation in such a manner that the suitable materials are
excavated separately for use in the Works without contamination by the
EN
unsuitable materials. The Contractor shall stockpile the material

separately for use as subgrade as specified in SUb-Section 2.4.7.
Removal of Excavated Material from Site

M
2.4.3.4
u Trial pit shall be carried out prior to removal of material to be excavated to

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confirm water table and depth of excavation.
No excavated material shall be removed from the Site except on the

direction or with the approval of the S.D. Should the Contractor be
O
permitted to remove suitable materials from the Site to suit his operational
procedure, then he shall make good any consequent deficit of fill material
D
arising there from , at his own expense.
Unless designated dump sites have been shown in the Drawings, the
Contractor shall dispose of surplus suitable material at his own dump
areas outside the Site as approved by the S.D. In doing so, the
Contractor shall comply with statutory requirements such as payment
of royalties, environmental protection, etc. Method statement as per Sub-
Section 2.3.1.7 shall be submitted to the S.D. for his approval prior to
dumping.
52-9
(JKRlSPJ/2020-S2)
2.4.3.5 Removal of Unsuitable Material andlor Soft Soil Layer
The depth of removal shall be as shown in the Drawings or as determined

by trial pits or JKRlMackintosh Probe test as approved by the S.O. The
trial pits or probe test shall be carried out at locations as indicated in the
Drawings or as instructed by the S.O.
Unsuitable material andlor soft soil layer shall be excavated to such depth
and over such area as shown on the Drawings andlor as directed by the
ER
S.O. and be transported and disposed of in an approved manner. Unless
approval of the S.O. to dump and spread the unsuitable material andlor
soft soil within the Site is obtained, the Contractor shall be responsible for
providing his own dump site for such unsuitable material andlor soft soil.
D
Voids created due to removal of unsuitable material shall be backfilled
N
with suitable material compacted to a dry density as specified by Sub-
Section 2.4.4.4 (c) or that specified for the respective part earthworks or
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as directed by the S.O.
2.4.3.6 Replacement of Excavated Material Under Standing Water

A
Where it is shown on the Drawings or directed by the S.O. that
replacement of excavated material shall be done under standing water,
EJ
voids created due to removal of excavated material shall be backfilled
with hard clean crushed rock, natural gravel or sand grading within the
respective limits specified in Table 2.2.
M
Table 2.2: Grading limits of materials for replacement of excavated material

EN
B.S. Sieve Size % Passing By Weight

M
Crushed Rock or Gravel
63.0mm 100
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37.5mm 85 -100
20.0mm 0 - 20
O
10.0mm 0- 5
Sand
D
10.0 mm 100
5.0mm 90 - 100
1.18 mm 45-80
300 ~m 10 -30
150 ~m 2 -1 0
52-10
(JKRlSPJ/2020-52)
2.4.3.7 Sides of Excavation
The Contractor shall ensure that at all times, area of the excavation are
maintained in a safe and stable condition, and shall be responsible for the
adequate provision of all shoring and strutting including sheet piling
required for this purpose. All temporary works shall comply with the
requirements of BS 5975 - Code of practice for temporary works
procedures and the permissible stress design of false work.
2.4.3.8 Widening Cuts
ER
The 5 .0 . may instruct the Contractor or the Contractor himself may
choose to obtain material for the Works by widening cuts. In the latter
case, the Contractor shall first obtain permission and approval in writing
D
from the 5 .0 .
N
Widening of cuts shall not be permitted beyond the limits of the road
() reserve.
TE
Any add~ional costs and time incurred that resulted from widening cuts
shall be borne by the Contractor.
A
2.4.3.9 Excavation of Rock Mass
EJ
Rock mass excavation shall be carried out by methods appropriate to s~e
requirements as approved by the 5 .0 .
M
Where the excavation is too hard to be performed by digging, dozing,

scraping, ripping, splitting, breaking, jack picking or other such methods,
the Contractor may apply in writing to the 5 .0 . for permission to blast.
EN
Such permission will be granted only if the 5 .0 . is satisfied that all

reasonable measures have been tried to carry out the excavation by
methods other than blasting.
M
Where explosives materials are used, the Contractor shall provide a

() complete method statement and shall comply fully with requirements of
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these Specifications, or any direction, order, requirement or instruction

given by the Polis Diraja Malaysia (PDRM) or any other competent
authority to do so under any written law. The Contractor shall comply to
the safety and hazard requirements as specify in Occupational Safety and
O
Health Act (OSHA) and any misconduct and the use of excessive
explosive shall be the responsibility of the Contractor.
D
All material from rock mass excavations shall be used in the works
whenever it is practical.
Where the rock is at satisfactory quality, the Contractor may propose to

cnush and screen it to produce aggregates required for concrete, road
base, sub-base, or other purposes with the prior approval of the 5 .0 . If
the Contractor choose to use substitute aggregate materials, it shall be on
the Contracto~s own expense and the materials shall be at acceptable
and good quality and approved by the 5.0.
52-1 1
(JKRlSPJ/2020-S2j
Otherwise, excavated rock shall be used in the construction of

embankment and fill, to the fullest practical extent, in either of the two (2)
following ways:
(a) Excavated rock shall be broken down to maximum particle size of

300 mm and used as rock fill as described in Sub-Section 2.4.5;
(b) Excavated rock shall be broken down to maximum particle size of

150 mm, blended with suitable earth fill material in a proportion not
exceeding 1 rock to 1 earth , and used as common fill.
The Contractor may fully utilize excavated rock material. The excavated
ER
rock needed for earthwork construction which the Contractor choose not
to use shall be replaced at the Contractor's own expense by borrowed
materials of satisfactory quality from alternative locations approved by the
D
S.O.
N
2.4.3.10 Storage and Handling of Explosives
o
TE
The storage and handling of explosive shall be adhered to all Authorities'
requirement. The prevention of any unauthorised issue or improper use of
any explosive brought on the Wor1<s shall be the responsibility of the
Contractor and only experienced and qualified personnel shall be
A
employed to handle explosives for the purpose of the Works.
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2.4.3.11 Blasting
Explosives shall be used in the quantities and manner recommended by

M
the manufacturers and blasting specialist. Blasting shall be restricted to

such periods as the S.O. may prescribe and to comply with all authorities'
requirements. If, in the opinion of the S.O., blasting would be dangerous
EN
to persons or properties or to any finished work, or is being carried on in a

reckless manner, he may prohibit it and order the rock to be excavated by
other means. Such authorisation shall not in any way relieve the
Contractor of his liabilities under the Conditions of Contract.
M
All necessary precautions shall be taken to avoid over break. As the

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excavation approaches its final face, blasting with pre-splitting technique

shall be carried out to reduce blast damage and create reasonably even
finished surface.
O
2.4.3.12 Safely Measures

D
When blasting is carried out close to properties or roads, safety rules

complying to all authorities' requirements must be strictly adhered to.
Where necessary or as directed by the S.O., heavy mesh blasting mats or
any other controlled materials shall be used to ensure that no damage or
any harm caused to persons or properties on or off Site. Special care
shall be taken on highly weathered rock mass and sensitive ground.
Plaster shooting will not be permitted within 400 m of any building or
structure. If traffic on any road or railway has to be interrupted for blasting
operations, the Contractor shall obtain approval of his schedule for such
interruption from the appropriate authorities and shall prove to the S.O.
82-12
(JKRlSPJ/2020-S2)
that he has obtained it, prior to the interruption.
When blasting is carried out with close proximity to sensitive structures

and environmental sensitive areas, thresholds and criteria of vibration, air
blast, dust, fly rock and other blasting impact shall be established for
monitoring purpose.
In the event where blasting is to be executed at nearby existing

structures, the Contractor shall provide monitoring instrumentation before
an}! blasting work can commence. The Contractor shall monitor any sign
ER
of vibration! movement that might occur during the blasting work. Any
damage caused by the blasting work shall be borne by Contractor.
2.4.3.13 Insecure Material
D
The cut slopes shall be cleared of all rock fragments which move when
N
pried with a crow-bat. The Contractor shall excavate any insecure
material to an approved depth and build up the resulting spaces with
TE
Grade 15P concrete or masonry using rock that similar to the adjoining
natural rock so as to ensure a solid face.
A
2.4.4 Filling Works
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2.4.4.1 Material
Fill materials to form formation level shall be of suitable material obtained

M
from excavation in cuttings. Where the quantity of such materials is

inadequate, the Contractor shall obtain suitable materials from the
designated borrow pits or from his own source which have been approved
EN
by the S.D.
The fill material shall be free from roots, grass, other vegetarian, clay
lump or material of particles size larger than 150 mm.
M
() The following tests should be carried out for each 1,500 m3 of material to
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be placed or more frequent tests as required by the S.D. :
Atterberg limits
Gradation analysis
O
MS 1056: Method of Test for Soil for Civil Engineering Purposes -

Compaction Test (4.5 kg rammer method)
D
Additional test only for material for lower sub-base and top 300 mm of
subgrade:
California Bearing Ratio (CBR) Test (4 days soak with surcharge

and swell measurement)
Sand shall not be used as fill materials at outer edges of the

embankment.
82-13
(JKRlSPJ/2020-S2)
2.4.4.2 Borrow Pits
The Contractor shall be responsible for locating actual borrow pits on site.
Designated borrow pits shown on the Drawings only indicate to the
Contractor for the potential areas for borrow. Whether the Contractor
obtains materials from the designated or his own borrow pit, it shall be his
responsibility to ascertain the suitability of the pit with respect to the
quantity and quality of the materials, which shall be subjected to the
approval of the S.O. The Contractor shall pay all necessary fees, taxes or
royalties to the appropriate authorities and observe all relevant and
ER
related regulations.
The Contractor shall keep the borrow pits free from water ponding and the
excavation are neat and tidy. The contractor shall make sure the side-wall
D
of the borrow pits is stable , protect the slope surface by turfing and shall
carry out other necessary erosion and environmental protection measures
N
following the agreed method statement and as instructed by the S.O.
()
TE
2.4.4.3 Placement of Fill Materials
All fill materials shall be deposited in layers and brought up at a uniform

rate so that all of site reach the designed level at the same time. The
A
loose depth for each layer of fill shall be determined from the trial
compaction. Each layer shall extend over the full width of the fill area and
EJ
shall be compacted in accordance with the requirements of Sub-Section

2.4.4.4. Each compacted layer shall be maintained at all times with
sufficient even surface of longitudinal and cross slope in order to maintain
M
the stability and to drain away the surface water.
Where embankment is to be constructed on ground with a cross slope

EN
flatter than 1 (vertical) to 10 (horizontal) but steeper than 1 (vertical) to 30

(horizontal), the foundation material, except rock, shall be scarified to a
depth of 100 mm, blended with embankment fill material and compacted
as described in Sub-Section 2.4.4.4.
M
Where embankment is to be constructed against existing embankment or

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on ground with a cross-slope steeper than 1 (vertical) to 10 (horizontal),

the foundation shall be excavated in all materials (including hard rock) to
form benches with horizontal and vertical faces from which construction of
the embankment shall proceed. The benches shall be contiguous beneath
O
the full width of the embankment, and shall be within suitable width to
accommodate construction equipment such as motor-graders, trucks,
D
rollers, etc. Scarifying of the horizontal and vertical faces of the benches
shall not normally be required, and the material excavated in forming the
benches may normally be used as fill in the embankment as approved by
the S.O.
2.4.4.4 Compaction
(a) General
All materials used in embankments and as fill material elsewhere shall be

compacted as soon as practicable after being placed and spread.
S2-14
(JKRlSPJ/2020-S2)
Compaction shall be undertaken to the requirements of this Section by

plant approved by the S.O. All compaction requirements shall be
controlled by means of field density measurement.
For compaction of embankment slope, the Contractor may either extend

each compacted layer beyond the design slope surface by at least 600
mm then trim back to the required slope angle, or he may employ an
agreed tow type roller to compact the sloping surface.
(b) Compaction Trials
ER
The latest MS 1056: Method of Test for Soil for Civil Engineering
Purposes - Compaction Test (4.5 kg rammer method) shall be used in
determining the moisture versus density relation of soil.
D
The Contractor shall submit to the S.O. for his approval the proposed
N
method of compaction for each main type of material to be used in the
() embankment. This shall include the type of compaction plant for each
TE
type of material and the number of passes in relation to the loose depth of
material to achieve desired compaction. The maximum loose thickness for
fill shall generally be limited to 400 mm unless trial compaction shows
compliance with larger loose thickness and with the approval from the
A
S.O.
EJ
The Contractor shall carry out field compaction trials, supplemented by

any necessary laboratory investigations, as required by the S.O. This
shall be done by using the procedures proposed by the Contractor for
M
earthworiks and shall demonstrate properly to the S.O. that all the
specified requirements regarding compaction can be achieved .
Compaction trials with the main types of material likely to be encountered
EN
shall be completed before the woriks with the corresponding materials will
be allowed to commence. Each trial area shall be not smaller than 8 m x
15m.
M
(J For earthwork compaction of less than 100 m 3 , trial compaction can be

waived with approval from the S.O., but field density testing as per Sub-
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Section 2.4.4.4 (d) still remain necessary as and when instructed by the
S.O.
O
The work of compaction shall be carried out as specified in Sub-Section

18.5.4 of Section 18: Soil Stabilisation .
D
(c) Degree of Compaction
The whole of the embankment below the top 300 mm of the subgrade
shall be compacted in layers until no visible track line and to not less than
90% (for cohesive material) or 95% (for cohesionless material) of the
maximum dry density determined in the latest MS 1056: Method of Test
for Soil for Civil Engineering Purposes - Compaction Test (4.5 kg rammer
method), unless otherwise specified in the Drawings.
S2-15
(JKRlSPJ/2020-52)
(d) Field Density Testing
Field density tests on each layer of compacted earth fill shall be carried
out using the sand replacement method in accordance with the latest MS
1056: Method of Test for Soil for Civil Engineering Purposes or by using
other means of testing of comparable similar accuracy approved by the
S.O.
(e) Moisture Control
ER
Each layer of earth fill shall be processed as necessary to bring its
moisture content to a uniform level throughout the material and suitable
for compaction .
D
The optimum moisture content as determined by the latest MS 1056:
N
Method of Test for Soil for Civil Engineering Purposes - Compaction Test ()
(4.5 kg rammer method) shall be used as guide in determining the proper
TE
range of moisture content preferably on the wet side. at which each soil
type shall be compacted. Water shall be added in fine spray for consistent
moisture absorption in the fill. Dry sand or cement or mixture of sand and
cement be added to the proper range of moisture content to obtain the
A
required density. Satisfactory method and sufficient equipment as
approved by the S.O. shall be used for the furnishing and handling of
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water.
If the natural water content of suitable material is too high for the proper
M
compaction to be carried out. the Contractor can either bring down the
moisture content by aeration or drying or alternatively replace it with
suitable materials of compactable moisture range at his own cost.
EN
(f) Air voids
To reduce potential of collapse compression of unsaturated cohesive fill

M
due to wetting. the moisture content range at fill placement shall be

controlled to achieve a compacted fill with allowable air void content not
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exceeding 5%.
2.4.4.5 Control Tests

O
For filii imported material. control test shall include a series of test consist
of:
D
(a) Soil Classification Test: Moisture Content (Me). Liquid Limit (ll).
Plastic Limit (Pl). Plasticity Index (PI). Sieve Analysis and Organic
Content; and
(b) MS 1056: Method of Test for Soil for Civil Engineering Purposes -
Compaction Test (4.5 kg rammer method).
For compacted material . control test shall consist of one field density test
which allocated evenly to each compacted layer of the entire compacted
S2-16
(JKRlSPJ/2020-S2)
fill.
The frequency of control tests shall be in accordance with Table 2.3.
Table 2.3: Frequency of control test for earth embankment
Type of Material Frequency of Test ":

"
Fill/Imported material 1 series test per 1500 m3
ER
Com pacted material 1 field density test per 500 m2
D
If specific test methods are used for the factors time of speed and
N
economic, calibration between such tests and the master test method as
n per latest MS 1056: Method of Test for Soil for Civil Engineering Purposes
TE
shall be carried out at the interval of every 100 tests subject to the S. O.
agreement. The calibration must be material specific and shall be
performed for each material type. The non-master test method with
variation of more than ± 5 % shall be rejected.
A
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2.4.5 Rock Fill Embankment
Rock used in rock fill embankments shall be of maximum particle size of 300
mm so that it can be deposited in horizontal layers, each layer not exceeding
M
500 mm in compacted depth and extended over the full width of the
embankment except for any specified external cover to slopes or new
formation level. The materials shall be spread and levelled by a crawler
EN
tractor weighing not less than 15 tonnes.
Each layer shall consist of reasonably well graded rock and all large voids
M
with averaging dimension of exceeding 150 mm shall be filled with broken

u fragments before the next layer is placed. The top surface and side slopes of
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embankments formed shall be thoroughly blinded with approved fine graded

material to seal the surface.
There shall be a transition layer between rock fill and earth fill or the top 300
O
mm of subgrade of at least 300 mm compacted thickness. This shall consist

of uniformly graded crushed rock between 6 mm and 150 mm as approved
D
by the S.O.
Each layer of rock used as rock fill in embankments shall be systematically

compacted by:
at least 12 passes of a vibrating roller with a static load per 25 mm width

of roll of at least 45 kg: or
a grid roller with load per 25 mm width of roll of at least 200 kg: or
Other machinery and/or equipment as approved by the S.O.
82-17
(JKRlSPJ/2020-S2)
2.4.6 Filling on the Soft Ground
2.4.6.1 General
This Section shall be read together with JKR Standard Specification for
Roadworks, Section 20: Ground Improvement.
2.4.6.2 Foundation treatment
ER
Where soft ground under embankment is to be treated as shown on the
Drawings or as directed by the S.O. , the foundation soil shall be improved
as specified in Section 20: Ground Improvement.
D
The first layer of fill materials shall be deposited over the full width of the
N
embankment and berms in thicknesses not more than 500 mm or as
approved by the S.O. to sufficiently support earthwork machineries. ()
TE
If fill materials are required to be placed under standing water, hard clean
crushed rock, natural gravel or sand having grading within the respective
limits specified in Table 2.2 shall be used to backfill the embankment not
A
less than 300 mm, or as shown on the Drawings, above the standing
water to receive compacted suitable fill thereafter.
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2.4.6.3 Surcharge and Staged Construction
Where indicated in the Contract or directed by the S.O., the embankment

M
shall be built to different heights in stages with or without surcharge and

with allowance for consolidation time periods in between stages, all in
EN
accordance with the Contract. Where surcharge is specified, the

Contractor shall be responsible for the provision of surcharge material and
the removal and disposal of excess material on completion of
consolidation or when directed by the S.O.
M
The work of surcharging shall be carried out as specified in Sub-Section

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20.3 of Section 20: Ground Improvement.
2.4.6.4 Geotechnical Instrumentation

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Geotechnical instruments shall be provided and installed by the

Contractor in the positions as shown on the Drawings for measuring
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intended reading at specified locations or as directed by the S.O., during

and after the construction period comply to requirement specified under
Section 20: Ground Improvement. The details of the geotechnical
instruments shall be as shown on the Drawings and the Contractor shall
be responsible for supplying, installing and maintaining the functionality of
the geotechnical instruments as the work proceeds.
The Contractor shall always take all necessary measures to protect the
geotechnical instruments from damage and shall repair any such damage
throughout the whole duration of the Works. Necessary visible barriers
shall be installed around each geotechnical instrument wherever required .
S2-18
(JKRlSPJ/2020-S2)
The geotechnical instrumentation shall comply to Sub·Section 20.10 in

Section 20: Ground Improvement.
2.4.6.5 Monitoring Records
Joint recording of geotechnical instruments reading shall be conducted as

specified. The monitoring records shall be submitted to the S.O. on an
approved printed form to be supplied by the Contractor. Softcopy of
monitoring records shall be submitted together with the hard copy
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records.
For the measurement of the volume that has settled below the original
level of the foundation of the embankment, the measured settlement of
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each settlement gauge shall be used for volume computation.
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The monitoring records of the installed instrument shall comply to Sub-
() Section 20.10 in Section 20: Ground Improvement.
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2.4.7 Subgrade
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Wherever applicable, this Section shall be read together with JKR Standard
Specification for Roadworks, Section 18: Soil Stabilisation.
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Material for the top 300 mm of subgrade shall have a minimum California
Bearing Ratio (CBR) and specified shear strength or modulus as shown on
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the Drawings.
Where the CBR is not specified in the Drawings, a minimum CBR of:
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5% (T1 - T3): and

12% (T4 & T5)
shall be adopted when the material is compacted to 95 % of the maximum
dry density determined in the MS 1056: Method of Test for Soil for Civil
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Engineering Purposes - Compaction Test (4.5 kg rammer method) under 4

(j days-soaked condition .
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{rraffic category, T1 - T5 can be referred to Table 2.5, ATJ 5185 (Pindaan

2013) Manual for the Structural Design of Flexible Pavement]
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Throughout the top 300 mm of subgrade, the material shall be compacted to

not less than 95 % (for cohesive material) or 100 % (for cohesion less
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material) of the maximum dry density determined in the MS 1056: Method of

Test for Soil for Civil Engineering Purposes - Compaction Test (4.5 kg
rammer method).
In cut area, the top 300 mm of the subgrade shall be scarified and re-
compacted not less than 95 % (for cohesive material) or 100 % (for
cohesion less material) of the maximum dry density determined in the MS
1056: Method of Test for Soil for Civil Engineering Purposes - Compaction
Test (4.5 kg rammer method). If the S.O. is agreeable that the subgrade in its
natural state possesses a density exceeding the requirements , then the
8 2- 19
(JKRlSPJ/2020-S2)
surface of the subgrade shall be trimmed and rolled to obtain a smooth finish.
Where the material in cut area is not complying with a minimum California
Bearing Ratio (CBR) as stated above, the top 300 mm of subgrade it shall
be:
stabilised as specified in Section 18: Soil Stabilisation when it suitable to

stabilise and the stabilised material shall be compacted as indicated
above; or
removed and replaced with suitable material when it unsuitable to
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stabilise and the replacement material shall be compacted as indicated
above.
The subgrade shall be finished in a neat and workmanlike manner, and the
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widths of embankments and cuts shall be everywhere at least those specified
or shown on the Drawings on both sides of the centreline. The top surface of
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the subgrade shall have the required shape, super elevation, levels and
grades and shall be finished everywhere up to within plus (+) 10 mm and o
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minus (-) 30 mm of the required level.
(a) Where rock surface extends over the whole width of the fonmation
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The rock surface shall be trimmed to free draining profile, at or below
fonmation levels. No high spot shall protnude above the fonmation levels.
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Any voids or cavities more than 0.5 m below the fonmation level shall be filled
up with approved crusher run, gravels or lean concrete that have 7 days cube
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strength greater than 7 N/mm 2. The rock surface shall then be brought up to
the fonmation levels with approved cnushed rock or gravel, regulated and
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blinded.
(b) Where rock outcrop occurs over part of the fonmation only
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The rock outcrop shall be cut down to a level not less than 300 mm below the
fonmation level. The surface shall then be brought up to level with compacted
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suitable subgrade material as indicated above.
2.4.8 Protection and Maintenance for Erosion Control

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2.4.8.1 Topsoil
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Topsoil stockpiled for the Works in accordance with Sub-Sections 2.3.1.3

and 2.4.2 shall be spread and lightly compacted to even thickness of 50
mm as directed by the S.O. in areas to be turfed and/or hydroseeded, or
used as directed by the S.O. for tree planting, landscaping and other
purposes.
2.4.8.2
Turfing shall be carried out immediately after the exposed slope surface
exceeds 100 square meters or a flight of slope within a berm/bench one
S2-20
(JKRlSPJ/2020-52)
week after cutting/filling on all earth slopes and other areas as shown on
the Drawings or where directed by the S.O. The type of turf shall be as
indicated on the Drawings or other alternative type as approved by the
S.O. Turf shall be delivered to Site within 36 hours after removal from the
nursery and when stored, turf shall be stacked grass to grass to a
maximum height of one meter. They shall be kept moist and in shade and
shall be planted within 24 hours of lifting. Where turfing is required for
earthworks protection, they shall be planted immediately after cutting or
filling.
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Turf shall be obtained in unbroken sods with substantial amount of topsoil
and shall be approximately 300 mm x 300 mm in size and 50 mm thick
topsoil, from approved source, and shall be placed in position as stated
above.
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Turf sods shall be stacked and watered if they cannot be laid immediately
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after cutting .
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The surfaces to be turfed shall be trimmed and thoroughly wetted. The
turf shall then be carefully laid to form a complete and uniform cover as
shown on the Drawings. Turf laid on slopes steeper than 1 (vertical) to
1.75 (horizontal) shall be anchored down with bamboo/wooden stakes
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approximately 200 mm in length where required. Approved fertiliser shall
be applied after placing of turf at suitable times and at rates of application
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Where close turfing is specified, the turf shall be laid to well bonded
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pattern with no gaps between turves and lightly tamped . For the area of
spot turfing, the turf shall be laid in alternating and staggered diamond
pattern with maximum gap of not exceeding 100 mm .
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All turf shall be regularly watered and fertilised until the vegetation and its
roots is satisfactorily established. Any dead turf shall be replaced with
new turf at the Contracto~s own expense.
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() 2.4.8.3 Hydroseeding
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The work of hydroseeding shall be carried out accordance with Sub-

Section 16.11 in Section 16: Slope Stabilisation.
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2.4.8.4 Creepers
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Where creepers are introduced on gunited slopes, rocks or unsuitable

materials, species shall be of Malaysian origin such as creeping fig (ficus
pumila), butterfiy pea (centrosema pubescens), creeping daisy
(sphagnetico/a trilobata) or to the approval of the S.O.
The Contractor shall submit to the S.O. for his consideration and
approval, at least four (4) weeks in advance of the proposed work, full
details of his proposed method of planting the creepers. The infonmation
submitted shall include, but not limited to a full description of the following
aspects of the work:
82-21
(JKRlSPJ/2020-S2)
(a) the preparation of the areas to be planted with creepers, including

the amount of topsoil if appropriate to be used and its method of
application;
(b) the details and results of investigations to determine which types of

creepers are compatible with the soil in the areas to be planted;
(c) the types of creepers to be used, and the function , root and growth
characteristics of each type;
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(d) the composition of fertilizer to be used at the time of planting the
creepers and its rate of application ;
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(e) the composition of fertilizer to be used after planting, the times of
application and the rate of application;
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(I) the amounts of lime or other chemicals (if any) to be applied to ()
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improve the soil before, during and/or after planting;
(g) the cuttivation and after care of the areas, including rates and
frequencies of watering, fertilizing and general maintenance for at
least one (1) year after planting;
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(h) the time after planting required for establishing permanent, dense
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growth of creepers, which will require minimal maintenance;
(i) guarantees the success of the creepers planting work.

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All creepers shall be regularly watered until the vegetation is satisfactorily

established to the requirements of these Specifications. Any dead
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creepers shall be replaced at the Contractor's own expense.
2.4.8.5 Temporary Slope Protection

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Should the Contractor be unable to turf / hydroseed the exposed slopes

within one week after cutting, temporary protection measures such as
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covering with tarpaulin sheet or artificial cover to control erosion shall be

taken such that no infiltration and/or no serious erosion to the adjacent
slope/works.
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2.4 .8.6 Failure to Comply to Specification

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Should the Contractor fail to implement the Works as per above Sub-
Sections 2.4.8.1, 2.4.8.2, 2.4.8.3, 2.4.8.4 and 2.4.8.5 the Contractor shall
bear the time and cost of turfing / hydroseeding / planting creepers
/temporary slope protection works carried out by others under S.O
directive.
52-22
(JKRlSPJ/2020-S2)
Appendix A
Table 2.4: Equivalent production rate of hard mass based on types of excavators
Excavator Weight Engine Factor Equivalent

Series (Tonnes) Horsepower (HP) Compared with Production Rate
41 .4 Tonnes for Hard Mass
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(Excavator (m3/hr)
Series 400)
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150 15.4 99 0.33 16.5
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n 200 21 .2 170 0.58 29.0
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250 27 188 0.63 31 .5
300 31 242 0.67 33.5

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350 36 271 0.75 37.5

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400 41 .4 321 1.0 50.0

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Table 2.5: Equivalent production rate of rock mass based on types of track-type tractors with
ripping equipment (bulldozer ripper)
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() Dozer Flywheel Operating Fac10r Compared Equivalent

Power(kW) Weight with 37 Tonnes
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Produc1lon Rate
(Tonne) (Bulldozer Ripper) for Rock Mass
(m3/hr)
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06,07 200 - 240 20 - 25 0.54 11 .0

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08 303 37 1.0 20.0
09 405 48 1.3 26.0
Note: If the Contractor provides to use machinery larger than as specified above, it should be
considered equivalent to the specified capacity for the purpose of approval.
52-23
(JKRlSPJ/2020-S2)
Appendix B
Table 2.6: Example form for Point Load Test (PLT).
Project Name:
Samples from Trial Excavation No. (
Location I CH _ _ _ _ (RHS I LHS I N.A )
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Type of Machine Series
Minimum Weight Tonnes BHP
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Sample Depth, Length, Average Load, Do' D. F I, I.(so)
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No. D L Width,W P (mm) (MPa) (MPa)
(mm) (mm) (mm) (kN)
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0.2 = 4/TT D.= F= (0.1 SO).... 1.=P/D.2 I.(so) = F x I.
tWxD) (o."»,~
(1)
(2)
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(3)
(4)
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(5)
(6)
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(7)
(8)
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(9)
(10)
(11)
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(12) i
(13)
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(14)
(15)
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Centre of PLT
S2-24
(JKRlSPJ/2020-S2)
AppendixC
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D
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()
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Photo 2.1: Portable Hydraulic Point Load Tester with a stain-gauged load cell and digital
readout for load monitoring (or equivalent).
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Photo 2.2: Portable Hydraulic Point Load Tester with a pressure-gauged readout for load
monitoring (or equivalent).
52-25
(JKR/SPJ/2020eS2)
Appendix C
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0
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Photo 2.3: Excavator (Series 400) of 41.4 tonnes and 321 BHP (or equivalent).
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Photo 2.4: Track-type of tractor (D8 Dozer) of 37 tonnes and 303 BHP (or equivalent).
S2-26
(JKRlSPJ/2020-S2)
AppendixC
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Photo 2.5: Ripper un~ I ripping equipment (or equivalent).

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Photo 2.6: Track-type of tractor (Dozer) attached with single shank ripping equipment (Bulldozer
ripper) (or equivalent).
S2-27
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Section 3 - Drainage Works (JKR/SPJ/2013-S3)
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KERAJAAN MALAYSIA
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FOR ROAD WORKS A
Section 3: Drainage Works
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KLlUA PEI"GARAH KERJA RA YA

Mil ,\TAN Ki-.RJA R 'Y 1\ . 1ALA YSIA
JAI.AN SlItTA , S.'\I.A II LDIlI .
S05H2 KUAI.A I.UM l' lll{.
FOREWORD
As practices in road construction change over time, it is imperative for Jabatan Kerja Raya
Malaysia (JKR) to continuously update and improve their standard specifications. These
also helping in improving the quality of constructed product. In unison, these new
specifications have a significant positive impact on the construction industry especially
with the incorporation of new products and technologies.
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Standard Specification for Road Works is an essential component in the road
infrastructure construction industry. This specification provides an improved guidance in
the material selection and the production of good quality workmanship and products,
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based on current best practices. The purpose of this standard specification is to establish
uniformity in road works to be used by road designers, road authorities, manufacturers
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and suppliers of road related products.
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This document ' Standard Specification for Road Works - Section 3: Drainage Works' is a
part of a series of improved specifications in the Standard Specification for Road Works.
The compilation of this document was carried out through many discussions by the
technical committee members. Additionally it has been presented at a technical workshop
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held on 16th July 2008. Feedbacks and comments received were carefully considered and
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incorporated in the specification where appropriate.
This Specification had also been presented in the Mesyuarat Jawatankuasa Spesifikasi
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Piawai JKR bagi Kerja-kerja Jalan Bil. 3/2012 on 11th July 2012 and finally approved in the
Mesyuarat Jawatankuasa Pemandu Pengurusan Bil. 18/2013 on 3 nt September 2013.
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This document will be reviewed and updated from time to time to cater for any changes on
policies and current requirements. In this respect, any comments and feedback regarding
this specification should be forwarded to Unit Standard & Spesifikasi, Cawangan
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Kejuruteraan Jalan & Geoteknik.

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Published by: -
Cawangan Kejuruteraan Jalan & Geoteknik

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Ibu Pejabat Jabatan Kerja Raya

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50400 Kuala Lumpur.
Email: USSJ@jkr.gov.my
February 2014
S3-i
ACKNOWLEDGEMENT
This Standard Specification for Road Works - Section 3: Drainage Works has been
prepared by a technical committee comprised of the following members:
Committee Members
Dang Anum Binti Md Zin (Ex-Chairman) Retired
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Sujatiah Binti Tamrin (Chairman) Caw. Kej . Jalan & Geoteknik
Ir. othman Bin Ibrahim Caw. Pengurusan Korporat
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Asniyati Binti Ali Retired
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n Kamalaldin Bin Abd Latif Pasukan Projek Lebuhraya
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Pantai Timur Fasa 2
Badrul Hisham Bin Abdullah Caw. Jalan

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Mat Rodi Bin Junoh Caw. Kej . Jalan & Geoteknik
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Ir. Amir Hamzah Bin Mustapha Caw. Jalan

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Wan Zuhaimie Bin Wan Salleh Caw. Kej. Jalan & Geoteknik
Hamdan Bin Mat Noh JKR PERLIS

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Mohd Sharip Bin Wahijan Caw. Kej . Jalan & Geoteknik

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Zulkifli Bin Ismail Caw. Jalan

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Munira Akhmal Binti Hashim Caw. Jalan
Mohd Kamal Bin Ismail@Omar Caw. Jalan

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Syariful Anuar Bin Mohamed Nasir Caw. Kej. Jalan & Geoteknik
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En. Anwar bin Ahmad Caw. Kej . Jalan & Geoteknik
Finally, the publisher would like to express its gratitude to the above committee members
for their substantial contributions towards the successful completion of this document.
S3-ii
(JKRl5PJ/2013-S3)
SECTION 3 - DRAINAGE WORKS

PAGE
3.1 GENERAL 53-1
3.2 EXCAVATION AND BACKFILLIN G FOR DRAINAGE WORKS 53-1

3.2.1 Description 53-1
3.2.2 Materials 53-1
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3.2.2.1 Excavation 53-1
3.2.2.2 Granular Bedding Material 53-1
3.2.2.3 Concrete Bedding 53-1
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3.2.2.4 Ordinary Backfill Material 53-1
3.2.2.5 Granular Backfill Material 53-2
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3.2.2.6 Concrete Backfill 53-3
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3.2.3 Excavation 53-3
3.2.4 Backfilling with Ordinary or Granular Backfill Materials

A 53-4
3.3 CHANNEL EXCAVATION 53-5

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3.3.3 Construction Methods 53-5

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3.4 SURFACE DRAINAGE 53-6

3.4.2 Surface Drain Construction 53-6

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( ) 3.4.2.1 Unlined Drains 53-6

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3.4.2.2 Cast In Situ Concrete Drains 53-7

3.4.2.3 Precast Concrete Drain Sections 53-7
3.4.2.4 Stone Pitching Drains 53-8
3.4.2.5 Sumps 53-8
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3.4.2.6 Half Round Glazed Earthenware Drains 53-8

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3.5 STONE PITCHING 53-8

3.5.2.1 Stones 53-9

3.5.2.2 Cement Mortar 53-9
3.5.3.1 Grouted Stone Pitching 53-9
53-iii
(JKRlSPJ/2013-S3)
PAGE
3.5.3.2 Ungrouted Stone Pitching S3-10
3.6 BRICKWORK S3-10

3.6.1 Description S3-10
3.6.2 Materials S3-10
3.6.2.1 Cement S3-10
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3.6.2.2 Sand S3-10
3.6.2.3 Cement Mortar S3-10
3.6.2.4 Clay Bricks S3-11
3.6.2.5 Cement Sand Bricks S3-11
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3.6.3 Construction Methods S3-11
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3.6.3.1 Brick Laying S3-11
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3.6.3.2 Plastering Brickwork S3-11
3.7 SUBSOIL DRAINS S3-12

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3.7.2.1 Pipes S3-12

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3.7.2.2 Filter Material S3-12

3.7.2.3 Filter Cloth S3-13
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3.7.2.5 Construction Methods S3-14
3.7.3 Weep holes S3-15

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3.8 R.C. PIPE CULVERTS S3-15

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3.8.2.1 Pipes S3-15

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3.8.2.3 Bedding Material S3-15
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3.8.3 Excavation and Backfilling for R.C . Pipe Culverts S3-16
3.8.3.1 Excavation S3-16

3.8.3.2 Backfilling S3-17
3.8.4 Installation of R.C Pipe Culverts S3-17
3.8.4.1 General S3-17

3.8.4.2 Butt Ended Pipe Culverts with Precast Concrete Collars S3-18
3.8.4.3 Rebated Pipe Culverts S3-18
S3-iv
(JKRlSPJI2013-S3)
PAGE
3.8.4.4 Spigot and Socket Pipe Culverts S3-19
3.9 PRECAST BOX CULVERTS S3-19

3.9.2.1 Precast Box Culverts S3-19
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3.9.2.3 Bedding Material S3-20
3.9.3 Excavation and Backfilling S3-20
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3.9.3.1 Excavation for Precast Box Culverts S3-20
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() 3.9.3.2 Backfilling S3-20
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3.9.4 Installation of Precast Box Culverts S3-20
3.10 EXTENSION OF CULVERTS S3-21

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3.10.1 Extension of Pipe Culverts S3-21
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3.10.2 Extension of Box Culverts S3-21

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S3-v
(JKRl5PJ/2013-S3)
PAGE
LIST OF TABLE
TABLE 3.1 : Grading Limits for Sand Backfill S3-2
TABLE 3.2: Grading Limits for Granular Backfill other than Sand S3-2
TABLE 3.3: Nominal Sizes of Cement Sand Bricks S3-11
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TABLE 3.4: Grading Limits for Filter Material S3-12
TABLE 3.5: Physical Property Requirements for Filter Cloth S3-13
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53-vi
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SECTION 3 : DRAINAGE WORKS

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(JKR/SPJ/201~3)
3.1 GENERAL
This work shall consist of the construction of surface drains, subsoil drains, pipe
culverts, box culverts, sumps and other drainage structures in accordance with this
Specification or as directed by the S.D .. Drainage works shall be constructed to
the lines, levels, grades and cross-sections shown on the Drawings or as directed
by the S.O.
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3.2 EXCAVATION AND BACKFILLING FOR DRAINAGE WORKS
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3.2.1 Description
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o This work shall consist of excavation for the construction of surface drains,
subsoil drains, cast in site box culverts, and other drainage structures, pipe
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culverts, unless otherwise provided in tihe relevant works Specification, and
shall include furnishing, placing, compacting and shaping foundation
bedding materials, backfilling excavations against completed structures
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with suitable material or granular backfill where specified, and the removal
and disposal of all excess excavated material, in accordance witih this
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Specification and as shown on tihe Drawings and as required by the S.O.

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3.2.2 Materials
3.2.2.1 Excavation
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Material excavated shall be classified as common excavation, hard

material or rock as defined in Section 2-Earthworks of this Specification.
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3.2.2.2 Granular Bedding Material

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Granular bedding material for the foundations of structures shall be suitably
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graded broken rubble, crushed stone, crushed gravel, sand or other

material as specified on the Drawings or as required by the S.O.
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3.2.2.3 Concrete Bedding
Concrete bedding or blinding for the foundations of structures shall conform

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to the requirements of Section 9-Concrete of this SpeCification for the

class of concrete specified on the Drawings or required by the S.D.
3.2.2.4 Ordinarv Backfill Material
Ordinary backfill material shall be suitable material as defined in Section 2-

Earthworks of this Specification.
S3-1
(JKRlSPJ/2013-S3)
3.2.2.5 Granular Backfill Material
Granular backfill material shall be sand, crushed stone; crushed gravel or a

mixture of crushed and natural aggregates, shall be essentially free from
vegetative and other organic matter and clay, and shall not contain lateritic
or concretionary materials.
The material shall conform to the following physical and mechanical quality
requirements:
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i) the fines shall be non-plastic;
ii) sand shall have a gradation conforming to the envelope shown in

Table 3.1;
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TABLE 3.1 - GRADING LIMITS FOR SAND BACKFILL
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10.Omm 100
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5.0mm 90 -100
1.18mm 45-80
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300llm 10 - 30
150llm 2-10
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iii) material other than sand shall have a gradation conforming to one of
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the envelopes shown in Table 3.2
TABLE 3.2 • GRADING LIMITS FOR GRANULAR BACKFILL

OTHER THAN SAND
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% Passing By Weight
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B.S. Sieve
Size
A B C
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- -
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37.5mm 100
28.0mm 70 - 100 100 -
20.0mm 60-90 70 -100 100
10.0mm 45-75 45-75 -
5.0mm 30-60 35-65 45 - 75
2.0mm 20-50 25-50 30-60
4251lm 10-30 10-30 15-35
751lm 0-2 0-2 0- 2
S3-2
(J KRiSPJ/2013-S3)
3.2.2.6 Concrete Backfill
Concrete backfill where specified shall be of the grade as shown on the

Drawings and shall conform to Section g·Concrete of this Specification.
3.2.3 Excavation
The Contractor shall notify the S.O. sufficiently in advance of the beginning
of any excavation so that cross-section elevations and measurements may
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be taken of the undisturbed ground. The natural ground adjacent to the
structure shall not be disturbed without permission of the S.O.
Trenches and foundation pits for structures and underdrains shall be
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excavated to the lines, grades and levels as shown in the Drawings or as
directed by the S.O.. Excavations must be kept free from water and
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temporary drains, sumps and pumps shall be provided when necessary.
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The rate of excavation, temporary shoring and backfill shall be approved by
the S.O .. The levels of the bottoms of footings shown in the Drawings are
approximate only and the S.D. may order in writing such changes in the
dimensions or levels of footings as may be deemed necessary to secure a
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satisfactory foundation.
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Boulders, logs and other objectionable materials encountered in excavation

shall be removed.
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After each excavation is completed the Contractor shall notify the S.O. to
that effect and no footing, bedding material or structure shall be placed until
the S.O. has approved the depth of excavation and the type of the
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foundation material as shown on the Drawings.
Rock and other hard foundation material shall be cleared of all loose
materials and cut to a firm surface, either level or stepped or serrated, as
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u shown in the Drawings or directed by the S.O .. All seams and crevices
shall be cleared out and grouted with Portland cement grout at the time the
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footing is placed.
All loose and disintegrated rocks and thin strata shall be removed. When
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the footing is to rest on material other than rock, special care shall be taken
not to disturb the bottom of the excavation, and excavation to final grade
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shall be deferred until just before the footing is to be placed. When, in the
opinion of the S.O., the foundation material is unsuitable, the Contractor
shall remove and replace with suitable material or concrete as specified in
the Drawings or as directed by the S.O.. If foundation fill material is
required il shall be placed and compacled in layers not more Ihan 150mm
thick or as directed by the S.O .. Compaction by tamping, rolling and
vibration shall be carried oul 10 achieve a minimum relative density of 90%
(cohesive material) or 95% (cohesion less malerial) of Maximum Dry
Density (MDD).
S3-3
(JKRlSPJ/2013--S3)
All excavation surfaces and surfaces of backfill material against which

concrete is to be placed shall be even and firm and true to line and level.
All excavated materials, so far as suitable, shall be utilized as backfill or

embankment. The surplus material, whether or not temporarily allowed to
be placed within a stream area, shall be finally disposed of in such a
manner as not to obstruct the stream nor otherwise impair the efficiency or
appearance of the works, nor is it to endanger the partly finished structure.
Excavated materials suitable for use as backfill may be deposited by the
ER
Contractor in storage piles at pOints convenient for rehandling of the
material during the backfilling operation.
D
Excavated materials shall be deposited in such places and in such a
manner as not to cause damage to highway, services or property either
N
within or outside the road reserve, and so as to cause no impediment to the
drainage of the Site or surrounding area.
TE
3.2.4 Backfilling with Ordinary or Granular Backfill Materials
All spaces excavated under this Specification and not occupied by a

A
permanent structure shall be backfilled. Backfill material shall be free from
EJ
large lumps, wood and other extraneous material.
Backfills not within the embankment areas shall be placed in layers

M
not more than 300mm in depth (compacted measurement) and shall be

compacted to a density comparable with the adjacent undisturbed material.
EN
Backfills within the embankment areas shall be made with approved

material placed in uniform layers not to exceed 150mm in depth
(compacted measurement) and each layer shall be constructed in
accordance with Section 2 - Earthworks of this SpeCification except that
M
mechanical tampers may be used for compaction. Each layer of backfill

shall be wetted uniformly as necessary and compacted to the same
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requirements as the adjacent earthwork as speCified in Section 2 -

Earthworks of this Specificat(on. Unless otherwise approved by the 5 .0 .,
hand tamping will not be accepted.
O
In placing backfill and embankment, the materials shall be placed insofar

D
as possible to approximately the same height on both sides of the

structure. If conditions require backfilling appreciably higher on one side,
the additional materials on the higher side shall not be placed until
permission is given by the 5.0. or until the 5.0. is satisfied that the
structure has enough strength to withstand any pressure created.
Backfills for embankment shall not be placed behind the walls of box
culverts until the top slab is placed for the required time and not less than
three days.
S3-4
(JKRl8PJ/2013-S3)
Backfill and embankment behind abutments held at the top by

superstructure shall be carried up simultaneously behind opposite
abutments and side walls.
No backfilling shall be placed against any structure until permission shall

have been given by the S.O.. Jetting of fill or other hydraulic methods
involving, or likely to involve, liquid or semi-liquid pressure shall be
prohibited.
Special care shall be taken to prevent any unduly high pressures against
ER
the structures.
The placing of embankment and the benching of slopes shall continue in

such a manner that at all times there will be a horizontal berm of thoroughly
D
compacted material for a distance at least equal to the height of the
N
abutment or wall to be backfilled.
()
TE
3.3 CHANNEL EXCAVATION
3.3.1 Description
A
This work shall consist of excavation for waterway channels both inside
EJ
and outside the road reserve as shown on the Drawings or as directed by
the S.O. and shall include all required excavation for widening, training or
permanently diverting rivers, streams and irrigation and drainage channels
M
other than drains and ditches appurtenant to the roadway, except

excavation of topsoil for use in the Works and excavation required for
clearing and grubbing. This work shall also include the backfilling of old
EN
channels, haulage to their points of utilization in the Works or the removal

and disposal of all excavated materials, the construction of appurtenant
bunds, dikes and berms, and the shaping and finishing of all earthworks
M
involved in the construction of channels in accordance with the required

lines, levels, grades and cross-sections as shown on the Drawings or as
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3.3.2 Materials
O
Channel excavation shall be classified as common excavation, hard

D
material or rock as specified in Section 2-Earlhworks of this Specification.
3.3.3 Construction Methods
All suitable materials removed from channel excavations shall be used for
backfilling waterways to be abandoned and constructing bunds, dikes and
other earth appurtenances as directed by the S.O.. Surplus suitable
materials shall be used as far as is practicable in constructing the roadway.
The Contractor shall provide borrow of satisfactory quality and approved by
the S.O. should this be necessary to complete the work. Borrow which is
83-5
(JKRlSPJI2013-S3)
required to replace suitable excavated materials needed for construction

which the Contractor elects to waste shall not be paid for.
Excavated unsuitable material, suitable material surplus to that needed for

construction and suitable material that the Contractor elects to waste, shall
be disposed of at deSignated areas in such a manner as to present a neat
appearance and not obstruct flow in any channels, ditches or drains, nor
cause damage to road works or property, all to the satisfaction of the S.O.
During construction , channel excavations shall be kept drained as far as is
ER
practicable and the work shall be carried out in a neat and workmanlike
manner.
All channels and appurtenances shall be excavated and constructed to the
D
lines, levels, grades and cross-sections shown on the Drawings or as
0
N
directed by the S.O .. Excavation beyond the limits required shall not be
paid for and shall be backfilled at the Contractor's expense as directed by
TE
the S.O. should he deem it necessary.
Sections of channel abandoned owing to diversions shall be backfilled as

A
3.4 SURFACE DRAINAGE
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3.4.1 Description
M
Surface drains of the types shown in the Drawings shall be constructed to

the lines, levels, grades and cross-sections as specified or as directed by
the S.O .. Surface drains shall include interceptor drains, roadside drains,
EN
embankment toe drains, shoulder drains, bench drains, berm drains,

median drains, outfall drains, cascade drains, sumps etc.
M
Any of the above drains may be constructed either unlined or lined using
cast in situ concrete, precast or porous concrete drain sections, or stone
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pitching.
3.4.2 Surface Drain Construction

O
3.4.2.1 Unlined Drains

D
Excavation for unlined drains shall be trimmed to form a smooth, firm

surface to the required lines, levels, grades, and cross-sections as
specified in the Drawings or as directed by the S.O.
In case of swale, it shall be trimmed to form a smooth, firm surface to the

required lines, levels, grades, cross-sections and close turfed as specified
in the Drawings or as directed by the S.O.
Any areas of over excavation shall be made good to the satisfaction of the
S.O., all at the Contractor's expense.
S3-6
(JKRJSPJI201~3)
3.4.2.2 Cast In-Situ Concrete Drains
Excavation shall be carried out to the lines and levels as shown on the
Drawings. Templates which may be of timber or steel shall hen be provided
to ensure the thickness and shape of the concrete drains.
Concrete drain without reinforcement, the concrete shall be cast in

alternate bays in 2m length. The intermediate bays shall be carried out 24
hours after the construction of the preceding sections or as directed by the
S.O.. If raining, concrete drain shall be covered by necessary means or as
ER
directed by the S.O.. Construction jOints shall not be formed in the inverts.
Concrete drain with reinforcement shall refer to Section 9-Concrete of this

Specifications.
D
All concrete shall be grade 20 concrete unless otherwise specified and
N
shall conform to the requirements of Section 9-Concrete of this
TE
Specification.
Weepholes shall be installed as shown in the Drawings or as directed by

the S.O. and shall comply with Sub-Section 3.7.3.
A
3.4.2.3 Precast Concrete Drain Sections
EJ
Precast concrete block inverts shall be of the shapes and dimensions as

shown on the Drawings and shall be of grade 20 concrete unless otherwise
M
speCified and shall conform to the requirements of Section 9-Concrete of

this Specification.
EN
The precast concrete drain sections shall be manufactured using good

quality moulds and the finished product shall be round and have smooth
inside surfaces all to the approval of the S.O.
M
Ready made or alternative precast concrete drain sections may be used

l) subject to the approval of the S.O.. Samples of ready made drain sections
KU
shall be submitted to the S.O. for his approval before placing of orders.
Notwithstanding any approval given by the S.O., any defective or broken
drain section shall be replaced by the Contractor at his own expense before
or after laying in position.
O
All precast drain units shall be of a dense and impermeable type.

D
Notwithstanding any approval given by the S.O., any defective or broken

drain section shall be replaced by the Contractor at his own expense before
or after laying in position.
Precast concrete drain sections shall be laid on concrete bedding in

trenches excavated to the lines and levels as specified and jointed to
produce a neat even alignment and gradient. The joint shall be grouted
with 1:3 cement mortars complying with Sub-Section 3.5.2.2 and
S3·7
(JKRlSPJ/2013-S3)
weepholes shall be provided as specified in the Drawings or as directed by

the S.O.
Mass concrete for bases shall be of grade 15 concrete unless otherwise

specified and shall conform to the requirements of Section g-Concrete of
this Specification and to the dimensions and thicknesses as shown in the
Drawings.
3.4.2.4 Stone Pitching Drains
ER
Excavation shall be carried out to the lines and levels as specified in the
Drawings.
The constituent materials and construction methods of stone pitching shall
D
comply with the appropriate requirements of Section 3.5 of this
Specification.
N
Weep holes shall be installed as shown in the Drawings or as directed by
TE
the S.O. and shall comply with Sub-Section 3.7.3.
3.4.2.5 Sumps
A
Sumps shall be constructed of brickwork or stone pitching in accordance
with Section 3.6 and Section 3.5 or in-situ concrete accordance with
EJ
Section g-Concrete of this Specification.
Foundations to sumps shall be of concrete of a quality and dimensions

M
indicated in the Drawings and shall finish flush with the sides unless the
Drawings indicate other requirements.
EN
3.4.2.6 Half Round Glazed Earthenware Drains
Half round glazed earthenware for surface drainage shall comply with
M
MS 1061 .
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3.5 STONE PITCHING
3.5.1 Description
O
This work shall consist of the construction of all structures or parts of

structures to be composed of stone pitching either grouted or ungrouted as
D
shown in the Drawings or as directed by the S.O. including erosion

protection works, aprons, drain linings, culvert inlets and outlets, etc. The
work shall be carried out all in accordance with this Specification and to the
lines, levels, grades, dimensions and cross-sections shown on the
Drawings and as required by the S.O.
S3-8
(JKRl8PJ/2013-S3)
3.5.2 Materials
3.5.2.1 Stones
Stone shall be clean rough quarry stone, or pit or river cobbles, or a mixture
of any of these materials, and shall be essentially free from dust, clay,
vegetative matter and other deleterious materials. Individual pieces of
stone shall be approximately cubical or spherical and shall have least
dimensions in the range 100 to 150mm and a maximum dimension of
250mm, unless otherwise specified. The stone shall be hard, tough,
ER
durable and dense, resistant to the action of air and water, and suitable in
all respects for the purpose intended.
3.5.2.2 Cement Mortar
D
Cement mortar, unless otherwise specified, shall contain 1 part Ordinary
N
Portland Cement to 3 parts fine aggregate by volume . Water shall be
added to the mix to produce a suitable consistency for the intended use, all
TE
to the satisfaction of the S.O .. The constituent materials of the mortar shall
comply with the appropriate requirements of Section 9-Concrete of this
Specification.
A
The ingredients for mortar shall be measured in proper gauge boxes and
EJ
mixed on a clean boarded platform or in an approved mechanical batch
mixer.
M
All mortar shall be used within 30 minutes of mixing and no reworking of

mortar shall be permitted thereafter.
EN
3.5.3.1 Grouted Stone Pitching

M
C) Prior to constructing grouted stone pitching, the surfaces against which it is

to be placed shall have been finished in accordance with the appropriate
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provisions of this Specification. Notwithstanding any earlier approval of

these finished surfaces, any damage to or deterioration of them shall be
made good to the satisfaction of the S.O. before grouted stone pitching is
O
placed.
D
Construction of grouted stone pitching shall commence at the lowest part of

each structure or section of a structure and continue progressively upward.
Long structures such as drain linings and slope protection shall be
constructed in section of practicable length, to the satisfaction of the S.O ..
The surface against which the work is to be placed shall be moistened with
clean water a little in advance of construction, and covered with a layer of
cement mortar about 50mm thick. Stones shall then be firmly set by hand
into the mortar, densely packed against adjacent stones and built up to
form a stone structure of more or less uniform thickness which shall
nowhere be less than 150mm (measured perpendicularly to the surface
83-9
(JKRl8PJ/2013-S3)
covered}. All the while that stones are being placed, all voids in the
structure shall be packed solidly with mortar and stone spalls; however the
surfaces of stones in the exposed faces and edges shall not be covered
with mortar. The exposed surfaces and edges of the structure shall be
constructed such that they have as large a proportion as practicable
composed of stone faces. Weep holes shall be provided as shown in the
Drawings or as directed by the S.O.
Mortar which has been mixed for more than 30 minutes shall not be used in
ER
the works. Nor shall mortar be laid against the supporting surface more
than 2 minutes before pitching stone and building up the structure to full
thickness is commenced on any section of the work, as the construction
advances.
D
The work shall be carried out and finished all to the satisfaction of the S.O.
N
3.5.3.2 Ungrouted Stone Pitching
TE
Where shown in the Drawings, ungrouted stone pitching shall be hand set
to provide maximum interlocking effect. The stones, the largest of which
shall be used at the bottom, shall be well bedded on a 75mm layer of
A
gravel or aggregate rammed to an even surface. The whole work shall be
finished to the satisfaction ofthe S.O.
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3.6 BRICKWORK
M
3.6.1 Description
EN
This work shall include the laying of brickwork to the lines, levels and
grades shown in the Drawings or as directed by the S.O.
M
3.6.2 Materials
KU
3.6.2.1 Cement
The cement, unless otherwise described, shall be Ordinary Portland

Cement complying with M.S. 522 and as specified under Section 9.
O
Concrete of this Specification.

D
3.6.2.2 Sand
Sand for mortar shall comply with M.S. 29 and as specified in Section 9·
Concrete of this Specification.
Cement mortar shall comply with Sub-Section 3.5.2.2.
83-10
(JKRlSPJ/201 3--S3)
3.6.2.4 Clay Bricks
Clay bricks shall be sound, hard, well burnt, of proper size and clean and
shall give a clear ring when struck. They shall be of Class 3 standard
format complying with the requirements of M.S. 76. Bricks shall be obtained
from manufacturers approved by the S.O.
3.6.2.5 Cement Sand Bricks
(a) All cement sand bricks shall comply with M.S. 27.
ER
(b) Size
Cement sand bricks shall be of a nominal size as given below:
D
TABLE 3.3 - NOMINAL SIZES OF CEMENT SAND BRICKS
N
n Length (mm) Width (mm) Depth (mm)
TE
225 ± 3.2 113±1.6 75 ± 1.6
(c) The Contractor shall only use cement sand bricks supplied by approved
A
manufacturers or as approved by the S.O.
EJ
3.6.3.1 Brick Laying

M
Brickwork shall be executed with cement mortar and shall be of the

thickness and bonds as shown in the Drawings. Bricks shall be kept damp
EN
until used and shall be laid on a full bed of mortar. The brickwork shall be
true to line and plumb, and courses shall be kept level.
M
The thickness of mortar joints shall not exceed 10mm and shall be such
() that 4 courses of brickwork forms a height of 300mm. Newly laid brickwork
KU
shall be protected from the harmful effects of sunshine, rain, running and
surface water and shocks.
Any brickwork that is damaged shall be taken down and rebuilt, and the
O
joints raked out and pointed as directed by the S.O .. Any such remedial
work shall be at the Contractor's own expense.
D
3.6.3.2 Plastering Brickwork
All exposed brickwork surfaces shall be plastered . The plaster shall be

applied generally to a minimum total thickness of 20mm unless otherwise
specified in the Drawings and shall be finished to Class U3 unformed
surfaces as per Section 9-Concrete of this Specification.
Plain plaster shall consist of 1 part masonry cement complying with M.S.
794 to 3 parts of sand by volume. Where Ordinary Portland Cement is
S3-11
(JKRlSPJ/2013-S3)
used, plasticizer of a type approved by the S.O. may be added to the mix in
accordance with the manufacturer's instructions.
Ordinary Portland Cement and water shall comply with the appropriate
requirements of Section 9-Concrete of this Specification.
Weep holes not more than 3 meters center to center shall be provided ,
unless specified in the Drawings or as directed by the S.O. and shall
comply with the appropriate requirements of Sub-Section 3.7.3.
ER
3.7 SUBSOIL DRAINS
3.7.1 Description
D
This work shall include the supply and installation of subsoil drains
N
constructed in accordance with this Specification at the locations and in
accordance with the lines, levels and grades as shown in the Drawings or
TE
3.7_2 Materials
A
3.7.2.1 Pipes
EJ
Porous concrete pipes for subsoil drains shall comply with M.S. 525.
M
Clay pipes for subsoil drains shall comply with B.S. 1196.
Polyvinyl Chloride (PVC) pipes for subsoil drains shall comply with
EN
Australian Standard Specification 2439 or B.S. 3656.
3.7.2.2 Filter Material

M
Filter material used in the construction of subsoil drains shall consist of

hard, clean sand confonming to the grading limits given in Table 3.4. The
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material passing the 425IJm sieve shall be non-plastic when tested in

accordance with B.S. 1377.
TABLE 3.4 - GRADING LIMITS FOR FILTER MATERIAL

O

D
10.0 mm 100
5.0 mm 90 - 100
2.36mm 95 -100
1.18 mm 55 - 90
600 IJm 35 - 59
300 IJm 8 - 30
150 IJm o -10
S3-12
(JKRl8PJ/2013-S3)
3.7.2.3 Filter Cloth
The synthetic filter cloth shall be a non-woven type of approved

manufacture having the following properties: -
(a) Chemical Composition Requirements
Fibres used in the manufacture of the engineering fabric shall

consist of a long chain synthetic polymer, composed of at least 85%
by weight of polypropylene, ethylene, ester amide or vinylidene
ER
chloride and shall contain stabilizers andlor inhibitors added to the
base plastic (as necessary) to make the fabric resistant to
deterioration from ultraviolet and heat exposure.
D
(b) Physical Property Requirements
N
() The physical properties of the filter cloth shall comply with
TE
Table 3.5.
TABLE 3.5 - PHYSICAL PROPERTY REQUIREMENTS FOR FILTER CLOTH

A
Test
No Description Unit Properties
Standard
EJ
1. Tensile Strength ISO 10319 kNlm >9

2. Tensile Elongation ISO 10319 % > 40
M
CBR Puncture
3. ISO 12236 N > 1500
Resistance
4. Cone Drop BS 6906/6 mm < 27
EN
ASTM D
5. Grab Strength N > 550
4632
6. Nominal Mass ISO 9864 g/m2 > 125
M
7. Thickness (2kPa) ISO 9863 mm > 1.2

(J 8. UV Resistance
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- Tensile Strength ISO 10319 > 70% Strength retention after 3

months outdoor weatheri ng
- Puncture Strength ISO 12236 > 70% Strength retention after 3

O
months outdoor weathering

9. Chemical Resistance No influence at pH range 2 - 13
D
(c) Filtration Requirement
Equivalent opening size of the filter cloth determined by sieving as

described in ASTM D422 shall be less than the eighty-five
percentage size of the adjacent soil.
83-13
(JKRlSPJ/2013-S3)
(d) Permeability Requirement
The equivalent Darcy Permeability of the filter cloth shall be

greater than 10 times the Darcy Permeability of the soil to be
drained or as shown in the Drawings or as directed by the S.O.
Cement mortar shall comply with SUb-Section 3.5.2.2.
ER
3.7.2.5 Construction Methods
Excavation for subsoil drains shall be carried out all in accordance with the
D
appropriate provisions of Sub-Section 3.2.3.
N
Trench shall be lined with filter cloth of 500mm minimum overlapping .
TE
Filter material shall be placed and uniformly compacted by a suitable
method approved by the S.O. to form a firm and even bedding for the pipe
drain.
A
The pipe sections shall be set firmly against the filter material bedding with
the flow lines in the design position . For pipes with mating joints, the
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receiving ends shall be at upgrade position, and the pipe joints shall be
fully mated. For butt jointed pipes with collars, the pipe sections shall be
fully contiguous, and the collars properly centered over the joints.
M
Joints shall be spot mortared as necessary to hold the pipe sections

correctly centered and aligned, but not so as to unduly restrict the
EN
infiltration of water through the joints.
Slotted or perforated pipes shall be tightly wrapped in filter cloth such that
M
the entire length of the mortared pipe is covered by at least 2 layers of

cloth . All joints in both layers shall have an overlap of at least 100mm and J
joints in the outer layer shall be offset by at least 300mm from joints in the
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inner layer, all to the satisfaction ofthe S.O.
After pipe laying and, if appropriate, wrapping has been approved by the
O
S.O., the remainder of the filter material shall be placed and uniformly
compacted by a suitable method approved by the S.O . to form a dense
D
evenly surrounding to the pipe or as specified in the Drawings. Care shall

be taken that the pipe is neither damaged nor displaced.
Backfill shall then be placed and compacted in accordance with the

appropriate provisions of Sub-Section 3.2.4.
S3-14
(JKRlSPJ/2013--S3)
3.7.3 Weep holes
Weep holes shall be of PVC pipes, unless otherwise specified in the

Drawings. Filter materials and filter cloth of the weep holes shall comply
with Sub-Section 3.7.2.2 and 3.7.2.3. Filter material shall be wrapped with
filter cloth and shall be packed behind weep holes before backfilling.
3.8 R.C. PIPE CULVERTS
ER
3.8.1 Description
This work shall comprise the supply and installation of reinforced concrete
pipe culverts, inclusive of excavation, backfilling, jointing, bedding,
D
construction of headwalls, wingwalls,- aprons and sumps and channel
N
protection works, all in accordance with this Specification and the details
n shown in the Drawings.
TE
3.8.2 Materials
3.8.2.1 Pipes
A
Reinforced concrete pipes shall conform to the requirements of M.S. 881
EJ
and shall be supplied by manufacturers approved by the S.O.
Rebated pipes of diameter 600mm and above shall be internally rebated.

M
Collars shall be pre-cast with minimum grade 25 concrete and shall be

suitably reinforced all in accordance with Section 9-Concrete of this
EN
Specification. The width of the collar shall be not less than 150mm and the
minimum thickness shall be 50mm.
Rubber rings for spigot and socket pipes shall comply with the
M
l) requirements of Type 2 as specified in B.S. 2494.

KU
1:3 cement mortar for jointing of reinforced concrete pipes shall conform to
O
the requirements of Sub-Section 3.5.2.2.
3.8.2.3 Bedding Material

D
Type A bedding shall consist of grade 20 concrete or otherwise stated in

the Drawings, complying with Section 9-Concrete of this Specification.
Type B bedding shall consist of clean, natural sand or gravelly sand of

suitable gradation and quality, approved by the S.O .. The material shall
have a maximum particle size of not more than 20mm.
Bedding material shall have a gradation conforming to the envelope shown

in Table 3.1 for sand and Table 3.2 (Envelope C) for granular of this
Specification.
S3-15
(JKRlSPJ/2013--S3)
3.8.3 Excavation and Backfilling for RC. Pipe Culverts
3.8.3.1 Excavation
(a) General
Unless otherwise directed by the S.O., prior to construction of a

pipe culvert, the earthworks at the required location shall have been
constructed to a level at least 600mm above the top of culvert
design levels or to the top of subgrade levels, whichever is lower.
ER
Pipe culverts specified to be constructed in trench conditions shall
be excavated in accordance with Sub-Section 3.8.3.1 (b) below.
Where drainage conditions or other circumstances so require, the
D
S.O. may direct the Contractor to construct the pipe culvert without
N
first constructing the earthworks to the level specified above, in ()
which case excavation and foundation preparation shall be in
TE
accordance with Sub-Section 3.8.3.1 (c) below.
(b) Trench Method

A
The trench to receive a culvert pipe shall be of sufficient width and
depth to enable the placing of bedding material and construction of
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pipe joints in accordance with this Specification. Minimum side

clearance shall be 300mm or 0.2 times diameter of culvert
whichever is greater to accommodate an operator and compactor
M
beside the pipe. In unstable soil conditions, shoring of the trench

should be considered and additional trench width is required for
trench wall support system. The bottom of the trench shall be
EN
trimmed to a suitably smooth plane surface which shall be kept free

from water, all to the satisfaction of the S.O.
J
M
Where rock or other hard material foundation is encountered in the

trench, it shall be excavated to a depth below the bottom of pipe
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design levels of at least 300mm or 12.5mm per 300mm of fill to be

placed over the top of the pipe, whichever is greater, up to a
maximum of 75% of the internal diameter of the pipe. The hard
material so excavated shall be replaced with suitable material
O
uniformly compacted in layers of not more than 150mm compacted

D
thickness to provide satisfactory support for the pipe, all to the

satisfaction of the 8.0.
(c) Open Ground Method
Where existing ground levels are above top of bedding material

design levels and firm foundation materials are encountered,
excavation and foundation preparation shall be similar to that
described in the trench method above. Otherwise a firm foundation
plane shall be prepared, which shall be essentially free draining
along the line of the culvert, by trimming the existing ground, or
83-16
(JKRlSPJ/2013-SJ)
such fill as it is necessary to place and compact, over a width

sufficient to permit satisfactory construction of the pipe bedding, all
to the satisfaction of the S.O .. Hard materials shall be excavated
from the pipe foundation over a width equal to the outside diameter
of the pipe to the same depth as specified in the trench method, and
shall be replaced with suitable materials uniformly compacted in
layers of not more than 150mm compacted thickness to provide
satisfactory support for the pipe, all to the satisfaction of the S.O.
ER
Where soft or unstable soil is encountered in the foundation, it shall
be excavated over a width of at least 1.5 times the outside diameter
of the pipe on each side of the culvert centre-line to the depth
directed by the S.O. and replaced with suitable material uniformly
D
compacted in layers of not more than 150mm compacted thickness
to provide satisfactory support for the pipe, all to the satisfaction of
N
() the S.O.
TE
3.8.3.2 Backfilling
Backfilling against reinforced concrete pipe culverts and their appurtenant

structures shall be carried out in accordance with the construction methods
A
described in Sub-Section 3.2.4, using material conforming to the
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requirements of Sub-Section 3.2.2.5. Special care shall be taken to
properly compact backfill against the undersides of culvert pipes without
disturbing or damaging the pipes and jOints. Backfill shall be built up evenly
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on both sides of each pipe culvert along its entire length.
Heavy plant and equipment shall not operate within 1.5m of any pipe
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culvert until backfilling and, where appropriate, pavement construction has

advanced to a stage which provides at least 600mm of cover to the culvert.
Subject to the approval of the S.O., light compaction equipment may be
operated a~ove pipe culverts after a minimum of 300mm of cover has been
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C) placed and compacted.

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3.8.4 Installation of R.C Pipe Culverts
3.8.4.1 General
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The type, size and class of pipe to be installed at each location shall be as
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shown in the Drawings or as directed by the S.O.. Culverts shall not be

installed at any location until the type of pipe, the exact location, the lines,
levels and grades, the length of pipe and details of inlet and outlet
structures and have been confirmed by the S.O.. In addition, special
requirements recommended by the manufacturer with respect to assembly
and installation shall be complied with. Especially where elliptically
reinforced pipe sections are used, care shall be taken to ensure that the
loading axes are positioned exactly vertically.
S3-17
(JKRl8PJ/2013-S3)
3.8.4.2 Butt Ended Pipe Culverts with Precast Concrete Collars
The pipes shall be laid on Type A bedding in conformity with the

dimensions shown in the Drawing. Before placing any concrete bedding,
the pipes shall be assembled complete with precast concrete collars to the
correct levels and grades on pre-cast concrete spacing blocks of the same
class of concrete as the bedding material and of sufficient size to eliminate
any risk of settlement of the pipes before or during concreting .
All joints shall be fully mortared with 1:3 cement mortars before concreting
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of the cradle, all to the satisfaction of the 8.0 .. The concrete cradle shall be
cast as one monolithic unit. Alternatively, part of the concrete cradle below
the underside of the pipe may be constructed monolithically at least 24
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hours before the assembly and mortaring up of the pipe sections and
collars on condition that shear connectors are provided across horizontal
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construction joints to the satisfaction of the S.O.
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During installation, the ends of the pipes shall be butted and the collar
centered about the joint using wedges or other approved means. The
annular shall be completely filled with 1:3 cement mortar with only sufficient
water added to ensure adequate workability and the wedges removed
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before finally fairing the joint. Special care shall be taken to ensure that
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excess cement mortar is neatly cleaned off. For pipes over 900mm in
diameter the jointing space shall be filled from inside the pipe after
completion of embankment construction using 1:3 cement mortar. When
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installed, the clearance between the outer diameter of pipe and the inner
diameter of collar shall be at least 20mm.
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Following pipe assembly and mortaring up as above, the remainder of the

cradle shall be cast monolithically, all to the satisfaction of the S.O.
Where vertical construction joints in the concrete cradle are unavoidable

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due to circumstances on site, transfer bars shall be provided to the

satisfaction ofthe S.O.
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Special care shall be taken when plaCing the concrete cradle to avoid the
entrapment of air underneath the pipe. To eliminate this possibility,
concrete shall be placed to one side of the pipe only until such time as the
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level of the concrete surface rises above the underside of the pipe on the
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side remote from that on which concrete is being placed . The concrete
shall then be brought up at the same level on both sides of the pipe.
3.8.4.3 Rebated Pipe Culverts
The pipes shall be laid on Type A bedding in conformity the dimensions

shown in the Drawings.
The method of construction shall follow that described in Sub-section

3.8.4.2 for butt ended pipe culverts for the exclusion of pre-cast concrete
collars.
83-18
(JKRl8PJ/2013-S3)
The rebated joint shall be internally flush and fully mortared with 1:3
cement mortar all to the satisfaction of the S.O.
3.8.4.4 Spigot and Socket Pipe Culverts
The pipes shall be laid on Type B bedding in conformity with the

dimensions shown in the Drawings. The bedding material shall be
accurately shaped by a template to fit the lower part of the pipe exterior for
a height of at least 10% of the outside diameter of the pipe. Gaps shall be
left in the bedding material and recesses dug in the earth foundation of
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sufficient width and depth to accommodate the socket without it resting on
the bottom of the recess. The widths of the recesses in the foundation and
the bedding shall both exceed the width of the socket by more than 50mm.
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Jointing of the pipes shall be carried out strictly in accordance with the
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manufacturer's recommendations, all to the satisfaction of the S.O.
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Concrete pipes as specified above shall be laid true to lines and level, to
the satisfaction of the S.O .. Pipes shall be laid in an upstream direction with
the sockets towards the inlet and shall rest on even foundations for the full
length of the barrel. Rubber ring joints shall be installed strictly in
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accordance with the manufacturer's instructions. Prior to jointing, rubber
rings and jointing surfaces shall be cleaned of all contaminants except for
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specified lubricants. The spigot of each pipe shall be inserted concentrically

in the socket of the one previously laid, and the pipe then adjusted and
fixed in its correct position with the spigot correctly entered in the socket.
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Care shall be taken to see that the rubber ring is adequately compressed to
seal the joint. All pipes shall be laid to the satisfaction of the S.O.
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3.9 PRECAST BOX CULVERTS

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( ) 3.9.1 Description
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This work shall comprise the supply and installation of precast box culverts
inclusive of excavation, backfilling, jointing, bedding, construction of
headwalls, wingwalls, aprons and sumps and channel protection works, all
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in accordance with this Specification and the details shown in the

Drawings.
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3.9.2 Materials
3.9.2.1 Precast Box Culverts
Precast box culverts shall be of approved manufacture complying with

M.S. 1293, or any equivalent altemative standard acceptable and approved
by the S.O.
83-19
(JKRlSPJ/2013--S3)
1: 3 cement mortar for jointing of precast box culvert sections shall conform
to the requirements of Sub-Section 3.5.2.2.
3.9.2.3 Bedding Material
Precast box culverts shall be laid on Type A or Type B bedding as specified

in the Drawings and as per Sub-Section 3.8.2.3.
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3.9.3 Excavation and Backfilling
3.9.3.1 Excavation for Precast Box Culverts
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Unless otherwise directed by the S.O., prior to construction of a pre-cast
box culvert, the earthworks at the required location shall have been first
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constructed to a level at least 600mm above the top of the culvert deSign
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levels or to the top of subgrade levels, whichever is lower, and the precast
box culvert shall then be constructed in a trench excavated in accordance
with Sub-Section 3.8.3.1 (b).
Where drainage conditions or other circumstances so reqUire, the S.O.

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may direct the Contractor to construct the precast box culvert without first
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constructing the earthworks to the level specified above, in which case
excavation and foundation preparation shall be in accordance with
Sub-Section 3.8.3.1 (c).
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3.9.3.2 Backfilling
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Backfilling against precast box culverts and their appurtenant structures

shall be carried out in accordance with the construction methods described
in Sub-Section 3.2.4, using material conforming to the requirements of Sub-
Section 3.2.2.5. Special care shall be taken to properly compact backfill
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without disturbing or damaging the precast box culvert sections. Backfill

shall be built up evenly on both sides of each box culvert along its entire
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length.
Unless otherwise approved by the S.O., heavy plant and equipment shall
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not operate within 2.0m of any pre-cast box culvert until backfilling and,
where appropriate, pavement construction has advanced to a stage which
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provides at least 300mm of cover to the culvert.
3.9.4 Installation of Precast Box Culverts
The type and size of precast box culvert to be installed at each location
shall be as shown in the Drawings or as directed by the S.O.. Precast box
culverts shall not be installed at any location until the exact location, the
lines, levels and grades, the length of culvert and details of inlet and outlet
structures have been confirmed by the S.O.. In addition, special
requirements recommended by the manufacturer shall be complied with.
S3-20
(JKRlSPJ/2013-S3)
All joints shall be fully sealed with 1:3 cement mortar, all to the satisfaction
of the S.O.. In addition, a 3mm layer of 1:3 cement mortar shall be spread
on top of the legs of the invert in order to ensure uniform bearing between
the invert and lid.
Lifting holes shall be filled with 1: 3 cement mortar.
3.10 EXTENSION OF CULVERTS
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3.10.1 Extension of Pipe Culverts
The existing wingwalls, aprons and concrete bedding shall be demolished

wherever specified in the Drawings to expose the existing pipe culvert on
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the side(s) to be extended. The end of the existing pipe culvert to be
extended shall then be wire-brushed or some other means employed to
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() give a clean pipe end.
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Extension joints shall be formed as shown in the Drawings and such
material to be of a type approved by the 5.0. and accordance with the
manufacturer's specification or otherwise specified in the Drawings.
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Piles shall be installed as shown in the Drawings, unless otherwise directed
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by the S.O.
3.10.2 Extension of Box Culverts

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The existing wingwalls, aprons and concrete bedding shall be demolished

wherever specified in the Drawings to expose the existing box culvert on
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the side(s) to be extended. The end of the existing box culvert to be

extended shall then be wire-brushed or some other means approved by the
5 .0 . be employed to give a clean surface.
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Extension jOints shall be formed as shown in the Drawings and such

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material to be of a type approved by the S.O. and accordance with the

manufacturer's speCification or otherwise specified in the Drawings.
Piles shall be installed as shown in the Drawings, unless otherwise directed

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by the S.O.
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S3-21
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ISBN 978-967-6967-34-6
9""R'Q~7
SECTION 3 - DRAINAGE WORKS (ADDENDUM)
This Addendum shall be made part of the' JKR Standard Specification For Road Works
Section 3: Drainage Works
3.11 HANDLING OF CULVERTS .......................................................................•............................... AS3-2

3.12 REMOVAL AND/OR RELA YING OF EXISTING CULVERTS ............................................. AS3-2
3.1 2.1 REMOVAL OF CULVERTS ..... ............... .......... .. ....... .... .. ...... ........ .................................... .......... AS3-2
3.12.2 RELAYING OF SALVAGED CULVERT SECTIONS ..... ......... .................. ..... .................... ............. AS3-2
3.12.3 TREATMENT OF EXCAVATION ...................................................... .......... ............. .... .... .... ...... .. AS3-3
WORK IN STAGES..... ............ ... .... ... .. .. ..... .... ...... ... .... ... .................. .. ... .. ....... .. ............ ...... .. ..... . AS3-3
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3.1 2.4
3.13 INSTALLATION OF CULVERTS UNDER EXISTING ROAD .............................................. AS3-3

3.13.1 MINIMUM DANGER To TRAFFiC .............. .................... .. ........ ...... .................. .. ... ...... .. ...... ....... AS3·3
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3.14 CONNECTIONS TO EXISTING MANHOLES AND DRAINS ............................................... AS3-3
3.14.1 GENERAL.. .......... .... .... ...... .... ........................ .... .. .................. .................. ................ .. ............... AS3-3
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o 3.14.2
3.14.3
PROTECTION .... ...... ..... ..... ................. ...... ..... ..... ................................. ................ ..................... AS3-3
PRIOR NOTIFICA TlON ....... ......... .................... ... .. .. .... ............ ..... ....... ............. ...... .................... AS3-4
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3.15 MANHOLES AND DRAINAGE SUMPS ........•••..••........................••.....••.............••••................... AS3-4
3.15 .1 GENERAL. ........................... ........................... .......................................................................... AS3-4
3.1 5.2 FOUNDATIONS ......... .. .............................................................................. .......... ...................... AS3-4
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3.15 .3 CEMENT MORTAR .............. ............. ........................... ....... .......................................... ............ AS3-4
3.15.4 REQUIREMENTS .... ...................................... .. ........ ........ ......... .. ......... ...................................... AS3-4
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3.15.5 ACCESS ............... ................................... ............ ............ ..................... .............................. ...... AS3-4
3.16 PRECAST CONCRETE SLABS .................................................................................................. AS3-4

3.1 6.1 GENERAL. ....... .............. ..................... ................................ ........................................... ... ........ AS3-4
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3.1 6.2 COVER .. .... ... ............... .. ........................................... .... ........... ........................................ ......... AS3-4
3.1 6 .3 RECESS EDGE .......... .... ........ .......................... ........... ............. ........ .. ....................... ........... .... AS3-4
3.16.4 MARKING .................. ..... ....... .......... ........... ... .... ......... .. ......... .............................. ...... ............... AS3-4
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3.17 WEEPHOLES ................................................................................................................................. AS3-S

3.18 GRADIENT ..................................................................................................................................... AS3-S
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3.19 CONSTRUCTION OF DRAIN AND CULVERT IN FLOWING STREAM ...................•..•.... AS3-S

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AS3 -i
ADDENDUM NO.1
This Addendum shall be made part ofthe 'JKR Standard Specification For Road Works, Section 3:
Drainage Works - JKR/SPJ/2013-S3'.
Add the following items after item 3.10.2
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3.11 HANDLING OF CULVERTS
The Contractor shall employ adequate means in handling precast culverts and shall be
responsible for all damage done to these during delivery to the site and laying in position. All
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precast culverts damaged in these operations wi ll be replaced or repaired as directed by the
S.O. at the Contractor's expense. No cracked, peelled or damaged precast culverts shall be laid
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and all such culverts shall be removed by the Contractor from the site of Works.
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Corrugated pipe culverts shall be unloaded and handled in such a manner as to prevent
bruising, scaling, breaking or in any manner damaging the zinc bitumen coatings ofthe pipe.
In the event that the bitumen coating is damaged, the damaged surface shall be cleaned and
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painted with sufficient number of coals of approved bitumen paint so that the thickness of the
coating is not less than the original coating all to tbe satisfaction of the S.O.
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If both the bitumen and the zinc coatings are damaged, then the zinc coating shall be repaired
by thoroughly wire bruising the damaged areas and removing all loose and cracked coating,
after which the gleaned areas shall be painted with 2 coats of an approved paint with high zinc
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content. A bitumen coating shall then be added in the manner described in the proceeding
paragraph.
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3.12 REMOVAL AND/OR RELAYING OF EXISTING CULVERTS
3. 12.1 Removal of Culverts

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Where existing culverts are to be removed and salvaged the Contractor shall uncover tbe
culvert to a depth sufficient to enable it to be removed without damage but the width of the
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excavation shall be kept to a minimum consistent with ease in removing the culvert. Due care
shall be exercised by the Contractor and any culvert section or sections damaged through
negl igence or improper method shall be replaced by the Contractor at his expense. All
materials excavated shall be removed from the site and used in fills or dumped to waste unless
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otherwise approved by the S.O.

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3.12.2 Relaying of Salvaged Culvert Sections
Where salvaged culvert sections are to be re-Iaid they shall be carefully cleaned by the
Contractor for exa mination by the S.O. and only such sections as he may designate shall be re-
laid. Where such sections are re-Iaid the method of laying and jointing shall be as here before
specified.
AS3( 1)-114
3.1 2.3 Treatment of Excavation
Where the existing road is to be abandoned and new culvert has been provided at a
corresponding location on the new alignment the excavation shall be neatly battered and
trimmed to batters not steeper than 1.5 to 1 so as not to interfere with drainage into or out of
the new culvert.
Where the existing road is to be retained and the culvert is not to be replaced the excavation
shall be backftlled to the level of the pavement subgrade with approved crushed rock or
material complying with the requirement specification. This material shall be compacted at or
near optimum moisture content in layers not exceeding 150 mm losses thickness to a dry
density not less than 95 per cent of the maximum value obtained in the Modified AASHO
Committee Test. Approved pavement materials shall then be placed and fully compacted in
layers to the approval of the S.O. Where the existing surface prior to excavation was of a
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bituminous type the75 mm of new pavement material shall consist of approved premixed
bituminous material. In all cases the final surface shall be shaped to conform to the general
profile on road.
Where the existing road is to be retained and a culvert is to be laid in the excavation, the
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culvert shall be laid jointed as hereinbefore specified and the excavation backfilled as specified
above.
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The work shall be carried out in stages so that an adequate width of pavement is available for
the traffic at all times. All material excavated shall be removed from the site and used in fills or
dumped to waste unless otherwise approved by S.O. The culvert shall be laid and jointed as
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hereinbefore specified and the excavation shall be backfilled in such a manner that at least one
section of culvert shall remain on covered until the adjoining section has been laid and jointed.
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No backfilling shall be placed without the approval of the S.O.
3.13 INSTALLA TION OF CULVERTS UNDER EXISTING ROAD

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3.13.1 Minimum Danger To Traffic

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Where a culvert is to be installed under an existing road any danger of inconvenience to traffic
shall be reduced to a minimum and the Contractor shall be responsible for the safety of traffic.
He shall erect and maintain all necessary warning signs, lights and barriers and will be held
responsible for any damage arising from the neglect or insufficiency of such precautions.
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3.14 CONNECTIONS TO EXISTING MANHOLES AND DRAINS
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3.14.1 General
Where shown on the Drawings, existing manholes and drains shall be properly extended,
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connected and jointed to new manholes, culverts, drains or channels. All such connections shall
be made during the construction of the drain or other work and their positions recorded by the
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Contractor who shall hand to the S.O. daily copy of the record of the connections made the
previous day. Where pipe connections are made to a brick manhole, concrete culvert, stone
built or lined channel, the pipes shall be well and tightly built into the concrete, brick or
masonry work and be so placed as to discharged at an angle 10 the direction of the flow of the
main drain or channel and with the end of the pipe carefully cut to the necessary angle.
3.14.2 Protection
Where a pipe of 305 mm diameter or larger is to be jointed to an existing brick manhole the
opening and the pipe shall be protected by the construction of a brick arch of two rings of
bricks on edge.
AS3(1)-2/4
3. 14.3 Prior Notification
Before entering or breaking into an existing manhole or drain, the Contractor shall give notice
of his intention to the authority responsible for the pipe line to which the connection is to be
made.
3.15 MANHOLES AND DRAINAGE SUMPS
3.15. 1 General
Manholes and drainage sumps shall be constructed of brickwork, or concrete in situ , or of

precast concrete sections complying with B.S. 556 as described in the Contract.
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3.15.2 Foundations
Foundations to manholes and drainage sumps shall be of concrete of the quality and
dimensions indicated on the Drawings and shall finish flush with the manhole sides un less the
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Drawings indicate other requirement. Channels shall be fonned in concrete finished smooth or
pre-fonned half circle channels and benched up to the manhole sides in neat cement.
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3.15 .3 Cement Mortar
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Brickwork shall be built in 1:3 cement mortars. The joints of brickwork where exposed shall be
finished with a neat flat joint as work proceeds. The ends of all pipes shall be neatly built into
the brickwork and fini shed flush with 1:3 cement mortars. Where the diameter of a pipe is 230
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mm or more a 115 mm, brick arch shall be turned over the end of the pipe for the full thickness
of the brickwork.
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3.15.4 Requirements
The manholes cast in situ shall be constructed in accordance with the requirements of this
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specification.
3.15 .5
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Where the depth of invert of manholes and inspection pits exceeds I m below the finished
surface of the carriageway, or the adjacent ground, galvanised iron bars shall be built in at a
vertical interval of 305 mm with alternate steps in line vertically and at 230 mm centre to
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centre horizontally.
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3.16 PRECAST CONCRETE SLABS
3.16.1 General
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All precast concrete slab covers to drains, manholes and kerb channel outlets shall be cast on
site and shall be of concrete Grade as shown in Drawings.
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3.16.2
Slab covers shall be placed as indicated on the Drawings OF as directed by the S.O.
3.16.3 Recess Edge
The sides of drains to receive slabs shall have recess edges to fit slabs.
3.16.4 Marking
Precast slabs for kerb outlet channels shall have marks to indicate the under face orthe slab.
AS3(1)-3/4
3. 17 WEEPHOLES
Weepholes of75 mm earthware (E.W.) pipes or PVC pipes shall be built into stone pitching at
distances as indicated in the drawing. Approximately one half cubic foot of graded filter
material of broken bricks shall be packed behind weep holes before backfilling above
weep holes is carried out
3.18 GRADIENT
All drains shall have a minimum gradient of 0.2 per cent unless otherwise stated. Where the
gradient of any drain exceeds 6 per cent, the invert shall be stepped as show on the Drawings
or as directed by the S.D. Side drains shall be concrete lined where the gradient exceeds 2.5
percent.
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3.19 CONSTRUCTION OF DRAIN AND CULVERT IN FLOWING STREAM
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When construction drains and culverts in a flowing stream, the Contractor shall allow for
deviation of stream or damming and pumping or damming and use of chutes and/or damming
half the stream by use of sandbags or gunny sacks filled with clayed soil or such other
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measures required in order to create dry conditions for carrying out concreting works.
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AS3(J)-4/4
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Section 4 - Flexible Pavement (JKRISPJ/2008-S4)
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JKRISP J/2008-S4 .
. JKR 20403 0003 07 .,
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KERAJAAN MALAYSIA
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STANDARD SPECIFICATION TE
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FOR ROAD WORKS
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Section 4: Flexible Pavement

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CAWANGAN JALAN, KETUA PENGARAH KERJA RAYA,
1,_, . IBU PEJABAT JABATAN KERJA RAYA,

JALAN SULTAN SALAH UDDIN,
50582 KUALA LUMPUR.
JABATAN KERJA RAYA MALAYSIA,
JALAN SULTAN SALAH UDDIN,
5058;2 KUALA LUMPUR •
•
FOREWORD
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As practices in road construction change over time, it is imperative for Jabatan Kerja Raya (JKR)
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to continuously update and improve their standard specifications. These new specifications are
not only aimed at keeping abreast with current technologies but also to help in improving the
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quality of constructed product. In unison, these new specifications have a significant positive
impact on the construction industry especially with the incorporation of new products and
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technologies.
construction industry. This specification provides an improved guidance in the material selection
and the production of good quality workmanship and products, based on current best practices.
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The purpose of this standard specification is to establish uniformity in road works to be used by
road designers, road authorities, manufacturers and suppliers of road related products.
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This document "Section 4: Flexible Pavement" is a part of a series of improved specifications in

the Standard Specification for Road Works. The compilation of this document was carried out
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through many discussions by the technical committee members. Additionally it was vetted
through by a group of independent consultants and presented at various workshops. Feedbacks
and comments received were carefully considered and incorporated in the specification where
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appropriate.
Standard Specification for Road Works - Section 4: Flexible Pavement consists of two (2) parts
namely "Standard Specification" and "Specialty Mix and Surface Treatment". The part on
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"Specialty Mix and Surface Treatment" is entirely new.

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ACKNOWLEDGEMENT
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This Standard Specification For Road Works Section 4: Flexible Pavement has been prepared
by a technical committee consisting of engineers mainly from Cawangan lalan, labatan Kerja
Raya. The members of the committee involved in preparing this Standard Specification For Road
Works - Section 4: Flexible Pavement are:-
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Committee Members
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Dato' Jr. Dr. Azmi bin Hassan Cawangan lalan (Chainnan)
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Jr. Aishab Binti Othman Cawangan lalan, Ibu Pejabat lKR
Jr. Hj . Abdul Rahman Bin Babaruddin Cawangan lalan, Ibu Pejabat JKR
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Jr. Zulakmal Bin Hj. Sufian Cawangan lalan, Ibu Pejabat JKR
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Jr. Abdul MutalifBin Abdul Hameed Cawangan lalan, Ibu Pejabat JKR
Jr. Mobd Hizam Bin Harun Cawangan Kejuruteraan Awam

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& Pakar, Ibu Pejabat JKR
Pn. Wan Fatimab Suhaila binti Wan Mabmud Cawangan lalan, Ibu Pejabat JKR
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En. Ismail bin Mohamad Cawangan lalan, Ibu Pejabat JKR
Tuan Hj. Abu Harith Bin Hj. Shamsudin Cawangan lalan, Ibu Pejabat JKR
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Jr. 10hari B. Emby Cawangan lalan, Ibu Pejabat JKR

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The Committee would also like to thank other JKR personnels and individuals who have
contributed towards the successful completion of this specification.
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JKRlSPJ/2008-S4
SECTION 4 - FLEXIBLE PAVEMENT
4.1 UNPAVED ROADS

4.1.1 Drainage Layer S4-1
4.1.2 Sub-Base S4-1
4.1.3 Gravel Surfacing S4-3
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4.2 PAVED ROADS
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Unbound Pavement Courses
4.2.1 Drainage Layer S4-6
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4.2.2 Sub-Base S4-6
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4.2.3 Crushed Aggregate Roadbase S4-8
4.2.4 Wet-Mix Roadbase S4-10
Bound Pavement Courses
4.2.5 Bituminous Roadbase S4-11
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4.2.6 Cement-Treated Base 84-12
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4.3 BITUMINOUS PAVEMENT COURSES

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4.3.1 Bituminous Prime Coat S4-19

4.3.2 Bituminous Tack Coat S4-23
4.3.3 Asphaltic Concrete S4-24
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4.4 SHOULDERS
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4.4.3 Cons1ruction Methods S4-41
4.5 HORIZONTAL ALIGNMENT, SURFACE LEVELS AND SURFACE

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REGULARITY OF PAVEMENT COURSES

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4.5. 1 Horizontal Alignment S4-43

4.5.2 Surface Levels of Pavement Courses S4-43
4.5.3 Surface Regularity S4-43
S4-;
JKRlSPJ/2008-54
4.6 SPECIALTY MIX 1- POROUS ASPlIALT

4.6.3 Gradation of Combined Aggregates S4-49
4.6.4 Mix Design S4-50
4.6.5 . Sampling and Testing of Porous Asphalt S4-53
4.6.6 Construction Method S4-54
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4.7 SPECIALTY MIX 2 - STONE MASTIC ASPlIALT
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4.7.5 Equipment 84-67
4.7.6 Construction Method 84-68
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4.8 SPECIALTY MIX 3 - GAP GRADED ASPlIALT
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4.8.1 Description S4-7l

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4.8.3 Gradation Of Combined Aggregates S4-73

4.8.5 Equipment S4-77
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4.8.6 Construction Method S4-78

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4.9 SPECIALTY MIX 4 HOT IN-PLACE RECYCLING

() 4.9.1 Description S4-82
KU

4.9.4 Job Mix Formulae S4-84
O
4.9.5. Equipment S4-85

D
4.9.6 Construction Methods S4-86

4.9.7 Laying and Compaction S4-87
4.9.8 Joints 84-87
4.9.9 Finished HIPR Surface S4-87
4.9.10 Opening to Traffic S4-88
JKRlSPJI200B-S4
4.10 SPECIALTY MIX 5 - COLD IN-PLACE RECYCLING

4.10.3 Mix design 84-92
4.10.4 Equipment 84-97
4.10.5 Construction Method 84-99
ER
4.11 SPECIALTY MIX 6 - POLYMER MODIFIED ASPlIALTiC CONCRETE
D
4.11.2 Materials 84-107
4.11.3 Mix Design 84-111
N
4.11.4 Equipment 84-117
TE
4.12 SURFACE TREATMENT I-CHIP SEAL

A
4.12.2 Materials 84-128
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4.12.3 8urface Preparation S4-133
4.12.4 8etting Out 84-133
4.12.5 8tockpile 8ites 84-134
M
4.12.6 Precoating Aggregate 84-134

4.12.7 8praying of Binder 84-134
EN
4.12.8 Application of Aggregate 84-136

4.12.9 Traffic 84-137
4.12.10 Waste Material 84-137
M
4.12.11 Conformance 84-137

KU
4.12.12 Measurement and Payment 84-137
4.13. SURFACE TREATMENT 2 - MICRO-SURFACING

O

4.13.2 Materials 84-140
D
4.13.3 Gradation of Combined Aggregates 84-142

4.13.4 Mix Design 84-142
4.13.5 Equipment 84-143
4.13.6 Surface Preparations 84-144
4.13 .7 Application 84-144
4.13 .8 8ite Control 84-145
54-iii
JKRlSPJI2008-54
4.14 SURFACE TREATMENT 3 - CRACK SEALING

4.14.3 Application Methods S4-150
4.15 SURFACE TREATMENT 4 - COLOURED SURFACING SYSTEM

4.15.1 Description S4- 158
ER
4.15.2. Materials S4- 158
4.15.3 Properties S4-159
D
4.15.4 Applications 84-159
4.15.5 Precautions S4-161
N
4.15.6 Maintenance and Repair S4-161
TE
APPENDIX 84-1
APPENDIX 2 84-X
A
APPENDIX 3 84-XIII
APPENDIX 4 84-XIV
EJ
APPENDIX 5 84-XVTI
M
EN
M
( )
KU
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D
54-Iv
JKRlSPJI2008·S4
4.1 UNPAVED ROADS
4.1.1 Drainage Layer
4.1 .1.1 Description
This work shall consist of furnishing, placing, compacting and shaping drainage layer
on a prepared and accepted subgrade in accordance with this Specification and the
ER
lines, levels, grades, dimensions and cross-sections as shown on the Drawings and/or
as directed by the S.O .
4.1 .1.2 Materials
D
Coarse aggregate shall be screened crushed bard rock and fme aggregate shall be
screened quarry dust or sand. The aggregate shaU be well graded and lie within the
N
limits as shown in Table 4.1 .1.
()
TE
TABLE 4.1.1: GRADATION LIMITS FOR DRAINAGE LAYER
BS Sieve Size (mm) Percentage Passing by Weight

A
75.0 100
37.5 75·100
EJ
20.0 60- 90
10.0 25 - 75
5.0 10- 45
2.00 0- 20
M
1.18 0- 10
4.1 .1.3 Construction Methods

EN
Not withstanding any earlier approval of finished subgrade, the surface of the
subgrade shall be, on completion of compaction and immediately before placing
drainage layer, well closed and free from movement under the compaction plant and
from ridges, cracks, loose material, pot holes, ruts or other defects. Any damage to or
deterioration of the subgrade shall be made good in accordance with Section 2 of this
M
Specification.
KU
The material shall be transported, laid and compacted at a moisture content within the
range + I % to -2% of the optimum moisture content detennined in compliance with
BS 5835 and without drying out or segregation.
The drainage layer shall be placed and compacted to the required width and thickness
O
as shown on the Drawings, in one single layer.
The material shall be spread and lightly compacted with tracked spreading plant or
D
other approved equipment with consideration given to the protection of the subgrade.
4.1.2 Sub-Base
4.1 .2. 1 Description
This work shall consist of furnishing, placing, compacting and shaping sub-base
material on a prepared and accepted subgrade in accordance with this Specification
and the lines, levels, grades, dimensions and cross-sections as shown on the
Drawings and/or as directed by the S.O.
S4-1
JKRiSPJ/200B-S4
4.1.2.2 Materials
Sub-base shall be a natural or artificial mixture of locally available materials such as

sand, gravel, crushed aggregate etc, free from organic matter, clay lumps and other
deleterious materials. It shall be well graded and confonn to Table 4.1.2 and the
following quality requirements;
TABLE 4.1.2: GRADATION LIMITS FOR SUB-BASE
as Sieve Size (mm) Percentage Passing by Weight
ER
75.0 100
37.5 85 - 100
20.0 65 - 100
D
10.0 45 - 100
5.0 25 - 85
0.600 8 - 45
N
n 0.075 0- 10
The particle size shall be determined by the washing and sieving method of BS
TE
1377.
i. The CDR of the sub-base shall not be less than 30% or as shown on the
Drawings when compacted to 95% of the maximum dry density determined
in the BS 1377 Compaction Test (4.5 kg nnnmer method, soaked for 4 days
A
under a surcharge of 4.5 kg). This shall involve carrying out a series ofeBR
tests at various dry densities, using the field moisture content. The field
EJ
density shall then be measured at a number of points using the sand
replacement method and the CBR deduced from the mean of the field
density measurements.
M
ii. If more than 10% of the material is retained on the BS 20.0 mm sieve, the
whole material can be assumed without test to have a CBR value of 30% or
more.
EN
iii. The plasticity index when tested in accordance with BS 1377 shall be not
more than 12.
iv. The 10% fines value when tested in accordance with MS 30 shall be not less
M
than 30 kN.
l) v. The sand equivalent of aggregate fraction passing the No.4 (4.75 mm) sieve
KU
when tested in accordance with ASTM D 2419 shall be not less than 45%.
Prior to placing any sub-base material, the underlying subgrade (particularly the top
O
300 mm of the subgrade) shall have been shaped and compacted in accordance with
the provisions of Sub-Section 2.2.7 or Sub-Section 4.1.1 as appropriate. Not
D
withstanding any earlier approval of finished subgrade, the surface of the subgrade
shall be, on completion of compaction and immediately before placing sub-base
layer, well closed and free from movement under the compaction plant and from
ridges, cracks, loose material, potholes, ruts or other defects. Any damage to or
Specification.
Sub-base material shall be transported, laid and compacted at a moisture content

within the range + 1% to -2% of the optimum moisture content without drying out or
segregation.
S4-2
JKRlSPJ/200B-S4
Sub-base material shall be placed over the full width of the formation to the required
thickness as shown on the Drawings or directed by the S.D. in onc layer or more,
each layer not exceeding 200 mm compacted. thickness. Where two or more layers
are required, they shall be of approximately equal thickness and none shall be less
than 100 nun compacted thickness.
Each layer of sub-base shall be processed as necessary to bring its moisture content
to a uniform level throughout the material suitable for compaction, and shall then be
compacted using suitable compaction equipment approved by the S.O. to not less
than 95% of the maximum dry density determined in the BS 1377 Compaction Test
(4.5 kg rammer method). Compaction shall be camed out in a longitudinal direction
ER
along the roadbed, and shall generally begin at the outer edge and progress unifonnly
towards the crown on each side in such a manner that each section receives equal
compactive effort, all to the satisfaction of the S.O.
D
All loose, segregated or other defective areas shall be removed to the full thickness of
the layer, and new sub-base material laid and compacted.
N
The sub-base shall be finished in a neat and workmanlike manner, and shall have an
average thickness over any 100 metre length not less than the required thickness . The
TE
top surface of the sub-base shall have the required shape, superelevation, levels and
grades, and shall be everywhere within the tolerances as specified in ·Sub-Section
4.5.2.
4.1.3 Gravel Surfacing

A
4.1.3.1 Description
EJ
This work shall consist of furnishing, placing, compacting and shaping gravel
surfacing material on a prepared and accepted subgrade or sub-base in accordance
with this Specification and the lines. levels, grades, dimensions and cross-sections as
shown on the Drawings and/or as directed by the S.D.
M
4.1.3.2 Materials
EN
Gravel surfacing material shall be a natural or prepared soil-aggregate mixture

comprising gravel and sand size particles together with a small proportion of plastic
fines, and shall be essentially free from vegetative and other organic matter,
expansive clay minerals and lumps of clay. The material shall conform to the
following physical and mechanical quality requirements;
M
i. The liquid limit when tested in accordance with BS 1377 shall be not more
than 35%.
u
KU
ii. The plasticity index when tested in accordance with BS 1377 shall be in the
range 4 to 10.
O
iii. The aggregate crushing value when tested in accordance with MS 30 shall
be not more than 35%.
D
iv. The gradation shall conform to one of the envelopes as shown in Table 4.1.3
with the fraction passing the BS 75 urn sieve not greater than 213 of the
fraction passing the as 425 um sieve.
v. The sand equivalent of aggregate fraction passing the No.4 (4.75 mm) sieve
S4-3
JKRl5PJf200B-S4
TABLE 4.1.3: GRADATION LIMITS FOR GRAVEL SURFACING
-
A B C D
37.5 100 \00 100 \00
12.5 45-75 55-85 60-\00 -
4.75 30-60 35-65 50-85 55-90
ER
2.00 20-45 25-50 40-70 40-70
0.425 15-30 15-30 25-45 20-50
0.Q75 8-20 8-20 8-20 8-25
1377.
D
Material with a maximum particle size of37.5 rom, while otherwise not conforming
N
n to the gradation specification but satisfying the other requirements, shall be
acceptable provided that it shall have a CBR value of 30% or more when compacted
TE
to 95% of the maximum dry density determined in the BS 1377 Compaction Test
(4.5 kg rammer method, soaked for 4 days under asurcbarge of4.5 kg).
Prior to placing any gravel surfacing material. the underlying subgrade or sub-base
A
shall have been shaped and compacted in accordance with the provisions of Sub-
Section 2.2.7 or Sub-Section 4.1.2 as appropriate. Notwithstanding any earlier
EJ
approval of finished sub-base, the surface of the sub-base shall be. on completion of
compaction and immediately before placing gravel surfacing material, well closed
and free from movement under the compaction plant and from ridges, cracks, loose
material, pot holes, ruts or other defects. Any damage to or deterioration of the
M
subgrade shaU be made good in accordance with Section 2 of this Specification.
Gravel surfacing shall be placed to the required width and thickness as shown on the
EN
Drawings or directed by the S.O. in one layer or more, each layer not exceeding 200
mm compacted thickness. Where two or more layers are required, they shall be of
approximately equal thickness and none shall be less than 100 m.m compacted
thickness.
M
Spreading of the material shall be carried out by motor grader or other approved.
() mechanical plant.
KU
Each layer of gravel surfacing shall be processed as necessary to bring its moisture
content to a unifonn level throughout the material suitable for compaction, and shall
then be compacted using suitable compaction equipment approved by the S.O. to not
less than 95% of the maximum city density determined in the BS 1377 Compaction
Test (4.5 kg rammer method). Compaction shall be carried out in a longitudinal
O
direction along the carriageway, and shall generally begin at the outer edge and
progress uniformly towards the centre on each side, except on super elevated curves
D
where rolling shall begin at the lower edge and progress uniformly towards the
higher edge. In all cases compaction shall be carried out in such a manner that each
section receives equal compactive effort, all to the satisfaction of the S.O.
Throughout the placement, adjustment of moisture content and compaction of gravel

surfacing material, care shall be taken to maintain a uniform gradation of the material
and prevent segregation.
All loose, segregated or otherwise defective areas shall be removed to the full
thickness of the layer, and new material laid and compacted.
54-4
JKRl5PJ/2008-S4
The gravel surfacing shall be finished in a neat and workman like manner; its width
shall be everywhere at least as specified or shown on the Drawings on both sides of
the centre-line, and its average thickness over any 100 metre length shall be not less
than the required thickness and its minimum thickness at any point shall be not less
than the required thickness minus 20 mm. The top surface of the gravel surfacing
shall have the required shape, superelevation. levels and grades, and shall be
everywhere within the tolerances as specified for 'roadbase' in Sub-Section 4.5.2.
ER
D
N
()
TE
A
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M
EN
M
KU
O
D
54-5
JKRlSPJI2008-S4
4.2 PAVED ROADS
Unbound Pavement Courses
4.2.1 Drainage Layer
4.2.1.1 Description
ER
This work shall consist of furnishing, placing, compacting and shaping drainage layer
on a prepared and accepted subgrade in accordance with this Specification and the
lines, levels, grades, dimensions and cross-sections as shown on the Drawings and/or
D
4.2.1.2 Materials
N
n Coarse aggregate shall be screened crushed hard rock and fine aggregate shall be
screened quarry dust or sand. The aggregate shall be well graded and lie within the
TE
limits as shown in Table 4.2.1
TABLE 4.2.1 GRADATION LIMITS FOR DRAINAGE LAYER

A
B.S. Sieve Size (rom) Percentage Passing by Weight
75.0 100
EJ
37.5 75 - 100
20.0 60- 90
10.0 25 - 75
M
5.0 10 - 45
2.00 0 - 20
l.lS 0 - 10
EN
4.2. 1.3 Construction Methods
Not withstanding any earlier approval of finished subgrade, the surface of the
subgrade shall be, on completion of compaction and immediately before placing
M
drainage layer. well closed and free from movement under the compaction plant and
() from ridges, cracks, loose material, pot holes, ruts or other defects. Any damage to or
KU
Specification.
The material shall be transported, laid and compacted at a moisture content within the
range + 1% to -2% of the optimum moisture content determined in compliance with
BS 5835 and without drying out or segregation.
O
The drainage layer shall be placed and compacted to the required width and thickness
D
as shown on the Drawings, in one single layer.
The material shall be spread and lightly compacted with tracked spreading plant or
other approved equipment with consideration given to the protection of the subgrade.
4.2.2 Sub-Base
4.2.2.1 Description
This work shall consist of furnishing, placing, compacting and shaping sub-base
material on a prepared and accepted subgrade in accordance with this Specification
S4-6
JKRiSPJ/2008-S4
and the lines, levels, grades, dimensions and cross-sections as shown on the
Drawings and/or as directed by the S.D.
4.2.2.2 Materials
Sub-base shall be a natural or artificial mixture of locally available materials such as

sand, gravel, crushed aggregate etc, free from organic matter, clay lumps and other
deleterious materials. It shall be well graded and conform to Table 4.2.2 and the
following quality requirements ;
TABLE 4 .2.2: GRADATION LIMITS FOR SUB-BASE
ER
D
75.0 100
37.5 85 - 100
20.0 65 - 100
N
10.0 45 - 100
5.0 25 - 85
TE
0.600 8 - 45
0.075 0- 10
1377.
A
i. The CBR of the sub-base shall not be less than 30% or as shown on the
Drawings when compacted to 95% of the maximum dry density detennined
EJ
in the B.S. 1377 Compaction Test (4.5 kg rammerrnethod) and soaked for 4
days under a surcharge of 4.5 kg. This shall involve carrying out a series of
CBR tests at various dry densities, using the field moisture content. The
field density must then be measured at a number of points using the sand
M
replacement method and the CBR deduced from the mean of the field
density measurements.
If more than 10% of the material is retained on the BS 20.0 mm sieve, the
EN
whole material can be assumed without test to have a CBR value of 30% or
more.
ii. The plasticity index when tested in accordance with BS 1377 shall be not
M
more than 12.
iii. The 10% fines value when tested in accordance with MS 30 shall be not less
KU
than 30 kN.
iv. The sand equivalent of aggregate fraction passing the No.4 (4.75 mm)
sieve when tested in accordance with ASTM D 2419 shall be not less than
45%.
O

D
Prior to placing any sub-base material, the un~er1ying subgrade (particularly the top
300 mm of the subgrade) shall have been sbaped and compacted in accordance with
the provisions of Sub-Section 2.2.7 or Sub-Section 4.2.1 as appropriate. Not
withstanding any earlier approval of finished subgrade, the surface of the subgrade
shall be, on completion of compaction and immediately before placing sub-base
layer. well closed and free from movement under the compaction plant and from
ridges, cracks, loose material, potholes, ruts or other defects. Any damage to or
Specification.
S4-7
JKRlSPJ/2008-S4
Sub-base material shall be transported, laid and compacted at a moisture content

within the range + 1% to -2% of the optimum moisture content without drying out or
segregation.
Sub-base material shall be placed over the full width of the formation to the required
thickness as shown on the Drawings or directed by the S.O. in one layer or more,
each layer not exceeding 200 mm compacted thickness. Where two or morc layers
are required, they shall be of approximately equal thickness and none shall be less
than 100 m.m compacted thickness.
ER
Each layer of sub-base shall be processed as necessary to bring its moisture content
to a uniform level throughout the material suitable for compaction, and shall then be
compacted using suitable compaction equipment approved by the S.O. to not less
than 95% of the maximum dry density determined in the as 1377 Compaction Test
(4.5 kg rammer method). Compaction shall be carried out in a longitudinal direction
D
along the roadbed, and shall generally begin at the outer edge and progress uniformly
towards the crown on each side in such a manner that each section receives equal
compactive effort, all to the satisfaction of the S.O.
N
All loose, segregated or other defective areas shall be removed to the full thickness of
TE
the layer, and new sub-base material laid and compacted.
The sub-base shall be finished in a neat and workmanlike manner, and sball have an
average thickness over any 100 metre length not less than the required thickness.
The top surface of the sub-base shall have the required shape, superelevation, levels
A
and grades, and shall be everywhere within the tolerances as specified in Sub-Section
4.5.2.
EJ
4.2.3 Crusbed Aggregate Roadbale
4.2.3. 1 Description
M
This work shall consist of furnishing, placing, compacting and shaping crushed
aggregate roadbase material on a prepared and accepted subgrade or sub-base in
accordance with this Specification and the lines, levels, grades, dimensions and
EN
cross-sections as shown on the Drawings andlor as directed by the S.O.
4.2.3.2 Materials
Crushed aggregate roadbase material shall be crushed rock, crushed gravel or a

M
mixture of crushed rock and gravel, which shall be hard, durable. clean and
() essentially free from clay and other deleterious materials.
KU
The material shall conform to the following physical and mechanical quality
requirements;
i. The plasticity index when tested in accordance with BS 1377 shall be not
O
more than 6.
ii. The aggregate crushing value when tested in accordance with MS 30 shall
D
iii. The flakiness index when tested in accordance with MS 30 shall be not more
than 25%.
iv. The weighted average loss of weight in the magnesium sulfate soundness
test (5 cycles) when tested in accordance with AASHTO Test Method T 104
shall be not more than 18%.
S4-8
JKRl5PJ/200B·54
v. The material shall have a CBR value of not less than 80% when compacted
to 95% of the maximum dry density determined in the B.S. 1377
Compaction Test (4.5 kg rammer method) and soaked for 4 days under a
surcharge of 4.5 kg;
vi. The sand equivalent of aggregate fraction passing the No.4 (4.75 rom)
sieve when tested in accordance with ASTM D 2419 shall be not less than
45%.
vii . The gradation shall comply with the envelope as shown in Table 4.2.3
ER
TABLE 4.2.3: GRADATION LIMITS FOR CRUSHED AGGREGATE
ROADBASE
D
B.S. Sieve Size (mm) Percentage Passing by Weight
N
50.0 100
37.5 85 ·100
28.0 70 - 100 ()
TE
20.0 60 - 90
10.0 40 - 65
5.0 30- 55
2.00 20-40
0.425 10- 25
A
0.075 2 ·)0
EJ
1377.

M
Prior to placing any crushed aggregate roadbase material, the subbase shaU have been
constructed in accordance with the provisions of Section 4.2.2.3.
Crushed aggregate roadbase shall be placed to the required width and thickness as
EN
shown on the Drawings or directed by the 8.0. in one layer or more. each layer not
exceeding 200 mm compacted thickness.
Where two or more layers are required, each layer shall be of approximately equal
M
thickness and none shall be less than 100 mm compacted thickness.
The material shall be spread using a motor grader of sufficient capacity or other
KU
approved mechanical spreader. at the optimum moisture content ±l %.
Compaction shall be carried out using suitable approved equipment, in a longitudinal

direction. and begin at the lower edges and progress towards the crown, or in the case
of superelevation towards the upper edge, in such a manner that each section receives
O
equal compactive effort, sufficient to produce a density of not less than 95% of the
dry maximum density as determined by as 1377: Test 13.
D
Throughout the placing. adjustment of moisture content and compaction of crushed

aggregate roadbase material, care shall be taken to maintain a uniform gradation of
the material and prevent its separation into coarse and fme parts, all to the
satisfaction of the S.D.
The crushed aggregate roadbase width shall be everywhere at least that specified or
shown on the Drawings on both sides of the centre-line; and its average thickness
over any 100 metre length shall be not less than the required thickness .
54·9
JKRl5PJ/2008·S4
The surface of the roadbase shall on completion of compaction and immediately

before placing bituminous surfacing be well closed and free from movement under
the compaction plant and from ridges. cracks, loose material, pot holes, ruts other
defects.
All loose, segregated or otherwise defective areas shall be removed to the full
thickness of the layer, and new material laid and compacted. The addition of fine
material will not be permitted.
The surface shall be to the required level and grade and comply with the tolerances as
specified in Sub-Section 4.5.2.
ER
4.2.4 Wet-Mix Roadbase
4.2.4.1 Description
D
This works shall consist of furnishing, placing, compacting wet-mix roadbase on a
prepared and accepted sub-base in accordance with this Specification and the lines
N
and levels as shown on the Drawings andlor as directed by the S.O.
()
TE
4.2.4.2 Materials
Aggregate for wet-mix roadbase shall be crushed roc14 crushed gravel or a mixture of
crushed rock and gravel, which shall be hard, durable, clean and essentially free from
clay and other deleterious materials.
A
The aggregate shall conform to the following physical and mechanical quality
requirem.ents:-
EJ
i. The flakiness index when tested in accordance with MS 30 shall be not more
than 25%.
M
ii. The aggregate crushing value when tested in accordance with MS 30 shall
EN
iii. The weighted average loss of weight in the magnesium sulfate soundness
test (5 cycles) when tested in accordance with ASSHTO Test Method T 104
iv. The sand equivalent of aggregate fraction passing the No. 4 (4.75 mm)
M
u sieve when tested in accordance with ASTM D 2419 shall be not less than
45%.
KU
v. The gradation shall comply with the limits shown in Table 4.2.4.
TABLE 4.2.4: GRADATION LIMIT FOR WET-MIX ROADBASE

O
B.S. Sieve Size (nun) Percentage by Weight Passing

D
50.0 100
37.5 95 - 100
20.0 60 - 80
10.0 40 - 60
5.0 25 - 40
2.36 15 - 30
0.060 8 - 22
0.075 0-8
The particle size shall be detennined by the washing and sieving method of BS
1377.
54-10
JKRlSPJ/2008-54
Not withstanding any earlier approval of finished sub-base, prior to placing wet-mix
roadbase material, any damage to or deterioration of the sub-base shall be made good
in accordance with Sub-Section 4 .2.2.
Wet-mix roadbase material shall be placed to the required width and thickness as
shown on the Drawings or as directed by the S.O. in one layer or more, each layer not
exceeding 200 mm compacted thickness. Where two or more layers are required,
they shall be of approximately equal thickness and none shall be less than 100 mm
compacted thickness.
ER
The material shall be laid using a paving machine at a moisture content ±O.S% of the
optimum which shall be maintained during the compaction operation.
D
Compaction shall be carried out using suitable approved equipment in a longitudinal
direction, and begin at the lower edges and progress towards the crown, or in the case
of superelevation towards the upper edge, in such a manner that each section receives
N
equal compactive effort, sufficient to produce a density of not less than 95% of the
maximum dry density as detennined by BS 1377: Test 13. ()
TE
Throughout the placing, and compaction of wet-mix roadbase material, care shall be
taken to maintain a unifonn gradation of the material and prevent its separation into
coarse and fine parts.
A
All loose. segregated or otherwise defective areas shall be removed to the full
thickness of the layer, and new wet-mix roadbase material laid and compacted, the
addition of fine aggregate ooly sball not be pennitted_
EJ
The wet-mix roadbase width shall be everywhere at least that specified or shown on
the Drawings on both sides of the centre-line.
M
The average thickness measured over any 100 m length shall be not less than shown
on the Drawings or specified and the minimwn thickness measured at anyone point
shall be not less than 20 rom of the thickness shown or specified.
EN
The surface of the wet-mix roadbase shaH, on completion of compaction and

immediately before placing bituminous surfacing, be well closed and free from
movement under the compaction plant and from ridges, cracks, loose material, pot
holes, ruts or other defects .
M
The surface shall be to the required level and grade and comply with the tolerances
specified in Sub-Section 4.5.2.
KU
Bound Pavement Counes
4.2.5 Bituminous Roadbase

O
4.2.5.1 Description
D
This work shall consist of furnishing, placing, shaping and compacting bituminous
roadbase on a bitumen primed pavement course.
The work shaH be carried out to the lines, levels, grades, dimensions and cross-
section as shown on the Drawings and/or as directed by the S.O.
4.2.5.2 Materials
The materials for bituminous roadbase shall conform to the physical and mechanical
quality requirements as specified in Sub-Section 4.3.3.2.
54-11
JKRl5PJI2008-S4
The gradation of the combined coarse and fine aggregates and mineral filler, shall
conform to the appropriate envelope shown in Table 4.2.5.
TABLE 4 _2_5: GRADATION LIMITS FOR ASPIIALTIC CONCRETE
Mix Type Bituminous Roadbase

Mix Desi~ation AC28
28.0 100
20.0 72 - 90
ER
14.0 58 -76
10.0 48 - 64
5.0 30 -46
3.35 24 - 40
D
1.18 14 - 28
0.425 8 - 20
0.150 4- 10
N
0.075 3-7
TE
4.2.5.3 Mix Design
The design for the bituminous roadbase mixture shall be canied out in accordance
with Sub-Section 4.3.33.
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4.2.5.4 Equipment
The equipment shall all as specified in Sub-Section 4.3.3.4.

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All the provisions of Sub-Section 4.3.3.5 for the construction of asphaltic concrete
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pavement courses shall apply as appropriate to the construction of bituminous

roadbasc.
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The bituminous roadbase shall be finished in a neat and workmanlike manner; its
width shall be everywhere at least that specified or shown on the Drawings on both
sides of the centre-line; and its average thickness over any 100 metre length shall be
not less that the required thickness. The top surface of bituminous roadbase shall
have the required shape, superelevation, levels and grades, and shall be everywhere
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within the tolerances as specified for ' binder course' in Sub-Section 4.5.2.
( ) 4.2.6 Cement-Treated Bue
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4.2.6.1 Description
This work shall consist of furnishing, placing, shaping and compacting cement-
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treated base course on a bitumen primed pavement course. Cement-treated base

material shall compose of mineral aggregate and ordinary Portland cement uniformly
blended and mixed with water in the plant. The mixed material shall be spread,
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shaped and compacted in accordance with this Specification and in conformity to the
lines, grades, dimensions and typical cross-sections as shown on the Drawings. This
pavement course shall be built in a series of parallel lanes that may reduce
longitudinal and transverse joints to a minimum.
54-12
JKRlSPJf2008-54
4.2.6.2 Materials
(a) Water
Water shall be clean, clear and free from injurious of sewage, oil, acid, strong alkalis
or vegetable matter and it shall be free from clay or silt. If the water is of
questionable quality, it shall be tested in accordance with the requirements ofMS 28.
(b) Cement
Cement shall be ordinary Portland cement, and shall comply with the requirements of
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MS 522.
Manufacturers' certificates of test shall in general be accepted as proof of soundness,

but the S.O. may require additional tests to be carried out on any cement which
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appears to have deteriorated through age, damage to containers, improper storage or
for any other reason .
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The S.O. may, without tests being made, order that any bag of cement, a portion of
the contents of which has hardened, or which appears to be defective in any other ()
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way. to be removed from the site.
The cement shall be transported to the site in covered vehicles adequately protected
against the entrance of water. It shall be stored in a weather.proof cement store to the
approval of the S.O. and shall be taken for use in the works in the order of its
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delivery into the store.
Where cement is delivered in bulk containers, additional anangements shall be made

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for bulk storage to the approval of the S.O., or the Contractor may use his bulk
container lorries for storage at his own expense.
(c) Aggregate
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The soW'Ce of aggregate to be used shall be the one approved by the S.D. The
aggregate shall be selected crushed materials meeting the gradation requirements
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given in Table 42.5. The material shall be free of roots, sod and weeds. The crushed
aggregate shall cODsist of hard, durable particles of accepted quality, free from an
excess of flat, elongated, soft or disintegrated pieces or objectionable matter. The
method used in producing the aggregate shall be such that the finished product shalt
be as consistent as practicable. All stones and rocks of inferior quality shall be
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removed
The gradation in Table 4.2.6 represents the limits which shall determine suitability of
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aggregate for use from the sources of supply. The fmal gradation decided on. within
the limits designated in Table 4.2.6, shan be well graded from coarse to fine and shall
not vary from the low limit on one sieve to the high limit on adjacent sieves, or vice
versa. The portion of the base aggregate, including any blended material, passing the
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BS 425 urn sieve shall have a plasticity index of not more than 6 when tested in
accordance with BS 1377.
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The aggregate shall have the Los Angeles abrasion value of not more than 45% when
tested in accordance with ASTM C 131 and the aggregate crushing value of not more
than 40% when tested in accordance with MS 30.
All aggregate samples required for testing shall be furni shed by the Contractor at his
own expense. Sampling shall be done in accordance with ASTM D 75. No aggregate
shall be used in the production of cemenHreated base mixtures without prior
approval by the S.O .
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JKRl5PJ12008-54
TABLE 4.2.6: GRADATION LIMITS FOR CEMENT-TREATED BASE
BS Sieve Size (mm) Percentage by Weight Passing
50.0 100
37.5 90 - \00
20.0 70 - 90
\0.0 45 -70
5.0 35 - 65
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0.600 15 - 30
0.075 5 -15
(d) Bituminous Prime Coat
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The bituminous prime coat material shall be slow-setting, cationic bitumen emulsion
of grade SS-tK conforming to MS 161. The bitumen emulsion shall be sprayed at
ambient temperature at a spray rate of 1.5 to 2.0 11m2 to underlying pavement course.
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The exact amount shall be specified by the S.D. The S.~. may require trial areas to
be carried out in order to determine the exact amount of the bituminous prime coat to
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be used.
4.2.6.3 Laboratory Tests And Cement Content
(aj Laboratory Tests for Job Mix Design

A
At least thirty days prior to the time the Contractor is expected to begin placement of
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cement-treated base (CTB) course, he shall submit to the S.O. for approval ajoh mix
design. The job mix design shall be submitted with certified laboratory reports
showing material compliance, strength requirements and required laboratory tests.
After approval of the job mix design, no substitution of materials or proportions shall
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be made without approval of a new mix design submitted by the Contractor in

accordance with this Specification and approved by the S.O.
The CTB specimens shall develop a minimum characteristic compressive strength of

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5 MPa in seven days and 10 MPa in 28 days when tested in accordance with BS
1924. The specimens shall also develop a flexural strength of not less than 2 MPa in
28 days when tested in accordance to BS 1924. The strength specified are
Characteristic Strengths based on at least 6 tests.
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u (b) Cementitious Material Content

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The quantity of ordinary Portland cement to be used with the aggregate and water
shall be determined from tests of materials submitted by the Contractor for the job
mix design and shall not be less than 80 kg/m 3• The cost of the cement shall be
absorbed in cost per cubic metre for the cement-treated base course.
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(a) Weather Limitations

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The cement-treated base shall not be mixed or placed when the weather is rainy.
(b) Preparing Underlying Course
Prior to placing cement-treated base course, the sub-base shall have been constructed
in accordance with the provisions of Sub-Section 4.2.2.
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JKRlSPJ/200B-S4
(c) Mixing
The aggregate shall be proportioned and mixed with cement and water in a mixing
plant. The location of the mixing plant shall be such that the mixture can be placed
within the time stipulated in the specification. The plant shall be equipped with
feeding and metering devices which will introduce the cement, aggregate and water
into the mixer in the quantities as specified. Mixing shall continue until a thorough
and unifonn mixture has been obtained.
The aggregate storage bins on the mixing plant shall be provided with approved
'scalper' screens to eliminate the possibility of oversize or other objectionable
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materials from entering the bins.
The water shall be proportioned by weight or volume, and a means shall be provided
for the S.O. to verify the amount of water per batch or the rate of flow for continuous
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mixing. The discharge of the water into the mixer shall not be started before part of
the aggregate is placed into the mixer. The inside of the mixer shall be kept free from
any hardened mix.
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The cement shall be added in such a manner that it is uniformly distributed
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throughout the aggregate during the mixing operation.
The mixing plant shall be either batch mixing or continuous mixing type of adequate
capacity and proper verifiable controls.
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(d) Test Section
Prior to full production, the Contractor shall prepare a quantity of the cement-treated
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base according to the job mix design. The amount of mixture shall be sufficient to
construct a test section of 30 metres long and 2 spreader widths placed in two
sections and shall be of the same depth specified for the construction of the course
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which it represents. The underlying grade or pavement structure upon which the test
section is to be constructed shall be the same as the remainder of the course
represented by the test section. The equipment used in construction of the test section
shall be of the same type and weight to be used on the remainder of the course
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represented by the test section.
In no case shall the plant-produced mix be considered acceptable if the mix

properties or field densities of the test section do not meet the requirements of the
mix design criteria.
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If the test section should prove to be unsatisfactory. the necessary adjustments to the
mix design. plant operation, andlor rolling procedures shall be made. Additional test
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sections, as required, shall be constructed and evaluated for conformance to this

Specification. When test sections do not conform to this Specification, the sections
shall be removed and replaced at the Contractor's own expense. A marginal quality
test section that has been placed in an area of little or no traffic may be left in place.
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If a second test section also does not meet this Specification, both sections shall be
removed at the Contractor's own expense. Full production shall not begin without the
S.O. ' s approval . There shall be no separate payment for test sections.
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(e) Placing
The mixture shall be transported to the job site in suitable vehicles and shall be
deposited on the moistened underlying layer in unifonn layers by means of approved
mechanical spreaders. Not more than 60 minutes shall elapse between the start of
mixing and the start of compaction of the cement-treated base mixture on the
prepared underlying layer.
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The cement-treated base course shall be placed in successive horizontal layers not to
exceed 250 m.m in compacted depth. Prior to the placement of each successive layer,
the surface of the preceding layer shall be moistened, when in the opinion of the
S.O., the surface is too dry to provide proper bond.
The cement-treated base material shall be spread by a spreader box, self-propelled

spreading machine or other methods approved by the S.O. If spreader boxes or other
spreading machines are used that do not spread the material the full width of the lane
or the width being placed in one construction operation, a sufficient number of them
shall be provided and operated in staggered formation to obtain a full-width
spreading. If in the opinion of the S .O., full-width construction is undesirable because
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of inadequate equipment, operating difficulties or climatic conditions, the cement-
treated base course shall be constructed in partial widths_ If the time elapsing
between the placing of adjacent partial widths exceeds 30 minutes, a construction
joint satisfactory to the 8.0_ shall be provided_
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The equipment and methods employed in spreading the cement-treated base material
shall ensure accuracy and uniformity of depth and width_If conditions arise where
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uniformity in spreading cannot be obtained, the S.D. may require additional
equipment or modification in spreading procedure to obtain satisfactory results_
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Spreading equipment shall be not more than 10 metres nor less than 3 metres in
width_
(f) Compaction
A
Immediately upon completion of the spreading operations, the mixtures shall be
thoroughly compacted_ The number, type and weight of rollers shall be sufficient to
compact the mixture to the required density_
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The field density of the compacted mixture shall be at least 98 percent of the
maximum density of laboratory specimens prepared from samples of the cement-
treated base material taken from the material in place_ The specimens shall be
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compacted and tested in accordance with ASTM D 1557 Method D _ The in-place
field density shall be determined in accordance with ASTM D 1556 and ASTM D
2167. Any mixture that has not been compacted shall not be left undisturbed for more
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than 30 minutes_The moisture content of the mixture at the start of compaction shall
not be below nor more than 2 percentage points above the optimum moisture content_
The optimum moisture content shall be determined in accordance with ASTM D 558
and shall be less than that amount which will cause the mixture to become unstable
during compaction and finishing_
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() (g) Pre-cracking
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The cement-treated base course shall be pre-cracked. For sections identified to be

pre-cracked, the time between placements of successive layers shall be at least 4
hours_ Each layer shall be kerfed (not cut) to a depth of at least one-third of that layer
with a suitable equipment_ The resultant width shall not exceed 10 mm and shall be
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filled with a bituminous emulsion conforming to the requirements ofMS 161 diluted
with water at a ratio of 1:2 or as agreed by the S.D. The layers shall be water-cured
except for the top layer, where curing compound shall be used. The pre-cracking
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shall be done in 3m x 3m panels unless specified otherwise by the S.D.
(h) Layer Thickness
The maximum depth of a compacted layer shall be 250 mm, except where the total
depth of the compacted base course is required to be greater than 150 mm, no layer
shall be in excess of 200 mm or less than 100 mm when compacted_ In multilayer
construction, the surface of the compacted material shall be kept moist until covered
with the next layer_ Successive layers shall be placed and compacted so that the
required total depth of the base course is completed the same day_
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(i) Finishing
The completed base course shall conform to the required lines, grades and cross-
sections. [f necessary. the surface shall be lightly scarified to eliminate any imprints
by the compacting or shaping equipment. The surface shall then be re-compacted to
the required density.
The compaction and finishing operations shall be completed within 2 bours of the
time water is added to the mixture and shall produce a smooth, dense surface that is
free of s urface checking, ridges or loose materials.
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(j) Surface Tolerance
The fmished surface shall not vary by more than 10 mm when tested with a 3 metre
straight edge applied parallel with or at right angles to the centerline of the stabilised
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area. Any deviation in excess of this amount shall be corrected at the Contractor's
own expense.
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(k) Construction Joints
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At the end of each day's construction, a transverse construction joint shall be formed
by a header or by cutting back into the compacted material to fonn a true vertical
face free of loose material.
Longitudinal joints shall be formed by cutting back into the compacted material to
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fonn a true vertical edge.
The curing seal shall be maintained and protected for 7 days.

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Finished portions of the base course that are used by the equipment in the
construction of an adjoining section shall be protected to prevent damage to the
completed work.
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(I) Protecting and Curing

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The completed cement-treated base course shall be cured with a bitumen emulsion
applied as soon as possible and in no case later than 4 hours after completion of the
finishing operations. The surface of the base course shall he kept moist until the
curing compound material is applied.
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The curing compound specified shall be uniformly applied to the surface of the
completed cement-treated base course with approved heating and distributing
equipment and give complete coverage without excessive runoff. At the time the J
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bituminous material is applied, the surface shall be dense free of all loose and
extraneous material and shall contain sufficient moisture to prevent penetration of
curing compound. Water shall be applied in sufficient quantity to fill the surface
voids immediately before the bituminous curing compound is applied.
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If there is a need for construction equipment of other traffic to use the bituminous
covered surface before the bituminous material has dried sufficiently to prevent pick-
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up, sufficient granular cover shall be applied before such use.
The curing material shall be maintained and applied as needed by the Contractor
during the 7 -day protection period so that the entire treated base course will be
covered effectively during this period.
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(m) Strength Testing
To ensure that the strength requirements of the cement-treated base are met, a
minimum of six compressive strength test on 150mm x 150mm x; lSOnun cubes and
one flexural strength on lOOmm x lOOmm x 600mm beams, as specified in BS 1924,
shall be determined of the cement-treated base course for every 1,000 m2 0fmaterial
placed. A minimum of one set of test per day shall be performed if less than 1,000 rn 2
is placed. The compressive and flexural strengths shall be determined on seven-day
laboratory specimens. Material for the laboratory specimens shall be sampled at the
same area the density test is carried out, on the day the material is placed. Three (3)
laboratory cubes and beams shaH be produced and from each set of three (3) cubes
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and beams. two (2) shall be tested for compressive and flexural strengths at seven (7)
days with one spare cube and beam being held in reserve to replace any obviously
defective cube or beam that may develop.
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()
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()
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54-18
JKRlSPJI200B-S4
43 BITUMINOUS PAVEMENT COURSES
4.3.1 Bituminous Prime Coat
4.3.1.1 Description
This work shall consist of the careful and thorough cleaning of the surface of a
prepared and accepted unbound roadbase and cement-treated base (CfB), and the
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furnishing and application to the cleaned roadbase and CTB surface of a bituminous
prime coat, all in accordance with this Specification and the lines, dimensions and
cross sections as shown on the Drawings and/or as directed by the S.D.
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4.3.1.2 Materials
The material shall be cut-back bitumen of grade MC-70 conforming to the
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requirements of MS 159 (refer Table 4.3.1) or slow.setting cationic bitumen
emulsion of grade SS-lK conforming to the requirements of MS 161 (refer Table ()
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4.3.2) or other materials as approved by the S.O.
TABLE 43_1 MS 159 REQUIREMENTS FOR CUT-BACK BITUMEN MC-70
Properties Min Max Test Methods

A
(or technically
ideotical with)
Kinematic viscosity at 60 °C, cSt
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70 140 ASTMD2170
Flash Point (fag Opeo-Cup), 'C 38 - ASTMDI3IO

M
Distillation test: ASTMD402

Distillate, percent by volume
of total distillate:
225'C - 20
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260'C 20 60
316'C 65 90
Residue from distillation to

360°C, percent volume by 55 -
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difference
Tests on residue from

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distillation:
Penetration at 25 °e, IOOg. 5 sec. 120 250 ASTM D402IASTM 05
Ductility at 25°C, em 100 - ASTM 04021ASTM 0113

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Solubility in trichlorethylene,
percent, mass 99 - ASTM 04021ASTM 02040
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Water, percent, volume - 0.2 ASTM095
S4-19
JKRlSPJI2008-S4
TABLE 4-3_2 MS 161 REQUIREMENTS FOR BITUMEN EMULSION SS-lK
Properties Unit Grade Test Methods

SS-IK (or technically
identical with)
Tests on emulsion:
Saybolt Furol viscosity at 25 °C,

minimum sec. 20 ASTMD244
maximum 100
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Storage stability test, 24 h, maximum % I ASTMD244
difference
Sieve test, maximum % 0.10 ASTMD244
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Cement mixing test, maximum. % 2 ASTMD244
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() Residue from distillation,
minimum
% mass 57 ASTMD244
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Tests on residue from distillation:
Penetration at 25 °C,lOOg, 5 sec.

minimum 0.1 rom 60 ASTMD5
A
maximum 200
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Solubility in trichlorethylene, % mass 97.5 ASTMD2042
Minimum
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The S.D. shall receive a copy of the test results for each delivery of cut-back
bitumen, bitumen emulsion or other materials employ~ in_~e Works.
4.3.1.3 Equipment
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The Contractor shall provide the plant and the equipment necessary for the execution
of the work in accordance with this Specification. Details of this equipment including
manufacturer, model type, capacity, etc shall be forwarded to the S.D. for bis
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approval before the plant or equipment is mobilised.
u (a) Mechanical Power Broom

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The power broom is to be of the self propelled suction type capable of removing all
loose particles and dust from the surface to receive the bituminous prime coat, or a
self propelled power broom fitted with an air blower with a delivery pressure of 0.7
N/rom'.
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(b) Pressure Distributor for Bituminous Material

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The distributor shall be a putpose built model of recognised manufacture and shall be
approved by the S.D. It shall conform to the requirements described hereunder.
The distributor shall have a suitable capacity and shall be equipped with a gas or oil
fired heating system capable of heating a full charge of bituminous material to 180°C.
The heating system shall be such that overheating of the bituminous prime coat will
not occur and shall be of a type in which flames from the burner do not come into
direct contact with the casing of the tank containing the bituminous prime coat. The
tank shall be insulated in such a manner that when filled with bituminous prime coat
at 180 °C and not heated, the drop in temperature shall be less than 3 °C per hour. A
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JKRJSPJ/2008-54
thermometer shall be provided to measure continuously the temperature of the

bituminous prime coat in the tank and shall be so arranged that the highest
temperature in the tank is measured. The tank shall be fitted with an accurately
calibrated dipstick or contents gauge, and the pipe for filling the tank shall be fitted
with an easily replaceable filter.
The distributor shall run on pneumatic tyeed wheels of such width and number that
the load produced on the road surface when the vehicle is fully charged shall not
exceed 12 kg/mm of tyre width. The vehicle shall be equipped with a ' fifth wheel'
tacheometer system to accurately measure its forward speed during spraying
operations.
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The distributor shall be equipped with a full circulation type spray bar with nozzles
from which the bituminous prime coat is sprayed on to the road surface wtiformly
over the full spraying width. The spraying width shall be variable in increments of
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not more than 100 nun up to a maximum of 5.0 metres. The spraying pump shall be
driven by a separate power unit and shall be equipped with an accurate pressure
gauge and an accurate flow rate gauge or meter. On the suction side the pump shall
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be fitted with an easily replaceable fitter. The spray bar and pump shall be so
designed that bituminous prime coat at even temperature and uniform pressure may
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be sprayed uniformly over the spraying width at controlled rates in the range 0.25 to
8.0 litres/sq.m at normal distributor operating speeds, such that deviation from the
prescribed rate of application shall not exceed 10%.
The distributor shall be equipped with a hand spraying system.

A
The meters for the 'fifth wheel' tachometer system and the bituminous prime coat
pumping flow rate, pwnpiog pressure and temperature shall be located in such a
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manner that the vehicle driver can easily read them while operating the distributor.
The spray bar shall be controlled by a second operator riding at the rear of the vehicle
in such a position that all the discharge sprays are in his good view.
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All measuring equipment on the distributor shall have been recently calibrated and
accurate, and satisfactory records of the calibrations shan be submitted to the S.O. If
in the course of the work the rates of application of bituminous prime coat are found
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to be inaccurate, the distributor shall be withdrawn from the Works and recalibrated
to the satisfaction of the S.O. before being returned to service.
The S.O. may require such performance tests as he considers necessary to check that
the distributor is operating satisfactorily. As directed by the S.O., the Contractor shall
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make the distributor and its equipment available for such tests and shall supply aU
necessary assistance, materials, tools, testing apparatus, etc., all at the Contractor's
own expense.
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(c) Storage and Heating Facilities/or Bituminous Prime Coat
Tanks for storage of bituminous prime coat shall have a capacity suited to the
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proposed rate of utilisation of the material and the method and frequency of its
delivery to the Works, all to the satisfaction of the S.O. The bituminous prime coat
storage tanks and barrel decanters shall be equipped with indirect heat transfer oil
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heating, to raise the bituminous prime coat to the specified temperature, without over
heating.
4.3. 1.4 Construction Methods
(a) General Conditions
Bituminous prime coat work shall only be canied out in dry and warm weather when
the surface to be treated is essentially dry.
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(b) Suiface Preparation and Cleaning
Prior to applying the bituminous prime coat, the unbound aggregate roadbase shall
have heen shaped and compacted in accordance with the provisions of this
Specification. Notwithstanding any earlier approval of finished roadbase, any
damage to or deterioration of the roadbase shall be made good to the satisfaction of
the S.D. before bituminous prime coat is applied.
Immediately prior to applying the bituminous prime coat, the full width of the surface
to be treated shall be swept using a power broom followed by a compressed air
blower and, if necessary, scraped using hand tools to remove aU dirt, dust and other
ER
objectionable materials, all to the satisfaction of the S.D.
(c) Application a/Bituminous Prime Coat
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The bituminous prime coat shall be sprayed on to the cleaned roadbase surface by
means of a pressure distributor. Any areas inaccessible to the distributor spray bar
shall be treated using the distributor's hand spraying system. The rate or rates of
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n application shall be as directed by the S.O. based on the results of test applications,
but shall usually be in the range 0.5 to 1.0 litre/sq.m. The temperature of cut-back
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bitumen MC-70 shall be maintained in the range 50 °C to 70 °C during spraying
operations.
For the bitumen emulsion SS-IK, the spraying temperature shall be in the range 25
°C to 45 °C. After the bitumen emulsion "breaks", sand or quarry dust shall be lightly
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spread over the primed surface. The covered surface shall be left undisturbed to cure
for a period of 24 hours after which the surface can be swept clear of the sand or
quany dust before construction of the overlying pavement course.
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If necessary, in order to prevent the bituminous prime coat from flowing on the
sprayed surface, the prescribed prime coat shall be applied in two separate spraying
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operations. Where the condition of the treated surface indicates that it is necessary,
bituminous prime coat additional to that prescribed shall be applied as the S.O. shall
direct.
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Bituminous prime coat shall be distributed unifonnly over the surface to be treated
without streaking; the quantities applied shall not deviate by more than 10% from
those prescribed. Areas with insufficient bituminous prime coat shall be resprayed as
necessary to make up the deficiency, all to the satisfaction of the S.O.
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u The surfaces of structures, road furniture and trees adjacent to the areas being
sprayed shall be protected in such a manner as to prevent their being spattered or
marred by bituminous prime coat. Bituminous prime coat shall not be discharged into
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road drains, gutters, etc.
(d) Curing and Opening to Traffic

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Bituminous prime coat shall normally be left undisturbed for at least 24 hours after
application and shall not be opened to traffic until, in the opinion of the S.O., it has
penetrated the roadbase and cured sufficiently such that it will not be picked up by
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the wheels of vehicles.
The Contractor shall maintain the bituminous prime coat, all to the satisfaction of the
S.O., until the overlying pavement course is constructed, which shall not be within 24
hours after the application of the bituminous prime coat nor within such longer
period as is required, in the opinion of the S.O., for the prime coat to achieve
maximum penetration of the roadbase and become fully cured.
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4.3.2 Bituminous Tack Coat
This work shall consist of the careful and thorough cleaning of the surface of a
prepared and accepted bituminous or bitumen primed pavement course, and the
furnishing and application to the cleaned surface of a bituminous tack coat prior to
the construction of an overlying bituminous pavement course, all in accordance with
this Specification and the lines, dimensions and cross-sections as shown on the
Drawings and/or as required by the S.O.
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4.3.2.2 Materials
Bituminous tack coat material shall be rapid-setting cationic bitumen emulsion of

grade RS-IK conforming to the requirements ofMS 161 .
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4.3.2.3 Equipment
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The equipment shall be as specified in Sub-Section 4.3.1.3.
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Bituminous tack coat shall only be applied on to a clean and dry surface of
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bituminous or bitumen primed pavement course.
Bituminous tack coat shall amy be applied as far in advance of the construction of
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the overlying bituminous pavement course as is necessary to achieve a satisfactory

degree of tackiness before the overlying material is placed, all to the satisfaction of
the S_O.
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(b) Surface Preparation and Cleaning
Prior to applying bituminous tack coat, the surface to be treated shall have been
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prepared in accordance with the appropriate Sections of this Specification.

Notwithstanding any earlier approval of this swface, any damage to it or
deterioration of it shall be made good before bituminous tack coat is applied.
Immediately prior to applying bituminous tack coat, the full width of the surface to
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be treated shall be swept using a power broom followed by a compressed air blower,
and if necessary, scraped using hand tools, to remove all dirt, dust and other
objectionable materials, all to the satisfaction of the S.D.
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(c) Application o/Bituminous Tack Coat
The bituminous tack coat shall be sprayed on to the clean and dry surface of
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bituminous or bitumen primed pavement course by means of a pressure distributor.

Aoy areas inaccessible to the distributor spray bar shall be treated using the
distributor's hand spraying system. The rate or rates of application shall be as directed
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by the 8.0. based on the results oftest applications, but shall usually be in the range
0.25 to 0.55 litres/sq.m. The temperature of the bituminous tack coat shall be
maintained in the range 25 °C to 45 °C during spraying operations.
Bituminous tack coat shall be distributed unifonnly over the surface to be treated
without streaking; the quantities applied shall not deviate by more than 10% from
those prescribed. Areas with bituminous tack coat in excess of these limits shall have
the excess removed at the Contractor's expense, and areas with insufficient
bituminous tack coat shall be resprayed as necessary to make up the deficiency, all to
the satisfaction of the S.O.
54-23
JKRlSPJf2008·S4
The surfaces of structures, road furniture and trees adjacent to the areas being
sprayed shall he protected in such a manner as to prevent their being spattered or
marred by bituminous tack coat. Bituminous tack coat shall not be discharged into
road drains, gutters, etc.
Traffic shall be kept off the bituminous tack coat at all times, and the Contractor shall
maintain ·the bituminous tack coat, all to the satisfaction of the S.O., until the
overlying pavement course is constructed.
4.3.3 Asphaltic Concrete
ER
4.3.3.1 Description
This work shall consist of furnishing, placing, shaping and compacting asphaltic
concrete binder course andlor wearing course on a prepared and accepted bituminous
D
or bitumen primed pavement course, and shall include the careful and thorough
cleaning of surfaces which are to be covered prior to the application of bituminous
prime coat and tack coat. The work shall be carried out all in accordance with this
N
n Specification and the lines, levels, grades, dimensions and cross-sections as shown on
the Drawings andlor as required by the S.O.
TE
4.3.3.2 Materials
(a) Aggregates
A
Aggregates for asphaltic concrete shall be a mixture of coarse and fine aggregates,
and mineral filler. The individual aggregate shall be of sizes suitable for blending to
EJ
produce the required gradation of the combined aggregate, all to the satisfaction of
theS.O.
Coarse Aggregate
M
Coarse aggregate shall be screened crushed hard rock, angular in shape and free from
dust, clay, vegetative and other organic matter, and other deleterious substances.
They shall confonn to the following physical and mechanical quality requirements;
EN
i. The Los Angeles abrasion value when tested in accordance with ASTM C
131 shall be not more than 25%.
ii. The weighted average loss of weight in the magnesium sulfate soundness
M
u test (5 cycles) when tested in accordance with AASHTO Test Method T 104
shall be Dot more than 18%.
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than 25%.
iv. The water absorption when tested in accordance with MS 30 shall be not
O
more than 2%.
v. The polished stone value when tested in accordance with MS 30 shall be not
D
less than 40 (only applicable to aggregates for wearing course).
Fine Aggregate
Fine aggregate shall be clean screened quany dust. Other types of fine aggregate may
be used subject to the approval of the S.O. Fine aggregate shall be non-plastic and
free from clay, loam, aggregation of material, vegetative and other organic matter,
and other deleterious substances. They shall conform to the following physical and
mechanical quality requirements;
54-24
JKRlSPJI200B-S4
i. The sand equivalent of aggregate fraction passing the No.4 (4.75m.m) sieve
ii. The fine aggregate angularity when tested in accordance with ASTM C
1252 shal l be not less than 45%.
iii. The Methylene Blue value when tested in accordance with Ohio Department
of Transportation Standard Test Method shall be not more than 10 mg/g.
iv. The weighted average loss of weight in the magnesium sulphate soundness
test (5 cycles) when tested in accordance with AASHTO Test Method T 104
ER
V. The water absorption when tested in accordance with MS 30 shall be not

more than 2%.
D
Notwithstanding compliance with the requirements of this Specification, limestone
aggregates shall not be permitted for use in wearing course.
N
The gradation of the combined coarse and fme aggregates, together with mineral
TE
filler, shall conform to the appropriate envelope shown in Table 4.3.3.
TABLE 433 GRADATION LIMITS FOR ASPHALTIC CONCRETE
Mix Type Wearing Course Wearing Course Binder Course

A
Mix Designation ACIO I ACI4 I AC28
EJ
28.0 100
20.0 100 72 - 90
14.0 100 90 -100 58 -76
10.0 90 - 100 76 - 86 48 - 64
M
5.0 58 -72 50- 62 30 -46

3.35 48 - 64 40 - 54 24 -40
1.18 22-40 18 - 34 14 - 28
EN
0.425 12 - 26 12 - 24 8 -20
0.150 6 - 14 6 -14 4 - 10
0.Q75 4-8 4-8 3-7
For each type of mix required in the Works, the Contractor shall propose a laboratory
M
design mix. gradation which shall consist of a single definite percentage passing for
each sieve size in the above Table and shall produce a smooth curve within the
appropriate gradation envelope. This job laboratory design mix gradation, with the
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allowable tolerances for a single test as specified in Sub-Section 4.3.3.3 (c), shall
then become the job standard mix or job mix fonnula.
(b) Mineral Filler

O
Mineral fIller shall be incorporated as part of the combined aggregate gradation. It

shall be of fmely divided mineral matter of hydrated lime (calcium hydroxide). At the
D
time of mixing with bitumen, the hydrated lime shall be sufficiently dry to flow
freely and shall be essentially free from agglomerations. Not less than 70% by weight
shall pass the BS 75 urn sieve. The total amount of hydrated lime as mineral filler
shall be limited such that the ratio of the combined coarse aggregate, fine aggregate
and mineral filler of the final gradation passing 75 um sieve to bitumen, by weight,
shall be in the range of 0.6 to 1.2. As a guide, the total amount of hydrated lime shall
be approximately 2% by weight of the combined aggregates. The hydrated lime shall
also be treated as an anti-stripping agent.
If hydrated lime is not available, ordinary Portland cement shall be used as an
54-25
JKRlSPJ/2008-S4
alternative, subject to approval by the S.O.
(e) Bituminous Material
Bituminous binder for asphaltic concrete shall be bitumen of penetration grade 60-70
or 80-100 which conforms to MS 124, or polymer modified binder. The use of
polymer modified binder in asphaltic concrete shall conform to Sub-Section 4.11 of
this Specification.
4.3.3.3 Mix Design
ER
(aJ Job Mix Formulae
The Contractor shall propose a job mix formula for each type of mix required in the
Works. In order to obtain optimum quality of the mixes, the job mix formula for each
D
type of mix shall be prepared on the basis of testing several laboratory design mix
aggregate gradations within the limits set in Table 4.3.3 at an appropriate range of
bitumen content. As a guide to the testing range of bitumen content, the design
N
bitumen content will usually be in the range given in Table 4.3.4.
TE
Each combination of laboratory design mix aggregate gradation and bitumen content
shall be subject to the Marshall test procedure and volumetric analysis as follows;
i. Preparation of laboratory specimens for the standard stability and flow test
in accordance with ASTM 0 1559 using 75-blow/face compaction standard,
A
ii. Determination of the bulk specific gravity of the specimens in accordance
with ASTM D 2726,
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iii. Determination of the stability and flow values in accordance with ASTM D
1559,
M
iv. Analysis of the specific gravity and air voids parameters to determine the
percentage air voids in the compacted. aggregate, the percentage air voids in
the compacted aggregate fined with bitumen and the percentage air voids in
EN
the compacted mix.
For each laboratory design mix gradation, four specimens shall be prepared for each
bitumen content within the range given in Table 4.3.4 (see Note 1) at increments of
0.5 percent, in accordance with ASTM D 1559 using 75 blows/face compaction
M
standard All bitumen contents shall be in percentage by weight of the total mix.
C) As soon as the freshly compacted specimens have cooled to room temperature, the
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bulk specific gravity of each test specimen shall be determined in accordance with
ASTM D 2726.
The stability and flow value of each test specimen shall then be determined in
O
accordance with ASTM D 1559.
After the completion of the stability and flow test, specific gravity and voids analysis
D
shall be carried out for each test specimen to determine the percentage air voids in
the compacted aggregate filled with bitumen (VFB) and the percentage air voids in
the compacted mix (VIM).
Values which are obviously erratic shall be discarded before averaging. Where two
or more specimens in any group of four are so rejected, four more specimens shan be
prepared and tested.
S4-26
JKRlSPJ/2008-S4
The average values of bulk specific gravity, stability, flow, VFB and VIM obtained
above shall be plotted separately against the bitumen content and a smooth curve
drawn through the plotted values.
The mean optimum bitumen content shall be determined by averaging five optimum
bitumen contents so determined as follows;
i. Peak of curve taken from the stability graph (see Note 2),
ii. Flow equals to 3 nun from the flow graph,
ER
iii. Peak: of curve taken from the bulk specific gravity graph (see Notc 3),
iv. VFB equals to 75% for wearing course and 70% for binder course from the
VFB grapb,
D
v. VIM equals to 4.0% for wearing course and 5.0% for binder course from the
VIM graph.
N
The individual test values at the mean optimum bitumen content shall then be read
TE
from the plotted smooth curves and shall comply with the design parameters given in
Table 4.3.5
If all the values comply with Table 43.5, the mixture with the mean optimum
bitumen content shall be used in plant trials.
A
If any of the values does not comply with Table 4.3.5, the mix design procedure shall
be repeated using different laboratory design mix aggregate gradation until all the
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design parameters are satisfied.
Now·
t. The range of bitumen content shall be atendcd if necessary to ensure that the curves of
M
stability and bulk: specific gravity have their peak: within the range selected.
2. Where the stability curve exhibits more than one peak, the bitumen content chosen for the
determination of the mean optimum bitumen content shall be the one which satisfies the voids
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requirements better. It is sometimes necessary where no peak stability is obtained, to prepare

and test supplementary specimens at intervals of 0.25% bitumen contetlt on either side of the
expected optimum.
3. With highly absorptive aggregate, some difficulty in determining peak bulk specifie gravity
may occur. In such eases, the bitumen content at which the increase in bulk specifie gravity
M
shows a marked falling off shall be adopted.
TABLE 43_4: DESIGN BITUMEN CONTENTS

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AC 10 - Wearing Course 5.0- 7.0%

AC 14 - Wearing Course 4.0-6.0 %
O
AC 28 - Binder Course 3.5 - 5.5%

D
S4-27
JKR/SPJ/2008-S4
TABLE 4.3.5: TEST AND ANALYSIS PARAMETERS
Parameter Wearing Course Binder Course
Stability, S > 8000N > 8000N
Flow, F 2.0-4.0mm 2.0-4.0mm
Stiffuess, SfF >2000N/mm >2000N/mm
ER
Air voids in mix (VIM) 3.0 - 5.0% 3.0 -7.0%
Voids in aggregate 70 - 80% 65 -75%

filled with bitumen (VFB)
D
(b) Plant Trials
N
After having received the S.0. preliminary approval or
his proposed job mix formula,
the Contractor shall arrange to mix, lay and compact asphaltic concrete conforming
TE
to the proposed formula for each type of mix required in the Works. A minimum of
20 tonnes of each mix shall be placed in trial areas to demonstrate to the satisfaction
of the S.O. that the mixing, laying and compacting equipment conforms to the
requirements of this Specification. and that the proposed mix is satisfactory. The trial
areas shall not be part of the Contract Works but shall be provided by the Contractor
A
at his own expense. The proposed trial area shall be approved by the S.O.
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As directed by the S.D., comprehensive sampling and testing of each class of mix
shall be carried out to check for satisfactory compliance with its job mix formula, and
for a satisfactory degree of compaction. In order to demonstrate to the satisfaction of
the S.D. that mixing, laying and compacting equipment confonn to the requirements
M
of the specification, and that the proposed mix is satisfactory, the following
observations and tests shall be carried out;
i. Record the type and weight of rollers. Check the tyre pressure of the
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pneumatic lyre roller (shall comply with Sub-Section 4.3.3.4 (e)).
ii. Record the type of paver (sball comply with Sub-Section 4.3.3.4 (d)).
M
iii. Check that the trial area is suitable (not on soft ground, uneven surface or
u part of the Contract Works).

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iv. Take samples of the mix. one set from each lorry load, and carry out the
following tests;
• Binder content and aggregate grading (shall conform to the precise
aggregate gradation and bitumen content as determined from the mix
design and within the tolerances set forth in Table 4.3.6.
O
• Preparation of Marshall specimens.

o Bulk specific gravity.
D
o Volumetric properties (shall comply with Table 4.3.5).

o Marshall stability and flow (shall comply with Table 4.3.5).
v. Record temperatures of mix on the lorry. at plant and site (shall not exceed
163°C at any time and shall be not less than 130 °C (increased by 10°C for
penetration grade 60-70 bitumen) immediately before unloading into the
paver hopper).
vi. Record laying (uncompacted) thickness.
S4-28
JKR/5PJ/2008-S4
vii. Check texture of paved surface before rolling (there shall be no substantial
blemishes and irreguJarities).
viii Record temperatures of mix immediately before rolling starts (rolling

temperatures). The temperature of mix at the commencement of rolling shall
be not less than 120 DC (increased by 10 °C for penetration grade 60-70
bitumen). Rolling shall not be continued when the mix has cooled to 80 DC
and lower.
ix Record rolling pattern.
ER
X. Check texture of compacted surface.
xi. Take core samples after the laid material has sufficiently hardened (at least
three samples from each lorry load).
D
xii. Measure compacted thickness and density of the core samples (shall comply
with Sub-Section 4.3.3.5 (i) and 0)).
N
If the composition of the mix does not conform to the precise aggregate gradation o
TE
and bitumen content as determined in the mix design procedure as described in Sub-
Section 4.3.3.3 (a) and within the tolerances set forth in Table 43.6, and/or the
Marshall specimens do not comply with any oftbe properties set forth in Table 4.3.4
the mix design procedure sball be repeated using different aggregate gradation and
the plant trial shall be repeated.
A
If the texture of the paved and/or compacted surface are not satisfactory, and/or the
compacted thickness and/or density are inadequate, the plant trial shall be repeated
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using different paver and/or roller{s).
Upon satisfaction by the S.O., the Contractor shall be required to produce a full
report of the plant trials and this document shall be used in full scale production in
M
the Works.
(c) Compliance with the Job Mix Formula

EN
The S.O. final approval of the job mix formula shall bind the Contractor to produce
aspbaltic concrete mixes conforming to the precise gradation and bitumen content
specified in the formula within the tolerances set forth in Table 4.3.6.
M
Modifications to the job mix formula shall only be made with the approval of the
S.O. Should the s.o. at any time have reasons to believe that the asphaltic concrete
mixes and methods of mixing and laying are different from those approved, he shall
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so advise the Contractor and instruct that asphaltic concrete works be discontinued
pending proper mix design and plant trials.
O
D
54-29
JKR/5PJI2008-54
TABLE 4.3.6: TOLERANCES FOR ASPHALTIC CONCRETE MIXES
Parameter Permissible Variation

% by Weight or Total Mix
Bitumen content ± O.2%
Fractions of combined
aggregate passing 5.0 mm
and larger sieves ± 5.0%
ER
aggregate passing 3.35 nun
and 1.18 mm sieves ± 4.0%
D
aggregate passing 425 urn
N
n and 150 urn sieves ±3.0%
TE
aggregate passing 15 urn sieve ±2.0%
4.3.3.4 Equipment
A
The Contractor shall provide all the plant and equipment necessary for executing the
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work in accordance with this Specification and shall :furnish the S.O. with such
details of particular items of equipment, e.g. manufacturer, model type. capacity,
weight, operating features, etc., as the 8.0. shall require.
M
(a) Road Cleaning Equipment
Immediately prior to applying bituminous tack coat, the full width of the surface to
be treated shall be swept using a power broom followed by a compressed air blower.
EN
and if necessary, scraped using hand tools, to remove all dirt, dust and other
objectionable materials. all to the satisfaction of the S.O.
(b) Asphalt Mixing Plant

M
The asphalt plant shall be either a batch plant or a drum mix plant or a continuous
l) mix plant of recognized manufacture and shall be approved by the S.O. It shall
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conform to the requirements described hereunder.
The mixing plant shall have a capacity suited to the Works and sufficient to enable
the paver to operate more or less continuously when paving at normal speeds at the
required thicknesses. The plant shall be to designed as to enable cODsistent
O
production of asphaltic concrete mixes within the tolerances prescribed in this

Specification, aU to the satisfaction of the S.O.
D
Mixes produced and delivered shall have actual tonnages of aggregates, filler and
bitumen components recorded. The temperature of the mix leaving the plant sha1l be
recorded for each batch or every 15 minutes. Where the control system incorporates a
computer and a printer capable of printing the information, copies of the printouts
shall be provided to the S.O. for quality assurance.
Tanks for storage of bitumen shall have a capacity suited to the proposed rate of
utilizations of the material and the method and frequency of its delivery to the
Works, all to the satisfaction of the S.O. The tanks shall be provided with means of
measuring the volume of their contents at aU times and of drawing off samples of the
54-30
JKRlSPJI200B-S4
contents. The bitumen feeding system shall provide for continuous circulation of hot
binder tluougb the system and back into the feed tank. The end of the return line
discharging into the feed tank shall always be kept submerged in the bitumen in the
tank in order to prevent oxidation of the returning hot binder. The storage tanks, and
where necessary barred decanters, and aU elements of the bitumen feeding system
shall be equipped with heating system or insulating jackets as necessary to provide
for effective and positive control of the temperature of the bitumen at aU times up to
the temperature required for utilizations. The method of heating shall be such that
neither flames nor the products of combustion shall come into direct contact with the
bitumen or the casing of its immediate container, and such that no portion of the
bitumen shall be subject to overheating.
ER
Calibration of the plant to an accuracy of ± I % error must be carried out before the
production of the trial mixes. This calibration is to test the integrity of all the
weighing system of the storage bins and bitumen hopper.
D
Calibration is also required for the feeders to match the production capacity. Once the
calibration is set and mixes production commence, calibration procedures shall be
N
repeated every 30,000 tonnes or one month whichever is earlier.
TE
i) Batch Plants
The plants shall be provided with accurate mechanical means for uniform1y
feeding the aggregate into the dryer so that uniform production and
temperature of the heated aggregate will be obtained. A separate feed bin
A
with an adjustable gate opening shall he provided for eacb aggregate to be
included in the combined aggregate for the mix; normally four bins will be
required. The reed bins and gates shall be constructed and equipped that
EJ
they shall be readily accessible for calibrating at all times, and shall provide
for a continuous and uniform flow of each aggregate required in the mix.
The plant shall have a rotary drum dryer of satisfactory design for drying
M
and heating the combined aggregate so that its temperature will be at the
required level at the time it is mixed with the bitumen. The burner shall be
so designed that complete combustion of the fuel will be obtained, and the
EN
aggregate will remain clean and not become coated with soot or oil.
The plant shall be equipped with four (or more) screens. the smallest of
which shall generally be not more than 3.2 mm. The screens shall have a
normal capacity slightly in excess of the maximum output of the mixing
M
plant. The screens shall be readily accessible for inspection.
The plant shall include four (or more) storage bins for screened aggregates,
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each with a capacity of not less than twice the pugmill dead load capacity.
The bins shaU be arranged so as to provide separate dry storage for each
screened fraction of the aggregate. Each bin shaU be provided with an
overflow pipe of such size and location as to prevent any backing up of
O
material into other bins. Each bin shall be so constructed that representative
aggregate samples can be readily obtained, and shall have means for
observing the aggregate level. Separate dry storage shaU be provided for
D
mineral fiUer, and the plant shall be satisfactorily equipped to feed filler into
the mixer.
Accurate means of weighing by load cells shall be provided for weighing

the aggregates and filler and also for weighing the bitumen required for each
batch of mix.
Suitable means shall be provided for maintaining the prescribed temperature

of the bitumen in the pipelines, weigh bucket of flow meter, and spray bars.
54-31
JKRlSPJf2008-54
An armoured thermometer with a range of 30°C to 200 °C shall be fitted in

the bitumen feed line at a suitable location near the discharge valve at the
mixer unit. Suitable dial-scale mercury actuated thennometer, electric
pyrometers or other thermometer instruments shall be fitted at the discharge
chute of the dryer and in each hot aggregate storage bin to indicate the
temperature of the heated aggregate.
The plant shall be equipped with adequate and safe stairways to the mixing
platform and sampling location and guarded ladders and cat-walks shall
provide access to atl other positions as necessary for proper operation,
inspection and maintenance of the plant, all to the satisfaction of the SO. All
ER
gear, pulley. chains. sprockets and other dangerous moving parts shall be
property guarded and protected. Ample and unobstructed space shall be
provided on the mixing platform. and clear and unobstructed passage shall
be maintained at all times in and around the truck loading area, which shall,
D
be kept free from drippings from the mixer.
Each storage bin for screened aggregate shall be provided with a bottom
N
n outlet gate so constructed as to prevent leakage when closed. These gates
shall have a quick and complete closing action. The plant shall be equipped
TE
with a weigh box or hopper for accurately weighing out aggregate from each
of the screened aggregate storage bins. The weigh box or hopper shall be
suspended from its scale's lever mechanism and shall be sufficiently large to
holds a full batch equal to the pugmill capacity without hand raking of the
aggregate. The discbarge gate shall be so constructed as to allow rapid and
A
complete emptying of the weigh box or hopper into the mixer, and prevent
leakage when closed.
EJ
The plant shall be equipped with a binder weigh bucket which sball be
charged through a fast acting non-dip valve in the binder feed pipe located
directly over the bucket. The bucket shall be suspended from its scate's
M
lever mechanism and shall have a capacity sufficient to weigh out binder up
to 20% of the weight of the pugmill dead load capacity_ The bucket sbaU
have a discharge mechanism which shall provide for rapid and complete
emptying of the bucket in a thin unifonn sheet or multiple sprays over the
EN
full length and width of the mixer_ The discharged shall not leak or drip
when closed
The batch mixer shall be a suitable twin-shaft pugmill, with a capacity of at

least 500 kg of aspbaltic concrete, capable of producing a thoroughly
M
homogeneous mixture. The clearance of the paddle blades from all fixed and
\. ) moving parts of the mixer shall be not more than 20 mm. If the pugmill is
not enclosed, it shall be equipped with a dust hood to prevent loss of fmes
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from the mixture. The discharge gate shall be so constructed as to allow

rapid and complete emptying of the mixer, and prevent leakage of any mix
constituent when closed.
O
The mixer shall be equipped with an accurate time lock system for
controlling the operations of a complete mixing cycle. [t shall lock the
aggregate weigh box or hopper gate after charging the mixer with aggregate,
D
until the closing of the mixer gate at the completion of the mixing cycle; it
shall lock the binder weigh bucket discharge mechanism during the dry
mixing and wet mixing period. The dry mixing period is defmed as the
interval of time between the opening of the aggregate weigh box of hopper
gate and the start of discharging the binder weigh bucket The wet mixing
period is defined as the interval of time between the start of discharging the
binder weigh bucket and the opening of the mixer gate. The dry and wet
mixing periods shall both be adjustable in increments of not more than 5
seconds from zero to not more than 60 seconds total for dry and wet mixing.
54-32
JKRlSPJ/2008-S4
The filler silo shall have suitable a screw conveyor system to discharge into
the pugmill.
The control system for the plant shall be housed in a weather proof cabin
with windows to view the plant operations. Cootrol in the cabin shall have
the capability to accurately batch the aggregates, filler and bitumen for the
mix, transfer to the pugmill mixer and control the mixing time. The
temperature of the heated aggregates, filler and bitumen shall also be
displayed in this cabin and adjusted to meet the Specification when required.
ii) Drum Mix Plants
ER
The cold material feeder unit shall consist of not less than 5 bins with
suitable heaped capacity appropriate for the plant. Each bin shall be
equipped with a variable speed weighing belt feeder (driven by variable
D
speed electric motor fitter with a tachometer) with a load cell for accurate
weight measurement of each type of aggregate used in the mix in equivalent
dry tonnes per hour. The cold feed system shall incorporate a device for
N
moisture compensation capable of producing an accurate and continuous
blend of the individual aggregate sizes from the cold feed compartment. The
TE
cold feed system shall also be equipped with a scalping screen of screed size
of not more than 5Om.m to discard any oversized aggregates before entering
the dryer drum.
The drum mixer shaH have flight designs to accomplish the proper transfer
A
of heat from the exhaust gases of the burner to the aggregates and to blend
the aggregates and bitumen together adequately. The flight, at the upper end
of the drum, shall be able to direct the aggregate into the dnnn beyond the
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tip of the flame, thereafter the subsequent flight shall be efficient to lift and
tumble the aggregates with the cumulation of a veil of aggregates across the
whole cross-sectional area near the mid-point of the length of drum where
the aggregate temperature shall have been raised to dew point. This veil of
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aggregates shall be sufficiently complete and dense to maximise heat

transfer and to screen the bitumen from the direct flame to minimise
hardening and oxidation of the bitumen during the mixing process. The
EN
downstream mixing flight designs shall complete the heat transfer process
and raise the mix temperature to the desired level for discharge. The length
to diameter ratio of the drum shall be appropriately designed to obtain more
complete heat transfer; to enable the bitumen to be injected in an inert
atmosphere where proper coating/adhesion onto aggregates can take place
M
without severe oxidation or hardening of bitumen and effective mixing and

sufficient designed mix temperatures are achieved. The drum shaU be
inclined, oil-flIed and suitably and sufficiently insulated.
KU
The control system of a drum mixer shall be automatically computer

controlled with a fully independent manual back-up system. The system
shall be such that the operator is able to view the operation of the whole
O
plant and of the individual component stations. All relevant information of

the plant operation and the progress of the tonnage of mix tonnage produced
and mix design information shall be made available. The control system
D
shall possess a Quality Assurance package to act as an audit tool (when

required to be used) whereby the information on Plant Monitor, Progress
Monitor, and Mix Temperatures can be made available at pre-set, variable
time intervals.
Freshly mixed material shall be collected and delivered to be stored in a

surge silo through a proper conveyor system.
Note: Continuous Mix Plant' has been left out due to its uncommon use today.
S4-33
JKRlSPJI200B-S4
(cJ Tip-Truck
The Contractor shall provide a suitable number of tip-trucks of a type approved by

the S.O. for transporting asphaltic concrete from the mixing plant to the paving sites.
The trucks shall have trays with smooth. flat beds and sides, and shall have load
capacities of not less than 5 toones. Prior to loading. the inside of each truck tray
shall be lightly and evenly coated with a soap or detergent solution, or such other
liquid as the S.D. shall approve, to prevent adhesion of the asphaltic concrete. The
trucks shall be equipped with covers of canvas or other suitable material to protect
the asphaltic concrete.
ER
(dJ Asphalt Paver
The asphalt paver shall be of recognized manufacture and shall be approved by the
S.O. It shall conform to the requirements described hereunder.
D
The paver shaU be self-propelled and capable of reverse as well as forward travel. It
shall be equipped with a hopper at the front designed to receive the paving mix from
N
tip-trucks, and shall have a mechanical distribution system for spreading the mix
evenly and without segregation over the surface to be paved in front of a screeding
TE
and compacting unit which shall be equipped with a suitable heating device. The
screeding and compacting mechanism shall be capable of confining the edges of the
material being laid without the use of stationary side forms, shall be adjustable to
strike off the mixture to the thickness and cross-section shape required, and shall be
controlled by an automatic levelling device to produce an even carpet of bituminous
A
mixture with a uniform surface texture free from indentations, ridges, tear marks or
other irregularities. The paver shall be capable of laying the bituminous mixture in
paving widths in the range 2.5 to 3.75 m and of finishing the pavement layer true to
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the required lines, grades. levels, dimensions and cross-sections, subject to

compaction by rolling. all to the satisfaction of the S.D.
(eJ Rollers
M
A pneumatic tyred roller and two steel wheeled tandem rollers shall be provided.
However, a three wheeled steel roller may be substituted for one of the tandem
EN
rollers if the S.D. shall so approve. All rollers shall be of recognised. manufacture and
shall be approved by the S.D.
i) Pneumatic Tyred Roller

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The pneumatic tyred roller shall be self-propelled and capable of being

() reversed without backlash; it shall be equipped with power steering and dual
controls allowing operation from either the left or right side.
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The roller shall have nine wheels equipped with smooth treaded tyres all of
the same size and construction, and capable of operating at inflation
pressures of up to 0.9 Nlrnm2• Five wheels shall be on the driven axle and
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four on the steering axle, all equally spaced on both axles and arranged so
that the tyres on the steering axle track midway between those on the driven
axle with a small overlap. The roller shall be equipped with water tanks,
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sprinkler systems and pads of coconut matting to keep all tyres evenly
wetted during operation.
The roller shall be equipped with means of adjusting its total weight by
ballasting so that the load per wheel can be varied in the range 1.0 to 2.0
tonnes. In operation, the ballasted weight a..,d the tyre inflation pressure
shall be adjusted to meet the requirements of each particular operation. Each
tyre shall be kept inflated at the specified pressure such that the pressure
difference between any two tyres shall not exceed 0.04 N /mm2 • Means shall
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be provided for checking and adjusting tyre pressures at all times at the
place of the works.
The Contractor shall provide the S.D. with a calibration chart for the roller
showing the relationship between the quantity or depth of ballast and total
weight, and also a chart showing the relationship between wheel load, tyre
inflation pressure and contact pressure.
ii) Steel Wheeled Tandem Roller
The steel wheeled tandem roller shall be self-propelled and capable of being
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reversed without backlash; they shall be equipped with power steering and
dual controls allowing operation from either the left or right side. The roller
shall be equipped with water tanks, sprinkler systems and scraper blades to
keep all wheels evenly wetted and clean during operation.
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Each steel wheeled tandem roller shall be ballasted so that itslotal operating
weight is in the range 8 to 10 tonnes and its driven roll (or rolls) shall exert a
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rolling force of not less than 3.5 toones/metre of roll width. The Contractor
shall provide the S.O. with a calibration chart for each roller showing the
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relationships between the quantity or depth of ballast and total weight and
rolling force.
4.3.3.5 Coll.'!truction Methods

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Asphaltic concrete paving work shall only be carried out in dIy weather when the
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surface to be covered is clean and dry, and has received a bituminous tack coat which
shall have achieved a satisfactory degree of tackiness, all to the satisfaction of the
5.0. All laying. rolling and finishing works shall be carried out during daylight
hours, unless the Contractor shall have provided suitable flood-lighting for the job
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site. to the satisfaction of the S.O.
The S.O. may order the discontinuation of work on account of adverse weather,
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unsatisfactory condition of materials, equipment or surface to be paved. or such other

conditions as he or she shall consider detrimental to the work.

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Prior to constructing an asphaltic concrete pavement layer, the surface to be covered

shall have been prepared in accordance with the appropriate Sections of this
Specification. Notwithstanding any earlier approval of this surface, any damage to or
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deterioration of it shall be made good before asphaltic concrete paving work is

commenced.
If the surface to be covered is to be provided with a bituminous tack coat, then this
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shall be applied all in accordance with the provisions of SulrSection 4.3.2.
(c) Aggregate Handling and Heating

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Each aggregate to be used in the asphaltic concrete mixes shall be stored in a separate
stockpile near the mixing plant. Stockpiles of sand and other fine aggregates shall be
kept dry using waterproof covers and other means as necessary. In placing the
aggregates in the stockpiles and loading them into the mixing plant's cold aggregate
feed bins, care shan be taken to prevent segregation or uncontrolled combination of
materials of different gradation. Segregated or contaminated materials shall be
rescreened or rejected for use in the Works and removed from the mixing plant site.
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The aggregates shall be fed into the dryer at a uniform rate proportioned in
accordance with the appropriate job mix formula. The rate of feed for each aggregate
shall be maintained within 10010 of the rate prescribed, and the total rate of feed shall
be such that the plant's screens shall never be overloaded.
The aggregates shall be dried and heated so that when delivered to the mixer they
shall be at a temperature in the range 150 °C to 170 °C.
Immediately after heating, the aggregates shall be screened into four (or more)
fractions which shall be separately stored in the hot aggregate storage bins in
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readiness for mixing.
Mineral filler cum anti-stripping agent to he used in the mix. shall be stored separately
and kept completely dry, Its rate of feed into the plant shall be accurately controlled
by weight or volumetric measurement, all to the satisfaction of the S.D.
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(d) Heating ojBitumen
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The bitumen shall be heated so that when delivered to the mixer it shall be at a
() temperature in the range 140 DC to 160 DC.
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(e) Miring Asphaltic Concrete
The mixing plant shall be so coordinated and operated as to consistently produce

asphaltic concrete mixes within the tolerances prescribed in this Specification. all to
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i) Mixing in Batch Plants
For each batch the screened hot aggregates shall be weighed out into the
aggregate weigh hopper in accordance with the proportions prescribed in the
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appropriate job mix formula; the sequence of weighing out shall commence
with the largest sized aggregate and progress down to the fines. unless the
S.O. shall otherwise approve. Mineral filler shall be weighed out into the
filler weigh hopper. where this is provided, or added last to the aggregate
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weigh hopper. in accordance with the job mix formula proportions.
The hot binder shall be weighed out into the binder weigh bucket in
accordance with the proportions prescribed in the job mix formula.
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The hot aggregates and filler shan be discharged into the pugmin and mixed
dry for the dry mixing time prescribed in the job mix formula. which shall
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usually be in the range five to 10 seconds. The hot binder shall then be
added and wet mixing performed for the wet mixing time prescribed in the
job mix formula; this shall be sufficient so that all particles of aggregate are
uniformly coated with bitumen. and shall usually be 45 seconds or less for
dense graded mixtures.
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The volume oblades just break out of the mixture at the height of their
action.
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After the completion of wet mixing, each batch of asphaltic concrete shall
be discbarged from the pugmill either into a storage hopper or directly into a
truck for hauling to the paving site. Care shall be taken that no segregation
of the mix occurs.
ii) Mixing in Drum Mix Plants
The screened hot aggregates and filler shall be fed continuously from their
storage bins in accordance with the proportions prescribed in the appropriate
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job mix formula, combined in the plant, and fed continuously into the mixer.
The hot binder shall be sprayed on to the combined aggregate as it enters the
pugmiU at the rate required to achieve the bitumen content prescribed in the
job mix formula. The materials shall then be carried through the pugmill
and in the process be thoroughly mixed by the action of the paddles and
discharged over the dam into the storage hopper. The mixing time shall be
sufficient so that all particles of aggregate are unifonnly coated with
bitumen, and shaH usually be 45 seconds or less for dense graded mixtures.
The plant shall be so adjusted as to maintain the level of mixture in the

pugmill such that the tips of the paddle blades just break out of the mixture
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at the height of their action.
(f) Transportation ofAsphaltic Concrete
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Asphaltic concrete shall be transported from the mixing plant to the site of the paving
works in loads of not less than 5 tonnes using tip-trucks as specified in Sub-Section
4.3.3.4 (c) . Except where asphaltic concrete is to be hand laid, it shall be discharged
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directly into the paver hopper, as required, from the tip-trucks . Care shall be taken in
the truck loading, hauling and unloading operations to prevent segregation of the
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mix. During transportation, the asphaltic concrete shall be protected from
contamination by water, dust, dirt and other deleterious materials.
The temperature of asphaltic concrete immediately before tmloading from the truck
either into the paver hopper or on to the road for hand spreading shall be not less than
130 ·c (increased by 10 ·c ror penetration grade 60-70 bitumen). Any load which
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has cooled below the specified temperature in the truck shall be rejected for use in
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the Works and removed from the Site of the Works.
(g) Laying Asphaltic Concrete

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The sequence of laying operations shall be planned in advance by the Contractor and
approved by the S.O. Generally each paving layer shall have a compacted thickness
of not less than twice the nominal maximum aggregate size of the mixture, and not
more than 100 mm. Where applicable, e.g. on superelevated sections and on
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carriageways with cross-slope in one direction only, laying shall commence along the
lower side of the carriageway and progress to the higher side. Laying shall not be
carried out in a downhill direction along any section of road.
As far as is practicable, laying shall be carried out using a paver approved by the S.O.
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Hand-casting of bituminous mix. on to the machine finished swface shalt be kept to

the practicable minimum necessary for correcting blemishes and irregularities. In
any areas inaccessible to the paver, laying shall be carried out by hand methods using J
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rakes, lutes and other hand tools, all to the satisfaction of the S.O. AU laying of
bituminous mix shall be such that after compaction by rolling the specified course or
layer thickness and swface profile shall be achieved. Care shall be taken to achieve a
uniform surface texture free from indentations, ridges, tear marks or other
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irregularities, and to prevent segregation of the mix.
At the commencement of initial rolling the temperature of asphaltic concrete shall be

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not less than 120 °C (increased by to °C for penetration grade 60-70 bitumen).
Material which has cooled below the specified temperature before laying shall not be
used and shall be removed from the Site of the Works. The Contractor shall provide
accurate thermometers at the paving site at all times, and shall check the temperature
of asphaltic concrete in the paver hopper at regular intervals and before laying
restarts after each intenuption of the paving operation.
As far as is practicable, the paver shall be operated continuously and the supply of
bituminous mix shall be regulated so as to enable continuous paving. Transverse
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joints in a paving lane shall be kept to a practicable minimum, and intermittent

stopping and restarting of the paver shall b e avoided as far as is practicable.
Care shall be taken that no bituminous mix is placed on expansion joints at bridges,
inspection covers for utilities ducts, drainage and sewerage manholes and the like.
and that catchpits, drainage openings througb kerbs. etc., remain properly open and
serviceable. During laying operations, such areas and openings shall be protected by
suitably shaped and secured boards or other materials approved by the S.D., and
compaction of mix in the immediately surrounding or adjacent areas shall be
completed by hand methods, all to the satisfaction of the S.D. Alternatively,
bituminous mix shall be laid and compacted by hand methods as necessary around
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surfacing discontinuities of these types, all to the satisfaction of the S.O.
(h) Construction Joints
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Existing bituminous surfacing which new bituminous mix is to adjoin shall be cut
back to present a straight, vertical edge not less than 25 m.m deep and a smooth
transition section not less than 500 mm long against which to lay the new material.
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The specified thickness of the new surfacing shall be built up gradually from the
() vertical joint to avoid any bumps or ridges across the carriageway.
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Where longitudinal or transverse joints are required in a layer of bituminous mix
under construction,. the material first laid and compacted shall be cut back to a
vertical face for the full thickness of the layer on a line satisfactory to the S.O. before
the adjacent area is paved.
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At all construction joints, a thin uniform coating of bitumen emulsion of grade RS-
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1K shall be brushed on to the vertically cut joint faces some 10 to t 5 minutes before
laying the next section of bituminous mix commences to ensure good bonding. Also,
all contact surfaces of kerbs, gutters, manholes, catchpits, etc. shall be similarly
treated with a coating of bitumen emulsion before bituminous mix is placed against
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them.
Construction joints in a layer of bitwninous mix shall be offset from those in any
immediately underlying bituminous layer by at least 100 mm for longitudinal joints
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and at least 500 mm, for transverse joints.
Construction joints shall not be pennitted along wheelpaths.
(i) Compaction ofAsphaltic Concrete.

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() For each layer of asphaltic concrete, compaction by rolling shall commence as soon
after laying as the material will support the rollers without undue displacement;
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nevertheless the temperature of asphaltic concrete at the commencement of rolling

shall be not less than 120 ·C (increased by 10 ·C for penetration grade 60-70
bitumen). Rolling shall not be continued when the temperature of asphaltic concrete
has decreased to 80 °C or lower.
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In any areas inaccessible to the rollers, proper compaction shall be carried out using
vibrating plate compactors, hand tampers or other suitable means, all to the
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Initial (or breakdown) rolling shall be carried out with an approved steel wheeled
tandem roller or three wheeled steel roller. The principal heavy rolling shall be
carried out with an approved pneumatic tyred roller immediately following the initial
rolling; the pneumatic tyred roller shall be ballasted to an operating weight of not less
than 15 toones and its tyre inflation pressure shall be not less than 0.7 N /mm 2 • The
final rolling shall be carried out with an approved steel wheeled tandem roller and
shall serve to eliminate minor surface irregularities left by the pneumatic tyred roller.
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All rollers shall operate in a longitudinal direction along the carriageway with their
driven wheels towards the paver. Rolling shall generally commence at the lower edge
of the paved width and progress unifonnly to the higher edge, except that where there
is a longitudinal construction joint at the higher edge, this shall be rolled first ahead
of the normal pattern ofroUing. Generally, successive roller passes shall overlap by
half the width of the roller, and the points at which the roller is reversed shall be
staggered. However, when operating on gradients in excess of 4%, the breakdown
roller shall not pass over any previously unrolled mix when operating in the downhill
direction.
In all cases, compaction shall be carried out in such a manner that each section
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receives equal compactive effort, all to the satisfaction of the S.O.
The steel wheeled rollers shall operate at speeds of not more than 5 kmIh and the
pneumatic tyred rollers shall operate at speeds of not more than 8 kmIh. No roller or
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heavy vehicle shall be allowed to stand on newly laid bituminous mix before
compaction has been completed and the material has thoroughly cooled and set.
Rolling shall be carried out to achieve the appropriate requirement as shown in Table
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4.3.7.
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TABLE 4.3.7: REQUIREMENTS OF COMPACTED DENSITY FOR
ASPHALTIC CONCRETE
Type of Pavement Layer Required Compacted Density

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Wearing course 98 - 100% Manhall density
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Binder course 95 - 100% Marshall density
Care shall be taken to prevent over-compaction of asphaltic concrete.

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Within 24 hours of laying and compacting the bituminous mix, the Contractor shall
cut core samples of Dot less than 100 mm nominal diameter at locations selected by
the S.D. The rate of sampling shall be one sample per 500 m 2 of mix laid, but not less
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than two samples for the work completed in each paving session. These core
samples shall be used by the S.O. to determine the thickness of the compacted layer
of mix and the compacted density of the material in accordance with either ASTM
Test Method D 1188 or ASTM Test Method D 2726, whichever is applicable.
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(j) Finished Asphaltic Concrete

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Asphaltic concrete binder and wearing courses shall he fmished in a neat and
workmanlike manner; their widths shall he everywhere at least those specified or
shown on the Drawings on both sides of the centre-line; the average thickness over
any laO-metre length shall be not less than the required thickness, and the minimum
thickness at any point shall be not less than the required thickness minus 5 mm.
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The top surface of asphaltic concrete binder and wearing courses shall have the
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required shape, superelevatioo, levels and grades, and shall be everywhere within the
tolerances specified in Sub-Section 4.5.
(Ie) Opening to Traffic
Asphaltic concrete shall not be opened to traffic until compaction has been completed
and the material has thoroughly cooled and set in the opinion of the S.O. This will
usually be oot less than four hours after the commencement of rolling. Where it is
necessary to allow earlier use of the fInished surface to facilitate the movement of
traffic, vehicles may be anowed to run 00 the work after rolling has been completed,
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provided that speeds are restricted to 30 km/h or less and sharp twning movements
are prohibited.
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4.4 SHOULDERS
4.4.1 Description
This work shall consist of furnishing, compacting and shaping earth, gravel or paved
shoulder material on a prepared and accepted sub-base or subgrade, all in accordance
with this Specification and the lines, levels, grades, dimensions and cross-sections as
shown on the Drawings and/or as required by the S.D.
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4.4.2 Materials
4.4.2.1 Paved Shoulders
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The bituminous surfacing and underlying pavement courses shall be constructed as
described in the appropriate Sections of this Specification.
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4.4.2.2 Gravel Shoulders
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Gravel shoulder material shall conform to the requirements for gravel swfacing
material set forth in Sub-Section 4.1 .3.
4.4.2.3 Earth Shoulders

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Earth shoulder materia) shan be suitable material as described in Sub-Section 22.1.
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4.4.3 CODstruction Methods
Shoulders shall be constructed in stages or in one operation as directed or approved

by the S.O., but in no instance shan a shoulder be built up to a level higher than that
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part of the abutting carriageway structure which has been completed and accepted.
Prior to placing any shoulder material, the underlying sub-base or subgrade shall
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have been shaped and compacted in accordance with the provisions of Sub-Sections
4.1.2.3 and 2.2.7 respectively, and the abutting carriageway structure course or
courses shall likewise have been shaped and compacted in accordance with the
provisions of the appropriate Sub-Sections of this Specification. Notwithstanding any
earlier approval of the underlying and abutting pavement courses, any damage to or
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deterioration of these underlying and abutting pavement courses shall be made

good to the satisfaction of the S.O. before shoulder construction proceeds.
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Shoulders shall be placed to the required width and thickness as shown on the
Drawings or as directed by the S.D. in one layer or more, each layer not exceeding
200 nun compacted thickness at the point of maximum thickness. Where two or more
layers are required, they shall be of approximately equal shape and thickness, and
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none shall be less than 100 mm compacted thickness at the point of maximum
thickness.
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Each layer of shoulder material shall be processed as necessary to bring its moisture
content to a uniform level throughout the material suitable for compaction, and shan
then be compacted using suitable compaction equipment approved by the S.O. to not
less than 95% of the maximum dry density determined in the BS 1377 Compaction
Test (4.5 kg rammer method). Compaction shan be carried out in a longitudinal
direction along the shoulder and shall generally begin at the outer edge and progress
uniformly towards the carriageway, except on super-elevated curves where rolling
shall begin at lower edge and progress unifonnly towards the higher edge. In all
cases, compaction shall be carried out in such a manner that each section receives
compactive effort appropriate to its thickness, all to the satisfaction of the S.O.
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Throughout the placing, adjustment of moisture content and compaction of shoulder

material, care shall he taken to maintain a uniform gradation of the material and
prevent its separation into coarse and separate parts, all to the satisfaction of the S.~ .
Where shown on the Drawings or directed by the S.D., earth shoulders shall be turfed
in accordance with Sub-Section 2.2.8.2.
Shoulders shall be fmished in a neat and workmanlike manner. The total width of
carriageway and shoulder shall be everywhere at least that specified or shown on the
Drawings on both sides of the centre-line. The top surface of each shoulder shall
have the required shape, super-elevation, levels and grades, shall be everywhere
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within 10 mm of the required plane. and shall provide a flush joint with the
carriageway surface and shall be uniformly free draining away from the carriageway.
aU to the satisfaction of the 8.0.
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4.5 HORIZONTAL ALIGNMENT, SURFACE LEVELS AND SURFACE REGULARITY

OF PAVEMENT COURSES
4.5.1 Horizontal Alignment
The horizontal alignment shall be determined from the centre-line of the pavement
surface shown on the Drawings. The edges of the pavement as constructed and all
other parallel construction lines shall be correct within a tolerance of + 50 mm and
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minus 0 mm from the centre-line, except for kerbs. channel blocks and edge lines
which shall be laid with a smooth alignment within a tolerance of + 25 mm and
minus 0 mm from the centre-line.
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4.5.2 Surface Levels of Pavement Courses
The design levels of pavement courses shall be calculated from the vertical profile,
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cross fall and pavement course thicknesses shown on the Drawings. The level of any
point on the constructed surface of a pavement course shall be the design level
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subject to the appropriate tolerances given in Table 4.5.1.
TABLE 45_1: TOLERANCES IN SURFACE LEVE!-S OF PAVEMENT

COURSES
A
Pavement Course Tolerance
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Wearing Course ±5mm

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Binder Course ±5mm
Roadbase +0 mmto -20mm

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Sub-base + lOmmto-20mm
The combination of pennitted tolerances in the levels of different pavement courses

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shall not result in a pavement thickness less than that shown on the Drawings. Each
pavement course shall have an average thickness not less than that shown on the
Drawings.
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4.5.3 Surface Regularity
4.5.3.1 Description
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Riding quality on a road surface is positively correlated with roughness of the

surface. Low roughness corresponds to good riding quality and vice versa.
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Roughness of a pavement surface is brought about by uneven settlement, short and

long wave undulations, rutting, wide cracking and other surface defects such as
potholes, delamination etc ..
The International Roughness Index (IRI) is used internationally to measure the

degree of roughness of a pavement surface. It is representative of the vertical motions
induced in moving vehicles for the freq uency bandwidth which affects both the
response of the vehicle and the comfort perceived by the occupants
The IRI describes a scale of roughness which is zero for a true planar surface,
increasing to about 6 mIkm for moderately rough paved roads, 12 mIkm for
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JKRlSPJ/200B·S4
extremely rough paved roads with potholes and patches, and up to about 20 mIkm for
extremely rough unpaved roads.
4.5.3.2 Measurement ofiRI
The regularity of the completed pavement surface shall be measured before traffic is
allowed on it and is measured in terms of its lane IRI. Lane IRI shall be measured
using the ARRB Walking Profiler (WP) following the procedures as outlined in
AUSTROADS PAT 01 :2001 (Appendix 1)
Other types of equipment may be used to measure lane IRI provided that the output
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from the equipment correlate strongly with the output from WP (R2 > 0.95).
4.5.3.3 Acceptance criteria
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The Contractor shall make available lane IRI values for the whole road length as well
as for each 100 meter section of the completed pavement sw'face.
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n The lane IRl measured for the whole road length and each 100 meter section shall be
less than 2.0 mIkm.
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4.5.3.4 Rectification work for non-compliance
In case of non-compliance, the Contractor shall carry out rectification works on any
part of the completed pavement surface so that the lane IRI values for the whole road
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length and for each 100 meter section are less than 2.0 mIkm.
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Porous Asphalt
Porous asphalt is a special-purpose wearing

course. It is produced using open-graded
aggregate mixed with polymer modified
binder and contains a relatively high air
voids after compaction. The design and in-
place air voids shall be in the range of 20 to
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25 percent to ensure drainability.
It offers the following benefits;

1. Improved skid resistance at high speeds,
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especially during wet weather. Porous asphalt shall not be laid in areas
ii. Reduced hydroplaning effects. where;
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lll . Reduced splash and spray.
tv. Reduced headlight reflection and glare i. The pavement structural strength is o
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on wet pavement surface. sub-standard.
v. Reduced rolling tyre noise levels. ii. There is considerable traction due to
sudden acceleration, braking and
Porous asphalt shall be laid on impermeable turning like at major junctions.
and relatively even bituminous surface with iii. There are tight radius curves, loops of
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adequate cross fall. A minimum cross fall of radii less than 75 meters.
2.5 percent is recommended. Existing cracks
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iv. The gradient exceeds 10 percent.
and depression shall be sealed and patched v. Excessive deposits of debris, oil and
prior to application of porous asphalt. fuel may be experienced.
vi. Free drainage cannot be
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A minimum thickness of 50 mm is essential accommodated along the road

to provide adequate drainage within the shoulders.
porous asphalt layer. vii. Length of roads less than 100 meters
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because of spray carry-over from

Porous asphalt shall he compacted using adj acent surfacing.
static steel wheel tandem rollers only. viii. There is high flexibility like on
Vibratory rollers are not permitted because bridges.
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they lead to excessive compaction and the ix. Frequent excavations by statutory
possibility of aggregate crushing. Pneumatic undertakers may occur.
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tyre rollers are not permitted because they x. Traffic levels exceed 4000
knead and close the surface, affecting the commercial vehicles per lane per day
drainability of porous asphalt. They also at opening.
cause stripping of aggregates that stick to xi. Slow moving traffics are expected as
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their tyres. Three wheel rollers are also not there is no beneficial reduction in
permitted because they leave roller marks spray or noise levels achieved at
that can be difficult to remove. speeds below 40 kmIh.
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Porous asphalt is a non-structural layer.

Therefore, it shall not be applied on
pavements which are experiencing structural
deficiency.
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4.6 SPECIALTY MIX 1- POROUS ASPHALT
4.6.1 Description
This work shall consist of furnishing, placing, shaping and compacting porous
asphalt as a wearing course on an existing, impermeable and accepted bituminous
pavement course. This Specification shall be read in conjunction with Sub-Section
4.3.3 of the Standard Specification for Road Works of JKR (JKRISPJ/2007). All
requirements in the Sub-Section 4.3.3 sball apply unless stated otherwise in this
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Specification.
Porous asphalt is a special-purpose wearing course. It is produced using open-graded

aggregate mixed with polymer-modified binders and contains a relatively higb and
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interconnected air voids after compaction. It offers the following benefits;
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i. Improved skid resistance at high speeds, especially during wet weatber.
(, ii. Reduced bydroplaning effects.
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iii. Reduced splash and spray.
iv. Reduced beadlight reflection and glare on wet pavement surface.

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v. Reduced rolling lyre noise levels.
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4.6.2 Materials
4.6.2.1 Coarse Aggregate

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Coarse aggregate shall be screened crushed bard rock, angular in shape and free from
dust, clay, vegetative and other organic matter, and other deleterious substances.
They shall conform to the following physical and mechanical quality requirements;
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i. The loss by abrasion and impact in the Los Angeles machine when tested in
accordance with ASTM C 131 sball be not more than 25%.
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ii. The weighted average loss of weight in the magnesium sulfate soundness
\) test (five cycles) when tested in accordance with AASHTO T 104 shall be
not more than 18%.
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iii. The flakiness index when tested in accordance with MS 30 sball be not
more than 25%.
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iv. The water absorption wben tested in accordance with MS 30 shall be not
more than 2%.
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v. The polisbed stone value when tested in accordance with MS 30 shall be not
less than 40.
Notwithstanding compliance with the aforementioned requirements, crushed or

uncrushed limestone and gravel shall not be pennitted.
4.6.2.2 Fine Aggregate
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Fine aggregate shall be screened quarry fines. They shall be non-plastic and free
from clay. loam, aggregations of material, vegetative and other organic matter, and
other deleterious substances. They shall confonn to the following physical and
i. The sand equivalent of aggregate fraction passing the No.4 (4.75rrun) sieve
ii. The fine aggregate angularity when tested in accordance with ASTM C
1252 shall be not less than 45%.
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iii. The Methylene Blue value when tested in accordance with Ohio
Department of Transportation Standard Test Method shall be not more than
10mg/g.
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iv. The weighted average loss of weight in the magnesium sulfate soundness
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test (five cycles) when tested in accordance with AASHTO T 104 shall be
not more than 20%.
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v. The water absorption when tested in accordance with MS 30 shall be nol
more than 2%.
4.6.2.3 Mineral Filler

A
Mineral filler shall be incorporated as part of the combined aggregale gradation. II
shall be of finely divided mineral malter of hydraled lime (calcium hydmxide). AI
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the time of mixing with bitumen, the hydraled lime shall be sufficiently dry 10 How
freely and shall be essentially free from agglomerations. Not less than 70% by
weight shall pass the BS 75 um sieve. If hydrated lime is not available, ordinary
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Portland cement shall be used as an alternative, subject to approval by the S.O. The
amount of mineral filler to be added sball be not less than 2% by weight of the
combined aggregates. However, the amount shall be limited to not more than 2% if
hydrated lime is used.
EN
4.6.2.4 Bituminous Binder
The bituminous binder for use with porous asphalt shall be of performance grade PG
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76 or higher in compliance with AASHTO Standard M320-02.

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(a) Polymer Modified Binder
The performance grade PG 76 or higher shall be achieved by incorporating an

appropriate quantity of polymer additives 10 conventional bitumen which shall be
penetration grade 70-100 conforming to MS 124. The polymer shall be non-
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carcinogenic. The Contractor shall submit material safety data sheet of the proposed
polymer modified binder. The properties of the polymer modified binder (PMB)
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shall be as given in Table 4.6.1.
TABLE 4_6_1: PROPERTIES OF POLYMER MODIFIED BINDER
S4-47
JKRlSPJ/2008-S4
TEST REQUIREMENT
TEST
SPECIFICAnON
PMB prior to Rolling Thin Film Oven Test (RTFOl)
Viscosity. max. 3 Pa.s, test 135 ASTMD4402

temperature ·C (see Note I)
Dynamic shear, G*/sin 0 minimum
1.00 kPa, 10 rad/s, test temperature 76 AASHTOT315
ER
·C
Penetration, 100 g, 5 s, 25 · C, 0.1 Report ASTMD5
mm (see Note 2)
Ring and ball softening point, 60 ASTMD36
minimum, DC
D
Flash point, minimum, ·C 230 AASTHOT48
N
Moisture sensitivity test, minimum, 80 AASHTOT283
%
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Emission of toxic gases, maximum, 15
mg/m'
PMB after RTFOT (AASHTO T 240 or ASTM D 2872)

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Mass loss, maximum, % 1.00 AASHTO T 240 or
ASTM D 2872
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Dynamic shear. G*'sin {; minimum
2.20 kPa, 10 rad/s, test temperature 76 AASHTOT315
·C
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Notes:
I. The requirement may be waived at the discretion of the S.D. if the supplier warrants that the
polymer modified binder can be adequately pumped and mixed at the temperatures that meet
all applicable safety standards.
EN
2. The penetration value will be taken as the reference for consistency check on the production.
(b) Determination ofMixing and Compaction Temperatures

M
u A viscosity-temperature relationship shall be established, using suitable rheometer,

for the modified bitumen. The temperatures to which the modified bitumen must be
heated to produce a viscosity of 0.2 - 0.5 Pa.s shall be the mixing temperatures. The
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temperatures to which the modified bitumen must be heated to produce a viscosity of

5 - 30 Pa.s shall be the compaction temperatures.
(c) Storage ofPolymer Modified Binder

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The Contractor shall provide a polymer modified binder storage system capable of
D
delivering modified bitumen to the asphalt mixing plant. The storage system should
be located close to the asphalt mixing plant and it should include distribution and
circulation pipes that are properly insulated to prevent rapid temperature drop.
The storage tank shall have suitable mechanical agitator and be connected through
delivery pipes and back-circulation pipes. Suitable orifices shall be provided at
convenient points in the storage system for taking samples. Sampling shall be done
in accordance with MS 539.
4.6. 2.5 Tack Coat
S4-48
JKRlSPJ/2008-S4
Tack coat shall be modified bitumen emulsion (eg. Neorned) or conventional

bitumen emulsion of grade RS-3K (tbe latter sball comply witb MS 161). Spraying
shall be carried out using a suitable sprayer capable of providing uniform spray at a
rate of 0.5 to 1.0 litrelm'.
(aJ Composition
The composition of tack coat material shall be as given in Table 4.6.2.
ER
TABLE 4.6.2: COMPOSITION OF TACK COAT MATERIAL
Tack Coat Water, % mass Bitumen, % mass Latex, % mass
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RS-3K 35 65 0
N
Neomedor 35 - 41 60-65 2- 4
equivalent
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(bJ Properties
The properties of Neomed or equivalent modified bitumen emulsion shall comply

A
with the requirements as given in Table 4.6.3.
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TABLE 4.6.3: PROPERTIES OF MODIFIED BITUMEN EMULSION
Property Requirement Test Specification

M
Percentage retained on 850 max 10 ASTM D 244

J..lmsieve
EN
Saybolt Furol viscosity at 50 min 100, max 400 ASTMD244

"C
Penetration on residue at 25 45-70 ASTMD244&
"C, 100 g, 5 s, 0.01 mm ASTMD5
Ring and ball softening 45-60 ASTMD244&
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point on residue, °C ASTMD36

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4.6.3 Gradation of Combined Aggregates
The gradation of the combined coarse and fine aggregates, together with at least 2%
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mineral filler, shall conform to the appropriate envelope as given in Table 4.6.4.
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TABLE 4.6.4: GRADATION LIMITS OF COMBINED AGGREGATES
S4-49
JKRlSPJ/200B-S4
BS Sieve Size, mm Percentage Passing, by weight
Grading A Grading B
20.0 - 100
14.0 100 85 - 100
10.0 95 - 100 55 -75
5.0 30 - 50 10 - 25
2.36 5 - 15 5 - 10
0.D75 2-5 2-4
ER
4-6.4 Mix Design
With high air voids and open-graded aggregates, high binder contents are essential to
D
ensure mix integrity. increase resistance to oxidation and raveling, and improve
durability. The quantity of binder shall be carefully balanced such that it is not
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deemed too excessive to cause binder drain-down during production, transport and
laying, and neither it is deemed too little to adversely affect durability.
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4 .6.4.1 Laboratory Compacted Specimens
Porous asphalt mixes shall be compacted in the laboratory by using the Marshall
method, in accordance with ASTM D 1559. The specimens shall then be used for
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further analysis as described hereof.
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Because of the limited compaclive effort applied in the field on porous asphalt
mixes, the number of blows per face shall be 50.
4.6.4.2 Air Voids Reouirements

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The desigo and in-place air voids shall be in the range of 18 to 25 percent.
4.6.4.3 Binder Drain-Dowo Test

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Binder drain-down test shall be carried out in accordance with the test method as
specified in Appendix 1. A sample of porous asphalt shall be placed in an oven for 3
hours at an anticipated mix production temperature in a wire basket fabricated using
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standard 6.3 mm sieve cloth. Any binder drain-dowo from the asphalt shall be
1..) collected in a pan. The binder drain-dowo shall be not more than 0.3% by weight of
the total mix.
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4.6.4.4 Cantahro Test
Cantabro test shall be carried out in accordance with the procedure as given in
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Appendix 2. Three Marshall specimens shall be simultaneously subjected to 300

revolutions in the Los Angeles drum. minus the steel balls. at 25°C. The average
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loss of mass shall be not more than 15%.
4.6.4.5 Detennination of Design Binder Content
Using a selected desigo aggregate gradation that comply with Table 4.18, prepare
nine laboratory mixes at each binder content in the range 4.0 - 6.0%, in increments
of 0.5%.
For each binder content, conduct binder drain-down test on the first three laboratory
mixes at the anticipated production temperature.
S4-50
JKRlSPJ/200B-S4
For each binder content, detennine theoretical maximum specific gravity on the next
three laboratory mixes in accordance with ASTM D 2041 .
Use the remaining laboratory mixes to fabricate three Marshall specimens at each
binder content. Apply 50 blows per side at the anticipated compaction temperature at
site.
Determine the air voids of the Marshall specimens in accordance with ASTM D
3023.
ER
Using the same Marshall specimens, conduct Cantabro test in accordance with the
test method as given in Appendix 2.
The lower limit of the design binder content shall be determined in accordance with
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the following two criteria;
N
i. Average loss of mass in the Cantabro test shall be not more than 15%.
n. Average air voids shall be not more than 25%.
TE
The upper limit of the design binder content shall be determined in accordance with
the following two criteria;
i. Average binder drain-down shall be not more than 0.3%.

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II. Average air voids shall be not less than 18%.
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Note that the binder drain-down test shall be used to adjust the mixing temperature
of porous asphalt and/or the viscosity of the binder.
M
Take the mean of the lower limit and upper limit of the design binder content as
determined from the Cantabro test and binder drain down test respectively as the
initial design binder content. Use this value to check for air voids and make
EN
adjustment where necessary such that the air voids is between 18% and 25% but the
design binder content shall be within the lower limit and upper limit.
The binder content that meets all the above criteria shall be recommended as the
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design binder content.
The aggregate gradation selected and the design binder content recommended shall
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be proposed to the S.O. as thejob mix formula.
4.6.4.6 Trial Lay

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After having received the S.O.'s preliminary approval of the proposed job mix
fonnula, the Contractor shall arrange to mix, lay and compact the porous asphalt
mix. A minimum of 20 tons shall be placed in trial areas to demonstrate to the
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satisfaction of the S.O. that the mix is satisfactory and the mixing, laying and
compacting equipment conforms to the requirement of this specification. The trial
at his own expense. They shall be approved by the S.O.
As directed by the S.O., comprehensive sampling and testing of the porous asphalt
mix shall be carried out to check for satisfactory compliance with the job mix
formula and satisfactory degree of compaction . The observations and tests to be
carried out shall be, but not restricted to, as follows;
S4-51
JKRlSPJI2008-S4
i. Check that the trial site is suitable.
ii. Record the type and weight ofreller.
iii. Record the type of paver.
iv. Carry out the following tests on the mix specimen;

• Binder content and aggregate grading (ASTM D 2172IBS 598, ASTM C
136).
ER
• Theoretical maximum specific gravity (ASTM D 2041).
• Preparation of Marshall specimens (ASTM D 1559).
• Bulk specific gravity of Marshall specimens (ASTM 3203).
• Calculation of air voids (ASTM D 3203).
D
v. Record temperatures of mix on the tipper lorry, at plant and site.
N
vi. Record laying temperatures.
TE
vii. Record laying thickness.
viii. Observe the surface texture of mix laid behind paver.

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ix. Record rolling temperatures i.e. immediately before rolling starts.
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x. Record rolling pattern.
xi. Observe the surface texture of compacted mix.

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xii. Take at least three core samples from each lony load after the mix has
sufficiently hardened.
xiii. Record compacted thickness, density and air voids of the core samples.
EN
xiv Check drainability of the compacted surfacing (refer to Sub-Section 4.6.6.5)
xv. Check at least one longitudinal joint to ensure that the joint is satisfactorily
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constructed.
CJ 4.6.4.7 Compliance with Job Mix Formula
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The S.O.'s final approval of the job mix fonnula shan bind the Contractor to furnish
the porous asphalt mix meeting the precise aggregate gradation and binder content
specified in the formula within the tolerances set forth in Table 4.6.5.
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D
TABLE 4.6.5: TOLERANCES FOR POROUS ASPHALT
S4-52
JKRlSPJI2008-S4
Parameter Permissible Variation,

% by weight of total mix
Bitumen. +1- 0.2%
Fractio~s of combined aggregate passing +1- 5.0%

5.00 mm and larger sieves.
Fractions of combined aggregate passing +1- 4.0%
ER
2.36 mm sieve.
Fraction of combined aggregate passing 75 +1- 2.0%

J..1m sieve.
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N
4_6.5 Sampling and Testing of Porous Aspbalt
TE
Frequency of sampling and testing sball be not less than that shown in Tables 4.6.6
and 4.6.7. Table 4.6.6 provides for two levels of minimum frequency. The reduced
frequency may only be adopted if the test results consistently conform to the
requirements. Where a non-conformance occurs in any test, the frequency of
sampling and testing for that particular property shall be increased to the normal
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level until conforming results have been obtained on five consecutive lots.
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TABLE 4.6.6: FREQUENCY OF SAMPLING AND TESTING OF
POROUS ASPHALT
M
Test Normal Reduced

Minimum Frequency Minimum Frequency
One test per 500 tons

EN
Aggregate gradation One test per 300 tons of

asphalt Dlant oroduction. asDhalt Dlant oroduction.
Binder content One test per 300 tons of One test per 500 tons of
asphalt plant production. asphalt plant production.
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Maximum specific One test per 300 tons of One test per 500 tons of
gravity and air voids asphalt plant production. asphalt plant production. J
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Temperature Each loaded truck. Each loaded truck.

