MCHW

MANUAL OF CONTRACT DOCUMENTS FOR HIGHWAY WORKS
VOLUME 1 SPECIFICATION FOR

HIGHWAY WORKS
SPECIFICATION FOR HIGHWAY

WORKS
AMENDMENT OCTOBER 2022
This document contains replacement pages for

incorporation into the Specification for Highway Works.
INSTRUCTIONS FOR USE

1. Insert replacement pages listed on the Instruction
Sheet (Amendment – October 2022), remove the
corresponding existing pages, which are
superseded by this amendment and archive in
accordance with the relevant quality management
system. (Advice on archiving is given in Standard
SD 0/14.)
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2. Remove and archive existing April 2022
Instruction Sheet and insert the latest Instruction
Sheet (October 2022) at the front of the
document.
3. Enter details of Amendment – October 2022 on
the Registration of Amendment Sheet, sign and
date to confirm that the amendment has been
incorporated.
4. Archive this sheet as appropriate.
Note: A quarterly index with a full set of Volume

Contents Pages is available separately from
The Stationery Office Ltd.
Amendment – October 2022

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A BRIEF DESCRIPTION OF OCTOBER 2022 AMENDMENTS
VOLUME 1
DOCUMENT DESCRIPTION
Volume 1 Specification for Highway Works (MCHW 1)
General The user’s attention is drawn to the following note which has been abstracted from
Implementing Standard SD 1/22 Amendment No. 1:
‘‘Contracts for which tenders are to be invited after 1st January 2023 shall incorporate by
reference the amendments implemented by this Standard, except where the preparation of
a contract has reached a stage at which in the opinion of the Overseeing Organisation use
of the amendments would result in significant additional expense or delay progress.’’
Feedback Arrangement
To provide feedback on Highways England’s standards and specifications, please email:
Standards_Enquiries@nationalhighways.co.uk
Series 000 The Schedule of Pages and Relevant Publication Dates for the Specification for Highway
Introduction Works (MCHW 1) is amended.
Series 700 Road Amendments are made to Clauses 706 and 706NI
Pavements -
General
Appendix F Consequential amendment is made to Sections 10.
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AMENDMENTS TO VOLUME 1 – OCTOBER 2022

Instruction Sheet
Section Revision
Series 000 Replace pages 4 to 5 with new pages 4 to 5
Series 700 Replace pages 6 to 7 and N5 to N6F with new pages 6 to 7 and N5 to N6F
Appendix F Replace pages 1 to 60F with new pages 1 to 60F
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VOLUME 1
SPECIFICATION FOR HIGHWAY WORKS – MARCH 1998
Incorporating amendments dated:
1998 June, July and August
2001 May
2002 May and November
2003 February, May, August and November
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2008 May, August and November
2014 May, August and December
2016 February
2017 February and May
2018 May
2019 July
2020 January, February and March
2021 February, April, July and November
2022 April and October
Series 000 Introduction
Series 100 Preliminaries
Series 200 Site Clearance
Series 300 Fencing
Series 400 Road Restraint Systems (Vehicle and Pedestrian)
Series 500 Drainage and Service Ducts
Series 600 Earthworks
Series 700 Road Pavements – General

Series 800 Road Pavements – Unbound, Cement and Other Hydraulically Bound Mixtures
Series 900 Road Pavements – Bituminous Bound Materials
Series 1000 Road Pavements – Concrete Materials
Series 1100 Kerbs, Footways, Cycleways and Paved Areas
Series 1200 Traffic Signs
Series 1300 Road Lighting Columns and Brackets, CCTV Masts and Cantilever Masts
Series 1400 Electrical Work for Road Lighting and Traffic Signs
Series 1500 Highway Communications
Series 1600 Piling and Embedded Retaining Walls
Series 1700 Structural Concrete
Series 1800 Structural Steelwork
Series 1900 Protection of Steelwork against Corrosion
Series 2000 Waterproofing for Concrete Structures
Series 2100 Bridge Bearings
Series 2200 Not Used
Series 2300 Bridge Expansion Joints and Sealing of Gaps
Series 2400 Brickwork, Blockwork and Stonework
Series 2500 Special Structures

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Series 2600 Miscellaneous
Series 3000 Landscape and Ecology
Series 5000 Maintenance Painting of Steelwork
Series 5700 Concrete Repairs
Appendix A Quality Management Schemes
Appendix B Product Certification Schemes
Appendix C Product Acceptance Schemes
Appendix D Statutory Type Approval
Appendix E Type Approval/Registration/Listing
Appendix F Publications Referred to in the Specification
Appendix G Not used
Appendix H Quality Records

Volume 1
Specification for Highway Works Registration of Amendments
REGISTRATION OF AMENDMENTS
Amend Page No Signature & Date of Amend No Page No Signature & Date of
No incorporation of incorporation of
amendments amendments
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Volume 1
Specification for Highway Works Registration of Amendments
REGISTRATION OF AMENDMENTS
Amend Page No Signature & Date of Amend No Page No Signature & Date of
No incorporation of incorporation of
amendments amendments
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VOLUME 1 SPECIFICATION FOR HIGHWAY WORKS
SERIES 000
INTRODUCTION
Contents
Clause Title Page
000 (05/14) Introduction 2

001 (05/14) National Alterations of the
Overseeing Organisations of
Scotland, Wales and Northern
Ireland 2
002 (05/14) Terms and Abbreviations 2
003 (05/14) Appendices 2
004 (05/14) Normative and Informative
Reference Documents 2
Schedule of Pages and Relevant
(05/14)
Publication Dates 4
005 (05/14) Thickness of Material and
Tolerances 7F
006 (05/14) Acknowledgements 7F
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Amendment – May 2014 1

Volume 1 Series 000
Specification for Highway Works Introduction
INTRODUCTION
000 (05/14) Introduction
1 (05/14) The Specification for Highway Works is published as Volume 1 of the Manual of Contract Documents
for Highway Works and in addition to this Introduction contains numbered Series and Lettered Appendices.
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2 (05/14) Reference shall be made to the Schedule of Pages and Relevant Publication Dates in the Contract to
determine the publication date of each page of the Specification for Highway Works applicable to the Contract. The
current schedule is included here at Table 0/1.
001 (05/14) National Alterations of the Overseeing Organisations of Scotland, Wales and
Northern Ireland
1 (05/14) Additional and Substitute specification requirements of Transport Scotland, the Welsh Government and
the Department for Regional Development, a department of the Northern Ireland Executive, are contained within
Volume 1 of the Manual of Contract Documents for Highway Works. These Additional and Substitute Clauses are
identified by the suffix TS, NAW or NI respectively and are located immediately after the end of each Series or
Lettered Appendix of the Specification. (The suffix SE is also used in Series 1900 for National Alterations for the
Overseeing Organisation of Scotland).
Unless stated otherwise in contract specific Appendix 0/5, these Clauses are deemed to be included in contracts
administered by the above Overseeing Organisations. Clauses with suffix SE, TS, NAW or NI are deemed to
replace Clauses of equal number but without suffix.
002 (05/14) Terms and Abbreviations

1 (05/14) Unless specifically defined otherwise the definitions of terms used in the Specification and associated
documents are those in BS 6100, Building and Civil Engineering Vocabulary.
The term Overseeing Organisation means the Highways Agency, Transport Scotland, the Welsh Government or the
Department for Regional Development, depending on which is responsible for the Contract.
2 (05/14) Unless otherwise stated systems of quantities and units are in accordance with BS ISO 80000, Quantities
and Units. Abbreviations listed in Table 0/2 have the meanings shown therein. Other abbreviations used in the
Specification have meanings given in the relevant Clauses.
003 (05/14) Appendices

1 (05/14) Appendices identified by the letters A to H contain standard information and requirements.
2 (05/14) Numbered Appendices (identified by digits, e.g. 17/2) contain contract specific information and
requirements. The contract specific Numbered Appendices incorporated in the Contract are listed in contract
specific Appendix 0/3.
004 (05/14) Normative and Informative Reference Documents

1 (05/14) The following documents to which reference is made in the Specification are listed in Appendix F:
(i) British Standards;
(ii) British Standard Drafts for Development (DD) Documents;
(iii) European Standards;
(iv) International Standards;

Volume 1 Series 000
(v) Publications of the Department for Transport and other Government Offices;
(vi) UK Overseeing Organisations’ publications including their predecessor’s publications;
(vii) Transport Research Laboratory Reports;
(viii) UK and EU Legislation;
(ix) Quality Management Schemes Publications;
(x) Miscellaneous.
2 (05/14) Where Standards and other documents are incorporated into the Contract by reference the respective
edition used shall be that which is current at the Contract Reference Document Date unless otherwise stated in the
Specification. The Contract Reference Document Date shall be as stated in the Preambles to the Specification or
where no date is stated therein it shall be the tender invitation date.
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Volume 1 Series 000
(10/22) TABLE 0/1 SCHEDULE OF PAGES AND RELEVANT PUBLICATION DATES

Series/Appendix Page Number Publication Date
000 1 to 3 May 2014
000 6 to 7F February 2016
000 4 to 5 October 2022
100 2, W1F, N2 to N11F May 2014
100 N1 December 2014
100 1, 3 to 30F April 2022
300 1 May 2001
300 4 November 2002
300 2 to 3, 5 to 6F May 2008
400 1, 9 to 11, 13, 17 to 20, 21, 23F May 2017
400 2 to 8, 12,14 to 16, 22 March 2020
500 1 to 2, 4 to 39F, N1 to N2F February 2020
500 3 March 2020
600 1 to 68, 70 to 77F, S1 to S4F, W1 to W4F, N1 to N5F February 2016
600 69 February 2017
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700 1 to 5, 8 to 36F, N1 to N4 February 2016

700 6 to 7, N5 to N6F October 2022
800 1 to 42F November 2021
900 1 to 83F, S1 to S3F, W1 to W2F, N1F July 2021
1000 3 to 33 January 2020
1000 1 to 2, 34 to 58F November 2021
1200 5 May 2001
1200 2 to 3, W1F August 2003
1200 1, 14 to 16F May 2004
1200 4, 9 to 11, 13 May 2005
1200 12 November 2006
1200 6 to 7, N1 to N4F November 2007
1200 8 May 2008
1300 N2F November 2003
1300 3 to 4 November 2004
1300 1, 5 to 10, 12F November 2005
1300 2, 11 and N1 May 2006
1400 2, N1F May 2001
1400 1, 3 to 9F May 2006
1600 1, 4 to 5, 9, 15, 17 to 18, 24 to 26, 29 to 31, 35, 38, 49F March 1998
1600 2, 6 to 8, 10 to 14, 16, 19, 27 to 28, 32 to 34, 36 to 37, 39 to 42, November 2003
44 to 48
1600 3, 20 to 23, 43 November 2005
1700 2, 4, 6 to 7, 19, 24 to 27, 30 to 34 December 2014
1700 1, 3, 5, 8 to 18, 20 to 23, 28 to 29, 35 to 39F March 2020
1800 1 August 2014
1800 2 to 39F April 2021
1900 1 to 35F, S1 to S2F August 2014
Amendment – October 2022 4

Volume 1 Series 000
(10/22) TABLE 0/1 SCHEDULE OF PAGES AND RELEVANT PUBLICATION DATES (Cond.)
Series/Appendix Page Number Publication Date
2000 1, 3 to 4F May 2001
2000 2 November 2004
2300 1 March 1998
2300 2 to 3F May 2001
2400 1, 4, 7F May 2005
2400 2 May 2006
2400 3, 5 to 6 May 2008
2500 1 May 2001
2500 2, 8, 11F November 2003
2500 10 November 2004
2500 6 to 7, 9 May 2005
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2500 5 May 2006

2600 6 May 2005
2600 1, 8F March 2020
3000 4 to 7, 10, 12 to 17, 19, 22 to 27F May 2001
3000 20 November 2004
3000 2 to 3 May 2006
3000 8 to 9, 11, 18, 21 May 2008
5000 1, 4 to 19F, S1F May 2005
Appendix A 1 to 4F May 2014
Appendix B 1 to 3F May 2014
Appendix C 1 to 2F May 2014
#Appendix D 1F May 2014
Appendix D (NI) N1F May 2014
Appendix E 1F May 2014
Appendix F 1 to 60F October 2022
Appendix G Not used
Appendix H 1 May 2004
Appendix H 2 November 2005
Appendix H 3 November 2006
Appendix H 4 to 9F November 2008

Volume 1 Series 000
(12/14) TABLE 0/2 Abbreviations
Abbreviation Meaning
AASHTO American Association of State Highway and Transportation Officials
AAV Aggregate Abrasion Value
ACEC Aggressive Chemical Environment for Concrete (Class)
AISI American Iron and Steel Institute
AMD Amendment to British Standard
ASR Alkali Silica Reaction
ASTM American Society for Testing and Materials
BBA British Board of Agrément
BRE Building Research Establishment Ltd
BS British Standard
BSI British Standards Institution
CAC Calcium Aluminate Cement
CBM Cement Bound Material
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CBR California Bearing Ratio
CHS Circular Hollow Section
CIRIA Construction Industry Research and Information Association
CP British Standard Code of Practice
CPD Construction Products Directive
CPF Controlled Permeability Formwork
CPR Construction Products Regulation
DC Design Chemical (Class)
EEA European Economic Area
EN European Standard
ETA European Technical Assessment
FTD Flat Traffic Delineator
EU European Union
HAC High Alumina Cement
HAPAS Highway Authorities’ Product Approval Scheme
HCD Highway Construction Details
HMSO/TSO Her Majesty’s Stationery Office/The Stationery Office
HSE Health and Safety Executive
ISO International Organization for Standardization
MCV Moisture Condition Value
MDPE Medium Density Polyethylene
NA National Annex
NG Notes for Guidance on the Specification for Highway Works
NHSS National Highway Sector Scheme
NR No Requirement
PC Portland Cement
PD Published Document – British Standards Institution
PRD Percentage Refusal Density
PSV Polished Stone Value
PVC Polyvinyl Chloride
RA Recycled Aggregate
RCA Recycled Concrete Aggregate
RHS Rectangular Hollow Section
SHW Specification for Highway Works
SCC Self Compacting Concrete
Amendment – February 2016 6

Volume 1 Series 000
Abbreviation Meaning
SI Statutory Instrument
SMC Saturation Moisture Content
SRPC Sulfate Resisting Portland Cement
TG Technical Guide
TR Technical Report
TRL (formerly TRRL) Transport Research Laboratory (formerly Transport and Road Research Laboratory)
TSA Thaumasite Sulfate Attack
TSRGD Traffic Signs Regulations and General Directions
TSS (Highways Agency) Traffic Systems and Signs
UKAS United Kingdom Accreditation Service
PVC-U Unplasticised Polyvinyl Chloride
XLPE Cross-linked Polyethylene
DC direct current
dft dry film thickness
ggbs ground granulated blast furnace slag
mc moisture content
mdft minimum dry film thickness (of paint)
omc optimum moisture content
pfa pulverised-fuel ash (also known as fly ash)
005 (05/14) Thickness of Material and Tolerances

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1 (05/14) Unless stated to the contrary, the thickness of material described shall mean the finished or compacted
thickness.
2 (05/14) The requirements for tolerances, where necessary, are incorporated in the Specification, on the Drawings
and by reference in the publications listed in Appendix F.
006 (05/14) Acknowledgements

1 (05/14) The Overseeing Organisations acknowledge the permission given by:
(i) The British Standards Institution for reprinting extracts from BS 1722 and BS 6779.
Amendment – February 2016 7F

Volume 1 MANUAL OF CONTRACT DOCUMENTS FOR HIGHWAY WORKS Series 100
Specification for Highway Works
VOLUME 1 SPECIFICATION FOR HIGHWAY WORKS Preliminaries
(iv) details of where the goods are incorporated into the works.
SERIES
These 100
details shall be provided to the Overseeing Organisation by the Contractor upon request and at completion of
PRELIMINARIES
the works.
(05/14) Sampling and Testing
Contents
2 (05/14) The testing scheduled in contract specific Appendix 1/5, including sampling and provision of the
associated samples, shall be undertaken by the Contractor. The Contractor shall carry out each of the tests required
Clause Title Appendix 1/5 within an elapsedPage
in contract specific Clause
time from the takingTitle
of the respective samples which shall Page
be
reasonable in all the circumstances unless otherwise prescribed by the Overseeing Organisation. The Contractor
shall supply to
101 the Overseeing
(05/14) Temporary Organisation,
Accommodation within
and 24 hours of the completion of each test, a copy of the results.
122 (05/14) Progress Photographs 28
The following Equipment
operationsfor arethe
notOverseeing
included in contract specific Appendix 1/5:
Organisation 2 123 Not used 28
(i) checking, inspecting, examining, measuring (except in connection with testing);
102 (05/14) Vehicles for the 124 (05/14) Health and Safety Restrictions,
(ii) trials and demonstrations;
Overseeing Organisation 2 Precautions and Monitoring 28
103 (iii) routine
(05/14)testing
Radio carried out by manufacturers
Communication System for and 125 suppliers in compliance with a Closed
(05/14) Temporary specified standard or
Circuit
specification;
the Overseeing Organisation 3 Television (CCTV) System for
the Monitoring of Traffic 28
#104(iv) testing
(05/14)ofStandards,
plant. Quality Management
3 (05/14) Whereand Acceptance
required in contract specific Appendix 3 1/5126 (05/14) Timber and Products
test certificates and/or product certification complying
with the provisions of the relevant standard or specification where Containing
applicable Wood Supplied
and certifying that the goods or
105 (05/14) Goods, Materials,
Under the Contract
materials meet the specified requirements,
Sampling and Testing Goods and shall be supplied to the Overseeing Organisation by the Contractor at30F
least four weeks prior to the incorporation of the goods9or materials in the works.
Materials
Where
106 goods(05/14)or materials
Designare required
of Works byto be CE marked or where the Contractor proposes to use CE marked goods
or materials the Contractor
the Contractor shall supply the Overseeing 11Organisation with the CE marking information including
any relevant instructions and safety information at least fourNATIONAL weeks prior to ALTERATIONS
the incorporation of theOFgoods
THE or
107 Site Extent and Limitations on
materials in the works. This information shall be in English.OVERSEEING ORGANISATIONS OF
(05/14)
Use 12
4 (05/14) Where required in contract specific Appendix 1/5SCOTLAND, WALES
tests and associated AND
sampling shallNORTHERN
be undertaken by
108 laboratories
testing (05/14) Operatives
accredited in foraccordance
the Overseeing IRELAND
with BS EN ISO/IEC 17025. The accreditation shall be by UKAS or
Organisation
equivalent European accreditation organisation which is 12party to a multi-lateral agreement (MLA) with UKAS or any
other
109 equivalent International
(05/14) Control ofAccreditation Forum MLA
Noise and Vibration 12 signatory with a scope that includes BS EN ISO/IEC 17025.
Clause Title Page
Where UKAS(05/14)
110 or equivalent
Information laboratory
Boards accreditation is13required the results shall be reported on an official UKAS or
equivalent accredited laboratory test report or certificate. Wales
111 (05/14) Existing Ground Levels 13
5 (05/14) Where goods or materials are accepted on the basis 150NAW (05/14) Checking Bar Schedules
of an equivalent standard, quality management W1F
#112 Setting Out
scheme, product certification scheme or product acceptance151NAW 13 scheme as provided for in Clause 104, testing and W1F
(05/14) Dimensional Accuracy
sampling
113 as specified in or applicable
(05/14) Programme of Works to such an equivalent
14 standard quality management scheme, product
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152NAW (05/14) Agreement on