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D
TABLE 4.6.7: FREQUENCY OF SAMPLING AND TESTING OF

COMPONENT MATERIALS
S4-53
JKRlSPJ/2008-S4
Test Minimum Frequency
Los Angeles abrasion Monthly

Water absorption Monthly
Flakiness index of coarse aggregate Monthly
Magnesium sulfate soundness Monthly
ER
Polymer modified binder Certification of each delivery
Construction Method
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4.6.6.1 Pavement Preparation
N
n Porous ·asphalt sh.all be laid only on structurally sound pavement with minimal
cracks, ruts and depressions.
TE
A strong, durable bond of porous asphalt to the underlying pavement surface is
essential.
A thick tack coat is essential to ensure;

A
i. A good bonding of the relatively small surface area of contact of the open-
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graded porous asphalt to the underlying pavement surface.
ii. A good resistance to damage induced by residual moisture which may be

M
trapped at the bottom of the porous asphalt layer.
iii. Effective sealing of cracks and other surface deficiencies which may be
present in the existing pavement surface, thus providing an impervious
EN
underlying surface.
Porous asphalt shall not be used to restore poor road profile.

M
Existing pavement surface shall be regnlated with dense continuously graded asphalt
( ) to remove depression which may trap and hold water under porous asphalt layer.
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4.6.6.2 Laying
Porous asphalt shall be laid only on impermeable and plane pavement surface with
adequate cross fall. A minimum cross fall of 2.5 percent is recommended.
O
Porous asphalt shall be laid by machine aod compacted within three hours of mixing.
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Laying shall commence on the low side of the carriageway.
A minimum thickness of 50 mm is essential to provide adequate drainage within the

porous asphalt layer.
Haod casting shall be kept to minimum.

Porous asphalt shall not be laid directly over an existing concrete pavement because
the difficulty in establishing ao adequate bond. However, it shall be preceded with a
layer of dense bituminous mix on the existing concrete pavement to assist bonding.
S4-54
JKRlSPJ/2008-S4
When the rehabilitation of a deteriorated concrete pavement includes bituminous

mixes overlay. porous asphalt shall be used as the final wearing course.
Porous asphalt shall not be laid in areas where;
I. The pavement structural strength is sub-standard.
ii. There is considerable traction due to sudden acceleration, braking and

turning like at major junctions.
ER
iii. There are tight radius curves, loops of radii less than 75 meters.
iv. The gradient exceeds 10 percent.
D
v. Excessive deposits of debris, oil and fuel may be experienced.
N
vi. Free drainage cannot be accommodated along the road shoulders.
TE
vii. Length of roads less than 100 meters because of spray carry-over from
adjacent surfacing.
viii. There is high Oexibility like on bridges.

A
lX. Frequent excavations by statutory undertakers may occur.
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x. Traffic levels exceed 4000 commercial vehicles per lane per day at opening.
xi. There is a 40 kmIh speed limit because there is no beneficial reduction in

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spray or noise levels achieved at low speeds.
4.6.6.3 Compaction
EN
Porous asphalt shall be compacted using static steel wheel tandem rollers only.
Vibratory rollers are not permitted because they lead to excessive compaction and
the possibility of aggregate crushing.
M
Pneumatic tyre rollers are not permitted because they knead and close the surface,
affecting the drainability of porous asphalt. They also cause stripping of aggregates u
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that stick to their tyres.
Three wheel rollers are also not permitted because they leave roller marks that can be
difficult to remove.
O
Compaction by rolling shall commence as soon after laying as the material will
support the rollers without undue displacement; nevertheless the temperature of the
D
porous asphalt at the commencement of rolling shall be not less than 110°C.
vibrating plate compactors, hand tampers or other suitable means, all to the
The steel wheel tandem rollers shall operate in a longitudinal direction along the
carriageway with their driven wheels towards the paver. Rolling shall generally
commence at the lower edge of the paved width and progress uniformly to the higher
S4-55
JKRlSPJ/2008-S4
edge, except that where there is a longitudinal construction joint at the higher edge,
this shall be rolled first ahead of the nonnal pattern of rolling. Generally, successive
roller passes shall overlap by half the width of the roller, and the points at which the
roller is reversed shall be staggered. However, when operating on gradients in excess
of 4%, the breakdown roller shall not pass over any previously unrolled mix when
operating in the downhill direction.
ER
The rollers shall operate at speeds of not more than 5 kmIh. No roller or heavy
vehicle shall be allowed to stand on newly laid bituminous mix before compaction
has been completed and the material has thoroughly cooled and set. Rolling pattern
shall be in accordance with trial lay carried out earlier and shall give field density not
D
less than 97% of the laboratory mix design density.
N
n The porous asphalt layer shall be finished in a neat and workmanlike manner; their
widths shall be everywhere at least those specified or shown on the Drawings on
TE
both sides of the centre-line; the average thickness over any IOO-metre length shall
be not less than the required thickness, and the minimum thickness at any point shall
be not less than the required thickness minus 5 rom.
Care shall be taken to prevent over-compaction of porous asphalt.

A
Within 24 hours of laying and compacting the bituminous mix, the Contractor shall
cut core samples of not less than 100 mm nominal diameter at locations selected by
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the S.D. The rate of sampling shall be one sample per 500 m' of mix laid, but not
less than two samples for the work completed in each paving session. These core
samples shall be used by the S.D. to determine the thickness of the compacted layer
M
of mix and the compacted density of the material in accordance with either ASTM
Test Method D 1188 or ASTM Test Method D 2726, whichever is applicable.
4.6.6.4 Joint Construction

EN
The fonnation of all joints shall be made in such a manner as to ensure a continuous
bond between old and new sections of the course. All joints shall present the same
texture, density, and smoothness as other sections of the course
M
( ) Cold longitudinal joints shall not be cut as the inherent rough texture of the mixture
will readily provide good bonding along the joints. Cutting the joints may incur
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damages to the mixture along the joints as the aggregate gradation of mixture is of
open-graded nature. Application of tack coat along the joints is deemed unnecessary
as it may clog the voids along the joints and impede the flow of water across the
joints.
O
4.6.6.5 Shaping Edges

D
While the surface is being compacted and finished, the Contractor shall carefully
trim the outside edges of the pavement to the proper alignment.
Edges so formed shall be beveled while still hot and compacted.
4.6.6.6 Drainabilitv
S4-56
JKRlSPJ/2008-S4
Being tbe principle benefit of porous aspbalt, the drainability sball be sufficient to
allow satisfactory drainage of rain water during heavy rainfall. The drainability of
porous asphalt wearing course having a minimum thickness of 50 rnrn shall be not
less tban 10 litres/minute through a discbarge area of 54 cm' immediately after
construction.
4.6.6.7 Finished Porous Asphalt
Porous Asphalt wearing courses shall be finished in a neat and workmanlike manner;
their widths shalt be everywhere at least those specified or shown on the Drawings
ER
on both sides of the centre-line; the average thickness over any 100-metre length
shall be not less than the required thickness. and the minimum thickness at any point
shall be not less than the required thickness minus 5 mm.
D
The top surface of a wearing course shall have the required shape, superelevation,
levels and grades, and shall be everywhere within the tolerances specified in Sub-
N
Section 4.5.
()
The International Roughness Index (IRl) value of the finished wearing course
TE
surface sball be carried out as described in Sub-Section 4.5 and shall be not more
than 2.0 mIkm.
4.6.6.8 Opening to Traffic

A
Porous aspbalt sball not be opened to traffic until compaction bas been completed
and the material has tboroughly cooled. This will usually be not less than 4 hours
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after the commencement of rolling.

M
EN
M
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S4-57
JKRl5PJ/2008-S4
STONE MASTIC ASPHALT (SMA)
Stone Mastic Asphalt (SMA) originated in This mix is recommended to be used in high
Germany in the 1970's to provide maximum stress areas such as climbing lanes or where
resistance to rutting caused by the studded excessive axle loads are expected.
tyres on European roads. SMA is a dense,
gap graded hot mix asphalt with a large SMA however does not provide permanent
ER
proportion of coarse aggregate (>65%) and a solution to diesel spillage problem. Due to
rich bitumen filler mastic. SMA is its relatively high cost compared to the
characterized by its high coarse aggregate conventional asphalt, it should not be used
content which forms a stone skeleton indiscriminately.
D
structure. The voids of the structural matrix
are filled with high viscosity bituminous
N
mastic.
n
TE
Typically, SMA mixes have polymer
modified bitumen contents that range
between 5.5 - 7.5%. The polymer modified
bitumen may be further stabilised using
cellulose fibres to prevent excessive binder
A
draindown. Additionally, the presence of the
fibres enhances the durability of the SMA Aggregate composition of SMA
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mix by allowing the use of higher bitumen

content.
M
SMA is able to provide durable surfacing

and exhibit high resistance to rutting due to
heavy axle loads. This type of surfacing also
EN
offers improved texture depth, in the range

of 0.7 - I.Ornm, thus providing good skid
resistance. Aggregate composition of dense graded
asphalt
M
( )
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54-58
JKRlSPJ/2008-S4
SPECIALTY MIX 2 - STONE MASTIC ASPHALT
4.7.1 Description
This work shall consist of furnishing. placing, shaping and compacting stone mastic
asphalt as a wearing course. This specification shall be read in conjunction with the main
Standard Specification for Road Works of JKR (JKRISPJ/2007) . All requirements in the
JKRISPJ12007 shall apply unless stated otherwise in this specification.
ER
Stone mastic asphalt or SMA is a polymer modified hot bituminous mixture with a large
proportion of coarse aggregate and rich bitumen·fiUer mastic. Generally, SMA comprises
approximately over 65% coarse aggregate and a minimum of 8% filler content as per
Table 4.7.2. The coarse aggregate, through point to point contact, forms a high skeleton
with good internal friction and aggregate interlock to resist load-induced shear. It
D
provides durable surface that is resistant to cracking and rutting.
N
4.7.2 Materials
TE
Coarse aggregate shall be screened crushed hard rock and retained on 5.0 mm sieve
opening angular in shape and Dee from dnst, clay, vegetative and other organic matter,
and other deleterious substances. They shall conform to the following physical and
A
EJ
accordance with ASTM C 131 shaJJ be not more than 25%,
ii. The flakiness indo< when tested in accordance with MS 30 shall be not more
M
than 25%,
iii. The polished stone value when tested in accordance with MS 30 shaJJ be not less
EN
than 40,
iv. The weighted average loss of weight in the magnesium sulfate soundness test
(five cycles) when tested in accordance with AASHTO T 104 shall be not more
than 18%,
M
v The water absorption when tested in accordance with MS 30 shall be not more
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than 2%.

uncrushed limestone and gravel shall not be permitted.
O

D
Fine aggregate shall be screened quarry fines. They shall be non-plastic and free from
clay. loam. aggregations of material, vegetative and other organic matter, and other
deleterious substances. They shall conform to the following physical and mechanical
quality requirements;
i. The weighted average loss of weight in the magnesium sulfate soundness test
than 20%.
$4-59
JKRl5PJ/2008-S4
ii. The water absorption when tested in accordance with MS 30 shall be not more
than 2%.
iii. The sand equivalent of aggregate fraction passing the No. 4 (4.75mm) sieve
iv. The fine aggregate angularity when tested in accordance with ASTM C 1252
shall be not less than 45%.
v. The Methylene Blue value when tested in accordance with Ohio Department of
ER
Transportation; Standard Test Method shall be not more than 10m mg/g.
4. 7.2.3 Mineral Filler
D
Mineral filler shall be added as part of the combined aggregate gradation. Limestone
dust, hydrated lime or ordinary portland cement shall be used as filler. The material shall
N
pass 75 flm sieve by not less than 70% by weight. The amount of filler to be added shaH
be not less than 8% by weight of the combined aggregates, where if cement is used it
TE
shaH not exceed 2% by weigh of the combined aggregates.
The bituminous binder for use with Stone Mastic Asphalt shaH be of performance grade
A
PG76 or higher in compliance with AASHTO Standard M320-02.
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(a) Polymer-Modified Binder
The performance grade PG76 or higher shall be achieved by incorporating an appropriate

quantity of pnlymer additives to conventional bitumen which shall be penetration grade
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80/ 100 conforming to M.S.124. The polymer shall be non- carcinogenic. The contractor
shall submit Material Safety Data Sheet on the proposed PMB. The properties of the
polymer modified binder shall be as given in Table 4.7.1.
EN
(b) Determination ofMixing and Compaction Temperature
A viscosity-temperature relationship shall be established, using suitable rheometer, for

the, modified bitumen. The temperatures to which the modified bitumen must be heated
M
to produce a viscosity of 400 +/- 100 cSt shall be the mixing temperatures. The
temperatures to which the modified bitumen must be heated to produce a viscosity of 600
+/- 100 cSt shall be the compacting temperatures.
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(c) Storage oj Polymer Modified Binder (PMB)
The Contractor shall provide a PMB storage system capable of delivering modified
O
bitumen to the asphalt mixing plant. The storage system should be located close to the
asphalt mixing plant and it should include distribution and circulation pipes that are
D
properly insulated to prevent rapid temperature drop.
convenient points in the storage system for taking samples. Sampling shall be done in
accordance with MS 539,
54-60
JKRlSPJ/2008-S4
TABLE 4_1-1 : PROPERTIES OF POLYMER-MODIFIED BINDER
TESTS REQUIREMENT
TEST SPECIFICATION
PMB prior to Roiling Thin Film Oven test
Viscosity. max. 3 Pa.s, test 135 ASTMD4402

temperature C. (see Note I )
ER
Dynamic shear, G/sin cS min.
1.00 kPa, 10 radls, test 76 AASHTOT315
temperature C.
Penetration, 100 g, 5 s, 25 C, Report ASTMD5
0.1 mm. (see Note 2)
D
Ring and Ball softening point, 60 ASTMD36
min. C.
N
Flash Point, min 'c 230 AASTHOT48
Moisture sensitivity test, 80 AASHTOT283
TE
greater than (%)
PMB after Rolling Thin Film Oven test (AASHTO T 240) or ASTM D 2872
Mass loss, max %. 1.00 AASHTO T 240 or

A
ASTMD2872
Dynamic shear, G/sin (\ min.
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2.20 kPa, 10 radis, test 76 AASHTOT315
temperature C.
M
Notes:
L The requirement may be waived at the discretion of the 8.0. if the supplier warrants that the
polymer-modified binder can be adequately pumped and mixed at the temperatures that meet all
applicable safety standards.
EN
(d) Resistance to Fuel Spillage

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The polymer modified bitumen shall be tested for its resistance to fuel spillage. Three
Marshall specimens shall be fabricated at optimum binder content and kept immersed in
Octane-97 petrol for 24hours. The average loss of weight before and after the immersion
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shall not be more than 4%, based on an average of3 tests.
4.7.2.5 Stabilising Agent

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The PMB serves both as property enhancer and stabilising agent. However, other
stabilizers, in the form of organic loose cellulose fibre or bitumen pre-coated pelletized
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cellulose fiber, may also serve as stabilizing agent and incorporated into SMA mix to
prevent undue draining during transportation and bleeding during its service life. Dosage
rates for organic stabilising agent is 0.3% by weight of the total mix. Allowable
tolerances of fibre dosage shall be ± 10% of the required fiber weight. The selected loose
cellulose fibres should meet the properties described in Table 4.7.2 while the properties
of bitumen pre-coated pelletized cellulose fibre shall meet the properties described Table
4.7.3.
S4-61
JKRl5PJ/2008-S4
TABLE 4.1-2: PROPERTIES OF CELLULOSE FmER
MESH SCREEN ANALYSIS
Fiber Length 6 rom (0.25") (Maximum)
Passing 850 ~m (No. 20) ASTM sieve 85% (± 10%)
ER
OTHER PROPERTIES
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Ash content 10% (± 5%) non - volatiles
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n pH 7.5 (± 1.0)
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Oil Absorption, % 5.0 (± 1.0)
Moisture content < 5% (by weight)
Notes:
A
I. Mesh Screen Analysis
This test is performed using standard 850, 425, 106 pm (No. 20.40, 140) sieves. nylon brushed and
EJ
a shaker. A representative 10 gram sample of fiber is sieved, using a shaker and two nylon brushes
on each screen. The amount retained on each sieve is weighed and the percentage passing calculated
Repeatability of this method is suspect and needs to be verified.
2. Ash Content
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A representative 2 - 3 gram sample of fiber is placed in a tarred crucible and heated between 595" C
(1100 0 and 1200" F) for not less than two hours. The crucible and ash arc cooled in a desiccator and
reweighed.
EN
3. pH Test
Five grains of fiber is added to 100 m1 of distiUed water, stirred and let sit for 30 minutes. The pH is
determined with a probe calibrated with pH 7.0 buffer.
4. Oil Absorption Test

Five grams of fiber is accurately weighed and suspended in an excess of mineral spirits for not less
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than five minutes to ensure total saturation. It is then placed in a screen mesh strainer (approximately
, 0.5 square millimeter hole size) and shaken on a wrist action shaker for ten minutes (approximately
~ ) 1 - 1/4 motion at 240 shakes/minute). The shake mass is then transferred without touching, to a
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tarred container and weighed. Results are reported as the amount (number of times its own weight)
the fibers are able to absorb.
5. Moisture Content
Ten grams of fiber is weighed and placed in 121 0 C (250 0 F) forced air oven for two hours. The
sample is then reweighed immediately upon removal from the oven.
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TABLE 4.7-3: PROPERTIES OF BITUMEN PRECOATED PELLETIZED

D
CELLULOSE FIBRE
Properties Requirement
Bulk density (gIL) 470 -540
Fine material. vibration sieve (%) < 3500_~m Max.5
Abrasion vibration sieve (%) <3500 !.1m Max. 6
Fiber content after extraction (%) 85-90
54-62
JKRlSPJ/200B-S4
Notes:
I. Bulk density
A standard IOOOml measuring cup is used. Without any pressure the sample is filled smoothly to the
top of measuring cup. The filled measuring cup is then weighed. The hulk density is calcuJated by
weight of filled measuring cup over weight of empty measuring cup.
2. Fine material.
A 100g of sample is weighed and placed into a 3.55mm sieve. The sieve is then vibrated by using
vibrating sieve machine for 2 min @ amplitude 2. Fine material is determined by weighing the
residue aftcr sieve in percentage.
3. Abrasion test
ER
A 100g of sample is weighed and placed into a standard abrasion tester and strain it for 6 seconds.
After strained. the sample is discharged and placed into a 3.55mm sieve. The sieve is then vibrated
by using vibrating sieve machine for 2 min@amplitude2. Abrasion value is detennined by weighing
the residue after sieve in percentage.
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4. Fibre content after extraction.
A 6-1 Og of sample is weighed and placed into a glass fiber or pure cellulose extraction thimble. The
timble with sample is then placed vertically in an extractor. Naphta or toluene e:dracting agent is
N
used and extraction is continued until the extracting agent become colorless. The thimble is taken out
and dried in an oven at 105°C for minimum 2 hrs. Let the thimble cooled down to room tempemture
in a dessicator and weighed Fiber content after extraction is calculated by weight of dried thimble
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minus weight of empty thimble and divide by of sample.
4.7.2.6 TackCoat
A thin tack coat of asphalt emulsion RS-IK of similar material conforming to MS 161
A
shall be applied to ensured uniform and complete adhere ofth. overlay.
Gradation or Combined Aggregate

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4.7.3
The gradation of the combined coarse aggregate, fine aggregate and mineral filler shall
conform to the appropriate envelope as given in Table 4.7.4.
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TABLE 4.7.4: GRADATION LIMITS OF COMBINED AGGREGATES

EN
ASTMSieve Percentage by weight Passing Sieve
SMAI4 SMA 20
Sieve size (mm)
19.0 100 100
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12.5 100 85 -95

9.5 72 - 83 65-75
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4.75 25 - 38 20-28
2.36 16 - 24 16-24
0.600 12 - 16 12 - 16
0.300 12 - 15 12-15
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0.075 8 - 10 8- 10
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4.7.4 Mix Design
4.7.4.1 Laboratory Compacted Specimen
The Contractor shall propose a job mix formulae required in the Works. In order to obtain
optimum quality of the mixtures, the job mix formulae for the mix shall be prepared on
the basis of testing several laboratory design mix gradations within the limits set in Table
4.7.5 at an appropriate range of bitumen content. As a guide, the design bitumen content
will usually be in the range of 5 - 7%.
S4-63
JKRlSPJI2008-S4
Each combination of laboratory design mix aggregate gradation and bitumen content
i. Preparation of laboratory specimens for the standard stability and flow test in
accordance with ASTM D 1559 using 50 blowslface compaction standard,
ii. Determination of the bulk. specific gravity of the specimens in accordance with
ASTMD2726,
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1559,
iv. Analysis of the specific gravity and air voids parameters to detennine the
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percentage air voids in the compacted aggregate, the percentage air voids in the
compacted aggregate filled with bitumen and the percentage air voids in the
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compacted mix.
For the proposed design mix gradation, four specimens shall be prepared for each
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bitumen content within the range of 5 - 7% (see Note I) at increments of 0.5 percent, in
accordance with ASTM D 1559 using 50 blows/face compaction standard. All bitumen
content shall be in percentage by weight of the total mix.
As soon as the freshly compacted specimens have cooled to room temperature, the bulk
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specific gravity of each test specimen shall be detennined in accordance with ASTM D
2726.
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The stability and flow value of each test specimen shall then be determined in accordance
with ASTM D 1559.
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mineral aggregate (VMA) and the percentage air voids in the compacted mix (VIM).
EN
Values which are obviously erratic shall be discarded before averaging. Where two or
more specimens in any group of four are so rejected, four more specimens shall be
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The average values of bulk specific gravity, stability, flow, VFB and VMA obtained
above shall be plotted separately against the bitumen content and a smooth curve drawn
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thmugh the plotted values.
The mean optimum bitumen content shall be determined by averaging four optimum
bitumen contents so detennined as follows;
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ii. Flow equals to 3 mm from the flow graph,
iii. Peak of curve taken from the bulk specific gravity graph (see Note 3),
iv. VIM equals to 3.5% from the VIM graph.
The individual test values (Stability, Flow, VMA and VIM) at the mean optimum
bitumen content shall then be read from the plotted smooth curves and shall comply with
the design parameters given in Table 4.7.5
S4-64
JKRl5PJ/200B-54
If all the values comply with Table 4.7.5, the mixture with the mean optimum bitumen
content shall be used in plant trials.
If any ofthe values does not comply with Table 4.7.5 the mix design procedure shall be
repeated using a different laboratory design mix aggregate gradation until all design
parameters are satisfied.
Note:
1. The range of bitumen content shall be elttended if necessary to ensure that the curves of stability and
bulk specific gravity have their peak within the range selected.
ER
2. Where the stability curve exhibits more than one peak. the bitumen content chosen for the
detennination of the mean optimum bitumen content shall be the one which satisfies the voids
requirements better. It is sometimes necessary, where no peak stability is obtained, to prepare and
test supplementary specimens at of 0.25% bitumen content on either side of the expected optimum.
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3. With highly absorptive aggregate, some difficulty in determining peak bulk. specific gravity may
occur. In such cases, the bitumen content at which the increase in bulk specific gravity shows a
marked falling off shall be adopted.
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TABLE 4.7.5 SMA MIX REQUIREMENTS
TE
VIM (MS·2) 3 - 5%
VMA rMS-2) Min 17% .
Stabilitv Min 6200N
Flow 2-4mm
A
DraindownrADoeDdix 4) Max 0.3%
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4.7.4.2 Binder drain-down Test

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Binder drain-down test sball be conducted on three laboratory mix at the mean optimum
binder content to ascertain that the binder draining property of the mix is satisfactory.
Binder drain-down test shall be earned out in accordance with procedures in Appendix 4 .
EN
The samples shall be placed in an oven for 3 hour at an anticipated mix production
temperature in a wire basket fabricated using standard 6.3 mm sieve cloth. Any binder
drain down from the aspbalt shall be collected in a pan. The binder drain-down shall be
not more than 0.3% by weigbt oftbe total mix. (See Appendix 4).
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If the average binder drain-down exceeds 0.3%, the mix design procedure shall be
repeated using a different laboratory design mix aggregate gradation until all design
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parameters are satisfied. Alternatively, stabilizing agents shall be added to reduce binder
drainage.
4 .7.4.3 Detennination of Optimum Binder Content

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The binder content that meet the criteria in Table 4.7.5 and satisfy the binder drain-down
test requirement shall be selected as the optimum binder content. The aggregate gradation
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selected and the optimum binder content determined sball be proposed to the S.O. as the
Job Mix Fonnulae.
4.7.4.4 Trial Lay
After baving received the S.O. 's preliminary approval of the proposed job mix formulae,
the Contractor shall arrange to mix, lay and compact the stone mastic asphalt mix . A
minimum of20 tons shall be placed in trial areas to demoDstrate to the satisfaction of the
S.O. that the mix is satisfactory and the mixing, laying and compacting equipment
54-65
JKRl5PJ/20011-S4
conforms to the requirement of this specification. The trial areas shall not be part of the
Contract Works but shall be provided by the Contractor at his own ..pense. They shall be
As directed by the S.O., comprehensive sampling and testing of the stone mastic asphalt
mix shall be carried out to check for satisfactory compliance with the job mix fannulae
and satisfactory degree of compaction. The observations and tests to be carried out shall
be, but not restricted to, as follows;
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ii. Record the type and weight of rollers.
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iv. Cany out the following tests on the loose mix specimen;
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Binder content and aggregate grading (ASTM D 2172IBS 598, ASTM C 136)
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• Bulk specific gravity of Marshall specimens (ASTM 3203)
• Calculation of air voids (ASTM 3203).

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viii. Observe the surface texture ofmix laid behind paver.
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EN
xii. For each lorry load, take at least three core samples after the mix has been laid,
compacted and sufficiently hardened.
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( ) xiii. Record compacted thickness, density and air voids of the core samples.
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xiv. Check at least one longitudinal joint to ensure that the joint is satisfactorily
constructed.
4.7.4.5 Compliance with lob Mix Formulae

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The S.O. 's final approval of the job mix formulae shall bind the Contractor to furnish the
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Stone Mastic Asphalt meeting the precise aggregate gradation and binder content
specified in the formulae within the tolerances set forth in Table 4.7.6
54-66
JKRl5PJ/200B·54
TABLE 4.7.6: TOLERANCES FOR STONE MASTIC ASPHALT

% by weight oftotal mix
Bitumen +1- 0.3%
Fractions of combined aggregate passing +1- 5.0%

Fractions of combined aggregate passing +1· 4.0%
ER
2.36 mm sieve.
Fraction of combined aggregate passing +1· 2.0%

75 urn sieve.
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4.7.5 Equipment
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4.7.5. 1 SMA Mixing Plant
Plants used for the preparation oflbe SMA mixture shall conform to AASHTO M 156
and the following;
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(a) Handling Mineral Filler
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Adequate dry storage shaU be provided for the mineral filler and provisions shall be made
for proportioning the filler into the mixture unifonnly and in the desired quantities.
Mineral filler in a batch plant will be added directly into tbe mixture uniformly and in the
desired quantities. Mineral filler in a batch plant will be added directly into the weigh
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hopper. In a drum plant mineral filler will be added directly into the drum mixer. Special
attention is directed to providing appropriate equipment for accurately proportioning the
relative large amounts of mineral filler required for an SMA mixture.
EN
(b) Fiber Addition
Adequate dry storage shaU be provided for the fiber additive, and provisions shall be
made for proportioning fiber into the mixture uniformly and in the desired quantities.
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Mixing in Batch Plant Fiber shall be added through a separate inlet directly into the J
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weigh hopper the pugmill. The addition of fiber should be timed to occur during the hot
aggregate charging the hopper. Adequate dry mixing time is required to ensure proper
blending of the aggregate and fiber stabiliser. DI)' mixing time shall be increased 5 to 15
second. Wet mixing time shall be increased at least 5 seconds for cellulose fibers and up
to 5 seconds for mineral fibers to ensure adequate blending with the PMA.
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Mixing inDrurn Mix Plant In a drum mix plant fiber shall be added into the drum mixer
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to ensure complete blending of the fiber into the mix. For this purpose, when adding
loose fiber a separate fiber feeding system shall be utilised that can accurately and
unifonnly introduce fiber into the drum at such a rate as not to limit the nonnal
production of mix through the drum. At no time shall there be any evidence of fiber in the
baghouse or returned/wasted baghouse fines.
54-67
JKRlSPJ/200B-54
(c) Hot-Mixture Storage
When the hot mixture is not to be hauled immediately to the project and placed, suitable
bins shall be provided. Such bins shall be either surge bins to balance production capacity
with hauling and placing capacity or storage bins which are heated and insulated and
which have a controlled atmosphere around the mixture. The holding time shall be within
limitations imposed by the S.O., based on laboratory tests of the stored mixture. In no
case will SMA mixture be kept in storage overnight or for the next days paving.
4.7.5 .2 Hauling Equipment
ER
Hauling equipment should be of a type normally used for the transport of dense grade
asphalt hot mix. Truck beds shall be covered and insulated if necessary, so that the
mixture may be delivered on the road at the specified temperature.
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4.7.5.3 Pavers
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(j Pavers shall be of a type normally used for the placement of asphaltic concrete. They
shall be self-contained, power-propelled units provided with an adjustable activated
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screed, heated and capable of spreading and fmishing courses of asphalt plant mix
material in lane widths applicable to the specified typical section and thickness shown on
the plans.
The paver shall be capable of being operated at forward speeds consistent with
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satisfactory placement and compaction of the mixture. The paver shall be capable of
striking a smooth finish of uniform texture.
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4.7.6 Construction Method

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4.7.6.1 Surface Preparation
i. Immediately before placing the SMA mixture, the surface shall be cleaned of
loose or deleterious material by brooming or other approved means.
EN
ii. A thin tack coat of asphalt emulsion RS-IK or similar material conforming to
(JKRJSPJ/2008) shall be applied to ensure uniform and complete adhere of the
overlay.
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( ) iii. Where the existing surface is distorted, a leveling coun<e of Hot Mix Asphalt
shall be required to restore proper cross-section prior to construction of the
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overlay.
4.7.6.2 Weather Limitations

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The SMA mixture shall be placed on a dry clean surface when the atmospheric
temperature in the shade and of the roadbed is above 25°C and rising and the mix
confonns to the applicable requirements shown under "Laying".
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4.7.6.3 Control Of Asphalt Mixture
The SMA mixture furnished by the Contractor shall conform to the job-mix formulae,
within the allowable deviations as shown in Table 4.7.6.
S4'{)B
JKRlSPJ/200B-54
4.7.6.4 Laying
The mixture when delivered to the paver shall have a temperature of around 1500 C. The
mixture temperature shall be measured in the truck just prior to dumping into the
spreader.
The mixture shall be spread and struck off to the established grade and elevation with
asphalt layers. Placing speed will be adjusted so that sufficient time is allowed for
compaction operations and to provide continuity.
ER
4.7.6.5 Compaction
Immediately after the mixture has been spread and struck off, it shall be thoroughly and
uniformly compacted by rolling.
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i. Due to the nature of SMA mixture the surface shall be rolled immediately.
Rolling shall be accomplished with steel wheel rollers of a minimum weight of 8
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tonnes. Pneumatic tire rollers and vibratory rollers shall not be used on SMA.
Rolling procedures should be adjusted to provide the specified pavement
TE
density. Rollers shall move at a uniform spec not to exceed 5 km/h with the
drive roller nearest the paver. Rolling shall be continued until all roUer marks
are eliminated and the minimum density has been obtained but not after the mat
has cooled to 1160 C or lower. The Contractor shall monitor density during the
compaction process by use of density gauges to assure that the minimum
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required compaction is being obtained.
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ii. To prevent adhesion of the mixture to the rollers, it shall be necessary to keep
the wheels properly moistened with water mixed very small quantities of
detergent or other approved material.
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iii. The pavement should be compacted to at least 94% of maximum theoretical

density.
EN
iv. Once sufficient in place density has been achieved rolling operations should
cease as over rolling may cause migration of PMA and filler to the compacted
pavement surface.
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4.7.6.6 Finished Stone Mastic Asphalt
Stone Mastic Asphalt wearing courses shall be finished in a neat and workmanlike
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manner; their widths shall be everywhere at least those specified or shown on the
Drawings on both sides of the centre·line; the average thickness over any IOO·metre
length shall be not less than the required thickness, and the minimum thickness at any
point shall be not less than the required thickness minus 5 nun.
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The top surface of a wearing course shaH have the required shape, superelevation, levels
and grades, and shall be everywhere within the tolerances specified in Sub-Section 4.5.
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The International Roughness Index (IRI) value of the finished wearing course surface
shall be carried out as described in Sub-Section 4.5 and shall be not more than 2.0 mIkm.
4.7.6.7 Opening To Traffic
Traffic should not be placed on the newly compacted surface until the mat has cooled to
60°C or lower.
54-69
JKRlSPJI2008-S4
GAP GRADED ASPHALT
Gap Graded Polymer Asphalt is used by cracking and deformation problem high skid
many developed countries. It is a wearing resistance standard. It offers high texture in
course containing polymer modified the range of 0.8-1.2mm.
bitumen and made up of 100 percent
ER
crushed aggregates. Essentially, the Gap The mix is recommended to be used in
Graded aggregate gradation skip a number highly stressed areas such as climbing lanes
of sieve sizes resulting in better stone to or where there is a high volume of heavy
stone contact that enhance mechanical vehicles. It is also suitable to be laid on
D
interlocking and increase mix stiffness. The roads that require high skid resistance. Gap
stiff polymer modified bitumen improves graded asphalt however does not provide
N
mix stability at high bitumen content. permanent solution to diesel spillage
problem. Due to its higher cost compared to
TE
This polymer modified wearing course is the conventional asphalt, its use should be
used to increase durability, strength and limited to high volume roads only. When
safety aspects of the riding surface in dry or used on roads with shaIp corners, ravelling
wet driving. The mix is suitable to solve may develop after some time.
A
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EN
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()
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S4-70
JKRlSPJ/200B-S4
4.8 SPECIALTY MIX 3 - GAP GRADED ASPBALT
4.8.1 Description
This work shall consist of furnishing, placing, sbaping and compacting gap graded
asphalt as a wearing course on an existing, impermeable and accepted bituminous
pavement course. This Specification shall be read in conjunction with Sub-Section 4.3.3
of the main Standard Specification for Road Works of JKR (JKR/SPJ/2007). All
requirements in the Sub-Section 4.3.3 shall apply unless stated otherwise in this
ER
Specification.
The gap graded asphalt is a wearing course containing polymer modified bitumen and
made up of 100 percent crushed aggregates. This modified wearing course is used to
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increase durability, strength and safety aspects of the riding swface in dry or wet driving
conditions.
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4.8.2 Materials
TE
4 .8.2.1 Coarse Aggregate
Coarse aggregate sball be screened crusbed bard rock, retained on 5.0 mm sieve, angular
in shape and free from dust. clay. vegetative and other organic matter. and other
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deleterious substances. They sball COnfOIUI to the following pbysical and mechanical
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accordance with ASTM C 131 sball be not more than 25%.
M
ii. The flakiness index wben tested in accordance with MS 30 sball be not more
than 25%.
iii. The weighted average loss of weight in the magnesium sulfate soundness test
EN
(five cycles) wben tested in accordance with AASHTO T 104 sball be not more
than 18%.
iv. The water absorption when tested in accordance with MS 30 shall be not more
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than 2%.
v. The polished stone value when tested in accordance with MS 30 shall be not less
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than 40.

uncrusbed limestone and gravel shall not be permitted.
O

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Fine aggregate sball be screened quarry fines. They sball be non-plastic and free from
clay, loam, aggregations of material, vegetative and other organic matter, and other
i. The sand equivalent of aggregate fraction passing the No. 4 (4.75mm) sieve
wben tested in accordance with ASTM D 2419 shall be not less than 45%.
54-71
JKRlSPJ/2008-54
li. The fine aggregate angularity when tested in accordance with ASTM C 1252
iii. The Methylene Blue value when tested in accordance with Ohio Department Of
Transportation; Standard Test Method shall be not more than 10 mg/g.
iv. The weighted average loss of weight in the magnesium sulfate soundness test
than 20%.
ER
v. The water absorption when tested in accordance with MS 30 shall be not more
than 2%.
4.8.2.3 Mineral Filler
D
Mineral filler shall be incorporated as part of the combined aggregate gradation. It shall
N
be of finely divided mineral matter of hydrated lime (calcium hydroxide). At the time of
(j mixing with bitumen, the hydrated lime shall be sufficiently dry to flow freely and shall
TE
be essentially free from agglomerations. Not less than 70% by weight shall pass the BS
75 um sieve. The total amount of hydrated lime as mineral filler shall be limited such that
the ratio of the combined coarse aggregate, fine aggregate and mineral filler of the final
gradation passing 75 urn sieve to bitumen, by weight, shall be in the range of 0.6 to 1.2.
As a guide, the total amount of hydrated lime shall be approximately 2% by weight of the
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combined aggregates. The hydrated lime shall also be treated as an anti-stripping agent.
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If hydrated lime is not available, ordinary Portland cement shall be used as an alternative,
subject to approval by the S.O.
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The bituminous binder for use with gap graded asphalt shall be of performance grade PG
76 or higher in compliance with AASHTO Standard M320-02.
EN
(a) Polymer Modified Binder
The performance grade PG 76 or higher shall be achieved by incorporating an

M
appropriate quantity of polymer additives to conventional bitumen which shall be

~ ) penetration grade 80 - 100 conforming to MS 124. The polymer shall be non-
carcinogenic. The contractor shall submit Material Safety Data Sheet on the proposed
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polymer modified binder. The properties of the polymer modified binder (PMB) shall be
as given in Table 4.8.1.
(b) Determination ofMixing and Compaction Temperature

O

the. modified bitumen. The temperatures to which the modified bitumen must be heated
D
to produce a viscosity of 0.2 - 0.5 Pa.s shall be the mixing temperatures. The
temperatures to which the modified bitumen must be heated to produce a viscosity of 5 -
30 Pa.s shall be the compacting temperatures.
(c) Storage of Polymer Modified Binder (PMB)
The Contractor shall provide a PMB storage system capable of delivering modified
bitumen to the asphalt mixing plant. The storage system should be located close to the
54-72
JKRl5PJ12008-54
asphalt mixing plant and it should include distribution and circulation pipes that are
properly insulated to prevent rapid temperature drop.
convenient points in the storage system for taking samples. Sampling shall be done in
accordance with MS 539.
TABLE 4.8.1: PROPERTlES OF POLYMER MODIFlED BINDER
ER
TEST
TESTS REQUIREMENT SPECIFICAnON
PMB prior to Rolling Thin Film Oven Test
Viscosity, max. 3 Pa.s, test temperature 135 ASTMD4402
D
C. (see Note 1)
Dynamic shear, Glsin 8 min. 1.00 kPa, 10
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rad/s, test temperature C. 76 AASHTOT315
Penetration, 100 g, 5 s, 25 C, 0.1 rnm. Report ASTMDS
TE
(see Note 2)
Ring and Ball softening point, min. C. 60 ASTMD36
Flash Point 230 AASHTOT48

Moisture Sensitivity Test,min 80% AASHTOT283
A
PMB after Rolling Thin Film Oven (AASHTO T 240 or ASTM D 2872)
Mass loss, max %. 1.00 AASHTO T 240 or
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ASTM D 2872
Dynamic shear, Glsin 8 min. 2.20 kPa, 10
radls, test temperature C. 76 AASHTOT315
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Notes:
I. The requirement may be waived at the discretion of the S.D. if the supplier warrants that the
polymer·modified binder can be adequately pumped and mixed at the temperatures that meet all
EN
(d) Resistance to Fuel Spillage

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The polymer modified bitumen shall be tested for its resistance to fuel spillage. Three
Marshall specimens shall be fabricated at optimum binder content and kept innnersed in
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Octane-97 petrol for 24hours. The average loss of weight before and after the immersion
shall not be more than 4%, based on an average of 3 tests.
(e) Bituminous Tack Coat

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A thin tack coat of bitumen emulsion RS-IK or similar material conforming to MS 161
shall be applied to ensure uniform and complete adherence oftbe overlay.
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4.8.3 Gradation or Combined Aggregates
The gradation of the combined coarse and fine aggregates, together with 2% mineral
filler shall conform to the appropriate envelope as given in Table 4.8.2.
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JKRl5PJ/2008-S4
TABLE 4.8.2: AGGREGATE GRADATION FOR GPA WEARING COURSE
ASTM Sieve size Percentage by Weight Passing Sieves
GPAII GPAII
Size
(layer thickness < 50mm) (layer thickness> 50mm)
25.0mm . 100
ER
20.0mm 100 76 - 100
14.0mm - 64 - 89
D
12.5 mm 85 - 100 -
N
( 10.Omm - 56 - 81
TE
8.0mm 65 - 85 -
4.0mm 40- 65 41 - 55
2.00mm 20-40 16 - 31
A
600 11m - 12 - 16
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300 11m 10-20 6 - 10

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75 11m 3 - 10 3-7
Bitumen Content
5 -7% 5-7%
(%)
EN
4.8.4 Mix Design

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4.8.4.1 Job Mix Formulae

\ )
The Contractor shall propose a job mix formula required in the Works. In order to obtain
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optimum quality of the mixtures, the job mix formula for the mix shall be prepared on the
basis of testing several laboratory design mix gradations within the limits set in Table
4.30 at an appropriate range of bitumen content. As a guide, the design bitumen content
will usually be in the range of 5 - 7%.
O
Each combination oftaboratory design mix aggregate gradation and bitumen content
D
i. Preparation of laboratory specimens for the standard stability and flow test in
accordance with ASTM D 1559 using 75 blows/face compaction standard.
ii. Detennination of the bulk specific gravity of the specimens in accordance

with ASTM D 2726.
iii. Detennination of the stability and flow values in accordance with ASTM D
1559.
54-74
JKRlSPJ/200B-S4
iv . Analysis of the specific gravity and air voids parameters to determine the
compacted aggregate filled with bitumen and the percentage air voids in the
compacted mix.
For the proposed design mix gradation, four specimens shall be prepared for each
bitumen content within the range of 5 - 7% (see Note 1) at increments 0[0.5 percent, in
accordance with AS1M D 1559 using 50 blows/face compaction standard. All bitumen
content shall be in percentage by weight of the total mix.
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specific gravity of each test specimen shall be determined in accordance with ASTM D
2726.
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with AS1M D 1559.
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TE
mineral aggregate (VMA) and the percentage air voids in the compacted mix. (Vllv1).
more specimens in any group of four are so rejected. four more specimens shall be
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The average values of bulk specific gravity, stability, flow, VFB and VMA obtained
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above shall be plotted separately against the bitumen content and smooth curves drawn
1hrnugh the plotted values.
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The mean optimum bitumen content shall be determined by averaging four optimum
bitumen contents so determined as follows;
I. Peak of curve taken from the stability graph (see Note 2).
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ii. Flow equals to 2 mm from the flow graph.
iii. Peak of curve taken from the bulk specific gravity graph (see Note 3).
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iv. VIM equals to 4% from the VIM graph.

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The individual test values (Stability, Flow, VMA and VIM) at the mean optimum
bitumen content shall then be read from the plotted smooth curves and shall comply
with the design parameters given in Table 4.8.3.
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If aU the values comply with Table 4.8.3, the mixture with the mean optimum
bitumen content shall be used in plant trials.
If any ofthe values does not comply with Table 4.8.3, the mix design procedure shall
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be repeated using a different laboratory design mix aggregate gradation until aU

design parameters are satisfied
Notes
I. The range of bitumen content shall be extended if necessary to ensure that the curves of
stability and bulk specific gravity have their peak within the range selected.
2. Where the stability curve exhibits more than one peak, the bitumen content chosen for the
determination afthe mean optimum bitumen content shall be the one which satisfies the voids
requirements better. It is sometimes necessary. where no peak stability is obtained, to prepare
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and test supplementary specimens at intervals of 0.25% bitumen content on either side of the
expected optimum.
3. With highly absorptive aggregate, some difficulty in determining peak bulk specific gravity
may occur. In such cases, the bitumen content at which the increase in bulk specific gravity
shows a marked falling off shall be adopted.
TABLE 4.8.3: DESIGN PROPERTIES
Marshall Properties Specification limit

Marshall Stability > 6200N
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Marshall Flow 2 - 4mm
Stiffness > l550Nlmm
Voids in mix 3 -5 %
Voids filled with bitumen 76 - 82 %
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n 4.8.4.2 Determination of Ootimum Binder Content
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The binder content that meet the criteria in Table 4.8.3 shall be selected as the
optimum binder content. The aggregate gradation selected and the optimum binder
content determined shall he proposed to the S.O. as the job mix formula.
4.8.4.3 Trial Lay

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formula, the Contractor shall arrange to mix, lay and compact the gap graded asphalt
mix. A minimum of 20 tons shall he placed in trial areas to demonstrate to the
satisfaction of the S.O. that the mix is satisfactory and the mixing, laying and
compacting equipment conforms to the requirement of this specification. The trial
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at his own expense. They shall be approved by the S.O.
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As directed by the S.O., comprehensive sampling and testing of the gap graded
asphalt mix shall be carried out to check for satisfactory compliance with the job mix
formula and satisfactory degree of compaction. The observations and tests to be
earried out shall be, but not restricted to, as follows;
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( )
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ii. Record the type and weight of rollers.
iv. Carry out the following tests on the loose mix specimen;
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• Binder content and aggregate grading (ASTM D 2172IBS 598, ASTM C

136).
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o Bulk specific gravity (ASTM 2726).
o Air voids (ASTM 3203).
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Xl. Observe the surface texture of compacted mix,
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xii. For each lorry load, take at least three core samples after the mix has been laid,
compacted and sufficiently hardened.
xiii. Record compacted thickness, density and air voids of the core samples.
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xiv. Check at least one longitudinal joint to ensure that the joint is satisfactorily
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constructed.
4.8.4.4 Compliance with Job Mix Fonnula
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The S.D. 's final approval of the job mix fonnula shall bind the Contractor to furnish
the Gap Graded Asphalt meeting the precise aggregate gradation and binder content
specified in the fonnula within the tolerances set forth in Table 4.8.4.
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TABLE 4.8.4: TOLERANCES FOR GAP GRADED ASPHALT
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% bv weieht oftotal mix
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Bitumen +/-0.2%
Fractions of combined aggregate passing +/- 5.0%

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Fractions of combined aggregate passing +/-4.0%

2.36 mm sieve.
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Fraction of combined aggregate passing +/-2.0%

75 J..lmsieve.
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Void content in the total mixture +/- 1.0%
4.8.5 Equipment
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4.8.5.1 Asphalt Mixing Plant

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i. Mixing plants shall be suitable for the job and of sufficient capacity in
accordance with the specifications as laid down in A8TM D 915.
ii. The 8.0. or his authorized representative shall have access, at all times, to all
parts of the mixing plant for checking the adequacy of equipment, for the
preparation of the mixtures.
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iii. The temperature of the bituminous material delivered to the mixer shall be
sufficient to provide a suitable viscosity for adequate coating of the aggregate
particles, but shall not exceed the applicable maximum temperature set forth in
bitumen clause.
iv. The aggregate for the mixture shall be dried and heated to the temperature
designated by the job formulae within the job tolerance specified. The maximum
temperature and rate of heating shall be such that no pennanent damage occurs
to the aggregates.
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v. The aggregates and the bituminous material shall be measured or gauged and
introduced into the mixer in the amount specified by the job mix fonnulae.
vi. The combined materials shall be mixed until a complete and uniform coating of
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the particles and a thorough distribution of the bituminous material throughout
the aggregate are secured. Wet mixing time shall be as short as practically
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feasible to prevent excessive aging in the plant.
4.8.5.2 Hauling Equipment
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Trucks used for hauling bituminous mixtures shall have suitably treated beds to prevent
the mixture from adhering to them. When necessary the mixture shall be protected to
ensure delivery to the site at tbe specified temperature.
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4.8.5.3 Pavers
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Bituminous pavers shall be self-contained, power-propelled units with an activated screed

or strike-off assembly, beated if necessary, and shall he capable of spreading and
finishing courses of bituminous plant-mix material which will meet the specified
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thickness, smoothness, and grade.
4.8.5.4 Rollers
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Rollers shall be 4 - II tons, steel wheel, tandem or equivalent.
4.8.6 Construction Method

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hnmediately before placing the bituminous mixture, the underlying course shall be
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cleared of aU loose or deleterious material with power blowers, power brooms, or hand
brooms as directed. Tack coat shall then be applied as specified.
4.8.6.2 Weather Limitations

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The bitwninous mixture shall not be placed on a wet surface.

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4.8.6.3 Laying
i. Deliveries shall be so scheduled so that it is compatible with the speed of

spreading and rolling.
ii. Hauling over freshly placed material shall not be permitted until the material has
been compacted. as specified, and allowed to cool to atmospheric temperature.
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iii. The mix shall be placed at a temperature of not less than 150°C. Prior to the
beginning ofthe compaction, the temperature shall not be less than 120 °C.
iv. Upon arrival, the mixture shall be spread to the full width by an approved
bituminous paver. It shall be struck off in a unifonn layer of such depth that,
when the work is completed, it shall have the required thickness and shall
conform to the grade and contour indicated. The speed of the paver shall be
regulated to eliminate; pulling and tearing of the bituminous mat.
v. Unless otherwise directed, placing shall begin along the center line of areas to be
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paved on a crowned section or on the high side of areas with a one-way slope.
The mixture shall be placed in consecutive adjacent strips having a minimum
width of, 3 m, except where edge lanes require strips less than 3 m to complete
the area.
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vi. The longitudinal joint in one layer shall offset that in the layer inunediately
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below; by at least 3 m.
vii. Transverse joints in one layer shall be offset by at least 60 em from transverse
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joints in the previous layer. Transverse joints in adjacent lanes shall be offset a
minimum of 3 m.
viii. The mixture may be spread, raked and luted by haod tools on areas
(irregularities or unavoidable obstacle) where application of equipment for
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spreading and finishing is found to be impractical.
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4.8.6.4 Compaction
i. Rolling of the mixture shall begin as soon after spreading as it will bear the
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roller without undue displacement or hairline cracking.
ii. Over-compaction shall be avoided.

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iii. The compaction temperature shall be at 120 - 150 "C.
iv. Rolling shall be accomplished using the plant as approved by the S.O. during
lliallay.
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v. Once sufficient in place density has been achieved rolling operations should
cease as over rolling may cause migration of PMA and filler to the compacted
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pavement surface.
vi. The pavement should be compacted to at least 98% of Marshall density.

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4.8.6.5 Joints
i. The formation of all joints shall be made in such a manner as to ensure a

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continuous bond between old and new sections of the course. All joints shall
present the same texture, density, and smoothness as other sections of the course
ii. Cold longitudinal joints shall be cut back by sawing or kerbing over their full
length to expose a clean, sound surface for the full depth of the course. All
contact surfaces shall be given a tack coat of bituminous material prior to
placing any fresh mixture against the joint. The tack coat shall be applied
uniformly on the cut joint surface using hand brush.
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4.8.6.6 Shaping Edges
i. While the surface is being compacted and finished, the Contractor shall carefully
trim the outside edges of the pavement to the proper alignment.
ii. Edges so formed shall be beveled while still hot and compacted.
4.8.6.7 Finished Gap Graded Asphalt
Gap Graded Asphalt wearing courses shall be finished in a neat and workmanlike
ER
manner; their widths shall be everywhere at least those specified or shown on the
Drawings on both sides of the centre-line; the average thickness over any IOO-metre
length shall he not less than the required thickness, and the minimum thickness at any
point shall be not less than the required thickness minus 5 mm.
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The top surface of a wearing shall have the required shape, superelevation, levels and
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grades, and shall be everywhere within the tolerances specified in Sub-Section 4.5.
The International Roughness Index (lRI) value of the finished wearing course surface
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shall be carned out as described in Sub-Section 4.5 and shall be not more than 2.0 mIkm.

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Traffic should not be placed on the newly compacted surface until the mat has
cooled to 60°C or lower.
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HOT IN-PLACE RECYCLING
Hot In-Place Recycling (HIPR) is areas, it maintains kerb heights for safety
generally used to address functional and drainage purposes. It also addresses
pavement failures such as bleeding, deteriorated pavement surfacing whereby
ravelling, surface cracking and undulation. cracks propagation are mitigated, ruts and
HIPR is a rehabilitation technique that depression are filled, shoves and bumps
involves beating. scarifying, mIXing, are levelled. In addition, cross-fall and
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levelling and compacting the existing crowns are also reinstated and utilities
bituminous surface. This technique also manhole covers need not be raised.
includes blending the scarified material
with fresh bituminous mix, bitumen Since the effective recycling depth is limited
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rejuvenatingagent and if necessary. virgin to 60mm only, HIPR shall not be used to
bitumen. address pavement failures that are related to
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the base and sub grade layers. Localised
HIPR technique is an economical and subgrade andlor base failures shall be treated
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practical solution for the rehabilitation of prior to the use of this technique. Proper site
surface distresses by reducing the haul of selection is therefore of paramount
materials, usage of fresh aggregates and importance for the success of this technique.
bituminous mix. TItis technique restores
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the ride quality and surface condition of
structurally sound pavements. In wban
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TH rlR" r.:;
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C~ ~ A4
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4.9 SPECIALTY MIX 4 HOT IN-PLACE RECYCLING
4.9.1 Description
This work shall consist of repair of surface failures, surface cracks and general
rehabilitation of the pavement surface using the Hot In-Place Recycling process,
which includes heating, scarifying, mixing, levelling and compacting the existing
bituminous surface to the levels, grades, thickness and cross-sections as shown in the
Drawings or as instructed by the S.D. This process shall also include blending the
scarified material with an asphalt rejuvenating agent and if necessary, bitwnen and
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fresh bituminous mix all as specified and as instructed by the S.O. Areas with
subgrade and/or base failures shall be treated prior to the use of this technique.
4.9.2 Materials
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Recycled asphalt mixture is the combined reclaimed and fresh bituminous material
obtained after the remixing process in the field.
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4.9.2.1 Recycled Asphalt Mixture
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Fresh bituminous mix where necessary shall be added. The properties of the recycled
asphalt shall meet the requirements below.
(a) CCJarse Aggregate For Fresh Bituminous Mix

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Coarse aggregate shall be screened crushed hard rock, retained on 5.0 mm sieve,
angular in shape and free from dust, clay, vegetative and other organic matter, and
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other deleterious substances. They shall conform to the following physical and
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accordance with ASTM C 131 shall be not more thao 25%,
ii. The aggregate crushing value when tested in accordance with BS 812 shall
be not more than 25%, (for remixing with additional thickness and remixing
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and new overlay only)
than 25%,
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iv. The polished stone value when tested in accordance with MS 30 shall be not
less thao 40,
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v. The weighted average loss of weight in the magnesium sulfate soundness

not more than 18%. If sodium sulphalte is used as the test medium, the
weighted average weight loss of weight shall not be more than 12%.
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vi The water absorption when tested in accordance with MS 30 shall be not

more than 2%.
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(b) Fine Aggregate For Fresh Bituminous Mix
Fine aggregate shall be screened quarry fines. They shall be non-plastic and free from
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i. The weighted average loss of weight in the magnesium sulfate soundness

not more than 20%.
ii. The water absorption when tested in accordance with MS 30 shall be not
more than 2%.
iii. The sand equivalent of aggregate fraction passing the NO.4 (4.75mm) sieve
iv. The fine aggregate angularity when tested in accordance with ASTM C
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1252 shall be not less than 45%.
vi. The Methylene Blue value when tested in accordance with Ohio Department
of Transportation Standard Test Method shall be not more than 10 mg/g.
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(c) Aggregate Properties/or Existing Pavement
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The properties of the aggregate in the existing bituminous mix shall not deviate by
more than 20% from values specified in Clause 4.9.2.1(a) and4.9.2.1 .(b)
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(d) Binder
Fresh bituminous binder shall be 80-100 and 50-70 penetration grade bitumen
conforming to M.S. 124. The penetration of the bitumen recovered from the recycled
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asphalt, after laying, shall be within the range of 50 to 70.
4.9.2.2 Marshall Properties For Fresh Bituminous Mix

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The fresh bituminous mix to be used for all recycled asphalt shall oonfonn to Table
4.9.1
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4.9.2.3 Rejuvenating Agent
The rejuvenating agents used consist of hydrocarbon compounds or liquid bitumen

EN
type and shall have the physical properties so that when added to the existing
bituminous mix, the blended binder shall be within the requirements of Clause
4.9.2.2.
The rejuvenating agent shall not be carcinogenic and the contractor shall provide
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relevant technical information and material safety data sheet of the proposed type of
rejuvenating agent to be used for approval by the S.D.
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4.9.3 Mix Design
Prior to starting hot in-place recycling operations, the Contractor shall furnish the
S.D. with a proposed mix design. The proposed mix design shall be based on samples
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obtained by the Contractor, and shall include the following elements:
i. The bitumen content of the existing pavement to be recycled.

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ii The penetration at 25°C and softening point of the recovered binder obtained
from the existing pavement to be recycled.
iii. Aggregate gradation of the existing pavement to be recycled.
iv. Type and amount ofrejuvenating agent recommended.
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v. The penetration at 25°C and softening point of the binder recovered from the
recycled mixture (includes binder from the existing pavement to be
recycled, fresh binder, and rejuvenating agent),
vi. Aggregate gradation of the blended mix (includes aggregates in the existing
pavement to be recycled combined with the newly added aggregates), which
shall conform to the envelope given in Table 4.9.1
vii. Marshall properties on the proposed blended mix shall conform to Table
4.9.2
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Table 4.9.1: Aggregate Gradation for Blended Mix
Mix design Typel TypeZ
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B.S. Sieve % Passing By Weight
n 37.5 -
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28.0 - \00
20.0 100 76 - \00
14.0 80 - 95 64 - 89
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\0.0 68 - 90 - 56 - 81
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5.0 52 - 72 46 - 71
3.35 45 - 62 32 - 58
1.18 30 - 45 20 - 42
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0.425 17 - 30 12 - 28
0.150 7 - 16 6 - 16
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0.075 4 - \0 4 - 8
5.0 - 7.0% _ 4.5 - 6.5%
Tar~et Bitumen Content
Air Voids 3.0 - 5.0% 3.0 - 5.0%
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(j 4.9.3.1 Selection Criteria for Existing Pavement

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HIPR is used to repair pavement that suffers surface fai lures only such as ravelling,
stripping and low skid resistance. HIPR shall not be used on pavement which
contains geotextile, geogrid, tar and cutback bitumen.
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4.9.3.2 Treatment of Existing Pavement

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Areas with base andlor subgrade failures shall be reconstructed accordingly from the
subgradeJbase up to the wearing course. The recycling process shall continue over
this area, unless the reconstructed length is greater than 5 metres lane-length.
4.9.4 Job Mix Formulae
The contractor shall carry out a trial lay of Hot In-Place Recycling over a section of
at least 150 metres length. Job mix formulae for the blended mix shall be established
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from the trial lay and the gradation shall conform to the appropriate envelope
selected in the mix design process.
The Marshall properties of blended mix shall confonn to requirement as stated in
Table 4.9.2 below.
Table 4.9.2: Marshall Properties
Parameter < 2 million ESA > 2 million ESA
Stability S > 500 kg > 700 kg
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Flow F >2.0kg > 2.0 kg
Stiffness SIF >250kglmm > 350kglmm
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Air voids in mix 3.0%- 5.0% 3.0% - 5.0%
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Voids in aggregate filled 75%- 85% 75%- 85%
with bitumen
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4.9.5. Equipment
4.9.5.1 General
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In general, the recycling machine shall not operate OD more than one lane width of
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carriageway and shall be capable of performing the in-situ recycling in a single pass.
Where liquid petroleum gas or an equivalent is used, all the necessary safety devices
shall be fitted and approved by the Deparbnent of Occupational Safety and Health
(DOSH) prior to commencement of any works. The Contractor must submit a
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certificate from the manufacturer of the recycling machine, certifying that the
machine is fit for use (mechanically in working condition) prior to commencement of
the works.
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4.9.5.2 Safety Measures
The contractor shall ensure that all necessary safety measures are taken prior to the
commencement of work, in particular the gas tanks of the preheaters and remixers
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and the transfer of gas from the transporter to the tanks. In the event of any gas
leakages, the contractor shall ensure that the necessary emergency procedures are
taken so that the safety of its personnel and surrounding areas is not compromised.
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4.9.5.3 Catalogues and relevant infonnation on machine
The Contractor shall provide catalogues, relevant technical information and data
pertaining to the proposed recycling machine to be used.
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4.9.5.4 Hot In Place Recycling System

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The proposed hot in place recycling system shall consist and be capable of the
following:
i. A road beater of the indirect heating type machine capable of high heating
efficiency for providing a suitable temperature gradient. The heating
mechanism shall be capable of heating the bituminous surface to a
temperature so as to allow for scarifying the parent material to the
prescribed depths without breaking the aggregate particles, charring the
existing bituminous material and producing undesirable pollutants. In any
case, the beating mechanism shall be so equipped that the application would
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be executed in an enclosed or shielded hood. The depth of heat penetration

should not be less than the intended depth to be recycled.
iL Scarifiers capable of unifonnly loosening the bituminous pavement to the

depth specified and equipped with separate automatic height adjustments in
order to clear existing manholes and other obstructions.
iii. A collecting system capable of collecting the heated and scarified material
for remixing, and distributing over the widths being processed and finishing
so as to produce a uniform cross-section.
ER
iv. A system for adding and uniformly blending a rejuvenating agent andlor
bitumen to the reclaimed mix during remixing and levelling operations. The
application rate for the added material shall be synchronized with the
machine speed to provide uniform application.
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v. A mixer unit to uniformly mix fresh bituminous material with the reclaimed
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mix and distributing the blended mixture over the width that is being
processed.
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vi. A screed to spread the blended mixture in the prescribed widths and
thickness. These shall be equivalent in performance to screw spreaders and
screeds of conventional aspbalt spreaders/finishers.
4.9.6 Construction methods

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4.9.6.1 General
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Prior to commencement of work, tbe contractor shall survey the site for any
obstruction or services that may be affected or damaged by this process and inform
the S.O. for further instructions. Hot in-place recycling shall not be carried out over
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areas with obstruction or services that may be damaged by the process. The
contractor shall replace and make good any damaged services and facilities due to the
work at this own expense.
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4.9.6.2 Surface preparation and cleaning
The existing pavement surface to be recycled shall be free of any loose and
deleterious material such as silt, dirt and other debris that might interfere with the
heating process. These shall be removed by grading. blowing, brooming or other
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methods approved by the S.O. prior to the heating and scarifying process. The
contTactor shall ensure that all other obstructions are protected.
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4.9.6.3 Heating. Scarifying. Mixing and Placing Processes
The pavement surface shall be evenly heated to a temperature of not less than 120°C
at the scarified depth behind the screed and not more than 180°C, with a continuously
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moving radiant heater to allow the pavement to be scarified without breaking the
coarse aggregate in the bituminous mixture . The heating operation shall be applied
under an enclosed hood extending at least 100 mm beyond the width of scarification
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on both sides. Heating shall be controlled to ensure uniform heat penetration without
causing differential softening of the pavement surface. Charring of the bitumen shall
not be allowed. Any charred areas, shall be removed from the site and replaced
immediately with fresh asphalt before the scarifying process is carried out. Similarly,
existing thermoplastic line marking material shall be removed before the scarifying
process is carried out.
The heated pavement shall be immediately scarified by carbide tipped teeth. set on
less than 25 mm centers, mounted in multiple racks or on a rotating mandrel,
controlled by the machine operator. The scarifying equipment shall be able to cut a
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plane through the pavement that is within 20 nun of the alignment of the grade and
slope of the fmished pavement. Where appropriate, liquid bitumen, rejuvenating
agent or new asphalt mix shall be added during the remixing process, before the mix
is paved.
4.9.6.4 Remixing
(a) Remixing Process (For Normal Reshaping and ReprofilingJ
Where remixing is specified by the S.O., the existing pavement shall be heated and
ER
scarified to the specified depth. Rejuvenating agent and additional asphaltic concrete
material shall be added to the reclaimed mix and compacted all in a single pass. The
purpose of the additional material is to reprofile existing ruts, to restore binder
properties and to correct aggregate gradation.
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(b) Remixing with Additional Thickness
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Where remixing to a specified overlay thickness is required for strengthening and
restoring the original pavement, the existing bituminous pavement layer shall be
heated and scarified to a predetermined depth. Rejuvenating agent and additional
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asphaltic concrete material shall be added to achieve the specified thickness and
required material composition. The whole process of heating, scarification and
addition of rejuvenating agent and binder, paving and compaction shall be executed
in a single pass.
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(c) Remixing and New Overlay
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Where a new overlay of asphaltic concrete is required on top of the remixed layer.
the process of remixing, as described in Sub-Section 6.4.1 above shall be carried out
and in addition to that, a new asphaltic concrete overlay of a specified thickness as
approved by the S.D. shaH be simultaneously paved on top of the newly remixed
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pavement. Both layers shall be compacted at the same time, provided that the
combined thickness does not exceed lOOmm.
4.9.7 Laying and Compaction

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The recycled layer shall achieve a compacted density of not less than 98% of
Marshall density.
4.9.8 Joints
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When a pass is adjacent to a previously placed mat, the heating shall extend at least J
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IOOmm into the adjacent mat to enable a hot~on~hot longitudinal joint to be

constructed.
4.9.9 Finished HIPR Surface

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The completed HIPR surface shall be finished in a Deat and workmanlike manner,
with recycling and paving widths conforming to those specified or shown in the
Drawings. The average thickness over any IOOmetre length shall be not less than the
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specified thickness, and the minimum thickness at any point shall be not less than the
specified thickness minus 5 mm.
4.9.9.1 Regularity of Completed Pavement Surface
(aJ Description

Roughness of a pavement surface is brought about by uneven settlement, short and
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long wave undulations, rutting, wide cracking and other surface defects such as
potholes, delamination etc..
The International Roughness Index (00) is used internationally to measure the

degree of roughness of a pavement surface. It is representative of the vertical motions
induced in moving vehicles for the frequency bandwidth which affects both the
response of the vehicle and the comfort perceived by the occupants
The IRI describes a scale of roughness which is zero for a true planar surface,
increasing to about 6 mIkm for moderately rough paved roads, 12 mIkm for
extremely rough paved roads with potholes and patches, and up to about 20 mIk:m for
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extremely rough unpaved roads.
(b) Measurement ofIRl
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The regularity of the completed pavement surface is measured in terms of its lane
!RI. Lane IRI shall be measured using the ARRB Walking Profiler (WP) following
the procedures as outlined in Appendix 1.
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n Other types of equipment such as high speed profiler may be used to measure lane
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IRI provided that the output from the equipment correlate strongly with the output
from WP (R'>O.95).
(c) Acceptance Criteria

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The Contractor shall make available lane IRI values for the whole road length as well
as for each 100m length of the completed pavement sW'face.
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The lane IRI measured for the whole road length and each 100 meter section for
IDPR treatment involving remixing with additional thickness and remixing and new
overlay shall be less than 2.0mIkm.
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The lane IRI measured for the whole road length and each 100 meter section for
IDPR treatment involving only remixing process shall be less than 2.SmIkm.
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(d) Rectification Work/or Non-Compliance
In case of non-compiiance. the contractor shall carry out rectification works on any
part of the completed pavement surface so that the lane IRI values for the whole road
length and for each 100 meter section are less than 2.0mlkm.
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( (e) Quality Control of Finished HlPR Surface

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Mix samples shaU be taken after the placing of the blended mixture at the frequency
of one sample per Soo metre length of lane or a minimum of once per working day,
whichever is the greater. The mix sample shall be checked for bitumen content,
penetration and softening point of the recovered binder and aggregate grading.
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Core samples shall be taken from the finished asphalt layer at a frequency of one core
per 250 metre per lane length or a minimum of three cores, whichever is the greater.
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Core samples shall be checked for the thickness of the recycled layer and its
compacted density.
4.9.10 Opening to Traffic
The pavement shall not be opened to traffic until compaction has been completed and
the material has thoroughly cooled and set in the opinion of the S.O. This will usually
be not less than 4 hours after the commencement of railing.
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COLD IN PLACE RECYCLING
Cold in-place recycling (CIPR) is a The main advantages of CIPR technique

structural pavement rehabilitation technique. include conservation of materials and
It re-uses the existing pavement materials. energy, full utilisation of local materials,
This technique involves scarifying, minimise use of new materials, reduction of
stabilising and re-Iaying the recycled traffic disruption, improved pavement
materials with minimal off-site hauling or strength, and lower capital costs.
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mixing.
CIPR is applied to older pavements that are
CIPR involves the processing and stabilising structurally deficient and no longer are
of the existing pavement layers without candidates for a simple overlay. Most
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heating to produce a rejuvenated pavement pavement distresses, such as fatigue
layer. There are many types of stabilising cmcking, transverse thermal cmcking,
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agents that can be used in CIPR but the most reflective cracking can be successfully
common are bitumen emulsion, foamed corrected using cold in place pavement
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bitumen, lime, Portland Cement and fly ash. recycling technique. Genemlly, CIPR
Stabilising agents can be injected directly technique costs lower than full
into the recycler mixing chamber while the reconstruction method.
scarifying opemtion is carried out, ensuring
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excellent mixing of the stabilizing agent CIPR should not be used to rehabilitate
with the scarified materials. Where required, pavement that has failed due to poor
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the scarified materials may be modified by embankment or foundation support.
the addition of fresh aggregates andlor Normally, a snrfacing layer is required on
bitumen. top of the recycled pavement layer
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""--""-'1.--_ .. __
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4.10 SPECIALTV MIX 5 - COLD IN-PLACE RECYCLING
4.10.1 Description
This work shall include all achVlt1es in connection with the construction of a new
pavement layer using the cold in-place recycling process to recycle material from the
pavement layers of an existing road. The work shall include;
i. breaking down and recovering material of an existing pavement using a

purpose-built recycling machine;
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11. where required, modifying the characteristics of the recovered material by the
addition of imported material;
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iii. the provision and application of stabilising agents and water; and
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iv. mixing. placing, compacting and shaping the recycled material to achieve a new
n pavement layer.
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New pavement layers shall conform to the lines, grades, thickness and typical cross-
sections shown on the Drawings and/or descn"hed in detailed pavement design report
and/or as required by the S.O.
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4.10.2 Materials
4.10.2.1 Existing Pavement Material

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Investigations carried out, together with the results of tests conducted on representative
samples of materials in the existing pavement structure, shall be detailed in pavement
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design report and/or issued separately by the S.O. As a minimum, these shall include;
i. a description of the pavement structures that is/are likely to be encountered

when cold in-place recycling;
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ii anticipated grading, plasticity and other relevant properties of the materials to be

recycled from the pavement layers;
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iii. n-situ moisture contents measured at the time of investigation;

l.J iv . structural and mix designs.
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These information shall be supplied in good faith but any reliance placed by the
Contractor on these information shall be at his own risk, and he shall undertake his own
separate testing programme to determine the conditions prevailing at the time of
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construction.
Any significant deviation in the physical or mechanical properties of the material

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recovered by recycling that are indicative of changes in the existing pavement shall be
immediately reported to the S.O. The Contractor shall take whatever action he deems
necessary to ensure that the new pavement layer produced in the cold in-place recycling
process complies with the design requirements, unless otherwise directed by the S.O.
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4.10.2.2 Imported Pavement Material
Natural material (sand, gravel, etc). crushed stone products (graded products, crusher
dust, etc) andlor salvaged Recycled Asphalt Pavements (RAP) from other sites may be
required to be mixed with the recycled material for the purposes of;
i. altering the grading of the recycled material; and/or
ii. supplementing the volume of the recycled material (e.g. for shape correction);
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iii. improving the structural properties of the pavements.
The specific requirements for imported materials shall be detailed out in pavement design
report andlor as directed by the S.O.
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4.10.2.3 Stabilising Agents
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(a) General
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All stabilising agents shall be of the quality and type specified, and the Contractor shall
provide documentaIy evidence to this effect when required by the S.O. Aoy stabilising
agent that is not satisfactory shall be rejected.
(b)
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Cement
Cement used in the cold in-place recycling process shall be ordinary Portland cement
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complying with MS 522.
The use of any other class or type of cement shall only be considered if the Contractor
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can demonstrate that it will provide a cost benefit without any technical detriment to the
Works, subject always to the written approval from the S.O.
(c) Bitumen Emulsion

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Bitumen emulsion used in the cold in-place recycling process shall be of slow-setting
type complying with the requirements ofMS 161 and as shown in Table 4.10.1.
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TABLE 4.10.1: LIMITS FOR BITUMEN EMULSION (SLOW-SETTING)
Parameter Minimum Maximum

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i. Viscosity, Saybolt Furol at 25° C (sec): 20 100

ii. Settlement, 5 days (%): 0 5
w. Stora~e stability test, 24hr (%): 0 I
iv. Sieve test (%): 0 0.1
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v. Cement mixing test (%): 0 2.0

vi. Distillation for oil, by volume of bitumen 0 5
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emulsion (%):
vii. Distillation for residue (%): 60
viii. Penetration for residue (%): 60 200
lX. Ductility of residue, 25° C, 5cm/min (cm) 40
x. Solubility in trichloroethylene (%) 97.5
xi. Particle charge test Positive
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The use of any other class or type of bitumen emulsion shall only be considered if the
Contractor can demonstrate that it will provide a cost benefit without any technical
detriment to the Works, subject always to the written approval from the S.O.
(dJ Bitumen for Foaming
Bitumen used for foaming in the cold in-place recycling process shall be of penetration
grade 80/100 complying with MS 124, and free of any anti-foaming agent. The foamed
bitumen shall be produced at a temperature range of between 160 'c - 180 'c and at the
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designed water content. The bitumen shall have the following foaming properties;
i. Expansion ratio I: minimum 8 times
ii. Half Hfe2 : minimum 8 seconds
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The use of any other class or type of bitumen for foaming shall only be considered if the
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Contractor can demonstrate that it will provide a cost benefit without any technical
detriment to the Works, subject always to the written approval of the S.O.
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(eJ Water
Water used in the cold in-place recycling process shall be potable, clean and free of
harmful matter.
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4_10.3 Mix design
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4.10.3.1 General
Details regarding materials to be used, application rates of stabilising agent, type and
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application rate of any required additives, any specific pre-treatment requirements and the
compacted thickness of the recycled stabilised layer shall be determined in advance of the
Work.
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Laboratory tests on materials sampled from the existing pavement andlor borrow areas
shall be carried out to detennine the basic properties of the recycled pavement material
prior to addition of stabilising agent. Samples taken from the existing pavement material
shall be representative of the material that will be recycled for the particular section.
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\. ) The preliminary laboratory testing shall form the basis for determining the feasibility of
cold in-place recycling and indicating the most appropriate method.
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For sections determined as feasible for cold in-place recycling, further laboratory tests
shall then be undertaken to determine the following key parameters;
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i. the volume of any additional material to be imported from specific borrow areas;
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ii. the type and optimal application rate of the stabilising agent;
iii. the amount and type of any required additives.
The additional laboratory tests shall be as specified in Sub-Section 4.10.5 for each of the
stabilising agents to which this Specification apply.
I Maximum volume of foam/original volume of bitumen

2 Time taken for the foam volume to reduce to half its maximum volume
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4.10.3.2 Preliminary Laboratory Testing
Testing of the existing pavement material shall be undertaken and shall conform to the
following physical and mechanical quality requirements;
1. the plasticity index shall be not more than 6 for unbound material;
ii. the aggregate crushing value when tested in accordance with MS 30 shall be not
more than 25%;
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111. the flakiness index when tested in accordance with MS 30 shall be not more than
25%;
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iv. the material shall have a CBR value of not less than 80% when compacted to
95% of the maximum dry density determined in the BS 1377 Compaction Test
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(4.5kg rammer method) and soaked for 4 days under a surcharge of 4.5kg;
v. the gradation shall comply with the envelope shown in Table 4. 10.2.
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TABLE 4.10-2: GRADATION LIMITS FOR RECYCLED LAYER
MATERIAL
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Sieve size Cumulative % passing
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50.0mm 100
37.5 mm 85 - 100
20.0mm 60 - 100
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1O.0mm 40-90
5.0mm 30 - 75
2.36 mm 20 - 60
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425 m 10 - 45
75 m 2-20
Compliance with the conformance requirements of Sub-Section 4.10.3.3 shall not be

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deemed as acceptance for its use in cold in-place recycling. It shall be regarded as
indicating potential suitability. J
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Non-compliance with the conformance requirements of Sub-Section 4.10.3.3 shall not be

deemed as non-acceptance for its use in cold in-place recycling. It shall be regarded as
indicating deficiencies that require attention to render it potentially suitable.
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Where the existing pavement material is deemed potentially suitable for cold in-place
recycling, the Contractor shall provide the S.D. with recommendations of proposed
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stabilisation type and additional materiaV treatment required. Such additional materiaV
treatment shall be used to correct any deficiencies in the properties of the existing
pavement material that would otherwise render it unsuitable for stabilisation.
Subject to no objection by the S.D. to the recommendations, the Contractor shall

undertake detailed testing as specified in Sub-Section 4.10.5.
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4.10.3.3 Compliance Requirements for Recycled Layer Materials
(aJ General Requirements
The following sub-sections set out the speCific compliance requirements for the recycled
pavement layer. The Contractor shall provide the S.D. with the results of all tests together
with his proposals for the mix and pavement designs for each section of the road. The
minimum length of anyone section shall be 500m. After review, the S.D. shall either
accept such proposals, in writing, or describe his concerns and suggest that specific
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changes be made.
The untreated material shall comprise existing pavement layer material and any other
additional materiaVtreatment required as recommended in Sub-Section 4.10.4, and its
physical and chemical composition shall be representative of the material expected on
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site immediately prior to the addition of stabilising agent.
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The stabilising agent shall be in conformance with the requirements of Sub-Section
() 4.10.2.3 and shall be applied such that the resulting material shall be representative oflbe
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recycled material expected on site.
Laboratory tests on stabilised material shall be undertaken to detennine the application

rate of the stabilising agent. Specimens shall be prepared at the optimum fluid content for
the particular stabilising agent based on and derived from the optimum moisture content
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of the untreated material detennined in the AASHTO T 180 (mndified moisture density
relationship) or BS 812IBS 1924.
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Modification of the specimen moisture content to attain the appropriate optimum fluid
content for the particular stabilising agent shall be in accordance with current best
practice and the Contractor's own experience.
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(b) Cement Stabilisation
The compliance requirements for cement stabilised cold-in-place recycled layer material
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requirements are given in Table 4.10.3.
TABLE 4_10_3: REQUIREMENTS FOR CEMENT STABILISED COLD

IN-PLACE RECYCLED LAYER MATERIAL
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( ) Requirement
Parameter
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Unconfmed Compression
Test (UCS), in accordance Minimum 97% Range(MPa)
with B.S. 1881 , part 116. 7- of Modified (minimum and
2-5
day strength, moist curing AASHTO maximum
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@ 25°C, height/width I: I density limits)
Indirect tensile test (ITS) on

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Minimum 97%
150mm diameter briquette
of Modified Minimum
cured as for UCS 0.2
AASHTO (MPa)
specimens, in accordance
density
with AASHTO T-198
Maximum cement content by weight 5%
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JKRlSPJ/2008-S4
The job mix stabilising agent content shall be determined from the testing and submitted
to the S.O., together with all other details of the mix for quality control purposes,
including target moisture content and density.
(c) Bitumen Emulsion Treatment
The compliance requirements for bitumen emulsion treated cold-in-place recycled layer
material are given in Table 4.1004.
TABLE 4.10.4: REQUIREMENTS FOR BITUMEN EMULSION TREATED
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COLD IN-PLACE RECYCLED LAYER MATERIAL
Minimum
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Parameter
Strength (MPa)
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Unconfined Compression Test
Minimum 97% of
(UCS), in accordance with B.S.
Modified AASHTO 0.7
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1881, part 116. 7-day strength, moist
density·
curing· @ 25"C, height/width I: I
Indirect tensile test (ITS) on lOOmm
Marlihall
diameter briquette cured at 40"C for
compaction 0.2
72 hours, in accordance with
(75 blows per side)
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AASHTOT-198
Indirect tensile test (ITS) on cured Marlihall
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briquettes, soaked for 24 hours as compaction 0.15
above (75 blows per side)
Maximum added cement content by weight 2%

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• DensIty determined at optimum fluId content for the mature at the relevant
compactive effort.
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The job mix stabilising agent content shall be determined from the testing and submitted
In the S.O. together with all other details of the mix for quality control purposes,
including target fluid content and density.
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(d) Foamed Bitumen Stabilisation
The compliance requirements for foamed bitumen stabilised cold-in-place recycled layer
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material are given in Table 4.10.5. The classification is based on the indirect tensile
strength test (ITS).
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TABLE 4.10.5: REQUIREMENTS FOR FOAMED BITUMEN STABILISED

COLD IN-PLACE RECYCLED LAYER MATERIAL
Minimum Strength
Parameter
(MPa)
Unconfined Compression Test

Minimum 97% of
(UCS), in accordance with B.S.
Modified 0.7
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1881, part 116. 7-day strength, moist
AASHTO density"
curing-@ 25'C hei.htlwidth I: I
Indirect tensile test (ITS) on 100mm
Marshall
diameter briquette cured at 40°C for
compaction 0.2
72 hours, in accordance with
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(75 blows per side)
AASHTOT-198
Indirect tensile test (ITS) on cured Marshall
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briquettes, soaked for 24 hours as compaction 0. 15
above (75 blows Der side)
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Maximum added cement content by weight 2%
* Density determined at ophmum mOisture content for the mixture at the relevant
compactive effort.
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The job mix stabilising agent content sball be determined Iiom the testing and submitted
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to the S.O., together with all otber details of the mix for quality control purposes,
including target moisture content and density.
4.10.3.4 Trial Sections

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Trial (pilot) section construction sball be undertaken on eacb contract section for whicb
the layer and/or material design requirements are expected to change. Eacb accepted trial
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section shall demonstrate compliance with the specification requirements to the

satisfaction of the S.O., prior to cold-in place recycling continuing on the section. As a
minimum, the following details shall be included;
i. Gradation of the recycled material;

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( ) ii. Compaction requirements including type of roller and rolling pattern to be

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employed to achieve tbe required density;
iii. Strength of the recycled layer material in terms of UCS and ITS as specified in
Table 4.10.8;
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iv. Recycling depth and compacted thickness of new recycled layer material as
specified in detailed pavement design report;
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v. In-situ moisture content in order to determine the application rate of water to

achieve the OMC;
vi. Percentage by weigbt of the stabilising agent used as specified in Table 4.10.8,
aod
vii. Speed of advaoce of the recycler machine as specified in Table 4.10.8.
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JKRlSPJ/200B-S4
The trial section shall have a nummum 150m length at the proposed laying width.
Quality control sampling and testing frequency shall be at least double that specified for
normal job production as directed by the S.O.
If the trial lay results are within the pennissible tolerance, then the trial lay results shall
be designated as Job Standard Mix (JSM).
Trial sections deemed to comply with the specification requirements shall be accepted as
part of the permanent works and the Contractor shall be permitted to proceed on the
specific section.
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For trial sections deemed as non-compliance with the specification requirements, the
Contractor shall submit a work proposal for making good such sections for approval by
the S.O. Trial sub-sections made good and subsequently approved as being in compliance
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with the specification requirements shall be paid for at the same nominal rate as the
nonnaljob for the particular section of work.
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4.10.4 Equipment
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4.10.4.1 General
All equipment shall be supplied and operated in such a manner as to recycle the in situ
pavement to the specified depth and construct a new pavement layer, all in accordance
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with the requirements of the specifications. All equipment deployed on the site shall be of
adequate rated capacity and in good working order. Obsolete, poorly maintained or
dilapidated equipment shall not be allowed on site.
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The minimum compliance requirements for the equipment to be used for cold in-place
recycling are given in the following sub-sections. The Contractor shall provide the 8.0.
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with details and technical specifications of the equipment at least two weeks in advance
of the first proposed usage.
4.10.4.2 Equipment for Cold In-Place Recycling

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Cold in-place recycling shall be carried out using a modified milling machine or a
purpose-built recycling machine to;
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i. add the required amounts of water and stabilising agents;
ii. mix all ingredients together to achieve a uniform consistency; and

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iii. place the reconstituted material within the excavation created by the initial
milling.
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Unless specified in the detailed pavement design report or directed by the S.O., all the
operations described above shall be effected simultaneously in a single pass of the
machine.
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Unless otherwise specifically permitted within the contract documents, the modified
milling machine or recycler to be used for cold in-place recycling shall meet the
following minimum requirements;
I. It shall be factory-built by a manufacturer baving a demonstrable rack record

and manufacturing history in the particular type of equipment.
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ii. The milling drum shall have a rrurumum cut width of 2 metres with the
capability of changing the speed of rotation.
iii. A level control system that maintains the depth of milling within a tolerance of±
10 millimetres of the required depth during continuous operation.
iv. The milling drum shall rotate within an enclosed chamber inside which water
and stabilising agents are added to the recovered material at the rate required to
achieve compliance with the specified laboratory design mixture during
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continuous operation.
v. All spray systems fitted to the recycler shall be controlled by micro-processor to

regulate the flow rate with the speed of advance of the machine. All spray
systems shall also have the ability to allow variable widths of application.
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vi. It shall have sufficient power to mix the recycled material together with all
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additives to produce a unifonn homogenous reconstituted material during
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All ancillary equipment for supplying water. stabilising agents and other additives to the
recycler during operation shall he in accordance with the recycler manufacturer's
recommendations.
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4.10.4.3 Additional Requirements when Stabilising with Cement
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Where the cement stabilising agent is not applied directly on the surface of the road prior
to recycling. the recycler shall be fed with cement slurry that is produced in a separate
mobile mixing unit pushed ahead of the recycler. Such a mixing unit shall be equipped
as follows;
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i. It shall have the capability to supply the cement slurry at the required rate to
comply with the mix design during continuous operation.
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ii. It shall be capable of regulating the application rate of cement slurry in

accordance with the speed of advance of the recycler and volume of material
during continuous operation.
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iii. It shall provide uniform mixture of the cement slurry to the recycler to produce a
) homogenous recycled mixture.
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iv. There shall be a method for monitoring cement usage during operation that can
be validated by simple physical measurement for control purposes.
4.10.4.4 Additional Requirements when Stabilising with Bitumen Emulsion

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In addition to the requirements specified in 4.10.4.2. the recycler shall be equipped as

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follows;
i. It shall have the capability to supply the bitumen emulsion at the required rate to
ii. It shall be capable of regulating the application rate of bitumen emulsion in

accordance with speed of advance of the recycler and volume of material during
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JKRlSPJ/200B-S4
iii. It shall provide uniform application of the bitumen emulsion to the reconstituted
pavement material to produce a homogenous mixture.
iv. There shall be a method for monitoring bitumen emulsion application during
operation that can be validated by simple physical measurement for control
purposes.
4.10.4.5 Additional Requirements when Stabilising with Foamed Bitumen
In addition to the requirements specified in 4.10.4.2, the recycler shall be equipped as
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follows;
I. It shall have the capability to supply the foamed bitumen at the required rate to
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ii. It shall be capable of regulating the application rate of foamed bitumen in
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accordance with speed of advance of the recycler and volume of material during
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iii. It shall provide uniform application of the foamed bitumen to the
reconstituted pavement material to produce a homogenous mixture.
iv. There shall be a method for monitoring bitumen application during operation
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that can be validated by sirople physical measurement for control pwposes.
v. It shall be equipped with temperature and pressure gauges for monitoring

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purposes prior to foaming.
vi. There shall be a means to provide a representative sample of foamed bitumen at

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any stage during normal operation.
4.10.5 Construdion Method

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4.10.5.1 General
(aJ Surface Preparation

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Prior to commencement of cold in-place recycling, the surface of the existing section to
be recycled shall;
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i. be cleared of all foreign matter and standing water from the entire width of cut
and to a minimum of one metre to either side;
Ii. be accurately marked showing the proposed cut lines.

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(bJ Production Plan

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Prior to commencement of cold in-place recycling, the Contractor shall prepare a

production plan detailing the proposed day's work, which shall include the following;
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JKRl5PJI2008-S4
i. an annotated sketch showing the overall layout of the existing section intended
for recycling during the day showing the proposed cut pattern, sequence of cut
and overlap dimensions between cuts;
ii. the estimated time required for proposed day's production;
iii. the amount and type of stabilising agents to be applied to each cut;
iv. the proposed control testing programme;
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v. any other infonnation relevant to the intended work.
(c) Weather Limitations
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No cold in-place recycling work shall he undertaken during wet conditions or in such
other conditions that may result in the work quality being negatively compromised,
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unless otherwise directed by the S.O.
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(d) Equipment, Materials and Material Delivery
The Contractor shall ensure that all logistical requirements for unhindered production of
the day's proposed WOlX are prepared prior to commencement of the Work.
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All equipment for the cold in-place recycling process, from milling to final compaction
and finishing, shall be on site and in good working condition, as described in Sub-Section
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4.10.4.
All materials required for the day's production, including stabilising agents and any
additional material, shall be available.
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All ancillary equipment for the delivery of stabilising agents and any additional material
to the site shall be available as required and in good working condition.
EN
Specific equipment checks to be nndertaken prior to the start of each production run shall
include;
i. All supply pipes, chambers and jets for supply of stabilising agent, water, or
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other additives, are free of blockage and primed;

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ii. Sufficient quantities of stabilising agent, water, or other additives, are available
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in their supply equipment for unhindered continuous production during the run;
iii. Bitumen temperature (where foamed bitumen is applied) is correct;

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iv. AU equipment settings are correct and gauges and monitoring equipment are
functioning;
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v. Equipment operators and crew are ready. and equipped as appropriate to

undertake their tasks and fulfill their responsibilities.
(e) Time Limitations
The maximum pennissible time between IDlXlDg the recycled material with any
stabilising agent and final compaction of the placed material is given in Table 4.10.6.
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TABLE 4.10.6: MAXIMUM TIMES BETWEEN MIX1NG AND FINAL COMPACTION
Stabilising agent Time Limit (hours)

Cement 3
Bitumen emulsion 6
Foamed bitumen 12
(f) Application Quantities a/Stabilising Agents. and any additional materials
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The Contractor shall record the area of application and quantity of stabilising agent and
any additional materials used per run, and shall keep these records for at least 12 months
after completion of the project.
(g) Others
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The Contractor shall undertake the cold in-place recycling process with due diligence and
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shall instigate immediate corrective measures in the event of any other occurrence or
event that may lead to a sub-standard end product.
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4.10.5.2 Laying
The mixed material shall be continuously placed back in the excavation created by
milling as the recycler advances. The recycler shall be equipped to place mixed material
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to the thickness and uniformity required to achieve the design properties of the layer after
trimming and final compaction, in accordance with the design and specifications.
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The Contractor shall provide necessary ancillary equipment and resources to ensure that
deficiencies in thickness or uniformity of the re-placed layer material can be corrected
immediately. and prior to initial compaction.
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4.10.5.3 Compaction
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(aJ Initial Compaction
The recycled layer shall be initially compacted immediately. or as soon as any

deficiencies are made good in accordance with Sub-Section 4.10.5 above. Initial
compaction shall be undertaken by a smooth-drum or pad foot vibrating roUer, operating
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on high-amplitude vibration. The static mass of the roller shall be selected in accordance
with Table 4.10.7.
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TABLE 4.10.7: MINIMUM STATIC ROLLER MASS
Thickness of compacted layer Minimum static mass of roller (tonne)

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< 150mm 12
150mm to 200mm 15
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200mm to 250mm 19
>25Omm 24
Note: The operating speed of the primary roller shall never exceed 3k:m!hr and roliing shall be applied
over the full width of each cut
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(b) Trimming and Final Compaction
After primary rolling has been completed, a grader sball be used if required to cut the
fmal surface levels. Grader work shall be limited to the minimum necessary to achieve
the required final surface shape, evenness and texture. Skimmed material shall be
removed and under no account compacted into the trimmed layer.
Final compaction shall commence as soon as possible after trimming. Final compaction
comprises secondary rolling, to achieve the specified density. and finishing. Secondary
rolling sball be undertaken using a smooth-drum vibrating roller (nominal 12 tonne static
ER
mass) operating on low-amplitude vibration. Any additional moisture required
maintaining workability and achieving the specified density requirements sball be applied
by spraying the surface with multiple light applications from a water tanker.
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Finishing shall be undertaken with a pneumatic-tyred roller to achieve a close-knit
surface appearance. For bitumen emulsion and foamed bitumen treated layer materials
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additional water shall be sprayed on to the surface and rolled whilst wet to achieve this
finish.
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For cement stabilised layer materials, water shall be sprayed regularly using full-width
spray bar fitted with fine nozzles to prevent the surface from drying out and for curing
pwposes. Alternatively, if early opening to traffic is required, a rapid setting bitumen
emulsion curing membrane with a rninimwn spray rate of 0.6 litre/m2, or such other
A
curing membrane as otherwise approved by the S.O., shall be applied inunediately after
finishing operations.
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4.10.5.4 Joints
Two types of joint can be required during the cold in-place recycling process longitudinal
M
(between adjacent cut sections), transverse construction/operational joints); formed

transverse (in cement stabilised layers). Joints shall be constructed to avoid built-in
weakness using best practice techniques, and in accordance with the following;
EN
(a) Longitudina/Joints
Longitudinal joints between adjacent cuts shall overlap by at least 100mm to ensure
complete treatment across the full width of the road. Guidelines marked on the road
M
surface for each cut shall be checked to ensure that only the first cut is the same width as
l) the milling drum. All successive cut widths into existing original material shall be less
than the drum width by at least 10Omm.
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(b) Transverse Joints
Transverse joints, created at the start and eod of each cut and each time the recycling
O
process stops, shall be formed to ensure that there is continuity of treatment across the
resulting joint. The overlap shall be at least l.5m or equal to the diameter of the milling
drum.
D
4.10.5.5 Protection and Maintenance
The Contractor shall protect and maintain the completed layer until the next pavement
layer or surfacing is applied.
Curing agents or a temporary surfacing in the forms of sand blinding, surface dressing,
slurry seal or other method as approved in the contractor's work plan shall be applied
after finishing as required. The treatment shall be appropriate to the cold in-place
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JKRlSPJI200B-S4
recycled material type, and the time and trafficking levels prior to application of the next
pavement layer.
Minimum curing time of 72 hours shall be allowed for cement stabilised layer prior to
overlaying of hot mix over the treated layer. For foamed and bitumen emulsion stabilised
layers a minimum curing period of 48 hours shall be allowed. The Contractor shall
overlay with hot mix immediately, after the minimum curing time bas been achieved.
The Contractor shall undertake necessary maintenance activities to ensure that the curing
agent or temporary surfacing remains intact and protects the cold in-place recycled
ER
pavement layer against deterioration prior to application of the next pavement layer. The
contractor shall also make good any damage to the stabilised surface at his own cost by
using approved method prior to laying of the hot mix.
D
4.10.5.6 Quality of Materials and Workmanship
N
The general quality control requirements applicable to cold in-place recycling that shall
be complied with during nOITIlal operation are given in Table 4.10.8.
()
TE
Tolerances on horizontal alignment, swface levels and surface regularity for the cold in-
place recycled layers shall conform to the following requirements;
(a) Horizontal Alignment

A
The horizontal alignment shaH be detennined from the centre-line of the pavement
surface shown on the Drawings. The edges of the pavement as constructed and all other
EJ
parallel construction lines shall be correct within a tolerance of + sOmm and minus 0 mm
from the centre-line, except for kerbs, channel blocks and edge lines which shall be laid
with a smooth alignment within a tolerance of + 2Smm and minus Omm from the centre-
M
line.
(b) Surface Levels of Pavement Courses

EN
The design levels of pavement courses shall be calculated from the vertical profile, cross
fall and pavement course thickness shown on the Drawings. The level of any point on the
constructed surface of a pavement course shall be the design level subject to the
appropriate tolerances given in Table 4.10.9.
M
(c) Surface Regularity ofRecycled Layer

KU
The transverse regularity of completed recycled surface shall be measured with a 3m

straight-edge and no depression shall exceed IOmm.
Any individual irregularity measured with the rolling straight-edge, or 3m straight-edge,

O
laid parallel to the road centre-line shall not exceed lOmm.

D
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TABLE 4_10_8: GENERAL QUALITY CONTROL REQUIREMENTS FOR COLD

IN-PLACE RECYCLING
Pammeter Test Method Frequency Acceptance

95% for natural
graveVcrushed
Field B.S. 1377 Sand One test per 500m2
aggregates; 97% for
compaction Replacement and at least one test
mixture of crushed
(Density) Method per daily operation
aggregates and RAP;
ER
98% for RAP of JSM
Stabilising Consumption
agent records reconciled Every completed
± 10% of target rate
application with theoretical section and daily
D
rate usage.
No result less than the
minimum required
N
2
One test per 200Om
Unconfined As defined in Table strength for the
and at least one test
Compression 1.4, 1.5 or 1.6 for particular stabilising
TE
per daily operation,
Strength the particular agent.
each test comprising
(UCS) stabilising agent For cement stabilised
four (4) specimens
layer no result shall faU
outside specified range.
One test per 2000m<
A
Indirect As defined in Table No result less than the
and at least one test
Tensile 1.4, 1.5 or 1.6 for minimum required
per daily operation,
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Strengtb the particular strength.
each test comprising
(ITS) stabilising agent
four (4) specimens
Physical
measurement of
M
Depth of At least two tests per

cutting depth ±IOmm of target depth
recycling 50m linear progress
relative to final
surface elevation
EN
Thickness of
Small inspection
new One test per 250m of ± IOmm of specified
holes cut through
recycled completed layer layer thickness
completed layer
layer
M
+20% of the Optimum

Moisture Content
( ) Moisture B.S 1377: Part 2 At least once each
(OMC) determined
KU
content 1990 500m lengtb of cut

from AASHTO test
Tl80.
Speed of Manufacturer's At least once each

5m1min - 12m1min.
O
advance advisory note. 250m lengtb of cut.

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TABLE 4.10.9: TOLERANCES IN SURFACE LEVELS OF

PAVEMENT COURSES
Pavement Course Tolerance

Wearing Course +/- 5 nun
Binder Course +/- 5 nun
Roadbase +0 mrn
- 20 nun
Sub-base + 10 nun
ER
- 20 nun
The combination of permitted tolerances in the levels of different pavement courses shall
not result in a pavement thickness less than that shown on the Drawings. Each pavement
D
course shall have an average thickness not less than that shown on the Drawings.
N
TE
A
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M
EN
M
u
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O
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Polymer Modified Asphaltic combination of both. However, other

Concrete types of polymer shall be used provided
that the specified properties of the
Polymer modified asphaltic concrete is resulted binder and asphaltic concrete
an option to prolong the life or enhance mix are complied.
the performance of bituminous pavement
layers. It is a mixture of continuously Polymer shall be pre-blended with
conventional bitumen before mixing
ER
graded aggregate and polymer modified
binder. The binder is produced by with the aggregate in the asphalt mixing
incorporating an appropriate quantity of plant. It shall either be a high-shear
synthetic polymer to conventional blending equipment system provided
D
bitumen. Polymer modified asphaltic whereby polymer modified binder can
concrete offers the following benefits; be manufactured on site, or polymer
N
modified binder obtained from an
i. Improved resistance to rutting. approved source. In either case, a
TE
ii. Improved resistance to fatigue binder storage tank equipped with
cracking. suitable mechanical agitator shall be
iii. Improved resistance to cracking due provided close to the asphalt mixing
to binder hardening. plant. Continuous agitation during
A
iv. Improved adhesion of binder to prolonged storage is essential to prevent
aggregate. separation of the binder.
EJ
In carrying out mix design for polymer

modified asphaltic concrete, additional
M
testing are essential and these includes

resilient modulus and dynamic creep.
EN
This mix is recommended for use in high

stress areas such as climbing lanes or
where excessive axle loads are expected.
M
Polymer modified binder shall be of Due to its relatively high cost compared
C) performance grade PG 76 or higher in to conventional asphaltic concrete, it
KU
compliance with AASHTO Standard should not be used indiscriminately.

M320-02. This premium grade binder
shall be produced by pre-blending
conventional bitumen with an
O
appropriate quantity of synthetic

polymer.
D
The polymer shall be either a plastomer

such as low-density polyethylene
(LDPE) and ethylene vinyl acetate
(EVA) or an elastomer such as styrene
butadiene styrene (SBS) and styrene
butadiene rubber (SBR), or a
54-106
JKRl5PJ/2008-S4
4.11 SPECIALTY MIX 6 - POLYMER MODIFIED ASPIIALTIC CONCRETE
4.11.1 Description
This work shall consist of furnishing, placing, shaping and compacting polymer modified
asphaltic concrete wearing course and/or binder course on a prepared and accepted
bituminous or bitumen primed pavement course, and shall include careful and thorough
cleaning of surfaces which are to be covered prior to the application of bituminous tack
ER
coat andlor prime coat. The work shall be carried out all in accordance with this
Specification and the lines, levels, grades. dimensions and cross-sections as shown on the
Drawings andlor as required by the S.O.
Polymer modified asphaltic concrete is a mixture of continuously graded aggregate and
D
polymer modified binder. The binder is produced by incorporating an appropriate
quantity of synthetic polymer to conventional bitumen. Polymer modified asphaltic
N
concrete offers the following benefits;
TE
i) Improved resistance to rutting.
ii) Improved resistance to fatigue cracking.
iii) Improved resistance to cracking due to binder hardening.
iv) Improved adhesion of binder to aggregates.
A
4.11.2 Materials
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(a) Aggregate
Aggregate for polymer modified asphaltic concrete shall he a mixture of coarse and fine
aggregates, and mineral filler. The individual aggregate shall be of sizes suitable for
M
blending to produce the required gradation of the combined aggregate, aU to the

satisfaction of the 8.0.
EN
Coarse aggregate shall be screened crushed hard rock, angular in sbape and free from
dust, clay, vegetative and other organic matter, and other deleterious substances. They
shall conform to the following physical and mechanical quality requirements;
i. The Los Angeles Abrasion Value when tested in accordance with ASTM C 131
M

KU
ii. The weighted average loss of weight in the magnesium sulphate soundness test
(5 cycles) when tested in accordance with AASHTO Test Method T 104 shall he
not more than 18%.
O
than 25%.
D
than 2%.
than 40 (for wearing course only).
Fine aggregate shall be clean screened quarry dusts. Other types of fine aggregate may be
used subject to the approval of the 5.0 . Fine aggregate shall be non-plastic and free from
clay, loam. aggregation of material, vegetative and other organic matter, and other
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deleterious substances. They shall confonn to the following physical and mechanical
i. The sand equivalent of aggregate fraction passing the No.4 (4.75mm) sieve
ii. The fine aggregate angularity when tested in accordance with ASTM C 1252
ER
iii. The Methylene Blue value when tested in accordance with Ohio Department of
Transportation Standard Test Method shall be not more than 10 mg/g.
iv. The weighted average loss of weight in the magnesium sulphate soundness test
(5 cycles) when tested in accordance with AASHTO Test Method T 104 shall be
D
not more than 20%.
N
v. The water absorption when tested in accordance with MS 30 shall be not more
n than 2%.
TE
aggregate shall not be pennitted for use in wearing course.
The gradation of the combined coarse and fine aggregates and mineral filler, shall
A
conform to the appropriate envelope shown in Table 4.11.1.
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design mix gradation which shall consist of a single definite percentage passing for each
sieve size in Table 4.11.1 and shall produce a smooth curve within the appropriate
gradation envelope. This job laboratory design mix gradation, with the allowable
M
tolerances for a single test as specified in Sub-Section 4.11.3 (a), shall then become the
job mix formula.
(b) Mineral Filler

EN
be of finely divided mineral matter of hydrated lime (calcium hydroxide). At the time of
mixing with bitumen, the hydrated lime shall be sufficiently dry to flow freely and shall
M
be essentially free from agglomerations. Not less than 70% by weight shall pass the BS
( ) 75 um sieve. The total amount of hydrated lime as mineral filler shall be limited such that
the ratio of the combined coarse aggregate, fine aggregate and mineral filler of the final
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gradation passing 75 urn sieve to bitumen, by weight, shall be in the range of 0.6 to 1.2.
As a guide, the total amount of hydrated lime shall be approximately 2% by weight of the
combined aggregates. The hydrated lime shall also be treated as an anti-stripping agent.
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If hydrated lime is not available, ordinary Portland cement shall be used as an alternative,
subject to approval by the S.D.
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TABLE 4.11.1: COMBINED AGGREGATE GRADATION
Mix Type Wearing Course Wearing Course Binder Course

Mix Designation AC 10 AC14 AC28
BS Sieve Size, mm Percentage Passing (by weight)
28.0 100
20.0 100 72-90
14.0 100 90 - 100 58 - 76
10.0 90 - 100 76 - 86 48 - 64
ER
5.0 58 - 72 50 - 62 30 - 46
3.35 48 - 64 40 - 54 24 - 40
!.I 8 22 - 40 18 - 34 14 - 28
0.425 12 - 26 12 - 24 8 - 20
D
0.150 6 -14 6 - 14 4 - 10
0.075 4- 8 4- 8 3- 7
N
TE
(c) Polymer Modified Binder
Polymer modified binder sbaU be of performaoce grade PO 76 or higher in compliaoce

with AASHTO Standard M320-02_This premium grade binder shall be produced by pre-
blending conventional bitumen, which shaU confono to MS 124, with an appropriate
A
quaotity of synthetic polymer.
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A polymer is a large molecule that is made up of many small molecules or monomers.
There are naturally occurring polymer aod synthetic polymer.
Naturally occurring polymer can be organic or mineral substances such as hair, rubber,
M
diamond aod sulphur. Even bitumen cao be regarded as a polymer because of the long-
chain nature of some of the organic molecules that are the constituent parts of bitumen.
Synthetic polymer shall be mannfactured in a chemical process to combine particular

EN
molecules in a way that would not occur naturally and shall be non-carcinogenic. There
are two types of polymer which are described as follows;
i) Plastomer, or Polyolefm.
M
A plastomer will generally stiffen the binder to increase its high temperature
performance. For bituminous mixture used as surfacing course, this results in
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greater resistance to rutting and deformation. For intennediate and base courses,
this results in an increased strength of the pavement structures.
Some examples of plastomer are low-density polyethylene (LDPE) and ethylene

O
vinyl acetate (EVA).
ii) Elastomer, or Block Copolymer.

D
An elastomer will generally both stiffen and increase the flexibility or

slretchiness of the binder, improving both high aod low temperature
performance. An elastomeric binder will rebound after being stretched, thus the
bituminous mixture is able to recover from the stresses that occur under heavy
loadings.
Some examples of elastomer are styrene butadiene styrene (SBS) and styrene
butadiene rubber (SBR).
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JKRl8PJ/2008-S4
Either type of the polymer or a combination of both types of polymer shall be used in the
production of the polymer modified binder. However, other types of polymer shall also
be used provided that the properties of the resulted binder and mix are complied.
When added to bitumen, the polymer does not chemically combine or change the
chemical nature of the bitumen but it dissolves into certain component fractions of the
bitumen, spreading out its long chain polymer molecules to create an inter-connecting
matrix of the polymer throughout the bitumen. It is this matrix of the long chain polymer
molecules that modifies the physical properties of the bitumen.
ER
The properties of the polymer modified binder (PMB) shall be as given in Table 4.11.2.
TABLE 4.11.2 - PROPERTIES OF POLYMER MOD1FIED BINDER
D
TEST REOUIREMENT TEST
N
SPECIFICAnON
n PMB prior to Rolling Thin Film Oven Test (RTFOT)
TE
Viscosity, max. 3 Pa.s, test temperature 135 ASTM D 4402
"C (see Note \)
Dynamic shear, GO/sin Ii min. 1.00 kPa,
10 radls, test temperature "C 76 AASHTOT315
A
Penetration, 100 g, 5 s, 25 C, 0.1 mm Report ASTMD5
(see Note 2)
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Ring & balI softening poin~ min. "C 60 ASTMD36
Flash point. min °c 230 AASTHOT48

M
Moisture sensitivitv test, min. % 80 AASHTO T 283

Emission of toxic I!ases, max. m~m3 15
EN
Mass loss, max. % 1.00 AASHTO T 240 or

ASTM D 2872
Dynamic shear, GO/sin Ii min. 2.20 kPa,
M
10 rad/s, test temnerature °C 76 AASHTO T 315

l)
KU
Note:
1. The requirement shall be waived at the discretion of the S.D. if the supplier warrants that the
polymer modified binder can be adequately pumped and mixed at the temperatures that meet all
2. The penetration value shall be taken as the reference for consistency check on the production.
O
Polymer shall be pre-blended with conventional bitumen before mixing with the
D
aggregate in the asphalt mixing plant. The Contractor shall either provide a high-shear
blending equipment system close to the asphalt mixing plant whereby polymer
modified binder can be manufactured on site, or shall obtain polymer modified binder
from an approved source. In either case, the Contractor shall provide a binder storage
tank. equipped with a suitable mechanical agitator close to the asphalt mixing plant.
This tank shall also include distribution and circulation pipes that are properly
insulated or heated. Continuous agitation of the binder during prolonged storage is
essential to prevent separation. A suitable orifice shall be provided at a convenient point
in the storage tank system for taking samples. Samples shalI be taken after prolonged
storage or at any other circumstances deemed necessary by the S.O. and tested for the
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JKRl5PJ/2008-S4
properties as shown in Table 4.11 .2 above at an approved laboratory. Sampling shall be

done in accordance with MS 539.

the polymer modified binder. The temperatures to which the polymer modified binder
must be heated to produce a viscosity of 0.2 - 0.5 Pa.s shall he the mixing temperatures.
The temperatures to which the polymer modified binder must be heated to produce a
viscosity of 5 - 30 Pa.s shall be the compaction temperatures.
ER
4.11.3 Mix Design
(aJ Job Mix Formulae
D
Stage 1
The Contractor shaU propose a job mix formula for each type of mix required in the
N
Works. In order to obtain optimum quality of the mixtures, the job mix fannula for each
type of mix shall be prepared on the basis of testing several laboratory design mix
TE
gradations within the limits set in Table 4.11.1 at an appropriate range of polymer
modified binder content. As a gnide to the testing range of the binder content, the design
binder content will usually be in the range given in Table 4.11.3.
Each combination of laboratory design mix aggregate gradation and binder content shall
A
be subject to the Marshall test procedure and volumetric analysis as follows;
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I. Preparation of laboratory specimens for the standard stability and flow test in
accordance with ASTM D 1559 using 75-blowslface compaction standard at
compaction temperature as determined from the above viscosity-temperature
relationship,
M
ii. Detennination of the bulk specific gravity of the specimens in accordance with
ASTMD2726,
EN
1559,
M
iv. Analysis of the specific gravity and air voids parameters to determine the
compacted aggregate filled with the binder and the percentage air voids in the
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compacted mix.
For each laboratory design mix gradation, four specimens shall be prepared for each
binder content within the range given in Table 4.11.3 (see Note I) at increments of 0.5
O
percent, in accordance with ASTM D 1559 using 75 blowslface compaction standard. All
binder content shall be in percentage by weight of the total mix.
D
specific gravity of each test specimen shall be determined in accordance with ASTM D
2726.
with ASTM D 1559.
shall be carried out for each test specimen to determine the percentage air voids in the
54-111
JKRlSPJI200B-S4
compacted aggregate filled with binder (VFB) and the percentage air voids in the
compacted mix (VIM).
Values which are obviously erratic shall he discarded before averaging. Where two or
The mean values of bulk specific gravity, stability, flow, VFB and VIM obtained above
shall be plotted separately against the binder content and a smooth curve drawo through
ER
the plotted values.
The mean optimum binder content shall be detennined by averaging five optimum binder
contents so determined as follows;
D
N
11 Flow equals to 2 mm from the flow graph,
n
TE
iii. Peak of curve taken from the bulk specific gravity graph (see Note 3),
iv. YFB equals to 75% for wearing course and 70% for binder course from the VFB
graph,
A
v. VIM equals to 4.0% for wearing course and 5.0% for binder course from the
VIM graph.
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The individual test values at the"mean optimum binder content shall then be read from the
plotted smooth curves and shall comply with the design pararoeters given in Table 4.11.4.
M
If all the values comply with Table 4.11.4, the mixture with that mean optimum binder
content shall be used in Stage 2 below.
If any of the values does not comply with Table 4.11.4, the mix design procedure shall be
EN
repeated using a different aggregate gradation until all design pararoeters are satisfied.
Note:
1. The range of binder content shall be extended if necessary to ensure that the curves C!f stability and
M
bulk specific gravity have their peak within the range selected.
() 2. Where the stability curve exhibits more than onc peak. the binder content chosen for the
determination of the mean optimum binder content shall be the one which satisfies the voids
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requirements better. It is sometimes necessary where no peak stability is obtained, to prepare and
test supplementary specimens at intervals of 0.25% binder content on either side of the expected
optimum.
3. With highly absorptive aggregate, some difficulty in determining peak bulk specific gravity may
O
occur. In such cases, the binder content at which the increase in bulk specific gravity shows a
marked falling off shall be adopted.
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TABLE 4.11.3: RANGE OF DESIGN BINDER CONTENTS
AC 10 - Wearing Course 5.5 -7.5 %
AC 14 - Wearing Course 4.5 - 6.5%
AC 28 - Binder Course 4.0 - 6.0%
ER
TABLE 4.11.4: TEST AND ANALYSIS PARAMETERS
FOR POLYMER MODIFIED ASPHALTIC CONCRETE
D
Parameter Wearing Course Binder Course
N
Stability. S > l3000N > 13000 N
o
TE
Flow. F 2.0 - 5.0mm 2.0 - 5.0mm
Stiffness. SIF > 2600 N/mm > 2600N/mm
Air voids in mix (VIM) 3.0 - 5.0% 3.0 - 7.0%

A
Voids in aggregate 70 - 80% 65 - 75%
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filled with bitumen (VFB)

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Stage 2
From the mean optimum binder content established in Stage 1, five values of binder
EN
content shall be selected (one below and three above that mean optimum binder content).
For each of these binder content, test specimens shall be prepared using the same
aggregate gradation and compaction effort as established in Stage 1.
The job mix formula shall be the mix which satisfies the following properties;
M
i) Indirect tension test for resilient modulus (ASTM D 4123)

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Total resilient modulus > 2500 MPa
Test temperature 25'C

Applied load 20 N/mm of specimen thickness
O
(max. 1500 N)
Loading frequency I Hz
D
Loading time 0.1 s

Rest period 0.9 s
Rise time 70ms
Poisson's ratio 0.35
No. of preconditioning pulses 50
No. artest pulses 5
Rotation of specimen 90'
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Report mean value of total resilient modulus (ERT) from two alignments
(rotation). Disregard test result if ERT values for the same test specimen differ
by more than 10% from the mean value.
ii) Dynamic, unconfined, compressive creep test (EN 12697-25)
Dynamic creep modulus > 75 MPa

Slope at steady state < 0.25
ER
Specimen end treatment Silicone based lubricant + graphite dust
Pre-conditioning;
Test temperature 40"C
Applied axial stress 150 kPa
D
Loading frequency 0.5 Hz
Loading time 0.2 s
N
Rest period 1.8 s
n No. ofload cycles 30
TE
Testing;
Test temperature 40"C
Applied axial stress 300kPa
A
Loading time 0.28
Rest period 1.8s
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No. ofload cycles 3600
Report dynamic creep modulus and slope at steady state, the latter shall be log
strain divided by log load cycle between 2000 and 3600 load cycles.
M
The mean values of total resilient modulus, dynamic creep modulus and slope at steady
state shall be plotted separately against the binder content and a smooth curve drawn
EN
thmugh the plotted values.
The new mean optimum binder content shall be detennined by averaging three optimum
binder contents as follows;
M
i. Peak of curve taken from the total resilient modulus graph,

ii. Peak of curve taken from the dynamic creep modulus graph,
iii. Peak of curve taken from the slope at steady state graph.
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The individual test values at the mean optimum binder content shall then be read from the
plotted smooth curves and shall comply with respective design parameters.
O
If all the values comply with respective design parameters, the mixture with that binder
content shall be considered as the job mix fonnula.
D
(b) Plant Trials
After having received the S.O. preliminary approval of his proposed job mix formula, the
Contractor shall arrange to mix, lay and compact polymer modified asphaltic concrete
conforming to the proposed formula for each type of mix required in the Works. A
minimum of 20 tonnes of the mix shall be placed in trial areas to demonstrate to the
satisfaction of the S.O. tbat the mixing, laying and compacting equipment conforms to
the requirements of this Specification, and that the proposed mix is satisfactory. The trial
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areas shall not be part of the Contract Works but sball be provided by the Contractor at
bis own expense. The proposed trial area shall be approved by the S.D.
As directed by the S.D., comprehensive sampling and testing of the mix shall be carried
out to check for satisfactory compliance with its job mix formula, and for a satisfactory
degree of compaction. rn order to demonstrate to the satisfaction of the 8.0. that mixing,
laying and compacting equipment conform to the requirements of the specification, and
that the proposed mix is satisfactory, the following observations and tests shall be carried
out.
ER
I. Record the type and weight of rollers. Check the tyre pressure of the pneumatic
tyre roller (shall comply with Sub-Section 4.11.4 (e».
ii. Record tbe type of paver (shall comply witb Sub-Section 4.11.4 (d».
D
iii. Check that the trial area is suitable (not on soft ground, uneven surface or part of
N
the Contract Works).
o
TE
iv. Take sample of the mix and carry out the following tests;
• Binder content and aggregate grading (shall confonm to the precise

aggregate gradation and bitumen content as determined from the mix
design and within the tolerances set forth in Table 4.11.5)
A
• Preparation of Marshall specimens.
• Bulk specific gravity of Marsball specimens.
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• Volumetric properties of Marshall specimens (sball comply with Table
4.11.4).
• Marshall stability and flow (shall comply with Table 4.11.4).
• Resilient modulus.
M
• Dynamic creep.
v. Record temperatures of mix on the lorry, at plant and site (shall not exceed 180
EN
·C at any time and shall be not less than 145 ·C immediately before unloading
into the paver hopper).
vi. Record laying (uncompacted) thickness.

M
vii. Check texture of paved surface before rolling (there shall be no substantial
blemishes and irregularities).
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viii. Record temperatures immediately before rolling starts (rolling temperatures)
ix. Record rolling pattern.

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x. Check texture of compacted surface.

D
Xl. Cut core samples after the laid material has sufficiently hardened (at least three
samples from each lorry load).
xii. Record compacted thickness and density from core samples (shall comply
with Sub-Section 4.1 !.5 (i) and (j).
H the composition of the mix does not confonn to the precise aggregate gradation and
bitumen content as determined in the mix design procedure as described in Sub~Section
4. 11.3 and within the tolerances set forth in Table 4.11.5, andlor the Marshall specimens
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do not comply with any of the properties set forth in Table 4.11.4 as well as resilient
modulus, creep modulus and slope at steady state in Stage 2 of the mix design, the mix
design procedure shall be repeated.
If the texture of the paved andlor compacted surface are not satisfactory, and/or the
compacted thickness andlor density are inadequate, the plant trial shall be repeated using
different paver andlor roller(s).
Upon satisfaction by the S.O., the Contractor shall be required to produce a full report of
ER
the plant trial and this document shaH be used in full scale production in the Works.
(c) Compliance with the Job Mix: Formula
The S.D. final approval of the job mix formula shaH bind the Contractor to produce
D
polymer modified asphaltic concrete mixes conforming to the precise gradation and
binder content specified in the formula within the tolerances set forth in Table 4.11 .5 and
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using polymer modified binder that consistently comply with the properties as specified
n in Table 4.1 1.2.
TE
Modifications to the job mix formula shall only be made with the approval of the S.D.
Should the S.D. at any time have reasons to believe that the materials and methods of
mixing and laying are different from those approved, he shall so advise the Contractor
and instruct that polymer modified asphaltic concrete works be discontinued pending
A
finther plant trials and testing.
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TABLE 4.11.5: TOLERANCES FOR POLYMER MODIFIED
ASPHALTIC CONCRETE
Parameter Permissible Variation

M
% By Weight of Total Mix
Binder content ±O.2%

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and larger sieves ±5.0%
M
( ) Fractions of combined
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and 1.18 mm sieves ±4.0%
aggregate passing 425 um
O
and 150 urn sieves ±3.0%

D
aggregate passing 75 urn sieve ± 2.0%
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4.11.4 Equipment
The Contractor shall provide all the plant and equipment necessary for executing the
work in accordance with this Specification and shall furnish the S.D. with such details of
particular items of equipment, e.g. manufacturer, model type, capacity, weight, operating
features, etc., as the S.O. shall require.
(aj Road Cleaning Equipment
Immediately prior to applying bituminous tack coat, the full width of the surface to be
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treated shall be swept using a power broom followed by a compressed air blower, and if
necessary, scraped using hand tools, to remove all dirt, dust and other objectionable
material, all to the satisfaction of the S.D.
D
(b) Asphalt Mixing Plant
N
The asphalt plant shall be either a batch plant or a drum mix plant of recognized
manufacture and shall be approved by the 8.0. It shall conform to the requirements
()
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described hereunder.
The mixing plant shall have a capacity suited to the Works and sufficient to enable the
paver to operate more or less continuously when paving at normal speeds at the required
thicknesses. The plant shall be so designed as to enable consistent production of polymer
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modified asphaltic concrete mixes within the tolerances prescribed in this Specification,
all to the satisfaction oflbe 8.0.
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Mixes produced and delivered shall have actual tonnages of aggregates, filler and binder
components recorded. The temperature of the mix leaving the plant shall be recorded for
each batch or every 15 minutes. Where the control system incorporates a computer and a
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printer capable of printing the information, copies of the printouts shall be provided to the
8.0. for quality assurance.
Tanks for storage of binder shall have a capacity suited to the proposed rate of
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utilizations of the material and the method and frequency of its delivery to the Works, all
to the satisfaction of the S.O. The tanks shall be provided with means of measuring the
volume of their contents at all times and of drawing off samples of the contents. The
binder feeding system shall provide for continuous circulation of hot binder through the
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system and back into the feed tarue The end of the return line discharging into the feed
tank shall always be kept submerged in the binder in the tank in order to prevent
oxidation of the returning hot binder. The storage tanks, and where necessary barred
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decanters, and all elements of the binder feeding system shall be equipped with heating
system or insulating jackets as necessary to provide for effective and positive control of
the temperature of the binder at all times up to the temperature required for utilizations.
The method of heating shall be such that neither flames nor the products of combustion
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shall come into direct contact with the binder or the casing of its immediate container,
and such that no portion of the binder shall be subject to overheating.
D
Calibration of the plant to an accuracy of ± 1% error must be carried out before the
production of the trial mixes. This calibration is to test the integrity of all the weighing
system of the storage bins and binder hopper.
calibration is set and mixes production commence, calibration procedures shall be
repeated every 30,000 tonnes or one month whichever is earlier.
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i) Batch Plants
The plants shall be provided with accurate mechanical means for uniformly feeding the
aggregate into the dryer so that uniform production and temperature of the heated
aggregate will be obtained. A separate feed bin with an adjustable gate opening shall be
provided for each aggregate to be included in the combined aggregate for the mix;
normally four bins will be required. The feed bins and gates shall be constructed and
equipped that they shall be readily accessible for calibrating at all times, and shall
provide for a continuous and uniform flow of each .aggregate required in the mix.
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The plant shall have a rotary drum dryer of satisfactory design for drying and heating the
combined aggregate so that its temperature will be at the required level at the time it is
mixed with the bitumen. The burner shaH be so designed that complete combustion of the
fuel will be obtained, and the aggregate will remain clean and not become coated with
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soot or oil.
N
The plant shall be equipped with four (or more) screens, the smallest of which shall
generally be not more than 3.2 mm. The screens shall have a normal capacity slightly in
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excess of the maximum output of the mixing plant. The screens shall be readily
accessible for inspection.
The plant shall include four (or more) storage bins for screened aggnegates, each with a
capacity of not less than twice the pugrnil1 dead load capacity. The bins shall be arranged
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so as to provide separate dry storage for each screened fiaction of the aggnegate. Each bin
shall be provided with an overflow pipe of such size and location as to prevent any
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backing up of material into other bins. Each bin shall be so constructed that
representative aggnegate samples can be readily obtained, and shall have means for
observing the aggregate level. Separate dry storage shall be provided for mineral filler,
and the plant shall be satisfactorily equipped to feed filler into the mixer.
M
Accurate means of weighing by load cells shall be provided for weighing the aggregates
and filler and also for weighing the bitumen required for each batch of mix.
EN
Suitable means shall be provided for maintaining the prescribed temperature of the
bitumen in the pipelines, weigh bucket of flow meter, and spray bars.
An armoured thermometer with a range of 30 · C to 200 · C shall be fitted in the bitumen

M
feed line at a suitable location near the discharge valve at the mixer unit. Suitable dial-
( ) scale mercury actuated thermometer, electric pyrometers or other thennometer
instruments shall be fitted at the discharge chute of the dryer and in each hot aggregate
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storage bin to indicate the temperature of the heated aggregate.
The plant shall be equipped with adequate and safe stairways to the mixing platform and
sampling location and gnarded ladders and cat-walks shall provide access to all other
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positions as necessary for proper operation, inspection and maintenance of the plant, all
to the satisfaction of the S.O. All gear, pulley, chains, sprockets and other dangerous
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moving parts shall be property guarded and protected. Ample and unobstructed space
shall be provided on the mixing platform, and clear and unobstructed passage shall be
maintained at all times in and around the truck loading area, which shall, be kept free
from drippings from the mixer.
Each storage bin for screened aggregate shall be provided with a bottom outlet gate so
constructed as to prevent leakage when closed. These gates shall have a quick and
complete closing action. The plant shall be equipped with a weigh box or hopper for
accurately weighing out aggregate from each of the screened aggregate storage bins. The
weigh box or hopper shall be suspended from its scale's lever mechanism and shall be
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sufficiently large to holds a full batch equal to the pugmill capacity without hand raking
of the aggregate. The discharge gate shall he so constructed as to allow rapid and
complete emptying of the weigh box or hopper into the mixer, and prevent leakage when
closed.
The plant shall be equipped with a binder weigh bucket which shall be charged through a
fast acting non-dip valve in the binder feed pipe located directly over the bucket. The
bucket shall be suspended from its scale's lever mechanism and shall have a capacity
sufficient to weigh out binder up to 20% of the weight of the pugmill dead load capacity.
The bucket shall have a discharge mechanism which shall provide for rapid and complete
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emptying of the bucket in a thin unifonn sheet or multiple sprays over the full length and
width of the mixer. The discharged shall not leak or drip when closed.
The batch mixer shall be a suitable twin-shaft pugmill, with a capacity of at least 500 kg
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of asphaltic concrete, capable of producing a thoroughly homogeneous mixture. The
clearance of the paddle blades from all fixed and moving parts of the mixer shall be not
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more than 20mm. If the pugmill is not enclosed, it shall be equipped with a dust hood to
prevent loss of fines from the mixture. The discharge gate shall be so constructed as to ()
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allow rapid and complete emptying of the mixer. and prevent leakage of any mix
The mixer shall be equipped with an accurate time lock system for controlling the
operations of a complete mixing cycle. it shall lock the aggregate weigh box or hopper
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gate after charging the mixer with aggregate, until the closing of the mixer gate at the
completion of the mix.ing cycle; it shall lock the binder weigh bucket discharge
mechanism during the dry mixing and wet mixing period. The dry mixing period is
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defined as the interval of time between the opening of the aggregate weigh box of hopper
gate and the start of discharging the binder weigh bucket. The wet mixing period is
defined as the interval of time between the start of discharging the binder weigh bucket
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and the opening of the mixer gate. The dry and wet mixing periods shall both be
adjustable in increments of not more than 5 seconds from zero to not more than 60
seconds total for dry and wet mixing.
EN
The filler silo shall have suitable a screw conveyor system to discharge into the pugmill.
The control system for the plant shall be housed in a weather proof cabin with windows
to view the plant operations. Control in the cabin shall have the capability to accurately
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batch the aggregates, filler and bitumen for the mix, transfer to the pugmill mixer and
control the mixing time. The temperature of the heated aggregates, filler and bitumen
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shall also be displayed in this cabin and adjusted to meet the Specifications when
required.
ii) Drum Mix Plants

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The cold material feeder unit shall consist of not less than 5 bins with suitable heaped
capacity appropriate for the plant. Each bin shall be equipped with a variable speed
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weighing belt feeder (driven by variable speed electric motor fitter with a tachometer)
with a load cell for accurate weight measurement of each type of aggregate used in the
mix in equivalent dry tonnes per hour. The cold feed system shall incorporate a device for
moisture compensation capable of producing an accurate and continuous blend of the
individual aggregate sizes from the cold feed compartment. The cold feed system shall
also be equipped with a scalping screen of screed size of not more than 50mm to discard
any oversized aggregates before entering the dryer drum.
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The drum mixer sball bave flight designs to accomplish tbe proper transfer of beat from
the exhaust gases of the burner to the aggregates and to blend the aggregates and bitumen
together adequately. The flight, at the upper end of the drum, must be able to direct tbe
aggregate into the drum beyond the tip of the flame, thereafter the subsequent fligbt must
be efficient to lift and tumble the aggregates with the cumulation of a veil of aggregates
across the whole cross-sectional area near the mid-point of the length of drum where the
aggregate temperature must have been raised to dew point. This veil of aggregates must
be sufficiently complete and dense to maximise heat transfer and to screen the bitumen
from the direct flame to minimise hardening and oxidation of the bitumen during the
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mixing process. The downstream mixing flight designs must complete the heat transfer
process and raise the mix temperature to the desired level for discharge. The length to
diameter ratio of the drum must be appropriately designed to obtain more complete heat
transfer; to enable the bitumen to be injected in an inert atmosphere where proper
coating/adhesion onto aggregates can take place without severe oxidation or hardening of
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bitumen and effective mixing and sufficient designed mix temperatures are achieved. The
drum must be inclined, oil-fired and suitably and sufficiently insulated.
N
() The control system of a drum mixer must be automatically computer controlled with a
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fully independent manual back-up system. The system must enable the operator to view
the operation of the wbole plant and of the individual component stations. All relevant
infonnation of the plant operation and the progress of the tonnage of mix tonnage
produced and mix design information must be made availed. The control system sbould
possess a Quality Assurance package to act as an audit tool (when required to be used)
A
whereby the information on Plant-Monitar~ Progress Monitor, and Mix Temperature can
be made availed at pre-set, variable time intervals.
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Freshly mixed material sball be collected and delivered to be stored in a surge silo
througb a proper conveyor system.
M
(c) Tip-Trucks
The Contractor sball provide a suitable number of tip-trucks of a type approved by the
S.O_ for transporting polymer modified asphaltic concrete from the mixing plant to the
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paving sites. The trucks shall bave trays with smooth, flat beds and sides, and shall have
load capacities of not less than 5 tonnes. Prior to loading, the inside of eacb truck tray
sball be ligbtly and evenly coated with a soap or detergent solution, or sucb other liquid
as the S.O. shall approve, to prevent adhesion of the polymer modified aspbaltic concrete.
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The trucks sball be equipped with covers of canvas or other suitable material to protect
the polymer modified aspbaltic concrete.
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(d) Asphalt Paver
The aspbalt paver shall be of recognized manufacture and sball be approved by the S.O.
It shall conform to the requirements described hereunder.
O
The paver shall be self-propelled and capable of reverse as well as forward travel. It sball
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be equipped with a hopper at the front designed to receive the paving mix from tip-trucks.
and shall have a mechanical distribution system for spreading the mix evenly and without
segregation over the surface to be paved in front of a screeding and compacting unit
whicb shall be equipped with a suitable beating device. The screeding and compacting
mecbanism shall be capable of confining the edges of the material being laid without the
use of stationary side forms, shall be adjustable to strike off the mixture to the thickness
and cross-section shape required, and shall be controlled by an automatic leveling device
to produce an even carpet of bituminous mixture with a unifonn surface texture free from
indentations, ridges, tear marks or other irregularities. The paver shall be capable of
laying the bituminous mixture in paving widths in the range 2.5 to 3.75 m and of
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JKRlSPJI2008-S4
finishing the pavement layer true to the required lines, grades, levels, dimensions and
cross-sections, subject to compaction by rolling, all to the satisfaction of the S.O.
(eJ Rollers
A pneumatic tyred roller and two steel wheeled tandem rollers shall be provided. All
rollers shall be of recognised manufacture and shall be approved by the S.O. They shall
conform to the requirements described hereunder.
Pneumatic Tyred Roller
ER
Pneumatic Iyred roller shall be self-propelled and capable of being reversed without
backlash; it shall be equipped with power steering and dual controls allowing operation
from either the left or right side.
D
The roller shall have nine wheels equipped with smooth tyres all of the same size and
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construction. Five wheels shall be on the driven axle and four on the steering axle, all
equally spaced on both axles and arranged so that the tyres on the steering axle track
midway between those on the driven axle with a small overlap. The roller shall be
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ballasted to an operating weight of not less than 15 tonnes with a tyre inflation pressure
of not less than 0.7 Nlsq.mm.
The Contrnctor shall provide the S.O. with a calibration chart for the roller showing the
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relationship between the quantity or depth of ballast and total weight, and also a chart
showing the relationship between wheel load. tyre inflation pressure and contact pressure.
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Steel Wheeled Tandem Roller
Steel wheeled tandem rollers shall be self-propelled and capable of being reversed
M
without backlash; they shall be equipped with power steering and dual controls allowing
operation from either the left or right side. They shall be equipped with water tanks,
sprinkler systems and scraper blades to keep all wheels evenly wetted and clean during
operation.
EN
Steel wheeled tandem rollers shall be ballasted so that their total operating weight are in
the range 8 to 10 tonnes and their driven roll (or rolls) shall exert a rolling force of not
less than 3.5 tonnes/metre of roll width. The Contractor shall provide the S.O. with a
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calibration chart for each roller showing the relationships between the quantity or depth
of ballast and tota! weight and rolling force.
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4.11.5 Construction Method.

O
Polymer modified asphaltic concrete paving work shall only be carried out in dry weather
when the surface to be covered is clean and dry, and has received a bituminous tack coat
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which shall have achieved a satisfactory degree of tackiness, all to the satisfaction of the
S.O. All laying, rolling and finishing work shall be carried out during daylight hours,
unless the Contractor shall have provided suitable flood-lighting for the job site, to the
The S.D. may order the discontinuation of work on account of adverse weather.
unsatisfactory condition of materials, equipment or surface to be paved, or such other
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Prior to constructing a polymer modified asphaltic concrete pavement layer, the surface
to be covered shall have been prepared in accordance with the appropriate Sections of
this Specification. Notwithstanding any earlier approval of this surface, any damage to or
deterioration of it shall be made good before polymer modified asphaltic concrete paving
work is commenced.
[f the surface to be covered is to be provided with a bituminous tack coat, then this shall
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be applied all in accordance with the provisions of Sub-Section 4.3.2.
(c) Aggregate Handling and Heating
Each aggregate to be used in the polymer modified asphaltic concrete mixes shall be
D
stored in a separate stockpile near the mixing plant. Stockpiles of sand and other fine
aggregates shall be kept dry using waterproof covers and other means as necessary. In
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placing the aggregates in the stockpiles and loading them into the mixing plant's cold
aggregate feed bins, care shall be taken to prevent segregation or uncontrolled
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combination of materials of different gradation. Segregated or contaminated materials
shall be rescreened or rejected for use in the Works and removed from the mixing plant
site.
The aggregates shall be fed into the dryer at a uniform rate proportioned in accordance
A
with the appropriate job mix formula. The rate of feed for each aggregate shall be
maintained within 10% of the rate prescribed, and the total rate of feed shall be such that
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the plant's screens shall never be overloaded.
The aggregates shall be dried and heated so that when delivered to the mixer they shall be
at a temperature in the range 160 'c to 180 'C.
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Immediately after heating, the aggregates shall be screened into four (or more) fractions
which shall be separately stored in the hot aggregate storage bins in readiness for mixing.
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Mineral filler cum anti- stripping agent to be used in the mix shall be stored separately
and kept completely dry. Its rate of feed into the plant shall he accurately controlled by
weight or volumetric measwement, all to the satisfaction of the S.O.
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(d) Heating Polymer Modified Binder

() The polymer modified binder shall be heated so that when delivered to the mixer it shall
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be at a temperature in the range I SO 'c to 170 'C.
(e) Mixing Polymer Modifed Asphaltic Concrete

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The mixing plant shall be so coordinated and operated as to consistently produce polymer
modified asphaltic concrete mixes within the tolerances prescribed in this Specification,
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all to the satisfaction ofthe S.O.
i) Mixing in Batch Plants
For each batch the screened hot aggregates shall be weighed out into the aggregate weigh
hopper in accordance with the proportions prescribed in the appropriate job mix fonnula;
the sequence of weighing out shall commence with the largest sized aggregate and
progress down to the fines, unless the S.O. shall otherwise approve. Mineral filler shall be
weighed out into the filler weigh hopper, where this is provided, or added last to the
aggregate weigh hopper, in accordance with the job mix fonnula proportions.
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The hot binder shall be weighed out into the binder weigh bucket in accordance with the
proportions prescribed in the job mix fannula.
The hot aggregates and filler shall be discharged into the pugmill and mixed dry for the
dry mixing time prescribed in the job mix fannula, which shall usually be in the range
five to 10 seconds. The hot binder shall tben be added and wet mixing performed for the
wet mixing time prescribed in the job mix fannula; this shall be sufficient so that all
particles of aggregate are uniformly coated with bitumen, and shall usually be 45 seconds
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or less for dense graded mixtures.
The volume of each batcb shall be such that the tips of the pugmill paddle blades just
break out of the mixture at the height oftbeir action.
D
After the completion of wet mixing. each batch of polymer modified asphaltic concrete
shall be discharged from the pugmill either into a storage hopper or directly into a truck
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for hauling to tbe paving site. Care shall be taken that no segregation of the mix occurs.
TE
ii) Mixing in Drum Mix Plants
The screened hot aggregates and filler shall be fed continuously from their storage bins in
accordance with the proportions prescnbed in the appropriate job mix fannula, combined
in the plant, and fed continuously into the mixer. The hot binder shall be sprayed on to
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the combined aggregate as it enters the pugmill at the rate required to achieve the
bitumen content prescribed in the job mix. formula. The materials shall then be carried
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through the pugmill and in the process be thoroughly mixed by the action of the paddles
and discharged over the dam into the storage hopper. The mixing time shall be sufficient
so that all particles of aggregate are uniformly coated with bitumen, and shall usually be
45 seconds or less for dense graded mixtures.
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The plant shall be so adjusted as to maintain the level of mixture in the pugmill such that
the tips of the paddle blades just break out of the mixture at the height of their action.
EN
(j) Transporting Polymer Modified Asphaltic Concrete
Polymer modified asphaltic concrete shall be transported from the mixing plant to the site
of the paving works in loads of not less than 5 tonnes using tip-trucks as specified in Sub-
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Section 4.11.4 (c). Except where polymer modified asphaltic concrete is to be hand laid,
it shall be discharged directly into the paver hopper, as required, from the tip-trucks.
Care shall be taken in the truck loading, hauling and unloading operations to prevent
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segregation of the mix. During transportation, the polymer modified asphaltic concrete
shall be protected from contamination by water, dust, dirt and other deleterious materials.
The temperature of polymer modified asphaltic concrete immediately before unloading

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from the truck either into the paver hopper or on to the road for hand spreading shall be
not less tban 150 'c. Any load which has cooled below the specified temperature in the
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truck shall be rejected for use in the Works and removed from the Site of the Works.
(g) Laying Polymer Modified Asphaltic Concrete
approved by the S.O. Generally each paving layer shall have a compacted thickoess of
not less than twice the nominal maximum aggregate size of the mixture, and not more
than 100 mm. Where applicable, e.g. on superelevated sections and on carriageways with
cross-slope in one direction only, laying shall commence along the lower side of the
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carriageway and progress to the higher side. Laying shall not be carried out in a dowohill
direction along any section of road.
Hand-casting of bituminous mix on to the machine finished surface shall be kept to the
practicable minimum necessary for correcting blemishes and irregularities. In any areas
inaccessible to the paver, laying shall he carried out by hand methods using rakes, lutes
and other hand tools, all to the satisfaction ofthe S.O. All laying ofbiturninous mix shall
be such that after compaction by rolling the specified course or layer thickness and
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surface profile shall be achieved. Care shall be taken to achieve a uniform swface texture
free from indentations, ridges. tear marks or other irregularities, and to prevent
segregation of the mix.
At the commencement of initial rolling, the temperature of polymer modified asphaltic
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concrete shall be as determined fonn the viscosity-temperature relationship. Material
which has cooled below the specified temperature before laying shall not be used and
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shall be removed from the Site of the Works. The Contractor shall provide accurate
() thermometers at the paving site at all times, and shall check the temperature of asphaltic
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concrete in the paver hopper at regular intervals and before laying restarts after each
interruption of the paving operation.
bituminous mix shall be regulated SO as to enable continuous paving. Transverse joints in
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a paving lane shall be kept to a practicable minimum, and intermittent stopping and
restarting of the paver shall be avoided as far as is practicable.
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Care shall he taken that no bituminous mix is placed on expansion joints at bridges,
inspection covers for utilities ducts, drainage and sewerage manholes and the like, and
that catchpits, drainage openings through kerbs, etc., remain properly open and
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suitably shaped and secured boards or other materials approved by the S.O., and
compaction of mix in the immediately surrounding or adjacent areas shall be completed
EN
by hand methods, all to the satisfaction of the S.O. Alternatively, bituminous mix shall be
laid and compacted by hand methods as necessary around surfacing discontinuities of
these types, all to the satisfaction of the 8.0.
(h) Construction Joints

M
( ) Existing bituminous surfacing which new bituminous mix is to adjoin shall be cut back to
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present a straight, vertical edge not less than 25 mm deep and a smooth transition section
not less than 500 mm long against which to lay the new material. The specified thickness
of the new surfacing shall be built up gradually from the vertical joint to avoid any bumps
or ridges across the carriageway.
O
Where longitudinal or transverse joints are required in a layer of bituminous mix under
construction. the material first laid and compacted shall be cut back to a vertical face for
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the full thickness of the layer on a line satisfactory to the S.O. before the adjacent area is
paved.
At all construction joints, a thin uniform coating of bitumen emulsion of grade RS- IK
shall be brushed on to the vertically cut joint faces some 10 to 15 minutes before laying
the next section of bituminous mix commences to ensure good bonding. Also, all contact
surfaces of kerbs, gutters, manholes, catchpits, etc. shall be similarly treated with a
coating of bitumen emulsion before bituminous mix is placed against them.
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Construction joints in a layer of bituminous mix shall be offset from those in any
immediately underlying bituminous layer by at least 100 mm for longitudinal joints and
at least 500 rnm, for transverse joints.
Construction joints shall not be permitted along wheelpaths.
(i) Compacting oj Polymer Modified Asphaltic Concrete
For each layer of polymer modified asphaltic concrete, compaction by rolling shaH
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commence at temperature as detennined from the viscosity-temperature relationship
during the mix design process.
vibrating plate compactors, hand tampers or other suitable means, all to the satisfaction of
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the S.O.
N
Initial (or breakdown) rolling shall be carried out with an approved steel wheeled tandem
roller. The principal heavy rolling shall be carried out with an approved pneumatic Iyred
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roller immediately following the initial rolling; the pneumatic Iyred roller shall be
ballasted to an operating weight of not less than 15 tonnes and its lyre inflation presswe
shall be not less than 0.7 N/mm'. The final rolling shall be carried out with an approved
steel wheeled tandem roller and shall serve to eliminate minor surface irregularities left
by the pneumatic Iyred roller.
A
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driven wheels towards the paver. Rolling shall generally commence at the lower edge of
the paved width and progress uniformly to the higher edge, except that where there is a
longitudinal construction joint at the higher edge, this shall be rolled first ahead of the
normal pattern of rolling. Generally, successive roller passes shall overlap by half the
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width of the roller, and the points at which the roller is reversed shall be staggered.
However, when operating on gradients in excess of 4%, the breakdown roller shall not
pass over any previously unrolled mix when operating in the downhill direction.
EN
In all cases, compaction shall he carried out in such a manner that each section receives
equal compactive effort, all to the satisfaction of the S.O.
M
pneumatic Iyred rollers sball operate at speeds of not more than 8 kmIh. No roller or
heavy vehicle shall be allowed to stand on newly laid bituminous mix before compaction J
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has been completed and the material has thoroughly cooled and set. Rolling shall
continue as long as is necessary to achieve the appropriate requirement as shown in Table
4.11.6.
TABLE 4.11.6: REQUIREMENTS OF COMPACTED DENSITY FOR POL¥MER

O
MODIFIED ASPHALTIC CONCRETE

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Wearing course 98 - 100% of Marshall density
Binder course 95 - 100% of Marshall density
Care shall be taken to prevent over-compaction of polymer modified asphaltic concrete.
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Within 24 hours of laying and compacting tbe bituminous mix, tbe Contractor sball cut
core samples of not less than 100 mm nominal diameter at locations selected by the S.O.
The rate of sampling sball be one sample per 500 m' of mix laid, but not less than two
samples for the work completed in each paving session. These core samples shall be
used by the S.O. to determine the compacted thickness and density of the material in
accordance with ASTM Test Method D 2726.
0) Finished Polymer Modified Asphaltic Concrete
Polymer modified aspbaltic concrete binder and wearing courses shall be finished in a
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neat and workmanlike manner; their widths shall be everywhere at least those specified
or shown on the Drawings on both sides of the centre-line; the average thickness over any
100-metre lengtb sball be not less tban the required thickness, and the minimum thickness
at any point shall he not less than the required thickness minus 5 mm.
D
The top surface of a wearing or binder course shall have the required shape,
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superelevalion, levels and grades, and shall be everywbere within tbe tolerances specified
in Sub-Section 4.5.
TE
The International Roughness Index (IRI) value of the finisbed wearing course snrface
sball be carried out as described in Sub-Section 4.5 and sball be not more than 2.0 mIkm.
(Ie) Opening to Traffic

A
Polymer modified aspballic concrete sball not be opened to traffic until compaction has
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been completed and the material bas thorougbly cooled and set in the opinion of the S.O.
This will usually be not less than four bours after the commencement of rolling. Where it
is necessary to allow earlier use of the finished surface to facilitate the movement of
traffic, vehicles may be allowed to run on the work after rolling bas been completed,
M
provided that speeds are restricted to 30 kmIb or less and sharp turning movements are
prohibited.
EN
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(
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S4-126
(JKRl5PJ/2008}-S4
CHIP SEAL
Chip Seal is an application of a binder in tbe emulsion or bitumen can be used to mitigate
form of an emulsion or bitumen, followed reflection cracking. Chip Seal is an
by an application of single-size aggregate. It economical surface treatment designed to
is used to correct functional pavement protect and prolong tbe pavement life.
distresses only such as bleeding, polishing,
ravelling etc. Chip Seal is a three-stage Chip Seal on aged but structurally sound
ER
process; after tbe existing surfacing has been pavement surfacing will belp to prolong the
prepared by patching, cracks are filled by pavement functional condition. Chip Seal
spraying binder, followed by application of can be used on new bituminous surfacing to
single size aggregates. The final operation is increase skid resistance.
D
several passes of pneumatic tyre roller. The
road is usually opened to traffic after Cbip Seal shall not be applied on pavements
N
sweeping excess aggregates or may be suffering from structural deficiency. To
immediately opened to slow moving traffic. minimise windscreen breakages due to
TE
flying aggregates, rolling shall be completed
Chip Seal is used to restore skid resistance, before the emulsion breaks to ensure
provide water proofing layer and retard adequate embedment of aggregates into the
binder hardening. Polymer modified binder.
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54-127
(JKRlSPJ/2008)-S4
4.12 SURFACE TREATMENT 1 - CIDP SEAL
4.12.1 Description
This work shall consist of furnishing, placing and shaping chip seal surfacing as a
wearing course. This specification shall be read in conjunction with Sub-Section 4.3 of
the Standard Specification for Road Works of JKR (JKRJSPJI2007). All requirements in
the Sub·Section 4.3 shall apply unless stated otherwise in this Specification.
ER
Chip sealing (also known as surface dressing) is a thin surfacing course that involves
sequential application of bitumen and chipping, either singly or in layers . It is primarily
applied to restore the surface characteristics of an aged surface such as surface texture
and skid resistance. It can also be applied on new pavements to provide more durable
surface. Pavements with structural failures should be treated prior to chip sealing work.
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4.12.2 Materials
N
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Coarse aggregate shall be screened crushed hard rock, retained on 5.0 mm sieve, angular
in shape and free from dust,. clay, vegetative and other organic matter, and other
A
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accordance with ASTM C 131 shall be not more than 25%.
ii. The flakiness index when tested in accordance with MS 30 shall be not more
than 25%.
M
EN
than 18%.
than 2%.
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lJ than 40.
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Fine aggregate shall be screened quarry dust. They shall be non-plastic and free from
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than 20%.
than 2%.
S4-128
(JKRl5PJ/2008)-S4
iii. The sand equivalent of aggregate fraction passing the No.4 (4.75mm) sieve
IV. The fine aggregate angularity when tested in accordance with ASTM C 1252
ER
(a) Conventional Bitum en
Conventional bitumen used for binder shall be penetration grade 80- 100. Prior to
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the commencement of the chip sealing works, the Contractor shall provide to the
8.0. test results from a sample of conventional bitumen which shall comply with
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MS 124. During executing the Works, the Contractor shall obtain manufacturer's
compliance certificates for the bitumen from which the material delivered to site is
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sourced.
(b) Polymer Modified Bitumen
Polymer modified bitumen shall be a mixture of penetration grade 80-100 bitumen

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and 8% of minus 40 mesh size scrap rubber additive, or otherwise approved by
S.O.
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The Contractor shall provide manufacturer's certification of polymer properties

which shall confonn with the following Production Control Properties;
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Minimum 20% Torsional Recovery at 25 °C when tested in accordance with

Austroads Modified Binder Test, MBT 22: 1995 (Appendix 5)
EN
(c) Bitumen Emulsion
Bitumen emulsion shall be RS-3K conforming to MS 161. The Contractor shall

provide manufacturer's test results showing compliance of the batch from which
the material to be incorporated into the Works is sourced.
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Rubber/polymer modified emulsion shall be approved by the S.O. The emulsion

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shall be anionic or cationic, as appropriate to the source rock, and shall have a
minimum bitumen content of 60%. The spraying temperature of the emulsion shall
be between 25 and 45 'c and it shall be utilised within 90 days of manufacture.
(d) Cutter and Flux

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Kerosene shall be used as cutter while diesel as flux.

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(e) Precoat and Adhesion A.gent
Precoat shall conform to the following blend;
Bitumen residue (by volume) 50%

Kerosene (by volume) 49%
Adhesion agent (by volume) 1%
Adhesion agent shall be Wetfi x N422 or equivalent.
54-129
(JKRl5PJ/2008)-S4
4.12.2.4 Gradation of Combined Aggregate
Checks on the gradation of combined aggregate shall be undertaken each week to

ensure compliance with Table 4.12.1. Test results for any aggregate intended for
incorporation into the Works from other than previously approved sources shall be
provided.
Subsequent testing of any materials for which compliance certificates have already
been provided shall be undertaken at the expense of the S.D.
ER
TABLE 4.12.1: GRADATION LIMIT OF COMBINED AGGREGATE
PERCENTAGE %
Sieve (mm) 14mm 10mm 6mm
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25 .0 - - -
20.0 100 - -
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14.0 85 - 100 100 -
() 10.0 0-20 85 - 100 100
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6.3 - 0-20 85 - 100
4.75 0-5 0-10 0-25
2.36 0-2 A 0-2 0-10
4.12.2.5 Plant. Equipment and Personnel

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The Contractor shall supply all plant, equipment and personnel necessary for the
competent execution of the Works.
(a) Personnel
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The Contractor shall ensure that sprayer driver and operator are skilled and trained
with an understanding of sprayer calibration and an appreciation of the requirements
EN
of the Works. The Contractor shall also ensure relevant personnel understand the
types and quantities of the various materials and mixtures to be used.
(b) Pressure Distributor for Bituminous Materials

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The Contractor shall provide documentation to show that the binder distributor has
) undergone initial calibration, and that it satisfies the requirements of a transverse
distribution test wherein the variation in output between adjacent lOOmm wide
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sections is within plus/minus 15% of the average over the full spray bar width,
excluding the external 250mm of each end of the spray bar.
The distributor shall have suitable controls to maintain constant speed in the range of 5 -
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10 kmIh as recorded on a reliable speedometer fitted to the fifth wheel. The distributor
shall be fitted with heating elements capable of heating the binder to at least 200 · C and
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shali be capable of spraying the binder uniformly at this temperature.
(c) Storage and Heating Facilities for Bituminous Materials
The Contractor shall provide on-site heating tank to store excess bituminous binder.
The tank shall be so equipped as to enable stored binder to be sufficiently heated to
enable the binder to be pumped, and it shall have agitation facilities to ensure
homogeneity of blended binders.
54-130
(JKRl5PJ/2008)-S4
The tank shall be fitted with temperature controls to ensure that the binder
temperature does not exceed spraying temperatures.
(d) Aggregate Spreading EqUipment
The Contractor shall use mechanical spreader of a type capable of spreading

aggregate uniformly over the full width of the area being treated, and having suitable
controls to allow adjustment of the application rate during the spreading operation.
ER
Sufficient tipping trucks shall be provided to enable full coverage of each sprayed
area.
Any bituminous material adhering to tyres which might cause pick-up of cover
aggregate shall be cleaned. Any vehicles which leak fuels shall be removed from the
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Works site.
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(e) Pneumatic Tyred Roller
()
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Pneumatic Iyred roller shall be self-propelled, equipped with power steering and dual
controls allowing operation from either left. or right side and capable of being
reversed without backlash. The roller shall have nine wheels fitted with smooth tyres
of the same size and constriction? capable of being inflated to pressures up to 0.6
N/mm2 •
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Any bituminous material adhering to lyres which might cause pick-up of cover
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aggregate shall be cleaned. Any rollers which leak fuels shall be removed from the
Works site.
UJ Power Broom
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The Contractor shall provide a rotary power broom of a type specifically designed for
removing material from road surfaces.
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4.12.2.6 Traffic Control
All temporary traffic controls shall comply with the requirements of Arahan Teknik
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(Jalan) 2C/8S . Traffic control plan shall be submitted for approval by S.O. at least 48
hours prior to commencement of the Works .
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The Contractor shall set out all traffic control devices and position traffic control
personnel prior to establishing plants on the road.
Traffic control shall be maintained at all times to ensure the safety of traffic through
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and around the Works.

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4.12.2.7 Treatment of Existing Surface
(a) Description
Prior to the construction of chip seal, failed areas in the existing pavement shall be
treated to provide a sound surface for chip sealing works. All materials used for this
purpose shall comply with requirements of Sub-Sections 4.2 and 4.3 .
54-131
(JKRlSPJ/2008}-S4
(b) Pothole Repairs
The Contractor shall inspect the site, locate and mark out damaged pavement. Damaged
portions shall be removed to expose the roadbase and the excavated materials shall be
disposed to a suitable site. The roadbase shall be reshaped and recompacted.
For prime coat prior to placing binder course, cut-back bitumen of grade MC-70
confonning to MS 159 or bitumen emulsion of grade SS-IK confonning to MS 161 shall
be used. Application rate shall be between 0.5 and 1.0 litre/m'.
ER
For tack coat prior to placing wearing course, bitumen emulsion of grade RS-IK
confonning to MS 161 shall be used. Application rate shall be between 0.25 and 0.55
litre/m2 .
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Potholes in excess of 80mm depth shall be patched using asphaltic concrete AC 28,
compacted flush with the existing level. Potholes less than 80mm depth shall be
N
patched using asphaltic concrete AC 149 compacted flush with the existing level.
n
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(c) Surface Failure Repairs
The site shall be inspected to locate and mark areas with surface failures. Surface failures
shall be milled off to a depth of 50mm or lOOmm as appropriate, and the debris shall be
removed from site. Milling shall be carried out in the longitudinal direction and a unifonn
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milling depth in the transverse direction shall be maintained. Prior to overlaying milled-
off surface, all debris and granular materials shall be removed. Bituminous tack coat sball
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be applied to tbe surface before overlaying.
Bitumen emulsion of grade RS-IK shall be used for tack coat on milled-off surface.
Application rate shall be between 0.25 to 0.55 Iitre/m'.
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Prepared milled-off surface shall be overlaid witb 50mm or 100mm thickness of AC

14 as appropriate.
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(d) PavementRecons~cnon
Areas to be reconstructed shall be located and marked out, and the extent of such
treatment shall be proposed to the S.O.
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C) Upon the S.O.'s approval, damaged areas shall be excavated and removed to a depth
deemed necessary for the treatment, but not exceeding 1m deep from the existing
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surface. Excavated materials shall be disposed to a suitable site, and the exposed
subgrade shall be scari tied and recompacted.
Excavated areas shall be filled with sub-base and roadbase materials conforming to the
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requirements of Sub-Section 4.2. Each layer shall be reshaped and recompacted to the
required density. Where the treatment requires substitution of good materials to a depth
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deeper tban 1m, such requirement shall be notified to the S.O. who shall then issue
instructions for the necessary actions.
The thickness of sub-base and roadbase to be reconstructed shall normally match the
thickness found in the existing road. However, the compacted thickness of sub-base
and roadbase shall not be less than 100mm and 300mm respectively.
For prime coat, cut-back bitumen of grade MC-70 confonning to MS 159 or bitumen
emulsion of grade SS-lK confonning to MS 161 shall be used at application rate
between 0.5 and 1.0 litre/m' .
54-132
(JKRl5PJ/2008)-S4
For tack coat, bitumen emulsion of grade RS-IK conforming to MS 161 sball be used
at application rate between 0.25 and 0.55 litre/m 2•
Prepared roadbase sball be overlaid witb aspbaltic concrete AC 28, flushed witb
the existing pavement level. The compacted thickness of AC 28 shall normally
match the thickness found in the existing pavement However, it shall not be less
than 100mm.
(e) Regulation with Leveling Course
ER
Pavement areas which need regulating or overlaying shall be located and marked,
and the amount of bituminous mix necessary for this work shalt be surveyed and
estimated, Upon the 8.0.'s approval, these areas shall be prepared to receive regulating or
overlay course. All debris and loose materials shall be removed before applying tack
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coat. Surface irregularities shall be regulated to restore cross fall profile.
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Bitumen emulsion of grade RS ~ lK shall be used as tack coat on milled-off surface.
Application rate sball be between 0.25 and 0.55 Iitre/m'. ()
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Asphaltic concrete AC 14 shall be used fOT regulating and overlay courses in
excess of 40mm thickness and asphaltic concrete AC 10 for courses with less than
40mm thick.
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(f) Crack Sealing
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Areas for crack sealing shall be located and marked, and all detritus, vegetation
and moisture from within and adjacent to the cracks shall be removed.
Rubberised bituminous product sball be applied into the cracks by means of a band
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lance or other appropriate equipment. Avoid excessive application of the bitumen.
Tbe treated areas shall be excluded form traffics until the crack sealing material
has 'set up' and there is no likelihood of the material adhering to vehicle tyres.
EN
Crusher fines or similar shall be applied when necessary to prevent 'pick-up',
4.12.3 Surface Preparation

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The pavement surface shall be swept to remove loose stones, dust, dirt and foreign
matter immediately before spraying.
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For unkerbed roads, sweeping shall be extended by 0.5 m clear of the area to be
sealed.
Adherent patches of foreign material and water shall be removed prior to applying
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the binder.
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All pavement markers and adjacent fixtures and properties shall be protected from
contamination by bitumen.
4.12.4 Setting Out
The Contractor shall mark out by string line or paint where necessary and this shall
include pavement widening.
54-133
(JKRlSPJ/200B)-S4
4.12.5 Stocknile Sites
A separate site for each aggregate size shall be provided. Allow 5 metres between
adjacent sites.
The sites shall be well drained and on hard ground. Every precaution shall be taken
to prevent dust from coating precoated chippings to such a degree as would prevent
the precoated chippings from adhering to hot binder. Access roads to stockpile sites
shall be maintained.
ER
Sites under trees, telephone lines, overhead transmission lines or where overhead
clearance is less than 6 metres shall be avoided.
All vegetation to 5 metres beyond stockpile boundary shall be cleared. Any non·
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conforming aggregate shall be removed from site.
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Every precaution shall be taken to ensure that the aggregate remains dry.
()
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4.12.6 Precoating Aggregate
A uniform film of precoating material to the aggregate shall be applied at an

application rate of between 8 and 12 litres/m]'
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Aggregate which has been excessively precoated to the extent that it fOnDS lumps
shall be rejected.
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Aggregate which has been insufficiently precoated shall be resprayed to achieve a

uniform black coating to the aggregate.
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4.12.7 Spraying of Binder
4.12.7.1 Preoaration
EN
The S.O. shall be informed at least 48 hours of the intention to spray bitumen.
Trial run shall be undertaken to confirm the calibration of the Pressure Distributor.
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4.12.7.2 Weather Conditions

()
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Spraying shall commence only when pavement temperature is in excess of 20°C, or

bas been in excess of 15 °C for at least one hour.
Cease spraying if rain threatens, or in windy or dusty conditions. Protect the work in
the event of an adverse change in weather by closing the affected section of road or
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by rigidly controlling traffic speed.

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4.12.7.3 Preoaring the Sprayer
The mixture in the sprayer shall be circulated.
The horizontal and vertical alignment and the cleanliness of the spray bar and its
extensions shall be checked. Determine the appropriate number of nozzles for the
width to be sprayed. Ensure the end nozzles fitted are the correct type and the
nozzles are not chocked at all time .
S4-134
(JKRl5PJ/2008)-S4
The alignment and setting of the nozzle shall be checked to ensure that the fans of
material from intennediate nozzles are paraliel and at an angle of 30 degrees to the
center line of the spray bar. Ensure that the fans from the end nozzles are parallel to
each other and at an angle of 45 degrees to the center line of the spray bar.
The height of the spray bar shall be set so that the lower faces of the nozzles are 250mm
ahove the pavement when the sprayer is full.
Shielding shall be provided when necessary to prevent spraying material on the kerb,
ER
or to counter any wind effects which would compromise uniform spraying.
The guide rod shall be positioned to conform to the setting out and edges of spray.
Check by making a dummy run.
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Protection sheeting shall be provided at end nozzles to protect traveling vehicles
from being smeared.
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4.12.7.4 Preoaring the Sprayer Run
TE
The volume and temperature of the sprayer contents shall be recorded while it is on
level ground. The length of sprayer run shall be determined from the available
quantity in the sprayer and the application rate. For chip sealing works, the
Contractor shall ensure that the area to be sprayed is not greater than the area that
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can be covered by aggregate in the loaded trucks.
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Each spray run shall start on a protective strip of paper placed on tbe pavement.
The paper shall be wide enough to ensure the pavement is protected for the full
width of spray. Place sufficient protective paper to protect road fixtures.
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Whenever the sprayer is stationary on the road pavement, paper shall be placed on
the pavement as masking around areas to be sprayed and beneath time spray bar.
4.12.7.5 Sprayer Run

EN
Uniform spraying speed shall be attained before spraying commences.
Avoid an excess or deficiency of material due to faulty overlap at longitudinal

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joints when spraying a road in part widths .
Overlap shall be 300mm with an intermediate nozzle. End nozzles shall not be used
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on an overlap.
Spraying shall be stopped before the level of material in the tank falls to a level
which reduces the full discharge of the pump.
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Remove and dispose of all cut-on/off paper.

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Clean off any sprayed material from road fixtures .
4.12.7.6 Application Rates
Polymer modified bitumen shall be applied within the following parameters;
1.50 - 1.70 litreslm'

1.30 - 1.50 litres/m'
1.1 0 - 1.30 litreslm'
54-135
(JKRl5PJ/2008)-S4
4.12.7.7 Hand Spraying
Work shall be planned in advance to minimize the requirement for the use of a
hand sprayer. Any strips of pavement not adequately covered with sprayed material
shall be sprayed later with the hand attachment.
4.1 2.7.8 Heating and Storage of Binder.
Bituminous materials shall not be heated to spraying temperatures too soon in
ER
advance of requirements. Avoid heating the bitumen in quantities excess to
requirements and holding the bitumen beyond 10 hours at spraying temperatures.
The bitumen shall be stored or held at temperatures below minimum spraying
temperature. It shall be heated to spraying temperatures but shall not exceed
maximum.
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The bitumen shall be removed from the site where;
N
(j i. Stored/held beyond 48 hours at temperatures exceeding 120 "C.
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ii. Heated to above 190 °C for straight run bitumen or above the maximum
recommended temperatures specified by the polymer manufacturer.
4.12.7.9 Spraying Temperatures

A
Unmodified bitumen shall be sprayed within the range ISO to 180 "C whereas
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polymer modified bitumen shall be sprayed within the range 180 to 200 "C.
4.12.8 Application of Aggregate

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4.12.8.1 Application Rates
Aggregate application rates shall be maintained within the following parameters;

EN
Nominal 14mm aggregate 12·18 kglm'

Nominal IOmm aggregate 8· 12 kg/m'
Nominal 6mm aggregate 5 - 8 kglm'
Spread the aggregate evenly and uniformly over the sprayed surface.
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( Avoid placing aggregate more that one stone deep.

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Use a mechanical spreader.
Re-run or hand cover bare Of insufficiently covered places after the first spreading.
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4.12.8.2 Rolling of Chippings

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The treated surface shall be rolled with self-propelled rubber tyre rollers with a
minimum tyre pressure of 600 kPa and a minimum wheel load of 1 tonne.
After initial slow pass, the roller speed shall be between 10 and 25 kmlh.
Rolling shall conform to the following minimum requirements;
i. Entire area to receive one roller pass immediately after covering.
Ii. 25% of roUing requirement to be completed within 20 minutes of covering.
54-136
(JKRl5PJ/2008)-S4
iii. Minimum of 50% of rolling requirement to he completed on the same

day as covering next day after covering.
Minimum rolling requirement: Eight (8) complete roller passes.
For two coat treatments when the second coat is to he applied immediately, the
total rolling on the first coat shall be double that specified.
Rolling shall be done in daylight hours only. Sweep the surface after rolling.
ER
Ensure a uniform distribution of aggregate.
Drag broom sball be adjusted to distribute surplus aggregate, but not to dislodge
embedded aggregate. Ensure aggregate on the final surface is uniformly
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distributed, and finnly held by the binder.
N
TE
Probibit traffic;
i. from new work until at least 100% of rolling has taken place.
ii. from adjacent strip of roadway during spraying.

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All loose aggregate shall be removed from the new work.
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4.12.10 Waste Material
All waste materials shall be removed from the site and disposed.
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4.12.11 Conformance
Any work on which the binder is applied at less than 90%, or more than 115% of
EN
the design application rate shall be rectified at the Contractor's own expense.
4.12.12 Measurement and Payment

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4.12.12. lBinder Application
Measured in square metres of area coated for each of the following application J
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rates;
i. 1.50 - 1.70 litres/m'
ii. 1.30 - 1.50 litres/m'
iii. 1.10 - 1.30 litres/m'
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Payment shall be made for the total area sprayed, as recorded on binder application
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sheets.
4.12.12.2 Aggregate Application
Measured in square metres for each oftbe following;-
Nominal 14mm aggregate

54-137
(JKRl5PJ/2008)-S4
Areas for each aggregate size shall be detennioed from records of binder
application.
4.12.12.3 Precoat Applied to Aggregate
Not measured for payment purposes.
Measured in square metres for.mark. clean and seal with crack filler material.
ER
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54-138
JKRl5PJ/200B-54
MICRO-SURFACING
Micro-Surfacing is a modified version of hardening, and improve surface texturing.

slurry seal and was introduced in Canada in With relatively short curing time of about
early 1990s. Micro-Surfacing consists of a one hour, it minimises disruption to traffic.
mixture of polymer modified bitumen
emulsion, selected mineral aggregate, Micro-Surfacing may be used on low and
high traffic roads to fill ruts, improve skid
ER
mineral filler, water and other additives such
as cement and latex, properly proportioned, resistance and riding quality and arrest
mixed and spread on existing bituminous ravelling. This system is well suited as
surfacing. preventive maintenance treatments to extend
the life of sound pavements.
D
Micro-Surfacing is used to restore the
Micro-Surfacing is a thin surface treatment,
N
surface characteristics of pavement or to
preserve pavement surfacing. This surfacing
mixture can be designed to correct rutting,
thus it is not appropriate to resolve
pavement structural deficiencies. This o
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improve skid resistance, seal surface cracks, mixture shall not be used on pavement
protect pavement surfacing against A surfacing having major and active cracks.
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54-139
JKRl5PJ/2008-S4
4.13 SURFACE TREATMENT 2 - MICRO-SURFACING
4.13.1 Description
This work shall consist of furnishing, placing and shaping Micro-Surfacing as a wearing
course. This Specification shall be read in conjunction with Sub-Section 4.3.3 of the
Standard Specification for Road Works of JKR (JKR/SPJ/2007). All requirements in the
Sub-Section 4.3.3 shaU apply unless stated otherwise in this Specification.
ER
Micro-Surfacing shall consist of a mixture of quick setting polymer modified asphalt
emulsion, selected mineral aggregate, mineral filler, water and other additives, properly
proportioned, mixed and spread on a paved surface in accordance with this Specification
andlor as directed by the S.O. The mix shall be able to accept traffic after a short period
oftime, typically 60 minutes after laying, depending on site conditions.
D
4.13.2 Materials
N
n 4.13.2.1 Coarse Aggregate
TE
Coarse aggregate shall be screened crushed hard rock, retained on 5.0 nun sieve, angular
in shape and free from dust, clay. vegetative and other organic matter, and other
deleterious substances. They sball conform to the foUowing physical and mechanical
A
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accordance with ASTM C 131 shall be not more than 25%.
ii. The flakiness index when tested in accordance with MS 30 shall be not more
than 25%.
M
(five cycles) when tested in accordance with AASHTO T 104 sball be not more
EN
than 18%.
than 2%.
M
v. The polished stone value wben tested in accordance with MS 30 shall be not less
than 40.
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uncrnshed limestone and gravel shall not be permitted.

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Fine aggregate shaU be screened quarry dust. They shall be non-plastic and free from
D
deleterious substances. They sball conform to the foUowing physical and mechanical
(five cycles) when tested in accordance with AASHTO T \04 shall be not more
tban 20%.
than 2%.
54-140
JKRl5PJ/2008-54
1II. The sand equivalent of aggregate fraction passing the No.4 (4.75mm) sieve
iv. The fme aggregate angularity when tested in accordance with ASTM C 1252
ER
4.13 .2.3 Mineral Filler
Mineral filler shall be added as part of the combined aggregate gradation. Ordinary
Portland cement that is free of lumps shall be used. The material shall pass 75 Ilm sieve
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by not less than 70% by weight and the amount of filler that need to be incorporated shall
be determined by a laboratory mix design.
N
4.13.2.4 Binder
TE
(a) Bitumen Emulsion
The emulsion shall be of a quick-set polymer-modified type. The polymer material shall
be milled into the emulsifier solution prior to the emulsification process.
A
The polymer shan be Styrene Butadiene Rubber (SBR) or natural rubber latex.
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When tested, the emulsion and residual bitnmen shall meet the following requirements in
Table 4.13.1.
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TABLE 4.13.1: PROPERTIES OF EMULSION AND RESIDUAL BITUMEN
DESCRIPTION SPECIFICAnON
EN
TEST
RESIDUAL BITUMEN
ASTMD36 Softening Point ("C, Ring & Ball) 54°C minimum

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ASTMD5 Penetration at 25°C 40- 90 J

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EMULSION
ASTMD244 Viscosity @ 25"C SSF, seconds 15 - 50

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ASTM D 244 Particle Charge Test Positive

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ASTMD244 Water Content 40% maximum
ASTM D244 Residue on 850llm 0. 1% maximum
54 -141
JKRlSPJ/2006-S4
(b) Water
The water shall be free ofhannful salts and contaminants.
(c) Quick-Setting Additives
Quick-setting additives shall be added to provide the quick-set properties of the mixture.
They shall be included as part of the mix design and be compatible with other
components of the mix.
ER
4.13.3 Gradation of Combined Aggregates
The aggregate gradation shall be within the limits as specified in Table 4.13.2.
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TABLE 4.13.2: AGGREGATE GRADATION
N
n AS1M Sieve Size (mm)
8.0
% Passin)! by Weil!ht
90 - 100
Tolerance (%)
±5
TE
4.75 60-74 ±5
3.35 45 - 58 ±4
2.0 36-50 ±4
1.0 23 - 38 ±4
A
0.710 20- 33 ±3
0.090 5 - 12 ±3
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4.13.4 Mix Design

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CompatIbility of the aggregate, polymer modified bitumen emulsion, mineral filler and
additives shall he verified by the mix design. The mix design shall he made of combined
aggregate gradation as shown in Table 4.13.2. The mix properties shall comply with
EN
requirements in Table 4.13.3.
TABLE 4.13.3: TEST REQUIREMENTS
DESCRlPTION SPECIFICATION TEST

M
l ) Cohesion;
@ 30 minutes 12 kg-em min.
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ISSA TB-139
@ 60 minutes 20 kg-cm min.
Wet track abrasion loss

75 gift' (800 glm') max. ISSA TB-lOO
O
(One hour soak)

D
Mix time @ 25 'c 40 - 120 sec. ISSA TB-113
S4-142
JKRl5 PJ/2008-S4
The component materials used in the mix design shall be within the following limits;
TABLE 4.13.4: LIMITS OF COMPONENT MATERIALS
5.5 to 8.0 by weight of combined

Binder content (%)
aggregates.
0 - 2% by weight of combined
Mineral fi ller
aggregates.
Quick-setting additive As required.
ER
As required to produce proper mix
Water
consistency.
D
4.13.5 Eguipment
N
All equipment, tools and machines used in the perfonnance of this work shall be
maintained in satisfactory working condition at all times to ensure a high quality ()
TE
product.
The material shall be mixed by a self-propelled micro-surfacing mixing machine which

shall be a continuous flow mixing unit able to accurately deliver and proportion the
aggregates, emulsified bitumen, mineral filler, additive and water to a revolving multi-
A
blade double shafted mixer and discharge the mixed product on a continuous flow
basis. The machine shall have sufficient storage capacity for the aggregates, emulsified
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bitumen, mineral filler, additive and water to maintain an adequate supply to the
proportioning controls.
4.13 .5.1 Proportioning Devices

M
Individual volume or weight controls for proportioning each material to be added to the
mix (i.e. aggregate, mineral filler, emulsified asphalt, additive and water) shall be
EN
provided and properly marked.
These devices are usually revolution counters or similar devices and are used in
material calibration and detennining the materials output at any time.
M
4.13 .5.2 Machine Calibration

KU
Each mixing unit to be used in perfonnance of the work shall be calibrated prior to
construction. The documentation shall include the individual calibration of each
material at various settings, which can be related to the machine metering devices.
O
4.13.5.3 Spreading Equipment
The mixture shall be spread uniformly by means of a conventional augured surfacing

D
spreader box attached to the mixer and equipped with paddles to agitate and spread the
material evenly throughout the box. A fron t seal shall be provided to insure no loss of
the mixture at the road contact point. The rear metal seal shall act as final strike-off and
shall be adjustable. The spreader box shall have suitable means provided to side shift
the box to compensate fo r variations in the pavement geometry.
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JKRl5PJ/2008-S4
4.13.5.4 Auxiliary Equipment
Suitable surface preparations equipment, traffic control equipment hand tools and any
other support equipment shall be provided as necessary to perform the work.
4.13.6 Surface Preparations
The area to be surfaced with micro-surfacing shall be thoroughly cleaned of vegetation,

loose material, silt spots and other objectionable material. Water used in pre-wetting
ER
the surface shall be applied by the mixing machine immediately ahead of the spreader
box at a rate to dampen the surface without any free flowing water allowed. Manholes
and other service entrance shall be protected from the micro-surfacing by a suitable
method. Area with base andlor sub grade failures shall be reconstructed accordingly
from the subgradelbase up to the wearing course.
D
4.13.7 Application
N
. .
n The surface may be pre-wetted by fogging ahead of the spreader box. The micro-
TE
surfacing shall be of the desired consistency upon leaving the mixer. A sufficient
amount of material shall be carried in all parts of the spreader box at all limes so that a
complete coverage is obtained.
4.13.7.1 Unsuitable Weather

A
Work shall stop during the period of heavy rain or when there is standing water on the
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surface.
4.13.7.2 Thickness and Spreading Rate

M
The micro-surfacing mixture shall be of proper consistency at all times so as to provide

Ihe application rate required by the surface condition. The application shall be
undertaken in two layers, with an initial regulating layer followed by a uniform
EN
wearing course carpet giving a total combined thickness for both the layers between 10
- 12 mm in thickness. The recommended spreading rate for the micro-surfacing using
the 0 - 8 mm aggregate gradation shall be between 18 - 25 kg/m' for two layers.
4.13.7.3 Joints
M
( ) No excessive build-up, uncovered areas, or unsightly appearance shall be permitted on

KU
longitudinal or transverse joints. The contractor shall provide suitable width spreading
equipment to produce a minimum number of longitudinal joints throughout the project.
4.13.7.4 Mix Stability

O
The Micro-Surfacing shall possess sufficient stability so that premature breaking of the
material in the spreader box does not occur. The mixture shall be homogeneous during
D
and following mixing and spreading.
4.13.7.5 Hand Work
Areas that cannot be reached with the mixing machine shall be surfaced using hand
squeegees to provide complete and uniform coverage. If necessary. the area to be band
worked shall be lightly dampened prior to mix placement.
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JKRl5PJ/2008-S4
4.13.8 Site Control
Throughout mixing periods, the mix proportions shall be rigidly controlled and the
weight of all materials incorporated there shall be recorded. The quantity of bitumen
emulsion used and the rate spread of the mixed material in terms of kilograms of
aggregates per square metre shall also be recorded for each load of aggregates.
4.13.8.1 Test Requirements
ER
Whenever spreading is taking place, the tests prescribed in the Table 4.12.5 shaU be
carried out. A copy of the results for each of the tests and for each recorded rate of spread
shaU be given to the s.o.
TABLE 4.13.5: AGGREGATE GRADATION
D
Test Frequency
N
TE
Binder content in cured mix 2 samples I machine load
Grading of samples of aggregates 2 samples I machine load

A
4.13.8.2 Finished Surface
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The finished Micro-Surfacing shall be of nniform surface texture and appearance

throughout the work, without variations within the lane width, or from lane to lane and
shall be free from holes, streaks and surface irregularities. Any Micro-Surfacing, which
M
does not comply with the clause, or is non-uniform in surface texture or appearance, shall
be made good by replacement of fresh material. Any surface which shows continual
material loss, or extension non~adherence to the substrate shall be made good by removal
EN
and replacement of fresh material.
4.13 .8.3 Trafficking Time
The process shall be such that the laid material may be opened to traffic within typically
M
sixty (60) minutes.

KU
4.13.8.4 Protection of Newly Laid Surface
Traffic shall be kept off newly treated surfaces until material is deemed to have set, and
traffic speeds shall be kept to a minimum until the surface does not experience
detrimental effects.
O
4.13.8.5 Skid Resistance

D
The skid resistance value of the completed material on carriageway shall have a
minimum average value of 46 (corrected to 35 'C) as measured by the SRT pendulum
device or equivalent for a number of tests to be agreed by the S.D. and the Contractor,
depending on the size and type of site involved.
4.13.8.6 Remedial Measures
The Contractor shall carry out appropriate remedial works on failed Micro-Surfacing
works, the type and extend of which shaU be at the discretion ofthe s.o.
54-145
JKRlSPJ/200a-54
Crack Sealing Crack sealing is not recommended on

crocodile cracks, high-density multiple
Crack sealing is a preventive road cracks and other types of crack which are
maintenance technique whereby cracks in due to structural damage.
the road surfacing are sealed to prevent
water from infiltrating into the underlying Prior to crack sealing, the cracks must be
pavement layers. The water, once in the free of all dirt, dust, debris, moisture and
pavement structure, can cause early failure other foreign materials. The crack sealant
of road pavement in a number of ways; shall have a clean, dry bonding surface. This
ER
shall be accomplished with compressed air
1. It can cause stripping of the bitumen and a simple blow pipe. The area to be
from the aggregates, decreasing strength sealed shall be kept clean and dry until all
of the bituminous mixture. sealing operations are completed.
D
ii. Forces from passing traffic will exert
hydraulic pressure in the water trapped
N
inside the cracks. The pressure will then
be transmitted to the sound areas and
TE
break them open.
iii. It can weaken the road base and sub-
base layers and eventually the subgrade.
This will result in increased deflections
A
and accelerating deterioration of the
surface due to development of more and
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wider cracks, depressions and potholes.
This will ultimately lead to failure and
the need for reconstruction.
M
There are many crack sealing materials in In a crack sealing operation, appropriate
the market, each with distinct crack sealant is either poured or sprayed into
characteristics. The principal material types the crack. The surface is then blinded with
EN
are; sand and finished with a rubber squeegee.
i. Cold-applied polymer modified bitumen

emulsion,
M
ii. Hot-applied polymer modified bitumen,

(\ and
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iii. Chemically cured thermosetting

materials.
The best candidates for crack sealing are

O
relatively new pavements that are beginning

to form cracks, with crack width greater than
D
3mm.
54-146
JKRl5PJ/2008-s4
4.14 SURFACE TREATMENT 3 - CRACK SEALING
4.14.1 Description
This work shall consist of furnishing and placing specialised crack sealing materials
above or into cracks in the road surfacing to prevent the intrusion of water and
incompressible materials into the cracks.
ER
4.14.2 Materials
The crack sealing material shall be able to fill and/or seal the cracks to prevent water and
incompressible materials entering the pavement at the surface. The material shall be
selected on the basis of the key properties that it has in order to be efficiently placed and
D
perform satisfactorily. Some of the more desirable properties are as follows;
N
1. Short preparation time.
TE
ii. Quick and easy to place (good workability).
iii. Short curing time.
iv. Adhesiveness.
A
v. Cohesiveness.
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vi. Resistance to softening and flow.
vii. Flexibility.
M
viii. Elasticity.
Resistance to ageing and weathering.

EN
lX.
x. Resistance to abrasion by traffic.
There are many crack sealing materials in the market, each with distinct characteristics.
M
The principal material families and types are as follows;
i. Cold-applied thermoplastic bituminous materials.

KU
• Bitumen emulsion.
• Polymer modified bitumen emulsion.
ii. Hot-applied thermoplastic bituminous materials.

O
• Penetration grade bitumen.

• Polymer modified bitumen.
D
iii Chemically cured thennosetting materials.

• Self· leveling silicone.
The desirable properties of these di fferent types of crack sealing materials are shown in
Table 4.14.1.
54-147
JKRlSPJ/2008-S4
TABLE 4.14.1: CRACK SEALING MATERIAL

- TYPES AND PROPERTIES
Property Material Type

Emulsion Bitumen Polymer Polymer Self-
Modified Modified Leveling
Emulsion Bitumen Silicone
Short • • ••
preparation
• •• • ••
ER
Good
workability
Short curing •• •• •
time
•• •• • • •
D
Adhesiveness
Cohesiveness • •
N
n Resistance to • • ••
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softening
Flexibility • • ••
Elasticity • • ••
A
Resistance to • ••
aging
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Resistance to ••
abrasion
• Applicable •• Very appbcable
M
Bitumen emulsion and penetration grade bitumen possess little, if any, flexibility and
highly susceptible to temperature. Hence, their use is limited in crack filling for non-
working cracks. Similarly, since fiber particles provide minimal elasticity to bitumen and
EN
do not significantly affect temperature susceptibility, fiberised bitumen is most

appropriate for non-working cracks.
Three materials excluded from the list above are cutback bitumen, mineral-filled (granite
M
dust, limestone dust etc) bitumen and sand-bitumen mixes. Cutback bitumen is rarely
used because of environmental hazards, whereas mineral-filled bitumen is Dot cost-
~ ) effective. Sand-bitumen mixes are considered to be crack repair (partial-depth patching,
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spot patching etc.) materials.
4.14.2.1 Polymer Modified Emulsion

O
Polymer modified emulsion shall be a mixture of bitumen emulsion conforming to MS

161 and appropriate quantity of polymer additive. The resultant mixture shall have the
properties as given in Table 4.14.2.
D
S4-148
JKRl5PJI200S-S4
TABLE 4.14.2: PROPERTIES OF POLYMER MODIFIED EMULSION
Property Requirement Test Specification

Percentage retained on 850 IJ.m max 10 ASTMD244
sieve
Saybolt Furol viscosity at 50 'c min 100, max 400 ASTM D 244
Penetration on residue at 25 °C, 45 - 70 ASTMD244&

100g, 5s ASTMD5
ER
Ring and ball softening point on 45 - 60 'c ASTMD244&
residue ASTMD36
D
4.14.2.2 Polymer Modified Bitumen
Polymer modified bitumen (PMB) sball be a mixture of penelr.ltion grade bitumen
N
conforming to MS 124 and appropriate quantity of polymer additive. The polymer shall
be non-carcinogenic. The resultant mixture shall be of performance grade PG 70 or
TE
bigber in compliance with AASHTO Standard M320-02.
The properties of the polymer modified bitumen sball be as given in Table 4.14.3.
TABLE 4.14.3: PROPERTIES OF POLYMER MODIFIED BITUMEN

A
TEST I REQUIREMENT
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TEST
PMB prior to Rolling Thin Film Oven Test (RTFOl) SPECIFICATION
M
Viscosity, max. 3 Pa.s, test temperature 135 ASTMD4402

'c (see Note I)
Dynamic shear, Glsin Ii min. LOO kPa,
10 radls, test temperature 'c 70 AASHTOT315
EN
Penelr.ltion, 100 g, 5 s, 25 C, 0.1 nun. Report ASTMD5

(see Note 2)
Ring and ball softening point, min. ' C. 55 ASTMD36
M
Flasb point, min 'c 230 AASTHOT48
Moisture sensitivity test min. % 80 AASHTOT283 J

KU
Emission of toxic gases, max. mg/mJ 15

O
Mass loss, max. %. 1.00 AASHTO T 240 or

ASTM D 2872
Dynamic sbear, Glsin Ii min. 2.20 kPa,
D
10 radls, test temperature 'c 70 AASHTO T 315
Notes:
I. The requirement may be waived at the discretion of the S.O. if the supplier warrants that the
polymer-modified binder can be adequately pumped and mixed at the temperatures that meet all
2. The penetration value shall be taken as the reference for consistency check on the production.
54-149
JKRlSPJ/2oo6-S4'
4.14.2.3 Self-Leveling Silicone
Self-leveling silicone shall conform to ASTM D 5893 with specifications as given in

Table 4.13.4.
TABLE 4_13-4: SELF-LEVELING SILICONE SPECIFICATIONS
ASTMD5893
Test Test Method
Test Criteria*
ER
Extrusion Rate, mVrnin ASTM C 1183 50
Tensile stress at 150% strain
ASTM D 412(C) 310
I (23'C), kPa
Rheolo~ical properties ASTMD2202 Type I , smooth
D
Tack-Free Time, h ASTM C 679 5
Bond (-29'C, 100% extension,
immersed, non-immersed, ASTM D 5893 Pass
N
oven-aged)
() Hardness (-29'C, type A2) ASTMC661 25
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Hardness (23 'C, type A2) ASTMC661 30
Flow ASTM D 5893 No flow
mtimate elongation, % ASTM D 412(C) 600
Accelerated weathering ASTM C 793 Pass
Resilience, % ASTMD5893 75
A
• Based on 21-day cure time.
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4_14-3 Aoplication Methods
Sealing of individual cracks is often regarded as being tedious and time consuming.
M
However, when done correctly, it often provides the most effective treatment in terms of
waterproofing and extending the pavement life.
Crack sealing materials shall be placed in cracks in four different configurations as

EN
described below.
4.14.3.1 Configurations
M
(a) Flush Fill

\. ) In a flush fill configuration, the crack sealing material shall be simply placed into the
KU
existing, uncut crack and excess material is struck off. Figure 1 illustrates the flush fill
configuration.
FIGURE 1- FLUSH FILL

O
D
S4-150
JKRlSPJ/2008-S4
(b) Reservoir
In a reservoir configuration, the crack sealing material shall be placed only within the
confines of a cut crack. The material sball be placed either flush witb or slightly below
the pavement surface. Figure 2 illustrates the reservoir configuration.
FIGURE 2 - RESERVOm
12 mm
ER
D
N
Standard Reservoir-aod-F1ush
TE Deep Reservoir-aDd-Flush
A
(c) Overhand
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In an overhand configuration, tbe crack sealing material shall be placed into and over an
uncut crack. The material shall be shaped into a band over the crack by using a rubber
blade squeegee or a sealing shoe that flattens the material over the crack which assists in
establishing a hot bond for the band. If not, the unshaped material may continue to flow
M
and level out after being applied and the bonds occwring as a result of this self-leveling
are relatively weak because the material will have decreased in temperature. Figure 3
illustrates the overhand configuration.
EN
Overhand configuration is most appropriate for cracks having a considerable amouot of

edge deterioration (more than 10% of crack length) because the overhand simultaneously
fills and covers the deteriorated segments in the same pass.
M
FIGURE 3 - OVERBAND
KU
75 t o 125 mOl
( Iy pical)
"m
'\....;;~~;;;;;;;;~;;;;;;;;;;;;~~~ 25
25
w~ ~ w ~m. m
wip e 'Zo ne wi pe ZO ne
.
O
;
:;,'''' ~.
D
l.J
Simple Band-Aid
54-151
JKRl5PJ/2008-S4
(d) Combination (reservoir and overband)
In a combination configuration, the crack sealing material shall be placed into and over a
cut crack. A squeegee shall be used to shape the material into a band that is centred over
the crack reservoir. Figure 4 illustrates the combination configuration.
FIGURE 4 - COMBINATION (RESERVOIR AND OVERBAND)
ER
12 mm
D
N
n
TE
Standard Recessed Band-Aid Deep Recessed Band-Aid
A
For long term crack sealing performance, configurations (c) and (d) shaD be considered.
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4.14.3.2 Selection of Crack
The S.O. shaD designate the location of the cracks to be sealed. Crocodile cracks, high-
M
density multiple cracks and other types of crack which are due to structural damage shaD
not be treated with crack sealing. The best candidates for crack sealing are relatively new
pavements that are beginning to form cracks, with crack width greater than 3 mm but less
than 20 mm. Cracks with crack width greater than 20 mm and are not due to structural
EN
damage shaD be cut and patched.
4.14.3.3 Preparation of Crack

M
Cracks shaD be prepared to receive sealants. The better the preparation, the better the
chance that the sealant wiD last and perform. Cracks shaD be free of aD dirt, dust, debris,
moisture and other foreign materials. These materials are likely to be encountered
KU
particularly if cracks are cut. The sealant shall have a clean, dry bonding surface. The
area to be sealed shall be kept clean and dry until all sealing operations are completed.
Crack preparation shall be accomplished with compressed air and a simple blow pipe.
O
This technique works well when the dirt is dry and packed hard. If the cracks are filled
with wet dirt, the dirt needs to be removed and the crack must be completely dried. An air
compressor or a bot air lance generating temperatures in excess of 1370 °C is the best
D
tool.
Results from the SHRP study showed there is a 40% greater chance of crack sealant
success if cracks are cut prior to sealing. Cutting a reservoir above the cracks allows
adequate crack sealant expansion and contraction. The reservoir also ensures that the
proper amount of crack sealant penetrates the crack. An operator passes the pavement
cutter over the crack and cuts a reservoir into the crack. Once the cutting is complete.
compressed air (hot or cold) or engine-powered steel wire brush shall be used to remove
the dust created by the cutting operation.
54-152
JKRl5PJ/200B-S4
Table 4.14.5 lists the types of equipment commonly used for cutting and cleaning/drying
cracks.
TABLE 4.14.5: CRACK CUTTING AND CLEARINGIDRYING EQUIPMENT
Operation Type of Equipment Recommendations

Crack cutting. Vertical-spindle router. Use only with sharp carbide·tipped or
diamond router bits.
Rotary-impact router. Use only with sharp carbide·tipped router
ER
bits.
Random crack saw. Use only on fairly straight cracks.
Diamond-blade saw, 200 mm maximum
diameter.
D
Crack cleaning Blower (backpack or Not recommended. Insufficient blast
and drying. Dower-driven). velocity (75 to 110 mls).
Air compressor. Equipped with oil and moisture mters.
N
Pressure - 690 kPa minimum.
Flow - 0.07 m3/s minimum.
TE
Velocity - 990 mls minimum.
Hot-air lance. Velocity - 610 mls minimum.
Temperature - 1370 C minimum.
No direct flame on pavement.
Sandblaster. Nor recommended. Environmental and
A
health concerns.
Wirebrusb. Do not use with worn brushes. Not
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recommended for cleaning previously

treated cracks as there is a tendency to
smear material.
M
(a) Cutting o/Crack

EN
Crack cutting shall be carried out by using a high production machine that follows cracks
well and produces minimal spalls or fractures, otherwise it may inflict additional damage
on the pavement.
M
The vertical-spindle router is the least damaging and most maneuverable pavement
cutting machine though its cutting rate is quite low.
J
KU
The rotary-impact router is much more productive than the vertical-spindle router.
However, it may cause considerable more damage, depending on the type of cutting bit
used. Carbide router bits are highly recommended over steel router bits.
O
The random crack saw with 150 to 200 mm diameter diamond blades can follow
meandering cracks moderately well. Althougb its cutting rate is not nearly as high as the
rotary-impact router, it provides a more rectangular reservoir with smoother walls and a
D
higher percentage of aggregate surface area.
(b) Cleaning and Drying a/Crack
Crack cleaning and drying are perhaps the most important aspect of crack sealing and
filling operations because a high percentage of failures are adhesion failures that result
from dirty or moist crack channels.
The four primary procedures used in cleaning and drying crack channels are
described in the following sections.
54·153
JKRlSPJI2008-S4
i) Air blasting
Air blasting shall be done with either one ofthe following equipment;
• Portable backpack or power-driven blowers.
• High-pressure air compressors with boses and wands.
Backpack and power-driven blowers deliver high volumes or air at low
ER
pressures. As a result, blast velocity is generally limited to between 75 and 110
mls which is undesirable. The advantages of these blowers are they require only
one worker and provide good mobility.
High-pressure air compressors which can deliver a minimum blast pressure of
D
690 kPa, blast flow of 0.07 m'ls and blast velocity of 990 mls are more effective
in cleaning cracks. They are reconunended to be equipped with oil and moisrure
N
filtering systems as the introduction of oil or moisture to the crack channel can
seriously inhibit bonding of the crack sealing material to the sidewall.
TE
As high-pressure air blasting provides no heat and very little drying, it shall only
be performed when the pavement and crack channel are completely dry.
High-pressure air blasting shall be conducted in two steps;

A
I. First pass, made along the crack, shall dislodge loose dirt and debris
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from the crack channel (and surrounding pavement if overband
configoration is to be applied). The wand shall be held no less than 50
mm above the crack channel.
M
2. Second pass shall completely remove all the dislodged particles from
the pavement surface. The wand shall be held further away from the
pavement surface to make use of a larger blast area.
EN
High-pressure air blasting shall be conducted immediately ahead of the sealing

material application. The greater the time interval between these two operations.
the more likely dust and debris will resettle into the crack channel.
M
ii) Hot Air blasting

~)
KU
Hot air blasting shall be performed with a hot compressed-air lance connected to
a compressed-air unit. The extreme heat it delivers to a crack provides two
benefits;
i. Crack moisture is quickly dissipated, thereby improving the bonding of

O
the sealing material.

D
ll. Heated crack surface can enhance bonding of hot-applied sealing

materials if the material application operation follows closely behind
the hot air blasting operation.
Minimum requirements for hot air blasting unit shall be a 1370 °C heat capacity
and a 610 mls blast velocity.
Hot air blasting shall be conducted in two steps;
i. First pass, made along the crack, shall clean and heat the crack
sidewalls (and surrounding pavement if overband configuration is to be
S4-154
JKRlSPJ/2006-S4
applied). The heat lance shall be held approximately 50 mm above the

crack channel. Proper heating is manifested by a slightly darkened
colour; burning is apparent by a black colour and a very gritty texture.
ii. Second pass shall completely remove all the dislodged particles from
the pavement surface. The beat lance shall be held further away from
the pavement surface to make use of a larger blast area.
Hot air blasting shall be conducted immediately ahead of the sealing material
ER
application. This will limit the amount of dust and debris blown into the cleaned
crack channel, maximise crack warmth for enhanced bonding and minimise
moisture condensation into the crack channel.
iii) Sandblasting
D
Due to environmental and health hazards, sandblasting is Dot recommended.
N
iv) Wire brushing
TE
Cut cracks shall be cleaned by using mecbanical, power-driven wire brushes in
conjunction with air blasting (bot or cold). Depending on the brusb and bristle
characteristics, this combination is quite effective at removing debris lodged in
the crack. Brusb attachment shan contain bristles wbich are flexible enough to
A
allow penetration into the crack channel, yet rigid enough to remove dirt and
debris.
EJ
Notwithstanding the use of the cleaning and drying procedures as described

above, if the equipment is unable to remove dirt, debris and any form of loose
fragments, they shall be removed manually with band tools.
M
4.14.3.4 Application of Crack Sealing Material
(a) Cold-applied thennoplastic bituminous materials

EN
Bitumen emulsion materials shall be applied in various ways. They shall be loaded into
distributors for partially heated application or kept in dmms for unheated application.
Distributors shall be equipped witb pressure or gravity hoses for wand application. Hand-
M
held or wbeeled pour pots shall be used to apply heated or unheated bitumen emulsion to
the cracks. The emulsion shall be applied at ambient temperature or sball be partially
J
KU
heated to between 52 and 66 'C.
(b) Hot-applied thermoplastic bituminous materials
Unmodified bitumen shall be heated and placed using bitumen distributors or direct-
O
beating kettles. These units typically bum propane gas for heat and the heat is applied
directly to the melting vat containing the bitumen.
D
For modified bitumen, the direct-heat system is not recommended as it can cause uneven
heating or overheating of the material, particularly when no agitation devices are
available. The modified bitumen shan be heated and mixed in indirect-heat, agitator-type
kettles. These units bum either propane or diesel fuel, and the resulting heat is applied to
a transfer-oil that surrounds a double-jacketed melting vat containing the treahnent
material. They shall be equipped with agitation devices.
54-155
JKRl5PJI2008-S4
(c) Chemically cured thermosetting materials
Silicone pumps shall be capable of being directly attached to the original material
container, typically a 19-1itre or 208-litre drum. Pumps and applicators shall provide the
sealing material to the crack at a minimum flow rate of 0.03 litrelsecond. Teflon-lined
application hoses and seals are recommended because they are able to prevent silicone
from curing in the pump or hose.
4.14.3.5 Material Finishing and Shaping
ER
Material finishing and shaping shall be accomplished in two ways;
i. Various sizes of dish-shaped attachments shall be connected to the end of the

application wand for one-step application, finishing and shaping.
D
ii. Industrial rubber squeegees shall be used behind the material applicator to
N
provide the desired shape.
TE
The one-step method requires ODe less worker but often does not provide as much control
in finishing as the squeegee method especially for overband configurations.
Prior to installation, the finishing and shaping tool shall he tested to ensure that the
desired configuration is achieved.
A
Dish attachment to the application wand shall be of proper size and aligned to facilitate
EJ
application.
Squeegees shall he properly molded into a 'U' or 'V' shape so that the sealing material
can be concentrated over the crack. If the strike-off is to be flush, the rubber insert shall
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be flat. If overhand configuration is required, the rubber insert shall be cut to the desired
dimensions. The depth of the cut shall be a little larger than the desired thickness of the
overhand because some thickness will be lost as a result of the squeegee being pushed
forward and slightly downward. The squeegee shall be operated closely behind the
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application wand. However. if the sealing material is runny enough to sink. into the crack
or flow underneath the mold provided by the squeegee, a little distance shall be kept to
allow for material cooling.
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( )
Traffic shall not be allowed on the crack sealing material until it has cured and the
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possibility of tracking no longer exists. However, if the S.O . so decides that it is

necessary to allow traffic to pass over the material before adequate curing, clean sand,
quany dust or other approved materials shall be spread by using shovels over the sealed
cracks. These materials shall be applied immediately after finishing and sbaping so that
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they can stick to the sealing material and serve as temporary covers. They shall be
applied in a thin layer and shall fully cover the exposed sealing material.
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COLOURED SURFACING SYSTEM
Coloured surfacing is a treatment with

specific colour on the wearing course
and may be used to differentiate the
various elements. It may be used to
improve traffic flow and traffic safety. It
is a resin-based surfacing with anti
skidding properties. It consists of a layer
of epoxy and polyurethane mixture
topped with fme aggregate. This
surfacing has to achieve a suitable level
of surface friction but its primary
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function is to retain an appropriate level The use of coloured surfacing does
of colouration for a certain minimum not improve night time visibi lity
period. unless it is enhanced with white or
yellow foreground colour road
Coloured surfacing provides a clear markings to provide the necessary
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definition between areas of the road visual contrast.
elements that are allocated for specific
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use with benefits that include: Correct colouration is achieved with
• Improved delineation and definition the right amount of pigment for the
of road space; coloured resin and this must be
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• Increased compliance with the checked against a standard colour
traffic rules; requirement. It is also necessary to
• Increased awareness of other road incorporate suitable quality pigment to
users; ensure the specified colour is
• Reduction in baffic collisions and; maintained for the specified period.
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• Improved road safety. Quality pigment is more resistant to
ultra violet light and bas slow rate of
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The presence of anti-skid properties fading.

inherent in the fine aggregates
significantly reduces skidding related The application of coloured surfacing
accidents. This coloured surfacing is should be delayed for at least 28 days
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primarily used for demarcation on for newly paved surface due to the
various road elements and special relatively fresh bitumen coating of the
markings. Examples of these are aggregates. This would cause poor
adhesion between the coloured
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pedestrian crossings, exit ramps,

motorcycle lanes, gore areas and special surfacing material and the pavement
markings such as on-pavement speed surface which may result in cracking
limit sign. and peeling of the material.
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4.15 SURFACE TREATMENT 4 - COLOURED SURFACING
4.15.1 Description
This work shall consist of furnishing. placing, shaping and compacting coloured mixture
as a wearing course on an existing, impermeable and accepted bituminous or concrete
pavement course. This Specification shall he read in conjunction with Sub-Section
4.3.3 of the Standard Specification for Road Works of JKR (JKRJSPJ/2007-S4). All
requirements in the Sub-Section 4.3.3 shall apply unless stated otherwise in this
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Specification.
This Specification describes resin-based coloured surfacing system.
Resin-based coloured surfacing system (RCSS) is a range of flexible pigmented
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polyurethane binder, specially formulated to provide a durable anti-slip screed on the
surface of an existing, impenneable and accepted bituminous or concrete pavement
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course when mixed with aggregates.
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RCSS comprises three layers of applications. A modified epoxy basecoat and an
intermediate layer of aliphatic polyurethane, both filled with aggregates, followed by a
finaJ layer of aliphatic polyurethane topcoat.
Basecoat is a solvent free high flexibility epoxy binder filled with aggregates. Topcoat
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and the intermediate layer are high flexibility polyurethane coating with excellent ultra-
violet and abrasion resistance.
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4.15.2. Materials
The RCSS epoxy and polynrethane materials shall be prepared in three basic
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components; Part A - resin base, Part B - hardener. and Part C - aggregates.
(aj Epoxy basecoat

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The Epoxy Basecoat shall be a solvent free bisphenol-A type epoxy resin cross-linked
with a highly flexible modified cycloaliphatic amine hardener.
(bj Fine aggregate

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Fine aggregate shall be clean screened quarry dust. Other types of fine aggregate may be
used subject to the approval of the S.O. Fine aggregate shall be non-plastic and free
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from clay, loam, aggregation of material, vegetative and other organic matter, and other
deleterious substances. They shall confonn to the following physical and mechanical
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i. The fine aggregate size shall be between 40 - 60 mesh.

ii. The fine aggregate anguJarity when tested in accordance with ASTM C 1252
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iii. The Methylene Blue value when tested in accordance with Ohio Department of
Transportation Standard Test Method shall be not more than 10 mg/g,
iv. The weighted average loss of weight in the magnesium sulfate soundness test (5
cycles) when tested in accordance with AASHTO Test Method T 104 shall be not
more than 20%.
than 2%.
Notwithstanding compliance with the aforementioned requirements, limestone aggregate
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JKRlSPJ/2008-S4
shall not be pennitted for use in resin-based coloured surfacing system.
(c) The Polyurethane Topcoat
The Polyurethane intennediate layer and topcoat shall be a pigmented Aliphatic

Polyester Polyurethane with high flexibility, abrasion resistance, chemical resistance
and excellent resistance against ultra-violet (UV) radiation.
(d) Colour Pigments
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Colour pigments used for coloured resins shall be of good quality and highly resistant
to IN light with slow rate of fading. Prior approval from the S.O. shall be obtained for
use of colour pigments.
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The amount of pigments that sball be added to the resin is extremely important to
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provide effective colouration. The Contractor shall add adequate amount of pigments to
produce the required colour of the surfacing material to the satisfaction of the S.O.
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4.15.3 Properties
(a) Physical Properties
Compressive Strength (BS 6319:Part 2: 1983) ... .. .. .. ... ... .. .... 75 N/mm2
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Flexural Strength (BS 6319:Part 3: 1990) ...... .... . . .. . . .. .. .. .. ... 25 N /mm 2
Skid Resistance Value (BS 8204:Part 3:1993) .. . . .. . .. ... ..... ... 60
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Abrasion Resistance (BS 8204:Part 2:2002) ... .. ... ......... .. .... 9000 cycles
Shrinkage Coefficient of Thermal Expansion (ASTM C 531) < I %
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Curing time;
Pedestrian traffic.. .. .. ... . ... . . .... .. . .. ...... ... ... ....... .. . ... ... .. 2 hours
Vehicular traffic . . . .. . ...... ..... ...... .. ...... .. ...... . .. . .... ..... . .. 12 hours
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(b) Chemical Properties
RCSS shall be resistant to petrol, diesel, lubricant brake fluid and battery water.
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(c) Weathering Properties
RCSS shall not crack upon subjecting to natural weathering. The surfacing system shall
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not easily fade or change colour upon exposure to UV radiation.
4.15.4 Applications
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Installation of RCSS shall be carried out only by approved installers who has
undergone application trainings and certified as qualified applicator by the
manufacturer.
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RCSS shall be suitable for use as high friction coloured surfacing on highways
with surface texture depths of between 0.5 mm to 2.0 nun.
Installation of the surfacing system shall be carried out only when the road surface
temperature is between to °C to 50 DC.
For newly paved surface, the application of RCSS shall not be earlier than 28 days
after the completion of the pavement wearing course due to the presence of relatively
fresh bitumen coating the aggregates.
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JKRl5PJ/2008-S4
(a) Surface Preparation
All imperfections on the road surface which are deemed not acceptable to the installer
shall be reinstated with appropriate materials approved by the manufacturer.
The road surface shall be clean, dry and free from loose aggregates, oil, grease and other
loose matters which are likely to impair the adhesion of the system to the road surface.
Installation shall not be carried out if the road surface temperature is outside the range of
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\0 °e and 50 °C.
(b) Basecoat Application
The pre~weighed component B shall be poured into the container of the pre-weighed
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component A.
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The components shall be mixed until homogeneous, using a high torque, slow speed
n electrical or mechanical stirrer.
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The mixed epoxy binder shall be applied by using roller brush onto the prepared surface at
a minimum coverage rate which will vary according to the texture and porosity of the
surface but shall not be less than 1.20 kg/m'.
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After the binder is applied, fine aggregates shall be broadcast over the binder and shall
be evenly spread out using a broom or squeegee.
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After the binder is sufficiently cured (between 2 - 4 hours), the excess fme aggregates
shall be removed by industrial vacuum machine or other suitable means before
the application of the intermediate layer
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(c) Intermediate Coat Application

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The pre-weighed component B shall be poured into the container of the pre-weighed
component A.
The components shall be mixed until homogeneous, using a high torque, low speed
electrical or mechanical stirrer.
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( ) The mixed polyurethane coating shall be applied over the hardened surface of the ,,\,oxy
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screed using a paint roller at a minimum coverage rate of not less than 3.5 m per
litre.
After the binder is applied, fme aggregate shall be broadcast over the binder and shall be
evenly spread out using a broom or squeegee.
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After the binder is sufficiently cured (between 2 - 4 hours) , the excess aggregate shall
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be removed by industrial vacuum machine or other suitable means.
(d) Topcoat Application
The pre-weighed component B shall be poured into the container of the pre-weighed
component A.
The components shall be mixed until homogeneous, using a high torque, low speed
electrical or mechanical stirrer.
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JKRl5PJf2008-S4
The mixed polyurethane coating shall be applied over the hardened surface of the epoxy
screed using a paint roller.
4.15.5 Precautions
(a) Cleaning
Primer and coloured mixture shall be removed from tools and equipment with suitable
solvent immediately after use. Hardened material shall only be removed mechanically.
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(b) Limitation
The coloured surfacing shall not be applied on to surfaces known to suffer or are
likely to suffer from rising damp conditions. The surfacing material shall not be laid on
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wet surfaces and on diesel damaged bituminous surfaces
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(c) Health and Safety
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Coloured surfacing primer shall not come in contact with the skin and eyes, or be
swallowed. Ensure adequate ventilation and avoid inhalation of vapours. Wear suitable
protective clothing. gloves and eye protection. When working in confined areas,
suitable respiratory protective equipment shall be used. The use of barrier creams
provides additional skin protection. In case of contact with skin, rinse with plenty of
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clean water. Do not use solvent. In case of contact with eyes, rinse immediately
with plenty of clean water and seek medical attention immediately. Do not induce
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vomiting.
(d) Fire
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Resin-based coloured surfacing and primer are non-flammable. Most solvents are
flammable. Keep away from sources of ignition. No smoking. In the event of fire,
extinguish with CO 2 or foam. Do not use a water jet.
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(e) Disposal
Spillages of component products shall be absorbed on to earth, sand or other inert

material and transferred to a suitable vessel. Disposal of such spillages or empty
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packaging shall be in accordance with local waste disposal regulations
4.1 5.6 Maintenance and Repair

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Should the coloured surfacing system be damaged or become debonded from the
substrate, it shall be repaired by cutting the damaged area back to finn1y bonded
material, cleaning the damaged area using compressed air or industrial vacuum,
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masking the perimeter and reinstate to the original specification.

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APPENDIX!
AUSTROADS PAVEMENT TEST
Determination of the International Roughness Index (IRI)

Using ARRB TR. Walking Profiler
This test method was prepared by a Working Group ofthe AUSTROADS Pavement Reference Group.
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Foreword
This test method defines the procedure for measuring the International Roughness Index (IRI) of pavement
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surfaces using the ARRB TR Walking Profiler.
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Definitions
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(a) The IRI CInternational Roughness Index)
The IRI is the roughness index determined by applying a mathematical model (referred to as a
quarter-car model) which has the dynamic response of a simulated response-type road roughness
measuring vehicle along a single wheel-path of measured road profile. The IRI is expressed in
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tenns of accumulated vertical displacement of the simulated suspension in metres per measured
kilometre (m/km). IRI can be reported in different ways. as follows:
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• Single Track IRI

The IR1 based on a quarter car model run over a single track oflongitudinal profile.
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• Lane IRI
This is a composite IRI value representing the roughness of a road lane section. It is
determined by averaging two individual. Single Track IR1 values obtained separately in each
wheel-path of a lane (at 0.75 metres either side of the lane mid-track).
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(b) NAASRA Roughness
The NAASRA Roughness is determined by applying a mathematical model (referred to as a

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half-car model aod having the dynamic response of a standard vehicle) to two longitudinal profiles
measured simultaneously. NAASRA Roughness is expressed in couots per kilometre (cIkm).
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Note: An approximate value ofNAASRA Roughness can be calculated from measured IR] as follows:
NAASRA Roughness = -1.3 + 26.5(IRI) c/lan.

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(c) A Surface Profile ofa line on a surface is the representation of the vertical locations of points on
the line against their horizontal distances along the line from a specified starting point.
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(d) Grade is the rate of longitudinal rise or fall of the surface with respect to the horizontal distaoce.
ex:pressed as a ratio or a percentage. The longitudinal grade of the pavement surface to be
measured shall not exceed 1 in 6.
(e) Road Roughness is a measure of the riding quality of pavement in response to longitudinal profile.
(f) Absolute Offset is the machine-specific average output value between forward and reverse offset.
(g) Absolute Slope is the machine specific average value between forward and reverse slope.
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Test Method
1.0 Scope
This test method defines the procedure for measuring the International Roughness Index (IRI) of
pavement surfaces using the ARRB TR Walking Profiler. This device is pushed over the pavement
surface by an operator at a slow walking pace.
It is assumed tbat tbe reader is familiar with the Walking Profiler Instruction Manual published by
ARRB Transport Research and/or has a copy available for reference,
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2.0 Referenced Documents
The following documents are referred to in this test method:
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ARRB Transport Researcb (1996) - Walking Profiler Instruction Manual, Model APRI, February
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1996 (Published: ARRB Transport Research Ltd., Vermont South, Victoria 3133).
3.0 Apparatus o
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(a) A manually operated walking profiler fitted with a lap-top computer and measuring beam
which enables the collection and presentation of pavement surface profile and roughness
information. The profiler shall be calibrated in accordance with the procedure specified in the
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manufacturer' s Instruction Manual reproduced as Appendix IA of this test method.
(b) Calibrated Smart Level or other similar device which can measure pavement grade or slope to
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an accuracy of ± I % of grade.
(c) Paint, crayon or similar for marking reference points along the intended survey path.
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Note: The use of a chalked string line facilitates the marking of the survey path.
(d) Ruler or tape measure, graduated in millimetres, for establishing reference marks along the
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intended survey path. The ruler or tape measure used shall be accurate to at least ± 5 mm.
(e) Broom for sweeping the survey surface.

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(I) Thermometer, suitable for the measurement of temperatures within the range 0 - 100 ·C
readable to at least I ·C and baving an accuracy of ± 1 ·C.
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Note: A digital thermometer with a sensor remote from the display is recommended. This wiJl enable the probe to be
secured under the cowling while the display is mounted near the lap~top computer.
4.0 Procedure
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4.1 Pre-Operation Set-Up

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(a) Ensure the profiler battery and the lap-top computer internal battery are fully cbarged and all
leads are correctly connected and secured on the walking profiler and computer.
(b) Clean tbe foot pads of the measuring beam by lightly brushing.
(c) Ensure that the tyres, on the profiler wheels, and other components are free from the build up
of deposits of road-making materials (eg. bitumen, cements etc.) by cleaning witb a mild
solvent or brushing.
(d) Ensure that the power to the machine is switched on at least 20 minutes prior to any use of the
walking profiler.
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JKRl5PJ/2008-S4
4. 2 Operating Conditions
Do not operate the walking profiler in ambient temperatures outside the temperature range of 0 to
45°C or on road surface temperatures exceeding 75 dc.
4.3 Field Offset Trim
(a) Switch on the power to the walking pro filer and wait at least 20 minutes before performing
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the field offset trim procedure.
(b) Perform the field offset trim immediately prior to use of the walking profiler for the IRI
survey. If. during perfonnance of the IRI survey, the air temperature within the cowling
changes by more than lOoe from the temperature recorded when the most recent field offset
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trim was performed, then another field offset trim shall be performed.
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(c) Record the temperature within the profiler cowling, then perform the field offset trim in
(, accordance with the manufacturer's Instruction Manual (the procedure is reproduced as
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Appendix IB to this Test Method). If necessary repeat the procedure until a successful run is
obtained.
4.4 IRl Surveys

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4.4.1 Single TracklRl Survey
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(a) Define the length of the test section to be surveyed, which should have a length
exceeding 100 metres. Select the wheel-path or other tracking line upon which the
single track survey is to be performed.
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Note: The lRI result is applicable for runs greater than or equal to 100 m in length.
(b) Check that the longitudinal grade of the test section does not exceed 1 in 6. If the
grade is greater abandon the test.
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(c) Mark the starting point of the line of survey with a cross as indicated in the
Instruction Manual and mark the transverse position survey line every 3 to 5 metres
along its length to facilitate accurate tracking of the machine. Ensure the line to be
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surveyed is free from all loose material.

\. ) Note· For inexperienced operators the tracking line may best be marked by use of a chalked string tine.
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(d) Record the time and the temperature, within the profiler cowling. Conduct the survey
in the direction of lane traffic flow in accordance with the manufacturer's Instruction
Manual and within the operational speed range. Note: Care should be taken to
minimise the deviations from the survey line, with even greater care required as the
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transverse cross-slope of the site increases. If, during the survey the centre line of the
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machine beam is permitted to deviate from this line by greater than ± 100 mm, repeat
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the run.
(e) Display and then record the Single Track IRI value calculated by the lap top
computer for the surveyed section.
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JKRlSPJ/200B-S4
4.4.2 Lane lRl Survey
(a) Defme the length of the test section to be surveyed, which should have a length
exceeding 100 metres. Unless othetwise stipulated, the tracking lines shall be located
0.75 metres either side of the centre of the lane to be surveyed. Note: The IRl is
accurate for runs greater than or equal to 100 m in length.
(b) Check that the longitudinal grade of the test section does not exceed I in 6. If the
grade is greater abandon the test.
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(c) Mark the starting points for each line of survey as in the instructions in the
manufacturer's Instruction Manual, such that both starting points are coincident at
the same road chainage location. Ensure that each line of survey is free from all
loose material.
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(d) Record the tinne and the temperature within the profiler cowling, then conduct the
first survey in the direction of lane traffic flow in accordance with the manufacturer's
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Instruction Manual and within the operational speed range.
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(e) Display and record the single track lRI value (lRII) calculated by the lap top
computer for the first completed line of survey.
(I) Record the tinne and the temperature, within tbe profiler cowling, then conduct the
second survey in the direction of lane traffic flow in accordance with the
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manufacturer's Instruction Manual and within the operational speed range.
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(g) Record the lRI value (lRI2) calculated for the second line of survey.
5.0 Calculations
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When a Lane IRI Survey has been carried out by the completion of two single lane surveys, one in
tbe inner wbeel-path and the other in the outer wbeel-path, calculate the Lane IRI using the
following equation:
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Lane lRI ~ II, (lRI1 + lRI2)
Where lRIl ~ The result of the first Single Lane lRI as computed by the on-board lap-top
computer and
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lRI2 ~ The result of the second Single Lane lRI as computed by the on-board lap-top computer.
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6.0 Reporting
Report the following:

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(a) The start and end cbainage of the test section for which either Single Track lRI or Lane IRl
was determined.
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(b) The Single Track IRI and the transverse location of each completed line of survey which
exceeds 100 metres in length.
(c) Where appropriate the Lane IRl for the test section.
If required, the following may also be reported for each 100 metre long sub-section of the test
section:
i. The start and end chainage of each sub-section,
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JKRlSPJ/2008-S4
ii. The Single Track IRI and the transverse location of each completed line of swvey within
each sub-section,
iii. The Lane IRl for each sub-section.
t. When the length of the test section is not exactly divisible by 100 metres then one sub-section of length between
100 to 200 meters shall be included.
2. The average of the Lane IRI values from sequential sub-sections will equal the overall test section Lane IRl
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only if the length of all the sub-sections is identical.
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APPENDIX 13
Calibration Procedure
1a.l Calibration Frequency
The following calibration procedure shall be performed at least once every six months or if a
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satisfactory field offset trim cannot be achieved. This procedure is specific to calibration of the
ARRB TR Walking Profiler.
1a.2 Apparatus
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(a) Stainless steel calibration surface plate with minimum dimensions of at least 320 mrn long, 75
nun wide and 25 nun high. The top surface of the plate shall be machined plane with an out-
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of-flatness not exceeding 0.1 mm. The bottom of the plate shall be fitted with three adjustable
legs to enable adjustment, for level, of the top surface.
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(b) Stainless steel step block conforming to the following dimeosions:
I. Width 74.0 ± 1.0 nun,

11. Length 74.0 ± 1.0 mm.
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iii. Height 25.0 ± 0.1 mm.
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with the two large faces parallel to within 0.1 mm.
(c) Bulls eye spirit level.

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(d) A small paint brush for cleaning the calibration plate and block
1a3 Calibration Procedure

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Laboratory Offset and Slope Calibration
(a) Stabilise the temperature of the measuring beam and profiler by placing the walking profiler,
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with the beam attached, in a clean, temperature controlled environment for at least twelve
hours prior to commencement of the calibration. The cowl should be left in position during
the conditioning period to prevent accidental damage to or dirt contamination of the J
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mechanism and measuring foot.
(b) Remove the cowl and ensure there is sufficient room beside the walking profiler to carry out
the calibration procedure.
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(c) Set the Test/Survey selector switch, on the walking profiler, to the TEST position.
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(d) Place the calibration surface plate on the ground beside the walking profiler, immediately
adjacent too and with the long side parallel to the measuring foot. Place the bulls eye level on
top of the surface plate and establish a level surface by adjusting the legs.
(e) Undo the two (2) M4 hexagon head screws which secure the accelerometer cable clamp.
Check that the 6 foot pads. on the measuring beam, are clean.
(I) Clean the top of the surface plate by lightly brushing with the paint brush. Disengage the rear
pick up arm cones and remove the measuring beam from the walking profiler. Place the
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JKRlSPJ/200B-S4
measuring beam on top of the surface plate in the forward position ie as it was removed from
the walking profiler. Do not lift the measuring beam by the accelerometer or the resilient
mounting plate. Ensure the accelerometer cable is not pulling or twisting on the accelerometer
at any time throughout the calibration process.
(g) Gently lift the measuring beam ends, one at a time and gently tap each end on the surface
plate as necessary to position it correctly. Check to ensure there is no overhang of the
measuring beam, at either end on the surface plate.
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(h) Activate the calibration menu and then follow the prompts from the computer. Continue the
calibration, through forward offset to reverse offset, forward slope and reverse slope as
directed by the computer prompts. The calibration is complete when the absolute offset lies
between - 300 mV and +300 mY, and the absolute slope lies between - 2900 m V and - 3100
mY.
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(i) Replace the measuring beam in the walking profiler and reposition the accelerometer cable
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clamp. Ensure the cable is free to move without pulling tight or snagging any other leads
n when the walking profiler is in use and confirm the correct operation of the entire machine
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before field use by performing an offset calibration check.
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APPENDIX Ib
Field Offset Trim Procedure
I b.1 Introduction
The field offset trim procedure is undertaken to initialise the walking pro filer for the ambient
conditions, particularly temperature, under which an IRl survey will he conducted. A field offset
trim should be carried out each time the walking profiler is used, to make full allowance for local
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variables.
Prior to any use of the walking profiler, including the field offset trim procedure, the power to the
machine must have been switched on for at least twenty (20) minutes.
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The field offset trim procedure should be carried out on a 20 metre portion of the section to be
surveyed, that portion being as level and smooth as possible and free of any loose material.
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The field offset trim procedure is carried out under the direction of the on-board computer system
()
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discussed in the Manufacturer's Instruction Manual. It is assumed that the reader is familiar with
that Manual andlor has a copy available for reference.
Ib.2 Apparatus
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As listed in Section 3 oftbe Test Melbod.
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I b.3 Field Offset Trim Procedure
(a) Set up Ibe walking profiler in the intended working situation, switch on the power and wait at
least 20 minutes before perfonning Ibe field offset trim procedure.
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(b) Select a section approximately 20 metres long, and as level and smooth as possible, of Ibe
pavement to be measured, and sweep it clear of all loose debris.
EN
(c) Using a chalked string line or similar, mark a straigbt line along the selected section of
pavement, to be the palb of Ibe field offset trim run.
(d) At one end of the chosen path, rule a chalk line about 0.7 metres long in Ibe direction of the
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intended walking profiler run, Iben approximately bisect this line at right angles with another
chalk line, again about 0.7 metres long. This cross will mark both Ibe beginning and Ibe end
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of the field offset trim run.
(e) Press the <FlO> key on the on-board computer to activate the main menu, select Calibration
using the horizontal arrow key, and press <Enter> to display the vertical selection panel.
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(I) Use the vertical arrow keys to select Field Oiftet Trim, then press <Enter>.
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(g) Ensure that the machine is in the staged condition as defined in the Manufacturer's lnstruction
Manual. Manoeuvre the walking pro filer on its back wheels to position it over the chalked
cross such that the arrow markings on the machine align with the lines on the pavement (see
Figure 2 of Quick Guide to Conducting a Precision Survey in the Manufacturer's Instruction
Manual).
(b) Press <Enter> to start data logging for the field offset trim run.
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JKRl5PJ/2008-S4
(i) Squeeze the staging release bar to the push handle, then push the machine forward in a
straight line for at least 20 metres and stop in the staged condition by letting go of the staging
release bar and gently pushing until the mechanism locks.
0) Press <H> (for half-way) to mark the end of the outward phase.
(k) Mark the pavement with chalk directly below each of the arrow markings on the machine,
then remove the machine and join opposite chalk marks on the pavement with two ruled lines,
one in the direction of the walking profiler run, the other at right angles (see Figure 4 of Quick
Guide to Conducting a Precision Survey in the Manufacturer's Instruction Manual). The
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intersection of these two lines marks the position of the front foot of the walking profiler at
the last placement of the measuring beam, and is the precise end of the swvey.
(I) Tum the machine to face it back toward the starting point of the run and position it over the
cross drawn on the pavement in (k), using the procedure described in (g).
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(m) Press <Enter> to continue the field offset trim run, then push the machine back along the
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sarne line, finishing the run by staging it precisely over the starting cross. q the finishing
position is more than 5 milt horizontally from precisely over the starting cross, the
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procedure must be repeated from point (e).
(n) Press <F> (for finish) to indicate the end of the field offset trim run. The software then
automatically calculates the new offset correction and incorporates it into the processing
system. The new value will be displayed and a message will indicate that the process was
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successful and prompt the operator to press <Enter> to return to the main menu.
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(0) Check that there are no particles adhering to the footpads after compleling the field offset trim
procedure. If there are any present, the offset co"ection may be in 6"or and the procedure
should be repeated.
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APPENDIX 2
BINDER DRAIN-DOWN TEST PROCEDURE
1.0 Scope
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This test method covers the determination of the amount of binder drain-down in an uncompacted
porous asphalt sample when the sample is held at elevated temperatures comparable to those
encountered during the production, storage, transport and placement of the mixture.
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The values stated in gram-millimeter units are to be regarded as the standard.
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This Standard may involve hazardous materials, operations and equipment. This Standard does not
pwport to address all of the safety problems associated with its use. It is the responsibility of the
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user of this Standard to establish appropriate safety and health practices and determines the
applicability of regulatory limitations prior to use.
2.0 Reference Documents

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AASHTO Standards 1'245 Resistance to Plastic Flow of Bitnminous Mixtnres Using Marshall
Apparatns and M92 Standard Specification for Wire Cloth Sieve for Testing Purposes.
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3.0 Binder Drain-Down
For the purpose of this test method, binder drain-down is considered to be that portion of the
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bituminous mixture which separates itself from the sample as a whole and is deposited outside the
wire basket during the test. (Note, any noticeable aggregate particles that are deposited outside the
basket should be added back into the mixtnre and not counted as binder drain-down. Alternatively
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the test should be re-run).
4.0 Summary of Method

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A sample of the porous asphalt mi"tnre of mass 1.1 kg is prepared in the laboratory or obtained
from field production. The sample is placed in a wire basket that is positioned on a pre-weighed
paper plate. The sample, basket and plate are placed in a forced air oven for one hour at a pre- J
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selected temperature. At the end of three hours, the basket containing the sample is removed from
the oven along with the paper plate and the paper plate is weighed to determine the amount of
binder drain-down that occurred
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5.0 Significance and Use
Test method can be used to detennine whether the amount of binder drain-down measured for a
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given porous asphalt mixture is within acceptable levels. It also provides an evaluation of the
binder drain-down potential of a porous asphalt mixture produced in the field.
6.0 Apparatus
(a) Oven capable of maintaining the temperature in a range from 1200 - 1750 °C. The oven
should maintain the set temperatnre to within ± 2 'c (± 3.6 'F).
S4·X
JKRl5PJ/2008-S4
(b) Paper plates of appropriate size. The paper plates shall be of appropriate durability to
withstand the oven temperatures.
(c) Standard cylindrical shaped basket meeting the dimensioI15 shown in Figure I. The basket
shall be constructed using standard 6.3mm (0.25inch) sieve cloth as specified AASHTO M92.
(d) Spatulas, trowels, mixer and bowls as needed.
(e) Balance accurate to 0.1 gram.
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7.0 Prepared Samples
7. 1 Laboratory Prepared Samples
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7. 1.1 For each mixture, the binder drain-down characteristics should be determined at the
anticipated plant production temperature. Duplicate samples should be tested.
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n 7.1 .2 Dry the aggregate to constant mass and sieve it into appropriate size fractions as indicated
in AASHTO T 245, Section 3.2.
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7.1.3 Determine the anticipated plant production temperature or select a mixing temperature in
accordance with AASHTO T 245, Section 7.3.1. The supplier's recommendatioI15 should
be sought when using modified bitumen.
1. 1.4 Weigh into separate pans for each test sample the amount of each size fraction required to
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produce complete bituminous mixture samples having a mass of 1200 grams. The
aggregate fractions shall be combined such that the resulting aggregate blond has the
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same gradations as the job mix formula. Place the aggregate samples in an oven and heat
to a temperature not to exceed the mixing temperature established in 7.1.3 by more than
approximately 28 "C (50 "F).
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7.1.5 Heatthe PMA to the temperature established in item 7.1.3.
7.1.6 Place the heated aggregate in the mixing bowl. Add any stabiliser (Note I) as directed by
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the supplier and thoroughly mix the dry components. Form a crater in the aggregate blend
and add the required amount of asphalt. The amount of asphalt shall be such that the final
sample bas the same asphalt content as the jab-mix-formula. At this point, the
temperature of the aggregate and PMA shall be within the limits of the mixing
temperature established in 7.1.3. Using a spatula (if mixing by band) or a mixer, mix the
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aggregate and binder quickly, until the aggregate is thoroughly coated.

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Note 1 . Some types of stabilisers such as fibers or some polymers must be added directly to the aggregate prior
to mixing with the binder. Other types must be added directly to the binder prior to blending with the aggregate.
7.2 Plant Produced Samples

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7.2.1 For plant produced samples, duplicate samples should be tested at the plant production
temperature.
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7.2.3 Samples may be obtained during plant production by sampling the mixture at the tricks
prior to the mixture leaving the plant. Samples obtained during actual production should
be reduced to the proper test sample size by the quartering method.
8.0 Procedure
8.1 Transfer the laboratory produced or plant produced uncompacted porous asphalt mixture
sample to a tarred wire basket described in 6.3. Place the entire sample in the wire basket.
54-XI
JKRlSPJ/2008-S4
Do not consolidate or otherwise disturb the sample after transfer to the basket. Determine
the mass oftbe sample to the nearest 0. 1 gram.
8.2 Detennine and record the mass of a paper plate to the nearest 0.1 gram. Place the basket
on the paper and place the assembly into the oven at the temperature as determined in
7.1.3 for 3 hours ± I minute.
8.3 After the sample has been in the oven for 3 hours, remove the basket and paper plate.
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Determine and record the mass of the paper plate to the nearest O. t gram.
9.0 Calculations
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9.1 Calculate the percent of mixture which drained by subtracting the initial paper plate mass
from the final paper plate mass and divide this by the initial total sample mass. Multiply
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the result by 100 to obtain a percentage.
10.0 Report
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10.1 Report the average percent binder drain-down at the lest temperature.
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APPENDIX 3
CANTABROTESTPROCEDURE
1.0 Scope
Cantabro test shall be done on the proposed mix to measure its resistance to stone loss at high
frequency. The test procedures and apparatus are described below;
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2.0 Apparatus
2.l Marshall Compactor - see description in AS1M D 1559.
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2.2 Loss Aogeles Drum - see description in ASTM C 131.
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2.3 Thermometers: to measure the temperatures of the aggregate, binder and bituminous mix,
n metal thermometers with a scale up to 200 DC and accuracy of 3 DC are used. To measure
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the temperature at which the test is carried out, a thermometer with a scale from 0-50 DC
and an accuracy of 0.5 DC is used.
2.4 Balances: a balance with a capacity of 2 kg and an accuracy of 0.1 g to weight the
samples and another with a capacity of 5 kg and an accuracy of I g to prepare the mixes.
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2.5 General materials: tray, pots, spatulas, asbestos gloves, curved scoops, filter paper rings
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etc.
3.0 Procedure
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The different aggregate fractions which make up the mix are dried in a stove at \05-110 ·C
until constant weight is reached. At the proposed optimum binder content, fOUT Marshall
specimens are manufactured with 50 blows on each side at adequate temperature (see Note 1).
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The relative density and void percentage can be determined as soon as they have cooled to
ambient temperature. The procedure to determine the density and void percentage shall be
based on geometric procedures.
The specimens are dried at ambient temperature for 2 days. Before testing the specimens, they
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are kept at test temperature, 25°C. for at least six hours. After the specimens have been kept
l ) for the required time, weigh it (Mo), then place immediately into the Los Angeles drum
without abrasion loads (balls). The drum is turned at a velocity between 188 and 208 radls
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and submitted to 300 revolutions. This is repeated for the four specimens.
Weigh the specimen after test (M,). For each specimen, the stone loss or attrition resistance is
computed;
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L = (Mo -M,)I(MoJ x 100

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The average stone loss (L) is reported and shall be not more than 15%.
Note I: Mixing temperatures are usually 130°C for pure bitumen and 170 °C for polymer modified bitumen.
54-XIII
JKRlSPJ/200B-S4
APPENDIX 4
SMA ASPHALT DRAINDOWN TEST PROCEDURE
1.0 Scope
1. 1 This test method covers the determination of the amount of draindown in an

uncompacted SMA mixture sample when the sample is held at elevated temperatures
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comparable to those encountered during the production, storage, transport and placement
of the mixture.
1.2 The values stated in gram-millimeter units are to be regarded as the standard.
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1.3 This standard may involve hazardous materials, operations and equipment. This standard
does not purport address all of the safety problems associated with its use. It is the
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responsibility of the user of this standard to establish appropriate safety and health
practices and determines the applicability of regulatory limitations prior to use.
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AASHTO Standards T245 Resistance to Plastic Flow of Bituminous Mixtures Using Marshall
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Apparatus and M92 Standard Specification for Wire Cloth Sieve for Testing Purposes.
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3.0 Draindown
For the purpose of this test method, draindown is considered to be that portion of the PMA which
separates itself from the sample as a whole and is deposited outside the wire basket during the test.
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(Note, any noticeable aggregate particles that are deposited outside the basket should be added
back into the mixture and not counted as draindown. Alternatively the test should be rerun).
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A sample of the SMA mixture to be tested is prepared in the laboratory or obtained from field
production. The sample is placed inn a wire basket that is positioned on a pre-weighed paper plate.
The sample, basket and plate are placed in a forced air oven for three hour at a pre-selected
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temperature. At the end of three hoW'S, the basket containing the sample is removed from the oven
along with the paper plate and the paper plate is weighed to determine the amount of draindown
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that occurred.
Test method can be used to determine whether the amount of draindown measured for a given
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SMA mixture is within acceptable levels. It also provides an evaluation of the draindown potential
of a SMA mixture produced in the field.
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6.0 Apparatus
6.1 Oven capable of maintaining the temperature in a range from 120 - 2000 C. The oven
should maintain the set temperature to within ± 02° C.
6.2 Paper plates of appropriate size. The paper plates used be of appropriate durability to
withstand the oven temperatures.
S4-XIV
JKRlSPJI2008-S4
6.3 Standard cylindrical shaped basket meeting the dimensions shown in Figure I. The
basket shall be constructed using standard 6.3mm (0.25inch) sieve cloth as specified
AASmOM92.
6.4 Spatulas, trowels, mixer and bowls as needed.
6.5 Balance accurate to 0.1 gram.
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o Top view
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Side view
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O",ket 5mm
Bottom"
! I---~
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------l
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25 mm
108mm
•
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7.0 Sample Prenaration
7.1 Laboratory Prepared Sample

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7.1.1 For each mixture tested the draindown characteristics should be determined at the
anticipated plant production temperature. Duplicate samples should be tested.
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7. 1.2 Dry the aggregate to constant mass and sieve it into appropriate size fractions as indicated
in AASHTO T 245 section 3.2.
( )
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7.1.3 Detennine the anticipated plant production temperature or select a mixing temperature in
accordance with AASHTO T 245, Section 7.3.1. the PMA supplier's recommendations
should be sought when using modified bitumen.
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7.1.4 Weigh into separate pans for each test sample the amount of each size fraction required to
produce complete SMA mixture samples having a mass of 1200 grams. The aggregate
fractions shall be combined such that the resulting aggregate blond has the same
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gradations as the job mix formulae. Place the aggregate samples in an oven and heat to a
temperature not to exceed the mixing temperature established in 7.1.3 by more than
approximately 28 ' C (50 'F).
7.1.5 Heat the PMA to the temperature established in 7.1.3.
7.1.6 Place the heated aggregate in the mixing bowl. Add any stabiliser (Note I) as directed by
the supplier and thoroughly mix the dry components. Form a crater in the aggregate blend
and add the required amount of asphalt. The amount of asphalt shall be such that the fmal
sample has the same asphalt content as the jab-mix-formulae. At this point, the
54-XV
JKRlSPJ/2008-S4
temperature of the aggregate and PMA shall be within the limits of the rruxmg
temperature established in 7.1.3. Using a spatula (if mixing by hand) or a mixer, mix the
aggregate (and stabiliser) and PMA quickly, until the aggregate is thoroughly coated.
7.2 Plant Produced Sample
7.2.1 For plant produced samples, duplicate samples should be tested at the plant production
temperature.
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7.2.2 Samples may be obtained during plant production by sampling the mixture at the trucks
prior to the mixture leaving the plant. Samples obtained dwing actual production should
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Note : • Some types of stabilisers such as fibers or some polymers must be added directly to the aggregate prior to mixing
with the PMA Other types must be added directly to the PMA prior to blending with the aggregate.
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8.0 Procedure
8.1 Transfer the laboratory produced or plant produced uncompacted SMA mixture sample to
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a tarred wire basket described in 6.3. Place the entire sample in the wire basket. Do not
consolidate or otherwise disturb the sample after transfer to the basket. Determine the
mass of the sample to the nearest 0.1 gram.
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8.2 Determine and record the mass of a paper plate to the nearest 0.1 gram. Place the basket
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00 the paper and place the assembly into the oven at the temperature as determined in
7. 1.3 for 3 hours ± 1 minute.
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8.3 After the sample has been in the oven for 3 hours, remove the basket and paper plate.
Determine and record the mass of the paper plate to the nearest 0.1 gram.
9.0 Calculations
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9.1 Calculate the percent of mixture which drained by subtracting the initial paper plate mass
from the final paper plate mass and divide this by the initial total sample mass. Multiply
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the result by 100 to obtain a percentage.
10. Report
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10.1 Report the average percent drainage at the test temperature.

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54-XVI
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APPENDIX 5
AUSTROADS MODIFIED BINDER TEST MBT 22:1995
Torsional Recovery of Polymer Modified Binders
Foreword
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Polymer modified binders (PMBs) are thought to provide benefits due to their increased elastic
behaviour. A simple means of detennining the elastic properties of a PMB is to measure its
Torsional Recovery. The Torsional Recovery test is simple and can be readily utilised for routine
quality control purposes.
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Method
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1.0 Scope
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This test method sets out the procedure for the determination of Torsional Recovery of
polymer modified binders using a simple bolt and cup assembly.

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The following documents are referred to in this test method:
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ASINZS 2341 Methods of testing bitumen and related roadmaking products
2341.12 Method 12: Determination of penetration
ASTMEI Standard specification for ASTM thermometers
AUSTROADS Method of sampling polymer modified binders, polymers and scrap
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MBTOI rubber
MBT02 Protocol for handling polymer modified binders in the laboratory
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3.0 Principle
The Torsional Recovery apparatus operates by manually rotating an aluminium bolt,

previously embedded in a cup of modified binder, through an angle of 180 degrees and
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measuring the extent of recovery of the original applied rotation. The initial 180 degree twist
() is applied with a spanner over a 10 second period. The recovery after 30 seconds is reported.
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4.0 Apparatus
(a) Bolt assembly - a cylindrical headed aluminium bolt assembly, with a total mass of
45 ± 5 g. The bolt has a cylindrical head with a diameter of 28.6 rom and a thickness
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of 9.52 rom. The threaded shank of the bolt is 44.5 rom long. A metal 'spider", with
three radial pins and two nuts, can be used to centre the assembly. A pointer is
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required for angle measurements in the absence ofthe spider.
(b) Sample tin - sample tin of 80 - 85 ml capacity and internal diameter 51-52 rom. A
penetration can, as defined in AS2341.12, is suitable.
(c) Angle measuring device - angle measuring device and sample clamp assembly for
clamping the samplelbolt assembly and determining the initial and recovered angle.
The recommended device provides a scale, of 80 mm radius and graduated in degrees
around at least half its circumference, and a clamp capable of holding the sample cup
S4-XVII
JKRlSPJ/2008-s4
within 3 mm of its center and without deforming the cup by more than 3 mm in any
direction.
(d) Water bath capable of operating at 25 ± 0.5 ·C, fitted with an appropriate
thennometer.
Note: A suitable thennometer is an IP 39 C, or ASTM 90C, as specified in ASTM E 1.
(e) Forced convection oven - capable of operating in the range 60 °C to 200°C, with a
set point accuracy of ± 5 °e.
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(t) Stop-watch
(g) Spanner - to suit the bolt assembly.
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5.0 Procedure
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5.1 General
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PMBs are complex mixtures of polymers and a variety of petroleum products. If handled
in accordance with the directions of the suppliers, there should be no significant risk. The
hazard of bums with PMBs is greater th30 with st30dard bitumens, due to the (normally)
higher handling temperatures. It is recommended that notices, describing the action to be
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taken in the event of bitumen or PMB burns, should be displayed in the laboratory in the
areas where bitumen and PMBs are handled. A suitable warning could be as follows :
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WARNING: HOT BITUMEN & PMBs CAN CAUSE SEVERE BURNS
The following precautions should be taken when handling bitumen, or PMBs;

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(a) Eye protection, such ask safety glasses 3Odlor face shields, shall be worn when
h30dling hot bitumen or PMBs.
EN
(b) Heat-resistant gloves, with close-filling cuffs, and other suitable protective clothing,
shall be worn when handling hot bitumen or PMBs.
(c) There shall be no smoking while handling hot bitumen or PMBs.

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(d) While the material is still cold, loosen the lid of the sample container (invert the can
and warm the lid, if necessary), or punch a hole in the lid.
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(e) Examine the cold sample for the presence of water. If water is thought to be present,
drain most of it out, or blow with clean compressed air to evaporate the free water.
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5.2 Sample preparation
Samples for testing shall be provided in accordance with MBT 01 and MBT 02.
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5.3 Measurements
(a) Assemble the bolt, spider and nuts to position the surface of the bolt head 8 ± 2 mm
below the top of the sample cup.
(b) Preheat the assembly and cup to 180 ·C.
54-XVIII
JKRlSPJ/2008-S4
(e) Pour the modified binder into the cup assembly, until it begins to form a meniscus on
the top surface of the bolt.
(d) Allow the assembly to cool for one hour by leaving it to stand at room temperature
(25 ± 3°C). Adjust the assembly height to keep the top surface of the bolt flush with
the sample surface.
(e) Place the assembly into the 25 °C water bath and allow it to stabilise for one hour
(see Note I).
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NR!ti: The test should be conducted in an air conditioned laboratory at 25 ± 3 .. C. Alternatively,
the test can be conducted within the water bath.
(I) Adjust the spider to a position 7 ± 2 mm above the rim and return the assembly to the
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bath.
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(g) Place the sample assembly on the base-plate and fit the pointer to the 180 degree
position without disturbing the sample.
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(h) Using the spanner, turn the bolt moving the pointer from the 180 degrees position to
the zero position using a steady motion for 10 seconds (see Note 2).
Note 2: The rate at which the torque is applied to the sample is critical for reproducible results. The
objective is to apply 180 degrees of rotation in 10 seconds. A scale marked from zero (0 degree)
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to 10 (180 degrees) will help with this task.
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(i) Release the bolt when the pointer reaches the zero position and commence timing.
(j) Record the recovered angle after 30 seconds as A.

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6.0 Calculation
EN
The Torsional Recovery is given by the following equation;
Torsional Recovery, %= 100 Nl80

where A = recovered angle. in degrees.
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7.0
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Report the Torsional Recovery as the mean of two results. together with the Temperature
of the test and the Recovery Time.
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S4-XIX
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KERAJAAN MALAYSIA
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FOR ROAD WORKS
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• JALAN SULTAN SALAHUDDlN.
~ 50582 KUALA LUMPUR.
ACKNOWLEDGEMENT
This specification on Rubber Modified Asphalt has been prepared by a committee

consisting of engineers and specialists from Centre of Excellence for Engineering and
Technology (CREaTE), Cawangan Senggara Fasiliti Jalan (CSFJ) and Cawangan
Jalan (CJ), Public Works Department (PWD) Malaysia, and industrial players; their
cooperation is greatly acknowledged.
The members of the comittee involved in preparing the Standard Specification for
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Road Works - Section 4.16: Natural Rubber Modified Asphalt are:-
Authors:
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Ir. Mohd Hizam bin Harun CREaTE, PWD
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Ir. Syahida binti Aripin CREaTE, PWD
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Siti Nor Faizah binti Kamaruddin CREaTE, PWD
Contributors:
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Ir. Sufiyan bin Zakaria CSFJ , PWD
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Roziawati binti Razali CJ, PWD

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The members of the comittee involved in preparing the Standard Specification for
Road Works - Section 4.17: Crumb Rubber Modified Asphalt are:-
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Ir. Mohd Hizam bin Harun CREaTE, PWD

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Ir. Syahida binti Aripin CREaTE, PWD

Siti Nor Faizah binti Kamaruddin CREaTE, PWD
0
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Nafisah binti Abdul Aziz Roadcare (M) Sdn. Bhd.

Wan Radhiah binti Wan Hanafi Roadcare (M) Sdn. Bhd.
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Prof. Cao Rongji RH & JSTI (M) Sdn. Bhd.

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Chen Gang RH & JSTI (M) Sdn. Bhd.

Johan Leslie Hare Abdullah Questech (M) Sdn. Bhd.
The committee would also like to thank all other individuals who had contributed
towards the successful completion of this specification.
IKRiSPl120 19-54
RUBBER MODIFIED ASPHALT
~
4.16 NATURAL RUBBER MODIFIED ASPHALT
4.16.1 DESCRIPTION S4.16- 1
4.16.2 MATERIALS S4.16-1

a) Aggregates S4.16- 1
b) Mineral Filler S4 .16-2
c) Natural Rubber Modified Binder S4 .16-3
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4. 16.3 NATURAL RUBBER S4.16-3
a) Natural Rubber Latex S4.16-3
b) Dry Natura l Rubber S4.16-3
c) Properties of Natural Rubber S4 .16-4
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4 .16.4 PREPARATION OF NATURAL RUBBER MODIFIED S4.16-5
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a) Blending Natural Rubber Latex into Bitumen S4.16-6
( b) Blending Dry Natural Rubber into Bitumen S4. I 6-6
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c) Completion of Blending S4. I 6-7
d) Storage of Natural Rubber Modified Binder S4.16-7
e) Application of Natural Rubber Modified Binder S4.16-7
4. 16.5 MIX DESIGN S4.16-8

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a) Job Mix Formula S4.16-8
b) Plant Trials S4.16-11
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c) Compliance with the Job Mix Formula S4.16-12
d) Sampling and Testing of Natural Rubber Modified Asphaltic S4 .16-13
Concrete
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4.16.6 EQUIPMENT S4 .16-13

a) Road Cleaning Equipment S4.16-14
b) Asphalt Mixing Plant S4.16-\4
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c) Batch Plant S4.16- 15

d) Drum Mix Plant S4.16-16
e) Tip-Trucks S4.16- 17
f) Asphalt Paver S4.16- 17
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g) Rollers S4.16- 18
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4 .16.7 CONSTRUCTION METHODS 84.16-19
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a) General Conditions S4.16- 19

b) Surface Preparation and Cleaning S4.16- \9
c) Aggregate Handling and Heating S4.16- 19
d) Heating Natural Rubber Modified Binder S4.16-20
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e) Mixing Natural Rubber Modified Asphaltic Concrete S4.16-20

f) Transporting Natural Rubber Modified Asphaltic Concrete S4.16-21
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g) Laying Natura l Rubber Modified Asphaltic Concrete S4.16-21

h) Construction Joints S4.16-22
i) Compacting Natural Rubber Modified Asphaltic Concrete S4. I 6-22
j) Finished Natural Rubber Modified Asphaltic Concrete S4.16-23
k) Opening to Traffic S4.16-24
JKRlSPJI20 19-S4
4.17 CRUMB RUBBER MODIFIED ASPHALT
4.17.1 DESCRIPTION S4.17-1
4.17.2 MATERIALS S4.17-1

a) Aggregates S4.17-1
b) Mineral Filler S4.17-3
c) Crumb Rubber Modified Binder (CRMa) S4.17-3
4.17.3 PREPARATION OF CRUMB RUBBER MODIFIED BINDER S4.17-5
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(CRMB)
a) Blending Equipment S4.17-5
b) Blending Process S4.17-5
c) Fonnulation S4.17-6
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d) Completion of Blending S4.17-6
e) Sampling ofCRMB S4.17-7
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f) Storage of CRMB S4.17-7
g) Application ofCRMB S4.17-7
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4.17.4 CRUMB RUBBER - STONE MASTIC ASPHALT (CR-SMA) AND S4.17-8
CRUMB RUBBER - GAP GRADED ASPHALT (CR-GGA)
a) Mix Design S4.17-8
b) Construction Equipment S4. 17-13
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c) Construction Method S4. 17-14
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4.17.5 CRUMB RUBBER - OPEN GRADED FRICTION COURSE S4.17-16
(CR-OGFC)
a) Mix Design S4.17-16
b) Construction Equipment S4.17-19
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c) Construction Method S4.17-19
4.17.6 CRUMB RUBBER - STRESS ABSORBING MEMBRANE S4.17-23

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INTERLAYER (CR-SAMI)
a) Equipment S4.17-23
b) Construction Method S4 .17-24
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APPENDIX A Binder Drain-Down Test S4.17-26

APPENDIXB Schellenberg Binder Drainage Test S4.17-29
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APPENDIXC Cantabro Test S4.17-31

APPENDlXD Semi-Circular Bend (SCB) Test S4.17-32
APPENDIX E Hamburg Wheel-Tracking Test S4.17-37
APPENDIXF Water Permeability Test of Asphalt Mixtures S4.17-44
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JKRISP J120 19-54
4.16 NATURAL RUBBER MODIFIED ASPHALT
4.16.1 DESCRIPTION
This work shall consist of furnishing, plac ing, shaping and compacting natural rubber
modified asphalt (hereinafter referred to as asphaltic concrete) wearing course on a
prepared and accepted bituminous pavement course, and shall include careful and
thorough cleaning of surfaces which are to be covered prior to the application of
bituminous tack coat. The work shaIl be carried out all in accordance with this
Specification and the lines, levels, grades, dimensions and cross-sections as shown on
the Drawings and/or as required by the S.O.
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Natural rubber modified asphaltic concrete is a mixture of continuously graded
aggregate and natural rubber modified binder. The binder is produced by incorporating
an appropriate quantity of natural rubber into the conventional bitumen.
D
4.16.2 MATERIALS
N
( aJ Aggregates
TE
Aggregates for natural rubber modified asphaltic concrete shall be a mixture of coarse
and fine aggregates, and mineral filler. The individual aggregate shall be of sizes
suitablc for blending to produce the required gradation of the combined aggregates, all
to the satisfaction of the S.O.
A
Coarse aggregates shall be screened crushed hard rock, angular in shape and free from
EJ
dust, clay, vegetative and other organic matter, and other deleterious substances. They
shaIl conform to the following physical and mechanical quality requirements;
M
i) the Los Angeles abrasion value when tested in accordance with ASTM C 131
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ii) the weighted average loss of weight in the magnesium sulfate soundness test
(5 cycles) when tested in accordance with AASHTO Test Method T 104 shall
iii) the flakiness index when tested in accordance with MS 30 shall be not more
M
( than 25%.
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iv) the water absorption when tested in accordance with MS 30 shall be not more
than 2%.
v) the polished stone value when tested in accordance with MS 30 shall be not
less than 40.
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Fine aggregates shall be clean screened quarry dusts. Other types of fine aggregate may
D
be used subject to the approval of the S.O. Fine aggregates shall be non-plastic and free
from claY,loam, aggregation of material, vegetative and other organic matter, and other
54 . 16-1
)KRlSP)/2019-S4
i) the sand equivalent of aggregate fraction passing the No.4 (4.75mm) sieve
ii) the fine aggregate angu lari ty when tested in accordance with ASTM C 1252
iii) the Methylene Blue value when tested in accordance with Ohio Department
of Transportation Standard Test Method shall be not more than 10 mglg.
iv) the weighted average loss of weight in the magnesium sulfate soundness test
(5 cycles) when tested in accordance with AASHTO Test Method T 104 shall
ER
v) the water absorption when tested in accordance with MS 30 shall be not more
than 2%.
D
aggregates shall not be permitted.
N
The gradation of the combined coarse and fine aggregates and mineral filler, shall o
TE
confoorn to the appropriate envelope shown in Table I.
Table J Combined aggregate gradation for asphaltic concrete

A
Mix Designation ACIO AC 14
BS Sieve Size, mm Percentage Passing (by weight)
EJ
28.0 - -
20.0 - 100
14.0 100 90-100
M
10.0 90 - 100 76-86

5.0 58-72 50-62
3.35 48-64 40-54
EN
1.18 22-40 18-34

0.425 12 -26 12-24
0. 150 6-14 6-14
0.075 4-8 4-8
o
M
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design mix gradation which shall consist of a single definite percentage passing for
each sieve size in Table I and shall produce a smooth curve within the appropriate
gradation envelope. This job laboratory design mix gradation, with the allowable
tolerances for a single test as specified in sub-section 4.16.5 (c), shall then become the
job standard mix or job mix formula.
O
D
b) Mineral Filler
be hydrated lime (calcium hydroxide). At the time of mixing with bitumen, it shall be
sufficiently dry to flow freely and shall be essentially free from agglomerat ions. Not
less than 70% by weight shall pass the BS 75 ~m sieve. The total amount of mineral
S4.16-2
JKRlSP J/20 19-54
filler shall be approximately 2% by weight of the combined coarse and fine aggregates.
The mineral filler shall also be treated as an anti-stripping agent.
If hydrated lime is not available, ordinary Portland cement shall be used as an

alternati ve, subject to approval by the 5.0 .
c) Natllral Rllbber Modifie<1 Billder
Natural rubber modified binder shall be of performance grade PO 76 or higher in

compliance with AASHTO Standard M320-02. This premium grade binder shall be
produced by pre-blending conventional bitumen, penetration grade 60 - 70 wh ich shall
ER
conform to MS 124, with an appropriate quantity of natural rubber.
4.16.3 NATURAL RUBBER
D
Natural rubber shall be the material extracted from rubber trees. It shall be either in the
N
form of natural rubber latex or dry natural rubber.
(
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a) Natllrlll Rllbber Latex
Natural rubber latex is a sticky, milky colloid obtained by tapping rubber trees. The
latex is collected before it coagulates and transferred into air-tight containers with
A
sieving for ammoniation. The arnmoniation is necessary to preserve the latex in a
colloidal state for longer periods of time. Natural rubber latex shall be either
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centrifuged latex which has a minimum rubber content of 60% or evaporated latex
which has a higher rubber content.
M
b) Dry Natural Rllbber
Dry natural rubber is natural rubber latex that has dried. A fter tapping the rubber trees,
EN
the latex will drip for usually about four hours into a cup and will stop as the latex
coagulates naturally on the tapping cut. After the liquid latex is collected from the cup,
some trees will continue to drip and this leads to a small amount of ' cup lump' which
is collected at the next tapping. The latex that coagulates on the tapping cut is also
collected as 'tree lace'. Rubber collected by small holders and coagulated by any means
M
( is called 'smallholders' lump' . Latex that drips onto the ground is collected too as 'earth
scrap'. The following paragraphs describe the four types of dry natural rubber;
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i) Cup Lump
Cup lump is the coagulated latex found in the collection cup when the tapper
O
next visits the tree to tap it aga in. It arises from latex clinging to the wall of
the cup after the liquid latex was last collected, and from late-dripping latex
before the latex coagulates on the cut, or from latex which is purposely left to
D
coagulate in the cup and collected on the following day. It is of higher purity
and of greater value than the other three types.
ii) Tree Lace
Tree lace is the latex that has coagulated on the tapping cut that the tapper
peels off the previous cut before making a new cut. It usually has higher
S4. 16-3
JKRlSP J/20 19-54
copper and manganese contents than cup lump. Both copper and manganese
are pro-oxidants and can lower the physical properties of the natu ral rubber.
iii) Smallholders' Lump
Smallholders' lump is produced by smallholders who collect rubber from

trees far away from the nearest factory. As it is often impossible to preserve
the latex sufficiently to get it to the factory that processes latex in time for it
to be used to make high quality products, and as the latex would anyway have
coagulated by the time it reaches the factory, the smallholder will coagulate
it by any means avai lable, in any container like small buckets. Often the latex
is coagulated in holes in the ground, which are usually lined with plastic
ER
sheeting. Acidic materials and fermented fruit juices are used to coagulate the
latex, a fonm of assisted biological coagulation. Little care is taken to exclude
leaves, barks etc. from the lumps that are fonmed .
D
iv) Earth Scrap
N
Earth scrap is the latex that gathers around the base of the tree. It arises from
latex overflowing from the cut and running down the bark of the tree, from
o
TE
rain flooding a collection cup containing latex, and from spillage from tappers
buckets during co llection. It contains soil and other contaminants, and has
variable rubber content, depending on the amount of contaminants mixed
with it. Earth scrap is collected by the field workers two or three times a year
and will be cleaned to recover the rubber. However, the product is of very low
A
quality.
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Of the fou r types of dry natural rubber described above, only cup lump shall be allowed
to be used as additive to bitumen. However, of the two forms of natural rubber
described above, latex is the most effective additive to bitumen. Whether natural rubber
latex or dry natural rubber cup lump is used as additive to bitumen, the modified binder
M
shall comply with performance grade PO 76 or higher in compliance with AASHTO

Standard M320-02.
EN
cj Properties of Natllral RlIbber
Natural Rubber Latex
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Natural rubber latex shall be a sticky, milky colloid obtained from rubber trees. Initially
when collected after tapping the rubber tree, the latex usually contains 30% dry rubber
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and 70% water. It shall be collected before it coagulates and shall then be transferred
into air-tight containers with sieving for ammoniation whereby an ammonia solution
shall be used to preserve the latex in a colloidal state for longer periods of time. The
latex shall then be processed into high quality latex concentrate by centri fugation or
O
evaporation. The dry rubber content of the latex shall be not less than 60%. The latex
shall be of low ammonia with a maximum ammonia content of 0.3%. The complete
requi rements for the natural rubber latex are shown in Table 2.
D
S4. 16-4
JKRlSPJI2019-S4
Table 2 Properlies ofnalural rubber lalex

Characteristic Requirement Test Specification
Total solid content, % by mass, min. 61.5 ISO 124
Dry rubber content, % by mass, min. 60.0 ISO 126
Coagulum content, % by mass, max. 0.03 ISO 706
Ammonia content, % by mass, max. 0.3 ISO 125
Mechanical stability time (MST) 650 ISO 3S
@l55% TSC, seconds, min.
The Contractor shall submit full technical details of the natural rubber latex and obtain
the s.o.'s approval ofthe material prior to the commencement of works.
ER
Natural Rubber Cup Lump
D
Natural rubber ·cup lump, for use as bitumen additive, shall be produced through
stringent quality control of the raw cup lump collected from the plantations. The
production shall involve clean ing, size reduction via wet pre·breaker, creeper and
N
( shredder, and drying. The requirements for the processed natural rubber cup lump are
shown in Table 3.
TE
Table 3 Properties of nalural rubber cup lump
Characteristic Requirement Test
A
Specification
Dirt retained on 44 aperture, % by mass, max. 0.16 ISO 249
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Ash content, % by mass, max. 1.00 ISO 247
Nitrogen contenl, % by mass, max. 0.60 ISO 1656
Volatile matter content, % by mass, max. 0.80 ISO 248-1
Wallace rapid plasticity (Po), min.
M
30 ISO 2007
Plasticity retention index (PR!), %, min. 40 ISO 2930
The Contractor shall submit full technical details of the processed natural rubber cup
EN
lump and obtain the S.O.'s approval of the material prior to the commencement of
works.
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4.16.4 PREPARATION OF NATURAL RUBBER MODIFIED BINDER

(
Natural rubber shall be pre-blended with conventional bitumen before mixing with
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the aggregate in the asphalt mixing plant. The Contractor shall either provide a
blending equipment system or tank close to the asphalt mixing plant whereby natural
rubber modified binder can be manufactured on site, or shall obtain natural rubber
modified binder from an approved source which is referred to as terminal blend. The
O
terminal blend shall be transported in a well insulated tanker, and transferred into a binder
storage tank at the asphalt mixing plant as described below. In either case, the
D
Contractor shall provide a binder storage tank equipped with a suitable mechanical
agitator close to the asphalt mixing plant. This tank shall also include distribution and
circulation pipes that are properly insulated or heated. Continuous agitation of the
binder during prolonged storage is essential to prevent separation . A suitable
sampling point shall be provided at a convenient point in the storage tank system for
taking samples . Samples shall be taken after prolonged storage or at any other
S4.16-5
JKRlSPJI2019· S4
circumstances deemed necessary by the S.O. and tested for the properties as shown in
Table 5 at an approved laboratory. Sampling shall be done in accordance with MS 539.
The blending equipment system or tank shall be of adequate capacity which will allow
for at least 50% increase in volume when natural rubber, in particular natural rubber
latex, is added. It shall be fitted with piping inside for heating with hot oil that are
capable of raising the temperature of the bitumen to a maximum of 200'C. The tank
shall be insulated with a minimum of 75 mm thick rockwool and aluminium cladding.
The tank shall also be equipped with a mechanical agitator, either a paddle wheel type
which will sweep the natural rubber down through the depth of the tank or a propeller
type stirrer which will create a vortex, drawing the natural rubber down into the body
of the bitumen. Either type of ag itator shall be able to produce a homogenous bitumen
ER
- natural rubber blend.
aJ Blellllirrg Natural Rubber Latex inlo Bittlmell
D
Natural rubber latex has a water content of up to 40% which will cause foaming,
N
irrespective of whether it is first added to cold bitumen which is then heated, or whether
it is added to bitumen already heated to above the boiling point of water. o
TE
Bitumen shall be heated to a temperature of 150 - 170' C. Natural rubber latex shall be
added gradually into Ihe blending equipment system or tank, through a pump and spray
or through a sprinkler system or poured manually, at an appropriate rate so as not to
cause excessive foaming. Whichever method is used, the natural rubber latex shall fall
A
gently onto the surface of the bitumen and not splash into the bitumen. It shall be
allowed to float on the bitumen surface for about 20 seconds to allow its constituent
EJ
water to evaporate (flash oft) before being drawn into the bitumen by the mechanical
agitator. It should not float on the surface for a longer period as, once the water has
evaporated, coagulation will start and a lumpy mixture result. When the intensity of
foaming has been gauged, the remainder of the natural rubber latex shall be added as
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fast as seems desirable to ensure that the foaming is not too great for the capacity of
the blending tank, and agitated vigorously into the bitumen. As long as the latex is
added slowly and the degree of foaming assessed, there will be no danger of the
EN
bitumen foaming over. Alternatively, anti·foaming agent shall be used as approved by

the S.O ..
Stirring shall be continued for a minimum period of20 minutes after complete addition
o
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of the natural rubber latex. After blending is complete, the natural rubber modified
binder shall be allowed to cool to below 120'C but with continuous stirring unless it is
to be used immediately. After storage, the binder shall be heated to a temperature of
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150 - 170'C before use.
b) Blending Dry Na/llral Rnbber ill/o Bitllmell

O
Bitumen shall be heated to a temperature of 150 - 170' C. Dry natural rubber shall be
D
dispersed over the surface of the bitumen in a thin layer. It is then drawn into the
bitumen by the mechanical agitator. Further dry natural rubber shall be added when the
previous thin layer has been drawn down away from the surface.
S4. 16·6
1K RlSP1120 19-54
c) CompletioJ/ of Blelldillg
Blending shall be deemed 10 be complete when a small drop of natural rubber modi fied
binder from the tank, placed on an impervious surface, shows only a few specks of
rubber which are soft enough to be spread into the binder by a knife or spatula. If the
rubber particles still preserve their entity and cannot be rubbed away into the binder,
blending is considered incomplete and further heating and agitation are necessary.
d) Storage of Natl/Till RI/bber Modified Billder
The natural rubber molecule consists of a very long chain of many isoprene units which
ER
can be broken into several smaller ones by various processes; the natural rubber is said
to be degraded or broken down chemically. Heating is one of the processes which lead
to degradation of natural rubber. It degrades with time at high temperatures. It is
recommended that the effective rubber content should not be allowed to drop below
D
about half of the original rubber content added to ensure that the extent of degradation
of the natural rubber modified binder will not significantly affect the properties of the
N
asphaltic concrete. Therefore, it is recommended that the binder after blending is
( complete shall not be stored at elevated temperatures for longer than the periods shown
in Table 4 as given in Road Research Laboratory Road Note 36. The total storage time
TE
allowable at different temperatures shall be calculated as follows; after storage at one
temperature, the allowable storage time at any subsequent temperature sha ll be reduced
by the following ratio;
Time at first temperature
A
Time allowable at first temperature
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Table 4 Allowable storage time for natural rubber modified binder

Temperature Storage Time
M
(OC) (hours)
200 I
180 3
EN
160 12
140 48
120 or below' 7 days
Ambient Indefinitely
M
(
e) Applicatioll of Natl/ral RI/bber Modified Billder
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At the time of application, the rubber additive shall be thorough ly dissolved in and
dispersed unifonmly throughout the bitumen without any coagulation of the rubber
particles or the presence of undissolved lumps.
O
The properties of the natural rubber mod ified binder shall be as given in Table 5.
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I Above ambient lemp erotures.
S4.16-7
lKRlSPl/20 19-54
Table 5 Properties of natural rubber modified binder

Test I Reauirement Test Specification
Natural rubber modified binder prior to rolling thin film oven test (RTFOT)
lViscos ity, max. 3 Pa.s,
135' ASTM D4402
test temperature 'C
'Dynamic shear, G'/sin Ii
min, 1.00 kPa, 10 radis, 76 AASHTO T 315
test temperature °C
' Penetration, 100 g, 5 s, 25 ' C, 0, I mm Report' ASTMD5
4Ring and ball softening point, min. °C Report' ASTM D36
ER
4Flash point, min. °C 230 AASTHOT48
Natural rubber modified binder after RTFOT (AASHTO T 240) or ASTM D
2872
AASHTO T 240 or
D
lMass Joss, max. % 1.00
ASTM D2872
3Dynamic shear. G*/sin 5
N
min, 2,20 kPa, 10 radis,
test temperature 'C
76 AASHTOTJI5
o
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the natural rubber modified binder, The temperatures to which the natural rubber
modified binder must be heated to produce a viscosity of 0,2 Pa.S shall be the mixing
temperatures, The temperatures to which the natural rubber modified binder must be
A
heated to produce a viscosity of2 - 20 Pa,S shall be the compaction temperatures,
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4.16.5 MIX DESIGN

M
oj Job Mix Formula
The Contractor shall propose a job mix formula for each type of mix required in the
Works, In order to obtain optimum quality of the mixtures, the job mix formula for
EN
each type of mix shall be prepared on the basis of testing several laboratory design mix
gradations within the limits set in Table I at an appropriate range of natural rubber
modified binder content. As a guide to the testing range ofthe binder content, the design
binder content will usually be in the range given in Table 6,
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Table 6 Range of design binder contents

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AC 10 - Wearing Course 5,5 -7.5%

AC 14 - Wearing Course 4.5 - 6.5%
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2 rhe requirement may be u'oived at the discretion of the s.o. if the supplier warrants that Ihe natllral rubber
modified binder can be adeqllately pumped alld mixed at Ihe temperatllres 'hat meet all applicable safety standards.
J These tesls shall be carried 0111 as and IIIhe" required by the S.o. bUI shall he not lesslhan one tesl per 30 lOllS of
binder produced or at leasl once per projecl iflhe lolal quantity a/binder produced is less Ihall 30 Ions. The
binder samples shall he taken immediately prior to the production of asphalt. Tesf/requency may he reduced if test
results consistently conJorm to the requirements.
4 These tests shall he carried alii minimum once Jor each blendlllg process for quality control purposes during
blending atlhe asphalt mixing plant or terminal blending.
S The pellelration and softening point values shall be taken as reference for consfstency check on the production.
S4,16-8
JKRlSPJnOI 9-S4
Each combination of laboratory design mix aggregate gradation and binder content
shall be subject 10 the Marshall test procedure and volumetric analysis as follows;
i) Preparation of Marshall specimens for the standard stability and flow test in
accordance with ASTM D 1559 using 75-blows/face compaction standard at
compaction temperature as determined from the above viscosity-temperature
relationship,
ii) Determination of the bulk specific gravity of the specimens in accordance

with ASTM D 2726,
iii) Determination of the stability and fl ow of the specimens in accordance with
ER
ASTM D 1559,
iv) Analys is of the specific grav ity and air voids parameters to determine the
percentage air voids in the compacted aggregate, the percentage air voids in
D
the compacted aggregate filled with the binder and the percentage air voids
in the compacted mix.
N
( For each laboratory design mix gradation, four Marshall specimens shall be prepared
TE
for each binder content within the range given in Table 6' at increments of 0.5 percent,
in accordance with ASTM D 1559 using 75 blows/face compaction standard. All binder
contents shall be in percentage by weight of the total mix.
As soon as the freshly compacted Marshall specimens have cooled to room

A
temperature, the bulk specific gravi ty of each specimen shall be determined in
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The stability and flow value of each specimen shall then be determined in accordance
with ASTM D 1559.
After the completion of the stability and flo w test, specific gravity and voids analysis
M
shall be carried out for each specimen to determine the percentage air voids in the
compacted aggregate filled with binder (VFB) and the percentage air voids in the
compacted mix (VIM).
EN
M
( The mean values of bulk specific gravity, stability, flow, VFB and VIM obtained above
shall be plotted separately against the binder content and a smooth curve drawn through
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the plotted values.
The mean optimum binder content shall be determined by averaging five optimum
binder contents so determined as follows;
O
i) Peak of curve taken from the stability graph',

D
ii) Flow equals to 3.5 mm from the flow graph,
, The rOllge ofbil1der content shall be extended ijl1 ecessory to ensure thaI the curves of sta bility alld bulk specific
gravity have their peak within Ihe rallge selected.
1 Where the sta bility curve exhibits more Ihan olle peak, Ihe binde,. con/enl chosen/or tire de termina tion o/tlre mean
optimum binder content shall be the one which satisfies the voids requirements beller. It is sometim es necessary
where no peak sta biliry is o b tained. to pr epare and lest slipplementary specimens at in tervals 0/0.25% binder conlem
on either side o/the expected optilllum.
S4. 16-9
JKRlSPJ/2019-S4
iii) Peak of curve taken from the bulk specific gravity graph',
iv) VFB equals to 7S .0% from the VFB graph, and
v) VIM equals to 4.0% from the VIM graph.
The individual test values at the mean optimum binder content shall then be read from
the plotted smooth curves and sha ll comply with the design parameters given in Table
7.
If any of the values ·does not comply with Table 7, the mix design procedure shall be
repeated using a different aggregate gradation until all design parameters are satisfied.
ER
Table 7 Test and analysis parameters for natural rubber modified asphaltic concrete
Parameter Requirement
D
Stability (S) > 13,000 N
Flow (F) 2.0 - S.0mm
N
Stiffness (S/F) > 2,600 N/mm
TE
Voids in mix (VIM) 3.0 -S.0%
Voids in aggregate filled 70-80%

with bitumen (VFB)
A
Additional eight Marshall specimens shall be prepared using the same aggregate
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gradation and compaction effort, with the mean optimum binder content established
during the mix design stage. Four of these specimens shall be tested for resilient
modulus and another four specimens for dynamic, unconfined, compressive creep as
described below;
M
i) Indirect tensile test for resilient modulus (ASTM D 4(23)

EN
Total resilient modulus > 3,000 MPa
Test temperature 2S·C

Applied load 20 N/mm of specimen thickness
o
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(max. I ,SOO N)
Loading freq uency I Hz
Loading time 0.1 s
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Rest period 0.9 s

Rise time 70ms
Poisson's ratio O.3S
No. of preconditioning pulses SO
O
No. oftest pulses S

Rotation of specimen 90·
D
Report mean value of total resilient modulus (ERT) from two al ignments
(rotation). Disregard test result ifERT values for the same test specimen
differ by more than 10% from the mean value .
• With highly absorpUw aggregates. some difficulty in determining peak bulk specific gravity may occur. In s/lch
cases, the hinder content at which the increase in bulk specific gravity shows a marked falling off shal/ he adopted.
S4.16-I O
JKRlSPJ/2019-S4
ii) Dynamic, unconfined, compressive creep test (EN 12697-25)
Dynamic creep modulus > 75 MPa

Slope at steady state < 0.25
Pre-conditioning;
Loading time 0.2 s
Rest period 1. 8s
No. of load cycles 30
ER
Testing;
D
Loading time 0.2 s
N
Rest period 1.8 s
( No. of load cycles 3,600
TE
Report dynamic creep modulus and slope at steady state, the latter shall
be log strain divided by log load cycles between 2,000 and 3,600 load
cycles.
A
b) Plant Trials
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After having received the S.O. preliminary approval of his proposed job mix formula,
the Contractor shall arrange to mix, lay and compact natural rubber modified asphaltic
concrete confonning to the proposed formula for each type of mix required in the
M
Works. A minimum of20 tons of the mix shall be placed in trial areas to demonstrate
to the satisfaction of the S.O. that the mixing, laying and compacting equipment
conforms to the requirements of this Specification, and that the proposed mix is
EN
satisfactory. The trial areas shall not be part of the Contract Works but shall be
provided by the Contractor at his own expense. The proposed trial area shall be
approved by the S.O ..
M
As di rected by the S.O., comprehensive sampling and testing of the mix shall be carried
( out to check for satisfactory compliance with its job mix formula, and for a satisfactory
degree of compaction. In order to demonstrate to the satisfaction of the S.O. that
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mixing, laying and compacting equipment conform to the requirements of the

specification, and that the proposed mix is satisfactory, the following observations and
tests shall be carried out.
O
i) Record the type and weight of rollers. Check the tyre pressure of the
pneumatic tyre roller (shall comply with sub-section 4.16.6 (g».
D
ii) Record the type of paver (shall comply with sub-section 4. 16.6 (I).
iii) Check that the trial area is suitable (not on soft ground, uneven surface or
actual contract site).
iv) Take samp le of the mix and carry out the following tests;
54 .16- 11
JK RlSPJI20 19-S4
• Binder content and aggregate grading (shall comply with sub-section

4.16.5 (e)).
• Preparation of Marshall specimens,
• Bulk specific gravity of Marshall speci mens.
• Volumetric properties of Marshall specimens (shall comply with
Table 7).
• Marshall stability and flow (shall comply with Table 7).
• Resilient modulus .
• Dynamic, unconfined, compressive creep.
v) Record temperatures of mix on the lorry, at plant and site (sha ll not exceed
ER
180"C at any time and shall be not less than 150"C immediately before
unloading into the paver hopper).
vi) Record laying (uncompacted) thickness.
D
vi i) Check texture of paved surface before rolling (there shall be no substantial
blemishes and irregularities).
N
viii) Record temperatures immediately before rolling starts (rolling lemperatures) o
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ix) Record rolling pattern.
x) Check texture of compacted surface.

A
xi) Cut core samples a fter the laid material has sufficiently hardened (at least
three samples from each lorry load).
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xii) Record compacted thickness and density from core samples (shall comply
with sub-section 4.16.7 (i» .
M
As a result ofthe plant trials, the S.O. may require amendments to the job mix formula,
further tests and analysis, and additional plant trials.
EN
Upon satisfaction by the S.O., the Contractor shall be required to produce a full report
of the plant trial and this document shall be used in full scale production in the Works.
,.i,,, '''e Job Mix Formula

o
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cJ Compliance
The S.O. final approval of the job mix formula shall bind the Contractor to produce
KU
natural rubber modified asphaltic concrete mixes conforming to the prec ise gradation
and binder content specified in the formula within the tolerances set forth in Table 8
and using natural rubber modified binder that consistently comply with the properties
as specified in Table 5.
O
Modifications to the job mix formula shall only be made with the approval of the S.O.
D
Should the S.O. at any time have reasons to believe that the materials and methods of
mixing and laying are different from those approved, he shall so advi se the Contractor
and may instruct that natural rubber modified aspha ltic concrete works be di scontinued
pending further plant trials and testing.
S4. 16- 12
JKRlSPJI20 19-S4
Table 8 Tolerances f or natural rubber modified asphaltic concrete
Permissible Val'iation
Parameter
% By Weight of Tota l Mix
Binder content ± 0.2%
Fractions of combined aggregates ±5.0%

passing 5.0 mm and larger sieves
Fractions of combined aggregales ±4.0 %

passing 3.35 mm and 1.1 8 mm sieves
ER
Fractions of combined aggregates ±3.0 %
passing 425 I'm and 150 I'm sieves
Fractions of combined aggregates ± 2.0 %
D
passing 75 I'm sieve
N
( d) Samplillg ami Testillg of NallIral Rubber Moclified Asphaltic COllcrete
TE
Frequency of sampling and testing shall be not less than that shown in Table 9. It
provides fo r two levels of m inimum frequency. The reduced frequency may only be
adopted if the test results consistently confonn to the requirements.
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Table 9 Frequency ofsampling and testing of nalliral rubber modified asphaltic
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concrete
Test Normal Min imum Reduced Minimum

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Frequency Frequency
Binder content, One test per 200 tons One test per 300 tons
aggregate gradation, asphalt plant production. asphalt plant production .
stabili ty, flow, VIM and
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VFB
These tests shall be carried out as and when required by
the S.O. but shall be not less than one test per 1,000 tons
Resilient modulus and
of asphalt produced or at least once per project if the
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dynamic, unconfined,
( compressive creep
quantity of as phalt produced is less than 1,000 tons. Test
frequency may be reduced if test results consistently
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conform to the requirements.

Temperature Each loaded tip-truck. Each loaded tip-truck.
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4.16.6 EQUIPMENT
The Contractor shall provide all the plant and equ ipment necessary for executing the
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work in accordance with this Specification and shall furnish the S.O. wilh such detai ls
of particular items of equ ipment, e.g. manufacturer, model type, capac ity, weight,
operating features, etc., as the S.O. shall require.
S4. 16- 13
JKRlSPJ/20I 9-S4
a) Road Cleaning Equipmellt
Immediately prior to applying bituminous tack coat, the full width of th e surface to be
treated shall be swept using a power broom followed by a compressed air blower, and
if necessary, scraped using hand tools, to remove all dirt, dust and other objectionable
material, all to the satisfaction ofthe S.O.
b) Asplwll Mixillg Plalll
The asphalt plant shall be either a batch plant or a drum mix plant of recognised
manufacturer and shall be approved by the S.O. It shall conform to the requirements
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described hereunder.
The mi xing plant shall have a capacity suited to the Works and sufficient to enable the
paver to operate more or less continuously when paving at normal speeds at the
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required thicknesses. The plant shall be designed so as to enable consistent production
of natural rubber modified asphaltic concrete mixes within the tolerances prescribed in
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this Specification, all to the satisfaction of the S.O.
o
TE
Mixes produced and delivered shall have actual tonnages of aggregates, filler and
binder components recorded. The temperature of the mix leaving the plant shall be
recorded for each batch or every 15 minutes. Where the control system incorporates a
computer and a printer capable of printing the information, copies of the printouts shall
be provided to the S.O. for quality assurance.
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Tanks for storage of binder shall have a capacity suited to the proposed rate of
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utilizations of the material and the method and frequency of its delivery to the Works,
all to the satisfaction of the S.O. The tanks shall be provided with means of measuring
the volume of their contents at all times and of drawing off samples of the contents.
The binder feeding system shall provide for continuous circulation of hot binder
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through the system and back into the feed tank. The end of the return line discharging
into the feed tank shall always be kept submerged in the binder in the tank in order to
prevent oxidation of the returning hot binder. The storage tanks, and where necessary
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barred decanters, and all elements ofthe binder feeding system shall be equipped with
heating system or insulating jackets as necessary to provide for effective and positive
control of the temperature of the binder at all times up to the temperature required for
utilizations. The method of heating shall be such that neither flames nor the products
of combustion shall come into direct contact with the binder or the casing of its
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immediate container, and such that no portion of the binder shall be subject to
overheating.
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Calibration of the plant load cells to an accuracy of ± I % error must be carried out
before the production ofthe trial mixes. This cal ibration is to test the integrity of all the
weighing system of the aggregate bins, filler hoppers and binder hopper.
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Temperature-measuring equipment, such as thermometers or electrical thennocouples.

providing temperature measurements of plant processes and materials, shall also be
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calibrated accordingly.
calibration is set and mixes production commence. calibration procedures shall be
repeated every 30,000 tons or one month whichever is earlier.
S4 . 16-14
JKRlSPJ120 19-54
c) Blitch Plllllt
The plant shall be provided with accurate mechanical means for unifonnly feeding the
aggregate into the dryer so that unifonn production and temperature of the heated
aggregate will be obtained. A separate feed bin with an adjustable gate opening shall
be provided for each aggregate to be included in the combined aggregate for the mix;
nonnally four bins will be required . The feed bins and gates shall be constructed and
equipped that they shall be readily accessible for calibrating at all times, and shall
provide for a continuous and unifonn flow of each aggregate required in the mix.
The plant shall have a rotary drum dryer of satisfactOl), design for drying and heating
the combined aggregate so that its temperature will be at the required level at the time
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it is mixed with the bitumen. The burner shall be so designed that complete combustion
of the fuel will be obtained, and the aggregate will remain clean and not become coated
with soot or oil.
The plant shall be equipped with four (or more) screens, the smallest of which shall
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generally be not more than 3.2 mm. The screens shall have a nonnal capacity slightly
in excess of the maximum output of the mixing plant. The screens shall be readily
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( accessible for inspection.
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The plant shall include four (or more) storage bins for screened aggregates, each with
a capacity of not less than twice the pugmill dead load capacity. The bins shall be
arranged so as to provide separate dry storage for each screened fraction of the
aggregate. Each bin shall be provided with an overflow pipe of such size and location
as to prevent any backing up of material into other bins. Each bin shall be so constructed
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that representative aggregate samples can be readily obtained, and shall have means for
observing the aggregate level. Separate dry storage shall be provided for mineral filler,
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and the plant shall be satisfactorily equipped to feed filler into the mixer.
Accurate means of weighing by load cells shall be provided for weighing the aggregates
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and filler and also for weighing the bitumen required for each batch of mix.
Suitable means shall be provided for maintaining the prescribed temperature of the
bitumen in the pipelines, weigh bucket of flow meter, and spray bars.
EN
An annoured thermometer with a range of 30'C to 200'C shall be fitted in the bitumen
feed line at a suitable location near the discharge valve at the mixer unit. Suitable dial-
scale mercury actuated thermometer, electric pyrometers or other thermometer
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( instruments shall be fitted at the discharge chute ofthe dryer and in each hot aggregate
storage bin to indicate the temperature of the heated aggregate.
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The plant shall be equipped with adequate and safe stairways to the mixing platfonn
and sampling location and guarded ladders and cat-walks shall provide access to all
other positions as necessary for proper operation, inspection and maintenance of the
plant, all to the satisfaction of the S.D. All gear, pulley, chains, sprockets and other
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dangerous moving parts shall be property guarded and protected. Ample and
unobstructed space shall be provided on the mixing platform, and clear and
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unobstructed passage shall be maintained at all times in and around the truck loading
area, which shall, be kept free from drippings from the mixer.
Each storage bin for screened aggregate shall be provided with a bottom outlet gate so
constructed as to prevent leakage when closed. These gates shall have a quick and
complete closing action. The plant shall be equipped with a weigh box or hopper for
accurately weighing out aggregate from each of the screened aggregate storage bins.
S4. 16-t5
JKRISPJI20 19-S4
The weigh box or hopper shall be suspended from its scale' s lever mechanism and shall
be sufficiently large to holds a full batch equal to the pugmill capacity wilhout hand
raking of the aggregate. The discharge gate shall be so constructed as to allow rapid
and complete emptying of the weigh box or hopper into the mixer, and prevent leakage
when closed.
The plant shall be equipped with a binder weigh bucket which shall be charged through
a fast acting non-dip valve in the binder feed pipe located directly over the bucke!. The
bucket shall be suspended from its scale's lever mechanism and shall have a capacity
sufficient to weigh out binder up to 20% of the weight of the pugmill dead load
capacity. The bucket shall have a discharge mechanism which shall provide for rapid
and complete emptying of th e bucket in a th in unifonn sheet or multiple sprays over
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the full length and width of the mi xer. The discharged shall not leak or drip when
closed.
The batch mixer shall be a suitable twin-shaft pugmill, with a capacity of at least 500
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kg of asphaltic concrete, capable of prod ucing a thoroughly homogeneous mixture. The
clearance of the paddle blades from all fi xed and moving parts of the mixer shall be not
more than 20 mm. If the pugmill is not enclosed, it shall be equipped with a dust hood
o
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to prevent loss of fines from the mixture. The discharge gate shall be so constructed as
to allow rapid and complete emptying of the mixer, and prevent leakage of any mix
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The mixer shall be equipped with an accurate time lock system for controlling the
operations of a complete mixing cycle. It shall lock the aggregate weigh box or hopper
gate after charging the mixer with aggregate, until the closing of the mixer gate at the
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completion of the mixing cycle; it shall lock the binder weigh bucket discharge
mechanism during the dry mixing and wet mixing period. The dry mixing period is
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defined as the interval of time between the opening of the aggregate weigh box of
hopper gate and the start of discharging the binder weigh bucket. The wet mixing period
is defined as the interval of time between the start of discharging the binder weigh
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bucket and the opening of the mixer gate. The dry and wet mixing periods shall both
be adjustable in increments of not mOTe than 5 seconds from zero to not more than 60
seconds total for dry and wet mixing.
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The filler silo shall have suitable a screw conveyor system to discharge into the pugmill.
The control system for the plant shall be housed in a weather proof cabin with windows
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to view the plant operations. Control in the cabin shall have the capability to accurately
batch the aggregates, filler and bitumen for the mix, transfer to the pugrnill mixer and
control the mixing time. The temperature of the heated aggregates, filler and bitumen
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shall also be displayed in this cabin and adjusted to meet the Specifications when
required.
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d) Drum Mix Plum
The cold material feeder unit shall consist of not less than 5 bins with suitable heaped
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capacity appropriate for the plant. Each bin shall be equipped with a variable speed
weighing belt feeder (driven by variable speed electric motor fitter with a tachometer)
with a load cell for accurate weight measurement of each type of aggregate used in the
mix in equivalent dry tons per hour. The cold feed system shall incorporate a device
for moisture compensation capable of producing an accurate and continuous blend of
the individual aggregate sizes from the cold feed compartment. The cold feed system
S4. 16- 16
JKRlSPJI2019-S4
shall also be equipped with a scalping screen of screed size of not more than 50 mm to
discard any oversized aggregates before entering the dryer drum.
The drum mixer shall have flight designs to accomplish the proper transfer of heat from
the exhaust gases of the burner to the aggregates and to blend the aggregates and
bitumen together adequately. The flight, at the upper end of the drum, shall be able to
direct the aggregate into the drum beyond the tip of the flame, thereafter the subsequent
flight shall be efficient to lift and tumble the aggregates with the cumulation of a veil
of aggregates across the whole cross-sectional area near the mid-point of the length of
drum where the aggregate temperature shall have been raised to dew point. This veil of
aggregates shall be sufficiently complete and dense to max imise heat transfer and to
screen the bitumen from the direct fl ame to minimise hardening and oxidation of the
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bitumen during Ihe mixing process. The downstream mixing flight designs shall
complete the heat transfer process and raise the mix temperature to the desired level
for discharge. The length to diameter ratio of the drum shall be appropriately designed
to obtain more complete heat transfer; to enable the bitumen to be injected in an inert
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atmosphere where proper coating/adhesion onto aggregates can take place without
severe oxidation or hardening of bitumen and effective mixing and sufficient designed
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( mix temperatures are achieved. The drum shall be inclined, oil-fired and suitabl y and
sufficiently insulated.
TE
The control system of a drum mixer must be automatically computer controlled with a
fully independent manual back-up system. The system shall be such that the operator
able to view the operation of the whole plant and of the individual component stations.
All relevant information of the plant operation and the progress of the tonnage of mix
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produced and mix design information shall be made available. The control system shall
be possess a Quality Assurance package to act as an audit tool (when required to be
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used) whereby the information on Plant Monitor, Progress Monitor and Mix
Temperature shall be made available at pre-set, variable time intervals.
Freshly mixed material shall be collected and delivered to be stored in a surge silo
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through a proper conveyor system.
ej Tip-Trucks
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The Contractor shall provide a suitable number of tip-trucks of a type approved by the
S.O. for transporting natural rubber modified asphaltic concrete from the mi xing plant
to the paving sites. The trucks shall have trays with smooth, flat beds and sides, and
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shall have load capacities of not less than 5 tons. Prior to loading, the inside of each
( truck tray shall be lightly and evenly coated with a soap or detergent solution, or such
other liquid as the S.O. shall approve, to prevent adhesion of the natural rubber
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modified asphaltic concrete. The trucks shall be equipped with covers of canvas or
other suitable material to protect the natural rubber modified asphaltic concrete.
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f) Asphalt Paver
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The asphalt paver shall be of recognised manufacturer and shall be approved by the
S.O. It shall conform to the requirements described hereunder.
The paver shall be self-propelled and capable of reverse as well as forward travel. It
shall be equipped with a hopper at the front designed to receive the paving mix from
tip-trucks, and shall have a mechanical distribution system for spreading the mix evenly
and without segregation over the surface to be paved in front of a screeding and
S4. 16-17
JKRl5PJ120 19-84
compacting unit which shall be equipped with a suitable heating device. The screeding
and compacting mechanism shall be capable of confining the edges of the material
being laid without the use of stationary side forms, shall be adjustable to strike off the
mixture to the thickness and cross-section shape required, and shall be controlled by an
automatic levelling device to produce an even carpet of bituminolls mixture with a
uniform surface texture free from indentations, ridges, tear marks or other irregularities.
The paver shall be capable of laying the bituminous mixture in paving widths in the
range 2.5 to 3.75 m and of finishing the pavement layer true to Ihe required lines,
grades, levels, dimensions and cross-sections, subject to compaction by ro lling, all to
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g) Rollers
A pneumatic-tyred roller and two steel-wheeled tandem rollers shall be provided. All
rollers shall be ofrecognised manufacture and shall be approved by the S.O. They shall
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conform to the requ irements described hereunder.
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Pneumatic-Tyred Roller o
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Pneumatic-tyred roller shall be self-propelled and capable of being reversed without
backlash; it shall be equipped with power steering and dual controls allowing operation
from either the left or right side.
A
The roller shall have nine wheels equipped with smooth tyres all of the same size and
construction. Five wheels shall be on the driven axle and four on the steering axle, all
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equally spaced on both axles and arranged so that the tyres on the steering axle track
midway between those on the driven axle with a small overlap. The roller shall be
ballasted to an operating weight of not less than 15 tons with a tyre inflation pressure
of not less than 0.7 N/mm2 •
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The Contractor shall provide the 5 .0 . with a calibration chart for the roller showing the
relationship between the quantity or depth of ballast and total weight, and also a chart
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showing the relationship between wheel load, tyre inflation pressure and contact
pressure.
Pneumatic-tyred rollers shall be equipped with water tanks, sprinkler systems and
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scraper blades to keep all wheels evenly wetted and clean during operation. Soap or
detergent solution, or such other liquid as the S.O. shall approve, shall be used to
prevent the asphalt from sticking to the roller tyres.
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Steel-Wheeled Tandem Rollers

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Steel-wheeled tandem rollers shall be self-propelled and capable of being reversed

without backlash; they shall be equipped with power steering and dual controls
allowing operation from either the left or right side. They also shall be equipped with
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water tanks, sprinkler systems and scraper blades to keep all wheels evenly wetted and
clean during operation. Soap or detergent solution, or such other liquid as the S.O. shall
approve, shall be used to prevent the asphalt from sticking to the roller tyres.
Steel-wheeled tandem rollers shall be ballasted so that their total operating weight are
in the range 8 to 10 tons and their driven roll (orrolls) shall exert a rolling force of not
less than 3.5 tons/meter of roll width. The Contractor shall provide Ihe S.O. with a
84.16-18
J KRISP J120 19-54
calibration chart for each roller showing the relationships between the quantity or depth
of ballast and total weight and rolling force.
4.16.7 CONSTRUCTION METHODS
a) General Conditions
Natural rubber modified asphaltic concrete paving work shall only be carried out in dry
weather when the surface to be covered is clean and dry, and has received a bituminous
tack coat which shall have achieved a satisfactory degree of tackiness, all to the
satisfaction of the S.O. All laying, rolling and finish ing work shall be carried out during
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daylight hours, unless the Contractor shall have provided suitable flood-lighting for the
job site, to the satisfaction of the S.O.
The S.O. may order the di scontinuation of work on account of adverse weather,
unsatisfactory condition of materials, equipment or surface to be paved, or such other
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( b) Slir/ace Preparation allli Clealling
TE
Prior to constructing a natura l rubber modified asphaltic concrete pavement layer. the
surface 10 be covered shall have been prepared in accordance with the appropriate
Sections of this Specification. Notwithstanding any earlier approval of this surface, any
damage to or deterioration of it shall be made good before natural rubber modified
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asphaltic concrete paving work is commenced.
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If the surface to be covered is to be provided with a bituminous tack coat, then this shall
be applied all in accordance with the provisions of sub-section 4 .3.2 in JKRlSPJI2008-
S4 .
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c) Aggregate Halldlillg alld Heating

EN
Each aggregate to be used in the natural rubber modified aspha ltic concrete mixes shall
be stored in a separate stockpi le near the mixing plant. Stockpiles of sand and other
fine aggregates shall be kept dry using waterproof covers and other means as necessary.
In placing the aggregates in the stockpiles and loading them into the mixing plant's cold
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aggregate feed bins, care shall be taken to prevenl segregation or uncontrolled

l combination of materials of different gradation. Segregated or contaminated materials
shall be rescreened or rejected for use in the Works and removed from the mixing plant
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site.
The aggregates shall be fed into the dryer at a uniform rate proportioned in accordance
with the appropriate job mix formula. The rate of feed for each aggregate shall be
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maintained within 10% of the rate prescribed, and the total rate of feed shall be such
that the plant's screens shall never be overloaded.
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The aggregates shall be dried and heated so that when delivered to the mixer they shall
be at a temperature in the range of 160' C to 180'C.
Immediately after heating, the aggregates shall be screened into four (or more) fractions
which shall be separately stored in the hot aggregate sto rage bins in readiness for
mixing.
S4.16-19
lKRlSr1/20 19-54
Mineral filler cum anti- stripping agent to be used in the mix shall be stored separately
and kept completely dry. Its rate of feed into the plant shall be accurately controlled by
weight or volumetric measurement, all to the satisfaction of the S.O.
d) Heatillg Natural Rubber Modified Billder
The natural rubber modified binder shall be heated so that when delivered to the mixer
it shall be at a temperature in the range of 150'C to 170'C.
e) Mixillg Natural Rubber Modified Asphaltic Concrete
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The mixing plant shall be so coordinated and operated as to consistently produce
natural rubber modified asphaltic concrete mixes within the tolerances prescribed in
this Specification, all to the sati sfaction of the 8.0.
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o
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Mixing in Batch Plants
TE
For each batch the screened hot aggregates shall be weighed out into the aggregate
weigh hopper in accordance with the proportions prescribed in the appropriate job mix
formula; the sequence of weighing out shall commence with the largest sized aggregate
and progress down to the fines, unless the 8.0. shall otherwise approve. Mineral filler
shall be weighed out into the filler weigh hopper, where this is provided, or added last
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to the aggregate weigh hopper, in accordance with the job mix formula proportions.
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The hot binder shall be weighed out into the binder weigh bucket in accordance with
the proportions prescribed in the job mix formula.
The hot aggregates and filler shall be discharged into the pugmill and mixed dry for the
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dry mixing time prescribed in the job mix formula, which shall usually be in the range
five to 10 seconds. The hot binder shall then be added and wet mixing performed for
the wet mixing time prescribed in the job mix formula; this shall be sufficient so that
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all particles of aggregate are uniformly coated with bitumen, and shall usually be 45
seconds or less for dense graded mixtures.
The volume of each batch shall be such that the tips of the pugrnill paddle blades just
o
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break out of the mixture at the height of their action.
After the completion of wet mixing, each batch of natural rubber modified asphaltic
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concrete shall be discharged from the pugrnill either into a storage hopper or directly
into a truck for hauling to the paving site. Care shall be taken that no segregation of the
mix occurs.
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Mixing in Continuous Mix Plants

D
The screened hot aggregates and filler shall be fed continuously from their storage bins
in accordance with the proportions prescribed in the appropriate job mix fonnula,
combined in the plant, and fed continuously into the mixer. The hot binder shall be
sprayed on to the combined aggregate as it enters the pugmill at the rate required to
achieve the bitumen content prescribed in the job mix formula . The materials shall then
be carried through the pugmill and in the process be thoroughly mixed by the action of
the paddles and discharged over the dam into the storage hopper. The mixing time sha ll
S4.16-20
JKRlSP Jl20 \9-S4
be as prescribed in the job mix formula; this shall be sufficient so that all particles of
aggregate are uniformly coated with the natural rubber modified binder, and shall
usually be 45 seconds or less for dense graded mixtures.
The plant shall be so adjusted as to maintain the level of mixture in the pugmill such
that the tips of the paddle blades just break out of the mixture at the height of their
action.
j) Transporting Natural Rubber Modified Asphaltic Concrete
Natural rubber modified asphaltic concrete shall be transported from the mi xing plant
ER
to the site of the paving works in loads of not less than 5 tons using tip-trucks as
specified in sub-section 4.2.4.4 (c) of JKRlSPJI2008-S4. Except where natural rubber
modified asphaltic concrete is to be hand laid, it shall be discharged directly into the
paver hopper, as required, from the tip-trucks. Care shall be taken in the truck loading,
hauling and unloading operations to prevent segregation of the mix. During
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transportation, the natural rubber modified asphaltic concrete shall be protected from
contamination by water, dust, dirt and other deleterious materials.
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(
The temperature of natural rubber modified asphaltic concrete immediately before
TE
unloading from the truck either into the paver hopper or on to the road for hand
spreading shall be not less Ulan 150'C. Any load which has cooled below the specified
temperature in the truck shall be rejected for use in the Works and removed from the
Site of the Works.
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g) Laying Natural Rubber Modified Asphaltic COllcrete
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approved by the S.O. Generally each paving layer shall have a compacted thickness of
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not less than twice the nominal maximum aggregate size of the mixture, and not more
than \ 00 mm. Where applicable, e .g. on superelevated sections and on carriageways
with cross-slope in one direction only, laying shall commence along the lower side of
the carriageway and progress to the higher side. Laying shall not be carried out in a
EN
downhill direction along any section of road.
Hand-casting of bituminous mix on to the machine finished surface shall be kept to the
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( practicable minimum necessary for correcting blemishes and irregularities. In any areas
inaccessible to the paver, laying shall be carried out by hand methods using rakes, lutes
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and other hand tools, all to the satisfaction of the S.O. All laying of bituminous mix
shall be such that after compaction by rolling the specified course or layer thickness
and surface profile shall be achieved . Care shall be taken to achieve a uniform surface
texture free from indentations, ridges, tear marks or other irregularities, and to prevent
segregation of the mix.
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At the commencement of initial rolling, the temperature of natural rubber modified

D
asphaltic concrete shall be as determined form the viscosity-temperature relationship.

Material which has cooled below the specified temperature before laying shall not be
used and shall be removed from the Site of the Works. The Contractor shall provide
accurate thermometers at the paving site at all times, and shall check the temperature
S4. \6-2\
JKRlSP J120 19-54
of asphaltic concrete in the paver hopper at regular intervals and before laying restarts
after each interruption of the paving operation.
bituminous mix shall be regulated so as to enable continuous paving. Transversejoints
in a paving lane shall be kept to a practicable minimum, and intermittent stopping and
restarting of the paver shal l be avoided as far as is practicable.
Care shall be taken that no bituminous mix is placed on expansion joints at bridges,
inspection covers for utilities ducts, drainage and sewerage manholes and the like, and
that catchpits, drainage openings through kerbs, etc., remain properly open and
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suitably shaped and secured boards or other materials approved by the S.O., and
compaction of mix in the immediately surrounding or adjacent areas shall be completed
by hand methods, all to the satisfaction of the S.O. Alternatively, bituminous mix shall
be laid and compacted by hand methods as necessary around surfacing discontinuities
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of these types, all to the satisfaction of the S.O.
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hJ Construction Joints
TE
Existing bituminous surfacing which new bituminous mix is to adjoin shall be cut back
to present a straight, vertical edge not less than 25 mm deep and a smooth transition
section not less than 500 mm long against which to lay the new material. The specified
thickness of the new surfacing shall be built up gradually from the vertical joint to
avoid any bumps or ridges across the carriageway.
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Where longitudinal or transverse joints are required in a layer of bituminous mix under
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construction, the material first laid and compacted shall be cut back to a vertical face
for the full thickness of the layer on a line satisfactory to the S.O. before the adjacent
area is paved.
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At all construction joints, a thin uniform coating of bitumen emulsion of grade RS-I K
shall be brushed on to the vertically cut joint faces some 10 to 15 minutes before laying
the next section of bituminous mix commences to ensure good bonding. Also, all
contact surfaces of kerbs, gutters, manholes, catchpits, etc. shall be similarly treated
EN
with a coating of bitumen emu lsion before bituminous mix is placed against them .
Construction joints in a layer of bituminous mix shall be offset from those in any
immediately underlying bituminous layer by at least 100 mm for longitudinal joints
o
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and at least 500 mm, for transverse joints.

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Construction joints shall not be permitted along wheel paths.
i) Compactil/g Natural Rubber Modified Asphaltic COl/crete

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For each layer of natural rubber modified asphaltic concrete, compaction by rolling
shall commence at temperature as determined from the viscosity-temperature
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relationship during the mix design process.
vibrating plate compactors, hand tampers or other suitable means, all to the satisfaction
ofthe S.O.
S4.16-22
JKRlSPJ/20 19-54
Initial (or breakdown) rolling shall be carried out with an approved steel wheeled
tandem roller, The principal heavy rolling shall be carried out with an approved
pneumatic tyred roller immediately following the initial ro lling; the pneumatic tyred
roller shall be ballasted to an operating weight of not less than IS tons and its tyre
inflation pressure shall be not less than 0,7 Nlmm' , The final rolling shall be carried
out with an approved steel wheeled tandem roller and shall serve to eliminate minor
surface irregul arities left by the pneumatic tyred roller.
driven wheels towards the paver, Rolling shall generally commence at the lower edge
of the paved width and progress uniformly to the higher edge, except that where there
is a longitudinal construction joint at the higher edge, this shall be rolled first ahead of
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the normal pattern of rolling, Generally, successive roller passes shall overl ap by hal f
the width of the roller, and the points at which the roller is reversed shall be staggered,
However, when operating on gradien ts in excess of 4%, the breakdown roller shall not
pass over any previo usly unrolled mix when operating in the downhill direction,
D
In all cases, compaction shall be carried out in such a manner that each section receives
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equal compactive effort, all to the satisfacti on ofthe S,O,
(
TE
pneumatic tyred rollers shall operate at speeds of not more than 8 kmIh. No roller or
heavy vehicle shall be allowed to stand on newly laid bituminous mix before
compaction has been completed and the material has thoroughly cooled and set. Rolling
shall continue as long as is necessary to achieve the appropriate requirement as shown
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in Table 10,
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Table 10 Compacted density fo r natural rubber modified asphaltic concrete

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Wearing course 98 - 100% of Marshall density

EN
Care shall be taken to prevent over-compaction of natural rubber modified asphaltic

concrete.
Within 24 hours of laying and compacting the bituminous mix, the Contractor shall cut
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( core samples of not less than 100 mm nominal diameter at locations selected by the
S,O. The rate of sampling shall be one sample per 500 m' of mix laid, but not less than
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two samples for the work completed in each paving session. These core samples shall
be used by the S.O. to determine the compacted thickness and density of the material
in accordance with ASTM Test Method D 2726.
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j) Finished Natural Rubber Modified Asphaltic Concrete

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Natural rubber mod ified asphaltic concrete wearing courses shall be fini shed in a neat
and workmanlike manner; their widths shall be everywhere at least those specified or
shown on the Drawings on both sides of the centre-line; the average thickness over any
S4.16-23
JKRISP J120 19-54
100-metre length shall be not less than the req uired thickness, and the minimum
thickness at any point shall be not less than the required thickness minus 5 mm.
The top surface of a wearing or binder course shall have the required shape,
superelevation, levels and grades, and shall be everywhere within the tolerances
specified in sub-section 4.5 of JKRlSPJ/2008-S4.
The International Roughness Index (IRI) value of the finished wearing course surface
shall be carried out as described in sub-section 4.5.3 of JKRlSPJ/2008-S4 of this
specification and shall be not more than 2.0 mlkm.
ER
k) Opening 10 Traffic
Natural rubber modified asphaltic concrete shall not be opened to traffic until
compaction has been completed and the material has thoroughly cooled and set in the
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opinion of the S.O. This will usually be not less than four hours after the
commencement of rolling. Where it is necessary to allow earlier use of the finished
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surface to facilitate the movement of traffic, vehicles may be allowed to run on the
work after rolling has been completed, provided that speeds are restricted to 30 kmlh
or less and sharp turning movements are prohibited.
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4.17 CRUMB RUBBER MODIFIED ASPHALT
4.17.1 DESCRIPTION
This Specification provides information on the design. production and use of

crumb rubber modified asphalt (CRMA).
Crumb rubber modified asphalt is a mixture of aggregates and crumb rubber

modified binder (CRMS).
CRMS is a blend of hot bituminous binder and crumb rubber manufactured

from reclaimed tyre rubber which are produced from tyres with a typical
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outside diameter greater than 660 mm and less Ihan 1,520 mm used on
commercial vehicles such as lorries and busses.
This Specification focuses on CRMB (asphalt-rubber) in ASTM 0 8, which
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defines asphalt-rubber as "a blend of asphalt cement, reclaimed tyre rubber,
and certain additives in which the rubber component is at least 15 percent by
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weight of the total blend and has reacted in the hot asphalt cement sufficiently
( to cause swelling of the rubber particles".
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The CRMB is formulated and reacted at elevated temperatures and under high
agitation to promote physical interaction of the bituminous binder and
reclaimed tyre rubber constituents, and to keep the rubber particles suspended
in the blend. The CRMB contains visible particles of reclaimed tyre rubber.
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The application ofCRMB as described in this Specification is for crumb rubber
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- stone mastic asphalt (CR-SMA), crumb rubber - gap graded asphalt (CR-
GGA), crumb rubber - open graded friction course (CR-OOFC) and crumb
rubber - stress absorbing membrane interiayer (CR-SAMI).
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4.17.2 MATERIALS
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a) Aggregates
Aggregates for CRMA shall be a combination of coarse and fine aggregates,

and mineral filler. The individual aggregate shall be of sizes suitable for
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blending to produce the required gradation of the combined aggregates, all to

( the satisfaction of the S.O.
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Coarse aggregates shall be screened crushed hard rocks, angular in shape and
free from dust, clay. vegetative and other organic matters, and other deleterious
substances. They shall conform to the following physical and mechanical
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i. The Los Angeles abrasion value when tested in accordance with

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ASTM C 13 1 shall be not more than 25%.
ii. The weighted average loss of weight in Ihe magnesium sulfate

soundness test (5 cycles) when tested in accordance with AASHTO
Test Method T 104 shall be not more than 18%.
iii . The fl akiness index when tested in accordance with MS 30 shall be

not more than 25%.
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JKRlSPJI2019-S4
iv. The water absorpt ion when tested in accordance with MS 30 shall be
not more than 2%.
v. The polished stone value when tested in accordance with MS 30 shall

be not less than 40 (for wearing course only).
Fine aggregates shall be clean screened quarry dust. Other types of fine
aggregate may be used subject to the approval ofthe S.O. Fine aggregates shall
be non-plastic and free from clay, loam, aggregation of materials, vegetative
and other organic matters, and other deleterious substances. They shall
conform to the following physical and mechanical quality requirements;
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i. The sand equivalent of aggregate fraction passing the No. 4 (4.75mm)
sieve when tested in accordance with ASTM 02419 shall be not less
than 45%.
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ii . The fine aggregate angularity when tested in accordance with ASTM
C 1252 shall be not less than 45%.
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iii. The Methylene Blue value when tested in accordance with Ohio
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Department of Transportation Standard Test Method shall be not
more than 10 mg/g.
iv. The weighted average loss of weight in the magnesium sulfate

soundness test (5 cycles) when tested in accordance with AASHTO
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Test Method T 104 shall be not more than 20%.
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v. The water absorption when tested in accordance with MS 30 shall be
not more than 2%.
Notwithstanding compliance with the requirements of this Specification,

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limestone aggregates shall not be permitted for use in wearing course.
The gradation of the combined coarse and fine aggregates, and mineral filler,
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shall conform to the appropriate envelopes shown in Table I.
Table J Combined Aggregate Gradation/or CRMA Mixtllres
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Mix
CR-SMA CR-GGA CR-OGFC CR-SAMI
Deshmation
OS Sieve Size,
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Percentage Passing (by weight)

mm
20.0 100 100 100 100
14.0 85 - 100 85 - 100 85 - 100 75 - 100
10.0 50 - 75 50-70 45-80 0 - 15
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5.0 20-35 18 -35 3-30 -

2.36 15 - 25 8 - 20 0 - 15 0-5
- - -
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0.6 8 - 20
0.3 6-15 - - -
0.075 5- 10 0-7 0-4 0- 2
For CR-SMA, CR-GGA and CR-OGFC, the Contractor shall propose a

laboratory design mix gradation which shall consist of a single definite
percentage passing for each sieve size in Table I and shall produce a smooth
curve within the appropriate gradation envelope. This job laboratory design
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JKRlSPJ/2019-S4
mix gradation, with the allowable tolerances for a single test as specified in
Table 6 (for CR-SMA, CR-GGA) and Table 7 (for CR-OGFC), shall then
become the job mix formula.
b) Milleral Filler
Mineral filler shall be incorporated as part of the combined aggregate gradation

(except CR-SAMI) and shall be hydrated lime (calcium hydroxide). At the time
of mixing with CRMA, it shall be sufficiently dry to flow freely and shall be
essentially free from agglomerations. The quantity which pass the BS 0.075
mm sieve shall not be less than 75% by total weight of the hydrated lime.
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[fhydrated lime is not available, ordinary Portland cement shall be used as an
alternative, subject to approval of the S.O.
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The mineral filler shall also be treated as an anti-stripping agent.
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( c) Crl/mb Rl/bber Modified Binder (CRMB)
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CRMB shall be of perfomlance grade PG 76 or higher in compliance with
AASHTO Standard M320-02. This premium grade binder shall be produced
by pre-blending conventional bituminous binder of penetration grade 60 - 70
which shall conform to MS 124, with an appropriate quantity of crumb rubber.
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Crumb Rubber
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Crumb rubber shall be obtained by grinding reclaimed rubber tyres from heavy
commercial vehicles to mesh sizes 20 to 40 (0.8 to 0.4 mm) because in
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general they contain higher proportion of natural rubber as compared to tyres

from cars, pickups and small lorries which are made of styrene-butadiene
synthetic rubber (SBR) or polybutadiene synthetic rubber.
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Crumb rubber shall be either buffed crumb or whole tyre crumb.
1. Buffed crumb ' shall be produced from worn tyres when the tyres
are submitted for retreading. Rubber material shall be first removed
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( from the tread in the form of ' buffing' or rasping. These buffing shall
undergo ambient grinding process and shall be sieved to produce
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crumbs of various particle sizes. Since they are removed from the tyre
tread, buffed crumb comprise high quality, abrasion resistant rubber
material free from tyre reinforcement fabric or steel.
ii. Whole tyre crumb rubber shall be produced from reclaimed rubber
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tyres by ambient grinding process. The whole tyres shall be cut into
large pieces and then shredded into chips about 3 to 5 mm in size.
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These chips shall be subsequently passed through a coarse mill or

cutter, before being sent through fine grinding mills and screens.
I Wile n buffed cr umb a re Jised, contamination wilh excessive fibers, meta ls or minerals is generally negligible.
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JKRlS PJI20 19-S4
Fiber content
The fiber content shall be less than 0.5% by weight. Fiber content shall be
determined by weighing fiber agglomerations which are formed during the
gradation test procedures. Rubber particles shall be removed from the fiber
agglomerations before weighing.
Moisture content
The moisture content shall be less than 0.75% by weight after dryi ng to
constant mass at 60 r .
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Mineral contaminants
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The minera l conlaminants shall not be greater th an 0.25% by weight as
determined by sedimentation analysis ofa 100 g crumb rubber sample in a one-
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litre glass beaker filled with water.
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Metal contaminants
The rubber shall contain no visible metal particles as indicated by thorough

stirring of a 100 g crumb rubber sample with a magnet.
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Chemical composition
The chemical composition of crumb rubber derived from different types andlor
parts of lyres are shown in Table 2. For use as bituminous binder modifier,
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crumb rubber derived from different sources shall be mixed to obtain a

satisfactory composition. After selecting and evaluating crumb rubber from a
single or from multiple sources, the chemical composition shall remain the
EN
same throughout the project.
Table 2 Chemical Composition a/Crumb Rubber
Test Parameter Specification

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Acetone Extract (%) < 22

Rubber Hydrocarbon (%) 42-65
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Carbon Black Content (%) 28 -38

Natural Rubber Content (%) > 30
Ash Content (%) < 8.0
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Crumb rubber from more than one source may be used to ensure satisfactory
compliance with gradation and compositional requirements. Whichever source
or sources are used, they and their proportion shall remain the same as
submitted to the S.O. and approved for the project. If the source of crumb
rubber need to be changed, all relevant information shall be submitted to the
S.O. and the new material shall not be used until approved by the S.O.
54 . 17-4
JKRl5PJ12019-54
Packaging and labelling
Crumb· rubber shall be supplied in reusable bulk containers or in weather

(moisture) resistant disposable bags. If crumb rubber dosage is not controlled
through a hopper equipped with accurate load cells (and connected through a
screw feeder with the blending tank), the weight of bags containing crumb
rubber shall be accurate to ± 2.0%. Stacking of crumb rubber containers and
bags shall be minimised to avoid excessive consolidation of crumb rubber.
Each crumb rubber container or bag shall be labelled with the manufacturer's
designation for the rubber, including the specific type and grade of rubber, the
nominal rubber weight (per container or bag), the manufacturer's lot number
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designation and date, and any other infonnation deemed pertinent by the crumb
rubber supplier.
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4.17.3 PREPARATION OF CRUMB RUBBER MODIFIED BINDER (CRMB)
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aj Blelldillg Equipmellt
( The Contractor shall provide a blending equipment system located at the
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asphalt mixing plant.
The blending equipment shall have suitable heating system to raise the
temperature of CRMB blend to its optimum blending temperature which shall
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be 170 to 190 · C. The blending equipment system, including its distribution
and circulation pipes, shall be properly insulated to prevent rapid temperature
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drop during blending and discharging to the asphalt mixing plant. Suitable
storage tank(s) that matches the capacity of the blending equipment and
complete with suitable mechanical agitators shall be provided and the tank(s)
shall be connecled through the distribution and circulation pipes.
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The blending equipment system shall be capable of producing CRMB with

consistent required properties.
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Alternatively, the CRMB shall be obtained ITom the supplier(s) approved by

the S.O., hereafter referred to as terminal blend which is described in sub-
section 4.17.3 (b).
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( bj Blelldillg Process
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CRMB shall be produced by blending hot bituminous binder with crumb

rubber. The bituminous binder shall be penetration grade 60 - 70 and shall be
heated to about 170 to 190 'c.
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The crumb rubber shall be added to the hot bituminous bi nder and thoroughly
mixed. The dosage of crumb rubber shall be at least 15% by weight of the
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bituminous binder. Olher additives may also be incorporaled into the blended
bituminous binder and crumb rubber. Examples of such additive are natural
rubber, extender oil and anti-stripping agent.
During heating and mixing of the bituminous binder and crumb rubber, the
rubber particles will swell and softens as it reacts with the binder. This reaction
is influenced by the blend ing temperature, the time the temperature remain s
54. 17·5
JKRlSPJI2019-S4
elevated, the type and amount of mechanical mixing, the size and texture of
the crumb rubber, and the aromatic component ofthe binder. The crumb rubber
absorbs aromatic oils and light fractions (small volati le or active molecules)
from the binder and releases some of the similar oils used in the rubber
production into the binder.
The reSUlting CRMB blend shall then be pumped into storage tank(s) where it
shall be kept at a minimum temperature of 170 ' C for a period of 45 to 60
minutes to allow for further swelling of the crumb rubber.
Terminal Blend
ER
Terminal blend is a mixture of bituminous binder and crumb rubber, which is finely
ground to sizes less than 40 mesh. It shall be essentially produced elsewhere
outside the asphalt mixing plant, hereafter referred to as the 'terminal'. by using a
wet process, The binder shall be heated in a tank to an elevated temperature and
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crumb rubber sha ll be introduced into the tank and digested into the binder using
a high shear process. During this process, samples shall be taken and tested for
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solubility in accordance to ASTM 0 2042 to ensure the crumb rubber has been
completely digested. The solubility of the terminal blend after completion of
blending shall be not less than 97.5%.
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After completion ofthe blending, the terminal blend shall be transported in well
insulated tankers, and transferred into storage tanks at the asphalt mixing plant
as described above. The tenminal blend may be held in the storage tanks for a
maximum period of 3 days without agitation as the crumb rubber is considered
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completely digested into the binder. However, if the storage period exceed 3
days, proper agitation shall be provided.
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The primary difference between terminal blend and the CRMB produced at the
asphalt mixing plant (field blend) is the amount of crumb rubber used in the
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binder (tenminal blend less than 10%; field blend at least 15%). However, the
crumb rubber content in the tenminal blend can be increased to 15 - 20% or
more.
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c) Formulation
The Contractor shall provide a blend formulation to the S.D. for approval at
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least 10 days before paving works is scheduled to commence. The blend

fonmulation shall consist of the following infonmation;
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i. Bituminous binder
• Source
• Grade
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ii. Crumb rubber

• Source
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• Percentage by total weight of bituminous binder
d) Completion of Blent/ing
The blending process shall be deemed to be complete when a small drop of

CRMB from the blending system, placed on an impervious surface, shows only
S4.17-6
JKRlSPJI2019-S4
a few specks of rubber which are soft enough to be spread into the CRMB by
a knife or spatula. If the rubber particles sti ll preserve their entity and cannot
be rubbed away into the CRMB, blending is deemed incomplete, thus further
heating and agitation are required .
e) Samplillg of CRMB
The S.O. may, as and when required, instruct the Contractor to sample the
CRMB !Tom the blending system and send them for testing. Sampling points
shall be provided at convenient points in the blending system. Sampling shall
be done in accordance with MS 539. The Contraclor shall bear all charges
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related to the testing as specified in Table 3.
j) Storage ofCRMB
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The Contractor shall provide a storage system capable of de livering the
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mod ified binder to the asphalt mixing plant. The storage system shall be
( located close to the aspha lt mixing plant and it shall include distribution and
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circulation pipes that are properly insulated to prevent rapid temperature drop.
The storage tank shall have suitable mechanical agitator and be connected
through delivery pipes and back-circulation pipes. Suitable sampling points
shall be provided at convenient points in the storage system for taking samples.
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Sampling shall be done in accordance with MS 539.
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The CRMB shall be used within 24 hours. If storage is necessary due to
inevitable reasons, the binder shall be cooled to 145 - 155 'C and the storage
time shall be limited to 3 days. During storage, the binder shall be continuously
agitated.
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If prolonged storage (more than 3 days) is unavoidable, the CRMB shall be

tested for compl iance as specified in Table 3. If non-compliance occurs, the
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CRMB shall be modified by adding more crumb rubber until the CRMB
complies with the requirement.
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g) Applicatioll o/CRMB
(
At the time of app lication, the crumb rubber shall be dispersed uniformly
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throughout the bituminous binder. The properties of the CRMB, whether it is

blended close to the asphali mixing plant or produce by terminal blending, shall
be as given in Table 3.
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JKRlSPJI2019-S4
Table 3 Properties ofCRMB
Test
Test Requirement
Specification
CRMB prior to rolling thin film oven test (RTFOT)
'Viscosity, test temperature 177 ·C, Pa.s 1.5 - 4.0' ASTM 04402
'Dynamic shear, G"/sin 6 min. 1.00 kPa, AASHTOT
76
10 radls, test temperature ·C 315
'Penetration, 100 g, 5 s, 25 ·C, x 0.1 mm,
25' ASTM 05
min.
'Ring and ball softening point, ·C, min. 60 ASTMD36
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'Flash point, · C, min. 240 AASTHOT48
CRMB after RTFOT (AASHTO T 240 or ASTM D 2872
AASHTOT
3Mass loss, %, max. 1.00 240 or
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ASTM 02872
'Dynamic shear, G"/sin 6 min. 2.20 kPa, AASHTOT
76
10 radls, test temperature·C 31 5
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4.17.4 CRUMB RUBBER - STONE MASTIC ASPHALT (CR-SMA) AND
CRUMB RUBBER - GAP GRADED ASPHALT (CR-GGA)
a) Mix Design
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Job Mix Formula
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The Contractor shall propose a job mix formula required for the Works. In
order to obtain optimum quality of the mixtures, the job mix formula shall be
prepared on the basis of testing several laboratory design mix gradations within
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the limits as shown in Table I at an appropriate range of CRMB content. As a

guide, the designed CRMB content for CR-SMA and CR-GGA will usually be
in the range given in Table 4.
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Table 4 Range of Design Binder Contents
Type of Asphalt Mixture Design Binder Content

CR-SMA 5% - 7%
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CR-GGA 6% - 8%
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Each combination of laboratory design mix aggregate gradation and CRMB

content shall be subj ect to the Marshall test procedure and volumetric analysis
as follows;
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2 HIt requirement may be waived at the discretion of the s.O. if the Con /raclol' ,~arranls that the e RMB can be
adequately pumped and mixed 01 the remperalllres that meet all applicable safety standards.
l These tesls shall be carried aliI as and witt " required by the S.O. but shall be not less than one lest per 30 tons
a/e RMB produced or ai /easl once per project if the 10101 quantity ofCRMB produced is less than 30 tOilS. The
CRMB samples shall be taken immediately prior 10 the prodllction ofCR-SMA or CR·OGA . Testfrequency may
be redllced if lest rest/Its consistently conform to Ihe requirements.
4 These tests sha{{ be carried oul minimum ollce for each blending process for quality control purposes during
blending althe asphalt mixing plant or lerminal blending.
S The penetration and softening point values shall be taken as reference for consistency check on the prodllction.
S4. 17-8
JKRl5P J120 19-54
i. Preparation of laboratory specimens for the standard stability and

flow test in accordance with ASTM D 1559 using 75 blows/face
compaction standard,
I I. Determination of the bulk density of the specimens in accordance

with ASTM D 2726,
iii. Determination of the stability and flow values in accordance with
ASTM D 1559,
iv. Analysis of the density and air voids parameters to determine the
percentage air voids in the compacted aggregates, the percentage air
voids in the compacted aggregates filled with CRMB and the
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percentage air voids in the compacted mix.
For the proposed design mix gradation, 4 specimens shall be prepared for each
CRMB content within the range of Table 4 6 at increments of 0.5%, in
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accordance with ASTM D 1559 using 75 blows/face compaction standard. All
CRMB content shall be in percentage by weight of the total mix. Prior to
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mixing with aggregates, the CRMB shall be heated to a temperature of 160 to
( 175 'C.
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As soon as the fresh ly compacted specimens have cooled to room temperature,
the bulk density of each test specimen shall be determined in accordance with
ASTM D2726.
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The stabil ity and flow value of each test specimen shall then be determined in
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After the completion of the stability and flow test, density and voids analysis
shall be carried out for each test specimen to determine the percentage air voids
in mineral aggregate (VMA) and the percentage air voids in the compacted mix
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(VIM).
Any erratic values shall be discarded before averaging. When 2 or more

EN
specimens in any group of 4 are so rejected, 4 more specimens shall be

The average values of bulk density, stability, flow and VIM obtained above
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shall be plotted separately against the bitumen content and a smooth curve
( drawn through the plotted values.
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The mean optimum CRMB content shall be determined by averaging 4

optimum CRMB contents so determined as follows;
i. Peak of curve taken from the stability graph',

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I I. Flow equals to 3.5 mm from the flow graph,

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6 The range of binder confem shall be extended. i/necessary, 10 ensure thal lhe cllrves o/stability and bllik
density have their peak within the range selected.
7 Where Ihe slability cllrve exhibits more than olle peak, the bitumen cOlltent chose" Jar the determinatioll of the
mean optimum bitumen content shall be (he one which satisfies Ihe voids requirement,f better. It is sometimes
necessary. where no peak stability is obtained. to prepare and test supplemel1fary specimens at intervals oj
0.25% bitumen content on either side of the expected optimum.
S4. I 7-9
JKRlSPJI2019·S4
iii. Peak of curve taken ITom the bulk density graph' ,
iv. VIM equals to 4.5% (for CR-SMA) and 5.5% (for CR-GGA) ITom
the VIM graph.
The individual test values (stability, flow and VIM) at the mean optimum
CRMB content shall then be read ITom the plotted smooth curves and shall
comply with the design parameters given in Table 5.
If all the values comply with Table 5, the mixture with the mean optimum
CRMB content shall be used in plant trials. Otherwise, the mix design
procedure shall be repeated using a different laboratory design mix aggregate
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gradation until all design parameters are satisfied.
Table 5 CR-SMA and CR-GGA Requirements
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Requirement
Test
CR-SMA CR-GGA
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VIM 3-6% 4.5 - 6.5%
Stability min. 6,000 N min. 6,000 N
TE
Flow 2.0-5.0mm 2.0-5.0mm
Binder dmin-down max. 0.2% max. 0.2%
9Semi-Circular Bend, critical strain energy min. 0.5 kJ/m' min. 0.5 kJ/m'
release rate, J" test tempemture 25 'C, aged
'Hamburg Wheel-Tracking, rut depth @ max. 12.5 mm max. 12.5mm
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20,000 no. of passes, test temperature 50 'C
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Binder Drain-Down Test
Binder drain-down test shall be conducted on 3 samples at mean optimum

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CRMB content to ascertain that the binder draining property of the mix is
satisfactory.
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Binder drain-down test shall be carried out in accordance with the test method
as specified in Appendix A. A sample of CR-SMA and CR-GGA shall be
placed in an oven for 3 hours at the anticipated asphalt mixing temperature in
a wire basket fabricated using standard 6.3 mm sieve cloth. Any binder drain-
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down ITom the asphalt shall be collected in a pan. The binder drain-down shall
be not more than 0.2% by weight of the total mix.
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Ifthe average binder drain-down exceeds 0.2%, the mix design procedure shall
be repeated using a different laboratory design mix aggregate gradation until
all design parameters are satisfied.
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Alternatively, this test shall be carried out in accordance to the Schellenberg

method. A sample ofCR-SMA and CR-GGA (I kg) shall be placed in 800 ml
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glass beaker in an oven at 170 'C for I hour. The beaker shall then be taken out
ITom the oven and turned upside down to pour out the sample. Then, the beaker
shall be weighed to get the mass of the binder which remain inside the beaker.
, With highly absorptive aggregate. some difficlilty in determining peak hlllk density may occur. In Sitch cases, Ihe
billlmen conlent at which the increase In bulk density ShOlt'S a marked f alling off shall be adopted.
9 These tests shall be carried 01/( once/or each sOl/ree (asphalt mixing plant) oj CR-SMA or CR-GGA . Refer 10
Appendixes D and Efor test procedures.
S4 .17· 10
JKRlSPJI2019-S4
The binder drain-down shall be calculated as a percentage loss of mass to the

initial mass of sample (I kg). The complete procedure of the test method is
gi ven in Appendix B.
Determination of On tim urn Binder Content
The binder content that meet the criteria in Table 4 and satisfy the binder drain-
down test requirement shall be selected as the optimum binder content. The
aggregate gradation selected and the optimum binder content determined shall
be proposed to the S.O. as the j ob mix formula.
ER
Mixing and Compaction Temneratures
As a guide, the mixing temperature for CR-SMA and CR-GGA will usually be
D
between 175 to 185 'C. If higher than 195 'C, the asphalt mixtures shall be
disposed. The CR-SMA and CR-GGA mixtures shall be compacted
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immediately after laying and the compaction process shall be completed at
( temperature higher than I 10 'C. The mixing, laying and compaction
temperature shall be determined during trial lay_
TE
Trial Lay
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formula, the Contractor shall arrange to mix, lay and compact the CR-SMA
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and CR-GGA mi xtures. A minimum of 50 tons shall be placed at the job site
to demonstrate to the satisfaction of the S.O. that the mixtures is satisfactory
and the mixing, laying and compacting equipment conforms to the requirement
of this specification.
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As directed by the S.O., comprehensive sampling and testing of the CR-SMA

and CR-GGA mixtures shall be carried out to check for satisfuctory compliance
EN
with the job mix formula. If the asphalt mixture used in the trial lay complies
with the job mix formula as well as compacted thickness and density
requirements, the trial section shall be accepted as part of the Contract Works.
Otherwise, the trial section shall not be considered as part of the Contract
Works and shall be removed by the Contractor at his own expense.
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( The observalions and tests to be carri ed out during trial lay shall be, but not
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restricted to the following;
i. Select a suitable location for the trial lay within the job site.
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ii. Record the types and weight of roller.
iii . Record the type of paver.

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iv. Carry out the following tesls on the asphall mixture;

• Binder content and aggregate grading (ASTM D 2 I72/BS 598,
ASTM C 136).
• Theoretical maxim um density (ASTM D 2041 ).
S4. 17- 11
JKRlSPJI2019-S4
• Bulk density of Marshall specimens (ASTM 3203).

• Calculation of air voids (ASTM D 3203).
v. Record temperatures of asphalt mixture on the tipper lorry, at plant

and site.
vi . Record laying temperatures.

viii. Observe the surface texture of mixture laid behind paver.
IX. Record rolling temperatures i.e. immediately before rolling starts.
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x. Record rolling paltem.
xi. Observe the surface texture of compacted mixture.
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xi i. Take at least 3 core samples from each tipper lorry load after the
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mixture has sufficiently hardened.
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x iii. Record compacted thickness, density and air voids of the core
samples.
xiv. Check at least one longitudinal joint to ensure that the joint is
satisfactorily constructed.
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Compliance with Job" Mix Formula
The S.O. 's final approval of the job mix fonnula shall bind the Contractor to
furnish the CR-SMA and CR-GGA mixtures meeting the precise aggregate
M
gradation and CRMB content specified in the fonnula and within the tolerances
set forth in Table 6.
EN
Table 6 Tolerances for CR-SMA and CR-GGA
Permissible Variation
Parameter
(% by wei~ht of total mix)
o
M
CRMB content ± 0.3% xCR

Fractions of combined aggregate
±5 .0%
oassine 5.00 mm and lareer sieves
KU

±4.0%
oassine 2.36 mm sieve
±3 .0%
passine 0.6 mm and 0.3 sieves
O
Fraction of combined aggregate

± 2.0%
, passi ng 0.075 mm sieve
D
Nole: CR is the percentage of crumb rubber (by weight oflhe bituminous binder) blended
with II,e binder. It shaff be applicable to the lower limil only as there are
discrepancies between the actllal and the measured hinder contents when tested in
accordance (a ASTM D 2172 dlle 10 the following COlIUS:
a) Most of the crl/mb rubber with mesh sizes 20 to 40 (0.8 - 0.4 mm) remains
on the filter paper. and
b) A small amount afthe binder remains in the extracted aggregate.
The upper limit shall be CRMB content as specified in the formula + D.3%.
S4 . 17- 12
JKRlSPJI20 19·S4
b) COllstructioll Equipmellt
Mixing Plant
The contractor shall provide all the plant and equipment necessary for
executing the work in accordance with this Specification and shall furnish the
S.O. with such details of items of equipment, e.g. manufacturer, model type,
capacity, weight, operating features etc.
The asphalt plant shall be either a batch plant or a drum mix plant or a
continuous mix plant of a recognized manufacture and shall be approved by
the S.O. It shall conform to the requirements described hereunder.
ER
The mixing plant shall have a capacity suited to the Works and shall be
sufficient to enable the paver operate more or less continuously when paving
at normal speeds at the required thickness. The plant shall be designed so as to
D
enable consistent production of asphalt mixtures within the tolerances
prescribed in this Specification, all to the satisfaction of the s.o.
N
( The plant shall also comply with the following requirements;
TE
i. Handling mineral filler :
Adequate dry storage shall be provided for the mineral filler and
provisions shall be made for proportioning the filler into the mixture
unifonnly in the desired quantities. Mineral filler in a batch plant will
A
be added directly into the mixture uniformly in the desired quantities.
Mineral filler in a batch plant will be added directly into the weigh
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hopper. In a drum plant mineral filler will be added directly into the
drum mixer. Special attention is directed to providing appropriate
equipment for accurately proportioning the relative large amounts of
mineral filler required for CR·SMA mixture. Two separate silos shall
M
be provided, one to keep the mineral filler (i.e. limestone powder) and
another one to keep cement or hydrated lime.
EN
ii. Hot-mixture storage:

When the hot mixture is not to be hauled immediately to the project
and placed, suitable bins shall be provided. Such bins shall be either
surge bins to balance production capacity with hauling and placing
capacity or storage bins which are heated and insulated and which
M
( have a controlled atmosphere around the mixture. The holding time

shall be within limitat ions imposed by the S.O., based on laboratory
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tests of the stored mixture. CR·SMA and CR·GGA mixtures shall not
be stored overnight for paving on the next day.
O
Hauling Equipment
Hauling equipment should be of a type normally used for the transport of

D
asphalt mixtures. Tipper lorry beds shall be covered and insulated if necessary,
so that the mixture may be de livered on the road at the specified temperature.
The paver shall be of a type normally used for the placement of asphaltic
S4. 17· 13
JKRlSPJIZO I9-S4
concrete. It shall be self-contained, power-propelled units provided with an

adjustable activated screed, heated and capable of spreading and finishing
courses ofasphaJt plant mix material in lane widths applicable to the specified
typical section and thickness shown on the plans.
The paver shall be capable of being operated at forward speeds consistent with
satisfactory placement and compaction of the mixture. The paver shall be
capable of striking a smooth fini sh of uniform texture.
Steel Wheel Tandem Roller
ER
reversed without backlash; they shall be equipped with power steering and dual
controls allowing operation /Tom either the left or right side. The roll er shall
be equipped with water tanks, sprinkler systems and scraper blades to keep all
D
wheels evenly wetted and clean during operation.
N
Each steel wheeled tandem roller shall be ballasted so that its total operating
weight is in the range 8 to 10 tons and its driven roll(s) shall exert a rolling
force of not less than 3.5 tons/m of roll width.
TE
cj COllstmetion Method
Surface Preparation
A
Immediately before placing the CR-SMA and CR-GGA mixtures, the
EJ
I.
surface shall be cleaned of loose or deleterious material by brooming
or other approved means.
M
II . A thin tack coat of bitumen emulsion RS- I K or similar material

conforming to MS 161 shall be applied to ensure uniform and
complete adherence of the overlay.
EN
iii. Where the existing surface is non-unifonn, a leveling course of

asphaltic concrete shall be required to restore proper cross-section
prior to construction of the overlay.
o
M
Weather Limitations
KU
The CR-SMA and CR-GGA mixtures shall be placed on a dry clean surface
when the atmospheric and the road surface temperatures are above 20 'C and
the mixtures conforms to the applicable requirements as described in sub-
section 4. 17.4 (c).
O
D
Control of Asphalt Mixture
The CR-SMA and CR-GGA mixtures furnished by the Contractor shall

conform to Ihe job mix formula, within the allowable tolerances as shown in
Table 5.
S4 .17-14
JKRfSPJI2019-S4
The temperature of asphalt mixture when delivered to the paver shall be greater
than 160 ' C, measured in the tipper lorry immediately prior to dumping into
the paver hopper. If the temperature drops to 140 'C or below, the asphalt
mixture shall be rejected.
The asphalt mixture shall be spread and struck off to the established grade and
elevation with asphalt layers. Placing speed will be adjusted so that sufficient
time is allowed for compaction operations and to provide continuity.
ER
Compaction
Immediately after the asphalt mixture has been spread and struck off, it shall
be thoroughly and uniformly compacted by rolling.
D
i. Due to the nature of CR-SMA and CR-GGA mixtures, the surface
N
shall be rolled immediately. Rolling shall be accomplished with steel
( wheel tandem rollers of minimum weight of 8 tons. Pneumatic tyred
rollers shall not be used. Rolling procedures shall be adjusted to
TE
provide the specified pavement density. Rollers shall move at a
uniform speed not to exceed 5 kmlh with the drive roller nearest the
paver. Rolling shall be continued until all roller marks are e liminated
and the minimum density has been obtained but not after the layer
A
has cooled to 110 'C or lower. The Contractor shall monitor density
during the compaction process by using density gauges or approved
EJ
rolling pattern to ensure that the minimum required compaction is
obtained.
ii. To prevent adhesion of the mixture to the rollers, it shall be necessary

M
to keep the wheels properly moistened with water mixed very small
quantities of detergent or other approved material.
EN
iii. The pavement shall be compacted to minimum 94% of theoretical

maximum density which shall be determined using the Rice method
as described in ASTM D 204 1 or minimum 98% of Marshall density.
M
( Opening to Traffic
KU
Traffic shall not be allowed on the newly compacted surface until compaction
has been completed and the material has thoroughly cooled to 60 ' C or lower.
As a guide, this will usually be not less than 4 hours after the commencement
of rolling. Where it is necessary to allow earlier use of the finished surface to
O
facilitate the movement of traffic, vehicles may be allowed to run on the

pavement after rolling has been completed, provided that speeds are restricted
to 30 km/h or less and sharp turning movements are prohibited.
D
S4. 17- IS
JKRlSPJ1201 9·S4
4.17.5 CRUMB RUBBER· OPEN GRADED FRICTION COURSE (CR-OGFC)
a) Mix Design
With high air voids and open-graded aggregates, high binder contents are
essential to ensure mix integrity, increase resistance to oxidation and raveling,
and improve durability. The quantity of binder shall be carefully balanced such
that it is not deemed too excessive to cause binder drain-down during
production , transport and laying, and neither is deemed too little to adversely
affect durability.
ER
Laboratory Compacted Specimens
CR-OGFC mixtures shall be compacted in the laboratory by using the Marshall

method in accordance with ASTM D 1559. The specimens shall then be used
D
for further analysis as described hereof.
N
Because of the limited campactive effort applied in the field on CR-OGFC
mixture, the number of blows per face shall be 50. o
TE
Air Voids Requirements
The design and in-place air voids shall be in the range of 18 to 25%.
A
EJ
Binder Drain-Down Test
Binder drain-down test shall be conducted on 3 samples at mean optimum

CRMB content to ascertain that the binder draining property of the mix is
M
satisfactory.
Binder drain-down test shall be carried out in accordance with the test method
EN
as specified in Appendix A. A sample ofCR·OGFC shall be placed in an oven

for 3 hours at the anticipated asphalt mixing temperature in a wire basket
fabricated using standard 6.3 mm sieve cloth. Any binder drain-down from the
asphalt shall be collected in a pan and shall be not more than 0.2% by weight
o
M
of the total mix.
If the average binder drain·down exceeds 0.2%, the mix design procedure shall
KU
be repeated using a different laboratory design mix aggregate gradation until

all design parameters are satisfied.
O
Cantabro Test
Cantabro test shall be carried out in accordance with the procedure as given in
D
Appendix C. 3 Marshall specimens shall be simultaneously subjected to 300

revolutions in the Los Angeles drum, without the steel balls, at 25 'C. The
average loss of mass shall be not more than 15% .
S4. 17· 16
JKRl5PJ12019-54
Determination of Design Binder Content
Using a selected design aggregate gradation that comply with Tab le I, prepare
9 laboratory mixtures at each binder content in the range 8 to 10%, in
increments of 0.5%.
For each binder content, conduct binder drain-down test on the first 3
laboratory mixtures at the anticipated production temperatu re.
For each binder content, determine theoretical maximum density on the next 3
laboratory mixtures in accordance with ASTM D 2041 .
ER
Use the remaining laboratory mixtures to fabricate 3 Marshall specimens at
each binder content. Apply 50 blows per side at the anticipated compaction
temperature at site.
D
Determine the a ir voids of the Marshall specimens in accordance with ASTM
03023 .
N
( Using the same Marshall specimens. conduct Cantabro test in accordance with
TE
th e test method as given in Appendix C.
The lower limit of the design binder content shall be determined in accordance
with the following two criteria;
A
i. Average loss of mass in the Cantabro test shall be not more than 15%.
EJ
ii. Average air voids shall be not more than 25%.
The upper limit of the design binder content shall be determ ined in accordance
with the following two criteria;
M
i. Average binder drain-down shall be not more than 0.2%.

EN
ii . Average air voids shall be not less than 18%.
Take the mean of the lower limit and upper limit of the design binder content
as determined from the Cantabro test and binder drain-down test respectively
M
as the initial des ign binder content. Use this value to check for air voids and
( make adjustment where necessary such that the air vo ids are between 18 to 25%
but the des ign binder content shall be within the lower limit and upper limit.
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The binder content that meets all the above criteria shall be recomm ended as
the design binder content.
O
The aggregate gradation selected and the desi gn binder content recommended
shall be proposed to the S.O. as the job mix formula .
D
Trial Lay
formula, the Contractor shall arrange to mix, lay and compact the CR-OGFC
mixture. A minimum of 50 tons shall be placed at the job site to demonstrate
to the satisfaction of the S.O. that the mix is satisfactory and the mixing, laying
54. 17- 17
JKR/SPJI2019·S4
and compacting equipment conforms to the requirement of this specification.

As directed by the S.D., comprehensive samp ling and testing ofthe CR·OGFC
mixture shall be carried out to check for satisfactory compliance with the job
mix formula. If the asphalt mixture used in the trial lay comply with the job
mix formula as well as compacted thickness and density requirements, the trial
section shall be accepted as part of the Contract Works. Otherwise, the trial
section shall not be considered as part of the Contract Works and shall be
removed by the Contractor at his own expense.
The observations and tests to be carried out during trial lay shall be, but not
restricted to the following;
ER
i. Select a suitable location for the trial lay within the job site.
ii . Record the types and weight of roller.
D
iii . Record the type of paver.
N
iv. Carry out the following tests on the asphalt mixture;
• Binder content and aggregate grading (ASTM D 2 I 72/BS 598, o
TE
ASTM C \36).
• Theoretical maximum density (ASTM D 2041).
• Bulk density of Marshall specimens (ASTM 3203).
• Calculalion of air voids (ASTM D 3203).
A
v. Record temperatures of asphalt mixture on the tipper lorry, at plant
EJ
and site.
vi. Record lay ing temperatures.

M

EN
o
M

KU
xii. Take at least 3 core samples from each tipper lorry load after the mix
has sufficiently hardened.
xiii. Record compacted thickness, density and air voids of the core
O
samples.
D
xiv. Check permeability of the compacted surfacing (refer to sub·section

4.17.5 (c)).
xv. Check at least one longitudinal joint to ensure that the joint is
satisfactorily constructed.
54 .17· 18
JKRiSPJI20 19-S4
Compliance with Job Mix Formu la
The S.O.'s final approval of the job mix formula shall bind the Contractor to
furnish the CR-OGFC meeting the precise aggregate gradalion and CRMB
content specified in the formula within the tolerances set forth in Table 7.
Table 7 Toleroncesfor CR-OGFC
Permissib le Variation
Parameter
(% by weight of total mix)
CRMB content ± 0.3% xCR
ER
±5.0%
passing 5.00 mm and larger sieves
±4.0%
passing 2.36 mm sieve
Fraction of combined aggregate
D
±2.0%
passing 0.075 mm sieve
N
Note : Refer 10 Table 6 with regol-cis to CR .
(
TE
bj Samplillg alld Testillg of CR-OGFC
Frequency of sampling and testing shall be not less than that shown in Table 8
which provides for two levels of minimum frequency. The reduced frequency
A
may only be adopted as instructed by the S.O. if the test results consistently
conform to the requirements.
EJ
Table 8 Frequency afSampling and Tesling ofCR-OGFC

M
Normal Minimum Reduced Minim um

Test
Frequency Frequency
Aggregate gradation One test per 300 tons of One test per 500 tons
EN

CRMB content One test per 300 tons of One test per 500 tons of
Binder drain--down One test per 300 tons of One test per 500 tons of
M
( asphalt planl production. asphalt plant production.

Temperature Each loaded tipper lorry. Each loaded tipper lorry.
KU
cj COllstructioll Method
O
Pavement Preparation
D
CR-OGFC shall be laid only on structurally sound pavement with minimal

cracks, ruts and depressions.
A strong, durable bond of CR-OGFC to the underlying pavement surface is
essential.
A thick tack coat is essential to ensure;
S4. 17- 19
JKRlSPJnOI9-S4
i. A good bonding of the relatively small surface area of contact ofthe

open-graded CR-OGFC to the underlying pavement surface.
ii. A good resistance to damage induced by residual moisture which may

be trapped at the bottom of the porous asphalt layer.
iii . Effective sealing of cracks and other surface deficiencies which may
be present in the existing pavement surface. thus providing an
impervious underlying surface.
CR-OGFC shall not be used to restore poor road profile.
ER
Existing pavement surface shall be regulated with dense continuously graded
asphalt mixture to remove depression which may trap and hold water under
CR-OGFC layer.
D
N
CR-OGFC shall be laid only on impermeable and plane pavement surface with o
TE
adequate cross fall. A minimum cross fall of2.5% shall be provided.
CR-OGFC shall be laid by machine and compacted wilhin 3 hours of mixing.
Laying shall commence on the low side of the carriageway.

A
CR-OGFC shall be laid to a minimum and maximum thickness of25 mm and
EJ
40 mm respectively.
Hand casting shall be kept to minimum.

M
CR-OGFC shall not be laid directly over an existing concrete pavement

because the difficulty in establishing an adequate bond. However, it shall be
preceded with a layer of dense graded bituminous mixture on the existing
EN
concrete pavement to assist bonding.
When the rehabilitation of a deteriorated concrete pavement includes

bituminous mixture overlay, CR-OGFC shall be used as the final wearing
o
M
course.
CR-OGFC shall not be laid in areas where;

KU
i. The pavement structural strength is sub-standard.
ii. There is considerable traction due to sudden acceleration, braking and

O
turning like at major junctions.
iii.
D
There are tight radius curves, loops of radius less than 75 m.
iv. The gradient exceeds 10%.
v. Excessive deposits of debris, oil and fuel may be experienced.
vi. Free drainage cannot be accommodated along the road shoulders.
S4 . 17-20
JKRiSPJI20 19-S4
vii. Length of roads less than 100 m because of spray carry-over from
adjacent surfacing.
viii. There is high flexibility like on bridges.
ix. Frequent excavations by statutory undertakers may occur.
x. Traffic levels exceed 4,000 commercial vehicles per lane per day at
opening.
xi. There is a 40 kmlh speed limit because there is no beneficial
ER
reduction in spray or noise levels achieved at low speeds.
Compaction
D
CR-OGFC shall be compacted using static steel wheel tandem rollers only.
N
( Vibratory rollers are not permitted because they lead to excessive compaction
TE
and the possibility of aggregate crushing.
Pneumatic tyred rollers are not permitted because they knead and close the
surface, affecting the permeability ofCR-OGFC. They also cause stripping of
aggregates that stick to their tyres.
A
3 wheel steel rollers are not permitted because they leave roller marks that can
EJ
be difficult to remove.
Compaction by rolling shall commence as soon after laying as the material will
support the rollers without undue displacement; nevertheless, the temperature
M
of the CR-OGFC at the commencement of rolling shall be not less than 110 'C.
In any areas inaccessible to the rollers, proper compaction shall be carried out
EN
using vibrating plate compactors, hand tampers or other suitable means, all to
The steel wheel tandem rollers shall operate in a longitudinal direction along
M
the carriageway with their driven wheels towards the paver. Rolling shall
( generally commence at the lower edge of the paved width and progress
uniformly to the higher edge, except that where there is a longitudinal
KU
construction joint at the higher edge, this shall be rolled first ahead of the
normal pattern of rolling. Generally, successive roller passes shall overlap by
quarter of the roller width, and the points at which the roller is reversed shall
be staggered. However. when operating on gradients in excess of 4%, the
O
breakdown roller shall not pass over any previously unrolled mix when
operating in the downhill direction.
D
The rollers shall operate at speeds of not more than 5 kmlh. No roller or heavy
vehicle shall be allowed to sland on newly laid bituminous mix before
compaction has been completed and the material has thoroughly cooled and
set. Rolling pattern shall be in accordance with trial lay carried out earlier and
shall give field density not less th an 97% of Marshall density.
S4. 17-2 1
JKRlSPJI2019-S4
The CR-OGFC layer shall be finished in a neat and workmanlike manner; their
wi dths shall be everywhere at least those specified or shown on the Drawings
on both sides of the centre-line; the average thickness over any 100 m length
sha ll be not less than the required thickness, and the minimum thickness at any
point shall be not less than the required thickness minus 5 mm.
Care shall be taken to prevent over-compaction ofCR-OGFC.
Within 24 hours of lay ing and compacting the bituminous mixture, Ihe
Contractor shall cut core samples of not less than 100 mm nom inal diameter at
ER
locations selected by the S.O. The rate of sampling shall be one sam ple per 500
m' of mixture laid, but not less than 2 samples for the work completed in each
paving session. These core sa mples shall be used by the S.O. to determine the
thickness of the compacted layer of mixture and the compacted density of the
material in accordance with ei ther ASTM D 1188 or ASTM D 6857.
D
N
Joint Construction
TE
The formation of all joints shall be made in such a manner as to ensure a
continuous bond between old and new sections of the course. All joints shall
present the same texture, density, and smoothness as other sections of the
course
A
Cold longitudi nal joints shall not be cut as the inherent rough texture of the
mixture will readily provide good bonding along the joints. Cutting the joints
EJ
may incur damages to the mixture along the joints as the aggregate gradation
of mixture is of open-graded nature. Application of tack coat along the joints
is deemed unnecessary as it may clog the voids along the joints and impede the
M
flow of water across the joints.
Shaping Edges
EN
While the surface is being compacted and finished, the Contractor shall
carefully trim the outside edges of the pavement to the proper alignment.
o
M
Edges so formed shall be beveled while still hot and compacted.

KU
Permeability
Being the principle benefit of CR-OGFC, the permeability shall be sufficient

to allow satisfactory drainage of rain water during heavy rainfall. The
O
permeability ofCR-OGFC wearing course having a minimum thickness of25

mm shall be not less than 900 ml per 15 seconds immediately atter construction
D
if tested in accordance to the test procedure as described in Appendix F.
Opening to Traffic
Traffic shall not be allowed on the newly compacted surface until the layer has
cooled to 60 'C or lower.
S4. I 7-22
JKRiSPJI20t9-S4
4.17.6 CRUMB RUBBER STRESS ABSORBING MEMBRANE

INTERLA YER (CR-SAMI)
Crumb rubber - stress absorbing membrane interlayer (CR-SAMI) is a

pavement layer constructed by spraying CRMB on the surface of the existing
pavement and then spreading and rolling in aggregate chipping prior to
overlaying with asphalt mixture. The main function of the CR-SAMI is to
retard propagation of cracks from the existing pavement into the new overlay.
a) Equipmellt
ER
CRMB Distributor
The distributor shall be equipped with an internal heating device capable of

heating the material evenly up to 220 °C; an internal mixing unit capable of
D
maintaining a proper mixture of bituminous binder and crumb rubber~ have
adequate pump capacity to maintain a high rate of circulation in the tank and
N
to spray the CRMB; have adequate pressure devices and suitable manifolds to
( provide constant positive cut-off to prevent dripping from the nozzles. The
TE
distributor shall be equipped with an electronically controlled computerised
compensation unit for controlling application rates at various width and speed
changes. The application unit shall have electronic controls and a digital read
out installed and operated from the inside of the cab of the distributor. The
distribution bar on the distributor shall be fully circulating. Any distributor that
A
produces a streaked or irregular distribution of the material shall be promptly
repaired or removed from the site.
EJ
Distributor equipment shall include a tachometer, pressure gauges, volume

measuring devices, and a thermometer for reading temperature of tank contents.
Controls for spray bar shall be located in cab of truck, for controlling width
M
and rate of spray of product. It shall be so constructed that uniform applications

may be made at the specified rate per m' with a tolerance of ± 0.2 kg/m' .
EN
Aggregate Spreader
The aggregate spreader shall be hydrostatically driven and self-propelled. It

M
<. shall be equipped with a hydraulically controlled variable adjustable head that
is capable of spreading aggregate in widths from 1.5 to 5.5 m. The spreader
shall be mounted on pneumatic tyres, and shall spread the aggregate on the
KU
road surface in a manner that ensures that the lyres do not contact the road
surface until after the aggregate has been applied. The unit shall be equipped
with an electronic radar type sensor used to measure ground speed and will
automatically adjust the aggregate application rate depending on width of
O
application and the speed of chip spreader. It shall have the ability to apply
aggregate on any gradient from 0 - 6%. The spreader shall be equipped with an
D
integral hopper with a minimum capacily of 5 tons of aggregate which shall be

filled by trucks in a manner which ensures that the truck tyres never come in
contact with the road surface until the aggregate has been properly applied. To
maintain constant aggregate application, a self-locking truck hitch will pennit
towing of aggregate trucks without stopping the chip spreader. It shall be
capable of maintaining positive engagement over irregular terrain.
S4. t7-23
JKRlSPJf2019-S4
Pneumatic-Tyred Roller
A minimum of 2 self-propelled, multiple wheel, pneumatic-tyred rollers shall

be used, both shall weigh a minimum of 15 tons, and shall have a total
compacting width of at least 1.5 m.
b) Constructioll Method
Surface Preparation
Defects on the existing pavement surface such as potholes and depressions
ER
shall be patched or regulated accordingly. The surface shall then be thoroughly
cleaned by sweeping with power broom andlor air blower prior to application
of CRMB and aggregate chipping.
D
Seasonal and Weather Limitations
N
Construction shall proceed only when the atmospheric temperature is at least
TE
20°C. No water shall be present on the road surface.
Application of eRMB
A
The CRMB shall be applied at a temperature in the range between 180 to 200
'C and at a rate of 2.0 to 2.6 kglm 2•
EJ
Longitudinal joints shall be parallel to centrelines. Where any construction

joint occurs, the edges shall be broomed back and blended so there are no gaps
and the elevations are the same, and free from ridges and depressions.
M
Longitudinal joints shall be overlapped by 100 mm.

During application, adequate provision shall be made to prevent marring and
discoloration of adjacent pavements, structures, vehicles, foliage or personal
EN
properties.
The CRMB distributor shall be operated at constant speed to ensure the
o
M
homogeneity during the spraying process. Over-spray shall be avoided and

partial-miss shall be made good manually.
KU
Construction equipment or other vehicles shall not drive on the CRMB layer
before aggregates are applied.
O
Application of Aggregate
The application of aggregate shall follow as close as possible behind the

D
application of the CRMB which shall not be spread further in advance of the
aggregate spread than can be immediately covered. The aggregate shall be
spread uniformly by a self-propelled spreader at a rate ranging from 12 to 16
kglm 2 which shall be detennined from a trial section. During conslruction, the
aggregate shall fully cover the CRMB area and no loose aggregate shall be
allowed. Any deficient areas shall be covered with additional aggregate
manually.
S4 .17-24
JKRlSPJI2019-S4
Compaction
A minimum of2 pneumatic-tyred rollers, each with operating weight of at least

15 tons, shall be used for aggregate embedment into the CRMB. Rolling shall
commence immediately after spreading the aggregate. There shall be at least 3
passes (a pass being I movement ofa roller in either direction) by the roller to
embed the aggregate parlicles firmly into the CRMB. Each pass shall overlap
at least 113 of the wheel width.
Compaction sequence shall be from the lower side to the crown.
ER
Sweeping
When all the aggregate has been finnly embedded into the CRMB and Ihe
pavement has cooled, all loose aggregate shall be swept or removed manually.
D
This shall be done at a time in a manner, which will not displace any embedded
aggregate or damage the CRMB. The aggregate removed shall be disposed
from the site.
N
(
TE
Preparation for Overlay
Tack coat, using RS-I K bituminous emulsion, shall be applied at 0.25 to 0.5
11m 2 before overlay is carried out.
A
Opening to Traffic
EJ
CR-SAMI layer construction shall be immediately followed by overlay. No

traffic is allowed between these processes. Where it is necessary to allow
M
earlier use of the finished CR-SAMI to facilitate the movement of traffic,

vehicles shall only be allowed at least 3 hours after the CR-SAMI construction,
provided that speeds are restricted to 25 kmIh or less and sharp turning
EN
movements are prohibited.

M
<.
KU
O
D
S4. 17-25
JKRlSPlI2019-S4
Appendix A - Binder Drain-Down Test
1.0 Scope
This test method covers the determination of the amount of binder drain-down in an un-
compacted asphalt mixture sample when the sample is held at elevated temperatures
comparable to those encountered during the production, storage, transport and placement ofthe
mixture.
ER
AASHTO Standards T 245 Resistance to Plastic Flow of Bituminous Mixtures Using Marshall
Apparatus and M 92 Standard Specification for Wire Cloth Sieve for Testing Purposes.
D
o
N
3.0 Binder Drain-Down
TE
For the purpose of this test method, binder drain-down is considered to be that portion of the
bituminous mixture which separates itself from the sample as a whole and is deposited outside
the wire basket during the test.'o A
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A sample of the asphalt mixture of mass 1. 1 kg is prepared in the laboratory or obtained ITom
field production. The sample is placed in a wire basket that is positioned on a pre-weighed
paper plate. The sample, basket and plate are placed in a forced air oven for one hour at a pre-
selected temperature. At the end of 3 hours, the basket containing the sample is removed ITom
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the oven along with the paper plate and the paper plate is weighed to determine the amount of
binder drain-down that occurred.
EN
Test method can be used to determine whether the amount of binder drain-down measured for
o
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a given asphalt mixture is within acceptable levels. It also provides an evaluation of the binder
drain-down potential of asphalt mixture produced in the field.
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10 Any noticeahfe aggregate particles that are deposited outside the basket shall be added back into tire mixture
and 1101 counted as binder drain-down. Alternatively 'he lest sholl be repeated.
S4. 17-26
JKRlSPJI2019-S4
6.0 Apparatus
i. Oven capable of maintaining the temperature in a range from 1200 - 1750 'C. The
oven shall maintain the set temperature to within ± 2 'C.
ii . Paper plates of appropriate size. The paper plates shall be of appropriate durability
to withstand the oven temperatures.
iii . Standard cylindrical shaped basket meeting the dimensions shown in Figure I. The
basket shall be constructed using standard 6.3 mm sieve cloth as specified
AASHTOM92 .
iv . Spatulas, trowe ls, mixer and bowls as needed.
v. Balance accurate to 0.1 g.
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..
..,' TlJ p "i~w
•
,. .
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," I
, :', IO'lmm
g'"''''
" ,.
- '-mrn
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...
,,'
" "
", I
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- y- '," - y-
r-,o'~'-1
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FIGURE 1 - Wire basket assembly

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7.0 Prepared Samples
7.1 Laboratory Prepared Sam ples

EN
1. For each mixture, the binder drain-down characteristics shall be determined at the
anticipated plant production temperature. Duplicate samples shall be tested.
ii. Dry the aggregate to constant mass and sieve it into appropriate size fractions as
indicated in AASHTO T 245, Section 3.2.
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iii. Determine the anticipated plant production temperature or select a mixing

temperature in accordance with AASHTO T 245, Seclion 7.3 .1. The supplier's
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recommendations shall be sought when using mod ified bitumen.

iv. Weigh into separate pans for each test sample the amount of each size fraction
required to produce complete bituminous mixture samples having a mass of 1,200
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g. The aggregate fractions shall be combined such that the resulting aggregate
blend has the same gradations as the job mix formula. Place the aggregate samples
in an oven and heat to a temperature not to exceed the mixing temperature
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established in (iii) by more than approximately 28 ' C.

v. Heat the asphalt mixture to the temperature established in item (iii).
VI. Place the heated aggregate in the mixing bowl. Form a crater in the aggregate blend
and add the required amount of asphalt. The amount of asphalt shall be such that
the final sample has the same binder content as the job mix formu la. At this point,
S4. 17-27
JKRlSPJI2019-S4
the temperature of the aggregate and asphalt mixture shall be within the limits of
the mixing temperature established in (iii). Using a spatula (if mixing by hand) or
a mixer, mix the aggregate and binder quickly, until the aggregate is thoroughly
coated.
7.2 Plant Produced Samples
For plant produced samples, duplicate samples shall be tested at the plant production
temperature.
Samples shall be obtained during plant production by sampling asphalt mixtures from tipper
lorries prior to the mixtures leaving the plant. Samples obtained dur ing actual production shall
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8.0 Procedure
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\. Transfer the laboratory produced or plant produced un-compacted open graded
friction course mixture sample to a tarred wire basket described in 6.0 (iii). Place
o
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the entire sample in the wire basket. Do not consolidate or otherwise disturb !he
sample after transfer to the basket. Determine !he mass of the sample to the nearest
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0.1 g.
ii. Determine and record the mass of a paper plate to the nearest 0. 1 g. Place !he
basket on the paper and place the assembly into the oven at the temperature as
determined in 7.1 (iii) for 3 hours ± I minute.
A
iii. After the sample has been in the oven for 3 hours, remove the basket and paper
plate. Determine and record the mass of the paper plate to !he nearest 0.1 g.
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9.0 Calculations
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Calculate !he percent of mixture which drained by subtracting the initial paper plate mass from
the final paper plate mass and divide this by the initial total sample mass. Multiply the result
by 100 to obtain a percentage.
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10.0 Report
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Report the average percent binder drain-down at the test temperature. Q

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S4.17-28
JKRlSPJI201 9-S4
Appendix B - Schellenberg Binder Drainage Test
1.0 Scope
This method is to detennine the fTee asphalt quantity of asphalt binder separated fTom asphalt
mixtures at the condition of high temperature and used to inspection of maximum binder
content of crumb rubber - stone mastic asphalt (CR-SMA), crumb rubber - gap graded asphalt
(CR-GGA) and crumb rubber - open graded fTiction course (CR-OGFC).
2.0 Apparatus and Materials
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i. 800 ml beaker
ii . Oven
iii. Small-size asphalt mixtures mixer
iv. Glass plate
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v. Balance: with a sensibility not greater than 0.1 g
vi . Others: hand shovel, cotton yarn, etc.
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(
TE
3.0 Test Procedure
1. Prepare 3 duplicate asphalt samples which comply with the job mix fonnula . Each
sample shall be I kg.
ii. Clean the 800 ml beaker, dry it and weigh the beaker mass III. to an accuracy of
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0.1 g.
iii . Pour 1 kg of the mixture into the beaker, and weigh the total mass of the beaker
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and the mixture to an accuracy of 0.1 g.
iv. Cover the beaker with a glass plate, put the beaker into a 170 ± 2 'C oven, if it is
the CR-SMA, the temperature shall be 185 'C for 60 ± I minutes.
v. Take the beaker out without any impact or vibration, put the mixture downwards
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on the glass plate, weigh the total mass III, of the beaker, binder attached on the
beaker, fine aggregate and mastic to an accuracy of 0.1 g.
For construe lion quality inspection, samples shall be obtained during plant production
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by sampling asphalt mixtures fTom tipper lorries prior to the mixtures leaving the
plant. Samples obtained during actual production shall be reduced to the proper test
sample size by the quartering method.
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( 4.0 Calculation
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The drainage mass loss of the asphalt shall be calculated according to Equation /.
t!Jn = m, - m. x 100 (Equation 1)

nll-InO
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where:
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III. = The beaker mass (g);

III, = The tolal mass of beaker and asphalt mixtures for test use (g);
III, = The total mass of beaker, asphalt binder attached on the beaker, fine
aggregate, and masti c (g);
l!.1II = The drainage mass loss ofthe asphalt (%).
S4. 17-29
JKRlSPJnO I9-S4
5.0 Report
The test shall be carried out on at least 3 samples and the average va lue shall be taken as the
test result.
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S4. t7-30
JKRiSPJI2019-S4
Appendix C - Cantabro Test
1.0 Scope
Cantabro test shall be done on the proposed mix to measure its resistance to stone loss at high
frequency. The test procedures and apparatus are described below;
2.0 Apparatus
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i. Marshall Compactor· see description in ASTM D 1559.
ii . Loss Angeles Drum· see description in ASTM C 131 .
iii . Thermometers: to measure the temperatures of the aggregate, binder and
bituminous mix, metal thennometers with a scale up to 200°C and accuracy of3
°C are used. To measure the temperature at wh ich the test is carried out, a
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thermometer with a scale from 0 to 50°C and an accuracy of 0.5 °C is used,
iv. Balances: a balance with a capacity of 2 kg to an accuracy of 0.1 g to weight the
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( samples and another with a capacity of 5 kg to an accuracy of I g to prepare the
mixes.
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v. General materials: tray. pots, spatulas, asbestos gloves, curved scoops, filter paper
rings etc.
3.0 Procedure
A
The different aggregate fractions which make up the mix are dried in a stove at 105 - 110
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°C until constant weight is reached . At the proposed optimum binder content, 4 Marshall
specimens are manufactured with 50 blows on each side at adequate temperature " . The
relative density and void percentage shall be determined as soon as they have cooled to
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ambient temperature. The procedure to determine the density and void percentage shall be
based on geometric procedures.
The specimens shall be dried at ambient temperature for 2 days . Before testing the
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specimens, they shall be kept at test temperature, 25 'C, for at least six hours. After the
specimens have been kept for the required time, weigh it (Mo), then place immediate ly into
the Los Angeles drum without abrasion loads (balls). The drum shall be turned at a velocity
between 188 and 208 radls and submitted to 300 revolutions . This shall be repeated for the
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4 specimens.
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Weigh the specimen after test (M ,). For each specimen, the stone loss or attrition resistance
is computed;
L = M,-M, x 100% (Equation 2)
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The average stone loss (L) is reported and shall be not more than 15%.
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II Mixing temperatures are uSllally 130 DC for conventional binder and 170 "e Jor eRMB.
S4 . 17-31
JKRlSPJI2019·S4
Appendix D - Semi-Circular· Bend (SCB) Test
1.0 Scope
This test method covers the procedures for preparation, testing, and measurement of asphalt
mixture cracking resistance at Long Term Pavement Performance (LTPP) database
intermediate temperatures using semi·circular bend (SC8) geometry laboratory prepared or
pavement core asphalt mi x samples tested monotonically. The SC8 sample is a half·disk with
a notch cut parallel to the loading and vertical axis. The test method describes the determination
of the critical strain energy release rate, Je • and other parameters detennined from the load-
displacement curve. These parameters can be used to rank the resistance of aspha lt mixtures to
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cracking.
2.0 Summary of Test Method
D
A semi-circular specimen is loaded monotonically until fracture failure occurs under at constant
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rate of deformation in a three·point bending load configuration. The load and deformation are
continuously recorded and 8re used to compute the critical strain energy release rate, Je . High
J, values are desirable for fracture-resistant mixtures. A J, value ranging from 0.5 to 0.60 kJ/m'
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is typically recommended to ensure adequate fracture resistance of the mixture.
This test procedure considers the elasto-plastic/viscoelastic relationship of asphalt mixtures and
fracture mechanics (Mull, et aI., 2006, Anderson 2005 and suggested by Wu et aI., 2005).
A
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3.0 Apparatus
i. Load Test System :
A load test system consisting of an axial loading device, environmental chamber,
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and control and data acquisition system. The test system shall meet the minimum
requirements specified in Table 9.
• Axial Loading Device - The load apparatus shall be capable of maintaining a
constant cross-head deformation rate of 0.5 mm/min.
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• Environmental Chamber - A chamber capable of maintaining 60.3 ' C of the

climatic intennediate temperature calculated in Equation 3.
• Control and Data Acquisition System - The system shall include a data
acquisition system comprising analog to digital conversion or digital input, or
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both, for storage and analysis on a computer. The system shall be capable of
measuring and recording 3 signals during the test including load, displacement,
and chamber temperature 10Hz. The minimum resolution of the measurements
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is provided in Table 9.
Table 9 see Test System Minimum Requirements

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Measurement Range Accuracy

Load Measurement and Control Oto 10kN ± 1%
oto 30 mm
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Displacement Measurement and Control ± 0.5%

Temperature Measurement and Control Range 5 to 35 ' C ± 0.3 'C
S4. 17-32
JKRlSPJI2019-S4
Ii. Measurement Devices:

• Load Measuring Device - The load measuring device shall consist of an
electronic load cell, designed for placement between the load platen and piston,
with the minimum capacity and sensitivity stated in Table 9. The load cell shall
be calibrated in accordance with ASTM Standards E4.
• Axial Deformations - Axial deformations shall be measured with linear
variable differenlial transformers (L VDT) or other devices capable of
measuring displacement within the range and tolerance provided in Table 9.
The L VDT shall be calibrated in accordance with Practice ASTM Standards
E3029, Class B.
• Temperature - Chamber temperature shall be measured with Resistance
Temperature Delectors (RTD) or olher suitable devices accurate to within ± 0.3
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' C.
iii. Gyratory Compactor - A gyratory compactor and associated equipment for
preparing laboratory specimens in accordance with ASTM Test Method 06925
shall be used.
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IV. Saw - The saw shall be capable of producing three different notch sizes ranging
from 0 to 50 mm. The width of the saw blade shall be < 3.5 mm.
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v. Test Fixture- The loading frame shall consist of a loadi ng rod and 2 sample
( support rods. The schematic of the test apparatus is shown in Figure 2. The
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diameters of the loading and supports rods shall be 25 mm and the anvil span shall
be 127 mm.
vi. Reaction Surface Treatment-Polytetranuoroethylene (PTFE) strips are used to
reduce friction between the specimen and the lower two support rollers.
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Figllre 2 Shop Drawing o[SCB Test Fixture
84. 17·33
JKRlSPJI2019·S4
4.0 Sampling, Test Specimens, and Test Units

Semi·circular bend testing may be performed on field cores or laboratory prepared test
specimens.
4.1 Laboratory-compacted asphalt mixture samples:

i. Specimen Size - The test specimens shall be 150 mm in diameter by 120 mm
thick.
ii. Air Void Content - Prepare a minimum of3 gyratory test specimens at the target
air void content using the Superpave Gyratory Compactor (SGC) according to
ASTM Test Method D6925 at the target air void content ± 0.5%. The typica l air
void target for the test specimens is 7.0 %,
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iii. The semi-circular shaped specimens are prepared by first cutting a 150 mm
diameter by 120 mm thick specimen into 2 equal circular samples 57 mm thick.
These samples are cut along its central axis into 2 equa l circular samples. The
height (radius) of the 2 halves shall be within I mm of each other.12
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4.2 Samples Cored from Asphalt Pavement:
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i. Roadway cores can be used if pavement thickness is between 38 to 60 mm. Cores
shall be taken full depth so that no prying action is needed to extract the cores from
the pavement. o
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ii. Care shall be taken to avoid stress or damage to the interface during coring,
handling, and transportation. The cores shall be trimmed such that only a single
layer is tested.
Ill. Roadway core specimens shall be approximately 150 mm diameter with all surface
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of the perimeter perpendicular to the surface of the core within 6 mm . If the
thickness of the core being tested is greater than 57 mm, it shall be trimmed with
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a wet masonry saw to a height of 57 mm.
iv. The semi-circular shaped specimens are prepared by slicing the 150 min diameter
specimen prepared in 7.2.3 along its central axis into 2 equal circular samples. The
hei ght (radius) of the 2 halves shall be within I mm o f each other.
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Notching - A straight vertical notch is cut along the symmetrical axis of each semi-circular
specimen. The location of the notch shall be in the center ofthe specimen within 0.3 mm. The
EN
three nominal notch depths are 25 mm, 32 mm, and 38 mm. The notch depth tolerance is ± 1.0
mm . The width of the notch shall be <3.5 mm."
Aging - Laboratory-prepared test specimens shall be long term temperature-conditioned in

according to AASHTO R30. Roadway cores need not be aged prior to testing.I'
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A minimum of 4 specimens shall be tested at each of the following notch depths: 25 mm, 32
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mm, and 38 mm.

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12 Some practitioners believe 'hat 'he test should be conducted 011 specimens with 2 cut / aces. If this approach Is
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tlsed, increase the compacted sample height by approximately I j ± 5 mill Sl/ch that tile semi-circli/ar shaped
specimens with 2 cl/t/aces have afina/ thickness 0/57 ± J mm.
13 Ruggedness testing behveen 4 laboratories has shown the J, jor split samples 10 have a within laboratory COV
0/9.9 %/or specimens with notch widths behl'een 1.3 mm and 3.4 111m. The specimens shoilld be symmetrical
about the cut notch.
14 A loose mix aging method is under development that may be able 10 achieve the AASHTO R30 level 0/ aging in
12 (0 24 h. NCHRP 9-54 Long Term Aging 0/ Asphalt Mixll/res/or Per/onl/ance Testing al1d Prediction. The
long term temperature aging ;s needed (0 account jor binder SOl/rce, RAP, RAS and rej l/venalors on mix
performance (Reinke, et 01., 2009, 2015, Cooper, et 01. 2014, 20/5).
54 .17·34
JKRl5PJi20 19·54
5.0 Procedure
i. Inspect the fixture to ensure all contact surfaces are clean and free of debris. Place
the PTFE tape or pads to reduce friction caused by interactions between the
specimen and testing fi xture during loading. Depending on fixture geometry the
PTFE pads can be placed either:
• between the specimen and the bottom support roll ers Of,
• with the specimen resting on the support rollers between the rollers and the
base of the text fixture .
II . Load the specimen in the fixture, ensuring the specimen is centered and making
uniform contact (level) on the support rollers (as shown in Figure 3).
III . Set the environmental chamber temperature and allow it to stabili ze to the test
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temperature 60.3 °c. A dummy specimen with a temperature sensor mounted to
its center can be monitored to detennine when the specimen reaches the test
temperature 60.3 'C. In the absence of a dummy specimen, the specimens should
be placed in the environmental chamber set at the test temperature for a minimum
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0[2 ± 0.5 h to reach the required temperature equilibrium.
iv. Select test temperature based on the climati c intermediate temperature
performance grade temperature as defined in AASHTO M320 or M332 and
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( provided below in Equation 3:
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PC IT = PC HT+PC
2
LT + 4 (Equation 3)
where:
PC IT ~ Intermediate performance grade temperature (' C),
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PC HT ~ Climatic high performance grade temperature, and
PC LT ~ Climatic low performance grade temperature.
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v. After temperature equi librium is reached, apply a preload of 45 ± ION for a

maximum duration of30 5 to specimen to ensure the sample is seated properly.
After ensuring the sample is level, release the load.
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VI. Begin to apply load to specimen in displ acement control at a rate of 0.5 mm/min
ensuring that time, force, and displacement are measured and recorded at a
sampling rate of 10 Hz. Test may be terminated when the applied load decreases
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to 25% of the peak load.
6.0 Calculation or Interpretation or Results

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( The critical value of J-integral (Ie) is determined usi ng Equation 4:
-1 (dU)
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Jc = b da (Equation 4)
where:
Ie critical strain energy release rate (kJ/m2),
=
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b ~ sample thickness (m),

a ~ notch depth (m),
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U ~ strain energy to fai lure (kJ), and

dU/da ~ change of strain energy with notch depth (kJ/m).
$4. 17-35
JKRlSPJI2019-S4
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o
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Figure 3 Examples a/SCB Test Fixtures/or a Universal Testing Machine (a and b) and a
Marshall Press (c) or AMPT (d)
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S4. 17-36
JKRlSPJ12019-S4
Appendix E - Hamburg Wheel-Tracking Test
1.0 Scope
This test method describes a procedure for testing the rutting and moisture-susceptibility of
asphalt mixture pavement samples in the Hamburg Wheel-Tracking Device.
The method describes the testing of submerged, compacted asphalt mixture in a reciprocating
rolling-wheel device. This test provides information about the rate of permanent deformation
ITom a moving, concentrated load. A laboratory compactor has been designed to prepare slab
specimens. Also, the Superpave Gyratory Compactor (SGC) has been designed to compact
specimens in the laboratory. Alternatively, field cores having a diameter of 150 mm, 250 mm,
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or 300 mm, or saw-cut slab specimens may be tested.
The test method is used to determine the premature failure susceptibility of asphalt mixture due
to weakness in the aggregate structure, inadequate binder stiffness, or moisture damage. This
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test method measures the rut depth and number of passes to failure.
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The potential for moisture damage effects are evaluated since the specimens are submerged in
( temperature-controlled water during loading.
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AASHTO Standards:
i. R 30, Mixture Conditioning of Hot Mix Asphalt (HMA)
A
ii. T 166, Bulk Specific Gravity of Compacted Hot Mix Asphalt (HMA) Using
Saturated Surface-Dry Specimens
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III . T 168, Sampling Bituminous Paving Mixtures

IV . T 209, Theoretical Maximum Specific Gravity and Density of Hot Mix Asphalt
(HMA)
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v. T 269, Percent Air Voids in Compacted Dense and Open Asphalt Mixtures
vi. T 312, Preparing and Determining the Density of Asphalt Mixture (HMA)
Specimens by Means of the Superpave Gyratory Compactor
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A iaboratory-compacted specimen of asphalt mixture, a saw-cut slab specimen, or a core taken
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ITom a compacted pavement is repetitively loaded using a reciprocating steel wheel. The
( specimen is submerged in a temperature-controlled water bath of 40 to 50 ' C or a temperature
specified for the binder being used . The deformation of the specimen, caused by the wheel
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loading, is measured.
The impression is plotted as a function of the number of wheel passes. An abrupt increase in
the rate of deformation may coincide with stripping of the asphalt binder ITom the aggregate in
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the asph alt mixture specimen.

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S4.17-37
JKRl5PJ120 19·54
4.0 Apparatus
i. Hamburg Wheel-Tracking Device - An electrically powered machine capable of
moving a 203 .2 diameter, 47 mm wide steel wheel over a test specimen. The load
on the wheel is 705 ± 4.5 N. The wheel reciprocates over the specimen, with the
position varying sinusoidally over time. The wheel shall make 52 ± 2 passes across
the specimen per minute. The maximum speed of the wheel shall be approximately
0.305 mls and will be reached at the midpoint of the specimen.
ii . Temperature Control System -A water bath capable of controlling the temperature
within ± 1.0 'C over a range of 25 to 70 ' C. This bath shall have a mechanical
circulating system to stabilize the temperature within the specimen tank.
iii. Impression Measurement System - A linear variable differential transducer
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(L VDT) device capable of measuring the depth of the impression of the wheel
within 0. 15 mm, over a minimum range of a to 20 mm. The system shall be
mounted and capable of measuring the depth of the impression at different
intervals across the width of the wheel' s path on the test specimen. The impression
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shall be measured at least every 400 passes of the wheel. This system must be
capable of measuring rut depth without stopping the wheel. This measurement
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must be referenced to the number of wheel passes.
iv. Wheel Pass Counter-A non-contacting solenoid that counts each wheel pass over
the specimen. The signal from this counter shall be coupled to the wheel o
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impression measurement, allowing for the rut depth to be expressed as a function
of the wheel passes.
v. Slab Specimen Mounting System - A stainless steel tray that can be mounted
rigidly to the machine. This mounting system must restrict shifting of the specimen
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to within 0.5 mm during testing. The mounting system shall suspend the specimen,
allowing for free circulation of the water bath on all sides. The mounting system
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shall be designed to provide a minimum of20 mm of free circulating water on all
sides ofthe specimen.
vi. Cylindrical Specimen Mounting System - A stainless steel tray that can be
mounted rigidly to the machine. This mounting system must restrict shifting of the
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specimen to within 0.5 mm during testing. The mounting system shall include 2
high-density polyethylene molds (as shown in Figures 4 and 5) placed in a stainless
steel tray to secure the specimen. The stainless steel tray is suspended in the
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machine, allowing for free circulation of the water bath on all sides. The mounting
system shall be designed to provide a minimum of20 mm of free circulating water
on all sides of the specimen.
vii. Linear Kneading Compactor - A hydraulic powered unit used to compact asphalt
mixtures into rectangular slabs. The mixture is placed in a mold and compacted
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through a series of vertically aligned steel plates that compress the asphalt mixture
into a flat slab of predetermined thickness and density.
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viii. Balance of 12000 g capacity, accurate to 0. 1 g.

ix. Ovens for heating aggregate and asphalt binders.
x. Superpave Gyratory Compactor (SGC) and molds conforming to T 312.
XI. Bowls, spoon, spatula, etc.
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54.17·38
JKRlSPJI2019-S4
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Figure 4 Cylindrical specimen mounting system
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High·Density Polyethylene Molds
Thickness"" 60 ± 1 mm
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T
,
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Gnp width, 7.5 mm max.

L-____________________
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~ ~
·Varies
• Dimension may vary depends Of! mallufactllrer.
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Figure 5 Schematic a/Cylindrical Specimen Mounting System

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3_0 Specimen Preparation

2 test specimens shall be prepared for each test Specimens may either be slab specimens or
cylinders.
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3_1 Laboratory-Produced Aspha lt Mixture:

Mixture proportions are batched in accordance with the desired job mi x formula.
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i.
ii. The temperature to wh ich the asphalt binder must be heated to achieve a viscosity
of 170 ± 20 cSt shall be the mixing temperature. For modified asphalt binders, use
the mixing temperature recommended by the binder manufacturer.
iii. Dry-mix the aggregates and mineral adm ixture (if used) first; then add the correct
percentage of asphalt binder. Mix the materials until all aggregates thoroughly
coated. (Wet-mix the aggregates if a lime slurry or other wet material are used).
S4 . 17-39
JKRlSP J/20 19-54
iv. Test samples shall be conditioned at the appropriate compaction temperature in

accordance with the short-term conditioning procedure for mechanical properties
in R30.
v. The temperature to wh ich the asphalt binder must be heated to achieve a viscosity
of280 ± 30 cSt shall be the compaction temperature. For mod ified asphalt binders,
use the compaction temperature recommended by the binder manufacturer.
VI. Specimens compacted in the laboratory shall be either compacted slab specimens
or SOC cylindrical specimens.
• Compacted Slab Specimens:
Material shall be compacted into slab specimens using a Linear Kneading
Compactor (or equivalent) and shall be 320 mm long and 260 mm wide. A
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slab specimen thickness of 38 mm to 100 mm can be used. The slab
specimen thickness shall be at least twice the nominal maximum aggregate
size. Compacted slab specimen shall be cooled at room temperature on a
clean, flat surface until the specimen is cool to the touch.
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• SOC Cylindrical Specimens:
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Material shall be compacted into specimens using an SOC according to T
312. A specimen thi ckness shall be at least twice the nominal maximum o
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aggregate size. Two 150 mm diameter specimens are needed. Compacted
specimens shall be cooled at room temperature on a clean, flat surface until
the specimen is cool to the touch.
3_2 Field-Produced Asphalt Mixture - Loose Mix:
i. Obtain a sample of asphalt mixture in accordance with T 168.
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II . Specimens compacted in the laboratory shall be either compacted slab specimens
or SOC cylindrical specimens as specify in 3. 1 (vi).
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3_3 Field-Produced Asphalt Mixture - Field Compacted (Core/Slab Specimen):

i. Cutting Field Cores or Field Slab Specimens - Field cores or field slab specimens
shaH consist of wet saw-cut compacted specimens taken from asphalt mixture
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pavements. Field cores shall be 300 mm, 250 mm, or I SO mm in diameter. Field
slab specimens shall be wet saw-cut to approximately 260 mm wide by 320 mm
long. A slab specimen thickness is typically 38, but may be adjusted to fIt the
specimen mounting system by wet saw-cutting. Field cores shall also be cut
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according to 3.4 (ii).15

ii. Cutting SOC Cylindrical Specimens and Field Cores - Cut specimens using a wet
saw after a minimum of 24 hr from the time of compaction. Saw the specimens
along a secant line (or chord) such that when joined together in the molds, there is
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no space between the cut edges. The amount of material sawed 1T0m the SOC
cylindrical specimens may vary to achieve a gap width no greater than 7.5 mm
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between the molds.

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15 Care should be taken to load the sample so it is (evel to the surface a/the mold. The sample IIIUSt be trimmed if
it is loa tall or shimmed lip if it is too short (supporting with plaster if needed). The down presSl/re from the
wheel Is calibrated 10 be 705 N (158 fb) at Ihe center, level to Ihe lOp of the mold position. E'lien a small change
in e/eWllion will change the dOlYn pressure significantly.
S4 . 17-40
JKRl5PJ12019-$4
4.0 Determining Air Void Content

I. Determine the bulk specific gravity of the specimens in accordance with T 166.
ii. Determine the maximum specific gravity of the mixture in accordance with T 209.
iii . Determine the air void content of the specimens in accordance with T 269. It is
recommended for laboratory-compacted specimens, that the target air void content
be 7.0 ± 1.0%. Field specimens may be tested at the air void content at which they
are obtained .
5.0 Procedure
Slab and Large Field Core Specimen Mounting :
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I.
Use Plaster-of-Paris to rigidly mount the 300 mm, 250 mm, or slab specimens in
the mounting trays. Mix the plaster at approximately a I: I ratio of plaster to water.
Pour the plaster to a height equal to that of the specimen so that the air space
between the specimen and the sides of the mounting tray is filled . The slab
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specimen shall be in direct contact with the mounting tray; however. plaster may
flow underneath the specimen. The plaster underneath the specimen shall not
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exceed 2 mm. Allow the plaster at least 1 h to set. [f using other mounting material
( is used, it should be able to withstand 890 N of load without cracking.
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ii . SOC Cylindrical and Field Core Specimen Mounting:
Place the high-density polyethylene molds in the mounting tray. [nsert the cut
specimens in the molds. Shim the molds in the mounting tray as necessary. Secure
the molds into the mounting tray by thightening the bolts of the edge plate 'hand
tight' .
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iii. Place the mounting tray(s) wi th the test specimens into the device and secure by
tightening the bolts 'hand tight'.
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iv. Tum the testing device and computer on.
v. Start the software used to communicate wilh the testing device.
vi . Enter the pertinent project information and testing configuration requirements.
a) Select the test temperature based on the appl icable specifications.
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b) Select the maximum allowable rut depth based on the applicab le

specifications.
c) Select the maximum number of passes based on the applicable
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specifications.
d) Enter a start delay of 30 min to precondition the test specimens. The
temperature of the specimens in the mounting tray shall be the test
temperature selected in 5.0 (vi)(a) upon completion of this preconditioning
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period.
<. vii. Proceed to 5.0 (viii) to operate the testing device in "Auto" mode. Proceed to 5.0
(ix) to operate the testing device in "Manual" mode.'·
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viii. Performing the Test in Auto Mode:

• Adjust the height of the LVDT to a location as per manufacturer's
recommendations. I?
• Lower the wheels onto the edge of the test specimens such that a majority
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of the wheel is in contact with high-density polyethylene molds in the

mounting tray.
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16 Perform thl! test in "Attlo " mode lor testing de vices manllfactur~d in the United States later titan 1998, where
sojMare will automatically open and close the valves to jill and drain fhe wafer bath. Devices made available
fO tire United Sfmes prior 10 J998 do not have fhis option and must be operated manllally.
17 Tire LVDTjor each stee /wlteel is automatically =eroed at the start of the test. The software will display Q =ero at
Ih e starf of fhe feSf.
54.1741
JKRlSPJI20 19·S4
• Start the test by selecting the "Start" button ofthe testing device software."
• The wheel-tracking device shall shut off when 20,000 passes have occulTed
or when the test has achieved the maximum impression depth established in
5.0 (vi)(b). The testing device software automatically saves the test data file.
• Raise the wheel(s) and remove the specimen mounting tray(s) and rutted
specimens.
• Proceed to 5.0 (x).
ix. Performing the Test in Manual Mode:
• Close the drain valve(s) and fill the water bath of the wheel-tracking device
with water until the fl oat device(s) raises to a horizontal position.19
• Precondition the test specimens in the water bath for 30 min after the water
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has reached the selected test temperature.
• Lower the wheels onto the specimens after the test specimens have
preconditioned at the selected test temperature for 30 min. For machines
that start automatically after the selected preconditioning time, it is
allowable to lower the wheels before the preconditioning cycle. The wheel
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shall not be in contact with the specimen for more than 5 min prior to
starting the wheel.
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• Ensure the micro-control unit's LVDT reads between 10 mm and 18 mm.
Adjust the LVDT height to obtain this reading. Loosen the 2 screws on the
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LVDT mount and slide the LVDT up or down to the desired height. Tighten
the screws.
• Start the test.
• The wheel-tracking device will disengage when 20,000 passes have
occulTed. The devise will also disengage if the average LVDT displacement
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(read from the micro-control unit, not the screen) is 40.90 mm or greater for
an individual specimen. Note that the screen readout subtracts the initial
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LVDT reading from the total displacement.
• Open the valve(s) beneath the tanks and drain the water bath. Raise the
wheel(s) and remove the specimen mounting tray(s) and rutted specimens.
x. Clean the water bath, heating coils, wheels, and temperature probe with water and
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scouring pads or per the manufacturer's recommendations. Use a wet·dry vacuum

to remove particles that have settled to the bottom of the baths. Clean the filter
element and spacers after every test or as per the manufacturer's recommendations.
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Do not use solvents to clean the water bath.

Xl. Tum the wheels after each test, so the same section ofthe wheel surface is not in
contact with the test specimen from test to test. This rotation will provide for even
wear over the entire wheel. The test should operate with a smooth movement
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across the test specimen.

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18 The start delay time or preconditioning lime will start after the IYater heats 10 the tes/ lemperature selected in
5.0 (v;j(a).
19 AdJllstthe amou1!/ oj hot and cold waler if necessary, as the water temperatllre may vary.
S4 . 17-42
JKRiSPJI2019·S4
6.0 Calculation
Plot the rut depth versus number of passes for each test. A typical plot of the output produced
by the Hamburg Wheel-Tracking Device is shown in Figure 6. From this plot, obtain the
following values:
• slope and intercept of the first steady-s tate portion of the curve, and
• slope and intercept of the second steady-state portion of the curve.
-, Stripping Inflection Point

... (SIP)
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E
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,;
-.
15. -10
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~
0
"5 -"
'"
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Number 01 Passes to Number of Passes to
-"
C
Stripping Inflection Point Failure , N,
(SIP)
- 16
TE
-"
- 20
, • 10 16
0 6
Number of Passes )( 1000

" " " 20
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Figure 6 Hamburg Curve with Test Parameters
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Calculate the following test parameters, all expressed in "Passes."

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Stripping inflection point (SIP) = In tercep! (sccond portiorl)-ln!crccpt{first ~ortIOrt) (Equation 5)

slope (fErst portlon)-sfopc (second port Io n)
where:
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Failure rut depth is the specified maximum allowable rut depth for the test.
7.0 Report
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<- The report shall include the following parameters:

Asphalt mixture production (field or lab);
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I.
ii. Compaction method (slab or SOC cylindrical specimen);
iii. Number of passes at maximum impression;
iv. Maximum impression;
v. Test temperature;
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vi. Specimen(s) air voids;

vii. Type and amount of an ti-strippin g additive used;
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viii. Creep slope;

ix. Strip slope; and
x. Stripping inflection point.
S4 .17-43
JKR/SPJI20I 9-S4
Appendix F - Water Permeability Test of Asphalt Mixtures
Scope
This mel hod is applicable to determinate the permeability coefficient of asphalt mixtures
specimen prepared by rolling and to inspect asphalt pavement in field .
2.0 Apparatus and Materials

i. Pavement water permeameter: It's shape and dimension are shown as Figure 7 ~ the
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measuring cylinder filled with water at the upper part is made of clear organic
glass with a volume of600 ml with graduation; at 100 ml and 500 ml, there are
thick mark lines; the base is connected with the lower part through a 0 10 mm
tubule with a valve in the middle. The measuring cylinder is coupled through the
support and for the opening below the base, inside diameter is 150 mm and outside
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diameter is 220 mm. The apparatus is attached by 2 stainless steel rings, S kg for
each and the inside diameter is 160 mm .
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ii.
iii.
Measuring cylinder and large funnel.
Stopwatch. o
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iv. Sealing material: water-proof putty, putty or plasticine.
v. Others: water, chalk, plastic ring, scraper, broom, etc.
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/ 1 Clear organic glass cylinder

//-/
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./ 2 Threaded connection
X,
~lIll ~1_0l_1 _ --:r:/ .
J Top slab
-'-
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Ii Ballasting steel ring
~" {,.
1- 1-
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_-_-_-"Ibn!) -I__.I
!">."'.I."SO'-_-_
' X Sealing material
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Figllre 7 Wate, Permeamete, (Dimension Unit: mm)
S4 .17-44
JKRlSPJI2019·S4
3.0 Procedure
L Assemble and install pavement water perrneameter.
ii . Prepare asphalt mixtures specimen according to preparation method of asphalt
mixtures specimen (rolling method) of this specification, extracled from mold
after being cooled down to the specified time and remove the paper on the surface
at preparation of the specimen.
ii. Place specimen on a stable plane and plastic ring at the measuring points at the
center of the specimen, draw 2 circles with a chalk along the inner side and outer
side of the plastic ring and the part between the outer ring and the inner ring is the
sealing area required to be sealed with sealing material.
III . Make a sealing treatment to the annular seal area with sealing material and notice
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not to make the sealing material into the inner circle; if the sealing material enters
by accident, tear it away with scraper. Pile the strip sealing material which is
twisted into thumb shape at the center of the annular seal area and pile it inlo a
circle.
iv. Erect the specimen at left and righl sides with suitable cushion block or wood
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block. Place a water receptor below the specimen. Place the water permeameter on
the measuring points of the specimen and superpose the water permeameter center
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to the ring center as much as possible, then press Ihe water permeameter slightly
( on the surface of the strip sealing material and add the counterweight in case of
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pressure water Qutflowing from the part between the base and the specimen.
v. Close the valve, fill the measuring cylinder with water, then open the valve to make
the water in the measuring cylinder flow downwards to remove the air in the
bottom of the water permeameter; when the water surface in the measuring
cylinder falls down slowly, press Ihe water permeameter slightly with both hands
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to discharge all the bubbles at the bottom of the water permeameter. Close the
valve and fill the measuring cylinder with water again.
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vi. Open the valve and start the stopwatch immediately when the water surface falls
to 100 ml and read and record the graduation ofmesuring cy linder at an interval
of 60 s until the water surface falls to 500 ml. In the test, if the water permeates
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from the parts between the base and the sealing material, it means the sealing
between the base and pavement is poor and resealing is required. When the water
surface faJls at a slow rate, stop after the seepage amount is determined for 3 min;
when the water surface falls at a fast rate and reaches 500 ml within 3 min, record
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the time when the water surface reaches 500 ml ~ if the water surface remains
unchanged after falling at a certain height, it means to be basically watertight or
watertight ultimately which shall be indicated in the report.
vii. 3 specimens made of the same materials shall be used to determine the
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permeability coefficient in accordance with the procedure above and take the
average value as the test result.
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S4 . 17-4S
JKRlSPJI20 19-S4
4.0 Calculation
Penneability coefficient of asphalt mixtures specimen shall be calculated according to Fonnula
(Equation 6), subject to the time required by the water surface fTom 100 ml to 500 ml ; if the
water penetration time is overlong, the water amount passed in 3 min may be adopted for
calculation.
(Equal ion 6)
Where:
Cw = The pavement permeability coefficient (mllmin);
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V, = The water amount at the fi rst timing (ml), 100 ml usually;
V, = The water amount at the second timing (ml), 500 ml usually;
= The time at the first timing (s);
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I,
I, = The time at the second timing (s).
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5.0 Report
Report the permeability coefficient of each specimen point by point and the average value of 3
specimens. If the specimen is watertight, it shall be indicated in the report.
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S4. 1146
4.5 HORIZONTAL ALIGNMENT, SURFACE LEVELS AND SURFACE

REGULARITY OF PAVEMENT COURSES ....................................................................... AS4-I
4.5.1 HORIZONTAL ALIGNMENT ...... ....... ........ .... ........................................................... .. ............. . As4-1
4.5.2 SURFACE LEVELS OF PAVEMENT COURSES ................ .... .... ........ .... .......... ...... .. .. .......... .. . As4- 1
4.5.3 SURFACE REGULAR ITY ... .......... ... ...... .. ......... ........ ... .. ... ...... ..... .. ...... ....... .. .... .. ... .. ... .... .......... . As4- 1
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AS4 - i
This Addendum shall be made part of the ' JKR Standard Specification For Road Works, Section 4:
Flexible Pavement - JKRlSPJ/2008-S4 ' .
4.5 HORIZONTAL ALIGNMENT, SURFACE LEVELS AND SURFACE REGULARITY OF

PAVEMENT COURSES
4.5.1 HORIZONTAL ALIGNMENT
ER
Please refer to the JKRlSPJ/2008-S4.
4.5.2 SURF ACE LEVELS OF PAVEMENT COURSES
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Please refer to the JKRlSPJ/2008-S4.
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4.5.3 SURFACE REGULARITY
After first paragraph, add the following paragraph:-

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The regularity of surfaces shall be within the relevant limits given in Table 4.5.3.
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A longitudinal irregularity is a variation in profile of the road surface as measured by the rolling
straight-edge or wedge and straight-edge device. The permissible number of such longitudinal
irregularities is indicated in Table 4.5.3.
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The traverse length of 300 m and its associated maximum permissible number of irregularities
shall apply wherever the continuous length of the completed carriageway is 300 m or more,
EN
whether or not it is constructed in shorter lengths.
Where the total length of pavement is less than 300 m the measurements shall be taken on 75 m
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lengths.
The transverse regularity of a newly laid surface shall be measured with a 3 m straight-edge and
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shall have no greater depression under the straight-edge than that shown in Table 4.5.3.
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AS4(1)-1 /2
TABLE 4.5.3 - TOLERANCE FOR SURFACE IRREGULARITIES
Longitudinal Direction Transverse

Direction
Maximum Permissible Number of Surface Irregularities

Class of Surface Maximum
Regularity Permissible
Depth Exceeding 4 mm Depth Exceeding 7 mm Depth of
Transverse
Over Over Over Over Irregularities
traverse traverse traverse traverse
length of length of length of length of
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300m 300m 300m 75 m
Class SR I 20 9 2 I 4mm
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Class SR 2 40 18 4 2 8 mm
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Class SR 3 60 27 6 3 12mm
(
TE
No longitudinal irregularity exceeding 10 mm shall be permitted for Class SR I Surface
Regularity and no longitudinal irregularity exceeding 15 mm shall be permitted for Class SR2 and
Class SR3 Surface Regularities.
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The class of Surface Regularity for each portion of the Works shall be as stated on the Drawings
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or in the Bill of Quantities

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For further specifications related to sub-clause 4.5.3, please refer to the

EN
JKRlSPJ/2008-S4.
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AS4( 1)-2/2
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Section 5 - Concrete Pavement (JKR/SPJ/2020-SS)
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(JKRlSPJ/2020-S5)
SECTION 5 - CONCRETE PAVEMENT
5.1 DESCRIPTION
This work shall consist of constructing Concrete Pavement with or without

reinforcement in accordance with this Specification, including all relevant requirements
of JKRlSPJ/2017-S9 (Revision 2018) or latest, Standard Specification For Road Works
(Section 9 : Concrete), and in conformity with the lines, levels, grades, dimensions and
cross-sections shown on the Drawings. Concrete slab shall consist of a mixture of
cement, fine aggregate, coarse aggregate, water (with or without admixture) for plain
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concrete and include steel bar for reinforced concrete.
Typically, a concrete pavement structure consists of subbase, road base and concrete
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slab constructed on a subgrade formation. The requirement usage of these layers
based on design.
,
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)
The road base consists of minimum two (2) compacted layers (bound and unbound)
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made up of granular or stabilized material between the subbase and concrete slab.
Bound layer consist of bituminous layer or cement-treated base. On the other hand,
unbound layer consist of drainage layer and crushed aggregate of road base or wet
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mix road base.
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The Preparation of subbase and road base shall refer to JKRlSPJ/2008-S4 or latest,
Standard Specification for Road Works (Section 4: Flexible Pavement).
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There are two (2) types of concrete slab for pavement, namely:
i) Plain Concrete Pavement (PCP)

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a) Undowelled
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Direction of travel ~
Top View
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)torn Spilthll
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FIGURE 1: PLAIN CONCRETE PAVEMENT (PCP)
1
(JKRlSPJ/2020-S5)
The PCP evolved in response to the problems of slip forming the Jointed
Reinforced Concrete Pavement (JRCP). It is essentially the most 'natural'
of all formats in the jointing patterns closely resemble cracks that would
form if the pavement were allowed to crack with no external influence other
than from cyclic temperature variations and live traffic loading.
The spacing of the jointing patterns shall be constructed as per designed

drawing approved by the S.O.
b) Dowelled
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Dlrecllonof \riNel ~
Top Veew
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. Lorrrttudll'lli Joint v
" 11, 011
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Side View
Transverse Joint
A > OOWtl
!, .
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FIGURE 2: PLAIN CONCRETE PAVEMENT (PCP) WITH DOWELLED

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Plain Concrete Pavement with dowelled also known as Jointed Plain

EN
Concrete Pavement (JPCP) features sufficient joints to control naturally

occurring cracks. Without any steel reinforcement, JPCP depends on load
transfer devices (e.g. dowel bars) at transverse joints and deformed steel
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bars (e.g. tie bars) at longitudinal joints.

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The spacing of the jointing patterns shall be constructed as per deSigned

drawing approved by the S.O.
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2
(JKRlSPJ/2020-S5)
ii) Reinforced Concrete Pavement (RCP)
a) Continuously Reinforced Concrete Pavement (CRCP)
Top View
Direction of travel ---7
Typical Crack pattern (Transverse)
;L 1;t~,_
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FIGURE 3: CONTINUOUSLY REINFORCED CONCRETE PAVEMENT
(CRCP)
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CRCP is constructed by placing steel reinforced bars within the concrete, along
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the entire length of the pavement. CRCP forms naturally tight transverse cracks
to transfer loads evenly.
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The reinforced bars control the width of the transverse cracks, holding them
close. These cracks will not impair the structural integrity of the pavement.
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The result is a continuous, smooth-riding surface capable of withstanding the

heaviest traffic loads and the most adverse environmental conditions.
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\. ) b) Jointed Reinforced Concrete Pavement (JRCP)

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Direction of travel
Top View
-.-~
Slab Spacing
Crack Spacing
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Midpanel
Transverse Joint
Side View Crack
Relnlorclnl Joint
. '.' ; .
-
" Sub-grade .;'
_ ~ c ~, , ~ , ' ,
FIGURE 4: JOINTED REINFORCED CONCRETE PAVEMENT (JRCP)
3
(J KRISPJ/2020-S5)
JRCP uses contraction joints and reinforced steel to control cracking .

Temperature and moisture stresses cause cracking between jOints which is why
reinforced steel or a steel mesh is used to hold these cracks together. Dowel bars
are typically used at transverse joints to assist in load transfer while the reinforced
steel or wire mesh assists in load transfer across cracks.
The spacing of the jointing pattems shall be constructed as per designed drawing
ER
Selection type of concrete pavement to be used are recommended as TABLE 5.1
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TABLE 5.1: RECOMMENDATION FOR SELECTION TYPE OF CONCRETE
PAVEMENT
TE
Type of Pa v e m e n t:
Rein f orced Con c rete Pavefnent Pla in Concrete P_erne nt:
Descr ipt ion
_Ithoul Dint s W'lth ai n u D owel s lInOowe l s
C R CP JRCP JPCP -RCe PCP
-
R q ad Categprl c 'S
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M Rl./Ul. M in or Road! Loca l Str eet: N N N HR R
- R2/U 2 Min or Road/ l oca l Street N N R R
- R3jU 3 Secondary Road! Collector N R HR N R
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- R4/U4 P r im a r y Road/ Collecto r R R HR N
•
- RSj U S H lghway/ Arter ials
• R HR N N
- R6/U6 EICpressway HR
• R N N
Concrete H a rd stand
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- Layby a r ea
- Bu s s t a n d R HR R R R
- R & R area R R HR R R
- G e ne ra l P."r kl n g
- H e a vy ve h icle R HR R R R
-
EN
- Contain e r Yard
- Lig h t vehicle
N
N
R
N
HR
R
R
•
R
- Petrol Station R R HR N N
_ Toll Pl a z a R R HR N N
- Industrial Area
- P a r king
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- H eavy vehicle
- Ugh t vehic le
- Access road
. Maln
R
N
HR
N
R
R
R
HR
R
R
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R R HR N N
- Se condary N N R HR R
~
R Hig hly Recomme nde d
R Recomme nded
N No t r ecomme nde d
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Not e: .. Refe~ t o SPECI ALTY MI X 1 - R olle ~ Compacted Con cre t e ( RCCI

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Before commencing production work, the contractor shall submit to the S.O. a
written Construction Plan detailing all aspects of his proposed methods to carry
out the works .
Before starting of production work, the contractor is also required to submit to the
S.O. a Quality Control (QC) Plan for acceptance of all phases of the work, based
on the standard set in this Specification. The QC Plan shall include the following:
4
(JKRfSPJ/2020-S5)
i. An organization chart identifying the Contractor's manager of QC by name,

and his team and their responsibilities.
ii. A proposed QC programme and documents for all phases of the work,
including details/dates on submissions of materials approvals, equipment
approval, method approval, trial mixes, and trial pave areas, etc.
iii. The tests to be conducted, the method of reporting such tests, and their
standard and frequency.
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iv. The method, sequence and authority for correclion measures.
v. Proposed remedial measures for any kind of remedial works.
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vi. Safety procedures and programme.
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5
(JKRlSPJ/2020-S5)
5.2 MATERIALS
5.2.1 Cement
Cement for Concrete Pavement and bound road base shall be of the types
described in MS EN 197-1 as shown in TABLE 5.2 and MS1037.
TABLE 5.2: COMPOSITION OF COMMON CEMENT

Composition {percentage by ma ss·~
MaIn constituents
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Pozzolano FI • • h
NotaUon of 27 products
~
~ ~
,• ~
,• 0
~
c
M ain (types of common cement)
.,. • e ~
~ ~
2 e e.3 .~• .~ 11 E
• ~~
~ E ,¥ ~ ,
B iii 2 U) z ~ B in 0 • m
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K S 0 "' P Q V W T L LL
Portland
CEM I CEM I 95·100 - - - - - 0-5
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cement
CEM !!
80 -94 6 -20 0-5
Portland- slag IA-S - - - -
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cement CEM II
IB-S
65 -79 21 -35 - - - - - 0-5
PorUand-
CEM II
silica fum e
IA-D 90-94 6 -10 - - - - - - 0 -5
oement
CEM II
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IA...
80-94 - 6-20 - - - - - 0-5
Portfand CEM II
65-79 - 21-35 - - - - 0-5
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types - IB-?
pozzolana CEM II
cement IA-Q 80-94 - 6-20 - - - - 0-5
CEM II
65-79 - 21-35 - - - - 0-5
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IB-Q
CEM II
80 -94 6-20 0 -5
CEM IA-V - - - - -
II CEM II
65-70 - - -
EN
Portland-fly
21-35 0 -5
IS-V
ash cement CEM II
IA-W
80-94 - - - 6-20 - - 0-5
CEM !!
I B-W
65-79 - - - - 21-35 - - 0 -5
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CEM II
Porttand-
IA-T
80-94 - - - - - 6-20 - - 0-5
bomtshale
CEM!!
cement
IB-T
65 -79 - - - - 21-35 - - 0-5
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CEM !!
IA-L
80-94 - - - - - - 6-20 - 0-5
Portland- CEM II
limestone IB-L
65.79 - - - - - 2 1-35 0-5
cement CEMI1
- - - - -
O
80-94 6-20 0-5

/A-LL
GEM II
IB-LL
65-7. - - - - - - - 21-35 0-5
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CEM I1
80-94 610 20 0-5
Portland· IA·M
compoSite CEM II
6S.79 2 1 to 25 0-5
cementc) I8-M
CEMIII
35-64 36 · 65 - - - - - - - 0-5
Blast· IA
CEM furn ace CEM III
20 ·34 66· 80 - - - - - - - - 0 -5
III cement IB
CEM III
5 · 19 81 · 95 - - - - - - - - 0-5
IC
CEM IV
65 · 89 11 to 35 - - - 0-5
CEM Pozzolanic IA
IV cement ") CEMIV
45 · 64 36 to 66
- - - 0-5
IB
6
(JKRlSPJ/2020-S5)
CEMV - - -
CEM
Composite
fA
40 -64 18 - 30 18 to 30
- - 0-5
V
cementc:J
CEMV
20 - 38 31 ·50 - 31 to 50 - - - 0 -5
IB -
I) The values in the table refer to the sum of the msin and minor additional constituents
b) The proportion of silica fume is limited to 10%
c) In Portland-composite cements CEM II/A-M and CEM 1I/8-M, in Pozzolanlc cements CEM IVIA and CEM IVIB and in composite
cements CEM VIA and CEM VlB the main constituents other than clinker shall be declared by designation of the cement.
Manufacturer's certificates of test will, in general, be accepted as proof of

soundness. Additional tests shall be carried out on any cement which
ER
appears to have deteriorated through age, damage to containers, improper
storage or any other reason. In any event, the batch of cement which has
been sampled and tested and found not to have complied with the
requirements shall be rejected and removed from the site.
D
N
(') Cement shall be transported to the site in covered vehicles adequately
protected against water. It shall be stored in a weatherproof cement store to
TE
the approval of the S.O. and shall be taken for use in the Works in sequence
order of its delivery into the store. Cement delivered in bulk shall be stored
in silos of approved design.
A
5_2_2 Aggregate
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Aggregates shall be naturally occurring sand, gravel or stone, crushed or

uncrushed except as otherwise specified, and shall comply with MS EN
M
12620. They shall be from a source approved by the S.O. and shall be hard,
strong, durable and clean . They shall be free from adhering coatings and
shall not contain any harmful materials in sufficient quantity so as to
EN
adversely affect the strength, durability and impermeability of the concrete.
Marine aggregates shall not be used unless otherwise specified.

M
( J
KU
Coarse aggregate shall comply with MS EN 12620.

O
Fine aggregate shall comply with MS EN 12620.