certification scheme or product acceptance scheme is accepted and shall be substituted for those specified in
114 (05/14) Payment Applications 14 Measurements Involving
contract specific Appendices 1/5 and 1/6 respectively.
115 (05/14) Accommodation Works 14 Computer Equipment W1F
6 (05/14) The Contractor shall provide samples, which shall include source samples, of goods and materials and
shall these toPrivately
116 deliver (05/14) and Publicly
the Overseeing Owned as described in contract specific Appendix 1/6. Unless otherwise
Organisation
Services or Supplies
stated in contract specific Appendix 1/6, the Contractor 14shall
Northern Ireland
arrange for the sampling of such goods and materials
to be
#117 undertaken by qualified staff of testing
(05/14) Traffic Safety and Management 15
laboratories holding UKAS or equivalent European Accreditation
104NI (05/14) Standards, Quality Management
Organisation accreditation to BS EN ISO/IEC 17025 for such sampling. These samples shall be supplied in
118 Temporary Highways for and Acceptance N1
sufficient time for them
(05/14) to be tested for acceptability by the Overseeing Organisation, taking into account the
programme for Traffic
the works. Production samples shall be19delivered 112NIin a condition
(05/14) Setting
which isOut
representative of the N6
material’s
119 state for the purpose of
(05/14) Routeing of Vehiclesthe test. 20 117NI (05/14) Traffic Safety and Management N6
7120 (05/14) The Contractor
(05/14) Recoveryshall provideand
Vehicles for rates of sampling specified in contract specific Appendix 1/6. These
rates of sampling
Operations for Breakdowns of each of the
shall apply at the outset 20 respective activities and for the duration of each of the
# denotes
activities. Following an initial period of sampling, the Contractor may applyor to
a Clause the Appendix
Sample Overseeing whichOrganisation for a
has a substitute National
121 (05/14) Tidal, Flowing and Standing
relaxation in these rates of sampling having demonstrated to the Overseeing Organisation an acceptable
Clause or Sample Appendix for one or more of level of
the Overseeing
confidence inWater
control. Provided, at any subsequent time 28 when test results ofindicate
Organisations Scotland, the
Walesneed for improved
or Northern Ireland. control in
the opinion of the Overseeing Organisation, the Contractor samples at the rate specified in contract specific
Appendix 1/6.
Amendment - April
May 2014
2022 91
Volume 1 Series 100
Specification for Highway Works Preliminaries
PRELIMINARIES
These details shall be provided to the Overseeing Organisation by the Contractor upon request and at completion of
the works.
101 Temporary
Sampling
(05/14)
(05/14) Accommodation
and Testing and Equipment for the Overseeing Organisation
21 (05/14) The Contractor shall provide,
testing scheduled maintain,
in contract service
specific and remove
Appendix all accommodation
1/5, including sampling andincluding
provisioncontents,
of the
access roads
associated and hardstanding
samples, thereto, asbydescribed
shall be undertaken in contract
the Contractor. The specific
ContractorAppendix 1/1,out
shall carry for each
the use of the
of the Overseeing
tests required
Organisation.
in contract specific Appendix 1/5 within an elapsed time from the taking of the respective samples which shall be
reasonable in all the circumstances
2 (05/14) Equipment, furnishings, unless
fittingsotherwise prescribed
and supplies shall beby the Overseeing
located Organisation.
as described in contract The Contractor
specific Appendix
1/1. All temporary initial accommodation shall be ready for occupation on the date for commencementthe
shall supply to the Overseeing Organisation, within 24 hours of the completion of each test, a copy of of results.
the works
and
The all other accommodation
following operations are not complete
includedwith
incontents, access roads
contract specific and hardstanding
Appendix 1/5: shall be ready for occupation
and use by the Overseeing Organisation within four weeks of the date for commencement of the works unless
otherwise stated in Appendix 1/1.
3 (05/14) Where stated in contract specific Appendix 1/1 the Contractor shall furnish and service accommodation
made(iii) routine
available by testing carried out
the Overseeing by manufacturers and suppliers in compliance with a specified standard or
Organisation.
specification;
4 (05/14) The Contractor shall organise the provision of all telephones, mobiles and/or land lines, for the
(iv) testing
Overseeing of plant.as described in contract specific Appendix 1/1. The Contractor shall undertake all liaison
Organisation
with telecommunications
3 (05/14) Where requiredcompanies
in contractasspecific
required. Where stated
Appendix in certificates
1/5 test contract specific
and/orAppendix 1/1 the landcomplying
product certification lines shall
be
with the provisions of the relevant standard or specification where applicable and certifying that the goods orthe
for the exclusive use of the Overseeing Organisation. Any provision for data connections shall also be for
exclusive use ofthe
materials meet thespecified
Overseeing Organisation.
requirements, shall be supplied to the Overseeing Organisation by the Contractor at
least four weeks
5 (05/14) prior to the incorporation
All accommodation of the goods
shall be regularly cleanedorfor
materials
so longinasthe
it isworks.
in use and suitable arrangements be
made
Wherefor the disposal
goods of any
or materials arewaste arising
required to befrom
CE use of such
marked accommodation.
or where the Contractor proposes to use CE marked goods
or
6 materials theequipment
(05/14) All Contractorsupplied
shall supply
by thethe Overseeing
Contractor Organisation
shall withand
be of a quality the precision
CE marking information
appropriate including
to its proposed
any relevant
use and shallinstructions
be deliveredand
in asafety information
serviceable at least
condition. Thefour weeks prior
Contractor shalltomaintain
the incorporation of the goods
all such equipment in or
materials
serviceablein condition
the works.andThis information
replace, shall beany
if necessary, in English.
that becomes unserviceable. The Contractor shall ensure that
any
4 (05/14) Where required in contract specific Appendix on
equipment needing periodic calibration is calibrated 1/5delivery,
tests andannually
associated and/or at other
sampling times
shall as and whenby
be undertaken
required by the Overseeing
testing laboratories Organisation.
accredited in accordance Unless
withotherwise stated in17025.
BS EN ISO/IEC contractThespecific Appendix
accreditation shall1/1
beequipment
by UKAS or
supplied
equivalent European accreditation organisation which is party to a multi-lateral agreement (MLA) withrequirements
by the Contractor shall comply with ‘Government Buying Standards’ minimum mandatory UKAS or any
and
other‘EU Green Public
equivalent Procurement’
International core criteria.
Accreditation Forum MLA signatory with a scope that includes BS EN ISO/IEC 17025.
7Where (05/14) When major components of the works are manufactured off the site the Contractor shall arrange to make
UKAS or equivalent laboratory accreditation is required the results shall be reported on an official UKAS or
available
equivalentadequate
accreditedandlaboratory
secure accommodation as described in contract specific Appendix 1/1 at or adjacent to the
test report or certificate.
place of, and during the period of, manufacture and testing.
5 (05/14) Where goods or materials are accepted on the basis of an equivalent standard, quality management
scheme, product certification scheme or product acceptance scheme as provided for in Clause 104, testing and
102
sampling asVehicles
(05/14) specified infororthe Overseeing
applicable to suchOrganisation
an equivalent standard quality management scheme, product
1contract(05/14) The Contractor
specific Appendices shall
1/5provide
and 1/6transport as described in contract specific Appendix 1/2 for the exclusive
respectively.
use of the Overseeing Organisation for any purpose in connection with the works. The vehicles shall be delivered
6and maintained
(05/14) The Contractor shall provide
in good roadworthy samples,
condition. which
They shallshall
haveinclude source
a current MOT samples, of goods
Certificate whereand materials
required, be and
shall deliver these to the Overseeing Organisation as described in contract specific Appendix
licensed for use on the public highway and shall have comprehensive insurance cover for any qualified driver 1/6. Unless otherwise
stated in contract
authorised by the specific
OverseeingAppendix 1/6, thetogether
Organisation Contractor
withshall
any arrange
authorisedfor passengers
the sampling andofthe
such goods of
carriage andgoods
materials
or
to be undertaken
samples. by qualified
The Contractor shall staff of testing
provide laboratories
fuel, oil holdinginUKAS
and maintenance or equivalent
conformity with theEuropean Accreditation
vehicle manufacturer’s
Organisation
recommendations accreditation
and shalltokeep
BS EN ISO/IEC
clean 17025inside
the vehicles for such
and sampling. These basis
out on a regular samples shall be supplied
as described in
in contract
sufficient time for them to be tested for acceptability by the Overseeing Organisation,
specific Appendix 1/2. A suitable replacement shall be provided for any vehicle out of service for more than taking into account the8
programme
working hours. for the works. Production samples shall be delivered in a condition which is representative of the
material’s state for the purpose of the test.
The choice of vehicle type, engine size and transmission shall reflect the acceleration and manoeuvrability required
7of that
(05/14) Theduring
vehicle Contractor
normalshall provideconditions.
working for rates ofUnless
sampling specified
stated otherwisein contract specific
in contract Appendix
specific Appendix 1/6.1/2
These
all
rates of sampling shall apply at the outset of each of the respective activities and for the
vehicles shall have all round visibility from the driver’s position. Where vans are identified in Appendix 1/2 duration of each of the
activities.
additional Following
mirrors shallan be
initial period
fitted of sampling,
to eliminate blind the Contractor may apply to the Overseeing Organisation for a
spots.
relaxation in these rates of sampling having demonstrated to the Overseeing Organisation an acceptable level of
confidence in control. Provided, at any subsequent time when test results indicate the need for improved control in
Appendix 1/6.
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Amendment - May 2014 92

Volume 1 Series 100
2 (iv)(05/14) details
Unlessof where the
otherwise goods
stated in are incorporated
contract specific into the works.
Appendix 1/2 all vehicles shall have sign boards reading
‘Highway Maintenance’ or where appropriate ‘Motorway Maintenance’ in accordance with Diagram 7404 of
Schedule 12, Part V of the Traffic Signs Regulations and General Directions 2002 on the rear of the vehicle (the
the works.
lettering shall be the largest x height that can be accommodated from the range 37.5mm to 150mm. Unless
otherwise
(05/14) stated in
Sampling andAppendix
Testing 1/2 the vehicles shall have chevron markings and a roof mounted amber flashing light
bar in accordance with Section O5 of Chapter 8 (Part 2 Operations) of the Traffic Signs Manual.
Volume
3 (05/14) 1 Unless otherwise stated in contract specific Appendix 1/2 all vehicles provided for the use of the Series 100
Specification
Overseeing for Highwayshall
Organisation Works
be within
free from markings identifying Preliminaries
in contract specific Appendix 1/5 an elapsed time from theany company
taking associated samples
of the respective with the which
Contract.
shall be
shall supplyRadio
103 (05/14) to the Overseeing
CommunicationOrganisation,
Systemwithinfor24thehours of the completion
Overseeing of each test, a copy of the results.
Organisation
2 (05/14) Unless otherwise stated in contract specific Appendix 1/2 all vehicles shall have sign boards reading
The following operations are not included in contract specific Appendix in 1/5:
1‘Highway
(05/14) Maintenance’
When requiredorinwhere appropriate
contract ‘Motorway
specific Appendix Maintenance’
1/3 the Contractor accordance
shall providewith Diagram
a radio 7404 of
communication
Schedule 12, Part
(i) for checking,
system V of the Traffic
inspecting,
the Overseeing Signs
examining,
Organisation Regulations
measuring
as described and General
(except
therein, Directions
in connection
within 4 weeks of 2002
with on
date for commencement (the
the rear
thetesting); of the vehicle of the
lettering
works shallabe
unless the largest
different datexfor
height that can
provision be accommodated
is required in Appendixfrom theThis
1/3. range 37.5mm
would be into 150mm.
addition to Unless
any telephones
otherwise
or stated in Appendix
telecommunications 1/2 the
equipment vehiclesforshall
provided have chevron
in contract specificmarkings
Appendix and a roof mounted amber flashing light
1/1.
(iii)
bar in routine with
accordance testing carried
Section O5outofby manufacturers
Chapter 8 (Part 2 and suppliersofinthe
Operations) compliance withManual.
Traffic Signs a specified standard or
2 (05/14) The system, unless otherwise described in contract specific Appendix 1/3, shall be entirely separate from
specification;
3 provision
any (05/14) Unless
for aotherwise stated in contract
radio communication system specific
providedAppendix
by the 1/2 all vehicles
Contractor provided
for his own use forexcept
the use of any
that the aerial
(iv)
Overseeing testing of plant.
Organisation
installation may be shared. shall be free from markings identifying any company associated with the Contract.
3 (05/14) Where The system required shallinhave
contract specific Appendix
an operating range which 1/5ensures
test certificates
receptionand/or throughoutproduct thecertification
site. complying
with
103 the provisions
(05/14) TheRadio of the relevant
Communication standard or specification
Systemforfor where
the Overseeing applicable and
Organisation certifying that the goods or
4 (05/14) Contractor shall be responsible obtaining any necessary radio licences.
materials meet the specified requirements, shall be supplied to the Overseeing Organisation by the Contractor at
15 (05/14)
least four weeksWhen
The required
prior
Contractor to thein contract
incorporation
shall maintain specific Appendix
of the
the goods
system, or1/3 the Contractor
materials
dismantling andin removing shall itprovide
the works. at the end a radio communication
of the period stated in
system for
contract the Overseeing
specific AppendixOrganisation
1/3. If the system as described therein,forwithin
is inoperative 4 weeks
any reason, of theeither
it shall date for commencement
be repaired or a of the
Where goods or materials are required to be CE marked or where the Contractor proposes to use CE marked goods
works unlessprovided
replacement a different date for
within provision is required in Appendix 1/3. This would be in addition to any telephones
24 hours.
or materials the Contractor shall supply the Overseeing Organisation with the CE marking information including
or telecommunications equipment provided for in contract specific Appendix 1/1.
any relevant instructions and safety information at least four weeks prior to the incorporation of the goods or
2 (05/14)
materials
#104 inThe
(05/14) the system,
works. This
Standards, unless otherwise
information
Quality described
shall
Management be in in contract
English.
and specific Appendix 1/3, shall be entirely separate from
Acceptance
any provision for a radio communication system provided by the Contractor for his own use except that any aerial
4 (05/14) Where required in contract specific Appendix 1/5 tests and associated sampling shall be undertaken by
0installation
(05/14)
testing Standards
(04/22) may beand
Where
laboratories
shared.
this specification
CE markings
accredited requires awith
in accordance product
BS EN to carry
ISO/IEC CE marking
17025. The thisaccreditation
shall be readshall as thebeproduct
by UKAS is or
required
3 (12/14) to carry the
The system conformity
shall have anassessment
operating marking
range required
which by
is partyensures current legislation.
receptionwith throughout The conformity
the assessment
equivalent
1mark (05/14) European
Where
and accompanying
accreditation
there isdeclaration organisation
a requirement in thiswhich
of conformity specification
or declaration
to acompliance
for multi-lateral
of performance
agreement
any part
shall of asite.
(MLA)
demonstrate
with UKAS
“British or any
thatStandard”
the selected
other
or
4 other equivalent
technical
(05/14) International
specification,
The Contractor Accreditation
that requirement
shall characteristics
be responsible Forum MLA
formay signatory with
be characteristics
obtainingmetany by compliance
necessary a scope that
with:
radio includes
licences. BS EN ISO/IEC 17025.
product's declared performance and other provide those required by the specification.
Where UKAS
(a) to or
a standard equivalent
or code laboratory
of practice accreditation is required the results shall be reported on an
theofficial UKAS inor
5 order
In (05/14)
equivalent
The Contractor
demonstrate
accredited thatshall
laboratory
maintain
a product
test isoflegally
report
a national
the
or
system,
placedstandards
dismantling
certificate.
body
on the market andorin equivalent
England,itbody
removing at theofend
Scotland any
andofEEA state
theorstated
period
Wales, Turkey;
contract
(b) specific
Overseeing Appendix
anyOrganisation
international 1/3. If the
recognises
standard system
the isfor
inoperative
UK Conformity
recognised for any reason,
use asAssessment
a standard codeitofshall
or(UKCA) mark either
practice beany
repaired
as abyconformity or a or Turkey;
assessment
EEA state
replacement
5mark provided
Where goods
equivalent to CE Mark.
(05/14) within
or 24 hours.
materials are accepted on the basis of an equivalent standard, quality management
scheme, (c) product
a technical specification
certification scheme recognised
or product for acceptance
use as a standardscheme byasa provided
public authority of any 104,
for in Clause EEAtesting
state orand
Turkey;
Note: CE ormarks are accepted in England, Scotland and Wales until
sampling as specified in or applicable to such an equivalent standard quality management scheme, product 31st December 2022. After 31st December
#104
2022, the status
(05/14)
certification
Standards,
of CE
scheme or marks Quality
product may Management
change.
acceptance scheme
and Acceptance
(d) a European Technical Assessment issued inisaccordance
accepted and withshallthebe substituted
procedure setforoutthose specified(EU)
in regulation in No
contract specific
305/2011 Appendices
(05/14) Standards and CE markings
1/5 and 1/6 respectively.
6provided
(05/14)thatThethe Contractor shall provide
relevant standard imposes samples, which shall
an equivalent levelinclude source samples,
of performance and safety of goods and materials
provided for by theand
1 (12/14)
shall deliver Where
these there
to the isOverseeing
a requirement in this specification
Organisation as described forincompliance
contract with any
specific part of a1/6.
Appendix “British
Unless Standard”
otherwise
stated Standard or technical specification.
or other technical specification, that requirement may be met by compliance
stated in contract specific Appendix 1/6, the Contractor shall arrange for the sampling of such goods and materials with:
to “EEA
be(a)State” means
undertaken by oraqualified
state which isofa testing
contracting party toholding
the European Economic Area Agreement.
a standard code ofstaffpractice laboratories
of a national standards body UKAS or equivalent
or equivalent bodyEuropean
of any EEA Accreditation
state or Turkey;
Organisation
“British Standard” accreditation
means any to BS EN ISO/IEC
standard published 17025 for British
by the such sampling.
Standards These samples
Institution shall be adopted
including suppliedEuropean
in
(b) any
sufficient timeinternational
for them to standard
be tested recognised
for acceptabilityfor usebyasthe a standard
Overseeing or code of practicetaking
Organisation, by any EEA
into state or
account theTurkey;
or other international standards.
programme for the works.
(c) a technical Production
specification samplesfor
recognised shall
usebeas delivered
a standardinbya condition which isof
a public authority representative
any EEA state ofor
theTurkey;
2 (05/14)state
material’s Electrical
for theequipment
purpose oftothe which
test.directives 2006/95/EC or 2004/108/EC apply and which are produced for
or
incorporation in a permanent manner in the works must have affixed to them CE marking attesting to their
7conformity
(05/14) The
(d) a European
to theContractor
Technical
provisions shall provide
ofAssessment
the for issued
applicable rates ofinsampling
accordance
directives. specified
with the
Declarations ofinconformity
contract specific
procedure set out Appendix
required in by
regulation1/6.(EU)
the above These No
rates of sampling
directives must beshall
305/2011 applytoatthe
provided theOverseeing
outset of each of the respective
Organisation prior toactivities
installation andorforuse theorduration of each
procurement or of the of
supply
activities.
the equipment.Following an initial period of sampling, the Contractor may apply to the Overseeing Organisation for a
provided that the relevant standard imposes an equivalent level of performance and safety provided for by the
3stated Standard
(05/14)
confidence
or technical
Construction
in control. Provided,
specification.
products atwhich are produced
any subsequent timeforwhen
incorporation
test resultsinindicate
a permanent the needmanner in the works
for improved and in
control are
covered
the“EEA by a harmonised
State”ofmeans
opinion European
a state which
the Overseeing standard
is a contracting
Organisation, or European
party to the
the Contractor Technical
European
samples Approval
at the Economicor Assessment
rate specifiedArea Agreement. must have
in contract specific the product
performance
Appendix 1/6. required by the specification for the intended use declared under the Declaration of Performance and
“British Standard” means any standard published by the British Standards Institution including adopted European
Amendment - April
May 2014
2022
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
93
2 (05/14) Electrical equipment to which directives 2006/95/EC
Provided by S&P Global
or 2004/108/EC apply
Licensee=Ramboll UK Ltd/5967592001, User=xu, jiandong
and which are produced for
incorporation in a permanent manner in the works must have
No reproduction or networking permitted without license from S&P Global
affixed to them CE marking attesting to their
Not for Resale, 02/21/2023 05:36:35 MST
(c) a technical specification recognised for use as a standard by a public authority of any EEA state or Turkey;
or
(d) a European Technical Assessment issued in accordance with the procedure set out in regulation (EU) No
Volume 1 Series 100
305/2011
stated Standard or technical specification.
2“EEA State”
(05/14) Unless
meansotherwise statedisina contracting
a state which contract specific
partyAppendix 1/2 all Economic
to the European vehicles shall
Areahave sign boards reading
Agreement.
‘Highway Maintenance’ or where appropriate ‘Motorway Maintenance’ in accordance with Diagram 7404 of
Schedule 12, Part V of the Traffic Signs Regulations and General Directions 2002 on the rear of the vehicle (the
lettering shall be the largest x height that can be accommodated from the range 37.5mm to 150mm. Unless
2 (05/14)stated
otherwise Electrical equipment
in Appendix 1/2tothe
which directives
vehicles 2006/95/EC
shall have chevron or 2004/108/EC
markings applymounted
and a roof and which are flashing
amber producedlight
for
incorporation
bar in accordance in a with
permanent
Sectionmanner
O5 of in the works
Chapter must
8 (Part have affixedoftothe
2 Operations) them CE marking
Traffic attesting to their
Signs Manual.
conformity to the provisions of the applicable directives. Declarations of conformity required by the above
3 (05/14) Unless otherwise stated in contract specific Appendix 1/2 all vehicles provided for the use of the
directives must be provided to the Overseeing Organisation prior to installation or use or procurement or supply of
Overseeing Organisation shall be free from markings identifying any company associated with the Contract.
the equipment.
Volume 1 Series 100
3 (05/14) Construction products which are produced for incorporation in a permanent manner in the works and are Preliminaries
103
covered by aRadio
(05/14) Communication
harmonised European standardSystem for the Technical
or European Overseeing Organisation
Approval or Assessment must have the product
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performance required by the specification for the intended use declared