D
If it is found necessary, the fine aggregate shall be washed and screened to

the satisfaction ofthe S.O.
7
(J KRlSPJ/2020-S5)
5.2.2.3 Grading
The Contractor shall carry out sieve analysis of all fine and coarse
aggregates to ensure that they comply in grading with the
requirements of this Specification. Samples shall be taken and
analysis made prior to the delivery of any materials to the site of the
work.
i) Coarse Aggregate
ER
The grading of the coarse aggregate shall be analyzed as
described in MS 30 and shall be within the limits given in TABLE
D
5.3.
N
TABLE 5.3: GRADING FOR COARSE AGGREGATE ()
Percentage by mass passing BS 410 sieve for
TE
nominal sizes
Sieve
Single-sized
Size Graded Aggregates
Aggregate
(BS
A
40mm 20mm 14mm
410) 40 20 10
to to to
mm mm
EJ
mm
5mm 5mm 5mm
50.0
mm
100 - - 100 - -
M
37.5 90 to 85 to
mm 100
100 - 100
100 -
EN
85
20.0 35 to 90 to
100
o to to -
mm 70 100 25
100
14.0 25 to 40 to 90 to oto
M
mm 55 80 100
- 70
100
10.0 10 to 30 to 50 to
o to 5 oto 85 to
KU
mm 40 60 85 25 100
5.0
o to 5 o to 10 o to 10 - oto oto
mm 5 25
O
2.36
mm
- - - - - o to 5
D
ii) Fine Aggregate
The grading of the fine aggregate shall be analyzed as described in

MS 30 and shall be within the Grading limits Coarse (C), Medium
(M) or Fine (F), as given in TABLE 5.4.
8
(JKRlSPJ/2020-S5)
TABLE 5.4: GRADING FOR FINE AGGREGATE
Sieve size Percentage by mass passing BS 410

(BS 410) sieve
Overall Additional limits for grading
limits C M F
10.0 mm 100 - - -
5.0mm 80 to 100 - - -
2.36 mm 60 to 100 60 to 100 65 to 100 80 to 100
ER
1.18 mm 30 to 100 30 to 90 45 to 100 70 to 100
600 11m 15to 100 15 to 45 25 to 80 55 to 100
300 11m 5 to 70 5 to 40 5 to 48 5 to 70
o to 15# - - -
D
150 11m
N
(j # Increase to 20% for crushed rock fines, except
when they are used for heavy-duty floors.
TE
Individual sands may comply with the
requirements of more than one grading.
Alternatively, some sands which satisfy the
NOTE: overall limits but may not fall within anyone of
the additional limit C, M or F may also be used
A
provided that the supplier can satisfy the S.O
EJ
that such materials can produce concrete of the
reouired oualitv.
M
5.2.2.4 Sampling and Testing of Aggregates

EN
Qualitative tests shall be carried out on all aggregates. The Contractor shall
execute all sampling and testing at his own expenses. Duplicate of samples
shall be delivered to the S.O., properly packed and clearly labeled so as to
be identifiable with the samples used in the tests. The results of the tests
M
) are to be submitted to the S.O. for his approval prior to the delivery or use
of the aggregates.
KU
Duplicate tests are to be made in all cases and the results of both sets of
tests reported .
O
Samples of the fine and coarse aggregates approved by the S.O. shall be
D
kept on Site, and shall give a fair indication of the general quality of the
aggregates for comparison with the aggregates delivered during the course
of the work. Tests shall be carried out on samples of the latter taken at
intervals as required by the S.O. The method of sampling and testing shall
be in accordance with MS 30 and other standards as speCified in TABLE
5.5. Any batch of aggregate rejected by the S.O. shall be removed from the
Site.
9
(J KRISPJ/2020-S5)
TABLE 5.5: TESTING OF AGGREGATE
TYPE OF
PROPERTIES TEST METHOD LIMITS
AGGREGATE
Tables 5.3 and
Grading Both M.S. 30
5.4
Not exceeding
Elongation Index Coarse M.S. 30
30%
Not exceeding
Flakiness Index Coarse M.S. 30
35%
ER
Not exceeding
Water Absorption Both M.S. 30
1.5%
Not exceeding
Clay Lumps Coarse M.S. 30
1% by weight
D
Not exceeding
Clay, Silt and Dust Fine M.S. 30
N
2%
Not exceeding
Organic Impurities Fine M.S. 30
TE
0.4%
Aggregate Crushing Not exceeding
Coarse M.S. 30
Value 25%
Soundness Test (Sodium AASHTO Test Loss not
A
Coarse
Sulphate) Method T104 exceeding 12%
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Soundness Test AASHTO Test Loss not
Coarse
(Magnesium Sulphate) Method T104 exceeding 18%
Not exceeding
M
Chloride Content Both M.S. 30 0.06% by weight

of chloride ions
Not exceeding
EN
Sulphate Content Both M.S. 30 0.44% by weight

ofS03
Polished Stone Value
M
(Concrete Pavement Coarse M.S. 30 Minimum 40

aggregates only)
KU
Los Angeles Wearing ASTM

Coarse Minimum 35%
Test C131/C131M
10% Fines Value (ssd) Fine M.S. 30 Minimum 100kN
O
D
5.2.2.5 Storage of Aggregates
Separate storage facilities with adequate provIsion for drainage shall be

provided for each different size of aggregate used. Aggregate shall be stored
and handled so as to minimize segregation and contamination.
To be read in conjunction with Clause 9.2.2 as specified in JKRlSPJ/2017-S9

(Revision 2018).
10
(JKRlSPJ/2020-S5)
5.2.3 Water
Water shall comply with the requirements of MS EN 1008. It shall be clean

and free from harmful matter and from source approved by the S.O.
5.2.4 Admixtures
Suitable admixtures may be used in concrete mixes with the prior approval of
or as directed by the S.O.
ER
All requirements for sampling, acceptance tests, uniformity tests, independent
tests, chloride content, manufacturer's information, compliance and storage
certificates and marking shall be in accordance with MS EN 934. All
D
admixtures shall be used strictly in accordance with the manufacturer's
N
( instructions.
TE
Admixtures containing calcium chloride or calcium formate shall not be used.
Before allowing the admixture to be used in the Work, relevant tests based on
trial mixes shall be carried out. A control mix shall be made using a conventional
A
trial mix that is without using the admixture, to determine the free water/cement
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ratio and mix proportion required to give the speCified strength with the required
slump. Using the same mix proportion as in the control mix but with a modified
water/cement ratio whenever necessary, a test shall be carried out using the
M
recommended dosage of the admixture. The results of the relevant test

obtained from the control mix and test mix shall be compared . The S.O. may
allow the use of the admixture only when the results are found to be satisfactory
EN
and comparable to the effects as claimed by the manufacturer. The admixture

acceptance test shall comply with the requirements specified in Table 5.6.
M
The uses of chloride based admixtures are not permitted to be used for
~ ) structural concrete containing reinforcement, prestressing tendons or other
KU
embedded metal. The Contractor shall submit documentary evidence on the

contents ofthe admixture to be used.
When the Contractor proposes the use of water reducing admixtures, special
O
control tests shall be carried out with prior approval of the S.O . The tests shall
be carried out in accordance with the latest standard and the manufacturer's
D
recommendations.
If two or more admixtures are proposed to be used simultaneously in the same

concrete mix, the Contractor shall furnish the S.O. with supporting data on their
suitability and compatibility.
11
(JKRlSPJ/2020-S5)
TABLE 5.6: ADMIXTURE ACCEPTANCE TEST REQUIREMENTS
ER
Stiffening Time Minimum Length change.
D
Strength as a Age maximum shrinkage
Categories Water Time from completion of mixing to reach a resistance to penetration percentage of
N
of Admixture Reduction of:- the control mix % of Increase
TE
0.5 N/mm 5 3.5N/mm 5 27.5 N/mm 5 Compressive control
125 24 hrs.
Type 1: - More than 1hr. Within 1hr. and 3hrs. At least 1hr. earlier 125 3 days 135 0.010
Accelerator earlier than control than control mix 100 7 days
A
mix 100 28 days
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Within 1hr. and 3hrs. Not more than 3h rs. 90 3 days
Type 2: - At least 1hr. later later than control mix later than control 90 7 days 135 0.010
Retarder than control mix mix 95 28 days
M
Type 3: Within + 1hr. 110 3 days
Nonmal water- At least 5% and - 1hr.of control
EN Within + 1hr. and - Within + 1hr. and - 110 7 days 135 0.010
reducing mix 1hr. of control mix 1hr. of control mix 110 28 days
125 24 hrs.
Type 4: At least 5% More than 1hr. Within 1hr. and 3hrs. At least 1hr. earlier 125 3 days
M
Accelerating earlier than control than control mix 100 7 days 135 0.010
water-reducing mix 100 28 days
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Type 5: At least 1hr. later Within 1hr. and 3hrs. Not more than 110 3 days
Retarding At least 5% than control mix earlier than control 3hrs.later than 110 7 days 135 0.010
water-reducing mix control mix 110 28 days
O
~ - - - ---- _. -
D
12
c..
(JKRlSPJ/2020-S5)
5.2.5 Additions
Addition Type I. Nearly inert addition. General suitability as type I addition is

established for:
(i) Filler aggregate conforming to MS EN 12620 or BS EN 13055;
(ii) Pigments conforming to BS EN 12878; for reinforced concrete, only

category B pigments
Addition Type II, Pozzolonic or latent hydraulic addition. General suitability
ER
as type II addition is established for:
(i) Fly ash (V,W) conforming to MS EN 450-1;
D
(ii) Silica fume conforming to MS EN 13263-1;
N
n (iii) Ground Granulated Blast-furnace Slag conforming to MS EN 15167-1
TE
To be read in conjunction with Clause 9.2.5 as specified in JKRlSPJ/2017-S9
(Revision 2018).
A
5.2.6 Joint Filler Material
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Join Filler Material or preformed compression seal shall be used for Expansion and
isolation joint filler material as per specified in the drawing and shall conform to the
M
requirements of AASHTO M153 or AASHTO M213.
5.2.7 Joint Sealants

EN
All joint sealants shall be one component cold applied gun grade or self-leveling
silicone sealant for casting in-situ , complying with the requirements of Table 5.7.
M
The Joint Sealant shall comply with the test method in Table 5.7. The Contractor
l ) shall provide all relevant test results endorsed by an accredited laboratory and full
KU
technical description as part of the Quality Plan, including the method of

installation recommended by the manufacturer. The Contractor shall furnish a
compliance certificate for each batch of production.
O
D
13
(JKRlSPJ/2020-S5)
TABLE 5.7- SILICONE JOINT SEALANTS
Test Method Attribute Requirements

ASTM-D792
Specific gravity 1.1-1 .55
(Method A)
ASTM-D2240
Durometer hardness 10-25
(Standard Curing)
ASTM-C603 Extrusion rate 90 - 250 g/minutes
ASTM-C679 Tack free time 30 - 70 minutes
No chalking, cracking,
Accelerated
ASTM-C793 or bond loss at 5000
ER
weathering
HRS.
Minimum 35N average
ASTM-C794 Adhesion to concrete
peel strength.
D
Movement
ASTM-C719 accommodation Minimum +/- 50%
N
factor, ten cycles
TE
Grey, compatible with
(Not applicable) Colour
A pavement concrete.
A manufacturer's certificate of compliance, indicating that the material has been

EJ
sampled, tested and inspected in accordance with the provision of the Specification,
and signed by the authorized agents of the manufacturer, may accepted by the S.O.
for the purpose of waiving supplementary tests on the materials. The manufacturer
M
shall also provide product bulletins, material safety data sheets and past performance
for at least 5 years on similar applications .
EN
An appropriate primer, compatible with the seal and either manufactured by or

approved by the sealant manufacturer, shall be used if recommended by the sealant
manufacturer.
M
)
Samples of all materials which the Contractor proposes to be used and copies of the
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sealant manufacturer's recommendations for installation, and certified test certificates

shall be submitted to the S.O. for approval at least thirty (30) days prior to the Trial
Area being paved.
O
5.2.8 Curing Material

D
The exposed surface of concrete pavements shall be cured and protected

immediately after the surface treatment by the application of one of the following
curing materials:
i) White pigmented Liquid

Membrane-Forming Compound
14
(JKRlSPJ/2020-S5)
White pigmented liquid membrane-forming compound shall conform to the

requirement of ASTM C309.
ii) Aluminised Curing Compound
Aluminised Curing Compound shall be stable and impervious to evaporation

of water from the concrete surface within 60 minutes after application.
It shall have test certificates from an approved testing laboratory to show that
the compound has a curing efficiency 90%.
The curing compound shall contain sufficient flaked aluminum in finely divided
dispersion to produce complete coverage of the sprayed surface with metallic
ER
finish . The curing compound shall not react chemically with the concrete to be
cured and shall not crack, peel or disintegrate within two (2) weeks after
application.
D
5.2.9 Steel Reinforcement
n
N
Steel reinforcement shall be furnished and placed in accordance with this
TE
Specification and in conformity with the Drawings, or as directed by the S.O.
Steel fabric reinforcement shall comply with MS 145 and shall be delivered to the
Site in flat sheets.
A
EJ
Dowel bars shall be plain round bars complying with MS 146. They shall be free
from burring and other deformities restricting slippage in the concrete. Where
required for expansion joints, dowel bar sleeves used for debonding shall be of
M
approved synthetic material, and closed end of the sleeves shall be filled with
25mm thick compressible foam filler, with sleeve fitting tightly over the length of the
bar to be debonded.
EN
Plain round dowel bars shall be factory produced. Before deliver to the construction
site, the length of each dowel bar shall be painted with one coat of zinc-chromate
M
( ) or bitumen. Dowel bar sleeves shall not be required for dowels in transverse
contraction joints.
KU
The Contractor shall furnish manufacturer's certificates for steel reinforcement

supplied and these shall be submitted for approval by the S.O. before any material
brought onto the Site. The characteristic strengths of steel reinforcement are given
O
in TABLE 5.B.
D
15
(JKRlSPJ/2020-S5)
TABLE 5.8: CHARACTERISTIC STRENGTH OF STEEL REINFORCEMENT
Nominal Sizes Characteristic

Designation
(mm) Strength fy (N/sq. mm)
Hot rolled grade 250 (MS 146) All sizes 250
Cold Worked (B.S. 4449) All sizes 460
Up to and
Hard drawn steel wire (MS 144) 485
Including 12
ER
..
Binding wire shall be In minimum 1.6mm diameter soft annealed steel wire complYing
with B.S.1052.
D
The Contractor shall , on request, furnish to the S.O. samples of reinforcement
brought onto the site, notwithstanding any previous acceptance based on the
N
manufacturer's test certificates. The reinforcement represented by the sample may
TE
be rejected by the S.O., and shall, if it fails to meet the Specification, be removed
from the Works Site.
Steel reinforcement shall be stored in clean and dry conditions. When placed in the
A
works it shall be clean and free from loose rust, mill scale, oil grease, paint, dirt, or
anything that may reduce its strength and bond with the concrete.
EJ
If directed by the S.O., the steel reinforcement shall be brushed or otherwise cleaned
before use, at the Contractor's expenses.
M
5.2.10 Surface Debonding Treatment

EN
The purpose of surface debonding treatment is to act as a bond breaker between

concrete slab and road base (bound and unbound) Debonding treatments nonmally
used are Single Bituminous Surface Dressing, Polyethylene sheeting, asphaltic layer, J
M
bituminous sprayed layer and other treatments as approved by the S.O. Contractor
shall furnish the required method statement to be approved by the S.O. The surface
KU
debonding treatment shall comply with the requirements specified in TABLE 5.9.
O
D
16
(JKRlSPJ/2020-S5)
TABLE 5.9: SURFACE DEBONDING TREATMENT REQUIREMENTS
Types Requirement Remarks

Single Bituminous Minimum = 6mm Bitumen conforming MS
Surface Dressing 159
Chipping Aggregate
nominal6mm
Polyethylene sheeting Minimum = 0.25mm Refer to ASTM 04397-
16
Asphaltic layer Minimum - 30mm Refer to JKRlSPJ/2008-
S4 item 4.3.3
ER
Bituminous sprayed Spray rate range Refer to JKRlSPJ/2008-
layer 0.5 Um2 - 1.0 Um2 S4 item 4.3.1
other treatments - as approved by the S.O.
D
N
()
TE
A
EJ
M
EN
M
l )
KU
O
D
17
(JKRlSPJ/2020-S5)
5.3 PRODUCTION OF CONCRETE
5.3.1 Supervision
The Contractor shall ensure the required standard of control over materials and
workmanship. The s.o. shall be afforded all reasonable opportunities and facilities
to inspect the constituent materials and the production of concrete and to take
samples for testing .
5.3.2 Site Mixed Concrete
The quantities of cement. fine aggregate and various sizes of coarse aggregate
ER
shall be measured by weight unless otherwise approved by the S.O. A separate
weighing machine shall be provided for weighing the cement. Alternatively, the
cement may be measured by using a whole number of bags in each batch. The
quantity of water shall be measured by volume or by weight. Any solid admixtures
D
to be added shall be measured by weight; liquid or paste admixtures shall be
N
measured by volume or weight.
TE
The batch weight of aggregate shall be adjusted to allow for the moisture content
of the aggregate being used. All measuring equipment shall be calibrated on site or
their calibration status established by certificates from accredited laboratories.
A
The mixing time shall be not less than two minutes and not more than five minutes
EJ
or any other time recommended by the mixer manufacturer after all the ingredients
have been placed in the mixer.
M
Mixers that have been out of use for more than 30 minutes shall be thoroughly
cleaned before any fresh concrete is mixed. Unless otherwise agreed by the S.O.,
the first batch of concrete through the mixer shall contain only two thirds of the
EN
normal quantity of coarse aggregate. The mixer shall be thoroughly cleaned before
changing from one type of cement to another.
M
The water content of each batch of concrete may be adjusted so as to produce

concrete of the workability required . However care shall be taken to ensure the free
)
KU
wateli'tement ratio is maintained. The total amount of water added to the mix shall
be recorded .
5.3.3 Ready Mixed Concrete

O
Ready mixed concrete are batched, either dry or wet, at a control plant and
D
transported in purpose-made agitators operating continuously or truck mixers to the

Site.
Ready mixed concrete shall comply with the requirements of designed mix as in
Sub-clause 5.3.8 and MS EN 206-1 . All concrete materials, including water and
admixtures shall mixed in the plant and delivered to Site in purpose made truck
mixers. No extra water or admixtures are allowed to be added after the concrete
has left the plant.
18
(JKRlSPJ/2020-S5)
Ready mixed concrete delivered to the Site shall be accompanied by delivery ticket
and manufacturer's batching record stating the details of mix proportions by weight,
grade of concrete, type and size of aggregate, date and time of loading at plant,
type and dosage of chemical admixtures and other relevant production details in
suitable format, failing which the S.O, or his representative, shall immediately reject
the total load of the concrete. The S.O, or his representative and the contractor
shall ensure the information provided in the delivery tickets and the manufacturer's
batching record complies with the details of the approved 'designed mix' and its
corresponding 'designed workability' as in Sub-clause 5.3.9.2 before discharging
the concrete.
ER
Rejected concrete shall be removed from the Site. The delivery ticket shall be
marked "REJECTED".
5.3.4 Transporting
D
N
Concrete shall be transported from the mixer to the formwork as rapidly as
\1 practicable by methods, which will prevent segregation or loss of any constituents,
TE
or ingress of foreign matter or water and maintain the required workability. It shall
be deposited as near as practicable in its final position to avoid rehandling or
moving the concrete horizontally by vibration. The concrete shall be conveyed by
chutes or concrete pumps only with permission from the S.O.
A
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5.3.5 Placing
5.3.5. 1 Placing of Concrete in Drv Condition

M
For all concrete, whether mixed on or off the site of the Work, each batch shall be
placed and compacted within two (2) hours of adding the cement to the dry
EN
aggregates and within 45 minutes (or any other period of time based on the initial
test as per JKRlSPJ/2017 -S9 (Revision 2018); Clause 9.3.1.3 and Sub-clause 5.2.4
and approved by the S.O. if an admixture is used) of adding water to the cement
M
and aggregate. Concrete shall not be placed in any part of the structure until the
( I
approval of the S.O. has been obtained. If concreting is not started within 24 hours
KU
of approval given, approval shall again be obtained from the S.O. as to ascertain
propose paving area condition.
All formwork and reinforcement contained in it shall be clean and free from standing
O
water immediately before the placing of concrete. Concreting shall be carried out
continuously between and up to predetermined construction joints in one sequence
D
of operation. It shall be thoroughly compacted by either hand tamping or

mechanical vibration or both and shall be thoroughly worked into the corners. After
tamping into place the concrete shall not be subjected to disturbance other than
such as incidental to compaction by vibration . In the event of unavoidable stoppage
in positions not predetermined, the concreting shall be terminated on a horizontal
plane and against vertical surfaces by the use of stop boards. The location for
termination shall be subjected to the approval of the S.O.
19
(JKRlSPJ/2020-S5)
Fresh concrete shall not be placed against in-situ concrete which has been in
position for more than 45 minutes (or any other period of time based on the trial mix
as per Sub-clause 5.3.8.3 and approved by the S.O. if admixture is used) unless a
construction joint is fonned in accordance with Sub-clause 5.5. When in-situ
concrete has been in place for four (4) hours, no further concrete shall be placed
against it for further 20 hours. Where retarding admixture has been used, the S.O.
may approve variation to this limit.
Except where otherwise approved by the S.O., concrete shall be deposited in

horizontal layers to compacted depth not exceeding 450 mm when internal vibrators
are used or 300 mm in all other cases. The surface of the concrete shall be
maintained reasonably level during placing.
ER
Concrete shall not be dropped into place from height exceeding 1.5 meters.
However, higher drops may be allowed provided the mix has been well designed
and proportioned. When trunking or chutes are used, they shall be kept clean and
D
used in such manner as to avoid segregation.
N
The Contractor shall maintain an experienced steel fixer at the site of reinforced
TE
concrete works during the placing of concrete to reposition any reinforcement which
may be displaced.
5.3_6 Placement Temperature

A
Placement temperature shall comply with MS EN 206-3 to prevent premature
EJ
setting and loss of water during placing of concrete in the formwork and the
following precautions shall be taken:
M
i) At the time of placing, no part of the concrete shall have a temperature

exceeding 36°C. This may be achieved by cooling the water and aggregate prior
EN
to mixing.
ii) Concrete shall not be placed in forms or around reinforcement whose

M
temperature exceeds 36°C. This can be achieved by providing shading or

other means to protect from direct sunlight. )
KU
iii) Freshly placed concrete shall be protected from direct sunlight and from
loss of moisture by covering, shading or other means.
O
iv) No concrete shall be placed when the air temperature at the point of
deposition exceeds 36°C. However, higher temperatures may be allowed
D
provided it can be proven that it shall not result in any detrimental effect to
the concrete work.
v) In the case of high potential of early thermal cracking may occur, the
apparatus and instrumentation for temperature monitoring shall be
installed at the location shown in the drawings or as directed by S.O.
20
(JKRlSPJ/2020-S5)
5.3.7 Classification of Concrete Mixes
Mixes for both bound road base and Concrete slab shall be Designed Mixes.
The Contractor shall select the mix proportions and workability in order to satisfy
the strength and all other requirements specified herein.
5.3.8 Requirements for Designed Mixes
5.3.8.1 Target Mean Strength
The concrete mix shall be designed to have at least the required minimum cement
ER
content and to have a target mean strength greater than the required characteristic
strength by at least the current margin.
The current margin for each particular type of concrete shall be determined by the
D
Contractor and shall be taken as the lesser of:-
N
i) 1.64 times the standard deviation of cube tests on at least 100 separate batches
TE
of concrete of nominally similar proportion of similar materials and produced
over a period not exceeding 12 months by the same plant under similar
supervision, but no less than 2.5 N/sq.mm for bound roadbase mixes or 3.75
N/sq.mm for Concrete slab mixes;
A
EJ
ii) 1.64 times the standard deviation of cube tests on at least 40 separate batches
of concrete of nominally similar proportion of similar materials and produced
over a period not exceeding 5 days, but not exceeding 6 months by the same
M
plant under similar supervision, but no less than 5 N/sq.mm for bound road base
mixes or 7.5 N/sq.mm for Concrete slab mixes;
EN
Where there are insufficient data to satisfy (i) or (ii) above the margin for the initial
mix design shall be taken as 7.5 N/sq.mm for bound roadbase mixes and 12
N/sq.mm for Concrete slab mixes. This margin shall be used as the current margin
M
only until sufficient data are available to satisfy (i) or (ii) above. However, subject to
( ) the approval of the S.O., when the speCified characteristic strength approaches the
KU
maximum possible strength of concrete made with a particular aggregate, a smaller

margin not less than 5 N/sq.mm for bound roadbase mixes or 7.5 N/sq.mm for
Concrete slab mixes may be used for the initial mix design.
O
5.3.8.2 Suitabilitv of Proposed Mix Proportions

D
The contractor shall submit for the approval of the S.O., prior to the supply of
any designed mix, the following: -
i) the nature and source of each material;

ii) full details of the tests on trial mixes carried out in accordance with Sub-
clause 5.3.8.3;
iii) the proposed quantities of each material per cubic metre of fully
compacted concrete.
21
(JKRlSPJ/2020-S5)
5.3.8.3 Trial Mixes
The contractor' shall give notice to enable the S.O. to be present at the making of
trial mixes and preliminary testing of the cubes. The Contractor shall prepare the
trial mixes, using samples of approved material typical of those he proposes to use
in the Works, for all grades to the satisfaction of the s.o. prior to commencement
of concreting .
Sampling and testing procedures shall be in accordance with MS 26 . Three

separate batches of concrete shall be made. The workability of each of the three
trial batches determined by means of the slump test, in accordance with MS 26,
ER
shall be appropriate to the proposed uses and methods of placing and compaction
of the mix and shall be approved by the S.O. Six cubes shall be made from each
batch . Three cubes from each set of six shall be tested at the age of 7 days and
three cubes at an age of 28 days. The average strength of the nine cubes tested
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at 28 days shall exceed the specified characteristic strength by the current margin
N
minus 3.5 N/sq .mm. The approved trial mix shall then be designated as the
"designed mix" and its corresponding workability as the ·'designed wor'kability".
TE
During the Trial Mix for Concrete slab mixes, the contractor shall also prepare three
(3) flexural strength beams per batch and determine their flexural strength at 28
days as per MS 26. He shall also prepare three (3) shrinkage specimens per batch
A
and determine their shrinkage after 7 days moist curing and 21 days air drying as
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per ASTM C157. These additional results shall be reported to the S.O. who will
evaluate them , and may order changes to the thickness of the Concrete slab, or
the contraction joint spacing as a consequence.
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During the Trial Mix for bound road base mixes, the contractor shall also prepare
three (3) shrinkage specimens per batch and determine their shrinkage after 7 days
EN
moist curing and 21 days air drying as per ASTM C157. The average drying
shrinkage of the 9 specimens shall not exceed 650 microstrain.
M
During production, the S.O . may require additional trial mixes to be made before
substantial change is made in the materials or in the proportion of the materials to J
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be used. Trial mixes need not be carried out when adjustment are made to the mix
proportions in accordance with Sub-clause 5 .3.8.4.
5.3.8.4 Control of Strength of Designed Mixes

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I) Adjustment to Mix Proportions

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Adjustment to mix proportions shall be made subject to the approval of the S.O.
in order to minimize the variability of strength and to maintain the target mean
strength . The specified limits of minimum cementitious content and maximum
water/cement ratio shall be maintained. Changes in cement have to be
declared. Such adjustment shall not be taken to imply any changes in current
margin.
22
(JKRlSPJ/2020-S5)
ii) Change of Current Margin
Change in the current margin used for judging compliance with specified
characteristic strengths become appropriate when the results of a sufficient
large number of tests shows that the previous established margin is
significantly too large or too small.
Recalculation of the margin shall be carried out in accordance with Sub-clause

5.3.8.1. Although a recalculated margin is almost certain to differ numerically
from the previous value, the adoption of the recalculated value will not
generally be justified if the two values differ by less than 18% based on tests
on 40 separate batches or less than 11 % based on 100 separate batches.
ER
On the adoption of the recalculated margin it shall become the current margin
for the judgment of compliance with the specified characteristic strength of
concrete produced subsequent to the change.
D
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5.3.9 Requirements for Concrete
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5.3.9.1 Concrete Grade
The grade of concrete to be used in the work shall be as stated in the

Drawings, tender documents and I or in the Bill of Quantities Concrete
A
shall be designated as Grade C XIY as where 'X' is a minimum
characteristic cylinder strength in N/mm 2 , and 'Y' is minimum
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characteristic cube strength in N/mm 2 .

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5.3.9.2 Workability
The "Designed Workability" shall be measured by the Slump Test in

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accordance with MS 26. The contractor shall select the designed

workability appropriate to his paving methods and within the following
limits:
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( ) • For slip-form paving machine, within 50 +1- 10 mm.

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• For fixed-form/hand-guided/manual construction, within 75 +/-

25mm
The workability of the fresh concrete shall be such that the concrete is
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suitable for the conditions of handling and placing so that after

compaction, it must surrounds all tie bars, dowels and reinforcement,
D
without visible honeycombing.
23
(JKRlSPJ/2020-S5)
5.3.9.3 Concrete Properties
i) Concrete Mix for Slab On Concrete Pavement
Proportioning requirements for Concrete slab shall be designed to

achieve a characteristic flexural strength of 4.5MPa at 28 days. The
correlation between the flexural strength and the compressive strength
of cubes shall be determined during the Trial Mix. The contractor shall
submit the test data supporting this correlation. and his proposed
characteristic compressive strength, with the other mix information
required in Sub-clause 5.3.8.2.
ER
In terms of cementitious material content, this should conform to the
MS EN 197-1 requirements and the approved mix by S.O. as per the
actual trial mixes carried out.
D
A certificate shall be obtained from the manufacturer verifying the
N
cement type
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The ratio of water to cementitious material , including free water above
the saturated surface dry moisture content of aggregates, shall not
exceed 0.5.
A
In the event of air entraining admixtures are used, entrained air content
of the fresh concrete shall be 4 .5% ± 1.5%, to enhance the pave ability
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of the Concrete Pavement. Air entraining admixtures shall comply with

the MS EN934.
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ii) Concrete Mix For Bound Road Base

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It is the intent of this SpeCification that bound road base constructed

as mass concrete without contraction joints, will develop a pattern of
relatively closely spaced cracks which in conjunction with the surface
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debonding treatment, will not reflect into the concrete pavement. This
is achieved by limiting both the upper strength and the shrinkage of the J
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bound road base concrete, as stated below.
a) Proportioning requirements for bound road base concrete shall be

designed to achieve minimum characteristic compressive
O
strength of 7.5 MPa at 28 days. The characteristic strength shall

not exceed 15 MPa at 28 days.
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b) In terms of cementitious material content, this should conform to

the MS EN 197-1 requirements and the approved mix by S.O. as
per the actual trial mixes carried out.
c) A certificate shall be obtained from the manufacturer verifying the

cement type.
24
(JKRlSPJ/2020-S5)
5.3.9.4 Total Chloride Content
The total chloride content of the concrete mix arising from the
aggregate or any other source shall not in any circumstances exceed
the limits in TABLE 5.10 expressed as a percentage of relationship
between chloride ions and weight of cement in the mix. When
necessary. test shall be carried out in accordance with BS 1881 : Part
124 for each grade of concrete to demonstrate that these limits are not
exceeded.
TABLE 5.1 0: MAXIMUM TOTAL CHLORIDE

Type or Use of Concrete Maximum Total
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Percentage of Chloride
Ions by Mass of
Cement
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Concrete containing 0.4
embedded and made with
n
N
cement complying with MS EN
197-1
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Prestressed concrete and 0.1
Heat-Cured Concrete
containing embedded metal
Plain, non structural concrete No Limit
A
Notes on Table 5.10:-
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1. =
% Chloride ions x 1.648 % equivalent sodium chloride.
2. % Chloride ions x 1.56 = % equivalent anhydrous calcium chloride
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5.3.9.5 Maximum Sulphate Content

EN
The total estimated sulphate content of any mix including that present
in the cement shall not exceed 4.0% by weight of cement in the mix.
Tests shall be carried out in accordance with B.S. 1881 : Part 124 for
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each grade of concrete to demonstrate that these limits are not

( )
exceeded .
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25
(JKRlSPJ/2020-S5)
5.4 CONSTRUCTION
5.4.1 Preparation
5.4.1 .1 General
Equipment and tools necessary for performing all parts of the work shall be
approved by the S.O. as to their design, capacity, and mechanical condition. The
equipment shall be at the job site before the start of construction operation for
examination and approval.
ER
As part of the Construction Plan, the contractor shall submit method statement for
approval for placing the concrete, including the Trial Areas , as part of Quality
Control Plan . No work shall be started prior to the written approval of the S.O.
D
Slab for Concrete Pavement shall be constructed by any method such as using
N
paving machine, hand guided or manual method as specified in the technical
requirement.
TE
5.4.1 .2 Trial Lay
Trial area of the concrete slab, for each width of construction proposed in the paving
A
plan, and not less than 200m 2 , shall be laid with each approved mix. The Trial Lay
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shall be constructed for Concrete using approved Method Statements. Additional
trial area(s) will be required for each proposed set of construction eqUipment,
including paver machine, hand-guided and manual equipment for each proposed
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mix, and for each slab thickness. Each area shall include all the requirements of
this specification and incorporate at least one of each type of joint required in the
work. Trial lay area(s) that had been constructed may be incorporated in the job if
EN
they comply with the specifications. Any area that are not comply shall be removed
and replaced at contractor's own cost.
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If, after carrying out the relevant tests, the Trial lay area(s) do not show that the
methods proposed by the contractor produce the specified quality including surface
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accuracy and texture, and/or do not satisfy the requirements for constructing and
sealing all joints, the contractor is to make modifications to the mix, and/or
modifications or additions to his plant, or to change his working methods, and he
shall lay new Trial lay areas until the S.O. gives his written approval for the
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amended method statement.

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During the trials, the Contractor shall ensure the uniformity of compaction
throughout the total depth of the pavement thickness. The contractor shall core four
numbers 100mm diameter cores from the area(s) approved by the S.O. as
specified in B.S. 1881. If any of the cores show defects as defined in MS 26,
further concreting will not be permitted until new trials have shown that
modifications or additions can be made which will result in a well- compacted
concrete, free from defects, which still permit the surface to be finished to the
26
(JKRlSPJ/2020-S5)
specified requirements.
When all of these requirements have been satisfactorily achieved, the Trial lay
area(s) will be approved by the S.O.
Two of the cores cut from the 'Approved' area/s shall be retained by the contractor
and the other two shall be passed to the S.O. Each shall be clearly marked
'Approved' and shall be exhibited throughout the contract period as examples of
the required standard of concrete compaction . The standard of workmanship and
finish of all concrete surfacing included in the contract shall be equal in all respects
to that of the 'Approved' cores and area/so
ER
Core holes shall be reinstated with compacted concrete with mix proportions of 1
part Portland cement: 2 parts fine aggregate : 2 parts 10mm nominal single sized
coarse aggregate by weight, as approved by S.O.
D
5.4.1 .3 Preparation of Subgrade, Sub base. and Road base
n
N
Prior to placing concrete slab, the underlying sub grade or sub base shall have
TE
been shaped and compacted in accordance with the Specification as follows:
a) JKRlSPJ/2013-S2; Clause 2.2.7 (Subgrade)

A
b) JKRlSPJ/2008-S4; Clause 4.2.2 (Sub base),
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c) JKRlSPJ/2008-S4; Clause 4.2.3,4.2.4,4.2.5 and 4.2.6 (Road base)

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d) JKRlSPJ/2020-S5; Sub-clause 5.3.9.3.ii (Bound Road base)
Notwithstanding any earlier approval of finished sub grade or sub base, any
EN
damage to or deterioration of the sub grade or sub base shall be made good to the
satisfaction of the S.O. before the concrete slab is constructed.
,
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) 5.4 .1 .4 Preparation of Surface Debonding Layer to Receive Concrete Pavement

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Preparation of surface debonding layer shall comply to Sub-clause 5.2.10.
5.4.1 .5 Formwork for Concrete Works

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All formwork works shall be complying with relevant requirement of JKRlSPJ/2017-

S9 (Revision 2018); Clause 9.7.
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5.4.1 .6 Fixing of Reinforcement
The number, size, length, form and position of all reinforcing bars, steel fabric, and
dowels shall be in accordance with the drawings. Fixing of reinforcement details
shall comply with JKRlSPJ/2017-S9 (Revision 2018); Clause 9.6.3.2.
27
(JKRlSPJ/2020-S5)
5.4.2 Construction by Machine
The Concrete slab shall be constructed by slip-form paving machine and manual
fixed-form placed in a single layer or double lift depending on design and
requirement of specification.
5.4.2.1 Slip Form Paving Method
A slip form paving train shall consist of powered machines which spread, compact
and finish the concrete in a continuous operation. The equipment shall be of
recognized manufacturer and shall be approved by SO.
ER
A 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.
D
N
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
TE
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 for changes in the average and
A
differential surcharge necessitated by changes in slab thickness or cross fall.
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The concrete shall be compacted by vibration or by combination of vibration and

mechanical tamping so as to comply with Sub-clause 5.4.4 and Sub-clause 5.4.5
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throughout the full depth of the slab.
5.4.2.2 Construction by Manual Fixed-Form

EN
Areas to be constructed by concrete fixed-form method shall be agreed with the

S.O. The slabs shall be constructed in one layer. Dowel bars, tie bars and
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reinforcements, if specified, shall be fitted in position as shown on the Drawings.

J
KU
The concrete shall be spread uniformly without segregation or varying degrees of

pre compaction by conveyor, chute or by other means approved by the S.O. The
concrete shall be struck off by a screed so that the average and differential
surcharge is sufficient to ensure that after compaction the finish surface is to the
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required level.
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The concrete shall be compacted by two (2) passes of twin vibrating finishing
beams. In addition, internal poker vibration shall be used for slabs thicker than
125mm. The pokers shall be inserted or dragged at locations not more than 300mm
apart over the whole area of the slab and adjacent to the side forms or the edge of
a previously constructed slab.
The concrete shall be compacted by vibration or by a combination of vibration and

mechanical tamping so as to comply with Sub-clause 5.4.4 and Sub-clause 5.4.5
28
(JKRlSPJ/2020-S5)
throughout the full depth of the slab.
The whole area of the slab shall be further regulated by two (2) passes of a scraping
straight edge not less than 1.8m wide.
The surface shall be textured as described in Sub-clause 5.6. All joints in Concrete
Pavement, other than construction joints, shall be sawn. All side forms shall be
made of steel and shall be sufficiently robust and rigid to withstand construction
forces without visible deflection. Timber forms can only be used with the written
approval of the SO. Formwork shall be designed to allow for stripping without
damage to young concrete.
ER
5.4.3 Manual Construction
Areas to be constructed by manual method shall be agreed with the S.O. The slabs
shall be constructed in one layer. Dowel bars, tie bars and reinforcements, if
D
specified, shall be fi xed in position as shown on the Drawings.
N
( )
The concrete shall be spread uniformly without segregation or varying degrees of
TE
pre-compaction by conveyor, chute or by other means approved by the S.O. The
concrete shall be struck off by a screed so that the average and differential
surcharge is sufficient to ensure that after compaction the finish surface is to the
required level.
A
The concrete shall be compacted by internal poker vibrator or other means
EJ
approved by the S.O. The vibrations shall be at points not more than 300mm apart
over the whole area of the slab and adjacent to the side forms or the edge of a
M
previously constructed slab.
The surface shall be regulated and finished to the level of the top of the forms or
EN
adjacent slab or pavement layer by using approved portable hand screed. The
screed shall be at least 600 mm longer than the width of the slab to be struck off
and compacted . It shall be in approved shape, sufficiently rigid to retain its shape
M
and constructed either of metal or of other material shod with metal.

( )
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Compaction shall be attained by raising and dropping the screed in successive

positions until the required compaction and reduction of surface voids is secured.
The screed shall then be placed on the forms and slid along them, without lifting,
O
in a combined longitudinal and transverse shearing motion moving always in the

direction in which the work is progressing. If necessary, this shall be repeated until
D
the finish surface is of uniform texture, true to grade and contour, and free from
porous areas.
After the concrete had been struck off and compacted, it shall be further smoothed,
screeded and compacted by means of a longitudinal hand float or other equipment
as approved by the S.O.
Details of joints shall be as shown on the Drawings. Joint grooves shall be
29
(JKRlSPJ/2020-S5)
constructed in compliance with Sub-clause 5.5. Any irregularities at wet formed

joint grooves shall be rectified by suitable means approved by the S.D.
As soon as surplus water has risen to the surface, the pavement shall be given a
broomed finish.
The concrete shall be cured in compliance with Sub-clause 5.8.
5.4.4 Compaction
Unless otherwise approved by the S.D., concrete shall be thoroughly compacted

by vibration and worked around the reinforcement, embedded fixtures and into
ER
corners of the formwork to form a dense, homogenous mass, free from voids and
which will have the required surface finish when the formwork is removed .
Vibration shall be applied continuously during the placing of each batch of
concrete until the expulsion of air has practically ceased and in a manner which
D
does not promote segregation of the ingredients.
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The concrete maintained between the two walls of formwork shall be compacted by
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internal vibrators. Concrete in slabs with no formwork on its upper surface shall be
compacted either by vibrators of the pan type or by a vibrating screen.
The internal vibrators shall be inserted and withdrawn slowly and at a uniform pace.
A
The compaction shall be deemed to be completed when there are no bubbles
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appearing or no major movement on the concrete surface. Over vibration leading
to segregation of the mix must be avoided. The internal vibrators shall be inserted
at points judged by the area of mortar showing after compaction, with certain
M
allowance made for overlapping and they shall not be allowed to come into contact
with the formwork or the reinforcement and shall be inserted at a distance of not
less than 75 mm from the formwork.
EN
The pan vibrator shall be placed on the surface of the concrete, which shall have
been tamped previously and leveled leaving an allowance in height for compaction
M
until the cement mortar appears under the pan. The vibrator shall then be lifted and
placed on the adjoining surface and this operation shall be repeated until the whole )
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surface has been compacted . Alternatively, a vibrating screen spanning the full
width of the surface may also be used.
Whenever vibration has to be applied externally, the design of formwork and

O
disposition of vibration shall receive special consideration to ensure efficient

compaction and to avoid surface blemishes. The vibration shall be such that there
D
will be no excess water on the top surface on completion of compaction .
External vibrators shall be firmly secured to the formwork which must be sufficiently
rigid to transmit the vibration and strong enough not to be damaged by it.
Internal vibrators shall be capable of operating not less than 10,000 cycles per
minute. Sufficient vibrators in serviceable condition shall be on Site so that spare
30
(JKRlSPJ/2020-S5)
equipment is always available in the event of breakdowns. Vibrators shall be

operated by workmen skilled in their use.
Concrete shall not be subjected to any disturbance within 24 hours after

compaction . No standing or flowing water shall be allowed to come into contact with
exposed concrete surfaces during the first two (2) hours after placing and
compaction of concrete.
In the event where inadequate or improper compaction is suspected, the 5 .0 . has

the right to inspect and carry out further tests. The tests may include non-
destructive and destructive methods. All expenses incurred in carrying out such
sampling, testing and remedial works shall be borne by the Contractor irrespective
ER
of whether the tests prove the structure to be sound or otherwise.
5.4.5 Geometry Control
D
The Contractor shall check the elevations and alignment of the concrete slab at
N
every stage of construction , and must maintain record of all these checks and of all
adjustments and corrections made.
TE
5.4.6 Dimensional Deviations
Concrete slab shall be finished in a neat and workmanlike manner; their widths shall
A
be everywhere at least those specified or shown on the Drawings on both sides of
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the center-line and the minimum thickness at any 10 meters interval shall be not
less than the specified thickness.
M
Control of Accuracy During Construction - Checking by the Contractor shall be

systematic and undertaken at all stages of construction . Particular attention shall
be given to monitoring of construction in areas where the work would be affected in
EN
appearance or performance.
i) Dimensional control, the Contractor shall ensure to achieve dimensional

M
control by:
\ }
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a) Checking that measured results within the tolerances specified.

b) Identifying sources of induced inaccuracy.
c) Taking appropriate corrective action subject to the approval of the 5 .0.
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ii) Recording, the dimensions measured shall be systematically recorded by the

Contractor and agreed by the 5 .0 . for the following :
D
a) Checking compliance.
b) Preparing as-built drawings showing the measurements achieved in
practice and the deviations from the target size.
c) Establishing characteristic accuracy.
31
(JKRlSPJ/2020-S5)
ii) Corrective action, by the Contractor in respect of work that does not comply
with the tolerances specified can include:
a) Rectification as approved by the S.O. of work already done.

b) Increasing Contractor's supervision at identified sources of inaccuracy.
c) Adjustment of design and/or details as approved by the S.O.
iv) Preventive action, systematic checking by the Contractor as the work

proceeds is essential to make sure that the monitoring and control systems
are adequate. Preventive action can be indicated from assessment of the
results of the monitoring, particularly at the initial stages of each work shall be
ER
made. This will permit the problems to be identified and addressed subject to
the approval of the S.O. at an early stage.
D
N
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A
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M
EN
M
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(JKRlSPJ/2020-S5)
5.5 JOINTS
5.5.1 General
Joints shall be constructed as indicated on the Drawings and in accordance with

these requirements. All jOints shall be constructed true to line on a plane
perpendicular to the surface of the pavement. Joints shall not vary in their location
by more than 6mm from that shown on the drawings. Transverse joints shall be at
right angles to the centerline of the pavement and shall extend the full width of the
slab.
ER
Joints shall be controlled joints or construction joints, as shown in the Drawings.
The location of all construction joints shall be shown in the contractors Construction
Plan.
D
Joints in the road base layer shall be either longitudinal or transverse construction
n
N
joints only, and no expansion or contraction jOints are required . The location of all
construction joints, relative to the future joints in the overlaying concrete slab layer,
TE
shall be as shown on the Drawings. In particular, no construction jOint in the bound
roadbase shall be closer than 300mm to any parallel joint in the concrete slab layer.
In the concrete slab only, when the full width of the pavement is constructed as a
A
series of lanes, the transverse joints in succeeding lanes shall be placed in line
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with similar joints in the first lane.
The location of any transverse expansion joints shall be shown on the Drawings.
M
Generally, they are only required at pavement terminal joints, or bridge approach
slabs. All expansion joints shall be formed as construction joints.
EN
Preformed expansion joint filler board shall be placed around any structure which
extends into or through the pavement over the full interface with the concrete
pavement slab before concrete is placed .
M
( ) No edges of transverse joints shall be rounded/ chamfered , except for expansion

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joints, as shown on the Drawings.
5.5.2 Transverse Contraction Joints

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Transverse contraction joints shall consist of planes of weakness created by cutting

grooves on the surface of the pavement and, when shown on the Drawings, shall
D
include load transfer dowel bar assemblies.
Grooves shall be sawn into the concrete after its initial set.
All joints shall be sawn before uncontrolled shrinkage cracking takes place but not
until the concrete has hardened to the extent that tearing and raveling is not
excessive, usually 4 to 24 hours after placing . Any procedure for sawing joints that
33
(JKRlSPJ/2020-S5)
result in premature and uncontrolled cracking shall be revised immediately, for

example by adjusting the sequence of cutting the joints or the time interval involved
between the placing of the concrete and cutting the jOints.
All transverse contraction joints in the concrete slab shall be saw cut. Saw cutting
shall comprise of an initial cut to prevent uncontrolled shrinkage and thermal
cracking, followed by second, shallower cut to accommodate the jOint sealant.
Notwithstanding the foregoing, the initial saw cut shall be completed prior to any
uncontrolled cracking . For the second cut, no spalling greater than 2mm in depth
is permitted.
ER
Following the initial cut, the groove and adjacent pavement surface shall be
immediately washed clean of sawing detritus with high-pressure water. Cotton cord
of diameter 4mm or more shall be installed in the saw cut immediately after the
washing to prevent further ingress of detritus. The cord shall be depressed between
D
6 and 10mm below the pavement surface, and maintained intact until the second
N
widening cut.
TE
To accommodate the joint sealing materials, the top portion of the initial saw cut
shall be widened by means of second, shallower cut. The amount of widening shall
be related to the shape factor of the joint sealing materials.
A
The amount of widening, timing of the second cut relative to sealing the joint, and
degree of cleaning, joint preparation and priming shall be as recommended by the
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sealant manufacturer, and is subject to approval by the S.O. Before commencing

the widening cut, the cotton cord shall be depressed to the bottom of the first saw
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cut groove.
Immediately after completion of the second widening cut, the completed saw cut
EN
shall be washed clean with high-pressure water. The widened groove shall be
maintained clean by the installation of a temporary seal , as recommended by the
sealant manufacturer.
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If dowel bars are required in concrete slab contraction joints, they shall conform to J
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Sub-clause 5.2.9 and Sub-clause 5.4.1.6. Dowels shall be supported by an

approved load transfer assembly device, which shall be a pre-fabricated dowel
basket, rigid enough to permit complete assembly as a unit, ready to be lifted and
placed into position at each contraction jOint location. Installation of dowel bars shall
O
be checked for exact position and alignment as soon as the joint device is fixed in
place, and the device shall be tested to determine whether it is firmly supported.
D
The assembly device is to be left permanently in place. The maximum permissible

tolerance on dowel bar alignment in each plane, horizontal and vertical, shall not
exceed 1 percent or 3mm per 300mm of a dowel bar.
Prior to concreting, one half of each dowel length, plus 2Smm, shall be thoroughly
coated with bitumen to prevent the concrete from binding to that portion of the
dowel.
34
(JKRlSPJ/2020-S5)
5.5.3 Longitudinal Joints
The locations of all longitudinal joints in both the concrete slab and the bound
roadbase shall be shown in the drawing and are subject to the approval of the 5 .0,
Longitudinal construction joints in road base shall be plain butt joints, as shown in
the drawings, and located so as not to be closer than 300mm to any planned
parallel jOints in the over laying concrete slab.
Tie bars across a longitudinal joint shall be placed perpendicular to the joint and
shall be rigidly supported as shown on the Drawings. The bars shall not be painted
or coated with bitumen or other materials
ER
All planes of weakness for longitudinal joints in concrete slab shall be created by
saw cutting.
D
When adjacent lanes are constructed separately, the longitudinal joints may be slip
N
n formed, or in hand-guided construction , steel side forms shall be used.
TE
For concrete slab construction, the slip form paver must incorporate an approved
tie bar inserter, or the tie bars shall be firmly preplaced prior to placing the concrete.
5.5.4 Transverse Construction Joints I End Day Joints

A
....
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Transverse construction joints for both bound roadbase and concrete slab shall be
installed at the end of each day's placing operations, and when concrete placement
is interrupted for more than 30 minutes, or when it appears that the concrete will
M
obtain its initial set before fresh concrete arrives. If the pouring of the concrete has
been stopped, surplus freshly placed concrete shall be removed back to the
proposed construction joint location.
EN
Transverse construction joints in bound road base shall be plain butt joints, as
shown in the Drawings, and located so as not to be closer than 300mm to any
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planned parallel joints in the overlaying concrete slab.

( )
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Transverse construction jOints in concrete slab shall not be constructed at

contraction joints. Such joints shall be formed against approved steel bulkheads,
shall include tie bars as shown in the Drawings, and shall be located no closer than
1m to any planned contraction joint.
O
5.5.5 Transition Joint between Concrete Pavement and Flexible Pavement

D
The transition joint is a joint between concrete pavement to flexible pavement. The
total length of the transition slab shall not be less than 2 meter length, and as shown
in the drawing.
35
(JKRlSPJ/2020-S5)
5.5.6 Expansion Joints
An expansion joint is placed at a specific location to allow the pavement to expand

without damaging adjacent structures or the pavement itself. It was common
practice to use plain, jointed slabs with both contraction and expansion joints. The
width of an expansion joint is typically 20 mm or more. Filler material is commonly
placed 20mm to 25mm inch below the slab surface to allow space for sealing
material. Smooth dowels are the most widely used method of transferring load
across expansion jOints. Expansion joint dowels are specially fabricated with a cap
on one end of each dowel that creates a void in the slab to accommodate the dowel
as the adjacent slab closes the expansion joint.
ER
5.5.7 Sealing of Joints
D
The sealing of joints shall be approved by the S.O.
N
Should sealing is required; joints shall be sealed as soon after completion of the
curing period as feasible and before the pavement is opened to traffic.
TE
All equipment necessary for joint sealing shall be as recommended by the
manufacturer of the sealant materials, and approved by the S.O. before sealing
work is permitted to start. Air compressors shall be equipped with suitable oil traps,
A
and be capable of furnishing air with a pressure greater than 0.6 MPa.
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Prior to sealing, the temporary sealant I cord shall be removed and the joint cleaned
of any foreign material with compressed air.
M
Joints shall be inspected for proper width, depth, alignment, and preparation, and
shall be approved by the S.O. before sealing is allowed. Sealant shall be installed
EN
in accordance with the manufacturer's recommendations.
A backer rod shall be installed, if recommended and specified by the manufacturer

M
and shall be applied in the correct sequence in accordance with the sealant
manufacturer's instructions. J
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Sealant that does not bond to the concrete surface of the joint walls contains voids,
or fails to set to a tack-free condition will be rejected and replaced by the Contractor
at no additional cost.
O
5.5.8 Concrete Saws For Joints

D
The concrete slab shall be saw to the required depth as specified in drawing as a
crack control. The sawing shall be carried out after 24 hours of laying and
compacting of the concrete slab. The Contractor shall provide sawing equipment
adequate in number of units and power to complete the sawing with a water-cooled
diamond edge saw blade, or an abrasive wheel , to the required dimensions and at
the required rate. The Contractor shall provide at least one stand-by saw in good
working order. An ample supply of saw blades shall be maintained at the site of the
36
(JKRlSPJ/2020-S5)
work at all times during sawing operations. The Contractor shall provide adequate
artificial lighting facilities for night sawing. All of this equipment shall be on the job
before and continuously during concrete placement.
ER
D
N
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A
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EN
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37
(JKRlSPJ/2020-S5)
5.6 SURFACE TEXTURE
5.6.1 Texture of Bound Roadbase Surface
The surface finish of the Bound Roadbase shall be assessed during the trial lay
required under Sub-clause 5.4.1.2. It is the intent of the Specification that the top
surface of the Bound Roadbase will require no additional texturing or treatment.
However, the surface of the Bound Roadbase is intended to produce a uniform
frictional drag on the underside of the concrete slab to be constructed upon it. Thus
the surface finish shall be uniform, dense and compact.
ER
5.6.2 Texture of Concrete Pavement Surface
The quality of the texturing of the surface of the concrete slab shall be assessed as
D
part of the Trial Lay required under Sub-clause 5.4.1.2.
N
The surface of the concrete slab shall be finished while the concrete is still soft
enough to take an impression. It shall be applied when the water sheen is beginning
TE
to disappear. The texturing equipment shall be mechanized or hand guided
operation, subject to the approval of the S.O. It shall operate transversely across
the pavement surface or as specified in the Drawings providing grooves that are
uniform in appearance and approximately ranging from 0.65mm to 1.25mm in
A
depth. It is important that the texturing equipment does not tear or unduly roughen
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the pavement surface during operation.
5.6.2.1 Sand Patch Test

M
The texture depth shall be determined by the 'sand patch' test described in
APPENDIX 1. Test shall be taken at least once for each day's paving, and wherever
EN
the 5 .0 . considers it necessary in the following manner: maximum 10 individual

measurement of the texture depth shall be taken at minimum 2m spacing anywhere
along the diagonal line across the road width between points 100m apart along the
M
lane. No measurement shall be taken within 300mm of the longitudinal edge of a

concrete slab constructed in one pass. )
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The average texture depth for each set of test shall not be less than 0.75mm and
not more than one test of each set shall show a texture depth of less than 0.65mm.
In no case shall the maximum texture depth exceed 2mm.
O
D
If continuous texture depth is measured at average of 100 meters length using High
Speed Road Surface Profiler, the average texture depth shall not be less than
0.75mm. The maximum texture depth shall not exceed 2mm. (APPENDIX 2).
If the texture of the paved surface are not satisfactory the Contractor shall make
good the texture across the full lane width over the length directed by the S.O., by
retexturing the harden concrete surface.
38
(JKRlSPJ/2020-S5)
Inadequately textured surfaced slabs shall be textured by sawing grooves in the

hardened concrete surface at right angles to the longitudinal axis of the pavement
with machines using diamond or other approved abrasive cutting discs.
Grooves shall be irregularly spaced and shall be not less than 2mm and not more
than 5mm wide. The recommended sequence of distances between groove centers
in millimeters shall be: 40, 45, 35, 45, 35, 50, 30, 55, 35, 30, 50, 30, 45, 50, 30, 55,
50, 40, 35, 45, 50, 40, 55, 30, 40, 55, 35, and 55. A tolerance of ± 3mm shall be
allowed on each of the spacing. The minimum width of grooving head shall be
500mm and a head not providing a complete sequence of spacing shall use the
number of spacing appropriate to its width commencing at the start of the
ER
sequence. The details as shown in FIGURE 5.
Saw blade thickness
D
2mmSASSmm 30mm sCS55 mm
Wide distance between centers
I-ILJ·••• :! .~ a. " .••:~.,
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n Id• • • • • :
---J. ' 0 . "", ' \>".Q
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. ", , 1> t> <I <! . \) ,<14 lloT 'q, • • <1 ' 00 <l <! ' <1.<1 to
• I!J. • ~ ~ <1. Ttl . I> d l> q 6 • <I \> . <I .
0 .65 mm :!'li 8 S 1.25 mm

Depth
A
FIGURE 5: CONCRETE PAVEMENT GROOVED DETAILS
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Groove depths shall be measured using a tire tread depth gauge in areas where
M
the S.O. considers it necessary and measurements shall be taken as follows:

EN
a) At maximum 10 locations at least minimum 2m apart along a diagonal line

across a lane width between points 100m apart longitudinally. No
measurement shall be taken within 300mm of the longitudinal edge of a slab.
M
l ) b) Where a grooved area is less then 100m in length the number of locations
where measurements are taken on the line of the diagonal across the
KU
grooved area shall be determined by the S.O.
c) The average of each set of measurements shall be not less than 1mm or
O
greater than 1.5mm.

D
Slurry from the sawing process shall be prevented from flowing into joints,
drains or into lanes being used by traffic, and all resultant debris from the
grooving shall be removed to the satisfaction of the S.O.
39
(JKRlSPJ/2020-S5)
5.7 ROUNDING OF CONCRETE SLAB EDGES
Where shown on the Drawings or directed by the 5.0., edges of concrete slabs shall be
rounded with an approved tool and rounded to a radius of not exceeding 5mm. A well-defined
and continuous rounded edge shall be produced and a smooth, dense mortar finish obtained.
5.8 CURING
The exposed surfaces of bound road base and concrete slab shall be cured immediately after
surface texturing by treating with curing compound. It shall be manually or mechanically
sprayed on the surface at a rate of 0.15 to 0.40 litre/m2 subjected to final approval by 5 .0.
ER
The difference of temperature between the ambiance and the concrete, within any period of
30 minutes, shall not exceed 10·C. For the sides of slip formed slabs or when the side forms
are removed within the curing period and for small areas where a mechanical distributor
cannot be used, the compound shall be sprayed manually.
D
N
The compound shall form a uniform, continuous, coherent film that shall not crack or peel and
shall be free from pinholes or other imperfections. If discontinuities, pinholes or abrasions
TE
exist, an additional coat shall be applied within 30 minutes to the affected area. Approved
stand-by facilities or approved alternative methods for curing concrete pavement shall be
provided.
A
In addition, the use of impermeable material such as polyethylene sheet, which should be
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well sealed and fastened to cover the concrete surface for not less than four (4) hours after
application of the curing compound.
M
Notwithstanding the foregoing, concrete surfaces, which are subjected to heavy rainfall within
three (3) hours after the curing compound has been applied , shall be resprayed, all as
specified above.
EN
Concrete liable to be affected by running water shall be adequately protected from damage
during the setting period.
M
The mechanical distributor shall traverse the concrete lanes both longitudinally and J
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transversely. In order to prevent windblown losses, the nozzles are to be as close to the
surface of the concrete as possible, and equipped with protective hoods, to ensure even
coverage. Where such machines cannot operate due to irregular panel sizes, hand operated
sprayers may be used to achieve the requirements of the specification.
O
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5.9 REMOVING FORMS
Side forms shall not be removed until the concrete placed against them is at least after 8
hours period.
This duration shall be increased should any damage to concrete occur during removal. Side
forms shall be so designed as to prevent such damage to the concrete during removal .
40
(JKRlSPJ/2020-S5)
As soon as the side forms are removed, any areas showing a minor degree of honeycombing
shall be repaired with structural grade patching mortar. Where the S.O. considers that a major
degree of honeycombing is present, the work shall be considered defective and shall be
removed and replaced at the expense of the Contractor. In such cases, the section of
concrete removed shall be to the full width and depth of the slab and at least 2.5m long.
5.10 TREATMENT OF MANHOLES AND GULLIES
Manhole covers, gullies and their frames shall be isolated from the main pavement slab as
ER
shown on the Drawings and their surrounds cast in separate operations.
Manholes and gully recesses shall be formed by casting the main slab against formwork
boxes with vertical sides, placed and fixed accurately. The formwork boxes shall be removed
D
before the concrete around the manhole or gully cover is to be placed and preformed joint
N
filler, fixed to the slab edges so exposed. This shall be to the full depth of the slab, allowing
for the depth of the groove required for sealing. Alternatively, the recesses may be sawn out
TE
after the concrete has hardened.
Reinforcement shall be placed as shown on the Drawings and concrete placed by hand in
the space between the main slab and the manhole or gully frame. This concrete shall be of
A
the same grade as that of the main slab, and the mix shall be modified as necessary to permit
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full compaction by the methods adopted.
M
EN
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()
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41
(JKRlSPJ/2020-S5)
5_11 HORIZONTAL ALIGNMENTS, SURFACE LEVELS AND SURFACE REGULARITY
5.11 .1 Survey
Before placing bound road base and concrete slab, the contractor shall survey the
pavement area to determine its conformance with the levels, alignments and joint
locations specified. Levels shall be taken at minimum 10 meter intervals
longitudinally and 1 meter interval transversely. Each level survey on successive
layers (subgrade, subbase, road base and concrete slab) shall be at the same plan
location, to enable layer thicknesses to be determined by subtraction. The
contractor shall prepare a survey drawing, note any non-conformances on this
ER
survey drawing, and submit it to the S.O for approval.
5.11 .2 Horizontal Alignment of Joints, Edges and others
D
The horizontal alignment shall be determined from the centre-line of the pavement
N
surface shown on the Drawings. The edges of the pavement as constructed and
all other parallel construction lines shall be correct within a tolerance of +50 mm
TE
and minus 0 mm from the center-line, except for kerbs, channel blocks and edge
lines which shall be laid with a smooth alignment with a tolerance of +25 mm and
minus 0 mm from the centre-line.
A
In addition, the plan position of the outer edge line of the road base shall be placed
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minimum 300mm wider than the edge of the concrete slab, to ensure full support
of the concrete slab by the roadbase at such edges.
M
5.11 .3 Joint Locations
The lateral deviation from established alignment shall not exceed ± 30mm for any
EN
longitudinal joint. The deviation from the plan position of any transverse joint shall
not exceed ± 50mm.
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5.11 .4 Surface Levels of Pavement Layers

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The design levels of pavement layer shall be calculated from the vertical profile,
crossfall and pavement layer thicknesses as shown on Drawings. The level of any
point on the constructed surface of the pavement course shall be the design level
subject to the appropriate tolerances given in TABLE 5 .B.
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D
TABLE 5.8 : TOLERANCES IN SURFACE LEVELS OF PAVEMENT LAYERS
Pavement Layer Tolerance (mm)

Top of concrete slab + 20, -0
Top of Roadbase +0, -20
Top of Subbase +10, -20
Top of Subgrade +10, -30
42
(J KRiSPJ/2020-S5)
5.1 1.5 Surface Regularity

Roughness of a pavement surface is brought about by uneven settlement, short
and long wave undulations, rutting, wide cracking and other surface defects such
as potholes, delamination etc.
The International Roughness Index (IRI) is used internationally to measure the
ER
degree of roughness of a pavement surface. It is representative of the vertical
motions induced in moving vehicles for the frequency bandwidth which affects both
the response of the vehicle and the comfort perceived by the occupants.
D
5.11.5.2 Measurement of IRI
N
n The regularity of the completed pavement surface shall be measured before traffic
TE
is allowed on it and is measured in terms of its lane IRI. Lane IRI shall be measured
using the profilometer following the procedures as outlined in AUSTROADS PAT
01 :2001 (Refer to JKRlSPJ/2008 S4 - APPENDIX I).
A
Other types of equipment may be used to measure lane IRI provided that the output
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from the equipment correlate strongly with the output from Class 1 Profilometer (R2
> 0.95).
M
5.11.5.3 Acceptance criteria
The Contractor shall make available lane IRI values for the whole road length as
EN
well as for each 100m section of the completed pavement surface.
The lane IRI measured for the whole road length and each 100m section not more
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than 2.0 m/km after 28 days of laying.

( J
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The Skid Resistant Value (SRV) using British Pendulum Tester shall not less than
55 corrected at 35°C of the completed pavement surface.
5.11 .5.4 Rectification work for non-compliance

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In case of non-compliance, the Contractor shall carry out rectification works on any
D
part of the completed pavement surface so that the lane IRI values for the whole
road length and for each 100m section not more than 2.0 m/km, at least 6 months
before end of Defect Liability Period (DLP).
43
(JKRlSPJ/2020-S5)
5_12 ACCEPTANCE, SAMPLING AND TESTING OF CONCRETE
5.12.1 Characteristic Compressive Strength
The characteristic compressive strength of concrete is that of 28 days cube

strength. Compliance with the specified characteristic compressive strength shall
be judged by tests made on cubes at an age of 28 days to comply with the
JKRlSPJ/2017-S9 (Revision 2018); Clause 9.3.2.1(iii)(b).
5.12.2 Sampling and Testing
ER
i) Samples of concrete shall be randomly selected and taken in accordance with
EN 12350-1. The minimum rate of sampling and of testing of concrete shall be
in accordance with Table 9.10 as specified in JKRlSPJ/2017-S9 (Revision
D
2018) at the rate that gives the highest number of samples for initial or
continuous production, as appropriate.
N
ii) The samples shall be taken after any water or admixtures are added to the
TE
concrete, but sampling before adding water reducing agent to adjust the
consistence is permitted where there is proof by initial testing that the water
reducing agent to be used has no negative effect on the strength of the
concrete.
A
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iii) The test result shall be that obtained from an individual specimen or the
average of the results when two or more specimens made from one sample
are tested at the same age.
M
iv) Where two or more specimens are made from one sample and the range of
the test values is more than 15% of the mean the result shall be disregarded
EN
unless an investigation reveals an acceptable reason to justify disregarding an

individual test value .
M
v) The sampling rate for identity testing shall be one sample every load.
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vi) Samples shall be taken in accordance with BS EN 12350-1. Test specimens

shall be prepared and cured in accordance with MS EN 12390-2. The
compressive strength of the specimens shall be determined in accordance with
MS EN 12390-3. The test result shall be obtained from the average value of
O
the specimens made from the same age. Where the range of test values is
more than 15% of the mean, the results shall be disregarded unless an
D
investigation reveals an acceptable to justify disregarding an individual test

value.
5.12.3 Testing Plan
Three test cubes and a slump test shall be made from every load of concrete. The
samples shall be taken at the point of discharge from the mixer or, in the case of
ready-mixed concrete, at the point of discharge from the delivery vehicle.
44
(JKRlSPJ/2020-S5)
One test cube from each sample shall be tested for the 7 days compressive
strength. If the cube strength falls below the 7 days strength from the design mix,
then the Contractor shall take the necessary steps to review the process of the
production of concrete and make certain adjustments where applicable .
The remaining two test cubes from the same sample shall be tested for the 28 days
compressive strength . The average strength of the two cubes shall constitute the
28 days compressive strength of the sample.
5.12.4 Reporting
ER
The contractor shall submit weekly reports calculating the Standard Deviation (SO)
of concrete cube test results.
The Contractor is to test all cubes and cores using an approved laboratory
D
accred ited by the government. If the 5 .0 . is not in every way satisfied with the
N
execution of the tests, the Contractor is to deliver the cubes and/or cores to an
alternative laboratory, nominated by the 5 .0 ., for testing. Records are to be made
TE
of all tests of whatever kind and copies are to be forwarded in duplicate to the 5.0.
Particular atlention is to be given all times to the use of methods whereby concrete
loads from which test specimens have been made, can be accurately located in
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the finished work.
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5.1 2.5 Yield Tests

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Yield tests, made in accordance with specification AASHTO T 121 MfT 121 shall be
made of every 1000m3 of concrete production by Certified Testing Laboratory for
the purpose of determining the cement content per cubic meter of concrete. If at
EN
any time such cement content is found to be less than that specified per cubic
meter, the batch weights shall be adjusted until the amount of cement per cubic
meter of concrete conforms to the requirements of the mix design.
M
( ) 5.12.6 Sl ump Test During Paving

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In addition to the slump tests required under Sub-clause 5.3.9.2, as a check on the
workability and uniformity of the concrete, slump tests are to be carried out at the
point of delivery to the paving site, at the following frequencies, and the results
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recorded as part of the Contractor's Quality Control Plan :

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i) Concrete deliveries that do not conform to the slump requirements shall be

rejected and removed from the site.
5.1 2.7 Core Extraction and Testing
The Contractor shall core one (1) numbers of minimum 100mm diameter cores
from concrete panels of at least seven (7) days old for visual inspection, thickness
and strength tests. One core is to be taken for each 500m 2 of concrete laid.
45
(JKRlSPJ/2020-S5)
The position of the cores will be decided by the S.D. If any such core shows honey
combing and/or fails of the specified characteristic compressive strength of the
concrete slab or bound road base, as appropriate, when correlated to in-situ cube
strength tested according to MS 26 at 28 days, the Contractor is to core one (1)
additional numbers at points indicated by the S.O. within 3 meters of the failed core.
If the compressive strength of any of these one (1) additional cores above shows
similar result, then the deficiency in strength will be the basis by which the S.D. will
reject the whole concrete panel. Further cores required by the S.D. to ascertain
the extent of unsatisfactory concrete, are to be obtained by the Contractor as
directed, and failed areas to be removed and replaced at the Contractor's expense.
ER
5.12.8 Flexural Beam Test
The contractor shall carry out flexural beam three point loading test method
D
N
made in accordance with specification MS EN12390-5. The tests shall be made of
every 1000m 3 of concrete production by the Certified Testing Laboratory for the
TE
purpose of determining the strength of the concrete in relation to compressive
strength. Contractor shall produce correlation between flexural strength with
compressive strength to the approval by the S.O.
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5.12.9 Tolerance on Pavement Thickness
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Bound road base and concrete slab shall be core individually. The cores taken in
Sub-clause 5.12.7 shall be the basis for determining the thickness of the
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pavements.
If the thickness of the cores is less than that specified by more than 10mm, the
EN
actual thickness of the pavement in this area shall be determined by taking

additional cores at not less than 3m intervals parallel to the centerline in each
direction from the affected location. Areas found deficient in thickness by more than
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10mm shall be evaluated by the S.D. and, if the deficient areas warrant removal,
they shall be removed and replaced with concrete of the thickness shown on the J
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Drawings.
The core holes shall be filled with an approved, pre-mixed and bagged proprietary
repair material, in accordance with the manufacturer's recommendations. The
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material shall be hand tampered in separate lifts, each lift not exceeding 100mm,
and the repair surface finished, textured and cured to the satisfaction of the S.O.
D
46
(JKRlSPJ/2020-S5)
5.13 OPENING TO TRAFFIC
Concrete pavement shall not be opened to any traffic until the concrete pavement achieved
minimum strength of 20N/mm 2 compressive strength after placement of the concrete for repair
and maintenance of an existing road with the approval of S.O. On the other hand, for a newly
constructed concrete pavement, targeted design strength shall be achieved before opening
to traffic.
The edges of the concrete pavement shall be protected from damage by construction traffic.
Prior to opening to traffic, the concrete pavement shall be cleaned.
ER
The Contractor shall erect and maintain suitable barricade and shall employ watchmen to
exclude public traffic and that of his employees and agents from using the newly constructed
pavement.
D
These barriers shall be arranged so as not to interfere with public traffic on any lane intended
N
to be kept open and necessary signs and lights shall be maintained by the Contractor clearly
indicating any lanes open to traffic.
TE
Where, as shown on the Drawings, it is necessary to provide for traffic across the pavement,
the Contractor shall, at his own expense, construct suitable and substantial crossings to
bridge the newly constructed concrete pavement as directed by the S.O.
A
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Any part of the pavement damaged by traffic or other causes prior to its final acceptance shall
be repaired or replaced at the expense of the Contractor in a manner acceptable to the S.O.
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EN
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( )
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47
(JKRlSPJ/2020-S5)
5.14 ROLLER COMPACTED CONCRETE (RCC)
Ree derives its name from the construction method . Ree is recommended for traffic loading
with maximum ESAL of 6 million standard axle (msa) (20 years design life) and a maximum
of 10% daily commercial vehicle (PCv). The concrete is lay with a high-density paver and
compact by rollers. It is only a concrete in the sense that its main constituents are aggregate.
water and cement. It does not behave in the same way as conventional concrete in terms of
construction or performance. It does not require reinforcing , dowel bars or formwork for
construction . Features and benefit of ReC as shown in TABLE 5.14.1 .
ER
D
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FIGURE 5.14.1 : USE OF ASPHALT TYPE PAVING EQUIPMENT TO LAY RCC
A
TABLE 5.14.1: FEATURES A ND BENEFITS
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Material characteristics Potential benefits

High flexural strength (4 Support heavy, repetitive loads without failure and can span
M
MPato 7 MPa) localized soft subgrade areas, reducing maintenance costs and
down time
EN
High compressive strength Withstands high concentrated loads and impacts

(30 MPa to 60MPa)
High shear strength Eliminates rutting and associated maintenance
High density, low Eliminates water seepage
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absorption
Low water content, low Increase strength , reduces permeability, and enhances
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water/cement ratio durability and resistance to chemical attack

Aggregate interlock Provides load transfer through high shear resistance at jOints
and uncontrolled cracks, preventing vertical displacement or
O
faulting between slabs

No steel reinforcing or Speeds and simplifies construction, reducing costs
D
dowels, forms or finishing

If required, joints may be Reduces the risk of degradation at construction joints
sawn and sealed
conventionally
Use of asphalt type paving Can utilize paving equipment that is normally available
equipment
Support light early Light vehicles can access the pavement soon after completion
trafficking
48
(JKRlSPJ/2020-S5j
Material characteristics Potential benefits

Light surface concrete Reduced lighting requirements in parking and storage areas
colour
Construction application By using higher compressive strength material, road can be
for maintenance of opened for heavy vehicle within 48 hours
existing road
Construction application Possibility of using lower compressive strength material (longer
for new road curing period allowed)
Common Applications
ER
Some major applications of RCC to-date are:
i. Commercial parking areas;
D
ii. Industrial storage hardstandings;
iii. Waste transfer and processing areas;
N
iv. Container port and dock storage areas;
v. Truck and freight interchange terminals; and
TE
vi. Military pavements, such as tank hardstands
The use of RCC in highways as road shoulder, structural base in a composite pavement and
in airfield pavements as a high strength base is increasing, as its versatility and cost-
A
effectiveness are increasingly acknowledged .
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EN
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l ) FIGURE 5.14.2: RCC APPLICATION AS INDUSTRIAL HARDSTAND

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5.14.1 Description
This work shall consist of furnishing, placing, shaping and compacting RCC course
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on a bitumen primed pavement course. RCC material shall compose of mineral

aggregate and cement uniformly blended and mixed with water in the plant. The
D
mixed materials shall be spread, shaped and compacted in accordance with this
SpeCification and in conformity to the lines, grades, dimensions and typical cross-
sections as shown on the Drawings. This pavement course shall be built in a series
of parallel lanes that may reduce longitudinal and transverse joints to a minimum.
49
(JKRlSPJ/2020-S5)
5.1 4.2 Materials
RCC has similar constituents to conventional concrete. However, they are mixed in
different ratios and the mix contains much less water than conventional concrete
mix, and generally dryer without slump. The strength of the finished material is
reliant on the constituents of the mix and the level of compaction that can be
achieved. Aggregate comprise up to 85% of the mixture and the correct selection
and grading of aggregates is a key element of successful RCC. A dense well-
graded aggregate blend is required as in Sub-clause 5.14.3.2.
i. Water
ER
Water shall be clean and free from injurious of sewage, oil , acid, strong alkalis
or vegetable matter and it shall be free from clay or silt. If the water is of
questionable quality, it shall be tested in accordance with requirements of MS
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EN 1008.
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ii. Cement
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Cement for RCC shall be of the types described in MS EN 197-1 and
MS1037.
A
Manufacturer's certificates of test will , in general, be accepted as proof of
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soundness. Additional tests shall be carried out on any cement, which
appears to have deteriorated through age, damage to containers, improper
storage or any other reason . In any event, the batch of cement, which has
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been sampled and tested and found not to have complied with the
requirements, shall be rejected and removed from the site.
EN
Cement shall be transported to the site in covered vehicles adequately

protected against water. It shall be stored in a weatherproof cement store to
the approval of the S.O. and shall be taken for use in the Works in the order
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of its delivery into the store. Cement delivered in bulk shall be stored in silos
of an approved design. J
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iii. Aggregate
Aggregate shall be naturally occurring sand, gravel or stone, crushed or

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uncrushed except otherwise specified, and shall comply with BS EN13242.

They shall be from source approved by the S.O. and shall be hard, strong,
D
durable and clean. They shall be free from adhering coatings and shall not
contain any harmful materials in sufficient quantity so as to adversely affect
the strength, durability and impermeability of the concrete.
a) Coarse Aggregate
Coarse aggregate shall comply with BS EN13242
50
(JKRlSPJ/2020-S5)
b) Fine Aggregate
Fine aggregate shall comply with BS EN13242. If it is found necessary, the fine
aggregate shall be washed and screened to the satisfaction of the S.O.
iv. Admixtures
Chemical admixtures such as water-reducing, retarding and accelerating

admixture shall conform to MS EN934 as in Sub-clause 5.2.4 and must be
approved by the S.O. prior use.
ER
Superplasticizers (Polycarboxylate) can be used in dry batch plant production
to improve workability and reduce mixing time, but pavement test section
must be constructed to verify the proper admixture to use for a particular mix.
D
Extensive laboratory and field test must be conducted prior to any use of
N
n admixtures to determine the effectivene:;s and proper dosage rates.
TE
Admixture/s may be added to the concrete mix to produce some desired
modifications to the properties of concrete if necessary, but not as partial
replacement of cement.
A
v. Additions
EJ
In addition to cement and pozzolan used in RCC mixes, the other

cementitious materials if specified or permitted, such as fly ash, shall meet
M
the required design strength and durability requirements of the finished RCC,
not exceeding thirty percent partial replacement of Roller Compacted in
concrete mix and shall base on its availability. It shall conform to the
EN
requirement of MS EN 450-1.
vi. Joint filler material

M
( )
Poured joint fillers materials shall confirm as in Sub-clause 5.2.6.
KU
vii. Joint Sealants
All joint sealants materials shall confirm as in Sub-clause 5.2.7.

O
viii. Curing Materials

D
All curing materials shall confirm as in Sub-clause 5.2.8.
ix. Steel Reinforcement
RCC pavement, unlike conventional concrete pavement, cannot be

reinforced with steel nor include dowel bars to provide joint load transfer
because steel reinforcement will hinder compaction effort of equipment on the
51
(JKRlSPJ/2020-S5)
pavement section, joint load transfer must rely on aggregate interlock and
base support for long-term joint performance.
In the event of tie bars are require to be install in the pavement, steel
reinforcement materials shall confirm as in Sub-clause 5.2.9.
x. Surface Debonding Treatment
All surface debonding treatment materials shall confirm as in Sub-clause

5.2.10.
5.14.3 Mix Design
ER
i. Considerations for RCC mix design
D
The mix design and materials must be chosen and tested for consistency so
that desired performance in these tests can be achieved. Durability is a
N
complicated subject interrelated to various parts of the design, material and
construction specification. In terms of Ree the main durability test is on the
TE
mixture, as is the normal practice for hydraulically bound base layers.
ii. Gradation of Blend Aggregates

A
Aggregate comprise up to 85% of the mixture and the correct selection and
EJ
grading of aggregates is a key element of successful Ree. A dense well-
graded aggregate blend is required . Recommended aggregate grading as
given in TABLE 5.1 4.1 .
M
TABLE 5.1 4.1: GRADING FOR RCC

EN
Sieve Size Percentage passing by weight

25mm 100
19mm 90 to 100
M
12.5mm 70 to 100
9.5mm 65 to 85
KU
4.75mm 50 to 70
1.18mm 25 to 45
150llm 5 to 20
o to 8
O
751lm
D
iii. Workability
Workability of the mix shall be tested with Vebe Test in accordance with the
standard testing procedure in APPENDIX 3.
52
(JKRlSPJ/2020-S5)
iv. Laboratory Tests
At least thirty days (30) prior to the time the Contractor is expected to begin
placement of RCC course, he shall submit to the S.O. for approval a job mix
design. The job mix design shall be submitted with certified laboratory reports
showing materials compliance, strength requirements and required laboratory
tests. After approval of the job mix design, no substitution of materials or
proportions shall be made without approval of a new mix design submitted by
the Contractor in accordance with this Specification and approved by the S.O.
TABLE 5.14.2: THE RCC SPECIMENS SHALL DEVELOP A MINIMUM
ER
CHARACTERISTIC
Properties Specifications
Flexural Strength 3MPa to 5.5MPa @ 3 days
D
Compressive Strength 30MPa to 60MPa @ 28 days
N
(j 96% (min)/98% (average)
Compaction
v. Sampling and Testing of RCC

TE
A
BS EN 14227-1 provides a framework for the production control of RCC
EJ
including testing of constituent materials.
To ensure that the strength requirements of the RCC are met, a minimum of
M
six compressive strength test on 150mm x 150mm x 150mm cubes and one
flexural beam test as confirm with Sub-clause 5.12.8, shall be determined of
the RCC for every 1,000 m2 of slab construct. A minimum of one set of test
EN
per day shall be performed if less than 1,000m2 is placed. The compressive
and flexural strengths shall be determined based on table 9 specimens.
Material for the laboratory specimens shall be sampled at the same area the
M
density test is carried out, on the day the material is placed. Three (3)
laboratory cubes and beams shall be produced and from each set of three (3)
KU
cubes and beams, two (2) shall be tested for compressive and flexural
strengths at three (3) days with one spare cube and beam being held in
reserve to replace any obviously defective cube or beam that may develop.
O
vi. Field Density

D
The Contractor's shall develop a moisture/density relationship of the actual

job materials in accordance with ASTM D1557. Optimum moisture content
and maximum wet densities shall be established and copies of the moisture-
density curves shall be provided to S.O. prior to any RCC placement.
Contractor shall perform density testing of the RCC in accordance with ASTM
C1040, direct transmission mode, direct behind the paver. Only wet density
shall be used for evaluation. At least five (5) tests shall be performed at the
53
(JKRlSPJ/2020-S5)
back of paver and after final compaction for each 200m' concrete placed. The
required density shall be achieved 98% of wet density after final rolling.
5.14.4. Construction Methods
i. Preparation
a) General
Equipment and tools necessary for performing all parts of the work shall be
approved by the S.O. as to their design, capacity, and mechanical condition .
The equipment shall be at the job site before the start of construction
ER
operation for examination and approval .
As part of the Construction Plan, the contractor shall submit a method

statement for approval for placing the concrete, including the Trial Areas, as
D
part of Quality Control Plan. No work shall be started prior to the written
N
TE
b) Trial Lay & Test Section
Prior to full production, the Contractor shall prepare a quantity of the RCC
according to the job mix design. The amount of mixture shall be sufficient to
A
construct a test section of minimum 200m 2 • The trial lay shall constructed
using approved method statement.
EJ
The test section shall be equal to the drawing thickness and panel width.
M
Same equipment proposed for use on the project shall be used for the trial
lay
EN
The Contractor shall demonstrate the ability to achieve a smooth, hard,

uniform surface free of excessive tears, ridges, spalls and loose materials.
Also, achieve 85% of the maximum wet density in accordance with ASTM
M
01557, directly out of the paver and 98% if the maximum wet density. After
completion of the test strip, cores will be extracted to verify mix compliance. J
KU
This will be performed by the approved Testing Laboratory, at the expense of

the Contractor.
c) Rolling Pattern
O
The Contractor shall establish a rolling pattern that will achieve the required
D
density with a minimum number of roller passes. During vibratory compaction,

the roller shall not be started, stopped, or left standing in vibratory mode.
Stagger the stopping point of successive rolling passes to avoid forming
depressions on the surface.
54
(JKRlSPJ/2020-S5)
The Contractor shall continually check the RCC surface while still plastic to
ensure surface and grade tolerances are met. Immediately correct excessive
variations in accordance with the spreading requirements. The contractor
shall remove any roller marks on the surface using a steel drum roller in static
mode. Each land edge shall be constructed with a face within 1:1 of vertical.
d) Preparing Underlying Course
Prior to placing RCC course, the underlying course of sub grade or sub base
shall have been shaped and compacted in accordance with the Specification
as in Sub-clause 5.4.1.3.
ER
e) Preparing of Surface Debonding Layer to Receive RCC
All preparing of surface debonding layer shall confirm as in Sub-clause
D
5.2.10.
N
ii. Weather Limitations
TE
a) Hot Weather
During periods of hot weather, special precautions should be taken to

A
minimize moisture loss due to evaporation. High temperatures will increase
EJ
the rate of evaporation from the RCC prior to compaction, reduce the working
time and retaining sufficient moisture at the surface to ensure full hydration.
M
b) Wet Weather
The RCC shall not be mixed or placed when the weather is rainy.
EN
iii. Quality Control Plan

M
The Contractor shall furnish the S.O. a Quality Control Plan detailing his production
l ) control procedures and the type and frequency of sarnpling and testing to ensure
KU
that the concrete produced complies with the Specifications. The test method that
may be used for making specimens and determining densities of laboratory-
produced RCC mixtures shall be in accordance to BS EN 12350-3.
O
The S.O. shall be provided free access to recent plant production records, and if
requested, informational copies of mix design, materials certifications and sampling
D
and testing reports .
iv. Quality Control Testing
The Contractor shall perform all sampling, testing and inspection necessary to
assure quality control of the component materials and the concrete.
55
(JKRlSPJ/2020-S5)
The Contractor shall be responsible for determining the gradation of fine and coarse
aggregates and for testing the concrete mixture for moisture content, temperature.
He shall conduct his operations to produce a mix conforming to the approved mix
design.
v. Production of Concrete
All production of concrete shall confirm to Sub-clause 5.3.3.
All concrete grade shall confirm to Sub-clause 5.3.9.1.
ER
vi. Machine
The Concrete Slab shall be constructed by asphalt paver, placed in a single layer
or multiple lift depending on design and requirement specification.
D
o
N
a) Paving Equipment
TE
i. Asphalt Paver
The asphalt paver shall be of recognized manufacture and shall be

approved by the S.O. It shall conform to the requirements described
A
hereinafter. The paver shall be a high density compacting, self-propelled
EJ
and capable of reverse as well as forward travel. It shall be equipped with a
hopper at the front designed to receive the paving mix from tip-trucks, and
shall have a mechanical distribution system for spreading the mix evenly
M
and without segregation over the surface to be paved in front of a screeding

and compacting unit that can achieve a minimum of 90% compaction
density. The screeding and compacting mechanism shall be capable of
EN
confining the edges of the material being laid without the use of stationary
side forms, shall be adjustable to strike off the mixture to the thickness and
cross-section shape required, and shall be controlled by an automatic
M
levelling device to produce even concrete surface with a uniform surface

texture free from indentations, ridges, tear marks or other irregularities. The J
KU
paver shall be capable of laying the concrete mixture in required paving

widths.
Concrete Slab shall not have any reinforcement or dowel or tie joint.
O
Double lifting should be allowed if the 2nd layer of laid;

D
a) Wet Joint - within 2 hours of operation.
b) Dry joint - after setting and achieved 85% of strength.
b) Compacting Equipment
i. Steel Wheeled Tandem Roller
56
(JKRlSPJ/2020-S5)
reversed without backlash; they shall be equipped with power steering and
dual controls allowing operation from either the left or right side. The roller
shall be equipped with water tanks, sprinkler systems and scraper blades to
keep all wheels evenly wetted and clean during operation.
Each steel wheeled tandem roller shall be ballasted so that its total
operating weight is in the range 8 to 10 tonnes and its driven roll (or rolls)
shall exert a rolling force of not less than 3.5 tonnes/metre of roll width. The
Contractor shall provide the S.O. with a calibration chart for each roller
showing the relationships between the quantity or depth of ballast and total
ER
weight and rolling force.
ii. Pneumatic Tyred Roller
D
The pneumatic tyre roller shall be self-propelled and capable of being
N
() reversed without backlash; it shall be equipped with power steering and dual
controls allowing operation from either the left or right side.
TE
The roller shall have nine wheels equipped with smooth treaded lyres all of
the same size and construction , and capable of operating at inflation
pressures of up to 0.9 N/mm2. Five wheels shall be on the driven axle and
A
four on the steering axle, all equally spaced on both axles and arranged so
EJ
that the lyres on the steering axle track midway between those on the driven
axle with a small overlap. The roller shall be equipped with water tanks,
sprinkler systems and pads of coconut matting to keep all lyres evenly
M
wetted during operation.
The roller shall be equipped with means of adjusting its total weight by
EN
ballasting so that the load per wheel can be varied in the range 1.0 to 2.0
tonnes. In operation, the ballasted weight and the tyres inflation pressure
shall be adjusted to meet the requirements of each particular operation.
M
Each lyre shall be kept inflated at the specified pressure such that the
( J pressure difference between any two lyres shall not exceed 0.04 N/mm2.
KU
Means shall be provided for checking and adjusting tyre pressures at all
times at the place of the works.
The Contractor shall provide the S.O. with a calibration chart for the roller
O
showing the relationship between the quantity or depth of ballast and total
weight, and also a chart showing the relationship between wheel load, tyre
D
inflation pressure and contact pressure.
c) Dump Trucks
Dump trucks shall be used for transporting the RCC material from the plant to
the paver. Trucks shall be clean and equipped with open-bed with retractable
protective covers to protect the RCC material from rain, evaporation, heat and
other detrimental weather conditions. A sufficient number of trucks shall be
57
(J KRiSPJ/2020-S5)
provided to ensure adequate and continuous supply of RCC material to the

paver. Adequate size and clearance height must be established through
inspection to determine the compatibility of the truck with the paving machine.
No part of the truck must hit the paving machine at any moment during the
laying operation.
d) Water Trucks
Water truck or other similar equipment shall be on-site and available for use
throughout the paving and curing process. The truck or devise shall be
equipped with 'spray bar capable of evenly applying a fine spray of water to the
RCC, subgrade or subbase surface without damage.
ER
e) Concrete Saw
The Contractor shall provide concrete saws that are capable of sawing new
D
RCC for crack control with minimal raveling and to the depth as speCific. Saw
N
cutting shall first be tested on sample areas starting at 24 hours after laying to
see if raveling will occur during cutting . Test cuts shall be done at one (1) hour
TE
interval until desired quality is achieved or until 48 hours. All saw shall be
equipped with blade guards and guides or devices to control alignment and
depth.
A
vii. Transporting
EJ
RCC mix is transported to the job site in dump trucks. Precaution should be paid to
prevent RCC segregation when loading trucks, transporting the mixture, or
M
discharging into paver hoper. Because of very dry consistency of RCC, fluidizing
admixtures are sometimes used when hauling RCC in transit mixers. The following
points should be considered in transporting RCC:
EN
a) The fleet capacity and configuration should be determined by taking into

account the mixer throughput, hauling distance, paving plant capacity, climate.
M
and time (day/night) of paving.

J
KU
b) While RCC can be placed directly into dump trucks from tilt drum and horizontal
shaft mixers, the use of transit mixers involves the additional step of
discharging into a dump truck for deliver.
O
c) Dump trucks are kept clean by frequent washing. RCC can stick to the dump
body and, if not washed away, can cause problems while unloading. In
D
addition, the box should be cleaned out after each delivery to ensure the older
and potentially dried out RCC does not end up in the next truck load.
d) RCC is covered with tarps or other suitable coverings in order to avoid

excessive moisture loss, which can cause problems in placement, compaction,
and performance. Additionally, the mixture should be kept slightly above the
optimum moisture content to accommodate water loss during transportation .
The optimum moisture content is required for proper compaction.
58
(JKRlSPJ/2020-S5)
e) An oscillating hopper at the discharge point is opened and shuted for every
load to prevent segregation. RCC is discharged into the truck uniformly through
the entire length of the truck box: one-third at the front, one-third at the center,
and one third at the back.
For adequate placement, the transportation time from the mixing plant to discharge
into the paver hopper is kept to minimum. Fresh RCC workability decreases with
time; as a result, transportation time is generally kept to no more than 45 minutes,
measured from the initial water cementitious materials contact to discharge into the
paver hopper. The time can be increased by using retarders, as long as evaporation
rate is controlled .
ER
viii. Placing
The RCC shall be transported to the job site in suitable vehicles and shall be
D
deposited on the moistened underlying layer in uniform layers by asphalt paver. Not
N
more than 60 minutes shall elapse between the start of mixing and the start of
compaction of the RGC on the prepared underlying layer. The time can be increased
TE
by using retarders . As long as the mix is workable and can be easily compacted to
achieved the required density upon placing.
RCC typically placed with an asphalt paver. The paver should be able to place RCG
A
at least 85 percent of the reference wet density across the entire paving width before
EJ
rolling begins. The underlying layer should be uniformly moist at the time of RCC
placement, if required, sprinkli~ g of water to remoisten certain areas shall take place
in order to ensure the uniformly moist.
M
To prevent segregation during placement, the paver hopper should never be

completely emptied, the sides of the hopper should never be raised, and the RCG
EN
should always cove~ the feed auger shaft.
The paver is to maintaining continuous forward motion with the paver helps prevent
M
the formation of bumps or depressions on the final pavement surface. Continuous

() forward motion is achieved by balancing paver speed with a consistent rate of
KU
delivery. The pavers are typically equipped with vibratory screeds to provide some
initial extemal compaction.
The surface of the RCG pavement once it leaves the paver is required to be smooth,
O
uniform and continuous without excessive tears, ridges or aggregate segregation.

D
All exposed surfaces of the ReC pavement must be kept moist until final curing. Fog
spraying and evaporation retarders are economical and effective techniques for
maintaining moisture without washing fines and paste from the surface.
a) Setting of the String Linel Guide Lines
i. Setting of String Lines
59
(JKRlSPJ/2020-S5)
String lines shall be used to guide the paver in laying RCC in grade, lift
thickness and alignment and must be installed with enough clearance as to
not be disturbed during laying operations. String lines to be used shall be
sufficiently tough under tension. String lines shall be set sufficiently in
advance of the point where concrete is being laid. After the string lines have
been set to correct grade, the grade shall be thoroughly tamped,
mechanically or by hand, at both the inside and outside edges of the base
of the string lines. The string lines shall not deviate from true line by more
than one (1) cm at any point.
ii. Grade and Alignment
ER
The alignment and grade elevations of the string lines shall be checked and
corrections made by the Contractor immediately before RCC laying. Testing
as to Crown and elevation with reference to the design, prior to placing of
concrete can be made by means of holding an approved template in a
D
vertical position and moved backward and forward along the string lines.
N
When any string lines have been disturbed or any grade has become
TE
unstable, the string lines shall be reset and rechecked.
ix. Compaction
A
The compaction stage of construction is important because of its strong influence on
the density, strength, permeability, and smoothness of the RCC pavement. Ree is
EJ
usually compacted with a 10-ton steel wheeled tandem roller immediately after
placement. Pneumatic tyred roller have also been used successfully, especially for
a final pass to remove surface cracks and tears and provide a smooth, tight surface.
M
Because there is no bleed water at the surface of Ree pavements, a good method
for determining that the RCC is ready for compaction is to observe the behavior of
EN
the fresh RCC under static roller passes. RGG that has proper consistency for
compaction will deflect uniformly under roller passes. If the RCe is too wet for proper
compaction, the surface will appear shiny and pasty, and the ReC will exhibit
M
pumping behavior under the roller.

J
If the RGG is too dry, the surface will appear dusty or grainy and may even shear
KU
horizontally, In addition, aggregate segregation is likely to occur and sufficient

density will be difficult to obtain, especially in the lower portion of the lift. In most
cases, troubleshooting mixture problems caused by variations in the moisture
O
content would indicate that a minor adjustment is necessary. If adjusting the water
content is not successful, checking the aggregate gradation or plant calibration may
D
be necessary.
ReG should be compacted as soon as possible after it is spread, especially in hot

weather. Typically, compaction should be completed within 15 minutes of spread and
60 minutes of initial mixing. The compaction time can be increased by using
retarders, the mix design and quality control plan shall submitted by the Contractor
and approved by the S.O. prior to any compaction to ensure that the concrete
produced complies with the Specifications.
60
(JKRlSPJ/2020-S5)
Typically, four to six passes of 10-ton steel wheeled tandem roller will achieved the
desired density of at least 95% for RCC lifts in range of 150 - 200mm.
Overcompaction or excessive rolling should be avoided.
The field density of the compacted mixture shall be at least 95% of the maximum
density of laboratory specimens prepared from samples of the RCC. The specimens
shall be compacted and tested in accordance with ASTM 01557 Method O. The in-
place field density shall be determined in accordance with ASTM 01556 and ASTM
02167.
x. Laying Thickness
The minimum compacted layer thickness shall be 150mm to maximum thickness of
ER
200mm.
In the case of total thickness of the slab is required to be greater than 200mm, it shall
D
be laid in multiple layers separated by a debonding layer as per Sub-clause 5.14.4
(i)(e).
N
n
TE
xi. Joints
All joints shall confirm as in Sub-clause 5.5.

A
xii. Curing
EJ
All curing shall confirm as in Sub-clause 5.8.
xiii. Horizontal Alignments, Surface Levels and Surface Regularity

M
All Horizontal Alignments, surface levels and surface regularity shall confirm as in
EN
Sub-clause 5.11 .
xlv. Acceptance, Sampling and Testing of Concrete

M
( ) All acceptance, Sampling and Testing of Concrete shall confirm as in Sub-clause

5.12.
KU
xv. Opening to Traffic

O
All opening to traffic shall confirm as in Sub-clause 5.13.

D
61
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APPENDIX 1
MEASUREMENT OF TEXTURE DEPTH BY SAND PATCH METHOD
A1 Apparatus
1. A cylindrical container - 25m I capacity

2. A flat wooden disc 60 to 75 mm in diameter with a hard rubber disc,
1.5mm thick, stuck to one face, the reverse face being provided with
a handle.
3. Dry natural sand passing a 300um b.s sieve and retained on a
ER
150um b.s sieve.
A2 Method
D
The surface to be measured shall be dried, any extraneous mortar and/or loose
N
material removed, and the surface swept clean using a wire brush both at right
angles and parallel to the centerline of the carriageway.
TE
The 25ml cylinder shall be filled with the sand, tapping the base three times on
a hard surface to ensure compaction, and striking off the sand, level with the
top of the cylinder.
A
EJ
The sand shall be poured into a heap on the surface to be tested. The sand
shall be spread over the surface, working the disc with its face kept flat, in a
circular motion so that the sand is spread into a circular patch with the surface
M
depressions filled with sand to the level of the peaks.
The diameter of the patch shall be measured to the nearest 5mm. A minimum
EN
of 4 measurements equally spaced around the circumference of the circular

patch should be ta ken to compute the average diameter, D.
M
The texture depth in mm of concrete surfaces shall be calculated as:-

KU
Texture depth = 4V / TTD'

O
Where:
D
v = volume of sand in mm 3 .
o = average diameter of the sand patch in mm.
A3 Result
The result of the test shall be the average texture depth of at least 4 tests
carried out by the same person on the test surface and expressed to the
nearest 0.01mm.
62
(JKRlSPJ/2020-S5)
APPENOIX2
Network Survev Vehicle
0 .1 General
1. Texture refers to the bumps that effect friction on the road

2. Wavelengths between O.Smm - SOmm
3. This is also called Macro Texture
microtexture A. < 0.5 mm
ER
and 0 - 0.2 mm (ampl itude)
macrotexture
0.5 mm<A<50 mm
D
0.2 - 1 mm (ampl itude)
N
TE
The deviation of a pavement surface from a true planar surface
(ISO 13473-1)
A
0.2 Sensor Measured Texture Depth (SMTO)
EJ
1. Profile broken down into smaller segments of SO sample points

(2S0 mm in total with a 5mm sampling interval).
M
2. A second order polynomial is fitted to these data points and the

residuals calculated .
EN
3. The use of small sub-sections of data and the application of the second
order polynomial helps deal with the effect of tyre bounce on the texture
lasers.
4. SMTD is then reported as the standard deviation of the residuals. By
M
() comi;)ining the SMTD results from these small segments the mean
texture depth may be reported over any desired length .
KU
x,
O
D
,, ,,
,, ,,
,, ,,
,, ,,
:. .'
: 5mm
,
63
(JKRlSPJ/2020-S5)
T
, y,
.
y,
y,
r
y, I
y,
• I •
Yo
L
YJ
ER
SMTD = ( L (y; - y,),/n )IIl
1
where y< = a + bx + ex' is a curve obtained by quadratic least squares regression.
D
0 .3 Mean Profile Depth (MPD)
N
1. Mean Profile Depth (MPD)
TE
2. Standards: ASTM E1845 and ISO 13473-1
3. Sampling' Interval: lmm
4. Spot Diameter: <1 mm
A
5. Laser measurement frequency: 32 kHz
6. Number of samples: 100 per metre
EJ
100 samples
M
- -- :50 mm ---~·:,...'- -- 50mm

EN
I y -' \V :
M
.!: / .!: u
KU
: Largest Dip or peak :; 1.2mm Largest Dip or pea k =1.7mm

O
MPD = Average of both = 1.45mm

D
64
(JKRlSPJ/2020-S5)
APPENDIX 3
EQUALITY CONTROL FOR ROLLER COMPACTED CONCRETE (RCCI
The quality of RCC will be controlled based on the fresh concrete and hardened
concrete performance. Quality of fresh RCC properties workability and density are
determined by the Vebe vibrating table. The workability of RCC is measured as the
time required for a given mass of RCC to be consolidated by vibrating in a cylindrically
ER
shaped mold. Density of the compacted RCC is then measured by determining the
mass of the consolidated RCC and dividing by its volume, which is determined by using
water displacement methods. Figure 1 shows the vibrating table that is used for the
Vebe Test. For detailed testing procedures, please refer to ASTM C1170 .
D
n
N
TE
A
EJ
M
Figure 1: Vebe Vibrating Table

EN
The Vebe test result obtained shall be recorded to control the mix quality sending to
site. RCC cubes are casted using a vibrating hammer instead of a tamping bar. Refer
M
to BS EN 13286 for detailed sample making procedures and to be cured for 16-23
C) hours from casting time.
KU
The quality of hardened RCC will be determined through the cube compressive
strength. Three (3) samples (minimum per day) shall be prepared for every 500 sq
meter of works. The cube samples were tested at 3, 7 and 28-days compressive
O
strength test, confirming the minimum strength requirement before open to traffic.
D
65
(JKRlSPJ/2020-S5)
APPENDIX 4
List Of Standards Refer in Section 5
Ref. ...n" -Description

stanctard
MS EN197-1 Cement - Part1 : Composition. specifications and conformity criteria
for common cements
MS 1037 Specification for Sulphate-resisting Portland cement
MS EN12620 Aggregate for Concrete
MS30 Method of testing aggregates
ER
MS EN1008 Mixing water for concrete - specification for sampling. testing and
assessing the suitability of water. including water recovered from
processes in the concrete industry. as mixing water for concrete
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MS EN934 Admixtures for concrete. mortar and grout - Part 1: Common
requirements
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MS EN450-1 Fly ash for concrete - Part 1: Definition. specifications and
conformity criteria
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MS 145 Steel fabric for the reinforcement of concrete - specification
MS 146 Steel for the reinforcement of concrete - weldable reinforcing steel -
bar. coil and decoiled product - specification
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MS 144 Steel wire for reinforcement of concrete products - specification
MS EN 206-1 Concrete - Part 1: Specification. performance. production and
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conformity
MS EN 206-3 Concrete - Part 3: Specification for Constituent material and
concrete
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MS26 Testing of Concrete

MS EN 12390-2 Testing hardened concrete - Part 2: Making and curing specimens
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for strength tests

MS EN 12390-3 Testing hardened concrete - Part 3: Compressive strength of test
specimens
MS EN 12390-5 Testing hardened concrete - Part 5: Flexural strength of test
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specimens
MS EN 13263-1 Silica fume for concrete. Part 1 : Definitions. requirements and
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conformity criteria
MS EN 15167- 1 Ground granulated blast furnace slag for use in concrete. mortar and
grout - Part 1: definitions. specifications and conformity criteria
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MS 159 Specification For Cutback Bitumen For Use In The Constructions

and/or Maintenance Of Pavement
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BS 410 Test sieves. Technical requirements and testing . Test sieves of

metal wire cloth
BS EN 13055 Lightweight aggregates
BS EN 12878 Pigments for the colouring of building materials based on cement
and/or lime. Specifications and methods of test
BS 4449 Steel for the reinforcement of concrete. Weldable reinforcing steel.
Bar. coil and decoiled product. Specification.
BS 1052 SpeCification for mild steel wire for general engineering purposes
BS 1881 -Part 124 Testing concrete. Methods for analysis of hardened concrete
(BS 1881-
66
(JKRlSPJ/2020-S5)
Standard Specification for Preformed Sponge Rubber and Cork
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Expansion Joint Fillers for Concrete Paving and Structural
Construction
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Industrial, and
M 213 Standard Specification for Preformed Expansion
n
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Concrete Paving and Structural Construction (Nonextruding and
Resilient Bituminous Types)
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i Liquid
for Curing Concrete A
T Standard Method of Test for Density (Unit Weight),
121MIT 121 Content (Gravimetric) of Concrete
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ASTM Standard Test Method for Resistance to Degradation of Small-Size

C131/C131M Coarse Aggregate by Abrasion and Impact in the Los Angeles
Machine
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Test Method for Extrusion Rate and

Elastomeric Sealants
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( ) ASTM C793 Standard Test Method for Effects of Laboratory Accelerated

W~latl1erina on Elastomeric Joint Sealants
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ASTM C794 Standard Test Method far Adhesion-in-Peel of Elastomeric Joint

Sealants
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Joint Sealants Under Movement

57 Standard Test Length
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Cement Mortar and Concrete

ASTM D1.557 Standard Test Methods for Laboratory Compaction
of Soil Using Modified Effort ft-lbf/ft3 700 kN ..m/m3\l
C1040 Standard Test for In-Place Density
Hardened Concrete, Including Roller Compacted Concrete, By
Nuclear Methods
ASTM Standard Test Method for Density and Unit Weight of Soil in Place
Sand-Cone Method
I in Place
67
(JKRlSPJ/2020-S5)
Method for Determining Consistency and Density of

Concrete Table
Profile
Part 1: Detenmination of mean
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68
(JKRlSPJ/2020-S5)
REFERENCES
1. JKRlSPJ/2017-S9 (Revision 2018), Standard Specification For Road Works

(Section 9 : Concrete)
2. JKRlSPJ/2008-S4, Standard Specification For Road Works (Section 4: Flexible

Pavement).
3. JKRlSPJ/1988 Section 5 - Portland Cement Concrete Pavement
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4. REAM - GL 7/2004 : Guidelines To the Design of Plain Concrete Pavemen
5. JKRlSPJ/2013-S2, Standard Specification For Road Works ( Section 2
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Earthworks)
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6. (NCPTC 2010) - Guide For RCC Pavements, National Concrete Pavement
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Technology Center, Aug 2010, IOWA STATE University
7. (AECOM 2017) - RCC - Background to the Development of Highways

England's Design Guidance and Specification, Highways England Specialist
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Professional and Technical Services (SPaTS), Apr 2017, AECOM
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Infrastructure & Environment UK
8. (BRITPAVE 2013) - Britpave Guide to RCC Pavements - Guidelines for

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Design Materials and Construction 1st Edition 2013, Britpave The British
Cementitious Paving Association
EN
9. (VIRGINIA 2015) - Use of RCC Pavement in Stafford, Virginia, Virginia Center

for Transportation Innovation & Research (VTRC), May 2015, VGRC
.
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10. (COLUMBUS 2009) - Supplemental Specification 1523 RCC , City of Columbus

\..) Public Service Department (PSD) Transportation Division, Feb 2009, PSD
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11 . (DPWH 2017) - Standard Specification on the Use of RCC Pavement in Road

Construction, Item 311 (6), Republic of the Philippines, Department of Public
Works Anad Highways, Nov 2017
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69
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Section 6 - Road Furniture (JKR/SPJ/2017-S6)
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JKRlSPJ f2017-S6
JKR 20400-0106-17
KERAJAAN MALAYSIA
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FOR ROAD WORKS
Section 6: Road Furniture TE

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KElUA PENGARAH KERJA RAYA

JALAN SULTAN SALAHUDDlN,
50582 KUALA LUMPUR.
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IS BN 978-967-5957-6 8-0
FOREWORD
As practices in road construction change over time, it is imperative for Jabatan Ke~a
Raya (JKR) to continuously update and improve their Standard Specifications. These
technologies.
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uniformity in road construction to be used by road designers, road authorities,
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Road Furniture", is a part of a series of improved specifications in the JKR Standard
many discussions that had been held by the technical committee. The draft had also
been presented and discussed at length in a specially held workshop to get feedback
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and comments from relevant parties involved, which were then carefully considered and
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incorporated into the Specification wherever appropriate or necessary.
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EN

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u Published by: -
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Cawangan Jalan
Tingkat 21 , Menara PJD,
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50400 Kuala Lumpur.
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Email: ussLikr@1govuc.gov.my
Mac 2017
S6-i
(JKRlSPJ/2017-S6)
ACKNOWLEDGEMENT
This Standard Specification for Road Works - Section 6: Road Furniture has been
prepared by a technical committee comprised of the following members: -
Committee Members
En. Ahmad Fahmi bin Abd Ghaffar (Chairman)
En. Anwar bin Ahmad (Former Chairman)
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En. Mohd Harizam bin Ibau Nui
Cik Aminah bt Ali
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Ir. Mohd Shahrom bin Ahmad Saman
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En. Wan Zuhaimie bin Wan Salleh
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En. Mohamad Hafzan bin Abd Aziz
En. Sufiyan bin Zakaria
En. Muhd Ridhuan bin Sulaiman

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Pn. Seri Ashikin bt Sofian
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Ir. Mohd. Azahar Bin Don Cawangan Jalan

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members for their substantial contributions towards the successful completion of this
document.
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A special thanks to Dato' Dr. Ir. Meor Aziz Osman, Deputy Director General of Works
(Infra Sector), Dato' Ir. Hj. Che Noor Azeman bin Yusoff, Director of Road and Bridge
Design, Ir. Dr. Lim Char Ching, Director of Forensics Engineering and Technical Support
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Division, Cawangan Jalan, Jabatan Kerja Raya Malaysia for their support and
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contribution towards the successful completion of this Specification.
S6-;;
(JKRl5PJ/2017-56)
SECTION 6 - ROAD FURNITURE
PAGE
6.1 CORRUGATED SHEET STEEL BEAM HIGHWAY GUARDRAIL S6-1
6.1.3 Installation of Guardrails S6-3
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6.1.4 Marking, Painting and Storage S6-4
6.1.5 Basic of Acceptance S6-5
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6.2 TRAFFIC SIGNS S6-6
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6.2.2 Sign Definitions 56-6
6.2.3 Sign Classifications S6-6

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6.2.4 Standards 56-7
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6.2.5 Permanent Traffic Signs S6-7
6.2.6 Temporary Traffic Signs S6-19

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6.2.7 Traffic Signs on Gantries S6-20
6.2.8 Preparation and Finish of Metal and Other Surface§. S6-20

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6.3 ROAD MARKINGS S6-21

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6.3.2 Road Marking Materials S6-21
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6.3.3 Preparation of Site S6-21
6.3.4 Preparation of Material on Site S6-22

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6.3.5 Laying S6-22

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6.3.6 Protection of Markings S6-23
6.3.7 Thickness S6-23
6.3.8 Tolerance on Width S6-23
6.3.9 Retroreflectivity Requirements S6-24
6.3.10 Skid Resistance Requirements S6-24
56-iii
(JKRlSPJ/2017-S6)
PAGE
6.3.11 Defective Materials or Workmanship 86-25
6.3.12 Clearing Up 86-25
6.3.13 Opening to Traffic 86-25
6.3.14 Removal of Road Markings 86-25
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6.4 CONCRETE KERB 86-26
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6.4.3 Installation of Kerbs 86-26
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6.4.4 Kerb Opening & 8pecial Features 86-28
6.4.5 Tolerances 86-28

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6.4.6 Curing and Protecting 86-28
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6.4.7 Kerb Painting 86-28

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6.4.8 Kerb Repairs 86-28
6.5 WIRE ROPE BARRIER SYSTEM 86-29

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6.5.3 Installation of Wire Rope Barrier System 86-30

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6.5.4 Basic Of Acceptance 86-30
6.6 DELINEATOR POST 86-31

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6.6.3 Delineators 86-32
6.6.4 Installation of Delineator Post 86-33
S6-iv
(JKRl8PJ/2017-S6)
6.1 CORRUGATED SHEET STEEL BEAM HIGHWAY GUARDRAIL
6.1.1 Description
This work shall comprise the supply and installation of corrugated sheet
steel beam highway guardrails inclusive of bolts, nuts, posts and other
ancillary works, all in accordance with this Specification, the Drawings, and
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6.1.2 Materials
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6.1 .2.1 Beam Element
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Unless otherwise specified in the Drawings, corrugated sheet
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steel beam highway guardrails shall conform to the requirements
of AASHTO Specification M180 for Class' A' Type II (galvanised)
guardrail. Guardrails shall be fabricated and fumished complete
with terminal or buffer sections, connecting and splicing bolts,
nuts and washers, etc., all conforming to the requirements of
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AASHTO Specification M180 and as necessary for erecting the
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guardrails as shown in the Drawings or as required by the S.O.
The mechanical properties of the base metal for beams shall

conform to the following tensile requirements:
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• minimum yield point - 345 MPa

• minimum tensile strength - 483 MPa
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• elongation on a 50mm test gauge of beam element shall not

be less than 12%
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The test specimens shall be prepared and tested as specified in

( ) ASTM A653/A653M. If galvanized test specimens are used, the
correction for thickness shall be O.08mm.
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The base metal of beam or sheet shall comply to AASHTO M180

with nominal thickness of 2.67mm. The nominal thickness for the
galvanized beam or sheet shall be 2.82mm with a tolerance for
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underspecified thickness of O.25mm. There shall be no limit for

over thickness. For fabricated beams, thickness measurements
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shall be made for tangent portions of the cross section.
Unless otherwise shown in the Drawings, the beam elements

shall be shaped from sheets having a nominal width of 483mm for
W beams and 749 mm for thrie beams. Tolerance from the
nominal width of minus 3.2mm will be permissible. The effective
length of the beam element shall in general be 4000mm long with
provision for mounting of post at 2000mm centres .
The beam shall be of uniform section, straight or curved as

required and so designed that when installed it will not hold water.
86· 1
(JKRlSPJ/2017-S6)
The edges shall be rolled or rounded to eliminate sharp edges.

Warped , kinked or bent sections shall be rejected .
The beam shall be hot-dipped galvanized after fabrication and

shall comply to ASTM A653/A653M . The zinc used for the coating
shall be as prescribed in ASTM B6 or MSHTO M120 and shall
be at least equal to the grade designated as 'Prime Western". No
test specimen shall have a coating weight of less than 1100 g/m2
for any Single Spot Test.
The sheets or beams shall be of prime finish, that is, free from
injurious defects such as blister, flux and uncoated spots.
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The coating shall be smooth, free of beading or sharp projections
along the edges and shall adhere tenaciously to the surface of
the metal. The adherence of the zinc coating to the surface of the
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base metal shall be determined by cutting or prying with a stout
knife applied with considerable pressure in a manner tending to
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remove a portion of the coating by parring or whiffling, and it shall 0
not be possible to peel any portion of the coating so as to expose
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the base metal.
Bolts and nuts shall conform to the requirements of ASTM A307.

All bolts, nuts and washers for use with guardrail shall be hot-
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dipped galvanized as specified in MS 740 or ASTM A153 or
MSHTOM232.
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The terminal sections shall be fabricated from sheet steel

manufactured from the Same type of metal and having the same
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gauge thickness and galvanized in the same manner as the beam

elements and also to conform to the same mechanical properties.
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6.1.2.2 Posts
The post and packers shall be structural steel conforming to the

requirement of ASTM A36. The dimensions of the posts shall
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follow the drawings and shall have a dimension of 178mm x

76mm x 6.0mm thick x 1830mm long. The packer shall be
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channel sections of dimension 178mm x 76mm x 6.0mm thick x

360mm and shall be of the same material as that used for the
posts. The post and packers shall be hot-dipped galvanized in
accordance with ASTM A123 or MSHTO M111 .
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The base metal of post and packer shall be of nominal thickness

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6.0mm. The nominal thickness for the galvanized post and packer
shall be 6.20mm with a tolerance for under specified thickness of
0.28mm.
Should other types or materials is proposed for posts or packers,

the Contractor shall supply technical specifications that address
those properties. The Contractor shall also provide warranty from
the manufacturer and test certificate indicating that the proposed
guardrail have been subjected to full-scale crash tests, Test Level
3(TL-3) minimum, as defined by ASSHTO MASH (Manual for
Assessing Safety Hardware).
S6-2
(JKRlSPJ/2017-S6)
6.1.2. 3 Delineators
Delineators shall be fixed on the beam or mounted on the packers

or posts and shall be of High Intensity Prismatic retrorefiective
sheeting or of a higher grade. The Contractor shall supply
technical specifications that address the details of the shape and
properties of the delineators for the S.O. approval.
6.1.3 Installation of Guardrails
6.1.3.1 Setting Posts
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Before posts are erected, the alignment and finished levels of the
guardrails shall be set accurately on site as per drawings, for
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approval by the S.O.
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n Post holes at the correct pOSitions shall be dug either manually or
mechanically to the required level. The po~ts shall then be set
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plumb in the holes with the front face forming a smooth line to the
approval of the S.O. After the posts are in place, the holes shall
be backfilled with grade 20 concre e compacted in such a manner
as not to displace the posts from correct alignment as shown in
the Drawings. All posts shall not lie anchored to concrete block in
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the ground unless otherwise specified such as when approaching
rigid object on lateral earth clearance of less than 600mm. Posts
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may be installed by means of driving with suitable equipment if

the S.O. is satisfied that the Contractor is capable of installing the
post to the designed depth, line and level, accurately.
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The posts s all be spaced at 2000mm apart except those of the

terminal sections. Unless otherwise specified in the Drawings, the
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length of post for all last three posts from the end or terminal
seelion shall be 2180mm without concrete surround. Due to the
nature of the terrain, there may be a need to use longer posts
than those shown in the drawing. The Contractor shall verify with
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) the S.O. before placing order for such posts.

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6.1 .3.2 Placing Beams
The guardrail beams shall be fixed and firmly bolted together with
the packers on to the post to the lines and grades as shown in the
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Drawings, and as directed by the S.O.

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The beam elements and terminal sections shall be formed to

proper shape and dimensions complying with AASHTO M180.
They shall be punched and drilled with holes for mounting and
splicing, and ready for assembly before being delivered to the
site. No punching, drilling, cutting or welding shall be permitted in
the field unless approved by the SO for special reasons and for
sampling.
Beam to be erected on a radius of less than 45m shall be shop-

curved . The beam element shall be spliced by lapping in the
direction of traffic. The splice shall be fastened with eight bolts
S6-3
(JKRlSPJ/2017-S6)
and shall not be less than 318mm in length. All connections or

splices shall be formed with oval shoulder button-headed bolts to
minimise projections on the road side of the guardrails. The
strength in tension of the beams and of the joint to adjacent rails
shall be not less than 330 kN . All bolt heads shall be embossed
with the manufacturer's brand. All bolts and nuts shall be anti-
theft type .
6.1.3.3 Terminal Anchorages
Terminal anchorages used for both ends of guardrail structure

shall be constructed as shown in the Drawings and as directed by
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the S.O. The approach and departure ends of guardrail structure
must be anchored to concrete block of minimum size 400mm x
400mm x 1100mm embedded deep in the ground to give the
needed stability to the adjoining section and should be flared well
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away from the travelled way to prevent vehicles from striking the
anchored ends with the resulting over-ride or roll over.
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The type of anchorage used on the approach end shall be
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Terminal Anchorage Unit Type 2. The anchorage on the
departure end of the guardrail structure shall be Terminal Unit
Type 2 or 90 degree Twist Terminal Unit Type 3.
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For 90 degree Twist Terminal Type 3, the beam element must be
curved in factory to provide a smooth curve without any kink. The
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top of the beam element shall be flushed with the finished ground
line.
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In the embankment section adjacent to a cut section, where the

guardrails need to be carried to cut section, the ends shall be
flared and anchored into the side of the hill, mound etc. by 2 nos.
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25nim dia. galvanized bolts 375mm long with galvanized nuts and
washer embedded in 300mm x 1200mm x 900mm size reinforced
concrete anchorage block embedded in the slope.
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Guardrails adjacent to bridge should be anchored to the bridge

parapet and the guardrails should form a smooth line with the
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face of the bridge parapet. Care shall be taken to drill in the

concrete parapet of the bridge for fixing bolts.
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6.1.4 Marking, Painting and Storage

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6.1.4.1 Marking
In addition to the marking speCified in AASHTO SpeCification

M180, the JKR logo shall also be marked on each beam element.
Each beam element shall be identified by the following :-
• Name or Brand of Manufacturer

• Identification Symbols or Code for Heat Number and
Coating Lot
• AASHTO Specification Number
S6-4
(JKRlSPJ/2017-S6)
• Class and Type
Markings shall not be placed at such a location on the beam

section that they will be obscured after erection or in a manner
that the brand will be conspicuous to any traffic. Marking material
shall be able to resist obliteration during storage, transportation
and erection.
Markings placed on the beam shall be placed in the centre of

corrugation and shall be die-embossed with letters and numbers
not exceeding 12mm in height.
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Marking for end sections and back-up plates may be on durable
tags securely attached to each section or bundle.
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6.1.4.2 Painting
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The beam shall normally not be painte·d However, when
specified, they shall be powder coated and baked using Polyester
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based powder. The powder coated sUlface shall be tough,
durable, colour stable, corrosion resistant and UV resistant.
6.1.4.3 Storage
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All galvanised beam elements, terminal sections, bolts, nuts and
washers and posts shall be stored under a cover that will protect
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them from rain until they are erected or used. While in storage,
the materials shall not be in direct contact with the soil and there
shall be a minimu.rn space of 300 mm between the lowest most
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elements and the ground surface.

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6.1.5 Basis of Acceptance
The manufacturer shall be accredited with ISO 9001 2000 and shall have
implemented standard procedures for checking the quality of the beam
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() elemeAts and terminal section which include incoming inspection of

material, dimensional verification, galvanizing thickness, final test and the
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inspection of finished goods. This is to ensure that the final product is of

high quality, good uniformity and free from all defects in manufacturing.
At the fabricating plant, warehouse or after delivery to the site of

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construction. Mill Test certificates for the raw materials used in the
manufacture and for the galvanized coating weight showing the results of
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tests carried out for the purpose of establishing compliance with the
standard shall be submitted for every 200 pieces or less of posts, beam
sections, back up plates, terminal sections, bolts and nuts delivered to the
site. The Contractor shall obtain approval for the material to be used from
the S.O. before starting work on the installation.
However, the S.O. may still select one piece of guardrail, backup plate and
terminal section from each lot of 200 pieces or less for testing before
installation to determine the specification requirements have been
complied with . This can be carried out at the manufacturer's fabricating
plant using calibrated testing equipment and witnessed by the S.O. or
S6-5
(JKRlSPJ/2017-S6)
carried out by independent testing laboratory, SIRIM. If one piece fails to

meet the requirements, then two additional pieces shall be tested . If either
one of these pieces fail to conform, the lot represented by these samples
shall be rejected and removed from the site. The cost of all sampling and
testing shall be borne by the Contractor.
The Contractor shall also provide warranty from the manufacturer in the
form of certified documentary evidence indicating that the guardrail system
have been subjected to full-scale crash tests, Test Level 3(TL-3)
minimum, as defined by National Cooperative Highway Research Report
350, Test Level 3 (NCHRP-350) or MSHTO MASH (Manual for Assessing
Safety Hardware).
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6.2 TRAFFIC SIGNS
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6.2.1 Description
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This work shall consist of the supply, assembly, erection and installation of
sign faces, sign plates, posts and backing frames, all in accordance with
the details shown in the Drawings and as specified herein. It shall include
all excavation and backfilling, all necessary foundations, anchorages,
fixtures and fastenings, brackets, lighting units and electrical installations
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where required, application of paints and finishes, etc., to complete the
works all to the satisfaction of the S.O.
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6.2.2 Sign Definitions

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For the purpose of this Specification, traffic signs are defined as follows:
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i) Non-illuminated signs are those signs which are not lit either
internally or externally and shall be retro-reflective;
ii) Externally illuminated signs are those which comprise either

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retroreflective or non-retroreflective facing with external lighting

luminaire.
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6.2.3 Sign Classification

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For the purpose of this Specification, the following classifications shall

apply:
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(a) Permanent Traffic Signs
Any of the traffic signs defined in Sub-Section 6.2.2 above or any

part thereof as shown in the Drawings or as directed by the S.O. to
remain in position upon completion of the Works.
(b) Temporary Traffic Signs
Any of the traffic signs defined in Sub-Section 6.2.2 above or any

part thereof designed by the Contractor with the approval of the
S6-6
(JKRlSPJ/2017-S6)
S.O. which will not remain in position at the completion of the

Works.
6.2.4 Standards
All traffic signs shall, except where specified otherwise, comply with the
requirements of the latest ARAHAN TEKNIK (JALAN) Series 2, published
by Ibu Pejabat JKR, Kuala Lumpur.
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6.2.5 Permanent Traffic Signs
6.2.5.1 General Requirements
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Permanent traffic signs shall be constructed, assembled, located
and erected as shown in the Drawings or as directed by the S.O.
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Each complete traffic sign or part thereof shall be capable of
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passing the tests specified in BS 8442:2006.
All externally illuminated traffic signs shall comply with BS EN

12899-1 unless shown otherwise in the Drawings.
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Before the commencement of fabrication of any traffic sign,
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unless shown otherwise in the Drawings, the Contractor shall
submit for the S.O.'s approval the details of fabrication drawings
for all signs.
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All traffic sign housings shall be provided with vandal and weather
resistant locks. Keys, in the quantities determined by the S.O.,
shall be provided to the S.O. Types of lock shall be kept to a
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minimum.
Traffic signs shall be carefully handled to prevent damage

(methods shall include the use of proper slings), and shall be
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l ) transported and stored in accordance with the manufacturer's

instructions.
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6.2.5.2 Foundations
The type and size of foundations for permanent traffic signs shall
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be as shown in the Drawings and, unless stated otherwise

therein, shall comply with this Specification and the latest
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ARAHAN TEKNIK (JALAN) Series 2, published by Ibu Pejabat

JKR, Kuala Lumpur.
All excavations, erection of formworks, placing of reinforcement,

etc., for foundations shall be carried out in compliance with this
SpeCification and shall be approved by the S.O. before placing of
concrete and backfilling.
Unless shown otherwise in the Drawings, signs supported by a

single post placed in the ground shall have the post installed
centrally in 300 mm diameter holes filled with grade 20 concrete
S6-7
(JKRlSPJ/2017-S6)
complying with Section 9 of this Specification, to minimum depth

of 900mm from the ground surface. The hole shall be excavated
either mechanically or manually.
Posts shall be supported for a minimum of three (3) days after

placing the concrete . Backfilling shall not take place until at least
48 hours after placing the concrete or other period as agreed by
the S.O.
Where signs are illuminated, provision shall be made for cable

entry through the foundation by means of ducting as shown in the
Drawings.
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All backfilling of foundation pits and reinstatement of existing
surfaces above the foundations shall comply with Section 2:
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Earthworks of this Specification. Where pockets are formed in
concrete foundations their plan dimensions shall be 100 mm
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larger than those of the post.
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Any pockets formed in concrete foundations to receive posts shall
be temporarily sealed or capped pending installation of the posts
and shall be cleaned out immediately prior to the erection of the
posts. The posts shall be placed centrally in the pockets and be
bedded on mortar deSignation cOmplying with Section 9: Concrete
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of this Specification and the pockets shall be filled up to existing
ground level with concrete in accordance with Section 9: Concrete
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of this Specification.
6.2.5.3 Posts
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Posts for permanent traffic signs shall be as shown in the

Drawings and shall comply with BS EN ISO 1461 :2009: Hot Dip
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Galvanised Mild Steel (HDGMS). The average galvanizing

coating for steel above 3 mm thick shall be 70 microns while for
steel above 6 mm thick shall be 85 microns. The supplier of
HDGMS shall produce galvanizing warranty certificate. No
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painting is required for galvanized steel.

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• Steel ~ 6mm thick - 85~m

• Steel ~ 3mm to < 6mm - 70~m
• Steel ~ 1.5mm to < 3mm - 551lm
O
Unless shown otherwise in the Drawings, posts shall be of tubular

hollow section steel of not less than 60 mm outside diameter
D
complying with BS EN 10255:2004.
Unless shown otherwise in the Drawings, posts shall not protrude

above the top of the sign unless supporting an extemal luminaire
where the protrusion shall be kept to a minimum.
Signs erected on a Single post shall be positioned so that the post

is in the centre of the sign, unless shown otherwise in the
Drawings.
S6-8
(JKRlSPJ/2017-S6)
Compartments for electrical equipment shall be as shown in the

Drawings. In the case of signs supported by more than one post,
such compartments shall be on the post furthest from the
carriageway unless directed otherwise by the S.O.
Flange plates shall have holes or slots as shown in the Drawings

to accommodate any holding down bolts.
6.2.5.4 Sign Plates
All permanent sign plates shall be as shown in Drawings and shall

comply with BS EN 12899-1 .
ER
a) Sign plates shall be made of 10 SW.G. sheets of aluminium
alloy HS 30WP conforming to BS EN 485-2:2013 with a
minimum thickness of 3 mm or ;
D
n b) Aluminium composite material. The aluminium composite
N
material shall have the following properties complying to MS
832 : 1984 and ASTM E 330-97:
TE
(i) Minimum total thickness : 4 mm
(ii) Minimum aluminium ~in thickness (each side): 0.5 mm
(iii)Peel strength (kgf/mm) : 0.85
A
(iv) Coefficient of Linear Expansion (x 10-5/°C) :
• Edgewise: 3,5
EJ
• Length~isEW2.5
(v) Flexural Sliffness (GPa) :380
(vi) Wind L:oail Test (@ 1500 Pal :8.2mm
M
The retroreflective sheeting shall be applied on non-coated

aluminium surface only. Back surface of aluminium plate shall be
EN
painted in executive grey or equivalent grey.
A sign plate not exceeding 1.2 m in height and 2.4m in width shall
be made from a single sheet. Where more than one sheet is used
M
( ) to make up a sign plate, the sheets shall be rectangular, of

approximately the same size and shape, and the position of the
KU
• joints shall be to the approval of the S.O.
Sign plates shall be drilled at all locations where rivets or bolts are
required for attaching the plate to the backing frame or mountings
O
before application of the sign face. However, riveting shall be

carried out only after the application of the sign face.
D
Subject to the S.O.'s approval, double sided "Very High Bond"

(V.H.B.) tapes may be used as an alternative to rivets.
Nevertheless, the tape shall comply with the following
requirements:
(a) Peel Adhesion 440 N per 100 mm;

(b) Tensile Adhesion 910 kPA;
(c) Dynamic Adhesion 550 kPA
S6-9
(JKRl8PJ/2017-S6)
Where top and bottom light spill screens are required as shown in
the Drawings, these shall extend for the whole width of the sign,
be fabricated out of the same material as the sign plate and shall
have corners cut to the same radius as the other corners of the
sign plate.
Top and bottom light spill screens shall be considered part of the
sign plate and any stiffeners and mounting fittings shall be
designed to accommodate the combined size.
6.2.5.5 Sign Faces
ER
Sign faces for permanent traffic sign shall be retroreflective
prismatic sheeting as shown in the Drawings and shall comply
with the Malaysian Standard Specification for Reflective Sign
Faces Materials (MS 1216 or ASTM 04956, whichever is relevant
D
and current) except for High Intensity Prismatic and Wide Angle
Prismatic sheeting.
N
Retroreflective sheeting is a material consisting of one or more
TE
retro-reflective elements embedded within a transparent film
having a smooth, flat outer surface. Two types of retroreflective
sheeting that have been established and identified for use on
traffic signs are High Intensity Prismatic and Wide Angle
A
Prismatic sheetings. Both these sheetings are available in sheets
and rolls using pressure sensitive adhesive. Application of
EJ
pressure sensitive adhesive sheeting to sign substrates is by

using hand squeezed roller applicator.
M
All retroreflective sheeting shall be fixed in accordance with the

manufacturer's instruction.
EN
Unless agreed otherwise by the S.O., sign faces shall be formed

from a single piece of retroreflective sheeting.
Where, with the agreement of the S.O., more than one

M
retroreflective sheeting is used, the number of sheets shall be

kept to a minimum. All faces up to 1 m in size shall be produced
KU
with a single sheet and no joint will be accepted.
Only vertical and horizontal joint shall be permitted and all joints in
retroreflective sheeting shall be overlapped by not less than 6
O
mm. The overlap in the horizontal joint shall be from the top and
the vertical joint shall be from the left; butt joints will only be
D
accepted for prismatic retroreflective sheeting.

Retroreflective sheeting shall be applied evenly over the whole
surface of the sign plate and shall adhere fully. It shall be free
from twists, cracks, folds or cuts, air bubbles and other
blemishes.
All retroreflective sheetings used on the same sign shall be

carefully matched for colour to produce a uniform appearance
both by day and by night. Non-uniform shades of colour on any
one sign will not be accepted.
86-1 0
(JKRlSPJ/2017-S6)
The edges of all the retroreflective sheeting shall be properly

fitted to ensure no delimitation of the sheeting from the base
substrate.
Where sheeting is applied to the extruded section by pressure

roller, it shall extend over the top and bottom edges of this section
by not less than 3 mm.
Any cut-out letters, 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
ER
The Contractor shall fumish to the S.O. a letter of warranty for the
specified period for all sign faces from the manufacturer of the
D
sheeting or the sign fabricator.
N
The retroreflective sheeting manufacturer shall fumish the S.O. a
written warranty that the fluorescent colours shall be durable for a
TE
minimum 7 years for pennanent signs and a minimum 3 years for
temporary signs.
The letter of warranty shall have minimum details as follows:

A
• Project title
• Name of end user
EJ
• Name of contractor
• Date of installation
• Defects warranted against; delamination, colour fading,
M
reflectivity, I>lemishes,
• Reference to relevant standards
• Totall:luantityof material used (grade to be stated)
EN
• Endorsement by authorised personnel

• Compliance to JKR specifications, MS 1216 and ASTM D
4956-09.
M
6.2.5.5.1 Requirements
KU
(a) Photometric - Coefficient of Retroreflection RA
(i) High Intensity Prismatic sheeting is a

O
retroreflective sheeting referred to as 'high-

intensity' which is typically an unmetalised
D
microprismatic retro-reflective element material

complying with ASTM D 4956-09 Table 1
S6-11
(JKRlSPJf2017-S6)
TABLE 1 : MINIMUM COEFFICIENT OF RETROREFLECTION (RA) CD/FC/FT"

(CDLX·1M·2) FOR HIGH INTENSITY PRISMATIC SHEETING
I:
.2
ro~
2: 0>
Q)
U
1: -
Q)
til 0> E
Q)
§
Q)
0>
I:
I:
Q)
Q)
"0 Q)
I:
~
-c:
Q)
u
I:
Q)
Q)
~
C
!'l ~
-
I:
Q)
~
Q)
a.
"
Q)
Q) I: ~ I: a; ~ 0~ "'(!)
"'« c« ~
>- 0
~
(!) ~ iii (IJ ~ ~

'"
Q)=
~
0
Q)
Q)
~ ~
I:
.0
0
W gg g>- go
u::~ u:: u::
*0.10B -40 500 380 200 70 90 42 25 400 300 150

*0.10B +30° 240 175 94 32 42 20 12 185 140 70
ER
0.2° _4° 360 270 145 50 65 30 18 290 220 105
0.2° +30° 170 135 68 25 30 14 8.5 135 100 50
0.5° _4° 150 110 60 21 27 13 7.5 120 90 45
0.5° +30° 72 54 28 10 13 6 3.5 55 40 22
D
(ii) Wide Angle Prismatic sheeting is a
N
retroreflective sheeting which is typically an
unmetalised cube comer micro prismatic
TE
retroreflective element material complying with
ASTM 04956 as shown in Table 2.
A
TABLE 2 : MINIMUM COEFFICIENT OF RETROREFLECTlON(RA) CD/FC/FT" (CDLX·
1M") FOR WIDE ANGLE PRISMATIC SHEETING
EJ
I:
.,
0
tIl~
Q)
U Q)
~
Q)
c:
-I:
c:Q) C C
1:- ~ 0> Q) "0 Q)
I: CD"
!'l ~
Q) Q)
2:0> til 0> .<::: .B I: ~ u~
~ 0:
~
5:~ ~ ~ "
M
~ I: 0~ "'(!)
.0
c«
W
~ Qj
>- 0 (!) iii (IJ ~~
'" 0
~ "
CD= Q)
~ ~
I:
0 00
" = g>- go
u:~ u:: u::
EN
*0.1° -40 830 620 290 83 125 37 25 660 500 250

*0.1° +30° 325 245 115 33 50 15 10 260 200 100
0.2° -40 580 435 200 58 87 26 17 460 350 175
M
0.2° +30° 220 165 77 22 33 10 7 180 130 66

0.5° -40 420 315 150 42 63 19 13 340 250 125
KU
0.5° +30° 150 110 53 15 23 7 5 120 90 45

1.0° -40 120 90 42 12 18 5 4 96 72 36
1.0° +30° 45 34 16 5 7 2 1 36 27 14
O
Notes:
• Values for 0.1° observation angle are supplementary requirements that shall only apply
D
when specified by the purchaser in the contract or order
(b) Daytime Color
Colour shall conform to the requirements of Table 3.

Daytime colour and maximum spectral radiance
factor (peak reflectance) of sheeting mounted on
aluminium test panels shall be determined
instrumentally in accordance with ASTM E 991 .
Computations shall be done in accordance with
ASTM E 308 for the 2° observer.
S6-12
(JKRlSPJ/2017-S6)
TABLE 3: COLOR SPECIFICATION LIMITS (DAYTIME) A
Color 1 2 3 4
x y x y x y x y
White 0.303 0.300 0.368 0.366 0.340 0.393 0.274 0.329
Yellow 0.498 0.412 0.557 0.442 0.479 0.520 0.438 0.472
Orange 0.558 0.352 0.636 0.364 0.570 0.429 0.506 0.404
Green" 0.026 0.399 0.166 0.364 0.286 0.446 0.207 0.771
Red 0.648 0.351 0.735 0.265 0.629 0.281 0.565 0.346
Blue" 0.140 0.035 0.244 0.210 0.190 0.255 0.065 0.216
ER
Brown 0.430 0.340 0.610 0.390 0.550 0.450 0.430 0.390
Fluorescent 0.387 0.610 0.369 0.546 0.428 0.496 0.460 0.540
Yellow-Green
Fluorescent 0.479 0.520 0.446 0.483 0.512 0.421 0.557 0.442
D
Yellow
Fluorescent 0.583 0.416 0.535 0.400 0.595 0.351 0.645 0.355
N
Orange
>
TE
A The four pairs of chromaticity coordinates determine the
acceptable colour in terms of the OlE 1931 Standard
Colorimetric System measured witfi CIE Standard lIIuminant
D65.
A
" The saturation limit of green and blue may extend to the
EJ
border of the CIE chromaticity locus for spectral colours.
M
(c) Night Time Colour
Night time colour of the sheeting applied to

EN
alumunium test panels shall be determined in

accordance with ASTM E 811 and evaluated in
accordance with ASTM E 308. Sheeting shall be
measured at 0.33° observation and -40 entrance at
M
90° rotation. Colour shall conform to the

requirements of Table 4.
KU
O
D
S6-13
(JKRlSPJ/2017-S6)
TABLE 4: COLOR SPECIFICATION LIMITS (NIGHTIIME) A
Color 1 2 3 4
x Y x Y x Y x Y
White (no - - - - - - - -
requirement)
Red 0.513 0.487 0.500 0.470 0.545 0.425 0.572 0.425
Orange 0.595 0.405 0.565 0.405 0.613 0.355 0.643 0.355
Brown 0.007 0.570 0.200 0.500 0.322 0.590 0.193 0.782
Yellow 0.650 0.348 0.620 0.348 0.712 0.255 0.735 0.265
Green 0.033 0.370 0.180 0.370 0.230 0.240 0.091 0.133
ER
Blue 0.595 0.405 0.540 0.405 0.570 0.365 0.643 0.355
Fluorescent 0.480 0.520 0.473 0.490 0.523 0.440 0.550 0.449
Orange
D
Fluorescent 0.554 0.445 0.526 0.437 0.569 0.394 0.610 0.390
Yellow
N
Fluorescent 0.625 0.375 0.589 0.376 0.636 0.330 0.669 0.331
Yellow - Green
TE
A The four pairs of chromaticity coordinates determine the
acceptable color in terms of the CIE 1931 Standard
Colorimetric System measured with CIE Standard Iliuminant
D65.
A
EJ
(d) Accelerated Outdoor Weathering Requirements
The retroreflective surface of the sheeting shall be

weather resistant and show no appreciable cracking,
M
blistering, crazing, or dimensional change after 1500

hours' exposure in a xenon arc weatherometer in
accordance with ASTM G 26, Type B, Method A.
EN
Following exposure, panels shall be washed in a 5%

HCL solution for 45 second, rinsed thoroughly with
clean water, blotted with a soft clean cloth and
brought to equilibrium at standard conditions. After
M
cleaning, the coefficient of retroreflective shall be not

less than 100 and the colour is expected to conform
KU
to the requirements of Table 3 and 4 for weathered

sheeting. The sample shall:
(i) Show no appreciable evidence of cracking,

O
scaling, pitting, blistering, edge lifting or curling

or more than 0.8mm shrinkage or expansion.
D
(ii) Be measured at 0.20 observation angle and _40

and +30 0 entrance angle, the coefficient of
retroreflection shall not be less than 80% of
initial values in Table 1 or 2.
S6-14
(JKRlSPJ/2017-S6)
(e) Field Performance
Retroreflective sheeting processed and applied to

sign blank materials in accordance with the sheeting
manufacturer's recommendations, is expected to
perform effectively for a minimum of 3 years.
The finish of all sign faces shall be capable of

passing the tests described in MS 1216, and the
standard of fabrication and workmanship shall be
such that under normal conditions of service and
ER
proper maintenance, the sign faces shall last not
less than 8 years for High Intensity and Wide Angle
Prismatic retroreflective sheeting (7 years for
fluorescent yellow & fluorescent yellow green) from
D
the date of issue of warranty letter without any
serious blemishes or defects.
N
(f) Shrinkage
TE
The retroreflective sheeting shall not shrink in any
dimension more than Q,8mm in 10 min or more than
3.2mm in 24 hOYfS When tested in condition all
adhesively bonded and unbonded test samples and
A
specimens at a -temperature of 73 ± 3'F (23 ± 2'C)
EJ
and 50 ± 5% relative humidity for 24 hours prior to
testing.
(g) F:lexillility
M
Tile sheeting shall be sufficiently flexible to show no

cracking when bending the sheeting, in 1 second,
EN
around a 3.2mm mandrel with adhesive contacting

the mandrel. For ease of testing, spread talcum
powder on the adhesive to prevent sticking to
mandrel. The test specimen shall be 70 by 229mm.
M
( ) The test temperature shall be 73 ± 3'F (23 ± 2'C).

KU
(h) Liner Removal
The liner, when provided, shall be easily removed

without soaking in water or other solutions, and shall
O
not break, tear, or remove adhesive from the

sheeting. The protective liner, if any, shall be easily
D
removed following accelerated storage for 4 hours at

160'F (71'C) under a weight of 2.5 psi (17.2 kPa).
(i) Adhesion
The adhesive backing of the retroreflective sheeting

shall produce a bond that will support a 1%-lb (0.79
kg) weight for adhesive classes 1, 2, and 3 or a 1 Ib
(0.45 kg) weight for adhesive class 4 for 5 mins,
without the bond peeling for a distance of more than
51 mm.
S6-15
(JKRlSPJ/2017-S6)
0) Impact Resistance
The retroreflective sheeting applied according to the

sheeting manufacturer's recommendations to the
test panel of alloy 6061 -T6, 0.10cm by 7.6 cm by
12.7 cm and conditioned for 24 hours, shall show no
cracking or delamination outside the impact area
when the face of the pane is subjected to an impact
of a 100 inch-pounds (11 .3Nm) using a weight with a
15.8 mm diameter rounded tip dropped from a height
necessary to generate an impact 100 inch-pounds,
at test temperatures of both 32°F (OOC) and 72°F
ER
(22°C) 2 Ib (0.91 kg) weight, with am15.8 mm
diameter rounded tip, dropped from the height
necessary to generate an impact of 10 inch lb. (1 .13
D
Nm).
N
(k) Specular Gloss
TE
The retroreflective sheeting shall have a specular
gloss of not less than 40 when tested with test
method as specified in MS 1216 at an angle of 85°.
6.2.5.6 Backing Frames

A
Backing frames for permanent traffic signs shall be as shown in
EJ
the Drawings and shall comply with this Specification.
Signs exceeding 600 mm in height or width shall be stiffened by

M
means of angles while signs exceeding 1 m in height or width

shall have a backing frame fabricated from 40 mm x 40 mm x 3
mm angles. The backing frame shall be made of Hot Dip
EN
Galvanised Mild Steel angles in accordance with BS EN ISO

1461 :2009 with average galvanizing coating thickness of 70
microns. The suppliers of HDGMS shall produce galvanizing
warranty certificate.
M
The angles shall be welded, bolted or riveted together to form the

KU
backing frames as shown in the Drawings.
Backing frames shall not project beyond the face of the sign.
O
Where large signs are built in sections, the backing frames of

these sections shall be bolted together with 8 mm diameter bolts
D
at not more than 200 mm centres.
The details of joints between angles of the backing frame and of

jOints between sections of large signs shall be to the approval of
theS.O.
The sign plate shall be riveted to the backing frame after the
application of the sign face.
S6-16
(JKRlSPJ/2017-S6)
6.2.5.7 Construction and Assembly
Traffic signs shall be constructed and assembled as shown in the

Drawings and shall comply with. BS EN ISO 1461: 2009.
All sign plates, backing frames, purlins, posts and other

components shall be de-burred prior to assembly.
Where framing and stiffening are not an integral part of the sign
plate, their joints shall be welded or joined with suitable brackets
utilising nuts, bolts and washers.
ER
Purlins shall be required for those traffic signs exceeding 1.50 m
in any dimension.
D
Where purlins are adopted, they shall be attached to each vertical
member of the backing frame and the sign stiffening and framing
N
shall be continuous in the vertical direction. Unless otherwise
permitted by the S.O., purlins shall be spaced equally apart.
TE
Connections shall be made at every point where a purlin crosses
a post.
Where purlins are not adopted, tI1e sign stiffening and framing
shall be continuous in the horizontal direction.
A
All rivets and other devices used in the fixing of sign plates to
EJ
their stiffeners or backing frames, or those used in the

construction of housings, shall be of a material compatible with
the materials beingljoined.
M
Spacing of rivets or other devices used in the fixing of sign plates

to their stiffeners or backing frames shall be uniform and shall not
EN
exceed 150 mm around the outside edge of any sheet or section

ot a sheet, and shall not exceed 300 mm on cross braces. Hollow
rivets shall be filled with a plastic plug flush with the head of the
rivet.
M
An additional washer of neoprene, nylon or other material

KU
approved by the S.O. shall be used against the sign face to

protect it from the effects of any metal nuts, bolts, washers and/or
screws.
O
Where traffic signs, including extemal lighting luminaires or their

supports, are required to have holding down bolt fixings, the bolts
D
shall be lightly greased before final installation and they and their
anchorages shall be installed so as to achieve the loadings,
torque settings and requirements shown in the Drawings.
Sign plates shall be connected to posts by a method approved by

the S.O. Banding systems shall be of stainless steel. Where
ferrous components are pennitted, any drilling of such
components shall be completed before the application of any
finish .
S6-17
(JKRl8PJ/2017-86)
Any hole drilled to accommodate rivets or bolts in plates with

plastic sheeting shall, immediately prior to the insertion of the rivet
or bolt, have a clear lacquer, as recommended by the
manufacturer of the plastic sheeting, applied to its edge to
prevent the ingress of moisture. The surfaces of rivets or bolts
exposed on the sign face shall be coloured by a material
approved by the 5.0. to match that part of the face.
Traffic signs to be erected on road lighting columns shall have

fixings compatible with the column cross-section and finish .
Unless otherwise permitted by the S.O., columns shall not be
drilled and wiring shall be contained in approved external
ER
conduits.
In addition to the requirements of this Specification, variable
D
message traffic signs shall be of a type approved by the relevant
authorities.
N
6.2.5.8 Location and Erection
TE
The approximate location of each pennanent traffic sign shall be
as shown in the Drawings. All traffic signs shall have their exact
location detennined by the 5.0. and recorded on the As-built
Drawings.
A
All posts shall be erected plumb and where two or more posts are
EJ
provided for anyone sign, the face of the posts shall be lined up.
Signs erected on two posts shall have each post positioned so

M
that the distance from the centre of the post to the edge of the
sign plate is 300 mm, unless directed otherwise by the S.O .
EN
Any pockets fanned in concrete foundations to receive the posts

shall immediately, prior to erection, be cleaned out. The posts
shall be placed centrally in the pockets and be bedded in and
filled up to finished foundation level with grade 20 concrete.
M
Traffic signs mounted on posts, except those on gantries, shall be

KU
erected to have their faces plumb and orientated in relation to the

carriageway in accordance with the latest ARAHAN TEKNIK
(JALAN) Series 2, published by Ibu Pejabat JKR, Kuala Lumpur.
O
Traffic signs mounted on gantries shall be erected as shown in

the Drawings.
D
No traffic sign shall be dismantled, resited or removed without

prior approval from the 5.0.
6.2.5.9 Covering of Penn anent Traffic Signs
Where it is required in the Contract that permanent traffic signs

are to be blanked-out or are to have an alternative message, the
covering to be adopted shall comply with the following
requirements.
86-18
(JKRlSPJ/2017-S6)
The covering shall be 1.5 mm (16 S.W.G.) thick made from a

material compatible with that of the sign plate, or a material
Cover plates shall be fixed by means of 5 mm diameter stainless

steel bolts, washers and nuts or non-ferrous rivets not more than
600 mm apart, the bolts passing through 12 mm diameter, 5 mm
thick plastic distance pieces between the sign face and cover
plate. Any holes remaining in the finished sign face shall be filled
with blocked rivets coloured on the face by methods approved by
the S.O.
ER
Where self-adhesive plastic film is used, it shall be compatible
with the sign face materials and be applied and removed in
compliance with the manufacturer's instructions.
D
Any loose covering used must be sufficiently opaque to prevent
N
reflection from the covered sign and be securely fastened to the
I') back of the sign. Under no circumstances sHall tape or other
TE
adhesive material be applied to the face of the sign. A minimum
space of 50 mm shall be left between the covering and the face to
permit airflow over the sign.
Traffic signs which are te be covered shall not be erected on

A
trafficked highways without the covering in place.
EJ
•
Removal of any cavering shall be carried out with minimum
disturbance to traffic and only after the S.O. has given his
approval.
M
Irrespective of any requirement in the Contract to cover signs,

any traffic sign erected at such a time that its legend does not
EN
relate either wholly or in part to the traffic movement and route in

operation, shall have its sign face securely covered with one of
tHe materials described above until such time as the S.O.
authorizes its removal.
M
KU
6.2.6 Temporary Traffic Signs
Temporary traffic signs shall be constructed either as non-illuminated or

extemally illuminated signs as directed by the S.O.
O
Sign faces for temporary traffic sign shall be Wide Angle (Fluorescent
D
Orange) Prismatic retroreflective sheeting as shown in the Drawing and

shall comply with the Sub-Section 6.2.5.5.1.
Retroreflective sheeting processed and applied to sign blank materials in

accordance with the sheeting manufacturer's recommendations, is
expected to perform effectively for a minimum of 3 years. The
retroreflective sheeting will be considered unsatisfactory if it has
deteriorated due to natural causes to the extent that :
(i) the sign is ineffective for its intended purpose when viewed from a
moving vehicle under normal day and night time driving conditions; or
S6-19
(JKRlSPJ/2017-S6)
(ii) the coefficient of retrorefiection is less than 100 when measured at 0.2°
observation and _4° entrance at 90° rotation . All measurements shall be
made after sign cleaning according to the sheeting manufacturer's
recommendations.
Location and erection of temporary traffic signs shall be in accordance with

the requirements of the latest ARAHAN TEKNIK (JALAN) ATJ 2C/85,
published by Ibu Pejabat JKR, Kuala Lumpur. Erection of temporary traffic
signs mounted on posts shall comply with Sub-Section 6.2.5.8 .
Any temporary covering of temporary traffic signs shall comply with Sub-
ER
Section 6.2.5.9.
Removal of temporary traffic signs shall be carried out as soon as they
D
become superfluous or pose a hazard to traffic. Methods of removal and
making good shall be submitted to the S.O. for approval beforehand.
N
Making good shall be carried out immediately after removal of the traffic
sign to the satisfaction of the S.O.
TE
6.2.7 Traffic Signs on Gantries
Where traffic signs are erected on gantries, the signs shall comply with the
A
relevant requirements of this Specification.
EJ
Fabrication and construction of gantries shall be as shown in the Drawings

and as directed by the S.O.
M
6.2.8 Preparation and Finish of Metal and Other Surfaces

EN
Traffic signs shall be prepared, protected against corrosion and finished in

compliance with B.S. 873 or its latest replacement.
Faces of sign plates shall be prepared to receive sign face materials in

M
compliance with B.S. 873 or its latest replacement and in accordance with
the manufacturer's recommendations.
KU
Steel backing frames, fittings and purl ins shall be prepared and protected
in compliance with B.S. 873 or its latest replacement. Steel posts and post
housings shall be prepared and protected in compliance with B.S. 873 or
O
its latest replacement.

D
Backs of aluminium or aluminium alloy sheets forming plate signs and

extemal parts of luminaire housings and other permanently exposed
components shall, to prevent retro refiection, be dulled with paint using a
method approved by the S.O.
Ferrous steel shall be finished both inside and out by galvanising, electro-
plating or application of zinc or aluminium spray or other equivalent finish
approved by the S.O. Aluminium and other metals shall be left untreated
unless shown otherwise in the Drawings.
S6-20
(JKRl8PJ/2017-86)
Unless shown otherwise in the Drawings, stainless steel shall be left

untreated except where the component is visible against the sign face
when it shall be coloured on the face by methods approved by the S.O.
Extemal surfaces shall be prepared and protected as described in the

Contract. Cabinets and feeder pillars shall have final coats of paint applied
on Site after final installation, including the fitting of any intemal apparatus
required as part of the permanent Works. Intemal surfaces shall, unless
shown otherwise in the Drawings, receive the same treatment as for
extemal surfaces except that final paint coats shall be applied before
intemal components are installed.
ER
6.3 ROAD MARKINGS
D
6.3.1 Description
N
This work shall consist of the supply of road marking material and its
application to form continuous or intermittent lines, letters, arrows, symbols
TE
or figures. The markings shall be white or yellow laid to the dimensions and
at the locations shown in the Drawings and as specified herein or as
directed by the S.O. The work includes the supply of all labour, tools,
equipment, materials, and waming and traffic guidance signs as necessary
for the safe and efficient completion of the entire work.
A
EJ
The requirements specified hereafter emphasise on the performance of
road markings during their funClionallife. The requirements are expressed
by several parameters representing different aspects of the performance of
road markings.
M
6.3.2 Road Marking Materials

EN
The road marking materials shall be of thermoplastic type and shall comply
with the requirements of BS EN 1871, and shall demonstrate compliance
M
with the relevant performance of BS EN 1436.

l )
Road marking paints shall be used for temporary road markings only and it
KU
shall comply with the requirements of MS 164.
6.3.3 Preparation of Site

O
Thermoplastic materials and road marking paints shall be applied only on a

D
surface which is clean and dry. It shall not be laid over loose detritus, mud
or extraneous matter, or over old material or paint marking incompatible
with the paint being applied.
A tack coat compatible with the marking material shall be applied on the
clean and dry surface in accordance with the manufacturer's instructions
prior to the application of thermoplastic material.
If a tack coat, primer or undercoat is necessary to ensure proper adhesion

of the marking paint to the road surface without bleeding or other
discoloration, the tack coat, primer or undercoat shall be fully compatible
with the marking paint and the road surface. The rate of application of tack
86-21
(JKRlSPJ/2017-S6)
coat, primer or undercoat shall be in accordance with the manufacturer's

instructions and to the satisfaction of the S.O.
Where the application of a tack coat, primer or undercoat is inappropriate,

the Contractor shall seek the approval of the S.O. to omit such application.
6.3.4 Preparation of Material on Site
6.3.4.1 Thermoplastic Material
Thermoplastic material shall be supplied in block or powder form.
ER
If the material is supplied in block form, it shall be broken into
pieces, each weighing not more than 4 kg, which shall be melted
in a heater fitted with a mechanical stirrer to prevent local
D
overheating and to ensure uniform distribution of the premix glass
beads or reflective elements.
N
A thermometer of sufficient accuracy shall be used during laying
TE
to ensure that overheating of the material does not occur.
Once molten, hydrocarbon resins shall be used within 6 hours

whereas wood and gum resins shall be used within 4 hours. The
material shall not be heated beyond the manufacturer's specified
A
temperature during application. Excess material shall be
discarded on completion of application.
EJ
6.3.4.2 Road Marking Paint

M
All paint shall be thoroughly stirred before application to keep the

pigments in uniform suspension. The use of thinners or other
additives shall not be permitted unless approved otherwise by the
EN
S.O.
6.3.5 Laying
M
Centre lines, lane lines and edge lines shall be marked by approved
mechanical means or as directed by the S.O. Other markings shall be
KU
applied by brush, spray, screed, hand-propelled or self-propelled machine

according to the marking configuration and the type of marking material
approved for use. The rate of application of the marking material for each
coat shall be that recommended by the manufacturer unless specified
O
otherwise. When more than one coat is used, the succeeding coat shall
not be applied until the previous coat has fully set.
D
The drop-on glass beads or reflective elements shall be applied by

pressure or gravity feed concurrently with the laying of the road marking.
The rate of application of these elements is recommended to be not less
than 400 g/m2 in order to achieve the specified minimum initial coefficient
of retroreflected luminance as specified in sub-section 6.3.9.
Road markings of a repetitive nature other than centre lines, lane lines,
etc., shall, unless decided otherwise by the S.O., be set out with stencils
which comply with the size and spacing requirements as shown in the
Drawings.
S6-22
(JKRlSPJ/2017-S6)
6.3.6 Protection of Markings
All markings shall be protected from traffic until they have dried sufficiently
so that no pick-up by vehicle tyre will occur.
6.3.7 Thickness
6.3.7.1 Thermoplastic Material
Thermoplastic material shall be laid to the following thicknesses
ER
and shall be measured from the surface of the pavement:-
(a) For synthetic hydrocarbon resin binder
D
(i) screed lines: not less than 2 mm, nor more than 5 mm;
(ii) extruded lines: not less than 2mm" nor more than 5
N
mm;
(iii) sprayed lines other than yellow lines: not less than 1.5
TE
mm;
(iv) sprayed yellow edge lines (for "no parking', "no
waiting', etc.): not less than 0.8 mm.
(b) For gum or wood resin binders

A
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(i) screed lines: not less than 3 mm nor more than 5 mm;
(ii) extruded lines: not less than 2 mm, nor more than 5
mm;
(iii) sprayed lines other than yellow lines: not less than 2
M
mm;
(iv) sprayed yellow edge lines (for 'no parking', "no
waiting', etc,): not less than 2mm nor more than 3 mm,
EN
The thickness shall be measured by using a suitable device such

as micrometer gauge or callipers, on samples of markings laid on
steel plates beneath the application machine during the laying
M
l) operations. In addition, thickness measurements shall also be

carried out on laid road markings at an interval of 250 meters on
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each line, and on each other markings,
6,3,7.2 Road Marking Paint

O
Road marking paint shall be laid to give a wet film thickness of

not less than 315 microns and not more than 400 microns,
D
6.3.8 Tolerance on Width
The tolerance on the specified width of the marking shall be within the
range of + 10% and minus 0%.
S6-23
(JKRlSPJ/2017-S6)
6.3.9 Retroreflectivity Requirements
Retroreflectivity is the ability of a road marking to reflect light from a

vehicle's headlight back to the driving position of a vehicle. Initially it will be
determined by the amount of glass beads or reflective elements spread on
the marking. The continuing performance of the marking is determined by
the amount and quality of glass beads included in the body of the marking.
Glass beads or reflective elements used in premix thermoplastic shall

comply with the requirements of BS EN 1424, while drop on glass beads or
reflective elements used on the road markings shall comply with the
ER
requirements of BS EN 1423, and shall demonstrate compliance with the
relevant performance of BS EN 1436.
For retroreflection under car headlamp illumination in dry condition, the
D
minimum initial coefficient of retroreflected luminance RL shall be 300
mcd/m2/1x .
N
For retroreflection under car headlamp illumination in wet condition, the
TE
minimum initial coefficient of retroreflected luminance RL shall be 75
mcd/m2/1x.
The Contractor shall demonstrate that the markings comply with the
retroreflectivity requirements by testing them with a retroreflectometer or
A
equivalent, in accordance to BS EN 1436 Annex B. The test shall be
carried out not more than seven (7) days after laying, at an interval of 250
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meters on each line, and on each other markings.

M
6.3.10 Skid Resistance Requirement
If so stipulated in the BQ or in the drawings for skid resistance

EN
requirement, the Contractor shall demonstrate that the markings comply

with the skid resistance requirement by testing them using the standard
British Pendulum apparatus, in accordance to BS EN 1436 Annex D.
M
Skid resistance of road markings will decrease in value due to the effects
of traffic and weathering.
KU
For both penmanent and temporary road markings, the skid resistance
shall be in the SRT units and shall be not less than 45SRT units.
O
A modified version of the UK formula shall be used to convert readings to

an equivalent skid resistance value at 35°Celsius, which is a more realistic
D
reference temperature to be adopted for the tropics. The skid resistance

value shall be determined using the formula: -
SRT(35°C) =(100 + t) X SRT

135
where, SRT (35°C) = equivalent skid resistance value at 35°Celsius

t = temperature of water lying on the road at the time of testing
SRT = mean of five readings as the skid resistance value
S6-24
(JKRlSPJ/2017-S6)
The test is only applicable for road markings with 300mm width or more
and shall be carried out not more than seven (7) days after laying.
6.3.11 Defective Materials or Workmanship
Materials which are defective or which have been applied in an

unsatisfactory manner or to incorrect dimensions or in a wrong location,
shall be removed by approved chemical or mechanical means. To the
extent necessary, the road pavement shall be made good and the
markings reapplied, all at the Contractor's expense and to the approval of
ER
the S.O.
Where directed by the S.O., existing markings shall be removed in the

same manner as above.
D
N
() 6.3.12 Clearing Up
TE
The Contractor shall clean up all spatters, splashes and smirches of the
marking materials completely to the satisfaction of the S.O.
A
6.3.13 Opening to Traffic
EJ
The completed road markings .shall not be opened to traffic until the
material has fully set and this will usually be not less than 1 hour after the
material has been laid.
M
6.3.14 Removal of Road Markings

EN
The unwanted road markings shall be removed from the pavement in such
a way so as to avoid any possible confusion of motorist especially in wet
conditions.
M
l) The Contractor shall remove the road markings completely and to the
satisfaction of the S.O by blasting, grinding, scraping, burning off or
KU
jabbing action using a suitable blade tool without damage to the underlying
road pavement. The Contractor shall seek the approval of the S.O. for
removal by burning off since this technique is not recommended where the
public are close to works, as the fumes are toxic. Removal by painting over
O
with paint of a colour to closely match the surrounding road surface shall
not be allowed.
D
Any excessive damage to the pavement shall be repaired by the

Contractor to the satisfaction of the S.O. Any road markings incorrectly
removed shall be remarked by the Contractor to the satisfaction of the S.O.
The Contractor shall clean up and remove from the roadway all materials
and debris from his operations and leave the roadway clear for use by the
public.
S6-25
(JKRl8PJ/2017-86)
6.4 CONCRETE KERB
6.4.1 Description
This work shall consist of the supply and installation of cast in situ or
precast concrete kerbs constructed at the locations and in accordance with
the lines, levels, grades, dimensions and types as shown in the Drawing,
all in accordance with the Specification .
6.4.2 Materials
ER
Concrete for kerb section shall be grade 20/20 concrete unless indicated
otherwise in the Drawings and shall conform to the requirements of Section
9: Concrete of this Specification.
D
Unless shown otherwise in the Drawings, bedding shall be grade 10/25
N
concrete .
TE
6.4.3 Installation of Kerbs
6.4.3.1 Excavation
A
Excavation shall be made to the required depth and the base
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shall be trimmed and oompacted to a firm and even surface. All
soft and unsuitable material shall be removed and replaced with
suitable material as defined in Section 2: Earthworks of this
M
Specification. The bedding material shall then be placed and

compacted to form a bed of required thickness as shown in the
Drawings.
EN
6.4.3.2 Cast In Situ Kerb
When cast in situ kerb is placed next to a concrete pavement,

M
expansion joints in the kerb shall be located in line with expansion

joints in the pavement.
KU
Concreting shall generally be in accordance with the

requirements of Section 9: Concrete of this Specification. Forms
shall not be removed within 24 hours of the concrete being
placed. Minor defects shall be repaired with mortar containing 1
O
part Portland Cement to 2 parts sand (1PC:2S). The kerb face

shall be trowelled smooth with a tool custom made to the design
D
profile. Other exposed surfaces of the sections shall be steel

trowel finished .
6.4.3.3 Precast Concrete Kerb
Precast concrete kerbs shall be cast using steel moulds and shall
be of the types as shown in the Drawings.
Each kerb shall be set so that its front top arris conforms to the
line and grade required . All spaces under the kerb shall be filled
86-26
(JKRlSPJ/2017-S6)
with bedding material which shall be thoroughly tamped to assure

a solid and even surface.
6.4.3.4 Machine Extruded Concrete Kerb
In situ concrete kerbs shall be laid by approved extrusion

machine or, if practicable, in the case of concrete pavements, by
the concrete paver itself. The kerbs shall be dense with regular
sides, edges, arrises and chamfers, finished to a fine surface free
from blow holes and dragging, and shall be impervious.
To overcome irregularities in the foundation , the machine shall be
ER
capable of automatically adjusting the mould position, while in
operation, to the required line and grade. The machine shall be
operated to produce compacted concrete with un-rendered
D
surfaces substantially free from pitting. The kerb faces and other
exposed faces shall be finished as specified for cast in situ kerb.
N
n Connection of extruded kerb to existing kerb shall be made by
TE
hand to give a smooth transition.
6.4.3.5 Expansion Joints
Construction joints shall be provided at maximum 3m intervals for

A
cast in situ and machine extrusion construction. Joints shall be
formed or cut through tile full cross-section using a template and
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the edges finished with a suitable grooving tool.
Expansion joints shall be provided at both sides of all pits

M
constructed prior to kerb. Construction joints for cast in situ and

machine extruded kerbs shall be 10mm wide and filled with
preformed filler extending over the full cross-section . Pits
EN
cor]Structed into broken out kerb do not require expansion jOints.
Precast concrete kerb shall be laid with joints as narrow as

possible and filled with mortar containing 1 part Portland cement
M
l ) and 2 parts sand. The expansion joint in the kerb shall be 20 mm

and shall be filled with an expansion joint filler of the same
KU
nominal thickness as the pavement joint. Any voids between filler

and the concrete kerb shall be filled with mortar. Where a
Portland cement concrete pavement is to be constructed
contiguous to a kerb, expansion joints shall be constructed in the
O
kerb directly in line with the pavement joints.

D
6.4.3.6 Backfilling
The spaces in the front and back of each kerb shall be refilled to
the required elevation with suitable material approved by the S.O.
which shall be tamped in layers of not more than 150 mm until
properly compacted .
The finished work shall be true to line, grade and level to within 1:
10 mm and shall present a smooth appearance free from kinks
and distortion visible to the eye.
S6-27
(JKRlSPJ/2017-S6)
Any kerb sections dislodged during backfilling or otherwise

misaligned shall be removed and re-Iaid by the Contactor at his
own expense. Care shall be taken in backfilling to ensure that no
damage, defacement or staining is caused to the kerbs and that
the compaction requirements are achieved.
6.4.4 Kerb Opening & Special Features
Kerb opening shall be located and installed in accordance with the

Drawings. Special features such as ramps, transitions and end treatments
shall be formed into the kerbs as required according to the details shown in
ER
the Drawings.
D
6.4.5 Tolerances
N
All sections shall be constructed with a smooth, uniform appearance and
the horizontal and vertical alignment shall not deviate from the design
alignment by more than :t. 25 and :t. 10 mm respectively. Cross-section
TE
dimensions shall be within :t. 5 mm of those shown in the Standard
Drawings. Notwithstanding the above tolerances, the alignments of the
kerb shall have smooth lines.
A
6.4.6 Curing and Protecting
EJ
Newly laid concrete surfaces shall be protected from any disturbance such
as premature drying, damage by rain, vandalism etc. for a period of 24
M
hours after pouring.
The concrete shall also be covered with suitable material and kept moist
EN
for a period of 5 days.
Sufficient signs, barricades and lights shall be erected to protect the newly
laid kerbs from traffic.
M
KU
6.4.7 Kerb Painting
The kerbs shall normally not be painted, unless specified otherwise in the
Drawings. If kerb painting is so directed by the S.O. painting works shall
O
conform to the requirements of JKR Standard Specifications For Building

Works, Section M: Painting Work.
D
6.4.8 Kerb Repairs
Broken or damaged kerbs shall be removed and disposed to the

Contractor's spoil site at his own expense. The exposed concrete repair
surface shall be roughened to remove all laitance and expose the
aggregate to provide a thorough bond with concrete cast subsequently.
The roughened surface shall be cleaned with water to remove loose chips
and foreign material. Immediately before fresh concrete is cast against the
surface, the existing surface shall be thoroughly wetted.
S6-26
(JKRl8PJ/2017-86)
6.5 WIRE ROPE BARRIER SYSTEM
6.5.1 Description
This work shall comprise the supply and installation of wire rope barrier
system inclusive of bolts, nuts, posts and other ancillary works, all in
accordance with this Specification, and the Drawings, and as directed by
the S.O.
Tensioned wire rope barrier systems shall be systems designed specifically

for the purpose of providing a restraining traffic barrier to reduce the
ER
severity of run-oft-road accidents.
6.5.2 Materials
D
6.5.2.1 Ropes
N
n All ropes shall be steel ropes, fitted with terminals . The ropes
TE
shall be 19mm diameter; 3 x 7 (6/1) coreless construction,
complying with BS 302 Part I or BS EN 12385-4.
The minimum breaking load of the rope shall be 17.7 tonnes.

A
The ropes shall exhibit a minimum Modulus of Elasticity of 11 ,600
EJ
kg/mm2 after pre-stressing.
6.5.2.2 Posts
M
All posts shall be formed so that it would bend forward uniformly

upon impact.
EN
The posts should be manufactured from mild steel, 6mm thick to

B.S. 4360 or its replacement, and galvanized to BS EN ISO 1461 :
2009.
M
( \ All concrete foundations shall be Grade 25/20.

KU
6.5.2.3 Plastic Cap
Plastic cap is to be fitted onto the post. Choice of red/yellow/white

O
1" x 4" (25mm x 102mm) reflector is to be placed on every 4th

post either on the cap or on the post as specified by S.O.
D
Reflector shall be of High Intensity Prismatic retroreflective

sheeting or of a higher grade.
6.5.2.4 Anchor Block
Minimum concrete grade for anchor block shall be Grade 25/20.

Dimension of the anchor block shall be as specified by
manufacturers.
86-29
(JKRl5PJ/2017-56)
6.5.3 Installation of Wire Rope Barrier System
The components of the tensioned wire rope barrier systems shall be

supplied and installed in accordance with the manufacturer's instructions,
as outlined in the test documents.
All post shall be installed in concrete footings with suitable sockets

including covers to the sockets. Driven post shall not be used.
Intermediate blocks or tension bays shall be installed at the dimensions

recommended by the manufacturers.
ER
Anchor blocks shall be installed in accordance with the manufacturer's
published recommendations. The maximum spacing between anchor
blocks shall be no longer than 1 km.
D
All ropes shall be tensioned appropriate to the ambient temperature and be
N
free-standing according to the manufacturer's instructions. Plastic ties for
intertwined ropes on both sides of posts are optional.
TE
6.5.4 Basis of Acceptance
6.5.4.1 Material
A
Test certificates for material used in the wire rope barrier system
EJ
showing the results of tests carried out for the purpose of

establishing compliance with Clause 6.5.2 of this standard shall
be submitted for every 500m or less of wire rope section.
M
6.5.4.2 Installation
EN
The post must be installed to the depth, line and spacing shown
in the Drawings. The installation must not cause any structural
damage to the post and to the pavement 100mm from any part of
any post. The Contractor shall also provide the relevant document
M
on:-
KU
(a) Current calibration certificates for the tensioning devices.

(b) Manufacturer's Instruction for installation and maintenance
procedures (if any).
(c) Anchor block testing (pull over test).
O
6.5.4.3 System
D
Tensioned wire rope barrier systems shall have been subjected to

full-scale crash tests, to Test Level 3 (TL-3) minimum as defined
by NCHRP-350 or ASSHTO MASH (Manual for Assessing Safety
Hardware) and CEN Acceptance Tests as defined in BS EN
1317-1:2010, to certify that the offered system can successfully
reduce the speed of colliding vehicles and deceleration within
acceptable limits.
Testing compliance shall be proven by certified documentary

evidence for the specific design.
56-30
(JKRlSPJ/2017-S6)
6.6 DELINEATOR POST
6.6.1 Description
This work shall consist of setting out, supply and installation of delineator
posts at the locations as shown in the Drawing, or as directed by the S.O.
6.6.2 Materials
6.6.2.1 Timber Posts
ER
Timber posts shall be seasoned or treated hardwood of
rectangular cross section with the dimension of 100mm x 50mm
and shall be 1700mm in length. Timber posts shall be straight,
D
sound and free from compression failures and other fractures,
termite galleries, end splits and bark.
N
n The entire timber post above ground level surface area of the
TE
guide posts shall be smooth and shall l5e coated in paint with
stripes of black and white either by brushing, spraying or
immersion in accordance with the paint manufacturer's published
requirements.
A
The surface of the guide post to be painted shall be dry and free
EJ
from all foreign matters including saw-dust, sand, dust, dirt, or
other material or sUl!lstance that could prevent the paint adhering
to it. The painting woi1<s shall conform to the requirements of JKR
Standard Specifications for Building Works, "Section M: Painting
M
Work.
6.6.2.2 Metal or Steel Posts

EN
Metal or steel posts shall be 50mm in diameter and 1700mm in

lertglh.
M
All faces of steel delineator posts shall conform to a smooth gloss

white powder coat finish to a minimum coat thickness of 0.1OOmm
KU
or galvanised to BS EN ISO 1461 :1999.
Steel delineator posts shall be free of rust or other defects for the
duration of the warranty period. Steel delineator shall not have
O
blunt edges exposed to passing motorists.

D
6.6.2.3 Flexible Delineator Posts
The flexible delineator posts shall be made to a design and from

material, which provide the properties of strength, flexibility,
impact and heat resistance and durability required. Flexible
delineator posts shall be minimum 750mm in length.
The Contractor shall supply test certificate and technical

specification that address those properties. The Contractor shall
also provide warranty from the manufacturer on the capability of
S6-31
(JKRlSPJ/2017-SB)
the delineator post in retaining 85% of its colour, appearance and

physical properties for a minimum of 5 years.
The material shall be resistant to mould growth and shall not be

affected by hydrocarbon solvents (such as turpentine, kerosene,
or diesel) which may be used for cleaning process.
The flexible delineator posts shall be capable of self erecting and

remaining serviceable after being subjected to a series of direct
impacts by a typical passenger vehicle. The delineator post shall
be installed in accordance with the recommendations of the
manufacturer.
ER
The delineator posts shall be capable of Withstanding a series of
10 bumper bar impacts at a speed of 60km/h and a 5 bumper bar
D
impacts at a speed of 100km/h directed at 90 degrees to the front
face of the delineator post. The impacting vehicle shall suffer little
N
or no damage during the impact test. The delineator post shall
return to within 5 deg. of vertical within Y, hour of impact. A trial
TE
installation shall be conducted with a minimum sample of three
(3) delineator posts as directed by the S.O. which shows the
delineator post is capable of withstanding the above vehicle
impacts.
A
6.6.3 Delineators
EJ
The delineators shall be red and white in colour of the circular shape,
corner-cubed prismatic lens and shall be not less than 75 mm diameter, or
M
of the rectangular shape of 180mm x 50mm for height and width

respectively and shall be of High Intensity Prismatic retroreflective sheeting
or of a higher grade. Retroreflective sheeting intended for fixing to timber
EN
posts shall be backed by light gauge aluminium.
Delineators shall be capable of clearly reflecting light under normal

atmospheric conditions from a distance of 300m when illuminated by the
M
upper beam of passenger vehicle light. )

KU
The delineators shall be mounted I fixed so that the top of the reflector is
50mm below the top of the delineator post. In each direction of travel, the
colour of the delineators shall be white on the left side of the road and red
on the right side of the road.
O
D
6.6.4 Installation of Delineator Post
6.6.4.1 Location
The location of delineator posts shall be as indicated in the

drawings or as directed by the S.O. Delineator posts shall be
placed at the edge of the road formation level with the wide face
presented to the oncoming traffic.
Unless shown in the drawings specified otherwise, the delineator

posts shall be placed near the outer edge of the shoulder and at a
SB-32
(JKRlSPJ/2017-S6j
uniform distance, minimum 1.2m and not more than 4.0m, from
the pavement edge line, in such a manner so as not to impede
the flow of water in the drain.
6.6.4.2 Buried or Drilled of Delineator Posts
Delineator post holes shall be drilled or dug with vertical sides and
having depth of 500mm for rigid post and as specified in the
drawing or manufacturer's specification for flexible delineator
post. Timber post shall not be driven The posts shall be firmly
embedded in the ground to the satisfaction of the S.O and the
ER
length of post above the ground shall be 1.2m at all time.
Allowance shall be made in the height of guide delineator posts

above the ground level for the effects of super elevation and other
D
road geometry parameters in order to keep the delineator posts
within the range of the beam of vehicle headlights.
N
6.6.4.3 Backfilling
TE
The excavated material shall be used for backfilling around the
delineator post and shall be compacted in layers of depth not
more than 150mm for the full depth of the guide posts up to the
ground level. Unless specified otherwise, the density of the
A
compacted backfill shall not be less than that of the adjacent
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shoulder pavement.
M
EN
M
1)
KU
O
D
S6-33
ADDENDUM NO.1
This Addendum shall be made part ofthe ' JKR Standard Specification For Road Works, Section 6:
Road Furniture - JKRlSPJ/2017-S6'
The following Clause 6.3.9 shall supersede the existing Clause 6.3.9
6.3.9 Retroreflectivity Requirements
ER
Retroreflectivity is the ability of a road marking to reflect light from a vehicle's headlight
back to the driving position ofa vehicle. Initially it will be determined by the amount of glass
beads and reflective elements spread on the marking (drop-on reflective materials). The
D
continuing performance of the marking is determined by the amount and quality of glass
beads and reflective elements included in the body of the marking (premix reflective
N
materials).
( )
TE
Reflective materials (glass beads and reflective elements) dropped on the road markings
shall comply with the requirements ofBS EN 1423 and shall demonstrate compliance with
the relevant performance ofBS EN 1436. While the reflective elements premixed in the road
markings shall comply with the requirements ofBS EN 1424.
A
Upon completion of laying the road markings, the Contractor shall demonstrate that the
EJ
markings comply with the retroreflectivity requirements by testing them with a
retroreflectometer or equivalent, in accordance to BS EN 1436 Annex B.
M
The test shall be carried out not more than seven (7) days after laying, at an interval of250
meters on each line, and on each other markings. The retroreflection requirements, which is
predominantly controlled by the drop-on reflective materials, shall be as follows;
EN
a) For retroreflection under car headlamp illumination in drv condition, the minimum
initial coefficient of retroreflected luminance RL shall be 300 mcdlm2/lx ; and
M
b) For retroreflection under car headlamp illumination in wet condition, the minimum
lJ initial coefficient of retroreflected luminance RL shall be 75 mcdlm2/lx.
KU
The Contractor shall ensure that sufficient quantity of reflective materials are
premixed prior to the application ofthe road marking. The quantity ofthe reflective
materials premixed with the road marking substrates shall have a minimum weight
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of 10% of the total mix which consist of;

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i) 50% of dry reflectivity materials; and
ii) 50% of wet reflectivity materials.
AS6( I)- III
SA KPKR Bil.l512019
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Section 7 - Road Lighting (JKR/SPJ/2011-S7)
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JKR/SP,J120 1\-S7
JKR 21300-0035-12
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KERAJAAN MALAYSIA
JABATAN KERIA RAYA MALAYSIA
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Section 7: Road Lighting

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@
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KETUA PENOARAH KEiUA RA YA
JALA~SIJLTAN SALAHUDDIN.
SOS82 j(UALA LUMPUR.
For the latest version of this specification,

please log on to: http://www. jkr.gov.my/cke/
FOREWORD
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As practices in road construction change over time, it is imperative for Jabatan Kerja Raya (JKR)
to continuously update and improve their standard specifications. These new specifications are
not only aimed at keeping abreast with current technologies but also to help in improving the
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quality of constructed product. In unison, these new specifications have a significant positive
impact on the construction industry especially with the incorporation of new products and
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technologies.
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construction industry. This specification provides an improved guidance in the material selection
and the production of good quality workmanship and products, based on current best practices.
The purpose of this standard specification is to establish uniformity in road works to be used by
road designers, road authorities, manufacturers and suppliers of road related products.
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This document "Section 7: Road Lighting" is a part of a series of improved specifications in the
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Standard Specification for Road Works. This document was fully adopted from the three (3)
specifications published by the Electrical Engineering Branch (Cawangan Kejuruteraan Elektrik)
of lKR Malaysia namely, Specification L-SI: Low Voltage Internal Electrical Installation,
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Specification L-S3 : Low Voltage Underground Cable and Specification L-S20: Road Lighting
Installation.
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The title of this document had been changed from Street Lighting to Road Lighting in order to
maintain the consistency of the wording used in the Specification.
This document will be reviewed and updated from time to time to cater the changes on polices
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and current requirements. In this respect, any comments and feedback regarding to this
specification should be forwarded to: -
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Unit Standard & Spesifikasi

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No. 50, lalan Tun Razak,
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50400 Kuala Lumpur.

ACKNOWLEDGEMENT
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This Standard Specification for Road Works Section 7: Road Lighting has fully adopted the
three (3) specification published by the Electrical Engineering Branch (Cawangan Kejuruteraan
Elektrik) of JKR Malaysia. Therefore, a special thanks to the Senior Director of Electrical
Engineering Branch of JKR for his kinds cooperation in approving the used of three Electrical
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Specifications to prepare this document and also to those who had contributed towards the
successful completion of this document.
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Published by: - A
lbu Pejabat Jabatan Kelja Raya
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Tingkat 26, Menara PID,
50400 Kuala Lumpur.
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August 2012
(JKRISPJI2011 -S7)
SECTION 7 - ROAD LIGHTING
7.1 GENERAL
This work shall consists of the supply, delivery, storage, assembly, installation, erection,
testing, commissioning, handing over in approved working order and maintenance during
Defect Liability Period of the Road Lighting Installation in accordance with the
Specification, Notes, Bill of Quantities, Conditions of Contract, Drawings and other
related documents.
The Road Lighting Installation works shall include low voltage underground cables,
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luminaries, fittings, brackets, spigots, other supporting devices, columns, feeder pillars,
bases, cables, switchgears and all necessary ancillary equipment, foundations, ducting and
all other necessary equipment for a complete Road Lighting System. The work shall also
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include cabling from the nearest specified power source of the local supply authority to
the Road Lighting System, if required.
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7.2 L-Sl: SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL
INSTALLATION (May 2011)
(Please refer to http://www.jkr.gov.my/cke/ forthe latest specification)
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7.3 L-S3: SPECIFICATION FOR LOW VOLTAGE UNDERGROUND CABLE
(April 1999)
(Please refer to http://www.jkr.gov.my/cke/ for the latest specification)
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7.4 L-S20: SPECIFICATION FOR ROAD LIGHTING INST ALLATION

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(August 1999)
(Please refer to http://www.jkr.gov.my/cke/ for the latest specification)
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S7- 1
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L-S1
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SPECIFICATION FOR LOW VOLTAGE
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INTERNAL ELECTRICAL
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INSTALLATION
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JKB
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SPECIFICATION FOR
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LOW
VOLTAGE INTERNAL TE
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ELECTRICAL
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INSTALLATION
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EN
(L-S1)
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JKR 20300-0107-22
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CKE.LS.01.01.(04).2017
CAWANGAN KEJURUTERAAN ELEKTRIK
CKE.LS.01 .01.(04).2017
Date Issued: April 1999
~
INTERNAL Revision: 4
ELECTRICAL INSTALLATION
(L-S1 ) Date: Jan 2018
Page: i of iv
SECTION CONTENT REVISION PAGE
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1.0 General 2 S1/1
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2.0 Switchboards 3 S2/1 - S2/8
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2.1 Types of Switchboard
2.2 Enclosures
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2.2.1 Self Contained Floor Mounted Cubicle Switchboards
2.2.2 Wall Mounted Switchboards
2.3 Busbars
2.4 Meter Panels
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2.5 Others
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3.0 Distribution Boards And 3 S3/1 - S3/2

Consumer Units
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4.0 Switchgears 2 S4/1 - S4/9
4.1 Air Circuit Breakers

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4.2 Moulded Case Circuit Breakers

4.3 Miniature Circuit Breakers
4.4 Residual Current Device
4.5 Fuse Switchgears
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4.6 Isolating Switches

4.7 Contactors
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4.8 Automatic Transfer Switchi ng Equipment
5.0 Protection Relays 2 S5/1 - S5/2

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6.0 Measuring Instrument And 2 S6/1 - S6/3

Accessories
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6.1 Measuring Instrument

6.2 Current Transformers
SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION

© Hak Cipta: 1999 Cawangan Kej uruteraan Elektrik, JKR Malaysia
CKE.LS.01.01.(04).2017
rf:J INTERNAL
(L-S1)
Revision: 4
Date: Jan 2018
Page: ii of iv
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7.0 Surge Protective Device 2 S7/1 - S7/3
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8.0 Busbar Trunking 2 S8/1 - S8/2
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n 9.0 System Of Wiring 2 S9/1 - S9/14
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9.1 Type Of Cables
9.1.1 PVC Insulated PVC Sheathed Cable
9.1.2 PVC Insulated Cable
9.1.3 XLPE/PVC Cable
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9.1.4 Armoured Cable
9.1.5 Mineral Insulated Cables
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9.2 Wiring In ConduitlTrunking (Surface Or Concealed)

9.3 Metallic And Non-Metallic Conduits
9.4 Cable Trunking
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9.5 Cable Tray

9.6 Cable Ladder
9.7 Identification of Pipelines And Services
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9.8 Mounting Heights
10.0 Wiring Accessories 2 S10/1 -S10/4

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10.1 Switches And Switch Plates

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10.2 Switched Socket Outlets And Unswitched Socket Outlets

10.3 Boxes For Switches, Switched Socket Outlets Unswitched Socket
Outlets And Distribution Boards (Box And Enclosure For Electrical
Accessori es)
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10.4 Ceiling Roses

10.5 Lampholders And Batten Holders
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SPECIFICA nON FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION

© Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia
CKE.LS.01.01 .(04).2017
Dale Issued: April 1999
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(L-S1 )
Revision: 4
Dale: Jan 2018
Page: iii of iv
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11 .0 Luminaires 4 Sll/1-S11/18
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11 .1 Fluorescent Luminaires
11.1.1 Tubular Type Fluorescent Luminaires
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n 11 .1.1.(a) Tubular Type Fluorescent Luminaires
T8(FD 26)
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11.1.1.(b) Tubular Type Fluorescent Luminaires
T5(FDH 16)
11.1.2 Downlight Type Compact Fluorescent Luminaires
11.2 Self Contained Emergency Luminaires
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11.3 LED Luminaires
11.4 Installation Of Luminaires
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12.0 Lamps 3 S12/1 -S12/15

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12.1 Tubular Fluorescent Lamp

12.2 Compact Fluorescent Lamp Without Integral Control Gear
12.3 Compact Fluorescent Lamp With Integral Control Gear
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12.4 LED Lamp

12.4.1 LED Bulb
12.4.2 LED Double Capped Lamps (T8 LED Tubes)
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13.0 Fans 3 S13/1 -S13/3
14.0 Earthing 2 S14/1-S14/5

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15.0 Labelling 2 S15/1

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16.0 Swilchroom 2 S16/1
SPECIFICATION FOR lOW VOLTAGE INTERNAL ElECTRICAllNSTAllAnON

CKE.LS.01.01 .(04).2017
........ SPECIFICATION FOR LOW VOLTAGE
rIJK~ INTERNAL Revision: 4
~ Date: Jan 2018
(L-S1 )
Page: iv of iv
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17.0 Requirement For Anti-Corrosive 2 S17/1o$17/4
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Type Installations
17.1 Wiring
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n 17.2 Switchboards (Main Switchboard , Sub Switchboard And
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Distribution Board)
17.3 Switches, Switched Socket Outlets & Unswitched Socket Outlets
17.4 Luminaires
17.5 Ceiling Fans & Exhaust Fan
17.6 Special Treatment For Housings of Electrical Items Used In Salt-
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Sprayed Environment
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18.0 Test, Test Instruments And Test 2 S18/1o$18/2

Certificates
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18.1 Test And Calibration Of Measuring And Test Instruments

18.2 Test And Test Certificates
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19.0 Service And Maintenance 2 S19/1
20.0 Shop Drawings, As-Installed 2 520/10$20/3

Drawings, Manuals And Tools
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l} 20.1 Shop Drawings

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20.2 As-Built Document And Tools
21.0 List of Standards 3 521/10$21/10

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Page: S1 - 1 of 1
1.0 GENERAL
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1.0.1 This section of the Specification describes and specifies requirements for the
supply, delivery, installation , testing , commissioning, handing over in approved
working order and maintenance during the Defects Liability Period of the whole
electrical installation in accordance with the Specification, Supplementary
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Notes, Bill of Quantities, Conditions of Contract, Drawings etc.
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n 1.0.2 Unless specified elsewhere , all equipment, switch gears, apparatus, appliances
and accessories for low voltage electrical installation shall be rated for
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operation on a 230/400V (within the tolerance as defined in MS IEC 60038;
230/400V, +10%, -6%), 3 phase , 4 wire, 50Hz. system with solidly earthed
neutral.
1.0.3 All standards shall conform to the latest MS, MS IEC, IEC, BS EN, BS and/or
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EN standard.
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SPECIFICAnON FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION

© Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik. JKR Malaysia
CKE.LS.01.01 .(04).2017
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(L-S1 )
Revision: 3
Date: Jan 2018
Page: S2 - 1 of 8
2.0 SWITCHBOARDS
2.1 TYPES OF SWITCHBOARD
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2.1.1 The types of switchboard shall be as specified in the Bill of Quantities andlor
Drawings and shall be of the following types: -
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2.1.1.1 Self-contained, floor mounted, flush fronted, metalclad cubicle
type suitable for front and rear access;
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n 2.1.1.2 Self-contained, floor mounted , flush fronted, metalclad cubicle
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type suitable for front access;
2.1.1 .3 Wall mounted metalclad type suitable for front access .

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2.1.2 The switchboards shall house their air circu it breakers , moulded case circuit
breakers, fuse switches, switch fuses, isolators , contactors , busbars, meters,
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protective relays, selector switches , indicating lamps , current transformers,

cable terminating boxes, cable glands , anti-condensation heaters complete
with automatic thermostats and isolators and all other necessary items of
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equipment whether specified hereinafter or in the Drawings or not, suitable for

operation on a 230/400V, 3 phase , 4 wire, 50Hz. system with solidly earthed
neutral. Unless otherwise specified elsewhere , the switchboards shall be
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capable of wi thstanding fault condition of not less than 50kA at 400V for 1
second as defined in MS lEe 60439-1. The switchboards shall comply with MS
lEe 60439-1 and the degree of protection shall be IP41 in accordance to MS
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lEe 60529.
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2.1.3 Outdoor switchboards shall also comply wi th MS lEe 60439-5 with protection
degree of IP54 in accordance to MS lEe 60529.
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2.1.4 Type testing for switchboard as per categorization shall be as per Table 2A
below:
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Category Current Rating Registration & Type Test Report
I I" 600A Suruhanjaya Tenaga
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II 600A < I " 2000A Suruhanjaya Tenaga & Partial Type
Test in accordance with MS IEC 60439-
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n 1
(i) Short Circuit Test
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(Clause:8.2.3)
(ii) Temperature Rise Test
(Clause:8 .2.1)
III I > 2000A
Suruhanjaya Tenaga & Full Type Test in
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accordance with MS IEC 60439-1
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Table 2A : Type testing for switchboard as per categorization
2.1 .5 Routine tests on the switchboard shall be carried out before delivery to site .
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The main circuits and the auxiliary circuits shall be tested to verify dielectric
properties with power-frequency test voltage of 2500Vac for 1 minute and
insulation resistance under test voltage of 1000V. Routine tests sha ll include
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inspection and checking of wiring , electrical continuity of the protective circuits ,

connections and effectiveness of mechanical actuating elements and interlock.
Test Results or Certificate duly certified by Competent Person as in Electricity
Regulations 1994 shall be issued for every switchboard supplied and installed .
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© Ha k Cipta : 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia
CKE.LS.01.01.(04).2017
--.. SPECIFICATION FOR LOW VOLTAGE
rJJK!l INTERNAL
Revision: 3
--- ""'" (L-S1 ) Date: Jan 2018
Page : 52 - 3 of 8
2.2 ENCLOSURES
2.2.1 SELF-CONTAINED FLOOR MOUNTED CUBICLE SWITCHBOARDS
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2.2.1.1 The framework of the switchboard shall be fabricated from rolled steel sections
of thickness not less than 2.5mm and shall be self-supporting when assembled,
uniform in height and depth from front to back. The rigid construction shall be
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designed to withstand without any sag , deformation or warping , the loads likely
to be experienced during normal operating, maintenance or maximum fau lt
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condition.
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2.2.1.2 The front shall be provided with covers/doors of box formation. The rear shall
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be provided with hinged removable doors of box formation. The rear doors
shall be of double-leaf type with rebated edges and each leaf should preferably
not be wider than 450mm. Each leaf of door shall have 2 pairs of approved
hinges. The door shall be fitted with approved type of surface-mounted
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espagnolette or cremone baits complete with approved locking device operated
by a satin chrome lever handle at the centre fixi ng. The top and sides shall be
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of removable panels.
2.2.1.3 Cover plates with openings for cable entry shall be provided at the base of the
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switchboard . All panels, covers and doors shall be fabricated from sheet steel
of thickness not less than 2.0mm and so constructed as to provide a clear,
flush and pleasing appearance. The panels, covers and front doors shall be
secured to the enclosure by means of chromed type of screws with cylindrical
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knurl ed head complete with retaining clips. Welded cross struts shall not be
used.
2.2.1.4 The switchboard shall be dust and vermin proof. All covers and doors shall be
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provided wi th grommets and dust seals to exclude dust and dirt. Louvres or
ventilation vent with filter shall be provided at the sides and back for adequate
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ventilation. Precaution shall be taken to prevent overheating due to hysteresi s

and eddy current using non ferrous plate (for single core cable) . All edges shall
be rounded . Serrated star washers shall be fitted to ensure satisfactory
earthing of the front cover.
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SPECIFICAliON FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLAliON

© Hak Cipta: 1999 Cawangan Kejuruteraan Elektrlk. JKR Malaysia
CKE.LS.01.01.(04).2017
Date Issued : April 1999
-, SPECIFICATION FOR LOW VOLTAGE
rlJK!l
'-. ~~
INTERNAL
Revision: 3
Page : S2 - 4 of 8
2.2.1.5 Unless otherwise specified in Ihe drawings and/or bill of quantities, the
switchboards shall be of Form 2b and comply with MS IEC 60439-1. The
busbars shall be separated from the switchgears/functional units and the
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incoming and outgoing terminals. The form of separation shall be achieved by
metallic or non-metallic rigid barriers/partitions. All switchgears shall be
mounted so as to give adequate clearance for cable and busbar connections.
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2.2.1.6 Switchgears shall be mounted on insulation runners where connected to
busbars and on steel supports where cable connection are made. The
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insulation runners shall be of minimum 10mm thickness and mounted on steel
() support or back panel of the enclosure whichever is more appropriate.
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2.2.1.7 Cables connection between the busbars and the switchgears shall be neatly
arranged and mounted on cable runner. The terminals of the switchgears for
external cable connections shall be at least 200mm above the base of the
switchboards and , moreover, so placed that the cables can be easily
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connected to them. Withdrawable type of switch gears shall be mounted on
the framework assembly, includi ng the runner rails and fixed rear isolation
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contacts, which shall be supplied as a part of the switchgear assembly. Each

withdrawable switchgear shall be housed in its own compartment with rear
connected busbars .
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2.2.1.8 All indicating instrument which need to be read by the operator shall not be
located higher than 2m above the base of the switchboard . All operating
devices such as handle , push buttons, etc., shall be located at such a height
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that they can easily be operated , and in general , the centerline shall not be
higher than 2m above the base of the switchboard. In the case where building
automation devices, transducers and relays are provided, they shall be
separately housed in a compartment of the section of the switchboard. All
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wiring from the devices, transducers and relays shall be neatly arranged and
con nected to the terminal blocks with removal links mounted on rail.
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Terminals shall be identified and labelled in accordance with IEC 60445.

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CKE.LS.01.01 .(04).2017
§ INTERNAL
(L-S1 )
Revision : 3
Date : Jan 2018
Page: S2 - 5 of 8
2.2.1.9 Where surge protective device is specified , the device and its associate
equipment shall be totally compartmentalized with clear transparent cover at
immediate lower subsection where the incoming switchgear is connected. A
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lockable tool compartment with keys and opening handle shall be provided
at the lowest subsection of the switchboard. The switchboard shall undergo
de-rusting treatment, anti-rust treatment with the exterior finished with epoxy
dry-powder and oven baked semi-gloss beige colour and interior finished
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matt white. The switchboard shall be bolted to mild steel channel base or
over concrete trench. The channel shall be anti-rusted and painted with a
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primer. There shall be a readily installed cable tray on the interior of both
side panels for outgoing cable . All cables shall be rigidly secured using
cable support bracket of non rotting material, before termination.
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2.2.1.10 Where top entry is specified or required, there shall be a readily installed
cable box for top entry cable.
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2.2.1.1 1 Where the incoming feeder circuit breaker in the switchboard is 2500A and
above, the switchboard shall be equipped with an arc protection system.
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The arc protection shall be installed against the internal arc in the
switchboard in order to improve personnel safety to minimize damage to the
switchgears in case of internal arc faults, thus improving the availability of
the electricity service. The arc protection shall be integrated with protection
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relays or of stand alone type. The relays shall be in accordance to the

requirements in Section 5.0. Only a simultaneous occurrence of over-current
and arc incidence(s) shall activate the trip signal in the relay.
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2.2.1.12 Arc sensors shall be mounted in the switchboard. The arc sensors for
detecting the arc shall be of photo transistor or lens sensors. The arc
sensors shall in practice be installed within the cable compartment of the
outgoing feeder, main incoming circuit breaker and busbar compartment.
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The arc protection system shall include a self -supervision function covering
all equipment, including the arc sensors. All internal faults shall be indicated
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on the arc protection unit and an alarm contact shall be activated. The arc-
monitoring unit shall contain a display capable of indicating the exact
compartment of the fault after the tripping.
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2.2.1.13 All outgoing MCCBs in the switchboard where the incoming feeder circuit
breaker is rated 400A and above shall be provided with panel mounting
external operating handle with padlocking facilities.
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CKE.LS.01.01.(04).2017
§ INTERNAL
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2.2.2 WALL MOUNTED SWITCHBOARDS
2.2.2.1 The switchboard shall be fabricated from sheet steel of thickness not less
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than 2.0mm . The enclosure shal l be of all welded construction with sheets
bent where possible so as to minimise the number of welded joints. The four
sides of the enclosure shall be returned at the front to facilitate fixing of front
cover plates. The front cover plates or doors shall be of box formation and
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flanged to facilitate fixing to the enclosure .
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2.2.2.2 The front cover of the switchboard shall be provided with grummets and dust
(j seal to exclude dust and dirt. Meshed louvre or ventilation vent with filter
shall be provided at both sides for ventilation. All edges shall be rounded.
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Serrated star washers shall be fitted to ensure satisfactory earthing of the
front cover. The switchboard shall undergo de-rusting treatment, anti-rust
treatment and be finished with epoxy dry-powder and oven baked semi-
gloss beige colour.
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2.2 .2.3 The switchboard shall not be mounted directly to the wall or structure. It shall
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be firmly bolted/welded on to galvanised C-channel brackets which in tum
sha ll be bolted to the wa ll or structure by means of bolts and nuts. The top of
the switchboard shall not be higher than 2100mm and the bottom shall not
be lower than 900mm from the floor.
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2.3 BUSBARS
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2.3.1 Busbars shall conform to BS EN 13601 and shall be tinned hard drawn high
conductivity copper with an adequate uniform rectangular cross section to carry
continuously their rated current without overheating. They shall be rigidly
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mounted on non-hygroscopic insulators so as to withstand any mechanical

l) stresses to which they may be subjected under maximum fault condition.
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2.3.2 Busbar sizes must not be less than that specified in the Drawings. However if
the busbar sizes are not specified , then the busbar rating shall be based on a
current density of not more than 1.5 Nsq. mm . In any case , the main busbars
rating shall not be less than the rating of the incoming switchgear (10). All
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busbars whether horizontal or vertical, shall be of the same size.
2.3.3 The main busbars shall be run for the full length of the switchboard without
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reduction in size. Neutral busbar shall be of full size and fu ll length as the
phase busbars. Connections shall be made up with bronze or other copper
alloy and nuts utilising tension washers on both outer faces. Where multiple
parallel bars are used , they shall be separated by tinned copper spacers at
spacing equal to the busbar thickness.

CKE.LS.01.01.(04).2017
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2.3.4 The main busbar shall be arranged in a horizontal plane in the order neutral-
blue-yellow-red, viewed from the rear of the switchboard. Busbars shall be
painted at appropriate points with colours red , yellow, blue and black to denote
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the phases.
2.3.5 Tinned copper earthing bar of cross sectional area not less than 50mm x 6mm
shall run along the switchboard for its entire length. This switchboard earthing
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bar shall be fastened and bonded at the base to each vertical frame member of
the switchboard . At least one earthing bar of similar cross sectional area shall
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n run the full height of the switchboard and connected to the main earthing bar.
All earthing bars shall be identified with green and yellow (twin-coloured)
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colour.
2.3.6 Distribution busbars shall be sized in accordance with the maximum outgoing
switchgear rating. Connections from busbars to the switchgears shall be
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effected by means of copper conductors securely clamped to the busbars and
colour coded to identify the phase and neutral conductors. Copper conductor
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either bare tinned busbars or insulated cable shall be rated in accordance with
the current rating of the switchgear. Neutral conductor shall be of full size as
phase conductor. Coloured cable sleeve shall be shrouded for cable end
termination.
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2.4 METER PANELS

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2.4 .1 The metalclad, mild steel or other approved material with thickness not less
than 1.5mm meter panel of box formation shall be installed adjacent to, but
physically separated from the main switchboard. Suitable flexible andlor rigid
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galvanised steel conduit with approved adaptors shall be supplied and fitted
between the main switchboard and the meter panel. The design, construction
and method of installation of the meter panel shall be to the requirement of
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Supply Authority or Licensee.

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2.5 OTHERS
2.5.1 All secondary wiring shall be of not less than 1.5 sq. mm . section insulated with
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PVC and shall be fixed securely withou t strain by cleats of the compression
type . All screws, locknuts , washers , bolts etc. shall be of copper alloy type.
2.5 .2 Indicating lights shall be long life coloured LED type. All indicating lights shall
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be adequately ventilated and easily be replaced from the front of the panel
without the use of extractors.
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(J 2.5.3 Instruments, meters, relays, protective fuses etc. located on the front of the
switchboard shall be so positioned that as far as possible, each instrument,
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meter, relay, protective fuse etc. is adjacent to the unit which it is associated.
All relays shall be of heavy duty type , unaffected by external vibration and
capable of operation in any position . All instruments , meters, relays, equipment
etc. shall be fully tropicalised .
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2.5.4 One number approved anti-condensation heater shall be installed for every two
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sections at the switchboards . Each heater shall be complete with automatic
thermostat control, ON-OFF switch and ind icating lamp.
2.5.5 Engraved labels with white lettering on a black background shall be fastened or
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riveted on the front panels of each switchgear and item of equipment. The
wording shall be approved by the 8.0.'s Representative. Engraved name plate
showing the rel evant earth fau lt setting, overcu rrent setting , curre nt transformer
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rati o, fuse rating , name of the circuit to which it is connected , etc. shall be fixed
to switchgear panels to which it refers .
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3.0 . DISTRIBUTION BOARDS AND CONSUMER UNITS
3.1 All Distribution Boards (metalclad and all insulated) shall be installed at
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locations indicated in the Drawings or as directed by the S.O.'s Representative.
The Distribution Boards shall be assembled by licensed switchboard
manufacturer, registered with Suruhanjaya Tenaga (ST) and Jabatan Kerja
Raya.
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3.2 They shall comply with MS IEC 60439-3 and unless otherwise specified, shall
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be surface mounted metalclad type. The sheet steel shall have minimum
thickness of 1.2mm. They shall have hinged cover, ru st-proof and finished wi th
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oven baked epoxy powder coating. Knockouts or other approved form of cable
entries and suitable brass earthing bolt and nut shall be provided .
3.3 The Distribution Boards shall be equipped with HRC fuses or Miniature Circuit
Breakers (MCB) of rating as specified in the Drawings. HRC fuses shall comply
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with relevant parts of IEC 60269 . MCB shall have rupturing capacity not less
than that indicated on Drawings andlor Bill of Quantities and shall comply with
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MS IEC 60898.
3.4 The busbars shall be hard drawn high conductivity copper. The current rating of
the busbars shall not be less than the incoming switchgear rating . The neutral
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and earth connection for each circuit shall be individually connected to the
neutral and brass earth barlterminal respectively. The sequence of termination
of the neutral and earth wires shall correspond to that of phase circuit.
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3.5 For all -insu lated Distribution Boardl Consumer Unit, the main switch shall be
double pole MCB (Miniature Circuit Breaker) provided with a clear indication of
'ON-OFF' positions. The main switch shall comply with MS IEC 60947-3 and
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have fully shrouded incoming cable terminals. The contacts shall be of long
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, J switching life type.
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3.6 Where surge protective device is specified, the device and its associated
equipment shall be housed in separate compartment immediately after where
the incoming switchgear is connected.
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3.7 All outgoing cables shall have alphanumeric circuits number labels. The labels
of the neutral and earth shall correspond to that of the phase circui!.
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3.8 Engraved labels with white lettering on a black background shall be fitted
externally (using rivet) on the front cover of the Distribution Board/Consumer
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Unit describing its usage and with a suitable designation for identification .
3.9 Each Distribution Board shall be provided with a laminated schematic diagram
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and paste on the inside cover of the Distribution Board . The details shall
include fuse rating/MCB rating, cable size , number and type of loads etc. The
description of each circuit printed thereon shall include the corresponding
circuit number in the as installed schematic diagram.
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3.10 All Distribution Boards shall be provided with top and bottom entry/exit with
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minimum 50mm x 50mm pre-cut hole. The opening shall be fitted with fiat,
removable gland plate to cover the hole.
3.11 Where Distribution Board is specified to be installed at special service

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conditions as per clause 7 of IEC 61439-3:2012 and clause 7.2 of IEC 61439-
1:2011 where variations in temperature and humidity take place at such speed
where condensation is liable to occur inside it, each Distribution Board
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shall be provided with meshed louvre or ventilation vent wi th filter for

adequate ventilation and/or one number anti condensation heater
complete with automatic thermostat control , ON OFF switch and indicating
lamp.
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4.0 SWITCHGEARS
4.0.1 All switchgears shall have voltage and frequency rating suitable for the power
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system to which they are connected . The current rating shall not be less than
the specified in the Drawing andl or Bill Quantities. They shall conform to the
latest MS, MS lEG or lEG standards.
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4.1 AIR CIRCUIT BREAKERS
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4.1.1 Air circuit breakers (AGB) shall be of withdrawable metalclad , flush mounted ,
horizontal drawout isolation and air break type suitable for installing on cubicle
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type of switchboard . They shall be three or four poles type as specified and
shall comply fully with MS lEG 60947-1 and 60947-2. They shall be ASTA,
KEMA or other accredited laboratories certified for minimum rupturing capacity,
rated short time withstand current, (Icw) of 50kA at 400V for 1 second or
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otherwise specified .
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4.1.2 They shall consist of quick-make , quick-break, mechanically and electrically trip
free mechanism arranged to give double break in all poles simultaneously. The
closing mechanism shall be of stored energy type, either manually or
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electrically charged. Mechanical ' ON' and ' OFF' or 'I' and '0 ' indicators shall
be provided. The tripping mechan ism shall be equipped with push button for
independent manual tripping and shall be stable and not being opened by
shocks.
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4.1.3 Each pole of the circuit breaker shall be provided with an arc chute to
extinguish the arc drawn between the breaker contacts each time a breaker
interrupts current, and interpole barriers to reduce arcing time for rapid
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( ) deionization of the arc and guard against flash over. The contacts shall be
renewable type .
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4.1.4 The operating mechanism and carriage shall have the following positions : -
4.1.4.1 Service- In this position the main and control contacts are engaged .
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4.1.4.2 Test - In this position the main contacts are isolated but the
control contacts are still engaged. It shall be possible to
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check the correct operation of the control circuits without

energising the main circu it.
4.1.4.3 Isolated - Both main and control contacts are isolated .

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4.1 .5 They shall be provided with marking to show the breaker positions wi th facility
for padlocking the carriage in the Test and Isolated positions. They sha ll be
equipped with the following interlock devices: -
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4.1.5.1 Prevent withdrawal of breaker while the breaker is in closed position .
4. 1.5.2 Prevent closure of breaker while the carriage is in any position between
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'fu lly isolated' and 'fully home'.
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4.1.6 The arrangement of the busbar connections shall be such that with the circui t
breaker withd rawn, the live parts shall be protected , either by suitable
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shrouding or lockable shutters.
4.1 .7 Minimum four num bers (2 -Norm ally-Open, 2-Normally-Close) double break
type auxiliary contacts shall be provided.
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4.1 .8 Mechanical interlocks and/or electrical interlocks , where specified , shall be
provided. Mechanical interlock shall be of code key type, arranged to
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mechanically operate the trip mechanism latch so that the breaker can on ly be
closed when the key is trapped in the lock. Electrical interlock sha ll be
controlled by means of operation of auxi liary switches of another breaker
designed to cut out the closing coils and mechanism of the parent breaker.
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4.1.9 Where used as bus-coupler, they shall be of 4 pole type and provided with
electrical and/or mechanical interlocks as required so that it is not possible for
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the coupler to close with its associated main incoming supply breakers closed.
4.1.10 Where used as incoming feeder from supply source (either from transformer,
generator set or coupler) , they shall be of 4 pole type.
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4.1.11 The neutral of the 4 pole type ACB terminals shall be of the same size as the
phase.
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4.1.12 The frame of ACB shall be bonded to the switchboard earthing bar using of
3mm x 25mm tinned copper tape.
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© Hak Cipta : 1999 Cawangan Kejuruteraan Elektrlk, JKR Malaysia
CKE.LS.01.01.(04).2017
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4.2 MOULDED CASE CIRCUIT BREAKERS
4.2.1 Moulded case circuit breakers (MCCB) shall have the number of poles as
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specified in the Drawings and/or Bill of Quantities. They shall comply with MS
IEC 60947-1 and MS IEC 60947-2. They shall be fully tropicalised and suitable
to be used up to an ambient temperature of 40°C, enclosed in glass-reinforced
polyester moulded case and suitable for use on 230/400V, 50Hz. a.c. supply
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system.
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4.2.2 They shall be of the quick-make, quick-break type having manually operable
() toggle type handle. Permanent position indicators shall be provided to show
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status of the breaker. When tripping occurs , the handle shall be in the 'trip'
position midway between the 'ON' and 'OFF' or T and '0' position so as to
provide positive indication of automatic interruption . The operating mechanism
shall be non-tamperable. The MCCB shall have trip-free feature to prevent the
breaker from being closed against fault conditions. Multipole MCCB shall have
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common-trip operating mechanism for simultaneous operation of all poles.
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4.2.3 The tripping units shall be one of the following types: -
4.2.3.1 Thermal-magnetic type with bimetallic elements for inverse time-dela y

overload protection and magnetic elements for short circuit protection.
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4.2.3.2 Solid state trip unit with adjustable overload protection and adjustable
short circuit protection with or without adjustable time-delay.
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4.2.4 An arc extinguisher shall be incorporated to confine, divide and extinguish the
arc drawn between the breaker contacts each time a breaker interrupts current.
The contacts shall be of non-welding type.
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l..) 4.2.5 Unless otherwise specified in the Drawings and/or Bill of Quantities, the
minimum rated ultimate short circuit breaking capacity (I,u) of the MCCB shall
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be 50kA rms at 400V for switchboards connected to transformer or Supply

Authority's or Licensee's incomer and 25kA for the subsequent switchboards.
4.2.6 The rated service short-circuit breaking capacity (10,) shall be 100% of the rated
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ultimate short-circuit breaking capacity (I,u) at 400 volts for incoming feeder,
and for all outgoing feeder I ~ shall be 50% of I,u.
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4.2.7 Unless otherwise specified the rated ultimate short circuit bre<lking capacity
(I,u) for MCCB at Distribution Board shal l be not less than 10kA at 230/400V
and I ~ shall not be less than 50% I,u at 230/400V.

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4.2.8 If current limiting types of MCCB are used, they shall be equipped with current
limiting device of either permanent self-resetting power fuse type or magnetic
repulsion moving contact type.
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4.2.9 The current limiting device shall coordinate with the normal trip mechanism so
that all fault and overload currents occurring within the safe capability of the
MCCB shall cause the MCCB to open , and all currents occurring beyond the
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capability of the MCCB shall cause the current limiting devices to operate.
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4.2.10 If required , the MCCB shall have facilities for shunt trip, under-voltage/no-volt
trip, externally connected earth fault protection, externally connected
overcurrent protection etc .. They shall also have auxiliary contacts, accessories
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etc. for indication , alarm and interlocking purposes if necessary. In area where
is specified , and door interlocking facilities to prevent the panel door from being
opened to access to the MCCB in closed position , shall be provided .
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4.2 .11 Where used as incom ing feeder from supply source (either from transformer
and/or generator set), they shall be of 4 pole type .
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4.3 MINIATURE CIRCUIT BREAKERS

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4.3.1 Miniature Circuit Breakers (MCB) shall be of the type approved by Suruhanjaya
Tenaga and JKR.
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4.3.2 Unless otherwise indicated in the Drawi ngs and/or Bill of Quantities , (MCB)
shall have breaking capacity not less than 6kA (rms) and of C-type with Class 3
energy limiting characteristics. They shall comply with MS IEC 60898-1 and/or
MS IEC 60898-2 , fu lly tropicalised and suitable for use on a 230/400V, 50Hz.
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a.c. system and up to an ambient temperature of 40°C.

4.3.3 They shall be quick-make, quick-break and trip free type complete with de-ion
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arc interrupters. The tripping elements shall be of thermal magnetic type with
inverse time delay overcurrent and instantaneous short circuit characteristic.
The response to overload shall be independent of variations in ambient
temperature.
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4.3.4 They shall be manually operated by means of toggle type handles having visual
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indication of whether the breaker is opened, closed or tripped. Multipole MCB

shall be of all pole protected type and provided with common-trip mechan ism
fo r simultaneous operation of all the poles.
4.3.5 Where used as incomer, they shall be of 2 pole type.

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4.4 RESIDUAL CURRENT DEVICE
4.4.1 Residual Current Device (RCD) shall be of the type approved by Suruhanjaya
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Tenaga and JKR.
4.4.2 RCD shall be residual current operated circuit breakers without integral
overcurrent protection (RCCB) and residual current operated circuit breakers
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with integral overcurrent protection (RCBO) shall be current operated
functionally independent of line voltage type, suitable for use on a 230/400V ,
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50Hz. a.c. system and up to an ambient temperature of 40°C. RCCB shall
comply with MS IEC 61008 -1 and MS IEC 61008-2-1 and RCBO shall comply
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with MS IEC 61009-1 and MS IEC 61009-2-1. They shall be of either two-pole
or four-pole type as indicated in the Drawings andlor Bill of Quantities. The
rated current and the rated residual operating current of the RCCB or RCBO
shall be as specified in the Drawings andl or Bill of Quantities. Rated conditional
short circuit current (Inc) shall be of minimum 6kA. For RCBO , protection
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against overcurrent shall of C-type with Class 3 energy limiting characteristic
complying with MS IEC 60898-1 and MS IEC 60898-2. The breaking capacity
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shall not be less than 6kA.
4.4 .3 RCCB and RCBO shall provide resistance against nuisance tripping due to an
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impulse voltage or transient overvoltage.
4.4.4 RCCB and RCBO shall be A or AC type unless otherwise specified .

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4.4.5 Test push button and visual indication for 'ON' and 'OFF' or 'j' and '0 ' shall be
provided. They shall be equipped with screw clamping type of cable terminals,
which shall be covered by moulded phonolic plastic with knockouts for cable
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entry.
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4.5 FUSE SWITCHGEARS
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4.5.1 Fuse-switch disconnector and swilch-disconnector fuse shall be of totally
enclosed,flush or surface mounting, double air break, quick-make and quick- break
type complete with phase barriers and fully comply with MS lEG 60947-1 and MS lEG
60947-3. They shall be of utilization category AG-23A. They shall be equipped with
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operating handle, position ON-OFF indicator and mechanical door interlock to prevent
the cover from being opened with the switch closed and the switch being closed with
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the cover opened. However this interlock shall be able to be defeated by competen t
person for maintenance purpose. Terminals and fuses shall be minimum IP20. The
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doors shall be provided with dust seal.
4.5.2 They shall be equipped with replaceable HRC fuses. The fuse holder shall have
shrouded base contact with provision for busbar mounting and front wiring. The fuse
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links and fuse carrier shall comply with relevant parts of MS lEG 60269. Suitable
knockouts shall be provided for cable entry.
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4.6 ISOLATING SWITCHES

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4.6.1 Isolating switches or switch-disconnector shall be of metalclad or high impact

insulating material (e.g. polycarbonate) type. They shall fully comply to MS lEG 60947-
1 and MS lEG 60947-3. The degree of protection shall be IP54 for indoor installation
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and IP65 for outdoor installation. They shall be able to operate continuously at full
current rating without de-rating , capable of making and breaking currents under normal
condition and when in open position , providing isolation from source of electrical
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energy for reasons of safety.

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4.6.2 They shall be quick-make, quick-break type suitable for use on 230/400V, 50Hz. a.c.
system and shall have pad locking faci lities to secure against unauthorised operation.
They shall be provided with removable top and bottom end plates or knockouts for
cable entry. The enclosure , the isolating mechanism and all other accessories shall be
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from the same manufacturer.

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4.6.3 The enclosure for metalclad type shall comprise of heavy gauge steel plates rust
protected and finished grey stove enamel. Front access doors for metalclad type,
which is detachable, shall be fitted with dust-excluding gasket and shall be interlocked
to prevent opening when the switch is 'ON'. However this interlock shall be able to be
defeated by competent person for maintenance purpose. It shall be provided with, if
required , facilities for lock-on and lock-off the operating handle.

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4.7 CONTACTORS
4.7.1 Contactor shall have the number of poles as specified in the Drawings and/or Bill
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of Quantities. They shall comply with IEC 60947-1 and 60947-4-1. They shall be
fully tropicalised , suitable to be used up to an ambient temperature of 40 ' C and
suitable for use on 230/400 V, 50 Hz. a.c. supply system.
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4.7 .2 The contacts shall be of quick-make and quick-break type, dust-proof and rust
protected. They shall be of utilization category as per Table 4A.
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Utilization
Current Cateqory Typical Applications
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AC-1 Non Inductive or slightly inductive loads, resistance furnaces , heater
AC-2 Slip-ring motors: switching off
Squirrel-cage motors: starting, switching off motors during running
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AC-3
Most tVDical industrial aDDlication
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AC-4 Squirrel-cage motors: starti ng , *plugging 1, *inch ing 2
AC-5a Switching of electric discharge lamps
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AC-5b Switching of incandescent lamps

AC
AC-6a Switching of transformers
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AC-6b Switching of capacitor banks
AC-7a Slightly inductive loads in household appliances : mixers, blenders

AC-7b Motor-loads for household applications: fans, central vacuum
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() I Hermetic refrigerant compressor motor control with manual resetting

AC-8a
overloads
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I Hermetic refrigerant compressor motor control with automatic

AC-8b
resettina overloads
*( 1) Plugging - Stopping a motor rapidly by reversing the primary power connections.
*(2) Inching - Energizing a motor repeatedly for short periods to obtain small
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incremental movements.
Table 4A - Utilization Categories
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4.7.3 The contactor shall have multiple auxiliary contacts, and unless otherwise
specified shall be normally-open.

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4.8 AUTOMATIC TRANSFER SWITCHING EQUIPMENT

4.8.1 The automatic transfer switching equipment (ATSE) shall comprise of a transfer
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switching device and a necessary monitoring and transfer control device for
monitoring supply circuits and for transferring load circuits from the normal supply
to an alternative supply in the event of a monitored supply deviation and
automatically returning the load to the normal supply when it is restored .
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4.8.2 ATSE shall be of utilization category AC 33B and shall comply to MS IEC 60947-
1 and IEC 60947-6-1 .
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n 4.8.3 Unless otherwise specified, the operating mechanism of the ATSE shall be
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reliably, electrically and mechanically interlocked to prevent simultaneous
connection to both normal mains and alternative supplies.
4.8.4 Unless specified otherwise in the Bill of Quantities andlor Drawings, the transfer
switching device of an ATSE shall be of automatic changeover contactors Class
A
CC type in accordance with IEC 60947-1 and IEC 60947-4.The automatic
changeover contactors shall be bar mounted type with fi xed bar and moving
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shaft made of steel and bearing supports made of aluminiumlbronze alloy. They
shall be of double air-break, quick-make and quick-break type complying with
MS IEC 60947-1 and IEC 60947-4-1 . They shall be dust-proof, nust protected ,
fully tropicalised and suitable for use on 230 VI400 V, 50 Hz A.C. system.
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4.8.5 The operating coil shall be 230 VI400 V 50 Hz A.C . type and shall operate
satisfactorily when the voltage at the coil terminals is between 85% and 110%
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of the nominal voltage. The electromagnet shal l be of laminated type.
4.8 .6 The automatic changeover contactors shall be four pole type. Each pole shall
comprise three main parts : -
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4.8.6 .1 The main contacts shall be of 'butt-contact' pattern without sliding

or rolling and shall operate with absolute minimum contact bounce.
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4.8.6 .2 The blowout coil sha ll be rated to carry the total current flowing
through the main pole and according to the thermal rating of the
contactor.
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4.8.6.3 The arc chute shall be De-ion type or the type having 'arc 'sp litt e~
for rapid extinction of electric arc. Each arc chute shall have a
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steatite disc on its internal faces for preventing rapid erosion of the
chute by the effect of arcs . The arc chutes shall be easily removable
to allow inspection of the main contacts and where necessary their
replacement.

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4.8.7 The main contacts sha ll able to carry continuously the rated current, capable of
making and withstanding short-circuit currents without damage in an enclosure
having an ambient temperature up to 40 DC.
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4.8.8 Unless otherwise specified, a minimum of four normally close and four normally
open auxiliary contacts shall be provided .
4.8.9 A transparent protection screen of full compartment size shall be provided in front
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of the automatic changeover contactors.
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4.8.10 For Class CB where the circuit breakers are specified as transfer switching
devices, the circuit breakers shall comply with MS IEC 60947-1 and MS IEC
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60947-2. Unless specified otherwise , the rated short-time withstand current shall
be of the same rating for the circuit breaker receiving supply from the Licensee or
Supply Authority.
4.8.11 For class PC, the ATSE shall comply with MS IEC 60947-1 and MS IEC 60947-
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6-1.The ATSE shall be of open transition (break -before-make) type or closed
transition (make-before -break) type according to the application stated on the
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design. Unless there is no type specified, all ATSE shall be of open transition
type.
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4.8.12 ATSE shall have the overlapping neutral feature during synchron izing and
changing over from normal mains supply to an alternative supply and vice versa .
4.8.13 ATSE shall be complete with a monitoring and transfer control device for
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monitoring supply circuits and for transferring load circuits from the normal mains
supply to an alternative supply in the event of a monitored supply deviation and
automatically returning the load to the normal mains supply when it is restored.
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4.8.14 The monitoring and transfer control device shall be of microprocessor based
C) controller comprising automatic transfer switching module or combination of
automatic transfer switching module and automatic mains failure module.
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5.0 PROTECTION RELAYS
5.1 The protection device shall provide either instantaneous or inverse time lag
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characteristics in the overload range and instantaneous with or without time
delay in the short circuit range as specified in the Drawings and/or Bill of
Quantities. The protection device shall be of the type acceptable to the Supply
Authority or Licensee and JKR. The protection relays shall be of panel flush
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mounting type. All relays shall comply with relevant parts of IEC 60255.
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5.2 Overcurrent and earth fault protection shall be provided by externally
() connected current transformers .
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5.3 Unless specified in the drawing and/or Bill Of Quantities, electromechanical
overcurrent and earth fault relay shall be of Inverse Definite Minimum Time
(IDMT) type.
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5.3.1 For overcurrent relay of IDMT induction disc type , current settings shall
be from 50% to 200% of rated current adjustable in seven equal steps
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and time multiplier settings from 0.1 to 1.0 adjustable continuously.
5.3.2 Earth fault relay of IDMT induction disc type shall have current settings
from 10% to 40% of rated current adjustable in seven equal steps and
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time multiplier settings from 0.1 to 1.0 adjustable continuously.
5.4 Earth leakage relay (ELR) shall be of the type suitable for use on a 230/400V,
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50Hz system and up to ambient temperature of 40 DC. ELR shall be provided

with test button for simulation of a fault, earth leakage , LED indicator, a reset
button , protection against nuisance tripping due to transient voltage and d.c.
sensitive. Unless otherwise specified in the Drawings and/or Bill of Quantities,
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ELR shall be of adjustable current sensitivity and adjustable time delay type .
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5.5 The selectivity range for current sensitivity shall be 0.03A to 10A and the time
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delay selectivity range of 0 second to 1 second . ELR shall be incorporated with

matching balanced core current transformer and shunt trip coil for the circuit
breaker to which it controls the tripping shall also be provided .
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5.6 Unless specified in the Drawings and/or Bill of Quantities, the microprocessor
based protection relays shall be rated at 230V/400V and operating voltage
shall be in a range from 90V to 250V. The relays shall be housed in robust
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panel fiush mounting case and shall be fully tropicalised and suitable to be
used up to an ambient temperature of 50 °C and relative humidity of 95%.
5.6.1 Unless otherwise specified , the microprocessor based protection relays
shall be of combined three phase over current and earth-fault
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protection with instantaneous, definite time and inverse time
n characteristics. Time / current chara cteristic of IDMT overcurrent and
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earth fau lt relays shall be of standard inverse curve (3/10).
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5.6.2 The microprocessor based protection relays shall give numerical digital
readout of set values, actual measured values and recorded values.
The relays shall include a serial communication port for external
connection to facilitate external reading, setting and recording of relay
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data and parameters by a personal computer (PC). PC connecting
cable and parameter reading/setting /recording PC program shall be
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provided.
5.6 .3 The microprocessor based protection relays shall be incorporated with

built-in self-supervision system with auto-diagnosis. The self-
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supervision system shall continuously monitor the relay microprocessor

programs. If a permanent fault is detected, an alarm indication shal l be
given . A 230V/5A alarm contact for connection to external alarm shall
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be provided .
5.6.4 If current and voltage measurements are specified , the microprocessor

based protection relays shall make available these measurements for
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l ) local display. The measurements shall include phase currents, phase-

to-phase voltages and phase-to neutral voltages.
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5.6.5 The microprocessor based protection relays shall comply with relevant
parts of IEC 60255 and shall also comply with relevant parts of IEC
61000 on electromagnetic compatibility.
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6.0 MEASURING INSTRUMENT AND ACCESSORIES
6.0.1 Measuring instrument and accessories shall comply with the relevant IEC
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Standards . They shall meet the requirement as specified in the Drawings
andl or Bill of Quantities.
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6.1 MEASURING INSTRUMENT
n 6.1.1 Measuring instrument shall be of panel flush mounting type with square
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escutcheon plate finished matt black and pressed steel case . They shall be of
industrial grade type adequately shielded against stray magnetic fields,
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conform to the measuring scales and arrangements as shown in the Drawings
and calibrated for correct read ings. They shall comply with MS 925 and
relevant parts of IEC 60051. External zero adjustment shall be provided for
ammeters and voltmeters.
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6.1.2 Ammeters, unless otherwise specified , shall be of moving iron type having
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continuous overload capacity of 120% of rated value and full scale value
accuracy of ±2%. They shall be provided with maximum demand indicator, if
specified.
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6.1.3 Voltmeters shall be of moving iron type having overload capacity of 200% of
rated value and full scale value accuracy of ±1 .5%.
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6.1.4 Kilowatt-hour meter shall be of 6 numbers wheel cyclometer aluminium type

with both the current and voltage coils on laminated cover fabricated from high
quality silicon steel strip. They shall have overload capacity of 200% of rated
value and accuracy of ±0.5% at the supply voltage and frequency
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u 6.1.5
characteristic.
Power factor meters shall be of balanced type using ferrodynamic, cross-coiled

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mechanism with measuring range from 0.5 lagging to 0.5 leading. Full scale
value accuracy shall be ±1.5%.
6.1.6 Frequency meters shall be of reed type with frequency range from 45Hz. to
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55Hz. and accuracy of ±5%. If specified in the Drawings andlor Bill of

Quantities, the microprocessor based power meter shall be rated at 230V/400V
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and operating voltage shall be in a range from 90V to 265V.

© Hak Cipta: 1999 Cawangan Kejuruteraan Elektrlk, JKR Malaysia
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6.1.7 The meters shall be housed in robust panel flush mounting case and shall be
full y tropicalised and suitable to be used up to an ambient temperature of 50°C
and relative humidity of 95%. The meters shall give direct numerical digital
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readout of actual measured values and recorded values. The meters shall
include one serial communication port for external connection to facilitate
external reading and recording of meter data and parameters.
6.1.8 The measurements and their accuracy of the microprocessor-based meters
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shall be as per Table 6A: -
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Parameters I measurements Accuracy
Volts (V): line-line I line-neutral 0.5% of readinQ + 2 diQit
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Currents (A): per phase 0.5% of readinQ + 2 diQit
Frequency (Hz) 0.1 Hz + 1 diqit
Power Factor: total 1% of readinq + 2 diQit
Active Power (kW): total 1% of reading + 2 digit
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Reactive Power (kVAr): total 1% of reading + 2 digit
Apparent Power (kVA): total 1% of readinq + 2 diqit
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Active Enerqy (kWh): total 1% of reading
Reactive Energy (kVArh): total 1% of reading
Maximum Demands (A, W, VA): total 1% of reading ± 2 digit
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Table 6A: Accuracy of Microprocessor-based Meter
6.1.9 If harmonics content measurement is specified, individual and total harmonics

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distortion on the cu rrent and voltage up to 30 th harmonic shall be measured

with the accuracy of 1% of reading.
6.1.10 There shall be a custom display screen, whi ch can be programmed to display
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customised specific parameter requirem ents .
6.1.11 All data shall be continuously and concurrently logged , recorded and stored in
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internal non-volatile memory. All time base logged-in data can be retrieved and
downloaded to a personal computer (PC) using serial communication port. PC
connecting cable and data retrieving PC program shall be provided.
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6.1.12 The meters shall comply with IEC 60359 and IEC 60688. The meters shall also
comply with relevant parts of MS IEC 61000 on electromagnetic compatibility.
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SPECiFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION

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6.2 CURRENT TRANSFORMERS
6.2.1 Current transformers shall comply fully with MS 1202 and IEC 60044-1 and
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shall have short time rating not less than that of the switchboard in which they
are incorporated. The secondary shall be rated for 5A. They shall be
adequately rated in VA to carry the summation of all VA burdens of the
connected loads but in any case. the rating shall not be less than 15VA. They
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shall be capable of withstanding, without damage, on open circuit secondary
with fu ll primary current.
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()
6.2.2 They shall be constructed from high quality silicon steel core. They shall be
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installed inside the switchboard in such a way that it is easily accessible for
maintenance purpose. Identification labels shall be fitted giving type, ratio,
rating , output and serial numbers.
6.2.3 Unless otherwise specified, current transformers used for measuring and
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metering shall be of Class 1.0 accuracy and those used for protection shall be
of Class 1OP1 0 accuracy.
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7.0 SURGE PROTECTIVE DEVICE
7.1 The surge protective devices (SPDs) shall be one-port type compatible with the
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230/400V. 3 phase, 4 wire, 50Hz with solidly earthed neutral supply system it is
protecting. The SPDs shall be of the type complying with MS lEG 61643-1 , MS
lEG 61643-12 and IEEE Std G62.41.2 and in accordance with
recommendations of MS lEG 62305 and the relevant parts and sections of MS
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lEG 60364.
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7.2 If the specifications conflict in any way, with any or all of the above/ standards,
the specification shall have precedence and shall govern.
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7.3 The SPDs shall be designed for the average isoceraunic level of approximately
200 thunder-days per year.
7.4 The SPDs modes of protection shall be each phase-to-neutral (L-N) , each
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phase-to-earth (L-E) and neutral-to-earth (N-E) for either single phase or three
phase supply system.
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7.5 The SPDs shall be of voltage limiting type with metal oxide varistors (MOVs) , or
voltage switching type with gas discharge tube (GDT)/spark gap , or
combination type with MOVs and GDT/spark gap. MOVs and GDT shall comply
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with MS lEG 61643-331 and MS lEG 61643-311 respectively.
7.6 The maximum continuous operating voltage (Uc) of SPDs shall be minimum
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275V for SPDs connected between L-N and L- E. When SPDs connected
between N-E, the rating of Uc shall be minimum 230V. The continuous
operating current (Ic) for each mode of protection shall not exceed 3mA. In the
case where the MOVs are used , the SPDs shall be provided with integrated
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thermal protection to avoid thermal runaway due to degradation.

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CKE.LS.01.01.(04).2017
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7.7 The SPDs to be installed with respect to the location of category shall be as in
Table 7A. The maximum discharge current (Imax) of SPDs shall be declared by
the SPD manufacturer by submitting the V-I characteristic of a MOVs / GOT /
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spark gap.
7.8 The SPDs shall be equipped with visual indicator showing the protection status
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of the SPDs. Unless otherwise specified , SPDs shall be provided with auxiliary
contact for connection to remote monitoring of SPDs protection status. A
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durable label with red lettering on a white background with words as stated
below shall be fastened externally on the front cover of the SPDs compartment.
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AMARAN
1. Pemasangan ini dilindungi oleh Surge Protective Device (SPD).

2. SPD tidak lagi berfungsi apabila "petunjuk" bertukar warna
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/ tidak menyala
3. Sila buat pemeriksaan pada SPD secara bulanan
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4. Sila hubungi 'orang kompeten' untuk penggantian SPD.
5. Pastikan juga 'circuit breaker' ke SPD sentiasa berada
dalam keadaan ON (I).
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7.9 The size of connecting conductors shall be as recommended by the SPD

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manufacturer. The connecting conductors shall be as short as possible

(preferably not exceeding 0.5m for the total length) and shall be tightly bound
together throughout the whole length with cable-ties or other approved means .
Either a MCCB or a fuse of rating as recommended by the SPD manufacturer
shall be provided for disconnecting the SPDs from the system in the event of
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\) SPDs fai lure or for maintenance. In the case where an MCCB is used , the
breaking capacity of the MCCB shall comply with the rated ultimate short circuit
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breaking capacity (I,, ) for the switchboards and DB respectively. The Ics shall
be 50% of the I" .
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SPECIFICAnON FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLAnON

© Hak Clpta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia
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MaXimum
1.2/50 ~s (Uoc) 8/20 ~s ( I ~ ) Voltage Discharge
Location Category Voltage Current Protection Level Current, Imax
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Generator Generator (Up) (8/20 ~s) per
mode
Main Switchboard
~ 20 kV ~ 10 kA ~ 1800 V ~65 kA
(MSB)
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Sub-Switchboard
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(SSB) receiving
( ) energy from MSB ~ 10 kV ~ 5 kA ~ 1500 V ~40 kA
tocated in the
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same building
SSB receiving
energy from MSB
located in other ~ 20 kV ~ 10 kA ~ 1800 V ~65 kA
A
building
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Distribution Board
(DB) receiving
energy from SSB
located in the
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same building ~ 6 kV ~3 kA ~ 1200 V ~ 20 kA

(for cases where
the SSB located in
the same building
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with MSB)
Distribution Board
(DB) receiving
energy from SSB
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located in the
same building ~ 10 kV ~ 5 kA ~ 1500 V ~40 kA
(for cases where
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the SSB located in

other building with
MSB)
DB rece ivi ng
energy from the
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licensee or ~ 20 kV ~ 10 kA ~ 1500 V ~40 kA

MSB/SSB located
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in other building
Socket Outlet or
Terminal ~ 2 kV ~ 1 kA ~ 500 V ~ 10 kA
Equipment
Table 7 A - SPOs Location Categories

CKE.LS.01 .01.(04).2017
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Date: Jan 2018
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8.0 BUSBARS TRUNKINGS
8.1 Busbar Trun kings System (busduct) shall comply with MS IEC 60439-2 , pre-
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assembled , totall y enclosed type and shall be as specified in the Drawings
andl or Bill of Quantities .
8.2 The insulation of the busbars in busduct shall be one of the fo llowing types as:-
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8.2.1 Air Insulated
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8.2.2 Resin Encapsu lated Insulated
8.2.3 Epoxy Insulated
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8.2.4 Polyester Film minimum Class B Insulation
8.3 Bu sbar tru nkings shall be suitable fo r operation on a 400 V, 3 phase, 4 wire,
50Hz. system with solidly earthed neutral. The rated short-time withstand
current, Icw shall be tested for 1 second as specified in MS lEG 60439-1.
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8.4 The neutral busbar shall be of the fu ll size as the phase busbars.
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8.5 The housing shall be of galvanised sheet steel of not less than 1.5mm
thickness finished with epoxy dry-powder and oven baked enamel grey. Fire-
resisting barriers shall be included as an integral part of each bus duct length
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and fitting. The maximum length of the busduct shall be not more than 3000mm
and the tap-off openings for plug-in units shall be provided at every interval of
not more than 900mm. Unless otherwise specified , the degree of protection
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shall be IP42 for indoor installation and IP65 for outdoor installation in
accordan ce to MS IEC 60529.
8.6 Busbars shall be of hard drawn tinned high conductivi ty copper to BS EN

13601. The busbar current ratin g shall not be less than that specified in the
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drawing based on current density as per table 8A below. The busbars shall be
fully insulated over its entire length except joint parts and totally enclosed in the
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housing . The insu lation shall be seamless and also be flame-retard ant. Earth
continuity of the busduct shall be provided by continuous length of copper strip
of dimension not less than 25mm x 3mm fitted on both external sides of the
busduct.
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Maximum Allowable
Current Rating (I) Current density
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(Nmm')
I " 600A 2.67
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600A < I " 1800A 2.42
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1800A < I " 2000A 2.33
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I >2000A 2.0
Table 8A : Current rating and current density for busbar trunking

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8.7 The plug-in unit shall be mechanically interlocked with the busway housing to
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prevent installation or rem oval of plug-in unit while the switch in ON position.
Plug-in unit enclosures shall make positive earth connections to the busduct
housing before contacts are made wi th the busbars .
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8.8 Expansion joints shall be provided for every interval of 3000mm at maximum ,
and at the end of busduct end box unit shall be provided . Busduct joints shall
have sufficient contact length of adjacent sections so as to provide rigidity and
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strength. A spring material shall be used in jointing so as to ensure a constant

contact pressure. All joint units, tee and elbow units, offset and combination
elbow units, flang ed end-feed units, expansion joint units and end joint units for
the busduct system installation shall be the type manufactured and supplied by
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the same busduct manufacturer.
8.9 The busduct system shall be supported rigidly and adequately by external
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spring hangers mounted on channel base. The busduct system shall be

supported at maximum intervals of 3000mm for vertical runs and 1500mm for
horizontal runs so that the busduct will not be in contact with the wall or fioor
slab surfaces . The spring hangers shall be supplied by the busduct
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manufacturer.
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8.10 The floor openings and wall openings where busduct passes through shall be
sealed with fire-resisting barrier approved by Jabatan Bomba Dan Penyelamat
Malaysia, according to the appropriate degree of fire resistance.

CKE.LS.01.01.(04).2017
SPECIFICA nON FOR LOW VOLTAGE
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9.0 SYSTEM OF WIRING
9.0.1 The system of wi ring shall be either surface wiring , concealed wiring , surface
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condui t wiring or concealed conduit wiring as indicated in the Drawings andlor
Bill of Quantities. The wiring systems shall comply with MS IEC 60364-5-52. All
wiring shall be ru n neatly and in an orderly manner. They shall be routed
parallel to building wall and column lines in a coordinated manner with other
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services. The wiring throughout shall be on the 'looping-in system' and no 'tee'
or other types of joints are allowed . No reduction of the strands forming the
n
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conductors are allowed at all terminals. Multi strand conductors with a minimum
of 7 strands shall be used. All strands shall be effectively secured by approved
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means.
9.0 .2 Wiring which are not embedded in concrete or concealed behind plaster shall
be run in an accessible manner on the beams , underside of slabs or below
pipes, ducts , and downdrops shall be run on the surface of columns or walls.
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Concealed wiring shall be installed in such a way that plaster can be applied
over their thickness without being subjected to spalling or cracking. Cables
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serving different operating voltages and functions shall be segregated.
9.0.3 All cables shall be legibly marked on the external surface with at least the
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following elements; Manufacturer's identification, Voltage designation, Nominal

area of conductor and Standard Numbers. Standard colour coded cable shall
be used for three phase circuit to identify the phase conductors, neutral
conductor and protective conductor respectively. Opening on floor, wall or
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partition through which cable , trunking , condui t or other wiring passes through
shall be sealed according to the appropriate degree of fire resistance after the
installation . Chipping and cutting of concrete are not allowed unless otherwise
approved by the S.O .'s Representative.
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l ) 9.0.4 The Electrical Contractor is required to work in conjunction with the building
contractor for the provision of openings , trenches, core-holes, chases etc. as
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the building concreting work progresses. In steel frame structures, the wiring
system shall be rigidly and securely supported and fastened in place onto the
structural steel beams , purlins and columns by fasteners such as clamps, clips,
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anchors , straps , hangers , supports or similar fittings . The fasteners shall be

designed and installed as not to damage either to steel structures or wiring
system.
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CKE.LS .01.01.(04).2017
§ INTERNAL
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Date: Jan 2018
Page: S9 - 2 of 14
9.0.5 The fasleners sha ll be installed at intervals not exceeding 1000mm, and within
300mm of every outlet box, junction box, device box, cabinet or fitting .
Fasteners shall be of spring steel andlor galvanised steel , and where wires ,
rods or threaded rods are used with fasteners, they shal l be of rolled carbon
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steel. The fasteners shall be finished with zinc coatings to resist rusting .
Samples for the fasteners used shall be submitted to S.O.'s Representati ve for
approval before they are used. Unless otherwise approved by S.O.' s
Representati ve, no welding on andlor drilling holes into any members or
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components of the steel frame structures for the installation of fasteners are
n allowed .
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CKE.LS.01 .01.(04).2017
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Date: Jan 2018
Page: S9 - 3 of 14
9.1 TYPES OF CABLES
9.1.1 PVC INSULATED PVC SHEATHED CABLE
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9.1.1.1 PVC insulated PVC sheathed cables shall be of 300/500V grade to
MS 2112-3 and MS 2112-4 and 600/1000 V grade to MS 274. The
conductors shall be of stranded plain annealed copper to MS 69 and
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MS 280. The insulation shall be suitable for continuous operation at a
maximum cable temperature of 70°C and comply with MS 138.
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9.1.2 PVC INSULATED CABLE
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9.1.2.1 PVC insulated cable shall be of 4501750V grade to MS 2112-3 and
MS 2112-4 and 600/1000V grade to MS 274. The conductors shall be
of stranded plain annealed copper to MS 69 and MS 280. The
insulation shall be suitable for continuous operation at a maximum
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cable temperature of 70°C and comply with MS 138.
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9.1.3 XLPE/PVC CABLE
9.1.3.1 Cable shall be manufactured and tested in accordance to BS 5467 or

IEC 60502 and shall have high conductivity plain copper stranded
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conductors , insulated with cross-lin ked polyethylene (XLPE), suitable

for a voltage of 600/1000V laid together and bedded with extruded
PVC and sheathed with PVC.
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9.1.4 ARMOURED CABLE
9.1.4.1 PVC/SWAlPVC CABLE - Cable shall be manufactured and tested in

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\. ) accordance with MS 274 or BS 6346 and shall have high conductivity

plain copper stranded conductors insulated with PVC suitable for a
voltage of 600/1 OOOV laid together and bedded with PVC, armoured
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with galvanised steel wi res and sheathed with PVC .
9.1.4.2 XLPE/SWAlPVC CABLE - Cable shall be manufactured and tested in

accordance to BS 5467 or IEC 60502 and shall have high
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conductivity plain copper stranded conductors, insulated with cross-

linked polyethylene (XLPE ), suitable for a voltage of 600/1 OOOV laid
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together and bedded with extruded PVC, armoured with galvanised

steel wires and sheathed wi th PVC.

© Hak Cipta : 1999 Cawangan Kejuruteraan Elektrik. JKR Malaysia
CKE .LS .01.01.(04).2017
@ INTERNAL
(L-S1 )
Revision: 2
Date: Jan 2018
Page: 59 - 4 of 14
9.1.4.3 XLPE/AWAJPVC CABLE - Cable shall be manufactured and tested

in accordance to BS 5467 or IEC 60502 and shall have high
conductivity plain copper stranded conductors, insulated with cross-
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linked polyethylene (XLPE), suitable for a voltage of 600/1 OOOV laid
together and bedded with extruded PVC, armoured with aluminium
wires and sheathed with PVC.
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9.1.5 MINERAL-INSULATED CABLES
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9.1.5.1 Mineral-insulated cables shall be manufactured complying with IEC 60702,
IEC 60331 and BS 6387 Category C, Wand Z for electrical circuit integrity in
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case of fire. The cables shall have been tested to comply with IEC 60332-1
and 60332-3 for fiame retardance, and IEC 61034 for smoke obscuration. The
cables sha ll be halogen free with low organic content and do not release any
corrosive em ission when subject to fire conforming to IEC 60754-2. The
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cables shall be able to withstand a short circuit temperature of 280°C for 5
seconds. For general lighting and power points fina l circuits, un less otherwise
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specified, cables of 600V insulation grade may be used.
9.1.5.2 For main circuits and major power points , the cables used shall be of 1000
volt insulation grade. They shall be installed strictly in accordance with the
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manufacturer's recommendation and instruction. The mineral-insulated cables

shall be as specified:
9.1.5.2.1 Mineral-insu lated copper clad sheathed copper conductor

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(MICC) cables comprise of pressure packed magnesium oxide

insulation contained within a solid drawn ductile seamless
copper sheath with solid high conductivity copper conductors ; or
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CJ 9.1.5.2.2 Mineral-insulated mineral sheathed copper conductor (MIMS)

cables comprise of multi stranded high conductivity copper
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conductors wrapped with layers of glass mica composite tape

flame barrier and be insulated with a non-melt cross linked
mineral insulation and mineral sheathed.
9.1.5.3 Cables installed on walls shall be fixed by means of copper clips or copper
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saddles at appropriate spacing. The clips or saddles shall be secured by

means of brass screws. Where cables are installed on cable trays, they shall
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be clipped at appropriate spacing by means of copper saddles. The saddles

shall be secured by means of brass bolts and nuts. Where single core cables
are used on mu lti-phase distribution work, the cables shall be laid on their
phase groups whether flat or trefoil.

CKE.LS.01.01.(04).2017
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9.1.5.4 Where single core cables pass through ferrous or other magnetic materials,
the area surrounding the cables shall be replaced with non ferrous plate of
appropriate dimensions. Adequate bonding shall be provided where cables
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break formation to enter terminating positions. Minimum bending radius shall
be not less than 6 times the cable diameter and saddle spacing not more than
60 times the cable diameter or 500mm whichever is less.
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9.1.5.5 Connection to motors, generators, transformers and other similar equipment
n shall be by one of the two methods listed below: -
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9.1.5.5.1 The cable shall be clipped at the appropriate spacing up to a
point adjacent to the equipment and an unsupported
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antivibration loop shall be left in the cable.
9.1.5.5.2 The cable shall be glanded into a suitable terminal box adjacent
to the equipment and connection to the equipment being
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effected by means of mechanically protected flexible cable of
adequate cross sectional area.
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9.1.5.6 For mineral -insulated copper clad sheathed copper conductor (MICC) cables ,
termination shall be of cold seal type. Silicon rubber sleeve insulation shall be
used to replace copper sheath stripped off near the termination for
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temperature not exceeding 150· C. For temperature exceeding 150· C,

varnished glass sleeve insulation shall be used. Insulation and continuity tests
shall be carried out before and after the cable is terminated. The insulation
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test reading shall be ·infinity'. A blow lamp may be used for drying out cable
ends.
9.1.5.7 If it is impracticable to cut to waste , in which event the cable should be brought
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to cherry red heat at about 600mm from the end and moisture driven carefully
towards the cut end . It is absolutely essential that great care shall be taken to
maintain earth continuity when terminating the cables. Dirt and metallic
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particles in the compound and any loose traces of dielectric left at face of the
sheath after stripping shall be removed prior to sealing . Cold sealing
compound shall be forced down one side of the pot only until slightly
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overfilling in order to avoid trapping of air at the base of the pot and to ensure
that when the sealing disc is entered before crimping a completely solid
insulation barrier is effected.
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© Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik. JKR Ma laysia
CKE.LS.Ol .0l.(04).2017
ct:J INTERNAL
(L-Sl )
Revision: 2
Date: Jan 2018
Page: S9 - 6 of 14
9.1.5.8 All other necessary accessories such as tap-off units, joint boxes, brass
compress ring glands, screw-on brass pots, earth tail seals, coloured
sleeving for phase identification , cone shape beads, fibre disc, brass
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locknuts etc. required for the proper installation work, unless otherwise
approved by the S.O.'s Representative , shall be of the type manufactured by
the cable manufacturer.
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9.1.5.9 For mineral-insulated mineral sheathed copper conductor (MIMS)
cables, termination shall be metal gland or close fitting metal bush of
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crimping type . All other necessary accessories such as tap-off units, joint
( , boxes including termination kits etc. required for the proper
installation work, unless otherwise approved by the 8.0.'s
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Representative , shall be of the type manufactured by the cable
manufacturer. A
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CKE.LS.01.01.(04).2017
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Date: Jan 2018
Page: 59 - 7 of 14
9.2 WIRING IN CONDUITITRUNKING (SURFACE OR CONCEALED)
9.2.1 The cables used in conduit wiring, unless otherwise specified shall be similar to
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that described in 9.1.2 above . Unless otherwise specified in the Drawings
and/or Bill of Quantities, the conduits shall be of galvanised steel and conduit
fittings shall be of galvanised steel or alloy materials. Cables above false
ceiling shall be run in conduit or trunking .
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n 9.2.2 The conduit shall generally be run on the underside of the floor slab or
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suspended from the floor slabs by mild steel brackets or suspenders. The
trunking shall be suspended from the floor slabs or mounted against the wall by
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mild steel brackets. The mild steel brackets shall be anti-rust treated , painted
with a primer and finished in an orange enamel. The suspension structure shall
be robust in constructions and adequately installed such that the
conduitltrunking will not sag.
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9.2.3 Conduit for lighting point shall be terminated in a junction box complete with
die-cast cone-shaped metal cover so that downdrop to luminaire shall be
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carried out through flexible steel conduit up to the luminaire. Ceiling fan points
shall be run in the similar way. Flexible conduit shall be used for termination to
equipment, which are subjected to movement or vibration. However, the length
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of this flexib le conduit shall not exceed 400mm unless approved by the 5 .0.'s
Representative.
9.2.4 For concealed conduit wiring , a spare conduit shall be provided from the
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distribution board to the ceiling space for future extension. The spare conduit
shall be plugged at the cei ling end with removable plug . The number of cables
drawn into the conduit or laid in trunking shall be such that the ratio of the sum
of the overall cross-sectional areas of the cables (including insulation and any
I~)
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sheath) to the internal cross-sectional area of the conduit or trunking in which

they are installed shall not exceed 40% for conduit and 45% for trunking
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© Hak Cipta : 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia
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9.3 METALLIC AND NON-METALLIC CONDUITS
9.3.1 Steel conduits shall be of galvanised, heavy gauge, screwed type complying
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with MS 275-1, MS 1534:PT.1 , MS 1534:PT.2:Sec1 , IEC 60423 , IEC 61386-1
and IEC 61386-21. All steel conduit fittings shall comply with MS 275-2, MS
1534:PT.1, MS 1534:PT.2:Sec1 , IEC 61035-1, IEC 61035-2-1, IEC 61386-1
and IEC 61386-21. The steel conduits shall be fitted with brass bushes at the
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free ends and expansion devices at appropriate intervals. The ends of each
length of steel conduit shall be properly reamed. The termination to the
n
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distribution boards , consumer units, switchgears and outlet boxes shall be
effected by brass type smooth-bore bushes. All steel conduits shall be
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effectively earthed.
9.3.2 For laying underground , steel conduit shall be used and buried at a minimum
depth of 450mm below ground level or 100mm below floor slab or
hardstanding. Junction boxes, outlet boxes etc. shall be alloy material or cast
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iron. The covers shall be galvanised sheet steel or alloy material with thickness
not less than 1.2mm. Accessories such as junction boxes downdropping to
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luminaires shall have diecast cone-shaped metal cover.
9.3.3 For non-metallic conduits and fittings, they shall be of rigid high impact PVC
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grade Heavy Duty Code No 4421 and shall be under Product Certification
Scheme. The colour of the conduit for concealed wiring shall be of orange.
Unless otherwise for purposes of identification or distinguishing from another
services, white coloured conduit shall be used for surface wiring. Rigid high
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impact PVC conduits shall comply with MS 1534:PT.1, MS 1534:PT2:Sec1,

IEC 60614-1 , IEC 60614-2-2, IEC 60423, BS EN 61386-2, BS EN 50086-1 and
fittings shall comply with MS 1534:PT.1, MS 1534:PT2:Sec1., IEC 61035-1 and
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IEC 61035-2-2.
9.3.4 All fittings and accessories for the rigid high impact PVC conduits shall be
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made and supplied by the same manufacturer for the rigid high impact PVC
conduit. The ends of each length of rigid high impact PVC conduit shall be
properly reamed. The termination to the distribution boards (metal clad and all
insulated), switchgears and outlet boxes shall be effected by adaptors and
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lock-rings. Flexible metallic and non-metallic conduits shall comply wi th MS

1534:PT.1, MS 1534:PT2:Sec1, IEC 60614-1 , IEC 60614-2-5 and its fittings
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complying with MS 1534:PT.1 , MS 1534:PT2:Sec1, IEC 61035-1 and IEC

61035-2- 3.
9.3.5 The conduits shall be fixed by means of saddles secured rigidly at intervals not
exceeding 750mm , and within 300mm of every outlet box, junction box, device
box, cabinet or fitting. Steel saddles shall be used for steel conduits. Unless
otherwise specified, steel conduits and steel fittings shall be used.
SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLAnON

CKE.LS.01.01.(04).2017
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9.4 CABLE TRUNKING
9.4.1 Cable trunking system shall comply with MS IEC 61084. They shall be
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fabricated from galvanised sheet steel (electrogalvanised steel and/or hot
dipped galvanized steel) and finished with epoxy oven baked or two coats of
standard orange enamel. They shall be equipped with removable covers at
suitable intervals. They shall be supplied in lengths to suit the installation and
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shall have the minimum wall thickness as per Table 9A: -
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NOMINAL SIZE (mm x mm) MINIMUM WALL THICKNESS (mm)
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50 x 50 and below 1. 0
75x50t0100x100 1. 2
150 x 50 to 300 x 150 1.6

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Table 9A: Size and thickness for cable trunking
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9.4.2 All trunking elbows, offset and combination elbows, adaptors and tees shall be
of same thickness as the straight trunking and shall be the type manufactured
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and supplied by the same trunking manufacturer. The trunking shall be

supported by fixing brackets so that the trunking will not be in contact with the
walls or floor slabs . The brackets shall be installed at intervals not greater than
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1500mm for vertical runs and not greater than 1OOOmm for horizontal runs. The
brackets shall be derusted , finished in a primer and coated with standard
orange enamel.
9.4.3 Wherever the trunking passes through a floor or a fire resistant wall, fire
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( ) resisting barrier shall be provided. At these positions the cables shall be sealed
•
with non-hygroscopic fire resisting material of minimum 2-hour fire rating . In
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addition, the floor openings and wal l openings shall be sealed with similar type
of compound. Cables running in the trunking shall carry conductor identification
colours and shall be supported by split hard wood racks securely fixed at the
base of the trunking and spaced not more than 600mm apart.
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9.4.4 Cables for each final circuit shall be properly bunched togelher and labelled .
Where conduit is tapped off from the trunking , suitable brass type smoothbore
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bushes shall be fitted at all conduit termination. Unless otherwise specified , all
trunkings shall have either tinned copper tape of dimension not less than
25mmx3mm as circuit protective conductor or earth cable of appropriate size.
In the latter case, all trunking joints shall be bridged by means of tinned copper
tape of dimension not less than 25mm x 3mm.
9.4.5 For colour code identification bands can refer to table 98 of 9.7.2.

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9.5 CABLE TRAY
9.5.1 Cable tray system shall comply with M8 IEC 61537 and shall be fabricated from
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perforated galvanised sheet steel complete with all necessary bends, tee
pieces, adaptors and other accessories. The minimum thickness of the sheet
steel shall be 1.5mm for cable trays with widths up to and including 300mm and
2.0mm for cable trays with width exceeding 300mm. However minimum
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thickness for the sheet steel of the perforated hot dipped galvanised cable trays
n shall be 2.0mm. Cable trays may either be suspended from floor slabs by
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hangers or mounted on walls or vertical structure by brackets at 600mm
intervals.
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9.5.2 However where the above methods of installation are not feasible or practica l,
suitable floor mounted mild steel structures shall be provided. All supports,
hangers and structures shall be robust in construction and adequately installed
to cater for the weights of the cables and trays supported on them so that cable
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trays and cables will not sag. All supports, hangers , bracket and structures
shall be antirusted, finished in primer and coated with standard orange enamel.
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9.5.3 All supports, hangers , bracket and structure for the perforated hot dipped
galvanised cable trays shall also be of hot dipped galvanised type. Fixing clips
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and cleats for cables on trays shall be insta lled by means of bolts,washers and
nuts.
9.5.4 All tees, intersection units, adaptor units etc. shall be the type manufactured by
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the cable tray manufacturer un less otherwise approved by the 8.0.'s

Representative. Wherever cable tray pass through a floor or a fire resistant
wall, fire-resisting barrier as mentioned in 9.4.3 above shal l be provided .
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© Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malays ia
CKE.LS.01.01 .(04).2017
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Page: S9 - 11 of 14
9.6 CABLE LADDER
9.6.1 Cable ladder system shall comply with MS IEC 61537 and fabricated from mild
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steel and finished in hot-dipped galvanised complete with all necessary
horizontal elbow, horizontal tee, horizontal cross, reducer straight, outside riser,
inside riser, reducer left, reducer right, cable clamp , cantilever arm , hold down
clip/clamp, hanger bar, vertical splice plate and horizontal splice plate for
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welded type and screwed type. The minimum thickness of the sheet steel shall
be 2.0mm.
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( )
9.6.2 Cable ladder may either be suspended from floor slabs by hangers or mounted
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on walls or vertical structure by cantilever arm. Cable ladder shall be supported
rigidly and adequately by external spring hangers mounted on channel base.
The cable ladder shall be supported at maximum intervals of 3000mm for
vertical runs and 1500mm for horizontal runs so that the cable ladder will not
be in contact with the wall or floor slab surfaces. The spring hangers shall be
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supplied by the cable ladder manufacturer. All supports, hangers and
structures shall be robust in construction and adequately installed to cater for
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the weights of the cables and ladder supported on them so that cable ladder
and cables will not sag.
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9.6.3 Rungs shall be spaced at 300mm nominal centres, welded to the rail sections
by approved welding procedures . All rung s shall be perforated in accordance to
the manufacturer's design.
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9.6.4 The cable ladders shall be supplied fully assembled with preparations for
connections to straight sections or accessories using splice plates
mechanically bolted together. Allowance shall be provided for longitutional
adjustments and expansion. The cable ladders when completed shall be
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() smooth, free from all sharp edges and shall be capable of discharging any
water that may be retained due to normal weathering.
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9.6.5 All accessories shall be the type manufactured by the cable ladder
manufacturer unless otherwise approved by the S.O.'s Representative.
Wherever cable ladder pass through a floor or a fire resistant wall , fire-resisting
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barrier as mentioned in 9.4 .3 above shall be provided.

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CKE.LS.01.01.(04).2017
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9.7 IDENTIFICATION OF PIPELINES AND SERVICES
9.7.1 Unless otherwise specified elsewhere , basic colours for the identification of
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electrical conduits and trunkings and their coverings from other pipeli nes or
services shall be orange for electrical services in compliance with BS 1710. For
Extra Low Voltage Electrical Services, colour code indication band shall be
provided. The basic identification colour shall be applied by painting over the
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whole length of the conduits and trunkings and their coverings.
()
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9.7.2 However, if decorative colour white or other decorative colour is used for
exposed electrical conduits and trunkings and their coverings as specified
and/or as directed by S.O .'s Representative , then orange colour identification
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band shall be provided . In addition, for all Extra Low Voltage Electrical Services
and Information Communication Technology (ICT) works , colour code
indication bands shall be provided as in the Table 9B below.
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Conduit I Trunking Basic Colour Code
Contents Identification Ind ication Band
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Colour Band (Approx. 100mm)
(Approx. 150
mm)
Public Address I Sound
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Orange Crimson
Reinforced System
Intercom System Orange Emerald Green
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Nurse Call i Digital Call

Orange Salmon Pink
System
MATV I CCTV System Orange Yellow
Building Automation I
Orange Blue
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l ) Security System
Audio Video I Data I White I Emerald
Orange
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Multimedia Link System Green I white

Information
Communication White White
Technology (lCT)
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Telephone System White Green
Table 98 : Colour Code Indications For Extra Low Voltage Electrical

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Services And Information Communication Technology (ICT)

© Hak Cipta: 1999 Cawangan Kejuruteraan Etektrik, JKR Malaysia
CKE.LS.01 .01.(04).2017
..... SPECIFICATION FOR LOW VOLTAGE
rJJK!l
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INTERNAL
Revision: 2
Page: S9 - 13 of 14
9.7.3 Colour identification bands shall be provided on the conduits and trunkings and
their coverings as a band over a length of approximately 150mm. The bands
shall comply to table 9B.
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9.7.4 The colour identification bands and colour code indication bands shall be
applied by painting or adhesive colour bands at intervals not more than
1000mm along the conduits and trunkings and their coverings. They shall be
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provided at junctions, both sides of service appliance, wall/floor penetration and
any other place where identification is required and necessary.
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( ) The colour reference to BS 4800 shall be as in Table 9C below.
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Colour Colour Reference (BS 4800)
Orange 06 E 51
White 00 E 55
Crimson 04045
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Emerald Green 14 E 53
Salmon Pink 04 C 33
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Yellow 10 E 53
Blue 18 E 51
Table 9C: Colour Reference

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9.8 MOUNTING HEIGHTS
9.8.1 Mounting heights listed below shall be measured from the underside of the
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fitting to the finished fioor level. Unless otherwise specified or directed on site
by the S.O.'s Representative , heights of fi xing shall be as in Table 90 below: -
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Type of Fitting Mounting Height
(mm)
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Suspended ceiling luminaires and ceiling fans 2400
TE
Wall mounted luminaires and wall bracket fans 2050
Switches and fan regulators 1450
Socket outlets (for surface wiring), and those in
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the kitchen and washing areas (for concealed
wiring)
1450
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Socket outlets (for concealed wiring) 300

Isolator points 1450
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Window unit air conditioner switches and

starters
1450
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Cooker points 1450
Water heater outlet points. 1450

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Distribution boards (in service duct) 1450

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Distribution boards(other than in service duct) 2050
Table 90 : Mounting Height

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10.0 WIRING ACCESSORIES
10.1 SWITCHES AND SWITCH PLATES
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10.1.1 All lighting switches and fan switches shall comply with MS 616 and MS IEC 60669-1
and generally be flush type. All cei ling mounted cord operated switches shall be
completed with mounting block comply wi th MS IEC 60669- 1.
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10.1.2 All switches shall be suitable for use in inductive circuit. Unless otherwise specified in
n the Drawings and/or Bill of Quantities, they shall be rated at 10A. Samples of switches
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shall be submitted for approval prior to installation .
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10.1.3 Switches for lighting and fans shall generally be grouped as shown in the Drawings .
Where several switches are grouped together, grid switches shall be used unless
otherwise directed by the S.O.'s Representative. Each group shall be of different
phase and separated accord ing to the supply source. All groups appropriately
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labelled .
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10.1.4 Refer Table 10A below for colour scheme .
10.1.5 In areas where plate switches cannot be used , ceiling mounted cord operated
switches or architrave switches shall be provided as directed by the S.O.'s
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Representative.
10.1.6 Maximum allowable number of switches for switch plate of size 85mm x 85mm is four
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(4) and maximum allowable number of switches for switch plate of size 85mm x
140mm is eight (8). Brand name and model shall be embossed at the front part of the
switch plate.
l )
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10.1.7 For switches wi th built-in indicator light, the wiring for indicator light shall be
permanently terminated and shall not used the terminal for clamping external
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conductors.
10.1.8 The positions of all switches shown in the Drawings are only approximate. The
Electrical Contractor should check the exact positions of the switches with the S.O.'s
Representative, and confirm the arrangement of all door swings and other fixtures
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before installi ng downdrops and switches.

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10.1 .9 The circuit protective conductor of the circuit shall terminate directly at the earth
terminal of the mounting box (back box).

© Hak Cipta: 1999 Cawangan KeJu ruteraan Elektrik, JKR Malaysia
CKE.LS.01.01.(04).2017
rt:J INTERNAL
(L-S1)
Revision: 2
Date: Jan 2018
Page: S10 - 2 of 4
Connected From Normal Generator Set UPS
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Switched Rocker White Yellow Red
Socket
Outlets And
Face Plate White White White
Switches
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Unswitched
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() Socket
Outlets
Face Plate White Yellow Red
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Table 10A: Colour Scheme for Switches and Socket Outlet
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10.2 SWITCHED SOCKET OUTLETS AND UNSWITCHED SOCKET OUTLETS
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10.2.1 Switched socket outlets shall be shuttered, two pole or single pole switch and
earthing pin type. They shall be of flush type. Both 13A switched and unswitched
socket outlet shall be of the rectangular pin type complying with MS 589.
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10.2.2 15A switched socket outlets and unswitched socket outlets shall be of round pin
type and comply with MS 1577.
EN
10.2.3 Circuit protective conductor of the circuit shall terminate directly at the box used
for mounting switched socket outlet and unswitched socket outlet.
10.2.4 Refer Table 10A for colour scheme.

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10.3 BOXES FOR SWITCHES, SWITCHED SOCKET OUTLETS, UNSWITCHED

SOCKET OUTLETS AND DISTRIBUTION BOARDS (BOX AND
ENCLOSURE FOR ELECTRICAL ACCESSORIES)
ER
10.3.1 Generally the boxes shall comply with MS 1873, lEG 60670-1 , MS 589 and l or
MS 616.
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10.3.2 Unless otherwise specified, boxes used for mounting switch plates , switched
socket outlets and unswitched socket outlets in concealed conduit wiring shall
N
be metalclad type of minimum 0.8mm thick galvanised sheet steel. Earth
() terminal complete with cable lug and brass screw shall be provided . Gable for
bonding the box to switch, switched socket outlet and unswitched socket outlet
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shall be the same size as the circuit protective conductor.
10.3.3 For surface conduit wiring , boxes for switches, switched socket outlets and
unswitched socket outlets shall be of the type manufactured and supplied by
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the manufacturer of the switch plates , switched socket outlets and unswitched
socket outlets respecti vely.
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10.3.4 Switch plates, switched socket outlet and unswitched socket outlets shall be
fixed to the boxes by means of original flat base chrome screws.
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10.3.5 The installations of Distribution Boards on the walls (as classified according to
some parts of MS 1873, lEG 60670-1 ) shall comply with MS 1873 Part 24, lEG
60670-24. Flushed adaptable metal back box of minimum size 200mm(W) x
EN
100mm(H) x 35mm(D) shall be installed recessed behind Distribution Boards

for rewirebil ity.
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10.4 CEILING ROSES
ER
10.4.1 Ceiling Roses shall comply with MS 770. They shall be either surface of sem i-
recess type with the base having a minimum of three knockouts for cable
entries . The base shall incorporate clearly labelled clamp type terminals
suitable for holding phase, neutral , earth and loop-in cables in a distinct
D
manner. The cover plates shall be of the screw-in type. The base and cover
shall be moulded non-track urea to B5 1322.
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10.5 LAMPHOLDERS AND SA TIENHOLDERS
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10.5.1 Lampholders and batten holders shall comply with MS 769, MS IEC 60838, and
MS IEC 61184. They shall be supplied complete with brass plunger and heat
resisting springs to ensure that plunger pressure is maintained throughout the
long life of the lampholders and battenholders. Cordgrip shall be provided to
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cover the exposed ends of cord sheathing and firmly grips the cord. Batten
holders shall be of three clearl y labelled terminal type. Edison screw
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lampholders shall comply with MS IEC 60238.
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EN
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SPECIFICATION FOR lOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION

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11.0 LUMINAIRES
11 .0.1 The luminaires together with lamp, lamp holders, control gear and other
ER
associated accessories shall , as a minimum requirement, conform to the
relevant parts and/or sections of MS lEe 60598.
11.0.2 All luminaires shal l be full y assembled, completed with lamp, control gear,
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internal wiring etc. Internal wires shall be terminated in terminal blocks in an
approved manner. Wiring shall be of heat resistant insulated coloured cables.
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The terminal blocks shall be suitably rated and clearl y labeled for connection to
external wiring.
TE
11 .0.3 All metal parts of the luminaires shall be effectively earthed and supplied with
an approved earth termin al.
11 .0.4 All components of the luminaires shall be able to withstand a voltage range of
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+10% to -6% of the rated voltage.
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11 .0.5 All discharge type luminaires shall be power factor corrected to at least 0.9
lagging using dry type capacitor.
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SPECIFICATION FOR lOW VOLTAGE INTERNAL ELECTRICAL INSTAllATION

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11.1 FLUORESCENT LUMINAIRES
11.1.1 TUBULAR TYPE FLUORESCENT LUMINAIRES
ER
11 .1 .1.1 Fluorescent luminaires shall be of the type approved by Suruhanjaya Tenaga
and JKR.
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11.1 .1.2 Fluorescent lu minaires shall comply with MS IEC 60598-1 and MS IEC
60598-2-1 or MS IEC 60598-2-2.
n
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11 .1.1.3 Fluorescent luminaires shall have housing made from good quality mild steel
sheet of minimum thickness 0.50 mm and shall be of sound and rigid
TE
constru ction suitable for suspended and surfaced mounted installation. The
metalwork shall be rust inhibited to prevent corrosion and, unless otherwise
approved by the S.O.'s Representative, shall be sprayed with an undercoat
of zi nc chromate primer and finished with two coatings of super white baked
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enamel.
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11.1.1.4 Wiring within the luminaire shall be carri ed out with heat resistant cable
marked with the word "HR 105° C ". It shall be done in a neat way with
holder to hold the cable in position and also to avoid contact witn heat
producing components. Cables shall be termin ated in a termin ation block
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marked "L" and "N" for connection to the incoming wires. A brass direct
pressure type earth terminal shall be provided in the casing near the
termination block for earth connection. This earth terminal shall be clearly
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marked with the standard earth terminal symbol.
11 .1.1.5 All components in the luminaire shall be guaranteed for a minimum of 2000
hour life. All components in the fluorescent luminaires shall be
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(, ,- ) manufactured by the manufacturer or being supplied by others. The

components shall be marked with "made for" if supplied
by other manufacturer except high freq uency electronics ballast if
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specifi ed, fluorescent tube, starter, cable and holders for fluorescent tube
and starter. The components shall be of the type approved by Suruhanjaya
Tenaga and JKR.
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11 .1.1.(a) TUBULAR TYPE FLUORESCENT LUMINAIRES T8 (FD 26)
11.1 .1.(a).i The electromagnetic ballast shall comply with MS IEC 61347-1,
ER
MS IEC 61347-2-8 and MS 141:PT.2. The ballast shall be of the
type approved by Suruhanjaya Tenaga and JKR. Unless
otherwise specified , they shall be polyester resin impregnated,
silent operation type filted wi th terminal block for easy wiring.
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For 18 walts and 36 walts fluorescent tubes, the walt loss of
the ballast shall be 6 watts . The mounting of the ballast shall
N
be in such a way that easy dismantling and replacement can
be effected within the casing.
TE
11 .1.1.(a).ii The fluorescent luminaires shall be power factor corrected to
at least 0.9 lagging .
11.1.1.(a).iii The capacitor shall comply with MS IE C 61048 and MS IEC

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61049 and shall be of dry, self-healing, aluminium metalised
polypropylene type. Proper tool cli p shall be provided to hold
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the capacitor in position .
11.1.1.(a).iv The starter shall comply wi th MS IEC 60155 and the starter
holders comply with MS IEC 60400. For the single channel
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luminaires, the starter shall be fitted at the side of the casing.

In cases where starters are to be fitted from the outside of the
luminaire casing , the starter holders shall be installed in such a
EN
way that the starters shall not protrude out of the casing by
more than 10mm. .
11.1.1 .(a).v In the case where high frequency electronics ballast is

specified , the ballast shall be of type approved by Suruhanjaya
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Tenaga and JKR. The ballast shall comply to MS IEC 61347-1 ,

~ ) MS IEC 61347-2-3 and MS IEC 60929, BS EN 55015 for radio
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frequency interference suppression and MS IEC 61000-3-2 for

harmonics distortion. They shall be of preheat start, non-
dimming , low in-rush starting current and low leakage current
type. Rated maximum operating temperature of a ballast case
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shall not exceed 70 aC. The Ballast shall be rated a minimum

Energy Efficiency Index Classification (EE l) of A2 as per
CELMAIELC Guide.
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CKE.LS.01.01.(04).2017
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11.1.1 .(a).vi Harmonics distortion shall be within the limits in accordance

with MS IEC 61000-3-2. However, total harmonics distortion
shall be less than 2S% where third harmonics component
ER
shall not be more than 1S%.The ballast shall operate and
maintain consistent light output over voltage variation from -
10% to +S% of the rated voltage and power factor of not less
than 0.9S. Overvoltage protection at 3S0 volts and automatic
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shutdown in the event of lamp failure shall also be
incorporated. The electronic ballast shall have five year
N
warranty from the manufacturer.
11.1 .1.(a).vii The lamp holders shall comply with MS IEC 60400 of robust
TE
and well designed construction suitable fo r bi-pin flu orescent
tubes. The lamp holders shall be made of polycarbonate
material. Lamp holders for use with electronic ballast shall be
rated minimum SOOV or higher than U-out rating of electronic
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ballast, (whichever is higher).
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11 .1.1 .(a).viii All fluorescent tube shall be provided with its own ballast
(except for electronic ballast).
11.1.1 .(a).ix Louvres and reflectors for the luminaires shall be made of
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high purity anodized aluminium with at least 99.8S% pure

aluminium with no iridescent mirror finished . The thickness of
the reflector shall be minimum OAmm and total light reflection
EN
of refl ector shall be minimum 86%.
11.1.1 .(a).x The pri smatic and opal diffuser shall be made of Ultra Violet
(UV) stabilised Flame Retardant Polyethylene Terephtalate
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Glycol (PETG ) or minimum UV-stabilised flame retardant

\ )
• material.
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11.1 .1.(a).xi Louvres , reflectors and diffusers shall give good even light
distribution with minimal glare in both the axial and transverse
planes . Photometric data for the lumi naires shall be made
available and submitted to S.O ."s Representatives when
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Page: Sll - 5 of 18
11 .1.1.(b) TUBULAR TYPE FLUORESCENT LUMINAIRES T5 (FDH 16)
ER
11.1.1.(b).i The high frequency electronics ballast shall be of type approved
by Suruhanjaya Tenaga and JKR. The ballast shall comply to
MS IEC 61347-1 , MS IEC 61347-2-3 and MS IEC 60929, BS
EN 55015 for radio frequency interference suppression and MS
IEC 61000-3-2 for harmonics distortion. They shall be of
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preheat start, non-dimming , low in-rush starting current and low
leakage current type. Rated maximum operating temperature of
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a ballast case shall not exceed 70°C. The Ballast shall be rated
a minimum Energy Efficiency Index Classification (EEl) of A2 as
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per CELMAIELC Guide.
11 .1.1.(b).ii Harmonics distortion shall be within the limits in accordance

with MS IEC 61000-3-2. However, total harmonics distortion
shall be less than 25% where third harmonics component shall
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not be more than 15%.The ballast shall operate and maintain
consistent light output over vo ltage variation from -10% to +5%
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of the rated voltage and power factor of not less than 0.95.
Overvoltage protection at 350 volts and automatic shutdown in
the event of lamp failure shall also be incorporated. The
M
electronic ballast shall have five year warranty from the

manufacturer.
11.1 .1.(b).iii The lampholders shall comply with MS lEG 60400 of robust and
EN
well designed construction suitable for bi -pin fluorescent tubes.

The lamp holders shall be made of polycarbonate material.
Lamp holders shall be rated minimum 500V or higher than U-out
rating of electronic ballast, (whichever is higher).
M
11.1.1.(b).iv Louvres and reflectors for the luminaires shall be made of

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high purity anodized aluminium with at least 99.85% pure

aluminium with no iridescent mirror finished. The thickness of
the reflector shall be minimum O.4mm and total light reflection
of refl ector shall be minimum 90%.
O
11.1.1.(b).v The prismatic and opal diffuser shall be made of Ultra Violet
(UV) stabilised Flame Retardant Polyethylene Terephtalate
D
Glycol (PETG) or minimum UV-stabilised flame retardant

material.

CKE.LS .01.01.(04).2017
rlJK!l
--.= .
INTERNAL
Revision: 4
Page: S11 - 6 of 18
11 .1.1.(b).vi Louvres, refiectors and diffusers shall give good

even light distribution with minimal glare in both the
ER
axial and transverse planes. Photometri c data for the
luminaires shall be made available and submitted to
S.O."s Representatives when required . For luminaires T5
cross louvre type, the Light Output Ratio (LOR) shall be
minimum 80%.
D
N
n 11.1.2 DOWN LIGHT TYPE COMPACT FLUORESCENT LUMINAIRES
TE
11.1.2.1 The luminaires shall be of type approved by JKR. The luminaires shall
comply with MS IEC 60598 and relevant part of IEC 60598 or equivalent.
11.1.2.2 The luminaires shall have two separate components comprising of an

electrical control gear and optical systems. The construction of the
A
luminaires shall be either in two separate housing/compartment or integral.
EJ
11 .1.2.3 Electrical control gear system comprises of ballast, capacitor etc. The optical
system shall incorporate a one piece full bowl reflector, lamp holder(s) etc.
Luminaires shall have either horizontal or vertical pin type lamp connection.
M
11 .1.2.4 The housing of the control gear system shall be made from extruded
aluminium or good quality mild steel sheet of thickness not less than 0.8
mm and shall be of sound and rigid construction suitable for suspended
EN
installation. The metalwork shall be rust inhibited to prevent corrosion. The

housing of the control gear system shall be coated by electrostatic powder.
The housing shall be provided with a mean to dissipate heal. Rubber
grommets shall be provided at cable entry.
M
11.1.2.5 Wiring within the control gear system shall be carried out with heat
l
resistant cable marked with the word 'HR 105 DC' . It shall be done in a neat
KU
way with holder to avoid contact with heat-producing components. Cables

shall be terminated in a termination block marked 'L' and 'N' for connection
to the incoming wires. A brass direct pressure type earth terminal shall be
provided in the control gear near the termination block for earth connection.
O
This earth terminal shall be clearly marked with the standard earth terminal
symbol. The HR 105 DC cable shall be used to connect the optical system
and the control gear system. It shall not be more than 300mm long . The
D
cables shall be enclosed in a cable sleeve HR 105 DC.

© Hak Cipla: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia
CKE.LS.01.01.(04).2017
~
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11.1.2.5.1 Electrical connection and disconnection of the control gear

system from the incoming supply cables and optical system
shall be through a plug & sockeUconnection unit. It shall be
ER
made from flame retardant material. The plug & socket shall
be rated at lOA. A conduits fitting that terminates the flexible
conduit to the lamp control gear shall be provided. The cable
clamp arrangement shall not damage the insulation of the
D
cables.
N
11.1.2.5.2 The manufacturer shall provide installation instruction for each
model of the luminaries by means of hook or other suitable
TE
method.
11 .1.2.6 The reflector shall be made of high purity anodized aluminium with at least
99.85% pure aluminium with no iridescent mirror finished (e.g. polished
A
aluminium). The thickness of the reflector shall be minimum 0.5 mm. The
support shall be made from mild steel with minimum thickness of 1.3
EJ
mm. The ring shall be made from die-cast aluminium with minimum
thickness of 1.3 mm. The support and ring shall be coated by electrostatic
powder. The clip shall be made from stainless steel. For horizontal lamp
M
connection , the diameter of the reflector shall be large enough for easy
relamping of lamps.
11.1.2.6.1 Photometric data for the luminaires shall be made available

EN
and submitted to S.O.'s Representatives when required. The

required photometric data for the luminaires shall be Polar
Curve, Utilization Factors , Luminance Distribution Table,
Downward Light Output Ratio, Upward Light Output Ratio,
M
Light Output Ratio, Spacing to Mounting Height Ratio and

Threshold Increment.
KU
11.1.2.6.2 Light Output Ratio for the luminaires shall be minimum 70%.
11.1 .2.7 The lamp holder shall be G24 type for the 10W/13W/18W/26W compact
O
fluorescent lamp (CFL) without integral control gear. The lamp holder shall
comply with MS IEC 60400, made to fit individual lamp wattage and not
D
interchangeable. The lampholder shall be made of non-metallic, heat

resistant material and be rigidly fixed onto the optical compartment. The
lampholder shall be incorporated with a housing made from extruded
aluminium or good quality mild steel sheet or aluminium die cast with a
mechanism to dissipate heat (heat sink).
SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INST ALLA TION

CKE.LS .01 .01.(04).2017
~ SPECIFICATION FOR LOW VOLTAGE
[JJK!1 INTERNAL
Revision: 4
~ Date: Jan 2018
(L-S1 )
Page: 511 - 8 of 18
11.1.2.8 The ballast shall comply with MS lEG 61347-1 , MS lEG 61347-2-8 and MS 141:
PT.2 and shall be of the type approved by Suruhanjaya Tenaga and JKR. The
ballast shall be polyester resin impregnated , silent operation type fitted wilh
ER
terminal block for easy wiring. The watt loss for the ballast shall be 6W.
11.1.2.8.1 For electronic ballast refer to 11.1 .1.(a). v
D
11.1.2.9 The capacitor shall comply with MS lEG 61048 and MS lEG 61049 and of
type approved by Suruhanjaya Tenaga and JKR. The capacitor shall be
N
(j cylinder shape type. The capacitor shall be dry, self healing, metalised
polypropylene type with terminal block for easy wiring .The casing shall be
TE
made from aluminium or flame retardant plastic. The capacitor shall be
mounted with nut and lock washer.
11 .1.2.10 All components in the fluorescent luminaires shall be manufactured by the

manufacturer or being supplied by others. The components shall be marked
A
with "made for" if supplied by other manufacturer except high frequency
electronics ballast if specified , compact fluorescent lamp , cable and holders
EJ
for compact fluorescent lamp. The components shall be of the type
approved by Suruhanjaya Tenaga and JKR.
M
EN
M
KU
O
D

CKE.LS.01.01.(04).2017
§ INTERNAL
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Date: Jan 2018
Page: S11 - 9 of 18
11.2 SELF CONTAINED LUMINAIRES
11.2.1 Self-contained emergency luminaires shall comply with MS 619 and IEC 60598-
ER
2-22 and approved by Jabatan Bomba Dan Penyelamat Malaysia and JKR.
11.2.2 The body shall be made from good quality mild steel sheet, aluminum extrusions or
injection moulded flame retardant material. For mild steel sheet, shall be rust
D
inhibited to prevent corrosion. The body shall be sprayed with an undercoat of zinc
chromate primer and finished with two coatings of super white baked enamel.
n
N
11 .2.3 The diffuser shall be of fiame retardant type. The material for the diffuser shall
TE
be of either polycarbonate or prismatic Polyethylene Terephthalate Glycol
(PETG) or equivalent.
11 .2.4 The luminaires shall be equipped with maintenance-free high temperature

rated sealed nickel cadmi um battery, solid state automatic charger, changeover
A
device, fiuorescent lamp, indicator lamp, test switch and interior disconnecting
device i.e. fuse, relay or other protective device. Other types of battery shall be
EJ
allowed provided they conform to their relevant safety and performance
standard and the relevant requirement of MS 619 and IEC 60598-2-22.
11.2.5 The battery shall be fu lly rechargeable to its operational capacity in not more than
M
24 hours after discharge. Low volt cut-off safety feature shall be incorporated to
prevent over discharge of battery. The response time for non -maintained
emergency luminaires shall be 2 second upon fai lure of the normal lighting.
EN
M
( )
KU
O
D
SPECIFICAliON FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLAliON

CKE.LS.01.01 .(04).2017
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Revision: 4
Date: Jan 2018
Page: 511 - 10 of 18
11.2.6 Unless otherwise specified , the fluorescent tube shall be 8 watt with minimum
output of 330 lumen. The duratio n for emergency operation shall not be less
than 3 hours . The initial lumen output of the self-contained emergency
ER
luminaires at changeover from normal to emergency mode shall be not less
than 25% of the nominal lumen output of the fluorescent tube. The lumen
output at the end of the rated duration shall be minimum 10% of the nominal
lumen output of the fluorescent tube.
D
11.2.7 The self contained emergency luminaires with "KELUAR" signage pictogram
N
shall be of the maintained 3 hours rating type as specified above, complying
() with relevant part of MS 983, MS 619 and IEC 60598-2-22 and approved by
Jabatan Bomba Dan Penyelamat Malaysia and JKR. The lamp shall be of 2
TE
fluorescent tubes type or minimum 10 units of super bright white LEOs . The
diffuser shall be of flame retardant type . The material for the diffuser shall be of
either polycarbonate or prismatic PETG or equivalent. The lettering and
directional arrow shall be white on green background.
A
11 .2.8 The LED shall face downward to provide uniform light distribution via the
EJ
transparent acryl ic on "KELUAR" signage pictogram and to provide courtesy
light source at the floor level for increase safety. The LED shall comply to the
following characteristics·
Module Type
M
Characteristics Dot Matrix

Operatinq Voltaqe 230V (+10%, -6%), 50Hz +1 %
Power Factor " 0.90
EN
Total Harmonic Distortion < 20 %

Power 8 W - 10 W (Typical : 10 W)
Intensity 200cd - 800cd
LED type 5 mm (AllnGaP , InGaN)
M
LED Mountinq Technology Through holes

\.. ) Gnromatlcity GOOrdinates White Green
(x , y) as on CIE chart
KU
, u.7:<u
~~~l : ~:~~~
u . uu~
0.284 , 0.520
0.280 , 0.250 0.209 , 00400
0.356 , 0.350 0 .028,00400
O
Table 11A: Electrical Characteristics of LED signal modu le

D

CKE.LS.01.01.(04).2017
-
[!JK!l
INTERNAL
Revision: 4
.....? (L-S1 ) Date: Jan 2018
Page: S11 -11 of 18
11.3 LED LUMINAIRES
ER
11.3.1. DOWNLIGHT TYPE LED LUMINAIRES
11.3.1.1. The luminaires shall be of type approved by Suruhanjaya Tenaga (ST).
11 .3. 1.2. The lum inaires shall comply with the relevant Malaysian Standards or
D
lEG Standards and other relevant standards in terms of safety and
n performance criteria. The luminaires shall comply to MS lEG 60598 Series,
N
IES LM-79-08 , IES LM-80-08, MS 62722-2-1 , MS lEG 62031 , lEG 62471 ,
lEG 61547, MS lEG 61000-3-2 and BS EN 55015 1 GISPR 15.
TE
11 .3. 1.3. The luminaires shall be designed and constructed that it is capable of
provid ing the service for which is intended. It shall be manufactured under
"Lighting Glass LED" and sha ll be commercially available.
A
11.3.1.4. The LED luminaires shall be new and complete with LED control gear (LED
driver), thermal management unit, surge and overvoltage protection and
EJ
suitable for supply voltage of 230 V, +10% , -6% at 50 Hz. The LED luminaire
shall consist of two separate components comprising of LED control gear
and optical system .
M
11.3.1.4.1 The construction of the luminaires shall be of either two

separate housing 1 compartments or integrated.
EN
11.3.1.4.2 The luminaire shall be shined downwards to provide uniform light

distribution and it shall have adequate heat sink for heat
dissipation 1 thermal management.
M
( ) 11.3.1.4.3 All components of the luminaires shall operate well within the
ratings with due consideration for the local conditions (high
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humidity of 95% RH and ambient temperature of 35' G).
11.3.1.4.4 Interchangeability of consumable components is preferred for

maintenance purposes.
O
11.3.1.4.5 The luminaires in mode of operation shall not produce voltage

disturbance 1 fluctuation to the electrical supply system
D

CKE.LS.01.01.(04).2017
liJK~ INTERNAL
Revision: 4
--...F-
Page: S11 -12 of 18
11 .3.1.4.6 The housing of the LED control gear and optical system shall
be of sound and rigid construction suitable for suspended
installation . A means of connecting the flexible GS conduit to
ER
the lamp control gear I luminaires shall be provided.
11.3.1.4.7 Material used for the construction of the luminaires and its
component shall be recyclable.
D
n
N
11.3.1.5. The LED control gear shall comply to MS lEG 61347-2-13, MS lEG 62384 ,
BS EN 55015 I GISPR 15 for radio frequency interference suppression and
MS lEG 61000- 3-2 for harmonics distortion. Rated maximum operating
TE
temperature of the LED control gear shall not exceed 70' G.
11.3.1.5.1 Harmonics distortion shall be within the limits in accordance

with MS lEG 61000-3-2. However, total harmonics distortion
A
shall be less than 20%. The LED control gear shall operate
and maintain consistent light output over voltage variation
EJ
from + 10% to -6% of the rated voltage and power factor of not
less than 0.9 lagging.
11.3.1.5.2 The LED control gear shall be able to withstand short circuit
M
current, overload, over voltage , under voltage and over

temperature.
EN
11.3.1.5.3 The optical system shall incorporate one piece full bowl
reflector where applicable and high power LED or LED
module of required wattage and shall comply to MS lEG
62031 and lEG 62471. The lum inaire shall continue to
M
operate safely even though there is failure of a partial number

) of LEOs I LED . The LEOs I LED module lumen output shall
not be depreciated to below 70% of the original output during
KU
the liability I warranty I contract period (whichever is

applicable). The initial luminous flux shall not be less than
90% of the rated luminous flu x.
O
11.3.1.5.4 There shall be no flickering of the light source in mode of

operation and when it reaches its end of life.
D
11.3.1.5.5 The LED I LED module shall not be driven more than the
rated drive current.

CKE.LS.01 .01.(04).2017
§ INTERNAL
(L-S1 )
Revision: 4
Date : Jan 2018
Page : S11 -13 of 18
11.3.1.6. The optical system support shall be made from mild steel I die cast
aluminum wi th minimum thickness of 1.3 mm . The ring shall be made from
die-cast aluminum with minimum thickness of 1.3 mm. The support and ring
ER
shall be coated with electrostatic powder. The clip shall be made from
stainless steel.
11.3.1.6.1 The optical system shall comprise of optical lens refl ector and
D
glass diffuser (if applicable). It shall give good even light
distribution with minimal glare in both the axial and transverse
N
planes.
11.3.1.6.2 When applicable, the reflector shall be made of high purity anodized
TE
aluminium with at least 99.85% pure aluminium with low iridescent I
iridescent free mirror finished(e .g.polished aluminium). The
thickness of the reflector shall be minimum 0.5 mm.
11 .3.1.6.3 Photometric data for the luminaires shall be made available and
A
submitted . The required photometric data for the luminaires shall
be Polar Curve, Utilization Factor, Luminance Distribution Table ,
EJ
Downward Light Output Ratio, Upward Light Output Ratio, Light

Output Ratio and Spacing to Mounting Height Ratio.
M
11.3.1.7. Connection cables shall be terminated in a termination block marked 'L'

and 'N' for connection of the incoming wires . For Class 1 Luminaires, a
brass di rect pressure type earth terminal shall be provided in the LED driver
EN
system near the termination block for earth connection. This earth
terminal shall be clearly marked with the standard earth terminal symbol.
11 .3.1.7.1 For separated optical and LED control gear, electrical connection
M
of the LED control gear and optical system shall be through a

plug and socket ( i.e. male I female connection unit) It shall be
KU
made from non-flammable material and shall be rated at 10A. It

shall comply to MS IEC 60838-2-2.
11.3.1.7.2 Heat Resistant (HR) 105' C cable shall be used to connect the
optical system and LED control gear and shall be of stranded
O
type. It shall not be more than 300 mm long . The cable sha ll be
enclosed in a cable sleeve HR 105' C.
D
11.3.1.7.3 Wiring shall be done in a neat way to avoid contact with heat
producing components. A means of clamping the electrical cable
shall be provided. The cable clamp arrangement shall not
damage the insulation of the cables.
SPECIFICA nON FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLAnON

CKE.LS .01 .01 .(04).2017
[f;J INTERNAL
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Revision: 4
Date: Jan 2018
Page: S11 -14 of 18
11.3. 1.7.4 Where optical and control gear system are not integrated , both
the optical and control gear system shall be provided with
hooks or other suitable means for hanging purposes .
ER
11.3.1.8. The LED Downlight shall comply to the following characteristic:
D
Characteristic Description
N
() Light Source Lighting Class LED
TE
Power Supply 230V +10, -6%, SO Hz
Correlated Colour
Temperature 2700K,3000K, 4000K, 4S00K SOOOK,6S00K
(CCT) 3S00K
A
Colour Rendering
Index " 80 " 80 " 80
EJ
Lumens " 8S0 " 8S0 " 9S0

Luminaire
" 7SIm/W " 7SImIW
M
Efficacy " 7SImIW
Beam Angle " 60'

Power
EN
,; 20W
Consumption
Power Factor " 0.90
Ambient
M
-20' C to 3S' C
( ) Temperature
Rated Lifetime " SO,OOO hours, 70% lumen maintenance at Ta=2S' C
KU
LED
Photobiological Exempt group ( IEC 62471)
Safety Class
Total Harmonic
O
,; 20%
Distortion (THO)
D
Table 11.4.1: Characteristics of LED Downlight
SPECIFICATION FOR LOW YOLTAGE INTERNAL ELECTRICAL INSTALLATION

CKE.LS.01 .01.(04).2017
rg, SPECIFICATION FOR LOW VOLTAGE

INTERNAL
(L-S1 )
Revision: 4
Date: Jan 2018
Page: Sll -15 of 18
11.3.1.9. The manufacturer shall provide a minimum 5 years period warranty

certificate as stated in the defect liability I warranty I contract period
(whichever is applicable) for the complete luminaire to guarantee the long
ER
life expectancy and maintenance-free luminaire. Warranty declaration shall
be filled and signed by manufacturer. Failure in the fun ctioning and
operation of the LED luminaire within the warranty period will result in the
replacement of the whole luminaire or required components by the
D
manufacturer at no cost to the JKR.
N
11.3. 1.10. Illuminance test shall be carried out every 6 months during defect liability
I warranty I contract period (whichever is applicable) to ensure the
performance of the installed system conform to the design requirement as
TE
per JKR specifications. This test shall also confirm the lumen maintenance
of the lum inaire .
11.3.1.10.1 The luminaire manufacturer shall provide calibrated illuminance

A
meter and have the capacity and competency to carry out the
illuminance test during the testing of the installed lighting system.
EJ
11.3.1 .11. Conformity with Standards

The LED luminaire shall comply with and be tested to the relevant latest edition
of Malaysia Standard or other relevant international standard as below:
M
Item Criteria Relevant Standard

EN
MS IEC 60598-1
Luminaires - Part 1: General requirements and
tests
M
MS IEC 60598-2-1
() Safety &
Luminaire Luminaires. Part 2: Particular requirements .
KU
construction Section One : Fixed general purpose luminaires

MS IEC 60598-2-2
Luminaires. Part 2: Particular requirements, Part 2
O
- Section 2: Recessed luminaires

Safety & MS IEC 61347-1
D
construction LED driver Lamp control gear - Part 1: General and safety
requirements

CKE.LS.01.01.(04).2017
~
Page: S11 -16 of 18
Item" Criteria III Relevant Standard
ER
MS IEC 61347-2-13
Lamp control gear- Part 2-1 3 - Particular
requiremenl for d.c or a.c supplied
D
eleclronic controlgear for LED modules.
N
() Safety &
MS IEC 62031
LED modu le LED modu les for general lighting -
TE
construction
Safety specifications
MS IEC 60838-2-2
Safety Lamp holder Miscellaneous lampholders - Part 2-2 -
A
Particular requirements - connectors for LED
modules
EJ
LED IEC 62471

Safety lamps/module Photobiological safety of lamps and lamp
(eye protection) systems
M
MS IEC 62384
• LED driver DC or AC supplied electronic control gear for
EN
LED modules - Performance requirements
Performance MS 62722-1
Luminaire Performance - Part 1: General
M
LED Requirements
Luminaires
MS 62722-2-1
KU
Luminaire Performance - Part 2-1 : Particular

Requirements for LED Luminaires
O
D
SPECIFICATION FOR LOW VOLTAG E INTERNAL ELECTRICA L INSTALLATION

© Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Ma laysia
CKE.LS.01.01.(04).2017
~
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Item Criteria Relexant Standard

Q
ER
IES LM-79-08
Photometric Approved Method: Electrical and Photometric
Measurements of Solid-State Lighting Products
D
LED Light
IES LM-80-08
N
Source
(J Performance
('by LED
Approved Method: Measuring Lumen
Maintenance of LED Light Sources
TE
Manufacturer)
LED Light IES TM 21-11

Source
Projecting Long Term Lumen Maintenance of
A
('by LED
LED Light Sources
Manufacturer)
EJ
IEC 61547
Equipment For General Lighting Purposes-
M
EMC Immunity Requirements
Safety IEC 61000-3-2

EN
ELECTROMAGNETIC COM PATIBILITY

EMC (EMC) - Part 3-2: Limits - Limits for harmonic
current emissions (equipment input cu rrent
M
,;16 A per phase)

~)
CISPR 15 (BS EN 50015)
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Performance Limits and Methods of Measurement of Ratio

Disturbance Characteristics of Electrical
Lighting And Similar Equipment
O
D
SPECIFICATiON FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION

© Hak Cipta: 1999 Cawangan Kej uruteraan Elektrik, JKR Ma laysia
CKE.LS.01.01.(04).2017
[@J INTERNAL
(L-S1)
Revision: 4
Date: Jan 2018
Page: Sll-18of18
11.4 INSTALLATION OF LUMINAIRES
11.4.1 For luminaires with pendant lampshade. the wiring shall terminate in ceiling
ER
rose. Connection from ceiling rose to lamp holder in the luminaire shall be by 3
core flexible cord of not less than 0.75 sq. mm. The flexib le cord may be used
for suspending the luminaires if the total mass of the luminaire does not exceed
2 kg . If the mass of the luminaires exceeds 2kg, a hook shall be installed and
D
the luminaire shall be suspended from the hook by means of decorative chain
approved by the 8 .0.'s Representative.
N
11.4.2 For ceiling mounted and wall mounted luminaires, the wiring shall terminate
directly into terminal block in the luminaires or into a batten lampholder as the
TE
case may be.
11.4.3 For luminaires to be recessed into suspended false ceiling , wiring shall run
through junction box and flexible steel conduit right up to the luminaires as
A
described in 9.2. The luminaires shall not sit on the ceiling structure but shall
be securely suspended from the floor slabs or beams of roof trusses by means
EJ
of suspension rods , brass chains or galvanised steel wires of minimum size
1.6mm diameter or as specified or as directed by the 8 .0.'s Representati ve.
11.4.4 Downlight type fluorescent luminaires shall be suspended from the floor slabs.
M
Where optical and control gear system are not integrated , both the optical and
control gear system shall be provided with hooks, galvanised steel wires of
minimum size 1.6mm diameter and necessary accessories or as specified or
EN
as directed by the 8.0.'s Representative . The luminaires shall not sit on the
ceiling structure but shall be securely suspended from the floor slabs or beams
of roof trusses.
11.4.5 Openings required for recessing the luminaire of item 11.4.3 and 11.4.4, shall
M
~ ) be done by the Main Contractor. However the Electrical Contractor shall

provide all details to the Main Contractor.
KU
11.4.6 Where fluorescent luminaires are to be surface mounted on the underside of

soft board or other type of ceilings which is combustible , suitable spacers shall
be inserted between the base of the luminaires and the ceiling such that a
O
minimum clearance of 10mm exists between the luminaires and the ceiling .
11.4.7 Where fluorescent luminaires are to be suspended from cei ling of floor slab ,
D
suitable suspension rods shall be provided . The wiring shall be terminated into
a terminal block in the suspension channel. Connection from the terminal block
to the luminaires shall be by 3 core fle xible cord as mentioned above. The
flexible cord shall be concealed inside the suspension assembly.

CKE.LS.01.01.(04).2017
C@J INTERNAL
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Date : Jan 2018
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12.0 LAMPS
12.1 TUBULAR FLUORESCENT LAMP
ER
12.1.1 The tubula r fl uorescent lamp shall comply with MS IEC 60081 and MS IEC 61195
and shall be bi-pin type. The lamp characteristic shall be as per Table 12A:
D
Nominal Nominal I ~ower Illase I Min. lumens Nominal Colour IL(;U:; I "ropnetary .i(ated
Diameter Length (W) (after 100 Colour Rendering code Code lifespan
(mm) (mm) hrs/25° C) Temp Index (hrs)
N
(') (Kelvin)
4000&
(Ra)
26 600 18 G13 1300 80 -89 FD T8 10,000
TE
6500
4000&
26 1200 36 G13 3250 6500 80 - 89 FD T8 10,000
4000 &
16 550 14 G5 1100 80 - 89 FDH T5 20,000
6500
4llOO&
A
16 550 24 G5 1700 6500 80 - 89 FDH T5 20,000
4llOO&
EJ
16 1150 28 G5 2400 6500 80 - 89 FDH T5 20,000
4000 &
16 11 50 54 G5 4150 80 - 89 FDH T5 20,000
6500
M
Table 12A : Lamp Characteri stics for Tubular

Fluorescent
EN
12.2 COMPACT FLUORESCENT LAMP WITHOUT INTEGRAL CONTROL GEAR
12.2.1 The compact fluorescent lamp without integral control gear shall comply with
M
IEC 60901 and IEC 61199 and shall be 2/4-pin type and of 2/4-limb and shall
~) be rated for 8000 hours life at rated voltage. The lamp characteristi c shall be
as per Table 12B.
KU
Min. Nominal Colour IColour Rendenng

Power ILCOS
Base lumens Temperature Index
(watt) lafter IKelvin) IRa) code
O
(j~4d-l l 4000
10 G24a-l 600 6500 80 -89 FSQ
D
G24d-1 1 900 4000

13 G24a-1 855 80 - 89 FSQ
6500
G24d-21 1200 4000
18 G24a-2 80 - 89 FSQ
1130 6500
G24d-31 1800 4000
26 G24a-3 80 - 89 FSQ
1700 6500
Table 12B: Lamp Characteristics for Compact Fluorescent

© Hak Cipta: 1999 Cawangan Kejuruteraan Elektrlk, JKR Malays ia
CKE.LS.01.01.(04).2017
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(L-S1 )
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Date: Jan 2018
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12.3 COMPACT FLUORESCENT LAMP WITH INTEGRAL CONTROL GEAR
ER
12.3.1 The compact fluorescent lamp with integral control gear shall comply with
lEG 60968 and lEG 60969 , and shall be of E14 or E27 screw type base and
shall be guaranteed for 10000 hours life at rated voltage. Unless otherwise
specified , they shall have an outer cylindrical or spherical diffusing bulb.
D
N
(j
TE
A
EJ
M
EN
M
KU
O
D

© Hak Cipta : 1999 Cawangan Kejuruteraan Elektrik. JKR Ma laysia
CKE.LS.01.01.(04).2017
[@) INTERNAL
(L-S1 )
Revision: 3
Date: Jan 2018
Page: S12 - 3 of 15
12.4 LED LAMP
12.4.1 LED BULB
ER
12.4.1.1 The bulb shall be of type approved by Suruhanjaya Tenaga (ST) . The bu lb
shall comply with the relevant Malaysian Standards or lEG Standards and other
relevant standard s in terms of safety and performance criteria . The bulb shall
D
comply to MS lEG 62560, MS 62722, IES LM-79 -08, IES LM-80-08, lEG
62471, MS lEG 60061 Series, MS 626 12, lEG 61547, MS lEG 61000-3-2 , BS
N
EN 55015 or GISPR 15 and fit to lum inaires that comply to MS lEG 60598
Series.
TE
12.4.1.2 The bulb shall be designed and constructed that it is capable of providing the
service for which is intended. It shall be manufactured under "Lighting Glass
LED" and shall be commercially available.
A
12.4.1.3 The bulb shall be designed and manufactured to suit with existing available
lamp holder that fits lamp cap as per standard lEG 60061 (e.g. E27 I E26 and
EJ
GU5.3 (MR 16)). The housing of the bulb shall be made from aluminum,
polycarbonate or other material that sufficiently proven to resistant to heat and
flame. Material used for the construction of the bulb shall be recyclable.
M
12.4.1.3.1 For self ballasted LED bulb (e.g. E26 I E27 and GU5.3) , the bulb
shall be manufactured as a unit which cannot be dismantled
without being permanently damaged , non- repairable and factory-
EN
sealed unit. It shall be provided with a lamp cap and incorporating

a LED light source, LED control gear (LED driver) and any
additional elements necessary for stable operation of the light
source.
M
\. ) 12.4.1.3.2 For non self-ballasted LED bulb (e.g. for GU5.3) , the LED control
gear (LED driver) shall comply to MS lEG 61347-2- 13, MS lEG
KU
62384 , lEG 61547, BS EN 55015 or GISPR 15 for radio frequency

interference suppression and MS lEG 61000-3-2 for harmonics
distortion. The Insulation protection shall be of Glass II. Rated
maximum operating temperature of the LED control gear (LED
O
driver) shall not exceed 70"G. The connection system shall comply
to MS lEG 60838-2-2. LED module shall comply to MS lEG 62031
D
and shall be of the type approved by Suruhanjaya Tenaga (ST) .
12.4.1.4 The bulb shall be new and totally enclosed. The beam angle shal l be as
specified I requirement of the intended application.

CKE.LS.01.01.(04).2017
~
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12.4 .1.5 The bulb shall be complete with thermal management unit (heat sink), surge
and overvoltage protection and suitable for supply voltage of 230V, +10%, -
6% at 50Hz with power factor corrected to at least 0.9 lagg ing and shall not
ER
produce voltage disturbance I fluctuation to the electrical supply system.
12.4.1.5.1 The bulb shall operate well with in the ratings with due
consideration for the local conditions (high humidity of 95% RH
D
and am bient temperature of 35' C)
N
12.4. 1.5.2 Harmonics distortion for LED control gear shall be with in the
(') limits in accordance with MS IEC 61000-3-2. However, total
TE
harmonics distortion shall be less than 20%. The LED driver
shall operate and maintain consistent light output over voltage
variation from + 10% to -6% of the rated vol ta ge and power
facto r of not less than 0.9 lagging.
A
12.4.1.6 The LED luminous flux output of LED light source shall not be depreci ated
to below 70% of the origin al output during life hours . The initial luminous
EJ
flu x shall not be less than 90% of the rated luminous flux.
12.4.1.7 The LED module shall not be driven more than the rated LED drive current.
M
12.4 .1.8 The bu lb which incorporating multiple numbers of LEOs or LED modules
shall continue to operate even though there is failure of a partial number
of LEOs or LED modules.
EN
12.4.1.9 Photometric data for the bulb sha ll be made available. The required
photometric data for the bulb shall be Polar Curve, Utilization Factor,
Luminance Distribution Table, Downward Light Output Ratio, Upward Light
M
Output Ratio, Light Output Ratio and Spacing to Mounting Height Ratio.
'- )
KU
12.4.1.10 The lamp caps interchangeability shall comply to MS IEC 6006 1. The bulb
shall come into its intended positi on with no perm anent deformation when
inserted into lamp holder and shall be capable of easy and correct
positioning by the user. The bulb shall not be fall apart from its cap in any
O
mounting I burning position.
12.4.1.11 The manufacturer shall provide a minimum 5 years period warranty

D
certificate as stated in the defect liability I warranty I contract period

(whichever is applicable) for the complete bu lb to guarantee the long life
expectancy and maintenance free bulb. Warranty declaration shall be
fi lled and signed by manufacturer. Fa ilure in the functioning and operation
of the LED luminairellamp within the warranty period will resu lt in the
replacement of the whole luminaire or required components by the
manufacturer at no cost to the government.

CKE.LS.01 .01.(04).2017
~
Page: S12 - 5 of 15
12.4.1.12 Illuminance test shall be carried out every 6 months during defect liability I
warranty I contract period (whichever is applicable) to ensure the
performance of the installed system conform to the design requirement as
ER
per JKR specifications. This test will also confirm the lumen maintenance
of the bulb.
12.4.1.12.1 The bulb supplier shall provide calibrated ill uminance meter and
D
have the capacity and competency to carry out the illuminance
test during the testing of the installed lighti ng system.
N
12.4.1.13 The bulb shall comply to the following characteristic:
TE
Characteristic Description II
Light Source Lighting Class LED
Lamp Cap E26/E27 GU5.3(MR16)

A
Correlated Colour 2700K,3000K, 4000Kl4100K, 2700K, 3000K
EJ
Temperature , CCT 3500K 4500K
Power Supply 230V +10% , -6%, 50Hz
Power
M
59W 59W 57W

Consumption
Power Factor
" 0.90
EN
Total Luminous
Flux (Lumens) " 450 " 550 " 200
System Efficacy
" 551mIW " 60lmIW " 50lmIW
M
Color Rendering
'- ) Index, CRI
" 80 " 80
KU
Ambient Temperature -20"C to 35"C
Rated Lifetime
" 40 ,000 hours, 70% lumen maintenance at Ta=25"C
O
LED Photobiological
Exempt group ( IEC 62471)
Safety Class
D
Heat sink material Aluminium

Diffuser I housing type Frosted
Total Harmonic 520%
Distortion (THO)
Table 12.4.1 Characteri stic of LED Bulb
SPECIFICAnON FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION ©

Hak Cipta : 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia
CKE.LS .01 .01.(04) .2017
§ INTERNAL
(L-S1 )
Revision : 3
Date: Jan 2018
Page: S12-60f15
LEDGear LED module

~ u mp tiP Gtlar and LED module: one unit
Supply
ER
voltage:
, BU1'~ \ I ~ LI~~~4_"_se_lf_.ba_'_lasted LED lamp"

AC
D
lupl. \ I ; . , BuUt, .
n
tOOOV
10Hz Gear without LEO's .1
N
,. flg's!
or
~~~L . I,.depernl••,
10 Hz)
TE
or
"Electronic Control Gear for CCC...
"tlllolllllono
..... ..........
DC LED modules"
IUPI.
llO V)
~I .. ~ ... ,J
---~
Built-in
A
Ge" + LEOS Inregral
"' ....
,--_I I ..~
EJ
pee 110111 Independent
"Self· ballasted LED module"

M
Figure 12.4.1: O verview of System Co mposed of Self Balla sted LED Lamp
(Informative)
EN
12.4.1.14 Conformity with Standards
The bulb shall compl y with and be tested to the relevant latest edition of
M
l) Malaysia Standard or other relevant latest international standard as below:

KU

MS IEC 62560
Self-ballasted LED-lamps for general
lighting services by voltage > 50V -
O
Luminaire Safety specifications

Safety & construction
& Lamps
D
MS IEC 60598-1 :
Lum inaires - Part 1: General
requirements and tests
SPECIFICATiON FoR LoW VoLTAGE INTERNAL ELECTRICAL INSTALLATiON

CKE.LS.01.01.(04).2017
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Date: Jan 2018
Page: S12 - 7 of 15

MS IEC 60598-2-1
Luminaires. Part 2: Particular
ER
requirements. Section Two: Fixed general
purpose luminaires
MS IEC 60598-2-2
D
Luminaires Part 2 :Particular requirements
- Section 2: Recessed lum inaires
N
MS IEC 61347-1
Lamp control gear - Part 1: General
TE
and safety requirements
LED driver MS IEC 61347-2-13
Lamp control gear- Part 2-13 - Particular
requirement for d.c or a.c supplied
A
electronic control gear for LED modu les.
EJ
MS IEC 62031
LED module LED modules for general lighting -
Safety specifications
M
MS IEC 60061
Lamp caps International recommendations regarding
and holder lamp caps and holders together with
EN
gauges for the control of interchangeability

MS IEC 60838-2-2
Miscellaneous lampholders - Part 2-2-
Safety Lamp holder
Particular requirements - connectors
M
~) for LED modules

LED
KU
lamps/modul IEC 62471

Safety (eye Photobiological safety of lamps and
protection) lamp systems
O
MS IEC 62384
DC or AC supplied electronic control
Performance LED driver gear for LED modules - Performance
D
requirements
MS 62722-1
Performance LED Luminaire Performance - Part 1: General
Lum inaires Requirements

CKE.LS.01.01.(04).2017
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Date: Jan 2018
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MS 62722-2-1
Luminaire Performance - Part 2-1 :
ER
Particular Requirements for LED
Luminaires
MS 62612
Performance Self Ballasted LED-Lamps For General
D
LED Lamp Lighting Services- Performance
Requirements
N
() IES LM-79-08
TE
Approved Method: Electrical and
Performance Photometric Photometric Measurements of Solid-
State Lighting Products
LED Light
Source IES LM-80-08
A
Performance «by LED Approved Method: Measuring Lumen
EJ
Manufacturer) Maintenance of LED Light Sources
LED Light
Source IES TM 21-11
M
Performance (' by LED Projecting Long Term Lumen

EN
MS IEC 61547
Equipment For General Lighting
Purposes- EMC Immunity Requirements
M
() EMC
ELECTROMAGNETIC
COMPATIBILITY (EMC) -Part 3-2:
KU
Limits - Limits for harmonic current

emissions (equipment input current
s16 A per phase)
O
Limits and Methods of Measurement of

Performance Ratio Disturbance Characteristics of
D
Electrical Lighting And Similar

Equipment

CKE.LS.01.01.(04).2017
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Page: S12 - 9 of 15
12.4.2 LED DOUBLE CAPPED LAMPS (T8 LED TUBES)
12.4.2.1 T8 LED Tubes shall be of the type approved by Suruhanjaya Tenaga (ST) .
ER
12.4.2.2 T8 LED Tubes shall comply with the relevant Malaysian Standards or lEG
standards and other relevant standards where applicable in terms of
safety and performance criteria. It shall be manufactured under "Lighting
D
Glass LED" and shall be commercially available.
N
12.4.2 .3 T8 LED Tubes, electroni c control gear (LED driver) and accessories shall
comply with MS lEG 61347-1 , MS lEG 61347-2-13, MS lEG 62031 , MS
TE
lEG 60838-2-2, MS lEG 60061 , MS lEG 62384 , MS 62722-1, MS 62722-
2-1 , IES LM-79-08, IES LM-80-08, IES TM 21-11, lEG 62471, lEG 61547,
lEG 61000-3-2, BS EN 55015 or GISPR 15 and shall fit to luminaires that
comply to MS lEG 60598-1 , MS lEG 60598-2-1 and MS lEG 60598-2-2.
A
12.4.2.4 The T8 LED Tu bes shall be designed and manufactured to suit standard
T8 bi-pin fluorescent lamps and capable of providing the service for which
EJ
is intended. The manufacturers shall provide complete technical
installation manual & maintenance manual.
12.4.2 .5 The T8 LED Tubes shall be suitable for supply voltage of 230V, +10% , -
M
6% at 50Hz with power factor corrected to at least 0.9 lagging and shall
not produce voltage disturbance or fluctuation to the electri cal supply
system during the mode of operation.
EN
12.4.2.6 The T8 LED Tubes shall operate well within the ratings with due
consideration for the local cond itions (high humidity up to 95% RH and
ambient temperature of 35· G).
M
~ ) 12.4.2.7 Interchangeability of consumable components is preferred for

KU
maintenance purposes.
12.4.2.8 T8 LED Tubes shall have housing made from Aluminum or Polycarbonate
or other materials that sufficiently proven resistance to heat and flame.
O
12.4.2.9 Material used for the construction of the T8 LED Tubes shall be recyclable.
D
12.4.2.10 The T8 LED Tubes shall be new, totally enclosed and shall have
protection against contact with live or moving parts inside the enclosure.

CKE.LS.01.01 .(04).2017
e SPECIFICATION FOR LOW VOLTAGE

INTERNAL
(L-S1 )
Revision : 3
Date: Jan 2018
Page: S12 -10 of 15
12.4.2.11 The electronic control gear (LED Driver) shall comply with MS IEC 61347-
1, MS IEC 61347-2-13 & MS IEC 62384 whi le LED Module shall comply
with MS IEC 62031 and shall be of the type approved by Suruhanjaya
ER
Tenaga (ST).
The possible combination systems composed of LED Modules and LED

Driver are described in Figure 12.4.2 below (Please note that MS IEC
D
62560: Self Ballasted LED Lamp is not applicable for T8 LED Tubes).
N
TE
Supply
voltage: ~ ~_ _ _
Sui/loin '--C~C-
Integral "Self·ballasted LED lamp"

~
A
AC \
Built-in
EJ
(uplo \
IOOOV
50 Hz Gear without LEO's
6() Hz)
M
or
. l lndependenl I
"Electronic Control Gear for
DC LED modules"
EN
.. ~
(upto
25O V)
,.. .. Bum';n
....._
Ge_ar_ .J....+....!.._ l : -~
LE_D_' ...... InlO9r.1
M
... ~- Independent I
KU
Figure 12.4.2: Overview of System Composed of LED Modules and

Control gear (Informative)
O
D

CKE.LS.01.01.(04).2017
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12.4.2.12 LED modules with integrated control gear and equipped wi th lamp cap
(i.e. self- ballasted lamp), intended for retrofit applications (thereby to
replace existing lamps with identical lamp caps) shall comply with
ER
requirement of IEC 60968.
12.4.2.13 The lamp holders and caps shall comply with MS IEC 60061 and shall
be made of polycarbonate material. The T8 LED Tubes shall fit into its
D
intended position wi th no permanent deformation when inserted into
lamp holder and shall be capable of easy and correct positioning by the
N
user. The lamp cap shall be G13 type and total weight of T8 LED Tubes
plus lamp cap shall not exceed 500 g as specified in MS IEC 60598- 1.
TE
12.4.2.14 The T8 LED Tubes shall be constructed with protection against
accidental contact with live parts when the tubes are installed .
12.4.2.15 Harmonics distortion shall be within the limits in accordance with MS

A
IEC 61000-3-2 and total harmonics distortion shall be less than 20%.
The T8 LED Tubes shall operate and maintain consistent light output
EJ
over voltage variation from +10%, -6% of the rated voltage and power
factor of not less than 0.9 lagging.
M
12.4.2.16 The LED luminous flux output of LED light source shall not be depreciated
to below 70% of the original output during life hours . The initial luminous
flux shall not be less than 90% of the rated luminous flux.
EN
12.4.2.17 The T8 LED Tubes which incorporating multiple numbers of LEDs or

LED modu les shall continue to operate even though there is fa ilure of a
partial number of LEDs or LED modules.
M
12.4.2.18 The LED I LED module shall not be driven more than the rated drive current.
t.. )
KU
12.4.2.19 Photometric data for the T8 LED Tubes shall be made available and
submitted to S.O.'s Representatives . The required photometric data for
the tubes shall be Polar Curve, Utilization Factor, Luminance
Distribution Table, Light Output Ratio and Spacing To Mounting Height
O
Ratio.
12.4.2.20 Conformity testing during manufacture of T8 LED Tubes shall be

D
carried out at 100% of production as per MS IEC 62031 with the

combination of measurement of input power at rated voltage, current
and electrical test shall be as specified in MS IEC 60598-1.

CKE.LS.01.01.(04).2017
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Page: S12 - 12 of 15
12.4.2.21 The manufacturer shall provide a minimum 5 years period warranty

certificate as stated in the defect liability / warranty / contract period
(whichever is applicable) for the complete LED Tubes to guarantee the
ER
long life expectancy and maintenance free bulb. Warranty declaration
shall be fi lled and signed by manufacturer. Fail ure in the functioni ng and
operation of the LED luminaire/tube within the warranty period will result
in the replacement of the whole luminaire or required components by
D
the manufactu rer at no cost to the government.
N
12.4.2.22 Illuminance test shall be carried out every six (6) months du rin g defect
liabi lity / warranty / contract period (whichever is applicable) to ensure
TE
the performance of the installed system conform to the design
requi rement as per JKR specifications. This test will also confi rm the
lumen maintenance of the LED Tube .
12.4.2.22 .1 The supplier/manufacturer shall provide calibrated

A
illuminance meter and have the capacity and competency
to carry out the illuminance test during the testing of the
EJ
installed lighting system .
12.4.2.23 The T8 LED Tu bes shall be bi-pin type and the minimum characteristic
M
shall be as per Table 12.4.2 below:
Specifications 600mmTs ii 1200mmTS

EN
Total Luminous Flux (lumens) ,,840 1m " 1400 1m

Power, W ,; 11 W ,; 20 W
Ingress of Protection , IP Min IP2X
M
l) Power Factor " 0.9

KU
System Efficacy, ImMl ,,70 1mMl ,,80Im/W

2700K, 3000K, 3500K, 4000/41 OOK
Correlated Colour Temperature, CCT
4500K,5000K, 6500K
O
Colour Rendering Index , CRI " 80

Diffuser/Lens Type Frosted
D
Beam Angles " 120'

Total Harmonic Distortion , THD < 20 %
Lifespan of T8 LED Tubes, Lx@hrs " L70@30 000

© Hak Cipta: 1999 Cawangan Kej uruteraa n Elektri k, JKR Malays ia
CKE.LS.01.01.(04).2017
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(L-S1)
Revision: 3
Date: Jan 2018
Page: S12 -13 of 15
Speclflcatlons U n 600mmT8 1200mmT8

Classifications; Integrated, built-in Integrated I built in
ER
or independent
Lamp cap G13
Housing material Aluminum , Polycarbonate
D
Heat sink material Aluminum
LED Photo biological class
n
N
(Group risk of eye safety) Exempt Risk group (as per IEC 62471)
TE
Working temperature , T -20' C to +45' C
Working humidity Up to 95% RH
Dimension: Length (mm) x Diameter Typical 600 x 26 Typical 1200 x 26
(mm)
A
Weight, g Typical 280 Typical 280
EJ
Table 12.4.2: Characteristics of T8 LED Tubes

M
12.4.2.24 Conformity with Standards
The T8 LED Tubes shall comply with and be tested to the relevant latest
EN
edition of Malaysia Standard or other relevant latest international

standard as below:
M

l )
MS IEC 60598-1
KU
Luminaires - Part 1: General requirements

and tests
MS IEC 60598-2-1
Safety &
O
Luminaire Luminaires. Part 2: Particular requirements

construction Section One: Fixed general purpose
D
luminaires
MS IEC 60598-2-2
Particular requirements , Part 2- Section
2: Recessed luminaires

CKE.LS.01 .01.(04).2017
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Page: S12 -14 of 15

MS IEC 61347-1
ER
Lamp control gear - Part 1: General and
safety requirements
LED driver MS IEC 61347-2-13
D
Lamp control gear- Part 2-13 - Particular
requirement for d.c or a.c supplied electronic
N
controlgear for LED modules.
MS IEC 62031
TE
LED module LED modules for general lighting - Safety
specifications
MS IEC 60061
A
Lamp caps International recommendations regarding lamp
and holder caps and holders together with gauges for the
EJ
control of interchangeability
MS IEC 60838-2-2
M
Lamp holder Miscellaneous lampholders - Part 2-2 -

Safety
Particular requirements - connectors for LED
modules
EN
LED
IEC 62471
lamps/module
Safety Photobiological safety of lamps and lamp
(eye
systems
M
protection)
~)
MS IEC 62384
KU
Performance LED driver DC or AC supplied electronic control gear for

LED modules - Performance requirements
O
MS 62722-1
Luminaire Performance - Part 1: General
D
Performance LED Requirements

Luminaires
MS 62722-2-1
Luminaire Performance - Part 2-1: Particular
Requirements for LED Luminaires

CKE.LS.01.01.(04).2017
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Hem ~ It Criteria Relev~nt Standard
ER
IES LM-79-08
Performance Photometric Approved Method: Electrical and Photometric
D
LED Light
Source IES LM-80-08
N
() Performance ('by LED Approved Method: Measuring Lumen
TE
LED Light
Source IES TM 21-11
Performance (' by LED Projecting Long Term Lumen Maintenance of
A
Manufacturer) LED Light Sou rces
EJ
IEC 61547
Equipment For General Lighting Purposes-
M
EMC Immunity Requirements

EN
ELECTROMAGN ETIC COMPATIBILITY (EMC)

-Part 3-2: Limits - Limits for harmonic current
EMC
emissions (equipment input current :516
A per phase)
M

KU
Perform ance Limits and Methods of Measurement of Ratio

Disturbance Characteristics of Electrical
Lighti ng And Similar Equipment
O
D

CKE.LS.01.01.(04).2017
~
(L-S1 ) Date: June 2022
Page: S13 - 1 of 3
13.0 FANS
13.1 CEILING FANS
ER
13.1 .1 Ceiling fans shall comply with IEC 60335-1, IEC 60335-2-80, MS 1597-2-80 and
MS 1220. For 1500 mm sweep ceiling fan , minimum air delivery at rated voltage
D
at full speed shall be not less than 210 m3/min. The ceiling fan shall have
maximum wattage of 80 W. All fans shall be equipped with safety thermal fuse
N
() minimum 130 'C, 2 A.
TE
13.1.2 All parts of the suspension system of the ceiling fan such as the fan hook, shank
assembly, down rod , motor shaft etc. shall be secured by means of high tensile
steel shackle bolts; locknuts complete with washers, spring washers and split
pins. The split pins shall be positioned as close as possible to the locknuts after
A
the latter have been properly tightened. Instructions in both languages, shall be
EJ
prominently displayed at the midway of the suspension rod : "AMARAN - Ketatkan
Semua Nut" (in Bahasa Melayu and English).
M
13.1.3 Ceiling fans shall be provided with a supplementary independent suspension

system which is safety wi re rope. In the event of failure of the rod suspension
system , the fan motor will be safely suspended by this safety wire rope from the
EN
fan hook and electricity supply to the ceiling fan shall be disconnected.
Disconnection of electricity supply to the ceiling fan shall be accomplished
without snapping or damaging the supply cable of the ceiling fan point. It shall
also not result in exposing any live terminal within the ceiling fan.
M
~)
13.1.4 The material used for the safety wire rope shall be anti-corrosive type . These
KU
features shall be assembled in the manufacturer's factory.
13.1.5 Standard rod ceiling fans shall be preassembled in the manufacturer's factory.
O
The factory supplied down rod shall be minimum 225 mm and other than 225 mm
of modified (non-standard rod) sha ll be supplied by the same manufacturer,
D
similar material, complete with safety wi re rope, marking and installation

instruction.
13.1.6 The rubber suspension bush shall properly fit the shank assembly. The upper
canopy shall be secured so that it will not slide downward . All ceiling fans shall be
provided with suitable earth terminal.

CKE.LS.01.01.(04).2017
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Date : June 2022
Page: S13 - 2 of 3
13.1 .7 All ceiling fans shall be provided with matching speed regulator of the ventilated
type complete with earth terminal. The regulator knob shall be secured in such
a way that it can only be removed by a tool. Fan shall be fitted with well-
ER
balanced blades with proper identification to prevent mixing of blades.
13.1.8 All ceiling fan sha ll be fitted with speed regulator mounting block. Where a
ceiling fan is installed near a beam , the suspension rod of the ceiling fan shall
D
be of suitable length such that there is a clearance of not less than 75 mm
N
between the underside of the beam and the fan blades.
n
TE
13.1.9 Capacitors used for ceiling fan motors sha ll comply with IEC 60252-1 . The rated
voltage shall be at least 500 VAC with a rated frequency of 50 Hz and a
maximum permissible operating temperature of 85 ·C. The capacitor shall be of
dry self-healing , metallised polypropylene type.
A
13.1.10 The windings of the capacitors shall be contained in a casing made from fire
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retardant material and totally encapsulated with a thermosetting resin.
13.1.11 The capacitors shall be of Class B and designed to comply with IEC 60252-1 for
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a minimum life expectancy of 10,000 hours when operating continuously at the

rated voltage, frequency and temperature as mentioned in 13.1.9.
EN
13.2 WALL FANS
13.2. 1 Wall fans sha ll comply with IEC 60335-1 , IEC 60335-2-80, MS 1597-2-80 and
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MS 1220.
'-.)
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13.2.2 For 400 mm diameter wa ll fan, the minimum air delivery at rated voltage at full
speed shall be minimum of 60 m 3/min with maximum wattage of 60 W. The fans
shall have 3 blades. The blade shall be fabricated from polyvinyl ch loride (PVC).
They sha ll be equipped with oscillation and minimum 3 speed control pull cords.
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13.2.3 For 500 mm diameter industrial wall fan , the value for noise level shall be
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maximum of 75 dB. The minimum air delivery at rated voltage at full speed shall
be minimum of 125 m3/min with maximum wattage of 165 W. The blade shall be
fabricated from polyvinyl ch loride (PVC) or aluminium. They shall be equipped
with oscillation and minimum 3 speed control and off by push button switch or
pull cords.

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13.3 AUTO FANS
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13.3.1 Auto fans shall comply with IEC 60335-1 , IEC 60335-2-80, MS 1597-2-80 and MS
1220. They shall be provided with safety thermal fuse minimum 130 ·c, 2 A.
13.3.2 Auto fans shall be of 400 mm diameter. The minimum air delivery at rated voltage
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at full speed shall be minimum of 60 m3/min with maximum wattage of 55 W.
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13.3.3 The material used for the safety wire rope shall be anti-corrosive type. These
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features shall be assembled in the manufacturer's factory.
13.4 VENTILATING FANS

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13.4.1 Venti lating fans shall comply with IEC 60335-1 , IEC 60335-2-80 and MS 1597-2-
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80. They shall be provided with safety thermal fuse minimum 130 ·c, 2 A.
13.4.2 Ventilating fans shall be wall mounted type with diameter of 200 mm , 250 mm and
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300 mm . They shall have a minimum air volume Cubic Feet per Minute (CFM) at
rated voltage at full speed as in Table 13A. They shall be equipped with automatic
shutter.
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Diameter Minimum Air Volume

(mm) (CFM)
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200 260
CJ 250 400
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300 550
Table 13A: Minimum Air Volume

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14.0 EARTHING
ER
14.1 All system earthing and equipment earthing shall comply with Electricity
Regulations 1994 and relevant parts of MS IEC 60364.
14.2 The protective conductor, copper tape and earth electrode shall comply with BS
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EN 13601.
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14.3 All protective conductors shall be of high conductivity copper conductor either
stranded or solid, continuous throughout the whole lengths and without joints.
In the instance where joints cannot be avoided, then the joints shall be of
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exothermic welding type. Mechanical clamps may only be used upon approval
of the S.O. The joint shall be robust design and protected from mechanical
damage and corrosion. Before connecting the protective conductor, the metal
works, the conductors and the metal work at the point of contact, including the
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clamps, shall be thoroughly cleaned of surface corrosion or paint and tinned to
ensure that good electrical contact is made .
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14.4 Every circuit of a switchboard , distribution board , control board and tap-off
units, all lighting points , lighting switches, fan points, fan switches , three pin
switched or unswitched socket·outlets, power point etc. shall be provided with
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circuit protective conductors. All exposed conductive parts and extraneous

conducti ve parts shall be effectively bonded to earth .
EN
14.5 Unless otherwise specified , the minimum cross sectional area of the protective
conductors shall be in accordance with the following Tables/Clause in the MS
IEC 60364-5-54 : -
(a) Circuit protective conductors - Table 54 .3 (or BS 7671 Table 54G)

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~ ) (b) Earthing conductors - Table 54.3 (where buried in the soil, the
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cross-sectional areas shall be in accordance with Table 54.2 or BS

7671 Table 54A)
(c) Bonding conductors - Clause 544 (or BS 7671 Clause 547)

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14.6 Where connections are made at switchgear and such items of electrical
equipment the protective conductors shall terminate in a cable lug or other
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approved means .
14.7 In the case of MICC cables, the copper outer sheath may be utilised as earth
protective conductor provided that at the termination of each cable run the
copper sheath is effectively bonded to earth.
SPECIFICATION FOR LOW VOLT AGE INTERNAL ELECTRICAL INSTALLATION

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14.8 Cable glands shall be installed for termination of armoured cables. It shall be
mechanical type complying with BS EN 50262 . Each cable gland shall be
installed with back nuts (lock nuts) for plain hole fixing .
ER
14.9 Cable gland shall be installed for termination of steel armoured multicore
cables and shall comply with BS EN 50262 . The cross sectional of a protective
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conductor connecting a gland earth tag washer to the earth terminal of an
enclose shall be selected in accordance with table 54.3 of MS IEC 60364-5-54.
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Minimum cross-sectional area of the corresponding
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Cross-sectional area protective conductor
of line conductor S (mm 2 )
If the protective conductor If the protective conductor is
(mm 2 ) is of the same material not of the same material
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as the line conductor as the line conductor
-k1 x $
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$:516 $
k2
16 < $:535 16 -k1 x 16

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k2
$ > 35 -$ k1 X $
-
2 k2 2
EN
Table 54 .3 of MS IEC 60364-5-54 - Minimum cross-sectional area of

protective conductors
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c)
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Mechanically protected Mechanically unprotected

2.5 mm Cu2
16 mm 2 Cu
Protected against corrosion
10 mm 2 Fe 16 mm 2 Fe
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Not protected against 25 mm 2 Cu

50 mm 2 Fe
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corrosion
Table 54.2 of MS IEC 60364-5-54 (BS 7671 Table 54A) - Minimum cross-
sectional areas of earthing conductors buried in the soi l

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14.10 The cable gland for aluminium arm ou red single-core cables shall be made of
non-ferrous male ri al.
ER
14.11 In the case of solid earthing, main earthing terminals or bars mounted on
porcelain insulators shall be provided extern al to the switchboard on the wall
near to the switchboard as indicated in the drawings. Unless otherwise
specified , main earthing bar shall be of tinned copper bar of dimension as in
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Table 14A with respect to the prospective earth fault current. Main earthing bar
shall be of sufficient length to accommodate termination for all protective
n
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conductors, earthing conductors and main equipotential bonding conductors of
electrical installation, lightni ng protection system bonding cond uctor and
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generator installation bonding conductor. Means shall be provided for
disconnecting the earthing conductors to permit measurement of the resistance
of the earthing arrangements. The joints shall be disconnectable only by means
of a tool , and shall be mechanically strong to ensure electrical continuity. A
Permanent label marked with words 'Mai n Earthing Bar - Safety Electrical
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Connections - Do Not Remove' sha ll be installed near to the main earthing bar.
All connections to the main earthing bars shall be soundly made and
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electrically satisfactory by means of bolts and nuts with spring washers and jam
nuts.
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14.12 Two sets of earthing conductors of copper tape dimension as in Table 14A shall
be provided to connect the main earthing bar to two different earth electrodes.
The earthing conductors shall be buried in the ground at a depth of not less
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than 600mm below finished ground level.
14.13 Protective conductors between switchboard and main earthing bar shall be
linked by copper tape of same cross sectional area as the main earthing bar.
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\ ) Prospective Earth fau lt

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Main Earthing Bar Earthing Conductors

currents (I) for 1s
(Width x Thickness) (No. x Copper tape size)
du ration
1510kA 25 mm x 3 mm 2 sets of 1 x 25mm x 3mm
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10 kA < I 5 25 kA 25 mm x 6 mm 2 sets of 1 x 25mm x 3mm

25 kA < I 5 30 kA 30 mm x 6 mm 2 sets of 2 x 25m m x 3mm
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30 kA < I 5 40 kA 40 mmx 6 mm 2 sets of 2 x 25mm x 3mm

40 kA < I 5 50 kA 50 mm x6 mm 2 sets of 2 x 25mm x 3 mm
Table 14A: Dimensions of Main Earthing Bar and Earthing Conductors

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14.14 Earth electrodes shall be of copper-jacketed steel core rods with 16mm
nominal diameter and supplied in 1500mm length and shall have provision for
screw coupling with another standard length. The copper jacket of 99.9 % pure
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electrolytic copper shall be of minimum radial thickness O.25mm and shall be
molecularly bonded to the steel core to ensure that the copper jacket and steel
core are non separable. Each earth electrode shall be driven 3000mm in depth.
Where the desired earth resistance value cannot be achieved after the first
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earth electrode have been driven, sufficient number of earth electrodes in
parallel shall be installed outside the resistance area until required value is
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reached. Mutual separation between two earth electrodes shall be more than,
() but less than twice, the driven depth of the earth electrode. Earth electrodes
shall not be installed close to a metallic fence. Unless the metallic fence is
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separately earthed , the fence shall be separated from the electrical earthing
system by at least 2000mm. Interconnection between different earth electrodes
shall be by means of 25mm x 3mm annealed copper tape.
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14.15 In cases where there is insufficient land area , an alternative earthing system
shall be proposed for the S.O. approval.
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14.16 Where the location of the installation is such that it is not possible in practice to
provide the two auxiliary earth electrodes for the test, two test earth electrodes
namely potential test probe and current test probe shall be installed . The test
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earth electrodes shall be one length of 1500mm in depth. The current test
probe shall be placed 30m from the first earth electrodes with potential test
probe midway between . Test leads of 2.5 sq. mm PVC insulated cable
EN
connecting test earth electrodes shall be terminated independently on the

porcelain insulators next to the main earthing terminals or bars. The test leads
shall be protected by means of non metallic conduit and buried in the ground at
a depth of not less than 600mm below finished ground level. Termination shall
be identified with permanent labels durably and legibly marked with words
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~ ) 'Potential Earth Test Probe - Do Not Remove' and 'Current Earth Test Probe -
Do Not Remove'. Similar labels of not less than 4.75mm high shall be
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permanently fixed in a visible position at earth electrodes.
14.17 The connection of the earthing conductor and/or the earth electrode to the earth
electrode shall be soundly made by the use of plumbed joints, either by brazing
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using zinc-free material with a melting point of at least 600°C or by exothermic

welding.
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14.18 Each earth electrodes shall be provided with heavy duty type inspection
chamber with removable cover. The inspection chamber shall be of square or
round type and tested in accordance with MS 26: Part 2. The minimum size of
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square type inspection chamber shall be 300mm (width) x 300mm (length) x
180mm (height) and for round type inspection chamber, the minimum size shall
be 300mm (diameter) x 180mm (height). The working load of the inspection
chamber shall be minimum 4500kg. Lifting hook shall be provided in the cover.
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The brand name shall be durably marked on the removable cover.
14.19 Residual current operated circuit breaker (RCCB) shall be provided wi th
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minimum cross sectional area 16mm 2 green PVC insulated copper conductor
cable as earthing conductors, one set of two (2) length of 1500mm earth
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electrodes, inspection chambers and removable covers. However, if the y are
connected to a main earthing system, separate earth electrode need not be
provided.
14.20 A permanent label durably marked with words 'Safety Electrical Connection -
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Do Not Remove' , in legible type not less than 4.75mm high , shall be
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permanently fixed in a visible position at or near: -
14.20.1 The point of connection of every earthing conductor to an

earth electrode, and
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14.20.2 The point of connection of every bonding conductor to

extraneous conductive parts.
EN
14.21 In addition, each earthing point shall be identified by permanent label legibly
marked with the words 'MSB Earth', 'SSB Earth ', 'RCCB Earth' or any other
appropriate words permanently fi xed to the point of connection of every
earthing conductor and earth electrode.
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15.0 LABELLING
15.1 Labels shall be filted on the outside of all switch gears, fusegears, distribution
ER
boards , sub swilchboards and main switchboards by means of non-corrodable
screws or rivet or any other method approved by the S.O.'s Representative.
The labels shall be of laminated plastic with engraved lettering with details such
as type of equipment, rating, setting , to/from where it is connected etc.
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15.2 The exact wording of the labels shall be agreed with the S.O.'s Representati ve.
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n Single line mimic schematic circuit diagram shall be provided at the fa cial of the
main switchboards showing the connection of all switchgears with respect to
busbars indicating the incoming and outgoing feeders . The diagram shall be
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single line of width 20mm with yellow perspex strip riveUed on the outside front
cover of the switchboard with arrow head indicating the direction of supply
incoming to the switchgears.
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EN
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16.0 SWITCHROOM
16.1 Approved type of rubber mat shall be provided in front of the switchboards and
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any other control boards. The rubber mat shall extend to the full length of the
switchboards , and shall be of thickness not less than 6mm and width 1000mm.
Standard notices displaying the words 'BAHAYA' and 'DILARANG MAS UK' and
Electric Shock Treatment Chart shall be provided and installed at a place as
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requ ired in accordance with Electricity Regulations 1994. Signage with words
'BILIK SUIS UTAMA', 'BILIK SUIS', 'BILIK KHIDMAT ELEKTRIK' and
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'DILARANG MEROKOK' shall be installed for all rooms containing electrical
switchboard and equipment to the satisfaction of the S.O.'s Representati ve.
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16.2 All electrical switch rooms shall be provided with one unit 9kg dry powder fire
extinguisher for A, B, C class of fire complete with pressure gauge , dischargel
hose with nozzle installed on wall bracket. The extinguisher shall be certified by
Jabatan Bomba Dan Penyelamat Malaysia valid to be used for a period of
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twelve months from the completion date of the Contract.
16.3 All trenches in the switchrooms shall be clear from debris and filled up with
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clean sand to a level above cable ducts. All cable duct entry into the cable
trench shall be sealed tight with cement against water and rodent entry. As-
installed layout plans, schematic wiring diagrams and plans showing cable
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routes and positions of earthing point with reference to easily recognizable

buildings and structures shall be suitably framed up in the switchroom. These
plans and diagrams shall be in addition to the 4 sets of prints required to be
EN
submitted to the S.O.'s Representative, after completion of the project as

stated in 20.2.
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CKE.LS.01.01.(04).2017
~ SPECIFICATION FOR LOW VOLTAGE
rJJ~ INTERNAL
Revision: 2
~ Date: Jan 2018
(L-S1 )
Page: S17 -1 of 4
17.0 REQUIREMENT FOR ANTI CORROSIVE TYPE INSTALLATIONS
17.0.1 Installation at coasta l areas (defined as within 3km from the coast) and other
ER
areas deemed necessary, material used shall be of rust proof type and/or anti
corrosive type or specially treated. The cost of the material used and treatment
applied is deemed to be included in the prices quoted.
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17.0.2 Areas wi thin 3km to 5km from the coast, special treatment for salt-spray
environment is applicable for external installation only.
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(j
17.1 WIRING
TE
17.1.1 Conduit shall preferable be buried in the wall or buried in the concrete cei ling
/ soffit of slab.
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17.1.2 In the fa lse cei ling , condui t used shall be of rigid high impact PVC type grade
Heavy Duty Code No. 4421 .
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17.1 .3 Surface conduit wiring if any, must be with the approva l of S.O. Steel conduits
shall not be used except for emergency ci rcuits. It shall be in rigid high impact
PVC conduit grade Heavy Duty Code No. 4421 with its associated system
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accessories.
17.1.4 Cable trunking and cable tray system shall be of hot dipped galvanized sheet
EN
steel. All trunking elbows, offset and combination elbows, adaptors and tees
shall be of same th ickness as the straight trunking and shall be the type
manufa ctured and supplied by the same trunking manufacturer. Any cut edges
shall be painted with galvanized paint. All screws and nuts used shall be made
from brass/stainless steel.
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\. )
17.1.5 All support accessories such as angle iron, brackets, etc. must be of hot
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dipped galvanized sheet steel.

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17.2 SWITCHBOARDS (MAIN SWITCHBOARD, SUB SWITCHBOARD AND

DISTRIBUTION BOARD)
ER
17.2.1 All switchboards shall be installed within enclosed electrical service rooms.
17.2.2 All switchboards shall be of stainless steel material (Grade SS 316).
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17.2.3 All screws and nuts shall be of brass/stainless steel.
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17.2.4 Special Treatment For Housings Of Electrical Items Used In Salt-
(") Sprayed Environment as per 17.6 shall be applied.
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17.3 SWITCHES, SWITCHED SOCKET OUTLETS AND UNSWITCHED SOCKET
OUTLETS
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17.3.1 For concealed installation, metalclad type back boxes shall be of
galvanized sheet steel.
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17.3.2 For surface and outdoor installation. switches, switched socket outlets and
un switched socket outlets shall be of sealed or anti corrosive type .
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17.4 LUMtNAIRES
EN
17.4.1 Fluorescent luminaires installed at external areas (e.g. covered walkways,

corridors) and non air-conditioned rooms, shall be of anti corrosive type with
a minimum Ingress Protection of IP65.
17.4.2 Other than ru st proof luminaires, all other luminaires (whether recessed or
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u surfaced mounting , together with all its related installation accessories i.e.
steel wires, suspension rods) shall undergo anti corrosive treatment process
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as per 17.6.
17.4.2.1 All screws and nuts shall be of brass/stainless steel.

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17.4.3 Special Treatment For Housings Of Electrical Items Used In Salt-Sprayed

Environment as per 17.6 shall be applied.
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17.5 CEILING FANS AND EXHAUST FANS
17.5.1 All fans shall be of rust proof type.
ER
17.5.2 Anti corrosive treatment for ceiling fan shall be similar to luminaires .
17.5.3 Special Treatment For Housings Of Electrical Items Used In Salt-Sprayed
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Envi ronment as per 17.6 shall be applied.
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(J 17.6 SPECIAL TREATMENT FOR HOUSINGS OF ELECTRICAL ITEMS USED IN
SALT -SPRAYED ENVIRONMENT
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17.6.1 The treatment shall produce a housing of high resistance to corrosion with a
durable finish with smooth reflective white paint. Both the inside and outside of
the metal housing shall be finished with double powder coatings of hybrid
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epoxy polyester compounds. All these housings shall undergo surface
preparation and surface pre-treatment before application of first powder
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coating.
17.6.2 The surface preparation shall consist of firstly chemical cleaning to effectively
remove mill scale , rust, contaminants and corrosive compounds; followed by
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solvent cleaning and degreasing to remove oil or grease. After rinsing , the
cleaned surface shall immediately undergo zinc phosphate surface pre-
treatment. However, prior to zinc phosphate surface pre-treatment, the surface
EN
shall be conditioned with a recommended conditioner. The pre-treated surface

shall then be rinsed and dried in the oven before undergoing first powder
coating application.
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17.6.3 The pre-treated surface shall undergo application of first powder coating and
\ ) baked in oven. The curing time and temperature shall be as recommended by
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the powder coating system manufacturer, otherwise at the temperature 204°C

for 10 minutes. The film thickness of the first powder coating shall be within 50
to 80 microns.
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17.6.4 Next, the part shall be inspected for any defect before applying second powder
coating. The second powder coat shall be applied and then the part shall be
baked in oven for the recommended time and temperature. The film thickness
ER
of the second powder coating shall be within 50 to 80 microns . The finished
part shall then be inspected for any defects. The finished colour shall be white.
17.6.5 Each fan blade and housing , luminaire housing and switchboard housing shall
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be labeled "Double Hybrid Epoxy Polyester Powder Coating". For identification
purposes they shall also carry a model/serial number, brand name and date of
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n manufacture.
17.6.6 The manufacturer shall give warra nty/guarantee for the special treatment to the
TE
metal parts against corrosion for at 12 months from the date of installation at
the site. This warranty/guarantee sha ll cover fu ll replacement of all defective
parts including installation at site at the manufacturer's expense. The
manufacturer shall replace and install the defective parts within 1 week after
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joint inspection at site.
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EN
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CKE.LS.01.01 .(04).2017
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Date: Jan 2018
Page: S18 -1 of 2
18.1 TEST AND CALIBRATION OF MEASURING AND TEST INSTRUMENTS
18.1.1 The test instruments shall be designed, manufactured, tested and shipped in
ER
accordance with IEC 61010-1 and IEC 61557-1. All measuring and test
instruments used for testing of the electrical installations and , calibration and
test for the protection relays shall be regularly tested and calibrated by the
manufacturers or accredited calibration laboratories for their functiona lity and
accuracy. The measurement accuracy of reading shall be ± 10 % for analog
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and digital instruments. Test and Calibration Reports or Certificates for the
n measuring and test instruments issued by the calibration laboratory shall be
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valid for 2 years from the date of issuance.
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18.1.2 The instruments and their Test and Calibration Reports or Certificates shall be
submitted to 8.0.'s Representati ve for verification 2 weeks before testing of the
electrical installations being carried out. No test on the electrical installations
shall be carried out without prior approval of the 8.0.'s Representative.
Notwithstanding the va lidity of the aforesaid Reports or Certificates the
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measuring and test instruments shall be re-calibrated if so required by the
8.0.'s Representative after any mechanical or electrical mishandling. Fee
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required for the testing and calibrating of the measuring and test instruments is
deemed to be included in the Contract.
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18.2 TEST AND TEST CERTIFICATES
18.2.1 After the installation work has been completed and before Certificate of
Practical Completion is issued , the electrical installations (covered under this
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part of the Contract shall be tested as prescribed in Electricity Regulations

1994 and IEC 60364-6 and any other tests deem necessary by the 8.0.'s
Representative. In the event the installation fails to pass any of these tests, the
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Electrical Contractor shall take such measures as are necessary to remedy the
l) defects and the installation shall not be considered as completed until all such
tests have been passed.
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18.2.2 The tests to be carried out where relevant, by the Electrical Contractor shall
consist of the following. In the absence of test method in IEC 60364-6, then the
testing method adopted shall be as per B8 7671: -
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18.2.2.1 Continuity of protective conductors including main and

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supplementary equipotential bonding conductors.
18.2.2 .2 Continuity of ring fina l circuit conductors.
18.2.2.3 Insulation resistance.
18.2.2.4 Protection by automatic disconnection of the supply:

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18.2.2.4.1 Operation of residual current devices (RCDs)

18.2.2.4.2 Measurement of the re sistance of the earth electrode
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18.2.2.5 Polarity.
18.2.2.6 Functional and operational tests.
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18.2.3 The following additional tests shall be carried out as and when instructed:
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18.2.3.1 Protection by Separated Extra l ow Voltage (SElV), Protective
Extra l ow Voltage (PElV), or by electrical separation .
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18.2.3.2 Insulation resistance/impedance of floor and wall.
18.2.3.3 Measurement of earth fault loop impedance.
18.2.3.4 Check of phase sequence.
18.2.3.5 Verifica tion of voltage drop.
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18.2.3.6 Prospective fault current (BS 7671)
18.2.4 All RCDs sha ll be checked and tested for their effectiveness in operation
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within specified sensitivity and tripping time. A ll protection relays and device
shall be checked, tested and calibrated by an Electrical Services Engineer
registered with Suruhanjaya Tenaga.
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18.2.5 The Electrical Contractor shall arrange wi th the Electrical Services Engineer to
conduct and carry out the stability and functiona lity test, check and calibration
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of the protection relays and device. Fee required for the test, check and
calibration as described above is deemed to be included in the Contract.
18.2.6 The S.O.'s Representative reserves the right to be present at all tests and the
Electrical Contractor shall give at least 1 week notice in writi ng to the S.O.'s
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l.J Representative for this purpose. In any case, no test shall be carried out
without prior approval of the S.O.'s Representative. Copies of all the test
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certificates together with As-Installed Drawings properly bound and titled shall
be submitted to the S.O.'s Representative within 1 week after the completion
of the testing.
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18.2.7 Supervision and Completion Certificate and Test Certificate including copies
of all the test results and drawings as prescribed in Electricity Regulations
1994 shall be submitted to the S.O.'s Representative within two weeks after
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the completion of the testing. The Certificates shall be properly bound in hard
cover and titled.

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19.0 SERVICE AND MAINTENANCE
19.1 During the Defects Liability Period, the Electrical Contractor shall be responsible
ER
for the service and maintenance work for the complete installation. All works shall
be carried out by competent person. All labour, material, tools and parts
necessary to rectify the defect due to manufacturing/installation faults shall be
supplied/executed at the Electrical Contractor's cost.
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19.2 The service and maintenance to be performed and defects to be rectified and
n making good shall include but not limited to the following: -
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19.2.1 Replacing or making good all luminaires, control gears , capacitors, lamps,
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switches, sockets-outlets, switched socket outlets, power points, fuses,
MCCB , MCB , ACB, RCCB , push buttons, contactors, starters, meters etc.
19.2.2 Replacing all consumable items that do not meet the manufacturer's
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guaranteed/declared life span or supplying 5% of the total quantity of
lamps of each type used in the project.
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19.2.3 Replacing and making good all loose and burnt cables and termination, all
mechanical support linkage, earth electrode chambers and covers,
conduits, trunkings etc.
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19.2.4 Making good any damage to roads, buildings , drains, cables, pipes,
concrete areas, paved areas etc. which had not been properly made
EN
good arising out of his work.
19.2.5 All other works as deemed necessary by the S.O.'s Representative.

M
u 19.3 All works shall be carried out as soon as the Electrical Contractor is being informed
by the S.O.'s Representative or the occupant and shall be carried out immediately
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and completed within a reasonable time except under emergency situation as

stipulated in the Supplementary Conditions for Electrical Work. If the Electrical
Contractor fails to comply with the above requirements, the S.O.'s Representative
reserves the right to engage another party to carry out the work, in which case , the
O
Electrical Contractor shall be responsible for all the expenses incurred.

D

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20.0 SHOP DRAWINGS, AS-INSTALLED DRAWINGS, MANUALS AND TOOLS
20.1 SHOP DRAWINGS
ER
20.1.1 2 sets of prints of shop drawings for construction andl or installation shall be
submitted to the S.O:s Representative for approval. The Electrical Contractor shall
prepare and submit shop drawings for the whole work or parts of the work at least
D
minimum 2 weeks before the work begins . If the shop drawings submitted are not
acceptable by the S.O:s Representative, the Electrical Contractor shall amend and
n re-submit the shop drawings within 2 weeks from the date of return of the shop
N
drawings. No work includ ing fabrication of the switchboards shall be carried out
without the shop drawings being approve d by the S.O : s Representative.
TE
20.1.2 The shop drawings shall include and show the following:
20.1.2.1 The dimensioned general arrangements, layouts and positions of

luminaires, wiring accessories such as switches and switched socket
A
outiets, switchgears , distribution boards, switchboards and all others
EJ
necessary for the complete electrical installations as specified in the
Drawings andlor Bill of Quantities;
20.1.2.2 Circuits and switching arrangements including schematic line diagrams

M
of the installation ;
20 .1.2.3 The dimensioned general arrangements , layouts and routes of final

EN
circuits;
20 .1.2.4 The dimensioned general arrangements, layouts, routes and positions

of all lateral and vertical mains andlor submains ;
M
I
\ ) 20.1.2.5 The dimensioned layouts and positions of all holes and cut through in
the walls and fioors for the lateral and vertical mains andlor submains;
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20.1.2.6 The dimensioned general arrangements and layouts of the equipment

and the schematic line diagram of the switchboards;
20.1.2.7 Cable routes for all cables laid underground , in ducts and trenches;
O
20.1.2.8 The dimensioned general arrangements and layout of earthing system

D
including routes for earthing conductors and positions of earth

electrodes . The cost of all these shop drawings , whether or not
provided in the Bill of Quantities, is deemed to be included in the
Contract.
SPECIFICATION FOR lOW VOLTAGE INTERNAL ELECTRICAL INSTAllATION

CKE.LS.01.01.(04).2017
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20.2 AS-BUILT DOCUMENT AND TOOLS
20.2.1 As-Built document shall consist of but not limited to the As-Installed drawings ,
ER
manuals, certificates, catalogues , inventories and parts lists.
20.2.2 The As-Installed drawing shall comprise of:-
D
20.2.2.1 Site plan
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20.2.2.2 Schematic Wiring Diagram
TE
20.2.2.3 Electrical Layout Plans
20.2.2.4 Control Circuits drawings
20.2.2.5 Layout plans of cable routes

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20.2.2.6 Earthing points with reference to easily recognisable buildings and
EJ
structures.
20.2.3 These drawings shall be labelled at the lower right hand corner with the Electrical
M
Contractor's name and address , date of commissioning, scale, drawing number

(the drawing number to be obtained from the S.O.'s Representative), title and
following particulars: -
EN
JABATAN KERJA RAYA

CONTRACT NO.:
M
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O
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20.2.4 If Ihe drawings submitted are not according to the actual installation at site and/or
not acceptable to the S.O.'s Representative, the Electrical Contractor shall
amend and re -submit the drawings within two weeks from the date of return of
ER
the drawings to the satisfaction of the S.O.'s Representative.
20 .2.5 Manuals and documents for ACB, MCCB and other important electrical
switchgears shall be supplied.
D
20 .2.6 The manual shall comprise of:-
N
() 20.2.6.1 Installation manual ;
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20.2.6.2 Operation manual;
20.2.6.3 Service and Maintenance Manual;

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20.2.6.4 Parts List;
20.2.6.5 Product Data and catalogue ;

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20.2.6 .6 Product Test Certificates ;

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20 .2.7 Certificates shall comprise of:-

EN
All Testing Certificates (as per section 18.2)
20 .2.8 Catalogues, parts lists, inventories, shall be as per project requirements
20 .2.9 Each of the As-Built documents shall be bound together with hard cover and
M
~ ) submitted in minimum four (4) sets upon issuance of Certificate of Practical

Completion of the project.
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20.2.10 In addition , one set of the As-Installed drawing shall be submitted in the form of
tracing/original document, and two sets in CD ROM.
O
20.2.11 Special tools required for the operation , service and maintenance of ACB ,
MCCB and other equipment shall also be provided.
D
20.2.12 The cost of all these prints, manuals , tools etc. is deemed to be included in the
Contract.

CKE.LS.01 .01.(04).2017
....... SPECIFICATION FOR LOW VOLTAGE
rIJK!l
....... ~...,-'
INTERNAL
Revision: 3
Page : S21 - 1 of 10
STANDARD DESCRIPTION
SPECIFICATION FOR PVC INSULATION AND SHEATH OF
MS 138
ELECTRIC CABLES
ER
SPECIFICATION FOR 'KELUAR' SIGNS (INTERNALLY
MS 983 ILLUMINATED) (SECOND REVISION)
SPECIFICATION FOR DIRECT ACTING INDICATING
MS 925 ELECTRICAL MEASURING INSTRUMENTS AND THEIR
D
ACCESSSORIES
n MS 619:PART 2-22 PARTICULAR REQUIREMENTS-LUMINAIRES FOR
N
EMERGENCY LIGHTING (F IRST REVISION)
TE
MS 1202 SPECIFICATION FOR CURRENT TRANSFORMERS
HOUSEHOLD AND SIMILAR ELECTRICAL APPLIANCES -
MS 1597: PART 2-
SAFETY - PART 2-80: PARTICULAR REQUIREMENTS FOR
80 FANS
PERFORMANCE AND CONSTRUCTION OF ELECTRIC
A
MS 1220
CIRCULATING FANS AND REGULATORS
EJ
METHODS OF TESTING CONCRETE PART 2 : METHODS
MS26: PART 2
OF TESTING HARDENED CONCRETE
SPECIFICATION FOR PVC-INSULATED CABLES FOR
MS274
M
ELECTRICITY SUPPLY
SPECIFICATION FOR CONDUCTORS IN INSULATED
MS69
CABLES AND CORDS
EN
SPECIFICATION FOR COPPER FOR ELECTRICAL

PURPOSES, WIRE FOR GENERAL ELECTRICAL
MS280 PURPOSES FOR INSULATED CABLES AND FLEXIBLE
CORDS
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SPECIFICATION FOR PVC INSULATION AND SHEATH OF

( ) MS 138
ELECTR IC CABLES
MS 275-1 SPECIFICATION FOR STEEL CONDUITS & FITTINGS WITH
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METRIC THREADS OF ISO FORM FOR ELECTRICAL

INSTALLATION PART 1 : STEEL CONDUITS, BENDS &
COUPLERS (INTERNATIONALLY ACCEPTABLE SIZES)
MS 1534: PT 1 SPECIFICATION FOR CONDUIT SYSTEMSFOR
O
ELECTRICAL INSTALLATION : PART 1 : GENERAL

REQUIREMENTS
D
MS 1534:PT2 :SEC1 SPECIFICATION FOR CONDUIT SYSTEMS FOR

ELECTRICAL INSTALLATION :PART 2: PARTICULAR
REQUIREMENTS :SECTION 1 : RIGID CONDUIT SYSTEMS

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SWITCHES FOR HOUSEHOLD AND SIMILAR FIXED-
ER
MS 616 ELECTRICAL INSTALLATION : PART 1 : GENERAL
REQUIREMENTS
SPECIFICATION FOR 13A PLUGS , SOCKET OUTLETS ,
MS589
ADAPTORS AND CONNECTION UNITS
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SPECIFICATION FOR 15 A PLUGS AND SOCKET -OUTLETS
MS 1577
FOR DOMESTIC AND SIMILAR PURPOSES
n
N
BOXES AND ENCLOSURES FOR ELECTRICAL
MS 1873 ACCESSORIES FOR HOUSEHOLD AND SIMILAR FIXED
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MS 770 SPECIFICATION FOR CEILING ROSES
SPEC IFICATION FOR BAYONET LAMPS - CAPS
MS 769
LAMPHOLDERS AND B.C . ADAPTORS
A
SPEC IFICATION FOR BALLASTS FOR TUBULAR
MS 141: PT 2 FLUORESCENT LAMPS : PART 2: PERFORMANCE
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REQUIREMENTS
MS IEC 60038 IEC STANDARD VOLTAGES
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HOUSEHOLD AND SIMILAR ELECTRICAL APPLIANCES -

MS IEC 60335-1
SAFETY - PART 1: GENERAL REQUIREMENTS
SPECIFICATION FOR CONDUIT FITTINGS FOR
EN
ELECTRICAL INSTALLATIONS - PART 2: PARTICULAR

IEC 61035-2-2 SPECIFICATIONS - SECTION 2: CONDUIT FITTINGS OF
INSULATING MATERIAL
SPECIFICATION FOR CONDUIT FITTINGS FOR
M
() ELECTRICAL INSTALLATIONS - PART 2: PARTICULAR

SPECIFICATIONS - SECTION 3: FITTINGS FOR FLEXIBLE
IEC 61035-2-3
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CONDUITS OF METAL, INSULATING OR COMPOSITE

MATERIALS AND FOR PLIABLE CONDUITS OF METAL OR
COMPOSITE MATERIALS
MS IEC 60598-1 LUMINAIRES PART 1 : GENERAL REQUIREMENTS AND
O
TEST(SECOND REVISION)
MS IEC 60598-2-1 LUMINAIRES PART 2 : PARTICULAR REQUIREMENTS .
D
SECTION ONE: FIXED GENERAL PURPOSE LUMINAIRES

MS IEC 60598-2-2 LUMINAIRES PART 2: PARTICULAR
REQUIREMENTS .SECTION TWO: RECESSED LUMINAIRES

© Hak Clpta: 1999 Cawangan Kejuruteraan Elektrlk, JKR Malaysia
CKE.LS.01.01.(04) .2017
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LOW-VOLTAGE SWITCHGEAR AND CONTROL GEAR
ASSEMBLIES - PART 3: PARTICULAR REQUIREMENTS
ER
FOR LOW-VOLTAGE SWITCHGEAR AND CONTROLGEAR
MS IEC 60439-3 ASSEMBLIES INTENDED TO BE INSTALLED IN PLACES
WHERE UNSKILLED PERSONS HAVE ACCESS FOR THEIR
USE - DISTRIBUTION BOARDS
D
LOW-VOLTAGE SWITCHGEAR AND CONTROLGEAR
ASSEMBLIES - PART 5: PARTICULAR REQUIREMENTS FOR
n
N
MS IEC 60439-5 ASSEMBLIES INTENDED TO BE INSTALLED OUTDOORS IN
PUBLIC PLACES - CABLE DISTRIBUTION CAB INETS (CDCS)
TE
FOR POWER DISTRIBUTION IN NETWORKS
CABLE TRUNKING AND DUCTING SYSTEMS FOR
MS IEC 61084 ELECTRICAL INSTALLATION PART 1: GENERAL
REQUIREMENTS
A
CABLE TRAY SYSTEMS AND CABLE LADDER SYSTEMS
MS IEC 61537
FOR CABLE MANAGEMENT
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SWITCHES FOR HOUSEHOLD AND SIMILAR FIXED

MS IEC 60669-1 ELECTRICAL INSTALLATION PART 1: GENERAL
REQUIREMENTS
M
SURGE PROTECTIVE DEVICES CONNECTED TO LOW-

MS IEC 61643-1 VOLTAGE POWER DISTRIBUTION SYSTEMS - PART 1:
PERFORMANCE REQUIREMENTS AND TESTING METHODS
EN
MS IEC 60947-1 LOW-VOLTAGE SWITCHGEAR AND CONTROLGEAR -

PART 1 : GENERAL RULES
MS IEC 60947-2 LOW-VOLTAGE SWITCHGEAR AND CONTOLGEAR - PART
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l) 2: CIRCUIT-BREAKERS
LOW-VOLTAGE SWITCHGEAR AND CONTROL GEAR-PART
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MS IEC 60947-3 3: SWITCHES , DISCONNECTORS,SWITCH-

DISCONNECTORS AND FUSE-COMBINATION UNITS
MS IEC 60947-4-1 LOW - VOLTAGE SWITCHGEAR AND CONTROLGEAR -
O
PART 4-1: CONTACTORS AND MOTOR- STARTERS-

ELECTROMECHANICAL CONTACTORS AND MOTOR-
D
STARTERS

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LOW-VOLTAGE SWITCHGEAR AND
MS IEC 60439-1 CONTROLGEAR ASSEMBLIES - PART 1:TYPE-TESTED
ER
AND PARTIALLY TYPE-TESTED ASSEMBLIES
LOW-VOLTAGE SURGE PROTECTIVE DEVICES - PART 12 :
SURGE PROTECTIVE DEVICES CONNECTED TO LOW-
MS IEC 61643-12 VOLTAGE POWER DISTRIBUTION SYSTEMS - SELECTION
D
AND APPLICATION PRINCIPLES
COMPONENTS FOR LOW-VOLTAGE SURGE PROTECTIVE
n
N
MS IEC 61643-331 DEVICES - PART 33 1: SPECIFICATION FOR METAL OXIDE
VARISTORS (MOV)
TE
COMPONENTS FOR LOW-VOLTAGE SURGE PROTECTIVE
MS IEC 61643-311 DEVICES - PART 311: SPECIFICATION FOR GAS
DISCHARGE TUBES (GOT)
- PERATURAN-PERATURAN ELEKTRIK 1994
A
ELECTRICAL INSTALLATION OF BUILDINGS - PART 5-54 :
SELECTION AND ERECTION OF ELECTRICAL EQUIPMENT:
EJ
MS IEC 60364-5-54 EARTHING ARRANGEMENTS , PROTECTIVE CONDUCTORS

AND PROTECTIVE BONDING CONDUCTORS
ELECTRICAL INSTALLATION OF BUILDINGS -PART 5-52:
M
MS IEC 60364-5-52 SELECTION AND ERECTION OF ELECTRICAL EQUIPMENT

- WIRING SYSTEMS
LOW-VOLTAGE SWITCHGEAR ANDCONTROLGEAR
EN
MS IEC 60439-2 ASSEMBLIES - PART 2: PARTICULAR REQUIRE MENTS

FOR BUSBAR TRUNKING SYSTEMS
SPECIFICATION FOR A.C SUPPLIED ELECTRONIC
MS IEC 60928 BALLASTS FOR TUBULAR FLUORESCENT LAMPS-
M
u GENERAL AND SAFETY REQUIREMENTS.

SPECIFICATION FOR A.C SUPPLIED ELECTRONIC
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MS IEC 60929 BALLASTS FOR TUBULAR FLUORESCENT LAMPS-

PERFORMANCE REQUIREMENTS.
MS IEC 61184 BAYONETLAMPHOLDERS
O
ELECTROMAGNETIC COMPATIBILITY (EMC) - PART 3 :

LIMITS - SECTION 2 : LIMITS FOR HARMONIC CURRENT
MS IEC 61000-3-2 EMISIONS (EQUIPMENT INPUT CURRENT LESS THAN AND
D
EQUAL TO 16A PER PHASE)

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AUXILIARIES FOR LAMPS - CAPACITORS FOR USE IN
ER
MS IEC 61048 TUBULAR FLUORESCENT AND OTHER DISCHARGE LAMP
CIRCUITS - GENERAL AND SAFETY REQUIREMENTS
CAPACITORS FOR USE IN TUBULAR FLUORESCENT AND
MS IEC 61049 OTHER DISCHARGE LAMP CIRCUITS PERFORMANCE
D
REQUIREMENTS
N
MS IEC 60155 GLOW-STARTERS FOR FLUORESCENT LAMPS
LAMPHOLDERS FOR TUBULAR FLUORESCENT LAMPS AND
MS IEC 60400
TE
STARTERHOLDERS (FIRST REV ISION)
LAMP CONTROL GEAR-
MS IEC 61347-1
PART 1:G ENERAL AND SAFETY REQUIREMENTS
LAMP CONTROL GEAR-PART 2-3:PARTICULAR
A
MS IEC 61347-2-3 REQUIREMENTS FOR A.C SUPPLIED ELECTRONIC
BALLASTA FOR FLUORESCENT LAMPS
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LAMP CONTROLGEAR - PART 2-8: PARTICULAR

MS IEC 61347-2-8 REQUIREMENTS FOR BALLASATS FOR FLUORESCENT
LAMPS
M
MS IEC 61000 ELECTROMAGN ETIC COMPATIBILITY (EMC)

RESIDUAL CURRENT OPERATED CIRCUIT-BREAKERS
WITHOUT INTEGRAL OVERCURRENT PROTECTION FOR
EN
MS IEC 61008-1 HOUSEHOLD AND SIMILAR USES (RCCBs) - PART 1:

GENERAL RULES
RES IDUAL CURRENT OPERATED CIRCUIT- BREAKERS
WITHOUT INTEGRAL OVERCURRENT PROTECTION FOR
M
u MS IEC 61008-2-1 HOUSEHOLD AND SIMILAR USES (ReCB's) -PART 2-1 :

APPLICABILITY OF THE GENERAL RULES TO RCCB's
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FUNCTIONALLY INDEPENDENT OF LINE VOLTAGE

MS IEC 61009-1 RESIDUAL CURRENT OPERATED CIRCUIT-BREAKERS WITH
INTEGRAL OVERCURRENT PROTECTION FOR HOUSEHOLD
AND SIMILAR USES (RCBOs) - PART 1: GENERAL RULES
O
MS IEC 61009-2-1 RESIDUAL CURRENT OPERATED CIRCUIT-BREAKERS WITH

INTEGRAL OVERCURRENT PROTECTION FOR HOUSEHOLD
D
AND SIMILAR USES (RCBOS) - PART 2-1 : APPLICABILITY

OFTHE GENERAL RULES TO RCBOS FUNCTIONALLY
INDEPENDENT OF LINE VOLTAGE

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ELECTRICAL ACCESSORIES - CIRCUIT-BREAKERS FOR
ER
OVERCURRENT PROTECTION FOR HOUSEH OLD AND
MS IEC 60898-1 SIMILAR INSTALLATIONS - PART 1: CIRCU IT-BREAKERS
FOR A.C . OPERATION
CIRCUIT-BREAKERS FOR OVERCURRENT PROTECTION
D
MS IEC 60898-2 FOR HOUSEHOLD AND SIMILAR INSTALLATIONS - PART
2:CIRCUIT-BREAKERS FOR A.C. AND D.C. OPERATION
n
N
PROTECTION AGAINST LIGHTNING - PART 1: GENERAL
MS IEC 62305
TE
PRINCIPLES (FIRST REVISION)
MS IEC 60838 MISCELLANEOUS LAMPHOLDERS
MS IEC 60238 EDISON SCREW LAMPHOLDERS (FIRST REVISION)
INSTRUMENT TRANSFORMERS - PART 1: CURRENT
A
IEC 60044-1
TRANSFORMERS
DIRECT ACTING INDICATING ANALOGUE ELECTRICAL
EJ
IEC 60051
MEASURING INSTRUMENTS AND THEIR ACCESSORIES
ELECTRICAL AND ELECTRONIC MEASUREMENT
IEC 60359
EQUIPMENT - EXPRESSION OF PERFORMANCE
M
IEC 60255 MEASURING RELAYS AND PROTECTION EQUIPMENT

LOW-VOLTAGE FUSES - PART 1: GENERAL
IEC 60269
EN
REQUIREMENTS
BASIC AND SAFETY PRINCIPLES FOR MAN-MACHINE
INTERFACE, MARKING AND IDENTIFICATION-
IEC 60445 IDENTIFICATION OF EQUIPMENT TERMINALS, CONDUCTOR
M
TERMINATIONS AND CONDUCTORS

l )
LOW-VOLTAGE SWITCHGEAR AND CONTROLGEAR - PART
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IEC 60947-6-1 6-1: MULTIPLE FUNCTION EQU IPMENT-TRANSFER

SWITCHING EQUIPMENT
LUMINAIRES -
IEC 60598-2-22 PART 2-22: PARTICULAR REQUIREMENTS - LUMINAIRES
O
FOR EMERGENCY LIGHTING

D
DEGREES OF PROTECTION PROV IDED BY ENCLOSURES

MS IEC 60529
I liP CODE)

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POWER CABLES WITH EXTRUDED INSULATION AND THEIR
IEC 60502 ACCESSORIES FOR RATED VOLTAGES FROM 1 KV (UM =
ER
1,2 KV) UP TO 30 KV (UM = 36 KV)
MINERAL INSULATED CABLES AND THEIR TERMINATIONS
IEC 60702
WITH A RATED VOLTAGE NOT EXCEEDING 750 V
D
TESTS FOR ELECTRIC CABLES UNDER FIRE CONDITIONS -
IEC 60331
CIRCUIT INTEGRITY
(j
N
TESTS ON ELECTRIC AND OPTICAL FIBRE CABLES UNDER
IEC 60332-1
FIRE CONDITIONS .
TE
TESTS ON ELECTRIC AND OPTICAL FIBRE CABLES UNDER
IEC 60332-3
FIRE CONDITIONS
MEASUREMENT OF SMOKE DENSITY OF CABLES BURNING
IEC 61034
UNDER DEF INED CONDITIONS
A
CONDUIT SYSTEMS FOR CABLE MANAGEMENT - OUTSIDE
DIAMETERS OF CONDUITS FOR ELECTRICAL
EJ
IEC 60423 INSTALLATION (L-S1)S AND THREADS FOR CONDUITS AND
FITTINGS
CONDUIT SYSTEMS FOR CABLE MANAGEMENT - PART 1:
M
IEC 61386-1
GENERAL REQUIREMENTS
CONDUIT SYSTEMS FOR CABLE MANAGEMENT - PART 21 :
IEC 61386-21
PARTICULAR REQUIREMENTS - RIGID CONDUIT SYSTEMS
EN
CONDUIT FOR ELECTRICAL INSTALLATION SPECIFICATION

IEC 60614-1
PART 1
CONDUIT FOR ELECTRICAL INSTALLATION . PARTICULAR
IEC 60614-2-2 SPECIFICATIONS. SPECIFICATIONS FOR RIGID PLAIN
M
CONDU ITS OF INSULATING MATERIAL

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ACCESSOR IES FOR HOUSEHOLD AND SIMILAR FIXED

IEC 60670-1 ELECTRICAL INSTALLATION (L-S1)S - PART 1: GENERAL
REQUIREMENTS
O
SINGLE-CAPPED FLUORESCENT LAMPS - PERFORMANCE

IEC 60901
SPECIFICATIONS
D
SINGLE-CAPPED FLUORESCENT LAMPS - SAFETY

IEC 61199
SPECIFICATIONS

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SELF-BALLASTED LAMPS FOR GENERAL LIGHTING
IEC 60968
SERVICES - SAFETY REQUIREMENTS
ER
SELF-BALLASTED LAMPS FOR GENERAL LIGHTING
IEC 60969
SERVICES - PERFORMANCE REQUIREMENTS
AC MOTOR CAPACITORS - PART 1: GENERAL -
D
PERFORMANCE, TESTING AND RATING - SAFETY
IEC 60252-1 REQUIREMENTS - GUIDANCE FOR INSTALLATION AND
n
N
OPERATION
SAFETY REQUIREMENTS FOR ELECTRICAL EQUIPMENT
TE
IEC 61010-1 FOR MEASUREMENT, CONTROL , AND LABORATORY USE-
PART 1: GENERAL REQUIREMENTS
ELECTRICAL SAFETY IN LOW VOLTAGE DISTRIBUTION
SYSTEMS UP TO 1 000 V A.C. AND 1 500 V D.C. -
A
IEC 61557-1 EQU IPMENT FOR TESTING , MEASURING OR MONITORING
OF PROTECTIVE MEASURES - PART 1: GENERAL
EJ
REQUIREMENTS
LOW-VOLTAGE ELECTRICAL INSTALLATION - PART 6:
IEC 60364-6
VERIFICATION
M
DOUBLE-CAPPED FLUORESCENT LAMPS -

MS IEC 60081
PERFORMANCE SPECIFICATIONS (IEC 60081:2003 , lOT)
EN
DOUBLE - CAPPED FLUORESCENT LAMPS - SAFETY

MS IEC 61195
SPECIFICATIONS (IEC 61195 : 1999, lOT)
TEST ON GASES EVOLVED DURING COMBUSTION OF
ELECTRIC CABLES - PART 2: DETERMINATION OF
M
IEC 60754-2 DEGREE OF ACIDITY OF GASES EVOLVED DURING THE

COMBUSTION OF MATERIALS TAKEN FROM ELECTRIC
CABLES BY MEASURING PH AND CONDUCTIVITY
KU
SPECIFICATION FOR CONDUIT FITIINGS FOR

IEC 61035-1 ELECTRICAL INSTALLATION PART 1: GENERAL
REQUIREMENTS .
O
SPECIFICATION FOR CONDUIT FITIINGS FOR

IEC 6 1035-2-1 ELECTRICAL INSTALLATION PART 2: PARTICULAR
D
SPECIFICATIONS - SECTION 1: METAL CONDUIT FITIINGS .

IEEE RECOMMENDED PRACTICE ON CHARACTERIZATION
IEEE Sid C62.41.2 OF SURGES IN LOW-VOLTAGE (1000 V AND LESS) AC
POWER CIRCUITS

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ELECTRIC CABLES. THERMOSETTING INSULATED ,
BS 5467 ARMOURED CABLES FOR VOLTAGES OF 600/1000 V AND
ER
1900/3300 V
ELECTRIC CABLES. PVC INSULATED, ARMOURED CABLES
BS 6346
FOR VOLTAGES OF 600/1000 V AND 1900/3300 V
D
SPECIFICATION FOR PERFORMANCE REQUIREMENTS FOR
BS 6387 CABLES REQUIRED TO MAINTAIN CIRCUIT INTEGRITY
N
UNDER FIRE CONDITIONS
SPECIFICATION FOR CONDUIT SYSTEMS FOR CABLE
BS EN 50086-1
TE
MANAGEMENT. GENERAL REQUIREMENTS
SPECIFICATION FOR IDENTIFICATION OF PIPELINES AND
BS1710 SERVICES
BS 4800 SCHEDULE OF PAINT COLOURS FOR BUILDING PURPOSES
A
SPECIFICATION FOR AMINOPLASTIC MOULDING
BS 1322
MATERIALS
EJ
COPPER AND COPPER ALLOYS. COPPER ROD, BAR AND
BS EN 13601
WIRE FOR GENERAL ELECTRICAL PURPOSES
BS 7671 REQUIREMENTS FOR ELECTRICAL INSTALLATION
M
LIMITS AND METHODS OF MEASUREMENT OF RADIO

BS EN 55015 DISTURBANCE CHARACTERISTICS OF ELECTRICAL
LIGHTING AND SIMILAR EQUIP MENT
EN
BS EN 50262 CABLE GLANDS FOR ELECTRICAL INSTALLATION

SPECIFICATIONS FOR CON DUITS FOR ELECTRICAL
IEC 60614-2-5 INSTALLATIONS - PART 2: PARTICULAR SPECIFICATIONS
FOR CONDUITS - SECTION 5: FLEXI BLE CONDUITS
M
~) BOXES AND ENCLOSURES FOR ELECTRICAL

ACCESSORIES FOR HOUSEHOLD AND SIMILAR FIXED
KU

MS 1873 PART 24 REQUIREMENTS FOR ENCLOSURES FOR HOUSING
PROTECTIVE DEVICES AND SIMILAR POWER CONSUMING
DEVICES (IEC 60670-24:2005, lOT)
O

ACCESSORIES FOR HOUSEHOLD AND SIMILAR FIXED
D

IEC 60670-24 REQUIREMENTS FOR ENCLOSURES FOR HOUSING
PROTECTIVE DEV ICES AND SIMILAR POWER CONSUMING
DEVICES (IEC 60670-24 :2005, lOT)

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MS 2112-3 ELE CTRIC CABLE AND WIRE - POLYVINYL CHLORIDE (PVC)
INSULATED CABLES OF RATED VOLTAGES UP TO AND
ER
INCLUDING 450/750 V - PART 3: NON-SHEATHED CABLES
FOR FIXED WIRING
MS 2112-4 ELECTRIC CABLE AND WIRE - POLYVINYL CHLORIDE (PVC)
INSULATED CABLES OF RATED VOLTAGES UP TO AND
D
INCLUDING 450/750 V - PART 4: SHEATHED CABLES FOR
n FIXED WIRING
N
IEC 60688 ELECTRICAL MEASURING TRANSDUCERS FOR
CONVERTING A.C. AND D.C. ELECTRICAL QUANTITIES TO
TE
ANALOGUE OR DIGITAL SIGNALS
IEC 6247 1 PHOTOBIOLOGICAL SAFETY OF LAMPS AND LAMP
SYSTEMS
IEC 61547 EQUIPMENT FOR GENERAL LIGHTING PURPOSES - EMC
A
IMMUNITY REQUIREMENT
IEC 61347-2-13 LAMP CONTROLGEAR - PART 2-13: PARTICULAR
EJ
REQUIREMENT FOR D.C. OR A .C. SUPPLIED ELECTRONIC
CONTROL GEAR FOR LED MODULES
IEC 62384 DC OR AC SUPPLIED FOR CONTROL GEAR FOR LED
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MODULES - PERFORMANCE REQUIREMENTS

IEC 62031 LED MODU LES FOR GENERAL LIGHTING - SAFETY
SPECIFICATIONS
EN
IEC 60838-2-2 MISCELLANEOUS LAMPHOLDER PART 2-2: PARTICULAR

REQUIREMENTS - CONNECTORS FOR LED MODULES
IES LM-79-08 APPROVED METHOD: ELECTRICAL AND PHOTOMETRIC.
MEASUREMENTS OF SOLID STATE LIGHTING PRODUCTS
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IES LM-80-08 APPROVED METHOD: MEASURING LUMEN MAINTENANCE

~ ) OF LED LIGHT SOURCES
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L-S3
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SPECIFICATION FOR
LOW VOLTAGE
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UNDERGROUND CABLE
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CKE.LS.01.03.(01).2020
EN
JKR 20300-0138-23
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CAWANGAN KEJURUTERAAN
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ELEKTRIK
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SPECIFICATION FOR LOW VOLTAGE Revision: 1
UNDERGROUND CABLE
(L-S3) Date: September 2020
Page i of iii
SECTION CONTENT PAGE
1.0 General S1-10f1

2.0 Types of Cables S2-1 of 2
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3.0 Cable Routes S3-1 of 1
4.0 Length of Cable S4-1 of 1
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n 5.0 Cable Trench S5-1 of 1
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6.0 Cable Ducts S6-1 of 1
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7.0 Traffic Safety and Control S7-1 of 1
8.0 Cable Laying and Installation S8-1 of 7

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8.1 Cable Laid Direct in Ground
8.2 Cable Installed in Cable Channel
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8.3 Cable Run on Walls and Underfloor Slabs

8.4 Cable Run on Cable Tray
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8.5 Cable Run on Cable Ladder
9.0 Cable Termination, Cable Jointing and Cable Lug S9-1 of 7

EN
9.1 Cable Termination for Armoured Cable

9.2 Cable Jointing
9.3 Cable Lug
9.4 Bi-metal Cable Lug
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10.0 Cable Markers S10-1 of 3
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11.0 Testing and Commissioning S11-10f1

11 .1 Test Instruments
11.2 Test and Test Certificates
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© Hak Cipta : 1999 Cawangan Kejuruteraan Elektrik, Ibu Pejabat JKR Malaysia
CKE.LS.01.03.(01 ).2020
@;J SPECIFICATION FOR LOW VOLTAGE

UNDERGROUND CABLE
(L·S3)
Revision: 1
Date: September 2020
Page: ii of iii
12.0 Service and Maintenance S12·1 of 1
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13.0 Working Drawings, As Installed Drawings and S13·1 of 2
As Built Documents
13.1 Working Drawings
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13. 2 As Installed Drawings
n 13. 3 As Built Documents
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14.0 List of Standards S14·1 of 2
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§ SPECIFICATION FOR LOW VOLTAGE

UNDERGROUND CABLE
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Revision: 1
Page: iii of iii
FIGURE CONTENT PAGE
1 Cable Laid Direct In Ground S8-2 of 7
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2 uPVC Cable Protective Cover S8-3 of 7
3 Markings of Cable Lug S9-5 of 7
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4 Markings of Bi-Metal Cable Lug S9-7of7
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5 Cable Marker - Joint Sign & Lettering S10-1 of 3
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6 Cable Marker - Directional Sign & Letter S10-2of3
7 Cable Marker - Construction S10-3 of 3

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TABLE CONTENT PAGE

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1 uPVC Cable Protective Cover Dimension S8-3 of 7

Minimum Cross-Sectional Area of
2 S9-2 of 7
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Protective Conductors
3 Material Specification for Cable Lug S9-4 of 7

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4 Finishing Specification for Cable Lug S9-4of7

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Material Specification for Copper Bi-Metal
5 S9-6 of 7
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Cable Lug
Material Specification for Aluminium Barrel Bi-
6 S9-6 of 7
Metal Cable Lug
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UNDERGROUND CABLE
Page: S1 - 1 of 1
1.0 GENERAL
1.1 SCOPE
1.1.1 This section of the Specification describes and specifies requirements for the
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supply, delivery, installation, testing , commissioning and handing over in
approved working order and maintenance during the Defects Liability Period of
the underground cabling works in accordance with the Conditions of Contracts,
Bill of Quantities, Drawings and other related documents.
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n 1.2 STANDARDS
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1.2.1 All standards shall conform to the latest Malaysia Standards (MS), International
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Electrotechnical Commission (IEC), MS IEC, British Standard (BS ), and lor BS
EN standard. A
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CKE.LS.01.03.(01 ).2020

UNDERGROUND CABLE
(L-S3)
Revision: 1
Page: S2 - 1 of 2
2.1 TYPES OF CABLES
2.1 This specification shall cover the following types of cables: -
2.1.1 PVC/SWAJPVC Cable (Polyvinyl Chloride 1 Steel Wire Armoured 1 Polyvinyl Chloride)
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- Cable shall be manufactured and tested in accordance with MS 2103. The conductors
shall be of Class 2 (stranded conductors) plain aluminium or plain annealed copper in
accordance with MS IEC 60228 insulated with polyvinyl chloride (PVC) suitable for a
voltage of 600/1000 V laid together and bedded with PVC, armoured with galvanised
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steel wires and sheathed with PVC. The maxi mum conductor temperatures during
normal operation is 70°C in accordance with MS 2103. The conductor shall be of
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annealed copper or else specified.
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2.1.2 PVC/AWAJPVC Cable (Polyvinyl Chloride 1 Aluminium Wire Armoured 1 Polyvinyl
Chloride) - Cable shall be manufactured and tested in accordance with MS 2101 . The
conductors shall be of Class 2 (stranded conductors) plain aluminium or plain annealed
copper in accordance with MS IEC 60228 insulated with polyvinyl chloride (PVC)
suitable for a voltage of 600/1 000 V laid together and bedded with PVC, armoured with
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aluminium wires and sheathed with PVC. The maximum conductor temperatures during
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normal operation is 70°C in accordance with MS 2101. The conductor shall be of
annealed copper or else specified.
2.1.3 XLPE/SWAJPVC Cable (Cross-linked Polyethylene 1 Steel Wire Armoured 1 Polyvinyl

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Chloride) - Cable shall be manufactured and tested in accordance with MS 2107 or IEC
60502-1 . The conductors shall be of Class 2 (stranded conductors) plain aluminium or
plain annealed copper in accordance with MS IEC 60228 insulated with cross-l inked
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polyethylene (XLPE) , suitable for a voltage of 600/1000 V laid together and bedded
with extruded PVC, armoured with galvanised steel wires and sheathed with PVC. The
maximum conductor temperature during normal operation is 90°C in accordance with
IEC 60502-1. The conductor shall be of annealed copper or else specified .
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2.1.4 XLPE/AWAJPVC Cable (Cross-linked Polyethylene 1 Aluminium Wire Armoured
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Polyvinyl Chloride) - Cable shall be manufactured and tested in accordance with MS

2105 and IEC 60502-1. The conductors shall be of Class 2 (stranded conductors) plain
aluminium or plain annealed copper in accordance with MS IEC 60228 insulated with
cross-linked polyethylene (XLPE), suitable for a voltage of 600/1000 V laid together
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and bedded with extruded PVC, armoured with aluminium wires and sheathed with
PVC. The maximum conductor temperatures during normal operation is 90°C in
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accordance with IEC 60502-1 . The conductor shall be of annealed copper or else
specified.

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SPECIFICATION FOR LOW VOLTAGE Revision : 1
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2.1.5 All cable shall be legibly and durable marked on the external surface of the cable with
at least the following elements ;
a) Manufacturer's identification,
b) Voltage designation ,
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c) Manufacturing year and the standard number.
d) Number of core (optional)
e) Nominal cross-sectional area and type of conductor (optional)
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Revision: 1

(L-S3)
Page: S3 - 1 of 1
3.0 CABLE ROUTES
3.1 Cable routes shown in the Drawings are for tendering purpose only. The Electrical
Contractor shall submit working drawings as required in Section 13.0 of the proposed
routes and peg out the cable routes for the approval of the S.O / S.O's Representative
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prior to excavation of the cable trenches . The work programme for excavation of
cable trenches, cable piping, laying of cables, reinstatement of trenches etc. shall be
submitted to the S.O / S.O's Representative for approval one week before execution
of the work.
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3.2 The Electrical Contractor shall make available all necessary insurance or guarantee
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and shall also ensure all approvals are obtained from relevant authorities prior to
commencing works. The Electrical Contractor shall be responsible in making good any
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damage to buildings, tarmacs, pavements, concrete areas, slopes , drains, culverts ,
pipes , etc. which had not been properly make good arising out of his work.
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4.0 LENGTH OF CABLE
4.1 The length of cable each indicated in the Drawings and/or Bill of Quantities is for
tendering purpose only. The Electrical Contractor shall ascertain the length of each
cable required before ordering. Actual length of each cable installed shall be
measured on site and the Electrical Contractor shall be paid according to the unit rate
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in the Contract. However, the rates quoted shall include wastage due to cutting to
lengths, terminations, etc.
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5.0 CABLE TRENCH
5.1 Unless otherwise specified. cable trenches shall be 750mm depth below fini shed
ground level. The trenches shall be of sufficient width to enable provision of adequate
spacing between cables but in any case, shall be of minimum 450mm wide .
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5.2 Trenches shall be kept as straight as possible and shall have vertical sides which
shall be protected where necessary to avoid subsidence and damage. The bottom of
the trenches sha ll be firm and of smooth contour and any other objects likely to
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damage the cable sheathing sha ll be removed . The material excavated from the
trenches shall be placed or removed so as to prevent nuisance or damage to adjacent
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areas or buildings.
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5.3 The trench excavation and filling-in shall be executed that all roads , walls, sewers ,
drains, pipes , cables , structures, etc. shall be reasonably secured against risk of
subsidence damage. Provision shall be made, during excavation and until interim
restoration has been completed, for reasonable access of persons and vehicles to
the areas of bu ildings adjacent to the trenches.
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5.4 The Electrical Contractor shall provide pumps and other appliances for the necessary
pumping required for the disposal of water to prevent any risk of the cables and other
materials to be laid in the trenches being detrimentally affected . Where necessary,
bailing shall be provided .
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5.5 Where trenches pass from a footway to a roadway or at other positions where a change
of level is necessary, the bottom of the trench shall rise or fall gradually as per S.O I
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S.O's Representative approval.

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© Hak Cipta : 1999 Cawangan Kejuruteraan Elektrik. Ibu Pejabat JKR Malaysia
CKE.LS.01.03.(01).2020

UNDERGROUND CABLE
(L·S3)
Revision: 1
Page: S6 • 1 of 1
6.0 CABLE DUCTS
6.1 At road crossings, sewerage pipe crossings, water pipe crossings, paved areas,
concrete areas, and where specified by the S.O I S.O's Representative, cables shall
be protected by heavy duty galvanised iron class B or class C (Road work), or heavy
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duty uPVC Class D or High-Density Polyethylene (HDPE) PN10 pipes buried to a
depth of 900mm below fin ished ground level. The pipes sha ll be of heavy-duty type,
complying with MS 863 or MS 628 or MS 1058 respectively and complete with
screwed and socketed joints. Unless otherwise specified the pipes shall be 150mm in
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diameter. Where it is necessary to cross drains, cu lverts or sim ilar obstructions, which
is too deep for the cables to be buried below, galvanised iron class B or uPVC class
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D pipes as specified above shall be provided. All ducts shall be extended at least
600mm beyond paved areas, concrete areas, drains, road crossings, pipe crossings,
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etc.
6.2 Cable entering a bu ilding shall be protected by heavy duty galvanised iron class B or
or heavy-duty uPVC class D or High-Density Polyethylene (HDPE) PN10 or
complying with MS 863 or MS 628 or MS 1058 respectively as specified of 150mm in
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diameter completed with bend pieces , and buried under the ground beam. The ducts
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shall be insta lled with a gradient to drain away any water in the ducts. All ducts passing
through walls shall be effectively sealed and made water resistant internally (in
between cables) and externally (in between pipes).
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6.3 The number of cables installed in each duct shall be such that the space factor shall
be of maximum 40%. A draw wire shall be provided for each duct.
EN
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Page: S7 - 1 of 1
7.0 TRAFFIC SAFETY AND CONTROL
7.1 When work is being carried out beside any public road or other existing road ,
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appropriate temporary signage for warning signs shall be erected by the Electrical
Contractor. The form, placing and light of the temporary signs must comply with all
local and national regulations, Arahan Teknik Jalan JKR and safety codes for road
works.
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7.2 Where it is necessary for any trench, pit or manhole to be left open overnight, ample
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flashing lights (blinkers) shall be placed at each end and at intervals not greater than
10 metres. In bui lt up areas barricades shall be erected along the length of the trench
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pit or manhole in addition to flashing lights. Flag-men shall be stationed at strategic
locations to control prevai li ng traffic . Where necessary or as directed by the S.O I
S.O's Representative.
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© Hak Cipta : 1999 Cawangan Kejuruteraan Elektrik, Ibu Pejabat JKR Malays ia
CKE.LS.01.03.(01).2020
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UNDERGROUND CABLE
Page: S8 - 1 of 7
8.0 CABLE LAYING AND INSTALLATION
8.0.1 All cables shall be handled , laid and installed according to this specification , MS IEC
60364-5-52 and cable manufacturer's recommendations by using proper installalion
equipment and tools.
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8.0.2 All cables shall be supplied in complete length to suit the circuits they serve, and no
straight through joints shall be used. Straight through jOints or other approved joints in
the cable, will only be permitted in very exceptional circumstances such as arising
from unavoidable limitations in manufacturing length. If straight through joints or other
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approved joints is permitted , the cost of such joints shall be borned by the Electrical
Contractor. No joints in the cable will be allowed unless approved in writing by S.O I
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S.O's Representative.
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8.0.3 The minimum internal bending radius of the cable shall be of minimum 12 times the
overall diameter of the cable. Wherever cables are cut, the ends shall be immediately
sealed in an approved manner unless it is intended to proceed with cable jointing for
termination stra ight away.
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8.0.4 No cable shall be laid and covered up in the absence of the S.O I S.O's
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Representative.
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8.1 CABLE LAID DIRECT IN GROUND
8.1.1 Before cable is laid , the trench shall be thoroughly inspected , any debris and sharp
objects shall be removed. The bottom of the trench shall be covered with a layer of
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75mm of washed river sand. The cables shall then be laid on this bedding in an orderly
manner without overlapping and crossing each other. After laying the cables, a layer
of 75mm of washed river sand shall cover the cables and carefully spread over the
trench before placing the cable protective covers as shown in Figure 1.
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proud
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50m m+ .,. /
.,.
Ground Level
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./
I + + + +
+ + + +
300mm + + + +
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+ + + +
+ + + + +
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~ + ~ , , 6mm Diameter
750mm Orange Nylon Rap e
+ + + +
:!"300mm + + + +
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+ + .j.
I.
+ BrickluPVC Cable
+ I Protective Cover
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75mm !
,
Cable
-+
75mm
'.-
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() ----L ,. Washed River

Sand
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450mm
(min )
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Figure 1: Cable Laid Direct In Ground

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© Hak Clpta : 1999 Cawangan Kejuruteraan Elektrlk, Ibu Pejabat JKR Malaysia
CKE.LS.01.03.(01 ).2020

UNDERGROUND CABLE
(L-S3)
Revision: 1
Page: S8 - 3 of 7
8.1.2 Unless otherwise specified , uPVC cable protective covers complying with BS EN
12613 shall be of polyvinylchloride without plasticizer type with specific density
between 1.37g/cm 3 to 1.42g/cm 3 as shown in Figure 2, Figure 3 and Table 1 approved
by the S.O 1 S.O's Representative. The uPVC cover shall be resistant to aggressive
soils and of dimension 150mm 1 250mm wide and 1000mm long. The covers shall be
single coloured green and top side shall be embossed with standard danger sign and
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bold letters "BAHAYA! KABEL ELEKTRIK DI BAWAH " . The covers shall be
provided with male and female interlocking device. The covers are laid together
lengthwise from end to end along the entire cable route and they are held together
tightly by the interlocking device. At least 25 mm overhang on each side of the cable
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shall be provided to protect the cable underneath.
- L ock:ing d e vi ce
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r - - ElD.b osse d l e t te r ing
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Hf BAHAYA , KABE L ELEKTRIK DI BAWAH Hf () a
1
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c
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d a
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c
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Thic k.n.ess t .... 2. 0:r::D..J:D.
S E C TION x - x
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Figure 2: uPVC Cable Protective Cover

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SIZE (mm) a b c d t
150/1000 150 1000 35 50 2.0
250/1000 250 1000 60 100 2.0
Table 1 : uPVC Cable Protective Cover Dimension

CKE.LS.01.03.(01).2020

UNDERGROUND CABLE
(L-S3)
Revision : 1
Page: S8 - 4 of 7
8.1.3 If the cable protective covers are of clay bricks , the bricks shall be new, well burnt and
in complete pieces. They shall be laid lengthwise from end to end along the entire
route of th e underground cable if the cable size is not more than 120mm 2 For cable
size more than 120mm 2 , more than one row of the bricks shall be laid. Each shall be
separately protected by these bricks and the cover shall have at least 25mm overhang
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on each side of the cable.
8.1.4 The trench shall then be backfilled with earth and shall be consolidated after every
150 mm of backfilling using a mechanical rammer / compactor. Multi-strand orange
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nylon rope of minimum (six) 6 mm diameter shall be laid at a depth of 300mm along
n the trench to identify the cable route. At every 10 meters interval, an extra (two) 2
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meters length of nylon rope shall be coiled. The finished surface shall be left llJ:Qili! by
50mm to allow for subsidence and the Electrical Contractor shall be responsible for
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the removal of any surplus to a position indicated by the S.O / S.O's Representative.
8.1.5 The surface of the refilled trench shall be temporarily reinstated and maintained in a
thoroughly safe condition until complete consolidation of the soil is achieved. As soon
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as the soil has consolidated , the trenches shall be made good to the original cond itions
to the satisfaction of the S.O / S.O's Representative.
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8.2 CABLE INSTALLED IN CABLE CHANNEL
8.2.1 Method of insta llation of cables in cable channel shall be in accordance with Method
in Table A.52.3 of MS IEC 60364-5-52.
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8.2.2 Cables laid at the bottom of the trenches shall be in accordance with Ta ble A.52.3 of
MS IEC 60364-5-52.
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8.2.3 The trenches inside the buildings shall be filled with washed river sand above cable
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ducts.
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8.3 CABLE RUN ON WALLS AND UNDER FLOOR SLABS
8.3.1 Cable run on walls and under floor slabs shall be mounted on perforated hot dipped
galvanised sheet steel cable trays or cable ladders. Method of installation of the cables
shall be in accordance with Table A.52 .3 of MS IEC 60364-5-52. The construction and
finished of the cable trays or cable ladders and the method of installation of the cables
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on the cable trays shall be as described in L-S1 Specification.
8.4 CABLE RUN ON CABLE TRAY
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8.4 .1 The cable tray system shall comply with MS IEC 61537 and shall be fabricated from
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perforated hot dipped galvanized sheet steel complete with all necessary bends , tee
pieces, adaptors and other accessories. The perforated hot dipped galvanised sheet
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steel cable trays shall be minimum of (two) 2.0mm thickness. The hangers, brackets
and other suspending and supporting structures shall be hot dipped galvanized. All
brackets shall be securely fastened with steel raw bolts and nuts. Samples of cable tray
and bracket shall be submitted to the S.O / S.O's Representative for approval prior to
installation.
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8.4.2 The cable trays shall be suspended from floor slabs by hangers or mounted on wall by
brackets at 600mm interval.
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8.4.3 Whenever cable trays pass through floors or fire-resistant walls, the cables shall be
sealed with fire resisting barrier of non-hygroscopic fire-resisting material at minimum
(two) 2-hour fire rating . The floor openings and wall openings shall also be sealed with
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similar type of compound .
8.4.4 To provide electrical continuity. all cable tray jOints shall be bridged by means of tinned
copper tape of dimension not less than 25 mm x 3 mm.
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8.4.5 The minimum bending radius shall be not less than 12 times the cable overall diameter
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and steel bend spacing not more than 500mm for vertical run and 1000mm for horizontal
run. All steel bend complying with BS EN 61914 for cables on cable trays shall be
installed by bolts, washers and nuts. All cable tray tees , intersection units, adaptor units
etc. shall be factory manufactured.
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Page: S8 - 7 of 7
8.5 CABLE RUN ON CABLE LADDER
8.5.1 Cable ladder system shall comply with MS IEC 61537 and fabricated from mild steel
and finished in hot-dipped galvanised steel complete with all necessary horizontal
elbow, horizontal tee, horizontal cross, reducer straight, outside riser, inside riser,
reducer left, reducer right, cable clamp, cantilever arm, hold down clip/clamp, hanger
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bar, vertical bar for welded type and horizontal splice plate for screwed type . The sheet
steel shall be minimum of (two) 2.0mm thickness.
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8.5.2 Cable ladder may either be suspended from floor slabs by hangers or mounted on walls
or vertical structure by cantilever arm. Cable ladder shall be supported rigidly and
()
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adequately by external spring hangers mounted on channel base. The cable ladder shall
be supported at maximum intervals of 3000mm for vertical runs and 1500mm for
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horizontal runs so that the cable ladder will not be in contact with the wall or floor slab
surfaces. The spring hangers shall be supplied by the cable ladder manufacturer. All
supports, hangers and structures shall be robust in construction and adequately
installed to cater for the weights of the cables and ladder supported on them so that
cable ladder and cables will not sag .
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8.5.3 All cable ladder joints shall be bridged by means of tinned copper tape of dimension not
less than 25mm x 3mm for electrical continuity.
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8.5.4 Minimum bending radius shall be not less than 12 times the cable overall diameter and
steel bend spacing not more than 500mm for vertical run and 1000mm for horizontal
run . All steel bend complying with BS EN 61914 for cables on cable ladder shall be
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installed by bolts, washers and nuts. All cable ladder tees, intersection units, adaptor
units, etc. shall be factory manufactured .
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Page: S9 - 1 of 7
9.0 CABLE TERMINATION, CABLE JOINTING AND CABLE LUG
9.0.1 All cable termination and jointing works shall only be carried out in the presence of the
S.O I S.O's Representative. A plastic laminated plate engraved with details such as size
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of cable, number of core, date of commissioning , date of jointing, length of cable,
distance of cable joint, etc. shall be securely fixed near the termination . All cable
terminations and jointing shall be undertaken by Certified Cable Jointer (PK1) as
prescribed in Electricity Regulations 1994. The Electrical Contractor shall submit the
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certificate of Certified Cable Jointer to S.O I S.O's Representative.
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UNDERGROUND CABLE
(L-S3)
Revision : 1
Page: S9 - 2 of 7
9.1 CABLE TERMINATION FOR ARMOURED CABLE
9.1.1 PVC/SWAJPVC, PVC/AWAJPVC , XLPE/SWAJPVC and XLPE/AWAJPVC cable shall

be provided with compression cable gland for termination.
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9.1.2 Cable glands shall be installed for termination of armoured cables. It sha ll be
mechanical type complying with BS EN 50262. Each cable gland shall be installed
with back nuts (lock nuts) for plain hole fixing.
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9.1.3 Cable gland shall be installed for termination of steel armoured multicore cables and
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sha ll comply with BS EN 50262. The cross sectional of a protective conductor
connecting a gland earth tag washer to the switchboard earthing bar shall be selected
in accordance with Table 54.3 of MS IEC 60364-5-54 (Table 2).
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Cross- Minimum cross-sectional area ofthe
sectional area corresponding protective conductor
A
of line (mm 2
conductor S If the protective
EJ
If the protective conductor
conductor is not of the
(mmj2 is of the same material as
same material
the line conductor
as the line conductor
M
kl
S ~ 16 S -xS
k?
kl
EN
16 < S ~ 35 16 - x16
kz
S kl S
S > 35 - - x -
2 k, 2
M
( ) Table 2: Minimum Cross-Sectional Area of Protective Conductors

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9.1.4 The heat shrinkable termination materials used shall be supplied in a complete kit to
suit various sizes of cable and to provide stress control, non-tracking and
environmentally sealed termination. It shall consist of high permittivity, high resistivity,
heat shri nkable, stress control , UV stable , non-tracking polymeric materials and heat
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activated sealant to prevent ingress of moisture and contamination. The termination

shall meet the sequence test of IEC 60112 and the conductors shall be identified by
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colour.
9.1.5 Protective conductor for sing le core aluminium wire armoured underground cables shall
be of aluminium braided type .

CKE.LS.01.03.(01 ).2020

UNDERGROUND CABLE
(L-S3)
Revision: 1
Page: S9 - 3 of 7
9.2 CABLE JOINTING
9.2.1 The type of cable boxes , compound and jointing materials used shall be factory
ER
manufactured. Cast iron joint boxes shall be used, and all jointing kits shall be
approved by the S.O I S.O's Representative before joints being carried out. Every
cable joint shall be started and finished on the same day. Whenever cables are to be
jointed openly during wet weather conditions, the Electrical Contractor shall take all
D
necessary precautions to prevent moisture getting into the cables . Phasing and
Insulation Resistance tests shall be carried out and witness by S.O I S.O's
n
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Representative before jointing is commenced.
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9.2.2 Core numbers printed on the papers shall be observed when jointing and whenever
possible such numbers shall be maintained throughout the system. Core number '0',
'1', '2' and '3' shall denote as neutral, red, yellow and blue phases respectively. In the
case of two core cables, number '1' shall denote the phase conductor and '0' the
A
neutral. Crossing of core in the boxes shall be avoided wherever possible but
connections shall be consistent with the foregoing requirements. The jointing of cables
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shall be undertaken by Certified Cable Jointer (PKI) as prescribed in Electricity

Regulations 1994. The Electrical Contractor shall submit the certificate of Certified
Cable Jointer to S.O I S.O's Representative .
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CKE.LS .01.03.(01 ).2020

UNDERGROUND CABLE
(L-S3)
Revision: 1
Date : September 2020
Page: S9 - 4 of 7
9.3 CABLE LUG
9.3.1 Cable lug shall comply with MS 1540.
9.3.2 The copper material for the cable lug shall comply with the following specifications:
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Description Specification
Material type Copper
D
Electrolytic Toug h Pitch Copper
n Grade of copper
N
(ETP Grade)
Electrical conductivity of
TE
99% IAcsa
copper
Purity of copper 99.9%
Note: alACS - International Annealed Copper Standard
A
Table 3: Material Specification for Cable Lug
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9.3.3 The finishing for the cable lug shall comply with the following specifications:
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Finishing type Electro tin plating

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Purity of tin 99%

Minimum thickness of tin
3 micron
platina
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() Table 4: Finishing Specification for Cable Lug

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CKE.LS.01.03.(01 ).2020

UNDERGROUND CABLE
(L-S3)
Revision: 1
Page: S9 - 5 of 7
9.3.4 The cab le lug shall be clearly marked by stamping the conductor size on the palm of
the cable lug, as shown in Figure 3:
ER
/
/
--- .....
»
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~
~,
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c
\
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"" _ _ _r
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~
Legend
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1 Manufacturer's symbol representation (for the minimum cable size of 70mm 2 and
above)
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2 Conductor size 120mm 2

3 Cable lug material and corresponding cable material type (for the minimum cable
size of 70mm 2 and above
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Figure 3: Markings of Cable Lug

EN
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CKE.LS.01.03.(01 ).2020

UNDERGROUND CABLE
(L-S3)
Revision: 1
Page: S9 - 6 of 7
ER
9.4 BI-METAL CABLE LUG
9.4.1 Cable lug used for alumin ium armoured cables termination shall be of bimetal type.
D
9.4.2 Connector comprising a copper palm , friction weld ing to an aluminium barrel , for
()
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connecting aluminium conductor to an equipment copper terminal. The bi-metal cable
lugs mentioned in MS 2584, applies to crimp type bi-metal lugs for low voltage
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applications.
9.4.3 The copper material for the bi-metal cable lug shall comply with the following
specifications: -
A
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Grade of Copper Electrolytic Tough - Pitch (ETP)

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Electrical conductivity of copper <:99% IAcsa
Purity Of Copper 99% IAcsa

EN
Finishing Natural
Note: alACS - International Annealed Copper Standard
M
Table 5: Material Specification for Copper Bi-Metal Cable Lug

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9.4.4 The aluminium barrel sha ll comply with the following specifications: -
Descri ption Specification

O
Grade of Aluminium 1050-0

D
Purity Of Aluminium Minimum 99.5%
Finishing Natural
Table 6:
..
Matenal Specification for Aluminium Barrel BI-Metal Cable Lug

CKE.LS.01 .03.(01 ).2020

UNDERGROUND CABLE
(L-S3)
Revision : 1
Page: S9 - 7 of 7
ER
9.4.5 Bi-metal cable lug shall be clearly marked by stamping the conductor size, model or
part number and manufacturer's marking or symbol as per Figure 4.
D
9.4.6 Additionally, the barrel of the bi-metal cable lugs shall be embossed or printed with the
name of manufacturer. Marked on the barrel as shown in figure 4:
()
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'TIl"-- - - A
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KKK_K,
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Legend
A Manufacturer's marking or symbol
150 Conductor size 150mm 2
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KKKK Name of manufacturer
Figure 4: Markings of Bi-Metal Cable Lug

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SPECIFICATION FOR LOW VOLT AGE UNDERGROUND CAB LE

© Hak Clpta : 1999 Cawangan Kejuruteraan Elektrik, Ibu Pejabat JKR Malaysia
CKE.LS.01 .03.(01 ).2020
~
UNDERGROUND CABLE
Page: S10 - 1 of 3
10.0 CABLE MARKERS
10.0.1 Cable marker with lettering and sign as shown in Figure 5 and Figure 6 shall be
ER
provided by the Electrical Contractor at every change in direction of underground cable
routes and at every 15m on straight run. Cable markers shall be of heavy duty
reinforced concrete construction. The cable marker and its actual locations shall be
approved by the S.O / S.O's Representative.
D
n
N
10.0.2 The cable marker shall be of trapezoidal block with 100mm square top face, 150mm
square bottom face and 400mm in height as shown in Figure 7. The top face shall be
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indented with bold lettering 'L.V.' and directional sign indicating the direction/directions
of the cable route . The lettering and directional sign shall be fu lly painted orange
colour. The cable marker shall be buried to a depth of 300mm. Cable joint marker of
similar construction but with the lettering and sign as shown in Figure 7 shall be
provided and installed at every cable joint in the similar manner.
A
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Lettering: 40mm (H) x 30mm (L) x 10mm (W) x 5mm (D)

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Figure 5: Cable Marker - Joint Sign & Lettering

CKE.LS.01 .03.(01) .2020
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UNDERGROUND CABLE
Page: S10 - 2 of 3
Lettering: 40mm (H) x 30mm (L) x 10mm (W) x 5mm (D)
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L
D
()
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.-
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Figure 6: Cable Marker- Directional Sign & Letter

CKE.LS.01.03.(01 ).2020

UNDERGROUND CABLE
(L-S3)
Revision: 1
Page: S10 - 3 of 3
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I I
I I
<oemm
I I
D
n A A
N
TE
A
1'00= 1
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..,
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, nOB . Bmm. dill. steel bar
<oOmm
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• DOB. lomm d1e.. steel bar
~~
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1-- =--1
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'50
SECTION X-X
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Figure 7: Cable Marker - Construction
Note:
D
1. All covers to be 40mm (W)

2. Grade 20 (1 :2:4) concrete 20mm (3/4) aggregate

CKE.LS.01.03.(01).2020

UNDERGROUND CABLE
(L-S3)
Revision: 1
Page: S11 -1 of 1
11.0 TESTING AND COMMISSIONING
11 .1 TEST INSTRUMENTS
11.1.1 All measuring and test instruments used for testing and comm issioning of the installations
ER
sha ll be regularly tested and calibrated by the manufacturers or accredited ca libration
laboratories for their functionality and accuracy. Test and Calibration Reports or
Certificates for the measuring and test instruments issued by the ca libration laboratory
shall be val id for two (2) years from the date of issuance.
D
11.1.2 The instruments and their Test and Calibration Reports or Certificates shall be submitted
()
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to S.O I S.O's Representative for verification two (2) weeks before testing of the
installations being carried out. No test on the installations shall be carried out without
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prior approval of the S.O I S.O's Representative. Notwithstanding the valid ity of the
aforesaid Reports or Certificates the measuring and test instruments shall be re-
calibrated if so required by the S.O I S.O's Representative after any mechanical or
electrical mishandling. Fee required for the testing and calibrating of the measuring and
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test instruments is deemed to be included in the Contract.
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11.2 TEST AND TEST CERTIFICATES

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11.2.1 After the instal lation work has been completed and before Certificate of Practical
Completion is issued, the whole system shall be tested for compliance and performance
as follows: -
EN
11.2.1.1 Insulation Resistance Test
11.2.1.2 Continuity Test

M
(j 11.2.2 The S.O I S.O's Representative reserves the right to be present at all tests and the
Contractor shall give at least one week notice in writing to the S.O I S.O's Representative
KU
for this purpose. In any case, no test shall be carried out without prior approval of the S.O
I S.O's Representative. A copy of test results certified by competent person shall be
submitted to the S.O I S.O's Representative. Copies of all the test certificates together
O
with As In stalled Drawings properly bound and titled shall be submitted to the S.O I S.O's
Representative within one week after the completion of the testing .
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CKE.LS.01.03.(01 ).2020
[§, SPECIFICATION FOR LOW VOLTAGE

UNDERGROUND CABLE
Revision: 1

(L-S3)
Page: S12 - 1 of 1
12.1 During the Defects Liability Period, the Contractor shall be responsible for the service
and maintenance work of the complete installation. All works shall be carried out by
competent person. All labour, material, tools and parts necessary to rectify the defect
due to manufacturing or installation faults shall be supplied and/or executed at the
ER
Contractor's cost.
12.2 The service and maintenance to be performed and defects to be rectified and making
good shall include but not limited to the following: -
D
12.2.1 Replace or make good any defective cables, cable joints and cable terminations
n
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12.2.2 Replace any broken or defective cable markers
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12.2.3 Making good any damage to roads . buildings, drains, existing cables, pipes,
concrete areas , paved areas , slopes, drains, culverts etc. wh ich had not been
properly made good arising out of his work; and
A
12.2.4 Any other works deemed necessary by the S.O / S.O's Representative.
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12.3 All works shall be carried out as soon as the Contractor is being informed by the S.O /
S.O's Representative or the occupant, and shall be completed with in a reasonable time
M
except under emergency situation . If the Contractor fails to comply with the above
requirements, the S.O / S.O's Representative reserves the right to engage another party
to carry out the work, in which case, the Contractor shall be responsible for all the
EN
expenses incurred.
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CKE.LS.01.03.(01 ).2020
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Page: S13 -1 of 2
13.0 WORKING DRAWINGS, AS INSTALLED DRAWINGS AND AS BUILT DOCUMENTS
13.1 WORKING DRAWINGS
Within 2 weeks after award of the Tender, the Electrical contractor shall submit to the
ER
S.O / S.O's Representative for his approval dimensioned general arrangement and
section drawings of the equ ipment ordered. These drawings are to be submitted in
quadruplicate. The drawings subm itted are to be modified if necessary as requested
D
by the S.O / S.O's Representative and re-submitted for final approval.
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13.2 AS INSTALLED DRAWINGS
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13.2.1 The as installed drawings shall comprise of: -
13.2.1.1 Site plan ;
13.2.1.2 External cable routes;

A
13.2.1.3 Site and type of cables ; and
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13.2.1.4 Location and type of joint.

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13.2.2 These drawings sha ll be labelled at the lower right hand corner with the Electrical
Contractor's name and address , date of commission ing, scale, drawing number (the
drawing number to be obtained from the S.O. / S.O's Representative), title and
EN
following particulars: -
JABATAN KERJA RAYA

u
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CONTRACT NO.:
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13.2.3 If the drawings subm itted are not according to the actual installation at site and/or not
acceptable to the S.O / S.O's Representative, the Contractor shall amend and re-
submit the drawings within two weeks from the date of return of the drawings to the
satisfaction of the S.O / S.O's Representative.
O
13.2.4 In addition , one (1) set of the as installed drawing shall be submitted in the form of
D
original document, and four (4) sets in physical digital storage.

CKE.LS.01.03.(01 ).2020

UNDERGROUND CABLE
(L-S3)
Revision: 1
Page: S13 - 2 of 2
13.3 AS BUILT DOCUMENTS
13.3.1 As built document shall consist of but not limited to the as installed drawings, manuals,
certificates, catalogues and inventories. Manual and documents for the installation
shall be supplied. It shall comprise of: -
ER
13.2.5.1 Inventories;
13.2.5.2 Product data and catalogue ;
D
13.2.5.3 Product test certificates; and
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13.2.5.4 Installation test resu lts.
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13.2.6 Each of the as built documents shall be bound together with hard cover and submitted
in minimum four (4) sets upon issuance of Certificate of Practical Completion of the
project.
A
13.2.7 The cost of all these prints, manuals, tools etc. whether or not provided in the Bill of
Quantities, is deemed to be included in the Contract.
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13.2.8 One set of the as installed drawing shall be properly framed up in the MSB Room .
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EN
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CKE.LS.01 .03.(01 ).2020
[@J SPECIFICATION FOR LOW VOLTAGE

UNDERGROUND CABLE
(L-S3)
Revision: 1
Page: S14 -1 of 2
14.0 LIST OF STANDARDS
Plastics Warning Devices For Underground Cables And Pipelines With

BS EN 1261 3
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Visual Characteristics (British Standard)
BS EN 50262 Cable Glands For Electrical Installation
D
BS EN 61914 Cable Cleats For Electrical Installation
N
Method For Determination Of The Proof And The Comparative Tracking
IEC 60112
Indices Of Solid Insulating Materials
TE
Power Cables With Extruded Insulation And Their Accessories For Rated
IEC 60502-1 Voltages From 1 kV (Urn = 1.2 kV) Up To 30 kV (Urn =36 kV) - Part 1:
Cables For Rated Voltages Of 1 kV (Urn = 1.2 kV) And 3 kV (Um = 3.6 kV)
A
MS628 Specification For Unplasticised PVC ((uPVC) Pipes For Water Supply.
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Non-Alloy Steel Tubes Suitable For Welding AndThreading - Technical

MS 863
Delivery Conditions
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MS 1058 Polyethylene (PE) Piping System For Water Supply

EN
Specification For Th e Material, Marking And Dimensions Of Crimp Type

MS 1540
Cable Lugs For Use With Copper Conductors In Low Voltage Applications
Electric Cable And Wire: 600/1000 (Um = 1.2 kV) Single Core PVC
M
MS 2101
Insulated Cable - Armoured
= 1.2 kV) Multi Core PVC

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Electric Cable And Wire: 600/1000 (Um

MS 2103
MS 2105
Electric Cable And Wire : 600/ 1000 (Urn = 1.2 kV) Single Core XLPE
O
Electric Cable And Wire : 600/ 1000 (Urn = 1.2 kV) Multi Core XLPE
D
MS 2107
Crimp Type Copper Aluminium Bi-Metal Lugs For Use With Compact
Copper Conductor In Single And Multi Core Power Cable In Low Voltage
MS 2584
Applications - Specification For The Material, Marking , Dimensions And
Type Test.

CKE.LS.01.03.(01 ).2020
~
UNDERGROUND CABLE
Page: S14 - 2 of 2
MS IEC
Conductors Of Insulated Cables
60228
MSIEC Electrical Installations Of Buildings -Part 5-52: Selection And Erection
ER
60364-5-52 Of Electrical Equipment - Wiring Systems
Electrical Installations Of Buildings -Part 5-54: Selection And Erection
MSIEC
Of Electrica l Equipment - Earthing Arrangements And Protective
60364-5-54
Conductors
D
MSIEC Cable Tray Systems And Cable Ladder Systems For Cable
n
N
61537 Management
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A
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EN
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© Hak Clpta : 1999 Cawangan Kejuruteraan Elektrik, Ibu Pejabat JKR Malaysia
ER
D
n L-S20
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SPECIFICATION FOR ROAD
TE
LIGHTING INSTALLATION
A
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EN
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SPECIFICATION FOR
ROAD LIGHTING
D
n
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INSTALLATION
(L-S20)TE
A
EJ
M
CKE.LS.01.20.(03).2020
EN
JKR 20300-0126-23
M
l )
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CAWANGAN KEJURUTERAAN
D
ELEKTRIK
CKE.LS.OI.20.(03).2020
------- Date Issued: Aug 1999
r~ JKRJ SPECIFICA TION FOR ROAD Revision: 1
«"'-'.':::-"'- LIGHTING INSTALLATION
Date: August 2022
RINGKASAN
ER
Pindaan kpd
Pengerusi JIK
No Ookumen Tarikh Catatan
Penggubal
Utama
D
1 Baru (1) Aug 1999 Spesifikasi asal. -
n Feb 2013
Tambahan: Addendum No.1 revision 1 to L-S20 Specification Noorfadzilah bt
N
2
for Road Lighting Installation (August 1999) Ram lee, BPR E
2
Road Lighting Lumina ires - LED
-
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Tambahan: Addendum No.2 to L-S20 Specification for Road Noorfadzilah bt
3 Feb 2015
Li ghting Installation (August 1999) Ramlee, BPR E
Appendix 01
Tambahan : Addendum No.3 to L-S20 Specification For Road Ir. Nooraini bt
A
4 3 Oct 2020 Lighting Installation (August 1999) Ibrahim, JEPK
Integrated Sola r LED Road Lighting System UPBS
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Revision 1 : Pindaan : Addendum No.3 to L-S 20 Specification For Road Ir. Nooraini bt
S ~ddendum No.3 Aug 2022 Lighting Installation (August 1999) Ibrah im, JEPK
Integrated Solar LED Road Lighting System UPBS
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*** Helaian ini hanya untuk rekod sahaja. Tid ak perlu disertakan bersama dokumen tender.
... ..
CKE.LS.01.20.(02).2013
I:--i JKR--J Date Issued : Aug 1999
. .. . . ~. .'
Rev ision: 2
Date: Feb 2013
SPECIFIC A TION FOR ROAD LIGHTING INST ALLA TION
ITEM CONTENTS PAGE
1.0 GENERAL 1
2.0 ROAD LIGHTING LUMINARIES
ER
2. 1 General
2.2 Conformity With Standards
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n 2.3 Construction And Components 2
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2.3.1 General 2
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2.3.2 The Optical System 3
2.3.3 Lamp 4
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2.3.4 Lampholder And Associated Supports And Brackets 4
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2.3.5 Electrical Control Gear 5

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2.3.6 Internal Wiring, Terminal Block And Earthing Terminal 6
3.0 PHOTOMETRIC DATA 7

EN
4.0 SAMPLE OF LUMINAIRES 7
5.0 SCHEDULE AND TECHNICAL INFORMATION ON 8

M
LUMINAIRES
C)
6.0 PROJECTS BASED ON THE 'TURNKEY', 'DESIGN AND 8
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BUILD' OR 'BUILD-OPERATE-TRANSFER' (B.O T)

APPROACH
7.0 OUTDOOR WEATHERPROOF FEEDER PILLARS

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7.1 General 8
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7.2 Fabrication 8
7.3 Factory Inspection 9
SPECIFICATiON FoR RoAD LIGHTING INSTALLATioN

; Hak Cipla :1999 Cawangan Elektrik JKR Malaysia
iiiv
CKE.LS.Ol.20.(02).2013
I· ..~~K~] Date Issued : Aug 1999

Revisio n: 2
-" -" Date: Feb 2013
ITEM CONTENTS PAGE
7.4 Foundation 9
7.5 Earthing 10
7.6 Switching Circuit 10
7.7 Contactors 10
ER
7.8 By-Pass Switch And Selector Switch 10
7.9 Miniature Circuit Breakers 10
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7.10 Termination II
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8.0 COLUMNS AND BRACKETS II
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8. 1 General II
8.2 Design Loading 11

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8.3 Fabrication 11
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8.3. 1 Hot Dip Galvanised Steel Column s II
8.3.2 Pre-stressed Spun Concrete Columns 12

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8.3.3 FibregJass Reinforced Columns 12

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8.4 Material 13
8.4.1 Hot Dip Galvanised Steel Columns 13

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U 8.4.2 Pre-stressed Spun Concrete Columns 13

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8.4.3 Fibreglass Reinforced Column s 14
8.5 Protection Against Corrosion 15

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8.5. 1 Hop Dip Gal vanised Steel Columns 15

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8.5 .2 Pre-stressed Spun Conc rete Column s 16
8.5.3 Fibreglass Reinforced Columns 16
8.6 Bracket Anns 16
8.7 Spigots 16
SPECIFICATI ON FOR ROAD LIGHTING INSTALLATION

;HakCipla :1999 Cawangan Elektrik JKR Ma la ysia
iiliv
". CKE.LS.01.20.(02).2013
l.i~KRJ Date Issued: Aug 1999
Revision: 2
.. ' -" Date: Feb 2013
ITEM CONTENTS PAGE
8.8 Doors, Door Openings And Opening For Wiring To 16

Decorative Signs/Lights
8.9 Baseboard 17
8.10 Earthing Terminal 17
8. 11 Service Slots 17
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8.12 Flange And Anti-Sink Base Plate 17
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8.12.1 Hot Dip Galvanised Steel ColulllJls 17
()
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8. 12.2 Pre-stressed Concrete Columns 17
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8.12.3 Fibreglass Reinforced Columns 17
8.13 Factory Testing Of The Columns 18
8. 13.1 Hot Dip Galvanised Steel Columns 18

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8.13.2 Pre-stressed Concrete Columns 19
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8.13.3 Fibreglass Reinforced Colunms 20

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8. 14 Tenninal Block 21
8.15 Cable Terminations And Internal Wiling 21

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8. 16 Erection Of Colunms 21
9.0 CABLES AND DUCTS 22

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U SHOP DRAWINGS
10.0 22
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11.0 CONSTRUCTION REQUIREMENTS 23
12.0 TESTING AND TEST CERTIFICATES 23

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13.0 SERVICE AND MAINTENANCE 24

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14.0 AS-INSTALLED ORA WINGS, MANUALS AND TOOLS 25
SPECIFICATION FOR ROAD LIGHTING INSTALLATION

; Hak Cipta :1999 Cawangan Elektrik JKR Ma laysia
3
CKE.LS.01.20.(02).2013
Date Issued: Aug 1999
Revision: 2
Date: Feb 2013
1.0 GENERAL
1.1 This section of the Specification describes and specifies requirements for the supply, delivery,
storage, assembly, installation, erection, testing, commissioning, handing over in approved
working order and maintenance during the Defects Liability Period of the Road Lighting
ER
Installation in accordance with the Specification, Notes, Bill of Quantities (B.Q.), Conditions
of Contract and Drawings.
1.2 The Road Lighting Installation shall include all luminaires, fittings, brackets, spigots, other
D
supporting devices, colunms, feeder pillars, bases, cables, switchgears and all necessary ancillary
equipment, fOlmdations, ducting and all other necessary equipment for a complete road lighting
n
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system in accordance with the details shown on the Drawings, Bill of Quantities.(B.Q.), Notes,
Appendices and as specified herein.
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2.0 ROAD LIGHTING LUMINAIRES
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2.1 General
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The luminaire shall be complete with integral control gears as a unit and shall be designed for
both side entry and post top mounting and suitable for use with 100W/ 150W/250W/400W
High Pressure Sodium Vapour (HPSV or SON) Tubular Lamp and on a suppl y voltage of 240
M
Volt, +5%, -10%, 50 Hz.

EN
The luminaire and its associated electrical components shall comply with and be tested to the
following lEC Standards together with all current amendments.
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ITEM STANDARD
Luminaire lEC 60598 Parts I & 2
Lamp lEe 60662
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Lampholder lEC 60598 Part I

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Ballast lEC 60922 & lEe 60923

Ignitor lEC 60926 & lEC 60927
Capacitor lEe 61048/61049
Others Relevant lEC Standards

; Hak Cipta ;1999 Cawangan Elektrik JKR Malaysia
1/49
CKE.lS.Ol.20.(02).2013
I ···~JKR-] Date Issued: Aug 1999
-"" .. . .. - Revision: 2
Date: Feb 2013
2.3 Construction And Components
2.3. 1 General
1. The luminaire shall be so designed and constructed that it is capable of providing the
service for which it is intended. Sound engineering principles shall be adopted
throughout and the luminaire shall be designed to enable ease of maintenance and
replacement of lamp, control gear, refl ector and lampholder without the use of special
tools.
II. The main supporting sl]"ucture of the luminaire shall be constructed from die-cast
ER
aluminium alloy mateliai such that no undue deterioration in its safety, performance or
appearance during nom1al life when operating in all climatic conditions prevailing in a
tropical country such as heavy rains, high winds, high humidity and hot day-time
temperatures. It shall be robustly constructed to withstand vibration in normal use.
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In . The lmninaire shall be designed so that condensation shall not fall on any operating part
n
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which may fail or deteriorate as a result.
IV. All luminaires shall be new, totally enclosed and protected against contact with live or
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moving PaTts inside the enclosure. The following Index of protection (IP) are required:-
IP 55 or higher for the optical compartment of the luminaires.

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IP 43 or higher for the main luminaire housing and control gear compartment.
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Full details of the IP system can be refen·ed to in lEe 60529.
v. Access to the interi or of the luminaire shall be from the top. Bottom access IS not
acceptable.
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v!. Materi al used for the construction of the luminaire shalJ be rec yclable. Glass/Fibre
glass reinforced polyester (GRP/FRP) matelial is not acceptable.
u Vll. Hinges and clips of the top housing cover if used, shall be robust and made of stainless
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steel and simple to operate and shall not be Liable to accidental detachment during
installation or maintenance.
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Vlli. The top cover or luminaire canopy giving access to the interior of the luminaire shall in
the closed position, be firml y attached to the frxed position of the luminaire. In the
open position, it shall be attached in such a way that there is no likelihood of it
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becoming accidentalJy detached and thereby damaging any part of the luminaire or the
bracket or the column.
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IX. Attachment of the luminaire to its bracket arm shall be by means of clamps or jam bolts
and designed to accommodate spigot sizes as shown in the table. A minimum of 2
(two) locking bolts 1jam screws shall be provided.
x. The minimum depth of penetration of the bracket am1 shall be as shown in the table.
The mounting aTrangement and attachment of the luminaire shall be such as to
withstand a
SPECIFICATION FOR ROAD LIGHTIN G INSTALLATION

;Hak Cipta :1999 Cawangan Eleklrik JKR Malaysia
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··0_0 Date : Feb 2013
windspeed of 150 km per hour on the projected surface of the assembly without due
dellection.
Rating of Lamp Diameter of Diameter for Side Min .Depth of

Bracket (mm.) Entry (mm.) Penetration
(mm .)
100 Watt 50 40 - 60 100
150 Watt 50 40 - 60 100
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250 Watt 50 40 - 60 100
400 Watt 50 40 - 60 110
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X l. All parts which carry the weight of the luminaire and internal accessOlies shall be
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provided with suitable locking devices to prevent the dislodgment of any part of the
luminai..re by vibration either in service or during maintenance.
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2.3.2 The Optical Sys tem A
I. The design of the optical system shall incorporate a one piece full bowl refl ector and
shall be replaceable as a unit, independent of the canopy. The rellector shall be made of
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at least 99.85% pure aluminium with a minimum thickness of I mm., be electricall y

brightened, anodised and chemically treated to give high rellectance.
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ii . T he optical compartment shall be tested and certified to IP 55 or higher.