1 (05/14) When required in contract specific Appendix 1/3 the Contractor shall under theprovide
Declaration of communication
a radio Performance and
be CE marked
system in accordance
for the Overseeing with the relevant
Organisation Britishtherein,
as described adoptedwithin
European standard
4 weeks of theordate
European Technical Approvals
for commencement of the
or Assessments
Amendment and
works unless a -different the regulation
April 2022date for provision is required in Appendix 1/3. This would be in addition to anythetelephones
(EU) No 305/2011. Unless otherwise described in the specification, declared3
performance of the product
or telecommunications shall meet
equipment the required
provided performance
for in contract of Appendix
specific all the essential
1/1. characteristics required by the
specification. Declarations of performance required by the above regulation shall be provided to the Overseeing
2 (05/14) The
Organisation system,
prior unless otherwise
to installation or use ordescribed in contract
procurement specific
or supply of theAppendix
product. 1/3, shall be entirely separate from
any provision for a radio communication system provided by the Contractor for his own use except that any aerial
Quality
installation
(05/14) mayManagement
be shared.
43 (05/14) The
Unless otherwise
system indicated
shall have in contract
an operating specific
range whichAppendix 1/24 or asthroughout
ensures reception required inthethesite.
Conditions of
Contract, the Contractor shall institute a quality management system complying with BS EN ISO 9001 and shall
4 (05/14) The Contractor shall be responsible for obtaining any necessary radio licences.
prepare a Quality Plan. The Contractor shall demonstrate compliance with this requirement to institute a quality
5 (05/14) The
management Contractor
system to the shall maintain
Overseeing the system, one
Organisation, dismantling andmethod
acceptable removingfor it at demonstration
this the end of the period stated in
is to evidence
registration to BS EN ISO 9001.1/3. If the system is inoperative for any reason, it shall either be repaired or a
replacement provided within 24 hours.
5 (05/14) The Quality Plan shall incorporate the requirements of contract specific Appendix 1/24 and the
requirements of the quality management schemes listed in Appendix A applicable to the works in accordance with
#104 (05/14)8 Standards,
sub-Clause of this Clause.Quality Management and Acceptance
The Quality Plan shall be submitted to the Overseeing Organisation within the period(s) stated in contract specific
(05/14) Standards and CE markings
Appendix 1/24, for acceptance, before any related work is commenced.
1Where any Where
(12/14) work, goods there isoramaterials
requirement to beinused
this specification
in the works are for thecompliance
subject of with
the any
qualitypartmanagement
of a “British schemes
Standard”
or other technical specification, that requirement may be met by compliance
listed in Appendix A, the Contractor shall require the supplier of such items to prepare a Quality Plan and the with:
Contractor shall submit
(a) a standard or code it toof thepractice
of a national Suchbody
standards Quality Plans shallbody
or equivalent comply with
of any EEA thestate
requirements
or Turkey;
of contract specific Appendix 1/24 and the individual requirements of the relevant Sector Scheme Documents for
Quality (b) Management
any international standardWorks,
in Highway recognised for use as a8.standard or code of practice by any EEA state or Turkey;
see sub-Clause
(c) a technical
6 (05/14) Quality Plans specification recognised
shall indicate “hold for use as
points” as afollows:
standard by a public authority of any EEA state or Turkey;
or
Contractor’s points where no further work shall
hold(d) points: a European proceed Technical
without Assessment
the writtenissued in accordance
approval of a designated with person
the procedure set out in regulation
of the Contractor’s (EU) No
management, who
305/2011 shall be named in the Quality Plan.
Overseeing
stated Standard or points wherespecification.
technical no further work shall
Organisation’s proceed without the written approval of
“EEApoints:
hold State” means a state which
a designated is a contracting
representative of theparty to the European Economic Area Agreement.
“British Standard” Overseeing
means any Organisation.
standard published by the British Standards Institution including adopted European
The Contractor shall ensure the Quality Plans and associated quality documentation are made available to all
2 (05/14)
parties Electrical
involved with equipment
the works. to which directives 2006/95/EC or 2004/108/EC apply and which are produced for
conformity
(05/14) Quality to the Recordsprovisions of the applicable directives. Declarations of conformity required by the above
7the equipment.
(05/14) For works, goods or materials other than those which are CE marked, the Contractor shall make
available contemporary quality records to the Overseeing Organisation when requested. This includes quality
3records(05/14)such Construction
as those identified products inwhich
BS ENare produced
ISO 9001 tofor incorporation
demonstrate in a permanent
achievement of the manner
requiredinquality
the works and are
and the
covered by a harmonised European standard or European Technical
effectiveness of the quality system. The Contractor shall require any member of the Contractor’s supply chain toApproval or Assessment must have the product
performance
make available required by the specification
such contemporary qualityfor the intended
records use declared
when requested. under the
Following Declaration
a request copiesofofPerformance
all quality and
records shall be made available immediately to the Overseeing Organisation. The Contractor shall report any
non-conforming- April
Amendment 2022 to the Overseeing Organisation and shall require any member of the Contractor’s 34
product/service
supply
chain to immediately report any non-conforming product/service to the Contractor. The Contractor shall
immediately pass these reports to the Overseeing Organisation,
and undertake no further related work until
Organisation’s proceed without the written approval of
hold points: a designated representative of the
Volume 1 Overseeing Organisation. Series 100
The Contractor shall ensure the Quality Plans and associated quality documentation are made available to all
parties involved with the works.
be CE Quality
(05/14) Records
marked in accordance with the relevant British adopted European standard or European Technical Approvals
or Assessments and the regulation (EU) No 305/2011. Unless otherwise described in the specification, the declared
7performance
(05/14) For
ofworks, goodsshall
the product or materials
meet theother thanperformance
required those which of areallCE
themarked, thecharacteristics
essential Contractor shall make by the
required
available contemporary quality records to the Overseeing Organisation when requested. This
specification. Declarations of performance required by the above regulation shall be provided to the Overseeingincludes quality
records such as those identified in BS EN ISO 9001 to demonstrate
Organisation prior to installation or use or procurement or supply of the product. achievement of the required quality and the
effectiveness of the quality system. The Contractor shall require any member of the Contractor’s supply chain to
(05/14) Quality Management
make available such contemporary quality records when requested. Following a request copies of all quality
4 (05/14) Unless otherwise indicated in contract specific Appendix 1/24 or as required in the Conditions of
non-conforming product/service to the Overseeing Organisation and shall require any member of the Contractor’s
Contract, the Contractor shall institute a quality management system complying with BS EN ISO 9001 and shall
supply chain to immediately report any non-conforming product/service to the Contractor. The Contractor shall
prepare a Quality Plan. The Contractor shall demonstrate compliance with this requirement to institute a quality
immediately pass these reports to the Overseeing Organisation, and undertake no further related work until
management system to the Overseeing Organisation, one acceptable method for this demonstration is to evidence
remedial or other measures have been undertaken.
registration to BS EN ISO 9001.
The Contractor shall submit the quality records required by this specification, as indicated in Appendix H, to the
5 (05/14)
Volume 1 The Quality Plan shall incorporate the requirements of contract specific Appendix 1/24 and theSeries 100
Overseeing Organisation. No item of work shall be considered complete until these records have been received by
requirements
Specification of the qualityWorks
forOrganisation.
Highway management schemes listed in Appendix A applicable to the works in accordance with
Preliminaries
the Overseeing
sub-Clause 8 of this Clause.
Note: Quality terms used in this Clause are as BS EN ISO 9000.
The Quality Plan shall be submitted to the Overseeing Organisation within the period(s) stated in contract specific
Appendix
(05/14) 1/24,Management
Quality for acceptance, before any related work is commenced.
Schemes
Where any work, goods or materials to be used in the works are the subject of the quality management schemes
8 (05/14) Except as described in sub-Clause 104.9, where any work, goods or materials to be used in the works
listed in Appendix A, the Contractor shall require the supplier of such items to prepare a Quality Plan and the
are the subject of a quality
Amendment management scheme listed in Appendix A, only work, goods or materials conforming
Contractor shall- Maysubmit2014
it to the Overseeing Organisation. Such Quality Plans shall comply with the requirements 4
with such a scheme shall be used and the organisations carrying out such work shall have current registration to the
relevant scheme(s). The Contractor shall in each case submit to the Overseeing Organisation a copy of the
Quality Management in Highway Works, see sub-Clause 8.
certificate of conformity affirming compliance with the scheme.
6 (05/14) Quality Plans shall indicate “hold points” as follows:
9 (05/14) Where any work, goods or materials to be used in the works are the subject of a quality management
Contractor’s
scheme listed in points
Appendixwhere no further
A and work
for which theshall
goods or materials are CE marked products in accordance with the
hold points:
relevant proceed
standard(s) withouttothe
exclusions written approval
mandatory of a designated
requirements as listed inperson of the
Appendix Contractor’s management, who
A apply.
shall be named in the Quality Plan.
10 (05/14) Where specific training and competency requirements are identified in any quality management scheme
listed in Appendix
Overseeing A, the
points Contractor
where shallwork
no further provide
shallcopies of the relevant training and/or competency assessments
certificates and/or registration/skill cards
Organisation’s proceed without the written approval of the workforce
of to the Overseeing Organisation for acceptance prior to
the commencement
hold points: of relevant work.
a designated representative of the
Overseeing for
11 (05/14) The requirement Organisation.
compliance with a registered quality management scheme listed in Appendix A
shall be satisfied by compliance with an equivalent quality management scheme of any Member State of the
The Contractor
European shall Area
Economic ensureorthe Quality
a State Plans
which and associated
is party quality
to a relevant documentation
agreement are made available
with the European to all that
Union, provided
parties involved
the proposed with is
scheme thedesigned
works. to ensure in use levels of safety, performance and fitness for purpose equivalent to
those provided for by the scheme specified. The proposed scheme will include third party assessment by bodies
(05/14) Quality Records
accredited in accordance with BS EN ISO/IEC 17021 by the United Kingdom Accreditation Service (UKAS) or
7equivalent
(05/14) European
For works,Accreditation Organisation,
goods or materials which
other than thoseis which
party toare
a multi-lateral
CE marked, theagreement (MLA)
Contractor shallwith
make UKAS or
any equivalent
available International
contemporary Accreditation
quality Forum
records to the (IAF) MLA
Overseeing signatorywhen
Organisation with arequested.
scope whichThisincludes
includesthe relevant
quality
standard(s).
records suchThis sub-Clause
as those applies
identified in BSalso
ENtoISO
works
9001only in so far as the
to demonstrate means of carrying
achievement out such
of the required worksand
quality arethe
indivisibly associated with the goods or materials for which an alternative quality management
effectiveness of the quality system. The Contractor shall require any member of the Contractor’s supply chain scheme is proposed.
to
make available such contemporary quality records when requested. Following a request copies of all quality
(05/14) Product Certification Schemes and CE Marked Products
non-conforming
12 (05/14) Works, product/service to the Overseeing
goods and materials, Organisation
other than those covered and shall
by the require anyProducts
Construction member Regulation,
of the Contractor’s
falling
supply chain to immediately report any non-conforming product/service to the Contractor. The Contractor
under the standards listed in Appendix B are required to have attestation or third party accreditation to demonstrate shall
immediately
compliance with passthe
these reportsstandard.
relevant to the Overseeing
This can beOrganisation, and or
satisfied by one undertake
more of nothefurther related work until
following:
remedial or other measures have been undertaken.
(i) Compliance with a relevant product mark scheme demonstrating compliance as described in sub-Clause
The Contractor shall submit the quality records required by this specification, as indicated in Appendix H, to the
13 below;
Overseeing Organisation. No item of work shall be considered complete until these records have been received by
(ii) Demonstration
the Overseeing Organisation.of compliance as described in sub-Clause 13 below;
Note:(iii) Demonstration
Quality terms used inofthis
compliance using
Clause are testing
as BS EN ISOand 9000.
calculation as described in sub-Clause 14 below.
Where works, goods or materials are covered by the Construction Products Regulation (EU) No. 305/2011 (CPR)
their compliance with the specification shall be demonstrated by the product being CE marked, the declared
performance of the product given in the Declaration of Performance meeting the required performance of all the
essential characteristics given in the specification and evidence being provided that demonstrates the product meets
Amendment May
of the2014
- April specification for aspects other than those covered by the essential characteristics, where 4
2022 5
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the requirements
such evidence meets the requirements of options (i) or (ii)Licensee=Ramboll
above. UK Ltd/5967592001, User=xu, jiandong
compliance with the relevant standard. This can be satisfied by one or more of the following:
(i) Compliance with a relevant product mark scheme demonstrating compliance as described in sub-Clause
Volume 1 13 below; Series 100
(ii) Demonstration of compliance as described in sub-Clause 13 below;
(iii) Demonstration of compliance using testing and calculation as described in sub-Clause 14 below.
WhereQuality
(05/14) Management
works, goods Schemes
or materials are covered by the Construction Products Regulation (EU) No. 305/2011 (CPR)
8performance
(05/14) Except as described in sub-Clause 104.9, where any work, goods or materials to be used in the works
of the product given in the Declaration of Performance meeting the required performance of all the
are the
essential subject of a quality
characteristics management
given scheme listed
in the specification in Appendix
and evidence being A,provided
only work, goods
that or materials
demonstrates the conforming
product meets
with such a scheme shall be used and the organisations carrying out such work shall
the requirements of the specification for aspects other than those covered by the essential characteristics, have current registration
where to the
relevant scheme(s). The Contractor shall in each case
such evidence meets the requirements of options (i) or (ii) above. submit to the Overseeing Organisation a copy of the
certificate of conformity affirming compliance with the scheme.
13 (05/14) Where option (i) or (ii) of sub-Clause 12 is used the product shall be certified as compliant with the
9specification
(05/14) Where any work, goods or materials to be used in the works are the subject of a quality management
and relevant standard, or equivalent as described in sub-Clause 1 of this Clause, by a Certification
scheme
Body. listed in Appendix A and for which the goods or materials are CE marked products in accordance with the
relevant standard(s) exclusions to mandatory requirements as listed in Appendix A apply.
The Certification Body shall be accredited in accordance with BS EN 45011 or BS EN ISO/IEC 17065 by the
10
United(05/14) Where specific training and competency requirements are identified in any quality management scheme
Kingdom Accreditation Service (UKAS) or equivalent European Accreditation Organisation, which is party
listed in Appendixagreement
A, the Contractor shallUKAS
provideorcopies of the relevant trainingAccreditation
and/or competencyForumassessments
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to a multi-lateral (MLA) with any equivalent International (IAF) MLA
certificates and/or registration/skill cards of the
signatory with a scope which includes the relevant standard(s).workforce to the Overseeing Organisation for acceptance prior to
the commencement of relevant work.
Unless otherwise described in the specification assessment of the product shall be carried out to the level of
11 (05/14) The requirement for compliance with a registered quality management scheme listed in Appendix A
attestation
Volume 1 as determined in the relevant standard for the intended use of the product in the works and shallSeries include
100
shall be satisfied
confirmation thatbythecompliance
product with aninequivalent
provides, quality
use, adequate management
levels scheme of anyand
of safety, performance Member
fitness State of the For
for purpose.
European Economic
products covered by Area
the Lowor aVoltage
State which is party
Directive to a relevant
(2006/95/EC) andagreement with the European
the Electromagnetic Union, provided
Compatibility Directive that
the proposed scheme is designed to ensure in use levels of safety, performance
(2004/108/EC) the safety aspects would be for aspects not covered by the relevant CE marking. and fitness for purpose equivalent to
those provided for by the scheme specified. The proposed scheme will include third party assessment by bodies
The Contractor
accredited shall provide
in accordance withinformation
BS EN ISO/IEC on the17021
product by to
thethe Overseeing
United KingdomOrganisation for acceptance.
Accreditation Service (UKAS) This or
information
Amendment shall
equivalent European include
- May 2014certification,
Accreditation attestation which
Organisation, detailsisand Certification
party Body details.
to a multi-lateral agreement (MLA) with UKAS or5
14any equivalent
(05/14) Where International
option (iii)Accreditation
of sub-ClauseForum (IAF)it MLA
12 is used signatory
shall be with a scope
demonstrated that thewhich
productincludes the relevant
is capable of
standard(s). This sub-Clause applies also to works only in so far as the means of carrying
performing as required using tests, calculations or other means. Such testing or other means shall have a minimum out such works are
indivisibly associated
level of attestation withdetermined
as that the goods or bymaterials
the relevantfor standard
which anand alternative quality
be suitably management
extensive to providescheme is proposed.
information on
all relevant parameters. Testing shall be carried
out by laboratories accredited to UKAS or equivalent Accredited
Organisations as described in sub-Clause 105.4.
12 testingWorks,
The (05/14) or othergoods
meansand materials,
shall includeother than those
confirmation thatcovered by theprovides,
the product Construction
in use,Products
adequate Regulation, falling
levels of safety,
under the standards
performance listedfor
and fitness in purpose.
AppendixFor B are required
products to have
covered by attestation or thirdDirective
the Low Voltage party accreditation
(2006/95/EC) to demonstrate
and the
Electromagnetic Compatibility Directive (2004/108/EC) the safety aspects would be for aspects not covered by the
relevant
(i) CECompliance
marking. with a relevant product mark scheme demonstrating compliance as described in sub-Clause
The Contractorbelow;
13 shall provide information on the product to the Overseeing Organisation for acceptance. This
information shall include testing
(ii) Demonstration or calculation
of compliance details in
as described and results, certification
sub-Clause 13 below; and attestation details.
(iii)
(05/14) Demonstration
Product ofSchemes
Acceptance compliance using testing and calculation as described in sub-Clause 14 below.
Where
15 works, goods or materials are covered by the Construction Products Regulation (EU) No. 305/2011 (CPR)
(05/14) Where there are references in the specification to particular industry product acceptance schemes such
their compliance
as British Board of with the specification
Agrément shall
Certificates, be demonstrated
Roads and Bridges by the productHAPAS
Certificates, being CE marked, the
certificates, declared
CARES certificate
performance of the product given in the Declaration of Performance
or equivalent scheme, these shall be taken as references to a product acceptance scheme that has the attributes meeting the required performance of all the
given
essential characteristics given in the specification and evidence being
in sub-Clause 16 below. The types of work, goods or materials listed in Appendix C are required to be certificated provided that demonstrates the product meets
the
by arequirements
product acceptance of the specification
scheme priorfor to aspects other than
their inclusion in thethose covered by the essential characteristics, where
works.
such evidence meets the requirements of options (i) or (ii) above.
16 (05/14) The works, goods or materials shall be assessed against a set of guidelines and criteria by a Certification
13
Body. (05/14) Where option (i) or (ii) of sub-Clause 12 is used the product shall be certified as compliant with the
Certification to confirm the products successfully meet the guidelines and criteria shall be issued by a
specification
Certification Body. and relevant standard, shall
The Contractor or equivalent as describedon
provide information in the
sub-Clause
product to 1 ofthethis Clause, by
Overseeing a Certification
Organisation for
Body.
acceptance. This information shall include the certification and, when requested, details of the scheme to confirm
its
Thecompliance
Certification with Body the shall
criteriabegiven belowinand
accredited accreditation
accordance with details
BS ENof the organisation
45011 or BS EN ISO/IEC issuing the certification.
17065 by the
United Kingdom Accreditation
The scheme shall meet the following criteria: Service (UKAS) or equivalent European Accreditation Organisation, which is party
to a multi-lateral agreement (MLA) with UKAS or any equivalent International Accreditation Forum (IAF) MLA
signatory(a) with Product a scope acceptance
which includesand certification specified
the relevant in this sub-Clause shall be structured and implemented to
standard(s).
provide assurance to the Overseeing Organisation that the product, when supplied for its intended use
Unless otherwise and installed described in the specification
or processed assessment
post manufacture, of the product
in accordance withshall be carried out toinstructions,
the manufacturer’s the level of will
attestation as determined in the relevant standard for the intended use
give the performance and level of safety required by the specification and be fit for purpose. of the product in the works and shall include
confirmation that the product provides, in use, adequate levels of safety, performance and fitness for purpose. For
products (b) covered The organisation
by the Lowcertifying products (2006/95/EC)
Voltage Directive and issuing theand certificates must be accredited
the Electromagnetic to the relevant
Compatibility Directive
(2004/108/EC) Certification
the safetyBody aspects standard,
wouldBS EN aspects
be for 45011 or notBS EN ISO/IEC
covered by the 17065relevantforCE product certification, or BS EN
marking.
ISO/IEC 17020 for site inspection, by UKAS or equivalent European Accreditation Organisation, which
is party to a multi-lateral agreement (MLA) with UKAS or any equivalent International Accreditation
Amendment Forum May
- April(IAF) 2014
MLA signatory with a scope which includes the relevant standard(s). This shall include 5
2022 6
accreditation to manage and execute a certification scheme as defined injiandong
this sub-Clause. Accreditation
Provided by S&P Global Licensee=Ramboll UK Ltd/5967592001, User=xu,
must cover a scope of activity relevant to the construction, installation, maintenance and operation of
its compliance with the criteria given below and accreditation details of the organisation issuing the certification.
The scheme shall meet the following criteria:
Volume
(a) 1 Product acceptance and certification specified in this sub-Clause shall be structured and implemented
Series 100
to
Specification for Highway
provide assuranceWorks Preliminaries
to the Overseeing Organisation that the product, when supplied for its intended use
and installed or processed post manufacture, in accordance with the manufacturer’s instructions, will
give the performance and level of safety required by the specification and be fit for purpose.
The (b)
Contractor shall providecertifying
The organisation information on theand
products product to the
issuing the Overseeing
certificates Organisation for acceptance.
must be accredited This
to the relevant
informationCertification
shall includeBody
certification,
standard,attestation
BS EN 45011 details andEN
or BS Certification
ISO/IEC 17065Body details.
for product certification, or BS EN
14 (05/14) ISO/IEC
Where option17020(iii)
forofsite inspection,
sub-Clause 12by
is UKAS or equivalent
used it shall Europeanthat
be demonstrated Accreditation
the productOrganisation,
is capable of which
is party to a multi-lateral agreement (MLA) with UKAS or any equivalent
performing as required using tests, calculations or other means. Such testing or other means shall haveInternational Accreditation
a minimum
Forum (IAF) MLA signatory with a scope which includes the relevant standard(s).
level of attestation as that determined by the relevant standard and be suitably extensive to provide informationThis shall includeon
all relevantaccreditation to manage
parameters. Testing shalland
beexecute a certification
carried out scheme
by laboratories as defined
accredited in this or
to UKAS sub-Clause.
equivalentAccreditation
Accredited
must cover a scope of activity
Organisations as described in sub-Clause 105.4. relevant to the construction, installation, maintenance and operation of
highway infrastructure.
The testing or other means shall include confirmation that the product provides, in use, adequate levels of safety,
(c) The
performance scheme
and fitnessmust cover asFor
for purpose. appropriate:
products covered by the Low Voltage Directive (2006/95/EC) and the
Electromagnetic
i) Compatibility
Manufacture and Directive (2004/108/EC)
installation the safety aspects
or post manufacture processing would be forproducts
of those aspects not covered
for which a by the
relevant CE marking.Declaration of Performance, and consequent CE marking, has not been made on the basis of any
The Contractor shallharmonised European Standard
provide information (hEN) or
on the product to European Technical
the Overseeing Assessment;
Organisation or
for acceptance. This
informationii)shall Only
include
thetesting or calculation
installation details
of a material and results,
or post certification
manufacture and attestation
processing details.
where the manufacturer has
made a Declaration of Performance of the material (with consequent CE marking); or
(05/14) Product Acceptance Schemes
iii) Product characteristics not included in the required essential characteristics of a hEN or in a
15 (05/14) WhereEuropean
there are Technical
referencesAssessment
in the specification to particular industry
if such characteristics provideproduct
additionalacceptance
protectionschemes
for the such
as British Board of Agrément Certificates,
consumer (e.g. road user). Roads and Bridges Certificates, HAPAS certificates, CARES certificate
Volume 1
or equivalent scheme, these shall be taken as references to a product acceptance scheme that has the attributes Series 100
given
(d) The
Specification assessment
for Highway and certification
Works requirements for a product certified under the scheme
in sub-Clause 16 below. The types of work, goods or materials listed in Appendix C are required to be certificated must be
Preliminaries
by a productdeveloped
acceptanceensuring
schemedue consideration
prior is given
to their inclusion into
thethe requirements of the users of the product and those
works.
responsible for the highways on which such products will be used or installed.
16 (05/14) The works, goods or materials shall be assessed against a set of guidelines and criteria by a Certification
(e) The scheme must have a technical supervisory panel that provides technical oversight on the operation
Body. Certification to confirm the products successfully meet the guidelines and criteria shall be issued by a
Amendment - May
of the scheme2014and formally consents to the issue of assessment and certification requirements of the 6
Certification Body. The Contractor shall provide information on the product to the Overseeing Organisation for
specialist groups developing the assessment and certification requirements. This panel must include a
balanced representation of key end users, recognized industry experts and those responsible for the
its compliance with the criteria given below and accreditation details of the organisation issuing the certification.
highways on which such products will be used or installed.
The scheme shall meet the following criteria:
(f) The product certification must include requirements for the audit and quality control of the production
(a) andProduct acceptance
installation and certification
processes specified
for the product whereinnecessary
this sub-Clause
taking shall be structured
account and implemented
of the product having its to
provide assurance
performance to the
declared Overseeing
under Organisation
a CE mark. that the product,
Installer certification must when
includesupplied for its intended
requirements use
for on-site
and installedof
surveillance orinstallation
processed post manufacture,
or post in accordance
manufacturing processes.with the manufacturer’s instructions, will
give the performance and level of safety required by the specification and be fit for purpose.
(g) For every product it has certified under a product certification scheme, an organisation must make open
(b) andThe publicly
organisation certifying
accessible products
details of the and issuing the
assessment andcertificates
certificationmust be accredited to the relevant
guidelines.
Certification Body standard, BS EN 45011 or BS EN ISO/IEC 17065 for product certification, or BS EN
(h) Where different organisations have certified the same generic form of product they must be able to
demonstrate to the Overseeing Organisation equivalence of performance of products certified under the
is party to a multi-lateral agreement (MLA) with UKAS or any equivalent International Accreditation
different schemes or agree a common set of guidelines for the assessment and certification of the
Forum (IAF) MLA signatory with a scope which includes the relevant standard(s). This shall include
product.
accreditation to manage and execute a certification scheme as defined in this sub-Clause. Accreditation
(i) The
mustcompetences
cover a scopeofoforganisations certifying
activity relevant to the products shall installation,
construction, be as the competency
maintenance requirements
and operationfor of
Technical Assessment Bodies given in Regulation (EU) No 305/2011, the Construction Products
highway infrastructure.
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Regulation, Annex IV, Table 2 with the additions given in Table 1/1.
(c) The scheme must cover as appropriate:
i) Manufacture and installation or post manufacture processing of those products for which a
Table 1/1Declaration
(05/14) Competency of Performance,
additions toandConstruction
consequent CE Product
marking, has not been made
Regulation (EU)onNo.
the 305/2011
basis of any
harmonised
Annex IV, (Table 2) European Standard (hEN) or European Technical Assessment; or
ii) Only the installation of a material or post manufacture processing where the manufacturer has
Competence made a Declaration Description of Competence
of Performance of the material (with Requirement
consequent CE marking); or
7. Determining the specific Understand and evaluate the A certification body shall have staff with
iii) Product characteristics not included in the required essential characteristics of a hEN or in a
installation or post installation or post manufacturing appropriate technical knowledge of the
European Technical Assessment if such characteristics provide additional protection for the
manufacturing control processes of the specific product in relationship between the installation/post
consumer (e.g. road user).
order to identify appropriate manufacturing processes and the product
(d) The assessment and certification requirements
measures ensuring for a product characteristics
consistent certified underrelated the scheme must be control
to production
developed ensuring due consideration
compliant deliveryis of
given to the requirements
the installed or for installation of the users of the
or post product and those
manufacture.
responsible for the highways on which such
post manufactured products will be used or installed.
product.
8. Constructive engagement Be prepared to engage constructively Be able to resolve differences in the
Amendment - April May 2014 2022 with highway infrastructure certified performance of products of the 67
Provided by S&P Global managers and other certifying bodies same generic type
Licensee=Ramboll UK Ltd/5967592001, User=xu, jiandong and where appropriate
for resolution of issues. Not for Resale, 02/21/2023agree a common set of guidelines for the
05:36:35 MST
product.
(i) The competences of organisations certifying products shall be as the competency requirements for
Volume 1 Series 100
(e)Table
(05/14) The1/1 Competency
scheme must have additions to Construction
a technical supervisory Product
panel that providesRegulation (EU) No.
technical oversight 305/2011
on the operation
Annex IV,of(Table
the scheme
2) and formally consents to the issue of assessment and certification requirements of the
specialist groups developing the assessment and certification requirements. This panel must include a
Competence balanced representation of key endofusers,
Description recognized industry
Competence experts and those responsible for the
Requirement
highways on which
7. Determining the specific Understand and evaluate the such products will be used or installed. A certification body shall have staff with
installation
(f) or post installation or post manufacturing
The product certification must include requirements for the audit appropriate
and qualitytechnical knowledge
control of the
of the production
manufacturing control processes
and installation processes
for theof product
the specific product
where necessary in taking relationship
accountbetween the installation/post
of the product having its
performance declaredorder undertoaidentify
CE mark. appropriate
Installer certification manufacturing
must include processes requirements and for
the on-site
product
surveillance of installation measures ensuring
or post consistentprocesses.characteristics related to production control
manufacturing
compliant delivery of the installed or for installation or post manufacture.
(g) For every product it has certified under a product certification scheme, an organisation must make open
post manufactured product.
and publicly accessible details of the assessment and certification guidelines.
(h) Where different organisations with highwayhave infrastructure
certified the same generic form ofperformance
certified product theyofmust be able
products of to
the
demonstrate to the Overseeing managers and other certifying bodies same generic type and where appropriatethe
Organisation equivalence of performance of products certified under
different schemes or for agree a common
resolution set of guidelines for the
of issues. assessment
agree a common andsetcertification
of guidelinesof the
for the
product. assessment and certification of such
(i) The competences of organisations certifying products shall be products.
as the competency requirements for
(05/14) European Technical Assessment (ETA)
17 (05/14) The requirements for works, goods or materials to be subject to a product certification scheme or
product acceptance scheme as discussed in sub- Clauses 12 to 16 above may alternatively be met by a product
Table 1/1 Competency additions to Construction Product Regulation with the(EU) No. 305/2011
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(05/14)
being attested using a European Technical Assessment (ETA) issued in accordance procedure set out in
Annex IV, (Table 2)
Regulation 305/2011, provided that the relevant attestation imposes an equivalent level of safety, performance and
fitness for purpose provided for by the specification.
Competence Description of Competence Requirement
(05/14) Statutory Type Approval
7. Determining the specific Understand and evaluate the A certification body shall have staff with
installation or post installation
18 (05/14) The requirements for statutory type approval are embodied in or post manufacturing appropriate
the Traffictechnical knowledgeand
Signs Regulations of the
General
manufacturing control processes of the specific product in
Directions 2002, the Zebra, Pelican and Puffin Pedestrian Crossings Regulations and General Directions 1997, and relationship between the installation/post
subsequent order to identify appropriate manufacturing processesD. and theContractor
product
Volume 1 amending Regulations. Traffic
measures
signs requiring
ensuring consistent
such approval are listed in Appendix
characteristics related to
The
production Series
control100
shall submit written
Specification for Highway evidence Works to the Overseeing Organisation that the relevant statutory type approval has been
Preliminaries
obtained. Where the Contractor compliant has designed delivery
part ofofthe
theworks
installed or forstatutory
for which installation typeorapproval
post manufacture.
is required,
post manufactured product.
application to the Secretary of State shall be made through the Overseeing Organisation.
(05/14) Statutory Authorisationwith highway infrastructure certified performance of products of the
Amendment - May 2014 managers and
19 (05/14) Statutory authorisation is required before any traffic signs are other certifying bodies same generic type
incorporated intoandthewhere where these 7
worksappropriate
for resolution of issues.
are of a character and/or are to be used in circumstances which have not been prescribed in the Traffic Signs agree a common set of guidelines for the
Regulations and General Directions 2002, the Zebra, Pelican and Puffin Pedestrian Crossings Regulations and assessment and certification of such
General Directions 1997, or subsequent amending Regulations. Where products. the Contractor has designed part of the
works for which such authorisation is required, applications in accordance with the Regulations shall be made
(05/14) European Technical Assessment (ETA)
through the Overseeing Organisation.
17 (05/14) The requirements for works, goods or materials to be subject to a product certification scheme or
(05/14) Type Approval/Registration/Listing
product acceptance scheme as discussed in sub- Clauses 12 to 16 above may alternatively be met by a product
20
being(05/14)attested Theusing typesaof works, goods
European or materials
Technical Assessmentwhich are required
(ETA) issued intoaccordance
have Type with Approval or Registration
the procedure set outprior
in
to their acceptance
Regulation 305/2011, forprovided
inclusionthat in the
theworks
relevantareattestation
given in Appendix
imposes an E, equivalent
with the exception
level of that safety,products that areand
performance
covered
fitness for bypurpose
the Constructionprovided for Products
by theRegulation
specification.(EU) No. 305/2011 (CPR) do not have to be listed prior to their
acceptance for inclusion in the works. For products not covered by CPR previously obtained type approval or
(05/14)
registration Statutory can beType used.Approval
The Contractor shall submit to the Overseeing Organisation a copy of the type approval/
registration certificate. Where previously obtained type approval or registration is not available the Contractor shall
18 (05/14) The requirements for statutory type approval are embodied in the Traffic Signs Regulations and General
submit documentation to the Overseeing Organisation which demonstrates compliance with the relevant
Directions 2002, the Zebra, Pelican and Puffin Pedestrian Crossings Regulations and General Directions 1997, and
specification and/or standards. For products covered by the CPR the information required in Clause 104.3 shall be
subsequent amending Regulations. Traffic signs requiring such approval are listed in Appendix D. The Contractor
provided by the Contractor in accordance with that sub-Clause.
shall submit written evidence to the Overseeing Organisation that the relevant statutory type approval has been
obtained.
(05/14) Where the
Provision Contractor has designed part of the works for which statutory type approval is required,
of Information
application to the Secretary of State shall be made through the Overseeing Organisation.
21 (05/14) Where information and documentation regarding works, goods or materials is required to be submitted
to the Overseeing Organisation for acceptance the Contractor shall submit such documentation in a timescale to
meet the requirements
Amendment May 2014
- April of the Contractor’s programme of works. The Contractor shall liaise with the Overseeing 7
2022 8
Organisation
to ensure that adequate time is allocated for the Overseeing Organisation to
undertake the required
assessments
No reproduction for
or networking permitted acceptance.
without The time allocated for acceptance
license from S&P Global shall
Not for Resale, not 05:36:35
02/21/2023 be less
MST than four weeks.
acceptance for inclusion in the works. For products not covered by CPR previously obtained type approval or
registration can be used. The Contractor shall submit to the Overseeing Organisation a copy of the type approval/
registration
Volume 1 certificate. Where previously obtained type approval or registration is not available the Contractor
Seriesshall
100
submit documentation to the
Specification for Highway WorksOverseeing Organisation which demonstrates compliance with the relevant
Preliminaries
(05/14) Provision of Information
Statutory Authorisation
21
19 (05/14) Where
Statutory information
authorisationand isdocumentation
required before regarding
any trafficworks,
signsgoods or materialsinto
are incorporated is required
the works to be submitted
where these
to
arethe
of Overseeing Organisation
a character and/or are to beforused
acceptance the Contractor
in circumstances whichshall
havesubmit such
not been documentation
prescribed in a timescale
in the Traffic Signs to
meet the requirements
Regulations and General of Directions
the Contractor’s
2002, programme of works.
the Zebra, Pelican andThe Contractor
Puffin Pedestrianshall liaise with
Crossings the Overseeing
Regulations and
Organisation to ensure
General Directions thatoradequate
1997, subsequent time is allocated
amending for the Overseeing
Regulations. Where theOrganisation
Contractor has to undertake
designed partthe required
of the
assessments
works for which for acceptance. The time
such authorisation is allocated
required, for acceptance
applications in shall not be with
accordance less than four weeks. shall be made
the Regulations
through the Overseeing Organisation.
22 (05/14) Unless otherwise specified, two copies of all information and documentation, including valid
certificates,
(05/14) Type in respect of work, goods or materials proposed by the Contractor shall be supplied to the Overseeing
Approval/Registration/Listing
Organisation in English.
20 (05/14) The types of works, goods or materials which are required to have Type Approval or Registration prior
23 (05/14)
to their Where the
acceptance forContractor
inclusion in proposes
the works to use an equivalent
are given in Appendix standard, quality
E, with management
the exception thatscheme,
productsproduct
that are
certification scheme, industry product acceptance scheme, or type approval/registration
covered by the Construction Products Regulation (EU) No. 305/2011 (CPR) do not have to be listed to that specified
priorthe
to their
Contractor
acceptance shall provide in
for inclusion relevant information
the works. to enable
For products the Overseeing
not covered by CPROrganisation to ascertain
previously obtained typewhether
approvalorornot the
proposal is equivalent
registration can be used.to The
the specified
Contractor requirement.
shall submitThe information
to the Overseeing provided by the Contractor
Organisation a copy of the shall provide
type full
approval/
disclosure and appropriate evidence regarding the works, goods or materials concerned in order
registration certificate. Where previously obtained type approval or registration is not available the Contractor shall to fully
demonstrate equivalenttolevels
submit documentation of safety, performance
the Overseeing Organisationand fitness
which for purpose.
demonstrates For products
compliance withwithin the scope of the
the relevant
Construction
specification and/or standards. For products covered by the CPR the information required in Clause 104.3and
Products Regulation this documentation would be the relevant Declaration of Performance shall be
associated
provided byCE themark for the in
Contractor intended
accordancespecified
withuse.
that sub-Clause.
24 (05/14) When required in contract specific Appendix 1/4, three copies of detailed working and fabrication
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(05/14) Provision of Information
drawings in the format detailed in contract specific Appendix 1/4, prepared by or on behalf of the Contractor, shall
21 (05/14) Where
be submitted information
for the Overseeing and documentation
Organisation’s regardingThe
acceptance. works, goods or
minimum materials
period is requiredoftothe
for submission be drawings
submitted
to thetoOverseeing
prior commencementOrganisation for acceptance
of the related the be
works shall Contractor
as statedshall submitspecific
in contract such documentation
Appendix 1/4.inSuch a timescale to
acceptance
meet in
shall thenorequirements
way relieve of thethe Contractor’s
Contractor programme
of his of works.
responsibilities for theThework
Contractor
under theshall liaise with the Overseeing
Contract.
Organisation to ensure that adequate time is allocated for the Overseeing Organisation to undertake the required
assessments for acceptance. The time allocated for acceptance shall not be less than four weeks.
105 (05/14) Goods, Materials, Sampling and Testing Goods and Materials
22 (05/14) Unless otherwise specified, two copies of all information and documentation, including valid
1certificates, in respect
(05/14) The of work,
Contractor shallgoods or the
provide materials proposed
Overseeing by the Contractor
Organisation shall
with details ofbe
thesupplied tofrom
suppliers the Overseeing
whom he
Organisation
proposes in English.
to purchase the goods and materials necessary for the execution of the works prior to their inclusion in the
works.
23 (05/14) Where the Contractor proposes to use an equivalent standard, quality management scheme, product
certification
Unless scheme,
otherwise industry
detailed productspecific
in contract acceptance scheme,
Appendix 1/5orthe
type approval/registration
Contractor shall keep and to maintain
that specified therecords
supply
Contractor
of all works,shall provide
goods relevant information
and materials incorporatedtointo
enable the Overseeing
the works. Organisation
These shall include: to ascertain whether or not the
proposal is equivalent to the specified requirement. The information provided by the Contractor shall provide full
Volume
(i) 1 supplier’s details, including name/company name and address; Series 100
disclosure and appropriate evidence regarding the works, goods or materials concerned in order to fully
(ii) date
demonstrate of supplylevels
equivalent to site;
of safety, performance and fitness for purpose. For products within the scope of the
Construction Products Regulation this documentation would be the relevant Declaration of Performance and
(iii) manufacturer’s information and safety information;
associated CE mark for the intended specified use.
(iv) details
Amendment of where
- May 2014 the goods are incorporated into the works. 8
These
drawingsdetails shall
in the be provided
format detailed to
in the Overseeing
contract specificOrganisation
Appendix 1/4, by prepared
the Contractor
by or upon request
on behalf andContractor,
of the at completion
shallof
the works. for the Overseeing Organisation’s acceptance. The minimum period for submission of the drawings
be submitted
prior to commencement of the related works shall be as stated in contract specific Appendix 1/4. Such acceptance
shall in no way relieve the Contractor of his responsibilities for the work under the Contract.
105 (05/14) Goods, Materials, Sampling and Testing Goods and Materials
reasonable
1 (05/14) Thein allContractor
the circumstances unlesstheotherwise
shall provide Overseeingprescribed by thewith
Organisation Overseeing Organisation.
details of the suppliersThefromContractor
whom he
shall supply to the Overseeing Organisation, within 24 hours of the completion of each test, a
proposes to purchase the goods and materials necessary for the execution of the works prior to their inclusioncopy of the results.
in the
works.
The following operations are not included in contract specific Appendix 1/5:
Unless
(i) otherwise detailed
checking, in contract
inspecting, specificmeasuring
examining, Appendix(except
1/5 the in
Contractor shall
connection keep
with and maintain supply records
testing);
of all works, goods and materials incorporated into the works. These shall include:
(i) supplier’s details, including name/company name and address;
(iii) routine testing carried out by manufacturers and suppliers in compliance with a specified standard or
(ii) date of supply to site;
specification;
(iii)
(iv) manufacturer’s
testing of plant. information and safety information;
Amendment May
3 (05/14) Where
- April 2014
2022
required in contract specific Appendix 1/5 test certificates and/or product certification complying8
9
with the provisions of the relevant standard or specification
where applicable and certifying that the goods or
materials meet the specified requirements, shall be supplied
to the Overseeing Organisation by the Contractor at
Volume 1 Series 100
specification;
(iv) details
testing of where
plant. the goods are incorporated into the works.
These details
3 (05/14) shallrequired
Where be provided to the Overseeing
in contract Organisation
specific Appendix bycertificates
1/5 test the Contractor upon
and/or request
product and at completion
certification of
complying
the
withworks.
the provisions of the relevant standard or specification where applicable and certifying that the goods or
(05/14) Sampling
least four and Testing
weeks prior to the incorporation of the goods or materials in the works.
2Where goods
(05/14) Theortesting
materialsscheduled in contract
are required to be CEspecific
marked Appendix
or where1/5,
theincluding
Contractor sampling
proposes andtoprovision of the goods
use CE marked
associated
or materialssamples, shall beshall
the Contractor undertaken
supply theby the Contractor.
Overseeing The Contractor
Organisation with theshall
CE carry out each
marking of the tests
information required
including
in contract
any relevantspecific Appendix
instructions 1/5 within
and safety an elapsed
information timefour
at least fromweeks
the taking
prior ofto the respective
incorporation samples
of thewhich
goodsshall
or be
reasonable in all the circumstances unless otherwise
materials in the works. This information shall be in English. prescribed by the Overseeing Organisation. The Contractor
shall supply to the Overseeing Organisation, within 24 hours of the completion of each test, a copy of the results.
The following
testing operations
laboratories are not
accredited included in with
in accordance contract
BS EN specific Appendix
ISO/IEC 17025. 1/5:The accreditation shall be by UKAS or
equivalent
(i) European accreditation organisation which is party to
checking, inspecting, examining, measuring (except in connection with a multi-lateral agreement (MLA) with UKAS or any
testing);
other equivalent International Accreditation Forum MLA signatory with a scope that includes BS EN ISO/IEC 17025.
Where UKAS or equivalent laboratory accreditation is required the results shall be reported on an official UKAS or
(iii) routine
equivalent accreditedtesting carriedtest
laboratory out report
by manufacturers
or certificate. and suppliers in compliance with a specified standard or
specification;
scheme,(iv) product
testingcertification
of plant. scheme or product acceptance scheme as provided for in Clause 104, testing and
sampling
3 (05/14)asWhere
specified in or in
applicable
contract to such an equivalent 1/5standard quality management scheme, product
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required specific Appendix test certificates and/or product certification complying
certification
with the provisions of the relevant standard or specification where applicable and certifying that the goodsin
scheme or product acceptance scheme is accepted and shall be substituted for those specified or
contract
materialsspecific
meet the Appendices 1/5 and 1/6 respectively.
specified requirements, shall be supplied to the Overseeing Organisation by the Contractor at
least four weeks
6 (05/14) prior to theshall
The Contractor incorporation of the goods
provide samples, whichorshallmaterials
includeinsource
the works.
samples, of goods and materials and
shall deliver these to the Overseeing Organisation as described in
Where goods or materials are required to be CE marked or where the Contractor proposes contract specific Appendix 1/6.CE
to use Unless
markedotherwise
goods
stated in contract specific Appendix 1/6, the Contractor shall arrange for the sampling
or materials the Contractor shall supply the Overseeing Organisation with the CE marking information including of such goods and materials
to
anyberelevant
undertaken by qualified
instructions staff ofinformation
and safety testing laboratories
at least fourholding
weeks UKAS
prior orto equivalent European
the incorporation Accreditation
of the goods or
Organisation accreditation to BS EN ISO/IEC
materials in the works. This information shall be in English. 17025 for such sampling. These samples shall be supplied in
sufficient time for them to be tested for acceptability by the Overseeing Organisation, taking into account the
4programme
(05/14) Where
for therequired in contract samples
works. Production specific Appendix 1/5 testsinand
shall be delivered associatedwhich
a condition sampling shall be undertaken
is representative of the by
testing laboratories accredited in
material’s state for the purpose of the test.accordance with BS EN ISO/IEC 17025. The accreditation shall be by UKAS or
equivalent European accreditation organisation which is party to a multi-lateral agreement (MLA) with UKAS or any
7other(05/14) The Contractor
equivalent International shall provide forForum
Accreditation rates ofMLA
sampling specified
signatory with ainscope
contract
thatspecific
includesAppendix 1/6. These
BS EN ISO/IEC 17025.
rates of sampling shall apply at the outset of each of the respective activities and for the duration of each of the
Where UKAS
activities. or equivalent
Following an initiallaboratory
period ofaccreditation
sampling, theisContractor
required the mayresults
apply shall be Overseeing
to the reported on Organisation
an official UKASfor a or
equivalent
relaxation
Volume accredited laboratory test report or certificate.
1 in these rates of sampling having demonstrated to the Overseeing Organisation an acceptable level of 100
Series
confidence
Specification in for
5 (05/14) Where control.
Highway
goods Provided,
orWorks at any
materials aresubsequent
accepted on time
thewhen
basistest results
of an indicate
equivalent the needquality
standard, for improved control in
Preliminaries
management
the opinion
scheme, of thecertification
product Overseeingscheme
Organisation, the Contractor
or product acceptancesamples
scheme at asthe rate specified
provided in contract
for in Clause specificand
104, testing
Appendix 1/6.
sampling as specified in or applicable to such an equivalent standard quality management scheme, product
certification
8Amendment scheme
(05/14) Where or product
testing acceptance
is undertaken by ascheme
supplierisoraccepted and shall
manufacturer be substituted
in accordance forthe
with those specified
Contract, in than
other
contract specific- May 2014
Appendices 1/5 and 1/6 respectively. 9
for products which are CE marked, the Contractor shall ensure that each supplier and manufacturer will admit the
Overseeing
6 (05/14) The Organisation’s representative
Contractor shall to his premises
provide samples, during
which shall normal
include working
source hoursoffor
samples, the purposes
goods of and
and materials
inspecting,
shall deliverselecting
these to the samples
OverseeingandOrganisation
witnessing the as testing.
described in contract specific Appendix 1/6. Unless otherwise
stated in contract
9 (05/14) Wherespecific Appendix
testing or 1/6, the Contractor
in use operation shall arrange
of works, goods for the
or materials sampling
which are CEofmarked
such goods and materials
identifies failure of
to be undertaken by qualified staff of testing laboratories holding UKAS or equivalent European
the CE marked works, goods or materials, the Contractor shall make formal notification of the failure to the Accreditation
Organisation
relevant Trading accreditation
Standards to BS EN
office. TheISO/IEC 17025
Contractor forcopy
shall suchsuch
sampling. These samples
correspondence to theshall be supplied
Overseeing in
Organisation.
programme for the works. Production samples shall be delivered in a condition which is representative of the
material’s
106 (05/14)state for the
Design ofpurpose
Worksofbythethe test.
Contractor
7 (05/14) The Contractor shall provide for rates of sampling specified in contract specific Appendix 1/6. These
rates ofPermanent
(05/14) Works
sampling shall Design
apply at the outset of each of the respective activities and for the duration of each of the
1activities.
(05/14)Following an initial
The Contractor shallperiod
designofthe
sampling, the Contractor
works items or elements may apply
listed to the Overseeing
specific Appendix 1/10for
(A)ato
relaxation in these rates of sampling having demonstrated to the Overseeing Organisation
comply with the design specifications and requirements therein. Where the Contractor proposes to design a works an acceptable level of
confidence
item or element for which a choice of designs is offered and listed in Appendix 1/10 (B) he shall comply with thein
in control. Provided, at any subsequent time when test results indicate the need for improved control
the
design opinion of the Overseeing
specification Organisation,
and requirements theThe
therein. Contractor
Contractorsamples at the rate
shall follow specified approval
the technical in contract specific given
procedures
Appendix 1/6.
in the Technical Approval Scheme adopted by the Overseeing Organisation for which purposes the Contractor shall
be deemed to be the designer.
Amendment - April May 2014
2022 9
10
Global Permanent Structures
(05/14)
Provided by S&P Licensee=Ramboll UK Ltd/5967592001, User=xu, jiandong
Overseeing Organisation’s representative to his premises during normal working hours for the purposes of
inspecting, selecting the samples and witnessing the testing.
9 (05/14)
Volume 1 Where testing or in use operation of works, goods or materials which are CE marked identifiesSeriesfailure100
of
the CE marked works, goods or
Specification for Highway Works materials, the Contractor shall make formal notification of the failure to the
Preliminaries
relevant Trading Standards office. The Contractor shall copy such correspondence to the Overseeing Organisation.
8 (05/14)
106 (05/14) Where
Designtesting is undertaken
of Works by theby a supplier or manufacturer in accordance with the Contract, other than
Contractor
for products which are CE marked, the Contractor shall ensure that each supplier and manufacturer will admit the
Overseeing
(05/14) Organisation’s
Permanent representative
Works Design to his premises during normal working hours for the purposes of
inspecting, selecting the samples and witnessing the testing.
1 (05/14) The Contractor shall design the works items or elements listed in contract specific Appendix 1/10 (A) to
9 (05/14)
comply Where
with testingspecifications
the design or in use operation of works, goods
and requirements or materials
therein. Where thewhich are CEproposes
Contractor marked toidentifies
design afailure
worksof
the CE marked works, goods or materials, the Contractor shall make formal notification of the failure to
item or element for which a choice of designs is offered and listed in Appendix 1/10 (B) he shall comply with the the
relevant Trading Standards
design specification office. Thetherein.
and requirements Contractor
Theshall copy such
Contractor shallcorrespondence to theapproval
follow the technical Overseeing Organisation.
procedures given
in the Technical Approval Scheme adopted by the Overseeing Organisation for which purposes the Contractor shall
be deemed to be the designer.
106 (05/14) Design of Works by the Contractor
(05/14) Permanent Structures
(05/14) Permanent Works Design
2 (05/14) Unless otherwise stated in contract specific Appendix 1/10 the Contractor shall follow the technical
1approval
(05/14) The Contractor
procedures given shall
in BD2design
(DMRBthe works
1.1.1).items or elements listed in contract specific Appendix 1/10 (A) to
comply with the design specifications and requirements therein. Where the Contractor proposes to design a works
3item(12/14) Unless
or element forotherwise stated in
which a choice of contract
designs is specific
offeredAppendix
and listed1/10 the Contractor
in Appendix shall
1/10 (B) hecomplete the Approval
shall comply with the
in Principle (AIP) form, or Record of Design Principles and Record of Assessment Principles
design specification and requirements therein. The Contractor shall follow the technical approval procedures for each structure or
given
element to be designed. The Contractor shall complete any other documentation required
in the Technical Approval Scheme adopted by the Overseeing Organisation for which purposes the Contractor shall for the Technical
Approval
be deemedprocedures such as Departures from Standard. The Contractor shall complete design and check
to be the designer.
certificates as required. The Contractor shall forward the completed forms and certificates to the Overseeing
Organisation
(05/14) for acceptance
Permanent Structures and onward transmission to the Technical Approval Authority. The format of these and
other submissions shall be agreed with the Overseeing Organisation, where paper copies are required three copies
2shall(05/14) Unlesstootherwise
be supplied stated in
the Overseeing contract specific Appendix 1/10 the Contractor shall follow the technical
Organisation.
approval procedures given in BD2 (DMRB 1.1.1).
4 (05/14) The Contractor shall make any necessary alterations to the AIP or other documentation as required and
3submit (12/14) Unless otherwise
the revised documentsstated
to theinOverseeing
Organisation 1/10
in the the Contractor
agreed format. shall complete the Approval
in Principle (AIP) form, or Record of Design Principles and Record of Assessment Principles for each structure or
5element
(05/14) Unless
to be otherwise
designed. stated in contract
The Contractor specific Appendix
shall complete 1/10 the Contractor
any other documentation shallfor
required allow six working weeks
the Technical
for
Approval procedures such as Departures from Standard. The Contractor shall complete design and checkto the
the review of the documentation by the Technical Approval Authority. Where revisions are required
documentation the Contractor
certificates as required. shall allow
The Contractor an additional
shall forward thefour workingforms
completed weeksand forcertificates
review of the revised
to the documents by
Overseeing
the Technical Approval Authority.
Organisation for acceptance and onward transmission to the Technical Approval Authority. The format of these and
6other(05/14)
submissions shall be agreed
Unless otherwise statedwith the Overseeing
in contact Organisation,
specific Appendix 1/10 where paper copies
three copies are required
of the completed threefor
‘Issue copies
shall be supplied
Construction’ to the
(IFC) Overseeing
drawings shall beOrganisation.
submitted to the Overseeing Organisation for acceptance. The Contractor
shall allow The
4 (05/14) fourContractor
working weeks shall for
makereview and acceptance
any necessary of thetoIFC
alterations the drawings
AIP or otherby the Overseeing Organisation.
documentation as required and
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submit the revised documents to the Overseeing Organisation in the agreed format.
7 (05/14) The works detailed in the documentation shall not commence until acceptance by the Technical
Approval
5 (05/14)Authority and the Overseeing
Unless otherwise Organisation
stated in contract specifichas been notified
Appendix 1/10 theto the Contractor.
Contractor shall allow six working weeks
for the review of the documentation by the Technical Approval Authority. Where revisions are required to the
(05/14) Temporary Works Design
documentation the Contractor shall allow an additional four working weeks for review of the revised documents by
8the Technical
(05/14) TheApproval
Contractor Authority.
shall comply with the requirements of contract specific Appendix 1/11 for the items of
temporary works design listed
6 (05/14) Unless otherwise stated therein.
in contact specific Appendix 1/10 three copies of the completed ‘Issue for
Construction’ (IFC)
(05/14) Temporary Structures
drawings shall be submitted to the Overseeing Organisation for acceptance. The Contractor
shall allow four working weeks for review and acceptance of the IFC drawings by the Overseeing Organisation.
9Volume
7 (05/14) Equipment
1 The
(05/14)
designedinby
works detailed thethe Contractor forshall
documentation temporary works, including
not commence bridge lifting
until acceptance by thesystems,
Technical structures
Series 100
demolition,
Specification support
for systems
Highway and
Works platforms used over or adjacent to highway,
Approval Authority and the Overseeing Organisation has been notified to the Contractor. railway, watercourse, footpath or
Preliminaries
other public right of way, or where failure could affect the integrity or safety of any persons or structure, shall be
considered
(05/14) as a temporary
Temporary Works structure
Design and subject to the requirements of this Clause.
810 (05/14) Unless
(05/14) The otherwise
Contractor stated
shall in contract
comply specific
with the Appendix
requirements of 1/11
contractthe Contractor
specific Appendix shall follow
1/11 the technical
for the items of
approval
Amendment procedures
temporary works given
- December in BD2
design listed2014 (DMRB
therein. 1.1.1) for which purposes the Contractor shall be deemed to be the 10
Designer. Works are to be designated as described in Section 4 of BD2 (DMRB 1.1.1). The design specifications,
Temporary
requirements
(05/14) Structuresfor equipment to be designed by the Contractor shall be as stated in contract specific
and constraints
Appendix 1/11.
9 (05/14) Equipment designed by the Contractor for temporary works, including bridge lifting systems, structures
11 (12/14) Where
demolition, supportrequired
systemsthe
andContractor
platformsshall
usedcomplete the Approval
over or adjacent to highway,in Principle
railway, (AIP) or Recordfootpath
watercourse, of Design or
Principles
other and
public Record
right of Assessment
of way, Principles
or where failure could for each
affect theitem incorporating
integrity or safetyall of equipment
any personstoorbestructure,
designed.shall
The be
Contractor shall
considered complete any
as a temporary other and
structure documentation required
subject to the for the of
requirements Technical
this Clause. Approval procedures such as
Departures from Standard. The Contractor shall complete design and check certificates as required. The completed
forms and certificates shall be submitted by the Contractor to the Overseeing Organisation for onward transmission
Amendment December
to the Technical- Approval
April 2022 2014 The format of these and other submissions shall be agreed with the Overseeing
Authority. 10
11
Organisation,
where paper copies are required three copies shall be supplied to the Overseeing
Organisation.
The Contractor shall make any necessary alterations to the AIP or other documentation as required and submit the
10 (05/14) Unless otherwise stated in contract specific Appendix 1/11 the Contractor shall follow the technical
approval1procedures given in BD2 (DMRB 1.1.1) for which purposes the Contractor shall be deemed to beSeries
Volume the 100
Designer. Works
Specification for are to be designated
Highway Works as described in Section 4 of BD2 (DMRB 1.1.1). The design specifications,
Preliminaries
requirements and constraints for equipment to be designed by the Contractor shall be as stated in contract specific
Appendix 1/11.
11 (12/14)
10 (05/14) Where
Unless required
otherwisethe Contractor
stated shallspecific
in contract complete the Approval
Appendix in Principle
1/11 the Contractor (AIP)
shallorfollow
Recordtheoftechnical
Design
Principles and Recordgiven
approval procedures of Assessment
in BD2 (DMRB Principles forfor
1.1.1) each itempurposes
which incorporating all equipment
the Contractor to be
shall be designed.
deemed to beThe
the
Contractor shall complete
Designer. Works any other documentation
are to be designated as described inrequired
Section for
4 ofthe Technical
BD2 (DMRBApproval procedures
1.1.1). The such as
design specifications,
Departures
requirements from
andStandard.
constraintsThe
forContractor
equipmentshallto becomplete
designeddesign
by theand check certificates
Contractor shall be asas required.
stated The completed
in contract specific
forms
Appendixand 1/11.
certificates shall be submitted by the Contractor to the Overseeing Organisation for onward transmission
to the Technical Approval Authority. The format of these and other submissions shall be agreed with the Overseeing
11 (12/14) Where required the Contractor shall complete the Approval in Principle (AIP) or Record of Design
Organisation, where paper copies are required three copies shall be supplied to the Overseeing Organisation.
Principles and Record of Assessment Principles for each item incorporating all equipment to be designed. The
The Contractor
Contractor shallshall makeany
complete anyother
necessary alterationsrequired
documentation to the AIPfororthe
other documentation
Technical Approvalasprocedures
required and
suchsubmit
as the
revised
Departuresdocuments to the Overseeing
from Standard. Organisation
The Contractor in the agreed
shall complete designformat.
and check certificates as required. The completed
forms and certificates shall be submitted by the Contractor to the Overseeing Organisation for onward transmission
12 (05/14) Unless otherwise stated in contract specific Appendix 1/11 the Contractor shall allow six working weeks
to the Technical Approval Authority. The format of these and other submissions shall be agreed with the Overseeing
for the review of the documentation by the Technical Approval Authority. Where revisions are required to the
Organisation, where paper copies are required three copies shall be supplied to the Overseeing Organisation.
documentation the Contractor shall allow an additional four working weeks for review of the revised documents by
the
TheTechnical
Contractor Approval
shall make Authority.
any necessary alterations to the AIP or other documentation as required and submit the
revised documents to the Overseeing Organisation in the agreed format.
13 (05/14) Unless otherwise stated in contact specific Appendix 1/11 three copies of the completed ‘Issue for
12 (05/14) Unless
Construction’ (IFC)otherwise
drawingsstated
shall in
be contract
submitted to the Appendix
specific Overseeing1/11 Organisation for acceptance
the Contractor shall allowandsix forwarding
working weeksto
the Technical
for the reviewApproval Authority. The
of the documentation byContractor
the Technicalshall allow four
Approval workingWhere
Authority. weeksrevisions
for reviewareand acceptance
required to theof the
IFC drawings by
documentation thethe Overseeing
Contractor Organisation.
shall allow an additional four working weeks for review of the revised documents by
the Technical Approval Authority.
14 (05/14) The works detailed in the documentation shall not commence until acceptance by the Technical
13 (05/14)Authority
Approval and the Overseeing
Unless otherwise Organisation
stated in contact specific has been notified
Appendix to the
1/11 three Contractor.
copies of the completed ‘Issue for
Construction’ (IFC) drawings shall be submitted to the Overseeing Organisation for acceptance and forwarding to
the Technical Approval Authority. The Contractor shall allow four working weeks for review and acceptance of the
107 (05/14) Site
IFC drawings by Extent and Limitations
the Overseeing Organisation.on Use
114 (05/14) The extent
works of
detailed inand
the site the any
documentation
limitations shall
on itsnot
usecommence
shall be as until acceptance
described by thespecific
in contract Technical
Appendix
Approval Authority and the Overseeing Organisation has been notified to the Contractor.
1/7.
107 (05/14) Operatives