Ill . The luminaire shall incorporate provisions to enable adjustments to shift the main light
distribution to wards the axis of the road to suit different road widths. Such adjustments
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shall be simple and positive and shall be firml y retained in clearl y identified positions.
Photometric data shall be supplied for the particular distribution recommended in a
given install ation. These data may be supplied in computer diskettes together with
software in the CIE format.
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() iv. The bowl shall be designed and constructed such that when in the closed position, it
will be firmly held. The bowl shall be easily detached from the canopy without having
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to use any tool and at the same time will not be detached when in the opened position
during maintenance. If an IP66 rating is specified for the optical compartment, the bowl
shall be designed, constructed and totally sealed to the reflector to fo rm a single
removable opticalulli!.
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v. The bowl shall be made of glass or acrylic material. Where acrylic material is used, it
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shall be stabilised against deformation, deterioration or discolouration due to the lamp

and/or solar radiation.
VI. The bowl shall be clear or pri smatic. In the case of prismatic bowls, the lluted surface
shall fOlm the inner surface to facilitate cleaning.
SPECIFICATI ON FOR ROAD LIGHTING INSTALLATION

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vii . The gasket shall be a one piece tropicalised weather resistant type made of suitable soft
resilient material that will not cause crazing of the bowl. The gasket shall form an
integral part of the bowl such that any bowl change will necessitate a change of the
gasket.
2.3.3 Lamp
I. The lamp to be accommodated in the luminaire shall be 100/150/250/400 watt tubular
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clear type High Pressure Sodium Vapour (HPSV) lamp.
II. The lamp shall comply with the requirements of IEC 60662 together with all cUlTent
amendmen ts.
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iii. The minimum lumen output specifications of the lamp shall be as follows:-
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Lamp Lamp Colour Lumen Output (Lm)
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Cap Conected Initial, After
Type Temperature at 100 hrs. 2000 Ills.
C.C.T
100 Watt E40 2000 K - 2 100 K 9500 9200
A
150 Watt E40 2000 K - 2100 K 14500 13500
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250 Watt E40 2000 K - 2100 K 28000 26500

400 Watt E40 2000 K - 2100 K 48000 46000
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IV. The lamp shall not take longer than 4 minutes after the initial 'switch on' to attain 80% of
its guaranteed lumen output at the rated voltage 240 Volts, +5%, -10% and frequency 50
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Hertz. The re-ignition period after an intelTuption of the supply shall not be longer than 1
minute to attain 80% of its lumen output.
v. The average luminous flux of the lamp shall not depreciate more than 10% of initial value
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after 10,000 switched operating hours.

()
vi. The average mortality rate for the 100/15 0/2 50/400 watt HPSV lamp shall not be greater
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than 10% at 12,000 switched operating hours.
2.3.4 Lampholder And Associated Supports And Brackets

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D
I. The lampholder shall be made of non-metallic, heat resistant materi al and be rigidly
fixed onto the optical compartment.
11. The lampholder shall be an E40 type for the 100/150/2501400 watt HPSV lamp. The
lampholder shall be complete with an appropriate brake system to prevent loosening of
the lamp.

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111 . The lampholder together with its supports and brackets shall withstand normal usage
throughout the life of the luminaire.
IV. A lamp fully inserted shall be rigidl y held with its axis substantially concident with that
of the lampholder under the normal conditions of wind, vibration and mechanical
shock.
v. The E40 lampholder shall be rated for 4.5kV pulse.
2.3.5 Electrical Control Gear
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A. General
1. The luminaire shall be furnished complete with integral e!ecuical conu'ol gear
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comprising of inductive ballast, capacitor and ignitor.
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11 . The electrical conU'ol gear shall be mounted on a suitable module uni t and shall be
easily removable and replaceable as a unit without the use of any special tools.
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iii. Electrical connection and disconnection of the electrical control gear unit from the
luminaire shall be tlHough a plug and socket type connection/ terminal block such that
incoming supply cables need not be removed when remo ving the electrical control gear
module.
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B. Ballast
1. The ballast shall be solidly filled with polyester compound and enclosed in a sheet steel
or die cast aluminium container or vacuum impregnated with polyester resin of not less
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than thermal class 'H' (180 'c in accordance with IEC 60085).
ii. The ballast shall be reactor type and comply full y with IEC 60922 - " Ballast for
Discharge Lamps : General and Safety Requirements" and IEC 60923 - "Ballast for
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discharge lamps (excluding tubular fl uorescent lamps) - Performance RequiJements".

Ill. The rated voltage of the ballast shall be 240 Volt, 50 Hz (Nominal) and shall be
suitable for operation on a 240 Volt, +5%, -10%, 50 Hz suppl y system. All ternunals
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() shall be of screw connector type.

IV. The lamp current crest factor of the ballast shall not exceed 1.8 for ±6% voltage
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variations. At normal operating temperature, the maximum ballast losses, as per

IEC 60923 shall not exceed 16 Watt for the 100 Watt HPSV lamp, 18 watts for the 150
watt HPSV lamp, 27 watts for the 250 waU HPSV lamp and 39 watts for the 400 watt
HPSV lamp.
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v. The rated maximum operating temperature of the ballast winding (t.,) shall not be less
than 130 °C whereas tbe maximum winding temperature rise (£>t) shall not be more
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than 70 °C.
C. Ignitor
SPECIFICATION FOR ROAD LIGHTING INSTAL LATION

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I. The ignitor shall be solid state, fully electronic, timed, superimposed multiple-pulse
type which does not require the use of tapped ballast to ignite the HPSV lamp.
ii. The ignitor shall be fully encapsulated and totally sealed against the ingress of
moisture.
111. The ignitor shall have a casing temperature rating of not less than 90°C.
I V. The case of the unit shall carry a label showing the cOfUlections and listing the
operating voltage and the precautions to take during its removal. The ignitor shall be
mounted with nut and lock washer.
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v. The ignitor shall comply with and be tested to lEC 60926 and lEC 60927 together with
all CUlTent amendments.
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D. Capacitor
The capacitors shall comply wi th and be tested to lEC 61048/61049.
n I.
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II. The capacitors shall have a minimum voltage rating of 250 Volt and a casing
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temperature rating not less than 85°C and shall be of sufficient capacity to raise the
power factor of the circuit to not less than 0. 85 lagging. The capacitors shall be housed
in extruded aluminium or thermoplastic cannisters and mounted with nut and lock
washer.
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111. Capacitors shall not be fused but incorporate a safety discbarge resistor.
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2.3.6 Internal Wiring, Terminal Block And Earthing Terminal

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A. Internal Wiring
1. The luminaire shalI be completely pre-wired, requiring only the connection of the
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electrical power suppl y cables to the terminal and the ear1h continuity conductor to the
earthing terminal.
11 . The control gear looping cables shall be non-hygroscopic heat resi stant copper-core
flexible cable, with a temperatlIre rating of not less than 105 °C and marked on the
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() insulation and securely clipped. The minimum size of the cable shall not be less than I
sq. mm.
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111. PTFE insulation or the equi valent, rated to a minimum of 250 °C shall be used for leads
to the lampholder.
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B Terminal Block
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I. A readily accessible barTiered terminal block with the ' live' and ' neutral ' connections
clear'ly and indelibly marked for the connection of incoming suppl y cables shall be
provided as close as possible to the point of entry of the suppl y cables. The terminal
block shall be made of non-inflam mable material.
SPECIFICATION FOR ROAD LIGHTING INSTALLAT ION

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CKE.lS.01.20.(02).2013
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11. A means of clamping the electrical supply cables shall be provided in the luminaire to
relieve the tenninations of strain where they are connected to the terminals. The cable
clamp arrangement shall not damage the insulation of the cables.
C Earthing Terminal
1. A separate terminal for the connection of an earth continuity conductor, clearly and
indelibly marked shall be provided.
ll . All exposed metal parts and other parts accessible when the luminaire is opened for
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maintenance and liable to become live in the event of an insulation fault shall be
permanently and reliably connected to this earthing terminal.
D
3.0 PHOTOMETRIC DATA
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The following Photometlic Data relevant to each luminaire type shall be provided together
with the Tender submi ssion.
i) Isolux Diagram
A
ii) Utilization Factor Curves
iii) Polar Curves of the folowing C-Planes: 0°/180°; 90°/270°; maximum intensity
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plane.
iv) Downward Light Output Ratio.
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v) Downward and Upward Flux Fractions

Tender documents without the appropriate PhotometTic Data will be disqualified.
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4.0 SAMPLE OF LUMINAIRES

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4.1 Tenderers may be required to submit a sampl e each of the various luminaires offered after the
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closing date of the tender submission. Such luminaires submitted shall be fumished complete
with control gear, lamp, wiring, etc. as per the tenderer 's offer in the tender document
together with suppl y cable and a 13 Ampere plug, ready for test.
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4.2 The name and address of the tenderer shall be affixed onto the samples of the luminaire.
4.3 Delivery of the 'SAMPLES' shall be within a period of ONE WEEK immediately following
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the request from JKR.

4.4 Tenderers who fail to submit the 'SAMPLES' of the luminaires within this stipulated
period shall be disqualified.
4.5 Tenderers shall anange to collect back the samples on notification.
5.0 SCHEDULE AND TECHNICAL INFORMATION ON LUMINAIRES.

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5. 1 Tenderers are required to furni sh the comprehensive infOlmation and technical particulars as
stipulated in the APPENDICES A, B, C and D.
5.2 The information required in each Appendix shall be completed full y and correctly and all
technical data entered therein shall be substantiated with relevant pamphlets and test
certificates from the manufacturers or the recognized testing authorities.
5.3 Failure to fulfil the above said requirements shall result in the disq ualification of the
tender.
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6.0 PROJECTS BASED ON THE 'TURNKEY', 'DESIGN AND BUILD' OR 'BUILD-
OPERATE-TRANSFER' (B.O.T.) APPROAC H.
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6.1 In the case of 'Turnkey' or ' Design and Build ' or ' Build-Operate-Transfer' (B .OT.) type
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() projects, the Road Lighting System shall be designed in accordance with the
recommendations set f0l1h in the CIE I IS - 1995 "Recommendations For The Lighting Of
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Roads For Motor And Pedest6an Traffic". The Tenderer shall obtain the consent of JKR
for the classifications of "Description of Road", " Conflict Areas" and "Lighting Class" from
JKR for the whole road system prior to designing the layout of the Road Lighting System.
6.2 Tllis Specification applies to such projects.
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7.0 OUTDOOR WEATHERPROOF FEEDER PILLARS

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7. 1 General
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The Feeder Pillars shall be supplied completely assembled with control gear and all internal
electrical and mechanical interconnections and structural parts for voltages up to and including
1000 volts A.C. It shall comply with and be tested to the requirements of IEC 60439 - 1 and
IEC 60439 - 5.
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7.2 Fabrication
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The Elecnical Contractor shall subnlit design drawings showing the plan, elevations, sections,
layout and construction details of the feeder-piJlar for the approval of the S.O's Representative
p60r to fabrication. The plinth, foundation work, ducting, etc. shall be included in the design
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drawing.
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The feeder-pillar housing shall comprise of a drip canopy with sufficient overhang, rigid
welded channelled steel framework as specified in the Drawings and/or Bill of Quantities
and/or Notes. Anti-colTosive treatment shall be applied to the pillar and it shall be painted . A
non perishable resilient gasket shall be provided all around the edge of the feeder door.
On the front and rear sides of the feeder-pillar, the following sign and lettering of 90 mm height
shall be stencilled in red paint:

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BAHAYA VOLTAN
ELEKTRlK
415 V
Side panels and front and back doors shall be fabricated from 12 swg sheet steel as specified in
the Drawings. The feeder pillar shall rest on an angle iron base where suitable holes have been
prepared to accomodate foundation bolts and to secure the feeder-pillar onto the concrete
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foundation.
The door of the feeder pillar shall be rigidly reinforced bonded and hinged inte111ally to the
main frame to prevent unauthorised access. The feeder pillar shall be of lockable type as
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approved by the S.O ' s Representative. The feeder-pillar shall be self-ventilated and
weatherproof, and such ventilation openings shall be protected by wire mesh to prevent th e
()
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entry of vennins, rodents and birds.
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A suitable size wire mesh glass window shall be provided to facilitate reading of the kWH
meter.
A pocket of suitable size for housing A4 size documents shall be fitted onto the inside of
feeder-pillar as specified in the Drawings.
A
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The hinged door must be earthed using copper braid as shown in the Drawings.
If a stainless steel feeder pillar is specified, all material including fi'amework, panels, bolts and
nuts used in the manufacture shall be totally stainless steel. The side panels and front and back
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doors shall be fabricated fro m 14 SWG stainless steel. No additional anti-corrosion and paint
treatment are required unl ess otherwise stated.
EN
7.3 Factory Inspection
The Electrical Contractor shall make anangements for a joint inspection and to witness the
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I )
electri cal tests at the factory prior to transportation to the site of the feeder pillars. All costs
'- .
incuned shall be deemed to be included in th e tender price. Test certifi cates shall be issued
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upon completion of all tests.
7.4 Foundation
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The site for the foundation of the feeder-pillar shall be excavated and filled where required,
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compacted and levelled before the reinforced concrete base is constructed to a minimum of
300 mm. (or otherwise specified ) above th e finished ground level and 700 mm. below the
finished ground level. Cable entry ducts shall also be provided as specified in the Drawings.
7.5 Earthing
SPECIFICAT ION FOR ROAD LIGHTIN G INSTALLATION

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The earthing system for the feeder-pillar shall comply with the requirements of MS IEC 60364,
BS 7671:1992 (formerly known as the IEE Wiring Regulations), JKR, mEG and in
accordance with the Drawings.
Each feeder-pillar shall be effectively earthed by using 16mm. diameter copper jacketed steel
core rods, 25nu11 x 3nu11 copper tape and heavy duty inspection chamber with removable cover,
etc.
7.6 Switching Circuit
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The time switch supplied for the control of the luminaires etc, shall be of the synchronous/step
motor wound handset dial, plug-in type. It shall incorporate a 24 hours spring reserve. The time
switch shall be suitably rated and operational on 220/240 V, 50 Hz supply.
D
r)
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7.7 Contaetors
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The contactor supplied shall comply to IEC 60947-4 with unintelTupted ratings, mechanical
duty class 2 and utilisation categolY of minimum AC3. The contactor coils shall be fully
tropicalised and wound for continuous operation for 240/415 V, 50 Hz suppl y. The contacts of
the contactor shall be rated for the breaking capacity on the cOlUlected load.
A
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7.8 By-pass Switch and Selector Switch
A single and three phase by-pass switch as applicable shall be connected in parallel with the
contactor for use in the event of the failure of the contactor. This by-pass switch shall be
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manufactured to B.S. 5419 and shall be capable of breaking the load connected without undue
wear or damage. A four position selector switch shall be provided to select the mode of
operation and shall be appropriately labelled.
EN
7.9 Miniature Circuit Breakers.

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Unless otherwise indicated in the Drawings andlor Bill of Quantities, miniature circuit breakers
(MCBs) shall have breaking capacity not less than 6 kA (rms) and of B-type with Class 3
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energy limiting charactelistics. They shall comply with IEC 60898, fully o'opicalised and
suitable for use on a 240/4 15 Y, 50Hz A.C. system and in an ambient temperature of 40' C.
They shall be quick-make, quick-break and trip free type complete with de-ion arc inten·upters.
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The tripping elements shall be of thermal magnetic type with inverse time delay overcurrent
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and instantaneous short circuit characteristics. The response to overload shall be independent of
variations on ambient temperature.
They shall be manually operated by means of toggle type handle having visual indication of
whether the breaker is opened, closed or n·ipped. Multiple breakers shall be provided with a
conUll0n nip mechanism for simultaneous operation of all the poles.
7.10 Termination
SPECIFICATION FOR ROAD LIGHTING IN STALLATION
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All cables tenninated into the various components including lIlconling and outgoing cables
must be tel1ninated through compression glands and heat shrinkable sleeves.
8.0 COLUMNS AND BRACKETS.
8. 1 General
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Unless otherwise specified, all columns and brackets shall be tapered octagonal or tapered
round type, made up of hot dip galvanised steel interchangeable sections or pre-stressed spun
concrete columns or fibreglass reinforced material to comply in all respects to tlle Drawings,
Bill of Quantities and Notes. They shall be manufactured to comply with the relevant sections
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of the latest edition of B.S. 5649 (EN 40) or ANSI C-136.20 and ASTM 04923-89, or other
approved international standards. The base plate, if any, (for planted type colu111l1s), brackets
n
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arms and spigots shall be manufactured as separate units suitable for mounting or fixing onto
the columns_ The data for the columns and brackets shall be provided in Appendix ' E'_
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8_2 Design loading
The col umns shall be designed to withstand loading comprising of:

A
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1. Loads of wind speed up to 35m/sec.
11. The loads due to the weight of the column and accessories, IUlllinaires and associated
control gear, the bracket rums and spigots.
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111. Other applied loads

EN
8.3 Fabrication
8.3. 1 Hot Dip Galvanised Steel Columns

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)
Each COl Ull1l1 section shall be mechanically fOl11led and longitudinally welded by continuous
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automatic gas shielded electric arc process (M.I.G. Process) or continuous auto matic electric
resistance welding, to B.S. 5135: 1984. The sections shall be constructed so as to overlap each
other by a miIlimum of 1.5 times the diameter of the imnlediate lower section (extemal across
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face dimension) and to be easily assembled on site by using simple tools without employing
welding. The manufacturer shall provide a mru-k on the finished colU1l1l1 sections indicating the
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nlinimum overlapping position of 1.5 times the extemal across-face dimension_
8.3.2 Pre-stressed Spun Concrete Column s
1. Pre-stressed Concrete wires and reinforcement
Pre-stressed Concrete (PC) wires, Non Tension (NT) wires and Spiral wires shall be cut
to correctly coincide with the shapes and dimensions specified in the Drawings. The PC

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wires and reinforcement wiJes shall be arranged so that tlley are unifol11lly distributed
in the cross-section of the concrete column.
All steel reinforcement shall have a concrete cover of not less tban 9nun.
Pre-stressed concrete colunms shall also comply to BS 607 : Prot 2 1970.
ii. Moulding
Moulds used shall be sufficiently ri gid in order to withstand the pre-stressing forces.
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The PC wires shall be tensioned in advance, before the compaction process.
w. Concrete
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The quality of the concrete and the curing process used shall be such that the
compressive strength of the concrete al 28 days in age is greater than 49.0 N/nun' in
n
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accordance with the tests stipul ated in JIS A 11 32 and JIS A 1 108.
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8.3.3 Fibreglass Reinforced Columns
1. Type 1.
A
Each colunm section shaH be mechanicaHy formed by a centrifugation process. Textile
glass fabrics shall be used as reinforcement with the majority of fi bre. Fibre only shaH
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be used to stabilj ze the fabric for extraordinary longitudinal al ignment for main
reinforcement of the tension diJection. On one side of the fabric a chopped strand mat
shall be provided to shear strength required in case of impact, compression or torsion.
The colunm section shall be produced and cured in a one-way operation, including the
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resin and colour pigmentation process.
Type 2.
EN
II .
The columns shaH be made from continuous E-glass roving, encapsulated in a high
temperature cured, cOlTosion resistant, epoxy resin matrix. The glass shaH be wound
under tension, and at required angles to provide suitable axial and transversal
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( ) mechanical propelties. The columns shall be cured by a process which allows the
epoxy resin to migrate to the surface of the column giving it an exceptionally smooth
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and unifoml fini sh. The glass content shall be approximately 65% by weight.
8.4 Material
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8.4.1 Hot Dip Gal vanised Steel Columns.

D
The colunm and accessories shall be fabricated from the foHowing materials:
MATERIAL
COMPONENT
Column and Door Steel to BS EN 10025 Grade Fe 51 OC or

BS EN 10025 Fe 430C or
BS 1387:1985 or JIS G3452:1978

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Bracket Arm and Steel to BS EN 10025 Fe 430C or

Spigot
BS 1387: 1985 or TIS G3452:1978
Base Flange Steel to BS EN 10025 Fe 360A
Base Plate Steel to BS EN 10025 Fe 360A
8.4.2 Pre-stressed Spun Concrete Columns
ER
The column and accessOlies shall be manufactured/fabricated from the following materials.
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COMPONENT MATERIAL
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Column I) Concrete grade 50 (50 N/mm')
2) P.C WiJ-e shall confol111 to lIS G 3536
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3) N.T WiJ-e & reinforcement bar shall
confolll1 to 1IS G 3532
4) SpiJ-al wire shall confonTI to TIS G 3532
A
Door & Spigot Steel to BS EN 10025 Grade Fe 510C or BS
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EN 10025 Fe 430C or BS 1387 : 1985 or JIS G 3452 : 1978
Bracket Ann Steel to BS EN 10025 Fe 430C or BS 1387 : 1985 or 1IS G

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3452: 1978
Base Plate Steel to BS EN 10025 Fe 360A

EN
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1. Type I
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The column and accessories shall be fablicated from the following matelials :
D
MATERIAL
COMPONENT
Column and Door Fibreglass mat and thel1110plastic polyester

resin combination
Bracket Arm and Spigot Bracket rum -seamless steel with polyurethane
coating.

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Spigot - galvanised steel
Base Flange Galvanised steel
Pigmentation Of Colour:
The colour pigmentatation of the col umns shall be guaranteed for at least 15 years of
use.
ER
ElectJical Properties:
The columns sball comply with the following electrical properties:
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Surface resistivity DIN 53482 - IO"Q
Resistivity DIN 53482 - IO"Q
n
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Creep resistance VDE0303 DIN53480 KA3c
Dielectric strength VDE0303 DIN5348I about 30 k VInun
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Insulation class II
The flame retardancy properties shall be similar to that of the type 2 composite
columns.
A
Mechanical Properties:
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The columns shall comply with the following mechanical properties:
Tensile strength DIN 53455 - 2.500 kp/cm2

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Flex elongation DIN 53455 - 7.5%

Flexural strength DIN 53452 - 1.700 kp/cm 2
- 70.000 kp/cm2
EN
Flex E-modulus DIN 53452

Impact strength DIN 53453 - 50 kp/cm'
Heat distortion temperature DIN 53458 above maximum of standard.
M
\ )
u. Type 2.
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The column and accessories shall be facricated from the following materials:
O
MATERIAL
COMPONENT
D
Column and Door E-glass roving and epoxy resin matrix. The
door may also be fabricated from aluminium
or galvanised steeL
Bracket arm - Same material as column or
Bracket AIm and Spigot
galvanised steeL
Spigot/tenon - aluminium
Base Flange Galvanised steel

; Hak Cipta :1999 Cawangan Elektrik JKR Malaysia
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-.... -- ----
Revision : 2
Date: Feb 2013
Flame Resistance:
Colunms shall not contain chlorine halogen gases or other toxic mater;als in excess of
trace levels which shall always be within the safe OSHA limits. When the column
material is subjected to 3 consecuti ve 60 second flame applications, it shall self
extinguish within 5 seconds after the last flame application. Flame resistance shaU be in
accordance with ASTMD635.
The fibreglass reinforced material shall be non-conductive.
ER
8.5 Protection Against Corrosion
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8.5. 1 Hot Dip Galvanised Steel Columns
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(j Indi vidual sections of the colunm, base-plate, door, spigots and bracket arms shall be protected
against corrosion by hot dip galvanising, intel11ally and externally in accordance with B.S.
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729: 197 1 or ASTM Standard A 123. All welding work shall be done before galvanising.
The treatment prior to galvanising shall include degt·easing, rinsing, pickling, further rinsing
and fluxing.
A
The minimum average weight of the zinc coating shaU be 460 glm' for any individual test area.
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The galvanised column and spigotslbracket arms shall be of prime fini sh and of good
uniformity, i.e. free from injurious defects, such as blister, flux or any uncoated spot.
The planted section of the column shall be factory-coated with bitumen using the hot dipping
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process conforming to AASHTO M 190.

EN
8.5.2 Pre-stressed Spun Concrete Columns

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All exposed metal parts of the concrete colunms shall be treated and protected agai nst
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corrosion.

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Fibreglass reinforced columns shall not erode, rot or corrode and shaU not deteriorate in the
Malaysian tropical climate coupled with high sunshine and heavy rainfall, together with other
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severe evironruental conditions of salt-laden air, acid rain, acid soil and marshy soil and shall be
finished in a UV -resistant surface.
A range of colour finish shall be available for the columns, with no colour fading over time.
Unless otherwise specified, the fini sh of the column shall be smooth.
8.6 Bracket Anns

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Bracket allns shall be of suitable outreach as indicated in the Drawings and/or the B.Q. Unless
otherwise indicated in the Drawings and/or B.Q. the bracket arms shall be arranged to give a 5
degree uplift. A spigot of approved material and of appropriate dimensions for tile luminaire
shall be welded or suitably attached at the base of the bracket arms. In the case of a steel
bracket arm, after welding and related work, the bracket arm shall be treated as per clause 8.5
before being hot-<lip galvanised.
8.7 Spigots
ER
Steel spigots or spigots made of other approved material shall be supplied and installed as
indicated in tile Drawings and/or B.Q. and o'eated as per clause 8.5 in the case of steel.
D
8.8 Doors, Door Openings and Opening for Wiring to Decorative SignslLights
N
A hingged weather-proof flush-type or overlapping door, hingged on the upper side with
provision to hold the full y opened (180 0 from the closed position) hingged door in place, shall
TE
be provided complete with an anti-vandal locking device over the door opening of each column
as shown in the relevant Drawings. The door openings shall have intemal reinforcement to
compensate for the loss of stiffness of the column caused by fOlming the door openings.
A
In addition, an opening of 16 nml. diameter complete with rubber plug shall be provided on the
column at a height of 5.6 m above the finished ground level for wiring to decorative
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lighting/signs. The opening shall be located on the same side of the column as the door
opening.
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EN
8.9 Baseboard
A piece of galvanised perforated steel baseboard shall be included in the base companmenl for
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cable termination of the control gear assembly. The baseboard shall have suitable dimensions as
indicated in the Drawings and securely fi xed in position inside the colunul .
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8.10 Earthing Terminal

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Columns shall be provided with a cOITosion-resistanl earthing telminal having substantial

contact surface for the attachment of an earthing lead. The tem-tinal shall be provided close to
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the door opening inside the colunms. Where a bolt is used, it shall be at least 6 mm. in diameter
and 20uun. in length and provided with two suitable washers and nuts. Unless otherwise
specified , the bolt, nuts and washers shall be made of stainless steel.
8. 11 Service Slots
For the planted type col unm, the service slot shall be on the same side and vertically below the
service door.
SPECIFICATION FOR ROAD LIGHTING IN STALLAT ION

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Revision: 2
--.. - ...... .
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For the flange mounted type of column, the cable entry shall be tlu'ough the flange plate having
a hole of suitable diameter as shown in the Drawings and a suitable duct for cable entry shall
also be provided at the concrete base.
8. 12 Flange and Anti-sink Base Plate
8.12. 1 Hot Dip Galvani sed Steel Columns
For the flange mounted type of colurrm, a flange plate of substantial thickness as shown in the
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Drawings shall be welded onto the colunm. As for the planted type column, a detachable anti-
sink base plate shall be supplied. The anti-sink plate, bolt, and nut etc. shall be hot-dip
galvanised after manufacture and treated as in clause 8.5.
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8.12.2 Pre-stressed Concrete Colunms
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(j For concrete colunms, a flange plate shall be assembled and cast together with concrete during
the manufacturing process.
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8. 12.3 Fibreglass Reinforced Columns
I. Type 1.
A
For the flange mounted type column, a flange plate with a rod adapted to the colunm
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shan be assembled. The base plate/concrete shell, bolt, and nut etc. shall be hot dip
galvanised steel assembled on concrete foundation as per Drawings.
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Prefabricated foundation shall be constructed to the column manufacturer's

recommendations.
EN
ii. Type 2.
In the case of the flange-mounted column, a hot-dipped galvanised steel base plate of
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) thickness and dimensions as shown in the Drawings shall be welded to the attachment
coll ar. The attachment collar shall be bonded and mechanically secured to the inside of
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the column. All required anchor bolts, nuts and washers shall be galvanised steel type
and supplied by the column manufacturer.
O
In the case of the planted column, the base of the cohmm shall be enlaraed via two
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0
integral anti-rotation bosses, located 180 from each other and appropriate1y cenu'ed
above the column butt. These bosses shall be large enough to effectively prevent
rotation and pull-alit of the colurrm and shall be fanned by the column manufac turer.
8.12.4 Where the concrete base for the flange mounted columns are included in the Electrical
Contractor's work, the bolts and nuts for mounting the flanged mounted colunms shall be
supplied by the colurrm man ufacturer.

;Hak Gipta :1 999 Cawangan Elektrik JKR Malaysia
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CKE.lS.01.20.(02).2013
Date Issued : Aug 1999
Revision: 2
.. ' - ' Date: Feb 2013
8.13 Factory Testing of the Columns
A sample of all types of columns and bracket arms shall be tested at the factory of
manufacture in the presence of the S.O's Representatives. The tests sball comprise of:
8.13. 1 Hot Dip Galvanised Steel Col umns
a) Dimensional and Weight Measurements of column and bracket.
b) Temporary Deflection Test :
ER
The colunm is to be mounted horizontall y and rigidly supported for the distance
equivalent to the planting depth from the base, and loaded, as a cantilever at a point
from the top of the column (excluding the bracket arm). The temporary defl ection
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measured at the point of application of load shall not exceed 150 mm. and the load to
cause 150 nun. deflection at the top of the colulllJl (excluding the bracket arm) shall
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not be less than the folowing figures:
TE
COLUMN MOUNTING 6 7 8 9 10 11 12
HEIGHT (m)
Load to cause 150 mm 1340 11 20 1230 800 700 550 480
defl ection at top of
A
column (excl uding
bracket arm) (~N)
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The deflection test shall be callied out with the colulllJl placed in the two weakest
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positions.
c) Galvanising Test :
EN
The columns and brackets shall be subjected to the gal vartising thickness test as laid
down in BS 729: 1971.
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l) d) Bitumen Test:
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The bitumen coating on the colunm base shall be subjected to thickness test.
e) Material Test:
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Steel material used for the manufacturing of columns and brackets shall be subjected
to test for compli ancee with BS EN 10025 (Grade 43C or Grade SOC). The supplier
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shall state the test method and the reference standards together with the tender. The
test method and the reference standards shall be subject to the approval of the S.O.'s
Representative.
t) Welding Test:
The welded portions of the columns and brackets shall be subjected to the welding
test as stipulated in the British Standard B.S. 5135 or equivalent Standard approved
by the S.O .'s Representative.
SPECIFICATION FOR ROAD LIG HTIN G INSTALLATION

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The minimum percentage peneo'at ion for the longitudinal seam weld shall be 60%.
g) Mechanical Property Test :
A small piece of steel plate of adequate size shall be cut off from the base of the
sample column for this test.
The tensile strength and yield of the sheet metal shall be measured. T he test results
shall comply with the limits specified in BS EN 10025 for Grade 510C and 430C
steel as follows:
ER
Fe SlOe Fe430C
Tensile SO'ength 490 to 640 430 to 580
(N/mm')
D
Yield Strength 355 275
n
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(Min. N/mm2)
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8. 13.2 Pre-stressed Concrete Columns
I. Bending Strength Test A

Tllis test shall be carried out in accordance with TIS A 5309.
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When the design load of 1.5kN is applied, cracks exceeding 0.25 nun in width shall not
appear. When the design load is removed there shall be no cracks exceeding 0.05num
in width.
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II. Breaking Test
This test shall be ca\Tied out in accordance to 11S A 5309. The load is applied to the
EN
colunl11 in one of the two loading directions until the colunl11 is broken. The breaking
load shall be more than twice the design load.
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lll . Inspection
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a) Quantity of Column to be Inspected

Inspection of the appearance, shape and dimensions shall be performed 0 11 all
colunms.
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Inspection of the concrete cover shall be performed on the colunl11 that was
subjected to the breaking test.
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The bending strength test shall be conducted on three column sampled from a
batch of 1000 colunms or part thereof.
The breaking test shall be perfonned on one of three colunl11s used in the
bending strength test.
b) Determination of Acceptability
All columns shall compl y to the specification with respect to appearance,

shape and dimensions.
SP ECIFICATION FOR ROAD LIGHTIN G INSTALLAT ION
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When all the three colunms subjected to the bending strength test comply with
the specification, then all the columns in the batch shall be accepted.
When one column does not confoml with the specification during the bending
strength test, the test shall be repeated one or two sampled colullms. When
both cohUlms conform to the specification, all columns in the batch shall be
accepted except for the initialJy rejected colunm.
When test colunm does not comply to the specification, the test shall be
repeated with two more sampled colunms.
When both columns conform, all the colullms in the batch shall be accepted
ER
except for the initially rejected column .
8. 13.3 Fibreglass Reinforced Columns
D
n Fibreglass Reinforced Colunms shall be tested to the relevant sections of the applicable BS,
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VDE, DIN, ANSIIAASHTO as the case requires, to ensure compliance with the mechanical
properties, strength, stiffness, fl ame retardancy, accepted deflection tolerances and breaking
TE
point loading including testing under full wind loading condition .
8. 13.4 All test and measuring equipment shall be provided by the column manufacturer and all such
A
test and measuring equipment shall be cel1ified to have been calibrated by an accredited
laboratory for testing and calibration. Proof of val idity of the calibration shall be submitted to
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the S.O's Representative for approval prior to making arrangements for the factory testing.
8.13.5 A verified Test Report for the tests on the columns shall be submitted by the manufacturer.
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8. 13.6 All expenses incuned for the tests shall be borne by the Electrical Contractor and shall be
deemed to have been included in the Contract Price.
EN
8. 14 Telminal Block
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C) The temlinal block shall be of a type manufactured for lise in road lighting installation. They
shall have facilities for double fusing loop-in loop-out terminals. The cut-out bases shall have a
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supply cable contact block rating of at least 50A and shall be capable of accepting circular
cable cores up to 25 mm' copper 2 core or 4 core as required. The cut-out shall be provided
with adeq uate shrouding to prevent cross phasing with live metal parts.
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8. 15 Cable Telminations and 111temal Wiling

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An appropriate type of earthing clamp shall be provided to bond the armouring of the cables
which shall be effectively earthed.
Cable glands c/w bot-dipped galvanised mild steel L-bracket shall be used for all armoured
cable termination.
The cables, including the earthing cable, from the road lighting cut-outs to the luminaires shall
not be less than 2.5 mn,' pvc. They shall be bundled togeuler with cable ties and terminated
with lugs.

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8. 16 Erection of Columns
Colunms shall be installed in accordance with the manufactnrer's reconnnendation and as per
Drawings. The Electrical Contractor shall peg out the positions of the columns for the approval
of the S.O's Representative before planting the columns or before the construction of the
concrete bases in the case of flange mounted columns.
The colunms shall be erected such that the service doors shall face the opposite side to the
ER
oncoming traffic except at parapets of blidges and retaining walls. At such locations the
orientation of the service doors shall be determined by the S.O's Representative. After erecting
the column, the backfill shall be compacted by means of a suitable ranuning equipment and the
uprightness of the colunms shall be verified with the use of a plmnb line or equivalent device.
D
n
N
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9.0 CABLES AND DUCTS
Road lighting cables and their installation shall be in compliance with the latest JKR
Specification for Low Voltage Underground Cable, and to any additional notes mentioned in
A
the Drawings and Notes to Tenderers.
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Ducts for road crossing, etc. shall be laid in accordance with the Drawings, B.Q. and
appropriate sections of the Specification.
M
Cables in the central median shall be laid close to the columns and as far away as possible from
the edge of the pavement. The minimum distance from the edge of the pavement shall be 1
metre or as directed by the S.O 's Representative.
EN
Cables along the road shoulders shall be laid as far away as possible from the usable shoulder
width or as directed by the S.O's Representative.
M
Data for voltage drop calculations for all the road lighting circuits shall be give in the fomlat of
Appendix F - "Voltage Drop Calculation For The Road Lighting Installation", together
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with the detailed calculations .
10.0 SHOP DRAWINGS

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Two sets of prints of shop drawings for construction and/or installation shall be submitted to the
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S.O.'s Representative for approval. The Electrical Contractor shall prepare and submit shop
drawings for the whole work or pillis of the work at least two weeks before the work begins. If
the shop drawings submitted ill'e not acceptable by the S.O.'s Representative, the Electrical
Contractor shall amend and re-submit the shop drawings within two weeks from the date of
retlUll of the shop drawings. No work including fabrication of the feeder pillars shall be cillTied
out without the shop drawings being approved by the S.O.'s Representative.
The shop drawings shall include and show the following:
SPEC IFICATION FOR ROAD LIGHTING INSTALLATION

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CKE.LS.01.20.(02j.2013
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The dimensioned general anangements, layouts and positions of columns and luminaires, feeder
pillars, and all others necessary for the complete road lighting installation as specified in the
Drawings and/or Bill of Quantities;
Circuits and switching arrangements including schematic line diagrams of tlle installation ;
The dimensioned general ruTangements and layouts of the equipment and the schematic line
diagram of the feeder pillars;
Cable routes for all cables laid underground, in ducts ruld trenches;
ER
The dimensioned general aJTangements and layout of earthing system including routes for
earthing conductors and positions of earth electrodes.
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The cost of all these shop drawings, whether or not provided in the Bill of Quantities, is deemed
to be included in the Contract.
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I 1.0 CONSTRUCTION REQUIREMENTS
TE
Adequate wanting signs including fl ashing lights, luminous signs and flagmen shall be
provided for the safety of the road user and general public. The general alTangement and
A
location of temporary warning signs shall be in strict accordance with ARAHAN TEKNIK
(JALAN) 2C/85 and runendments, published by Cawangan Jalan, Ibu Pejabat JKR Malaysia,
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Kuala Lumpur. All workers on the site shall be appropriately dressed with luminous jackets and
the work area adequately cordoned. No rLight work shall be permitted without the prior
approval of the S.O's Representative. All waJ'ning signs shall conform to standru'd JKR
requirements. Adequate illuminated, flashing and luminous warning signs shall be provided
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duri ng the rLight time.
The maximum trenching distance and working area for the day shall be detemuned after prior
EN
consultation with the S.O 's Representative. The mobile trenching method shall be employed as
far as is practicable and all excavations, installation of ductinglsand/cablinglbricks/accessmies,
backfIlling, compacting and cleaning up shall be executed in one coordinated operation to
expeditiously complete the work and therefore nurLi.l1use inconverLience and danger to the
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public. The cruTiageway and road shoulder aJ'ea including all work area shall be cleru'ed of all
debris and cleaned after each day' s work
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All excess excavated matelial and construction material shall be removed from the site and no
such material shall be pemlitted to be left by the road side without the consent of the S.O 's
Representative.
O
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12.0 TESTING AND TEST CERTIFICATES
On completion of the installation work on site and before the Cettificate of Practical
Completion is issued, the Elecltical Contractor shall at his own expense, ruTange for all
necessary tests to be callied out on the installation by competent person as part of the tests
required of him for the whole installation under this contract. The tests to be cruTied out shall be
as prescribed in the Electricity Regulations 1994, B.S. 7671: 1992 including all amendments
(fonnerl y known as the IEE Wiring Regulations), IEC 60364 and other tests deemed necessary
by the S.O.'s Representative.
;Hak Cipta :1999 Cawangan Ele ktrik JKR Malaysia
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CKE.lS.01.20.(02).2013
Revision: 2
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In the event the install ation fails any of these tests, the Electrical Contractor shall, at his own
expense, take such measures as 3.I·e necessary to remedy the defects and the installation shall
not be considered as completed until it complies with the requirements of all such tests.
The tests to be canied out by the Electrical Contractor shall consist of the following tests
(where applicable) :-
a) Continuity of final circuit conductors.

b) Continuity of protective conductors including main and supplementary equipotential
ER
bonding.
c) Insulation resistance.
D
d) Insulation of site-built assemblies.
n e) Protection by electrical separation.
N
f) Protection by baniers or enclosures provided during erection.
g) Insulation of non-conducting floors and walls.
TE
h) Polarity.
i) E3.lth fault loop impedance.
j) E3.lth electrode resistance.
k) Fuctional testing of all types of switches and switchge3.l·.
A
I) Alignment and uprightness of the col umns and the tilting angle of the bracket arms.
m) Luminance and illuminance readings in accordance with the computer plots.
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Two sets of Supervision and Completion Certificate and Test Certificate including copies of all
the test results and drawings as prescribed in the Electricity Regulations 1994 shall be
submitted to the S.O.'s Representative within two weeks after the completion of the testing.
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The aforesaid Certificates shall be properly bound in hard cover and titled.
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u During the Defects Liability Period, the Electrical ContraclOr shall be responsible for the
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service and mamten3.llCe for the complete installation. All works shall be cani ed out by
competent persall. All labour, tranpOl1, equipment, matelials, tools and patts necessat)' to
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service the installation and/or rectify the defect due to manufacturing/installation faults shall be
supplied/executed at ti,e Electrical Contractor's cost.
The Electrical Contractor shall provide a three-monthly report in the manner of Appendix G.
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The service and maintenance to be performed and defects to be rectified and made good shall
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include but not limited to the following :-

a) Replacing or making good all luminaires, lamps, ballasts, capacitors, ignitors, control
gears, switches, socket outlets, isolators, mcb, mccb, fuses , time switches, contactors,
relays, meters, etc.
b) Replacing all consumable items that do not meet the manufacturer's gU3.l·anteed or
declared lifespan .
c) Straightening columns and replacing missing doors, covers and locking devices .
SPEC IFICATI ON FOR ROAD LIGHTING IN STALLATION

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d) Replacing and maki ng good all loose/damaged cable terminations, damaged cables,
mechanical supp0l1linkages, earth electrode chambers and covers, etc.
e) Making good damage to roads, buildings, drains, cables, pipes, concrete areas, paved
areas, turfed areas, etc. which was his responsibility to make good but which had not
been properly rectified.
f) All other works deemed necessary by the S.O. 's Representative.
ER
All works shall be callied out as soon as the Electrical Contractor is infollned by the S.O. 's
Representative or the owner and shall be completed within a reasonable time except under
D
emergency situation as stipulated in the Supplementary Conditions for Electrical Work. If the
n Electrical Contractor fails to comply with the above requirements, the S.O.'s Representative
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reserves the right to engage a third party to carry out the work, in which case, the Electrical
Contractor shall be responsible for all the expenses incurred.
14.0 AS-INSTALLED DRAWINGS , MANUALS Al\TD TOOLS
TE
A
Within three calendar months after the practical completion of the project, one set of true to
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scale negati ve (1101115 gm.lsq.m. ISO AO or A l size) and four sets of prints for each of the
following drawings shall be submitted :-
a) Site plan
M
b) Schematic Wiring Diagrams and Control Circuit Drawings

EN
c) Road Lighting Layout Plans
d) Layout plan of cable routes and eal1hing points, with reference to easily recognisable
landmarks, buildings and structures.
M
\)
These drawings shall be properly stencilled and shall have at the lower right corner the
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Electlical Contractor's name and address, date of conunissioning, scale, drawing number (the
drawing number shall be obtained from the S.O.'s Representative), tiue and the following
particulars:-
O
JABATAN KERJA RAYAMALAYSIA

D
CAW ANGAN ELEKTRJK

CONTRACT NO:
TENDER NO :
If the drawings submitted are not acceptable to the S.O.'s Representative, the Electrical
Contractor shall amend and resubmit the drawings within two weeks from the date of
notification by the S.O. 's Representative.
If required and specified elsewhere, in addition to the aforesaid negatives and prints, the as-
installed drawings shall be stored in electronic media or any oUler media as specified. The
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Revision: 2
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electronic media shall be floppy disks and/or CD as specified which can be readily retrieved by
computer. The software programme shall be AutoCAD of a release specified or of the latest
release. Two sets or copies of the as-installed drawings in the fonnat required, appropriately
titled and stored in container or casing, shall be submitted.
ER
In addition, four sets of the following manualslbrochures and documents, suitably bound, shall
be submitted to the S.O's Representative:
D
a) Installation manual
(1
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b) Operation manual
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c) Service and Maintenance Manual
d) Parts List A
c) Product data and catalogues
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d) Product Test Celtificates
Each of [he above sets of plints together with the manuals shall be in a stiff cover ring file. In
addition, a set of A4 size schematic drawings shall be laminated and placed inside the pockets
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of the Feeder Pillars.
Special tools required for the operation, service and maintenance of the feeder pillars and
EN
switchgear, columns and other equipment shal l also be provided.
The cost of all these prints, manuals and tools shall be deemed to be included in the Contract
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I) Price.
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SPECIFICATION FOR ROAD LIGHTI NG INSTALLATION

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Date Issu ed : Aug 1999
Revi sion : 2
-"
-" --- Date : Feb 2013
APPENDIX A-I
SCHEDULE OF LUMINAIRE (400W HPSV/SON)
ITE M DESCRIPTION OAT A/MATERIAL
A MAKE
ER
I Manufacturer
2 Country of manufacture
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3 Brand of Luminaire
n
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4 Model of Luminaire
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B MATERIAL
5 Lamp Compaltment
A
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6 Control Gear Compartment
7 Sealing Gasket
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8 Reflector
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9 Cover Bowl
10 Lampholder
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() II Bowl Retainer Catch

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C PHOTOMETRY
12 Standard Position
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13 Facilities for Directional Light Control

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14 Optical Compartment (Degree of Protection)
15 Control Gear Compartment (Degree of Protection)
... cont. pg. 28/49

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.... . ...... .
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APPENDIX A-I
SCHEDULE OF LUMINAIRE (400W HPSV/S ON)
ITEM DESCRIPTION DATA/MATERIAL
16 Relevant Standard of Conformity
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17 Total Light Output Ratio - TLOR
18 Downward Light Output Ratio-DLOR
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19 Direction of maximum intensity measured from the
n
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downward verti cal (Cdll 000 1m)
0
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20 Maximum intensity at 80 from the downward
vertical (Cd/IOOO lumen)
21 Max imum intensity at 88 from the downward

vertical (Cdll 000 lumen)
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22 Maximum intensity above the horizontal (Cd/ J000
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lumen)
23 Relevant pamphlets to substantiate the above
mentioned data and test certificates to be enclosed
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EN
M
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O
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Tit, Nama & Cop Pengilang Tit, Nama & Cop Konu·aktor ElekU·ik
APPENDIX A-2
SPECtFtCATION FOR ROAD LIGHTING IN STALLATION

; Hak Cipta :1999 Cawangan Elek.trik JKR Malaysia
27 /4 9
..... ....
CKE.LS.01.20.(02j.2013
I:-~ :KR'] Date Issued: Aug 1999
Revision: 2
....... :::........ Date: Feb 2013
SCHEDULE OF LUMINAIRE (250W HPSV/SON)
ITEM DESCRIPTION DAT AlMA TERIAL
A MAKE
1 Manufactmer
ER
3 Brand of Luminaire
D
n
N
TE
B MATERIAL
5 Lamp Compartment
A
EJ
7 Sealing Gasket
M
8 Reflector
9 Cover Bowl
EN
10 Lampholder
11 Bowl Retainer Catch

M
~ )
C PHOTOMETRY
KU
O

D
14 Optical Cornpaltment (Degree of Protection)
... cont. pg. 30/49
APPENDIX A-2

; Hak Cipla :1999 Cawangan Eleklrik JKR Malaysia
28/49
. .. .. .- ... .. .
CKE.LS.01.20.(02).2013
I:- ~JKR-] Date Issued : Aug 1999
.... . ..... ..
Revision : 2
' .'-' Date: Feb 20 13
SCHEDULE OF LUMINAlRE (250W HPSV/SON)
ITEM DESCRIPTION DATAIMATERIAL
16 Relevant Standard of Con formity
17 Total Light O utp ut Ratio - TLOR
ER
18 Downward Light O utput Ratio-DLOR
19 Direction o f maximum intensity measured from the

downward vertical (Cd/1000 1m)
D
0
Maximum intensity at 80 from the downward
N
(j 20
vertical (Cd/1000 lumen)
TE
0
21 Maximum intensity at 88 fro m the downward

vertical (Cd/ lOOO lumen) A
22 Max im um intensity above the horizontal (Cd/ 1000
lumen)
EJ
23 Relevant pamphlets (0 substantiate the above

mentioned data and test certifi cates to be enclosed
M
EN
M
KU
O
D
Tit, Nama & Cop Pengilang Tit, Nama & Cop Kontraktor Elektrik

29/49
CKE.LS.01.20.(02}.2013
Revision: 2
" ""-""
Date : Feb 2013
APPENDIX A-3
SCHEDULE OF LUMINAIRE (l50W HPSV/SON)
A MAKE
ER
1 Manufacturer
2 Country of manufactme
D
n
N
3 Brand of Lurninaire
TE
B MATERIAL
A
5 Lamp Compartment
EJ
6 Control Gear Compar1ment

M
7 Sealing Gasket
8 Reflector
EN
9 Cover Bowl
10
M
Lampholder
( )
11 Bowl Retainer Catch
KU
C PHOTOMETRY
O
D
13 Facilities for Directional Light Conu"ol
... conl. pg. 32149

30149
CKE.LS.Ol.20.(02).2013
Revision: 2
-- ._. Date: Feb 2013
APPENDIX A-3
SCHEDULE OF LUMINAIRE ( l SOW HPSV/SON)
ITEM DESCRIPTION DATA/MATERIAL
ER
D
17 Total Light Output Ratio· TLOR
N
() 18 Downward Light Output Ratio-DLOR
TE
19 Direction of maximum intensity measured from the
downward vertical (Cd/1000 1m)

A
vertical (Cd/1000 lumen)
EJ
0
vertical (Cd/JOOO lumen)
M
22 Maximum intensity above the horizontal (Cd/IOOO

lumen)
EN

mentioned data and test celtificates to be enclosed
M
LJ
KU
O
D

3 1/49
_..... - .....
CKE.LS.Ol.20.(02).2013
r--~JKR-] Date Issued: Aug 1999
.... ~. --.- Revision : 2
" '-- Date: Feb 2013
APPENDIX A-4
SCHEDULE OF LUMINAIRE (lOOW HPSV/SON)
ITEM DESCRIPTION DATAIMATERlAL
A MAKE
ER
I Manufacturer
D
n
N
3 Brand of Lurrunaire
TE
B MATERIAL
A
5 Lamp Compartment
EJ

M
7 Sealing Gasket
8 Reflector
EN
9 Cover Bowl
10 Lampholder
M
( )
II Bowl Retainer Catch
KU
C PHOTOMETRY
O
D
... cont. pg. 34/49

32/49
CKE.LS.Ol.20.(02).2013
Revision: 2
"" " - '
Date: Feb 2013
APPENDIX A-4
SCHEDULE OF LUMINAIRE(lOOW HPSVISON)
ER
17 Total Light Output Ratio - TLOR
18 Downward Light Output Ratio-DLOR
D
n 19 Direction of maximum intensity measured from the
N
downward vertical (Cdll 000 1m)
TE
20 Maximum intensity at 80<> from the down ward
vertical (CdIIOOO lumen)
21 Maximum intensity at 88<> from the downward

A
veI1ical (Cdl IOOO lumen)
EJ
22 Maximum intensity above the horizontal (Cd/IOOO

lumen)
M

mentioned data and test certificates to be enclosed
EN
M
KU
O
D
APPENDIX B
;Hak Cipla :1999 Cawangan Eleklrik JKR Malaysia
33149
CKE.LS.01.20.(02).2013
Revision: 2
. . _--
Date: Feb 2013
SCHEDULE OF TECHNICAL DATA - HPSV LAMPS
ITEM DESCRIPTION 400W 250W 150W JOOW

1 Manufacturer
3 Model number
ER
4 Lamp type
5 Wattage
D
6 Efficacy (LumenlWatt)
n
N
7 Operating position
TE
8 Rated life (Hours)
9 Luminous flux after 100 buming hours

A
10 Colour temperature (K)
EJ
II Operating voltage
12 Operating lamp cunent

M
13 Max . starting CUlTent

EN
14 Waveband in which 80% of the spectral

energy disllibution will occur
15 Time to reach 80% of max. luminous
flux after switchincr
M
16 Time to re-sll'ike after power

interruption
Light depreciation after 5000 burning
KU
17
hours
18 Mortality rate after 5000 burning hours
O
19 Relevant Standards of confonnity
20 Relevant pamphlets to substantiate the

D
above-mentioned data and test

cel1ificates to be enclosed
T it, Nama & Cop Pengilang Tit, Nama & Cop Kontraktor Elektrik
APPENDIX C

34/49
_.... .- ... '.
CKE.LS.01.20.(02).2013
I:- ~ JKR'] Date Issued: Aug 1999
Revision: 2
.. .. . ... .. . .
" '. ' Date: Feb 2013
SCHEDULE OF TECHNlCAL DATA - CONTROL GEAR
BALLAST FOR THE FOLLOWING HPSV LAMPS
ITEM DESCRIPTION 400W 250W 150W 100W
I Manufacturer
2 Model number
ER
4 Nominal wattage
D
5 Losses (in watts)
N
6 Rated max. operatin temperature of
F
ballast winding - tw C)
TE
7 Max. winding temperature lise - t.t
eC)
8 Impedance
A
9 Resistance
EJ
10 lnductance
II Lamp cun-en! crest factor

M
12 Power factor before con-ection

EN
13 Power factor after cOlTection
14 Expected life
M
()
KU
O
D
... cont. pg. 37/49
APPENDIX C
SCHEDULE OF TECHNICAL DATA - CONTROL GEAR

35/49
CKE.LS.01.20.(02).2013
Revision: 2
""--- Date: Feb 2013
IGNITOR FOR THE FOLLOWING HPSV LAMPS
ITEM DESCRIPTION 400W 2S0W ISOW 100W
I Manufacturer
2 Model number
ER
4 Nominal voltage
5 Peak ignition voltage
D
6 Losses (in watts)
n
N
7 Max. housing temperature CC)
TE
8 Max. operating temperature CC)
9 Conventional or electronic
superimposed pulse type
A
10 Timed type ( Yes I No )
EJ
11 Guaranteed life (no. of strikes)

M
CAPACITOR FOR THE FOLLOWING HPSV LAMPS
ITEM DESCRIPTION 400W 2S0W ISOW lOOW

EN
I Manufacturer
M
2 Model number
KU
4 Capacitance
5 Material of container
O
D
Tit, Nama & Cop Pengilang Til, Nama & Cop Kontraktor Elektrik
APPENDIX D
SUBMISSION OF COMPUTER PLOTS.

; Hak Cipta :1999 Cawangan Eleklrik JKR Malaysia
36/49
eKE. LS.01.20. (02).13
Revision: 2
Date : Feb 2013
"" - "
Electrical Contractors are required to submit computer plots of typical road sections as per
format described in the layouts given.
APPENDIX 0 I (1 to 4) - Computer Calculation Format For Road Lighting Installation

(To be submitted for various typical layo ut and sections as given in
the Tender Document or obtained from JKR)
ER
APPENDIX 02 (I to 2) - Tabulated Summary Of Lighting Level CalculationlData For Road
Lighting Installation
The computer plots shall also be attached.
D
n
N
In addition, the photometric data of item 3.0 shall be submitted.
TE
All the above plots and data shall be celtified by the respective manufacturer.
A
EJ
M
EN
( )
M
Tandatangan dan Nama Kontraktor Elektrik Cop Kontraktor Elektrik

KU
Tarikh
O
D

; Hak Cipta :1999 Cawangan Eleklrik JKR Malaysia
37149
eKE. LS.Ol.20.(02).2013
Revision: 2
Date: Feb 2013
"'-"
APPENDIX D1-1
DESCR IPTI ON OF THE LAYOUT
Cross section (transyersa llv)
ER
.. Road surface type: R .
Lave = 2 cd/m 2
D
Uo = Lmin/Lave ~ 40%
n
N
Ul= Lmin/Lmax ~ 70%
TE
T.I. :515% (Threshold Increment)
I
"00 :
.. Maintenance factor;
A
• Source: HPSV(Son-T) ............ Watts
EJ
.. Flux (kim) : ............. kim

M
Tilting Angle : 5° Position of the calcu lation grids

Plan view [m[
.. Overhang;
EN
- - - - - - - - - - - - - - - - - - - - - - - - - - - .....f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --
SR (Surround Ratio) <:! 0.5
-----------------------------------65---------- ---- ---------------
a ()
:::::::::::::::::::::::~:::---------~-::::::::f:::::::::::::::::::
M
x Grid A
KU
LEGEND:
Cht - Column height (m)

'Iv
O
C s - Column spacing (m)

Lw - Lane width (m)
D
Mw - Median width (m)

Rw - Road width (m)
- Data to be filled in by JKRlDesigner
SPECIFICATIO N FOR ROAD LIGHTING INSTALLAT ION

©Hak Cipta :1999 Cawangan Elektrik JKR Malaysia 39/49
CKE.LS.01.20.(02).2013
Revision : 2
" ' -' Dat e: Feb 2013
APPENDI X 01-2
ILLU M INANC E ON T HE 'GRID A' (TYPI CAL FOR 3 LANE ROAD)
Y[m[ [LUX]
Lw[ 17/6) - c::::::::J • c::::::::J • c::::::::J • c::::::::J • c::::::::J • c::::::::J • c::::::::J • c::::::::J • c::::::::J • c::::::::J
ER
~1~ ) -c::::::::J'c::::::::J'c::::::::J'c::::::::J' c::::::::J ' .c::::::::J.c::::::::J.c::::::::J.c::::::::J
~ Lw( 1 IP . c::::::::J • c::::::::J • c::::::::J • c::::::::J • •c::::::::J • ~ • c::::::::J • c::::::::J
. __ ._. __ ._._._._._._----------_._._._._._._._._._._._._._._..•...•.•. _...... _._-_._--_._._._._._---._._._._._._._._----
P . c::::::::J
D
c::::::::J Lw( 11 6 • c::::::::J • c::::::::J • c::::::::J • c::::::::J • c::::::::J • c::::::::J • c::::::::J • c::::::::J
n
N
Lw(3/2) - c::::::::J • c::::::::J • c::::::::J • c::::::::J • c::::::::J • • c::::::::J • LJ . c::::::::J • c::::::::J
TE
c::::::::J ---CWltiJ'-'~' c::::::::J_.·..c::::::::J_~..c::::::::J_.~..c::::::::J._ '- ____ _' ___.__!CJ_._.'. _c::=:J...'..c:::::::::J
c:::J l.,..-..J.bW(Sl6P • c:::J • c:::J • c::::::::J • c:::J • c::::::::J • c:::J • c:::J • c::::::::J
Lw/2 c:::J.c:::J. c:::J .c:::J.c::::::::J.c:::J.c:::J.c::::::::J.c:::J. c::::::::J
A
Lw/6
EJ
0.0 O.1Cs O.2Cs O.3Cs OACs o.ses 0.6es O.7Cs D.BCs o.ges
M
Eave = _ _ _ Lux Uo = Emin/Eave = %

EN
Em in = Lux Ug = Emin/Emax = ~_%
Emax =_ _ _ Lux
Type of lumina ire :
l )
M
Data for 30 points per lane.

KU
LEGEND:
Cs - Column spacing in metres

Lw - Lane width in metres
O
D
Tandatangan Pengilang Tandatangan Kontraktor Elektrik
Cop Pengilang Cop Kontraktor Elektrik
Nama: _ _ __ _ _ __ Nama:
Jawatan : _ _ __ _ _ __ Jawatan: _ _ _ __ _ _
OpEQl EWO Tl Ot! [OR RO AD' 'AI Ir lrlD IriDI Al I Al lOt I

C>Hak Cipta :1 999 Cawa ngan Elektrik JKR Ma laysia 40/49
CKE.LS.01.20.(02).2013
Dat e Issued: Aug 1999
Revision: 2
Date: Feb 2013
APPE NDIX D1 -3
LUMINANCE ON THE 'GR ID A' (TYPICAL FOR A 3-LAN E ROAD)

(Observer's position: X= - 50.0m Y= Lw/2 H= 1.5m)
Y[m] [CD/M ' ]
ER
Lw(17/6)
Lw(15/6)
Lw(13/6)
D
n Lw(11/6)
N
Lw(3/2)
TE
Lw(7/6)
Lw(5/6)
Lw/2
A
Lw/6
EJ
X[m]
0.0 0.1Cs O.2Cs 0.3Cs OACs 0.5Cs 0.6Cs 0.7Cs O.BCs 0.9Cs
M
Lave = _ _ _ cd/m2 Uo = Lmin/Lave ;;: %

EN
Lmin = UI ;;: Lmin/Lmax ;;: _ _ _ %
Lmax ::: _ _ _ cdlm2

Type of luminaire :
M
~ ) Data For 30 Points Per Lane
LEGEND
KU
Cs - Column spacing in metres

Lw - Lane width in metres
O
D
Tandatangan Pengilang Tandatangan Kontraktor Elektrik
Cop Pengilang Cop Kontraktor E lektrik
Nama: Nama:
Jawatan: Jawatan:
SPECIFICATION FOR ROAD LI GHTING INSTALLATION

!O Hak Cipta :1999 Cawangan Elektrik JKR Malaysia 4 1/4 9
CKE.lS.Ol.20.(02).2013
I. ~" ;iiltJ Date Issued : Aug 1999
Revision: 2
.... .- ..... .
" '-"
Date: Feb 2013
APPENDIX D1 -4
LONG ITUDI NAL UNIFORMITY FOR EAC H LAN E (FOR A 3-LANE ROAD)
ER
Observer on the axis Y ::: + Lw/2 m
X= 0.0 0.1Cs 0.2Cs 0.3Cs OACs 0.5Cs 0.6Cs 0.7Cs O.BCs 0.9Cs [m]
L= • D ' CJ ' CJ ' CJ ' CJ ' CJ ' CJ ' CJ ' CJ ' CJ [cd/m' ]
D
N
Ugl1 = LminlLmax ::: _ _ _ %
(')
TE
Observer on the Y::: + Lw(3/2) m
A
L= • D 'CJ ' CJ ' CJ ' CJ ' CJ 'CJ 'CJ ' CJ ' CJ [cd/m']
EJ
Ugl2 ::: LminlLmax ::: %

M
Observer on the Y = + Lw(1S/6) m

EN
L= • D 'CJ ' CJ ' CJ ' CJ 'CJ 'CJ ' CJ ' CJ ' CJ [cd/m']
M
()
Ugl3 ::: Lmin/Lmax ::: _ _ _ %
KU
O
D
Tandalangan Pengilang T andatangan Kontraktor Elektrik
Cop Pengilang Cop Kontraktor Elektrik
Nama: _ _ _ _ __ _ _ _ Nama:
Jawatan: _ _ _ _ __ __ Jawatan: _ _ _ _ _ _ __
SPECIF ICATION FOR ROAD l iGHTING INSTAl I ATiON

e Hak Cipta :1999 Cawangan Elektrik JKR Malaysia 42/49
r-
c........
~
I ---~JKR'] CKE.LS.01.20.(02).2013
._--.. -- .-_.,- Revision: 2
Date: Feb 2013
ER
APPENDIX D2-1
TABI! ! AIED SIIMMARY OF [IGHTI NG I EyEl CAl GlJ I AIION/PATA (! ! IMINANCFl FOR ROAD LIGHTING INSTAl I AIION
D
PROJEK:
N
NO. RUJUKAN: PKR(L)
Luminaire Brand! Model No ..
TE
Please key in the results from the computer print-out or exact calculated values into the table below.
VARIOUS ROAD Luminance (cdlm )
I
GLARE SR COMPUTER
CROSS·SECTIONS! WATIAGE MOUNTING SPAC ING IL ,,)
(cdlm2)
(L min)
(cdfm2)
I (L max) I( Uo:: I, UI :: THRESHOLD SURROUND CALCULATION
A
JUNCTIONS NUMBER# HEIGHT 1m) (cd/m2) (LminILav) (lminfLma;>;) INCREMENT RATIO NUMBER
EJ
M
EN
M
NOTES: -
KU
1. The Tenderer shall provide the required data for all sections/junctions of the Road Lighting Installation.
2. The Tenderer shal l make duplicate copies of Ihis Form to be filled as necessary.
3. The coss-sections/junctions numbers are given in the Tender Document.
Tandatangan, Nama,
O
Tandatangan, Nama,
Alamat dan Cop Alamat dan Cop
Pembekal Tarikh : Kontraktor Elektrik :
D

© Hak Cipta :1999 Cawangan Elektrik JKR Malaysia 43/49
r
'- :J
11JKR] CKE.lS.01.20.(02).2013
Revision: 2
,.-'
Date: Feb 2013
ER
APPENDIX 02-2
TABULATED SUMMARY OF LIGHTING LEVEL CAL CUI ATiON/DATA OLLlJM INANCE) FOR ROAD LIGHTING INSTALLATION
D
PROJEK:
NO. RUJUKAN : PKR(L)
N
Luminaire Brand I Model No .. ..... .... ..
TE
Please key in the resu lts from the computer print"out or exact calculated values into the table below.
1 1 J
VARIOUS ROAD Illuminance (lux) COMPUTER
CROSS·SECTIONSI WATTAGE MOUNTING SPACING (E avl I (E min) (E max) Uo- Ug- CALCULATION
A
JUNCTIONS# HEIGHT (ml Emin/Eave Emin/Emax NUMBER
EJ
M
EN
M
KU
NOTES:-
1. The Tenderer shall provide the required data for all sections/junctions of the Road Lighting Installation.
2. The Tenderer shall make duplicate copies of this Form to be filled as necessary.
3. The cross-sections/junctions numbers are given in the Tender Document.
O
Tandatangan , Nama, Tandatangan, Nama,

Alamat dan Cop Alamat dan Cop
D
Pembekal Tarikh . Kontraktor Elektrik

e Hak Cipta :1999 Cawangan Elektrik JKR Malaysia 44149
CKE.lS.Ol.20.(02).2013
Revision: 2
-"- ' Date: Feb 2013
APPENDIX E
TECHNICAL SCHEDULE OF COLUMNS AND BRACKET ARMS
ITEM DESCRIPTION DATA

1 COLUMN
a Name of manufacnlrer
ER
b Address & country of manufacturer/fabricator
of colunm
c Type of colunm Hot-Dipped Galvanised Steel / * Pre-
*Delete whichever not applicable.
D
Stressed Spun Concrete /* Fibreglass
Reinforced Type Irrype2* Others*
n
N
d Compliance with relevant section of BS 5649 (EN40)*
TE
*Delete whichever not applicable. ANSI C-136.20 & ASTM D 4923-89*
Others (Specify)* ........................ . .....
e Name of hot-dip galvanising company
f Address & country of manufacturer of steel

A
tubes
0 Galvanising standards & minimunl. weight
EJ
e
per m' . (g/ m')
h Overall height of column (m)
M
J Tapeling ratio
J Weight of colunms (kg) - Whole

Upper section
EN
Lower section
k Thickness of steel column (mm.) /
Concrete wall thickness (mm)
()
M
1 Name of company applying bituminous paint

m Address of company applying bituminous
KU
paint
n Dry film thickness of bituminous paint (mm)
a Equivalent weight of bituminous coating per
sq.m. (g/m' )
O
p Longitudinal seam weld minimum

penetration (%)
D
q Reference standard of welding test

(Latest relevant B.S.)
T/t, Nama & Cop Pengilang Tit, Nama & Cop Kontraktor Elektrik
... cont. pg. 46/49
APPENDIX E
45
CKE.lS.01.20.(02).2013
Revision : 2
Date: Feb 2013
TECHNICAL SCHEDULE OF COLUMNS AND BRACKET ARMS
ITEM DESCRIPTION DATA
2 BRACKET ARM
a Name of manufacturer
ER
b Address & country of manufacturer
c Material of bracket arm
D
d Name of hot dip galvanising company
N
e Bracket arm projection (m)
TE
f Grade of steel usedlstandards complied
0
b
Weight of bracket (kg)
h Thickness of steel bracket (mm)

A
EJ
M
EN
()
M
KU
O
D
Tit. Nama & Cop Pengilang Tit, Nama & Cop Kontraktor Elektrik

46
I-~JKR-]
c :) CKE.LS.01.20.(02).2013
Revision: 2
-:..
...... . .-'
Date: Feb 2013
APPENDIX F
ER
YOI TAGE PROP CALCULATION FOR THE ROAP LIGHTING INSTALLATION
PROJEK:
FEEDER PILLAR No. (To be filled for each Feeder Pillar) :
D
REFERENCE PATA :-
N
LUMINAIRES WATTAGE CURRENT (Amps.) PER LUMINAIRE CABLE SIZE AND TYPE
TE
VOLTAGE PROP FOR THE ABOVE CABLES.
CIRCUIT Please insert the data below for TOTAL

ITEM No. each phase. (Refer T ender Drawings) VO LT DROP CATATAN
PHASE QTY" TOTAL WATTS (Volts)
A
1 Circuit 'a' R
EJ
y
B
2 C ircu it 'b' R
M
(if any) Y
B
3 Circuit 'c' R EN
(if any) Y
B
M
NOTES :- Tandatangan , Nama, Alamat dan Cop Kontraktor
1. The total voltage drop along the one complete circuit for each phase Elektrik:
must not exceed 20 volts.
KU
2 . The Tenderer shall attach together with this Form the complete voltage drop calculation.
3. All calculation shall be in accordance with the Tender Drawings.

O
4 ... - State the quantity of luminaires in this particular circuit.
Tarikh :
D

; Hak Cipla :1999 Cawangan Elektrik JKR Malaysia
47/49
APPENDIX G
SERVICE AND MAINTENANCE FOR THE ROAD LIGHTING SYSTEM

(For use during the Defects liability Period)
PROJEK:
NO. RUJUKAN : PKR(L)
Period of Service and Maintenance : ( .. .. ..1. .... .1..... to .... ..1. .... .1 ....... ) (dd/mm/yyyy)
ER
Schedule of work to be carried out at 3 monthly intervals.
ITEM DESCRIPTION ACTION REMARK
D
()
N
A COLUMNS
(Please specify column number/circuit under
TE
REMARK' for any defects found)
I Column Number or circuit label I I

2 Ensure all columns straight I I
A
I I
EJ
3 Ensure all service door covers intac t
4 Replace missing service doors I I

M
5 Clear debris around base/foundation I I

EN
6 Check Labels present and clean I I

7 Check for column damage I I
()
M
8 Others (please specify) I I

KU
B BASE SECTION· CABLE TERMINATION
I Check all cable terminatio n for signs of loose I I

contact and corrosion
O
2 Clean and tighten where necessary I I

D
3 Replace faulty MCBs, junction boxes for each I I

column
C LUMI NAIRES
1 Check functionality I I
2 Replace fa ulty lamp
... conl. pg. 49/49

; Ha k Cipta :1999 Cawangan Elektrik JKR Malaysia 48/49
APPENDIX G
SERVICE AND MAINTENANCE FOR STREET LIGHTING SYSTEM
(For use during the Defects liability Period)
PROJEK:
Period of Service and Maintenance : ( ..... .! ....... .! ........ to ...... .1. . .... .! .... .. ... ) (dd/mm/yyyy)
Schedule of work to be carried out at 3 month ly interva ls.
ER
ITEM DESCRIPTION ACTION REMARK
3 Replace faulty ignitor I I
D
4 Replace faulty capacitor I I
N
5 Replace faulty ballast I I
TE
6 Clean luminaire bowl (once in 12 months) I I
D FEEDER PILLARS
A
I Check and clean Feeder Pillars - both internall y I I
EJ
and the surro unding area.
2 Check and replace faulty components - MeBs. I I

M
timeswitc hes, relays, cabling, luminaires,

contactors. changeover switch , etc.
EN
E TESTING AND RECORDS
I Test system/installation and record all test I I

M
\) results, inspection and work done

KU
PERAKUAN KONTRAKTOR ELEKTRIK
Kami mengaku Lelah rnelaksanakan Adalah disahkan kerja-kelj a di alas Lelah

O
kerja-kerja penyelenggaraan seperti dilaksanaka n dan perkara-perkara bertanda

tercatit dalam kedua-dua muka surat -·(asterisk) perlu/akan diaillbil lindakan
borang Appendix G. o leh Kontraktor Elektrik
D
Tandatanga n
Ko ntraktor Elektrik : Tandatangan Pegawai JKR :
Nama: Nama
Alamat & Ja w atan :
Cop rasmi :
Tarikh: Tarikh:
SPEC IFICATION FOR ROAD LIGHTING INSTALLATION

;Hak Cipla :1999 Cawangan Elektrik JKR Malaysia 49149
ADDENDUM NO.1 REVISION 1
ER
TO
D
L-S20: SPECIFICATION FOR ROAD
n
N
TE
(August 1999)
A
EJ
SECTION A2.0: ROAD LIGHTING LUMINAIRES - LED

M
EN
-This addendum is additional to Section 2.0 of L-S20 :

SPECIFICATION FOR ROAD LIGHTING INSTALLATION (August 1999)
( ) and shall be read together with the comp lete specifications.
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rf.iiCR·l ADDENDUM NO.1
CKE.LS.Ol.20.(02).2013
....:.-.. ...."
"-'- Date Issued: Aug 1999
Revision of addendum: 0
SECTION: ROAD LIGHTING LUMINAIRES - Date: Feb 2013
A2.0
LED
Page: SA2· 1 of 9
ER
A2.1 General
Luminaires utilising Light Emitting Diode (LED) as light source are also known as Solid
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State Lighting (SSL).
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Solid State Lighting (SSL) i.e LED luminaire system shall be complete with electronic
contro l gear (dri ver), thermal management unit , surge & overvoltage protection and
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design for side entry suitable for supply voltage of 230 Volt, + 10%, ·6%, 50 Hz.
Computer simulation for lighting level calculation shall be supplied (prepared and submitted)
to meet the design criteria and lighting class required (APPENDIX 01 - l.IA) in accordance
with MS 825: Code of Practice for the Design of Road Lighting. The simulation shall be
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generated using internationally recognised design software . (e.g. Dialux, Caleu lux, Ulysee
etc.)
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A2.2 Conformity With Standards

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All products proposed must have product certification from accredited certification bodies.
LED luminaire shall be tested to compl y with the CllITent prevailing standards as below and of
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lates t version :·
No. Item Relevant IEC Standards Name of standard

1.0 Luminaire
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Safety MS lEC 60598-2·3 Luminaires - Part 2-3: Particul ar

Requirements - Section 3:
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1.1
Luminaires for Road and SU'eet
Lighting
Performance MS 62722· 1 Luminaire Performance - part 2·1 :
1.2 Particular Requirement for LED
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Luminaires
Performance lES LM·79-08 Approved Method: Electrical and
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1.3 Photometric Measuruments od Solid

State Lighting Products
PerfOiman ce lESTM 2 1· 11 Projecting Long Term Lumen
1.4
Maintenance of LED Light Sources
Control Gear
2.0
(LED Driver)
Safety MS lEC 61347 -2·13 Lamp Control Gear - Part 2·13 -
2.1
lEC 61 347-2· 13 Particular Requirement for DC
ADDENDUM NO.1 REV. 1 TO SPECIFICATION FOR ROAD LIGHTING INSTALL ATION

© Hak Cipta: 2013 Cawangau Kejufuteraan Elektrik, JKR Mala)'sia
r'f :Tiii-) ADDENDUM NO.1
CKE.LS.Ol.20.(02).2013
..-..... ........ -- .- Date Issued: Aug 1999
SECTION: ROAD LIGHTING LUMINAIRES - Da te: Feb 2013
A2.0 LED
Page: SA2 - 2 of 9
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No. Item Relevant lEe Standards Name of standard
or AC supplied Electronic Control
Gear for LED Modules.
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Performance MS IEC 62384 DC or AC supplied Electronic
n 2.2 IEC 62384 ed 1.1 Control Gear for LED Modules -
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Performance Requirements
3.0 LamD Holder
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Safety MS IEC 60838-2-2 Miscellaneous lampholders - Part2-2
(fEC 60838-2) - P31ticular Requirements -
Connectors for LED Modules.
4.0 LED
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Term & MS fEC 62504 General Lighting: LEOs and LED
4. 1
Defination fEC 62504 (Ed. I) Modules - Terms and Oefination.
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Performance IEC I PAS 62707 Ed. 1 LED - Binning - Part 1: General
4.2
(General) R equirements and White Grid
Performance MS 62717 LED Modules for General Lighting
4.3
(Modules) - Safety Requirements
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Peformance fECITR 6 1341 MeLhod of Measurement of Centre

4.4 (Lamps) Beam Intensity and Beam Angle (s)
of Reflector Lamps
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Performance IES LM-80-08 Approved M ethod: Measuring

4.5 (Light Source) Lumen Maintenance of LED Light
Sources
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( I Safety MS IEC 62031 LED Modul es for General Lighting

4.6 (Modules) IEC 6203 I (Edition 1.0) - Safety Specifications
AMD.l.ed I
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4.7 Safety (Lamps) IEC 61231 !ntemational Lamps Codino Systems

Safety (Eye IEC 6247 1 ed 1.0 Photobiological Safety of Lamps and
4.8
Protection) Lamp Systems
IECITR 62471-2
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Safety (Eye Photobiological Safety of Lamps and

Protection) Lamp Systems - Part 2 :Guidance on
4 .9 ManufactOling Requirements
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Relating to Non-Laser Optical

Radiation Safety
10.0 Connector
Safety IEC 61984 Connectors - Safety Requirement
and Test
ADDENDUM NO.1 REV. 1 TO SPECIFICATION FOR ROAD LIGHTING INSTALLATION

© Hak Cipta: 2013 Caw3ngan Kejuruteraan Elektrik, JKR Malaysia
r-f.ifili-] ADDENDUM NO_l
CKE.lS.Ol.20.(02).2013
..-.-- ....~- .--_ ... Date Issued: Aug 1999
SECTION: ROAD LIGHTING LUMINAIRES -
A2.0 Date: Feb 2013
LED
Page: SA2 - 3 of 9
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No. Item Relevant IEC Standards Name of standard
11.0 EMC
Performance IEC 6 1547 Edition 2.0 Equipment for General Lighting
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11.1 Purposes - EMC Immunity
n Requirements
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Performance IEC 61000-3-2 Edition 3.2 Electromagnectic Compability
(EMC) - Part 3-2: Limits - Limits
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11.2 for Harmonic Cunent Enunissions
(Eq uipment Input CUlTent :S I6 A per
phase)
Performance CISPR 15:2005 (BS EN 50015) Limits and Methods of Measurement
of Ratio Disturbance Characteristics
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11.3
of Electrical Lighting and Similar
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Eauioment
Lighting
12.0
Design
Performance MS 825 Code of Practice for The Design of
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12.1
Road Lighting
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A2.3 Construction And Components
a) The luminaire shall be so designed and constructed that it is capable of providing

the service for which it is intended . Sound engineering principles shall be adopted
( )
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tlu·oughout and the luminaire shall be designed to enable ease of maintenance and
replacement of light source, optica l le ns , electronic control gear , thermal
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management unit, reflector and holder without the use of special tools.
b) The main supporting structure of the luminaire shall be constructed from di e-cast
aluminium alloy material such that no undue detelioration in its safety. performance
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or appearance during normal life when operating in all climatic conditions prevailing
in a tropical country such as heavy rains, strong winds, high humidity and bot day-
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time temperatures. It sball be robustly constructed to withstand vibration in normal

use.
c) The luminaire shall be designed so that condensation shall not fall on any operating
part which may fail or deteriorate the performance of luminaire.

r-r;KR-l ADDENDUM NO_l
CKE.lS.01.20.(02).2013
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A2.0 LED
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d) All luminaires shall be new. totally enclosed and protected against contact wi th live
or moving parts inside the enclosure. Ingress Protection Index (IP) of LED luminaire
shall be minimum IP65 . Full detail s of the IP system can be refelTed to in MS IEe
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60529.
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e) The compartment for electronic control gear and light module shall preferably be
separated. Access to the electronic control gear (dri ver) compartment shall
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preferably be from the top.
f) Material used for the cons ~'ucti on of the luminaire shall be recyclable.
g) Hinges. screws and clips if used. shall be robust and made of stainless steel. simple
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to operate and shall not be liable to accidental detachment during installation or
maintenance.
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h) In the open position. it shall be attached in such a way that there is no

likelihood of it becoming accidentally detached and thereby damagi ng any part of
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the luminaire. the bracket or the column.
i) Attachment of the luminaire to its bracket arm shall be by means of clamps or jam
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bolts and designed to accommodate spigot size of the luminaires. A minimum of

two (2) locking bolts I jam screws shall be provided.
j) The minimum penetration depth of the bracket arm is 100mm. The mounting
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\ ) aITangement and attachment of the luminaire shall be such as to withstand a

windspeed of 42 m/s on the projected surface of the assembly without due deflection.
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k) All parts which can'y the weight of the luminaire and internal accessories shall be
provided with suitable lockin g devices to prevent the dislodgement of any part of
the luminaire by vibration either in service or during maintenance.
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1) All parts shall operate well within the ratings with due consideration fo r the local
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conditions (high humidity of 80% RH . hot (l ive) ambient temperature of 35°C).
m) Interchangeability of consumable components is prefeITed for maintenance purposes.
A2.3.1 Light Source
a) The light source for LED luminaires shall be of high powered LED type. The LED light
module shall not be driven more than the rated LED drive cUITent.
XBBtNbuM NU.I MC. i 16 gPkCfiiCX] iUN tuk ROAD [IdAliNe INStALLAtIUN

© Hak Cipta: 2013 Cawangan Kejuruteraan Elc ktrik, JKR Malaysia
r'f iliiil ADDENDUM NO.1
CKE.LS.01.20.(02}.2013
'--.•-.,..::=-- --- -~ Date Issued: Aug 1999
A2.0 LED
Page: SA2 - 5 of 9
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b) T he lumen output of LED luminaires (system efficacy) shall be minimum 90 Irn/W. The
usable lifetime of LED (l umen maintenance) at 36,000 hours shall not be less than SO%
(LSO @ 36,000 hours). The system effi ciency shall take into consideration the LED
efficacy, driver efficiency, optical effici ency and thermal effi ciency and shall not be
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less than SO%.
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c) T he Correlated Colour Temperature (CCT) for LED luminaire shall range between
2500K to 3500K.
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d) Photobiological safety of LED module or LED luminaires shall not be more than Risk
Group I Cas per IEC 6247 1). A
A2.3.2 The Optical System
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The optical system shall comprise of optical lens, reflector (if any) and luminaire cover.
a) Optical Lens
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The optical lens shall be made of UV resistant material (eg. poly methyl methacrylate
(PMMA), UV stabilized polycarbonate, silicon, etc) and shall be stabilised against
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deformation, deterioration or discolouration due to the lamp and/or solar radiation

(UV).
b) Reflector
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The reflector if any shall be made of at least 99.S5% pure al uminium with a minimum
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thickness of 1 nml, be electrically brightened, anodised and chemically treated to give

high reflectance.
c) Luminaire Cover (Secondary Optics)

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L uminaire cover shall be provided to protect the optical lens from accumulation of dust
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and for easy cleaning of the luminaire. It shall be mad e UV resistant material suitable
for outdoor used (in accordance with standard UL746C or equivalent).
For covers that is designed as li ght diffu ser/ di sperser, it shall be made of
cl ear tampered glas s.
d) The gasket used shall be silicone, one piece weather resistant type that will not cause
crazing of the Iuminaire cover. The gasket shall form an integral part of the
luminaire cover such that any cover change will necessitate a change of the gasket.

© Hak Cipta: 2013 Cawangall Kejuruteraan Elektrik, J KR M alaysia
l~ fjKiI'l ADDENDUM NO.1
CKE.LS.01.20.(02).2013
"-' ......-::::. _...... Da te Issued: Aug 1999
A2.0 LED
Page: SA2· 6 of 9
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A2.3.3 Thermal Management Unit
The luminaire shall be provided with suitabl e themlal management unit to effecti vely
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di ssipate heat generated from LED.
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A2.3.4 Electronic Control Gear (LED Driver)
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a) E lectronic control gear (LED driver) shall compli se of electronic circuit board,
converter, built-in power factor cOiTection unit (2 0.9), intemal surge protective device
(SPD) and THD <20% . The driver shall be able to wi thstand short circuit c urrent,
overload, over voltage and over temperature. The driver shall have self cooling system.
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LED driver shall be placed close to LED where possible to reduce electromagnetic
interference.
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b) The input range of the driver shall function conectly at the supply voltage and shall
allow for normal variation and surges (230Y , + 10%, -6%, 50 Hz).
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c) The working temperature for the dri ver shall suit the local condilion.
d) Ingress Protection Index (lP) of the driver shall be minimum lP65 as per MS lEC
EN
60529.
, A2.3.S Surge Protective Device (SPD)

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) a) InternallBuilt-In SPD
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The driver shall be protected against lightning surge with an internal surge protector
devices (SPD) of not less than 15kA with a le t-thro ugh voltage of less than 350Y test at
2kY, 1.2/50~Sec open circuit and I kA , 8/20~ Sec short circuit.
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b) Extemal SPD
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To enhance the dri ver life span and prolong the internal SPD performance, the external
SPD ma y be installed within the colunm after the modular termination box for safety
and ease of maintenance.
If required, the external SPD shall be rated not less than 20kA with a let- through
voltage of less than 850Y tested at 6kY, 1.2/50~Sec open circuit test and 3kA ,
8/20~ Sec short circuit test.
The SPD shall be Full Mode (L-N, L-E, N-E) protection wi th a working voltage of
275Vac series connection and comnlete with LED indicator
ADDENDUM NO.1 REV. 1 TO SPECIFICATION FOR ROAD LIGHTING INSTALLA nON
© Hak C ipla: 2013 Cawangan Kejuruleraan Elektrik, JKR Malaysia
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"-'-~ - ..~:.. ......
ADDENDUM NO,I
CKE.lS.Ol.20.(02).2013
A2.0 LED
Page: SA2, 7 of 9
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A 2.3.6 Internal Wiring and Earthing Terminal
2.3.6.1 Internal Wiring
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a) The luminaire shall be completely pre,wired, requiring only the connection of the
electtical power supply cables to the terminal and the earth continuity conductor to the
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earthing terminal.
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2.3.6.2 Earthing Terminal
a) A separate terminal for the connection of an earth continuity conductor, clearly and
permanently marked shall be provided. The installation shall comply to MS 60364.
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b) All exposed metal parts and other parts accessible when the luminaire is opened for
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maintenance and liable to become live in the event of an insulation fault shall be
permanently and reliably connected to this earthing terminal.
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A2.4 Compnter Simnlation for Lighting Level Calculation
2.4.1 Computer simulation for lighting level calculation shall include PhotomeUic Data
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which comprises of the following:
i) Isolux Diagram
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ii) Utilization Factor Curves

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iii) Polar Curves of thefollowing C,Planes 0' 1180' ; 90' 1270' ; maximum
intensity plane
iv) Downward Light Output Ratio
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v) Downward and Upward Flux Fractions
Tender docnments snbmitted without the appropriate Compnter

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Simulation will be disqualified.

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"--. ,"--_.- ......
ADDENDUM NO.1
CKE.LS.01.20.(02).2013
A2.0 LED
Page: SA2· 8 of 9
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2.4.2 Tenderers are required to furni sh comprehensive infOlmation and technical particulars as
stipulated in>
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i) APPENDIX 01 - Computer Calculation Format for Road Lighting Installation
(To be submitted for Road l and Road 2 as given in Attachment A)
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ii) APPENDIX 02 - Tabulated Summary of Lighting Level Calculation / Data For Road
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Lighting Installation
The computer plots shall also be attached .
All the above plots and data shall be certified by the respective manufacturer.
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A2.S Schedule and Technical Information on LED Luntinaires
2.5.1 Tenderers are required to furni sh comprehensive infollnation and technical particulars
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as stipulated in Attachment B (Product Features).

2.5.2 The information required in the attaclmlent shall be completed fully and correctly. All
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technical data entered therein shall be substantiated with relevant pamphlets and test
certificates from the manufacturers or the recognized testing authorities.
Failure to fulfill the above requirements shall result in the disqualification of the
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\ ) tender.
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© Hak Cipla: 2013 Cawangan Ke,iuruteraan Elektrik, JKR Malaysia
rf.TKR'] ADDENDUM NO.1
CKE.LS.Ol.20.(02).2013
..
'-.' ""........... Date Issued: Aug 1999
SECTION: ROAD LIGHTING LUMINAIRES· Date: Feb 2013
A2.0 LED
Page: SA2· 9 of 9
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A2.6 Warranty
2.6. 1 System Warranty
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The manufacturer / distributor shall provide a 5 year warranty certificate for the
n complete luminaire system to guarantee the longlife expectancy and maintenance free
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luminaire. Warranty declaration shall be filled and duly signed by distributor /
manufact urer as per Attachment C. Failure in the functioning and operation of the LED
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luminaire within the warranty period will result in the replacement of the whole
luminaire or required components by the manufacturer/distributor at no cost to the
goVe111ment.
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2.6.2 Performance Warranty
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Luminance and illuminance test shall be carried out every six (6) months dming defect
liability period, to ensure the performance of the installed system conform to designed
requirement. These tests will also confrrm the lumen maintenance of the luminaire.
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The contractor together wi th luminaire supplier shall carry out the above test and the
result must meet the design critetia as submitted in the computer simulation.
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( )
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Note:
1. System Efficacy LED Efficacy X Driver Efficiency X Optical Efficiency X Thennal Efficiency
2. System Efficiency System Efficacy (Luminaire Lumen Output)

LED Efficacy (Light Source Lumen OutpUI)
3. Maintenance Factor = Lmup Lumen Maintenance Factor X Luminaire Maintenance Fuetor

© Hak Cipta: 2013 Cawangan Kejuruteraan Elekt rik, JKR Malaysia
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Road 1 ATIACHMENT A-1
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A
Centerline
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1.5m O.5m O.5m 1.5m
i . i ! i ! I i
Varies 'Vories ! ! Ii Ii ! ! I!! Vorills Varies
I (max. 3.Om) j(max. .1Om
~.--.-.- .-.-.---.-. --,t--.--,- .--.
: !
-- '-!'---I-'-'
2.Om i 3.5m i 3.5m! j !: 15m : J.5m
--·----·--·i-----·----·-·-·---·-·-·j---·-·---·-·-·--·--_. __.-t-.-t--. -.-+-+.-.---.-.-.-----.-.---.;-.--.-.-.--.-.---.--.-.--r-·- ---·-·--r'-·j-·-;-·
i 2.Om!: I (max. 3.0m)
-_._--_._._._._._._._--t-: _._._----
(max ..10m)
_.__._-_._.
i I
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! lIer e Paved MIOIf1[101 MClf1ij,O I i Paved \fer e i
! .
i
shoulder: ii ~t Of ft if> i i shoulder
!
i i
I I I ! " ! I ! !
I ! ! I ! I I I
: : i ! i
: . I i I
i
: EN .
Camageway!
i .
COrrlogeway
, 1.0m I
iMe iori ' COrrlogeway
.
Carriageway ii Ii . ...
Utilities
reserve
Droin
reserve
. I
j
!
,
! !
I I
Droln
reserve
Utilities
reserve
I I.Om 1.Om I i
i Unpcved Unpaved i :
Li1"oJ ShOOlder Shoulder Lj....i
. __" ._
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r ___ l~ n_,_
(min~f.Om)
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DESIGN REQUIREMENT : LIGHTING CLASS MEl (MS825)

.... eruqa LunirIcIru (min, I'I'IIlintairled).
Overoil Un~orm;ty. Uo (min';)
Threshold Increment, n (max Xl SR. SurT'OlA'\d Rotio (min) lamp ldainlen!;W1Cl! faclar
longitudinal Un~ormity. UL (min" ) (Oisdilily Gklrtt)
laYo (cd/m')
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2.0 0.' 0.7 10 0.5 0.8

----
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Road 2 ATIACHMENT A-2
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I '----J '----J
A
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Centerline
I ~
'" , , J f I' 0.50 O.lm ,.50
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,.1m
i
, I .,
--~'- --/'~7i+---~---+----!~-r--~ "~ "t'~~----i------~~--- ------'--.lm--~t~ -+~L
I Vories I Varies
i I
- _.__
Vori=J Voriel
~:-~~li~ J.Om . __ ._ ._--_.1--------_.
(max.. J.orn) (max. l.om)
I I shoul fir I '

EN t 0' It shaul er
I I
,
~
I I
'
I!
II
I!
iI reserve I
I Co"'o,,"o, I Co"'o, ••o, I Corr;o,••o,
i
I": ;0 II Corr;o, ,"o, I I
Co,,;o, ••o,
Corr;o,m,
i
I
ii Droin Utilities
-
Utilities Drain
reserve reserve reserve
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.....
1.. .
.,"'"
1.. .
- f
1.. .
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DESIGN REQUIREMENT : UGHTING ClASS ME1 (MS825)

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.......
t-f<A/J)
t..or.ooo(m~ 00nII~,1Io(1IIk() ~ 1dornIr. I.l. (-.s)
--,
ftnoIdI ........ . {.-1) ~ ...... (....J
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Road 1 ATTACHMENT A-3
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A
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l.Sm O.5m O.5m 15m
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I : i ! !
Varies : Varies i : ! ! : i : . . Varies Vorie!!
(max. 10m) i(max. 3,Om I i 2.0m: 3.5m : 15m!:!: 3.5m : 3.5m I 2.0m i i i (max. 3.0m) i (max. 3.0m)
-----------'-'-'-----'-'t'-'-'-'-'-'- ---------+---!---- '-'- '-'- '-'- '-;'-'-'-'-'-'- '-'-'-'-'-'-'-'-'-- r----- '---'-'-'-'-'-'-'-'-'-'--I--.t" _·L.·_·t·_·_·_·_·_·_·_· _·_·_· _·_·_·_·_·j-·_·_-_·_·_-_·_------·-------j----------·- ·-j-·-·j-·- ·i·-·---·- ·-·-·-·-·-'-'-'-'--'--'i'---'-'-'---'--'--"
: Ver e Paved! ! M<iI. rgin Q.lrgjt'lOJ . ! Paved i Ver e !
I shoulder:: EN iStrp $tnp : shoulder !
! ! Ii ' i I
! ! t !
,i i, : :,
! Carriageway! Carriogewcy Carriageway Carriageway i
Utilities
reserve
Drain
reserve
t
i
:I ! Droin
reserve
Utilities
reserve
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i tOm 25 .Om
I Unpaved ..m Unpaved
! ! Shoulder Medlcn Shoulder
";r;..J
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Varies
(min. I.Om)
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DESIGN REQUIREMENT • LIGHTING CLASS MEl (MS825)

luminance (min. maintained),
A\'eroqe Threshold Increment, 11 (max %) SR, Surround Ratio (min)
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OVerall Uniformity, Uo (min) Longitudinal Uniformity, UL (min) Lamp t.lainlenance factor

LM (cd/ml) (Discbilily Glare)
2.0 0.4 0.7 10 0.5 0.8

-
,.---
-- ")
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Road 2 ADACHMENT A-4
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N
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A
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LlI'' I
-
I>m
o.~! o.~1
"
200m i l.5m i
----------- -- - ---.----.- •.--.--.-.---.~.-+-
3.Sm
EN i l.5m
I
Ii 3.5m I
j._.•- - _ . _ - - - - . - - - - _ .
305m J.om ,Om
Varies
(mox. 3.Om) (max. 3.Om)
Paved
shoulder ~~~'~er
I II
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Carriageway Carriageway Carriageway Carriageway Corriogewoy Carriageway
Drain
reserve
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1.Om
Unpa'led
Shoulder
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DESIGN REQUIREMENT LIGHTING CLASS ME1 (MS825)

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Awnoe ~ (..... ..--j. o..-.~. 1Io (fl'inl ~ 1W'onnly, l.l (n.) TInohoId ncr.md, 11 In. I) SlmonI Mo. SII (mil) l.oInp~~
lIM (ol/"') (!I~Qn)
...
" " " " "
Atwd/lllcntB
ROAD LIGHTING LUMINAIRE

PRODUCT FEATURES
NO. ITEM BRAND:
MODEL fOR ROAD 1: MODEL fOR ROAD 2:
1 Technical Specification
1.1 Input Requirements
Voltage,Hz
Models available
Power Connection Type
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1.2 Output Parameters
Power Consumption (@120VAC)
Power Factor 2 0.9

Total Harmonic Distortion
"""
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COIOUf Rendering Indel(, eRI (Ra)
luminous Intensity Distribution
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Provided?
(j Test Temperature that photometry is
(!roduced
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lIshting Class (results from Computer
Simulation)
Maintenance Factor
(MF: LLMFxLMF)
Column Height (10m 112 m)

A
Column span / spacing
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2 Additronallnformation
Country of Manufacture
Product o r:
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Project reference
3 ADDENDUM NO.1 to l·S20: Requirement on LED

EN
3.1 Construction And Components
Gross Weight
Mater ials Casing I Bodv

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Ingress Protection
IP65
(U<JI~d
()
wlrh ,mean go,kerJ
Jam bolts for clamping/securing/lock
[spiRot to bracket arm
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Operating Parameters
Operating Temperature hot(live)/cold( la b)
Ambient Temperature T. = 35· C

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Working Humidity RH> 80%

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Adendum No.1 Revision 1/0 L-S20

Arrachll1cl1l B
ROAD LIGHTING LUMINAIRE

PRODUCT FEATURES
NO.
"'M BRAND:
MODELFOR ROAD 1: MODEL FOR ROAD 2:
3.2 light Source
A. Type o f LED High Powere d LED
LED drive current
B. Brand of LED
C. Luminaire/System Efficacy (lume n/w) Min: 90 Im/W
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LED Efficacy (Iumen/W)
LED lumen Maintenance L80@36,OOO Max.lumen depreciati on "

D.
(f/ftcl/ve Burning HOIl". Useable lifrtlme ) 80% at 36,000hr5
Luminaire/System Effjciency
,.
D
(lLuminoire lumens oulput : light source / LED
IUrM:n. oul 111 )
LlD _ Efflcacv x
Luminaire lumens Output
(axb)(c)~80%
N
n al Electronic Control Gear (DRIVER)
Efficient
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bl Opt ic,,1Efficiency
c) Thermal M anagement Efficiency,Tj
The Correla te d Colour Tempera tu re

F. 250QK < en < 3500K
ccr)
A
3.3 The Optical System
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A. Component of Optical System
B. Optical Le ns
Material: Poly Methyl Methacrylate I UV stabilized polycarbonate I

Silicon
M
C. Refl ector
Material: 99.85% pure aluminium w ith a minimum thickness of
Imm
EN
D. Luminaire Cover (secondary optics)
a. designed as light diffuser Tampered Glass
b. designed as co ver on ly UV Res ista nt Material

M
,. one piece weather
u Silicon Gasket
res istant type
KU
3.' Thermal Management Unit
A. M aterial Type
B. Heat sink thermal resistance (wtC)

O
D
Adendum No. 1 Revision 110 L-5 20

AIMd llllf' IIIB
ROAD LIGHTIN G LU M IN AIRE

PRODUCT FEATURES
NO. ITEM BRAND:
MODEL FOR ROAD 1: M ODEL FOR ROAD 2:
3.5 Electronic Co nt rol Gea r (LED Driver) System

A. (omponent of LED Driver
withstand short drCl.lit
Ci.lrrent, overload, over
B. Protection features
vo ltage and over
tempe rature.
Sl.lrge Sl.lppressor
ER
Power Factor (or rect ion
c. (oolingSystem of LED Driver sel f-cooling
D. Input Range (230V, +10%, -6%, 50 Hz) .
E. D( OutPl.l t Range
D
F. Working Temperature for LED Driver to sl.lit loca l condition
N
n G. Ingress Protection Index (IP) Min: IP65
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3.6 Inte rn al Wiring a nd Earthing Te rminal
(ompletely Pre-wi re d
I I I
3.7 Warranty
I
A
System W arra nty:
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Wa r ran ty Period for t he co m ple te
luminaire (LED Driver, Op tic,, 1Syst em, S ye ar wa rranty certif icate
Housing, Thermal Ma nagement)
M

A Luminaire
M S62722 -1
EN
MS IE( 605 98-2 -3
IES LM-79-0B
IESTM 21 -11
M
B Co ntrol Gea r (LED Dri v er)
MS IE( 61347-2-13
KU
MS IEC 60838-2-2
O
D
Adendum No.1 Revision 1 /0 L-S20

Al/nelml(·",8
ROAD LIGHTING LUM INAIRE

PRODUCT FEATURES
NO. ITEM BRAND:
MODEL fOR ROAD 1: MODEl fOR ROAD 2:
C lamp Holder
MS IEC60838-2-2
0 LEO
MS IEC 62504
IEC/PAS62707 Ed. I
MS62717
ER
IEC/TR 61341
IES LM-80-08
MS I EC 62031
D
IEC 61231
IEC 62471 Ed. I
r)
N
IEC/TR 62471-2
, Conn ector
TE
IEC 61984
F Electromagnetic Compatib il ity (EMC)
IEC 61547
A
IEC 61000-3-2
as EN 5S01S
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M
EN
M
\
-'
KU
O
D
Adendum No.1 Revision 1 to L-S20

Attachm.ellt C
WARRANTY DECLARATION
ER
PROJECT:
D
N
(j
Declaration by Distributor/Manufacturer:
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A
We hereby guarantee that the complete LED luminaire systems supplied is
EJ
maintenance free and come complete with 5 years warranty. Should any of the LED
lum.inaires fail to function at anytime within the warranty period we, the
M
distributor/manufacturer, will duly replace the LED luminaire complete with

necessary components at our own cost.
EN
M
r)
Signature of distributor/manufacturer:
KU
Name of Authorized Personnel:
Official stamp:
O
D
Date:
'" Warranty certificate is attached
Adendum No.1 Revision 1 to L~S20

ADDENDUM NO.2
ER
TO
D
L-S20 : SPECIFICATION FOR ROAD
N
n LIGHTING INSTALLATION
TE
(August 1999)
A
EJ
M
APPENDIX Dl-l.1A: DESIGN CRITERIA

APPENDIX Dl-l.2A: DESCRIPTION OF THE LAYOUT
EN
APPENDIX Dl-2A : ILLUMINANCE MEASUREMENT GRID

APPENDIX Dl-3A : LUMINANCE MEASUREMENT GRID
APPENDIX Dl-4A : LONGITUDINAL UNIFORMITY FOR EACH LANE
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u
KU
This addendum shall be read together with the complete

O
specifications.
D
rf.i iCR ] ADDENDUM NO.2 TO L-S20
CKE.LS.Ol.20.(02).2013
..........::..... SPECIFICATION FOR ROAD
Revision or addendum: 0
APPENDIX 01
Date: February 2015
ER
Page: 1 of 7
I. Page 3/49, item 2.3.2 - The Optical System
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(iii) The luminaire shall incorporate provisions to enable adjustments to shift the
N
(J main light distribution towards the axis of the road to suit different road widths .
Such adjustments shall be simple and positive and shall be firmly retained in
TE
clearly identified positions. Photometric data shall be supplied for the
particular distribution recommended in a given installation. These data may be
supplied in computer diskettes together with software in the CIE format.
A
to be replaced with
EJ
(iii) The luminaire shall incorporate provisions to enable adjustments to shift the
main light distribution towards the ax is of the road to suit different road widths.
Such adjustments shall be simple and positive and shall be firmly retained in
M
clearly identified positions. Photometric data shall be supplied for the

particular distribution recommended in a given installation. These data may be
supplied in Compact Disc (CD) togeUler with software according to the current
EN
prevailing MS/CIE fOl1nat.

M
2. Page 37/49
(J
KU
to be replaced with
Page 2 of 7- Addendum No.2 to Specification for Road Lighting Installation.

O
3. Appendix Dl-l (Page 39/49), Appendix D1-2 (Page 40/49), Appendix Dl-3
D
(Page 41 /49), Appendix D 1-4 (Page 42/49)
to be replaced with
Appendix Dl-1.1A, Appendix Dl-1.2A, Appendix Dl-2A, Appendix Dl-3A,

Appendix Dl-4A
ADDENDUM NO.2 TO SPECIFICATION FOR ROAD LIGHTING INSTALLATION

© lIak Cipta: 2015 Cawangan Kejuruteraan Elcklrik, JKR Malaysia
rfiKii] ADDENDUM NO.2 TO L-S20
SPECIFICATION FOR ROAD CKE.LS.Ol.20.(02).2013
-" -.'---- ... -
. Date Issued: Aug 1999
APPENDIXDl
Date: February 2015
ER
Page: 2 of 7
The Electrical Contractors are required to submit computer plots of road sections as stated
D
in Appendix D2-1
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The Electrical Contractors shall also filled up the Appendix below:-
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I) APPENDIX DI-I.lA, 1.2A - Design Criteria
2) APPENDIX D1- (2A to 4A) - Computer Calculation Format for Road Lighting
Installation (To be submitted for various layout and
A
sections as stated in Appendix D2-1)
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3) APPENDIX D2 - (1 to 2) - Tabulated Sunmlary of Lighting Level CalculationlData

For Road Lighting Installation
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The computer plots shall also be attached.

EN
In addition, the photometric data of item 3.0 shall be submitted.
All the above plots and data shall be certified by the respective manufacturer/supplier.
M
<..)
KU
Tandatangan Kontraktor Elektrik

O
D
Cop Kontraktor Elektrik
Nama
Jawatan

© Hak Cipla: 20J5 Cawangan Kejuruteraan Elel..."1rik, JKR Malaysia
rf JKifl ADDENDUM NO.2 TO L-S20
CKE.lS.Ol.20.(02) .2013
....---::::.....
SPECIFICATION FOR ROAD
.- Date Issued: Aug 1999
APPENDIXDl
Date: February 2015
ER
Page: 30f7
APPENDIX Dl - 1.IA
D
DESIGN CRITERIA
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n *Road Lighting Class :ME_ _I CE
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*Road Surface Type : Asphalt I Concrete
Luminance Coefficient, Qu =
Average Luminance, Love 2:
A
Overall Uniformity, U o 2:
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Longitudinal Uniformity, U I 2:
Threshold Increment, Tl :S
M
SUITound Ratio, SR 2:
*Maintenance Factor , MF
' Column Height , H
EN
III
* Column spacing (m) III
' Lamp Type

M
' Lamp Wattage W

U Flux (kim) klm
KU
Lamp Tilting Angle

*Arm Length
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*Overhang
' Setback
D
Note:
* Data to be filled by Designer

Maintenance Factor , MF = Luminaire MF X Lamp Lumen MF
ADDENDUM NO.2 TO SPECIFICA TION FOR ROAD LIGHTING INSTALLATION

© Hak Cipta: 2015 Cawangan Kejuruleraan Elektrik, JKR Malaysia
rr;iCR' l ADDENDUM NO.2 TO L-S20
CKE.LS.Ol.20.(02).2013
..
•••• •• - '",,0- ,
- SPECIFICATION FOR ROAD
APPENDIXDI
Date: February 2015
Page: 4 of 7
ER
APPENDIX D1 -1.2A
DESCRIPTION OF THE LAYOJJT
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N
n
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A
_ fl.. DOli
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"","
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.... _L_
EN
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---=-----
u .- ~
~
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LEGEND
S = Column Spacing (m)

W L = Lane Width (m)
W R = CalTiageway Width (m)

rf ;iCii- l
... .
ADDENDUM NO.2 TO L-S20
SPECIFICATION FOR ROAD CKE.lS.Ol.20.(02).2013
...... . Date Issued: Aug 1999
-'-- -
,
LIGHTING INST ALLA TION
APPENDIXDI
Date: February 2015
ER
Page: 50f7
APPENDIX Dl-2A
D
ILLJ!MINANCE MEASUREMENT GRID
N
TE
-
-
-
A } Lane 1
-
}
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- Lane 2
-
-
}
M
- Lane 3
-
EN
Eave = lux Emu = lux

M
Emin= lux Uo= EmiJEave = %

l..)
KU
O
Tandatangan PengilangIPengedar Tandatangan Kontraktor Elektrik

D
Cop PengiJangIPengedar Cop Kontraklor Elektrik
Nama Na ma
Jawatan Jawatan :

rf ;iCR] ADDENDUM NO.2 TO L-S20
SPECIFICATION FOR ROAD CKE.lS.01.20.(02).2013
....• -- ......-'- Date Issued: Aug 1999
APPENDIXDl
Date: February 2015
ER
Page: 6 of 7
APPENDIX Dl-3A
D
LJJMINANCE MEASJJREMENT GRID
N
n
TE
-
-
-
A } Lane 1
--
}
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- Lane 2
--
}
-
M
- Lalle 3
-
EN
Laye= cd/m' Uo= L mijL :1ve = %

M
Lmin= cd/m2 UI = LminlLmax= %

\J
KU
Lrrux = cd/m' SR=

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Iandatangan PengiJangIPengedar Tandalangan Konlrahor EJehrik

D
Cop PengiJangIPengedar Cop Kontrahor EJehrik
Na ma Nama
Jawatan Jawatan:

© Hak Cipta: 2015 Cawanga n Kejuruteraan Elcl..1ri k, JKR Malaysia
rf JiCifl ADDENDUM NO.2 TO L-S20
SPECIFICATION FOR ROAD CKE.LS.01.20.(02).2013
_ •• __ .~ _ _ _ _ _ • _ _ oJ
Dale Issued: Aug 1999

APPENDIXDI
Dale: February 2015
ER
Page: 70f7
APPENDIX Dl-4A
D
LONGlTlJDINAL lJNIFORMITY FOR EACH LANE
N
TE
I I
A
UII = L mi n / L IlW =_ _ _ _ _ %
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M
U l2 = L mi n / L ma~ =_ _ __ _ %
EN
I I
M
VL3 = L min I L ma.... = _ _ _ _ _ %

KU
O
Tandatangan PengilangiPengedar Tandatangan Kontraktor Elel1rik

D
Cop PengilangiPengedar Cop Konu'aktor ElekU'ik
Nama Nama : _ _ _ __ _ _
Jawatan : _ _ _ _ __ Jawatan: _ _ _ _ _ __ _

© Hak Cipta: 2015 Cawangan Kejuruteraan EJeld rik, JKR Malaysia
ADDENDUM NO.3
ER
TO
D
L-S20: SPECIFICATION FOR ROAD
N
n LIGHTING INSTALLATION
TE
(August 1999) A
EJ
INTEGRATED SOLAR LED ROAD LIGHTING SYSTEM

M
EN
This addendum shall be read together with the complete

specifications.
M
u
KU
O
D
ADD ENDU M NO.3 TO L·S20: SPECIFICATION FOR ROAD LIGHTING INSTALLATION

© 2020 Cawangan Kejuruteraan Elektrik, JKR Malaysia
ADDENDUM NO.3
CKE.LS.01.20.(03).2020
TO
L-S20 : SPECIFICATION FOR ROAD Date Issued: Aug 1999
[@J LIGHTING INSTALLATION
Revision Of Addendum: 1
INTEGRATED SOLAR LED
Date: August 2022
ROAD LIGHTING SYSTEM
Page: i of i
1.0 General 1/12
ER
2.0 Construction 1/12
3.0 Components 2/12-5/12
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3.1 LED Luminaire
N
n 3.2 Solar Photovoitaic (PV) Module
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3.3 Rechargeable Deep Cycle Battery
3.4 Solar Charge Controller

A
3.5 Lighting Column
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4.0 Schedule and Technical Information on 5/12

Integrated Solar LED Road Lighting System
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5.0 Warranty 6/12
6.0 Conformity with Standards 6/12

EN
Appendix A 8/12 - 11/12
Appendix B 12/12
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\ )
KU
O
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ADDENDUM NO.3 TO L-S20 : SPECIFICATION FOR ROAD LIGHTING INSTALLATION

ADDENDUM NO.3
CKE.LS.01 .20.(03).2020
TO
e L-S20 : SPECIFICATION FOR ROAD


Date: August 2022
Page: 1 of 12
1.0 GENERAL
1.1 This section of the Specification describes and specifies requirements for the supply,
delivery, installation, testing, commissioning and handing over in approved working
ER
order and maintenance during the Defects Liability Period of the integrated solar LED
road lighting system in accordance with the Conditions of Contracts , Bill of Quantities,
Drawings and other related documents.
D
1.2 All standards shall conform to the latest Malaysia Standards (MS), International
N
Electrotechnical Commission (IEC), MS IEC, British Standard Institution (BS), and lor
BS EN standard.
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2.0 CONSTRUCTION
2.1 An integrated solar LED road lighting system is an outdoor lighting luminaire system
A
used for illuminating road or an amenity. A basic solar road lighting luminaire
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components are:
2.1.1 LED Luminaire;

M
2.1.2 Solar Photovoltaic (PV) Module;

2.1.3 Rechargeable Deep Cycle Battery;
2.1.4 Solar Charge Controller and
EN
2.1.5 Lighting Column
2.2 Solar Photovoltaic (PV) modu le, rechargeable deep cycle battery, solar charge
M
controller and light source of the integrated solar LED luminaire shall be in one
u enclosure. The Solar PV module shall provide electricity to charge the battery during
KU
daytime. The battery's charging shall be controlled by a solar charge controller. The
operation of the luminaire shall be controlled by a control circuit either by using
voltage or current sensor.
O
2.3 The configuration of integrated solar LED road lighting system shall be designed to
be robust and shall withstand the harsh environment condition as the system will be
D
continuously exposed to sun, rain , fog, pollution etc. The integrated solar road lighting
system installed shall enhance the aesthetic of the city or road.
2.4 The rough service of integrated solar LED road lighting system shall have adequate
resistance to vibrations. The luminaire shall comply with the vibration test according
to IEC 60598-1 , Section 4.20: Rough service luminaires - Vibration requirements.
ADDENDUM NO.3 TO L-S20: SPECIFICATION FOR ROAD LIGHTING INSTALLATION

ADDENDUM NO.3
CKE.LS.01 .20.(03).2020
TO
L·S20 : SPECIFICATION FOR ROAD Date Issued: Aug 1999
~
=
ROAD LIGHTING SYSTEM Date: August 2022
Page: 2 of 12
3.0 COMPONENTS
3.1 LED Luminaire
ER
3.1.1 The luminaire shal l be designed by using solid state lighting i.e. Light Emitting Diode
(LED) as a light source.
D
3.1.2 The LED luminaire and its associated electrica l components and technical
N
specifications sha ll be designed and comply with L·S20: Specification for Road
Lighting Installation (Addendum No.1: Road Lighting Luminaires - LED).
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3.1.3 The LED luminaire shall be designed and constructed to be capable of providing the
required lighting performance level as follows:
A
a) Solar PV module sha ll be sized such that they can provide sufficient
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energy to the system for the intended service life of 25 years;
b) System losses shall be considered including dust and dirt, wiring losses,
electronics losses and charging losses;
M
c) Batteries shall be sized for a minimum life cycle of 500 cycles at 80%
Depth of Discharge (DOD);
d) The average luminous flux of luminaire shall not depreciate more than
EN
30% from initial value at 50,000hours (L70 @ 50,000hours);

e) Lighting levels which include luminance and illuminance shall be at rated
levels for determining battery size for two (2) days of autonomy at 100%
M
intensity of luminaire for 12 hours operation. If different lighting levels at

l.) different times of the night is specified with reference to PO CENITR
KU
13201·1: Road Lighting· Guidelines on selection of lighting classes ,

detailed traffic flow ana lysis shall be carried out for determining luminance
and time setting;
f) The solar lighting system shall be based on a 12 VDC or 24 VDC system
O
voltage.
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3.1 Solar Photovoltaic (PV) Module
3.2.1 The solar PV module shall be of crysta lline type. Both monocrystalline and
polycrystalline technology PV modu les are allowed in the system. The solar PV
module shall be brand new and comply with IEC 61215·2 .
ADDENDUM NO.3 TO L-S20: SPECIFICATION FOR ROAD LIGHTING INSTALLATION

ADDENDUM NO.3
CKE.LS.01 .20.(03).2020
TO
L·S20 : SPECIFICATION FOR ROAD Date Issued: Aug 1999
[@J
=
Revision Of Addendum : 1
Page: 3 of 12
3.2.2 The rated power of solar PV module shall be designed to meet the following criteria:
a) Number of hours of operation of luminaire per day;
b) Total wattage of the luminaire;
ER
c) The peak sun hours per day shall not be more than 4.5 hours.
3.2.3 The solar PV modu le efficiency shall not be less than 12%. Efficiency of the solar PV
modu le is defined as the ratio of energy output from solar PV module to input energy
D
from the sun; maximum power, Pmp (W) over irradiance (in W/m2) multiply by area
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(m2) at Standard Test Condition (STC).
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3.2.4 The solar PV module shall consist of the following information:
a) Name of the manufacturer of solar PV Module;
b) Model number and type;
c) Month and year of manufactured;
A
d) I·V curve of modu le;
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e) Peak wattage of modu le;
f) Open circuit voltage (Voo);
g) Short circuit current (I ,,);
M
h) Maximum current (I mp);

i) Maximum voltage (V ma,);
j) Maximum power (Pmp);
EN
k) Serial number of the module.
3.2.5 The solar PV module shall be designed with the following features:
M
a) Covering material: Highly transparent, reflective , tempered solar glass;

\ ) b) Junction box : Junction box with integrated 1 minimum bypass diode,
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IP65, welded contacts, fully encapsulated;

c) Plugs: Touch·proof plug connectors with polarity reversal protection,
MC3 or MC4;
d) Dynamic load (wind load) : 2.4 kN/m 2 (2,400 Pal;
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e) Permitted operating temperature: ·10°C to +85°C;

f) Warranties:
D
i) Linear performance warranty of 25 years.

ii) Degradation of power shall be as per table 1A:
ADDENDUM NO.3 TO L·S20: SPECIFICATION FOR ROAD LIGHTING INSTALLATION

© 2020 Cawangan Kejuruteraan Elektrik, JKR Ma laysia
ADDENDUM NO.3
CKE.LS.01.20.(03).2020
TO
~
Page: 4 of 12
Degradation of actual power

Year
versus nominal power
ER
1 97%
D
2 - 24 96.3% - 80 .9%
(0.7 % annual degradation)
N
n
TE
~ 25 80.7%
Table 1A - Degradation of actual power versus nominal power

A
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3.3 Rechargeable Deep Cycle Battery

M
3.3.1 Batteries are used to store the electricity generated by the solar PV module. Battery
shall conform to the latest IEC 62133-2 or IEC 62619.
EN
3.3.2 The battery shall be only lithium-ion or lithium polymer or lithium iron phosphate
battery type.
3.3.4 The lithium batteries shall be designed with the following features:
M
a) System voltage: 12 VDC or 24 VDC;

b) Operating temperature : _5°C to 60°C;
KU
c) Cycle efficiency: not less than 90%;

d) Minimum life cycle: 500 cycles at 80% Depth of Discharge (DOD);
e) Sufficient autonomy: minimum of two (2) overcast or rainy days;
O
f) Discharge time: minimum of 12 hours

D
3.4 Solar Charge Controller
3.4.1 Solar charge controllers shall be used to control the charging of the batteries. Since
the output from solar PV module are variable and needs adjustments , solar charge
controller fetches the variable voltage and current from solar PV module to suit the
safety of the batteries. Solar charge controller shall conform to the latest IEC
62109-1.
ADDENDUM NO.3 TO L·S20: SPECIFICATION FOR ROAD LIGHTING INSTALLATION

I
I
f
ADDENDUM NO.3
CKE.LS.01 .20.(03).2020
TO
gJ
-
Date: August 2022
Page: 50f12
3.4.2 The main functions of solar charge controllers are to prevent over-charging of
batteries from solar PV module , over-discharging of batteries to the load and to
control the functionalities of the load.
ER
3.4.3 The solar charge controller sha ll be designed with the following features:
a) Total electronic efficiency: minimum 90% at full load;
b) Humidity : 95% non-condensing ;
D
c) Terminations: Connectors;
N
n d)
e)
Operating Temperature: O°C to 50°C;
Storage Temperature : O°C to 70°C;
TE
f) Protections: Reverse current protection from battery to solar PV
module;
g) No moving parts, switches or buttons;
h) Timer functions available for lighting control;
A
i) System voltage: 12 VDC or 24 VDC;
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j) Over-voltages from PV module;
k) Protection against lightning surges (voltages and current);
I) High temperature and overload protection;
M
m) Open circuit protection without battery;

n) Infrared remote-control programming accessory (if specified);
0) Internet of Things (loT) readiness (if specified)
EN
3.5 Lighting Column

M
() 3.5.1 Lighting column shall comply with L-S20 : Specification for Road Lighting Installation.
KU
It shall be designed and fabricated to withstand loading of all integrated solar LED
road lighting components.
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4.0 SCHEDULE AND TECHNICAL INFORMATION ON INTEGRATED SOLAR LED

D
4.1 Tenderers are required to furnish comprehensive information and technical

particulars as stipulated in Appendix A (Technical Schedule of Integrated Solar
LED Road Lighting System)
4.2 The information required in Appendix A shall be fully and correctly completed. All
technical data entered therein shall be substantiated with relevant cata logues and
test reports from the manufacturers and the accredited testing authorities
respectively.
ADDENOUM NO.3 TO L-S20 : SPECIFICATION FOR ROAD LIGHTING INSTALLATION

ADDENDUM NO.3
CKE.LS.01.20.(03).2020
TO
[f;J LIGHTING INSTALLATION
Page : 6 of 12
5.0 WARRANTY
5.1 The manufacturer / distributor shall provide a 5 years' warranty certificate for the
ER
complete integrated solar LED luminaire to guarantee the long life expectancy and
maintenance free luminaire.
5.2 Warranty declaration shall be filled and duly signed by manufacturer / distributor as
D
per Appendix B. Failure in the function ing and operation of the integrated solar LED
N
n luminaire within the warranty period wi ll result in the replacement of the whole
luminaire or required components by the manufacturer / distributor at no cost to the
TE
government.
5.3 The warranty shall cover failure due to external factor such as phenomenal influences,
etc. The cost to replace the integrated solar LED luminaire from uninstall to reinstall
A
new replaced luminaire shal l be borne by the manufacturer / distributor.
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6.0 CONFORMITY WITH STANDARDS

M
The luminaire shall comply with and be tested to the relevant latest edition of
Malaysia Standard or other relevant international standard as below:
EN
Item Criteria Relevant Standards

M
IEC 60598-1
Luminaires - Part 1: General requirements and
KU
tests
IEC 60598-2-3
Safety and Luminaires - Part 2-3: Particular requirements -
O
Luminaire Luminaires for road and street lighting

Performance
IEC 62471
D
Photobiological safety of lamps and lamp systems

and other relevant standards as stated in
L-S20 Specifications
IES LM-79
Photometric Luminaire Approved Method: Electrical and Photometric
ADDENDUM NO.3 TO L-S20 : SPECIFICATION FOR ROAD LIGHTING INSTALLATION

ADDENDUM NO.3
CKE.LS.01.20.(03).2020
TO
§ LIGHTING INSTALLATION
Page: 7 of 12
Item Criteria Relevant Standards
ER
IEC 61215-2
Solar Photovoltaic Terrestrial photovoltaic (PV) modules - Design
Design
(PV) Module qualification and type approval- Part 2: Test
D
Procedures
N
n
TE
IEC 62133-2
Secondary cells and batteries containin g alkalin e or
other non-acid electrolytes - Safety requirements
for portable sealed secondary lithium ce lls, and for
A
batteries made from them, for use in portable
Rechargeable applications - Part 2: Lithium systems
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Safety Deep Cycle

Battery or
IEC 62619
M
Secondary cells and batteries containing alkaline or

other non-acid electrolytes - Safety requirements
for secondary lithium cells and batteries , for use in
EN
industrial applications
IEC 62620
M
Rechargeable
Secondary cells and batteries containing alkaline or
CJ Performance Deep Cycle
other non-acid electrolytes - Secondary lithium cells
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Battery
and batteries for use in industrial app lications
IEC 62109-1
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Safety Solar Charge

Safety of power converters for use in photovoltaic
Controller
power systems - Part 1: General requirements
D
Safety and
Lighting Column Refer to Section B.O L-S20 Specification
Performance
PD CENITR 13201-1
Design Road Lighting Road Lighting - Guidelines on selection of lighting
classes
ADDENDUM NO.3 TO L-520: SPECIFICATION FOR ROAD LIGHTING INSTALLATION

ADDENDUM NO.3
CKE.LS.01.20 .(03).2020
TO
L-S20: SPECIFICATION FOR ROAD Date Issued: Aug 1999
@J LIGHTING INSTALLATION
Date: August 2022
Page: 8 of 12
APPENDIX A
TECHNICAL SCHEDULE OF INTEGRATED SOLAR LED ROAD LIGHTING SYSTEM
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Project: ..... .... ..... ... ........... ................................ ........ ... ... ............ .. ....... .
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DESIGN OFFERED
REQUIREMENT! SPECIFICATION
DESCRIPTION UNIT
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SPECIFICATION: (CONTRACTOR TO
(j -JKR SPECIFY)
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A1 GENERAL
1 Distributor Please attach letter

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2 Letter of Warranty Please attach letter
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A2 LED LUMINAIRE
Please attach
1 Manufacturer
catalo~ue
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Please attach
2 Brand & Model
cataloClue
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3 Efficacy (ImIW) ImIW ? 100
4 Wattage (W) W
Correlated Colour Temperature
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5 K 2500 - 3500
(Kelvin)
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a) Automatic dusk to
dawn function
b) PIR function not
allowed
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c) Dimming function
6 Control Features
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(minimum pre-set
required)
i) ...... hours! ...... %
ii) ..... hours! ...... %
iii) ..... hours! ..... %
7 Rated Lifetime L70 @ 50,000hours
ADDENDUM NO.3 TO L-520 : SPECIFICATION FOR ROAD LIGHTING INSTALLATION

© 2020 Cawangan Kejuruteraan Elektrik. JKR Malaysia
ADDENDUM NO.3
CKE.LS.01.20.(03).2020
TO
e L-S20 : SPECIFICATION FOR ROAD


Date: August 2022
Page: 9 of 12
DESIGN OFFERED
DESCRIPTION UNIT
SPECIFICATION : (CONTRACTOR TO
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-JKR SPECIFY)
A3 SOLAR PV MODULE
Please attach
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1 Manufacturer
catalogue
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() 2 Brand & Model
Please attach
catalogue
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Minimum module
capacity shall be
3 Modu le Capacity Watt designed using 4.5
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peak sun hours as a
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reference
Monocrystalline or
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4 PV module type
Polycrystalline
Minimum Module Efficiency at

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5 % '" 12
Standard Test Condition (STC)
Please attach Solar

6 I-V curve of module
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PV datasheet
() Please attach Solar
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7 Maximum current (Imp) Ampere

PV datasheet
'" 18.8
As per system
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voltage
8 Maximum voltage (V m, ) Volt
Please attach Solar
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PV datasheet
9 Maximum power (Pm,) Watt P= 1m, X V mp
10 Lifetime year 25
ADDENDUM NO.3 TO L-520: SPECIFICATION FOR ROAO LIGHTING INSTALLATION

ADDENDUM NO.3
CKE.LS.01 .20.(03).2020
TO
§ LIGHTING INSTALLATION
Page: 10 of 12
DESIGN OFFERED
DESCRIPTION UNIT
SPECIFICATION: (CONTRACTOR TO
ER
-JKR SPECIFY)
RECHARGEABLE DEEP
A4
CYCLE BATTERY
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Please attach
,
1 Manufacturer
catalogue
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<
( Please attach
2 Brand & Model
cata log ue
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Please attach
3 Battery Type
catalogue
4 Cycle Efficiency %
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" 90
a) Please provide
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detail calculation
b) Battery sha ll be
designed to ensure
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sufficient supply for

the whole operation
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of Solar LED
luminaire (from dusk
to dawn)
c) Capacity shall be
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5 Battery Capacity & Quantity Wh designed as per type

of LED luminaire &
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solar PV modu le
offered in Part A2
and according to 2
O
days autonomy &

80% DOD
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Note : Battery capacity

(Ah) varies based on
the rated battery
voltage
6 Operating Temperature °C _5°C to 60°C
7 Charging Mode Included
8 Days of Autonomy day ,,2
ADDENDUM NO.3 TO L.$20 : SPECI FICATION FOR ROAD LIGHTING INSTALLATION

© 2020 Cawangan Kejuruteraan Elektrlk, JKR Ma laysia
ADDENDUM NO.3
CKE.LS.01 .20 .(03).2020
TO
e L-S20: SPECIFICATION FOR ROAD


Date : August 2022
Page: 11 of 12
DESIGN OFFERED
REQUIREMENTI SPECIFICATION
DESCRIPTION UNIT
SPECIFICATION : (CONTRACTOR TO
ER
-JKR SPECIFY)
9 Discharge time hour ~12
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SOLAR CHARG E
n AS
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CONTROLLER
Please attach
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1 Manufacturer
catalogue
Please attach
2 Brand & Model
catalogue
A
Please attach
3 Electronic Protections
cata logue
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over-voltage
a) Solar Input warn ing,
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reverse polarity
overload, high
b) Load Output temperature,
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reverse polarity
4 Efficiency ~ 90%
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( ) 95% Non-
5 Humidity
condensing
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6 Operating Temperature Range °c DoC to 50°C

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7 System voltage V 12 VDC or 24 VDC

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Please provide detail

8 Maximum charging current A
calcu lation

ADDENDUM NO.3
CKE.LS.01.20.(03).2020
TO
[!;;]
Revision Of Addendum : 1
ROAD LIGHTING SYSTEM Date : August 2022
Page: 12 of 12
APPENDIX B
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WARRANTY DECLARATION
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PROJECT:
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Declaration by Manufacturer I Distributor:
We hereby guarantee that the complete integrated solar LED road lighting system supplied is
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maintenance free and complete with 5 years' warranty. Shall any part of the integrated solar
LED road lighting system fail to function at any time within the warranty period we, the
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manufacturer / distributor, shall duly replace the integrated solar LED road lighting system
complete with necessary components, labour and installation at our own cost.
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Signature of manufacturer/ distributor:

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Name of Authorized Personnel:

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Official stamp:
Date:
* Warranty certificate is attached

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Section 8 - Traffic Signal System (JKRlSPJ/2008-S8)
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JKRISPJI2008-S8
JKR 20403-0014-09
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KERAJAAN MALAYSIA
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FOR ROAD WORKS
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Section 8: Traffic Signal System
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e CAWANGAN KEJURUTERAAN JALAN DAN GEOTEKNIK.

I8U PEJABAT JASATAN KERJA RAYA,
TINGKAT 22, MENARA TUN RAZAK.
JALAN RAJA LAU'T.
50350 KUALA LUMPUR.
KE1lJAPENGARAH KERJARAYA,
JAMTAN KERJA RAYAIIAIAYSIA,
_
_
SULTAN SAl.AHOOOIN,
KUALA WIIPIJIl
FOREWORD
ER
As practices in road construction change over time, it is imperative for labatan Kerja Raya (JKR) to
continuously update and improve their standard specificat ions. These new specifications are not
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only aimed at keepi ng abreast wi th current technologies but also helping in improvi ng the qu ality of
constructed product. In Llllison, these new specifications have a signi ficm po\ itive impact on the
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constru ct ion industry especiall y with the incorporation of new products and ~chnologies.
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Standard Specification for Road \Vorks is an essential cOl11pon~vn the road infrastmcture
construction industry. This specificati on provides an improved guidance in the material selecti on
and the production of good qua lity workmanshi p and products Jj~d on current best pract ices. The
purpose of this standard spccification is to establish nnirol'll1lt'\l) n road works to be used by road
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designers, road authorities, llulIlutbcturers and suppliers of~ related products.
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This docu ment "S tandard Specificat ion for Road War s - Section 8: T raffi c Signal System" is a part
of a series of improved specifications in tl e Standard Specification for Road Works. The
compilation of this document was carried ou (h 'ough many discussions by the technical committee
members. Additionall y it has been re viewed a group of independent consultants and prescnted at
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a technical worksho p held o n J 5 - 17 Jul y 2008. Feedba cks and comments received were carefully
considered and incorporated in the spec~calion where appropriate.
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ACKNOWLEDGEMENT
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This Standard Specification for Road Works - Section 8: Traffic Signal System has been
prepared by a technical committee consisting of Civil and Electrica l engineers from Cawangan lalan
& Geo tcknik, Cawangan Kelja Elektrik and State JKRs. The members of the commi ttee involved in
preparing this Standard Specificat ion for Road Works - Secti on 8: Traffic Signal System are:-
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Comm ittee Members
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Ir. Hj . Abdu l Rahman B. Baharudd in (C//(Iil"ll/(lll)
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Pn Sabariah Bte Hussain (Deputy Chairmall) Cawangan Kelja Elektri k
En. Rijal Nazli B. Sulaiman ~C:,,~vangan Kcj. lalan & Geoteknik

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En. S hahrul Affendy B. A bu Bakar Cawanga n Ketj a Elektrik
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En. Abd ull Latif B. Sulaiman Cawangan Kelj a Elektrik

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Pn. S iti Nor Binti Hassan Cawangan Kelja Bangunan Am.
Pn. Noo r Fadzilah Bte R am l ~ Cawangan Kelja Elektrik.

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En Noorll Alum B. Hj A n~ JKR Elektrik Kedah
Pn. Rozina Bte Slldin '$ JKR Elektrik Perak

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l ) Pn Maznida S~hila Bte Mat Sall eh JKR Elektrik Negeri Sembi Ian
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Pn Siti Norleha Bte Rasid Cawangan Kej. Jalan & Geoteknik
En Mat Rodi B. Junoh Cawangan Kej . .Ialan & Geoteknik

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T he Committee would also like to thank our colleagues at JKR especially the staffs ti·Dlll Bahagian
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Kesela mal"n Jalan (Caw. Kej. Jalan & Geoteknik) who have assisted and contributed towards the
successfu l completion of this speci tlcation.
IKRJSPJI2008·S8
SECTION 8 - TRAFFIC SIGNAL SYSTEM
8.1 GENERAL
8.1.1 Scope of Work S8-1
8.1.2 Design and Construction

8.1.2.1 Cont mctor's Responsib iIity SS-I
8.1.2.2 Cleanl iness SS-1
8.1.2.3 Metric Range of PrefelTed Dimensions S8-1
8.1.2.4 Self-Tapping Screws S8-2
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8.1.2.5 Corrosion S8-2
8.1.2.6 Compliance With Manufacturer's InstlUctions S8-2
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8.1.3 Components and Materials
8.1.3.1 Conditions of Operat ion S8-2
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8.1.3.2 tvla int enance S8-2
8.1.3.3 Components S8 -2
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8.1.4 Identification of Equipment S8-3
8.1.5 Proteclive Requirements

8.1.5.1 General S8-3
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8.1.5.2 Insulating Bushes S8-3
8. 1.5.3 Isolation frolll Main Supply ()t\. SS-3
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8.1.5.4 Earthing of Transfonner Secontli"1 Circuits S8-3

8.1.5 .5 Current Loading of Wires '!..:.. S8 -3
8.1.5.6 Danger Notices 0
"" S8-4
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8.1.5.7 Cable Connect in\..~ i~ S8-4

8. 1.5 .S Insulation " S8-4
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8.1.6 S8-4
8.1.7 Testin~nd Commissioning S8-4

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() 8.1.8 ~, ocJ,mentation
S.I.8.1 )\ - nstalled Drawings, Manuals And Tools S8-5
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8.1.8.2 Hardware. Software and I'vIaintenance Manual S8-6
8.1.9 Guarantee of Supply S8-6

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8.1.10 Warranty Period S8-6

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8.2 LOW VOLTAGE UNDERGROUND CABLES
8.2 .1 Types of Cables

8.2.1.1 Power Cables SS -7
S.2 .1.2 Feeder Cables for Vehicle Detectors S8-7
8.2.1.3 Loop Cables for Vehicle Detectors S8-7
8.2. 1.4 EaI1hing System S8-7
S8-;
JK RJSP J/2008-S8
8.2.2 Cable Tennination S8-7
8.2.3 Cable Jointing 88-8
8.2.4 Cable and Detector Pit
8.3 SIGNAL LANTERNS / HEADS
8.3.1 Standard Reqnirements 88-9
8.3.2 Optical Requirements
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8.3.2. 1 Optical Arrangement for Drivers S8-9
8.3.2.2 Optical Arrangement for Pedestrians S8-9
8.3.3 Height of Signal Head
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8.3.3.1 Post-Mounted Signal Head Intended For Dlivers S8-9
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8.3.3.2 Signal Head Intended For Pedestrians S8-9
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8.3 .3.3 Overhead Mounted Signal Heac! S8-9
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8.3.4 Lamps
S.3.4. 1 Halogen Lamp SS-9
8.3.4 .2 LED Signal Module S8-1O
S.3.4.3 Construction ;JV:J0 S8-11
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8.3.4.4 Module Identi!ication S8-11
8.3.4.5 Target Boards S8-11
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8.3.4.6 Digital Countdown Unit <;:--fli- S8-12
8.4 SIGNAL POSTS / POLES AN~ ,iST ARMS

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8.4.1 Standard Requirelilents S8-14

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8.4.2 S8-14
8.4.3 connec3 1g Facilities for Cables S8-14

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8.4.4 d .tion and Erection S8-\4

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8.4.5 « FiniSh S8-\S
8.4.6 Signal Heads Mounted On Street Lighting Pole S8-1S

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8.4.7 Signal Heiuls ;\oIast Ann and Street Lighting Pole S8-1S
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8.5 PEDESTRlAi', PUSH-BUTTONS
8.5.\ Standard Requirements S8-16
8.5.2 Location 88-16
8.5.3 Pedestrian Demand Indicator S8-16
8.5.4 Audible Signal S8-\6
SS- jj
JKRlSP Jl2008-S8
8.6 TRAFFIC CONTROLLER
8.6.1 General Requirements S8-17
8.6.2 Housing S8-17
8.6.3 Contl'Oller Mains Supply Panel S8-18
8.6.4 Facility Switch S8-18
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8.6.S Pedestrian Facilities S8-19
8.6.6 Logic Module

8.6.6.1 Microprocessor System S8-19
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8.6.6.2 Input/Output Interf"ces S8-20
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8.6.6.3 Rea l Time-o f- Day Clock S8-20
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(') 8.6.6.4 Operato r Interface and Controller Display S8-20
Power Supply Monitoring System
8.6.6.5
0 S8-20
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8.6.7 Battery Back-up Systcm For Traffic Sign~ltilizing Light Emitting
8. 6.7.1
Diodes (LED) Traffic Signal Modules.
General Vg S8-20
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8.6 .7.2 Operation S8-21
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8.6.8 Mains Supply interrnptiolls S8-21
8.6.9 S8-21
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8.6.10 S8-21
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8.6.11 S8-22
8.6.12 Radio interference S8-22

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8.6.13 Safety S8-22

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Timi~g
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8.6.14« : S8-22
8.6.15 Sequence of phasing S8-22

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8.7 VEHICLE DETECTORS

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8.7.1 Standard Requirements S8-23
8.7.2 Number of Traffic Lanes S8-23
8.7.3 Performauce Requirements S8-23
S8-iii
JKRlSPJ /2008·S8
8.8 ROAD WORKS
8.8.1 Cencl'al S8-24
8.8.2 Permission to Excavate Road S8-24
8.8.3 Excavation, Backfilling, Reinstatement and Maintenance of

Excavations
8.8.3. 1 General S8-24
8.8.3.2 Excavat ion 88-24
8.8.3.3 Bedding of Excavation S8-25
8.8.3.4 Cable Ducts 88-25
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8.8.3.5 Cable Laying and Installation 88 -25
8.8.3.6 Backfilling of Excavations and Reinstatements 88-25
8.8 .3.7 Sensing Loop Slots S8-26
8.8.3.8 Maintenance of Drains and Services During Excavati ons S8-26
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8.8 .3.9 Reinstatement of Drains and Precast Units 88-26
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8.8.3. 10 Completion of Works S8-26
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('J 8.8.3. 11 Maintenance of Excavation S8-26
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8.8.4 Traffic Arra ngements
8.8.4. 1 General (l 88-27
8.8.4.2
8.8.4.3 Temporary Flashing \Varning Lamp~ ,'-J
Arrangemellt and Location of Signs, Ban~ ruld Barricrldes S8-27
S8-28
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8.8.4.4 Use of Traffic Guidance Cones "'-J 88-28
8.8.4.5 Temporary Traffic Diversions r>.. S8-28
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8.8.4.6
8.8.4.7
8.8.4.8
Temporary Traffic Control
Plant and Equipment
Vehicles t>"'
.t".r\....
V S8-28
S8-29
88·29
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8.8.4.9 Maintenance of Sig~I,,~rripS, Barriers, Temporary Traffic

Diversions, etc. '" ,""" S8·29
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JKRlSPJ/2008-S8
SECTION 8 - TRAFFIC SIGNAL SYSTEM
8.1 GENERAL
8.1.1 Scolle of Work
This work shall comprise Ihe des ign of cabling works prio r to constnJction, s upply and
installation o f all s igna l lante rns, traffic co ntrollers, detectors, posts, dllcting and
cabling, and s witchgears with all necessary ancillary eql1ipment, togethe r with the
transportatio n, storage, erec ti on, connec tion, test ing and co mmi ssioning of the same for
a co mple te traffic signal installation , all in accordance with the Drawings and this
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Spec ifi cntio n. T he work shall also in clude ca bling fro m the neares t spec ifi ed power
source of the local supply auth orit y to the Irnffic control syste m, if required.
The typ e o f signal operation, number of pirillS, number and seque nce o f phases, cycle
times, timings of each pho~e , offset times, locotions o f cont rollers and power source
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ta ppillg poi nts, and other speci fi c requireme nts shall be as shown on the Draw ings.
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('"') In Ihe case o f ' Design and Bnild ' or ' Bnild-O pemle-Tran sfer' (B.O : .) Iype projeels,
the tmfli c s ig na l shaH be deS igned m accord cUlcc with the I~e~ I-\ tahan Teknik (Jatan)
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on lhe des ign o fhaffi c signals. The T e nderer slwl! obtainlhe s ignal opclatioll
reqtnrcmc nts from JKR pn ol to dcslgnmg the traffic signal :yste m.
8.1.2 Design and Construction -0~0

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8. 1.2. 1 Contrac tor's Respons ibil ity
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The Contrac tor shaH design the interconnecting signal cabling tor the pro posed signClI
system as shown on the D -a\VillgS. The cabling design drawings are to be a pproved by
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the Superintending omc r s.01 before construction commences. Equipme nt o ffered

shall be in all respectS-sui aD e for the requi re ments and to r the e nvironme nta l co nditi ons
specified . The Contrac or shall be responsible for the design, material gUll tity and
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workmanship of- the system and every pa rt of the system offered, whethe r ma nufactured
by him or $ U~ to him by other nml1t1fa c lurer~. Approval by the S.O. does not relieve
the COlltracs of these respons ibilities.
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Matena s shall as far as possible be o f Malays ian ongm except whele suc h materia ls can
, lJe to be unavailable III Mnlnysia.
~e Conl,nelor shall proVIde relevanl Imining on Ihe syslem [[lSlalled fOi Ihe S O
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and
JKR operational stnff.
8. 1.2.2 Cleanliness
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Pnrliculnr atte ntion shall be given in the design of the equipment for the exclusion o f
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dust, dit1. e tc., especially in the case wh ere torced vent ilati on is e mpl oyed.
8.1. 2.3 Metric Range of Preferred D imens io ns
Except as ma y be agreed for practi cal reasons, des ign shall make use of the metric range
of preferred dimensions and tolerances.
S8-1
JKRl8PJf2008-S8
8. 1.2.4 Self-Tapping Screws
Self-lapping screws shall be lIsed only for retaining duties. They shall not be lIsed for
fixing removab le covers, nor for the support of direct loads.
8.1.2.5 Corrosion
All equipment shall be ab le to resist corrosion in the MalaysiElIi environment for a period
of 10 years from the dale of installati on.
8.1.2.6 Compliance With Manufacturer's Instmclions
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The Contractor shall en.sure that the equipment and pa rts lIsed shall be entirely suitable
for the work to be perfonned fllld that they shall be mnnufactured to proper tolerances
and fit. He shall further ellsure that the loading of equipment shall under all normal
circumstances not exceed the maximum laid down or agreed to in writi ng by the
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manufacturer.
The Contmctor shall be responsible for the inspection of all eCJl ipn~nt and parts before
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thei r incOlvoration in the \Vork.'l to ensure that they co mpl y witl ~\!; requirements of this
Speci fication and that they are not defective in ('my, \Va as regards materials or
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workmanship. Should any slich nOll-compliance or defects be fOllnd during the
inspection, the Contractor shall correct or cause to be COlTected slich nOll-compliance and
defects, nil at the ConhnctOl's expense al1d to the sati -faction of the S 0
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8.1.3 Compo nents und Materials
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8.1.3. 1 Conditions of Operation
The system shall be deSign{d;~ opemte continuously. Account shall be taken of

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equip ment being sited in all - xposed locations.
8.1.3.2 Maintenance
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III the eve 11 'f-system failure due to breakdown or accident, the contractor shall take
immediate action in identifying nnd rectifying the problem at site.
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The ontractor shall want the mo torist by placing warn ing signboards on traffic signal
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<Pist at all approach rends to avoid confusion and unwanted incidents. The contractor
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must attend the breakdown within the response time set by the aut horities.
The Contractor shall ensure that the materials and components, excluding consu mable
items such as lamps, shall have 10 years life expectancy warranty from the ma nufac turer.
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Components wh ich have a shorter life spa n but are easily replaceable may be accepted
with the approva l of the S.O.
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8. I .),) Components
All active and passive components, their mounting nlld the plugs, sockets and
cOIlllections, shall be designed for a life expec tancy of \0 years as specified in Sub-
Section 8.1.3.2. All shall operate we ll within their ratings with due consideration for the
environ mental conditio ns and temper<1ture rises within cabinets or enclosures.
88-2
JKRlSPJ/2008·58
8.1.4 Identification of Equipment
The Cont ractor shall mark or label clearly all module~, lIllits and main parts of the system
with a fUllctional code or title, type number, trade name nnd serial nltlllber. The marking
or labeling of HUlin items shall be cle(lrly visible on the outside. The labels and IlHlrkings
of encased units or modules shall be visible when the case or cover is removed.
Compo nents shall not be marked with circuit references. The marking shall be adjacent to
the compo nent. Markings required for cOlll rois, maintenance or wam illg shall be adjacent
to the part concel1led. rvlarkings shall maintain legibility throughout the life of the
equipment in the specified envirolUllcnlal conditions.
TeeJlll iques used shall be approved by the S.O.
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B.l.S Prot(>cti\'c Rcquirements
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8. 1.5. 1 General
All metal work not normally required to ca rry ell!Tent sha ll be cOlUlecled to an ea rt h point
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except where ot herwise dic tated by transmission or other requirelll~ (suc h metal work
sha ll include cases, scree ns, cores, cable glands, cable coU nl~ cable shealhs, etc.).
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8. 1. 5.2 Insulating Bushes 0
lnsu lating bushes shall be provided wherevel~dllclors carrying dangerous voltages
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pass through holes in metr:tl parts and where the ~ondllctor.s would be likely to touch the
edge of the holes.
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8. 1.5.3 Isolation trom Main Supply
Unless otherwise agreed by th'i.S> , systems sha ll be complete ly isolated from the mains
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supply by menns of a su·table~a.ouble- wollnd transfonner which sha H incl ude an earthed
screen. The primary ana se~o nd 8ry output tenllinations shall be separated in all approved
manner.
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The main ransformers at the controller shall be provided with primary tapping so that the
equ ipment ope ales wilh mains supply in the ra nge of200 to 260 volts.
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8. 1.5.4 'f1 llsfonner Secondm Circ uits

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'hen a dangerous voltage is connected to the primory winding of a transformer, the

secondary circuit shall be cOlU1ected where practicable to an earthed point.
8,1.5.5 CUlTent Loading of Wires

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All wirings shall be suitably rated 10 CH IT)' in excess of the CUlTent permitted by their
fuses, circu it breakers or olher curre nt linking devices, Similar precauti ons sholl be taken
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to reduce the possibility of overhenling components.
Provisions shall be made in the equipmenl>
l'I. to prevent damage to circu its due to failure of any pulses, power supplies or maills
supply;
b. to prevent damage to power supplies by inadvel1ent removal oflhe load.
58·3
JKRlSPJI2008-S8
8.1.5.6 Danger Notices
All equi pment or units work in g at a voltage tit or above 150 volts D.C. or 100 volts A.C.
(RlvIS) shall be protected by an npproved cover, which slm ll be removable. The cover
shall have n sig n wit h a dange r symbol indicati on of the vo ltage. The highest vo ltage to
wh ich access can be had by remova l o f the cover ~ h all be shown, where dangerous
voltages exist.
8.1.5.7 Cable COIUlectjng Units
Terminal strips and terminals shall be clearl y and indelibly coded. Tel111inals ca ny ing
mains electrical power sha ll be segregated fro m other terminals. Unless approved by the
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S.O., not more th an tlu"ee cable cores sha ll be retained by a ny tenni nal. All wiring and
cabling shell! be neal, adequately supported to prevent vibration, and so ammged as to
prevent strain o n individ ua l wi res, pfLrticulariy on hinged pane ls.
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8. 1.5.8 Insulati on
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Ifno value is spec ified, the insulation resi~t,l1lce between any two ) ~ not in tended to be
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in electrical contnc! shall not be less than 100 Mega ohms whe llucasurcd li t a vo ltage
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appropriate to the equipment.
8.1.6 Electricity SU!)u)y

C:J0
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The Con tractor shall ob ta in an exclusive electr.icit y ))upply fro m loca l powel' suppl y
authority for the traffic signal system without s hari ng with other services such as street
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lighting, Variable Messag ing System, s:tc.
The Contractor sh. 1I comp ly w· ~~C"I power supply aut hori ty requirements in
gett ing an elec tricity supply t tie insta ll atio n, rmd any costs associated with obtai ning
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this supply shall be includcU in the Tendered rates. The Contracto r sha ll ensure that the
equipmen t supplied wilt fu nct ion cOtTec tl y at the supply voltage, and shall allow for
normal variation and ~urges .
EN
8.1.7
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Up~o mp letion of the install ation work on s ite and before the Certificate of Practical
l ) ,Co n~ t ion is issued, the Contractor shall arrange for all neceSStuy tests to be CCl ITied out
""""0 1 the insta llation by co mpetent perso n as pm-t of the tests required of hi m under this
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contract. The cost of these works is deemed to be included in the co ntract.
The S.O. reserves the right to be present during testing and commi ssioning.
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The Contractor shall noti fy the s.o.

whe n the tests are to be cflITied out . The S.O.
reserves the right to be present during testi ng. The Cont ractor shall forward to the S.O.
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duly cert ified copies of the test results when the tests have been sliccessfull y completed.
If the S.O. dec ides the sys tem is not in accordance with the Contract, he may reject the
system, and he shall infonn th e Contractor of the reasons in writing.
The Contrac tor shaH provide app ropriate temporalY sign during testing and
comm issioni ng of the traffic s ignal system.
Upon ~at i srac ti on of the system, the S.O. shall notify the Contractor the dale for the
cOllunissioni ng of the traffic signal system.
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JKRlSPJ/200B-SB
8.1.8 Docllmcntnlion
8. 1.8. 1 As- Installed Drawings. Manuals And Tools
Within one ca lendar month after Ihe practical completi on of the project, fo ur sets of
prints (ISO AJ size) for eac h of th e foHowiug drawings s hall be submitted :-
a. Site plan
b. Schematic Wi ring Diagra ms and Control Circliit Drawings
c. Traffle Signals Layout Plans
d. loyall! plans of cable routes and ea rt hing points, with reference to easil y
recognizable landmarks, buildings and structures. The plans shall also show the final
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wiring cii ngrams, post locations, controller locations, detec tor placement (loops and
pits), galvan ised iron (0 .1.) duc ls and timi ng plan.
The as-installed drawings shall also be stored in Compac t Disc or any other elec tron ic
media as specified which ca n be read ily re trieved by comput er. The software
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programme shall be AUloCAD of a release specified or oflhe latest release.
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In addition, four sets of the fo llowing lnmlu.IS/brochl1reS~'d0i ulll en ts, suita bly
bound , shall be submitted to Ihe S.D.:
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a. Instnllaliol1 Mnllual
b. Operation Ma nu al
c. Service and ivfa intenance Mallual
d. Pnrts Li.st
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e. Product Data and Catalogues
f. Product Tes t Certificates
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g. Inventory Listing and Assets Tagging
,
These drawings shall ha ve al the I ~wcr right co rner the Contractor's name and address,
date of co mmissioning. sca e. rawing number (the drawing Ilumber shall be ob tained
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from the S.O.), title and the tbllowing particulars:-
JABATA~ KE RJA RAY A MALAYSIA

EN
CA WA 'CAN JALAN
CJ~WAII/GA.l'i KEJURUTERAAN ELEKTIUK
COtj'rRACT NO:
TFlNDER NO:
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) If tIO rawings su bmitted are not acceptable to the S.D., Ihe Contmctor slmll <l mend
a~ resubmit the drawings wi thin IwO weeks fro m the date of notifi cation by the S.O.
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A set of A4 size sc hematic draw ings and layout pla ns sholl be Imninated and placed
inside the pocket of the cont ro ller. SpeciallOols required for the operarion. service and
maimenance of the controller and J)witc hgear, post <lnd other equipment shall also be
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provided. The cost of all these prints, manuals <l neI tools shall be deemed to be included
in the Co nt ract.
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Grea t ca re shall be taken to ensure Ihat in the wri ti ng of all documen tat ion, expert
familiarity with <lpparently si mple fe<ltures is 110 ( adverte nt ly assumed. Difliculties should
be ant icipa ted.
All documentation shall be in English or Bahasa Melayu .
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JKRlSPJ/2008·S8
8.1.8.2 Hardware. Sotlware and lvlaintcnance .t.,'innunl
The manual shall contain descriptions of the complete hmdware system followed by
maintenance procedures. A desc ription of the complete software system shall also be
included.
The hardware description shall start with the overall confi guration of the system, with
la youts showing the location of every unit, with block dingrmns and an explanation of the
ope.ml ion ofille system.
-Detailed descriptions of co mponent units shall explain their operation, Block diagrams
showing the flow and interactio n of data, logic diagrams, circuit diagrams with
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componenl va lves, and la yout diagrams shall be provided. Parts lists and wiring
schedules slHtIl be provided, but eme shall be taken to avoid these obsc uring the
opemtional description. Maintenance procedures shall cover the diagnosis of faults,
testing and selling up adjustments, replacement of units and routine mechanical servicing.
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The software desc ription should aim at enabli ng new programs for an intersection to be
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written, [Iud to provide the basic standard techniques lIsed in wri ti ng the sys tem
programs. Where programming teclmique is 'dependent 0 11 a( icular fea tures of the
system, it is important thnt progrm l1 material is ~pccia lly ~rrm n.3his shall be in the form
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of guidance, referring to operational features in the software manual.
8.1.9 GU:1nmtee of Supnly

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The Contractor shall be required to ensure hat for a period arnot less tl13n IOsears from
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the date of commissioning the sys tem, R( uppl y ofreplacement compo nen ts and matednls
or thei r agreed equivalent is available, a§ tile S.O. may require. A Contractor who is not fl
manufacture r is required to sllbm:t letter from the manufacturer certifying that the
manufacture r will support the l~iplllents and components,
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8.1.10 \V'1I"rantv Pel'iod

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After acce fi IlGc-of the inslatlation, the Contractor shall still be subject to obligati on of
free servicing change in phasing, maintenance and free replace ment of all defective parts
and fused bulbs for a period of twelve (12) months from the date of issue of the
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\. ) Certifi are of Completion. A qualified Engineer provided by the Contractor must be

a 'ailab e on 24 hours service n day to allend to any breakdown at anytime includi ng
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p blic hoIidays.
All repairs and replacements required during the Wan'anty Period shall be carried out
with dispatch and nn adequate supply of spares shall be avai lable for this purpose. The
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Co ntractor shall be liable for damages if he do es not und ertake remedial works within 24
hours.
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The Cont ractor shall C,UTY Oll t any repai r wit hin 24 hours of being infonned of the
damages. Upon failure to do so, the S.O. has the option to <lppoint another party for repair
and the cost thus inclllTed will be home by the Contractor.
All maintenfi llce conducted shall be entered into the Local Controller Logbook, dated and
signed by the maintenance staffofthc Contractor.
Repainting of the sig nal posts shall be perfollned jma before the end of the Defect
Liability Period, if necessary.
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JKRlSPJ/2008-S8
8.2 LOW VOLTAGE UNDERGROUND CABLES
8.2.1 Types of Cables
8.2. 1.1 Power Cables
Power cables s hall be PVCISW A!PVC cable as spec ified in Appe nd ix 8A (L-S3 :
Specification For Low Voltage Underground Cable, Cnwongan Kejul1Ilermm Elektrik
JKR).
8.2. 1.2 Feeder Cables for Vehicle Detec tors
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Feeder cables to vchicle detectors sha ll be PVC/S\V,VP VC cable as specified in
Appendix RA (L·S3: Specification For Low Voltage Underground Cable, Cawangrlll
Kejul11ternan Elektrik JKR).
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8.2. \.3 loop Cabl es for Veh icle Detectors
n The materinl for inductive type vehicle-detec tor loop cables sh. lI ~n accol'drmce with
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A.S. 2276.3 or unless otherwi se specified herein. The Loo ) <w I~s shall be of a type
be approved by the S.O.
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which can be easily assembled From bulk cable on sile,
·S.2. 1.4 Earthin g Sys tem 0

The enrt hing system shall comply with the requ l€ments of (\"IS lEe 60364 flS spec itied
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in the Dra wing ~.
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The earthing conductors shall be 25111111 ;< 3 ml1l copper ta pe and the eart h electrodes
shall be of co pper·jacketed stee core rod ~ with 16111111 d iameter and supplied in
1500n1ln length. The copper ja~ of 99.9% purity electrol)'1ic coppe r shall be of
minimulll radial thickness .2 111m and ~hall be molecularly bonded to the ~teel core to
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ensure that the copper jac e and stee l core are non separab le. Each enrth electrode
shall be dri ven 30001 III '11 aepth. Where the des ired earth res istance vn lue cannot be
achieved aner the first ea rth electrode h.we been driven, su fficient number of the
~ Iectrodes ill p,atftibl shall be installed out s ide the resistances arca until requ ired value
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IS reached. "'
The cOlUlectioll of the earthing conductor andlo r the earth electrode shaH be soundly
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made the use of plumbed joints, ei ther by brazing usi ng zinc· free material with a
(; ~ poi nt o f at leas t 600°C or by thermi c welding or by cold pressure welding.
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Tbe inspection chamber shall be made of heavy duty pre-cast co ncrete of minimum
J OO mIH (L) oX 300111111 (W) oX 2 10111111 (H) co mplete with removable concrete cover.
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8.2.2 C nble Termination

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Unless otherwise permitted, all cab le tennination and jointing works shall be ca rried Ollt
ill the presence of the S.O.
Power altd t('eder cables shall be tenninated as specified in Appendix 8A (L·S3:

Specificat ion For Low Voltage Underground Cable, Cawangan Kejul1l1eraan Elektrik
JKR).
Loop cables shnll be terminated using appropriate cabl e CO IUlector.
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JKRlSPJ/200B·SB
8.2.3 Cable Jointing
No cab le jointing shall be allowed for interconnec ting signed cables. Jointing of mains
power cables shall be allowed only when npproved by the S.D.
8.2.4 Cabl e "nd Detcclol' Pil
All cables belwee n poles, loop deteclors and lraffic signal conlroller shall be full y
installed in ga lva nized steel pipes and cable pits. The galvan ized steel pipes shall be of
heavy duty type, complying with BS 1387 and complete with screwed and socketed
jo ints.
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The cflble pit shall be of heavy duty pre-cast concrete pit with n minimum size of 450
nun (L) x 450 nun (W) x 450 mm (H) unless oillenvise specified. The cable pil shall also
nct as a cable marker.
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8.3 SIGNAL LANTERNS I HEADS
8.3.1 Standard Requirements
All components, their installation and perfonm1llce, shall be in accorda nce wilh BS EN
12368 unless otherwise specified here in.
8.3.2 Optical Requirements
8.3 .2.1 Optical Arra ngement for Drivers
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Each signal face shall, unless otherwise shown on Ihe Drawi ngs, co ntain three optical
systems alTanged verticall y, each Im ving a nominal diame ter of 300111111.-The coloured
lenses of the upper optical system shall be red, the middle one amber, and the lower olle
green.
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Signal head s shall be filled with a type A vi,or.
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() 8.3.2.2 Oplicfl i Arrangement for Pedestrinns
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Erich sigmli face shall contain two optica l sys tems vertically, each havi ng a
nominal dinmelel' of JOOIll Ill as shown inJhc Drawings. The upper optical sy:.;tem shall
cons ist of either one o f the tbllowi ngs:- ~\()
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a. a double digit cou ntdown unit wit h amBer LEDs and red symbol ic waiting
pedestrian or
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b. an illuminated "TUNGGU/UNTtAS" indication with n green symbolic walking
ped estrian for th e lower optical sy-/tem.
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8.3.3
8.3.3.1
EN
Thc hcight of : ignol head shall be such that when erected the centre o f the green opti cal
system shalloe 2.5m above the carriageway level.
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8.3.3.2 Signal :lead Intended For Pedestrians

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~e height of signal hea d shall be sllc h that when erected the centre of the green optical
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system shall be 2.5 III above the ccllTiagewny level.
8.3.3.3 Overhead Monnted Signal Head

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The height o f overhead mounted signal hend shall be such thtlt when erected, the lowest
po int of the signal head assembly shall be no t less than 5.5 111 or marc than 6.5 III above
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the ca rringewny le ve l.
8.3.4 Lamps
8.3.4. t Halogen Lamp
The lamp lIsed in the optical sy.stem, to meet the requ irements o f A,S. 4 113 Part 2 slmll
be a 10 V. 50 \V. long life nlllg,ten haloge n lamp.
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JK RlSPJI2008-S8
The bulb shall be clear, uncoloured and the IiInment shall only be lIsed in the horizon tal
position. The lamp shnllmcct the fo llowing requ irements as tested in A.S. 4 113 Pat12 :
- TABLE 8.3.1: C HARACTERISTICS OF HALOGEN LAMP
Characteristics Vnlues
Nom innl lumens 820 1m allOV
Nomi nal life 6000 hours continuous
bumiug al IOV inpul
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Nomi nal cololu' tempemtme 2850 K al IOV iupul
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Each tungsten halogen la mp shall be provided with an appropriate transformer complying
with the requ irements of B .S. 9720, mounted wi thin the signa l head a nd connected to a
termin al block wh ich Illay be mounted remo tely. Wiring between the lamp holder mId the
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tnmsfonner and the terminal block shall be in compliance with the requirements onvr.s.
136 and B.S. fi007.
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8. 3.4.2 LED SIg na l Module
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Each module shnll conslst of an assembly th at utihzes g ns the light Salll ce in lieu
of an 1l1candescen t lamp for lise 111 tmffic slgnal'1ysle m. The LEDs sh,1I1 utilize
appropr iate Intest technology to achieve the reql1ired:1Qlour il nd sholl be the ultra bright
type rated for 100 1000 hours of continuous ope~ i o n from · 15°C to + 60°C.
u!H~~I: fe
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The modules shall be rated for a minimum of 48 months. All modules shall
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meet nil parameters of this speciticatiol during this period. The indiv id ual LEDs shall
be wired such that a catastrophic lo'S":<; or the failu re of one or more LED will result in
the loss of nol more than five percent of the signal module light output.
speCifi~!~ED signal modules shall have Ihe fo llowing electrical

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Unless otherwise
clmractcristics: :\. "'
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TABLE 8.3.2: ELECTRICAL CHARACTERISTICS OF LED SIGNAL

MODULES
Characteristics iHodnlo Type
Hi -Fill' Dol Malrix
Operation Vo ltage 230V (+ 10%,- 230V (+ 10%, - 6%),

6%), 50Hz + 1% 50Hz + 1%
Powe r Fnclor ~ 0.90 ~0.90
Total Harmonic :0 20% :020%

Distortion
Power 12W - ISW 8W - lOW (Typical :
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(Typical: 12W) lOW)
Inlensily 200cd - 800cd 200cd - 800cd
LED Iype AlinGa P,InGnN 5mm (AlinGaP,
InGnN)
LED Monnling Technology Surface moullt Thrall h holes
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C luoma ticity Coordinates (x I y) as Red Amb:' , Green
all CI E chart
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0.53~{~~
0660, 0.009 , 0.720
0.320 0.547 .4 52 0.284 ,0.520
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0.680, 0.613.l 0.387 0.209 , 0.400
0.320 ,~.593 , 0.387 0.028,0400
0.710, .(
o 290g :.J
0690
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... 0.290
"
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8.3.4 .3 Constl11ction
The LED s ignal module slHtI be a s ingle, se lf·contained device, not requiring on- site
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assembly for insta llation into ne\' or exis ting trame signal housing. The power supply
for the module shnll be integra to the unit.
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The assembl y a manufacturing process for th e LED signal modll le shall be designed
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to assure all rtlte lal co mponents nre adequately supported to withstand mechanical
shock and 'ib ation from hig h winds and other sources.
8.3.4.4
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Each modu le shall have the manu fact urer's na me, trademnrk. model number, se rial
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number, date of manufacture (month-ye nr) . and 101 number as identification

pennanently marked all the back ofl he modu le.
The fo llow ing operating charac terist ics sha ll be permanently marked on the back of the
modu le: rat ed vo ltage and rat ed po wer in \Vatts and Volt,;Ampere.
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If a specific Inountin g orientntion is required, each modu le shall ha ve prominent and

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permane nt Jlm rking(s) fo r correct indexi ng nnd orientntioll within a s ignnl housing. The
markings shall co nsist of an lip arrow, or the word "UP" or "TO P".
8.3.4.5 Target Boards
If specified , larget boards shall be provided with each signal face intended for ve hicle
dri vers, extending not less than 275 mill above the centre of the upper optical system nor
less than 250 Illm below the ce nl re of the lower optical sys tem. It shall extend not less
than 280 mill horizontall y ei ther side of the vertical centre line of the opt ica l sys tem.
O ther types of t<l rget boards shall be as shown on the Drawings. The target boards ghall
58-11
JKRlSPJf2008·S8
be manuG'lctured from (1 dumble resilient material and slmlt be stiffe ned where necessary
to resi:-;t distortion due to wind and extreme ambient temperature. All target boards shall
be black with orange border neither less than 45 mill nor more than 55 mm wide.
8.3.4.6 Digital Co untdown Unit
Each cou ntdown unit shall consist of an assembl y that utilizes LEDs as the light
source. The LEOs shall utilize appropriate technology to achieve the requi red colour
and shall be the ultra bright type rated for 100,000 hours of continuo ll s operation from
·15°C to + 60°C.
The countdown unit shall be rated for a Ill lnl mum useful life of 48 months. All
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modules shall meet all parameters of this specification during thi s period. The
individun l LEDs shall be wired stich that a ca tastrophic loss or the failure of olle or
more LED will result in the loss of not more than five percent of the signal module
light output.
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The Countdown unit shall consist of a doubl e digit display made of Red and Green
n LE Ds. Timing is derived directly Ji·om co ntroller using Vehicle Actuated Data and no
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li mi ng :-;hall be programmed or otherwise initiated.
Unless otherwise speci fi ed, the Cou ntdown Unit shal ~e the following elect rical
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characterist ics: V
... ,VJ
TABLE 8 3 3' ELECTRICAL CH ARACT ERIS<i?CS OF COUNTDOWN UNIT
A
C haracteristics '-J Values
Operation Voltage 230V (+ 10%, ·6%), 50Hz + 1%
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Power Factor ~0.90

.c :s
~
Totell Hannoni c
. . e." 20 %
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Distortioll
Power
Intensi ty
,,,.
•
f"t....... 8W - lOW (Typ ical: lOW)
200cd - 800cd
LED type /) 5 nlln (AlI nGaP , InG aN)
EN
LED tviollntin0-Tecllllology Tlu'ough holes

Chromatici ty Coordinates (x , y) as Red Amber Gree n
c1'!)1
,
on CIE
0.660,0.320 0.536 , 0.444 0.009,
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~ I 0.680,0.320 0.547,0.452 0.720

<,.,0 0.710,0.290 0.613 ,0.387 0.284,
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0.690 , 0.290 0.593 ,0.387 0.520

" 0.209.
Q.400
0.028,
0.400
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The coun tdown unit on-board circuitry shall include voltage surge protection to
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withstand high-repetition noise transients.
The Countdown circuitry shall prevent perceptible I1icker to the unaided eye over the
voltage range speci ti ed above.
The countdown unit shall be operati onally compatible with currently used co ntroller
asse mblies (solid state load switches, flashers, and conflict monitors).
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JKRlSPJ/2008-S8
Each unit ~JHlII have the lllilJlufncturcr's name, trademark, model number, serial
number, dntc of manufacture (month-year), [Iud lot Humber as identification
pennanently marked on the back of the module.
The rated voltage and power slwU be permanently I1wrked on the back of the rnodulc.
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8,4 SIGNAL POSTS I POLES ,IJ'I D MAST ARMS
8,4.1 Stand:l1'(1 Requirements
All signal posts /poles, signal masl arms and mounti ngs of signal lantems / h cad~ shall be
[IS shown in the Drawing!:l. The posts and mast anns shall be so designed and co nsll1lcted
as to provide adequate support and stabil ity for the signal head assembly.
All signal posts shall be of tubu lar hollow section of steel with fI nominal diameter of 100
nlln and fitted with a wealher-proof cap to prevent ingress of wa ter in com plinnce wit h
BS EN 40.
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i"last arms shall be tubul Cl r holtow sec tions of steel of a generally tapered [ann mou nted
on a base plate as shown 0 11 the Drawings.
The posts and mast al111S shall be capable of having holes drilled in the vertical section,
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I III above the ground, for the mount ing of aile pedestrian push· button assembly in
accOlda nce With Sub·Seclion 8.5 Any other type of post !-ilmll ~ \,'\pp rova l from S.O.
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(J prior to installation '"
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8.4.2 Cable En tl'\'
Cable cntry ho le shall be providcd fo r both planted a!l(f flange mOllnted type post~. For
the !longed mounted type posts, the cable ent ry. shall be through the nange plate wit h a
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hole of the same diameter as the inner diame e\,Sf the post.
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8.4.3 C Ollnectin g Facilities for Ca bles
Provision shnll be made for ~onnection of terminating and interconnecting cables

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coming Ii'olll wit hin the ~ or mast ann and of cables from the tra ffic signal lantems.
A service door shall be provided to facili tate for inspection and mai ntenance of the traffic
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signal Sys te~he details shall be as shown ill the drawing.
8.4.4 Locntiou niHI Erection

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lJ Q \e posts ,mel mas t arms !-ihnll be erected at the approximrut! iocations as shown on the
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Drawings. On roadwa ys whose edges are detlned by (l mised kerb, the posts shall be
erected so that no part of the signal heads other than overhead signals projects over the
roadway.
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Where possible, the signal heads should have a cleamnce of 3001111H to 450nun behind
the kerb line. However, the post shall be at a dista nce not less than I III from the edge line.
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In areas where there is no kerb, the posts should be erected so that the signal hend is clear
of the paved shoulder (or usab le area) and should not be less than 2m nor more than 3m
from the edge of the nearest tranic lane.
All posts and mast anus shall have their e;~.:act location determined by the S.O. and
recorded on the as-built Drawings.
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JKRlSPJ/2008·S8
8.4.5 Finish
The post shall be free [rom weldi ng scale, sh,uV corners and projections, which might
cause injury or damage to cable.
After the completion of all mmlufncturing operations, the post shall be hot-dipped
galvanised in accordance with D.S EN 40.
8.4.6 Signal Hends i\'lounted On Stl'eet Lighting Pole
Signal hends shnll also be mounted on street lighting pole. Nominal mouilling height of
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signal head shall fo llow as that ofl he pos t-monnted signal head.
Two numbers of service doors shall be provided to faci litate fo r inspection and
maintenance of the traffic signal and street lighting system as shown in the drawing.
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8.4.7 Signal Hea ds i\ 'Inst Arlll and Street Lighting Po le
Signalmflst ann shaH also be fabri cated together with sireet'ligluing pole. The poles find
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111<151 ann shall be designed and constl11cted to provide adequate supp0l1 and stability for
the signn l head assembly 0 11 th e mast ann, The poles shall be of hot-d ipped galv<lnised
steel. ~\()
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Two numbers of service doors shaH be ~ovidcd to facilitate for inspection and
maintenance oflhe traffic signal and street ighting system as shown in the drawing.
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8.5 PEDESTRIAN PUSH-BUTTONS
8.5.1 Standard Rcnuiremcnts
AU pedestrian push-bullon, th eir mec han ism and operation, shall be in accordance with
A.S . 2353 unless ot herwise specified herein.
8.5.2 Location
Pedeslri,m push·button detecto rs sha ll be provided facing the foo tpath al each end of each
crosswalk where pedestrian actuated signals are required as shown on the Drawings,
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8.5.3 Pedestrian Demand Indicntor
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When the bullon is pressed, nn internally illumi nated panel shall light lip bearing a
symbolic red standing [11(111. It shn ll continue to be displayed until the cross signal (gree n
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man) co mmences. The pedestrinn dema nd ind icator shall be prov ideo with all pedestrian
push-buttons.
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8,S A Audible Signal . 0
f\.n nudiblc 5ignn t shall, be provided wilh nil pe~trinl1 pllsh~bllHons in nccordnncc with
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A.S . 2353, if specified.
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8.6 TRAFFIC CONTROLLER
8.6.1 Gellernl Requirements
A COlli roller is the complete timing mechani1:'111 wh ich co nt rols the signrd phases at an
intersection. The controller shall be micl'Oproces$or-bnsed consisting of n
microprocessing lIllit, intcl'tacing unit for inp uts and outputs and fUlc il huy equipment. :
The co ntrol equipment and components shall be housed in a wea therproof-cab inet tes ted
to Class IP 55 in accorda nce with MS lEe 60529.
The controller shall be able to provide eight sigllfll groups of control and shall be cnpnb le
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of expansion to at least sixtee n signal groups by the additio n of modules on si te, which
shall be in add ition to any special phase required in connection wi th start lip seq uences,
all reds, etc. it shall also provide a variety of timing fUllctions and differing operationa l
modes, The co ntroller unit shall be capn bl e of operating a minimulIl of eight plans in a
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24hour period.
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8.6.2 Housing
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The hOllsing shall have a wea therproof enc!o:-;ure for t he~otec t io ll of power ~l1pplics,
kW H meter pnnei, maillS supply panel, facility switch logic module, vchicle detector::. ,
interfaci ng and lamp switching modules and battery I!.\ck-up mains supply system (if
speci fi ed) . .;::; "-'5
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The housing cabinet shall be in accorcla ce with A.S. 2578, ParI I, unless otherwise
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specified herein.
Housing sl10ll be manufactured fi',,~minium. s tainless steel, galvan ized steel or mild
~oved by the S.O.
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steel ma teri al as spec ified and
For mild steel. the hOUSlll~ IIUndergO de-mst ing Ireatment and anti-nlst treatment.
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All housing ex'cep~or stai nless steel shall be coa led with epoxy dry-powder nlld oven
baked semi.{.~ ennmel grey.
If a st~lles~eel housing is specified, all material shall be to tall y made of sta inless stee l.
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All co mponents shall be f,'lbricated lIsing stain les$ steel sheet no t thhmer than 14S\VG.
~ addlrion al anti cOll'Osion and paint treatille nt are requ ired unless otherwise speci tied.
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The hOllsing shnH be bolted to steel chatmel base all conc rete plinth.
Appropriate means of entlY and support lo r cables shall be provided.

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Suftlcient venti lnt ion shall be provided to prevent condensation inside the cabinet under
all weather conditi ons. Charcoal or some other dehydration agent shall be placed in the
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housing as directed by the S.O.
All nOIl-ClHTent canyi ng metal parts shall be bonded together and effectively earthed in
acco rdance with MS lEC 60364.
All mealls of access shall be protected by locks of differe nt paltelll s and the
corresponding loc ks and keys shall be identical for contro lle r housings of the same make,
type and series. Not less than two keys of eac h type shall be supplied with each controller
and they shall be hand ed over to the S.O. aner the completion of testing and
co mmissioning. For additional security, metal bracket bar with pad lock shall be installed
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JKRlSPJ/2008-88
to hold the con tro ller housing. A log book shall be provided and aUnched to the housing.
8.6.3 Controller Mains S lIppl" Panel
Tlte cont roller mains supply panel shall include one numbe r of si ngl e pole miniature
ci rcuit breake r (MeB) of minimum rated clmenl 30A with tl breaking capacity not less
Ihan IOkA (nlls) complying wilh MS IEC 60898 and of B-Iype wilh Class 3 energy
limiting characteristics.
Tinned copper earthin g bar of cross sectionnl-area not less than 25111111 x 6mm shall be
illslalled.
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The surge protective devices (SPDs) modes of protection shall be each phase-la-neutral,
each phm:c-to-earth and neutral-to-earth for either single phase or three phase supply
systems. The impulse ClUTen! (lilllp), nominal disc harge cun-ent ([II) ' maximum disc harge
CUtTent (Illl a,~) and open-circuit voltage (Uoc) rat ing per mode of prot eel ion of SPD and the
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respective voltage pro tection level (Up) shall be as indicated ill Table 4.
An these req uirements shall be compl y with unless ot herwise SpeGifie~ in the drawings.
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TABLE 8_6_1: CLASSIFICATI0l{?l)SPOS
Locat ion of Cont roller t"Iains Suppl y Panel 1ine1 Receiving Energy from
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Inc Power Suppl y Authority
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Impulse Test Classiticalion (MS IE",~43-1) Class I Class II
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Impulse Cu rreul, I,,,,, ( I~~~er mode ~ 12.5

kA
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Nominal DiSCharg~~;:' I" (8 /20 ps) per ~ 20 kA

,
mode ~
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MaXimuS~i~arge Clmenl, I""., (8 /20 ps) per ~65 kA

mode
.,
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( ) Q~e Proleclion Level, Up (L-N, L-E, N-E)

< :s 1500 :S1500V
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(It {imp or In or Uoc V
The coni roller shall be suilable for opemli on on 230V (+10%, -6%) 50Hz (± 1%) supply
systems.
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8.6.4 Facililv Switeh
A facility swi tch shall be provided to switch the signa llantems to ON, OFr or FLASH or
other facilities such as tmmual opera tion. The switch shall onl y cont rol the signal lamps
and Hashing amber circuits while lea ving the control equipment fu lly operati ve.
Access lo thi s facility shall be via a separate locked door or some ot her means which
does 110t give access to the controlle r. T he facility shall be located nol less Ihan I III from
the ground level.
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JKRlSPJ/2008-S8
8.6,5 Pedestrian Fncilities
Pedestrirm indications shall be allocated 8& exclusive phm;es or be connected in parallel to

a green phase(s).
When the pedestria n indications flrc cOlUlecled in paral lel 10 a green vehicle phase, the
steady pedest rian green shall commence at a preset period adjustab le 10 0, I, 2, 3, 4 or 5
seconds before or after the start of the gree n vehic le phase, The steady pedestrian green
shall persist until the end of a presel period.
It sha ll be [cHewed by the nashing pedestrian green or d igital countdown unit. 'For
flashing pedestrian green, the freq uency of bl inking s hall be at 76 to 84 flashes per
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minute, flnd the lamp shall be all for 50% 10 70% of the lime. The amber signal
terminatin g Ihe vehicle green phase shall not com mence until a preset period adjustable
to D, 1,2,3, 4 or 5 seconds has elapsed after the lennina tion of the flashing pedestria n
green.
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When the pedestrian indications are allowed an exclusive phase, the pedestrian steady
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green shall be controlled by the appropriate control cOlllmand and followed by the
nashing green pedestria n signal. The inter-green periods shall be inserted before the
pedestrinll steady green and between the end of the flashi 19 gree!l or countdown unit and
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the sHI rt of the next vehicle phase green. It shall be po~e to operate the pedestrirm
phase wit h or without pedestriflll detection. This shell be se lected by a switch or other
method s withinlhe contro ller, subject to the appro~ i,[ he S.O.
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8.6.6 Logic Module
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The microprocessor based logic ~0e shall consist of the fo llowing minimum
requirements:-
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8.6.6.1 Microprocessor System
The Microprocessot syste m shnll contain a stored program in read-only-memory (ROM),

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Part or all of the or. .t shall be reprogrammable. The stored program shall permit the
traffic controller to be operated il\ di ffe rent trCltTlc modes as follows:-
a. Urban ~fiC control operation (UTC)

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b, Isolrtled traffic-actuated operatioJ I;

c. <Sables or wireless tor synchronous operation;
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(I. Fixed time operation.
All information reln ting to a particulnr signa l installation, such as number of plans, signal
groups, detec tor logic, time setting and desc ripti on of logical and conditional features,
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shall be co ntainedin the reprogranunable ROM .
Time settings lIla y be stored by means of either:·

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a. electrically em,able ROM (EEROM)

b. reprogram lll able ROM (E PROM)
c. battelY back-up RAM
The time se ttings shall be such that they may be changed by means of a portable
programming unit whi le the controller is functioning, The reprogramnH~b l e ROt") shaH be
separate frolll the CPU and its associated c ircu itlY to facilit ate field servicing.
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JKRlSPJ/2008-S8
8.6.6.2 Input/Output In terfaces
The Co ntrac tor shall prov ide for the npproval of the S.O., detailed tcclmicn ! infonnnlion
on the input and ou tput interfaces. Inpu ts include those fro m vehicle detec tors, pedest rian
push buttons and signal links. The output shall be connected to the vehi cle signal light,
pedestri an light, wai t indica tors and signai linking.
8.6.6.3 Real Til11e-ot: Day Clock
For wireless syncluonous operations, a hardwnre clock sha ll be provided. The circuit
generating the ha rdware clock sha ll be backed lip by a sta ndby battery for up to 48 hollt's
or more (when full y charged).
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The clock s haH derive its tim ing from two sources, either from n crysta l osc ill ator or
Global Positioni ng Syslem (G PS) T ime Synchronization Modu le if specified. The real
time clock shall provide time in seconds, minutes, hours nnd days to the microprocessor
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via a dnta bus,
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8.6.6.4 Ope rator Inte rfn ce <l nd COlll ro Her Display
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A portflble programming unit ~ h all be provided ns all 0 clJltor interfnce with the
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contro ller logic module. if specilied. Visunl indicators sh~e provided to indicate the
stntus of variolls traffic para meters such ns the phas cu rrent ly llill ning, base phase step
for each phnse, demand tbr eaell plmsc, pedeslri a n~l1!,t1C1s recorded, etc,
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When opera ted in link mode, the displat snail be nble to provide all trnffic parameters
associa ted wit h the appropriate link mod~~
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8.6.6.5 Power Supply Moniloring System <:::--

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All D.C. power supplies t · G io us cards in the logic module shall be co nstantly
moni tored to ensure con'eel eraliol1 of til e co ntroller.
The moni toring shall be des igned so that if one or more of the suppl y output voltages
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fal b; below Cel1a11ljfrefet levels, the power fni lure detection circuit will ac ti vo te to cause
the cOl1lrOtlel~Sllt;t down the traffic signal system.
The mai ns snpply vo ltage shnll also be monitored. Any vo ltage drop below certain levels
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~) shall CRuse a black out si tulltion.
~l'a lC hdOg
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li mer shall be used 10 deicci fa ilure of Ihe micro processor syste m 10 execule
its tftlffic control program. Any fa il ure to execut e lrame inslmcti on .shall black-out the
intersection signali zati on and switch over 10 flas hing nmber signal.
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8.6.7 BRUen' IJrICk-lII) Svstem For TraFfic Signals utilizing Light E mitting Diodes (L ED)
T raffi c Signal Modul es.
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R.6.7. 1
The batt ery back-up system (BSS) :.:.ha ll inc lude. but no t be limi ted to the lo llowi ng:
inverter/cha rger, power tra nsfer re lay, bat teries, a separate ma nually operated non-
elec troni c by-pass switch and allnecessn ry hardware and inte rconnect wiring.
The BBS shall provide reliable eme rgency power to a traffic sig nal in the eve nt of a
power failure or intel11lption. The BBS shnll be capable of providing power for rull
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JKRlSPJ/2008-88
nllHime operation for an "LED-only" intersection (all colours red, amber and green)
o r !las hing mode operati on fo r an intersection using red LED.s. The BBS sha ll be
designed for outdoo r ftppiicati ons.
8.6.7.2 Operation
The BB S shall provide a minimum. two (2) hours of filII nm-lime operation for an
" LED- olll y" intersec tion (minimum 700\VII OOOVA active output capacit y with 80%
minimum in ve rt er efficiency).
The maxi mum transfer tim e [rom loss of utility power 10 switchover to brlttery backed
inve rter power shall be 150ms.
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Operating temperature for both the in verter/power tra nsfer relay and manual by-pass
switch shall be O°C to +74 °e.
Both the powe r transfer relay and llul.llllal by-pass switch shall be rated at 2JOVAt'
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(+ 10%, -6%) 130A.
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() The BB S shall use fI temp ernture-co mpemm ted battery charging S 'stcm. The clwrging
system shall compensate over a ra nge of 2.5 - 4.0111 VfOe per cell.
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Batteries sha ll not be rechnrged when battery temp erature exceeds 50°C ±3°C.
BBS shall be equipped to prevent a malfunction feedback to the cabinet or from

fced ing bnck to the loenl power utility se rViQ ~
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In the eve nt o f inverter/charger railur~battery fa ilure or complete battery di sc harge,
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the power transfer re la y shall revcI1 \10 1 the normally closed state, where utility line
power is reconnected to Ihe cabinet. V
Recharge time for the bat t.,c ry. rom "prot ec tive low-cLltoff' to 80% o r more o f full
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baltclY charge capacity. s h~n o exceed twent y (20) hours.

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8.6.8
In the event 0 a mains supply intcITltption :$ 501115, th e controller shall co ntinue to

nmct ioll cotTeclly. When n co ntroller commences 10 fnil (n(ler a mai ns suppl y
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intenllp,tion in excess of 50 milliseconds) it shall shut down for the duration of the llluillS
-< lterrup ion pillS n nominal period of abollt 5 to lOs. At the ex piration of this nominal
period the controller shall commence operation at an All Red state. This state shall persist
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for at leas t 5s and shall be fo llowed by the pre-se lected phose.
8.6_9 lnputs
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All inputs shall be suitably protected against high voltage peaks and sho rt circuits.
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8.6. 10 Intcl'changenbilitv
All parts shaH be interchangeable with like parIs for equipment of the smne Illnke, type
and series.
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8.6.11 Vibration and Noise
The apparatus shall be reasonably quiet and the mechanism shall not ca use undue
vibration. The apparatus shall be conslilicted so as to reduce to a minimum any damage
to lamps and equipment dlle to vibration caused by Imffic,
8,6,12 Radio Interference
The design of equipment shall be such as to prevent interference to telegraphic,

telephonic or radio transm issions. The apparatus will be considered to Illeet this
requi re ment, as far as rad io interference is cOllcemed, if the interference produced by it
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does not exceed the limits laid dowl1 in relevant parts ofrvlS lEe 61000.
8,6,13 Safety
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Where ~'ight of way s j~nals are shown f~r any co ntrolled traffic ill Due pIHts~, it s h:~ 11 not
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be pOSSIb le liuollgh failure of any operating co mponent of the confroiler to gIve a nght of
way signal to <1 contlieting tra ffic signal. ~
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The Contractor shall sntisfy the S.D. fl .... to how the C icting green (Green
Conflict) can be detected and what action is to be taken 011 its detectioll. The use of two
independent safeguard systems is favo ured. A metho of testing the operation of the
snfeguard s slmll be provided. ~
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8,6.14 Timjng
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The duration of all peri ods timed by the cont roller shall be within ± 10% of the nOlllinal
ti me when the applied main :o.'~ge is within the range between ± 10% of the nominal
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va lue and ± 4% of its nOininai frequency. This slmll apply to those timing nn"angements
which measure selected Ixed periods. The flashing rate of any flashing signals shEl II be
between 76 . nd ~n'Shes per minute within the same vo lt age and frequency limits,
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8,6,15 Sequence 0!1'lilsi ng

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) Un less\ therwise specified, the sequence of phasing for signal llsed jUllction :-;l1 all be in
<Inti-Glock wise directi on.
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8.7 VEHICLE DETECTORS
S.7.1 Sllllldnrd RCQuirements
All equipment, its constl1lctio ll and performance, shall be in acco rdance with A.S. 2703
un b;s ot herwise specified herein.
8.7.2 Number of Traffic Laue,
The loop detec tor shall sense name flow on one to fOllr traffic lanes depending 0 11 where
it is install ed. It sha ll sense traffic mov ing in one direc tion only and detec tion o n a two
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way road sha ll be achieved by using Iwo se ts o f detecto rs so thnt the infon nation obtained
for each d irect ion is separate.
Unless otherw ise specified, a trartie coullting loop shall be installed 011 each lane.
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8.7.3 PerfOl'lnflllCC Requirements
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The detector sllall respond to any vehi cle, nOlll1ally encountereo on public roads traveling
nt [my speed. T he Contractor ~hall satisfy the S.O. wil ll respect to th e accuracy of the
detector un it in terms of false or ni l prese nce aClum ioll at normal opera ting sensiti vity for
all typc.s of vehic les incl uding high~bodied vehiclds anC] rnll lti~axic vchicles.
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Other type ot' vehicle det ec tor shall get npproval tj'o mlhc S.D. prior to insta llation.
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8.8 ROAD WORKS
8.g.1 CO lleral
The Contractor shall carry out alillecessmy road works in connection wit h the
installation ar the traffic signal system. These shall include any road works assoc iated
wilh:-
n. installation of traffic signal controller;

b. installation ofsignai posts/po les and Jteads;
- c. installation o f cable du eling and heavy dUly pre-cast concrete pits;
d. cutti ng of slots for detector loops and bnckfill ing o f s lots;
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e. const mctio ll of cast in-situ pits when necessary.
If an existing ciuel has been install ed ac ross the road cftn'ingeway, all new cross-
cntTingeway cabli ng shall be can'jed in this duct when possible.
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S.8.2 Permission to Excavate Ron d
The Contractor slmll apply fo r penn iss ion from the S.O, to excavate the rand way. The
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<lpplic<lt ion shall be made not less than seven (7) work ing da¥§ before the cOlllmencement
of lhe work.
The Co ntnlclor shrill co mply with the folio~ condi ti ons and other mlditionnl
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inst ructi ons from the S.D. - ..J
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a. trenching ill side-t<lb les, foo tpaths an c<ln'iageways shall be excava ted. bnckfilled,
reins tntcd and maintn ined as sp cifie in th is Sub-Sec tion;
b. cable duc ts to be laid in: "
i. new can'inge\i Yshn~ 1 be at least 7501ll1ll below the carriageway level;
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ii. ex isting carriage vay shall be at least 450nun below the carriageway level;
c. cables nmnillg longitudinally in footpaths find side-lables shall be at least 600mm
clem of the ge of the kerb line or c,m"iageway and <It- least 75mm below the
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adjacem calTltg,e~flY chnlUlel level ;

d. no IVo' Shali b~ done duri ng traflie peak hOllr" lin less approved by the S.O.
Exc.W~iOIl
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l) 8.8.3 Bnckfillin Reinstatement nIHI Ma int("lIitllc(' of Ex:cllnttiolls

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g.8.3. 1 General
The Contractor shall cause as little obSll1Iction as possible to the general public during the
execution of all works under this Contract, and sha ll pay due regard to Ihe interests and
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convenience of the public m1(1of all private persons who have properlY in or are resident
in the neighborhood of the works.
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The Co ntmctor shall e nsure Ihat no de la y OCC lll'S betwee n opening excavat ions, laying of
cables, backlilling and reinstatement and that these f1clions forlll a continuous process.
8.8.3.2 E.xcavation
Each trench shall be excavated to the reqlli red level ,md materia ls taken out sha ll lIot be
re-llsed unless otherwise spec ified or direc ted by the S.O.
For excavation in side-tables, turfs shall be carefully removed , stacked ,mel periodically
watered for later re-use. T he remaining excavated materials may be stockpiled on the site
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JKRlSPJ/2008-S8
for later backfiHing but excavated topsoil shf1 11 be kept separate fo r landscape lise where
necessary.
All materials ii'o m excavntion wo rks arc not allowed to be reused as backfill ing material
and should be removed from the work site immediately after the exctl"fltioll. No materials
are allowed 10 be stockpil ed beside the catTiageway,
All sides of excavations shalt be vert ical. All hard surfaces including flexible pavement
shall be cut using appropriflte ma chinery slIch as diamond cutter. In so ft 01' un stable
ground the sides shall be adequately support ed.
All excava tions shall be kept free of standing wa ter.
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If, for unavoidable reasons, a trench I1Ilming laterally across n road ca nnot be backfilled
and must be left open ovcmight or for 0 longer period , then steel plotes, securely placed
and adequate to take traffic loading, shall be placed across the trench and the sec tion of
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road opened to tramc.
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8.8.3.3 Bedding of Excavation
Before ducts are laid, the tre nch beds shall be leveled a .£ \Iaced on the bed and
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halld tampered to a thick ness of not less than 75n1l11. 1\11 liets shall be covered by a
laye r of sand hand tampered to a t hi c kn es~ ofat leastQjll11 above the crown of the duct.
8.8.3.4 Cable Ducts ~Cj

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Cable duct shall be as specilied in ApH ndix 8A (L-S3: Specification For Low Vol tage
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Underground Cable, Cawnngun Kejun teman Elektrik, JKR) except thnt for the depth of
duct shall be at least ,
caa
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a. 450111111 below existing eway level; or

b. 750nllll below ne~tT' ageWay level.
8.8.3.5 Cable laying and ulstallnl10n

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All cables either laid direct in the grollnd or installed ill precast concrete trenches shall be
handled, !ai and installed as specified in Appe ndix SA (L·S3 : Specificat ion For Low
Vo ltage UnClerground Cable, Cnwangan Kejumteraan Elektrik JKR).
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8.8.3.6 acQ in' of EXCHVrl tioils and Re instateme nts
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For cxcnvn tions in sidetables, benns nnd slopes, the excavated nmterinl ~hnll be replaced
in 150mm lnyers in the reverse order to which th e material was excava ted. Each layer
shall be compacted with a power driven rammer. The top 150mm of the excavati on and
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adj acen t disturbed ground shall be filled· with good loamy topsoil rmd hnnd ta mpered.
Approved qua lity grnss turfs shall be closely and continuously fitted over the lOp soiled
area whe re necessary and directly pegged down to prevent displacement.
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For excavations in e.xisting calTiageways and foot paths the backfilling shall be do ne
using clea n sa nd and approved granu lar aggregate tor the first 150nun depth. The layer
shall be compacted using a power driven rammer. A tack coal of cCltionic bi tuminotls
emulsion shall be applied 0 11 the gra nu lar aggrega te surface and a timli layer of 300111111
thick laye r of asphaltic premi x shall be laid and comp(tcted in two 150null layers, all in
1\ccordance wi lh the relevant requ irements o f Section 4 - Flexible Pavement of this
Specific1\lion.
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8.8.3.7 Sensing Loop Slots
The Contmctor shall be responsible for providing the slot in the roadway for the loop
sensor; the ins tallation and jointing or the loop feede r cab le; the backfilling of the s lot in
the ro1tdway; and the slot or trenches for the feeder cables, nil as shown on the Drnwings.
The width o f the slot in the roadway required to accomlllodate Ihe de tector sensing loop
shall not exceed 12mm and the depth of the slot shall be slich that no part of the loop or
feeder, after reinstatement, shall have n cover of not less than 25nun,
Notwithstandi ng to the requirement tor the contractor to obtain approval from the S.o.
with respect to details of the loop configuration, the contractor shall also comply with the
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following slot filling procedures:
a. No water should be standing in the slot before laying loop cable.

b. Transfer pre-mixed sealant to a watering can and gentl y pour into the slot.
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c. Wipe or scrape e,xcess sealal't off the road surface only while sti ll liquid form.
d. Broken gutter areas where lead-in wires entering footpath shall ,be repai red by lIsing
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a sancVcement mix or the same sealant used for the loop iIlSf~~l.
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8.8.3.R Maintenance ofDmins and Services Durin" Excavations O '"
The Contrnctor shall ensure that he has fiJ lI knowledge of the loca ti on of all drnins fi nd
services in the arcn of fIny excavation prior I~the~ excrlvation commencing. The
Contractor shall ensure that all precautions ar :- rairen not to disturb such drains and
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services fi nd shall be responsibl e fo r their maintenance during the rei nstatement of SLich
excavations. ~
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The Contractor should note if the Site of the Works is subject to frequent and heavy
rainfall and all precautions spalJ be taken to maintain existing wa terw<tys to prevent
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fl oodillg. '"
8.8.3.9
"
Reinstatemellt of Drains and Precast Units
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The Contractor shall can1' OUI the reinstatement of all existing precast channel drains,
gu llies. pavement slabs. dividers, kerbs, etc., which have been affected by any trench
ope ning. Onl¥ excavated units in a !iound !Iud undamaged condition Jllay be reinstalled,
other\visc lIe Conlrncto r shall supply and lay similar new units. The units shall be
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l ) replaced to the original lines and levels and shall be bedded, backed and jointed to the
satisfaction of the S.D.
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8.S.3.10 CO lllpl etiolloflVorks
On completion of reitl's tatement works at anyone site, the Contractor shall clear away all
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debris, surplus materials and plant and leave the site in a clean nnd tidy condition. The
Contractor shall calry out any further remedial works as directed by the S.Q. and shalt
obtain the S.O's written approval for the reinstatement works.
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8.S.3.11 Maimenallce of Excnvntiol1
The Co ntractor shall be enti rely responsi ble for the proper maintenance and good
condition of each excavation and each reinstatement up 10 fI period of tluee (3) calendar
months after the date of the S.O.I~ wrillen approval of such reinstatement works.
All excavation siles prior to, during, and after reinslClIcmenl shall be maintained in a
sound and finn condition, free from depressions, humps, loose stones and any other
similar defects such as not to co nstitute danger or unrea~o llable nuisance to tratTic or
88-26
JKRlSPJ/2008-S8
members o f the public. Loose materials or stones shall not be allowed to accumulate
over or around any excavation, but shnll be promptly swept clear.
Any pan of reinsta tement in a foo tpa th or cl1lTiageway tlm l settles more tha n 15mlll
below the adjacent undisturbed surface level sha ll promptl y be re-surfnced to a level not
more than 15m111 above the adjacent undisturbed surface level. The resurfacing shall be
can'jed out by applying a pri me/Ulck coat and aspha ltic premix as specified in Sect ion 4
of this Spec ifica tion.
The Contractor shall be requi red to mainta in a slllall mobile ga ng of workmen for the
above purpose, and n regu lar system of daily inspection shall be instituted fo r all trenc hes
awa iting lempomry and perm anent rei nstatement. Should the Contrac tor d e t~ll1 lt in the
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main tenance of excavations llnd reinstatement where, in the S.O.'s judgement, ~uc h
dc filUIt wou ld const itute in any way a tra ffic hazard, then the 5.0 . shall have the power
to attend forthwith to such defects and the enti re cost of the work plus 25% shall be
bome by the Contractor.
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Before the expiratio n of the mai ntena nce pe riod of each ite m of work, the Contractor
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shall write to the 5,0. fo r fina l inspectio n of the work to detennille any outstand ing
defec ts which have to be rectified. The Contrnc tor will only e n solved of all the
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responsibilities of the maintenance nf\"c r such defec ts me rec ll fied to the satisfact ion of
IheS.O.
!n the event that the Con tra ctor fails to no ti fy the S.Q, of the date of expiration of the
maintennnce period and has 110 t arrn nged fo r the fQection of the work, the maintenn nce
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period of each ilem of work .shall be deemed 0 have been extended by the Contrnctor due
10 his fault 10 such Illne 1I111111he finol inZ;Clion is cmTied 0111.
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8.8.4 Trame AJ'nlllgenH'nts ~~

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8.8.4.1
Obstructions m d excAvations shall be adeq uately fenced and gll nrded at all times fo r the
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protect ion of a~ 1 p~'sons who use the roadway. Particular attentio n shall be paid to the
positioning of the barriers. The whole obstmction or excavation :.:hall be completely
fellced on-: but ullnecessnry blocking of tra ffi c lanes slwll not be pe rmitted. Roads shall
nol be usedt'-rt r the ull necessary storage of materials.
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~\ a li lane roads, nol mo re Ihon one lraffic lane in eilher direclion shall be closed
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except as may be otherwise directed by the S.Q. On roads of not more tha n one traffic
I,me ill each direction, the Contractor shall ensure Ihnt both lanes arc kept open during
peak periods as previously defi ned. This may be accomplished by the use of steel plates
as specified in Sub-Section 8.8.3.2.
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Whcn the work is sllch Ihal the simultaneolls closing of several lanes cantlot be avoided
and wou ld calise undue interfe rence with tmffic. the work should either be carried oul at
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night or during weekends. However, the S.D. Illay give permission fol' the simultmleous
closing of lanes fo r emergency work.s or other works as dee med necessary.
8.8A.2 Arrangement and Loctl ti on of Signs. Barriers and l3arricades
The ge neral an'a ngeme nl and loctttion of temporary signs at works in progress sha ll be
striclly in accorcla nce wilh ARAHAN TEKNIK (JALAN) 2e/S5, published by
Cawangan JIlIan, Ibu Pejabnt l KR, Kuala Lumpur, and shall be submitted by the
Contra ctor and approved by the S.D. before work co mm ences.
S8-27
JKRlSPJI200B-SB
Work on a road invo lving less than one·third of a tra ffic lane and work on a fOolpnth in
the immed iate vicinit y of the carriageway of a high speed road shall be dee med to be
Illinor obSll11ctiolls. In these C<1ses. as it will not be necessilry 10 close lip one fu ll lane,
approp riate length of bnnoiers shall be lIsed in accordrll1ce to AIW1:AN T EKN IK
(JA LAN) 2el85 or any I.test version of the guideline thereafter.
All traffic signs lIsed in tempormy signing must be I'eflectorised. When praet icable, signs
shall be sited where they will be clen rly visible at all times.
8.8 .4.3 Temporaty Flas hing \\fnm ing La mps
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Temporary flashing warning lamps or beacons shall be used dur ing the hours of darkness
in COl~llncti o ll wit h all temporary signs, barriers and other tra ffic control devices which
are to remain in position atnighl. Lamps shall be kept alight at nil times during the hours
or darkness and shall be placed at sa lient points orthe site every night.
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8.8.4.4 Use of Traffic Guidance Cones
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When a portion of a roadway is closed to traflic by the use 0 bgn'lcrs, ban·icadt'$ or
sig ns, tra ffic gu idance CO lles shall be placed 011 the road so as 0 guide tra ffi c smoot hl y
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fro m the wide section to the 1U'lITOW section in which a p~ of the roadway has been
closed to traffic. 0-
Cones shall be used onl y whe ll the work is in p Gs or where there is a
WtltChmflll who
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can reposition any of the co nes which may Imu een dislodged by the traffi c. Ot herwise
they shall be removed from the roadt 'ay w hen work ceases at night. At ni ght,
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continllollsly operat ing temporary Oasliijig "arning lamps or beacons shall be used to
guide the traffic.
Cones shall be of I11bber or cqu1~lc nt flexible malerial and shall be bright orange.
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8.8.4.5
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For the durati n f the work, a satisfac tory roadway shall be provided for the tramc.
Where a sllfficlen vidth of call"iageway is not ava ilable, a temporary traffic diversion
shaH be COllstl1lcted if possible. The ex tra carriageway shall be properly maintained at all
times for the duration of the work.
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( ~} The QiHel1<lIlCe of pedestrian movement shall be provided by CO llst11lc tton of tempora ry

walks, barricades and handrails. Certain areas along the constl1lction site may be
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restricted to pedestrian use where slich restri ctions urc inlhe interest of pedes trian safety.
8.8.4.6 Temporary Traffic Control

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It is essential tlmt traffic control at the site be exercised diligently and by co mpete nt
pcrsotUlel. (f the need arises.
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The methods of temporary Irnffic control are: -
a. Police .supervisio n: this appl ies where the works arc of n very short dUr<lI ioll wit h
some special fCflturC, slic h as a busy road junction;
b. Ma lllwlly operated 'S top' and 'Go' signs: this applies at works of Shotl dura tion,
provided that traffic is not dCllSe, Red and green fbgs should, under no
circulllstances, be used for traffic control, but could be lIsed to supplcmcnt the disc
signs.
SB-2B
JKRlSPJ/2008-S8
8.8.4.7 Plant and Equipmen t
In nil cases where tfame is permitted to use the whole or a portion of the e.x isling road,
all plant items and similnf ObSllllctions shall be remo ved from the road al night, jf at 1111
practicable. During the day, a red Ilag shall project beyond the ex tremity of all pl fl llt
items (ot her than vehicles) adjacent to the traffic lane.
Plant and equipment shall be Ht al night if within Sill of the edge of the carriageway by
two red lights suspended vertically from the point of obstlllClioll nea rest to the
cfllTiageway. The lights may be omitted in cases where there nre penmment obstructions,
such as trees less than 5111 from the edge of can'iagewny and the plant or equipm ent nre
not close r to the road than the penmlllent obstructions.
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8,8.4,8 Vehicles
Vehicles which call)' out ope rations 0 11 the road and which are required to travel slowly
or to stop at frequent intervflls should be nmde as noticeab le as possible. This shall be
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achieved by painting such vehicles with a distinctive colour, and painting thei r rea r
pOItiolls wi th diagonal stripes of cont rast ing colours, and providing ~s h ing lights on the
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() lap of the vehicles. They sho ul d also have a pla te oil lhe rear side with the words 'S LOW
MOVING' or ' KENDERAAN PERLA HAN',
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8,8.4.9 iVlaintenance ofSjulls lam s l3arrier$ Tem orar
Signs, lamps, barri ers and olher tmfli c canlml a~i~ sha ll be maintained in good order
and in the corrcct position day and night. S i¥~ shall be ncat, clear nnd legible at all
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times. Temporary traffic diversions shall be maintained in good order at all limes,
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S8-29
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REQUIREMENTS OF ISOLATION
TRANSFORMER FOR ROAD TRAFFIC
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CONTROL
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REQUIREMENTS OF ISOLATION TRANSFOMER FOR ROAD TRAFFIC CONTROL
I. The isolation transformer shall comply with LEC6 1558-2- J and shall have CE certifi cation.
2. The isolation transfonner shall be of cast resin construction suitable for outdoor use.
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3. The rating of the isolation transfonner shall not be less than 800 Y A and to be of 230Yac
input voltage and 230Yac output vo ltage, 50 Hz frequency.
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4. The insulation class of the isola tion tran sformer shall be Class 8-130°C.
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5. The windin g class of the isolation transformer shall be Class He -200oe.
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6. The ingress protection shall be IP 20.
7. An electrostatic shield for noise reduction shall be provided between the input and output
w indin gs of the isolation transfom1 er.
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8. The attenuation level at 10kHz for the reducti on of no ise vo ltage between the input and
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output shall be not less than 65 dB.
9. The insulation test voltage shall be:

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4Kv (l min,50 Hz) between primary and secondary

4Kv (1 min,50 Hz) between primary and earth
4Kv ( I min,50 Hz) between secondary and earth
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Section 9 - Concrete (JKRlSPJ/2018-S9)
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KERAJAAN MALAYSIA
JABATANKERJARAYAMALAYSIA
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FOR ROAD WORKS A
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KETUA PENGARAH KERJA RAY A

JABATANKERJARAYAMALAYSJA
JALAN SULTAN SALAHUDDIN.
50582 KUALA LUMPUR.
(JKRlSPJ/2018-S9)
FOREWORD
As practices in road construction change over time, it is imperative that Jabatan Kerja Raya
(JKR) to continuously update and improve their standard specifications. These new
specifications are not only aimed at keeping abreast with current technologies but also to
help improve the quality of construction works and its final product. Consequently, these new
specifications will ultimately have a significant positive impact on the construction industry
especially with the incorporation of new products and technologies.
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The JKR Standard Specification for Road Works is an essential document in the road
infrastructure construction industry. This Specification provides an improved guidance in the
material selection and quality control of workmanship and products, based on current best
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practices. The purpose of the JKR Standard Specification is to establish uniformity and
compliance in road design and construction and to be used by road designers, road
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authorities, manufacturers and suppliers of road related products.
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Concrete", is a part of a series of improved specifications in the JKR Standard Specification
for Road Works. The compilation of this document was carried out through a series of
discussions that had been held by the technical committee. The draft had also been
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presented and discussed at length in a specially held workshop to get feedback and
comments from relevant parties involved, which were then carefully studied and incorporated
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into the Specification wherever appropriate or necessary.
The Specification has also gone through different phases of vetting and approval before the
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production of its final draft and printed copy. It shall be reviewed and updated from time to
time to cater for any changes in policies and the inclusion of current requirements, if
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necessary. Any feedback or improvement to be considered for future revisions should be

forwarded to Sahagian Pembangunan Inovasi & Standard, Cawangan Jalan, JKR Malaysia.
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Published by: -
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Cawangan Jalan
Ibu Pejabat Jabatan Ke~a Raya
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Tingkat 21 , Menara PJD,

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50400 Kuala Lumpur.

Email: ussj.jkr@lgovuc.gov.my
July 2018
S9-i
(JKRlSPJ/2018-S9)
ACKNOWLEDGMENT
This "Standard Specification for Road Works - Section 9: Concrete" has been prepared
by a technical committee comprising of the following members;
Committee Members:
Late Ir. Abd Rahman bin Salleh ( Chairperson till April 2018) JKR
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Ir. Atikah binti Zakaria @ Ya ( Chairperson from April 2018 ) JKR
Ir. Dr. Fairul Zahri bin Mohamad Abas JKR
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Ir. Nor Azian binti Aziz JKR
n Ir. Tuan Khusairry bin Tuan Abdul Manaf
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JKR
Ir. Ihsan@Hasni bin Atan JKR
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Ir. Lee Cheong Siang JKR
En. Wan Zuhaimie bin Wan Salleh JKR
En. Sufiyan bin Zakaria JKR
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Ir. Wong Thian Chiun JKR
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Pn Nur Qistina binti Abdullah JKR

Prof. Madya Ir. Dr. Raizal Saifulnaz bin Muhammad UPM
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Cik Farah Zuhana binti Zullkefle JKR

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) Ir. Mohd Azahar bin Don

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Finally, the publisher would like to express its gratitude to the above committee members,
and all those who were involved, directly or indirectly, for their tireless effort and contribution
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towards the successful completion of this document.