108 Site Extent for
andthe
Limitations onOrganisation
Overseeing Use
extent of theshall
1 (05/14) The Contractor siteprovide
and anythe
limitations on its
Overseeing use shall bewith,
Organisation as described in contract
and maintain specific
continuity Appendix
of, operatives
1/7. to the tasks, and capable of performing the functions, described in contract specific Appendix 1/8.
equal
2 (05/14) For site surveys and setting out, operatives shall be experienced in assisting engineers in such work.
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108
3 (05/14) Operatives
(05/14) For for theduties,
laboratory-related Overseeing Organisation
operatives shall be capable of assisting laboratory staff in routine tasks.
14 (05/14) The
Operatives provided
Contractor shall under
providesub-Clauses 2 andOrganisation
the Overseeing 3 of this Clause shall
with, andhave validcontinuity
maintain driving licences and
of, operatives
driving
equal toexperience suitable
the tasks, and for of
capable theperforming
vehicles supplied in accordance
the functions, with
described in contract
contract specific
specific Appendix
Appendix 1/2.
1/8.
2 (05/14) For site surveys and setting out, operatives shall be experienced in assisting engineers in such work.
109
3 (05/14) Control
(05/14) For of Noise and
laboratory-related Vibration
duties, operatives shall be capable of assisting laboratory staff in routine tasks.
4 (05/14)
(05/14) Operatives
General provided under sub-Clauses 2 and 3 of this Clause shall have valid driving licences and
driving experience suitable for the vehicles supplied in accordance with contract specific Appendix 1/2.
1 (05/14) The Contractor shall comply with the recommendations for practical measures to reduce noise set out in
BS 5228: Noise and Vibration Control on Construction and Open Sites: 2009: Parts 1 & 2 and with any specific
109 (05/14) Control
requirements stated inof Noisespecific
contract and Vibration
Appendix 1/9.
2 (05/14)
(05/14) The Contractor
General shall comply with any specific requirements for the control of vibration stated in
contract specific Appendices 1/9, 2/4, 6/3, 6/13 and Clause 607.
1 (05/14) The Contractor shall comply with the recommendations for practical measures to reduce noise set out in
3 (05/14) The Contractor shall carry out the measurement and monitoring of construction noise and vibration
BS 5228: Noise and Vibration Control on Construction and Open Sites: 2009: Parts 1 & 2 and with any specific
effects as detailed in contract specific Appendix 1/9.
requirements stated in contract specific Appendix 1/9.
2 (05/14) The-Contractor
Amendment December 2014
shall comply with any specific requirements for the control of vibration stated in 11
contract specific Appendices 1/9, 2/4, 6/3, 6/13 and Clause 607.
3 (05/14) The Contractor shall carry out the measurement and monitoring of construction noise and vibration
effects as detailed in contract specific Appendix 1/9.
December
Amendment - April 2022 2014 11
12
Volume 1 Series 100
(05/14) Vibration
5 (05/14) The Contractor shall limit vibration levels arising from the site activities to the levels stated in contract
specific Appendix 1/9. Tracked plant shall be prohibited from travelling within 6m of buildings.
6 (05/14) Unless otherwise detailed in contract specific Appendix 1/9 the levels of vibration shall be monitored by
the Contractor using an approved vibration meter plus a graphical level recorder, a record of this shall be provided
to the Overseeing Organisation within 24 hours. Vibration control stations will be at locations as detailed in
contract specific Appendix 1/9.
110 (05/14) Information Boards

1 (05/14) The Contractor shall, within four weeks of the date for the commencement of the works provide and
erect information boards at the locations and to the specification given in contract specific Appendix 1/21. The
Contractor shall ensure that they are kept clean and maintained in a safe and legible condition and remove them on
completion of the works.
2 (05/14) The design, content and layout of information boards and any other project publicity material including
any and all Overseeing Organisation logos and branding shall be in accordance with policy requirements of the
Overseeing Organisation, the contract employer and the highway authority and in accordance with contract specific
Appendix 1/21. For the Highways Agency these requirements shall be in accordance with the requirements stated
in the document ‘The Highways Agency’s Visual Identity Specifications’.
111 (05/14) Existing Ground Levels

1 (05/14) The Contractor shall satisfy himself that the existing ground levels as described in contract specific
Appendix 1/12 are correct. Should the Contractor wish to dispute any levels he shall submit to the Overseeing
Organisation a schedule of the position of the levels considered to be in error and a set of revised levels. The
existing ground relevant to the disputed levels shall not be disturbed before the correct levels are determined.
#112 (05/14) Setting Out

1 (05/14) The Contractor shall, unless otherwise stated in contract specific Appendix 1/12, within 3 weeks of the
date for commencement of the works, carry out a check of the co-ordinates and levels of all permanent ground
markers and permanent bench marks described in Appendix 1/12 and shall supply the Overseeing Organisation, if
requested, with their position and level in order that they may be checked and revised if necessary. The Contractor
shall identify and bring to the attention of the Overseeing Organisation any markers that are missing. The
Contractor shall comply with any specific requirements for setting out described in contract specific Appendix
1/12.
2 (05/14) The Contractor shall keep updated schedules and drawings of all bench marks (which shall be based on
Ordnance Datum at Newlyn) used in the setting out and shall make these available to the Overseeing Organisation
when required.
3 (05/14) The Contractor shall ensure that where necessary, in order to maintain his programme, lines and levels
are set out in such time as to enable Statutory Undertakers’ apparatus and other publicly or privately owned services
or supplies to be installed, altered or removed.
4 (05/14) The Contractor shall survey and record existing details of items which he is required to remove and
subsequently replace. The level of survey information to be recorded is described in contract specific Appendix
1/12.
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113 (05/14) Programme of Works

1 (05/14) Subject and without prejudice to the Conditions of Contract, the programme which the Contractor
submits to the Overseeing Organisation shall comply with the constraints imposed by the Contract and specific
requirements stated in contract specific Appendix 1/13. The Contractor shall update the programme as necessary.
The programme and subsequent revisions of the programme shall show the level of detail appropriate to each stage
of the works and all activities and restraints, each of which shall be given a short title. All events shall be
numbered.
2 (05/14) When required in contract specific Appendix 1/13 the Contractor shall also provide a mass-haul diagram
showing his intended earthworks movements and locations and capacities of anticipated plant and other resource
input.
114 (05/14) Payment Applications

1 (05/14) Unless otherwise described in the Contract, the Contractor shall comply with the requirements described
in contract specific Appendix 1/14 concerning applications for payment.
115 (05/14) Accommodation Works

1 (05/14) The Contractor shall undertake and complete the accommodation works as described in contract specific
Appendix 1/15. The Contractor shall give the Overseeing Organisation at least ten days’ notice of the date he
intends to start work on individual plots, for the benefit of each owner, lessee or occupier.
116 (05/14) Privately and Publicly Owned Services or Supplies

1 (05/14) The Contractor shall satisfy himself as to the exact position of Statutory Undertakers and other publicly
and privately owned services or supplies affected by the works.
2 (05/14) The Contractor shall, during the progress of the works take all measures required by any Statutory
Undertaker or the management of other publicly or privately owned services or supplies, for the support and full
protection of all such services or supplies.
3 (05/14) Where privately or publicly owned services or supplies affected by the works are subject to alteration,
removal or addition, the Contractor shall be responsible for all arrangements with the owners and/or their agents for
the execution and phasing of such works in accordance with his programme. Details of such work, preliminary
arrangements made by the Overseeing Organisation, and/or any orders already placed are given in contract specific
Appendix 1/16.
4 (05/14) The Contractor shall take all measures required by the Overseeing Organisation for the location and
protection of all cabling, ducts and other devices which form part of the motorway or highway communications
system or other systems of the Overseeing Organisation. The Contractor shall comply with the requirements of
NRTS (National Roads Telecommunications Services) and the technology maintenance agent in relation to
motorway communications cables. Where the communications system or other system will be affected by the
works the Contractor shall ensure that an alternative system as described in contract specific Appendix 1/16 is fully
operational prior to interrupting the existing system; any connections or disconnections to the existing system may
only be undertaken by the Overseeing Organisation’s maintenance agent. The Contractor shall be responsible for
liaising, with the Overseeing Organisation’s maintenance agent.
5 (05/14) No services or supplies shall be interrupted without the written consent of the appropriate authority or
owner, and the Contractor shall provide a satisfactory alternative before interrupting any existing service or supply,
unless otherwise stated in contract specific Appendix 1/16.
6 (05/14) Disconnected apparatus shall be removed by the Contractor only with the prior consent of the Authority
concerned.
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#117 (05/14) Traffic Safety and Management

(05/14) General
1 (05/14) Unless otherwise stated in contract specific Appendix 1/17 the Contractor shall plan, design,
programme, provide, implement, maintain and remove all traffic safety and management measures necessary for
the completion of the works. This shall include undertaking all necessary liaison with the police and highway
authority responsible for each public highway affected by the works both before commencement and throughout
the duration of the works. The traffic safety and management measures shall be in accordance with the
requirements and constraints stated in contract specific Appendix 1/17 and the Contractor shall take into account
the information contained in contract specific Appendix 1/18. The traffic safety and management measures shall be
in accordance with Chapter 8 of the Traffic Signs Manual. The Contractor shall inform the Overseeing Organisation
of any details the Contractor has agreed with the police and/or the highway authority.
2 (05/14) All traffic safety and management operations shall be undertaken by a supplier registered to National
Highway Sector Scheme 12 with a scope of registration that includes reference to one or more of National
Highways Sector Schemes 12A/B, 12C or 12D as appropriate to the works.
3 (05/14) The Contractor shall, unless otherwise stated in contract specific Appendix 1/17, after consultation with
the police and highway authorities concerned, prepare and submit traffic safety and management proposals within
the timescale described in contract specific Appendix 1/17 to the Overseeing Organisation. These shall show the
proposed traffic safety and management measures including provision of safety zones. If stated in Appendix 1/17,
the proposals shall include the provision of running lanes for the use of emergency vehicles within the site. The
Contractor shall make such changes to his proposals as may be necessary to meet the requirements of the Contract.
Thereafter the Contractor shall furnish and update such details and information as may be necessitated by the
works.
4 (05/14) If stated in contract specific Appendix 1/17, the Contractor shall undertake the highway maintenance
functions described therein and to the extent there described, on the lengths of highway there specified, until the
issue of the appropriate certificate of completion.
5 (05/14) Traffic signs shall comply with the appropriate Clauses in Series 1200 of the specification.
6 (05/14) Where a temporary speed limit at road works has been imposed and the works have been temporarily
terminated, with the removal of traffic management measures, the Contractor shall ensure that the temporary speed
limit signs are covered or taken down for the duration of the cessation of the works. Where the temporary speed
limit signs are covered, the covering material shall prevent the sign being visible through the cover in natural light
and under vehicle headlamp or street lamp illumination at night, be non light reflective and securely fastened.
7 (05/14) Where the Contract provides that the Contractor shall not erect, maintain or reposition traffic signs, the
Contractor shall not change in any manner the permanent or temporary traffic signs without instruction from the
Overseeing Organisation and shall give such notice as is stated in contract specific Appendix 1/17 to indicate when
signs should be moved compatible with the progress of the works.
8 (05/14) All traffic safety and management measures necessitated by the works shall be fully operational before
the Contractor commences any work, which affects the public highway or the use of it.
9 (05/14) Any area of highway which has been closed because of the works shall not be re-opened to traffic until
all appropriate traffic safety and management measures have been completed and the highway is in a suitable
condition for public use.
10 (05/14) Where work is carried out on, or adjacent to a highway open to traffic the Contractor shall ensure that
vehicles and mobile plant under his control operating frequently or regularly on or adjacent to that highway in the
execution of the works shall be conspicuous and comply with Section O5 General Vehicle Issues of Chapter 8, Part
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2 Operations, of the Traffic Signs Manual.

11 (05/14) Where required in contract specific Appendix 1/17 or where required for the execution of the works the
Contractor shall provide temporary lighting in accordance with Clause 1405.
12 (05/14) Where required in contract specific Appendix 1/17 or where required for the execution of the works the
Contractor shall provide Temporary Emergency Telephones in accordance with Clause 1529.
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13 (05/14) The Contractor shall provide and suitably sign points of entry to and exit from the site, for vehicles and
plant engaged on the works. The Contractor shall ensure that when any vehicle or item of plant is reversing within
the site on or adjacent to a highway open to traffic, it does so only under the supervision of a person designated for
the purpose of regulating traffic within the site who shall be readily distinguishable from the remainder of the work
force.
14 (05/14) If an accident or breakdown occurs on a carriageway or hard shoulder open to traffic within or in the
vicinity of the site, the Contractor and operators of recovery vehicles provided in accordance with Clause 120 shall
act as requested by police officers or traffic officers acting under their statutory powers.
15 (05/14) Where work is carried out on or adjacent to a highway open to traffic the Contractor shall ensure that the
workforce and the site supervisory staff at all times wear high visibility warning clothing complying with BS EN
471. Clothing shall be to Table 1, Class 2 or 3 (Class 3 on motorways or other high speed roads) and shall comply
with the requirements of para 4.2.3(b). In addition on motorways or other high speed roads full length sleeves
meeting the requirements of para 4.2.4 shall be provided for coveralls and jackets. The colour of the clothing shall
normally be “fluorescent yellow” or “fluorescent orange-red” complying with Table 2. The retroreflective material
used shall be to Level 1 as defined at Table 5. Clothing complying with other specifications may be used in
accordance with Clause 104 where they offer equivalent levels of performance in so far as the specification given is
not inconsistent with the basic health and safety requirements set out in Annex 2 of the Personal Protective
Equipment Directive (89/686/EEC). The Contractor shall ensure that the person in charge of the workforce is
readily distinguishable from the person designated in sub-Clause 16 of this Clause and from the remainder of the
workforce.
(05/14) Traffic Safety and Control Officer
16 (05/14) Unless otherwise stated in contract specific Appendix 1/17, the Contractor shall appoint a suitably
qualified Traffic Safety and Control Officer (TSCO) who shall make all arrangements necessary for traffic safety
and control including the provision and operation of breakdown recovery vehicles.
17 (05/14) The TSCO shall be experienced in the control of temporary traffic management operations and shall
possess a National Highway Sector Scheme (NHSS) 12 Traffic Safety and Control Officer (2009) Registration
Card.
18 (05/14) The Contractor shall provide the Overseeing Organisation with the names and contact details of the
TSCO and any nominated deputies. Unless otherwise described in contract specific Appendix 1/17 the TSCO or a
nominated deputy shall be on the Site at all times when traffic management is in operation and shall be readily
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available to deal with matters related to traffic safety and control including breakdown recovery vehicles.
19 (05/14) Without prejudice to sub-Clause 16 above, whilst within the limits of a temporary traffic management
scheme, the TSCO shall manage any traffic management related requests given by a Police Officer or Traffic
Officer. The TSCO shall liaise with he Overseeing Organisation’s traffic management control centres and other
parties detailed in contract specific Appendix 1/17 on traffic management related matters including requests and
instructions.
20 (05/14) Unless otherwise stated in contract specific Appendix 1/17 the responsibilities of the Traffic Safety and
Control Officer and of his nominated deputies shall include the following:
(a) Monitoring, with the assistance of sufficient mobile personnel and of sufficient other suitable and
appropriate aids, the flow of traffic within the area of the site;
(b) Ensuring that, within 5 minutes of notification of the occurrence of an incident resulting in stationary
vehicle(s) on a highway open to the public, the incident is reported to the vehicle recovery service when
vehicle recovery is in operation;
(c) Recording and logging all incidents and all movements of recovery vehicles and, when called, all
movements of the emergency services.
Where an “incident” is a shed load, vehicle breakdown, vehicle abandonment or traffic accident, whether or not the
latter involves personal injury.
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(05/14) Statutory Orders, Temporary Traffic Regulation Orders