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Appreciation also goes to Dato' Ir. Haji Che Noor Azeman Bin Yusoff, the Director of Pakar
Kejuruteraan Jalan & Jambatan, Cawangan Jalan, JKR and Ir. Abdul Mutalif bin Abdul Hameed,
the former Director during whose tenure the document was initiated, for their full support and
cooperation throughout the preparation and compilation of the document.
S9-ii
(JKRlSPJ/2018-S9)
SECTION 9 - CONCRETE
PAGE
9 .1 GENERAL
9.1 .1 Classification of Concrete Mixes 59-1
9.1.2 Prescribed Concrete 59-1
9.1 .3 Designed Concrete 59-1
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9.1.4 Requirements for Concrete 59-2
9.2 MATERIAL
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9.2.1 Cement 59-3
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9.2.2 Aggregates 59-4
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9.2.3 Water 59-5
9.2.4 Admixtures 59-5

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9.2.5 Additions 59-6
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9.3 CONCRETE CONFORMANCE AND IDENTITY TESTING
9.3.1 Evaluation of Conformity 59-8

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9.3.2 Conformity Control for Designed Concrete 59-10
9.3.3 Non-conformity of Product 59-12

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9.3.4 Identity Testing 59-13

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9.4.1 General 59-15

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9.4.2 Production Control 5ystem 59-15
9.4.35upervision 59-15
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9.4.4 5ite Mixed Concrete 59-15

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9.4.5 Ready Mixed Concrete 59-16
9.4.6 Transporting 59-17
9.4.7 Placing 59-17
9.4.8 Placement Temperature 59-18
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(JKRlSPJ/2018-S9)
SECTION 9 • CONCRETE
PAGE
9.4.9 Compaction 59-19
9.4.10 Curing and Protection 59-20
9.5 CONSTRUCTION WITH CONCRETE
9.5.1 Geometry Control 59-21
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9.5.2 Dimensional Deviations 59-22
9.5.3 Construction Joints 59-24
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9.5.4 Fixing Blocks, Brackets, Built in Bolts, Holes, Chases, etc 59-25
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(j 9.5.5 Movement Joints 59-26
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9.5.6 5ealant and 5pecial Materials 59-27
9.6 STEEL REINFORCEMENT
9.6.1 General 59-28

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9.7 FORMWORK AND SURFACE FINISH FOR STRUCTURE
9.7.1 Design and Construction 59-31

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9.7.2 5urface Finish for Concrete 59-34
9.7.3 Preparation of Forms before Concreting 59-36

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9.7.4 Removal of Forms 59-37

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9.7.5 Inspection and Making Good 59-37
9.8 MASS AND LEAN CONCRETE 59-38

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9.9 STRUCTURE ACCURACY 59-38

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9.10 APPARATUS 59-38
9.11 PRECAST CONCRETE CONSTRUCTION
9.11 .1 Manufacture Off-5ite 59-39
9.11.2 5torage 59-40
9.11 .3 Handling and Transport 59-40
9.11.4 Assembly and Erection 59-40
S9-iv
(JKRlSPJ/2018-S9)
PAGE
9.11 .5 Forming Structural Connections S9-40
9.11 .6 Protection S9-41
9.12 OTHER CONCRETE WORKS
9.12.1 Abutments, Piers, Pile Caps and Foundation S9-41
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9.12.2 Deck Slab S9-42
9.12.3 Shop Drawing S9-43
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9.12.4 Drips S9-44
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9.12.5 Openings S9-44
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9.13 PROTECTIVE COATING SYSTEM
9.13.1 General 59-44
9.13.2 Surface Preparation 59-45

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9.13.3 Coating Materials to Deck Soffit, Girder, R.C. Diaphragms,
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Capping Beam, etc. 59-45

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9.13.4 Coating Materials to All Abutments and Piers 59-46
9.13.5 Protective Coating for Aesthetical and Decorative Purpose S9-47

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9.14 HIGH PERFORMANCE AND ULTRA-HIGH PERFORMANCE CONCRETE
9.14.1 General Requirements 59-48

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9.14.2 Material 59-49

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9.14.3 Concrete Conformance and Identity Testing S9-51
9.14.4 Production S9-52

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(JKRlSPJ/2018-S9)
PAGE
Table 9.1 Composition Of Common Cements S9-54
Table 9.2 Testing Of Aggregates S9-55
Table 9.3 Grading For Coarse Aggregate S9-55

Table 9.3A : Grading For Fine Aggregate S9-55
Table 9.3B : Grading For Fine Aggregate For HPC, UHPC S9-56
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Table 9.4 Admixture Acceptance Test Requirements S9-56
Table 9.5 Prescribed Mixes for General Use per Cubic Meter Of Concrete S9-57
By Weight Batching
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Table 9.5A : Proportion And Strength Requirements For Prescribed Mixes By S9-57
Volume Batching
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Table 9.6 Durability Recommendations For Reinforced Or Prestressed S9-58
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Elements With An Intended Working Life Of At least 50 Years
Table9.6A : Minimum Cement Content For Maximum Aggregate Sizes Other S9-59
Than 20 mm
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Table 9.7 Slump Classes S9-59
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Table9.7A : Compaction Classes S9-59
Table9.7B : Vebe Classes S9-59
Table9.7C : Flow Classes S9-59
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Table 9.7D : Consistence Suitable For Different Uses Of In-situ Concrete S9-60
Table 9.7E : Maximum Total Chloride S9-60
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Table 9.8 Compressive Strength Classes For Normal Weight And Heavy S9-60
Weight Concrete
Table 9.9 Compressive Strength Classes For Light Weight Concrete S9-61
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( ) Table 9.10 : Minimum Rate Of Sampling For Assessing Conformity S9-61

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Table 9.11 : Conformity Criteria For Compressive Strength S9-61
Table 9.12 : Compressive Strength Requirements For Prescribed Mix S9-62

Table 9.13 : Identity Criteria For Compressive Strength S9-62
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Table 9.14 : Identity Criteria For Slump Specified As A Slump Class S9-62
Table 9.15 : Identity Criteria For Slump Specified As A Target Value S9-62
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Table 9.16 : Recorded Data And Other Documents S9-63
Table 9.17 : Characteristic Strength Of Steel Reinforcement S9-63

Table 9.18 : Minimum Periods Between Concreting And Removal Of Forms S9-63
S9-vi
(JKRlSPJ/2018-S9)
9.1 GENERAL
This section shall apply to the construction of all structures or parts of structures to
be composed of concrete. with or without steel reinforcement. The work shall be
carried out all in accordance with this Specification and the lines, levels, grades,
dimensions and cross-sections shown in the Drawings and as required by the S.O.
9.1.1 Classification of Concrete Mixes
This subsection describes the classification of concrete mixes to be used in
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roadworks construction.
9.1.1.1 The concrete mix shall be designed concrete to MS EN 206-1 and

MS EN 206-2 unless otherwise stated in the Drawings or in the
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Tender Related Documents. However, prescribed concrete may
be used subjected to the following and as approved by S.O:
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(i) The work is of minor nature or involving a small quantity
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of concrete
(ii) Prior approval is given by the S.O.
(iii) The Contractor shall be responsible for the strength of the
concrete
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(iv) Only CEM I cement is speCified to be used
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9.1.1 .2 When other than CEM I cement is specified to be used, the concrete
mix shall be of designed concrete only.
9.1.1 .3 When the composition of concrete consists of additions such as

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steel or polymer fiber or any advanced cementitious materials, the

concrete mix shall be of designed concrete only.
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9.1.2 Prescribed Concrete
9.1.2.1 Prescribed concrete shall conform to MS EN 206-1 and MS EN

206-2. Prescribed concrete shall be as detailed in TABLE 9.5. The
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mix prescribed in the table does not require the use of admixture.
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9.1.2.3 For small volume concreting work, volume batching is permitted

provided prior approval of the S.O. is obtained. The proportion
shall be as specified in TABLE 9.5 A
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9.1 .3 Designed Concrete

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9.1.3.1 DeSigned concrete shall comply with the recommendations of

MS EN 206-1 and MS EN 206-2. The minimum cement content
and maximum free water to cement ratio to be used shall be as
shown on TABLES 9.6 and 9.6 A.
9.1.3.2 DeSigned concrete with intended use for High Performance

(HPC) and Ultra-High Performance concrete (UHPC) for the
purpose of strength and durability shall be in accordance to
Subsection 9.14 of this specification. Concrete is deemed as High
Performance (HPC) or Ultra-High Performance (UHPC) type
when it is mentioned in the Drawings, Bill of Quantities, Tender
Documents or whenever required by the S.O. for the purpose of
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strength and/or durability or concrete that possesses advanced

cementitious-based composites materials which is also described
in Subsection 9.14 of this specification.
9.1.3.3 The Contractor shall comply with the following requirements:
(i) Notify the S.O. whether the designed concrete is to be

produced as site-mixed or ready-mixed.
(ii) If the Contractor chooses to use ready mix concrete, he shall

notify the S.O. the name of the supplier, location of the ready
mix plant, journey time taken to transport the concrete to the
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Site and production capacity of the plant.
(iii) Submit a mix design report covering all concrete mixes to the
S.O. for approval. The designed concrete shall comply with the
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requirements specified in TABLES 9.6 and 9.6A.
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(iv) The Contractor shall ensure that the S.O. be permitted to visit
or station his representative at the plant at any stage of the
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concrete production.
9.1.4 Requirements for Concrete

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9.1.5.1 Concrete grade
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The grade of concrete to be used in the Works shall be as
stated in the Drawings, Tender Documents and/or in the Bill of
Quantities. Concrete shall be designated as Grade C XJY where 'X'
is minimum characteristic cylinder strength in N/mm 2 , and 'Y' is
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minimum characteristic cube strength in N/mm 2• For prescribed

mix, a suffix 'P' shall be added after 'X'.
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9.1.5.2 Cement content
(i) Cement content in this Specification shall refer to , the total

quantity of cement as approved in Subsection 9.2.1, or the
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total quantity of cementitious materials comprising Portland

cement and other constituents complying to MS EN 197-1 .
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(ii) Minimum cement content
The minimum cement content shall be in accordance with

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TABLES 9.6 and 9.6 A, unless otherwise shown on the

Drawings
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(iii) Maximum cement content
The maximum cement content shall not exceed 550

kg/ml unless otherwise shown on the Drawings or as
approved by the S.O. Cement content for HPC and UHPC
shall be in accordance to Subsection 9.14 of this
specification.
9.1.5.3 Consistency
(i) The consistency of the fresh concrete shall be judged by its

suitability for the condition of handling, workability and placing
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so that after compaction, it surrounds all reinforcement,

tendons and ducts and completely fills the formwork.
Consistency of the concrete shall be within one of the following
limits:
(a) Slump classes (Refer to TABLE 9.7)

(b) Compacting classes (Refer to TABLE 9.7A)
(c) Vebe classes (Refer to TABLE 9.7B)
(d) Flow classes (Refer to TABLE 9.7C)
(ii) Unless specified otherwise in the Drawings, consistent values
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expressed as slump and flow classes appropriate to the
different uses of concrete shall be as given in TABLE 9.70.
9.1.5.4 Total chloride content
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The total chloride content of the concrete mix arising from the
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aggregate or any other source shall not, under any circumstance,
exceed the limits in TABLE 9.7E expressed as a percentage of
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relationship between chloride ions and weight of cement in the mix.
When necessary, tests shall be carried out in accordance with BS
1881 : Part 124 for each grade of concrete, to demonstrate
that these limits are not exceeded.
A
9.1.5.5 Maximum sulphate content
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The total estimated sulphate content of any mix, including that

present in the cement shall not exceed 4% by weight of cement
in the mix. Where necessary, tests shall be carried out in
M
accordance with BS 1881: Part 124 for each grade of concrete to

demonstrate that this limit is not exceeded.
EN
9.1.5.6 Cement Additions
Pulverized Fly Ash (PFA) or Ground Granulated Blast-fumace Slag

(GGBS) with or without Silica Fume as approved in Subsections
M
9.2.4 and 9.2.5 shall be added to the mix to achieve not only the
specified strength but also meet the permeability requirement to
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enhance the durability of the concrete or any other specific

requirements.
When cement additions are used for structure close to the sea,
O
exposed to sea water spray or breeze, or subjected to high chloride

or sulphate exposure, then permeability requirements as per
D
Subsection 9.3 .2.2 shall be carried out or as deemed necessary by

the S.O.
9.2 MATERIAL
9.2.1 Cement
9.2.1.1 The cement to be used throughout the Works shall be cement

obtained from SIRIM-Certified manufacturer. The cement shall be
described and complied with MS EN 197-1 as shown in TABLE 9.1.
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9.2.1.2 Certificates of tests
Manufacturers' certificates of tests shall in general be accepted

as proof of soundness. Additional tests shall be carried out on any
cement which appears to have deteriorated through age, damage
to containers, improper storage, or any other reason. The test shall
be carried out at any approved laboratory in accordance with MS
EN196 at the expense of the Contractor. Any batch of cement that
has been sampled and tested and found not to have complied with
the requirements shall be rejected and removed from the Site.
The S.D. may, without tests being made, order that any bag
ER
of cement, a portion of the contents of which has hardened, or which
appears to be defective in any other way, be removed from the Site.
9.2.1.3 Transportation and storage
D
The cement shall be transported to the Site in covered vehicles
()
N
adequately protected against water. It shall be stored in a
weatherproof cement store to the approval of the S.D . Cement
TE
stored in bags shall not be laid directly on the ground. It shall be
taken for use in the Works in the order of its delivery into the store.
Cement delivered in bulk shall be stored in purposely built silos of
an approved design.
A
9.2.2 Aggregates
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9.2.2. 1 Aggregates shall be naturally occurring sand, granite or limestone,

crushed or uncrushed, except as otherwise specified, and shall
M
comply with MS EN 12620. They shall be obtained from a source

approved by the S.D . Marine aggregates shall not be used.
9.2.2.2 Coarse aggregates

EN
Coarse aggregates shall comply with MS EN 12620. For work below

ground level, only crushed granite shall be used. Unless otherwise
(.J speCified in the Drawings, tests shall be carried out according to MS
M
30. The property limits shall be as specified in TABLE 9.2. The

maximum nominal size of aggregate shall be as specifi ed in the
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Drawings.
9.2.2.3 Fine aggregates

O
Fine aggregates shall comply with MS EN 12620. In the context of

MS EN 12620, the term 'sand' is used to mean 'fine aggregate'.
D
Unless otherwise specified in the Drawings, tests shall be carried out

in accordance with MS 30. The property limits shall be as specified
in TABLE 9.2.
9.2.2.4 Grading
(i) Coarse aggregates
The grading of coarse aggregates shall be analysed as

described in MS 30 and shall be within the limits specified in
TABLE 9.3.
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(ii) Fine aggregates
The grading of fine aggregates shall be analysed as described in

MS 30 and shall be within the limits specified in TABLE 9.3A.
However, for prescribed mixes Grading Limit M only shall be
used.
9.2.2.5 Sampling and testing of aggregates
Where site mixing is used, samples of fine and coarse aggregates

approved by the S.O. shall be kept on Site. These samples shall give
a fair indication of the general quality of the aggregates for
ER
comparison with the aggregates delivered during the course of
executing the work. Tests shall be carried out on samples of the
latter, taken at intervals as required by the S.O., or whenever there
D
is a change of source. The appropriate method of sampling and
testing shall be in accordance with the standards as speCified in
N
TABLE 9.2. Any batch of aggregate rejected by the S.O. shall be
removed from the Site.
TE
9.2.2.6 Storage of aggregates
Separate storage facilities with adequate provision for drainage

shall be provided for each different size of aggregate used.
A
Aggregate shall be handled and stored so as to minimize
segregation and contamination.
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9.2.3 Water
M
Water shall comply with the requirements of MS EN 1008. It shall be clean

and free from materials deleterious to concrete in the plastic and hardened
state and shall be from a source approved by the S.O. The S.O. may instruct
EN
the Contractor to carry out chemical tests at any approved laboratory at the
expense of the Contractor. The Contractor shall make adequate
arrangement to supply and store sufficient water at the Site to be used in
mixing and curing of concrete.
M
9.2.4 Admixtures J
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9.2.4.1 Suitable admixtures may be used in concrete mixes with the prior
approval of or as directed by the S.O.
9.2.4.2 The admixtures, the sampling and testing of the admixtures

O
and the information to be provided with the admixture supplied

shall comply with MS EN 934 Pt. 1- 6.
D
9.2.4.3 All admixtures shall be used strictly in accordance with

manufacturers recommendation.
9.2.4.4 Before allowing the admixture to be used in the Works, relevant

tests based on trial mixes shall be carried out. A control mix shall
be made using a conventional trial mix that is without using the
admixture in order to determine the free water to cement ratio and
mix proportion required to give the specified strength with the
required slump. Using the same mix proportion as in the control
mix but with a modified water to cement ratio whenever necessary,
a test shall be carried out using the recommended dosage of the
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admixture. The results of the relevant test obtained from the

control mix and test mix shall be compared. The S.O. may
allow the use of the admixture only when the results are found
to be satisfactory and comparable to the effects as claimed by the
manufacturer. The admixture acceptance test shall comply with the
requirements specified in TABLE 9.4.
9.2.4.5 The use of admixtures that are of chloride based type are not
permitted for structural concrete containing reinforcement,
prestressing tendons or other embedded metal. The Contractor
shall submit documentary evidence of the contents of the
admixture to be used.
ER
9.2.4.6 When the Contractor proposes the use of water reducing
admixtures, special control tests shall be carried out with prior
approval of the S.O. The tests shall be carried out in accordance
D
with TABLE 9.4 or the latest established standard and with the
manufacturer's recommendations, as approved by the S.O.
N
9.2.4.7 If two or more admixtures are proposed to be used
TE
simultaneously in the same concrete mix, the Contractor shall
furnish the S.O. with the supporting data on their suitability and
compatibility.
A
9.2.5 Additions
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9.2.5.1 Addition Type I, nearly inert addition. General suitability as type I

addition is established for:
M
(i) filler aggregate conforming to MS EN 12620 or BS EN 13055;
(ii) pigments conforming to BS EN 12878; for reinforced concrete,

only category B pigments
EN
9.2.5.2 Addition Type II, Pozzolonic or latent hydraulic addition. General

suitability as type II addition is established for:
u
M
(i) Fly ash (V, W) conforming to MS EN 450-1 ; Ash obtained by

methods other than electrostatic or mechanical precipitation of
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dust-like particles from the flue gases from furnaces fired with
pulverized coal shall not be used in cement that conforms to
MS EN 197-1 .
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(a) Siliceous fly ash is a fine powder of mostly spherical

particles having Pozzolanic properties. It consists
D
essentially of reactive silicon dioxide (Si02) and

aluminium oxide (AI203). The remainder contains iron
oxide (Fe203) and other compounds. The proportion of
reactive calcium oxide shall be less than 10.0 % by mass,
the content of free calcium oxide, as determined by the
method described in BS EN 451-1 shall not exceed 1.0 %
by mass. Fly ash having a free calcium oxide content
higher than 1.0 % by mass but less than 2.5 % by mass
is also acceptable provided that the requirement on
expansion (soundness) does not exceed 10 mm when
tested in accordance with MS EN 196-3 using a mixture
of 30 % by mass of siliceous fly ash and 70 % by mass of
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a CEM I cement conforming to MS EN 197-1. The

reactive silicon dioxide content shall not be less than
25.0% by mass.
(b) Calcareous fly ash is a fine powder, having hydraulic

and/or Pozzolanic properties. It consists essentially of
reactive calcium oxide (CaO), reactive silicon dioxide
(SiO,) and aluminium oxide (AI, 0 3). The remainder
contains iron oxide (Fe,03) and other compounds. The
proportion of reactive calcium oxide shall not be less than
10% by mass. Calcareous fly ash containing between
10% and 15% by mass of reactive calcium oxide shall
ER
contain not less than 25% by mass of reactive silicon
dioxide. Adequately ground calcareous fly ash containing
more than 15% by mass of reactive calcium oxide, shall
have a compressive strength of at least 10.0 N/mm' at 28
D
days when tested in accordance with MS EN 196-1.
Before testing, the fly ash shall be grounded and the
N
fineness, expressed as the proportion by mass of the ash
retained when wet sieved on a 40Jlm mesh sieve, shall be
TE
between 10% and 30% by mass. The test mortar shall be
prepared with ground calcareous fly ash only instead of
cement. The mortar specimens shall be demoulded 48hrs
after preparation and then cured in a moist atmosphere of
A
relative humidity of at least 90% until tested . The
expansion (soundness) of calcareous fly ash shall not
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exceed 10mm when tested in accordance with MS EN

196-3 using a mixture of 30% by mass of calcareous fly
ash grounded as described above and 70% by mass of a
M
CEM I cement conforming to MS EN 197-1 .
(ii) Silica fume conforming to BS EN 13263-1; Silica fume

EN
originates from the reduction of high purity quartz with coal in

electric arc furnaces in the production of silicon and
ferrosilicon alloys and consists of very fine spherical particles
containing at least 85% by mass of amorphous silicon dioxide.
M
Silica fume shall meet the following requirements:

KU
The loss on ignition shall not exceed 4% by mass

determined in accordance with MS EN 196-2 but using
an ignition time of 1 hour.
The specific surface (BET) of the untreated silica fume

O
shall be at least 15.0 m2/g when tested in accordance

with ISO 9277.
D
For intergrinding with clinker and calcium sulfate the silica

fume may be in its original state or compacted or pelletized
(with water).
(iii) Grounded Granulated Blast-fumace Slag conforming to

MS EN 15167-1 .
Burnt shale, specifically burnt oil shale, is produced in a special

kiln at temperatures of approximately 800'C. Owing to the
composition of the natural material and the production process,
burnt shale contains clinker phases, mainly dicalcium silicate
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and monocalcium aluminate. It also contains, besides small

amounts of free calcium oxide and calcium sulfate, larger
proportions of Pozzolanically reacting oxides, especially silicon
dioxide. Consequently, in a finely grounded state burnt shale
shows pronounced hydraulic properties like that of Portland
cement and, in addition pozzolanic properties.
Adequately grounded burnt shale shall have a compressive

strength of at least 25,0 N/mm2 at 28 days when tested in
accordance with MS EN 196·1 . The test mortar shall be
prepared with finely grounded burnt shale only instead of
cement. The mortar specimens shall be demoulded 48hrs after
ER
preparation and cured in a moist atmosphere of relative
humidity of at least 90% until tested.
D
The expansion (soundness) of burnt shale shall not exceed
10 mm when tested in accordance with MS EN 196·3 using a
N
mixture of 30% by mass of grounded burnt shale and 70% by
mass of a CEM I cement conforming to MS EN 197·1 .
TE
9.3 CONCRETE CONFORMANCE AND IDENTITY TESTING
9.3.1 Evaluation of Conformity

A
9.3.1.1 General
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The Contractor is responsible for the evaluation of conformity for

specified requirements of the concrete. For this purpose, the
M
Contractor shall carry out the following tasks:
(i) Initial test,

EN
(ii) Production control including conformity control
9.3.1 .2 Concrete composition and initial testing

(i) Initial test is required for designed mix concrete only.
M
(ii) In the case of using a new concrete composition, initial testing

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shall be performed to provide a concrete that achieves the

specified properties or intended performance with an adequate
margin of strength. The concrete design and design
relationships shall be re-established in the case of a prescribed
O
concrete.
D
(iii) New concrete composition shall be reviewed periodically to

provide assurance that all concrete designs are still in
accordance with the actual requirements, taking into account
of the change in properties of the constituent materials and
the results of conformity testing on the concrete compositions.
(iv) Concrete for structures or members of structures in non·

abrasive, insignificant chloride attack environment or deemed
not to have been exposed to durability risk can be relieved from
permeability test requirements in this subsection, subjected to
S.O approval. Otherwise, or if it is mentioned in the drawings,
the permeability test shall be conducted in full to the S.O.'s
approval and acceptance.
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(v) Testing and compliances for HPC and UHPC shall be cross-
referenced with Subsection clause 9.14 of this specification.
9.3.1.3 Initial tests
(i) Frequency of initial tests
Initial test shall be repeated if there has been a significant

change either in the constituent materials or in the specified
requirements on which the previous tests were based .
ER
(ii) Test conditions
(a) In general, initial test shall be carried out on fresh concrete

with a temperature 27±2°C
D
(b) For the initial test of single concrete composition, at least
N
three (3) specimens from each of three (3) batches shall be
tested.
TE
(c) The strength of each batch or load shall be taken to be the
average of the three (3) specimen test results. The result of
the initial test of the concrete is the average strength of all
batches or loads.
A
(iii) Criteria for adoption of initial tests
EJ
For assessing the properties of concrete, in particular those

of fresh concrete, the differences between the type of mixer
M
and mixing procedure applied during the initial test and those
applied during actual production shall be taken into account.
EN
The compressive strength of the concrete with the

composition to be adopted for the actual case shall exceed the
characteristic strength, fel< values of TABLE 9.8 or TABLE 9.9
by an adequate margin. This margin shall be at least that
M
needs to satisfy the confonnity criteria given in Subsection

9.3.2.1(iii). The margin should be twice the expected Standard
KU
Deviation «(j) which means at least a margin of 6 Nfmm2 to

12Nfmm2 depending on the production facilities, the
constituent materials and the available background infonnation
about the variation.
O
The consistency of the concrete shall be within the limits of the

D
consistence class as in TABLE 9.7 orf and TABLE 9.70 at the

time at which the concrete is likely to be placed or delivered in
the case of ready mixed concrete .
For other properties that are specified, the concrete shall meet
the specified values with an appropriate margin as approved
by the S.O.
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9.3.2 Conformity Control for Designed Concrete
9.3.2.1 Conformity control for compressive strength
(i) General
(a) For normal-weight and heavy-weight concrete of

strength classes from CB/10 to C55/67 or light-weight
concrete from LCB/9 to LC55/60, sampling and testing
shall be performed on individual concrete compositions.
(b) In the sampling and testing plan, the conformity
ER
criteria of an individual concrete compositions distinction
are made between initial production and continuous
production. Initial production covers the production
until at least 35 test results are available.
D
(c) Continuous production is achieved after at least 35 test
N
results of initial production are obtained over a period not
exceeding 12 months.
TE
(d) Any continuation in the case of production of an
individual concrete composition that has been
suspended for more than 12 months, the criteria,
A
sampling and testing plan that are given for initial
production criteria shall be resorted and adopted.
EJ
(e) During continuous production, the sampling and

testing plan and the criteria for initial production may be
M
adopted.
(f) If the strength is specified for a different age of concrete,

EN
the conformity shall be assessed on specimens tested at

that specified age unless stated otherwise.
(g) Identity testing shall be carried out in accordance with

M
Subsection 9.3.4 in order to verify that a defined volume

comes from a conforming population.
KU
(h) While work on concreting is in progress, tests on

consistency of the mix shall be carried out at suitable
intervals and, in addition, whenever any materials or the
O
proportions of the mix are changed , or when directed by

the S.O.
D
(ii) Sampling and Testing
(a) Samples of concrete shall be randomly selected and taken

in accordance with EN 12350-1. The minimum rate of
sampling and of testing of concrete shall be in accordance
with TABLE 9.10 at the rate that gives the highest number
of samples for initial or continuous production, as
appropriate.
(b) The samples shall be taken after any water or admixtures

are added to the concrete, but sampling before adding
water reducing agent to adjust the consistence is
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permitted where there is proof by initial testing that the

water reducing agent to be used has no negative effect on
the strength of the concrete.
(c) The test result shall be that obtained from an individual

specimen or the average of the results when two or more
specimens made from one sample are tested at the same
age.
(d) Where two or more specimens are made from one sample
and the range of the test values is more than 15% of the
mean, the result shall be disregarded unless an
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investigation reveals an acceptable reason to not justify
disregarding of an individual test value.
(e) The initial testing process shall be witnessed by the S.D.
D
representative prior to further production of concrete or as
advised by S.D.
N
(iii) Conformity criteria for compressive strength
TE
(a) Conformance assessment shall be made on test
results taken during an assessment period that shall
not exceed the last twelve months.
A
(b) Conformance of concrete compressive strength is
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assessed on specimens tested at 28 days in
accordance with criteria given in TABLE 9.11:
Groups of n non-overlapping or overlapping

M
consecutive test results fcm (Criterion 1)
Each individual test result fel (Criterion 2)

EN
(c) Conformance is confirmed if both the criteria given in

TABLE 9.11 for either initial or continuous production
are satisfied.
M
(d) Initially, the standard deviation shall be calculated from

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at least 35 consecutive test results taken over a period

exceeding three months and which is immediately prior
to the production period during which conformity is to
be checked. This value shall be taken as the estimate
O
of the standard deviation (u) of the population. The

validity of the adopted value shall be verified during the
D
subsequent production using Method 1 as stated below.

However, Method 2 may be used if approved by the
S.D.
Method 1
The initial value of standard deviation may be
applied for the subsequent period during which
conformity is to be checked, provided the
standard deviation of the latest 15 results (u,s)
does not deviate significantly from the adopted
standard deviation. This is considered valid
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provided:
0.63as a'5s1.37a
Where the value of 015 lies outside these

limits, a new estimate of ashall be determined
from last available 35 test results.
Method 2
The new value of a may be estimated from a
continuous system and this value is adopted. The
sensitivity of the system shall be at least that of
ER
Method 1.
9.3.2.2 Permeability requirements
D
(i) Initial Surface Absorption Test (ISAT)
N
(a) ISAT shall be carried out on samples of different
components of the bridge or culvert structures before the
TE
mix designs are approved. The samples shall be
150mm x 150mm x 150mm cubes cut from the sample
in accordance with 8S1881-208 between 28 and 40
days after casting and water cured of the samples. The
A
maximum values shall not exceed the following limits at
10 minutes after starting the test:
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In-situ constructions: less than 0.1Oml/m 2/s

Precast concrete elements: less than 0.1 Oml/m 2/s
M
(b) During construction, the ISAT test shall be similarly

carried out on test samples and will form one of the basis
for rejecting or accepting the concrete elements.
EN
(ii) Rapid Chloride Permeability Test (RCPT)

M
(a) In addition to ISAT, RCPT shall be carried out using

) cores taken from the 150mm x 150mm x 600mm
samples cast, in accordance with AASHTO T277;
KU
"Standard Method of Test for Rapid Determination of the

Chloride Permeability of Concrete" and ASTM C1202;
"Standard Test Method for Electrical Indication of
Concrete's Ability to Resist Chloride Ion Penetration".
O
The following limits shall not be exceeded:

D
In-situ construction: 1000 coulombs

Precast concrete elements: 800 coulombs
(b) During construction, the ISAT test shall be similarly

carried out on test samples and will form one of the basis
for rejecting or accepting concrete elements.
9.3.3 Non-conformity of Product
9.3.3.1 The following actions shall be taken by the Contractor in the

event of non- conformity:
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(i) Check test results and if invalid, take action to eliminate

errors;
(ii) If non-conformance is confirmed e.g. by retesting, take

corrective actions including a management review of the
relevant production control procedures;
(iii) Where it is confirmed of non-conformance with the

specification that was not obvious at delivery, immediate
notice shall be given to the S.O. in order to avoid any
consequential damage;
ER
(iv) Record actions on the items above
9.3.3.2 If the Contractor has given notice of non-conformance of the

concrete or if the results of conformance tests do not fulfill the
D
requirements, supplementary testing according to MS EN 12504-
1 on cores taken from the structure or components or a
N
combination of tests on cores and non-destructive tests on the
structure or in structural components as given in MS EN 13791
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shall be instructed by the S.O.
9.3.3.3 For non-conformance on the 28-day compressive strength, the

section of work represented by the samples which fail the test
A
carried out in accordance with Subsection 9.3.2.1 shall be
removed.
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9.3.4 Identity Testing

M
9.3.4.1 General
Identity testing indicates whether the defined volume of concrete

EN
in question belongs to the same population as that verified as

conforming to the characteristic strength via conformity
assessment.
M
9.3.4.2 Identity testing for compressive strength

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(i) Sampling and testing plan
(a) The sampling rate for identity testing shall be as

follows:
O
One sample for concrete volume less than

10.0 m3 of structures e.g. drains, road barriers,
D
sumps, road kerbs, parapet, culverts etc.
One sample per 10.0 m3 or every group of 10

batches for critical structures e.g., piled
embankment slab, retaining walls, bored piles,
deck slabs, abutments, piers, Substructures, pile
caps, beams, etc.

batches e.g. rigid pavements, drains, road barriers,
sumps, road kerbs, parapet, etc,
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batches e.g. raft foundation and mass concrete.
(b) Sample that consist of minimum of three (3) specimens

shall be taken from different batches or loads in
accordance with BS EN 12350-1. Test specimens shall
be prepared and cured in accordance with MS EN
12390-2. The compressive strength of the specimens
shall be determined in accordance with MS EN 12390-
3. The test result shall be that obtained from the average
of the results of two (2) or more specimens made from
ER
one sample for testing at the same age. Where the range
of test values is more than 15% of the mean, the results
shall be disregarded unless an investigation reveals an
acceptable reason to not justify disregarding an
D
individual test value.
Cube strength tested at 7 day:
N
One cube from each sample batch shall be tested for the
TE
seven (7) days compressive strength. The cube compressive
strength shall not fall below the corresponding values given in
TABLE 9.12 for prescribed concrete, and two-third (2/3) of the
twenty eight (28) days compressive strength for designed
A
concrete.
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9.3.4.3 Identity criteria for compressive strength
(i) Concrete under production control certification

M
(a) Identity of concrete is assessed for each individual

strength test result and the average non-overlapping
discrete results as identified in TABLE 9.13.
EN
(b) Concrete is deemed to have come from a conforming

population if both the criteria in TABLE 9.13 are satisfied
for n results derived from strength tests on samples
M
(
~
) taken from the defined volume of concrete.
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(ii) Concrete not under production control certification
From the defined volume of concrete, at least three (3)

samples shall be taken for testing . The concrete is deemed to
O
have come from a conforming population if the conformity in

Subsection 9.3.2.1(iii) and TABLE 9.11 for initial production is
D
satisfied.
9.3.4.4 Identity testing for slump and flow
(i) Sampling and testing plan
(a) The sampling shall be either:
- In accordance with MS 26-1- 1; or

- Measured using a spot sample obtained from the initial
discharge, if concrete is delivered in a truck mixer or
agitating equipment. The spot sample shall be taken
after a discharge of approximately 0.3 m 3 by taking six
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(6) increments from the moving stream of concrete in

accordance with MS 26-1-1 .
(b) The sample shall be remixed on a non-absorbent

surface and tested for slump or flow. Slump shall
be measured in accordance with MS 26-1-2. Flow
shall be measured in accordance with MS 26-1-5.21 .
9.3.4.5 Identity criteria for the slump of an individual batch
If the measured slump meets the requirements specified in TABLE

9.14 and/or is within the tolerance specified in TABLE 9.15, the
ER
identity test confirms that the batch conforms to MS EN 206: Part
1 with respect to consistency.
For identity criteria for flow, reference shall be made to MS 523-2;
D
Annex B.
N
TE
9.4.1 General
All concrete shall be subjected to production control under the responsibility

of the Contractor.
A
Production control comprises all measures necessary to maintain the
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properties of concrete in confonmance to specified requirements. It includes:
(i) selection of materials.

M
(ii) concrete design.

(iii) concrete production.
(iv) inspection, sampling and tests.
EN
(v) the use of the results of test on constituent materials, fresh and
hardened concrete and equipment.
(vi) for ready-mixed concrete, inspection of equipment used in
transporting fresh concrete .
M
9.4.2 Production Control System

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The production control system shall contain adequately documented

procedures and instructions. These procedures and instructions shall, where
relevant, be established in respect of the control requirement as given in the
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TABLES 9.10, 9.11 and 9.16.

D
9.4.3 Supervision
The Contractor shall ensure the required standard of control over materials and
workmanship. The S.O. shall be afforded all reasonable opportunities and
facilities to inspect the constituent materials and the production of concrete
and to take samples for testing as or when necessary.
9.4.4 Site Mixed Concrete
9.4.4.1 Site mixed concrete shall include prescribed mix and designed mix.
9.4.4.2 The quantities of cement, fine aggregate and various sizes of coarse
S9- 15
(JKRlSPJ/2018-S9)
aggregate shall be measured by weight unless otherwise approved

by the S.O. A separate weighing machine shall be provided for
weighing the cement. Alternatively, the cement may be measured by
using a whole number of bags in each batch. The quantity of water
shall be measured by volume or by weight. Any solid admixtures
to be added shall be measured by weight; liquid or paste admixtures
shall be measured by volume or weight.
9.4.4.3 The batch weight of aggregate shall be adjusted to allow for the
moisture content of the aggregate being used. All measuring
equipment shall be calibrated on site or their calibration status
established by certificates from accredited laboratories.
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9.4.4.4 The mixing time shall be not less than two minutes and not more
than five minutes or any other time recommended by the mixer
manufacturer after all the ingredients have been placed in the mixer.
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9.4.4.5 Mixers that have been out of use for more than 30 minutes shall be
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thoroughly cleaned before any fresh concrete is mixed. Unless agreed
otherwise by the S.O., the first batch of concrete through the mixer
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shall contain only two thirds of the normal quantity of coarse
aggregate. The mixer shall be thoroughly cleaned before changing
from one type of cement to another.
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9.4.4.6 The water content of each batch of concrete may be adjusted so as
to produce concrete of the required workability. However care shall
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be taken to ensure the free water over cement ratio is maintained.

The total amount of water added to the mix shall be recorded .
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9.4.5 Ready Mixed Concrete
9.4.5.1 Ready mixed concrete are batched, either dry or wet, at a control
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plant and transported in purpose-made agitators operating

continuously or truck mixers to the Site.
9.4.5.2 Ready mixed concrete shall comply with the requirements of designed
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concrete as in Subsection 9.3.2 and MS EN 206-1. All concrete

materials, including water and admixtures shall be mixed in the plant
and delivered to Site in purpose made truck mixers. No extra water or
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admixtures are allowed to be added after the concrete has left the
plant.
9.4.5.3 Ready mixed concrete delivered to the Site shall be accompanied by

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delivery ticket and manufacturer's batching record stating the details

of mix proportions by weight, the grade of concrete, type and size of
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aggregate, date and time of loading at plant, type and dosage of

chemical admixtures and other relevant production details in suitable
format, failing which the S.O, or his representative, shall immediately
reject the total load of the concrete. The S.O. or his representative,
and the Contractor shall ensure the information provided in the
delivery tickets and the manufacturer's batching record complies with
the details of the approved 'designed concrete' and its corresponding
consistence as in subsections 9.3.2 and 9.3.4 respectively before
discharging the concrete.
9.4.5.4Rejected concrete shall be removed from the site. The delivery ticket
shall be marked 'REJECTED'.
S9-\6
(JKRlSPJ/2018-S9)
9.4.6 Transporting
Concrete shall be transported from the mixer to the form work as rapidly as
practicable by methods, which will prevent segregation or loss of any
constituents or ingress of foreign matter or water and maintain the required
workability. It shall be deposited as near as practicable in its final position to
avoid re-handling or moving the concrete horizontally by vibration . The
concrete shall be conveyed by chutes or concrete pumps only with
permission from the S.O.
9.4.7 Placing
ER
9.4.7.1 Placing of concrete in dry condition:
(i) For all concrete, whether mixed on or off the site of the
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Works, each batch shall be placed and compacted within two
(2) hours of adding the' cement to the dry aggregates and
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within 45 minutes (or any other period of time based on the
initial test as per Subsections 9.2.4 and 9.3.1.3 and approved
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by the S.O. if an admixture is used) of adding water to the
cement and aggregate. Concrete shall not be placed in any
part -of the structure until the approval of the S.O. has been
obtained . If concreting is not started within 24 hours of
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approval given, approval shall again be obtained from the S.O.
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(ii) All formwork and reinforcement contained in it shall be

clean and free from standing water immediately before the
placing of concrete. Concreting shall be carried out
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continuously between and up to the predetermined

construction joints in one sequence of operation. It shall be
thoroughly compacted by either hand tamping or mechanical
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vibration, or both and shall be thoroughly worked into the

comers. After tamping into place the concrete shall not be
subjected to disturbance other than such as incidental to
compaction by vibration. In the event of unavoidable stoppage
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in positions not predetermined, the concreting shall be

terminated on a horizontal plane and against vertical surfaces
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by the use of stop boards. The location for termination shall

be subjected to the approval of the S.O.
(iii) Fresh concrete shall not be placed against in-situ concrete

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which has been in position for more than 45 minutes unless a

construction joint is formed in accordance with Subsection
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9.5.3. When in-situ concrete has been in place for four hours,
no further concrete shall be placed against it for a further 20
hours. Where retarding admixture has been used, the S.O.
may approve variation to this limit.
(iv) Except where otherwise approved by the S.O., concrete shall

be deposited in horizontal layers to a compacted depth not
exceeding 450mm when internal vibrators are used, or
300 mm in all other cases. The surface of the concrete shall
be maintained reasonably level during placing .
(v) Concrete shall not be dropped into place from a height

exceeding 1.5m. However, drops exceeding 1.5m may be
S9-17
(JKRlSPJ/2018-S9)
allowed provided the mix has been well designed and

proportioned. When trunking or chutes are used, they shall be
kept clean and used in such a manner as to avoid
segregation.
(vi) The Contractor shall maintain an experienced steel fixer at the

site of reinforced concrete works during the placing of concrete
to reposition any reinforcement which may be displaced.
9.4.7.2 Placing of concrete under water
No concrete shall be placed in flowing water. Underwater
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concrete if deemed unavoidable, shall be placed in position by
Tremie pipes from the mixer. During and after concreting under
water, pumping or dewatering operations in the immediate vicinity
shall be suspended until the S.O. permits them to continue.
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Where the concrete is placed by a Tremie pipe, the following
requirements shall be applicable: -
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(i) The hopper and Tremie pipe shall be a closed system.
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The bottom of the Tremie pipe shall be kept as far as
practicable beneath the surface of the placed concrete.
(ii) The Tremie pipe shall be large enough with due regard to
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the size of aggregate. For 20mm aggregates, the Tremie pipe
shall be of a diameter not less than 150mm and for larger
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aggregates, a bigger diameter Tremie pipe approved by
the S.O. shall be used.
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(iii) Unless otherwise agreed by the S.O ., the first charge

of concrete shall be placed with a sliding plug pushed down
the Tremie pipe ahead of it to prevent mixing of concrete and
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water.
(iv) The Tremie pipe shall always penetrate well into the concrete
with an adequate margin of safety against accidental
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withdrawal if the pipe is surged to discharge the concrete.
(v) The concrete shall be deposited wholly by Tremie pipe and

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the method of deposition shall not be changed part way up to

prevent the laitance from being entrapped within the structure.
(vi) All Tremie pipes shall be properly cleaned after use.

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9.4.8 Placement Temperature

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Placement temperature shall comply with MS EN 206-3 to prevent

premature setting, early thermal cracking and loss of water during placing
of concrete in the formwork and the following precautions shall be taken:
9.4.8.1 At the time of placing, no part of the concrete shall have a

temperature exceeding 36°C. This may be achieved by cooling
the water and aggregate prior to mixing.
9.4.8.2 Concrete shall not be placed in forms or around reinforcement

whose temperature exceeds 36°C. This can be achieved by
providing shading or other means to protect from direct sunlight.
89-18
(JKRISPJ/2018-S9)
9.4.8.3 Freshly placed concrete shall be protected from direct sunlight

and from loss of moisture by covering, shading or other means.
9.4.8.4 No concrete shall be placed when the air temperature at the point
of deposition exceeds 36°C.
9.4.8.5 The Contractor shall provide the method statement for

temperature control in the case of large volumes of continuously
concrete pour exceeding 1aOm 3 or as deemed necessary by S.O.
No concreting shall take place without prior approval from the S.O.
9.4.8.6 In the case of high potential of early thermal cracking may occur,
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the apparatus and instrumentation for temperature monitoring
shall be installed at the location shown in the Drawings or as
directed by the s.o.
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9.4.9 Compaction
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9.4.9.1 Unless otherwise approved by the S.O., concrete shall be
thoroughly compacted by vibration and thoroughly worked around
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the reinforcement, tendons or duct formers, around embedded
fixtures and into comers of the formwork to form a dense,
homogenous mass, free from voids and which will have the
required surface finish when the formwork is removed . Vibration
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shall be applied continuously during the placing of each batch of
concrete until the expulsion of air has practically ceased and in a
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manner which does not promote segregation of the ingredients.
9.4.9.2 The concrete maintained between the two walls offormwork shall
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be compacted by intemal or extemal vibrators. Concrete in slabs

with no formwork on its upper surface shall be compacted either
by vibrators of the pan type or by a vibrating screen.
EN
9.4.9.3 The internal vibrators shall be inserted and withdrawn slowly and
at a uniform pace of approximately 100mm per second.
Compaction shall be deemed to be completed when cement
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mortar appears in an annulus around the vibrator. Over vibration ! •

leading to segregation of the mix must be avoided. The intemal V
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vibrators shall be inserted at points judged by the area of mortar

showing after compaction, with a certain allowance made for
overlapping and they shall not be allowed to come into contact with
the formwork or the reinforcement and shall be inserted at a
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distance of not less than 75mm from the formwork.
9.4.9.4 The pan vibrator shall be placed on the surface of the concrete,
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which shall have previously been tamped and leveled leaving an

allowance in height for compaction until the cement mortar
appears under the pan. The vibrator shall then be lifted and placed
on the adjoining surface and this operation shall be repeated until
the whole surface has been compacted. Alternatively, a vibrating
screen spanning the full width of the surface may also be used.
9.4.9.5 Whenever vibration has to be applied externally, the design of

formwork and disposition of vibration shall receive special
consideration to ensure efficient compaction and to avoid surface
blemishes. The vibration shall be such that there will be no excess
water on the top surface on completion of cornpaction.
89-19
(JKRlSPJ/2018-S9)
9.4.9.6 Extemal vibrators shall be firmly secured to the formwork which

must be sufficiently rigid to transmit the vibration and strong
enough not to be damaged by it. Intemal vibrators shall be capable
of operating at not less than 10,000 cycles per minute and extemal
vibrators at not less than 3,000 cycles per minute. Sufficient
vibrators in serviceable condition shall be on Site so that spare
equipment is always available in the event of breakdowns.
Vibrators shall be operated by workmen skilled in their use.
9.4.9.7 Concrete shall not be subjected to any disturbance within 24

hours after compaction. No standing or flowing water shall be
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allowed to come into contact with exposed concrete surfaces
during the first two (2) hours after placing and compaction of the
concrete.
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9.4.9.8 In the event where inadequate or improper compaction is
suspected, the S.O. has the right to inspect and to carry out further
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tests. The tests may include non-destructive and destructive
methods. All expenses incurred in carrying out such sampling,
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testing and remedial works shall be bome by the Contractor
irrespective of whether the tests prove the structure to be sound or
otherwise.
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9.4.10 Curing and Protection
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9.4.10.1 The Curing Class 3 in accordance with BS EN 13670 shall apply to

all concrete works to avoid premature drying out or any shrinkage
type of cracks and shall be cured for the full period of curing which
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shall not be less than five (5) days for F1, F2, F3 and F4 surfaces,
and not less than three (3) days for F11, F12, F13, F14 and F15
surfaces.
EN
9.4.10.2 Curing and protection shall start immediately after compaction of

the concrete to protect it from:
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(i) Impact damage such as shock, overloading or falling

earth which may disrupt the concrete and its bonding
interface with the reinforcements.
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(ii) Premature drying out from direct sunlight and wind.
(iii) Leaching out by rain and flowing water.

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(iv) High intemal thermal gradients.

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9.4.10.3 Normal curing and protection
Concrete, after it is placed and until the expiration of the curing

duration, shall not be allowed to dry out. Provision shall be made
for adequate protection against direct sunlight and wind to allow
the process of curing to complete within the specified period.
Curing and protection shall be accomplished by covering the

exposed concrete surface with an impermeable material such as
polyethylene sheet, which should be well sealed and fastened and
if required, this treatment can be continued efficiently throughout
the whole period of curing.
S9-20
(JKRlSPJ/2018-S9)
When the concrete has attained its final set, one of the following
curing methods shall be adopted:
(i) Water curing shall be accomplished by keeping the surface

of the concrete continuously wet by ponding with water.
(ii) Curing may be accomplished by sealing in the water as

specified above by covering with an approved waterproofed
curing paper or plastic sheeting laid with airtight jOints. It
must be securely positioned to prevent displacement by wind
and protected from tear or other damage.
ER
The use of other methods of curing may be deemed necessary
when the concrete is subjected to high internal thermal gradient, or
with large exposed surface area. The Contractor shall submit a
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method statement to the approval of the S.O.
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In the event where the Contractor fails to do proper curing, the
S.O. has the right to inspect and to carry out further tests which
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may include destructive methods. All expenses incurred in carrying
out such sampling, testing and remedial works shall be borne by
the Contractor irrespective of whether the tests proved the
structure to be sound or otherwise.
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9.4.10.4 Accelerated curing
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Elevated temperature curing may be used only with CEM I Cement

and subjected to the approval of the S.O.
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Curing can only be started 4 hours (hrs) after completion of the

placing of concrete, unless the Contractor is able to prove that
curing can start earlier by furnishing all the relevant supporting data
EN
to the S.O. The rise in temperature within any period of 30 minutes

shall not exceed 10·C and maximum temperature attained shall
not exceed 70·C unless it can be proven that any deviation from
this provision shall not result in any detrimental effect to the
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concrete works. The rate of subsequent cooling shall not exceed

the rate of heating. The total accelerated curing time shall not
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cause any detrimental effect to the concrete as approved by the

S.O. The use of accelerated curing methods for concrete with
CEM I in accordance to MS EN 197-1 or concrete containing other
types of any admixture or any additional shall be to the approval
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ofthe S.O
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9.5 CONSTRUCTION WITH CONCRETE
9.5.1 Geometry Control
9.5.1.1 Geometry Control
(i) The Contractor shall submit to the S.O. for approval a

geometric control plan which shall indicate in detail how the
survey is to be performed and Contractor's proposed actions
to assure proper erection of the structure to the final grade
shown in the drawings. The geometric control plan shall
S9-21
(JKRlSPJ/2018-S9)
provide for regular monitoring of the structure.
(ii) The Contractor shall check the elevations and alignment of

the structure, at every stage of construction, and must
maintain record of all these checks and of all adjustments and
corrections made. All curves shall be performed at a time that
will minimize the influence of temperature.
9.5.1.2 Deflection and Camber Data for Related Bridge Construction
The Contractor shall submit deflection andl or camber data for each
ER
stage of construction as required, prior to constructing the structure
to its final grade. The procedure used shall account for the effect
of the time dependent prestress losses and creep which will occur
during the construction phase.
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The camber of the structure will be monitored by the Contractor at
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each stage of construction and corrective actions as approved by
the S.O. shall be performed by the Contractor to assure proper
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erection of the structure to its final grade.
9.5.2 Dimensional Deviations

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9.5.2.1 Deviations arise at three stages of construction, i.e. during initial
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setting out, during in-situ construction and during erection and
assembly. It is important that effective control measures are
adopted by the Contractor to ensure that deviations are kept within
permissible limits.
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9.5.2.2 The following permissible deviations in BS 5606 are given as

tolerances values for specific dimensions.
EN
(i) In-situ Concrete

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Construction Location mm
Walls Thickness ±S
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Straightness in 5m ±9
Abrupt changes in continuous ±4
surface
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11
Verticality up to 2m 17
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Up to 3m 16
Up to 7m
Columns Size on plan up to 1m ±S
Verticality up to 3m 12
Up to 7m 16
Squareness 9
Beams Depth
(Perimeter beams) up to 600mm ±13
S9-22
(JKRlSPJ/2018-S9)
Construction Location .- mm
Over600mm ±20
(Internal beams) up to 600mm ±12
Over600mm ±16
Level
Variation from target plane ± 22
Straightness in 6m ±10
Structural slab Level
ER
Variation from target plane ±25
Structural soffit ±19
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Foundation Dimensions on plan ±50
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Rigid Pavement Level and dimensions on plan ±25
,
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Drainage Level and dimensions on plan ±25
Culvert
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(ii) Precast Concrete Members
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Dimension Location , mm
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Length Upt03m ±6
3m t04.5m ±9
EN
4.5mto 6m ± 12
Additional deviation for every ±6
subsequent 6m
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Cross section Up to 500mm ±6

500mm to 750mm ±9
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Additional deviation for every ±3

subsequent 250mm
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Straightness Up to 3m 6
3m to 6m 9
D
6m to 12m 12
Additional deviation for every 6
subsequent 6m
(iii) Control of Accuracy During Construction - Checking by the

Contractor shall be systematic and to be undertaken at all
stages of construction . Particular attention shall be given to
monitoring of construction in areas where the work would
seriously affect its appearance or performance.
S9-23
(JKRlSPJ/2018-S9)
(a) Dimensional control, i.e. the Contractor shall ensure to

achieve dimensional control by:
Checking that measured results are within the

tolerances specified .
Identifying sources of induced inaccuracy.
Taking appropriate corrective action subject to the
(b) Recording, i.e. the dimensions measured shall be
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systematically recorded by the Contractor and agreed
by the S.O. for the following :
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Checking compliance.
Preparing as-built drawings showing the
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n measurements achieved in practice and the
deviations from the target size.
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Establishing characteristic accuracy.
(c) Corrective action, i.e. corrective action by the Contractor

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in respect of work that does not comply with the
tolerances specified can include:
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Rectification as approved by the S.O. of works

already done.
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Increasing Contractor's supervision at identified

sources of inaccuracy.
EN
Adjustment of design and/or details as approved by

theS.O.
(d) Preventive action, i.e. systematic checking by the

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(j Contractor as the work proceeds is essential to make

sure that the monitoring and control systems are in place
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and adequate. Preventive action shall be +aken, based

on assessment of the results of the monitoring,
particularly at the initial stages of each work. This will
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allow problems to be identified and addressed at an

early stage, subject to the approval of the S.O.
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9.5.3 Construction Joints
9.5.3.1 Construction joints shall be made at the location as shown on the

Drawings and concreting work shall be carried out continuously
up to the construction joints. If the position and detail of any
construction joints is not described in the drawings, the Contractor
shall propose and obtain the approval of the S.O. prior to
commencement of concreting . The construction joints shall be
made as few as possible with reasonable precautions against
shrinkage. The joints shall be at right angles to the general
direction of the member and shall take due account of shear and
S9-24
(JKRlSPJ/2018-S9)
other stresses.
9.5.3.2 Concrete shall not be allowed to run to a feather edge and vertical
joints shall be formed against a stop end. The top surface of a
layer of concrete shall be level and flat unless design
considerations make this undesirable. Joint lines shall be so
arranged that they coincide with features of the finished work,
wherever possible.
9.5.3.3 At horizontal construction joints, gauge strips 0 f about 25mm

width shall be placed inside the forms along all exposed
ER
surfaces to ensure a straight joint on those surfaces. Where a
kicker (that is a starter stub) is used for the construction of walls
and columns, it shall be at least 75mm high, to be constructed
monolithically with the base concrete.
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9.5.3.4 Where vertical construction joints are necessary in mass
concrete structures, reinforcing bars shall be placed across the
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joints so as to make the structure monolithic, all to the approval of
the S.O.
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9.5.3.5 Prior to recommencement of concreting on a joint, action is to be
taken so as to ensure that the surface of the concrete, against
which new concrete will be cast, shall be free from laitance and
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shall be roughened to the extent that the coarse aggregate is
exposed but not disturbed. Care shall be taken to avoid damaging
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the lines of the joint. Care shall also be taken so that the joint
surface is clean and damp but not wet and the exposed adjoining
surfaces shall be of consistent colour. Immediately before the
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fresh concrete is placed against the joint, fresh rich cement mortar
(1 :2) shall first be applied to the exposed surface.
EN
9.5.3.6 Where the S.O. considers that special preparation is necessary,

e.g. for an in-situ structural connection, preparation shall be
carried out, preferably when the concrete has set but not
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hardened, by spraying with a fine spray of air and water or

brushing with a stiff brush sufficiently to remove the outer mortar
skin and expose the larger aggregates without disturbing them.
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Where this treatment is impracticable, sand blasting or a needle

gun shall be used to remove the surface skin and laitance.
Hardened surfaces shall be chipped manually or mechanically to
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free them from laitance and properly roughened to the extent that
the coarse aggregates are being exposed.
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9.5.4 Fixing Blocks, Brackets, Built In Bolts, Holes, Chases, etc
9.5.4.1 All fixing blocks, brackets, built in bolts, holes, chases, etc
shall be accurately set out and formed and carefully sealed prior
to the concrete being placed. It is the responsibility of the
Contractor to obtain all such information for these items of work
and to obtain the approval of the S.O. before incorporating such
works prior to the concrete being placed.
9.5.4.2 Bolts and other inserts to be cast into the concrete shall be
securely fixed to the formwork in such a way that they are not
displaced during the concreting operations and that there is no
S9-25
(JKRlSPJ/2018-S9)
loss of materials from the wet concrete through holes in the

formwork.
9.5.4.3 Unless otherwise shown on the Drawings or instructed by the

S .O., reinforcement shall be locally moved so that the minimum
specified cover is maintained at the locations of inserts, holes,
chases, etc. In the event where the minimum cover cannot be
maintained, the Contractor shall take all necessary precautions
to protect the reinforcements against corrosion by applying
approved coating materials to the reinforcements and the
concrete cover.
ER
9.5.4.4 Temporary plugs shall be removed and the threads of built in
bolts shall be cleaned and greased before handing over any part
of the Works.
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9.5.5 Movement Joints
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n 9.5.5.1 Movement joints, expansion jOints, contraction jOints or other
permanent structure joints shall be provided in the required
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positions and constructed and sealed with waterproofing materials
as detailed in the Drawings.
9.5.5.2 When forming movement joints, joint filler shall be fixed firmly
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to the first-placed concrete. If more than one strip is used within
a joint, it is essential to butt the ends tightly or tape them together
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to prevent grout leakage and restricting the closure of the jOint.
9.5.5.3 It is essential that the concrete on both sides of the jOint, when
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placed, is thoroughly compacted to form a dense uniform mass.

Where stop ends comprise more than one element, particular care
is necessary to ensure that joints between elements are
EN
sufficiently tight to allow no grout loss through them during

compaction of the concrete.
9.5.5.4 Where flexible water stops are used, they shall be fixed so as to
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ensure that they are not displaced from their intended position
during compaction of the concrete and that the concrete
surrounding them is fully compacted. The design of the water stop
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should be practical and take account of the problems often

associated with integral water stop construction in difficult placing
conditions.
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9.5.5.5 Water stops laid horizontally and located within the concrete
mass shall be avoided since they attract the greatest risk of local
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honeycombing.
9.5.5.6 Unless otherwise shown on the Drawings, all exposed

expansion joints interface to structure components shall be
covered with O.7mm thick aluminium cover strips fixed with
masonry nails at 300mm centers.
9.5.5.7 Polystyrene foam shall not be used as the filler material to form
the joints between any elements of the structures unless
approved and advised otherwise by the S .O.
S9-26
(JKRlSPJ/2018-S9)
9.5.6 Sealants and Special Materials
9.5.6.1 General
The installation method and the selection, mixing, application and

curing of all joint waterproofing materials shall be in accordance
with the manufacturer's recommendations. The Contractor may
propose to use alternative joint waterproofing materials by
submitting supporting technical information, test reports and
samples of the proposed waterproofing materials to the S.O. for
approval.
ER
9.5.6.2 Waterproofing materials
All waterproofing materials used at public access areas shall
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be protected with non-shrink grout covering .
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9.5.6.3 Water stops
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(i) Water stops shall be as specified in the Drawings and shall
be installed and butt jointed according to BS 8007 & BS EN
1992-3 and the manufacturer's recommendation.
(ii) Water stops shall be securely positioned in the formwork to

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prevent displacement during concreting.
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9.5.6.4 Two-part polysulphide or two-part polyurethane sealant
Two-part polysulphide or two-part polyurethane sealant for

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external use shall comply with the following requirements:
(i) Conformance to BS 4254

(ii) Minimum joint movement capacity of ± 27.5% of jOint width
EN
at 27.5°C
(iii) Shore 'A' Hardness of 25 ± at 27.5°C
(iv) Resistance to dilute acids, alkali and all kinds of fuel
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9.5.6.5 Preformed flexible strip sealant

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Preformed flexible strip sealant shall comply with the following

requirements:
(i) Shall only be used in horizontal joints and be subjected to

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pressure throughout its length

(ii) Good adhesion
(iii) Water resistant
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(iv) Non-staining
9.5.6.6 Bitumen/rubber cold applied membrane
Bitumen/rubber cold applied membrane shall comply with the

following requirements:
(i) Minimum joint movement capacity of ±10% of joint width

at 27.5°C
(ii) 90% solid content
(iii) Resistant to dilute acid and alkali
S9-27
(JKRlSPJ/2018-S9)
9.5.6.7 Hot-poured rubber/bitumen sealing compound
Hot-poured rubber/bitumen sealing compound shall comply

with BS 2499.
9.5.6.8 Bituminous sheeting
Bituminous sheeting with non-asbestos fiber shall comply with

the following requirements:
(i) Resistant to lime water (no visual effect after two (2) weeks
immersion)
ER
(ii) Maximum water absorption of 10% of dry weight
(iii) Minimum tensile strength of 50 kg/cm2
(iv) Ozone and ultraviolet resistant
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9.5.6.9 Polyurethane foam backing rods
N
Polyurethane foam backing rods used as sealant stops in
panel joints shall have the following properties: -
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(i) Minimum compressibility of 75% of original volume at 27.5°C
(ii) Excellent resilient properties
(iii) Density between 35 kg/em' and 45 kg/em'
(iv) Total resistance to common acids, lubricants and detergents
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(v) Total resistance to water infiltration by capillary action
(vi) Suitability for up to 70°C
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9.6 STEEL REINFORCEMENT

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9.6.1 General
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The Works shall consist of furnishing and plaCing reinforcing steel in

accordance with this specification and in conformity with the Drawings or as
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u 9.6.2 Materials
9.6.2.1 Hot rolled mild steel and high yield bars shall comply with the
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requirements of MS 146. Cold worked steel bars shall comply with

the requirements of BS 4461 . Hard drawn mild steel wire shall
comply with the requirements of MS 144.
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9.6.2.2 Steel fabric reinforcement shall comply with the requirements of

MS 145 and shall be delivered to the Site in flat sheets, unless
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specified otherwise.
9.6.2.3 Dowel bars shall be plain, round bars conforming to the

requirements of MS146. They shall be free from burring or other
deformations restricting slippage in the concrete. Dowel bar
sleeves used for debonding shall be of approved synthetic
material. The closed end of the sleeve shall be filled with
25mm thick compressible foam fillers and the sleeve shall fit tightly
over the length of the bar to be debonded.
9.6.2.4 Before any reinforcement steel is brought to the site, the

Contractor shall furnish the mill certificates of tests and these shall
S9-28
(JKRlSPJ/2018-S9)
be submitted for acceptance by the S.O. In addition, the

Contractor shall on request, furnish the S.O. with a test sheet from
approved laboratories for any batch of bars, giving the results of
each of the mechanical tests and! or chemical composition
analysis required under the MS or any equivalent international
standards approved by the S.O. The specified characteristic
strength of steel reinforcement shall be as given in TABLE 9.17.
9.6.2.5 During the course of the work, any reinforcement found to

be not in accordance with the MS or BS may be rejected by the
S.O., notwithstanding any previous acceptance on the strength of
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the test certificates . The S.O. may call for additional tests to be
carried out at the Contractor's expense on samples taken from the
batch of the defective reinforcement. If the samples do not comply
with the MS or BS, then the S.O. may reject the whole batch and
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instruct its removal from the Site.
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9.6.2.6 Steel reinforcement shall be stored in clean and dry conditions.
When placed in the work it shall be clean and free from loose rust,
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mill scale, oil, grease, paint, dirt or anything which may reduce its
bond with concrete. If directed by the S.O., the steel bars shall be
brushed or otherwise cleaned before use, at the Contractor's
expense.
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9.6.2.7 Binding wire shall be 1.6mm diameter soft annealed steel wire
complying with the requirements of BS 1052.
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9.6.3.1 Cutting and bending of reinforcement
(i) Bars shall be of their correct lengths and bent to the exact
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shapes required before being fixed in the work.
(ii) Bars shall be cut and bent cold by the application of slow,
steady pressure or in an approved bar-bending machine.
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Bending at temperatures in excess of 100De may only be

carried out with the S.O.'s approval and under his supervision.
Except where indicated otherwise in the Drawings, bars shall
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be bent and measured in accordance with BS 4449.
(iii) Cold worked and hot rolled bars shall not be straightened or
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bent again once having been bent. Where it is necessary to

bend the free end of mild steel reinforcement already cast in
the concrete, the internal radius of the bend shall not be less
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than twice the diameter of the bar.
(iv) Special care shall be taken so that the overall length of

bars with multiple bends is accurate and that after bending
and fixing in position the bars remain in place without wrap or
twist.
9.6.3.2 Fixing of reinforcement
(i) The number, size, length, shape, type and position of all
reinforcing bars, links, spacer bars and other parts of the
steel reinforcement shall be in accordance with the Drawings.
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(ii) Reinforcements shall be secured against displacement.

Unless specified otherwise, the actual concrete cover shall
be taken at the intersecting bars which shall be tied together
with binding wire and the ends of the wire shall be turned
into the main body of the concrete.
(iii) Reinforcement temporarily left projecting from the concrete at

construction or other joints shall not be bent out of position
during the periods in which concreting is suspended except
with the approval of the S.D.
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(iv) The Contractor shall take particular care so that the
reinforcement is laid out correctly in every aspect and
temporarily suspended by annealed wire or supported on
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concrete blocks or other approved spacers in the forms to
prevent displacement during the placing and compacting of
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concrete. Links shall tightly embrace the longitudinal
reinforcement to which they shall be securely wired or spot
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welded. The top reinforcement in slabs shall be rigidly
supported on mild steel 'chairs' or equivalent, spaced in each
direction to prevent sagging during concreting.
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(v) No concrete shall be placed until the reinforcement has been
inspected and approved by the S.D.
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9.6.3.3 Splicing
Joints to reinforcement bars shall be in accordance by lapping

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of bars at positions shown on the Drawings. Where other types

of jOints are to be used, prior approval of the S.O shall be obtained
and their use shall be strictly in accordance with manufacturer's
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recommendation, at the positions approved by the S.D. Splicing

or lapping of bar shall not impair the flow of concrete surrounding
the reinforcing bar including the cover in accordance to relevant
standards.
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9.6.3.4 Supporting and spacer blocks

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(i) The size of supporting and spacer blocks required for

ensuring that the reinforcement is correctly positioned shall be
not more than 50mm x 50mm consistent with their purpose,
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of a shape approved by the S.D., and designed so that they

will not overturn when the concrete is placed.
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(ii) The nominal size of aggregates used shall be 10mm. The

concrete spacers shall be of at least the same strength and
material's source as the concrete to be poured. Wires cast in
these blocks for the purpose of tying them to the reinforcement
shall be free from any corrosion or any other elements that may
affect the integrity of the reinforcing bar.
(iii) Spacers left in-situ shall not impair the desired appearance or
·durability of the structure by causing spalling, rust staining or
allowing the passage of moisture.
(iv) Other types of spacers may be used only with the approval
of the S.D.
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(JKRlSPJ/2018-S9)
9.6.3.5 Welding Reinforcement
(i) Welding workmanship, including welder qualification shall

comply with Section 12 of this Specification.
(ii) Reinforcement in structures shall not be welded except where

detailed in the Drawings or permitted in this Specification.
(iii) Welding shall be carried out in accordance with BS EN 1011

and BS EN 60974. Butt welds shall be of the double V type
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and two butt weld bond tests shall be carried out on a
specimen prepared to represent each form of the butt welded
joint used in welding the reinforcement an for each position of
welding . The method of making butt weld tests shall be as laid
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down in BS EN 17637. The specimen shall pass the test to the
approval of the S.O. before using the joint, which the specimen
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represents. Welded joints shall not be made at bends in
reinforcement. Unless approved otherwise by the S.O., joints
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in parallel bars of the principal tensile reinforcement shall be
staggered in the longitudinal direction at a distance not less
than the end anchorage length for the bar.
(iv) The S.O. shall be informed in advance when welding is to

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be carried out so that he may supervise and inspect the work.
Welding shall not be performed in the field during rain or other
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adverse conditions.
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9.7 FORMWORK AND SURFACE FINISH FOR STRUCTURE
9.7.1 Design and Construction

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9.7.1.1 Description
(i) Formwork shall include all temporary or permanent forms

required for forming the concrete, together with all temporary
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construction required for their support.

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(ii) The Contractor is deemed to have made a study of the

Drawings at tender stage and is aware of all areas of
construction, requiring heavy and specially designed
propping to provide the support and the necessary bracing
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for the stability of such propping.

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(iii) The design and construction of formwork shall be carried

out by a competent person. The Contractor shall identify all
critical formwork design and submit the strength and deflection
calculations and Drawings or the proposed deSign, certified by
a Professional Engineer to the S.O. for prior approval.
Notwithstanding any approval by the S.O. with respect to the
design submitted by the Contractor, the responsibility for the
adequacy and safety of the design shall remain with the
Contractor. The Contractor shall also appoint a competent
formwork coordinator whose duties would be similar to those
outlined in BS 5975.
(iv) When the use of proprietary type of formwork is proposed

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(JKRlSPJ/2018-S9)
by the Contractor, the design shall be certified by a

Professional Engineer.
(v) The formwork shall be sufficiently rigid and tight to prevent

loss of grout or mortar from the concrete at all stages of
construction and shall be appropriate for the methods of
placing and compacting.
(vi) Formwork (including supports) shall be sufficiently rigid to

maintain the forms in their correct position, shape, profile
and dimensions. The supports shall be designed to withstand
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the worst combination of forces due to self weight, formwork
weight, formwork forces, loads, together with all incidental
dynamic effects caused by placing, vibrating and compacting
the concrete. Guidance on these loadings is given in The
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Concrete Society Manual Formwork - Guide to good practice,
and in CIRIA Report lOB, Concrete Pressure in Formwork,
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and in BS 5975. Vertical propping to formwork shall be carried
down sufficiently far to provide the necessary support without
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overstressing the completed concrete structure.
(vii)Metal ties may only be used with the prior approval of the
S.O. Where metal ties are permitted the use of storey height
steel soldiers shall be used to reduce the number of tie bolls
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required. Tie bolts with rubber or plastic cone against the form
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face are to be used to prevent unsightly grout loss. No metal
part of any device for maintaining formwork in the correct
location shall remain permanently within the specified
concrete cover to the reinforcement. Except for ties used for
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anchoring void formers, all ties shall be at least l.2m apart

and through bolts will not be permitted on exposed form
finished faces. All holes left by ties shall be made good within
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one day of the removal of the formwork using a mortar of the

same strength as the cast concrete. Metal ties which allow for
holes through the concrete being cast shall not be permitted
to be used in concrete for water-retaining structure, roof slabs
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u and walls.
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(viii) The formwork shall be so arranged as to be readily

dismantled and removed from the cast concrete without shock,
disturbance or damage. Where necessary, the formwork shall
be so arranged that the soffit form, properly supported, can
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be retained in position for such period as may be required by

the condition of the maturing concrete or the Specification. If a
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component is to be prestressed whilst still resting on the soffit

form, provision shall be made to allow for elastic deformation
and any variation in weight distribution. As far as practicable,
formwork joints shall coincide with construction jOints.
(ix) Slip type of formwork shall be used in accordance to the

intended proprietary system. Contractor shall submit to the
S.O. the method statement of the slip formwork to be used on
site. The method statement shall include materials, method of
erection, safety precaution, tolerances and the number of
cycles usage.
89-32
(JKRlSPJ/2018-S9)
9.7.1 .2 Form lining
The type and treatment of any lining (plywood, metal, plastic,

Controlled Permeability Formwork liner, etc) of the forms shall be
appropriate to the concrete finish required .
The Controlled Permeability Formwork (CPF) liner shall have the

(i) The requirement for a special finish shall be as for
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traditional formwork finishes except that the formwork shall
be covered by a CPF liner.
(ii) CPF liner shall be used on all surfaces as detailed on the
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Drawings.
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(iii) The CPF liner shall be a Water Bylaws Scheme -
approved.
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(iv) Product for use with potable water in accordance with BS
6920. The CPF liner shall have the following properties:
(a) Compression of less than 10% under a pressure

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200 kPa.
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(b) Maximum pore size of less than 0.030mm.

(c) Minimum water retention capacity of 0.35I/m 2 .
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(d) Results in bleed water from the liner which is free from
cement and fine aggregate particles.
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(v) The concrete cast against the CPF liner shall have an even
uniformly textured matt finish and shall be free of blowholes
and other surface blemishes. The use of the CPF liner shall
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meet the following performance requirements which should

be demonstrated by the supply of test certificate:
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(a) The mean surface strength for the CPF cast face shall
exceed that for the control face by at least 70%.
(b) The mean 10 minute ISAT result for the CPF cast face
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shall be not more than 15% of that for the control face.
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(c) The mean depth of carbonation for the CPF cast face
shall be not more than 15% of that for the control face.
(d) The mean concentration of chlorides at a depth of

11 mm from the CPF cast face shall be not more than
15% of that for the control face.
(vi) The CPF liner shall be used once only. Release agents
shall not be used with the liner and any residual release
agent remaining on forms from previous use shall be
removed.
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.-" ~':.,." :'
. .~ (JKRlSPJ/2018-S9)
(vii) To ensure conformity with the performance requirements,

the CPF liner is to be used in accordance with the
manufacturer's technical guidelines.
(viii) The CPF liner shall, unless otherwise directed, be left in

place on the concrete after formwork removal for the curing
period as specified by the S.O. It shall be kept wet and
covered with plastic sheeting to promote efficient curing.
9.7.1.3 Projecting reinforcement, fixing devices
ER
Where holes are needed in forms, to accommodate projecting
reinforcement or fixing devices, care shall be taken to prevent loss
of grout when concreting or damage when removing forms .
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9.7.2 Surface Finishes for Concrete
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n 9.7.2.1 Control of colour
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When specified in the Drawings, the Contractor shall obtain each
constituent material from a single consistent source. The
aggregates shall be free of any impurities that may cause staining.
The mix proportions and the grading, particularly of the fine
aggregate, shall be maintained constant. The same type of
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plywood or timber shall be used in formwork throughout
similar exposed areas.
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9.7.2.2 Formed surfaces

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Unless specified otherwise, all exposed concrete surfaces shall

be of Class F12 and all unexposed surfaces shall be of Class Fl.
Other classes of finishes shall be used only where shown on the
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Drawings or as permitted by s.o. Formed concrete surfaces shall

have one of the following classes of finish:
(i) Class Fl
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This finish shall be obtained by the use of properly designed

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forms of closely joined sawn timber or other approved

material. Small blemishes caused by entrapped air or water
may be expected but the surface shall be free from voids
and honeycombing.
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(ii) Class F2
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This finish shall be obtained by the use of properly designed

forms of closely jOinted wrought boards, approved
plywood or other approved material. Only very minor
surface blemishes may occur, with no staining or
discoloration.
(iii) Class F3
(a) This finish shall be obtained by the use of properly

designed steel forms or plastic coated plywood or
wrought boards or other approved material.
S9-34
(JKRlSPJ/2018-S9)
(b) The surface shall be improved by carefully removing

all fins and other projections, thoroughly washing down
and then filling the most noticeable surface blemishes
with a cement and fine aggregate paste to match the
colour of the original concrete. Form release agents
shall be carefully chosen to ensure that the surface
shall not be stained or discolored. After the concrete
has been properly cured, the surface shall be rubbed
down where necessary, to produce a smooth and even
surface.
ER
(iv) Class F4
The requirements for Class F4 are as for Class F3 except

that internal ties and embedded metal parts will be
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permitted. The ties shall be positioned only in rebates, or in
other positions as shown on the Drawings or as agreed by
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the S.O.
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(v) Class F11
The requirements for Class F11 surface finish are

identical to those for Class F1 except that it shall be
achieved using Controlled Permeability Formliners.
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(vi) Class F12
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(vii) Class F13

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(viii) Class F14

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(ix) Class F15

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The requirements for Class F15 are as for Class F4 except

that plywood shutters lined with an approved patterned
formliner shall be used to produce a patterned profile
finish . Where possible, full height formliners shall be
employed so that no horizontal joints in the liners are
required. Tie holes shall be spaced so that they occur at
overlap joints in the lining sheet.
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(JKRlSPJ/2018-S9)
9.7.2.3 Unformed surfaces
(i) Class U1
The concrete shall be uniformly leveled and screened to

produce a plain, ridged or broom roughened surface. No
further work shall be applied to the surface unless it is used
as the first stage for a Class U2 or Class U3 finish.
(ii) Class U2
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After the concrete has hardened sufficiently, the concrete
Class U1 surface shall be floated by hand or machine to
produce a uniform surface free from screed marks.
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(iii) Class U3
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n When the moisture film has disappeared and the concrete
has hardened sufficiently to prevent laitance from being
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worked to the surface, a Class U 1 surface shall be steel-
trowelled under firm pressure to produce a dense, smooth
uniform surface free from trowel marks.
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(iv) Class U4
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This finish is for surfaces that are to receive waterproofing

systems. The concrete shall be levelled and floated to
produce a uniform surface and immediately before the
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waterproofing operation this surface shall be water jetted

or grit blasted to provide a lightly textured finish . The
finished surface shall not deviate from the required profile
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by more than 5mm over a 3m gauge length or have any

abrupt irregularities of more than 3mm.
9.7.2.4 Trial panels for exposed form finished surfaces:

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(i) In order to ensure that the specified formed finishes can

be obtained by the method of construction proposed and
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to provide a standard by which the finishes in the Works

can be assessed trial panels shall be cast on Site. These
panels shall be subjected to the S.O.'s approval before
similar casting is permitted in the Works.
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(ii) The trial panels shall employ the materials, plant and
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concrete mix proposed for the Works. They shall be at

least a storey height and 1m wide. They shall be of similar
thickness and similarly reinforced as the elements they
represent and shall incorporate all features which
contribute to the final appearance of the Works .
9.7.3 Preparation of Forms before Concreting
9.7.3.1 Before concreting, all forms shall be thoroughly cleaned out free
from sawdust shavings, dust, mud or other debris. The inside
surfaces offorms shall, unless otherwise approved by the S.O.,
be coated with an approved non-staining form oil or other
S9-36
(JKRlSPJ/2018-S9)
approved material to prevent adhesion of the concrete. Such

release agents shall be applied strictly in accordance with the
manufacturer's recommendation and shall not come into contact
with the reinforcement or prestressing tendons and anchorages.
For any exposed surface only one release agent shall be used
throughout the entire area.
9.7.3.2 All form works shall be inspected by the 5 .0 . after preparation and
immediately prior to depositing concrete and no concrete shall be
deposited until approval of the formwork has been obtained. The
Contractor shall ensure that all form works are in proper and
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correct geometrical position and orientati"on, within acceptable
tolerances and all necessary safety mitigation measures in place,
all to the S.O.'s satisfaction and approval.
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9.7.4 Removal of Forms
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9.7.4.1 The Contractor shall inform the 5 .0. and obtain his approval
before striking any formwork, but such approval shall not relieve
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the Contractor of his responsibilities for the safety of the work.
9.7.4.2 Formwork shall be removed without such shock or vibration as

would damage the concrete. A period of time shall elapse between
the placing of concrete and removal of the forrnwork for various
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parts of the structure so as to suit the requirements for its curing.
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9.7.4.3 The minimum periods between concreting and the removal of

forms are given in Table 9.18. The periods stated in this table are
based on the use of CEM I. They may be changed with the
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approval of the 5.0., if other types of cement as described in

Subsection 9.2.1, admixtures as described in - Subsection 9.2.4
are used. The result of the compressive strength obtained from
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cube strength at 7 days as described in Subsection 9.3.4.2(ii)

may also be used for early removal of forms provided the
Contractor provides proof of calculation to the 5 .0 . for approval.
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9.7.4.4 For prestressed in-situ components, temporary supports shall not

be removed until the components are stressed in accordance to
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the drawings and to the approval of the 5 .0 . Safety mitigation

must be taken to avoid any accidental falling or collapse of any
objects from the structures.
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9.7.4.5 Where it is intended that forms are to be reused, they shall be

cleaned and made good to the approval of the S.O.
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9.7.4.6 Following the removal of forms, no further loads shall be

imposed upon the concrete until at least after the completion of
the curing period or until such later time as in the opinion of the
5.0. the concrete shall have attained sufficient strength to safely
withstand such loads. Full design loads shall not be applied to
any structure until all load bearing concrete is at least 28 days old.
9.7.5 Inspection and Making Good
9.7.5.1 The surface of the concrete shall be inspected for defects and
for conformity to the surface finish specified and where
appropriate, with approved sample finishes.
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(JKRlSPJ/2018-S9)
9.7.5.2 Subject to the strength and durability of the concrete being

unimpaired, the making good of surface defects may be permitted
but the level of acceptance shall be appropriate to the type and
quality of the finish specified and to ensure satisfactory
permanence and durability throughout the design life of the
structures.
9.7.5.3 Any remedial treatment of surfaces shall be approved by the

S.O. following inspection immediately after removing the
formwork and shall be carried out without delay.
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9.7.5.4 No forms of honeycombs, excessive pinholes, spalling, chipping,
bulging or any surface defect shall presence on the concrete upon
the removal of formworks and S.O may instruct the Contractor to
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rectify any defects that may occur.
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n 9.7.5.5 Any prominent cold joints shall be brought to the attentions of S.O
for further advice. Cold joints that affect the integrity of the
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structures or structures element shall be rectified to the
satisfaction of S.O.
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9.8 MASS AND LEAN CONCRETE
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Mass arid lean concrete shall consist of cement, fine aggregate and coarse
aggregate in the nominal ratio by volume of 1:3:6 and 1:4:8 respectively. However
where a denser and more workable concrete can be produced by a variation in the
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ratio of the fine aggregate to that of coarse aggregate, this ratio may be varied
within the limits (1 :1%) and (1 :3), provided that the volumes of fine and coarse
aggregate, each measured separately, shall nevertheless equal the sum of the
volumes of fine and coarse aggregate appropriate to the nominal mix. The concrete
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shall be mixed as described for reinforced concrete.
STRUCTURE ACCURACY
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9.9
After removal of formwork, the Contractor shall take measurements as directed by

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the S.O. to check the deviation of the reinforced concrete works from specified
dimensions as shown on the Drawings. All measurements shall be recorded and
submitted to the S.O. Any deviation in structure accuracy shall comply with BS EN
13670 and Subsection 5 of this Specification. All levels, dimensions and
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measurements shall be captured in the as-built drawings.

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9.10 APPARATUS
The Contractor shall provide the following apparatus for use on the Site at all
times:
(i) Concrete slump test apparatus or flow test apparatus complying with MS 26.
One set of the apparatus shall be provided for each concreting location.
(ii) At least 12 numbers of steel or cast iron moulds for casting 150mm
concrete test cubes and six (6) numbers of 100mm mortar or grout test
cube moulds complete with tamping bars and base plates in accordance
with MS 26. A minimum number shall be provided such that no stripping of
S9-38
(JKRlSPJ/2018-S9)
cubes is required prior to 24 hours setting and hardening period.
(iii) Three (3) measuring cylinders of 250ml capacity, graduated to measure to

the nearest 2.0ml for determination of silt content (field setting method).
(iv) An approved apparatus for measuring moisture content in fine

aggregate.
(v) One (1) electronic calculator with statistical functions.
(vi) One (1) 300mm steel rule.
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(vii) One (1) set of sieves in compliance with BS 410.
(viii) Scale or balance 25kg maximum capacity and weights.
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(ix) Trowel, shovel, spanner and other tools.
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9.1 1 PRECAST CONCRETE CONSTRUCTION
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. 9.11 .1 Manufacture Off-Site
(i) Before commencing concreting the Contractor shall prepare a trial

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panel of size and surface finish acceptable to the S.O. The panel shall
be filled with the proposed concrete, mixed and compacted by the
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method to be used in the works. As soon as practicable, the forms
shall be removed to enable the S.O. to check the surface finish and
compaction achieved. Once a trial panel is accepted by the S.O., it
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shall be displayed on site and will form the basis of accepting or

rejecting concrete finish of the same specification.
(ii) After the method of manufacture has been approved, no changes

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shall be made without the approval of the S.O.
(iii) Precast structure element e.g beams, deck segments, cross head,
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pier, precast parapets, drainage panel, retaining wall etc. shall, as

soon as the fonnwork is removed, be kept continuously damped by a
double layer of gunny bags with excess water for a period of not less
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than 14 days. After the period of water curing, the segments shall be
membrane cured for a period of seven (7) days. During both periods
the segments shall be protected from wind, rain and direct sunlight.
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(iv) Curing compounds shall not be applied to surfaces to which further

concrete or a surface finish is subsequently to be bonded.
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(v) Any remedial treatment of surfaces shall be agreed with the S.O.
following inspection immediately after removing of formwork and shall
be carried out without delay.
(vi) The Contractor shall inform the S.O. in advance of the

date of commencement of manufacture and casting of each type
of precast concrete component.
(vii) When the S.O. requires tests to be carried out, none of the precast
concrete components to which the tests relate shall be dispatched to
the site until the tests have been completed and the results approved
S9·39
(JKRlSPJ/2018-S9)
by the S .O.
(viii) All precast concrete components shall be indelibly marked to show

the identification marking as specified in the Drawings, the production
batch on which they were manufactured and the date on which the
concrete was casted. If the components are symmetrical, the face
that will be uppermost when the member is in its correct position in
the work shall be clearly identified.
9.11 .2 Storage
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(i) When the precast concrete components are stored, they shall be firmly
supported only at the points specified in the Drawings. No accumulation
of trapped water and deleterious matter shall be allowed in the
components. Care shall be taken to avoid rust staining and
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efflorescence.
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(ii) The precast concrete components shall be stacked in such a manner
that their removal in correct order of age is facilitated.
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9.11 .3 Handling And Transport
The precast concrete components shall be lifted only at points specified in

the Drawings or otherwise approved by the S.O. and shall be handled and
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placed without impact. The method of lifting, the type of equipment and
transport to be used, and the minimum age of the components to be handled
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shall be to the approval of the S.O.
9.11 .4 Assembly and Erection

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(i) The method of assembly and erection specified in the Drawings

shall be strictly adhered to on site.
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(ii) Immediately afte r a unit of precast concrete component is placed

in position. and before the lifting equipment is removed. temporary
supports or connections between components as necessary. shall be
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provided. The final structural connections shall be completed as soon

u as is practicable.
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9.11 .5 Forming Structural Connections
(i) For structural purposes, cement mortar shall compose of one (1)
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part of cement to one (1) part of sand (1 :1), mixed with water so that
the free water: cement ratio does not exceed 0.4 by weight and
cement grout shall have a water: cement ratio between 0.4 and 0.6,
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or such other proportions as shall be directed by the S .O.
(ii) No structural connections shall be made until approval has been

given by the S .O.
(iii) Unless otherwise approved by the S .O., the composition and the
free water: cement ratio of the in-situ concrete or mortar used in any
connection and the packing of jOints shall be in accordance with the
assembly instructions.
(iv) Leveling devices shall be released or removed only with the

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(v) Non load bearing joints between precast concrete components and
adjoining structures shall be filled with appropriate grout and/or mortar
protected by proprietary sealants and backing rod . They shall be
waterproofed .
(vi) Load bearing joints and connection shall be grouted, mortar packed
or concreted. The respective mix design shall be free of lime and
chloride. They shall be durable, waterproof, non-shrink and possess
strength higher than that of precast concrete. Curing for at least three
(3) days shall be provided. Designed mixes shall be submitted to the
S.O. for approval.
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(vii) The method of sampling and testing of grout and mortar shall be
carried out according to MS 26. The compressive strength shall be
determined by crushing test on 100mm cubes. For each casting day
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and for each grade of grout and mortar, three samples shall be taken
from three (3) separate batches. Two (2) cubes shall be cast from
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each sample for testing at seven (7) and 28 days. The appropriate
strength requirement shall be considered to be satisfied if the
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average strength is greater than the specified characteristic strength.
(viii) Connection by using the shear key shall in accordance to approved

drawings or shop drawings and relevant design standards. The edge
surface of shear key shall free from any dirt or debris prior to the
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jointing process. Cracks or cold joints must be inspected by S.O. to
the acceptable limits that do not jeopardize the integrity of the
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structures or structures elements. Any unacceptable cracks or cold

joints must be rectified immediately to the satisfaction of S.O.
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9.11.6 Protection
At all stages of construction, precast concrete components and other

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concrete associated therewith shall be properly protected to prevent damage

to permanently exposed surfaces, especially arises and other decorative
features.
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9.12 OTHER CONCRETE WORKS

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9.12.1 Abutments, Piers, Pile Caps and Foundation
(i) All reinforced concrete abutments, piers and pile caps shall be
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constructed according to the Drawings and to the exact depths

required . The Contractor shall supply, maintain and remove any
necessary planking and strutting, sheet piling and coffer dams, and
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shall, by pumping or other approved means, keep the excavation free

from water. Alternatively, the S.O. may approve the use of self-
compacting concrete in accordance to Subsection 9.2 of this
specification.
(ii) Before commencing to construct the abutments, piers and pile caps,
the Contractor shall check and verify the eccentricities and the cut-off
levels of all piling works in the ground are as provided in the Drawings,
and shall notify the S.O. in the event of any discrepancy.
(iii) The bottom of excavation shall be cleaned or, if in loose or disturbed

ground, well rammed, and the hole shall be approved before it is
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covered with a blinding layer of lean concrete not less than 50mm
thick. The required cover of concrete under the reinforcement shall be
entirely above the blinding layer.
(iv) The Contractor shall straighten the steel reinforcement projecting

above the piles for anchoring pile caps, carry out excavation, and
erect formwork and temporary timbering for the construction of pile
caps .
(v) Reinforced concrete pile cap shall be continuously casted . The

Contractor shall comply with Subsection 9.4.8 and provide
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calculations of the estimated initial and peak temperature of concrete.
The S.O. may approve the adoption of concrete cube compressive
strengths up to the 56 days to assess compliance of the specified
characteristic compressive strength when high blended slag,
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pulverized-fuel ash cement or high performance concrete type is used
to reduce heat in large concrete pours. However, the requirements of
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structural loading at each construction stage must be complied . A
() proper curing in accordance to Subsection 9.4.10 of this specification
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or as requested further by S.O with additional method must be done
when dealt with massive volume of concrete.
(vi) All extemal wall surfaces of abutments in contact with soil shall be
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waterproofed with three (3) coats of bitumen solution complying with
BS 3416 or any other type of waterproofing material as approved by
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the S.O. The concrete surface shall be thoroughly cteaned and dried
before application of the waterproofing material.
(vii) The Contractor shall ensure the stability of the abutment, pier or wall
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during construction where the height of the structures or element(s)

of the structure may cause stability issues. S.O. may require
contractor to perform stability check during construction . Prop or other
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means may be used with the approval of S.O.
9.12.2 Deck Slab

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,) 9.12.2.1 Placement of fresh concrete is preferred at late evening or early

night. Concrete for bridge decks shall not be placed if the
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evaporation rate exceeds 0.75kglm 2Ih or at wind speed exceeding

30 km/h . If placement at the time is imperative, chilled water may
be used for mixing concrete, forms and bars cooled before
placement to avoid significant increase in concrete temperature
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and wind speed lowered by shielding.

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9.12.2.2 All pipes and fittings encased in the deck concrete shall be
provided with sleeves to the approval of the S.O. and shall be built
in-situ. No holes shall be left for later incorporation of fittings and
no subsequent hacking of deck slab shall be made.
The appropriate deck construction sequence shall be observed as

follows:
(i) place complete deck at one time whenever feasible within

the limitation of Subsection 9.4:7.
(ii) If multiple placement must be made on simple spans,

place each span in one placement.
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(iii) If the bridge comprises of simple spans, but cannot be

placed in a single placement, then divide the deck
longitudinally and make two placements.
(iv) If bridge is of simple spans, and single placement-cannot

be made over the full span length, then place the center of
span segment first and ensure this placement to be as
large as possible.
(v) If multiple placements must be made and the bridge is of

continuous spans, then place concrete in the center of the
sagging moment regions first, and then observe a 72 hour
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delay between placements.
9 .12.2.3 After initial set, the upper surface of concrete decks shall be
trowelled smooth with a steel float to true level and even
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surface. Care shall be taken to ensure that the steel
reinforcement is not displaced or lowered during trowelling. In
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order to prevent cracking of the trowelled surface on drying out,
the S.O. may direct a covering to be suspended above the
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concrete surface to prevent loss of water after compaction.
9.12.2.4 Wet curing should be implemented immediately at areas where

concrete has set to reduce the temperature of the concrete
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surface. Curing shall be by continuously damped double layer
of gunny bags or other approved methods with excess water
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for not less than 7 days.
9.12.2.5 Half-width Construction

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Traffic can be maintained on part of the bridge while the other

part is under construction if well proportioned, well compacted
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low slump concrete is approved by the S.O. in accordance to

Subsection 9 .3 . The effect of adjacent traffic may be minimized
further by imposing speed limitations on the bridge, as well as
restrictions of heavy vehicles including construction vehicles in
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lanes adjacent to the area under construction.

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9.12.3 Shop Drawing
9.12.3.1 The Contractor shall submit detailed shop drawings, including for
expansion joints, bearings, forms and form travelers for approval.
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The shop drawings shall include, but not necessarily limited to, the
following information;
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(i) Fully and accurately dimensioned views showing the

geometry of the items including all projections, recesses,
notches, openings, block-outs and other pertinent details.
(ii) Details of steel reinforcement shall be clearly shown as to

the size, spacing and location including any special
reinforcing required but not shown on the drawings. The
post-tensioning layout shall govem over the layout of steel
reinforcement and shall be adjusted to clear tendons.
(iii) Size and type of ducts for all post-tensioning tendons and
their horizontal and vertical profiles shall be clearly detailed.
Duct supports, grout tubes, vents and drains shall be
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shown including size, type and locations.
(iv) Details and locations of all other items to be embedded

such as inserts, lifting devices and post-tensioning
hardware shall be shown.
(v) Prestressing details shall include sizes and properties of

tendons, anchorages, plates, assemblies and stressing
equipment, as well as details of the stressing procedure
and stressing sequence, details and locations of all
couplers, and additional reinforcement necessary to resist
anchor block stresses.
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(vi) A table shall be provided showing elevations and geometry
to be used in positioning the forms for the next segment to
be casted.
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(vii) Graphs, charts or tables showing the theoretical location of
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each item, as erected or placed, shall be furnished to the
5 .0. for use in checking the erection of segments.
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Detailed procedures for making geometry corrections shall
be described.
(viii) Delails of tie down tendons, temporary and permanent

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bearing assemblies as required.
9.12.4 Drips
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Unless otherwise directed by the 5.0., a 15mm wide drip shall be formed along
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edges of soffits to concrete deck slabs, undersides of parapets, cantilevered

beams and other parts of bridge where rain water is likely to adhere in drops.
EN
9.12.5 Openings
Where shown in the Drawings, all cast-in-situ reinforced concrete openings

shall be constructed without bolt holes made through the walls or slabs. If such
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u holes are unavoidable then they shall be completely grouted with shrinkage
compensating cement mortar and as specified in Subsection 9.11.5 or sealed
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and waterproofed by other means to prevent leakage, to the approval of the

5.0.
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9.13 PROTECTIVE COATING SYSTEM

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9.13.1 General
Protective coating system shall be applied to the structures or element(s) of

the structures as mentioned in the drawings, bill of quantities or as directed
by 5 .0 . The protective coating is classified for two purposes namely:
a) Protective coating for durability and/or protection against abrasive

and harsh environmental influenced attack to the concrete structures.
b) Protective coating for aesthetical or decorative purpose.
The selection of the type and the intention of the coatings shall be based on
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the drawings, bill of quantities or as directed by S.O.
9.13.2.1 Prior to application, all surfaces must be dry and free from oil,
grease, loose particles, decayed matter, moss or algal growth and
general curing compounds . All such contaminations and laitance
must be removed by the use of grit blasting, high pressure water
jetting or equivalent mechanical means.
ER
9.13.2.2 Before proceeding to apply the protective coatings, all surfaces
which are not to be coated but which may be affected by the
application of the coating, shall be fully masked and, in particular,
flora/fauna shall be protected.
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9.13.2.3 Blow holes and areas of pitting shall be made good with a one part
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modified cementitious material, and allowed to cure in accordance
with the manufacturer's recommendations. The application shall be
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in accordance with the manufacturer's recommendations,
particularly with respect to the maximum application thickness of
3mm.
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9.13.2.4 Fresh concrete shall be at least 28 days old before receiving the
surface preparation.
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9.13.3 Coating Materials to (Superstructures): Deck Soffit, Beam/ Girder, R.C.

Diaphragms, Capping Beams, Parapet, etc. (for durability protection)
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9.13.3.1 The protective coating shall consist of a dual protective system

formed by two coats of silane-siloxane based primer or equivalent
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and two coats of solvent based methacrylate pigmented or

equivalent as the top coat.
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9.13.3.2 The Contractor is required to adhere strictly to the manufacturer's

recommendations regarding the use, storage, application and
safety rules in respect of the approved materials.
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9.13.3.3 The coating shall be applied by spray, roller or brush to achieve a

finish acceptable to the S.O. In all operations of storage, mixing
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and application, the Contractor is to comply with the Health and

Safety recommendations of the manufacturer and governing
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authorities.
9.13.3.4 Where required by the S.O, trial areas not exposed in the finished
work shall first be treated using the selected materials. These trial
areas shall be noted on the Drawings and shall be carried out using
the type of materials, mixing procedures and applications that will
be used in the Contract and shall be approved by the S.O. before
Contractor commences with the general work.
9.13.3.5 The material employed for the coating shall comply with the
following requirements or equivalent;
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l)escrlDtlon Requirements
Wet film thickness 150 microns per coat
Drv film thickness 75 microns per coat
Reduction in water absorption
80% minimum @ 28 days
(ASTM C642)
Carbon Dioxide diffusion
resistance A minimum equivalent to
(Research Laboratories Taywood 250 metres of air
Enaineerino Ltd)
Water vapour transmission
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Shall be more than
(Research Laboratories Taywood
13g/m' /day
Enaineerina Ltd)
Reduction in chloride ion
90% minimum @ 28 days
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penetration
FreezelThaw salt scaling Unaffected by 50
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IASTM C672) exposure cycles
Notes: Where test methods are not specified, the procedure for
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establishing compliance with the above criteria shall be agreed with the
S.O.
9.13.3.6 Primer shall be applied for at least two flood coats using a low
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pressure knapsack sprayer. Application shall be repeated until
correct coverage is achieved. On very porous surfaces, application
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shall be repeated until surface is completely saturated. All treated
surfaces shall be allowed to dry for at least two (2) hours.
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9.13.3.7 When the surface is visibly dry, the Topcoat shall be applied. If the
surface is porous, it shall be stabilized by a coat of the appropriate
grade diluted with 5% of an approved solvent.
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9.13.3.8 A two coat, pinhole free application of the Topcoat shall be applied.
Four hours drying between coats shall be allowed.
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u 9.13.3.9 The coating shall have the properties of resistance to weather,

ultra-violate light, high temperature and humidity. All layers of
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coatings shall have the effective service life with warranty of

minimum of 20 years.
9.13.4 Coating Materials to All Abutments and Piers (for durability protection)
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9.13.4.1 The solvent free based epoxy resin coating shall comply with the
following properties;
Description Requirements
SpecifY Qravity 1.67 (approx.)

Volume Solids 100%
Recommended dry film thickness (dft) 200 /!m. wet
thickness per coat film thickness 200 mm.
Theoretical coverage 5m'/lilre (3m'/kg) for a dft of 200

um.
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Description Requirements
Practical coverage Theoretical coverage is quoted for

guidance. Practical coverage may
be lower, depending on substrate
and application method.
Number of coats 2
Pot Life at 20°C at 35°C
30-40 mins 12-20 mins
DD£ing Time at 20°C at 35°C
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Touch dry 6 hours 3 hours
Fully dry 7 days 7 days
Recoatable 6-24 hours 3-12 hours
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Application temperature Minimum 5°C
Resistance of film The fully cured coat is resistant to :-
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- Distilled Water
- SeaWater
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- Chlorinated Water
- Sodium
- Brine 20%
- Hydroxide 10%
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- Marsh Water
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- Petrol·
- Sewage Water
- Gas Oil·
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- Kerosene
(·)May cause surface discoloration
EN
9.13.4.2 The coating shall have the properties of resistance to weather,

Ultra-violate light, high temperature and humidity. All layers of
coatings shall have the effective service life with warranty of
minimum of 20 years.
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9.13.4.3 Application - Brush shall be used and the first coat must be firmly
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applied and well-scrubbed into the surface and a continuous

coating of uniform thickness shall be ensured. The second coat
shall be applied 6 to 24 hours later.
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9.13.5 Protective coating for aesthetical or decorative purpose

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The protective coating shall consist of a inorganic dual protective system

formed by two coats of Acrylic binder or equivalent and two coats of solvent
based methacrylate pigmented or equivalent as the top coat and shall be
approved by S.O. prior to its application. The surface preparation prior to the
coating application shall be in accordance to Subsection 9.13.3 of this
specification.
The coating shall have the properties of resistance to weather, ultra-violate

light, high temperature and humidity. All layers of coatings shall have the
effective service life with warranty of minimum of 10 years. The materials or
substrate materials of the coating must not have any detrimental effect or that
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may cause chemical reaction to the concrete either intemally or extemally.
The coating shall be mocked up and approved by S.O . to ascertain its

appearance, colour, finishes, etc. The mocked up sample shapes and sizes
shall be as instructed by the S.O.
The Contractor is required to adhere strictly to the manufacturer's

recommendations regarding the use, storage, application and safety rules in
respect of the approved materials.
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9.14 HIGH PERFORMANCE (HPC) AND ULTRA-HIGH PERFORMANCE
CONCRETE (UHPC)
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9.14.1 General Requirements
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Designed concrete that has the intended use for its specific strength, durability
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and high workability can be regarded as High Performance Concrete (HPC) .
Where compressive strength class of the concrete exceeds C1 00/115, the
concrete can be classified as High Performance Concrete in view of its
strength capacity. The use of concrete at compressive strength class of
CS0175 or above for the purpose of durability function and specific workability
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shall also be regarded as High Performance Concrete. Where the
characteristic compressive cylinder strength of the concrete attains well
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beyond 140 N/mm2 or cube strength of 155 N/mm2 tested at the age of 28
days, the concrete shall be classified as Ultra-High Performance Concrete
(UHPC). Detailed definitions of UHPC shall be referred to standard NF P 18-
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470 or any established standards to the approval of S.O. when dealt with the
UHPC type of concrete.
EN
The concrete mix shall be designed concrete to MS EN 20S unless otherwise

stated in the Drawings.
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Initial guide for minimum cement content and maximum free water cement
C) ratio for HPC can be based on TABLES 9.S and TABLE 9.SA. Structures
subjected to abrasive and harsh environment, close proximity to the shoreline
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or open to sea-tidal may have the modification done on the waterlcement ratio
and cement content in order to provide adequate durability and required
permeability.
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Unless it can be proven otherwise, high early strength of cement or cement

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that is deemed to accelerate the rise and rate of hydration shall not be used
as the main constituent of HPC as it may cause formation of intemal cracks or
micro-cracks to the concrete.
When the compressive andlor tensile strength of the concrete is of prime

motive, in the case of UHPC, the maximum water cement or binder wlc ratio
can be as minimum as 0.18 and the minimum cement content shall be 750
kg/m3 subjected to S.O approval. The range of water cement ratio and cement
content shall be such that the workability and consistency of the concrete is
not compromised . Modification to the cement content can be made subject to
the approval of S.O. Contractor, fabricators or specialist contractor must
provide evidences that the concrete possesses adequate ductility when low
water-cement ratio is used in the mix. The S.O. may request the Contractor,
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fabricator or specialist contractor to undertake and carry out ductility test to the
concrete batch such as three-point bending test or its equivalent. Testing
methods shall be based on the current established method as approved by
S.O.
The designation of concrete grade of HPC shall have similar notation in

accordance to clause Subsection 9.2.9.1 of this specification. Where the
flexural strength property is of importance, additional notation that reflects the
value of flexural or direct tensile strength can be printed out and shown in the
Drawings orland in the Tender Documents. The Contractor must bring to the
attention of the S.O. the value of these strengths for his information and
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comprehension.
The workability of the fresh concrete shall be judged by its suitability for the
condition of handling and placing so that after compaction, it surrounds all
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reinforcement, tendons and ducts and completely fills the formwork. In
general, the workability of HPC and UHPC shall be in accordance to
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Subsection 9.2.9.3 of this specification. The Contractor may propose higher
workability and subject to S.O approval in the case of highly cohesive mixes
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without reducing the strength and durability requirements. The S.O may reject
the product that shows signs of honeycombing due to poor workability.
9.14.2 Material
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9.14.2.1 Cement
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The cement to be used throughout the Works shall be CEM 1 type

of cement to comply with MS EN 197-1 and obtained from an
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approved manufacturer. Blended cement shall not be used unless

it can be prove that it shall not cause any adverse effects to the
mix or as directed by S.O. Any specific use of other cement types
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for the positive improvement, such as to the fluidity, heat

generation, hydration, creep andlor shrinkage and chemical
resistance or other advantages shall be brought to the attention of
S.O for approval. Certificate of Test and Transportation and
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Storage of Cement material shall comply to Subsection 9.2.1 of

this specification.
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9.14.2.2 Aggregates
In general, for HPC and UHPC, the aggregate compliance shall be

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referred to Subsection 9.2.2 of this specification.

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In the case of UHPC type of concrete, the fine aggregate or fine

sand shall be washed, sieved and kiln dry with maximum granular
size not larger than 1.5 mm and complies with the requirement of
ASTM C33. The grading of fine aggregates shall be analyzed as
described in MS 30 and shall be within the limits specified in Table
9.38.
9.14.2.3 Water
Water compliance shall be referred to Subsection 9.2.3 of this

specification.
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9.14.2.4 Admixture
Admixture compliance shall be referred to Subsection 9.2.4 of this

specification.
9.14.2.4 Additions and Supplementary Cementitious Material (SCM)
In general, all additions and Supplementary Cementitious Material

added to HPC and UHPC shall be in accordance to Subsection
9.2.5 of this specification except wherever mentioned herewith.
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Additions used for HPC or UHPC which are not covered in the
clause 9.2.5 or exceed the stipulated limits shall be brought to the
attention and approval of S.D.
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In the case of production of UHPC, the addition of silica fume
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content shall be not less than 10% and not more than 25% of the
cement replacement by weight. Under normal circumstances other
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types of additive or supplementary cementitious materials are not
preferred in the production of HPC unless it can be proven through
conformance test that the physical properties of the materials are
either equivalent or exceed the value stated in this specification
with respect to strength, durability and efficiency.
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9.1 4.2.5 Fibres
HPC and UHPC concrete may have fibres in the form of straight or
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deformed piece of cold-drawn steel wire or polymer fibres

homogeneously mixed with the concrete to improve the toughness,
impact resistance and enhancing the tensile capacity of the
concrete. Steel fibre materials and properties requirement shall
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comply with BS EN 14889-1 while polymer fibres shall comply with

BS EN 14889-2.
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Minimum tensile strength for steel fibre shall be 2300 N/mm2 which
u is manufactured from high carbon steel wire and complies with the
requirement of DIN 17223 or equivalent.
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The Contractor shall provide in detail the following items for S.O.
approval prior to the concrete mix production:
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a) Method of statement for mixing the fibres

b) Storage method of the fibres
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c) Test certificates
d) Calculation of fibres dosage or ratio required in the concrete
mix.
Where the fibres content of fresh concrete is to be determined, it

shall be taken either as recorded on the print-out of the batch
recorder or where recording equipment is not used, from the
production record in connection with the batching instruction.
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9.14.3 Concrete Conformance and Identity Testing
9.14.3.1 General
In general, concrete conformance and identity testing for HPC and

UHPC shall be in accordance to Subsection 9.3 of this specification
unless stated otherwise herein. The Contractor shall be
responsible for the evaluation of conformance that consists of the
initial test and production control including conformance control in
accordance to Subsection 9.3.1.1 and 9.3.2 of this specification.
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Sampling and testing of HPC concrete shall be in accordance to
Subsection 9.3.2.1 of this specification. In case where there is
evidence that shows the required strength develops at later than
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28 days, more number of specimen can be proposed by the
Contractor with the agreement of S.O. This is for the purpose of
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specifying more tests to be done at later than 28 days. The ()
compliance of strength however is subjected to the discretion and
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acceptance by the S.O.
9.14.3.2 Flexural strength

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Flexural strength test shall be carried out to determine the
maximum tensile stress under bending load tested on a beam
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specimen. Where flexural strength is to be determined, it shall be

measured in accordance with EN 12390-5. Tests can be
conducted at similar stage and age of concrete as for compressive
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strength test i.e. 7 days, 14 days or 28 days. The S.O. may request
the method and procedural statement for approval prior to the test.
EN
In case of UHPC type of concrete, minimum of 6 units of beam

specimens shall be casted as the testing specimens. The flexural
strength (or modulus of rupture) shall be measured by testing on
beam specimen with nominal size of 100mm x 100mm x 500mm
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specified in BS EN 12390-5, 2009. Tests shall be carried out in an

engineering laboratory or manufacturer plant approved by the S.O. J
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The flexural strength at 7 days shall be tested on two beam

specimens from each sample batch. The flexural strength shall not
fall below 12 N/mm2. The remaining four prisms from the same
sample batch shall be tested for the 28 days flexural strength.
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For compliance purposes of the specified flexural strength, both

of the following conditions shall be satisfied:
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a) The average flexural strength shall not fall below 15 N/mm 2 •

b) The characteristic flexural strength tested at 28 days shall
not fall below 20 Nlmm 2 .
9.14.3.3 Tensile splitting strength
Where the tensile splitting strength of UHPC is to be determined, it

shall be measured in accordance with EN 12390-6. Unless
specified otherwise, the tensile splitting strength is determined on
specimens tested at 7 days and 28 days. The S.O may request the
method and procedural statement for approval prior to the test.
S9-S\
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The characteristic tensile splitting strength of the concrete shall be

equal to or greater than the specified characteristic tensile splitting
strength.
9.14.3.4 Permeability Test
All HPC and UHPC shall be tested with permeability test. The
permeability test shall be in accordance to Subsection 9.3.2.2 of
this specification or ASTM C1202-2005. The S.O. may request
additional tests based on established standards to ensure that the
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durability of the concrete cast on-site and during service is not
jeopardized. In case of the concrete sample that consists of steel
fibres that may be affected by the presence of chloride, other
approved test based on established standards to assess the
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permeability of the concrete may be proposed by the contractor.
Such test(s) must be brought to the attention of S.O. complete with
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procedural method of statements at least 2 months earlier prior to
the test date for the approval. The test must ascertain that the
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performance of the concrete shall not be exposed to the durability
issues which may cause the structure or element(s) of the structure
to be deteriorated within the designed serviceability period.
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9.1 4.4 Production
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9.14.4.1 General
The production of HPC and UHPC shall be in accordance to

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Subsection 9.4 of this specification unless stated otherwise herein.
No site mix of concretes is allowed for any type of HPC and UHPC
EN
at any time during the project duration, or at any stage of

construction of any structure.
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9.14.4.2 Batching and Mixing

u The Contractor shall provide the batching and mixing method of
KU
statement for HPC and UHPC and shall not commence any works
of batching and mixing without the approval of S.O.
The quantities of cement, silica fume or any other additive or
O
addition and sand shall be measured by weight. A separate

weighing machine shall be provided for weighing the cement. The
D
quantity of water shall be measured by weight. Any solid

admixtures to be added shall be measured by weight; liquid or
paste admixtures shall be measured by volume or weight.
If dry sand is used in the production of HPC or UHPC, the batch
weight of the fine aggregate need not to be adjusted to allow for
the moisture content. All measuring equipment shall be calibrated
on site or their calibration status verified by certificates from
accredited laboratories.
Mixers that have been out of use for more than 30 minutes shall
be thoroughly cleaned before any fresh blended cement or
concrete is mixed. The mixer shall be thoroughly cleaned before
S9-S2
(JKRlSPJ/201.6-S9)
changing from one type of cement to another.
The water content of each batch of concrete may be adjusted so

as to produce concrete of the workability required . However, care
shall be taken to ensure the free waterl binder ratio is maintained.
The total amount of water added to the mix shall be recorded . The
initial process shall be witnessed by the S.O. representative prior
to further production of concrete.
9.14.4.3 Placing
ER
Placing of HPC and UHPC shall be in accordance to Subsection
9.4.7 of this specification and placement temperature shall be in
accordance to Subsection 9.4.8 of this specification.
D
In fresh state, UHPC with or without fibres shall remain
homogeneous and there shall be no segregation of fibres or a solid
N
fraction of the constituents taking account of the means of placing.
TE
Any modification from the stipulated clauses shall be brought to the
attention and approval of S.O. including the plan to measure
development and control of temperature. The Contractor must
exercise due care and control of the final concrete product when
A
placing on the specified whole or part of structure as not to cause
any detrimental effect to the concrete hardening process. Any
EJ
method of placing shall be based on the established standards and
must be approved by the S.O.
M
9.14.4.4 Compaction
Compaction of HPC and UHPC shall be in accordance to

EN
Subsection 9.4.9 of this specification.
For fiber reinforced concrete, great care must be exercised during

compaction to avoid any fiber sedimentation or segregation from
M
occurring at whole or part of the concrete member. The S.O may

request for the plan and method of statement of compaction for this
type of concrete and may reject whole or part of structure or
KU
concrete member which has shown signs of fiber sedimentations

or segregations.
9.14.4.5 Curing and Protection

O
In general, curing and protection of HPC and UHPC shall be in

D
accordance to Subsection 9.4.10 of this specification.
Where further heat or steam curing of concrete is required after the

concrete has set for the purpose to improve strength and durability
great care must be taken not to cause any adverse effect to the
concrete member due to the temperature difference between the
concrete member and the surrounding temperature. The
Contractor must submit the plan and method of curing to the S.O.
for approval at least 2 weeks before the concreting takes place.
S9-53
(JKRlSPJ/2018-S9)
TABLE 9.1: COMPOSITION OF COMMON CEMENTS
" '" CompOsition [percentage b~ mass "1

Main constituents
Pozzolanic Fly ash ..g.l!l
Main
Notation of 27 products
(types of common
li;
'"
..8 ~
E
.2 ~
0
~
0
~
0
~
m
"'
0
~
..
c
B .., Iii
E
~
ce ment) •U E '"
.212
<'-
0 "
~ ~
z
~ ~ ~
,g
~
~
E
~
~
E
::;
-g ~
ac 8c
iii ~:Q
~ "'
.~
Jll
Z ~ ::E
"' 5
ER
K 0 P Q V W T L L
CEM I Portland 95·
- - - O·
cement
CEM I
100 · · - - - · 5
CEM II 80· 6· 0-
Portland- IA-S 94 20 - · - · - - - · 5
D
slag cement CEM II 65 · 21 -
- · - - - - - - o·
IB-S 79 35 5
Portland-
N
CEMII 90· 6- 0-
n silica fume
cement
IA·D
CEMII
94
80·
- 10
6
· · - - -
.
- · 5
0-
TE
IA-P 94
- · 20 · · - · -
5
Portland CEMII 65 - 21 - 0-
types - IB-P 79
- · 35 · - - - - - 5
pozzolana CE,~II 80- 6- 0-
cement IA· 94
- - - 20
- - - - - 5
CEMII 65 - 21 - 0-
-
A
IB-Q 79
- - 35
- - - - · 5
CEMII 80 · 6- 0-
- - - - · - - -
EJ
IA-V 94 20 5
CEMII 65 - 21 - . 0-
Portland-fly IB-V 79
· - - - 35
- - - 5
CEM ash cement CEMII 80 - 6- 0-
II - - - - - - - ·
M
IA-W 94 20 5
CEMII 65- 21 - 0-
IB·W 79
- - - - - 35
- - - 5
CEMII 80 - 6- 0-
Portland-
IA·T 94 - - - - - · 20
- - 5
EN
burnt shale
CEMII 65- 21 - 0-
cement
IB·T 79 - · - - - · 35 · - 5
CEM II 80 · 6- 0-
IA-L 94 - - - - - - - 20 · 5
CEM II 65-
- - - - - - 21 - O·
Portland- · -
M
u
IB·L 79 35 5
limestone
CEMII 80 - 6· O·
cement
IA·LL 94 · - · - · - - · 20 5
KU
CEMII 65- 21 - 0-
IB·LL 79 - - · · - · - - 35 5
CEM II 80 - 6 to 20 0-
Portland-
IA-M 94 5
composite
cement c) CEM II 65 - 21 to 25 0-
O
IB·M 79 5
CEM III 35 - 36 - - . - - - - - · O·
IA 64 65 5
Blast-
- - - - - - o·
D
FEM III furnace

CEM III 20- 66 · ·
IB 34 80 5
cement
CEM III
5 - 19
81 - - - - - · · - 0-
IC 95 5
CEM IV 65 - 11t035
...
- - - 0-
CEM Pozzolanic IA 89 5
IV cement c) CEM IV 45· 36 to 66 · - · 0-
IB 64 5
CEMV 40· 18 - 18t030 - - · - o·
CEMV Composite IA 64 30 5
cement c) CEMV 20· 31 - - 31 to 50 . - - 0-
IB 38 50 · 5
The values in the table refer to the sum of the main and minor additional constituents
) The proportion of silica fum e is limited to 10%
) In Portland --composite cements CEM II/A-M and CEM IU8-M, in Pozzolanic cements CEM IV/A and CEM IVIB and in composite
cements CEM VIA and CEM VIS the main constituents other than clinker shall be dedared .by .des.ignation of the cement
S9-54
(JKRlSPJ/2018-S9)
TABLE 9.2: TESTING OF AGGREGATES
Type of Test
Prqperties limits
Aggregate Methods
Grading Both MS30 Table 3 and Table 4
Elongation Index Coarse MS30 Not exceeding 30%
Flakiness Index Coarse MS30 Not exceeding 35%
Water Absorption Both MS30 Not exceedinQ 8%
Clay Lumps Coarse MS30 Not exceedinQ 1% by weiQht
Clay, Silt and Dust Fine MS30 Not exceedinQ 3% by weiQht or 8% by vol.
Organic Impurities Fine MS30 Not exceedinQ 0.4%
Aggregate
ER
Coarse MS30 Not exceeding 40%
Crushing Value
Loss in mass after 5 cycles shall not be more
MS30 than 12% for sodium sulphate or 18% for
Soundness Test Coarse
magnesium sulphate.
D
Not exceeding 0.06% by weight of chloride
Chloride Content Both MS30
ions
N
Sulphate Content Both MS30 Not exceedinQ 0.44% by weiQht of S03
TE
TABLE 9.3: GRADING FOR COARSE AGGREGATE
Percentage by mass passing BS 410 sieve for nominal sizes

Graded Aggregates Single-sized Aggregate
Sieve size
A
(B8410) 40mmto 20mmto 14 mm to
40mm 20mm 10mm
5mm 5mm 5mm
EJ
50.0mm 100 - - 100 - -
37.5mm 90 to 100 100 - 85 to 100 100 -
20.0mm 35 to 70 90 to 100 100 o to 25 85 to 100 -
14.0mm 25 to 55 40 to 80 90 to 100 - o to 70 100
M
10.0mm 10 to 40 30 to 60 50 to 85 Oto 5 o to 25 85 to 100

5.0mm Ot05 o to 10 o to 10 Oto 5 - Oto 25
2.36mm - - - - o to 5 -
EN
TABLE 9.3A: GRADING FOR FINE AGGREGATE

M
Sieve size Percentage by mass passing BS 410 sieve

(BS410) Additional limits for grading
Overall limits
KU
C *M F
10.0mm 100 - --
5.0mm 80 to 100 - - -
2.36mm 60 to 100 60 to 100 65 to 100 80 to 100
1.18 mm 30 to 100 30 to 90 45 to 100 70 to 100
O
600 ~m 15 to 100 15 to 45 25 to 80 55 to 100

300 ~m 5 to 70 5t040 5 to 48 5to 70
D
150 ~m o
to 15# - - -
# Increase to 20% for crushed rock fines, except when they are used for heavy-duty floors.
. For prescribed mix only Grading Limit M is applicable .
Individual sands may comply with the requirements of more than one grading. Altematively some
NOTE: sands which satisfy the overall limits but may not fall within anyone of the additional limit C, M or F
may also be used provided that the supplier can satisfy the S.O that such materials can produce
concrete of the required quality.
S9-55
(JKRlSPJ/2018-S9)
TABLE 9.3B - GRADING FOR FINE AGGREGATE FOR HPC AND UHPC
Sieve Size (BS410) PercentaQe by Mass PassinQ BS 410

Limit
2.36 mm 100
1.18 mm 90 -100
0.6mm 30-50
0.425mm 25-35
0.3mm 10-20
ER
0.15 mm 5 -10
< 0.15 mm 0-5
D
TABLE 9.4: ADMIXTURE ACCEPTANCE TEST REQUIREMENTS
N
n
TE
Stiffening Time Time Minimum
from completion of length change,
Strength as a
Age Maximum
Categories mixing to reach a percentage
Water shrinkage
of resistance to penetration of:- of the control
Reduction mix
Admixture
A
0.5 3.5 27.5 %of
Nlmm2 Compressive Increase
Nlmm2 Nlmm' control
EJ
Within
1hr.and At least
1hr. 12 24 hrs.
Type 1: 3hrs.
M
earlier 5 3 days
Accelerator earlier
- More
than than 12 7 days
135 0.010
than control 5 28 days
control
1hr. mix 10
mix
0
EN
Not more
Within
than
At least 1hr.and
Type 2: 3hrs. 9
1hr.later 3hrs. later 3 days
Retarder later 0
than 7 days
M
- than
control
than 9
28 days 135 0.010
() control
mix mix
control
mix
0
9
KU
Within + Within + Within

Type 3:
1hr. 1hr. and + 1hr. and 11
Normal 3 days
water- At least and - - - 0
7 days
5% 1hr.of 1hr.of 1hr.of 11 0.010
reducing 28 days 135
O
control control control 0

mix mix mix 11
Within
D
1hr.and At least
Type 4: 3hrs. 1hr. 12 24 hrs.
Accelerating earlier earlier 5 3 days
At least More
water- than than 12 7 days 0.010
5% than 135
reducing control control 5 28 days
1hr. 10
mix mix
0
Not more
Within
than
At least 1hr.and
Type 5: 3hrs. 11
1hr.later 3hrs. 3 days
Retarding later than 0
At least than earlier 7 days
water- control mix 11
5% control than 28 days 135 0.010
reducing 0
mix control
11
mix
0
S9-56
(JKRlSPJ/2018-S9)
TABLE 9.5: PRESCRIBED MIXES FOR GENERAL USE PER CUBIC METER OF
CONCRETE BY WEIGHT BATCHING
28 days Nominal Max. Size 01 Auureuate (mm) 2u

Grades of Strength of workabilitv Medium High Max free
Concrete 7r0ncre~i
2
Consistence 25 - 75 75 - 125 water cement
N/mm ratios
CEM I (kg)
Total aggregate 280 310
15P 15 (kg) 1800 1750 0.6
' Fine aggregate 35 -50 35 - 50
(%)
ER
CEM I (k~~
20P 20 (kg) 1800 1750 0.55
' Fine aggregate 20 - 40 20-45
D
(%) CEM I [kg)
CEM I (kg)
N
25P 25 (kg) 1750 1700
' Fine aggregate 20-40 30 -45 0.5
TE
(%) CEM I (kg)
Total
Aggregate (kg) 400 430
30P 30 'Fine (~0regate 1700 1650 0.45
% 20-40 30 -45
A
EJ
TABLE 9.5A: PROPORTIONS AND STRENGTH REQUIREMENTS FOR PRESCRIBED MIXES BY

M
VOLUME BATCHING
Cubic Meters of
Strength
EN
Aggregate Per 50 Max. Free

Quantity of Concrete
Slump kg ofCEM I Water:
Proportion Of Water
Limits Cement
(by weight) (Litres)
(mm) Ratio At7 At 28
(Grade) Coarse
Fine Days Days
M
(20mm)
(N/mm2) (N/mm2)
1:1 :2(30P) 25 - 50 0.035 0.07 0.45 22.5 20 30 J
KU
1:1.5:3(25P) 25 - 50 0.05 0.1 0.5 25 17 25

1:2:4(20P) 25 - 50 0.07 0.14 0.55 - 0.6 27.5 - 30 14 20
1:3:6(15P) 25 - 50 0.10 0.20 0.6 30# 11 15
# or as approved by S.O
O
D
S9-57
(JKRlSPJ/2018-S9)
TABLE 9.6: DURABILITY RECOMMENDATIONS FOR REINFORCED OR PRESTRESSED ELEMENTS

WITH AN INTENDED WORKING LIFE OF AT LEAST 50 YEARS
ompressive strength d ass where recommended, maximum water-cement raUo and minimum
Nominal Cement!
cover b) cement or combination content for normal-weight concrete~) with 20mm maxi mum aggregate sized) oomblnation
mm 25+6c 30+.6.c 35+.6.c 40+6.c 45+.6.c 50+.6.c
types
15 +.6.c 20+6c
Corrosion induced by carbonation (XC exposure classes)
C20/25 C20/25 C20f25 C20/25 C20/25 C20/25 C2 C20f25

All in Table 01
ER
XC 1 0.70240 0.70240 0.70240 0.70240 0.70240 0.70240
0.70240
C25/30 C25/30 C25130 C25130 C25J30 C25/30

XC2 · · 0.65260 0.65260 0.65260 0.65260 0.65260 0.65260
All in Table 0 1
C30/37 C28f35 C25130 C25130 C25130 C25/30
D
C40/50 All in Table D1
0.55300 0.60280 0.65260 0.65260 0.65260 0.65260
except IV8-V
XC3 · 0.45340 C25/30
C40f50 C30/37 C28/35 C25130 C25i30
· 0.45340 0.55300 0.60280 0.65260 0.65260 0.65260
IVB_V
N
Corrosion Induced by chlorides (XS from sea water, XO other than sea water) Also adequate for any
associated carbonation induced corrosion (XC)
TE
C40/50 C32140 C28/35 C28J35 C28J35 C28135
XD1 · ·
0.45360 0.55320 0.60300 0.60 300 0.60300 0.60 300
All in Table 0 1
C4S15 C35145 C32140 C32140 C32140 CEM ',IIA,IIB-

· · - 0.35380 0.45360 0.50 340 0.50 340 0.50 340 S,SRPC
A
C401SO C32i40 C28/35 C25I3O C25130 liB-V, lilA
- - - 0.35380 0.45360 0.50340 0.55320 0.55 320
XS1 C25130 C25/30 C2S130 C25130
- - - C32140 IIIB
EJ
0.40 380 0.50340 0.S0340 0.55320 0.55 320
C32140 C28J35 C25130 C25130 C25130 IVB-V
· · · 0.40380 0.50340 0.50 340 0.55320 0.55320
CEM I, 1IA, IIB-

M
C40/50 C32140 C28135 C28J35 C28135

- - -
0.40380 0.50340 0.55320 0.55320 0.55 320 S,SRPC
XD20r C35145 C28135 C25130 C25130 C25130 IIB-V, IIIA
XS2 - · -
0.40380 0.50340 0.55320 0.55320 0.55320
C32140 C25130 C20125 C20125 C20/25 IIIB, IVB-V
· · ·
EN
0.40380 0.50 340 0.55 320 0.55320 0.55320
·
· · - ·
C4S155 C40/50 C35145 CEM I, 1IA, IIB-
0.35 380 0.40380 0.45360 S, SRPC
XD3 - · - · ·
C35145 C32140 C28135 IIB-V, IIIA
0.40380 0.45360 0.50340
M
· · C32140 C28J35 C25130

\ ) · · · 0.40380 0.45360 0.50340
IIIB,IVB-V
KU
- C35145 C45155 C40/50 CEM I, ItA, IIB-

· · · · · 0.40380 0.35380 0.40380 S,SRPC
C28135 IIB-V,IIIA
XS3 - - - - - C32140
0.40380
C32140
0.45360 0.50340
C28/35 C25130 IIIB, IVB-V
· - · · ·
O
0.45360 0.50 340

D
S9-58
(JKRlSPJ/2018-S9)
TABLE 9.6A: MINIMUM CEMENT CONTENT FOR MAXIMUM AGGREGATE SIZES OTHER
THAN 20MM
Maximum aggregate
Limiting values given for 20 mm maximum aggregate size
size
Minimum cement or combination content ~ 40 14 10
Maximum wl c ratio
Ke/m 3 mm mm mm
0.70 240 240 260 280
0.65 260 240 280 300
0.60 280 260 300 320
ER
300 280 320 340
0.55 340
320 300 360
320 300 340 360
0.50
340 320 360 380
D
340 320 360 360
0.45
360 340 380 380
N
0.40 380 360 380 380
0.35 380 380 380 380
TE
TABLE 9.7: SLUMP CLASSES
Class Siumoin mm
A
Sl 10 to 40
S2 50 to 90
EJ
S3 100 to 150
S4 160 to 210
S5 " 220
M
TABLE 9.7A: COMPACTION CLASSES

EN
Class Degree Of Comoactibility

CO " 1.46
Cl 1.45 to 1.26
C2 1.25 to 1.11
,
M
C3 1.10 to 1.04
KU
TABLE 9.7B: VEBE CLASSES
Class Vebe Time In Seconds

VO ,,31
O
Vl 30 to 21
V2 20 to 11
V3 10 to 6
D
V4 5to 3
TABLE 9.7C: FLOW CLASSES
Class Flow Diameter In mm

Fl s 340
F2 350 to 410
F3 420 to 480
F4 490 to 550
F5 560 to 620
F6 " 630
S9-59
(JKRlSPJ/2018-S9)
TABLE 9.70: CONSISTENCE SUITABLE FOR DIFFERENT USES OF IN-5ITU CONCRETE
Consistence class
Use of concrete Form of compaction Normal-weight Lightweight
concrete concrete
Kerb bedding and braking Tamping S1 -
Floors and hand placed Poker or beam S2 82
pavements vibration
Strip footings, Pile Cap S3 -
-
ER
Mass concrete foundations S3
Blinding Poker or beam S3 -
Normal reinforced concrete in vibration andlor S3 S3
slabs, beams, walls, piers and tamping
columns
D
Sliding formwork construction S3 82
Pumped concrete S3 F5
N
Vacuum processed concrete S3 S3
Trench fill Self-weight S4 -
TE
In-situ piling compaction S4 -
TABLE 9.7E: MAXIMUM TOTAL CHLORIDE
A
Maximum Total Percentage of
Type or Use of Concrete
Chloride Ions by Mass of Cement
EJ
Concrete containing embedded metal and made with

0.4
cement complying with MS522
Prestressed Concrete and Heat-Cured Concrete
0.1
M
containing embedded metal

Plain, non-structural concrete No limit
Notes on Table 7.-
=
(1)% Chloride ions x 1.648 % equivalent sodium chlorides.
EN
(2)% Chloride ions x 1.56 = % equivalent anhydrous calcium chlorides.
TABLE 9.8: COMPRESSIVE STRENGTH CLASSES FOR NORMAL WEIGHT AND HEAVY
M
WEIGHT CONCRETE
~)
Minimum characteristic cylinder Minimum characteristic cube
KU
Compressive strength strength

strength class f , k'''''2 f ok,CUBi
N/mm N/mm
C8/10 8 10
O
C12/15 12 15
C16/20 16 20
D
C20/25 20 25
C25/30 25 30
C30/37 30 37
C32140 32 40
C35/45 35 45
C40/50 40 50
C45/55 45 55
C50/60 50 60
C55/67 55 67
C60175 60 75
C70/85 70 85
C80/95 80 95
C90/105 90 105
S9-60
(JKRlSPJ/2018-S9)
TABLE 9.9: COMPRESSIVE STRENGTH CLASSES FOR LIGHT WEIGHT CONCRETE
Minimum characteristic cylinder Minimum characteristic cube strength

Compressive strength f r
,'.CUB
strength class f "" ~2 N/mm
N/mm
LC8/9 8 9
LC12113 12 13
LC16/18 16 18
LC20/22 20 . 22
ER
LC25/28 25 28
LC30/33 30 33
LC35/38 35 38
LC40/44 40 44
D
LC45/50 45 50
LC50/55 50 55
N
LC55/60 55 60
LC60/66 60 66
TE
LC70r77 70 77
LC80/88 80 88
Other values may be used if the relationship between these and the reference cylinder
strength is established with sufficient accuracy and is documented.
A
TABLE 9.10: MINIMUM RATE OF SAMPLING FOR ASSESSING CONFORMITY
EJ
Production Minimum rate of sampling for assessing conformity
First 50m· Subsequent to first 50m· of production"
of production
Concrete with production Concrete without production
M
control certification control

certification
EN
Initial (until at least 3 samples· 1/200m· or 21production 1/150m· or 1/production day

35 test results are week
obtained)
M
Continuous' (when 1/400m· or 1/production

at least 35 test week
results are
KU
available)
Sampling shall be distributed throughout the production and should not be more than 1
O
sample within each 25 m'

1 sample shall be min. of 3 specimens or as directed by 5.0.
D
Where the standard deviation of the last 15 resu lts exceeds 1.370. the sampling rate
shall be increased to that required for initial production for the next 35 test results
TABLE 9.11 : CONFORMITY CRITERIA FOR COMPRESSIVE STRENGTH
Number n of test Criterion 1 Criterion 2

results for
Mean of n results
Production compressive Any Individual test result (t d)
strength in the (t,m) N/mm2 N/mm
2
group
Initial 3 "/",,+4 " /,, -4
Continuous 15 "1",, +1,48 cr " /,, -4
S9-61
(JKRISPJ/2018-S9)
TABLE 9.12: COMPRESSIVE STRENGTH REQUIREMENTS FOR PRESCRIBED MIX
28-day Strength of Cube Strength at 7 Average Cube Strength at

Grades of
Concrete N/mm' Days' N/mm' 28 Days' N/mm'
Concrete
20P 20.0 14 20.0
25i=' 25.0 17 25.0
30P 30.0 20 30.0
'Only for CEM1
ER
TABLE 9.13: IDENTITY CRITERIA FOR COMPRESSIVE STRENGTH
Criterion 1 Criterion2
D
Number n of test results for
Mean of n results (fan) Any individual test result
compressive strength from the
N/mm' (f.) N/mm'
defined volume of concrete
N
() 1 Not aoolicable "fck- 4
TE
2-4 "{,k+ 1 " f ck -4
5-6 "f,k- 4
.. "7,,,+2
NOTE. The Identity cntena of table 13 give probability that a conforming concrete volume IS rejected .
A
TABLE 9.14: IDENTITY CRITERIA FOR SLUMP SPECIFIED AS A SLUMP CLASS
EJ
ReQuirement
Specified
For composite samples taken in For spot samples taken from initial
Slump Class
accordance with BS EN ~ 2350-1 discharge
Not less than Not more than Not less than Not more than
M
S1 0 60 0 70
S2 40 110 30 120
S3 90 170 80 180
EN
S4 150 230 140 240

S5 210
.. - 200 -
NOTE: DimenSion In millimeters
M
l ) TABLE 9.15: IDENTITY CRITERIA FOR SLUMP SPECIFIED AS A TARGET VALUE

KU
Tolerance
Specified Target
For composite samples taken in For spot samples taken from
Slump
accordance with BS EN 12350-1 initial discharged
,;40 -20, +30 -30, +40
O
50 to 90 -30, +40 -40, +50

,,100 -40, +50 -50, +60
D
89-62
(JKRlSPJ/2016-S9)
TABLE 9_16: RECORDED DATA AND OTHER DOCUMENTS
Subject Recorded data and other documents
Cements, aggregates,
Name of suppliers
admixture, additions
ests on mixing water (not
Date and place of sampling . Test results
required for potable water)
est on constituent materials Date and test results
Concrete description
ER
Record of masses of constituents in batch or load
Composition of concrete
Water/cement ratio
r.hloride content
Date and place of sampling
D
ocation in structure
Consistence (slump or other methods)
N
Tests on fresh concrete
Density
Concrete temperature n
TE
Air content
Volume of concrete batch or load tested
~umber and codes of specimens to be tested
1Nater/cement ratio
pate of testing
A
Tests on hardened concrete
~ode and ages of specimens
Irest results for density and strength
EJ
~pecial remarks (e.g. unusual failure pattern of specimen)
Evaluation of confonmity Confonmity/non-confonmity with specifications
~ocation of work
Additionally for ready mixed
Numbers and dates of delivery tickets related to tests
M
concrete
Delivery tickets
EN
TABLE 9,17: CHARACTERISTIC STRENGTH OF STEEL REINFORCEMENT
Specified Characteristic
Type Nominal Sizes (mm)
Strength, fy (N/mm 2)
M

~old worked (BS 4461) All sizes 460
KU
Hard drawn steel wire (MS 144) Up to and including 12 485
TABLE 9.18: MINIMUM PERIODS BETWEEN CONCRETING AND REMOVAL OF FORMS

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~ertical faces of beams, culverts, wall, cross-head, columns, piles, foundation,

3 days
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plinths and precast components

Deck Slabs / Slabs (props left under) 4 days
Removal of props to slab 10 days
Beam/Girder soffits (props left underl 8 days
Removal of props to beams/Qirders 21 days
Note: This table Is applicable only for CEM1 cement. Where other types of cement, admixtures or
additional material are to be used, the minimum periods between concreting and removal of forms shall be
as approved by the S.O.
S9-63
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Section 10 - Foundation Works (JKRISPJ/2019-S10)
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JKRJSI J J /2019-S10
J KR 20400-0236-20
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KERAJAAN MALAYSIA
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STANDARD SPECIFIC~TION
FOR ROAD WO-R KS,
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Section 10: Foundation Works
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ISBN 978-967-22~ 7-8

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e
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ICEnJA PENGARAH KERJ.". RAYA

IABATANKBltJA R,&.YA MALAYSIA
1ALAN SOLTANSALAlIUDDIN.
50582J«WAllllMPUR.
FOREWORD
As practices in road construction change over time, it is imperative for Jabatan Kerja
new specifications not only aimed at keeping abreast with current technologies but
also helping in improving the quality of constructed product. In unison, these new
specifications have significant positive impact on the construction industry especially
with the incorporation of new products and technologies.
Standard Specification for Road Works is an essential component in the road
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infrastructure construction industry. This specification provides an improved
guidance in the material selection and the production of good quality workmanship
and products based on current best practices. The purpose of this standard
specification is to establish uniformity in road works to be used by road designers,
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road authorities, manufacturers and suppliers of road related products.
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This document Standard Specification for Road Works - Section 10: Foundation 0
Works (JKRlSPJ/2019-S10) is a part of series of improved specifications in the
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Standard Specification for Road Works. The compilation of this document was
carried out through many discussions by the technical committee members.
Additionally, it has been presented at a technical workshop held on October 2018.
Feedbacks and comments received had been carefully considered and incorporated
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in the Specification where appropriate as well as considering the ambiguities and
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difficulties that arise in the previous version .
This Specification also had been presented in the Mesyuarat Teknikal Cawangan
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Jalan Bil.2/2019 on 21 st February 2019, then approved in Mesyuarat Jawatankuasa

Spesifikasi Piawai JKR bagi Kerja-kerja Jalan Bil. 2/2019 on 24th May 2019, and
finally presented in Mesyuarat Pengarah Bil. 1/2020 on 14th January 2020.
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This document will be reviewed and updated from time to time to cater for any
changes on policies and current requirements . In this respect, any comments and
feedback regarding to this specification should be forwarded to Sahagian
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Pembangunan, Inovasi & Standard , Cawangan Jalan . 0

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Published by: -
Cawangan Jalan,
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Ibu Pejabat Jabatan Kerja Raya Malaysia

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50400 Kuala Lumpur.
May 2020
@2020 Jabatan Kerja Raya Malaysia

Hak Cipta Terpelihara
ACKNOWLEDGEMENT
This Standard Specification for Road Works - Section 10: Foundation Works has
been prepared by a technical committee comprising of the following members:
Committee Members:
Ir. Abdul Hadi bin Abdul Aziz Caw. Kej. Geoteknik, JKR
(Chairman until April 2018)
Ir. Edayu binti Saleh @ Aman Caw. Kej. Geoteknik, JKR
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(Chairwoman from April 2018)
Ir. Som Pong a/I Pichan A.M.N Caw. Kej. Geoteknik, JKR
Ir. Abdul Rahman bin Salleh Caw. Jalan, JKR
Ir. Razali bin Che Embi Caw. Kej . Geoteknik, JKR
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Ir. Ismail bin Mohamad Caw. Kej. Geoteknik, JKR
En. Rusli bin Basar Caw. Kej . Geoteknik, JKR
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n Ir. Eng Boon Cheng
Ir. Zaiton bin Zainal Badri
Caw. Kej . Geoteknik, JKR
Caw. Kej. Geoteknik, JKR
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En . Zaizul Hisham bin Zainol Caw. Kej. Geoteknik, JKR
Ir. Marzaki Faizi bin Mat Din Caw. Kej . Geoteknik, JKR
Ir. Ts. Mohd Faiz bin Mohd Faudzi Caw. Kej . Geoteknik, JKR
Ir. Khairul Nizan bin Khairudin Caw. Dasar Pengurusan dan
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Koporat, JKR
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Ir. Tuan Khusairry bin Tuan Abdul Manaf Caw. Jalan, JKR
En. Mhd Khair bin Nordin Caw. Jalan, JKR
Ir. Dr. Fairul Zahri bin Mohamad Abas Caw. Jalan, JKR
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Ir. Eow Thein Ewe Caw. Jalan, JKR

En. Khairul Abidin bin Hashim Jab. Taman Laut Malaysia
Ir. Amir Hamzah bin Mustapha Sejati Teguh Engineering
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Dato' Ir. Dr. Gue See Sew G & P Professionals Sdn. Bhd.
Ir. Dr. Lee Sieng Kai Glostrext Technology Sdn. Bhd.
En. Tan Hui Hock Geonamics Sdn. Bhd.
Ir. Chong Mun Fai Dynamic Pile Testing Sdn. Bhd .
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Ir. Dr. Hisham Mohamad Universiti Teknologi Petronas

Dr. Chew Soon Hoe National University of Singapore
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Special thanks and appreciation to proof reader Ir. Mohd Azahar bin Don from
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Cawangan Jalan, JKR. Appreciation also to Secretariat, Research and Development

Department of Cawangan Kejuruteraan Geoteknik throughout the preparation and
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compilation of the document.
members, and all those who were involved, directly or indirectly, for their tireless
effort and contribution towards the successful completion of this document.
(JKRlSPJ/2019-S10)
SECTION 10 - FOUNDATION WORKS
PAGE
10.1 DESCRIPTION S10-1

10.2 GENERAL REQUIREMENT AND TOLERANCES S10-1
10.2.1 Setting Out S10-1
10.2.2 Excavation S10-1
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10.2.3 Method Statement For Construction Operations S10-1
10.2.4 Unexpected Ground Conditions S10-2
10.2.5 Adjacent Structures S10-2
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10.2.6 Existing Services S10-2
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10.3 SHALLOW FOUNDATIONS S10-3
10.3.1 Definition S10-3
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10.3.2 Type of shallow foundation S10-3
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10.3.4 Confirmatory of Allowable Bearing Capacity of Soil S10-3
10.3.5 Plate Bearing Test 510-4
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10.4 DEEP FOUNDATIONS S10-8

10.4.1 Definition S10-8
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10.4.2 General Requirement 510-9

10.5 PRECAST REINFORCED CONCRETE PILES S10-11
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10.5.1 Material S10-11

10.5.2 Supply And Delivery Of Piles S10-12
10.5.3 Handling and Storage S10-12
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10.5.4 Damage to Piles S10-12

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10.5.5 Installation Of Precast Reinforced Concrete Piles S10-13

10.6 PRESTRESSED SPUN CONCRETE PILES S10-16
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10.6.2 Supply And Delivery Of Piles S10-17

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10.6.3 Handling and Storage S10-17

10.6.4 Installation of Prestressed Spun Concrete Piles S10-17
10.7 STEEL H·SECTION PILES S10-18
10.7.2 Manufacture And Storage Of Steel H-Section Piles S10-18
10.7.3 Installation Of Steel H-Section Piles S10-19
S10-i
(JKRlSPJ/2019-S10)
PAGE
10.8 STEEL PIPE PILES 810-20

10.8.2 Manufacture And Storage Of Steel Pipe Piles S10-20
10.8.3 Workmanship S10-22
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10.8.4 Protective Coatings S10-23
10.8.5 Installation Of Steel Pipe Piles 810-25
10.9 BORED CAST-IN-SITU PILES S10-26
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n 10.9.2 Boring Operations S10-26
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10.9.3 Placing Of Reinforcement S10-31
10.9.4 Concreting Operations S10-32
10.9.5 Extraction of Casing 810-33
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10.9.6 Construction of Pile Heads 810-34
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10.9.7 Pressure Grouting Of Piles 810-35
10.10 MICRO PILES 810-35
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10.10.2 Drilling Operation 810-36

10.10.3 Grouting Operations 810-36
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10.10.4 Construction of Pile Heads S10-37

10.10.5 Casing S10-37
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10.11 CAISSON S10-37

) 10.11 .1 Material S10-37
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10.11 .2 Excavation Operations S10-38

10.11.3 Placing of Reinforcement S10-42
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10.11.4 Concreting Operations 810-42

10.11 .5 Construction of Pile Heads S10-43
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10.11.6 Piling Records S10-43

10.11 .7 Safety Precaution 810-44
S10-ii
(JKRlSPJ/2019-S10)

PAGE
10.12 STATIC PILE LOAD TESTING 510-46

10.12.1 General 510-46
10.12.2 Construction of Pile to be Tested S10-46
10.12.3 Protection of Testing Equipment S10-47
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10.1 2.4 Method of Loading S10-48
10.12.5 Testing Procedure S10-54
10.12.6 Submission Of Results S10-56
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10.12.7 Completion of A Test S10-56
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10.13 HIGH STRAIN DYNAMIC PILE TESTING S10-57
10.13.1 General S10-57
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10.13.2 Construction of Pile to be Tested S10-57
10.13.3 Method ofTesting S10-58
10.13.4 Testing Procedures S10-60
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10.13.5 Submission of Results S10-61
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10.13.6 CAPWAP Computer Analysis Programme and Final Report S10-61

10.13.7 Completion of a Test S10-62
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S10-iii
(JKRlSPJ/2019-S10)
PAGE
LIST OF TABLES
TABLE 1 Tests For Bentonite Drilling Fluids S10-30
TABLE 2 Tests For Polymer Drilling Fluids S10-30
TABLE 10.1 Plate Bearing Test - Load Increments and
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Minimum Holding Time S10-62
TABLE 10.2 Specification of Precast Concrete Piles S10-63
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TABLE 10.3 Slump Range for Typical Concreting Situations S10-64
TABLE 10.4 Static Load Test - Load Increments and
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n Minimum Holding Time S10-64
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TABLE 10.5 Typical Allowable Driving Stresses S10-65
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LIST OF FIGURES
FIGURE 10.1 Plan View of Typical Pile Load Test Set Up S10-65
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APPENDIX 10A S10-67

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Bending Strength for Precast Concrete Piles S10-69

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TABLE 10A-1 : Maximum Allowable Crack Width S10-69

FIGURE 10A-1: Loading Method S10-70
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TABLE 10A-2 : Cracking Bending Moment (Mc) and

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Factor 'F' for Precast Reinforced Concrete
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Square Piles (RC Piles) S10-72

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TABLE 10A-3 : Cracking Bending Moment (Mo) and

Factor 'F' For Precast Pretensioned Spun
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Concrete Piles (Spun Piles) S10-72
TABLE 10A-4: Cracking Bending Moment (Mo) and

Factor 'F' For Precast Prestressed Concrete
Square Piles - Class Pc-X, Class Pc-Y,
Small Piles S10-73
S10-iv
(JKRlSPJ/2019-S 10)
10.1 DESCRIPTION
This work shall consist of the supply. installation/construction and testing of

foundation works in accordance with this specification and the lines, levels, grades
and cross-sections shown on the Drawings and as directed by the S.O.
10.2 GENERAL REQUIREMENTS
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10.2.1 Setting Out
Setting out shall be carried out using the data and reference points as shown
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on the Drawings. The foundation position shall be marked with su itable
identifiable pegs or markers at least 300mm length driven into the ground
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and the location marked with contrasting material. If raking piles are to be
installed then the setting out pins, pegs or markers is located in an offset
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position at piling platform level taking into account of depth to cut-off level
and rake value of the pile . In addition, the alignment of pins, pegs or markers
shall indicate the direction of the ·rake. Immediately before pile installation or
casting of foundation, the foundation point shall be checked by the Contractor
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again.
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10.2.2 Excavation
Foundations shall be excavated to the levels and dimensions as shown on

the Drawings, with sides trimmed and bottoms levelled and stepped as
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required .
All excavations shall be carried down to the required level as shown on the
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Drawings unless otherwise, the depths offoundation are decided on the site
by the S.O. The Contractor shall, at his own cost and expense, make good
any over excavation below the required depth with suitable granular material
or concrete as approved by the S.O.
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10.2.3 Method Statement for Construction Operations

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Two (2) weeks before the commencement of foundation works, the

Contractor shall submit to the S.O., a detailed method statement for the
foundation works. The method statement shall contain the followings:
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(i) A detailed construction sequence;

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(ii) Shop Drawings showing details of all special requirements for the
construction activities such as hoisting of piles, reinforcement cages,
cast in fixing , etc;
(iii) Design calculation of key temporary works endorsed by a Professional
Engineer;
(iv) Materials, plant and labour requirement at each construction stage;
(v) Rate of production output based on resources allocated;
(vi) Other information relevant to the foundation works.
S10-1
(JKRlSPJ/2019-S 10)
If requested by the S.O, the Contractor shall submit additional information

pertaining to the method of construction (including temporary works and the
use of the construction plant), calculation of the stresses, strain and
deflection that will arise in the permanent works of any part thereof during
construction .
The Contractor shall not deviate from the methods which have been
approved by the S.O. Approval by the S.O. on the Contractor's proposed
methods of construction shall not, in any way, relieve the Contractor of any
of his duties or responsibilities under the Contract.
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10.2.4 Unexpected Ground Conditions
The Contractor shall give a written notice immediately to the S.O. of any
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circumstances which , in the Contractor's opinion , indicate ground conditions
that may differ from those expected by the Engineer as shown in the
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n Drawings. The Contractor shall submit to the S.O. a report which contains all
information available to the Contractor that will materially assist the S.O. in
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verifying the conditions reported , and to mOdify the design, if necessary.
10.2.5 Adjacent Structures

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The Contractor shall carry out a dilapidation survey of adjacent properties to
establish the existing condition of the adjacent structures and facilities prior
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to commencement of foundation works. Dilapidation surveys shall be

conducted by a registered building surveyor and the result of the survey shall
be submitted to the S.O. for record .
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The Contractor shall pay very careful attention to the construction constraints
imposed by adjacent structures. The Contractor shall take adequate
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measures to ensure his foundation works do not disturb or damage existing

adjacent structures and surrounding environment. The Contractor shall
provide a proposal for monitoring adjacent structures and surrounding
environment for any detrimental effects arising from execution of the
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foundation works, so that appropriate and timely preventive action can be

) taken to minimise damage. The Contractor's proposal and monitoring
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programme shall be certified by a Professional Engineer.
The Contractor shall be responsible and bear the cost incurred including
claims for damages arising from his execution of the foundation works.
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10.2.6 Existing Services

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The Contractor shall give all required notices to the appropriate utility
authorities before commencement of foundation works. The Contractor shall
also locate existing services by piloting, protect existing services, rectify any
damage or interference to them and provide temporary support while repairs
are being carried out if so required.
S10-2
(JKRl5PJ/2019-510)
10.3 SHALLOW FOUNDATIONS
10.3.1 Definition
Shallow foundation is a foundation constructed in depth of not exceeding

3.0m from formation level. The depth to width ratio of the foundation is D/BS
3. Unless otherwise specified, shallow foundations shall conform with MS
1756. On no account shall isolated foundations be founded on made up or
filled ground unless detailed engineering analysis has been carried out.
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10.3.2 Type of Shallow Foundation
10.3.2.1 Pad Foundation
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Pad Foundation is spread or isolated foundation of rectangular
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or square reinforced concrete pad that supports localized single
point loads such as structural columns . o
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10.3.2.2 Strip Foundation
Strip Foundation is continuous strip of reinforced concrete that

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supports continuous loads such as walls.
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10.3.2.3 Raft Foundation
Raft Foundation is a combined strip or pad foundation that may

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cover the entire area under a structure supporting several

columns and walls.
10.3.3 Materials
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10.3.3.1 Concrete
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The materials and workmanship for concrete shall be as

specified under Section 9 of this specification.
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10.3.3.2 Reinforcement
The steel reinforcement shall be as specified under Section 9 of

this speCification.
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10.3.4 Confirmatory of Allowable Bearing Capacity of Soil

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The Contractor shall conduct probe test to confirm the required allowable
bearing capacity. For pad foundation, the probe test shall be conducted at
every column position. Other types of shallow foundation probe test shall be
conducted as stated in the Drawings. The Probe test shall be carried out
according to Standard Specification for Road Works, Section 17: Site
Investigation. The Contractor shall submit the results to the S.O. for approval.
510-3
(JKRlSPJ/2019-S10)
In the case where the allowable bearing capacity required is more than or
equals 150 kN/m2, the Contractor shall carry out the plate bearing test as
stated in the Drawings.
10.3.5 Plate Bearing Test
10.3.5.1 General
To verify the allowable bearing capacity, the Contractor shall

carry out plate bearing test as shown on the Drawings and I or
as instructed by the S.O. The recommended size of the test plate
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shall not be less than 500mm in diameter. Selection of bearing
plate is such that it shall not warp or deform under the applied
load.
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The design and construction of the load application system shall
be satisfactory for the required test. These details shall be made
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n available prior to the commencement of testing .
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10.3.5.2 Preparation at Test Level
Notice of Excavation
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The Contractor shall give at least 48 hours' prior notice of
commencement of excavation of the specified location to be
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tested.
Method of Excavation
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(i) Excavation to the test level shall commence as quickly as

practicable to minimize the effects of stress relief, particularly
when in cohesive soils. Temporary ground support shall be
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installed as and when necessary. Where the test is to be

carried out below the groundwater level in permeable
ground, the equipment for lowering the water level shall be
installed and water level shall be lowered before the
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excavation reaches the water table in order to prevent

) ground disturbance.
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(ii) All loose materials and any embedded fragments shall be

removed so that the area for the plate is generally level and
as undisturbed as possible. For uneven surface, place a
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layer of sand, nowhere exceeding 100mm in thickness to

obtain a level soil surface. The depth of the test area should
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be the same as the foundation depth of the structure to be

built on site.
Supervision
(i) The setting up of plate bearing test equipment shall be
carried out under competent supervision and the equipment
shall be checked to ensure that the setting-up is satisfactory
before the commencement of load test.
(ii) All tests shall be carried out only under the direction of an
S10-4
(JKRlSPJ/2019-S10)
experienced and competent supervisor conversant with the

test equipment and test procedures. All personnel operating
the test equipment shall have been trained in its use.
Notice of Test
The Contractor shall give at least 24 hours' prior notice of the
commencement of the test. No load shall be applied to the test
area before the confirmation of the specified test procedure.
10.3.5.3 Protection of Testing Equipment
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Protection from Weather
Throughout the test period, all equipment for measuring load and
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movement, and beams shall be protected from adverse effects
of sun, wind and precipitation.
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Prevention of Disturbance
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Construction activities and persons who are not involved in the
testing processes shall be kept at a sufficient distance from the
test location to avoid disturbance due to any unavoidable activity
and its effects.
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10.3.5.4 Method of Loading
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Test Load
The test load shall be applied in one (1) of the following ways:
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(i) By means of a jack which obtains its reaction from the load
heavier than the required load such as concrete blocks,
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water in tanks or others;
(ii) By means of a jack which obtains its reaction from tension

piles or other suitable anchors.
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In all cases, the reaction load or its supports shall be placed J

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sufficiently far from the proposed test position to reduce the

influence on the results to a tolerable level. Care shall be taken
to ensure that the reaction load remains stable throughout the
test without the possibility of load tilting or collapsing.
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In addition to the reaction load, it shall be necessary to provide a

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loading frame, a bearing plate, a loading column and a hydraulic

jack or other appropriate type of load measuring device. The
loading column shall be of sufficient strength to prevent undue
buckling under the maximum load. The total weight of the
kentledge or reaction force provided shall be at least 1.2 times
the maximum test load.
S10-5
(JKRlSPJ/2019-S10)
In all cases the Contractor shall ensure that when the hydraulic
jack and load measuring device are mounted on the loading
column, the entire system shall be stable up to the maximum load
to be applied. If in the course of carrying out a test, any
unforeseen occurrence should take place, further loading shall
not be applied until a proper engineering assessment of the
prevailing conditions has been made and steps taken to rectify
any fault.
Where an inadequacy in any part of the system might constitute
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a hazard, means shall be provided to enable the test to be
controlled from a position clear of the kentledge stack or test
frame.
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The hydraulic jack, pump, hoses, pipes, couplings and other
apparatus to be operated under hydraulic pressure shall be
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capable to withstand a pressure of 1.5 times the maximum
pressure used in the test without leaking. Test certificate shall be
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submitted before carrying the test.
The maximum test load expressed as a reading on the gauge in

use shall be displayed and all operators shall be made aware of
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this limit.
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When method (i) is used, care shall be taken to ensure that the
centre of gravity of the kentledge is on the axis of the loading
column . The longitudinal axis of the loading column and the
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centre of the bearing plate shall coincide, and the contact shall
be such that any tendency for the plate to tilt is resisted.
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When method (ii) is used, all anchor piles shall be at a distance

of at least three (3) times the bearing plate diameter from the
centre of the plate.
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If the anchor piles are to be permanent working piles, their levels

) shall be observed during application of the test load to ensure no
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residual uplift occurs.
Altematively, the Contractor may propose the use of other types,

patented or otherwise, in which case the requirements as below
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shall be fully complied with .

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Contractor's Load Test System
The Contractor may propose to use other different types from

those specified. The proposal shall be submitted to the S.O. at
least 90 days before the date of testing . The suitability or
adequacy of any system shall be determined by the S.O. In the
event that the testing system proposed by the Contractor is
acceptable, the Contractor shall obtain a Professional Engineer's
endorsement on the load settlement results.
S10-6
(JKRlSPJ/2019-S10)
Deformation Measurement System

The deformation measurement components of the test apparatus
shall be made to the required accuracy. Where a dial gauge or
other measuring device is used on the plate, a reference beam
may serve as the datum. At least four (4) dial gauges or other
measuring devices are to be used for measuring the
displacement. All settlement devices shall be readable to 0.01
mm. In addition, the levelling equipment shall be readable to 0.1
mm and placed at stable datum when specified. The levelling
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staff shall have a bubble attached to it so that the verticality of
the staff can be checked.
10.3.5.5 Testing Procedure
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General
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Prior to the performance of any load test, the Contractor shall
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submit to the S.O. for his approval, Work Drawings showing the
method and equipment he proposes to use in the performance of
the load test and the measurement of settlements.
Maintained Load Test

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The Maintained Load Test shall be carried out as follows:
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(i) The Full Test Load (FTL) on a tested ground shall be three
(3) times that of the Allowable Bearing Capacity specified
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on the Drawings.
(ii) The test shall be carried out in three (3) cycles with first
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cycle test up to working load, second cycle test up to twice

the Allowable Bearing Capacity and third cycle test up to
full test load .
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(iii) The load shall be applied in increments of 20% of the

working load, up to the working load and appropriately
smaller thereafter, until a maximum test load is reached .
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Each increment of load shall be applied as smoothly and

as expeditiously as possible. Settlement readings and time
observations shall be taken before and after each new load
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increment.
(iv) Settlement reading shall be taken for every 3 minutes. A

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time-settlement graph shall be plotted to indicate when the

rate of settlement of 0.05 mm per minute is reached. A
further increment of load shall be applied when this rate of
settlement is achieved, or until a minimum time of 15
minutes has elapsed, whichever is later. The process shall
be repeated until the maximum test load is reached .
(v) The maximum test load shall then be maintained for a

minimum of 2 hours, and time-settlement readings shall be
taken at regular intervals, as for the earlier load stages.
S10-7
(JKRl8PJ/2019-810)
(vi) The test load shall then be decreased in four (4) equal
stages, and time-settlement readings shall be as specified
a foresaid , until the movement ceases. At least 15 minutes
interval shall be allowed between the unloading
decrements.
(vii) During testing, if the result from each dial gauge or other
measuring devices differ by more than 20%, the Contractor
shall release the load and recheck the arrangement of the
load cell and redo the load test.
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(viii) Settlement readings shall be made immediately after and
before every load increment is applied or removed .
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The procedure of plate bearing test shall be as specified in
TABLE 10.1.
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n 10.3.5.6 Submission of Results
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Full test data, complete field test records and results from the
readout unit shall be jointly signed by the S.O.'s representative
and the Contractor's authorised agent and submit to the S.O.
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immediately upon completion of the load test. The submission
shall also consist of the following information:
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(i) Stage of loading

(ii) The depth of the test level from ground level
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(iii) The plate size

(iv) Period for which the load was held
(v) Final load and load increment
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(vi) Maximum settlement
These are to be plotted as time-settlement graphs.

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10.3.5.7 Interpretation of Test Results

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The S.O.'s interpretation and conclusions on the test results shall

be final. Unless otherwise specified, the plate bearing test shall
be deemed to have failed if the total settlement at any stage of
loading exceeds 25 mm.
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10.4 DEEP FOUNDATIONS
10.4.1 Definition
Deep foundation is defined as those where the depth is more than 3m below
the formation level. The types of deep foundation covered under this
specification are as follows, and not limited to:
(i) Precast reinforced concrete piles

(ii) Prestressed spun concrete piles
(iii) Steel H section piles
810-8
(JKRlSPJ/2019-810)
(iv) Steel pipe piles

(v) Bored cast in-situ piles
(vi) Micro piles
(vii) Caisson
10.4.1 .1 Trial Pile
A trial pile is a pile installed for ultimate pile load test for which
the pile is normally tested to 2.5 to 3.5 times working load, or until
failure occurs so that the design parameters can be verified . The
ER
location of the trial pile shall be as per drawing or as directed by
the S.O. The trial pile shall not be used as a working pile.
10.4.1.2 Preliminary Pile
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A preliminary pile is a pile installed before the commencement of
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the main piling works for the purpose of establishing the pile ()
installation criteria for subsequent working piles and for
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confirming the adequacy of the design, dimensions and working
load. This pile can be used as a working pile unless otherwise
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10.4.1.3 Working Pile
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A working pile is a pile which is installed as part of the permanent

foundation work.
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10.4.1.4 Working Load
The Working Load is the Design Load modified to allow for group
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effect, pile spacing or any other factors changing the efficiency

of the total foundation from that of a single isolated pile and is at
least equal to the dead plus imposed loads on the pile together
with the down drag or uplift loads as appropriate.
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10.4.1.5 Test Load

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Test load is load applied to a selected pile to confirm that it is

suitable for the load at the settlement specified. The Full Test
Load (FTL) on a pile shall be twice the Working Load (WL) noted
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on the Drawings.
10.4.2 General Requirement

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10.4.2.1 Position
For a pile cut off at or above ground level the maximum permitted
deviation of the pile centre from the centre paints shown on the
Drawings shall not exceed 75 mm in any direction. No pile edge
shall be nearer than 150 mm from the edge of any pile cap .
S10-9
(JKRlSPJ/2019-S10)
10.4.2.2 Verticality
The maximum permitted deviation of the finished pile from the

vertical is 1 in 75 at any level.
10.4.2.3 Rake
The piling rig shall be set and maintained to attain the required
rake . The maximum permitted deviation of the finished pile from
the specified rake or the rake shown on the Drawings is 1 in 25.
ER
10.4.2.4 Forcible Corrections
Forcible corrections to concrete piles shall not be permitted.
D
Forcible corrections may be permitted to specific types of piles if
approved by the S.O. However, no forcible corrections shall be
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made to piles which have deviated beyond the permissible limits
specified in Sub-sections 10.4.2.1, 10.4.2.2, 10.4.2.3.
TE
10.4.2.5 Piles Out of Alignment or Position
The Contractor shall, if instructed by the S.O., extract and

A
reinstall any pile which has deviated out of position or alignment
by more than the specified limit, or alternatively the substructure
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shall be modified and certified by a Professional Engineer with

Practicing Certificate to the approval of the S.O. The cost of such
extraction and reinstallation or any extra cost in the design and
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construction of a modified foundation shall be borne by the

Contractor if such extra works have been made necessary due
to the error and/or negligence of the Contractor.
EN
10.4.2.6 Welding
Unless otherwise specified or shown on the drawing, all welds

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shall be full penetration butt welds complying with the

l ) requirements of BS EN 12334.
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Redriving of the piles shall only be allowed after the welded joints
have sufficiently air cooled to 100·C or below.
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10.4.2.7 Welders' Qualification

D
All welding works shall be executed by qualified welders with

valid certificate issued by approved authorities such ClAST.
Only welders who are qualified to BS EN 287-1 or who have

attained a similar standard shall be employed on the Works.
Proof of welders' proficiency shall be made available on request
by the S.O.
10.4.2.8 Preboring and Jetting of Piles
Piles shall not be prebored without the written approval of the
S10-10
(JKRl5PJ/2019-510)
S.O. Preboring of piles may be allowed for the following reasons:
(i) To ease pile drivability by breaking through hard layers;

(ii) To reduce lateral soil displacement where this could cause
damage to nearby structure;
(iii) To investigate and possibly deal with obstruction in the
ground.
The piles shall be in contact with surrounding soil and the

completed piles shall comply with the requirements of this
specification. Diameter of preboring shall be in accordance with
ER
Sub-section 10.9.2.1 of this specification. If boring is oversize,
any gap between the tube and ground shall be filled with
compacted sand prior to driving the pile.
D
In some soils, jetting may lift adjacent structure or cause
undermining of nearby foundations. Pile shall not be jetted
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without the written approval of the S.O. Prior to jetting any pile,
the Contractor shall submit to the S.O. details of the equipment
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to be used and the proposed method to be adopted.
10.4.2.9 Safety Precautions

A
The Contractor shall take safety precautions throughout the piling
operation in accordance with the requirements of the relevant
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laws and by-laws.
10.4.2.10 Records
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The Contractor shall keep records of the installation of each pile

and shall submit two (2) Signed copies of these records to the
EN
S.O. not later than the next working day after the pile has been
installed. The signed records shall form part of the records for the
Works. Any unexpected driving or boring conditions shall be
noted in the records.
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10.4.2.11 As-built Locations Plan oJ

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The Contractor shall submit an As-built pile location plan certified

by a Licensed Surveyor to the S.O. within seven (7) working days
of completion of the last pile. Partial as-built plan may be
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submitted throughout construction of the foundation for

verification by the S.O.
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10.5 PRECAST REINFORCED CONCRETE PILES
10.5.1 Material
10.5.1.1 Reinforced Concrete
The materials shall be as specified in TABLE 10.2 or as in

MS1314.
510-11
(JKRl5PJ/2019-510)

10.5.1.2 Pile Shoes
The type of pile shoes to be used shall be as shown on the

Drawings and shall comply with MS 1314:
(i) "Chilled-hardened" cast iron shoes as used for making grey

iron castings to BS EN 1561, Grade 10; or
(ii) Mild steel to BS EN 10025 or equivalent, Grade 50B; or
ER
(iii) Cast steel to BS EN 10293, Grade A.
Mild steel straps cast into the shoes shall be as shown on the
Drawings. Rock shoes where requ ired shall consist of wrought
D
iron shoes and mild steel straps cast into "Chilled-hardened" cast
iron blocks, as shown on the Drawings.
N
The shoes shall be truly coaxial and firmly embedded on to end
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of the pile.
10.5.2 Supply and Delivery of Piles

A
The Contractor shall only use precast concrete piles supplied by approved
manufacturers. The Contractor shall produce the mill certificate and
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Perakuan Pematuhan Standard (PPS) from CIOB to the s.o. for approval.
No piles shall be allowed for transportation before achieving concrete
strength of 30 N/mm 2 •
M
10.5.3 Handling and Storage

EN
The method and sequence of lifting, handling, transporting and storing piles
shall be such that piles are not damaged or having crack width greater than
0.1 mm. Only the designed lifting and support points shall be used. During
transport and storage, piles shall be placed on adequate supports located
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under the lifting points of the piles. Piles shall be stored and stacked on firm
( ) ground not liable to settlement under the weight of piles. The supports shall
be vertically above one another. All piles within a stack shall be in groups of
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the same length. Packings of uniform thicknesses shall be provided between

piles at the lifting points.
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No pile shall be driven before the specified characteristic strength of

appropriate grade of concrete has been achieved.
D
10.5.4 Damage to Piles
The Contractor shall execute the work in such a manner so as to minimise

damage to piles.
All piles damaged during handling, transporting, pitching, and driving or at

any other time shall be replaced by the Contractor at his own expense. All
piles found damaged shall be taken out from site.
510-12
(JKRlSPJ/2019-S10)
10.5.5 Installation of Precast Reinforced Concrete Piles
10.5.5.1 Pitching of Piles
Piles shall be pitched accurately in the positions as shown on the

Drawings. At all stages during driving and until the pile has set or
been installed to the required length, all exposed piles shall be
adequately supported and restrained by means of leaders,
trestles, temporary supports or other guide arrangements to
maintain position and alignment and to prevent buckling and
ER
damage to the piles.
10.5.5.2 Driving of Piles
D
Each pile shall be installed continuously until the specified set
and/or depth has been reached , unless otherwise approved by
N
the S.O. The installation equipment used shall be of such type
and capacity to the approval of the S.O. A follower (long dolly)
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shall not be used unless approved by S.O., subject to the
(i) The first pile in each pile system and every tenth pile driven
A
thereafter shall be driven full length, without a follower, to
verify that adequate pile length is being attained to develop
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the desired pile capacity.

(ii) The follower and pile shall be held and maintained in equal
and proper alignment during driving;
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(iii) The follower shall be of such material and dimension to

permit the piles to be driven to the length determined
necessary from the driving of the full-length piles;
EN
(iv) The final position and alignment of the first two (2) piles
installed with follower in each substructure unit shall be
verified to be in accordance with the location tolerances
specified in Sub-section 10.2.1 before additional piles are
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installed.
Follower shall not be used in driving of raked pile.

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A detailed record of the driving resistance over the full length of

each pile shall be kept. The log shall record the number of blows
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for every 0.3 m of pile penetration. The Contractor shall inform

the S.O. without delay if an unexpected change in driving
characteristics is encountered. Where required by the S.O. set
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shall be taken at approved intervals during the driving to establish

the behaviour of the piles.
A set shall be taken only in the presence of the S.O. unless

otherwise approved. The Contractor shall provide all facilities to
enable the S.O. to check driving resistances. The final set of a
pile other than as friction pile, shall be recorded as the
penetration in millimetres per 10 blows. The temporary
compression of the pile shall be recorded if required .
S10-13
(JKRlSPJ/2019-S10)
When a set is being measured, the following requirements shall

be met:
(i) The pile shall be in good condition, without damage or

distortion;
(ii) The hammer blow shall be in line with the axis of the pile and
the impact surface shall be flat and perpendicular to the
hammer axis;
(iii) The hammer shall be in good condition , delivering the
required energy per blow and operating correctly;
ER
(iv) The rebound shall be measured and recorded accordingly.
When an acceptable resistance or set appears to have been
D
reached, the driving of pile should be suspended for an interval
sufficient to permit the soil to recover from the disturbance of pile
N
driving, and then resumed to determine whether there is any
(j increase or decrease in resistance.
TE
In soils that dilate when disturbed e.g. silts and some shales,
negative pore pressure can be set up temporarily and the driving
resistance may fall as these pore pressure returns to normal. In
clays disturbance can cause positive pore pressure to develop
A
and the strength of the soil may increase as these dissipate. The
necessary time interval before redriving may vary from one (1)
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hour to two (2) hours for non-cohesive soils or two (2) days or
more for clays.
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The resistance at the start of red riving is more likely to be

representative of the true bearing value of the pile, and each
red riving result should be taken into consideration when deciding
EN
the pile penetration length.
Piles shall be driven in an approved sequence to minimise the

detrimental effects of heave and lateral displacement of the
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ground. When required, careful levelling from a datum unaffected

\ ) by the piling shall be made on the pile heads already driven,
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before and after driving subsequent piles. Piles which have been
displaced vertically by more than 3 mm as a result of driving
adjacent piles shall be red riven to the required resistance.
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10.5.5.3 Repair of Damaged Pile Heads

D
If a pile is to be subjected to further driving, concrete in the

damaged pile head shall be cut off square at sound concrete,
and all loose particles shall be removed by wire brushing,
followed by washing with water. Care shall be exercised to
ensure that the reinforcement in the pile head is not in any way
damaged. Any damaged reinforcement shall be made good to
the satisfaction of the S.O. The head shall be replaced with
concrete of similar grade or higher.
The new head shall be cast truly in line with the remainder of the
pile and be properly cured and allowed to harden sufficiently to
S10-14
(JKRlSPJ/2019-S10)
develop the strength necessary for further driving. If a pile has

been driven to the required set or depth but the level of sound
concrete of the pile is below cut-off level, the pile shall be made
good to the cut-off level as described above so that the
completed foundation will safely withstand the specified ultimate
load.
10.5.5.4 Lengthening of Piles
Where piles have to be lengthened, other than by means of

welding of steel plates as detailed on the Drawings, the
ER
reinforcement shall be stripped of all surrounding concrete for a
distance equal to forty (40) times the diameter of the main
reinforcement measured from the pile head for spliced joints and
D
300 mm for butt welded joints and all lateral reinforcement shall
be removed .
N
The new concrete shall be of the same grade or higher as the
TE
original concrete on pile and shall be adequately compacted .
The lengthening bars shall butt on the exposed bars in true

alignment and shall be butt welded as specified or shall be
spliced with bars of the same diameter as the main pile bars, 60
A
diameters in length and lapping the main bars for a distance of
40 diameters above and below the joint and shall be securely
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bound with 1.63 mm soft annealed iron wire.
New binders of similar size shall be provided and spaced at half

M
the centres of the binders in the main body of the pile and shall
be securely bound with 1.63 mm soft annealed iron wire and the
pile extended by concreting in properly constructed mounds to
EN
the length required.
Care shall be taken to form the joint between the old and new
concrete as specified hereinbefore. The old concrete shall be
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adequately roughened , and all loose particles shall be removed

by wire brushing, followed by washing with clean water. The
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extension shall be truly in line at all stages of handling and driving

with the remainder of the pile and be properly cured and allowed
to harden sufficiently to develop the strength necessary for
further driving.
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10.5.5.5 Pile Joint

D
The bending strength test of pile joint shall be done for laterally
loaded pile only to determine the bending capacity at each
respective joint. The test shall be done as in 10.5.5.7 provided
that the joint is positioned at the centre of the span. The bending
capacity at the pile joint shall be greater than the bending
capacity of the pile body by 10%. The result shall be submitted
to S.O for approval prior to driving of any pile.
S10- 15
(JKRlSPJ/2019-S10 )
10.5.5.6 Pile Bending Strength Test
Pile bending strength test shall be performed in accordance with

Appendix 10A of this specification.
10.5.5.7 Cutting and Preparation of Pile Heads
When a pile has been driven to the required set or depth, the
head of the pile shall be cut off to the level specified or shown on
the Drawings. This shall be done carefully to avoid shattering or
ER
otherwise damaging the rest of the pile. Any cracked or defective.
concrete shall be cut away and made good with new concrete
properly bonded to the old . The length of reinforcing bars
projecting above this level shall be as shown or specified on the
D
Drawings. If the length of reinforcing bars left projecting is
insufficient, then they shall be extended by either of the following
N
methods:
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(i) Butt Welding
The extension bars shall butt on the projecting bars in true

alignment and shall be butt welded in accordance with Sub-
A
section 10.8.3 of this specification.
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(ii) Splicing
The projecting bars shall be stripped of all surrounding

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concrete as necessary to allow splices of length 60

diameters with extension bars. The extension bars shall be
securely bound to the projecting bars with 1.63 mm soft
EN
annealed iron wire. The concrete of the pile shall be made

good either before or together with the casting of the pile
cap, all to the satisfaction of the S.O. Care shall be taken to
avoid cracking or otherwise damaging the rest of the pile.
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Any cracked or defective concrete shall be cut away and

, ) made good with new concrete properly bonded to the old .
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10.6 PRESTRESSED SPUN CONCRETE PILES

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10.6.1 Materials
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10.6.1.1 Concrete
The materials shall be as specified in TABLE 10.2 or as in

MS1314.

The prestressing tendons and the non-prestressing
S10-16
(JKRlSPJ/2019-S10)
reinforcement of the piles including workmanship shall be as

specified under Section 9 of this specification and as per
manufacturer details and shall comply with MS 1314.
Prestressing steel shall comply with JIS G3137 or BS 4486 or BS

5896 or ASTM A416 or equivalent.
A Certificate of Conformance is required for every delivery of

reinforcement.
10.6.1.3 End Plates
ER
Details of end plates of each length of pile shall be as per
manufacturer details and shall comply with MS 1314. Each end
plate shall be machine-finished and provided with a chamfer to
D
accommodate the welding when two (2) lengths of pile are
jointed.
N
10.6.1.4 Pile Shoes
TE
If specified, the type of pile shoes to be used shall be as per
manufacturer details and shall comply with MS 1314.
A
10.6.2 Supply and Delivery of Piles
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The contractor shall only use Prestressed Spun Concrete piles supplied by
approved manufacturers. The Contractor shall produce the mill certificate
and Perakuan Pematuhan Standard (PPS) from CIDB to the S.O. for
M
approval. No piles shall be allowed for transportation before achieving

concrete strength of 30 N/mm 2 .
EN
10.6.3 Handling and Storage
Handling, storing and transporting prestressed concrete pile shall be done in

such a manner as to avoid excessive bending stresses, cracking, spalling or
M
injurious result. Piles that are damaged during handling and transporting
shall be replaced by Contractor at his own expenses. All damaged and J
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rejected piles shall be removed from the site.
10.6.4 Installation of Prestressed Spun Concrete Piles

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10.6.4.1 Pitching and Installation of Piles

D
Pitching and installation of piles shall be in accordance with Sub-

sections 10.5.5.1 and 10.5.5.2. Piles shall not be installed until
the concrete has achieved the specified characteristic strength.
S10-17
(JKRlSPJ/2019-S10)
Where lengthening of piles is required, the details of the joint

shall be as shown on the Drawings and in accordance with Sub-
section 10.8.3. When two (2) lengths of pile are jointed, the end
plates shall bear over their complete areas. Shims for packing
shall not be accepted. For laterally loaded pile, the pile jOint shall
be in accordance with Sub-section 10.5.5.5.
ER
When a pile has been driven to the required set or depth, the
head of the pile shall be cut off to the level specified or shown on
the Drawings using a diamond cutter. Pile heads shall be
constructed to details as per manufacturer details and shall
D
comply with MS 1314.
N
10.7 STEEL H-SECTION PILES
TE
10.7.1 Materials
All steel H- section piles including the cast steel shoe shall comply with the
A
requirement of BS EN 10025 andl or BS EN 10029, BS EN 10210, BS EN
10113, BS EN 10293, BS 7668 or JIS A5526. The profile and grade to be
EJ
used are as specified or as shown on the Drawings. The Contractor shall

provide mill certificate of the manufactured H-section pile as may be
requested by S.O.
M
10.7.2 Manufacture and Storage of Steel H-5ection Piles

EN
10.7.2.1 Manufacturing Tolerances
All piles shall be of the type and cross-sectional dimensions as

designed. For standard rolled sections the dimensional
M
tolerances and weight shall comply with the relevant established

\ ) standard. Length tolerance of H-section steel bearing piles shall
KU
be ± 50 mm in accordance with BS EN 10034.
The rolling or proprietary tolerances for H-section steel bearing

piles shall be such that the actual weight of the section does not
O
differ from the theoretical weight by more than ± 2.5%.

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10.7.2.2 Straightness of Sections
For standard rolled sections the deviation from straightness shall

be within the compliance provisions of BS EN 10034. When two
(2) or more rolled sections are joined by butt-jointing, the
deviation from straightness shall not exceed 1/600 of the overall
length of the pile.
For proprietary sections made up from rolled sections and for

tubular piles the deviation from straightness on any longitudinal
S10-18
(JKRlSPJ/2019-S10)
face shall not exceed 1/600 of the length of the pile nor 5 mm in
any 3 m length.
Based on the results of pile driving resistance and/or load tests

carried out on piles driven on the Site, the S.O. may, from time to
time, instruct the lengths of piles to be modified.
10.7.2.3 Strengthening of Piles
Unless otherwise approved by the S.O., the strengthening of the

toe of the pile in lieu of a shoe, or the strengthening of the head
ER
of a pile, shall be made from material of the same grade or
strength class as the pile and to the details as shown on the
Drawings.
D
10.7.2.4 Marking of Piles
N
Each pile shall be clearly marked with white undeletable marking
at the flanged head showing its reference number and overall
TE
length. In addition, each pile shall be marked at intervals of 500
mm along its length before being driven. The length of piles to be
supplied shall be as shown on the Drawings subject to revision
by the S.O.
A
10.7.2.5 Handling and Storage
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All operations such as handling and transporting of piles shall be

carried out in such a manner that damage to piles and their
M
coatings is minimized. Piles that are damaged during handling

and transporting shall be replaced by the Contractor at his own
expense. All damaged and rejected piles shall be removed from
EN
the Site forthwith.
Piles within a stack shall be in groups of the same length and on

approved supports.
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10.7.3 Installation of Steel H-Section Piles

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10.7.3.1 Pitching and Driving of Piles
Pitching and driving of piles shall be in accordance with Sub-

O
sections 10.5.5.1 and 10.5.5.1.

D
S10-19
(JKRl5PJ/2019-510)
Where lengthening of piles is required, the piles shall be joined

by butt welding. Butt welded joints shall be stiffened with plates
fillet welded on all four (4) sides as detailed on the Drawings. All
welding shall be continuous and complying with BS 638, BS EN
1011-1 and BS EN 1011-2 and BS EN 1993 for arc welding and
BS EN ISO 4577 for resistance welding as appropriate. All
welding procedures shall comply to BS EN ISO 15607, BS EN
ISO 15609-1, BS EN ISO 15613 and BS EN ISO 15614-1. The
ER
type and size of weld shall be as detailed on the Drawings. The
Contractor shall make available full details of the welding
procedure and electrodes with drawings and schedule as
D
requested by S.O.
Weld tests shall be performed by radiographic or ultrasonic
N
methods as specified. Provided that satisfactory results are being
obtained, one (1) test of a length of 300 mm shall be made for
TE
10% or more of the number of welded splices.

A
When a pile has been driven to the required set or depth and
before encasing in concrete, the piles shall be cut to within 20
EJ
mm tolerance of the levels shown on the Drawings. Pile heads

shall be constructed to the details as shown on the Drawings.
M
The remaining section which can be reused for lengthening of

piles shall be stored and protected as directed by the S.O.
EN
10.8 STEEL PIPE PILES
10.8.1 Materials
M
I. ) All steel pipes shall comply with BS EN 10296, BS EN 10297 and BS EN

KU
10305 with regard to sectional dimensions and the steel shall comply with
the requirements of BS EN 10113 or BS EN 10025. Mill certificates shall
be provided to the S.O. prior to pile installation.
O
10.8.2 Manufacture and Storage Of Steel Pipe Piles

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10.8.2.1 Fabrication of Piles
Pile lengths shall be set up so that the differences in dimensions

are matched as evenly as possible. The length of piles to be
supplied shall be as shown on the Drawings and subject to
revision by the S.O.
Based on the results of pile driving resistance and/or load tests

carried out on piles driven on the Site, the S.O. may, from time to
time, order the lengths of piles to be modified.
510-20
(JKRlSPJ/2019-S10)
For tubular piles where the load will be carried by the wall of the
pile, and if the pile will be subjected to loads that induce reversal
of stress during or after construction, the external diameter at any
section as measured by using a steel tape on the circumference
shall not differ from the theoretical diameter by more than ± 1%.
The ends of all tubular piles as manufactured shall be within a

tolerance on ovality of ± 1% as measured by a ring gauge for a
distance of 100 mm at each end of the pile length.
ER
The root edges or root faces of lengths of piles that are to be
shop butt-welded shall not differ by more than 25% of the
thickness of pile walls not exceeding 12 mm thick or by more than
3 mm for piles where the wall is thicker than 12 mm. When piles
D
of unequal wall thickness are to be butt-welded, the thickness of
the thinner material shall be the criterion.
N
10.8.2.2 Matching of Pile Lengths
TE
Longitudinal seam welds and spiral seam welds of lengths of pipe
piles forming a completed pile shall, whenever possible, be
evenly staggered . However, if in order to obtain a satisfactory
A
match of the ends of piles or the specified straightness, where
the longitudinal seams or spiral seams are brought closely to one
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(1) alignment at the joint, then they shall be staggered by at least

100 mm.
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10.8.2.3 Straightness of Piles
The deviation of pile from straightness shall be within the

EN
compliance provisions of BS EN 10034 and in accordance with

Sub-section 10.7.2.3.
10.8.2.4 Fabrication of Piles on Site

M
When pile lengths are to be made up on Site, all test procedures

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and dimensional tolerances shall conform to the specification for

the supply of pipe materials. Adequate facilities shall be provided
for supporting and aligning the lengths of pile.
O

D
All piles within a stack shall be in groups of the same length and
on approved supports. All operations such as handling,
transporting and pitching of piles shall be carried out in a manner
such that no damage occurs to piles and their coatings. Piles that
are damaged during handling and transporting shall be replaced
by the Contractor at his own expense . All damaged and rejected
piles shall be removed from the Site forthwith .
S10-21
(JKRlSPJ/2019-S10)
10.8.2.6 Marking of Piles
Each pile shall be clearly marked with white undeletable marking

near the pile head showing its reference number and overall
length. In addi.\ion, for pile installation monitoring purposes, each
pile shall be marked at intervals of 300 mm along its length before
being driven.
10.8.3 Workmanship
ER
10.8.3.1 Welding Procedures
The Contractor shall submit for approval, full details of the
D
welding procedures and electrodes with Drawings and
schedules as may be necessary. Tests shall be undertaken as
N
n may be required by the S.O. and shall be in accordance with the
requirements of BS EN 288.
TE
All welding procedures shall have been qualified to BS EN ISO
15607, BS EN ISO 15609-1, BS EN ISO 15613 and BS EN ISO
15614-1 and the Contractor shall make available full details of
A
the welding procedures and electrodes, with Drawings and
schedules as may be necessary. Tests shall be undertaken as
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may be required by the S.O.
10.8.3.2 Weld Tests

M
During production of welded tube piles, at least one (1)

radiograph or ultrasonic test approximately 300 mm long shall be
EN
required on each end of a length as a spot check on weld quality.

This shall be taken on a circumferential or longitudinal weld and
its position shall be as directed by the S.O.
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For spirally welded piles, one (1) of the following tests shall be
( ) carried out:
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(i) For tubes of wall thickness 12 mm or less, three (3) spot

check radiographs, one (1) at each end of each length of
the tube as manufactured and one (1) at a position to be
O
chosen at the time of testing by the S.O.; and spot check

radiographs as required by the S.O. on the weld joints
between strip lengths;
D
(ii) For tubes of any wall thickness, continuous ultra-sonic

examination over the whole weld, supplemented where
necessary by radiographs to investigate defects revealed by
the ultrasonic examination.
Weld tests shall be performed by radiographic or ultrasonic

methods as specified. Provided that satisfactory results are
being obtained, one (1) test of a length of 300 mm shall be made
for 10% or more of the number of welded splices in the case
S10-22
(JKRlSPJ/2019-S10)
where the load will be carried by the wall or section of the pile
will not normally exceed 10%. Results shall be made available
to the 5.0. within ten (10) days of completion of the tests.
10.8.3.3 Standards for Welds
(i) Longitudinal Welds In Tubular Piles
For piles of longitudinal or spiral weld manufactured where the

load will be carried by the wall of the pile, and if the pile will be
subject to loads which induce reversal of stress during or after
ER
construction other than driving stresses, the standard for
interpretation of non-destructive testing shall be the American
Petroleum Institute Specification 5L. The maximum
permissible height of weld reinforcement shall not exceed 3.2
D
mm for wall thicknesses not exceeding 12.7 mm and 4.8 mm
for wall thicknesses greater than 12.7 mm.
N
(ii) Circumferential Welds
TE
For circumferential welds in tubular piles the same maximum
height of weld reinforcement as specified above for
longitudinal welds in tubular piles shall apply, the standard for
A
interpretation of non-destructive testing shall be the American
Petroleum Institute Specification 5L.
EJ
If the results of any weld test do not conform to the specified

requirements, two (2) additional specimens from the same
M
length of pile shall be tested. In the case of failure of one (1)

or both of these additional tests, the length of pile covered by
the test shall be rejected.
EN
10.8.4 Protective Coatings
The term 'coating' shall include the primer and the coats specified. If
M
protective coatings are specified , the preparation of surfaces and the

application of the coatings shall be carried out by skilled labour having J
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experience in the preparation of the coatings specified.
Corrosion protection of permanent steel structure in accordance with

environment classified as C4 according to BS EN ISO 12944-2 shall require
O
durability resistance of 25 years.
The protective coating system shall comply with BS EN ISO 12944-5 and
D
shall comprise of at least:
(i) First Coating or Prime Coat Zinc Epoxy 0.08 mm thick

(ii) Two (2) layers of Intermediate coating 0.08 mm thick epoxy for each
layer
(iii) Top coating of Polyurethane 0.08 mm thick
(i) All surfaces to be coated shall be clean and dry
S10-23
(JKRlSPJ/2019-S10)
(ii) Surface preparation to cleanliness SA 2 Y. in accordance

with BS EN ISO 12944-4 and BS EN ISO 8501-1 .
(iii) Blast-cleaning shall be done after fabrication . Unless an

instantaneous-recovery blasting machine is used, the
cleaned steel surface shall be air-blasted with clean dry air
and vacuum-cleaned or otherwise freed from abrasive
residues and dust immediately after cleaning.
10.8.4.2 Application and Type of Primer
ER
(i) Immediately after surface preparation, the surface shall be
coated with an approved primer or the specified coating to
avoid recontamination. No primer coat shall be applied to a
D
metal surface which is not thoroughly dry. Within 4 hours
after surface preparation, before visible deterioration takes
N
() place, the surface shall be coated with an appropriate primer
or the specified coating .
TE
(ii) The primer shall be compatible with the specified coating
and shall be such that if subsequent welding or cutting is to
be carried out it shall not emit noxious fumes or be
A
detrimental to the welding .
EJ
10.8.4.3 Control of Humidity during Coating
(i) No coating shall be applied when the surface metal

M
temperature is less than 3°C above the dew point

temperature or when the humidity could have an adverse
effect on the coat.
EN
(ii) When heating or ventilation is used to secure suitable

conditions to allow coating to proceed, care shall be taken to
ensure the heating or ventilation of a local surface does not
M
have an adverse effect on adjacent surfaces or work already

) done.
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10.8.4.4 Part to be Welded
The coating within 200 mm of a weld shall be applied after

O
welding. The method of application shall comply with the

manufacturer's recommendations.
D
10.8.4.5 Thickness, Number and Colour of Coats
(i) The minimum dry film thickness of the finished coating,

including the minimum dry film thickness of each coat and
the minimum number of coats that are to be applied, shall
be as specified and shown on the Drawings. Coatings shall
be applied in accordance with the manufacturer's
instructions.
(ii) The nominal thickness of the finished coating and each coat
S10-24
(JKRlSPJ/2019-S10)
shall be as specified. The average coat or finished coating

thickness shall be equal to or greater than the specified
nominal thickness. In no case shall any coat or finished
coating be less than 75% of the nominal thickness. Each
coat shall be applied only after an interval that ensures the
proper hardening or curing of the previous coat.
(iii) Where more than one (1) coat is applied to a surface, each
coat shall be different colour from the previous coat. The
colour sequence and final coating colour shall be
established prior to application of coatings.
ER
10.8.4.B Inspection of Coatings and Acceptability
(i) The finished coating shall be generally smooth, of a dense
D
and uniform texture and free from sharp protuberances or
pin holes.
N
(ii) Any coat damaged by subsequent processes or which has
TE
deteriorated to an extent such that proper adhesion of the
coating may not be obtained or maintained, shall be
recleaned to the original standard and recoated with the
specified sequence of coats.
A
(iii) The completed coating shall be checked for thickness and
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continuity by an approved magnetic gauge or detector. Areas

where the thickness is less than that specified shall receive
approved additional treatment.
M
(iv) When specified, the completed coating shall be checked for

adhesion by means of an adhesion test to BS EN ISO 2409,
EN
BS 3900-EB, carried out on 10% of the piles. The adhesion of

any completed coating shall not be worse than Classification
2. If adhesion tests on the initial batch are satisfactory, then
on further batches only 1% of the piles shall be tested.
M
Adhesion tests shall not be carried out until seven (7) days
after coating .
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10.8.5 Installation of Steel Pipe Piles
10.8.5.1 Pitching and Driving Of Piles

O
Pitching and driving of piles shall be in accordance with Sub-

sections 10.5.5.1 and 10.5.5.2.
D
Unless otherwise approved, where lengthening of piles is

required, the piles shall be joined by butt welding along the entire
periphery as detailed on the Drawings. All procedures shall be in
accordance with Sub-sections 10.7.3.2.
S10-25
(JKRlSPJ/2019-S10)
When a pile has been driven to the required set or depth and
before encasing in concrete, the pile shall be cut to within 20 mm
of the levels shown on the Drawings and protective coatings shall
be removed from the surfaces of the pile head 100 mm above
the soffit of the concrete. Pile heads shall be constructed to
details as shown on the Drawings. If a steel structure is to be
welded to piles, the piles shall be cut square and to within +/- 5
mm.
ER
10.8.5.4 Concreting of Pile Shaft
D
If concreting is specified or shown on the Drawings after the pile
has been cut off to the specified level, the shaft shall be filled
with concrete in a continuous operation. The method of placing
N
shall be approved by the S.O.
TE
The reinforcement cage in the pile shall be made sufficiently rigid
and kept in its correct position during concreting .
The length of the reinforcing bars projecting above the pile cut-
A
off level shall be as shown on the Drawings.
EJ
Mixing and placing concrete infill shall be done in accordance to

Sub section 10.9.4.
M
10.9 BORED CAST-IN-SITU PILES

EN
10.9.1 Materials
10.9.1 .1 Concrete
M

( ) specified under Section 9 of this specification. The grade of the
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concrete shall be as shown on the Drawings.
10.9.1 .2 Reinforcement
O

this specification. The details of the steel reinforcement shall be
D
as shown on the Drawings.
10.9.2 Boring Operations
10.9.2.1 Diameter of Piles
The diameter of piles shall not be less than the specified

designed diameter at any level throughout its length.
The auger width shall be checked as necessary and recorded for

each pile to ensure the specified diameter is achieved. A
S10-26
(JKRlSPJ/2019-S10)
tolerance of 0% to +5% on the auger width is permissible.
10.9.2.2 Boring
Boring shall be carried down to the depth as required and

directed by the S.O. When deemed necessary by the S.O., the
Contractor shall take soil samples while the pile is being bored.
The samples shall be taken to an approved Laboratory for
testing, if necessary or as directed by the S.O.
Sampling and all subsequent handling and testing shall be
ER
carried out in accordance with BS EN ISO 1997, BS EN ISO
14688, BS EN ISO 14689, BS EN ISO 22475 and BS EN ISO
22476.
D
Piles shall not be bored at a distance less than three (3) times
diameter close to other piles which have been cast less than 24
N
hours or contain unset concrete.
TE
10.9.2.3 Coring in Rock
The Contactor shall submit a method statement when coring in

rock. Chiselling of rock may cause micro cracks in surrounding
A
rock and is not allowed. Rock coring shall mean coring of sound
bedrock using a coring bucket or any other approved method.
EJ
Confirmatory test to verify sound rock shall be carried out by the

Contractor.
M
Definition of coring in rock shall fulfil all two (2) criteria below:
(i) Change of tools to rock coring tools, and

EN
(ii) The rock materials shall be verified by carrying out point load
test on at least five (5) rock samples to achieve minimum
corrected point load strength index 15(50) of 2.0 MPa on
M
samples not less than 30mm and not more than 85mm with
the preferred dimension about 50mm based on ASTM
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05731 . The Minimum five (5) samples shall be taken for

every 1m depth of rock coring.
Any coring/boring in other materials that do not fulfil the definition

O
of rock coring mentioned above shall be considered as boring in

soils.
D
The provision of point load test equipment at site for the above-
mentioned testing shall be by Contractor's own cost and time.
The point load test equiment shall be calibrated and a valid
calibration certificate shall be made available to the S.O. upon
requested.
S10-27
(JKRlSPJ/2019-S10)
10.9.2.4 Socketing in rock to fulfil design criteria
The socketed length shall be as specified in the Drawing or as

directed by the S.O. The starting of the socketing length may not
be the same as the coring depth of rock. Rock socket length shall
be measured from the flattened horizontal bedrock surface. This
flat horizontal surface shall be proved using Kelly bar or steel bar
at a minimum of five positions over the borehole.
10.9.2.5 Permanent Casing
ER
Permanent casings which form part of the designed pile shall be
as specified on the Drawings.
10.9.2.6 Temporary Casing
D
Temporary casings of approved quality or an approved
N
n alternative rnethod shall be used to maintain the stability of pile
excavations which might otherwise collapse.
TE
Temporary casings shall be free from significant distortion. They
shall be of uniform cross-section throughout each continuous
length. During concreting they shall be free from internal
A
projections and encrusted concrete which might prevent the
proper formation of the piles being cast.
EJ
If a temporary casing is required to stabilise the borehole, it shall

be extended beyond the unstable strata for one (1) metre or more
M
to prevent the inflow of soil and the formation of cavities in the

surrounding ground.
EN
10.9.2.7 Stability of Piling Excavations Using Support Fluid
Where the use of support fluid or a column of water is approved

for maintaining the stability of boring , the level of fluid or column
M
of water in the excavation shall be maintained such that the fluid

) pressure always exceeds the pressure exerted by the soil and
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external ground water. The fluid water level shall be maintained

at a level not less than 1 m above the level of the external ground
water.
O
An adequate temporary casing shall be used in conjunction with

the method to ensure the stability of the strata near ground level
D
until concrete has been placed.
In the event of a rapid loss of bentonite suspension, polymeric

fluids or water from the piling excavation , the excavation shall be
backfilled with lean concrete or well compacted sand as specified
in Section 9 of this specification without delay and the instructions
of the S.O. shall be obtained prior to resuming boring at that
location.
S10-28
(JKRlSPJ/2019-S10)
10.9.2.8 Support Fluid
Support fluid material, bentonite, shall comply with the

manufacturer's certificate and mix proportion. A certificate shall
be obtained by the Contractor from the manufacturer of the
bentonite powder, showing the properties of each consignment
delivered to the site. This certificate shall be made available to
the S.O. Test should be carried out at regular interval to ensure
consistency of the batching process.
ER
Polymer can be used as an alternative to bentonite to maintain
stability of the bores with the approval of the S.O.
Bentonite or polymer shall be mixed thoroughly with water
D
complying with MS 28 to make a suspension which will maintain
the stability of the pile excavation for the period necessary to
N
place concrete and complete construction . Preparation of the
suspension shall comply with the manufacturer's instructions.
TE
Where saline or chemically contaminated ground water occurs,
special precautions shall be taken to modify the bentonite
suspension or pre-hydrate the bentonite in fresh water to render
A
it suitable in all aspects for the construction of piles.
EJ
Minimum frequency of testing are as follows:
(i) Fresh drilling fluid

M
(ii) Drilling fluid shall be tested before concreting

(iii) Recycle drilling fluid taken from desanding machine
(iv) Drilling fluid left in the bored hole for more than 12 hours
EN
The frequency of testing drilling fluid and the method and

procedure of sampling shall be proposed by the Contractor and
agreed by the Engineer before the commencement of the work.
M
The frequency may subsequently be varied with the approval of

the S.O. Control tests for density shall be carried out daily on the J
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drilling fluid using suitable apparatus. The measuring device

shall be calibrated to read within 0.01 glml. The results shall be
within the ranges stated in TABLE 1 for bentonite and TABLE 2
for polymer drilling fluids.
O
All reasonable steps shall be taken to prevent the spillage of

D
drilling fluid on the site. Discarded drilling fluid shall be removed

from the site without delay and such removal shall comply with
the regulations of the relevant authorities.
If sand content is more than 5%, the Contractor shall carry out
desanding to screen out sand from drilling fluid before
concreting.
S10-29
(JKRlSPJ/2019-S10l
TABLE 1: TESTS FOR BENTONITE DRILLING FLUIDS

Stages
Property Test
Units Fresh Ready for Before
Equipment
re-use concretina
Density. !11m I < 1.10 < 1.25 < 1.15 Mud balance
Marsh viscosity
sec 32 to 50 32 to 60 32 to 50 Marsh funnel
(946 mil
Fluid loss
ml < 30 < 50 NA Filter press
(30 min)
ER
pH - 7 to 11 7 to 12 NA pH meter
Sand content % NA NA <4 Sand content set
Filter Cake mm <3 <6 NA Filter Press
D
TABLE 2: TESTS FOR POLYMER DRILLING FLUIDS
N
n Property Stages Test
TE
Units
Before concreting Equipment
Density g/ml s 1.1 Mud balance
Marsh viscosity
sec 32 to 140 Marsh funnel
(946 ml)
A
pH - 7 to 12 pH meter
Sand content % s1 Sand content set
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10.9.2.9 Spillage and Disposal

M
All reasonable steps shall be taken to prevent the spillage of

bentonite suspension or water on the site in areas outside the
EN
immediate vicinity of the boring operations. Discarded bentonite

water shall be removed from the site without delay. The disposal
of bentonite water shall comply with the regulations of the Local
authorities and other related Government Agencies .
M
( ) Entrained solids shall be removed from the polymeric fluid by use

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of flocculants before disposal of the remaining fluid to the

approved deSignated disposal sites by the authorities.
10.9.2.10 Pumping of Boreholes

O
Pumping from the borehole shall not be permitted unless casings

D
have been placed into the stable stratum to prevent the further
ingress of water in significant quantities from other strata into the
borehole, or, unless it can be shown that pumping will not have
a detrimental effect on the surrounding soil or its properties.
10.9.2.11 Continuity of Construction
A pile constructed in the stable soil, without the use of temporary

casings or other support, shall be bored and concreted without
delay to ensure that the soil characteristics are not significantly
altered. The time interval between completion of boring and
S10-30
(JKRlSPJ/2019-S10)
placing of concrete should preferably be within six (6) hours.

Where prolonged delay in construction arises, the bore may have
to be backfilled with lean concrete as specified in Section 9 of
this specification or well compacted sand to minimise
deterioration of the shaft.
If the bored pile installation is carried out using permanent or

temporary casing, the time period between completion of boring
operation and completion of concreting is recommended not to
exceed twenty-four (24) hours.
ER
10.9.2.12 Enlarged Pile Bases
The enlarged pile base shall not be smaller than the dimensions
specified and shall be concentric with the pile shaft to within 10%
D
of the shaft diameter. A sloping surface of the frustum forming
the enlargement shall make an angle to the horizontal of not less
N
than 55". At the specified diameter of the under ream at the
perimeter of the base there shall be a minimum height of 150
TE
mm.
10.9.2.13 Cleanliness of Pile Bases

A
On completion of boring, loose, disturbed or remoulded soil or
fragments of rock shall be removed from the base of the pile.
EJ
10.9.2.14 Inspection
M
For dry boreholes, each hole shall be inspected prior to the

placing of concrete in it. The inspection shall be carried out from
the ground surface in the case where the borehole diameter is
EN
less than 1500 mm. Where the borehole diameter exceeds 1500
mm, adequate equipment shall be provided to enable the
Contractor and the S.O. to descend into the borehole for the
purpose of inspection. All works shall conform to the requirement
M
of BS 5573: 1978 Safety Precaution in the Construction of Large . \

Diameter Borehole for Piling and Other Purposes. For wet V
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boreholes, i.e. holes filled with drilling fluid or water, a suitable

probe shall be provided to ascertain the evenness and
cleanliness of the pile base.
O
10.9.3 Placing of Reinforcement

D
10.9.3.1 Joints In Longitudinal Bars
Reinforcement shall be such that the full strength of the bar is

effective across the joint and the joint shall be made so that
there is no relative displacement of the reinforcement during the
construction of the pile and the spacing of the reinforcing bars
shall be maintained in such a way that proper concreting shall
not be impeded.
S10-31
(JKRlSPJ/2019-S10)
10.9.3.2 Positions of Reinforcement
Adequate spacer blocks, guide tubes, and lifting wires shall be

provided so as to maintain the reinforcing steel in the positions
as specified.
Where temporary casings are employed, the longitudinal

reinforcement shall extend at least 1 m below the bottom of the
casing so that movement of the reinforcement during extraction
of the casing is minimised.
ER
10.9.4 Concreting Operations
10.9.4.1 Placing Concrete
D
The method of placing and the workability of concrete shall be
N
n such that a continuous monolithic concrete shaft of the full cross-
section is formed.
TE
10.9.4.2 Workability of Concrete
The workability of the concrete shall be determined by the slump

A
test as described in M.S. 26.
EJ
The suggested slump details for typical concreting situations

shall be as specified in TABLE 10.3 of this specification. The
slump shall be measured at the time of discharge into the
M
borehole.
10.9.4.3 Compaction
EN
Internal vibrators shall not be used to compact concrete unless

it can be satisfied that they will not cause segregation or arching
of the concrete.
M
) 10.9.4.4 Placing Concrete in Dry Borings

KU
Approved measures shall be taken to avoid segregation and

bleeding and to ensure that the concrete at the bottom of the pile
is not deficient in grout.
O
Where piles are vertical, concrete may be poured through a

D
tremie so that the flow is directed and does not hit reinforcement
bars or the side of the hole. Chutes extending to near the base
shall be employed for raking piles of large diameter.
10.9.4.5 Placing Concrete Under Water or Support Fluid
Concrete to be placed under water or support fluid shall be

placed by tremie unless otherwise approved and shall not be
discharged freely into the water or support fluid . Before placing
concrete, measures shall be taken to ensure that there is no
accumulation of silt or other material at the base of the boring.
S10-32
(JKRlSPJ/2019-S10)
The hopper and pipe of the tremie shall be clean and watertight
throughout. The pipe shall extend to the base of the boring and
a sliding plug or barrier shall be placed in the pipe to prevent
direct contact between the first charge of concrete in the pipe of
the tremie and the water or support fluid . The tremie pipe outlet
shall be kept at least 1.5 metres below the surface of the concrete
at all stages in the pour. The Contractor shall develop a system
of level checks for the concrete and pipe outlet to ensure that this
requirement is met. The tremie pipe shall be withdrawn upward
gently below the concrete level, and shall not be subject to any
ER
shock or violent movement either in dislodging the concrete
within the pipe or for any other reason.
At all times, a sufficient quantity of concrete shall be maintained
D
within the tremie pipe to ensure that the pressure from it exceeds
that from the water or support fluid. The internal diameter of the
n
N
tremie pipe shall not be less than 150 mm for concrete made with
20 mm aggregate and not less than 200 mm for concrete made
TE
with 40 mm aggregate.
The tremie pipe shall be so designed that external projections are

minimised, allowing the tremie pipe to pass through the
A
reinforcing cage without causing damage or uplifting. The internal
face of the tremie pipe shall be free from projections.
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10.9.5 Extraction of Casing

M
10.9.5.1 Workability of Concrete
Temporary casings shall be extracted while the concrete within

EN
them remains suffiCiently workable to ensure that the concrete is

not lifted together with the casing .
10.9.5.2 Concrete Level

M
When the casing is being extracted, a sufficient quantity of U

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concrete shall be maintained within it to ensure that the pressure

from extemal water, drilling fluid or soil is exceeded and that the
pile is neither reduced in section nor contaminated.
O
No concrete shall be placed in the bore once the bottom of the

casing has been lifted above the top of the concrete. It shall be
D
placed continuously as the casing is extracted until the desired

head of concrete is obtained .
The top of concrete level shall be brought to at least 1000mm or

more as speCified on the Drawings above the cut-off level of the
pile or the concrete be allowed to be flushed out from the bore
to permit alilaitance and weak concrete to be removed and thus
ensure that it can be properly keyed into the pile cap .
S10-33
(JKRl8PJ/2019-810)
Adequate precautions shall be taken in all cases where excess

heads of water or drilling fluid could be a cause for concern as
the casing is withdrawn because of the displacement of water or
fluid by the concrete as it flows into its final position against the
wall of the pile shaft. Where double casings are used in the
boring, the proposed method of working shall be with the
10.9.5.3 Vibrating Extractors
ER
The use of vibrating extractors shall be permitted subject to S.O
approval. The work shall be carried out in such a manner and
times to ensure the quality of concrete in the bore, minimise
nuisance and disturbance to the surrounding.
D
10.9.6 Construction of Pile Heads
N
10.9.6.1 Water Levels
TE
In the event of the ground water level being higher than the
required pile head casting level shown on the Drawings, the
Contractor shall submit his proposals for approval prior to placing
A
concrete. The pile head shall not be left below the ground water
level unless approved precautions are taken.
EJ

M
Pile head shall be cut using hand held cutting equipment or

hydraulic splitters. Pile heads after cutting shall consist of sound
concrete and free from debris. Pile heads shall be constnucted to
EN
the details shown on the Drawings.
10.9.6.3 Temporary Backfilling Above Pile Casting Level

M
After each pile has been cast, any empty bore remaining shall be
l ) protected and shall be carefully backfilled as soon as possible
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with well compacted sand.
10.9.6.4 Piling Records

O
Complete piling records shall be kept by the Contractor during

pile installation. The Contractor shall submit in duplicate the
following information to the S.O.:
D
(i) Signed records of all piles as the work proceeds. Individual

pile record shall be submitted not later than noon of the next
working day after the pile was installed. The Signed records
shall form record Qf the work. Any unexpected installation
condition shall be noted in the record.
(ii) Upon completion, compile a record of the work as carried out

and provide As-built Drawings. The Drawings shall be
prepared and endorsed by the Licensed Surveyor.
810-34
(JKRlSPJ/2019-S10)
The format of the record shall be approved by the S.O. and shall
contain , but not be limited to the following information where
applicable:
(i) Date and time of boring, speed of boring for every meter
(ii) Type of boring machine
(iii) Date and time of concreting
(iv) Depth of borehole, detail of soil/rock strata penetrated,
soil/rock samples taken, and in-situ tests carried out
(v) Concrete mix
ER
(vi) Type of stabilizing fluids
(vii) Method of concreting
(viii) Standing ground water level
(ix) Length of temporary/permanent casing
D
(x) Length and details of reinforcement.
(xi) Estimated and actual volume of concrete required to form
N
the pile shaft. ()
TE
All record shall bear the names of person who records and
person who checks.
10.9.7 Pressure Grouting of Piles

A
Grouting of piles shall be done if encounter any unstable shaft or base
EJ
disturbance to ensure compatible performance of piles. Method of grouting

shall be carefully controlled to prevent pile uplift and avoid other potential
problems with prior approval of the S.O.
M
Pressure grouting shall not be used to compensate for poor pile construction
practice.
EN
10.1 0 MICROPILES
M
10.10.1 Materials
oJ
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The type of reinforcement to be used, the diameter and/or

thickness, grade, yield strength and working stress shall be as
O
specified or as shown on the Drawings.