21 (05/14) Unless otherwise detailed in contract specific Appendix 1/17 the Contractor shall submit a formal
application to the appropriate authority for any temporary traffic regulation orders or other statutory orders required
to be made or notices required to be published in connection with his traffic safety and management proposals. The
Contractor shall comply with any procedural requirements given in contract specific Appendix 1/17.
22 (05/14) The Contractor shall allow for the notice periods required for obtaining and implementation of any
temporary traffic regulation orders or other statutory orders in the programme of works. Where applications are to
be made to the Overseeing Organisation the notice periods required shall be as given in contract specific Appendix
1/17.
23 (05/14) Where applications for temporary traffic regulation orders or other statutory orders are made by the
Overseeing Organisation prior to the commencement of the works the Contractor shall provide all necessary traffic
safety and management measures to implement the orders.
(05/14) Crossovers
24 (05/14) The Contractor shall design, construct and maintain, or if contract specific Appendix 1/17 so provides,
shall construct and maintain, the central reserve crossovers described in contract specific Appendix 1/17 in
accordance with the information stated therein. Unless otherwise described in contract specific Appendix 1/17, the
Contractor shall remove those crossovers when no longer required and reinstate the central reserve to its original
condition.
25 (05/14) If the Contractor proposes to construct central reserve crossovers as part of his traffic safety and
management proposals he shall submit such proposals to the Overseeing Organisation in advance, in accordance
with the requirements of sub-Clause 3 of this Clause.
(05/14) Driver Information Signs
26 (05/14) Where required in contract specific Appendix 1/17, the Contractor shall provide, erect, maintain and
remove Driver Information Signs to diagrams 7004 and 7005 of the Traffic Signs Regulations and General
Directions in accordance with sub-Clause 27 of this Clause and Chapter 8 of the Traffic Signs Manual. Information
signs shall only be displayed within roadworks where they accurately reflect the work being undertaken or the
reason for the inactivity.
27 (05/14) Legends shall be selected as appropriate from those permitted and listed in Chapter 8 of the Traffic
Signs Manual unless stated otherwise in contract specific Appendix 1/17.
Sign 7005 shall indicate how long delays are possible. This date shall be updated by the Contractor, if necessary,
until the restrictions are removed.
Sign 7004 shall be located within roadworks when part of the road is coned off, and the reason for this is not
apparent from the carriageway, for any period exceeding 30 minutes, or one hour if road capacity is maintained.
However, signs located within roadworks shall only be used where they can be located at least 50 metres beyond
the downstream end of a taper and in a position which does not prejudice traffic safety.
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If needed, Information Signs shall be sited at the beginning and at one kilometre intervals through the works. They
shall not be placed where they may distract drivers negotiating traffic management provisions.
Signs shall either be sited for the duration of the works where it is safe and appropriate to do so or provision made
to enable their use at short notice.
The Contractor shall provide adequate storage facilities clear of any safety zone. Storage within the central reserve
or in front of safety barriers shall not be permitted.
(05/14) Temporary Automatic Speed Camera System (TASCAR)
28 (05/14) Where required in contract specific Appendix 1/17, a Temporary Automatic Speed Camera System for
the Enforcement of Mandatory Speed Limits at Roadworks (TASCAR) shall be provided in accordance with the
following requirements and those given in contract specific Appendix 1/27. The type of system and the number of
speed monitoring sites and their locations shall be as specified in contract specific Appendix 1/27.
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29 (05/14) The Contractor shall be responsible for the design, installation, commissioning, maintenance and
removal of the system. This shall be undertaken using a suitably qualified Enforcement Equipment Supplier (EES).
The EES shall make all arrangements necessary for the provision and operation of the TASCAR system. The
Contractor shall supply evidence of the EES qualifications to the Overseeing Organisation prior to the
commencement of the works.
The equipment shall meet the requirements of the Speedmeter Handbook and have Home Office Type Approval
(HOTA) for the purpose required. The installation, commissioning, operation and maintenance of the system shall
be undertaken in accordance with the requirements of the equipment’s HOTA.
All equipment and training necessary to bring the sites into operation shall be provided and installed by the
Contractor, this shall include, but not be limited to, all equipment, poles, housings and power supplies. The
quantities of equipment required shall be as specified in contract specific Appendix 1/27. The Contractor shall
ensure that the System is completely installed and fully operational from the time defined in contract specific
Appendix 1/27 and that it remains in operation for the duration of the Contract unless otherwise specified in
Appendix 1/27 and is removed on completion of the works.
The Contractor shall commission any necessary third party certification of the system and shall supply copies of the
certification to the Overseeing Organisation.
30 (05/14) Unless otherwise required by the equipment’s HOTA requirements, the equipment and ancillary items
shall be compatible with all permanent and temporary installations associated with the works.
31 (05/14) The Contractor shall liaise with the relevant Enforcement Authority (EA) to determine how the system
for the scheme shall integrate with the EA’s existing facilities and operations. The Contractor shall comply with the
Overseeing Organisation’s procedures with respect to the liaison as described in contract specific Appendix 1/27.
The Contractor shall submit details of the system to the Overseeing Organisation four weeks in advance of its
operation for approval.
32 (05/14) The TASCAR equipment shall consist of a HOTA detection and measuring device, and ancillary
equipment that allows day and night operation. If a trailer mounted system is supplied it shall be fitted with
retractable de-mountable wheels.
33 (05/14) The Contractor shall arrange for the provision of a mains electrical supply of adequate power capacity to
all components of the system. Alternatively, he may provide an equivalent supply from a local electrical generator
or generators which shall be used only for this purpose. Such generator(s) shall have electric start mechanisms and
be adequately regulated as to voltage and frequency to suit the accuracy requirements of the equipment provided
for TASCAR and be capable of running constantly for 48 hours without refuelling at an output of not less than that
required by the equipment at 0.8 power factor, or equivalent output. All generators shall be housed in vandal-proof
containers and be securely locked. One set of keys shall be provided to the EA. Generators may only be used when
they will not adversely affect the equipment/systems operations or the equipments HOTA requirements.
34 (05/14) The housing and poles for the TASCAR equipment must be as required for the specific HOTA for that
equipment, and shall include security-locking mechanisms to prevent unauthorised access or operation.
35 (05/14) The Contractor shall install the poles/masts/cabinets or trailers required at each individual speed
monitoring location, any installation shall be within highway limits.
36 At completion of the works the Contractor shall remove all TASCAR equipment and reinstate ground as
described in contract specific Appendix 1/27.
37 (05/14) The Contractor shall ensure that suitable access arrangements are in place at each speed monitoring site
including vehicle hard standings, walkways and steps where necessary to allow for general maintenance and
servicing of the camera unit. Where supplied, suitable provisions shall be made for installing and recovering
trailers.
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38 (05/14) The Contractor shall ensure that the camera poles are located in accordance with road restraint systems
requirements detailed in TD 19/06.
39 (05/14) The Contractor shall ensure that the site reference number is clearly indicated on both the installation
and on the road surface within the field of view of the camera(s). Site reference numbers should be agreed with the
EA.
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40 (05/14) Any ducting provision, loop or piezo installation shall be carried out in accordance with the relevant
clauses of Series 500 and 1200 of the Specification.
41 (05/14) The Contractor shall be responsible for the commissioning of the TASCAR as a whole, including
secondary and in station checks. The Contractor shall, where required as part of the HOTA, provide a secondary
method of confirming the speed calculation.
42 (05/14) The commissioning of the TASCAR shall be carried out in the presence of, and for acceptance by, the
EA and shall be in accordance with any particular requirements in contract specific Appendix 1/27, the
commissioning shall only be complete when each site, and where applicable, the overall system is accepted as
being operational by the EA. The Contractor shall give notice to the Overseeing Organisation of his intention to
carry out this work, unless otherwise stated in contract specific Appendix 1/27 this shall be not less than four days
in advance of the intended time for the commissioning. An Evidential Trail (ET) which meets all the requirements
as stated in contract specific Appendix 1/27 including commissioning certificates shall be provided by the
Contractor to the Overseeing Organisation and shall include one pair of photographs or video images for
acceptance by the EA as part of the commissioning and acceptance procedure of the system. The Contractor shall
ensure that all relevant requirements of the Evidential Trails for Enforcement Systems documents are achieved.
43 (05/14) Cameras sited on the nearside of the carriageway shall be installed and commissioned prior to 24 hour
lane closures being put into operation. Cameras sited in the central reserve shall be installed and commissioned not
later than 12 hours after installation of the contraflow. Both sets of cameras shall then remain in continuous
operation until a completion certificate has been issued for the whole of the works. At the end of the period of
operation required under the Contract, the equipment shall remain the property of the Contractor.
44 (05/14) Following commissioning the TASCAR Operator will be the EA. The Contractor shall provide
assistance to the EA for the repositioning of the speed monitoring equipment between the housings, or switching of
detection equipment between zones and servicing as and when requested by the EA. Any repositioning during the
works that requires that the equipment parameters are changed must be supported by the issue of a calibration
certificate by the Contractor to the EA.
45 (05/14) All evidential media from speed monitoring sites will remain the property of the EA. The scheme ET
documents shall be kept up to date by the Contractor.
46 (05/14) The Contractor shall provide and install all necessary speed limit signing in connection with the
operation of the TASCAR system, any signing used shall either be prescribed or where necessary authorised. The
Contractor shall provide the EA, through the Overseeing Organisation, with a two hourly log showing the locations
of all the speed limit and speed limit repeater signs relative to existing marker posts. A repeater sign shall be
positioned such that one is visible in each photograph. Where there is a 24-hour CCTV system installed that is
monitoring ALL speed limit and repeater signs this log can be compiled remotely.
47 (05/14) Where digital HOTA equipment is used, the Contractor will provide either the communications service
to transfer data and control the device or appropriate media such as WORM (Write Once Read Many) drives, CDs,
memory sticks as appropriate, and in quantities required by the EA for the use of the equipment for the duration of
the works. If HOTA 35mm wet film systems are used, the film will be supplied to the EA by the Contractor,
typically at the rate of one film per day per live camera in operation, plus ten which shall be supplied at the
118 (05/14) Temporary Highways for Traffic

1 (05/14) The provisions of this Clause apply to the construction of temporary highways for use by traffic, they do
not apply to any temporary access or accommodation works which the Contractor may construct for his sole use in
the execution of the works or to existing highways used for diverted traffic. Requirements for existing highways
subject to temporary closure and associated diversion route signing are given in Clause 117.
2 (05/14) Each temporary highway, or part of highway, for traffic shall be made operative in advance of any
interference with the existing arrangements and shall be maintained to the standard stated in contract specific
Appendix 1/18 or if no standard is so stated, in accordance with sub-Clause 6 of this Clause.
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(05/14) Temporary Highways for Traffic Specified by the Overseeing Organisation

3 (05/14) The Contractor shall construct, maintain, remove and reinstate each temporary highway, or part of
highway, for traffic specified in contract specific Appendix 1/18 in accordance with the details stated therein.
Where stated in contract specific Appendix 1/18, the Contractor shall design each temporary highway, or part of
highway, for traffic, including any temporary structures, in accordance with the details stated therein. Unless
otherwise described in contract specific Appendix 1/18, the Contractor shall remove each temporary highway for
traffic as soon as it is no longer required. Unless otherwise stated in contract specific Appendix 1/18 the Contractor
shall reinstate the ground over which the temporary highway is provided to its original condition.
(05/14) Temporary Highways for Traffic Proposed by the Contractor
4 (05/14) If the Contractor proposes to construct a temporary highway, or part of highway, for traffic as part of his
intended traffic safety and management measures, he shall submit an outline of his proposals to the highway
authority for their agreement and consultation with the police in accordance with the requirements of Clause 117.
5 (05/14) The Contractor shall submit a formal application to the appropriate authority for any statutory orders
required to be made or notices required to be published in connection with the temporary highway or part of
highway. Details of such applications shall be agreed with the Overseeing Organisation prior to their submission.
The Contractor shall comply with procedural requirements given in contract specific Appendix 1/18.
The Contractor shall allow for the notice periods required for obtaining and implementation of any statutory orders
in the programme of works. Where applications are to be made to the Overseeing Organisation the notice periods
required shall be as given in contract specific Appendix 1/18.
6 (05/14) The standard and siting of every temporary highway, or part of highway, for traffic shall be suitable in
all respects for the class or classes of traffic using it, and its width shall be not less than that of the existing way
except where indicated in contract specific Appendix 1/18.
7 (05/14) The Contractor shall inform the Overseeing Organisation of any details agreed with the highway
authority for traffic signs, lighting, construction, maintenance, removal and reinstatement of any temporary
highway, or part of highway, for traffic proposed by the Contractor.
119 (05/14) Routeing of Vehicles

1 (05/14) The Contractor shall comply with the requirements described in contract specific Appendix 1/19 in
connection with routeing of site and delivery vehicles.
120 (05/14) Recovery Vehicles and Operation for Breakdowns

(05/14) General
1 (05/14) When required by contract specific Appendix 1/20 the Contractor shall provide and operate a vehicle
breakdown, recovery and removal service, including storage. This service shall recover broken down or accident
damaged vehicles or vehicles that have been abandoned on the highway within the limits of the site. The service
shall be provided in accordance with the requirements of this Clause and contract specific Appendix 1/20, it shall
also comply with contract specific Appendix 1/17.
2 (05/14) Vehicle recovery operations shall be carried out by organisations registered to National Highway Sector
Scheme 17/17B for Vehicle Recovery at Highway Construction Sites (17) and Vehicle Recovery and Removal on
Control Roads (17B) as listed in Appendix A.
3 (05/14) The Contractor shall ensure that, once a vehicle recovery organisation has been appointed, changes shall
only be made with the agreement of the Overseeing Organisation.
4 (05/14) When planning and undertaking any recovery work the Contractor shall comply with the requirements of
the Sector Scheme at all times, if applicable.
5 (05/14) The Contractor shall ensure that recovery vehicles are operated in accordance with all applicable
statutory requirements and the recommendations and requirements contained in the following, unless superseded by
more specific requirements of this Clause or the Sector Scheme:
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(i) “Code of Practice on Health and Safety for Vehicle Recovery Operators” published by the Association of
Vehicle Recovery Operators;
(ii) “PAS 43 Safe Working of Vehicle Breakdown and Recovery Operators - Management System
Specification” published by the British Standards Institution;
(iii) BS 7121-12 - Safe Use of Cranes - Recovery Vehicles and Equipment - Code of Practice; and
(iv) BS 7901 - Specification for recovery vehicles and vehicle recovery equipment.
6 (05/14) The Contractor shall ensure that, suitable insurances to cover all claims arising out of the operation of
the recovery service, are taken out and maintained in force for the duration of the works. The Contractor shall
submit copies of relevant certificates to the Overseeing Organisation not less than 14 days prior to the
commencement of recovery operations and within 14 days of policy renewal thereafter.
(05/14) Recovery Personnel
7 (05/14) The Contractor shall ensure that all recovery operations are carried out under the control of a competent
Recovery Controller. The Recovery Controller shall be an employee of the Vehicle Recovery Organisation and may
be either part of the recovery vehicle crew or a separate trained recovery technician. The Recovery Controller shall
be responsible for the planning and implementation of a safe and efficient system of work for recovery of the
casualty vehicle, unless subject to specific requests from police officers or uniformed traffic officers acting under
their statutory powers.
8 (05/14) Without prejudice to sub-Clause 7 above, whilst within the limits of a temporary traffic management
scheme, the Recovery Controller shall comply with any traffic management related instructions given by the Traffic
Safety and Control Officer or his deputy in accordance with sub-Clause 117.19. Elsewhere the Recovery Controller
shall comply with the traffic management related instructions of the Overseeing Organisation’s Regional Control
Centre.
9 (05/14) The Contractor shall ensure that vehicle recovery technicians hold a relevant training certificate, which
meets the requirements of the Sector Scheme. Such certificate shall certify successful completion of a course on
breakdown recovery applicable to the type of breakdown recovery vehicle(s) being operated. The Sector Scheme
requires the certificate to be in the form of an identity card containing such information and a photograph of the
technician. A copy of each certificate shall be provided to the Overseeing Organisation not less than 14 days before
the commencement of recovery operations.
10 (05/14) The Contractor shall check the validity of the certificates/cards on a regular basis, including checking
that the photograph matches with the card holder’s image, at intervals not exceeding 6 months and report his
findings to the Overseeing Organisation.
11 (05/14) The Contractor shall ensure by appropriate checks on a regular basis, that all operatives involved with
vehicle recovery are suitable to work with ‘vulnerable’ motorists. The Contractor shall report his findings to the
Overseeing Organisation not less than 14 days prior to the commencement of recovery operations and at regular
intervals thereafter not exceeding 12 months.
12 (05/14) The Contractor shall ensure by appropriate checks that each technician has a valid driving licence
covering the class of vehicle and trailer being driven. The Contractor shall submit copies of all driving licences for
operatives, to the Overseeing Organisation, not less than 14 days prior to commencement of recovery operations.
The Contractor shall carry out regular 6 monthly checks on driving licences and report his findings to the
13 (05/14) The Contractor shall ensure that all technicians involved with vehicle recovery display an identity card,
which incorporates the name of the Contractor, the name of the Vehicle Recovery Organisation and the name and a
photograph of the holder. This card must be available for inspection at all times and a copy must be submitted to
the Overseeing Organisation prior to the commencement of the operative working.
14 (05/14) In addition to any special provisions identified in the Contractor’s health and safety risk assessment for
recovery operations, the Contractor shall ensure that each recovery technician is provided with the following
personal protective equipment, as a minimum:
(i) a high visibility reflective safety jacket which prominently displays the word “RECOVERY” on the
front and back. It shall conform to BS EN 471 and the specific requirements of sub-Clause 117.18;
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(ii) safety helmet to BS EN 397 and chin strap where considered appropriate;
(iii) safety boots with steel reinforced toecaps and midsole conforming to BS EN ISO 20345;
(iv) protective goggles conforming to BS EN 166; and
(v) protective gloves conforming to BS EN 388.
The Contractor may upgrade the specification of personal protective equipment at their own cost.
15 (05/14) The Contractor shall ensure that all Personal Protective Equipment (PPE) is stored and maintained in
good and clean condition. The Contractor shall ensure that high visibility safety wear is replaced or cleaned, as
necessary, throughout the duration of the Contract, to maintain its conspicuity.
16 (05/14) The Contractor shall ensure that the operatives shall be familiar with their vehicles and the equipment
carried on board, before commencing recovery operations. Where appropriate, they shall be trained to use any
ancillary equipment carried on the vehicle, including fire extinguishers and first aid equipment for personal use.
(05/14) Recovery Operations
17 (05/14) Prior to the commencement of the works, the Contractor shall consult with the local representative of
the Chief Officer of Police and/or the Overseeing Organisation’s Regional Control Centre to establish procedures,
including contact telephone numbers, for:
(i) clearing shed loads; and
(ii) vehicle recovery which may be beyond the capabilities of the free recovery service.
18 (05/14) The recovery service is to be provided between the ‘Roadworks Ahead - 2 miles’ sign and the ‘Road
Works End’ sign unless otherwise stated in Sheet 1 of contract specific Appendix 1/20.
19 (05/14) The Contractor shall ensure that the recovery vehicles are only used to remove vehicles that are
stationary due to mechanical breakdown, accident damage or abandoned on the highway, within the limits of the
service.
20 (05/14) The Contractor shall ensure that the recovery vehicle operatives comply with the provisions contained
within Sheet 1 of contract specific Appendix 1/20 in connection with this service, subject to specific requests from
police officers and uniformed traffic officers acting under their statutory powers.
21 (05/14) The recovery vehicles shall be stationed at the points either specified in Sheet 1 of contract specific
Appendix 1/20 or otherwise agreed with the Overseeing Organisation, subject to specific requests from police
officers and uniformed traffic officers acting under their statutory powers.
22 (05/14) The Contractor shall provide the facilities required by Sheet 1 of contract specific Appendix 1/20 and
shall ensure that broken-down, accident damaged or abandoned vehicles are not removed by the recovery vehicles
other than to the location(s) described in Sheet 1 of contract specific Appendix 1/20 unless some other location has
first been agreed with a police officer or uniformed traffic officer acting under their statutory powers.
23 (05/14) The Contractor shall ensure that, after depositing a broken-down, accident damaged or abandoned
vehicle at one of the designated locations, the recovery vehicle returns immediately to its station described in Sheet
1 of contract specific Appendix 1/20. The Contractor shall ensure that recovery vehicle operatives at no time
attempt to repair vehicles that have broken down.
24 (05/14) The Contractor shall make no charge for this recovery service to the owner or driver of the recovered
vehicle.
25 (05/14) The Contractor shall ensure that the recovery vehicle operatives issue leaflets, as described in Sheet 3 of
contract specific Appendix 1/20, before the tow commences, to the drivers of vehicles requiring assistance.
26 (05/14) The Contractor shall submit weekly to the Overseeing Organisation:
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(i) duplicate completed information sheets logging the assistance given by the recovery vehicles; and
(ii) duplicate completed log sheets which record daily checks made on each recovery vehicle.
These shall be on printed forms provided by the Contractor in accordance with the samples given in Sheets 2 to 4
of contract specific Appendix 1/20.
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(05/14) Communications systems

27 (05/14) In addition to the requirements of contract specific Appendix 1/1 and Appendix 1/3 and this sub-Clause,
the Contractor shall provide and maintain dedicated equipment for communication with the Vehicle Recovery
Organisation, for the duration specified in the Contract, as described in Sheet 1 of contract specific Appendix 1/20.
28 (05/14) Unless otherwise described in Sheet 1 of contract specific Appendix 1/120, the communication system
shall also include the following:
(i) a secondary ‘back up’ communications system between the recovery base station(s) and all recovery
vehicles; and
(ii) an emergency telephone and line at the recovery base station(s) for the sole use of emergency calls.
Where possible, the link between the recovery base station(s) and the police shall be by direct land line.
29 (05/14) The communication system shall be fully established, tested and operational before the Contractor
commences the works.
30 (05/14) The Contractor shall be responsible for providing all associated equipment and payment of fees to
operate the system.
(05/14) Requirements for Recovery Equipment
31 (05/14) The Contractor shall ensure that all recovery vehicles are maintained in such condition that the vehicles
conform to appropriate current legislation (including, but not limited to, the Road Vehicle (Construction and Use)
Regulations, Road Vehicle Lighting Regulations, Road Transport Act and Road Traffic Act) at all times.
32 (05/14) All recovery vehicles shall have either a current goods vehicle test certificate or MOT certificate or other
certificate of roadworthiness issued by a Vehicle and Operator Services Agency (VOSA) approved testing station,
and also weigh bridge certificate stating individual axle and gross vehicle loadings. Copies of certificates shall be
provided to the Overseeing Organisation not less than 14 days prior to the commencement of recovery operations
using the vehicle concerned. Certificates shall be renewed annually on the due anniversary of the inspection and
new certificates shall be provided to the Overseeing Organisation immediately following the inspection.
33 (05/14) The Contractor shall make appropriate arrangements for any inspections required under the Sector
Scheme to be carried out in a place of safety, either on or off site for the duration of the contract.
34 (05/14) Recovery vehicles shall not be replaced without the prior agreement of the Overseeing Organisation.
35 (05/14) Photographs of each vehicle, clearly showing vehicle registration number, shall be provided to the
Overseeing Organisation not less than 14 days prior to the commencement of recovery operations using the vehicle
concerned. Any replacement vehicle shall normally be of the same vehicle class and category, shall conform to the
requirements of this Clause and shall have been inspected in accordance with any additional requirements of the
Sector Scheme, if applicable.
36 (05/14) Recovery vehicles shall prominently display the name and telephone number of the Vehicle Recovery
Organisation, and be of conspicuous colour (e.g., white, yellow or orange) and marking to emphasise the length and
outline of the vehicle. Suitable retroreflective markings not less than 200 mm wide shall be applied along the full
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length of the sides of the vehicle. Colours and usage of retroreflective markings must comply with the Road Vehicle
Lighting Regulations. High visibility chevron markings comprising of alternate strips of red retroreflective material
and yellow non-retroreflective material, of not less than 150mm width each, inclined at 45˚-60˚ to the horizontal,
shall be applied to the rear of the vehicle. The chevrons shall cover as much of the rear-facing portion of the vehicle
as possible without obscuring windows, vehicle lighting or registration plates. Red retroreflective tape shall be
applied to all rear facing edges of open doors and equipment lockers. The vehicle and all retroreflective markings
shall be maintained in good and clean condition.
37 (05/14) Each recovery vehicle shall display a sign with the legend “FREE RECOVERY TO END OF ROAD
WORKS”. This sign shall be securely mounted on the recovery vehicle in such position as to be clearly visible
from the driving seat of a car at a distance of 3 m from the rear of the recovery vehicle. This sign shall at all times
be clean and legible and shall not be obstructed.
38 (05/14) A lighting board shall be secured to the rear of the vehicle being towed. The board shall be clearly
visible to other drivers of vehicles approaching from the rear. It shall be maintained in good working order and
shall be cleaned after use to maintain its conspicuity.
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39 (05/14) Recovery vehicles shall be equipped with sufficient chains, wire rope and shackles for the safe recovery
of any fully laden vehicle within the appropriate class of recovery (e.g., heavy or light). All chains, wire ropes, tow
poles and shackles shall comply with relevant British standards and be fully certified by an independent competent
person to comply with all current legislation. All lifting equipment shall be accompanied by a valid proof loading
certificate, be suitably marked with the SWL and be free from snags, excess stretching and wear. Copies of all
certificates shall be supplied to the Overseeing Organisation not less than 14 days prior to the commencement of
recovery operations using the vehicle concerned.
40 (05/14) All equipment shall be suitably marked so as to be identifiable and provide an audit trail for inspection
purposes.
41 (05/14) All walkways at height on the recovery vehicle shall be fitted with hand rails and non slip tread systems.
Access steps shall be provided on the non-trafficked passenger side of the vehicle. Equipment shall be stored on the
passenger side of the vehicle, as far as is practicable.
42 (05/14) Where insufficient seating capacity is available in the recovery vehicle for transport of passengers, the
Contractor shall ensure that suitable arrangements are made to transport passengers to the setting down location.
43 (05/14) When carrying child passengers, the Contractor shall ensure that a child restraint seat appropriate to the
age of the child is used.
44 (05/14) The Contractor shall ensure that each light recovery vehicle has a crew including at least one trained
technician and that each heavy recovery vehicle has a crew including at least two trained technicians.
45 (05/14) Prior to commencement of the recovery service, the Contractor shall provide method statements for
Heavy and Light Recovery to be agreed by the Overseeing Organisation. The method statement shall include a
detailed list of the equipment carried on each Recovery vehicle. The list may be used for audit by independent third
party as required by the Overseeing Organisation.
(05/14) Heavy recovery vehicles
46 (05/14) A heavy recovery vehicle shall comply with the following as a minimum:
(i) It shall be a recovery vehicle with not less than three axles, capable of removing a loaded vehicle of 80
tons total train weight (i.e., Category 2 Special Types in accordance with Road Traffic Act Section 44
and Road Vehicles (Authorisation of Special Types)(General) Order). It must be able to maintain a
minimum road speed of 20 mph on a level road when fully loaded and pull away or hold back the
complete train weight when towing a maximum weight vehicle either up or downhill without wheel slip
or loss of traction. Axle loadings shall be within permissible legal loadings for the vehicle at all times.
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(ii) It shall be fitted with two power winches of not less than 12.5 tons each on bottom layer, safeguarded by
pressure relief devices as appropriate. Each winch shall have no less than 30 m of cable. All equipment
shall be power-operated with SWL indicated on both the winch and fixings. Operating levers/buttons
shall be clearly marked for operational use with key functions duplicated on a remote control unit.
Emergency stop controls shall be provided.
(iii) Without prejudice to sub-Clause 39 of this Clause, it shall carry the following recovery equipment as a
minimum:
(a) 1 no. full set of forks for use with underlift.
(b) 1 no. tool kit including both ¾ and ½ inch socket sets with AF/Metric sized sockets.
(c) 2 no. 12 tonne bottle jacks.
(d) 1 no. 24/12 volt engine starter pack.
(e) 1 no. crowbar.
(f) 1 no. sledge hammer - 7 lbs minimum.
(g) All lines and fittings necessary for connection of the air braking system on the casualty vehicle to
the air braking system on the recovery vehicle.
(h) 2 no. wheel chocks suitable for use with an HGV.
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(i) 4 no. suitable lengths of wood block skidding.