D
10.10.1.2 Grout
Unless otherwise specified , the grout shall be non-shrink cement

grout. The grout mix design such as the water-cement ratio, the
minimum cement and grout strength at 7 and 28 days shall be as
specified and shown on the Drawings.
S10-35
(JKRlSPJ/2019-S10)
If admixtures are used, details of admixtures shall be submitted

to the S.O. for approval before commencement of works. The use
of the admixture shall fully comply with the manufacturer's
instructions.
10.10.2 Drilling Operation
10.10.2.1 Diameter of Piles
The diameter of piles shall not be less than the

specified/designed diameter at any level throughout its 'Iength
ER
and shall be in accordance with Sub-section 10.9.2.1 .
10.10.2.2 Drilling
D
The Contractor shall submit to the S.O. details of drilling
equipment and drilling procedure for approval before
N
commencement of works. Drilling operations shall be carried out
in accordance with the relevant requirements of Sub-section
TE
10.9.2.
10.10.3 Grouting Operations

A
10.10.3.1 Mixing And Placing Grout
EJ
The Contractor shall provide details of the method and

equipment used in grout mixing. Further information such as
grouting pressure, grouting procedure, grouting equipment and
M
techniques employed in grouting underwater shall also be

furnished for approval.
EN
Grout shall be mixed on Site and shall be free from segregation,

slumping and bleeding. Grout shall be pumped into its final
position in one (1) continuous operation as soon as possible and
in no case more than half an hour after mixing.
M
l ) Micropile shall be grouted in one continuous process. If there is

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significant loss of grout, the Contractor may choose to carry out

pre-grouting in stages as necessary to prevent further loss of
grout for the construction of micropile. Method statement of pre-
grouting including details of equipment, materials and
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procedures have to be reviewed and approved by the S.O. If after

the process of pre-grouting and re-drilling of the hole is required,
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the Contractor has to bear the cost and the time of the pre-
grouting and re-drilling.
10.10.3.2 Testing Grout
Grout shall be tested in accordance with BS EN 12390 and BS

EN 196.
If the grout cube as tested fails to satisfy the criteria as

prescribed in the specification and Drawings, the pile
constructed using this batch of grout shall be rejected . The
S10-36
(JKRlSPJ/2019-S10j
Contractor shall undertake all necessary additional and

consequential remedial works to the approval of the S.O.
10.10.4 Construction of Pile Heads
Where lengthening is required, the pile reinforcement unit shall

be connected on Site to the details as shown on the Drawings.
Other means of jointing reinforcement shall be to the approval of
the S.O.
ER
10.10.4.2 Cutting And Preparation Of Pile Heads
Pile heads shall be constructed to the details as shown on the
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Drawings.
N
10.10.5 Casing
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Where permeant casing or temporary casing is specified or required upon
approval of S.O., the requirements shall be in accordance with Sub-section
10.9.5.
A
10.11 CAISSON
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10.11.1 Material
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10.11 .1.1 Concrete
The material and workmanship for concrete shall be as specified

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under Section 9 of this specification. The grade of the concrete

shall be as shown on the Drawings.
M

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this specification. The details of steel reinforcement shall be as

shown in the Drawings.
10.11 .1.3 Permanent Liner

O
Lining shall be constructed sufficiently quickly after excavation

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and in sufficiently short section to prevent inflow of sailor

excessive inflow of water. In-situ concrete tapered rings used as
permanent liners shall be at least 100mm thick and shall not
exceed 1m deep. The ring shall be constructed with well
compacted concrete. The concrete shall be cast tight up against
the side of excavation. The material and workmanship for
concrete shall be as specified under Section 9 of this
specification. The grade of the concrete shall be as shown on the
Drawings.
S10-37
(JKRlSPJ/2019-S10)
10.11.2 Excavation operations
10.11 .2.1 Diameter of Piles
The effective diameters of the caisson shaft and bell out shall not
be less than those shown on the Drawings nor exceed the
specified dimension by more than 50mm at any level of the whole
shaft.
10.11 .2.2 Depth of Excavation
ER
The anticipated depth of all caissons is as indicated in the
Drawings. All caissons shall be taken to a depth pre-determined
by the Drawings into the required bearing stratum over the full
area of the caisson base. The caisson base shall be levelled.
D
Where bell-outs are required they shall be formed entirely within
the bearing stratum.
N
10.11 .2.3 Method Statement
TE
The Contractor shall adopt a method of construction that will not
cause settlement or disturbance of any kind to adjacent
structures, pavement, public or private services. The Contractor
A
shall establish an approved monitoring system and take regular
readings and prepare and submit reports to the S.O. in the format
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and quantity as requested . The Contractor shall modify the

method of construction if the effects of ground movement are
detected in any such structures, pavements and services.
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10.11 .2.4 Minimum Clear Working Space

EN
The minimum clear working space inside a caisson (Le.

excluding the lining) shall not less than 1.8m. Caissons with
enlarge base shall not be used unless otherwise specified.
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10.11 .2.5 Method of Excavation

( )
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Excavation for caissons shall be carried out using manual

methods or power tools. Blasting shall not be used unless agreed
by the S.O . If blasting is adopted, the following have to be
adhered to;
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(i) Obtain approval from relevant authorities and comply with the
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requirement of statutory authorities,

(ii) The position of blast holes and the size of charges shall be such
that shattering of rock beyond the caisson is minimized,
(iii) The rock face shall not be shattered within the toe-in or bell-out
zone at the bottom of the caissons, and
(iv) The caisson opening shall be covered to prevent the projection
of fragments of material.
S10-38
(JKRlSPJ/2019-S10)
10.11 .2.6 Rock Proving
Rock proving load test machine shall be provided at site for

testing of recovered rock sample for shaft and base selected by
S.O.
In addition, the rock below each shall be proved before

concreting by sinking minimum 'N' size drill holes, as specified in
MS1056, to a minimum of 5m below the proposed caisson base
or 3 times the bell out diameter of the caisson whichever is the
ER
greater.
Socket length shall be measured from the flattened horizontal

bedrock surface.
D
10.11 .2.7 Inspection and Record of Caisson Shaft and Base
N
Each caisson base shall be inspected, logged and photographed
TE
by qualified Engineer from the Contractor before inspection and
checking by the S.O. CV of the Engineer from the Contractor
shall be submitted for review and approved by the S.O.
A
The shaft of every caisson shall be properly logged, especially
one encountering rock surface during excavation.
EJ
Prior to any concreting works, the shaft and base (for rock only)
for the caisson shall be properly cleaned by using water jet or
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other approved method so that no debris or soil stains the shaft

surface or base. The base of each completed excavation shall
be carefully trimmed and levelled to the minimum required toe
EN
level. Approval of the base of any caisson by the S.O. shall not
relieve the Contractor of his responsibilities and obligations under
the terms of the Contract.
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Photographs at 4 sides of the shaft, i.e. 0°,90°, 180° and 360° and
rock base shall be taken by the Contractor after the cleaning oJ
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works and attached together with the inspection forms for the
S.O.
The shaft and base of each caisson must be approved by S.O.

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before any reinforcement and concreting works are carried out.

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10.11.2.8 Stability of the Excavation
The stability of excavations for caissons shall be maintained

where necessary by linings.
Shaft lining shall be placed as soon as practicable and not more

than 24hours after each increment of excavation is complete.
Voids between the lining and face of excavation shall be filled

with concrete of the same grade as the lining or with others
material as agreed by the S.O.
S10-39
(JKRlSPJ/2019-S10)
Any unstable layers of subsoil encountered shall be stabilized by

grouting or similar methods. No further excavation will be
permitted to proceed until the stabilization works are completed .
10.11.2.9 Dewatering
A comprehensive Method Statement on dewatering for caisson

construction shall be submitted by the Contractor for approval.
As a minimum measure, individual caissons shall be kept dry
ER
during excavation and inspection by pumping from a sump or
pilot hole within each caisson as necessary. Submersible pumps
shall be used and placed in a sump not more than 0.6m deep
and approximately 0.5m diameter sunk in advance of the main
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excavation. Pump operation shall be continuous until the caisson
is concreted.
N
()
The Contractor shall at all times use, to a minimum degree, of
TE
dewatering that is required for the works to proceed. It will be the
Contractor's responsibility to ensure that draw down outside the
site does not exceed the limits as specified by the S.O. The
Contractor's method statement shall include details of measures
A
proposed to meet this requirement. All such measures shall be
subject to approval by the S.O.
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10.11.2.10 Water Pumped from Caissons

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Water sample pumped from caissons shall be screened through

sedimentation or settling tank and quantities of sediment shall be
monitored to ensure that excessive fines are not removed from
EN
the soil. Should excessive fines be observed from any caisson,

pumping from that caisson shall cease and the S.O. notified
immediately.
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When required by the S.O., the Contractor shall record the rate
( ) of pumping from the individual caissons and shall submit two
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copies of the records on the following day. The Contractor shall

report immediately to the S.O. any marked change in the rate of
flow of water from any caisson .
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Water pumped from caissons or the ground shall not be

discharged directly onto the ground surface without suitable and
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adequate provisions for drainage being made.
The Contractor shall be responsible for obtaining all necessary

permissions from statutory authorities for discharging water into
the public drainage system.
10.11.2.11 Cessation of Excavation
If the excavation and pumping from caissons results in settlement

outside the site of more than 25 mm, or as otherwise specified
by the S.O., caisson construction and dewatering at the
S10-40
(JKRlSPJ/2019-S10)
appropriate locations shall immediately cease and the S.O.

notified.
The Contractor shall not recommence caisson construction or

dewatering until the construction sequence has been reviewed
and measures taken to prevent further settlement occurring. In
all cases, work shall not be recommended to proceed without the
The Contractor shall be responsible for any damage, and any

claims arising from such damage, which may result from
ER
settlement caused by caisson construction . The Contractor shall
make good the damage as quickly as possible.
10.11 .2.12 Emergencies
D
The Contractor shall submit Emergency Response Plan (ERP)
N
for review and approval by the S.O. ()
TE
If the sides of a caisson start to collapse or an emergency arises
which could lead to instability of the excavation, the Contractor
shall immediately inform the S.O. and implement measures to
preserve the stability of the caisson and of neighboring structures
A
and services.
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10.11.2.13 Disposal of Spoil
Soil removed from the excavation shall be removed from the site
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and disposed off in accordance with statutory requirements.
10.11 .2.14 Sealing and Scaling of Caissons

EN
Leakage of groundwater through liners or into unlined shafts of

hand-dug caissons shall be stopped by a method agreed upon
by the S.O.
M
Loose rock on the face of unlined shaft shall be scaled off and U
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removed before concreting .
On completion of excavation, spoils shall be removed from the

base of caisson before concreting.
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10.11 .2.15 Inspection of Excavations

D
Each hole shall be inspected prior to the placing of concrete in it.

Adequate equipment shall be provided to enable the Contractor
and the S.O. to descend into the hole for the purpose of inspection.
All works shall confonm to the requirement of BS 5573: Safety
Precaution in the Construction of Large Diameter Boreholes for
Piling and Other Purposes.
S10-41
(JKRlSPJ/2019-S10)
Prior to any concreting works, the shaft and base (for rock only)
for the caisson shall be properly cleaned by using water jet or other
approved methods so that no debris or soil stains the shaft surface
or base. The base of each completed excavation shall be carefully
trimmed and levelled to the minimum required toe level and
10.11.3 Placing of Reinforcement
10.11 .3.1 Joints in Longitudinal Bars
ER
Reinforcement shall be such that the full strength of the bar is
effective across the joint and the joint shall be made so that there
is no relative displacement of reinforcement during construction
D
of the pile and the spacing of the reinforcing bars shall be
maintained in such a way that proper concreting shall not be
N
impeded.
TE
10.11 .3.2 Positions of Reinforcement
Adequate spacer blocks, guides tubes and lifting wires shall be

provided so as to maintain the reinforcing steel in the position as
A
specified.
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10.11.4 Concreting operations
10.11.4.1 Placing concrete

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All subsoil and debris shall be removed from the caisson to the
satisfaction of S.O. No concrete shall be placed without approval
EN
of the S.O.
The method of placing and the workability of concrete shall be

such that a continuous monolithic concrete shaft of the full
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section is formed.
)
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10.11.4.2 Workability of concrete
The workability of the concrete shall be determined by the slump

test as described in M.S. 26.
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The suggested slump details for typical concreting situations

D
shall be as specified in TABLE 10.3 of this specification. The

slump shall be measured at the time of discharge into the
borehole.
10.11.4.3 Compaction
Internal vibrators shall not be used to compact concrete unless it

can be proven that they will not cause segregation or arching of
the concrete.
S10-42
(JKRlSPJ/2019-S10l
10.11.4.4 Placing Concrete in Dry Borings
Approved measures shall be taken to avoid segregation and

bleeding and to ensure that the concrete at the bottom of the pile
is not deficient in grout.
Concrete may be poured through a funnel with a length of tube

so that the flow is directed and does not hit reinforcement bars or
the side of the hole.
ER
10.11 .5 Construction of pile heads
10.11 .5.1 Water Levels
D
Water levels shall be in accordance with Sub-sections 10.9.6.1 .
N
10.11 .5.2 Cutting and Preparation of Pile Heads
TE
Cutting and preparation of pile heads shall be in accordance with
Sub-sections 10.9.6.2.
10.11 .5.3 Temporary Backfilling above Pile Casting Level

A
Temporary backfilling above pile casting level shall be in
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accordance with Sub-sections 10.9.6.3.
10.11 .6 Piling records

M
Complete piling records shall be kept by the Contractor during pile

installation. The Contractor shall submit in duplicate the following information
EN
to the S.O.:
(il Signed records of all piles as the work proceeds. Individual pile record
shall be submitted not later than noon of the next working day after the
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pile is installed. The signed records shall form documented record of

the work. Any unexpected installation condition shall be noted in the
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record.
(ii) Upon completion , compile a record of the work as carried out and
provide As-built Drawings. The Drawings shall be prepared and
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endorsed by the Licensed Surveyor.

D
The format of the record shall be approved by the S.O. and shall contain,
but not limited to the following information where applicable:
(i) Caisson number.

(ii) Level of top of concreted caisson shaft referred to Principal Datum.
(iii) Level of top concrete lining referred to Principal Datum.
(iv) Depth to base of caisson from top of concreted shaft.
(v) Date(s) and time(s) of starts and finishes of excavations and
concreting.
(vi) Minimum internal diameter of caisson lining.
S10-43
(JKRlSPJ/2019-S10)
(vii) Full details of any bell-out and minimum diameter of caisson base.
(viii) Thickness and details of concrete lining.
(ix) Description of ground excavated, and methods employed.
(x) Length and details of reinforcement.
(xi) Estimated and actual volume of concrete required to form the pile
shaft
(xii) Details of all obstructions, delays and other interruptions.
(xiii) Complete record of bedrock proving test.
(xiv) Final log and photographic record of caisson base.
(xv) Results of core test.
(xvi) All tests made on materials used in the works.
ER
All records shall bear the names of person who records and person who
checks.
D
10.11 .7 Safety precaution
N
10.11 .7.1 General
TE
The Contractor shall at all times comply with the Govemment
regulations for safety on work sites. The working facilities
provided and the manner in which the works are conducted shall
conform to the requirements of BS 5573: Safety Precaution in the
A
Construction of Large Diameter Boreholes for Piling and Other
Purposes.
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10.11 .7.2 Electrical Equipment

M
All electrical equipment shall be wired in accordance with

'Regulations for the Electrical Equipment of Buildings', Latest
Edition, published by the Institution of Electrical Engineers.
EN
10.11 .7.3 Caisson Shafts
The Contractor shall ensure that construction of the concrete

M
caisson lining follows the excavation sufficiently closely to ensure

\ ) the stability of the works.
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The Contractor shall ensure that the concrete caisson lining

extends a minimum of 0.25 m above and adjacent surrounding
ground at all times.
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The Contractor shall keep all caissons not being worked covered
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at all times by a stout safety cover capable of supporting

a uniformly distributed load of 1.5 kN/m2 and preventing
entry of water into the caisson . The cover shall be attached
rigidly to the top of the concrete lining to fully cover the caisson .
If an access platform is provided at the top of the caisson the hole

through which access to the caisson is gained shall be
equipped with a stout 150 mm high kicker board around the full
perimeter. The area adjacent to the kicker board shall be kept
clear at all times of all loose rubble, tools or other objects
which may be knocked into the caisson.
S10-44
(JKRlSPJ/2019-S10)
The Contractor shall at all times ensure that there is a

hessian rope of minimum diameter 20 mm securely fixed at
ground level and passing over a block on the frame above
the caisson and reaching the bottom of the caisson .
10.11.7.4 Ventilation
The Contractor shall provide sufficient compressors, air pumps,

etc. including an adequate number of standby spares, in order to
ensure complete ventilation of all shafts whilst work is in progress
ER
and prevent the build-up of noxious gases or de-oxygenation .
Exhaust pipes from boring machines, winches and other

equipment shall be so positioned that no exhaust gas enters the
D
caisson or the intake of the air compressors supplying the fresh
air to the base of the caisson.
N
10.11.7.5 Lighting
TE
The Contractor shall maintain adequate artificial lighting at all
times in all caisson shafts being worked.
A
10.11 .7.6 Water in Caisson Shafts
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The Contractor shall provide suitable methods approved by the

S.O. to ensure the safety of the works.
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10.11.7.7 Access and Communications
The Contractor shall provide access to all levels of shafts at all

EN
times whilst work is in progress and a means of communication

with workmen in the shafts of a type that gives immediate notice
to and from the surface of hazards which directly affects safety
in the shaft.
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10.11 .7.8 Removal of Persons from Caisson Shafts

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The Contractor shall provide a means whereby persons,

including those semi-conscious or unconscious, may be
removed rapidly and safely from caissons.
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10.11 .7.9 Oxygen

D
The Contractor shall provide at all times equipment and spares

to enable oxygen to be administered to persons in an
asphyxiated condition . The Contractor shall ensure the
permanent presence on site during hours of work of an operator
fully trained in the use of this equipment.
S10-45
(JKRlSPJ/2019-S10)
10.12 STATIC PILE LOAD TESTING
10.12.1 General
To verify the working load, the Contractor shall carry out pile load test as
shown on the Drawings and / or as instructed by the S.O.
The design and construction of the load application system shall be

satisfactory for the required test. These details shall be made available
prior to the commencement of testing.
ER
10.12.2 Construction of Pile to be Tested
10.12.2.1 Notice of Construction
D
The Contractor shall give at least 48 hours' notice of
commencement of construction of any preliminary pile which is
N
n to be tested .
TE
10.12.2.2 Method of Construction
Each preliminary test pile shall be constructed in a manner

similar to that to be used for the construction of the working piles
A
and by the use of similar equipment and material. Extra
reinforcement and concrete of increased strength will be
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permitted in the shafts of preliminary piles where necessary and

agreed by the S.O. for carrying out the testing .
M
10.12.2.3 Boring or Driving Record
For each preliminary pile which is to be tested, a detailed record

EN
of the conditions experienced during boring or of the progress

during driving, shall be made available daily, not later than noon
on the next working day. Where soil samples are required to be
taken or in-situ tests to be made, the Contractor shall present the
M
results without delay.

\.)
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10.12.2.4 Concrete Test Cube
Three (3) test cubes shall be made from the concrete used in the
preliminary test pile and from the concrete used for building up
O
the working pile. If the concrete pile is extended or capped for the
purpose of testing, a further three (3) cubes shall be made from
D
the corresponding batch of concrete. The cube shall be made

and tested in accordance with Section 9: Concrete of this
specification.
10.12.2.5 Cut-Off Level
The cut-off level for the preliminary test pile/working piles shall
be as specified on the Drawings or as directed by the S.O.
Where the cut-off level of working piles is below the ground level
at the time of pile installation and where it is required to carry out
S10-46
(JKRlSPJ/2019-S10)
a load test from that installation level, either allowance shall be

made in the determination of the twice working load for friction
which may be developed between the cut-off level and the
existing ground level, or the piling may be sleeved appropriately
or otherwise protected to eliminate friction which can develop
over the extended length.
10.12.2.6 Preparation for Pile Head for Testing
For a pile that is tested in compression, the pile head or cap shall
be formed to give the plane surface which is normal to the axis
ER
of the pile, sufficiently large area to accommodate the loading
and settlement measuring equipment and adequately reinforced
or protected to prevent damage from the concentrated
application of load from the loading equipment.
D
For a pile that is tested in tension, means it shall be provided for
N
transmitting the test load axially witt.1out inducing moments in the
pile. The connection between the pile and the loading equipment
TE
shall be constructed in such a manner as to provide strength
equal to the maximum load which is to be applied to the pile
during the test with an appropriate factor of safety on the
structural design.
A
10.12.2.7 Supervision
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The setting up of pile testing equipment shall be carried out under

competent supervision and the equipment shall be checked to
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ensure that the setting-up is satisfactory before the

commencement of load test.
EN
All tests shall be carried out only under the direction of an

experienced and competent supervisor conversant with the test
equipment and test procedures. All personnel operating the test
equipment shall have been trained in its use. The Curriculum
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Vitae (CV) of Tester(s) shall be submitted 48 hours prior to

testing works being carried out.
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10.12.2.8 Notice ofTest
The Contractor shall give at least 24 hours' notice of the

O
commencement of the test. No load shall be applied to the test

pile before the commencement of the specified test procedure.
D
10.12.3 Protection of Testing Equipment
10.12.3.1 Protection from Weather
Throughout the test period, all equipment for measuring load and
movement and beams shall be protected from adverse effects of
sun, wind and precipitation. Temperature readings shall be taken
at the start, end and at the maximum load of each loading cycle.
S10-47
(JKRl5PJ/2019-510)
10.12.3.2 Prevention of Disturbance
Construction activities and persons who are not involved in the testing
processes shall be kept at a sufficient distance from the test location to avoid
disturbance.
10.12.4 Method of Loading
10.12.4.1 Test Load
The test load shall be applied in one (1) of the following ways:
ER
(a) By means of a jack which obtains its reaction from kentledge
heavier than the required load;
D
(b) By means of a jack which obtains its reaction from tension
piles or other suitable anchors.
N
(c) By means of a jack which obtains its reaction through bi-
n directional axial load from the top and bottom section of the
tested pile.
TE
In all cases, the reaction load or its supports shall be placed
sufficiently far from the proposed test position to reduce the
influence on the results to a tolerable level. Care shall be taken
A
to ensure that the reaction load remains stable throughout the
test without the possibility of load tilting or collapsing.
EJ
In addition to the reaction load, it shall be necessary to provide a

loading frame, a bearing plate, a loading column and a hydraulic
M
jack or other appropriate type of load measuring device. The

loading column shall be of sufficient strength to prevent undue
buckling under the maximum load. The total weight of the
EN
kentledge or reaction force provided shall be at least 1.2 times

the maximum test load.
In all cases the Contractor shall ensure that when the hydraulic
M
jack and load measuring device are mounted on the pile head,
) the entire system shall be stable up to the maximum load to be
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applied.
If in the course of carrying out a test, any unforeseen occurrence

should take place, further loading shall not be applied until a
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proper engineering assessment of the prevailing conditions has

been made and steps taken to rectify any fault.
D
Where an inadequacy in any part of the system might constitute

a hazard, means shall be provided to enable the test to be
controlled from a position clear of the kentledge stack or test
frame.
Where method (i) or (ii) is used; The hydraulic jack, pump, hoses,
pipes, couplings and other apparatus Oack assembly) to be
operated under hydraulic pressure shall be capable to withstand
a pressure of 1.5 times the maximum pressure used in the test
without leaking. For method (iii), the rated nominal capacity of
510-48
(JKRlSPJ/2019-S10)
jack assembly shall exceed the maximum anticipated jack load

by at least 10%. Test certificate shall be submitted before
carrying the test.
The maximum test load expressed as a reading on the gauge in

use shall be displayed and all operators shall be made aware of
this limit.
When method (i) is used, care shall be taken to ensure that the
centre of gravity of the kentledge is on the axis of the pile. The
nearest edge of the crib supporting the kentledge stack shall not
ER
be closer than 1300 mm to the surface of the test pile. Kentledge
shall not be used for testing raked piles. Refer Figure 10.1 for
typical set up requirement.
D
When method (ii) is used, all anchor piles shall be at a distance
of at least three (3) pile shaft diameters from the test pile, centre
N
to centre, and in no case, shall they be less than 2000 mm from
the test pile.
TE
If the anchor piles are to be pemnanent working piles, their levels
shall be observed during application of the test load to ensure no
residual uplift occurs.
A
When method (c) is used,
EJ
(i) Bi-directional axial compression test shall be carried out in

compliance with ASTM D8169-18 unless otherwise
M
approved by SO.
(ii) The test shall be carried out only under the direction of an
EN
experienced and competent supervisor conversant with the

test equipment and test procedures. All personnel
operating the test equipment shall have been trained in its
use. The Curriculum Vitae (CV) of Tester(s) shall be
M
submitted 48 hours prior testing works.

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(iii) The method consists of bi-directional pile load test; the jack
load unit is installed within the pile body and bi-directional
base load test; the jack load unit is installed at the pile base.
O
(iv) The jack load unit shall be placed in plane surface which is
normal to the axis of the pile. The elevation of the load unit
D
shall be located at the approved calculated equilibrium

geotechnical capacity of upper and lower segments of the
test pile as verified by a Professional Engineer.
(v) The steel bearing plates, stiffeners or equivalent as needed

to distribute the jack load evenly over the pile cross-
section.
(vi) The upper displacement tell-tale shall be fixed in sufficient

distance at the top section of the tested pile.
S10-49
(JKRlSPJ/2019-S10)
(vii) The lower displacement tell-tale for bi-directional pile load

test shall be fixed in sufficient distance at the bottom
section of the tested pile. Whereas the lower displacement
tell-tale for bi-directional base load test shall be fixed at the
bottom of the pile base plate.
(viii) The connection in between the top and bottom section of

the tested pile to the jack load unit shall be allowed for
opening mechanism at the split zone for the purpose of
testing .
ER
(ix) Tell-tale or any other tests to the pile such as sonic logging,
the instrumentation pipes or cabling which is located at the
jack load unit shall be in such extendable during the split
D
zone gap opening during pressurizations.
N
(x) The protection measures such as funnel rebar or other
methods as approved by the S.O. shall be fixed to the main
rebar cage to protect the jack load unit from damages
TE
during concreting .
(xi) The jack load unit shall be fully welded together with the
upper steel rebar cage. The bearing plates shall be spot-
A
welded with the load unit. The plate shall be made to
receive uniform load distribution prior to testing.
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(xii) Minimum two (2) grouting pipes shall be installed together

with the jack load unit. The pipes shall be pre-cut at the split
M
zone of the load unit to enable the pipes to split and allow
the cement grout to flow and grouting takes place. The
sonic logging pipes may also be treated as grouting pipes.
EN
(xiii) Post grouting shall be done to fill up the gap at the split
zone. Clean water shall be initially pumped to remove the
debris left at the split zone after testing. Grouting shall start
M
when the water returned to the nearby grouting pipe

\. ) becomes clean. Grouting operation shall be terminated
KU
when the returned cement grout is most likely similar to

previous grout applied.
(xiv) The test result shall be plotted as load versus displacement

O
curves for the upward and downward displacement

independently. The two (2) component curves shall be
D
utilized to construct an equivalent pile-top load versus

displacement curve.
(xv) To simulate compressive load, established correction

factor for shaft resistance and reduction of pile weight shall
be considered at the pile top section which is formally
subjected to tension load behaviour during bi-directional
testing. In addition, established correction factor and elastic
shortening shall be considered at the pile top section for
settlement computation due to the load.
S10-50
(JKRlSPJ/2019-510)
(xvi) The test report shall be endorsed by a Professional

Engineer with Practicing Certificate prior to submission to
the S.O.
Alternatively, the Contractor may propose the use of other types,

patented or otherwise, in which case the requirements as below
shall be fully complied with .
10.12.4.2 Contractor's Load Test System
ER
The Contractor may propose to use other different types from
those specified. The proposal shall be submitted to the S.O. at
least 90 days before the date of testing. The suitability or
adequacy of any system shall be determined by the S.O. In the
D
event that the testing system proposed by the Contractor is
acceptable, the Contractor shall obtain a Professional Engineer's
N
endorsement on load settlement results.
TE
10.12.4.3 Measurement of Load
The test load shall be measured by calibrated load cell(s) or

proving ring calibrated in divisions not exceeding 1% of the
A
maximum load to be applied. If an electronic transducer is used,
each reading shall be immediately saved so that in case of power
EJ
failure the readings are not lost.
The load cell or proving ring to be accepted for use shall be

M
calibrated within the test load range without extrapolation and

certificate of calibration within a validity of 6 months shall be
made available before the load test commences.
EN
All increments of load shall be maintained to within 1% of the

specified load.
M
A spherical seating or pivot bearing of appropriate size shall be

used to avoid eccentric loading. Care shall be taken to avoid any J
KU
risk of buckling of the load application and measuring system.

Load measuring and application devices shall be in short axial
length in order to secure stability. The Contractor shall ensure
that axial loading is maintained.
O
The loading equipment shall enable the load to be increased or

D
decreased smoothly or to be held constant at any required value.
S10-51
(JKRlSPJ/2019-S10)
10.12.4.4 Measurement of Settlement
The Contractor shall provide apparatus for measuring settlement

consisting of a primary system, at least one (1) auxiliary system
for pile head and reference frame scale. Minimum one (1)
independent temporary benchmark at least 15 m (unless
otherwise approved by the S.O. that nearer undisturbed and
stable temporary benchmark can be established) from the test
site to monitor the settlement reference point, shall be
established. If desired, the auxiliary system may also be
ER
referenced to these benchmarks.
All measuring devices, scales and reference pOints with numbers

or letters to ensure accurate data recording shall be clearly
D
identified.
N
n Settlements shall be measured by use of a reference beam
supported independently of the load test pile, reaction pile or
TE
piles supporting reaction loads. Settlements shall be measured
to the nearest 0.1 mm accuracy. The reference beams shall be
protected from the effects of temperature changes.
A
10.12.4.5 Primary System
EJ
Reference Beams and Displacement Measuring Devices
(i) At least four (4) Linear Voltage Displacement Transducers

M
(LVDT) and a Readout Unit are to be used for measuring

the displacement. DC/DC-type displacement transducer
having at least 75 mm of travel and a linearity of 0.5 % or
EN
less shall be used. A Readout Unit having a minimum

display of three (3) digits, capable of monitoring output from
DCIDC - Type LVDT shall be provided.
M
(ii) The measurement devices parallel to the longitudinal axis

( ) of the test pile and the axis of load application shall be
KU
aligned.
(iii) An independent reference beam or beams shall be set up

to enable measurement of the movement of the pile to be
O
made to the required accuracy and shall not be interfered

by the load application system.
D
(iv) Reference beam supports shall be embedded securely and

finmly into the ground, at a horizontal distance of not less
than 2m from the closest face of the test pile, or 1.5m from
the nearest corner of the support crib or platfonm/reaction
pile, whichever is greater.
(v) A clear distance of 150 mm to 300 mm from the test pile to

the reference beam or any projection used to support LVDT
shall be maintained. The beam and projections should be
at about the same elevation as the attachments to the pile
S10-52
(JKRlSPJ/2019-S10)
on which the measuring devices will bear.
(vi) The LVDT supports to reference beam shall be attached so

as to allow the stem of each device to rest on an
attachment to the pile sides.
(vii) Hardware and pile attachment for LVDT devices shall be

mounted using materials such as brass, aluminium or 303
series stainless steel, to avoid magnetic interference which
the instruments. The pile attachments are angles, about
75mm x 100mm with the 1OOmm dimension projecting from
ER
the pile. For round pile, these attachments shall be placed
on the perimeter of the pile at 120 degrees and an equal
radial distance. For pile of other cross section, the
attachments shall be placed at a convenient location as
D
N
(viii) Surfaces on which the gauge stems bear should have a 0
smooth finish, such as glass or sheet acrylic, attached by
TE
an epoxy or other suitable material approved by the S.O.
(ix) Observation of any movements of the reference beam or

beams shall be made and checking of the movement of the
A
pile head relative to a remote reference datum shall be
made and stopped at maximum load for each loading.
EJ
Refer FIGURE 10.1 for typical set up requirement.

M
10.12.4.6 Auxiliary Systems
This measuring system shall consist of one (1) or more of the

EN
following: wire, mirror and scale; surveyor's level and target road;
or, as alternatives, electrical or optical levels.
(i) Wire, Mirror and Scale

M
Pile movement shall be determined by means of a single

strand of wire drawn in front of graduated scale mounted on a
KU
mirror. This scale, at least 150 mm long and machine-divided

in graduations of 250 11m, is mounted on a 75 mm x 150 mm
mirror with metal and glass bonding adhesive or electrical
tape. The mirror shall be attached directly to the pile oriented
O
so that the mirror face is parallel to the reference beam. The

mirror shall be mounted to the wire between the ends of the
D
reference beam, with one (1) end fixed and the other is placed
over a pulley with a weight in order to maintain tension. The
wire shall be located so that it is level and within 20 mm of the
mirror face.
S10-53
(JKRl5PJ/2019-510)
(ii) Surveyor's Level and Target Rod

Use a level and levelling rod with a Vernier target that can be
read to 0.5mm. Determine deflections by readings on the two
fixed independent benchmarks, and on an established scale
or fixed point on the pile top.
(iii) Alternative Systems

Any other type of electrical or optical gauge yielding a
ER
precision equivalent to the primary system is acceptable as an
alternative, provided prior written approval is obtained from
the S.D.
D
10.12.4.7 Tell-tale Strain Measurements
N
When specify, strain measurements on the pile to determine
TE
elastic shortening of the pile shall be obtained by tell-tale strain
measuring devices.
Tell-tales extensometer or vibrating strain gauges or other

suitable measuring system shall be installed according to the
A
drawing shown or as directed by the S.D .
EJ
10.1 2.5 Testing Procedure
10.12.5.1 General
M
Prior to the performance of any load test, the Contractor shall

submit to the S.D. for his approval, working Drawings showing
EN
the method and equipment he proposes to use in the

performance of the load test and the measurement of
settlements. Such submission shall include design calculations
of lateral supports or other methods to be used in ensuring
M
against buckling. Horizontal supports to ensure bucking stability

\ ) shall be provided to the pile to be loaded whenever the ratio of
KU
the unsupported height to the least cross-sectional dimension is

20 or more. Horizontal supports shall provide full support without
restraining the vertical movement of the pile in any way.
O
10.12.5.2 Maintained Load Test

D
The Maintained Load Test shall be carried out as follows:
(i) The Full Test Load (FTL) on a pile shall be twice the Working
Load (WL) noted on the Drawings unless otherwise stated,
or directed by S.D.
(ii) The test shall be carried out in two (2) cycles, with first cycle
test up to working load and second cycle test up to full test
load as specified in Table 10.4 of this specification.
510-54
(JKRlSPJ/2019-S10)
(iii) The load shall be applied in increment of 25% of the working

load. Each increment of load shall be applied as smoothly
and as expeditiously as possible. Settlement readings and
time observations shall be taken before and after each new
load increment.
(iv) The minimum period for maintaining a load at each

increment before reaching the working load or test load is 30
minutes. A further increment of load shall be applied when
rate of settlement is less than 0.05mm in 15 minutes.
ER
(v) Time-settlement readings shall be taken at 2, 8, 15 and 30
minutes, and at 15 minutes interval thereafter. A time-
settlement graph shall be plotted to indicate when the rate of
D
settlement of 0.05 mm in 15 minutes is reached before load
increment is applied.
N
(vi) The working load shall be decreased in two (2) equal stages,
TE
and time-settlement readings shall be as specified a
foresaid, until the rate of settlement is less than 0.05mm in
15 minutes. At least 30 minutes interval shall be allowed
between the unloading decrements while minimum one (1)
A
hour shall be allowed when unloading to zero load.
EJ
(vii) The maximum working load in first cycle shall be maintained

for a minimum of 6 hours and time-settlement readings shall
be taken at regular intervals of every 15 minutes for the first
M
two (2) hours and every hour thereafter.
(viii) The maximum test load shall then be maintained for a

EN
minimum of 24 hours, and time-settlement readings shall be

taken at regular intervals for every 15 minutes for the first
two (2) hours and every hour thereafter.
M
(ix) The maximum test load shall be decreased in four (4) equal
stages, and time-settlement readings shall be as specified a
KU
foresaid, until the rate of settlement is less than 0.05mm in

15 minutes. At least 30 minutes interval shall be allowed
between the unloading decrements while minimum one (1)
hour shall be allowed when unloading to zero load.
O
(x) If large discrepancies occur between different measurement

D
system in clause 10.12.4.5 and 10.12.4.6 the test shall be

halted and the cause for the discrepancy corrected. The
test shall be restarted from the beginning in this instance.
(xi) Settlement readings shall be made immediately after and

before every load increment is applied or removed .
Refer TABLE 10.4 for Load Increments and Minimum Holding

Time.
S10-55
(JKRl8PJ/2019-810)
10.1 2.6 Submission of Results
Full test data, complete field test records and results from the readout unit
shall be jointly signed by the S.O.'s representative and the Contractor's
authorised agent and submit to the S.O. immediately upon completion of the
load test. The submission shall also consist of the following :
(i) Stage of Loading

(ii) Period for which the load was held
(iii) Final load and load increment
ER
(iv) Maximum settlement
These are to be plotted as load versus settlement and load - settlement
D
versus time graphs.
Interpretation of Test Results
N
10.12.6.1
n The S.O.'s interpretation and conclusions on the test results shall
TE
be final. Unless otherwise specified, the pile so tested shall be
deemed to have failed if:
(i) The total settlement under the Working Load exceeds

A
12.50 mm; or
EJ
(ii) The total settlement under twice the Working Load exceeds
38.0 mm, or 10% of pile diameter 1 width whichever is the
lower value, or
M
(iii) The residual settlement after removal of the test load at

working load exceeds [(diameter of pile or diagonal width
EN
for non-circular pile 1120) + 4] mm or 12.50 mm whichever

is the lower value; or
(iv) For pile longer than 30 m, the limit for maximum allowable
M
settlement (i) and (ii) above can be increased by 2.2% for

( ) every meter length of pile beyond 30 m.
KU
10.12.7 Completion of a Test
10.12.7.1 Removal of Test Equipment

O
On completion of a test, all measuring equipment and load

D
application devices shall be dismantled and checked . All other

test equipment, including kentledge, beams and supporting
structures shall be removed from the test pile location. Measuring
and other demountable equipment shall be stored in a safe
manner so that it is available for further tests, if required, or
removed from site.
Temporary tension piles and ground anchorages shall be cut off

below ground level and all cut-off materials removed from the
site. The ground shall be made good to the original commencing
surface level.
810-56
(JKRlSPJ/2019-S10)
10.12.7.2 Preliminary Test Pile Head
Unless otherwise specified, the head of each preliminary test pile

shall be cut off below ground level, and all cut-off materials
removed from the site. The ground shall be made good to the
original commencing surface level.
10.13 HIGH STRAIN DYNAMIC PILE TESTING
ER
10.13.1 General
The Dynamic pile testing using Pile Driving Analyzer (PDA) equipment is a
high strain non-destructive load test method which can be performed during
D
initial pile driving and during pile restrike to provide dynamic analyses using
Case Pile Wave Analysis Program (CAPWAP) or equivalent and Wave
N
Equation analyses programs approved by S.O. The analyses programs shall
be performed for the purposes of obtaining ultimate pile bearing capacity,
TE
pile stresses, pile integrity, and pile driving system performance. PDA testing
is undertaken in conformance with latest ASTM Standard D-4945.
The Contractor shall supply all material, equipment, and labour to perform
A
the dynamic monitoring. The Contractor shall obtain the dynamic
measurements with the PDA of monitor piles and furnish the necessary
EJ
dynamic data to the S.O.
10.13.2 Construction of Pile Head to be Tested

M
10.13.2.1 Driven Concrete Piles

EN
For a concrete pile subjected to PDA testing, the original pile

head is to be used. For a damaged pile head, it shall be cut off
square at sound concrete, and all loose particles shall be
removed by wire brushing, followed by washing with water. Care
M
shall be exercised to ensure that the reinforcement in the pile

head is not in any way damaged. Any damaged reinforcement
KU
shall be made good to the satisfaction of the S.O. The head shall
be replaced with concrete of similar grade or higher.
10.13.2.2 Castln-Situ Piles

O
For cast in-situ piles, a spiral welded steel casing of at least 6mm
D
thickness, same diameter as the cast in-situ pile and one

diameter in depth is used to prepare the pile head for testing.
Concrete of the same quality or better is used to build up the pile
head with the finished level just above the steel casing (with the
steel casing forming part of the pile head). Care should be taken
so that there is no cold joint between the build up pile head and
the pile.
The completed pile surface shall be flat and perpendicular to the

applied force.
S10-S7
(JKRlSPJ/2019-S10)
10.13.2.3 Steel Pile
The pile top shall be flat.
10.13.3 Method otTesting
10.13.3.1 Equipment and Personnel Qualification
The dynamic monitoring shall be performed using a Pile Driving

Analyzer (PDA) system or equivalent approved by S.O. All
ER
equipment necessary for the dynamic monitoring such as
sensors, cables or wireless transmitters, etc., shall be furnished
by Contractor and well calibrated at the time of testing . The
D
equipment shall conform to the requirements of the latest ASTM
D-4945.
N
(') Dynamic testing shall be performed by an independent specialist
TE
firm approved by S.O.
10.1 3.3.2 Preconstruction Wave Equation Analysis
Wave Equation Analysis shall be carried out to access the ability

A
of the proposed driving system to install the pile to the required
capacity and desired penetration depth within the allowable
EJ
driving stresses.
Ten working days prior to testing, the Contractor shall submit the
M
Wave Equation Summary Report and the report shall be

endorsed by Professional Engineer with Practicing Certificate
and submitted to the S.O. for review and approval.
EN
The output shall be:
(i) In the form of a relationship between pile capacity and

M
driving behaviour
(ii) An estimate of final set (mm/blow)
KU
(iii) Relationship between driving stresses in the pile and

penetration resistance.
Approval of the proposed driving system by the S.O. shall be

O
based upon the wave equation analyses indicating that the

proposed driving system can develop a pile capacity of twice the
D
pile design load at driving resistance. The hammer should also

be sized or adjustable such that the penetration per 10 blows at
the required ultimate capacity does not exceed 25 mm.
A new pile driving system, modifications to existing system, or

new pile installation procedures shall be proposed by the
Contractor if the pile installation stresses calculated by Wave
Equation Analysis or derived from the PDA measurements
exceed the maximum values specified by the S.O. or shown in
TABLE 10.5.
S10-58
(JKRlSPJ/2019-S10)
10.13.3.3 Apparatus for Applying Impact Force
The driving apparatus shall be positioned so that the impact is

applied axially to the head of the pile and concentric with the pile.
The device used to <lpply the impact force should provide
sufficient energy to cause pile penetration during the impact
event adequate to mobilize the desired capacity.
Conventional pile driving hammer, drop weight, or similar impact

device based on predictive dynamic analysis, experience, or both
ER
shall be approved by S.O. The impact shall not result in dynamic
stresses that will damage the pile. The S.O may require
cushions, variable control of the impact energy (drop height,
D
stroke, fuel settings, hydraulic pressure, etc.), or both, to prevent
excessive stress in the pile during all phases of pile testing.
N
10.13.3.4 Gauges for Obtaining Dynamic Measurement
TE
Dynamic measurement shall be carried out by attaching at least
two strain transducers and two accelerometers for pile sizes less
than 1000mm and at least four strain transducers and four
accelerometers for pile larger than 1000 mm diameter.
A
Care shall be taken to ensure that the gauges are securely
EJ
attached at least 1.5 pile diameter from the pile head for pile
diameter less than 1000mm and at least 1 pile diameter for pile
exceeding 1000mm. The gauges shall be attached above the
M
existing ground level and at opposite sides for a pair of gauges

and at every quarter of pile circumference for two (2) pairs of
gauges.
EN
The gauges shall be calibrated to an accuracy of 2% throughout

the applicable measurement range. The frequency of calibration
is as per stated in the latest ASTM 0-4945. If damage is
M
suspected during use, the-gauges shall be replaced.

KU
10.13.3.5 Apparatus for Recording, Processing and Displaying Data
The Contractor shall provide apparatus for measuring the

acceleration and strain of the pile head and the energy
O
transferred to the pile. The signals from the transducers during

the impact event, shall be transmitted to the PDA to allow
D
determination of the force and velocity versus time.
A cable or wireless transmission which connects the sensors

near the pile head with the PDA shall be located at safe distance
from the pile, but not more than 100m from the pile.
The PDA shall include a screen for displaying the force and
velocity, a hard disk for obtaining a record for future analysis, and
a means to process the data.
S10-59
(JKRlSPJ/20 19-510)
The apparatus shall have the capability of making an internal

calibration check of force, velocity and time scales. No error shall
exceed 2% of the maximum signal expected.
10.13.4 Testing Procedures
10.13.4. 1 General
Dynamic Test shall be conducted on test piles as selected by the

S.O. The test shall be carried out in accordance with Sub-section
ER
10.13.4.2.
Prior to the performance of any dynamic test, the Contractor shall

submit the specialist testing firm company profile and working
D
drawings showing the method statement and equipment
proposed to be used in the performance of conducting the test
N
n together with all relevant calibration certificates to the S.O.· for
approval. The S.O. may request additional piles to be
TE
dynamically tested if the hammer and/or driving system is
replaced or modified, the pile type or installation procedures are
modified, the pile capacity requirements are changed, unusual
blow counts or penetrations are observed , or any other piling
A
behaviour differing from normal installation. The Contractor shall
bear the cost and time for all necessary additional test.
EJ
10.13.4.2 Dynamic Load Test

M
The Dynamic Load Test shall be carried out as follows:
Driven Piles
EN
(i) Continuous pile monitoring as indicated in the Drawing or

as requested by the S.O.
M
(ii) Dynamic pile test shall be conducted on piled foundations

( ) at the end of driving or at restrike for selected piles.
KU
(iii) The pile shall to be at least 3 diameters or 100mm above

the ground level. The Contractor shall drill and prepare
holes for sensor attachment near the pile top after the pile
O
has been driven to the penetration depths as specified on

Drawing.
D
(iv) The Contractor shall supply and operate the piling hammer
to induce a driving force on to the pile. Dynamic
measurement of force and velocity shall be processed by
the PDA to give immediate visual and permanent record
on-site.
Cast In-Situ Piles
0) Dynamic pile test shall be conducted on cast in-situ piles at

28 days after pile concreting. Piles which are to be tested
S10-60
(JKRlSPJ/2019-S1 0)
prior the 28 days shall be proven that it has achieved the

required concrete compressive strength and subjected to
approval by the S.O. However, no testing shall be allowed
for piles less than 14 days after concreting .
(ii) The pile shall be casted so as to leave a height of at least

one (1) diameter above the ground or excavated level.
(iii) The Contractor shall supply and operate the drop hammer
to induce a driving force on to the pile . Dynamic
measurement of force and velocity shall be processed by
ER
the PDA to give immediate visual and permanent record
on-site. The proposed hammer weight shall be at least 1%
to 2% of the maximum test load.
D
10.13.5 Submission of Results
N
Full test data, complete field test records and results from the readout unit
shall be jOintly signed by the S.O.'s representative and the Contractor's
()
TE
authorised agent and submit to the S.O. immediately upon completion of the
Dynamic Test.
The Contractor shall submit preliminary results within three (3) days after
A
completion of the test to the S.O.
EJ
The Contractor shall also submit the raw data file (W01) or equivalent, upon
completion of the test at the site.
M
For all testing, CAPWAP analysis or equivalent shall be carried out. The
S.O.'s acceptance of the interpretation and conclusion based on the results
submitted shall be final.
EN
10.13.6 CAPWAP Computer Analysis Programme and Final Report
The final analysis and report shall consist of matches of forces and velocities,
M
resistance distribution, static simulation and complete tables of numeric

values. The Final Report shall be submitted to the S.O. within at least seven
KU
(7) working days upon completion of field testing. The specialist Contractor
shall complete and provide the following :
(i) Static Capacity of pile including the toe resistance and shaft friction
O
(ii) Hammer Efficiency

(iii) Integrity of Pile
D
(iv) Case Damping Factor

(v) Predicted load Vs Settlement Plots
(vi) Match Quality
(vii) Slack Value, efficiency & location (if used)
(viii) Force Wave Traces of measured and computed
(ix) Shaft Resistance Distribution
A PDA plot indicating all the gauges used for the testing and all the output of
the field results and the subsequent signal matching on the same blow for all
the piles are to be included in the Test Report. These reports should only be
prepared by an engineer who has achieved Advanced level or higher.
S10-61
(JKRlSPJ/2019-S10)
The report shall contain complete analysis, results and their interpretation
with Professional Engineer with Practicing Certificate's endorsement.
10.13.7 Completion of a Test
On completion of a test, all measuring equipment and load application

devices shall be dismantled and removed from the test pile.
Unless otherwise specified, the head of each test pile shall be cut off below
ground level, and cut-off materials removed from the site. The ground shall
ER
be made good to the original commencing surface level.
TAD' '" 10.1: PLATE .. .,A .. '.''1 TEST _, nAn, .AND
D
11M I-Inl niNe.; TIME
N
No. Load (% of Time No. Load (% of Time
working Interval working Interval
TE
load) (minute) loadl· (minute)
1. 20 15 20. 200 120
2. 40 15 21. 160 15
3. 60 15 22. 120 15
A
4. 80 15 23. 80 15
5. 100 120 24. 40 15
EJ
6. 80 15 25. 0 15
7. 60 15 26. 40 15
8. 40 15 27. 80 15
M
9. 20 15 28. 120 15
10. 0 15 29. 160 15
11 . 20 15 30. 180 15
EN
12. 40 15 31 . 240 15
13. 60 15 32. 280 15
14. 80 15 33. 300 120
15. 100 15 34. 240 15
M
16. 120 15 35. 160 15

l ) 17. 140 15 36. 80 15
KU
18. 160 15 37. 0 15

19. 180 15
Note : The rate of settlement for each load increment should be based on
O
the preliminary test

D
S10-62
(JKRlSPJ/2019-S10)
TABLE 10_2: SPECIFICATION OF PRECAST CONCRETE PILES (AFTER MS1314)
Minimum Minimum
Piles
Concrete Minimum Longitudinal Cement Method of
Strength Reinforcement Content Installation
Type Class (N/mm2) (kg/m 3)
Hammer
M 45 1.2 % of cross sectional area 400
driven
RC
Hammer
J 45 1.0 % of cross sectional area 400
ER
driven
Minimum effective prestressed of 4 Hammer
A 60 N/mm2 420
Spun driven
pile Minimum effective prestressed of 5 Hammer
D
B 60 420
N/mm2 driven
N
C 60 420
N/mm 2 driven
TE
X 60
N/mm2
420
driven
PC
y Minimum effective prestressed of 7 Hammer
60 420
N/mm 2 driven
Minimum effective prestressed of Hammer
1
A
60 420
3.5 N/mm2 driven
PCS
Minimum effective prestressed of
EJ
2 55 420 Jacked-in
3.5 N/mm2
RCS Hammer
1 45 1.0 % of cross sectional area 400
driven
M
2 45 0.8 % of cross sectional area 400 Jacked-in
Notes:
EN
1 Concrete strength means characteristic compressive strength at 28 days.

2 The nominal sizes and length for each class of piles are specified in Parts 3, 4, 5 or 6 of
Malaysian Standard, whichever relevant.
M
Definitions:
1 Precast reinforced concrete square pile (RC pile)
A pile made of concrete cast in a uniform four-sided cross section before driving into the ground.
J
KU
It shall be suitably reinforced mainly with steel bars .

2 Precast prestressed concrete square pile (PC pile)
A pile described in definition No. 1 but suitably reinforced mainly with prestressing steel.
3 Precast pretensioned spun concrete pile (Spun pile)
O
A hollow cylindrical pile made of concrete cast by centrifugal spinning before driving into the
ground. It shall be suitably reinforced mainly with pretensioned prestressing steel.
4 Small prestressed concrete square pile (PCS pile)
D
A small PC pile for sizes 200 mm and less.

5 Small reinforced concrete square pile (RCS pile)
A small RC pile for sizes less than 200 mm.
S10-63
(JKRlSPJ/2019-S1 0)
TABLE 10.3 : SLUMP RANGE FOR TYPICAL CONCRETING SITUATIONS
Typical Conditions of Use Slump Range

imm\
Placed into water-free unlined bore. Widely spaced reinforcement
75 to 125
leaving room for free movement between bars.
Where reinforcement is not 'spaced widely enough to give free movement
between bars.
Where casting level of concrete is within the casing . 100to 175
Where pile diameter is less than 600 mm.
Where concrete is to be placed by tremie under water or drilling fluid , 150 to collapse
ER
TABLE 10.4 : STATIC LOAD TEST - LOAD INCREMENTS AND MINIMUM
D
HOLDING TIME
N
(') LOAD INCREMENTS AND MINIMUM PERIODS OF OBSERVATION
TE
Load Cycles Load Increment (% WL) Minimum Holding Time
0
25 30 minutes'
50 30 minutes
A
1st cycle
75 30 minutes
100 6 Hours2
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50 30 minutes
0 60 minutes
25 30 minutes
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50 30 minutes
75 30 minutes
100 30 minutes
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125 30 minutes
2nd cycle 150 30 minutes
175 30 minutes
200 24 Hours3
M
150 30 minutes
\.. ) 100 30 minutes
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50 30 minutes
0 60 minutes
NOTES
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1. Time-settlement readings shall be taken at 2, 8, 15 and 30 minutes,

and at 15 minutes interval thereafter.
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2. Time-settlement readings shall be taken at regular intervals of every 15

minutes for the first 2 hours and every hour thereafter during load
holding time at working load.
3. Time-settlement readings shall be taken at regular intervals for every
15 minutes for the first 2 hours and every hour thereafter during load
holding time at test load.
S10-64
(JKRlSPJ/2019-S10)
TABLE 10.5 : TYPICAL ALLOWABLE DRIVING STRESSES
Compression Tension Stress Tension Stress

Pile Material
Stress (psi) (MPa)
Steel 0.9 Fy 0.9 Fy 0.9 Fy
Prestressed
0.85 f c - fpe 3 (fc )"2 + fpe 0.25 (fc )"2 + fpe
Concrete
Precast Concrete' 0.85 f c 0.70 fy (As I Ac) 0.70 fy (As I Ac)
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Timber 30. 3 0. 30.
' Allows for tension cracks; for uncracked section allow prestressed concrete tension
stress with f pe = O.
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Where,
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Fy = Steel Yield Strength
f c = Concrete Compressive Strength (MPa or psi)
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fpe = Effective Prestress (after losses) (MPa or psi)
As = Reinforcement Steel Cross Sectional Area
Ac = Concrete Cross Sectional Area
fy = Reinforcement Steel Yield Strength
o. = Allowable Timber Design Stress
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.. ~ ' . .:~ ' . .. d . .. ... .

. .
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cONcRm . •. CQ"!4Rp.E-
.. BLOCK
... ~ ' .. · ~ .......
'BLOCK
:
r
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REFERENC E .... JI
BEA'" ~..:
!2!.10
oi .-- DISTANCE "m" 2m - ,
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LVDT 5O-JOOmn>
SUPPORTS OF THE
RETER~ CE BEAM
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. .,. '
CONCRETE CONCRETE • <I CQI'{GRET-E-
· 'BLOCK
. BLOCK
!':'
. .BLOCK
~~
· ~ . .. ,, '
FIGURE 10.1 : PLAN VIEW OF TYPICAL PILE LOAD TEST SET UP
S10-65
(JKRlSPJ/2019-S10)
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APPENDIX 10A
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Bending Strength for Precast Concrete Piles

Pile Body Strength Test
General
Bending strength test on the pile body shall be done to determine the ability of the pile to
withstand the cracking bending moment (Mc) and the ultimate bending strength (Mu). The
bending strength test of pile body shall be made by the application of vertical load P to the
centre of the span. on the pile laid on two (2) supports which has a span equal to 3/5 of its
length.
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The applied bending moment shall be calculated from the following equation: -
M= _1
40
WL+ P(3L
4 5
-1)
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Where.
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M is the applied bending moment (kNm);
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W is the weight of pile (kN);
L is the length of pile (m); and
P is the applied load (kN)
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The cracking bending moment (Me)
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The pile shall be designed to withstand the cracking bending moment calculated based on the
maximum allowable crack width as shown in TABLE 1. The pile is considered to have passed
the requirement to withstand the cracking bending moment if when subjected to a test load
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equal to the cracking load (Pc) corresponding to the appropriate Me. no crack exceeding the
values in TABLE 1 occurs. The calculated values of Me are given in TABLE 2. TABLE 3 and
TABLE 4.
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TABLE 10A·1 : MAXIMUM ALLOWABLE CRACK WIDTH
Types of pile Maximum crack width (mm)

M
1 RCpile 0.20
2 Spun pile 0.05
3 PC and PCS pile 0.10
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4 RCSpile 0.20
The ultimate bending moment (Mu)

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The pile shall be tested to the largest applied load (Pm..) until the pile failure occurs or until the
applied load slightly exceeds the minimum ultimate load (Pm'.",) which corresponds to the
minimum ultimate bending strength. whichever comes first.
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The minimum ultimate bending strength (Pm'.",) is obtained by multiplying the cracking bending
moment (Me) by the factor 'f as given in.
The pile is considered to have passed the bend test if the pile does not fail when subjected to
Pm ..... load.
S10-69
(JKRlSPJ/2019-S10)
Testing
Apparatus setup
The pile manufacturer shall design and fabricate a suitable set-up for carrying out the bend
test. The test shall be carried out using any suitable equipment of sufficient capacity and
capable of applying the loads continuously and vertically.
The loading arrangement and the device for applying the loads shall consist of two supporting
rollers and two load-applying rollers as in Figure 1.
All rollers shall be manufactured from steel and shall have a circular cross-section with a
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diameter of 20 mm to 120 mm; the rollers shall be at least 20 mm longer than the width of the
test specimen . All rollers except one shall be capable of rotating around their axes and of being
inclined in a plane normal to the longitudinal axis of the test specimen. All rollers shall be
adjusted in their correct positions with all distances having an accuracy of ± 5 mm. Suitable
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safety precaution should be taken to ensure that the rollers do not fall off while adjustment is
made and during the testing.
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n , P o pplie d load
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FIGURE 10A-1 : LOADING METHOD
Rate of loading
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( ) The load shall be applied at the rate of (0 .06 ± 0.04) N/mm2s using suitable equipment which
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shall be capable of applying the load uniformly without shock using manual or automatic
control.
Load pacers
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If the equipment is not equipped with a device to maintain, automatically, the specified rate of
increase of load on the specimen, a load pacer shall be fitted or alternatively the control shall
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be done by manual method to ensure the rate of loading as described in the paragraph above
is complied . If the pacer has a scale, this scale shall be basically linear such that 1 mm
represents not more than 100 N/s. Over the operating range of the scale the accuracy shall be
within ± 5 %.
NOTE. The pacer may incorporate a scale with an indicator or alternatively, it may be, for
example, a marked disc or pointer, which rotates at the rate at which, the load pointer should
move on the load scale being used. If the pacer is fitted with a variable speed control or has
preset speeds, then once the variable speed control has been set, or preset speed has been
chosen, the pacer speed shall remain within ± 5 % of the specified speed over the operating
range. Alternatively if the rate of loading is controlled manually then the manufacturer shall
prepare the table of loading application against time.
S10-70
(JKRl8PJ/2019-S10)
Load scale indicators or digital displays

The equipment shall be provided with either: -
a) Easily read dials or scales; or
b) Electrical load indicators, which shall include a visual display.
These load scale indicators or digital displays shall be calibrated by an accredited laboratory.
Test specimens
Test specimens shall be selected randomly from piles casted and results shall be properly
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documented for inspection. The number of piles to be sampled is to be decided in accordance
with the agreement between the parties concerned.
Procedure
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1. Prior to testing, select a suitable load and time increment for a selected loading rate for
particular hydraulic equipment such that it will facilitate inspection of the pile at the calculated
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crack load and at the required minimum ultimate load .
2. Check the specimens thoroughly for initial crack before testing. Wipe clean the bearing
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surfaces of the supporting and loading rollers.
3. Place the test specimen on the support rollers, correctly centred with the longitudinal axis of
the specimen at right angles to the rollers. The trowelled surface direction shall be normal to
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the direction of loading and the moulded surface is in tension (see Figure 1). The moulded
surface may not therefore be orientated with its position in the structure. For Spun piles, the
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test specimen can be placed at any surface position. Do not use packing between the
specimen and the rollers.
4. Place the loading equipment and the load applying rollers correctly in the testing setup. Do
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not begin to apply the load until all loading and supporting rollers are in even contact with the
test specimen.
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5. Apply the load steadily and without shock at a rate of (0.06 ± 0.04) N/mm2s . Choose the
lower loading rates for low strength concrete and the higher loading rates for high strength
concrete (i.e. for RC Piles, fcu more than 45 N/mm2) .
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6. Once the loading rate has been adjusted , maintain the rate of loading without change until
the applied crack load (Pc) corresponding to crack moment (Mc) from the respective TABLES
2, 3 and 4 as shown below is reached. Then hold the load for a sufficient time to inspect the
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pile for possible cracking. If crack is present, it shall be checked by means of the test crack
measuring gauge and crack width and the location shall be recorded.
7. After step 5.6, continue the loading at the same uniform rate until failure occurs or when the
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applied load is slightly greater than the minimum ultimate load (Pmin-u), whichever comes first.
The minimum ultimate load (Pmin-u) is a value corresponding to the value of Mc multiplied by
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the factor ffrom the respective TABLES 10A-2,10A-3 and 10A-4 as shown below.
8. If pile failure comes first, the test specimen is considered fail. Record the maximum load
(Pmax) applied. Pmax is the maximum applied load (kN), if and when pile failure occurs during
the bend test.
9. If the pile does not fail, and when the applied load is slightly greater than Pmin-u is reached,
then hold the load for sufficient time to allow for inspection of pile body for cracking. If crack is
present, it shall be checked by means of the test crack-measuring gauge and crack width and
location shall be recorded.
810-71
(JKRlSPJ/2019-S10)
10. For record purposes, record all the deflection oftest specimen shown by dial gauge during
loading and unloading.
TABLE 10A-2 : CRACKING BENDING MOMENT (MC) AND FACTOR 'F' FOR
PRECAST REINFORCED CONCRETE SQUARE PILES (RC PILES)
Nominal Pile Size Cracking Bending Moment, Me (kN-m) 'f'
(mmxmm) Class M Class J Class M I Class J
200 x 200 8.3 7.3
1.5
225 x 225 - -
250 x 250 13.1 11 .6
1.8
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275 x 275 - -
300 x 300 22.1 19.6
325 x 325 - -
350 x 350 33.7 29.8
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2.0
375 x 375 - -
400 x400 47.9 42.5
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450 x 450 65.0 57.8
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TABLE 10A-3 : CRACKING BENDING MOMENT (Me) AND FACTOR 'F' FOR
PRECAST PRETENSION ED SPUN CONCRETE PILES (SPUN PILES)
Nominal Minimum Concrete Effective
Cracking Bending Factor
Diameter Class Sirength Prestress
Moment (Me) (kNm) 'f
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(mm) (N/mm2) (N/mm2)
250 B 60 12 1.5 5.0
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300 A 60 17 1.5 4.0

B 60 20 1.5 5.0
350 A 60 26 1.5 4.0
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B 60 30 1.5 5.0
400 A 60 38 1.5 4.0
B 60 43 1.5 5.0
C 60 54 1.8 7.0
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450 A 60 53 1.5 4.0

B 60 60 1.5 5.0
C 60 76 1.8 7.0
500 A 60 74 1.5 4.0
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B 60 84 1.5 5.0
\ ) C 60 106 1.8 7.0
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600 A 60 123 1.5 4.0

B 60 141 1.5 5.0
C 60 177 1.8 7.0
700 A 60 191 1.5 4.0
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B 60 1.5 5.0
C 60 273 1.8 7.0
800 A 60 278 1.5 4.0
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B 60 318 1.5 5.0

C 60 399 1.8 7.0
900 A 60 390 1.5 4.0
B 60 445 1.5 5.0
C 60 558 1.8 7.0
1000 A 60 527 1.5 4.0
B 60 601 1.5 5.0
C 60 755 1.8 7.0
1200 A 60 853 1.5 4.0
B 60 973 1.5 5.0
C 60 1217 1.8 7.0
510-72
(JKRlSPJ/2019-S10)
TABLE 10A-4: CRACKING BENDING MOMENT (Me) AND FACTOR 'F'FOR

PRECAST PRESTRESSED CONCRETE SQUARE PILES -CLASS PC-X, CLASS PC-Y,
SMALL PILES
Minimum Minimum
Cracking Bending
Size Class of Concrete Effective
Moment, Me Factor 'f
(mm) Pile Strength Prestress
(kNm)
(N/mm 2) (N/mm 2)
PCS-1 60 3.5 2.9 1.5
125
PCS-2 55 3.5 2.9 1.5
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PCS-1 60 3.5 4.9 1.5
150
PCS-2 55 3.5 1.5 1.5
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PCS-1 60 3.5 7.8 1.5
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175
PCS-2 55 3.5 7.8 1.5
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PCS-2 55 3.5 11 .7 1.5
200 PC-X 60 5.0 13.7 1.5
PC-Y 60 7.0 16.4 1.7

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PC-X 60 5.0 26.5 1.5
250
PC-y 60 7.0 31 .7 1.7
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PC-X 60 5.0 45.2 1.5

300
PC-y 60 7.0 54.2 1.7
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PC-X 60 5.0 70.9 1.5

350
PC-Y 60 7.0 85.2 1.7
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PC-x 60 5.0 104.5 1.5

400
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PC-y 60 7.0 125.9 1.7
PC-X 60 5.0 147.0 1.5

450
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PC-Y 60 7.0 177.4 1.7

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510-73
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A.2 BRIDGE WORKS
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1. Section 11 Prestressing for Structures (JKRlSPJ/2016-S11)
2. Section 12 Structural Steelwork (JKR 20601-0191-12)

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3. Section 13 Bridge Bearings (JKRISPJ/2013-S13)
4. Section 14 Expansion Joints (JKRISPJ/2013-S14)

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5. Section 15 Parapets (JKRISPJ/2013-S15)

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Section 11 - Prestressing for Structures (JKRISPJ/2016-S11)
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JKRISPJ/2016-S11
JKR 21400-0100-16
KERAJAAN MALAYSIA
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FOR ROAD WORKS
Section 11: TE
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PRESTRESSING FOR STRUCTURES
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KETUA PENOARAH KERJA RAY A

JABATAN KERJA RAY A MALAYSIA
JALAN SULTAN SALAHUDDIN.
50582 KUALA LUMPUR.
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ISBN 978-967- 5957-63-5
57635
(JKRlSPJ/2016-S11 )
FOREWORD
As practices in road construction change over time, it is imperative for Jabatan Ke~a
technologies.
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uniformity in road construction to be used by road designers, road authorities,
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Prestressing for Structures", is a part of a series of improved specifications in the JKR
Standard Specification for Road Works. The compilation of this document was carried
out through many discussions that had been held by the technical committee. The draft
had also been presented and discussed at length in a specially held workshop to get
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feedback and comments from relevant parties involved, which were then carefully
considered and incorporated into the Specification wherever appropriate or necessary.
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Published by: -
Cawangan Jalan
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50400 Kuala Lumpur.

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Januari 2017
S11-i
ACKNOWLEDGEMENT
This Standard Specification for Road Works - Section 11 : Prestressing for Structures
has been prepared by a technical committee comprised of the following members: -
Committee Members
Ir. Abdul Rahman bin Salleh (Chairman) JKR
Ir. Tn. Kusairry bin Tn . Abdul Manaf JKR
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Ir. Dr. Fairul Zahri Bin M. Abas JKR
Ir. Wong Thian Chiun JKR
Ir. Amir Bin Ismail Consultant
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Prof. Dr. Azmi Ibrahim UiTM
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En. Kelvin Wong Wai Yee Contractor
En. George Jacob all Alexander Jacob Supplier
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Ir. Mohd. Azahar Bin Don Cawangan Jalan
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members for their substantial contributions towards the successful completion of this
document.
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A special thanks to Ir. Abdul Mutalif Bin Abdul Hameed (fonmer) and Dato' Ir. Hj. Che
Noor Azeman Bin Yusoff (current) Director of Pakar Kejurutaraan JaJan dan Jambatan,
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Cawangan JaJan, Jabatan Karja Raya Malaysia for their support and contribution
towards the successful completion of this specification.
811-ii
SECTION 11- PRESTRESSING FOR STRUCTURES
PAGE
11.1 DESCRIPTION S11-1
11.2 GENERAL REQUIREMENTS S11 -1
11.3 TYPES OF PRESTRESSING S11-1
11 .3.1 Pre-tensioning S11-2
11 .3.2 Post-tensioning S11-2
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11 .3.3 Temporary Prestressing S11-2
11.4 MATERIALS S11-2
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11.4.1 Prestressing Tendons, Strands, Wire or Steel Bar S11-2
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11.4.2 Non-prestressing Reinforcement S11-4
11 .4.3 Concrete S11-4
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11.4.4 Duct Systems S11-4
11.4.5 Anchorages S11-6
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11 .4.6 Couplers S11-6
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11 .4.7 Grouts for Duct S11-7
11 .4.8 Debonding for Prestressed Cables 511-11
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11.5 PRESTRESSING EQUIPMENTS S11-11

11 .5.1 Mould and Formworks S11-11
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11 .5.2 Tensioning Equipment 511-11

11 .5.3 Grouting Equipment S11-13
11.6 CONSTRUCTION S11-13
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11.6.2 Preparation of Tendons Before Tensioning 511 -15

11 .6.3 Preparation of Anchorages Before Tensioning S11 -15
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11.6.4 Pre-tensioning S11-16

11 .6.5 Post-tensioning S11-19
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11 .6.6 Records of StreSSing S11-21

11 .6.7 Tensioning S11-21
11 .6.8 Protection and Bond of Prestressing Tendons S11-22
11.6.9 Grouting of Ducts S11-22
511-iii
SECTION 11 - PRESTRESSING FOR STRUCTURES
PAGE
11 .7 GENERAL REQUIREMENTS FOR PRECAST PRESTRESSED 511-26

CONCRETE MEMBERS
11 .7.1 General 511-26
11 .7.2 5torage 511 -26
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11.7.3 Handling and Placing 511-26
11 .7.4 Tolerance 511-28
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11 .7.5 Off 5ite Manufacture S11-30
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11 .7.6 Launching of Precast Elements S11-31
11 .7.7 Inspection and Testing S11-33
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11 .7.8 Load Test of Structure or Parts of Structures S11-34
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S11 -iv
(JKRlSPJ/2016-S11 )
SECTION 11- PRESTRESSING FOR STRUCTURES
11 .1 DESCRIPTION
This work shall consist of the construction of all prestressed concrete structures;
including casting, tensioning, grouting, storage, transporting and launching; all the
lines, level, grades, dimensions and cross-sections as shown on the Drawings and
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11 .2 GENERAL REQUIREMENTS
The Contractor shall submit to the S.O. for approval before the commencement of
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construction, all necessary shop drawings showing the location and number of
tendons, wires or strands, prestressing system, and methods of maintaining
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tendon alignment in the structure or structural element. The Contractor shall also
fumish complete outline of construction procedure including the stressing
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sequences, coefficient of friction, wobble, draw-in, stressing and anchoring forces,
bursting reinforcement and other incidental features, which are related to the
proposed type of prestressing system and equipment.
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In the case of prestressing components used in which the ducts are partially or
completely extemal to the concrete section, they shall be designed to allow the
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duct and tendon to be replaced.

All installation and fixing of the duct and sheath, anchorage plates, threading of
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tendon,strand or steel bar, tensioning works and the subsequent grouting

operations required shall be carried out under the direction of a competent
supervisor and by personnel who have had approved previous experience in the
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use of the type of system and equipment proposed and subjected to the approval
of the S.O. The sub-letting of all or part of this Work to a specialist Sub-Contractor
shall be subjected to the prior approval of the S.O.
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The Contractor shall be entirely responsible for the safe execution of tensioning
() operations. Specialist precautions against accident shall be taken when working
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with or near tendons which have been tensioned or are in the process of being
tensioned .
Where any modification are necessary to the reinforcement andlor concrete
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dimension to suit to the approved or proposed prestressing system, the Contractor

shall submit to the S.O. with the supporting design calculations, drawings and
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related information as required by the S.O. All submissions must be endorsed by a

Professional Engineer registered with the Board of Engineer Malaysia.
11.3 TYPES OF PRESTRESSING

The types of prestressing shall be to the details as shown on the Drawings. Below
are the typical type of prestressing systems used to apply the compressive force
to the structurel structure element.
S11-1
(JKRlSPJ/2016-S11 )
11.3.1 Pre-tensioning
A method of prestressing in which tendons are tensioned before the
concrete is placed. This shall be done either on or off Site as directed by
the S.O.
11.3.2 Post-tensioning
A method of prestressing in which tendons are tensioned after the
concrete has attained the transfer concrete cube strength. This method
can be for bonded or unbonded tendon. This shall be done on Site
unless otherwise directed by the S.O.
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11 .3.2.1 Bonded tendon
A grouted duct and tendon that provide a perfect bond between
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the tendon and the concrete section.
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11 .3.2.2 Unbonded tendon
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A post-tensioned members in which the ducts and tendons are
permanently ungrouted or surrounded with only protective
coating which may be encased in concrete after stressing and
provide no bond between the tendon and the concrete section.
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11.3.3 Temporary Prestressing
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A method of prestressing in which temporary tendons! steel bars are

tensioned during the construction stages for the purpose of completing
the final structure after the concrete has attained the required
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compressive stress at transfer. The method shall be submitted to the

S.O. for approval prior to commencement of the related works.
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11 .4 MATERIALS
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11.4.1 Prestressing Tendons, Strands, Wire or Steel Bar

(i) High tensile steel wire shall comply with the requirements of BS
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5896: or EN 10138 - Pt. 2, ASTM A416!A416M.

(ii) Prestressing steel strand shall comply with the requirement of EN
10138 - Pt 3.
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(iii) High tensile alloy steel bars shall comply with the requirements of
BS 4486 or ASTM A722M.
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(iv) Flat duct.
11 .4.1.1 Material Testing

The Contractor shall submit the Manufacturers' Certificates of
Test of the prestressing strands, wires or steel bars for each
batch to be used or delivered to the site for the approval of the
S.O.
S11 -2
(JKRlSPJ/2016-S11 )
The Manufacturers' Certificates of Test shall be submitted to the

S.O. at least 28 days before installation of the prestressing
tendons starts. The Manufacturers' Certificates will show the
manufacturer's name, the date and place of manufacture and
tendon or steel bar sample batch numbers. It must also include
particular details with reference to at least the following items :
(i) Diameter, cross-sectional area and unit mass.
(ii) Result of tests for mechanical properties, including the
characteristic breaking load, characteristic 0.1% proof load,
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yield strength, elongation at maximum load, relaxation to 1000
hours, fatigue behaviour test and Modulus of Elasticity and
Load versus e Elongation Curve.
(iii) Result of test for ductility of prestressing wires. When directed
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by the S.O., the Contractor shall arrange for samples of the
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steel intended for use in the Works to be tested at an
n approved accredited independent testing laboratory. If such
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samples fail to comply with the this Standards specification,
notwithstanding any previous acceptance on the
manufacturer's test certificate, that steel represented by the
sample may be rejected by the s.o. and shall require its
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removal from Site.
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All prestressing materials shall be stored in such a manner that

will not cause any harmful effect. The material shall be stored
under suitable weatherproof covers. No contact with the earth
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ground shall be allowed.

For any prestressing material that does not appear to be in a
suitable condition for use in the Works, independent tests shall be
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carried out to demonstrate the physical properties of the steel. As

( ) a result of these tests, the S.O may reject the batch of steel which
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shall then be removed from the Site.

Care shall be taken to avoid mechanically damaging, work-
hardening or heating induction to the prestressing materials.
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Under no circumstances shall prestressing tendons be subjected

to any welding operation, or 'on Site' heat treatment or metallic
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coating such as galvanizing. This does not preclude cutting as

speCified in clause 11.4.1.5 of this speCification.
The lifting, handling, transporting and storing of the tendons shall
be in a manner that ensures no damage is incurred to them.
11.4.1.3 Surface Condition

Prestressing materials shall be free from loose rust, loose mill
scale, oil, grease or other harmful and deleterious matter. A slight
Sll-3
(JKRlSPJI2016-S11 )
film of rust will be accepted, but the steel shall not be pitted. High
tensile steel bars shall be individually inspected for superficial
tears, nicks, roller marks or any other form of surface
imperfection.
Surface condition that shows imperfections that exceed 0.40 mm
in depth must be treated as non-conforming and shall be rejected .
11.4.1.4 Straightness of Wires, Strand and Bars
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Tendons supplied by the manufacturer shall be in coils large
enough to be self-straightening. Kinked or damaged strands or
bars shall not be used and shall be removed from the site.
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11.4.1.5 Cutting of Wires, Strand and Bars
All cutting of tendons, strands or steel bars shall be carried out
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using a high-speed abrasive cutting wheel, friction saw or any
mechanical method as approved by the S.O. Flame cutting is not
allowed.
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In post-tensioning system, trimming of ends shall be carried out
with high speed cutting discs to within 50 mm of the anchor block
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or blister.
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11.4.2 Non-prestressing Reinforcement

Non-prestressing reinforcement shall comply with all the clauses on steel
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reinforcement of Section 9 of the Standard Specification for Road Works,

except in such respects as they may be modified by the provisions of the
remainder of this Section of the specification.
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11.4.3 Concrete
Materials and workmanship for concrete shall comply with all the clauses
on concrete for structures of Section 9 of the Standard Specification for
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Road Works, except in such respects as they may be modified by the

provisions of the remainder of this Section of the specification.
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11.4.4 Duct Systems

The system of tendon ducting system that consists of sheath, sheath
connectors, grouting connections, vents, vent connections, drains,
transitions to anchorages and caps for anchors shall form a complete
encapsulation for the tendons which have resistance to the ingress of air
and water. Ducting which may exhibit potential degradation or corrosion
during the expected life of the structure shall not be permitted. The
S11-4
(JKRlSPJ/2016-S11)
system shall be fully compatible with the prestressing anchorages,

couplers and other details.
The design of the duct shall allow for grout to be injected from either end
of the cable.
Sheaths and duct formers used to form the duct system must maintain
their original cross section and profile during construction . There shall be
no sudden changes in the diameter of the duct.
Unless shown otherwise on the drawings, the friction coefficient between
ER
the duct and the tendon shall not be higher than 0.20.
The ends of all ducts systems shall be sealed and protected after the
tendon is threaded through and until the stressing operations are
D
commenced .
N
n 11.4.4.1 Sheaths
TE
All sheaths shall be either as described on the Drawings or
proprietary type approved by S.O and shall be-of steel type or
other materials as approved by S.O. The sheaths shall be rigid
A
and strong enough to retain their shape during the installation of
the tendon, fixing, and concreting. Sheaths must be able to
EJ
withstand the forces from the prestressing tendons without

damage.
M
Sheath material of galvanised steel type shall comply with BS

EN 523: 2003 and BS EN 524, Part 1 to Part 6. The minimum
thickness for intemal prestressing shall be 2.0 mm and
EN
minimum thickness for external prestressing shall be 4.0 mm.

Sheath material of plastic type shall comply with ASTM D3350
for HDPE with cell classification 335533C; or ASTM D1784 for
M
rigid PVC with classification 13464B or equivalent as approved

by the S.O .. It shall have a corrugated profile and an allowance
KU
in the wall thickness to account for abrasion during streSSing of

the tendon.
Wall thickness shall not be reduced to less than 1.5mm (from
O
original 2mm), to demonstrate the 'evidence of testing' after

tensioning of the internal tendons, and proof shall be submitted
D
by the Contractor to the S.O.

The number of joints shall be kept to a practicable minimum
and each joint shall be adequately sealed against the ingress of
any foreign material. Joints in adjacent sheaths shall be
staggered by at least 300mm. Enlarged portions of the
sheathing at couplings on anchorages shall be of sufficient
length to provide for the extension of the tendons. The joints
shall be sealed with unstretchable and water proof adhesive
tape prior to the installation of the tendon .
S11-5
(JKRl8PJ/2016-811)
Sheaths shall also be kept free of any matter detrimental to the

bond between the sheath and the concrete except for the
material sealing a sheath joint. The internal and external
surfaces of sheath shall be clean and free from pitting, loose
rust and loose scale at the time of incorporation in the Work .
The ends of all sheaths shall be sealed temporarily and
protected (temporary work) until the tendon is threaded through
and until the stressing operations are commenced .
ER
11.4.4.2 Duct Formers
When duct formers are used, they shall be coated with a
D
release agent only with the approval of the S.O. Duct formers
shall not be extracted until the concrete has hardened
N
sufficiently to prevent it from being damaged.
TE
11.4.5 Anchorages
Anchorages for post-tensioning shall comply with the procedure
A
described in BS EN 13391: 2004 or in accordance with that as specified
by the manufacture's proprietary system approved by S.O.
EJ
Size and shape anchorages or bearing plates to transfer anchor loads to

the concrete without overstress, irrespective of whether the load is
M
applied by the anchorage or the stressing jack. All anchorage devices

shall withstand a force of not less than 95% of the specified minimum
ultimate tensile strength of the tendon without damage from excessive
EN
deformation or draw-in. Unless otherwise approved, the steel for

anchorage bearing plates must be Grade 250 to BS EN 10025-2:2004 ,
S235JR.
M
Anchorages for unbounded tendons shall not cause a reduction in the

elongation under ultimate load of the tendon to less than 2% measured in
KU
a minimum gauge length of 3000mm.

All anchorage devices shall be free from rust, pitting, blow-holes and
shall be in accordance with the proprietary system specified tolerance.
O
D
11.4.6 Couplers
All couplers for presstresing tendon shall conform to BS EN13391: 2004.
The test certificates shall be submitted to the S.O prior to the
commencement of prestressing works.
The couplers used as joints for tendons shall achieved at least 95% of
the speCified characteristic tensile strength for strand tendons and shall
achieved more than 100% of the specified minimum breaking load for
tendons.
811-6
(JKRlSPJ/2016-S11)
11.4.7 Grouts for Duct

The Contractor shall undertake full scale trial tests of grout mix together
with the grouting operations as directed by S.O. The trials are required to
demonstrate that tlie grouting methods and procedures as proposed by
the Contractor are satisfied to ensure that the grout completely fills the
ducts and surround the prestressing steel.
Unless otherwise directed or agreed as a result of grouting trials, the
grout shall conform to BS EN 446, BS EN 447 and the following
requirements:
ER
(i) Consists only of ordinary Portland Cement (CEM I) complying with
BS EN 197-1, Class 42.5 N and water complying with BS EN 1008.
D
(ii) Admixtures shall not be used unless permitted by the S.O. and
N
complies with sub-Clause 11 .4.7.2
TE
(iii) The maximum total chloride content of grout, expressed as a
percentage relationship between the chloride ion and the
cementitious content by mass in the grout, shall not exceed 0.1%.
A
(iv) Have a water/cement ratio as low as possible, consistent with the
necessary workability and under no circumstances shall the
EJ
water/cement ratio exceed 0.4.

M
(v) Not subject to bleeding in excess of 2% after 3 hours or 4%

maximum when measured at 27"C in a transparent tube
approximately 60 mm to 80 mm diameter with a height of grout
EN
approximately 100mm and shall be re-absorbed after 24 hours. One

7-wire strand approximately and no less than 900 mm long which fits
inside the tube
M
\ ) (vi) Prebagged grout that is used shall be mixed in accordance with the
KU
Grouting of ducts shall produce no void . However, void which has either
a dimension greater than 5% of the duct diameter measured in the radial
O
direction of the duct or greater than 200mm measured in the longitudinal

direction of the duct can be acceptable subjected to the S.O. approval.
D
11.4.7.1 Testing of Grouts

Testing shall be performed in accordance with the test method
given in BS EN 445 and the testing requirements are
summarised in Table 11.1 below.
S11-7
(JKRlSPJf2016-S11)
TABLE 11 .1- MINIMUM TEST REQUIREMENTS FOR GROUT

Suitability Testing
i. Fluidity i. Sampled immediately after mixing. one
test.
ii. After estimated time to grout duct or
minimum of 90 mins from initial mixing .
ii i. Two tests averaged in both cases .
ER
i. Bleed i. Each sampled immediately after
mixing. 3 tests averaged .
ii. Volume change
D
iii. Sedimentation
N
iv. Strength
TE
Acceptance Testing
i. Fluidity i. Sampled immediately after mixing, one
test from mixer. After flow through
A
duct, one test from each anchorage
outlet.
EJ
ii. On completion, one test from the

mixer.
M
i. Bleed i. One test per day or one per 1.5 m3 of

grout unless otherwise agreed by the
ii. Volume Change
S.O.
EN
iii. Strength
i. Sedimentation i. One test per day for site batched
grout. or one test per pre-bagged
M
supplied batch (by manufacturer's

reference number); subject to a
KU
minimum of one test per continuous

grouting operation.
O
(i) Fluidity
D
The fluidity of the grout during the injection period have the
values given in Table 11.2 below. Fluidity should not change
by more than 20% from immediately after mixing to
30minutes after mixing.
S11-8
(JKRlSPJ/2016-S11 )
TABLE 11.2 - FLUIDITY TEST REQUIREMENT
Test method Immediate after mixing 30 mins. after mixing
Cone to s 25 s 1.2 to ~ 1,0 ~ 0,8 to and

130 s 25 s
Grout spread ao ~ 140 mm 1,2 ao ~ a30 ~ 0,8 ao and
a30 ~ 140 mm
ER
to = time recorded immediately after mixing
1,0 = time recorded 30 minutes after mixing
ao = average spread immediately after mixing
D
a30 = average spread recorded 30 minutes after mixing
N
TE
(ii) Bleeding
Tested by both wick induced method and inclined tube test
given in BS EN 445 for the average of three results. The
A
bleeding shall not exceed 0 .3% of the initial volume of the
grout after 3 hours kept at rest. Testing shall be carried out
EJ
at 24 hours .
M
(iii) Volume Change

The volume change assessed may be either an increase or
EN
decrease. When tested in accordance with the method

given in BS EN 445 the volume change of the grout at rest
for 24 hours shall be within the range of - 0 % and + 5 %.
M
~ )
(iv) Sedimentation
KU
The grout shall not exhibit variation in density from top to

bottom of a single test sample in excess of 5%.
O
D
(v) Compressive Strength

The compressive strength of grout assessed according to
BS EN 445 shall be not less than 30 N/mm2 at 28 days or
27 N/mm2 at 7 days if it is proposed to estimate the likely
28 day strength at 7 days. Cubes shall be made, cured and
tested in accordance with BS EN 12390-1 and BS EN
12390-3.
S11 -9
(JKRl8PJ/2016-811)
11.4.7.2 Admixtures
Admixtures shall be used where required to achieve a low
water/cement ratio and impart good fluidity, minimum bleed and
volume stability or expansion to the grout to comply with sub-
Clause 11 .4 .7.1. For site batched grout, admixtures shall be
added on site during the mixing process and used in
accordance with the manufacturer's recommendations. For pre-
bagged grout the admixtures shall form a pre-blended
component.
ER
(i) Types
D
Admixtures are divided into two types, expanding and non-
expanding and they may be used to obtain the required
N
grout performance. Admixtures used in combination shall
be checked for compatibility by the Contractor, and
TE
reported to the S.O for acceptance.
(ii) Chemical Composition

A
Admixtures shall not contain substances in quantities that
EJ
will adversely affect the grout or cause the grout to promote

corrosion of the prestressing steel by rusting , pitting, stress
corrosion or hydrogen embrittlement.
M
(iii) Material requirements

EN
The admixture shall not segregate and shall be uniform in

colour. The composition shall not change and the supplier
shall operate a quality system complying with BS EN ISO
M
9001 . The quality system shall be certified by a third party

accredited by an appropriate organisation in accordance
KU
with Section 9 of the Standard Specification for Road

Works .
O
Where appropriate, admixtures shall comply with BS EN

D
934-4. Other admixtures shall be permitted provided they

satisfy Clause 8 of BS EN 934-2 and full account is taken
of their effects on the finished product and their fitness for
purpose. Data on their suitability, including previous
experience with such materials, shall be made available
and records of the details and performance of such
materials shall be maintained.
81 1-10
(JKRlSPJ/2016-S11)
(iv) Dosage
The optimum dosage of any admixture shall be
determined by trial mixes with the cement to be used in
the grout. This dosage shall be expressed as percent by
mass of the cement. It shall be within the range
recommended by the supplier and shall not exceed 5% by
mass of the cement. The method of measuring dosage
and checking weights of prepacked dry materials shall
comply with Section 9 of the Standard Specification for
ER
Road Works or as otherwise agreed with the S.O.
11 .4.8 Debonding For Prestressed Cables
D
The sheathing or blanket for pre-tensioned strand, where it is required to
N
prevent bond over a specified length, shall consist of P.V.C. tubing or
other materials, of a quality, diameter and thickness such that bonding
TE
shall be effectively prevented. The sheathing/ blanket shall be fastened
to the strand in such a manner that the entry of cement mortar shall not
impair the efficiency of the bond-break and sheathing/blanket shall be
continuous through end plate for at least 2mm.
A
EJ
11.5 PRESTRESSING EQUIPMENTS

11.5.1 Mould and Formworks
M
The Contractor shall supply and maintain an adequate number of moulds

for the casting of prestressed structures. The moulds shall be
EN
manufactured from steel forms, coated plywood, wrought boards

controlled permeability formwork liner or others approved material by the
S.O. The controlled permeability formwork liner if used, shall be complied
M
to Section 9 of this specification.

~) The moulds shall be rigidly stiffened to prevent any distortion to the
KU
structure or structure element during installation and tensioning

processes. Where necessary, the mould shall allow for the incorporation
of form vibrators of approved capacity.
O
The void formers shall be able to withstand the pressure due to the
height of the concrete during concreting . Release agent shall be used for
D
the void former unless instructed otherwise by S.O. Void formers shall
not be extracted until the concrete has hardened sufficiently to prevent it
being damaged.
11.5.2 Tensioning Equipment

All tensioning equipment shall be of the type recommended by the
manufacturer of the prestressing system, subjected to the approval of
the S.O. StreSSing shall be done in the manner recommended by the
Sll-ll
(JKRlSPJ/2016-S11 )
manufacturer as detailed in the manual and their supplementary

publications where applicable.
The tensioning apparatus shall also meet the following general
requirements:-
(i) Tensioning and anchoring of tendon or strand shall only be done
with the equipment supplied by the manufacturers of the
prestressing system with the approval of the S.O. and their
recommended procedure shall be followed .
ER
(ii) Before commencing tensioning operation and also whenever
directed by the S.O., the jack pressure gauges or load cells shall
be calibrated against the load produced by dead load tester
D
device apparatus. The accuracy of the pressure gauges and/or
load cells throughout the prestressing operations shall be the
N
responsibility of the Contractor. Calibration certificates for the
pressure gauges, stressing jacks and load cells shall be duly
TE
certified by accredited testing laboratory.
(iii) The means of attachment of the tendon to the jack or tensioning

device shall be safe and secure.
A
EJ
(iv) Where two or more strands are stressed simultaneously, they
shall be approximately of equal length between anchorage points
at the datum of load and extension measurement. The degree of
M
variation between the stressed strands shall be not more than

5mm.
EN
(v) The tensioning apparatus shall be such that a controlled total

force is imposed gradually and no dangerous secondary stresses
are induced in the tendons, anchorage or concrete. An approved
M
device shall be fit in to the hydraulic system to avoid sudden 1055

of pressure.
KU
(vi) The force in the tendons during tensioning shall be measured by

direct-reading load cells or obtained indirectly from gauges fitted
O
in the hydraulic system to determine the pressure in the jacks.

The diameter of the gauge must not be less than 150 mm and
D
must be of such a type which will allow visual reading to the

nearest 0.5 Mpa. Facilities shall be provided for the measurement
of the extension of the tendon and any movement of the tendon in
the gripping devices. The load-measuring device shall be
calibrated to accuracy within ±2% and checked at intervals as
appropriate to the approval of the S.O.
(vii) Elongation of the tendon shall be measured to an accuracy within

2% or 2mm, whichever is more accurate.
511 -12
(JKRl8PJ/2016-811 )
(viii) The tensioning equipment shall be calibrated before the

tensioning operation and at intervals to the approval of the S.O.
11 .5.3 Grouting Equipment

The mixing equipment shall produce a grout of homogeneous consistency and
shall be capable of providing a continuous supply to the injection equipment.
The injection equipment shall be capable of continuous operation with little
variation of pressure and shall include a system for recirculation or agitating of
ER
the grout while actual grouting is not in progress. Compressed air shall not be
used.
The equipment shall provide a constant delivery pressure to the flow of grout
D
and maintained at 1 MPa. The equipment shall be capable of maintaining
pressure on completely grouted ducts and shall be fitted with a valve that can
N
be locked off without loss of pressure in the duct.
n
TE
All piping to the grout pump shall have a minimum of bends, valves and
changes in diameter.
Contractor shall provide adequate flushing-out plant to facilitate complete
removal of the grout in the cable in the event of breakdown before the
A
grouting process completed . Contractor to demonstrate to the approval of
EJ
S.O. that this facility is in full working order.
All baffles to the pump shall be fitted with sieve strainers of of S 2.0mm
nominal aperture size to BS 410-1: ISO 3310-1 . The pressure gauges shall
M
be calibrated before they are first used in the Works and thereafter as
required by the S.O.
EN
All grouting equipments, shall be thoroughly washed with clean water after the
grouting operation at the end of use for each day. The equipment shall be
kept free from build-up of adhering material.
M
11.6 CONSTRUCTION
KU
11 .6.1 Assembly of Cables and Sheaths

Prestressing tendon, prestressing components and ducts shall be
O
accurately located and maintained in the positions shown on the drawings

during all operations. Tendons shall be assembled with the individual wires
D
or strands lying parallel to the cable axis, and they shall be bound with
stretchable strong adhesive tape or wire to maintain them parallel during
handling. All joints shall be sealed by binding with approved stretchable
waterproof adhesive tape. Joints in adjacent duct shall be spaced at least
300mm apart. Spacers shall be provided where shown on the Drawings or
as directed by the S.O. Before concreting, the lines and levels off all duct
shall be subject to the approval of the S.O.
811 -13
(JKRlSPJI2016-S11)
Duct shall be assembled from lengths not less than 3000mm except where
make-up lengths are required; couplers shall be fully screwed . Duct shall
be screwed into the back of anchorages and, where required, adaptors can
be used . The methods of securing the prestressing tendon, prestressing
components and duct during all operations shall be submitted to the
approval of S.O
The methods of inserting tendons and duct, handling and placing of
completed cables shall be to the manufacturer's instructions and to the
approval of the S.O. Sheathing, punctured or damaged in any way, shall
ER
be re-placed and rectified completely at the Contractor's expense.
Duct shall be checked for leakages to the satisfaction of the S.O. before
concreting as according to CI 11 .6.9.1 of this Section.
D
Duct shall be supported at points not more than 1000 mm apart. The
Contractor shall provide such additional supports as necessary and cradles
N
for supporting the sheaths on the reinforcement. The means of supporting
TE
and locating the ducts shall not give rise to excessive friction when the
tendon is being tensioned.
All ducts shall be checked for blockages due to ingress of grout or damage
during placing and the Contractor shall be responsible for all necessary
A
precautions and remedial measures. During concreting and within 24 hours
EJ
after concreting, the Contractor shall demonstrate that all tendons already
in duct before concreting are still completely free to move.
Tendon shall be carefully aligned to the profile height arrangement as
M
shown on the Drawings and the tolerance profile height shall be as

follows:-
EN
i. up to 200mm ± D/40mm
ii. 200 to 1000mm ± 5mm
iii. over 1000mm ± 10mm
M
11.6.1.2 Installation of Grout Vents

KU
Unless otherwise indicated on the Drawings, 15mm minimum

internal diameter vent and drainage holes shall be provided at all
high and low points on the duct profiles with the interval of not
O
exceeding 15m.
D
The vents shall be rigidly connected to the ducts, it shall not be

blocked and shall be capable of being closed and re-opened
during all operations.
For external tendons, the Contractor shall submit for S.O.
approval, their proposal for the arrangement and detailing of
vents at positions within deflectors or diaphragms, inclusive of
detailed testing.
Sll -14
(JKRl8PJI2016-811 )
All anchorages shall be sealed by caps and fitted with grouting

connections and vents. Sealing of anchorages shall permit the flow
of grout through the anchor head.
Vents at high points shall extend to a minimum of 500mm above
the highest pOint on the duct profile.
11.6.2 Preparation of Tendons before Tensioning

All tendons, stressed at the same time shall be taken from the same
ER
parcel. Each tendon shall be tagged with its number and the coil number
of the strands or steel bar used.
Tendons shall not be welded within the length to be tensioned . Tendon
D
shall be sawn or cropped unless other methods of cutting are agreed by
the S.O. Flame cutting of tensioning tendon are not allowed.
N
n Tendons shall be built into the Works strictly in accordance with the
TE
system which is being and it shall not be exposed to stray heat from
flame torches or welding before stressing.
If the condition of the prestressing tendons, prestressing component and
A
sheaths are deteriorated such that it does not comply with the
requirements stated in Clause 11 .4, they shall be cleaned with the
EJ
methods approved by S.O.

M
11.6.3 Preparation of Anchorages Before Tensioning

Anchorages shall be positioned accurately according to the Drawings in
EN
such a manner that the axis of the anchorages shall coincide with the
axis of the tendons at the ends.
Anchorages shall be positioned within tolerances of ±6 mm across and
M
vertically and ± 15 mm along the tendon. The face of an anchorage shall

( ) be square to within 0.5" to the line of the tendon .
KU
Any anchorages outside this tolerance shall be deemed non-conforming.

Particular care shall be taken in placing and compacting the concrete
around the anchorages and anchorage blisters.
O
The working surfaces of all anchorages shall be cleaned prior to

D
tensioning.
Proprietary anchorages shall be handled and used strictly in accordance
with the proprietary system instructions and recommendations and to the
811-15
(JKRlSPJf2016-S11)
11.6.4 Pre-tensioning
Where pre-tensioning methods are used, the tension force in the strands
or wires shall be fully maintained by some positive means during the
period between tensioning and transfer. When concrete has reached the
age at which tests cubes taken from it had attained the specific transfer
strength, the stress shall be transferred gradually, without severance of
the strands or wires, to minimise shock. The tendon or strands shall be
protected against rust by applying neat epoxy resin of a suitable quality
or an epoxy mortar to the ends of the tendons or strands. The method of
ER
application and the thickness of the protective coating shall be to the
Provisions for the two types of tendon alignments are as follows:-
D
(i) Straight tendons
In the long-line method of pretensioning, sufficient locator plates
N
shall be distributed throughout the length of the bed to ensure that
TE
the wires or strands are maintained in their proper position during
concreting. Where a number of units are made in line, they shall be
free to slide in the direction of their length and thus permit transfer
of the prestressing force to the concrete along the whole line.
A
In the individual mould system, the moulds shall be sufficiently rigid
EJ
so as to provide the reaction to the prestressing force without
distortion.
M
(ii) Deflected tendons

Where possible, the mechanisms for holding down or holding up
EN
tendons shall ensure that the part in contact with the tendons is free
to move in the line of the tendon so that frictional losses are
nullified. If, however, a system is used that develops a frictional
M
force, this force shall be determined by test and due allowance

made.
KU
For single tendon, the deflector in contact with the tendon shall
have a radius of not less than 5 times the tendon diameter for wire
or 10 times the tendon diameter for strand, and the total angle of
O
deflection shall not exceed 15°.

The transfer of the prestressing force to the concrete shall be
D
effected in conjunction with the release of hold-down and hold-up

forces as approved by the S. O.
Sll-16
(JKRlSPJ/2016-S11)
11.6.4.1 Tensioning Procedure

The method of tensioning shall ensure that the required force is
applied to all tendons especially where more than one tendon is
tensioned in a single operation.
The force shall be measured by means of jack pressure gauge
readings, or by approved load cells, and shall be checked against
the measured extensions of the tendons.
The initial force applied to the tendon to take up the slack shall
ER
not exceed 5% of the minimum breaking load of the tendon.
The S.O. shall be notified in the case where the jacking force and
elongation values are different by more than 5% than the design
D
values. In such a case, the S.O. shall be advised before any
concrete is cast and tendons shall be retested with the calibrated
N
equipment or as instructed by the S.O.
n
TE
Every endeavour shall be made to obtain the required net force. A
tolerance of ±5% in elongation shall then be permitted for
individual tendons provided that the member as a whole is within
±2% of the required mean value. Non-compliance of this
A
requirement willi result in the Contractor having to justify by
means of additional calculation or related information and to be
EJ
submitted to the S.O. for acceptance and approval.

Tendons shall be located as shown in the drawings and suitable
M
devices shall be provided to ensure that the correct positioning of

the tendons is maintained during casting. When tendons are
being placed, particular care shall be taken that the tendons do
EN
not come into contact with the oiled surface of the forms or
otherwise be soiled. Any tendons so soiled shall be cleaned with
the methods approved by the S.O.
M
In the case of a slip occurs to any of the tendon within a group of

tendon, the tensioning of that particular group shall be de-
KU
tensioned, reset and shall be re-tensioned again. The Contractor

shall completely replace any tendon that are broken during the
tensioning process. For the breakage of individual tendon in a
O
group of tendons, the process shall be repeated as in the case of

a slip.
D
The prestressing force shall be transferred from the tensioning

jack to the abutment of the stressing bed immediately after the
required force has been reached and the pressure in the jack
shall be relaxed before any other operation is commenced.
Stressing shall be carried out at a smooth and even rate. The
maximum permitted loads in the tendons will not normally be
more than 80% the characteristic tensile strength but the actual
tension to be applied shall , in all cases, be as agreed with the
S.O.
Sll-17
(JKRlSPJ/2016-S11 )
The prestressing tendons shall not be released until the concrete

has attained the specified compressive strength at transfer as
proved by the appropriate test cube under similar condition as the
member being stressed.
The test cubes shall be made and tested in accordance with in
Section 9: of this Specification and shall be cured under similar
conditions as the concrete to which they are related .
Notwithstanding this, compressive strength tests shall be carried
out during the progress of Work. The rate of sampling shall be as
ER
specified in Section 9: of this Specification. Non-compliance of
the concrete strength requirement will result in the tensioning
process at transfer to be delayed or the particular member to be
D
discarded, subjected to the instruction of S.O.
Prior to transfer of the prestressing force from the abutments of
N
the casting bed to the members, all tendons shall be tested for
TE
tightness and any loose tendons found shall be reported to the
S.O. for approval. All tendonsshall be marked at each end of
every member so as to check the extension.
In the case of members which have been steam cured the
A
prestress shall be transferred while the member is still warm and
EJ
moist.
The procedure of release shall be continuous and the prestress
shall be transferred to the members in such a manner that the
M
tendons are released gradually and simultaneously.

Large differences of tension between the tendons or strands shall
EN
be avoided. No shock release of stress is to occur during de-

tensioning operations. De-tensioning equipment used shall have
adequate capacity to completely release all tendons strands in
M
one operation.
If the tension is released from one end only or if there are several U
KU
moulds in line, provision shall be made for the members to slide,

allowing a transfer of the force all along the tensioned line.
Where there are several moulds in line, cutting strand between
O
members shall proceed after de-tensioning in sequence from the

de-tensioned end.
D
If shock release of stress occurs due to any cause, members

adjacent to the shock-released strand may be rejected by the
S.O.
All tendons shall be cut off and ground flush with the concrete
surface. The system of cutting off the tendons shall be subjected
to the approval of the S.O. The tendons shall be protected
against rust by applying neat epoxy resin of a suitable quality or
an epoxy mortar to the ends of tendons. The method of
Sll-18
(JKRlSPJ/2016-S11)
application and the thickness of the protective coating shall be to

the satisfaction of the S.D .
11.6.5 Post-tensioning
The Contractor shall prepare, check and submit to the S.D. complete
detailed working or shop drawings and calculations or schedules
showing:
(i) Contractor's details of proposed manufacture and construction of
ER
prestressed member.
(ii) Proposed sequence of prestressing operations either for permanent
D
or temporary prestressing .
N
(iii) Dimensions and complete descriptions of all prestressing materials
n and devices, joints, bearings and anchorages not specified or
TE
detailed in the Contract.
(iv) Calculated eventual deflections, cambers and rotations of the

A
concrete due to the effects of prestress, elastic shortening, creep
and shrinkage in the concrete, strand relaxation, gravity and any
EJ
other effects.
No stressing shall be done without adequate prior notice being given to

M
the S.D. The Contractor shall prepare complete stressing schedules

describing the expected design elongation and jacking forces to be used
in tensioning and shall submit to the S.D. prior to commencing stressing.
EN
Under no circumstances shall the maximum jacking force exceed 80% of

the characteristic tensile strength of a tendon, or the rated capacity of the
jacking equipment used, whichever is the lesser. After the tendons have
M
been anchored, the stress exerted from the tensioning apparatus shall be
gradually decreased to avoid any shock to the tendons or the anchorage
KU
plate.
Where tendon are not stressed simultaneously, the use of spacers shall
O
be in accordance with the recommendations of the system manufacture

and approved by the S.D.
D
For deflected tendons, the tendon curvature shall, where possible, have
a radius of not less than 50 times the diameter of the tendon, and the
total angle of deflection shall not exceed 15'. Where the radius is less
than 50 times the diameter of the tendon and the angle deflection
exceeds 15', the loss of strength of the tendon shall be determined by
tests and due allowance made.
In the case of free or balanced cantilever Method, temporary stress bars
could be provided during segment erection prior to the installation of
permanent cantilever tendons . These bars shall not be removed upon
Sll-19
(JKRlSPJI2016-S11)
permanent stressing prior to the completion of the whole work or work

stage cycle. The removal of temporary prestressing can only be done if
a minimum factor of safety of 1.5 for the cantilever structure is
maintained. Removal of the temporary prestressing must be done with
the agreement of the S.O.
The Contractor shall be responsible for the safety of all personnel during
stressing and shall provide any safety equipment necessary in
accordance with OSHA:18001 .
All results and data relating to the tenSioning operations shall be
ER
recorded on the stressing records.
D
11.6.5.1 Tensioning Procedure
Tensioning shall be carried out only in the presence of the S.O.
N
Immediately before tensioning, the Contractor shall prove that
TE
all tendons are free to move in their sheaths or ducts and that
members are free to accommodate the horizontal and vertical
movements due to the application of prestress.
A
Concrete shall not be stressed until it has reached at least the
age at which two test cubes taken from it attain the transfer
EJ
strength as speCified in the Drawings and shall be at least 72

hours age or as directed by the S.O.
M
The test cubes shall be made and tested in accordance with

Section 9: Concrete of Standard Specification for Road Works
and shall be cured under similar conditions to the concrete to
EN
which they relate.

Notwithstanding this, compressive strength tests shall be
carried out during the progress of Work. The rate of sampling
M
shall be as in Section 9: Concrete of Standard Specification for

RoadWorks.
KU
Unless tendons are stressed at both ends, the wedges at the

dead ends, shall be checked for tightness when approximately
10% of the full prestressing load has been applied. The pull-in
O
of these wedges shall be measured at the same stages as the

stressing end extension is measured.
D
Grouting shall be done immediately after tenSioning, otherwise

all anchorage shall be sealed before grouting to prevent ingress
of water or moisture.
S11-20
(JKRlSPJ/2016-S11)
11 .6.6 Records of Stressing

The format of the record shall be approved by the S.O. and shall contain
but not be limited to the following information where applicable:
(i) Identification number of dynamometers, gauges, pumps and jacks;
(ii) Initial stressing force or pressure when tendons are marked for
measurement of elongation;
(iii) Force applied if a dynamometer is used or, alternatively, the pump
or jack pressure and area of the piston;
ER
(iv) before anchoring; and
(v) Elongation remaining after anchoring with load-extension curves
D
(vi) Records of lift off if required.
N
The fully completed streSSing records shall be made available to the S.O.
n within 24 hours after the completion of prestressing.
TE
11 .6.7 Tensioning
The Contractor shall establish the datum point for measuring extension
A
and jack pressure to the satisfaction of the S.O. The movement of the
EJ
jack ram will not be taken as the extension of the tendons.
The actual extension of tendons shall be extrapolated from zero to the
required jacking pressure to obtain the total extension of the tendons.
M
The order in which tendons shall be tensioned shall be in accordance

with the Drawings or as directed by the S.O.
EN
The Contractor shall provide the streSSing sequence and from which
ends of the member and submit them to the S .O. for approval. When
streSSing from one end only the pull-in at the end remote form the jack
M
shall be accurately measured and the appropriate allowance made in the

measured extension at the jacking end.
KU
The forces in the tendons shall be determined either by means of jack

pressure gauge reading or by approved load cells, and shall be checked
against the measured extensions of the tendons.
O
Reference shall be made to the manufacturer's load-extension curves to

D
determine the correct extension for each tendon, and the effect of the
tendon-friction, draw-in, jack and anchorage friction shall be taken into
account.
The Contractor shall informed the S.O. immediately, should he be unable
to obtain accurate agreement between jack loads and extensions and
shall make such necessary adjustments to the loads and/or extensions
as instructed by the S.O.
Sll-21
(JKRlSPJ/2016-S11)
If the friction losses or draw-in of the tendon at anchorage are higher

than the calculated or design values,it shall be rejected by the S.O.
After anchoring, the jack force shall be decreased gradually and evenly
without shock to the anchorage plate, tendons or concrete.
If it is necessary to crop the tendons to enable the ducts to be grouted,
this shall be delayed as long as practicable up to the time of grouting. In
all other cases, unless agreed otherwise by the S.O., tendons shall be
cropped prior to grouting works.
ER
Recesses' openings for cropped tendons shall be dressed in accordance
with the recommendations of anchorage proprietary system .
The Contractor shall keep full record of all tensioning operations
D
including the measured extensions, pressure gauge or load cell readings
and amount of pull-in at each anchorage . Copies of these records shall
N
be verified on Site by the Contractor and the S.O. immediately after each
tensioning .
11.6.8
TE
Protection and Bond of Prestressing Tendons
A
The prestressing tendons shall be protected in their permanent positions
from both mechanical damage and corrosion in accordance with the
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recommendations of the anchorage proprietary system .

M
11.6.9 Grouting Of Ducts

Grouting trials shall be undertaken when required by the S.O. and all
EN
grouting works shall be carried out in the presence of the S.O. and
grouting procedures shall conform to BS EN 446 or BSISO 14824-2.
Grouting of prestressing tendons shall be carried out as soon as
M
practicably possible. It shall not be more than 5 days after tenSioning of

the tendons unless as directed by the 5 .0 .
KU
All ducts shall be thoroughly cleaned by using compressed air.

O
11.6.9.1 Air Testing of Ducts before Grouting

The Contractor shall note that the air testing of ducts before
D
grouting is a critical activity. This test shall be carried out under

the supervision of a competent supervisor.
The Contractor shall determine the volume of air in the duct
before air testing by taking into account the intemal
dimensions of the duct and the space taken up by the tendon .
Any residual water in the duct shall be blown away with
compressed oil-free air.
Sll -22
(JKRlSPJ/2016-S11 )
The anchorage ends should be sealed, and each duct shall be

tested as follows:
(i) With all valves closed, the duct shall be pressurised at
the grout inlet with oil-free air to 0.25 MPa to confirm that
the installed system has sufficient integrity for grouting;
(ii) The pressure shall be held at 0.25 MPa for 30 seconds. A
sudden drop in pressure of more than 0.1 MPa, or a need
to continuously inject compressed air to maintain the
pressure system indicateds that the duct is not
ER
sufficiently sealed for grouting. As such, any leaks shall
be located and repaired and the test shall be repeated;
(iii) The pressure shall be reduced to 0.1 MPa;
D
(iv) The air source shall be locked off; and
N
(v) The air pressure loss over time shall be recorded .
TE
Maximum allowable pressure loss is 40% within a
duration of:
D = (1 .1 xV + 5)/60
A
where: D = duration in minutes;
V = the volume of the duct minus the strand
EJ
volume in litres.
If the pressure loss over time is greater than 40%, a
M
thorough inspection shall be made for any evidence of

leakage from, or between ducts. Leakages shall be rectified
and the duct retested before grouting.
EN
The S.O. shall make an assessment of the entire duct to

detenmine whether grouting can proceed.
M
Where air testing detects leakage between two adjacent

ducts that cannot be practically rectified, both ducts shall be
KU
air tested as a single system and the two ducts shall be

grouted simultaneously with two lines controlled by individual
lock-off valves.
O
The temperature of freshly mixed grout shall not exceed

32°C. This maximum temperature can only be increased
D
provided trials demonstrate that the grout meets the fluidity

requirement in accordance with BS EN 445.
The ducts shall be completely filled with grout.
S11 -23
(JKRlSPJ/2016-S11)
11.6.9.2 Injecting Grout

Unless instructed by the S.O except in exceptional
circumstances, grout shall only be injected from one end of a
duct.
The method of injecting grout shall ensure complete filling of
the ducts and complete surrounding of the prestressing steel.
Grout shall be allowed to flow from each vent and the remote
end of the duct until its fluidity is equivalent to that of the grout
injected, by visual acceptance. In the event of disagreement,
ER
testing for fluidity shall be carried out in accordance with BS
EN 445.
Additional 5 litres of grout at each vent shall be vented into a
D
clean receptacle and then discarded. The opening shall be
firmly closed . All vents shall be closed in a similar manner one
N
after another in the direction of the flow except that at
TE
intermediate crests the vents immediately downstream shall be
closed before their associated crest vent.
Grout vents at high points shall be reopened immediately after,
while the grout is still fluid, and any escape of air, water or
A
grout recorded and reported immediately to the S.O. A further
EJ
pumping of grout shall then be carried out to expel bleed water
and/or entrapped air. This shall be carried out with the vents
open one at a time sequentially in the direction of grouting and
M
a further 5 litres shall be vented at each open vent. A visual

inspection of the vented grout shall be carried out and, if there
is any doubt about its quality, bleed and fluidity testing shall be
EN
carried out immediately.

The injection tubes shall then be sealed off under pressure. A
pressure of 0.5 MPa shall be maintained for at least one
M
minute.
KU
The filled ducts shall not be subjected to shock or vibration,

construction traffic or similar loads until 24 hours after
completion of grouting.
O
When the grout has set, the grout vents shall be temporarily
reopened . If voids are apparent on inspecting vents at end
D
caps, the end caps shall be removed to demonstrate that they

are satisfactorily filled with grout. End caps that have been
removed shall then be replaced by end caps permanently
sealed against ingress of contaminants, and such sealing shall
be proven to the satisfaction of the S.O.
If the anchorage caps are removed, the Contractor shall
prepare and submit to the S.O. a report on such together with
photographic record clearly identifying the individual
anchorages.
S11-24
(JKRlSPJ/2016-S11)
If, in the opinion of the S.O., there is cause for doubt that the
ducts or any part of the system are not satisfactorily filled with
grout, the S.O. may require investigations to be carried out.
Grout vents shall be positively sealed to be waterproof on
completion of grouting by a means separate from the concrete
waterproofing .
If there is any blockage or breakdown or if the grout injection is
interrupted, the duct shall immediately be thoroughly washed
with clean water and blown dry with oil-free compressed air;
ER
regrouting shall start as soon as practicable.
As soon as possible within one month after grouting
operations, the anchorage and the anchor plate or blister shall
D
be thoroughly cleaned by abrasive blasting and the contact
N
surfaces of the anchorage and anchorage recess shall be
( ) coated with a wet or dry epoxy adhesive.
TE
Non-shrink grout shall be used to patch up the recesses to
avoid shrinkage cracks from occurring at the affected area.
Where there are blockages, the Contractor shall carry out
A
repair or remedial works to remove the blockage at the
contractor's own cost to the satisfaction of the S.O.
EJ
11.6.9.3 Record of Grouting Operations

M
(i) Full records of grouting for each duct shall be kept by the
Contractor and to supply copies of these records to the
EN
S.O. within 24 hours after grouting.

(ii) These records shall include, but not limited to, the
following details:
M
(a) location of grouting operations,

KU
(b) date and time of starting and completing grouting

operations,
(c) weather conditions,
O
(d) technical personnel supervising or carrying out

grouting operations,
D
(e) prestressing tendon reference numbers,

(f) grout mix, including any admixtures,
(g) grout injection pressure,
(h) volume of grout used,
(i) details of any interruptions and topping up, and
(j) batching record, including sampling and testing
details.
S11 -25
(JKRlSPJ/2016-S11)
11 .6.9.4 Test: Grout - General Requirements

Grout test shall be performed in accordance with BS EN
445:1997.
11.7 GENERAL REQUIREMENT FOR PRECAST PRESTRESSED CONCRETE

MEMBERS
ER
11.7.1 General
The precast prestressed beams members shall be designed to carry the
deck formwork and in-situ concrete without propping during the
D
construction of the deck. Should the Contractor chooses to make any
adjustments to the quantity and disposition of the prestressing tendons
N
he shall submit his proposals to the S.O. for approval. Although the
design of the proposed adjustments shall be checked, it shall not relieve
TE
the Contractor of his responsibility for the design.
The precast concrete construction shall comply with Section 9 of the
Standard Specification for Road Works, except in such respects as they
A
may be modified by the provisions of the remainder of this Section.
EJ
11.7.2 Storage
M
When members are stored, they shall be firmly supported at such

bearing positions to ensure that stress induced in them are always less
than the permissible design stresses of the precast prestressed member.
EN
The method of storage for precast prestressed members shall include full
safety measures for all personnel, use of non-staining support pads and
all shall be approved by the S.O. The storage bed or platform shall be
M
fully capable of sustaining the loads from the precast prestressed

members.
KU
Any reinforcing bars, which are projected from the units or members, are
to be covered by some approved method (by the S.O.) to prevent rust.
O
Precast members shall be stacked and supported under each lifting

device position.
D
Units or members shall not rest on any support at locations between the
approved support points.
The support timbers shall be sufficiently large to store the units clear off
the ground and to avoid subsidence under the supported weight when
the ground is wet. The ground beneath the units shall be levelled so as to
maintain the same clearance as at the supports.
Sll-26
(JKRlSPJ/2016-S11 )
To avoid twisting and overturning of units, all stacking areas are to be an

even plane from one end of the unit to the other. Where units are
stacked in layers, they shall be supported by timbers positioned directly
above those below. The Contractor is to ensu re all units or members are
in proper stability while stacking. Where practical, the units shall be
stacked so that access for inspection of all units is possible at any time.
Inspection of the member condition would be useful to ensure deflection
and bows are within tolerance.
ER
11 .7.3 Handling and Placing
The method of handling and storage shall be such as to avoid the danger
of fracture by impact, undue bending, twisting and whipping .
D
Prestressed concrete members shall be moved only while fully
N
suspended. In no case shall they be moved by dragging across the floor
() or terrain.
TE
All Quality Assurance checks shall be performed and repairs carried out
prior to placing units in a stack where access to individual units cannot be
gained.
A
No prestressed member shall be transported from a manufacturer's yard
EJ
until a minimum of 7 days has elapsed from the day of casting .
M
11.7.3.1 Marking
On each precast element, the following information shall be
clearly labelled with undeletable marking on the outer vertical
EN
face.
(i) The date of manufacture
M
(ii) The identification number

() (iii) The maximum mass of the element members
KU
(iv) The manufacturer's name or registered mark, and

(v) The dimension of precast members
O
D
11 .7.3.2 Lifting
Members shall be lifted or supported only at the points described
on the Drawings and shall be handled and placed without impact.
The Contractor shall submit to the 8.0. for his approval, the
method and sequence he intends to adopt, for launching or lifting
of the precast beams. The Contractor shall be responsible to
provide all necessary equipment and machinery for the launching
and lifting of the beams.
Sll -27
(JKRlSPJ/2016-S11)
Should any component in the opinion of the S.O. be so damaged

by mishandling as to be rendered inadequate for its purpose, the
S.O. may order its removal from the Site and shall be replaced at
the Contractor's own expense.
Pretensioned members shall not be lifted or handled until fully
stressed.
Post-tensioned members shall be either fully stressed or partially
stressed as shown in the Drawings and in general all stressed
tendons shall have been grouted for 5 days prior to lifting or
ER
handling of the member.
At all times, and especially during transportation, members shall
be secured in an upright position by means of suitable packing
D
pieces and braces which shall be provided before transferring the
load from lifting gear to the support. Members shall not be braced
N
against each other but shall be provided with independent
TE
bracing.
No superimposed load shall be placed on a member except with
the permission of the S.O.
A
The Contractor shall submit full details of the transport
arrangements, including means of limiting torsional stresses of
EJ
the members in transit, to a safe value against cracking, for the

S.O.'s prior approval.
M
Prestressed concrete members shall be held in such a position

that the top surface is uppermost at all times during handling,
transport and storage.
EN
All units shall be lifted by the lifting devices incorporated in the

units. Webs of prestressed concrete members girders shall
remain vertical with the top flange uppermost at all times.
M
When loading or transporting prestressed concrete members, the

KU
Contractor shall provide means of restraining the side whip.
11 .7.4 Tolerance
O
The manufacturing tolerances for the precast members shall comply with
D
BS 5606:1 990. In addition, where beams are laid side by side in a

composite slab deck, the following requirements shall be applicable:-
(i) The difference in soffit level between adjacent units before the in-situ
concrete is placed shall nowhere exceed 5 mm from the designed
difference in soffit level for units up to 4.5m long and not more than
10 mm for longer units.
(ii) In adjacent spans, the continuity of line of the outside members shall
be maintained.
S11-28
(JKRlSPJ/2016-S11)
(iii) The width of the gap between individual beams shall not exceed
twice the nominal gap described on the Drawing.
(iv) The alignment of transverse holes shall permit the reinforcement or
prestressing tendons to be placed without distortions.
The in-situ concrete shall be placed in such a sequence that the

advancing edge of the freshly deposited concrete over the full width of
deck or between longitudinal construction joints is approximately parallel
ER
to the deck supports.
All edge beams shall be prevented from moving laterally during the
placing of the in-situ concrete.
D
The manufacturer shall make allowance for deflections, pre-camber,
creep and shrinkage effects, taking into account effects nominated in the
N
(j design and actual properties. The length and hog of the first casted units
TE
for a structure shall be measured . Adjustments shall be made to the
manufacturing process to ensure that all subsequent units are within
allowable tolerances.
Tolerance in relation to length and hog shall apply at 28 days from the
A
date of manufacture. The determination of compliance of members in
EJ
relation to dimensional tolerances shall be based on dimensions
measured by the manufacturer during a period of 21 to 35 days from the
date of manufacture.
M
At no section, shall the longitudinal centerline deviate in the transverse

direction from a straight line joining the centre points of the ends of the
EN
girder (bow) by more than 20 mm.
11 .7.4.1 Cross-Section, Length and Out of Square

M
I) At any cross-section, the length, out of square and dimensional

deviations shall be in accordance with Clause 9, Section 9 of
KU
the Standard Specification for Road Works.

O
11.7.4.2 Camber
A maximum range of 20 mm for spans up to and including 20
D
metres and 25 mm for spans exceeding 20 metres are the

acceptable ranges of hog camber values of similar units and
girders of the same age, which are to be used in the same
span.
The design camber shall be as shown on the Drawings. Any
member or unit that shows the camber value of 1.5 times the
design value shall seek approval from S.O. for further
instruction .
S11 -29
(JKRlSPJ/2016-S11)
11 .7.5 Off Site Manufacture

The following provisions shall be additional to Section 9 of the Standard
Specification for Road Works.
The Contractor shall inform the S.O. in advance of the date of
commencement of manufacture and the dates when tensioning of
tendons, casting of members and transfer of stress will be undertaken for
the first time for each type of beam.
The Contractor shall submit the Method Statement of Construction and
ER
Quality Assurance at least 14 working days prior to manufacture of
precast concrete element.
The details of the method of manufacture shall be approved by the S.O.
D
before work starts. When the method has been approved no changes
shall be made without the consent in writing of the S.O.
N
Within 7 days after the transfer of stress, the Contractor shall send to the
TE
S.O. the following documents:
(i) The record shOwing the force and extension or elongation in the
tendons immediately after they were anchored.
A
(ii) The strength and age of the test cubes.
(iii) The minimum age of the concrete at the time the stress was
EJ
applied to the members.

A copy of all 28-day cube test results relating to the work shall be sent to
M
the S.O. as and when they become available.

Where the S.O. requires additional or independent tests to be carried
EN
out, no precast members to which the tests relate shall be delivered to

the Site until the tests have been satisfactory completed and accepted by
theS.O.
M
Records shall be kept so that the identity of those who stress the
tendons, cast the concrete and transfer the stress, of any member or line
KU
of members can be traced .

(i) Manufacturer of prestressed concrete members shall:
(ii) Operate based on a quality system certified to the requirements of
O
ISO:9001;
D
(iii) establish procedures for manufacture of prestressed concrete

members; and
(iv) have acceptable test and inspection plan (quality assurance and
quality control) submitted to the S.O.
Where a new prestressing process is being established, the
manufacturer shall submit the procedure for manufacture of the
prestressed concrete members to the S.O., giving details of materials,
equipment and processes not less than 28 days prior to establishment of
the plant.
S11-30
(JKRlSPJ/2016-S11)
The manufacturer shall not commence until approval of the new

procedure has been obtained from the S.O.
No Significant changes to the method of manufacture shall be permitted
without the approval of the S.O. A minimum of 14 working days notice
shall be given to the S.O of any proposed change.
When a bed is set up to manufacture a new member type, no concrete
shall be placed in the members until the formwork, reinforcement and
ER
stressing materials have been approved by the S.O.
11.7.6 Launching Of Precast Elements
D
The Contractor shall inform the S.O. at least one month in advance of
N
each launching operation and submit the following to the S.O. for
(j acceptance:
TE
(i) Method statement including the launching method, which includes
the systems, machineries and equipment used, time taken, traffic
closure and safety measures.
A
(ii) Method statement for the delivery of units or members including
transportation, route, proposal for traffic diversion or closure, as
EJ
appropriate or as directed by S.O.,

(iii) Detailed programme of each launching operation.
M
11.7.6.1 Transportation
EN
The Contractor shall obtain the necessary clearances for the

transportation of the prestressed pre-cast elements and
movement of the lifting equipment to the launching site.
M
Contractor's method of transportation shall demonstrate that the

) elements being transported would not be damaged.
KU
A certificate of test of the lifting equipment shall be submitted to

the S.O., together with particulars of the operator and details of
experiences.
O
D
11 .7.6.2 Ground Preparation

The ground for the launching area shall be prepared to ensure
that it is safe to carry the load during launching operation.
11 .7.6.3 Erection
Utmost precautions shall be taken to eliminate any danger to
the workers and general public while launching pre-cast
elements. All lifting equipment shall be designed such that, if
S11-31
(JKRlSPJ/2016-S11)
the primary lifting mechanism fails, a secondary mechanism will

ensure that the pre-cast element does not fall.
Upon erection, a fail-safe method shall be used to temporarily
secure the pre-cast unit until the permanent fixing
arrangements are implemented.
The securing systems, subject to the 8.0.'s acceptance, shall
include:
(i) providing chains between beams and supports;
ER
(ii) connecting adjacent beams by welding protruding bars of
the beams; or temporary bracings between the beams;
(iii) providing wedges or brackets to the beams.
D
The Contractor shall inform the 8 .0 . and obtain his approval
N
before removing any temporary works but such approval does
not, in any way, relieve the Contractor of his responsibilities for
TE
the safety of the work.
The Contractor shall:

A
(i) ensure that appropriate and sufficient waming signs, lights,
EJ
barricades and at least one rotating amber light are placed at
each point of road closure or diversion in accordance with
the latest Arahan Teknik (Jalan) For Temporary Traffic
M
Control.
(ii) station at least one person in a safe position at each point of
EN
road closure, to advise and guide motorists. The person

shall be equipped with a torch, reflective vest and walkie-
talkie or other means of communications within the
launching site.
M
(iii) have one person controlling the whole launching operation

KU
with a whistle or other means of communications with the

lifting equipment operators.
(iv) ensure that there is sufficient lighting at the launching site.
O
(v) ensure that no welding work on the bridge is carried out

unless a protective screen is used to prevent sparks and
D
other materials from falling onto the areas below.

(vi) install 4.5m height restriction signs of standard design
immediately after launching of any precast element above
the existing carriageway.
(vii) measure and record the actual height clearance of the
bridge at every 2m interval along the span of the bridge
above the carriageway.
811-32
(JKRlSPJ/2016-S11)
(viii) measure and record the location of the smallest clear height
between the carriageway and the bridge.
(ix) submit measurements showing that the height clearance of
the bridge satisfies the minimum clearance requirement to
the S.O. before opening the road under the bridge to traffic.
11.7.7 Inspection and Testing

The inspection and testing of precast concrete units shall be in
ER
accordance with BS EN 1992-2:2005.
The testing of concrete specimens to establish whether the concrete
used in the structure complies with the specification for structural
D
materials as described in Section 9 of the Standard Specification for
Road Works.
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t ') If the quality of the concrete is shown to be inadequate by the results of
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these check tests, or shows other defects, a loading test may be required
by the S.O., and should then be carried out by the Contractor in
accordance with 11 .7.8 in this section.
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11 .7.7.1 Types of Tests
(i) Surface Finish
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Inspect the surface of the concrete for defects, for

conformity with the specification and, where appropriate, for
comparison with approved sample finishes. The making
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good of surface defects may be permitted, but the standard

of acceptance should be appropriate to the type and quality
of the finish specified and should ensure satisfactory
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permanence and durability and is subjected to the strength

and durability of the concrete being unimpaired. Great care
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is essential in the selection of the mix proportions to ensure

that the final colour of the faced area blends with the parent
concrete in the finished structure on permanently exposed
surfaces.
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(ii) Rebound Hammer Test

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If a rebound hammer is used regularly by a trained

personnel and if continuously maintained individual charts
that show; for a large number of readings, the relation
between the readings and the strength of cubes made from
the same batch of concrete, are kept, an approximate
indication of the strength of the concrete in a structure or
element may be obtained by using such charts in
conjunction with hammer readings . When used by a trained
personnel in these circumstances, the expected degree
accuracy is within ± 3 MPa.
S11-33
(JKRlSPJ/2016-S11)
When making rebound hammer tests, each result should be

the average of at least nine individual readings. Do not take
readings within 25 mm of the edge of concrete members.
Clearly distinguish readings taken on a trowelled face and
those taken on a moulded face. Take special care to firmly
bed them against the impact of the hammer, when making
the test on precast units.
(iii) Electromagnetic Cover Measuring Devices
Verification of the position of reinforcement or tendons to
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depths of about 70 mm may be done by an electromagnetic
cover measuring device in accordance with the
recommendations of BS 4408-1.
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(iv) Gamma Radiography
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To test concrete up to 450mm thick for the presence of local
voids in the concrete and the efficiency of the grouting of
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ducts in prestressed members, gamma radiography may be
used. It may also be used to determine the presence and
location of any embedded metal. Special precautions are
necessary to avoid contamination from the radioactive
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source. Carry out the testing in accordance with the
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recommendations in BS 4408: Part 3.
(v) COring Test
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The drilling and testing of core samples from the concrete

must comply to the procedure requirements of BS 1881:
Part 4.,in circumstances where the compressive strength of
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the concrete in the structure may need to be assessed. To

investigate the presence of voids in the compacted
concrete, such cores may also be cut. Whenever possible,
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reinforcement should be avoided when core cutting.

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11 .7.8 Load Tests of Structures or Parts of Structures

The tests described in this clause are intended as a check on structures
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other than those covered by clause 11.7.7.1, where there is doubt

regarding serviceability or strength. Test loads are to be applied and
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removed incrementally.
The test should be carried out as soon as possible after the expiry of 28
days from the time of placing the concrete. When the test is for a reason
other than that the quality of the concrete in the structure being in doubt,
the test may be carried out earlier provided that the concrete has already
reached its specified characteristic strength.
When testing prestressed concrete, allowance should be made for the
effect of prestress at the time of testing being above its final value.
511-34
(JKRl8PJ/2016-S11 )
The test loads ,to be applied for the limit states of deflection and local
damage are 1he appropriate design loads, i.e. the characteristic dead
and imposed loads. When the ultimate limit state is being considered,
the test loads should be equal to the sum of the characteristic dead load
plus 1.25 times the characteristic imposed load and should be
maintained for a period of 24 h. If any of the final dead load is not in
position on the structure, compensating loads should be added as
necessary.
During the tests, struts and bracings strong enough to support the whole
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load should be placed in position, leaving a gap under the members to
be tested , and adequate precautions should be taken to safeguard
persons in the vicinity of the structure.
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Measurements of deflection and crack width should be taken
immediately after the application of load. In the case of the 24 h
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sustained load test, readings should be taken at the end of the 24 h
loaded period, after removal of the load and after the 24 h recovery
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period.
Sufficient measurements should be taken to enable side effects to be
taken into account. Temperature and Weather conditions should be
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recorded during the test.
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811-35
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Section 12 - Structural Steelwork (JKR 20400-0264-22)
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KERAJAAN MALAYSIA
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FOR ROAD WORKS
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Section 12 : Structural Steelwork
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@---
a-
KETUA PENGARAH KERJA RA VA
50582 KUALA LUMPUR.
FOREWORD
As practices in road construction change over time, it is imperative that Jabatan Kerja Raya
(JKR) to continuously update and improve their standard specifications . These new
specifications are not only aimed at keeping abreast with current technologies but also to help
improve the quality of construction works and its final product. Consequently, these new
specifications will ultimately have a significant positive impact on the construction industry
especially with the incorporation of new products and technologies.
ER
Structural Steelworks", is a part of a series of improved specifications in the JKR Standard
Specification for Road Works . This specification was revised from JKR Standard Specification
for Structural Steelwork No. JKR 20600-0019-99, which was adopted and adapted from the
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National Structural Steelwork Specification for Building Construction with permission from
Steel Construction Institute U.K, for the purpose of advancing the design, manufacture and
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use of the structural steel in PWO projects. 0
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The compilation of this document was carried out through a series of discussions that had
been held by the technical committee. The draft had also been presented and discussed at
length in a specially held workshop to get feedback and comments from relevant parties
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involved, which were then carefully studied and incorporated into the Specification wherever
appropriate or necessary.
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The primary objective of th is specification is to provide PWO engineers and contractors

sufficient information to permit safe fabrication, erection and construction procedures in
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accordance with commonly accepted and the best practice in construction industry.
The Specification has also gone through different phases of vetting and approval before the
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production of its final draft and printed copy. It shall be reviewed and updated from time to
time to cater for any changes in policies and the inclusion of current requirements, if
necessary. Any feedback or improvement to be considered for future revisions should be
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forwarded to Bahagian Pembangunan Inovasi & Standard, Cawangan Jalan, JKR Malaysia.
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Published by: -
Cawangan Jalan
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Ibu Pejabat Jabatan Kerja Raya Malaysia

Tingkat 21, Menara PJO
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No. 50, Jalan Tun Razak

50400 Kuala Lumpur
Email: uss j@jkr. gov.my
November 2022
51 2- i
ACKNOWLEDGMENT
This "Standard Specification for Road Works - Section 12: Structural Steelworks" has
been prepared by a technical committee comprising of the following members;
Committee Members:
Ir. Abd Rahman Bin Salleh (Pengerusi sehingga Apr 2018)

Ir. Atikah Binti Zakaria @ Ya (Pengerusi dari Mei 2018)
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Ir. Dr. Fairul Zahri Bin Mohamad Abas
Ir. Nor Azian Binti Aziz
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Ir. Tn Khussairry Bin Tn Abdul Manaf
Pn . Nur Qistina Binti Abdullah
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n Prof. Madya Ir. Dr. Raizal Saifulnaz Bin Muhammad (UPM)
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Cik Farah Zuhana Binti Zullkefle
Ir. Dr. Muhammad Khairil Bin Ibrahim
Ir. Amir Bin Ismail (Perunding Zeca)
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Special thanks and appreciation to the following proof reader:

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Pn. Hasniah Bt. Mat Ali
Finally, the publisher would like to express its gratitude to the above committee members, and
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all those who were involved, directly or indirectly, for their tireless effort and contribution
towards the successful completion of this document.
Appreciation also goes to Ir. Mohd Shahrom Bin Ahmad Saman, the Director of Pakar
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Kejuruteraan Jalan & Jambatan, Cawangan Jalan, Dato' Ir. Haji Che Noor Azeman Bin Yusoff
u and Ir. Abdul Mutalif bin Abdul Hameed, the former Director during whose tenure the document
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was initiated, for their full support and cooperation throughout the preparation and compilation
of the document.
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812- ii
SECTION 12 . STRUCTURAL STEELWORK
PAGE
12.1 GENERAL
12.1.1 Scope S12-1
12.1.2 Safety And Health S12-1
12.1.3 Quality Assurance S12-2
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12.2 MATERIALS S12-2
12.2. 1 Structural Steel Sections S12-2
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12.2.1 .1 Qualities S12-2
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12.2.1.2 Testing and Sampling S12-2
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12.2.1.3 Dimensions and Tolerances S12-3
12.2.1.4 Surface Cond ition S12-3

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12.2.2 Steel For Shear Connector S12-3
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12.2.3 Structural Fasteners S12-3

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12.2.3.1 Ord inary or Non Preloaded Assemblies S12-4
12.2.3.2 Preloaded Assemblies S12-4

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12.2.3.3 Foundation and Holding Down Bolt Assemblies S12-4
12.2.3.4 Cup and Countersunk Bolts S12-4

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12.2.3.5 Washers S12-4

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12.2.3.6 Lock Nuts for Bolts Assemblies S12-4
12.2.3.7 Coating for Bolts Assemblies S12-4

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12.2.4 Welding Consumables S12-5

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12.2.4. 1 Standards S12-5
12.2.4.1 Storage S12-5
12.2.5 Steel Castings and Forgings S12-5
12.2.6 Stainless Steel S12-5
12.2.7 Cast Iron S12-5
812- iii
12.2.8 Protective Treatment Materials S12-6
12.2.8.1 Metallic Blast Cleaning Abrasive S12-6
12.2.8.2 Surface Coating S12-6
12.2.8.3 Sherard ized Coatings S12-6
12.2.8.4 Galvanizing Materials S12-6
12.2.8.5 Electrodeposited Coatings S12-6
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12.2.9 Proprietary Items S12-6
12.3 INSPECTION AND TESTING S12-6
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12.3.1 Surface Defects and Edge Laminations S12-6
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() 12.3.2 Procedure Trials for Testing Of Welding For Structural Steels S12-7
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12.3.2.1 Non-Destructive Testing of Welds S12-7
12.3.2.2 Weld Metal and Heat Affected Zone (HAZ) S12-9

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Charpy V-Notch Impact Test Requirements for
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Tension Areas
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12.3.2.3 Testing Of Welding For Cast Steel S12-9
12.3.2.4 Stud Shear Connectors S12-10

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12.3.3 Production Tests S12-10
12.3.3.1 Requirements for Destructive Testing Of Welding S12-10

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'- ) For Structural Steel

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12.3.3.2 Non-destructive Testing Of Welding For Structural S12-12
Steel
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12.3.3.3 Testing Of Welding For Cast Steel S12-12

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12.3.3.4 Stud Shear Connectors S12-12
12.3.3.5 Checking Of Alignment at Joints S12-12
12.3.3.6 Temporary Erection at Contractor's Works S12-12
12.4 WORKMANSHIP S12-13
12.4.1 Identification S12-13
S12- iv
12.4.1.1 Traceability of steel product 812-13
12.4.1.2 Material grade identification 812-13
12.4.1.3 Marking steelwork 812-13
12.4.1.4 Interchangeability of Parts 812-13
12.4.2 Tolerances and Accuracy of Fabrication 812-13
12.4.2.1 Permitted Deviation 812-13
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12.4.2.2 Alignment at Splices and Butt Joint 812-14
12.4.3 Preparation of Edge, Ends and 8urfaces 812-14
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12.4.3.1 Edges 812-14
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12.4.3.2 Ends 812-14
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12.4.4 Cutting and 8haping 812-15
12.4.4.1 Cutting Operations 812-15

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12.4.4.2 Columns and compression member 812-15
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12.4.5 Machining 812-15

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12.4.6 Assembly 812-16
12.4.7 Curving and 8traightening 812-16

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12.4.8 Inspection 812-16
12.4.9 8torage 812-16

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12.4.10 Bolting 812-17 J

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12.4.10.1 Ordinary (Non-Preloaded) Assemblies 812-17
12.4.10.2 Holes for Bolt 812-18

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12.4.10.3 Fit-up Using Non-Preloaded Bolt Assemblies 812-19

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12.4.10.4 Preloaded Assemblies 812-19
12.4.10.5 Fit-up Using Preloaded Bolt Assemblies 812-20
12.4.11 Welding 812-20
12.4.11 .1 Welder Qualification Testing and Certification 812-20
12.4.11.2 Welding Procedures 812-21
512- v
12.4.11.3 Welding of 8teel Castings 812-22
12.4.12 8 hear 8tud Weldi ng 812-23
12.4.12.1 Method 812-23
12.4.12.2 Trial welding 812-23
12.4.13 Forging 812-23
12.4.14 Tie Rods 812-23
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12.4.15 Parallel Barrel Drifts 812-24
12.4.16 Pins and Pin Holes 812-24
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12.4.17 Camber 812-24
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n 12.4.18 Rectification of 8urface Defects and Edge Lam inations 812-24
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12.5 HANDLING, TRANSPORT AND ERECTION 812-25
12.5.1 Handling 812-25

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12.5.1.1 Handling and storage 812-25
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12.5.2 Packing for Transport 812-25

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12.5.3 Erection 8 12-25
12.5.3.1 Erection method statement 812-25

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12.5.3.2 Provision of setting-out lines by the employer 812-25
12.5.3.3 Damaged steelwork 812-25

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<...) 12.5.3.4 Column base plates and slabs 812-26

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12.5.3.5 Grouting 8 12-26
12.5.3.6 8tability 812-26

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12.5.3.7 Erection Loads 812-26

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12.5.3.8 Lining and Leveling 812-27
12.5.3.9 8 ite Welding 8 12-27
12.5.3.10 8ite Bolting 8 12-27
12.5.3.1 1 Certification Of Completion 8 12-27
12.5.3.12 Drifts 812-28
S12- vi
12.6 PROTECTION OF STEELWORK AGAINST CORROSION S12-28
12.6.1 General S12-28
12.6. 1.1 Specification S12-28
12.6.1 .2 Method statement S12-29
12.6.1.3 Coating procedures S12-29
12.6.1.4 Transportation , handling and storage of coated S12-29
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steelwork
12.6.2 Surface Preparation S12-29
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12.6.2.1 Surface cleanliness S12-29
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12.6.2.2 Surface profile S12-29
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12.6.2.3 Measurement of surface profile S12-29
12.6.2.4 Surface defects S12-29

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12.6.3 Paint System S12-29
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12.6.3.1 Specification S12-30

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12.6.3.2 Materials S12-30
12.6.3.3 Surface Preparation prior to painting S12-31

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12.6.3.4 Painting of site weld areas and fasteners S12-31
12.6.3.5 Inspection of site applied coatings S12-32

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12.6.4 Construction and Workmanship S12-32

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12.6.4.1 Reference Specimen S12-32
12.6.4.2 Storage And Mixing Of Paint S12-32

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12.6.4.3 Application of Paint S12-32

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12.6.4.4 Working Condition S12-33
12.6.4.5 Thickness of Paint System S12-33
12.6.4.6 Adhesion and Cohesion S12-34
12.6.4.7 Stripe Coats S12-34
12.6.4.8 Coated Surfaces S12-34
S12- vii
12.6.4.9 Storage of Painted Steelwork S12-34
12.6.4.10 Cleaning Equipment S12-35
12.6.5 Metallic Coating S12-35
12.6.5.1 Sprayed Metal Coating Procedure S12-35
12.6.5.2 Reinstatement of damaged coating S12-35
12.6.5.3 Sealing before painting S12-35
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12.6.6 Hot Dip Galvanizing S12-35
12.6.6.1 Procedures S12-35
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12.6.6.2 Vent Holes S12-36
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n 12.6.7 Treatments for Connections and Other Special Areas S12-36
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12.6.7.1 Bolts S12-36
12.6.7.2 Surfaces of Connection Joined By Bolts S12-37

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12.6.7.3 Coating of Surfaces to Be Encased in Concrete S12-37
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12.6.7.4 Repairs to Damaged Surfaces S12-37

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12.6.7.5 Health and Safety S12-38
12.6.7.6 Protective Coatings to All Structural Steels S12-38

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812- viii
12.0 STRUCTURAL STEELWORK
12.1 GENERAL
12.1.1 Scope
This specification provides the generally applicable requirements and

compliances for steel and metal works for the design and construction of bridge
structures, road signage structures, road furniture and all related building and
structural components within the road projects. It is deliberately deals with the
steelwork designed in accordance to MS EN 1993 and BS 5950.
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This specification can be used for steel structures execution and construction
works designed for static and dynamically loaded structures particularly
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bridgeworks. It is however not advisably be used for structures subjected to
seismic excitation or under earthquake condition unless appropriate
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amendments are made.
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It is intended that this specification shall be fully enforced to the permanent or
final structures of the project. Nevertheless, it may also be applied to any
temporary works constituted intrinsically to the permanent structures subject to
the consent of S.O/P.O.
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The governing scope of this specification shall encompass of supply of
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materials, workmanship, handling and erection for construction all in
accordance with the lines and dimensions shown on the Drawings. In addition,
the protection of steelwork against corrosion shall be as specified herein.
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All materials shall be confirmed to the relevant Malaysian and/or British and/or
European Standards or equivalent Standards that may be accepted with the
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approval of S.O/P.O
Where applicable, all materials shall be subjected to provision of the CIDB Act
(Act 520) and/or other requirements of regulatory bodies imposed to the project
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as agreed by S.O/P.O.
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All processes, stages and parts of construction related to steelworks as within

the scope of the project shall herewith in this specification be called and
referred to the term of The Works.
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12.1.2 Safety and Health

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The Contractor or The Steelwork Subcontractor carrying out the Works shall
comply with all relevant regulations given in the Factories and Machinery Act
1967 (Act 139) and Occupational Safety and Health Act 1994 (Act 154).
51 2- 1
12.1.3 Quality Assurance
The Contractor shall have a management system to ensure that his

responsibilities for design, detailing, fabrication and erection of steel
components and structures conform to the requirements of the Contract and
this Specification.
The system shall cover all procedures including:
i) Project management and planning;

ii) Design control
iii) Documentation control
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iv) Material purchasing
v) Detail and shop drawings preparation and production
vi) Fabrication
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vii) Professional Engineer with Practicing Certificate (PEPC) endorsement
where applicable
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viii) Inspection and testing
n ix) Surface preparation and protective treatment
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x) Erection
xi) Safety and health
xii) Records and book keeping A
12.2 MATERIALS
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12.2.1 Structural Steel Sections

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12.2.1.1 Qualities
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Materials shall be steel in rolled sections, structural hollow

sections, steel strips, plates or bars and shall comply with the
appropriate standards shown in Table 12.1. All steel members
delivered to site shall have proper designation including
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standard code, strength grade and impact quality.

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All materials and products used for the construction produced

locally or that are being imported must be certified by standard
compliance issued by CIDB or other approved regulatory body
as agreed by S.O/P.D.
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12.2.1.2 Testing and Sampling

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All steel products for use in The Works shall have been
specifically tested in accordance with the appropriate materials
product standard shown in Table 12.1. All samples for testing
must be undertaken by accredited Conformity Assessment
Body (CAB) approved by local construction authorities CIDB or
as approved by S.O/P.D. The steel product manufacturer shall
declare the results using an inspection certificate type 3.1 to BS
EN 10204 or other approved type by established standards as
agreed by S.O/P.D.
812- 2
The Steelwork Contractor shall have access to the inspection
documents to BS EN 10204 provided by manufacturers of all
steel products used in the Works. If requested, the Steelwork
Contractor shall makes these inspection documents available to
the Engineer or Inspection Authority.
The sampling of the product for testing shall be in accordance

to relevant clauses of MS EN 10025 with regards to respective
materials and applications.
12.2.1.3 Dimensions and Tolerances
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Dimensions and tolerances shall comply with the appropriate
standard shown in Table 12.1. The maximum thickness of the
steel members shall always be within the limits as specified in
MS EN 1993 for every respective steel grad~ and corresponding
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yield strength or mentioned on the drawings.
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12.2.1.4 Surface Condition
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Steel surfaces when used shall not be more heavily pitted or
rusted than Grade C of BS EN ISO 8501-1.
Surface defects in hot rolled sections, plates and wide flats

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revealed during surface preparation which are not in
accordance with the requirements of BS EN 10163 shall be
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rectified accordingly.
Surface defects in hot finished hollow or tubular sections of non-

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alloy and fine grain steel revealed during surface preparation

which are not in accordance with the requirements of BS EN
10210-1 shall be rectified accordingly.
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Surface defects in cold formed hollow or tubular sections of non-

alloy and fine grain steel revealed during surface preparation
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which are not in accordance with the requirements of BS EN

10219-1 shall be rectified accordingly.
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12.2.2 Steel for Shear Connector

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Steel for headed stud type shear connectors shall have a minimum yield
strength of 350 N/mm 2 and minimum ultimate tensile strength of 450 N/mm 2 •
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Other proprietary type of stud may be used subjected to approval of S.O/P.D

accompanied with established standards and best practice.
Generally, shear studs shall be in accordance with BS EN ISO 13918.
12.2.3 Structural Fasteners
The Steelwork Contractor shall make declarations of conformity provided by

suppliers of structural fasteners available to the S.O/P.D. /P .D., upon
requisitioned.
S12- 3
If the fasteners are to be surface coated in accordance with clause 12.2.8 of
this specification then this shall be included in the declaration of conformity.
12.2.3.1 Ordinary or Non-Preloaded Assemblies
Ordinary bolt and nut (and washer if used) assemblies without

preloading shall be in accordance to Table 12.2. Reference shall
be made to the requirement of BS EN 15048 in case of any
deviation of the properties as given in Table 12.2.
12.2.3.2 Preloaded Assemblies
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Contractor shall provide the method of preloading and/or
tightening method for S.O/P.D approval prior to the
commencement of the assembly works .
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Preloaded assemblies connections, fasteners and High
Strength Friction Grip (HSFG) bolts shall be in accordance to
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BS EN 14399 and as given in Table 12.3. Pre loaded HV
() (Hochfest Vorgespannte Verbindung) system assemblies shall
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only be used if accompanied with established standard and
approval of S.O/P.D. HV and HR (High Resistance) systems
shall not be mixed in any application.
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Coefficient of friction of HSFG shall be in accordance to MS EN
1993-1-8 with minimum slip factor of 0.45. Other value may be
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used subject to S.O/P.D approval.
12.2.3.3 Foundation and Holding Down Bolt Assemblies

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Holding down bolt assemblies shall be in as given in Table 12.4.

Holding down bolt details shall include provision of loose cover
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plates or washers with hole diameter 3mm greater than the

holding down bolts.
12.2.3.4 Cup and Countersunk Bolts

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u Cup and Countersunk Bolts for non-preloaded assemblies shall

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be as given in Table 12.5. For preloaded assemblies, contractor

shall furnish with relevant established standard.
12.2.3.5 Washers
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If washers are used they shall be as given in Table 12.2.

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Nuts shall be at least the strength grade appropriate to the grade

of bolts, parent material of the components or other threaded
element with which they are used.
12.2.3.6 Lock Nuts for Bolts Assemblies
Lock nuts shall be in accordance to BS 4190.
S12- 4
12.2.3.7 Coating for Bolts Assemblies
If specific coatings are required, they shall be provided by the

fastener manufactures and shall comply with appropriate part of
BS 7371.
12.2.4 Welding Consumables
12.2.4.1 Standards
Consumables for use in metals arc welding shall comply with BS
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EN ISO 2560, BS EN 440, BS EN 756 or BS EN 758 as
appropriates.
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Welding consumables used for the fusion welding of steel
casting shall comply with BS 4570. BS EN1011 : Part 8: 2018
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Unless otherwise approved by the S.O/P.D. the welding
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consumables and procedures used shall be such that the yield
and tensile strength of deposited weld metal shall not be less
than the respective minimum values of the parent metal being
welded.
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12.2.4.2 Storage
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Consumables in the Steelworks Contractor's works and on-site,

shall be stored and handled in manner described in BS EN
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1011-1 and in accordance with the relevant standard or

approved manufacturer's instructions. Any drying or baking
consumables before issued shall be carried out in accordance
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with the manufacturer's recommendations.
12.2.5 Steel Castings and Forgings

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Steel castings and forgings shall be in accordance to BS 3100 and BS

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EN 10250: Part 2 respectively and shall only be used when such material is
unlikely to be detrimentally affected by the process.
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12.2.6 Stainless Steel

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Stainless steel shall comply with the requirements of MS 2240 or either BS EN

10088: 2014 or BS ISO 16143: 2014 as appropriate. The constituted material
shall normally be of the 16% to 19% chromium and 8% to 12% nickel austenitic
type .
12.2.7 Cast Iron
Grey cast iron shall comply with grade 10 of BS EN 1561: 2011 except that
when stronger cast iron is required for special purpose it shall comply with a
higher grade of BS EN 1561 : 2011 as specified on the Drawing.
S12- 5
Malleable cast iron shall comply to BS EN 1562: 2019 or grade B340/12 or
B31 0/10, as appropriate.
Spheroidal or nodular cast iron shall comply with the requirements of BS EN

1563: 2018 for the grade specified .
12.2.8 Protective Treatment Materials
12.2.8.1 Metallic Blast Cleaning Abrasive
Chilled iron shall be in accordance with BS EN ISO 11124-2,
ER
and cast steel grit shall be in accordance with BS EN 1124-3
12.2.8.2 Surface Coating
D
Paint materials and other coatings supplied shall be in
N
accordance with the appropriate British Standard for material as
n speCified in clause 12.6.3 of this specification.
TE
12.2.8.3 Sherardized Coatings
Sherardized coatings shall in accordance with BS 7371 -8. The

A
thickness of the coating needs to be specified.
EJ
12.2.8.4 Galvanizing Materials
The composition of zinc in galvanizing baths shall be in

M
accordance with BS 7371-6.
12.2.8.5 Electrodeposited Coatings

EN
Electrodeposited coatings shall be in accordance with BS EN

ISO 4042. The thickness of the coating needs to be specified.
M
u 12.2.9 Proprietary Items

KU
All proprietary items shall be used in accordance with the manufacturer's

recommendations and instructions. Contractor shall furnish S.O/P.D with
O
related approval prior commencement of any works .

D
12.3 INSPECTION AND TESTING
12.3.1 Surface Defects and Edge Laminations
Steelwork shall be inspected for surface defects and exposed edge lamination
during fabrications and blast cleaning . Significant edge laminations found shall
be rectified.
Affected area shall be rectified and tested to the satisfaction of the S.O/P.D.
S12- 6
12.3.2 Procedure Trials for Testing Of Welding For Structural Steels
12.3.2.1 Non-Destructive Testing of Welds
The scope of inspection given here is intended to ensure that

the Steelwork Contractor can maintain welding processes at an
accepted standard which is generally suitable for structural
steelwork. The Engineer should check that any additional
project-specific requirements for non-destructive testing of
welds are clearly specified in the Project Specification. BS
5950-2 Annex A may be used as a reference for identifying
ER
critical welds which may require additional inspection .
(a) Scope of Inspection
D
Visual inspection of all welds shall be carried out and if all of
N
the following conditions apply, further non-destructive
testing is NOT mandatory: ()
TE
i. the "connection" is fillet welded
ii. the leg length of the fillet weld is not greater than
10mm
A
iii. the greatest component thickness is not greater than
20mm.
EJ
If these conditions are not met, the scope of inspection shall

be in accordance with Table B of Annex B.
M
If a workshop is only producing work where all these

conditions are met, then a monthly programme of further
EN
non-destructive testing shall be instituted by the person

responsible for welding coordination such that a
representative sample of each month's output is subjected
to appropriate non-destructive testing (NDT).
M
Conversely, if testing indicates that weld quality problems

KU
have occurred (in similar materials, assembly methods or

welding procedures) non-destructive testing requirements
should be increased and should be extended to non-
mandatory components.
O
Note: With the exception of the frequency attesting in Table

D
B, unless altered by the Project Specification these

requirements make no distinction between shop and site
welds. Inspection requirements may be reduced at the
Engineer's discretion, based upon satisfactory performance
in the initial production.
(b) Record of Testing
The results of visual inspection, surface flaw detection and

ultrasonic testing shall be recorded and be available for
inspection.
S12- 7
(c) Visual inspection of welds
100% visual inspection shall be carried out during welding

and on completion to determine the production quality is
being maintained. Unless specified in the Project
Specification, visual inspection shall be carried out in
accordance with the guidelines given in Annex 0 of this
specification.
ER
A suitably qualified person for visual inspection of welds
may be a welding inspector or a welder who can provide
evidence of having been trained and assessed for
competence in visual inspection of the relevant types of
D
welds during and after welding .
N
The quality level shall be in accordance with the levels given
n in Annex C of this specification and the Project
TE
Specification. All imperfections identified shall be assessed
in accordance with the required quality level to determine
the need for corrective and preventive action.
A
Any welds which will be rendered inaccessible by
subsequent work shall be examined in accordance with
EJ
Annexes A to 0 prior to the loss of access.
(d) Hold times before final NOT

M
If there is a risk of delayed cracking, a period may be needed

before the final inspection is made of as welded fabrications.
EN
Recommended minimum hold times are given in Annex A.
Whatever hold time period is used shall be stated in the

inspection records. If it can be demonstrated by the
M
Steelwork Contractor through records that delayed

u hydrogen cracking is not a risk, hold times may be reduced
KU
or waived at the discretion of the S.O/P.O.
Note: Notwithstanding the use of waivers or hold times,

whether in accordance with Annex A or otherwise, Annex C
O
requires that all identified cracks shall be repaired.

D
(e) Surface flaw detection
If a closer examination of a weld surface is required in

accordance with Annex B, magnetic particle testing shall be
used in accordance with the recommendations given in BS
EN 1290 and this shall be proceeded by visual inspection to
BS EN 970 undertaken by the NOT technician.
If magnetic particle testing is impractical, penetrant testing

may be used in accordance with the recommendations
given in BS EN 571 -1.
812- 8
Final surface flaw detection of a welded joint shall be carried
out after completion of the weld in accordance with the hold
times given in Annex A of this specification.
A suitably qualified person for surface flaw detection of

welds may be a welding inspector or a welder who holds a
current certificate of competence in surface flaw detection
of the relevant types of work, from a nationally recognised
authority (PCN, CSWIP or equivalent).
Note: If a welding procedure requires an inspection after

initial weld runs before further welding is performed, such
ER
inspections may be carried out when the weld metal has
cooled to ambient temperature.
(f) Ultrasonic testing
D
If ultrasonic testing is required in accordance with Annex B
N
of this specification, it shall be made in accordance with BS 0
EN 1714 using reference level to Method 1, evaluation
TE
reference level -14dB (20% DAC) and examination level B
unless agreed otherwise by the S.O/P.O.
Ultrasonic testing of a welded joint shall be carried out after

A
completion of the weld in accordance with the hold times
given in Annex A of this specification.
EJ
Persons carrying out final ultrasonic testing of the weld shall

hold a current certificate of competence from a nationally
M
recognised authority (PCN, CSWIP or equivalent).
Note: In addition to weld testing, through-thickness

EN
ultrasonic testing of the parent material may also be

necessary for weld geometries susceptible to lamellar
tearing.
M
(g) Acceptance criteria and corrective action

J
KU
Acceptance criteria, corrective action and re-testing shall be

in accordance with Annex C and the related Table of the
Annex for components subject to static loading. It is not
O
applicable for structures subjected to dynamic loading .

D
If non -conforming welds are identified the scope of

inspection shall be increased until the source of the defects
is established and rectified.
12.3.2.2 Weld Metal and Heat Affected Zone (HAZ) Charpy V-Notch
Impact Test Requirements for Tension Areas
The fusion boundary region of the HAZ of butt welds, including

corner of T-butt welds, which are transverse to and carry the
main tension stress shall have the notch ductility requirements
given in Table 12.6
S12- 9
12.3.2.3 Testing Of Welding For Cast Steel
Non-destructive and destructive testing of welding shall comply

with the requirements of BS EN 1011 Part 8: 2018
12.3.2.4 Stud Shear Connectors
(a) Tests and inspection
All studs are to be visually inspected and ring tested.

Studs shall be replaced if they show less than a full 360 0
collar of weld or if they do not give a clear ring when struck
ER
by a metal club hammer.
After satisfactory visual inspection and ring testing. bend

tests shall be made at locations agreed with the S.O/P.D.
D
A minimum of 5% of the studs, but not less than two studs
per beam shall be tested by bending the head of the stud
N
towards the nearer end of the beam. In addition, the studs
n immediately adjacent to any stud found to be defective
TE
shall be subjected to bend testing .
The bend test shall be made by means of a steel tube

placed over the stud and bending the head until it is
A
displaced laterally a distance of one quarter of the height
of the stud. The stud weld shall not show any signs of
EJ
cracking or lack of fusion.
Studs subjected to the bend test shall not be straightened.

M
(b) Defective studs

EN
Studs with defective welding or that have failed the bend test
shall be replaced with a new stud in an adjacent location. The
replacement stud shall be inspected, ring tested and tested by
bending it towards the defective stud. The defective stud shall
M
be removed from its position by cutting it off from its original

position. The defective stud may be left in place subjected to
KU
S.O/P.D approval.
12.3.3 Production Tests

O
D
12.3.3.1 Requirements for Destructive Testing Of Welding For

Structural Steel
(a) Production Test Plates
Unless otherwise specified on the Drawing, one in five pairs of

'run-off' plates for transverse butt welds in tension flanges and
one in 10 pairs for other butt welds shall be production test
plates. The combined size of each pair of production test plates
shall be adequate for the number and size of specimens to be
tested. The material shall be clamped in line with the joint. The
grade and quality of material, carbon equivalent, and rolling
812- 10
direction shall match the parent plate, but need not be cut from
the same plates' or cast. On the completion of the welds the
'run-off' production test plates shall not be removed until they
have been marked in manner, agreed by the S.O/P.D., to
identify them with the joints to which they are attached.
(b) Testing
The following tests as described in BS 709 shall be carried out

on the production test plates and shall comply with:-
ER
i. Transverse Tensile Test
One transverse tensile test comprising sufficient specimens
D
to cover the full plate thickness shall be made and the
tensile strength shall be not less than the corresponding
N
specified minimum value for the parent metal.
TE
If any specimen fails to meet the test requirement then a
further test shall be made from the same production test
plate. If any specimen from this further test fails to meet the
test requirement then the joint shall be rejected .
A
ii. Bend Test
EJ
For material less than 10mm in thickness one transverse

root bend test and one transverse face bend test shall be
M
made. For material 10mm in thickness and over, one site

bend test comprising sufficient specimens to cover the full
plate thickness shall be made. The diameter of the former
EN
and the angle bend used in the test shall comply with the
requirements of the BS EN 15614 Part 1: 2017 & Part 2:
2005
M
On completion of bending any defects in tension surface of J

the test specimen shall be investigated and their cause
KU
established before the specimen is either accepted or

rejected. Slight tearing at the edges of the test specimen
shall not be a cause for rejection.
O
If any specimen fails to meet the test requirement then a

D
further test shall be made from the same production test

plate. If any specimen from this further test fails to meet the
test requirement then the joint shall be rejected .
iii. Charpy V-notch Impact Test
Charpy V-notch impact test shall be made on weld metal in

butt welds transverse to and carrying the main tension
stress. Additionally where specified on the Drawing, Charpy
V-notch impact tests shall be made on the fusion boundary
region of the heat affected zone (HAl) and shall comply
with clause 12.4 of this specification where related .
S12-11
(c) Re-welding and Re-testing
In the event offailure to meet the test requirements of (a) or/and

(b) of the above, the Contractor shall carry out further trials
using revised procedures and further tests to the satisfaction of
the S.O/P.O.
Rejected joints shall be cut out in a manner approved by the

S.O/P.D. and the re-welded as well as the tests shall be
repeated.
12.3.3.2 Non-destructive Testing Of Welding For Structural Steel
ER
Where specified non-destructive testing of the following welds shall be
carried out using X-Ray method of other approved by the S.O/P.O.
D
(a) all transverse butt welds in tension flanges;
(b) 10% of the length of longitudinal butt welds in tension flanges;
N
(c) 5% of the length of longitudinal and transverse butt welds in
() compression flanges;
TE
(d) all transverse butt welds in webs adjacent to tension flanges as
specified on the Drawing .
In the case of (b) and (c) the particular length of welds to be tested shall
A
be agreed with the S.O/P.D.
EJ
Any lamination, lamellar tearing or other defect found shall be recorded

and reported to the S.O/P.D. The Contractor shall carry out the remedial
action as approved by the S.O/P.D.
M
12.3.3.3 . Testing Of Welding For Cast Steel

EN
The testing of welding for cast steel shall comply with the requirements
of BS EN 1011 Part 8: 2018.
12.3.3.4 Stud Shear Connectors

M
l) Stud shear connectors shall be subjected to the following tests:-

KU
(a) The fixing of studs after being welded in position shall be tested to
the satisfaction of the S.O/P.D. by striking the side of the head ofthe
O
stud with a 2 kg hammer.
(b) Any stud selected by the S.O/P.D. shall be capable of being bent by
D
striking the side of the head of the stud with 6 kg hammer until its
head is displaced laterally a distance of approximately 0.25 times
the height of the stud from its original position. The stud weld shall
not show any signs of cracking or lack of fusion. Satisfactory studs
shall not be bent back again.
Studs whose welds have failed the test given in (a) and (b) or which
do not comply with the requirements of 12.3.2 shall be replaced
according to a procedure approved by the S.O/P.O.
S12- 12
12.3.3.5 Checking Of Alignment at Joints
The alignment of plates at all bolted splice joints and welded butt
joints shall be checked for compliance with the requirements of
12.3.2.
12.3.3.6 Temporary Erection at Contractor's Works
Where specified, steelwork shall be temporarily erected at the

Contractor's Works .
ER
12.4 WORKMANSHIP
12.4.1 Identification
D
12.4.1 .1 Traceability of steel products
N
All steel products to be used shall have a reference to a suitable
TE
declaration and certificate of conformity so that the properties
are known and can be verified. Unless required by the Project
Specification individual pieces do not need to be traceable to a
particular inspection document.
A
12.4.1.2 Material grade identification
EJ
The material grade, quality and other relevant properties shall

be identifiable within the manufacturing system.
M
12.4.1 .3 Marking steelwork

EN
Individual pieces shall be capable of positive identification at all

stages of fabrication . Completed components shall be marked
with a durable and distinguishing erection mark in such a way
M
as not to damage the material. Hard stamping may be used for

steel grades up to and including S355.
KU
Where areas of steelwork are indicated on the drawings, or

fabrication information, as being unmarked, they shall be left
free of all markings and hard stamping.
O
12.4.1.4 Interchangeability of Parts

D
Unless specified on the Drawing, corresponding steel parts

need not be interchangeable.
12.4.2 Tolerances and Accuracy of Fabrication
All parts in assembly shall fit together accurately within the tolerance as
specified in Table 12.7.
512- 13
12.4.2.1 Permitted Deviations
Permitted deviations in cross section, length, straightness,

flatness , cutting , holing and position of fittings shall be as
specified in:
(a) Table 12.9 - Permitted Deviations For Rolled Components

After Fabrication (6) (including structural hollow sections)
(b) Table 12.10 - Permitted Deviations For Elements for
Fabricated Components (6)
(c) Table 12.11 - Permitted Deviations For Plate Girder Sections
(6)
ER
(d) Table 12.12 - Permitted Deviations For Box Sections (t.)
12.4.2.2 Alignment at Splices and Butt Joints
D
(a) Bolted Splices
N
Where necessary, all bolted splices shall be provided with steel
n packing plates of similar parent material to ensure that the sum
TE
of any unintended steps between adjacent surfaces does not
exceed 1 mm for pre loaded bolted joints and 2 mm for other
joints.
A
If plies of differing nominal thickness are being joined , no more
than three packing plates shall be used.
EJ
(b) Welded Butt Joints

M
Any unintended deviation from planarity due only to a

misalignment of parts to be jointed or, if, due either to different
thickness arising from rolling tolerances or a combination of
EN
rolling tolerances with the above permitted misalignment, the

deviation shall no exceeds that in Annex C of this specification.
M
12.4.3 Preparation of Edge, Ends and Surfaces

u
KU
Cut edges shall be dressed to remove dross, burrs, and irregularities. Holes
shall be dressed as required to remove burrs and protruding edges.
O
12.4.3.1 Edges
D
Edges shall be either:
(a) Left as rolled, sawn, machined, machine flame cut; or
(b) hand flame, cut with subsequent grinding to smooth profile;

or
(c) for stiffeners and gussets, both not more than 12 mm thick,
sheared and subsequently ground to a smooth profile.
Sharp edges shall be dressed, but a 90° rolled, cut, sheared or

machined edge is acceptable without further treatment.
812- 14
12.4.3.2 Ends
Ends shall be either:
(a) Sawn, machined, machine flame cut; or
(b) hand flame cut with subsequent grinding to a smooth

profile; or
(c) for stiffeners, of not more than 12mm thick, sheared and
subsequently ground to a smooth profile.
ER
If ends of stiffeners are required to be fitted they shall be
ground where necessary, so that the maximum gap over 60%
of the contact area does not exceed 0.25 mm.
D
12.4.4 Cutting and Shaping
N
TE
12.4.4.1 Cutting Operations
Cutting and shaping of steel may be carried out by sawing,

shearing, cropping , thermal cutting, nibbling, planning or
A
machining. Hand-held cutting shall only be used if it is
impractical to use machine thermal cutting.
EJ
Any areas where thermal cutting is not permitted or where the

manufacturing processes must be restricted including locations
M
where holes cannot be punched e.g. plastic hinge positions,

they .shall be so indicated in the Project Specification .
EN
Thermally-cut edges which are free from significant irregularities

shall be accepted without further treatment except for the
removal of dross. Otherwise cut edges shall be dressed to
remove irregularities.
M
Note: Thermal cutting refers to plasma cutting, laser cutting or

KU
flame cutting.
12.4.4.2 Columns and compression members

O
Columns and compression members with ends not in direct

bearing or intended to be erected on packs shall be fabricated
D
to the accuracy given in related clause of Table 12.9 and Table

12.10 respectively.
Columns and compression members intended to be in direct

bearing shall be fabricated to the accuracy given in related
clauses of Table 12.13 and Table 12.14 respectively.
The butting surfaces of column sections regardless of any

member shape which are one metre and over in width or depth
and are to be in direct bearing shall be specially prepared so
that after erection both the deviation in vertical plumb and the
812- 15
permitted gap that are given by related clause of Table 12.15
are not exceeded .
12.4.5 Machining
The thickness of machined parts shown on the drawings as requiring machining

shall mean the minimum thickness after the machining operations.
Where machining of surfaces at butted joints is specified, the abutting ends of

the parts shall be machined after the members have been fabricated .
ER
Outside arises of plate and sections, which are to receive corrosion protection,
shall be smoothed by grinding or filing.
D
12.4.6 Assembly
N
n Connected components shall be drawn together such that they achieve firm
contact consistent with the requirements for fit-up or direct bearing.
TE
Drifting of holes to align the components shall be permitted, but must not cause
damage or distortion to the final assembly.
A
12.4.7 Curving and Straightening
EJ
Curving or straightening components during fabrication, shall be performed by

one of the following methods:
M
(a) mechanical means, taking care to minimise indentations, or change of

cross-section
EN
(b) the local application of heat, ensuring that the temperature of the metal
is carefully controlled , and does not exceed 650°C
M
(c) the induction bending process if the procedure used includes careful
l) temperature control and the procedure is validated beforehand in
KU
terms of its ability to retain suitable properties for the as-bent material.
After curving or straightening, welds within the area of curving or straightening

shall be visually inspected . Welds which are to be subject to non-destructive
O
testing shall have these tests carried out after curving or straightening.
D
12.4.8 Inspection
Sufficient components shall be checked for dimensional accuracy and

conformity to drawing, to prove that the manufacturing process is working
satisfactorily. Any defects beyond acceptable limits shall be rejected . Record
of inspections must be accompanied with the batches prior to transporting to
site.
S12- 16
12.4.9 Storage
Fabricated components which are stored prior to being transported or erected

shall be stacked clear of the ground and arranged if possible so that water
cannot accumulate. They shall be kept clean and supported in such a manner
as to avoid permanent distortion.
Individual components shall be stacked and marked in such a way as to ensure

that they can be identified.
12.4.10 Bolting
ER
12.4.10.1 Ordinary (Non-Preloaded) Assemblies
(a) Bolt/Nut Combinations
D
The combinations of bolts and nuts which may be used are
N
as tabulated in Tables 12.2.and 12.3.
TE
Galvanised or sherardized bolts in grade B.B or 10.9 shall be
fitted with higher grade/class nuts as tabulated in Section
12.2
A
Any bolt assemblies which seize when being tightened shall
be replaced.
EJ
Different bolt grades of the same diameter shall not be used

in the same structure, except if agreed otherwise by the
M
S.O/P.D
Note: The pre-/oadab/e fasteners in Tab/e 12.4 may be used

EN
in non-pre/oaded applications
(b) Cup and countersunk head bolt assemblies

M
The combinations of bolts and nuts which may be used are

tabulated in Table 12.5.
KU
(c) Bolt Length

O
The bolt length shall be chosen such that, after tightening, at

least one thread plus the thread run-out will be clear between
D
the nut and the unthreaded shank of the bolt and at least one
clear thread shall show above the nut.
(d) Washers
If the components being connected have finished surface

protective treatment which may be damaged by the nut or
bolt head being rotated , a washer shall be placed under the
rotating part.
Where necessary, steel washers shall be provided to prevent

the nut binding on the shank of the bolt. Where the full
bearing area of the shank of the bolt is to be developed, the
512- 17
threaded portion of the bolts shall not extend within the
thickness of the connected parts.
For turned barrel bolts, steel washer with true bearing faces
shall be provided under the nut. The washer shall be as
tabulated in Table 12.2 and 12.3.
If the bolt head or nut is in contact with a surface which is

inclined at more than 30 from a plane at right angle to the
bolt axis, a taper washer shall be placed to achieve
satisfactory bearing.
ER
(e) Galvanized nuts
Nuts shall be checked after being galvanized for free running

on the bolt and re tapered if necessary.
D
(f) Bolt tightening
N
n Bolts may be assembled using power tools or shall be fully
TE
tightened by hand using appropriate spanners in accordance
with BS 2583: 2016.
(g) Fitted bolts

A
Precision bolts to BS 3692 may be used as fitted bolts if holes
EJ
drilled or reamed after assembly so that the clearance in the

hole is not more than 0.3mm.
M
12.4.10.2 Holes for Bolts
(a) Holes
EN
Round holes for fasteners or pins shall be drilled, punched

or plasma cut as given in clause 12.4.4 of this specification
where related .
M
u Any areas where thermal cutting or full size hole punching is

KU
not permitted or where the manufacturing processes must be

restricted including locations where holes cannot be
punched e.g. plastic hinge positions, they .shall be so
indicated in the Project Specification.
O
(b) Matching
D
All matching holes for fasteners or pins shall register with

each other so that fasteners can be inserted freely through
the assembled components in a direction at right angles to
the faces in contact. Drifts may be used but holes shall not
be distorted.
(c) Drilling through more than one thickness
If the separate parts are tightly clamped together drilling shall

be permitted through more than one thickness. The parts
shall be separated after drilling and any burrs removed .
812- 18
(d) Punching full size
Full size punching of holes shall be permitted if all the

following conditions are satisfied:
i. the tolerance on distortion of the punched hole does not

exceed that shown in Table 12.10.
ii. the holes are free of burrs which would prevent solid
seating of the parts when tightened;
ER
iii. the thickness of the material is not greater than 30mm for
material up to S355, not greater than 10mm for higher
grades, nor greater than the diameter of the hole being
punched;
D
iv. the holes in mating surfaces in spliced connections are
N
punched in the same direction and the splice plates
marked to show the assembly faces, if packed separately. ()
TE
(e) Punching and reaming
Punching is permitted provided that the holes are punched

A
at least 2mm less in diameter than the required size and the
hole is reamed to the full diameter after assembly.
EJ
(f) Slotted holes

M
Slotted holes shall be punched, thermally-cut or formed by

drilling two holes and completed by cutting.
12.4.10.3 Fit-up Using Non-Preloaded Bolt Assemblies
EN
(a) Fit-up
M
Connected parts shall be firmly drawn together. If there is a

remaining gap which may affect the integrity of the joint, it
shall be taken apart and pack inserted. J
KU
(b) Reaming
O
If parts cannot be brought together by drifting without

distorting the steelwork, rectification may be made by
D
reaming, provided the design of the connection will allow the

use of larger diameter holes and bolts.
12.4.10.4 Preloaded Assemblies
(a) Bolt/nut/washer Combinations
The combinations of bolts and nuts and washer may be used

as specified in Tables 12.3. The hardened washer is to be
placed under the nut or head being turned.
S12- 19
(b) Other Preloaded Assemblies
The combinations of preloaded assemblies other than those

tabulated in Tables 12.3 are to be in accordance with the
manufacturer's recommendations.
(c) Tightening
The used of preloaded fasteners in normal and high strength

friction grip applications shall be with B8 4604 Part 1 and 2.
Tightening which complies with B8 4604 PI. 1 may be by the
ER
torque control method, part-turn method, or direct tension
indicators used in accordance with the manufacturer's
recommendations.
D
(d) Calibration of Torque eqUipment
N
Torque spanners and other devices shall have a calibration
check at least once per shift, and shall be re-elected if
TE
necessary in accordance with B8 4604.
(e) Discarded Bolt Assemblies

A
If, after complete tightening , a bolt or nut has to be slackened
off, the whole bolt assembly is to be scrapped.
EJ
12.4.10.5 Fit-up Using Preloaded Bolt Assemblies

M
(a) Fit-up
Connected parts intended to transfer force in friction shall be

EN
firmly drawn together with all bolts partially tightened. The

jOint shall be examined and if there is any remaining gap
which may affect the integrity of the joint, it shall be taken
apart and a pack inserted before recommencing the
M
tightening procedure.
()
KU
(b) Reaming
If parts cannot be brought together by drifting without

distorting the steelwork, rectification may be made by
O
reaming, provided the design of the connection will allow the

use of larger diameter holes and bolts.
D
Calculation shall be made to demonstrate that the

connection remains adequate for the forces in the
connection.
12.4.11 Welding
Welding shall be a metal arc process in accordance with B8 EN 1011-1, the

guidance given in B8 EN 1011-2 as appropriate, together with other clauses
812- 20
contained in this section, unless otherwise specifically permitted by the
S.O/P.D.
Joints shall be prepared in accordance with BS EN ISO 9692-1 and -2.

Precaution shall be taken to ensure cleanliness of the joint prior to welding .
12.4.11 .1 Welder Qualification Testing and Certification
Welders shall be tested to meet the requirement of BS EN 287-

1.
As an alternative, if permitted by the S.O/P.D., welders may be
ER
tested to meet the requirements of the American Society of
Mechanical Engineers, ASME IX, or the American Welding
Society, AWS 01.1
D
Welder testing shall be witness and certificates endorsed by a
competent
N
Examiner or Examining Body.
TE
The certification shall remain valid providing it complies with the
conditions for re-approval of certification specified in BS EN 287-
1
A
12.4.11.2 Welding Procedures
EJ
Written welding procedure specifications (WPSs) shall be

available in accordance with BS EN ISO 15609-1, and tested in
accordance with BS EN ISO 15614-1 by the Steelwork
M
Contractor. They shall comply the guidance of BS EN 1011-2

Annex C, Method A to avoid hydrogen cracking, and Annex 0
to provide adequate toughness in the heat affected zone .
EN
a) Assembly
M
Fit -up
Joints shall be fitted up to the dimensional accuracy required by

KU
the welding procedure, depending on the process to be used, to

ensure that the quality given in Annex C of this Specification is
achieved.
O
Jigs
D
Fabrications assembled in jigs may be completely welded in the

jig, or may be removed from the jig after tack welding.
Tack welds
Tacks may be used provided:
i. they are laid in an area to be welded and are thoroughly

removed by grinding or gouging such that subsequent
welding is unaffected; or
812-21
ii. they are undertaken by a welder qualified as in 12.3.6.1 as
short length normal welds of a length at least four times the
thickness of the thicker part being joined and at least 50mm
long, and the procedure for welding complies with 12.3.6.2;
or
iii. they are subsequently fully re-melted using a welding

procedure that compiles with 12.3.6.2 and that
demonstrates that the tack is fully re-melted during
subsequent welding ; or
iv. they are located away from zones where subsequent
ER
welding is to take place and in a zone where only
compressive forces are present in service.
Distortion control
D
The sequence of welding a joint or a sequence of joints shall be
N
such that distortion is minimised.
TE
b) Fabrication or erection attachments
Welding of attachments required for fabrication or erection

purposes shall be made in accordance with the requirements for
A
a permanent weld.
EJ
If removal is necessary, they shall be flame cut or gouged at a

point not less than 3 mm from the surface of the parent material.
The residual material shall be ground flush and the affected area
M
visually inspected. If parent metal thickness is greater than 20

mm it shall also be checked by penetrant testing. Acceptance
criteria are as set out in Annex C of this specification.
EN
Attachments shall not be removed by hammering. Details of

holes and fittings in components necessary for safety or to
M
provide lifting and erection aids shall be included. Unless

specified otherwise by the Project specification, such holes and
fittings may remain on the permanent structure. Account shall
KU
be taken when detailing the welding of temporary attachments.
c) Extension pieces
O
If the profile of a weld is maintained to the free end of a run by

the use of extension pieces they shall be of material of a similar
D
composition, but not necessarily the same grade, as the

component. They shall be arranged so as to provide continuity
of preparation and shall be removed after completion of the weld
and the end surface of the weld ground smooth.
12.4.11 .3 Welding of Steel Castings
Unless otherwise specified on the Drawing, fusion welding of

steel castings shall comply with requirements of BS EN 1011
Part 8: 2018
812- 22
The proposed welding procedures shall be submitted in writing ,
in accordance with the requirements of either BS 4570: Part 1
or BS EN 1011 Part 8: 2018, for approval of the S.O/P.O before
commencing welding of steel castings. No departures from the
agreed welding procedures or from the details shown on the
Drawings shall be made without the approval of the S.O/P.D.
12.4.12 Shear Stud Welding
12.4.12.1 Method
ER
Shear studs shall be welded in accordance with the
manufacturer's recommendations for materials, procedures and
equipment. Adequate return earth connections shall be made
D
local to the area being stud welded.
N
If the studs are to be welded by other than drawn arc stud
welding, then the size of the fillet weld used shall be checked for
TE
compliance with the Project Specification.
The local area around where the stud is to be welded shall be

free of standing water before commencement of welding.
A
Note: See the BCSA Code of Practice for Metal Decking and
EJ
Stud Welding for further guidance.
12.4.12.2 Trial welding

M
If specified by the Engineer and before production welding of

studs commences, procedure trials shall be carried out. The
EN
trials shall be made on samples of material and studs

representative of those to be used in the work.
Any special welding procedures (such as for non-standard joint

M
types, or for restricted access situations) which have to be

approved prior to the work commencing is required a trial
KU
welding.
At the start of each shift when stud welding is in progress each

welder shall perform the fixing of at least two trial studs. If either
O
of these trial Studs fails a bend test in then further trials shall be
conducted until satisfactory performance is established.
D
12.4.13 Forging
Forging shall be carried out in such a manner that it will not impair the
strength of the metal.
12.4.14 Tie Rods

Tie rods with upset ends and plus threads and tie rods with forged eyes
shall be formed by being pressed up in a die or by another method
approved by the S.O/P.D. Where agreed by the S.O/P.O, suitable
8 12- 23
designed flame cut of forged eyes of machined stud ends may be metal-
arc welded or resistance welded to the rods. Hot forming shall be
carried out in such a way that it will not impair the strength of the metal.
12.4.15 Parallel Barrel Drifts
The barrel shall be drawn or machined to the required diameter for a

length of not less than one diameter over the combined thickness of the
metal through which the drift has to pass. The diameter of the parallel
ER
barrel shall be equal to the nominal diameter of the hole subject to a
tolerance of -0.05mm to -0.20mm. Both ends of the drift, for a length
equal to 1.5 times the diameter of the parallel portion of the bar, shall
D
be turned down with a taper to a diameter at the end equal to 0.5 times
that of the parallel portion.
N
n 12.4.16 Pins and Pin Holes
TE
Pins shall be parallel throughout and shall have smooth surface free
from flaws. They shall be of sufficient length to ensure that all types
connected thereby will bear fully on them . Where ends are threaded
A
they shall be turned to a smaller diameter and shall be provided, where
necessary, with a pilot nut to protect the thread.
EJ
The pin holes shall be bored smooth, straight and true to gauge and at
right angles to the axis of the member. Boring shall be done only after
M
the member is finally bolted or welded unless otherwise agreed with the
S.O/P.D.
EN
For pins up to and including 250mm diameter, the diameter of the pin
shall be within a tolerance of -O.25mm to -0.40mm and the diameter of
the pin hole shall be within a tolerance of 0 mm to +0.15mm.
M
For pins exceeding 250mm diameter, the clearance between the pin
and the pin hole shall be not less than 0.40mm and not more than
KU
0.75mm.
12.4.17 Camber
O
Unless otherwise specified, camber may be formed by connecting

D
straight sections of girder with change of slope at their junctions.
12.4.18 Rectification of Surface Defects and Edge Laminations
Surface defects revealed during fabrication or blast cleaning shall be

treated in accordance with the requirements of BS 4360 BS EN 10210
Part 1: 2006. Repair by welding of any surface defect or exposed edge
lamination shall only be carried out with the approval of the S.O/P.D.
and using a procedure complying with BS 5135. BS EN 1011 Part 1:
2018 & Part 2: 2005
812- 24
12.5 HANDLING, TRANSPORT AND ERECTION
12.5.1 Handling
Steelwork shall be bundled, packed, handled and transported (as appropriate)

in a safe manner-so that permanent distortion does not occur and surface
damage is minimised. Particular care shall be taken to stiffen free ends and
adequately protect any machined surfaces.
12.5.1.1 Handling and storage
ER
Components shall be handled and safely stacked in such a
manner as to minimise the risk of surface abrasion and damage.
Fasteners and small fittings shall be stored under cover in dry
D
conditions.
N
12.5.2 Packing for Transport
TE
All work shall be protected from damage in transit. Particular care shall be taken
to stiffen free ends and prevent permanent distortion and adequately protect all
machined surfaces. All bolts, nuts, washers, screws, small plates and small
A
articles generally shall be suitably packed and identified.
EJ
12.5.3 Erection
12.5.3.1 Erection method statement

M
The Steelwork Contractor shall prepare a written method

statement in accordance with the Construction (Design and
EN
Management) (COM) Regulations.
Erection shall not commence before the method statement has

M
been accepted by the S.O/P.D.
Note: Further guidance is available in the BCSA Codes of J

KU
Practice for Erection.
12.5.3.2 Provision of setting-out lines by the employer

O
The Employer shall establish and maintain a system for setting

D
out the building in accordance with BS 5964-1. Deviations in the

position of foundation supports for The Works shall be
measured relative to this system.
12.5.3.3 Damaged steelwork
Any steelwork damaged during off-loading, transportation,

storage or erection shall be restored to conform to the standards
of manufacture as given in this specification.
12.5.3.4 Column base plates and slabs
812- 25
Steel packs shall be supplied to allow the structure to be
properly lined and levelled and of sufficient size to avoid local
crushing of the concrete .
Base packs shall be placed so that they do not prevent

subsequent grouting to completely fill all spaces directly under
the base plates.
Base packs may be left permanently in place.
12.5.3.5 Grouting
ER
Grouting shall not be carried out under column base plates until
a sufficient portion of the structure has been aligned, levelled,
plumbed and adequately braced.
D
Immediately before grouting, the space under column base
plates shall be clean and free of all extraneous malter.
N
n 12.5.3.6 Stability
TE
(a) Temporary restraints until permanent features are built
The Engineer shall advise the Steelwork Contractor of

A
positions on the structure where temporary bracing,
metal decking or other restraints are needed to provide
EJ
stability to individual components or the structure until

walls, floors or other non-steel structures are in position.
M
The Steelwork Contractor shall design and provide the

temporary bracing or restraints. The Engineer shall
provide sufficient information to enable the Steelwork
EN
Contractor to design the necessary temporary works .
(b) Other temporary restraints used by Steelwork Contractor

M
If the Steelwork Contractor uses temporary restraints

U during erection which do not substitute for permanent
KU
features, they may be removed after the structure has

been lined, levelled and plumbed provided that sufficient
steelwork and/or permanent bracing has been erected to
O
ensure the stability of the structure under the worst

expected conditions of dead, imposed and wind loading.
D
12.5.3.7 Erection Loads
The Steelwork Contractor shall ensure that no part of the

structure is permanently distorted by stacking of materials or
temporary erection loads during the erection process.
The Employer shall ensure that no other contractor shall place

loads on the partly erected structure without the permisSion of
the Steelwork Contractor.
812- 26
12.5.3.8 Lining and Leveling
a) Alignment of part of the structure
Each part of the structure shall be aligned as soon as

practicable after it has been erected. Permanent
connections shall not be made between components until
sufficient of the structure has been aligned, levelled,
plumbed and temporarily connected to ensure that
components will not be displaced during subsequent
erection or alignment of the remainder of the structure.
ER
b) Temperature effects
D
Due account shall be taken of the effects of temperature on
the structure and on tapes and instruments when
N
measurements are made for setting out, during erection,
and for subsequent dimensional checks. The reference
TE
temperature shall be 20°C.
12.5.3.9 Site Welding

A
Site welding shall be carried out in accordance with Section 5.
EJ
In all cases precautions are to be taken so that the welding current

does not damage components it passes through and adequate
return earth connections are made local to the area being welded.
M
Welding shall not be permitted during inclement weather, unless

adequate protective measures are taken .
EN
12.5.3.10 Site Bolting

M
Bolting shall be carried out in accordance with section 12.3.4.

KU
12.5.3.11 Certification Of Completion
i. When the steelwork, or a portion of the steelwork, has been

completed , the Steelwork Contractor shall present a
O
certificate for the Employer and the Steelwork Contractor to

sign. The completion of the certificate means the following :
D
ii. The Steelwork Contractor's signature signifies that an

inspection has been made to ensure that all connections are
completed and that the steelwork is erected in accordance
with this specification and contract requirements.
iii. The Employer's signature signifies acceptance that the

structure, or part of the structure, has been built in
accordance with this specification and the contract
requirements.
S12- 27
12.5.3.12 Drifts
Drifts of the size specified in 12.3.11 may be used to bring the

pieces accurately into place.
12.5.4 Accuracy of Erection
The Steelwork Contractor shall as soon as possible inform the Engineer of any
deviation position of erected steelwork which is greater than the permitted
deviation in Table 12.10 to Table 12.14 that the effect can be evaluated and a
decision reached on whether remedial work is needed.
ER
Note; The survey and assessment of deviations of erected steel frames is
described in Annex A of the Commentary.
D
Permitted maximum deviations in erected steelwork shall be as specified in
N
respective Tables mentioned above taking account of the following:
n
TE
(a) All measurements to be taken in calm weather, and due note is to be
taken of temperature effects on the structure.
(b) The deviations shown for open sections apply also to box and tubular
sections.
A
Permitted deviations during erection shall specified in tables:
EJ
(a) Table 12.13 - Permitted Deviations For Foundation, Walls and

Foundation Bolts (il)
M
(b) Table 12.14 - Permitted Deviations of Erected Components (il)

EN
12.5.5 Foundation Inspection
The Contractor shall inspect the prepared foundations and holding down bolts
position and level not less than seven days before erection of steelwork starts.
M
Any discrepancies or deviation shall be brought to the attention of S.O/P.D and

u rectification works must be carried before any erection commenced.
KU
12.6 PROTECTION OF STEELWORK AGAINST CORROSION

O
12.6.1 General
D
12.6.1 .1 Specification
The coatings and associated surface preparation required for

structural. Steelwork shall be as specified on the Design
Drawings or in the Project Specification, If possible, the system
should be chosen from those listed in Annex E of this
specification. The system shall be in accordance with the latest
edition of DEFRA's Guidance Notes to Environmental Protection
Act 1990 [PG6/23].
812- 28
A single source of coating supply shall be used unless otherwise
agreed with the S.O/PD.
12.6.1.2 Method statement
Before any work commences for the application or reapplication

of Protective coating, a method statement shall be prepared and
given to the S.O/P.D. for approval.
A copy of the approved method statement shall be available

where the work is being carried out.
ER
12.6.1.3 Coating procedures
Coating materials shall be prepared, and coatings applied to

surfaces, In accordance with the manufacturer's
D
recommendations.
N
12.6.1.4 Transportation, handling and storage of coated steelwork
TE
The procedures for the transportation, handling and storage of
coated steelwork shall be so arranged as to minimise the risk of
damage to the coating .
A
EJ
12.6.2.1 Surface cleanliness

M
At the time of coating the surface cleanliness of the steelwork to

be coated shall be in accordance with BS EN ISO 8501-1.
EN
12.6.2.2 Surface profile
The surface profile of the steelwork to be coated shall be

M
compatible with the coating to be applied in accordance with BS

EN ISO 8503-2.
KU
12.6.2.3 Measurement of surface profile
Measurement of the surface profile of steelwork to be coated

O
shall be made using the methods given in BS EN ISO 8503.

D
12.6.2.4 Surface defects
Surface defects revealed during surface preparation shall be

dealt with in accordance with 12.2.1.4.
12.6.3 Paint System
12.6.3.1 Specification
Paint coatings shall be to a system designated on the Design

Drawings or in the Project Specification
812- 29
Unless otherwise specified. minimum protection coating shall be
a three coat protective system. Each coat of paint shall be of
different shade or colour from the proceeding coat.
The Contractor shall submit to the S.O/P.D . his painting plan for
approval two weeks before work commences. The painting plan
shall include the following:-
a) Method of Working
b) Work Schedule
c) Product and Manufacturer's name
d) Surface Preparation
ER
e) Painting System
f) Quality Control
g) Scaffolding and Site Painting (if required)
h) Other relevant matters
D
12.6.3.2 Materials
N
n All paints used in a paint system shall be compatible and
TE
supplied by one manufacturer. They shall be suitable for use in
a tropical climate and shall be free of supporting fungus growth.
The paint system shall consist of the following components:-

A
i) Primer
EJ
The primer shall be capable of 'wetting' the steel surface

and forming an adherent film on it to provide a base for
M
the following coats .
Special primer shall be used to protect blast-cleaned

EN
steel during fabrication or until the full coating system is

applied. These primers shall be sufficiently thin to weld
through and in no way take place of conventional
M
primers.
u ii) Undercoat( s)
KU
The paint shall have formulation similar to the finishing

coats . It shall be able to provide the build up to the
O
required film thickness and act as a barrier to corrosive

agents and also help to smooth out irregularities of the
steel surface.
D
iii) Finishing Coat
The paint shall be able to provide resistance to the

environment. It shall be a freely working product with
good levelling properties and shall be of such
consistency that can be satisfactorily applied by airless
spray. The paint, when applied, shall be in a uniform wet
film, free from pin holes, drops, runs, bubble, ridges and
variation in colour.
812- 30
iv) Manufacturer's Certificate
The Contractor shall supply manufacturer's Certificate for

each consignment of paint or paint material delivered to
the Work. Such manufacturer's certificate shall certify
that the paint material complied with relevant
Specification and in addition shall give:-
a) Description of Material
b) Vendor's Reference Number
c) Batch Number
ER
d) Quantity in Batch
e) Date of Manufacture
f) Shelf Lift of Material
D
12.6.3.3 Surface Preparation prior to painting
N
Steelwork shall be prepared for coating in accordance with
TE
clause 12.6.2 of this specification and other approved
manufacturer's instructions.
Manual cleaning shall be carried out by means of wire brushes,

A
hand scrapers, vibratory-needle guns and chipping hammers
and other approved method .
EJ
Excessive burnishing of the metal through prolonged application

of rotary wire brush shall be avoided. Surface shall be protected
M
within 4 hours of having been mechanically cleaned.
Manual cleaning shall be carried out to a minimum standard of

EN
STS of Swedish Standard SIS 05 59 00 and/or to S.O/P.D.'s

satisfaction .
M
Apart from the surface preparation of the bulk of the steelwork,

the Contractor shall give attention to the following details:-
KU
i) Sharp edges shall be removed;

ii) Burrs shall be ground flat;
iii) Welds shall be dressed and weld spatter removed
O
by grinding;
iv) Nuts and bolts shall be properly treated .
D
12.6.3.4 Painting of site weld areas and fasteners
Site weld areas and fasteners which are not suitably protected
shall be painted with an approved paint system to ensure similar
properties, performance and compatibility with the protective
treatment system being used on the surrounding surfaces.
Fasteners and bolt assemblies which are supplied with a

protective treatment which is equivalent to the protective
treatment on the steelwork need not be painted.
S12- 31
12.6.3.5 Inspection of site applied coatings
If the Project Specification permits or requires coatings, other

than those covered by 12.6.4.2, to be applied on site, then an
inspection plan for the site application work shall be included in
the project quality plan.
The inspection plan shall include steps to monitor the quality of

the materials being used, the thickness of the applied coatings,
and that the process of application is in accordance with the
product manufacturer's recommendations.
ER
12.6.4 Construction and Workmanship
D
12.6.4.1 Reference Specimen
N
The Contractor shall supply prepared specimen of steel plate
coated with the full coating system covered by this Specification.
TE
Plates shall be approximately 200mm x 200mm x 6mm thick.
Surface preparation and paint application shall be carried out in
accordance with the required methods. These plates shall be
available as reference pieces for colour comparisons during the
A
application of the coating system.
EJ
12.6.4.2 Storage And Mixing Of Paint
Paint shall be stored in sealed containers in a lock-up store

M
where it is not exposed to extreme temperature. Any special

condition recommended by the manufacturer shall be observed.
EN
Paint which has not been used within the 'Pot-Life' period
specified on the containers or within 12 months of the date of
manufacture, whichever is the lesser shall be replaced.
M
Paint from painter's kettle shall be returned to store and kept in

u a sealed container. Before it is reissued for use, it shall be
KU
thoroughly mixed and no fresh paint or thinner shall be added.
Paint mixed on the job shall not be mixed until the Contractor is
ready to use the paint. All paint shall be mixed and stored strictly
O
in accordance with the manufacturer's instructions.

D
Unless otherwise recommended by the manufacturer and

approved by the S.O/P.D. thinners or other addition shall not be
used.
The Manufacturer's instruction for mixing and applying the paint

shall be closely followed. All paint mixing shall be done in the
presence of the S.O/P.D.
12.6.4.3 Application of Paint
All paint shall be supplied from the store to the painters ready
for application, and the addition of thinners or any material shall
S12- 32
be thereafter prohibited. Any instructions given by the paint
manufacturer shall be strictly followed.
Paint shall be applied to dry surfaces which have prepared and

cleaned in accordance with this Specification. The interval
between preparation for the metal surface and the application of
the first priming coats of paint shall be in accordance with this
Specification.
Two pack paints of the epoxide resin type shall not be applied
when the temperature is below that required by the paint
manufacturer.
ER
Priming coats of paint shall be applied by brushing, rolling or
airless spray. Finishing coats of paint shall be applied by airless
spray.
D
If in the opinion of the S.O/P.D. the paint coating is
N
unsatisfactory, then it shall be removed and the surface shall be
cleaned thoroughly and repainted.
TE
Unless otherwise agreed by the S.O/P.D. the paint system, with
the exception of one final finishing coat, shall be applied under
coat in controlled conditions at the fabricator's works. One final
A
finishing coat shall be applied at Site.
EJ
12.6.4.4 Working Condition

M
Painting may be performed during any normal working hours

except as stated below.
EN
No paint shall be applied to any surface which is wet, damp or

dusty.
M
Paint shall not be applied when the relative humidity is greater

than 85%, or when rain is falling or about to fall, unless painting
is done indoors, or when the temperature of the receiving J
KU
surface exceed 500C. Material painted under cover in damp

weather shall remain under cover until dry or until weather
condition permits its exposure.
O
At least 24 hours shall elapse between applications of coats

D
except between application of etch primer and intermediate coat

which shall be applied within 8 hours of the application of the
etch primer.
Each coat shall be thoroughly dry before the application of the

next coat.
12.6.4.5 Thickness of Paint System
The total paint film thickness of the paint system shall not less
be than 0.1 mm. The dry paint film shall be measured by
Elcometer or other instrument approved by the S.O/P.D. In order
to obtain the dry film thickness specified the Contractor shall
512-33
ensure that the coverage rate given by the paint manufacturer
is followed.
Wet film thickness may be used for checking but shall not be
permitted as a means of predicting the dry film thickness.
12.6.4.6 Adhesion and Cohesion
The adhesion of the complete coating when applied as specified

shall be continuous over the whole surface and shall be such
that the coating cannot be peeled from the surface of the
specimen or separated between coats when tested in the
ER
following manner:-
Two parallel knife cuts about 1.5m apart and 50mm long shall
be scribed through the coating to the base metal at one end with
D
sharp knife. The loosened end shall be held between the knife
blade and a finger and a slow steady upward pull exerted on the
N
n paint strip normal to the coated surface.
TE
Any lifting of the strip either at the metal-paint interface or within
the paint film shall be interpreted as failure to comply with
adhesion or cohesion requirements.
A
12.6.4.7 Stripe Coats
EJ
As soon as the first priming coat and/or undercoat has dried, an

extra strips coat of paint shall be applied by brush on vulnerable
areas such as edges, corners , crevices, bolts heads and welds.
M
This paint shall be of similar composition to each coat but in a

contrasting shade.
EN
12.6.4.8 Coated Surfaces
Uncoated surfaces which will have concrete cast against thern

M
shall be left unpainted. The surface shall be thoroughly wire

1.....) brushed so as to remove loose rust mill scale and prevent
KU
surface contamination.
12.6.4.9 Storage of Painted Steelwork

O
Painted fabricated steelwork which is to be stored prior to

erection shall be kept clear of the ground and shall be laid out
D
or stacked in an orderly rnanner that will ensure no pool of water

or dirt can accurnulate on the surfaces. Suitable packing
materials where cover is provided and shall be ventilated .
Prime painted steelwork which is to be stored outdoors or

transported prior to fabrication or erection shall no be exposed
before being over coated for period longer than the following:-
812- 34
Outdoors
Etch primers Nil
Etch primers on metal coating 4 weeks
Red lead primers (1 coat) 8 weeks
Metallic lead primers (2 coat) 16 weeks
Calcium plumbate primers 4 weeks
Zinc chromate primers 2 weeks
Zinc chromate/Red oxide primers 2 weeks
Zinc chromate primers (1/2 mil to 1 mil thick) 4 weeks
12.6.4.10 Cleaning Equipment
ER
Any separate cleaner consisting of suitable solvents may be
furnished for the cleaning of paint equipment.
The cleaner shall be completely volatile so that a residual oily
D
film is not deposited in the painting equipment after the cleaning
operations. Separate cleaner mixture shall not be used a
N
thinners to reduce the viscosity of the paint.
()
TE
12.6.5 Metallic Coating A
12.6.5.1 Sprayed Metal Coating Procedures
EJ
Zinc or aluminium sprayed coatings shall be applied to the

surface as required by BS EN ISO 2063 to a thickness given in
the Project Specification or on the Design Drawings.
M
12.6.5.2 Reinstatement of damaged coating

EN
All reinstatement of damaged coatings shall be made good to

the standard of the original work.
12.6.5.3 Sealing before painting

M
If a sprayed metal coating is to be over-coated subsequently, it

KU
shall be sealed before the application of the over-coating.
12.6.6 Hot Dip Galvanizing

O
D
12.6.6.1 Procedures
Galvanizing shall be carried out in accordance with BS EN ISO

1461.
All galvanized components shall be subjected to 100% post-

galvanizing inspection in accordance with procedure PGI - 1 in
Table 12.9 unless otherwise specified in the Project
Specification.
The Project 'Specification shall identify:
S12- 35
i. any components for which post-galvanizing inspection is not
required (PGI-O);
ii. any components that shall be subjected to procedure PGI-2A

in addition;
iii. any specific locations that shall be subjected to procedure

PGI-2B in addition.
The results of post-galvanizing inspection shall be recorded.

These records shall be made available to the S.O/P.D on
request.
ER
If evidence of cracking is identified, then the component and all
similarly shaped components fabricated with similar materials
and weld details shall be identified and quarantined as non-
D
conforming products. A photographic record of the cracking shall
be made and procedure PGI-3 shall then be used to establish
N
n the scope and origin of the problem. The results shall be
submitted to the S.O/P.O. Quarantined components may only
TE
be repaired for use in The Works with the agreement of the
S.O/P.D.
12.6.6.2 Vent holes

A
The Steelwork Contractor shall agree with the Engineer the
EJ
position of vent and drainage holes in hollow components as laid

down in BS EN ISO 14713, and any requirements for
subsequent sealing.
M
12.6.7 Treatments for Connections and Other Special Areas

EN
12.6.7.1 Bolts
M
Bolts shall be treated in either of the following manner

u depending upon erection condition and S.O/P.D's approval:
KU
i. Black bolts in steelwork have been manually cleaned after

weathering may be prepared and coated in the same
manner as the general surfaces.
O
ii. Where black bolts are used for connections and all surfaces
D
are prepared by blast-cleaning after bolting-up completed,

the exposed surfaces of the bolt, nuts and washers shall be
cleaned at the same time as the general surfaces. This also
applies if high strength friction grip bolts are used in similar
circumstances.
iii. Where general surfaces of steelwork are prepared by blast-

cleaning before bolting-up and it is not practicable
subsequently to utilize the same preparation method for the
connector surfaces, pickling may be used to remove scale
and to assist in manual preparation of the exposed surfaces
for coating.
812- 36
iv. High strength friction grip bolt shall not use pickling for
plating or other coating without full consultation with the
manufacturer and the S.O/P.D.
v. Electroplating with zinc or cadmium shall be done in

accordance with BS 3382: Part 1 and Part 2. The thickness
of the coating shall be ensured so that the protection offer is
similar to that provided for the general surfaces. Additional
paint shall be applied to the plated bolt when protective
coating equivalent to that used on the general surfaces are
available. Where the components are subsequently to be
ER
protected with a full paint system, any corrosion products
visible after assembly shall be removed before primer is
applied and plating shall be without 'passivation'.
D
vi. Where the components are not to be painted, the plating
thickness shall be 25 m minimum, plating shall be with
N
'passivation' and the colour to the approval of the S.O/p.o.
o
TE
vii. Sherardizing shall be done in accordance with BS 4921
Class 1 with a minimum thickness of 30m. Primers of
suitable type shall be applied as soon as possible after
assembly.
A
EJ
viii. All fixings shall be stored in such a manner as to ensure that
they do not become corroded or contaminated . Exposed
parts of fixing, after assembly, shall be degreased before
surfaces are prepared or coating applied. Paint shall be
M
applied with brush where access to coat the surfaces is

difficult.
EN
ix. The Contractor may use other alternative type of treatment

for bolt but subject to the approval of the S.O/P.O.
M
12.6.7.2 Surfaces of Connection Joined By Bolts
Surfaces to be joined by high strength friction grip bolts shall not

KU
be painted. The treatment of interface to be joined by high

strength friction grip bolt shall comply with BS 5493. The
contractor shall submit his proposal for S.O/P.D.'s approval.
O
D
12.6.7.3 Coating of Surfaces to Be Encased in Concrete
Structural steel surfaces to be encased in concrete may be left

unpainted and need not be blast cleaned unless required by the
Project Specification.
12.6.7.4 Repairs to Damaged Surfaces
Area of paint which have damaged during handling, storing,

loading and off-loading, transportation, erection and
construction shall be cleaned to bare metal, or metal coating
where this has been applied, and the edges of the undamaged
pain bevelled with sandpaper.
8 12- 37
Where a metal coating has been damaged, the affected area
shall be rubbed down to remove excessive roughness, cleaned
and an additional coat of approved zinc-rich system shall then
be re-applied and the new paint shall overlap the existing paint
by at least 50mm all-round the effected part.
All galvanized surfaces damaged during construction shall be

cleaned by grit-blasting and coated with organic Air-Cured Ethyl
Silicate Coating.
12.6.7.5 Health and Safety
ER
The Contractor carrying out coating shall comply with all
relevant regulation which are given by the paint manufacturer
and as specified in BS 5493.
D
12.6.7.6 Protective Coatings to All Structural Steels
N
n i. All structural steel surfaces shall be sandblasted to SA21/2
TE
surface finish.
ii. Apply two (2) coats of very high solids, high build epoxy
coatings (85% solid content) e.g. COPON 8048 to a dry film
A
thickness of 125 microns each.
EJ
iii. Apply two (2) finish coats of 25 microns each of dry film
thickness of high duty finish e.g. NIPPON
POLYURETHANE.
M
iv. Application of protective coatings shall be done in the

presence of the manufacturer's inspector.
EN
M
KU
O
D
S12- 38
TABLE 12.1: MATERIAL AND DIMENSION STANDARDS
Form Dimensions Tolerances Material Quality

Non-alloy Fine grain Weathering
steels steels steels
Universal Beams
& Columns BS 4-1 BS EN
10034
Joists BS 4-1 BS EN
10024
Channels BS 4-1 BS EN
10279 MS EN
ER
Rolled Asymmetric 10025-3 (2 )
(7) (7)
Beams
Angl

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KERAJAAN MALAYSIA

JABATAN KERJA RA YA MALAYSIA

(REKA & BINA)

NO. TENDER: JKRlCKUB/22648/2023

1. SENARAI SEMAKAN MENGEMUKAKAN TENDER

- Senarai Semakan Mengemukakan Tender Panduan kepada Petender

- Senarai Semakan Kandungan Dokumen Pra-Bida

2. BORANG-BORANG MAKLUMAT YANG PERLU DILENGKAPKAN OLEH

KETUA PENGARAH KERJA RAYA

SENARAI SEMAKAN MENGEMUKAKAN TENDER

PROJEK: MEMBINA JALAN DAR! BEHOR MALI KE KAMPUNG KEPALA

b) Segala usaha telah diambil untuk menyenaraikan perkara-perkara yang lazimnya

c) Petender adalah digalakkan menggunakan senarai semakan ini sebagai panduan

d) Petender adalah bertanggungjawab sepenuhoya bagi memastikan setiap dokumen

menjadi tanggungjawab petender untuk merujuk kepada pejabat ini supaya

e) Petender hendaklah merujuk kepada Senarai Semakan Kandungan Dokumen

1.1. JANGAN gunakan dakwat mudah luntur,

1.2. JANGAN buat apa-apa perubahan atau tambahan

Appendix D Lampiran AI,Surat Akuan Pembida

Tandatangan hendaklah seorang ya ng dibenarkan

Appendix F - Surat Akuan Pembida Untuk Tujuan

Tandatangan hendaklah seorang ya ng dibenarkan

2. Form of Tender (PWD Form DB/T-A2002)

2.l. Muka surat No . 1

Tempoh Siap Kerja Maksimum boleh dirujuk

2.2. Muka surat No. 2

2. Form of Tender (PWD Form DB/T-A2002)

2.3 Muka surat No.3

'List of Consultants' - Senaraikan nama dan alamat

(selaraskan dengan Appendix A kepada Arahan

3. Lampiran-lampiran kepada Syarat-syarat Kontrak di

a) Appendix 4 - Tender Sum Analysis

Harga bagi kerja-kerja elektrik hendaklah di bawa dari

Services, Appendix Al2 - Electrical Works (Rujuk

b) Appendix 5B - Oaywork Rates for Labour and Plant

4. Borang-borang maklumat yang perlu diJengkapi oleh

lsi semua butir di borang-borang ini (6 muka surat

5.0 Borang-Borang Piawai

5.1 Borang laminaR

a) Borang laminan Bank / Jaminan Syarikat Kewangan /

Jaminan lnsurans Untuk Bon Pelaksanaan (Kontrak

b) Bank Guarantee for Design Guarantee - Appendix

c) Borang laminan Bank / laminan Syarikat Kewangan /

(Kontrak Bekalan / Kerja) - Appendix 6B

Borang-borang ini adalah untuk makluman sahaja.

5.2 Bon Pelaksanaan

Sebagaimana yang dinyatakan dalam Syarat-syarat Kontrak,

6.1 Dokumen-dokumen wajib

6.2 Dokumen-dokumen lain yang perlu dikemukakan

a) Senarai Semakan Kandungan Dokumen Pra-Bida

d) Tender's Organisation Chart

e) List of Works to be sublet to Bumiputera

6.3 Cadangan Teknikal

7.1 Cara Mengemukakan Tender

Asingkan dokumen-dokumen dalam dua (2) sampul

Masukkan kedua-dua sampul ini dalam satu sampul

7.2 Masukkan sampul surat ini di tempat dan pada tarikh

JILID 1/11 - CONTRACTUAL AND GENERAL REOUIREMENTS

PART DESCRIPTIONS PAGE NO

I. Contractual and General Requirements CGRlI 10 CGRl33 D

Appendix A I-A - Location Plan for the Work s AI-A D

Appendix A 1~C - Typical Cross-Section At Bridge A I-C

Appendix A3 - Fac iliti es for the Proj ect Director A3- 1 to A3 -\ II I

C FORM OF TENDER - (P.W.D. FORM DBrr-A2002) I to 5 D