(j) 8 no. screw pin bow shackles, minimum SWL 30 tonnes.
(k) 6 no. 16mm diameter G80 chains with grab hooks, 4 m minimum length.
(l) 2 no. 16 mm diameter G80 chains with grab hooks, 2 m minimum length.
(m) 4 no. 12 mm diameter G80 chains with grab hooks, 3 m minimum length.
(n) 4 no. 7 mm diameter G80 chains with grab hooks, 3 m minimum length.
(o) 2 no. 50 mm ratchet straps, 2m minimum length with “soft” eyes.
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(p) 2 no. 12 tonne SWL nylon straps with sewn eyes, no less than 8m long and 300mm wide.
(q) 2 no. snatch blocks per winch, each with a SWL of twice that of the winch. Snatch block sheaves
shall have a minimum diameter of 10 times the diameter of the winch cable.
(iv) It shall carry and use, when necessary, equipment designed and manufactured for the purpose of locking
the steering of the broken-down or accident-damaged vehicle in order to tow it safely in a reverse
direction.
(v) It shall carry equipment to enable the recovery crew to remove the drive line or shafts of the broken-
down or accident-damaged vehicle.
(vi) It shall have seating for not less than two recovery operatives. The Contractor shall make suitable
arrangements for the safe transport of passengers from the recovered vehicle to the setting down
location.
(vii) It shall be fitted with and where appropriate, operatives trained to use, the following ancillary
equipment, as a minimum:
(a) 1 no. full cab width amber warning lightbar (minimum 4 no. active light sources) visible through
360 degrees from road level and complying with the Road Vehicle Lighting Regulations and the
United Nations Economic Commission for Europe (UNECE) Regulation 65 on Special Warning
Lamps.Vehicle electrics must be capable of running the lightbar for a minimum of 15 minutes
with the ignition key removed.
(b) 2 no. fully adjustable work lights to illuminate both the sides and rear of the vehicle.
(c) 2 no. fire extinguishers (9 litre (nett) aqueous film forming foam in accordance with ADR)
marked with date of last inspection/test.
(d) 1 no. HSE approved 1-10 person first aid kit, marked with expiry date.
(e) 6 no. traffic cones minimum 450 mm height.
(f) 1 no. 900 mm diameter “Keep Right Arrow” traffic sign, complying with diagram 610 of the
current Traffic Signs Regulations and General Directions.
(g) 1 no. rear lighting board incorporating a duplicate of the recovery vehicle registration plate and
‘On Tow’ legend in lettering of not less than 70 mm on conspicuously coloured background to
conform with the size, colour and type illustrated in the Road Vehicles Lighting Regulations. The
board shall be fitted with lights, reflectors and indicators and sufficient cable to reach the rear of
any vehicle recovered.
(h) 1 no. ADR (HAZCHEM) chart.
(i) 1 no. spillage containment kit including oil/diesel absorbent granules (minimum 25 kg) in sealed
container.
(j) 1 no. intrinsically safe battery operated torch with spare batteries.
(k) 1 no. broom and shovel.
The number of the required heavy recovery vehicles shall be as stated in Sheet 1 of contract specific Appendix
1/20.
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(05/14) Light Recovery Vehicle

47 (05/14) A light recovery vehicle shall comply with the following as a minimum:
(i) It shall be capable of removing, by means of a slide bed and/or underlift, at least one vehicle weighing
3500 kg (including a vehicle with permanent four wheel drive) and shall be fitted with a suitable towing
hitch for the safe recovery of all forms of trailers (including caravans, boat trailers and horse boxes etc).
It must be able to maintain a minimum road speed of 20 mph on a level road when fully loaded and pull
away or hold back the complete train weight when towing a maximum weight vehicle either up or
downhill without wheel slip or loss of traction. Axle loadings shall be within permissible legal loadings
for the vehicle at all times.
(ii) It shall be fitted with at least one power winch of not less than 3.6 tonnes capacity on bottom layer,
safeguarded by pressure relief devices as appropriate. The winch shall have no less than 30 m of cable. All
equipment shall be power-operated with SWL indicated on both the winch and fixings. Operating levers/
buttons shall be clearly marked for operational use with key functions duplicated on a remote control unit.
Emergency stop controls shall be provided.
(iii) Slide bed vehicles shall have 1 tonne SWL lashing points fitted every half a metre on each side of the
bed, the last being no more than 15 cm from the end of the bed. There shall be a return anchorage point
of minimum 3600 kg SWL, fitted to or alongside the winch. Suitable anchorage points shall also be
provided at points on the bed to enable side pulls to be performed.
(iv) Without prejudice to sub-Clause 39 of this Clause, it shall carry the following recovery equipment as a
minimum:
(a) 1 no. 3.5 tonne straight tow pole.
(b) 1 no. tool kit including both ¾ and ½ inch socket sets with AF/Metric sized sockets.
(c) 1 no. 2 tonne minimum capacity trolley jack.
(d) 1 no. 12 volt engine starter pack.
(e) 1 no. crowbar.
(f) 1 no. wheel chock suitable for use with a light commercial size vehicle.
(g) 4 no. suitable lengths of wood block skidding.
(h) 2 no. 7.2 tonne SWL screw pin bow shackles.
(i) 2 no. 7 mm G80 chains, 3 m minimum length with grab hooks.
(j) 2 no. 2 tonnes SWL, 50 mm webbing straps, 2 m minimum length with “soft” eyes.
(k) 4 no. transporter straps, 4 m minimum length.
(l) 2 no. underlift frame straps.
(m) 1 no. snatch block per winch, each with a SWL of twice that of the winch.
(n) Snatch block sheaves shall have a minimum diameter of 10 times the diameter of the winch cable.
(o) 4 no. wheel skates.
(v) When specified in Sheet 1 of contract specific Appendix 1/20, it shall be capable of recovering motor
cycles using a damage free motorcycle lifting/recovery frame or dolly and/or lorry mounted crane as
appropriate to the condition of the casualty motorcycle.
(vi) It shall have seating capacity for up to five adult passengers (in addition to the recovery operatives) with
access from the passenger side of the cab. The Contractor shall make suitable arrangements for the safe
transport of additional passengers from the recovered vehicle to the setting down location. When
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carrying child passengers, the Contractor shall ensure that a child restraint seat appropriate to the age of
the child is used.
(vii) It shall be fitted with and where appropriate, operatives trained to use, the following ancillary
equipment, as a minimum:
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(a) 1 no. full cab width amber warning lightbar (minimum 2 no. active light sources and 2 no.
independent reflectors) fitted transversely, visible through 360 degrees from road level and
complying with the Road Vehicle Lighting Regulations and Economic Commission for Europe
(ECE) Regulation 65 on Special Warning Lamps. Vehicle electrics must be capable of running the
lightbar for a minimum of 15 minutes with the ignition key removed.
(b) 2 no. fully adjustable work lights to illuminate both the sides and rear of the vehicle.
(c) 2 no. fire extinguishers (1 No. 6 kg (nett) dry powder; 1 No. 9 litre (nett) aqueous film forming
foam) marked with date of last inspection/test.
(d) 1 no. HSE approved 1-10 person first aid kit, marked with expiry date.
(e) 6 no. traffic cones minimum 450 mm height.
(f) (For underlifts) 1 no. rear lighting board incorporating a duplicate of the recovery vehicle
registration plate and ‘On Tow’ legend in lettering of not less than 70 mm on conspicuously
coloured background to conform with the size, colour and type illustrated in the Road Vehicles
Lighting Regulations. The board shall be fitted with lights, reflectors and indicators and sufficient
cable to reach the rear of any vehicle recovered.
(g) 1 no. spillage containment kit including oil/diesel absorbent granules (minimum 25 kg) in sealed
container.
(h) 1 no. ADR (HAZCHEM) chart.
(i) 1 no. intrinsically safe battery operated torch with spare batteries.
(j) 1 no. broom and shovel.
(viii) It shall carry and use, when necessary, equipment designed and manufactured for the purpose of locking
the steering of the broken-down or accident-damaged vehicle in order to tow in a reverse direction.
The number of the required light recovery vehicles shall be as stated in Sheet 1 of contract specific Appendix 1/20.
(05/14) Impact Protection Vehicles
48 (05/14) Where specified in Sheet 1 of contract specific Appendix 1/20, the Contractor shall provide dedicated
Impact Protection Vehicles (IPVs) to protect recovery operations in the live carriageway.
49 (05/14) The Contractor shall ensure that IPVs comply with the requirements of Section O5 of Chapter 8 (Part 2
Operations) of the Traffic Signs Manual and that any non-prescribed traffic signs mounted on the vehicle meet the
requirements of the Traffic Signs Regulations and General Directions, particularly with respect to authorisation
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and/or type approval.
50 (05/14) The Contractor shall ensure that IPV drivers hold a relevant training certificate which meets the
requirements of the Sector Schemes 12A/B, 12C and 12D as detailed in Appendix A.
(05/14) Accommodation
51 (05/14) The contractor shall ensure that any accommodation (caravans or cabins) provided in connection with
the recovery service, complies with all appropriate legislation including health, safety and welfare requirements.
52 (05/14) The Contractor shall ensure that any accommodation sited within the highway, is afforded appropriate
protection from errant vehicles, is conspicuously coloured with retroreflective markings on the sides facing traffic
and is prominently marked with the name of the Vehicle Recovery Organisation.
53 (05/14) Where the recovery service is located on the hardshoulder, the Contractor shall make arrangements for
private vehicles to be parked off site and operatives transported to site by an appropriate vehicle complying with
sub-Clause 117.10.
54 (05/14) Unless stated otherwise in Sheet 1 of contract specific Appendix 1/20, where it is proposed to construct
or site temporary facilities for recovery services outside the highway boundary, the Contractor shall be responsible
for planning permission, waste arrangements and any statutory charges or other costs associated with the facilities
(e.g., ground rent).
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121 (05/14) Tidal, Flowing and Standing Water

1 (05/14) The Contractor shall take measures and carry out any operation necessary for dealing with tidal, flowing
or standing water within the site.
122 (05/14) Progress Photographs

1 (05/14) The Contractor shall arrange, as described in contract specific Appendix 1/22, to have record
photographs of the works taken at the times and/or intervals stated in contract specific Appendix 1/22. The format
of the photographs and the media used for submission to the Overseeing Organisation shall be as described in
contract specific Appendix 1/22. Unless otherwise stated in contract specific Appendix 1/22 the photographs shall
be taken by a professional photographer.
2 (05/14) All prints shall be marked on the reverse side with the date taken, identification reference number, and
brief description of the work or features including chainage and direction of view.
3 (05/14) The copyright of all photographs shall be vested in the Employer and the photographs shall be delivered
to the Overseeing Organisation within 1 week of the photographs being taken. The photographs shall not be used
for any purpose whatsoever without the Overseeing Organisation’s approval.
123 Not Used
124 (05/14) Health and Safety Restrictions, Precautions and Monitoring

1 (05/14) In addition to all other health and safety requirements the Contractor shall implement the requirements
described in contract specific Appendix 1/23 to protect the workforce, members of the public and persons visiting
the site from risks arising from the hazards defined therein. Where described in contract specific Appendix 1/23 the
Contractor shall also comply with the specific monitoring requirements described therein. The monitoring
requirements as described in contract specific Appendix 1/23 are in addition to contract specific monitoring
requirements described elsewhere in the specification.
2 (05/14) In addition to all other information required the Contractor shall provide copies of CE marking
information for all CE marked works, goods or materials used in the works for inclusion in the Health and Safety
File. This information shall include, as appropriate, the Declaration of Conformity or Declaration of Performance
and all safety information.
125 (05/14) Temporary Closed Circuit Television (CCTV) System for the Monitoring of Traffic
(05/14) General
1 (05/14) Where required in contract specific Appendix 1/25, the Contractor shall design, provide, install,
maintain, operate and, at the completion of the requirement, remove the temporary CCTV system as specified in
this Clause. Where associated work is subject to a Quality Management Scheme listed in Appendix A such work
shall be undertaken by organisations registered to the relevant scheme(s).
The Contractor shall be responsible for obtaining any licences, power supplies and approvals required, including
structural approvals, prior to the installation of any equipment.
2 (05/14) The system shall be designed such that the whole of the works area, including both carriageways and
hardshoulders, is covered at all times. There shall be sufficient overlap between the areas covered by adjacent
cameras such that there are no blind spots. Supplementary cameras shall be provided in accordance with sub-Clause
6 of this Clause.
3 (05/14) Where specified in contract specific Appendix 1/25, the Contractor shall interface the temporary CCTV
system with the permanent CCTV system, and ensure that it does not cause any interference to or interruption of
effective operation and functionality of any other element of the existing or permanent CCTV system or motorway
communications equipment and network.
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4 (05/14) The Contractor shall restore each site to its original condition following the removal of cameras and
other temporary equipment.
(05/14) Cameras
5 (05/14) The temporary CCTV system shall provide coverage of the works area specified in sub-Clause 2 using
cameras that are fixed in their direction of view. The orientation of all cameras on each carriageway shall be the
same.
6 (05/14) Where specified in contract specific Appendix 1/25, the Contractor shall design, provide, install,
maintain, operate and, at the completion of the requirement, remove supplementary cameras at the locations
specified in contract specific Appendix 1/25. These supplementary cameras shall have pan, tilt and zoom facilities
providing an unimpaired view of traffic in all directions.
7 (05/14) The cameras and their location shall take account of the sun and lighting such that their effectiveness is
not reduced by glare over a 24 hour period.
8 (05/14) Cameras shall be of a type that provides 24 hours per day operation.
(05/14) Camera Supports
9 (05/14) The Contractor shall be responsible for the design, provision, construction, maintenance, operation and,
at the end of the requirement, removal of all necessary supporting structures and associated safety barriers, paving,
steps and hand rails.
(05/14) Maintenance
10 (05/14) The minimum requirements for maintenance shall be:
(i) any faults shall be repaired or the equipment replaced within 4 hours of any fault or failure;
(ii) the whole system, including cameras, monitors and video recording equipment, shall be in full working
order for no less than 160 hours in any 7 day period.
11 (05/14) The cameras shall be located such that they can be removed, replaced and maintained without the need
for traffic management.
(05/14) Monitoring
12 (05/14) The Contractor shall provide, train and maintain suitable staff for the monitoring of the works area
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covered by the temporary CCTV system.

13 (05/14) The Contractor shall provide, maintain and, at the end of the requirement, remove suitable temporary
accommodation for monitoring equipment and staff.
14 (05/14) The monitoring staff shall be competent in the use of the system and shall be responsible for the
reporting of breakdowns and faults to the Contractor.
15 (05/14) The monitoring staff shall maintain a daily log of all incidents within the roadworks area. This log shall
be available for inspection by the Overseeing Organisation and the police at all times. The monitoring staff shall
report all incidents immediately to the Contractor’s Traffic Safety and Control Officer. The Contractor shall provide
a suitable communications system for use by the monitoring staff. Where an “incident” is a shed load, vehicle
breakdown, vehicle abandonment or traffic accident, whether or not the latter involves personal injury, or any other
incident which causes a change to traffic flow or a potential for personal injury.
16 (05/14) The monitoring equipment shall include video recording equipment with sufficient capacity and
recording media for the duration of the requirement.
The system shall be such that the image on the monitor and any video recording taken from it shall provide a
legible image of the registration plate of any stationary vehicle within 150 metres of the camera.
All monitor images shall include the date, time and unique camera reference.
17 (05/14) The Contractor shall provide, install, operate, maintain and, at the completion of the requirement,
remove a dedicated communication link to the Regional Control Centre, Police Control Office or other control
centre as detailed in contract specific Appendix 1/25.
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126 (05/14) Timber and Products Containing Wood Supplied Under the Contract
1 (05/14) All Timber and wood-derived products for supply or use in the works shall be independently verifiable
and either from a Legal and Sustainable source or a FLEGT-licensed or equivalent source.
The Contractor shall submit documentary evidence to demonstrate this to the Overseeing Organisation prior to its
inclusion or use in the works.
The verification and evidence shall comply with the criteria in this Clause.
2 (05/14) Management of the forest or plantation shall be audited at intervals confirming ongoing good forest
management and by organisations with appropriate forest management experience that are independent of the
organisation that holds timber harvest and/or management rights for that forest.
3 (05/14) The Overseeing Organisation will accept evidence from any of the following three categories:
(a) Category A evidence: Certification under a scheme recognised by the UK government as meeting the
criteria set out in the document entitled “UK Government Timber Procurement Policy: Criteria for
Evaluating Certification Schemes (Category A Evidence)” The edition current on the day the contract is
awarded shall apply. Acceptable schemes must ensure that at least 70% (by volume or weight) is from a
Legal and Sustainable source with the balance from a legal source.
(b) Category B evidence: Documentary evidence, other than Category A evidence and FLEGT evidence,
that provides assurance that the source is sustainable. In this context “sustainable” is defined in the
document entitled “UK Government Timber Procurement Policy: Framework for Evaluating Category B
evidence” The edition current on the day the contract is awarded shall apply. Such Category B evidence
may include, for example, independent audits and declarations by the Contractor or his suppliers. Where
Category B evidence is to be relied on, the Contractor is required to notify the Overseeing Organisation
of the source or sources of all virgin timber and wood-derived products supplied. Source in this context
means the forest or plantation where the trees were grown and all subsequent places of delivery through
the supply chain prior to receipt of the timber or wood-derived product on site. The Contractor shall
separately identify virgin timber and wood-derived products supplied from forests and plantations that
are claimed to be subject to sustainable timber production and shall submit to the Overseeing
Organisation documentation in respect of such wood to confirm that the criteria for sustainable timber
production set out in this specification have been met.
(c) FLEGT evidence, from either or both of the following categories: Evidence of timber and wood-derived
products being exported from a timber-producing country that has signed a bilateral Forest Law
Enforcement, Governance and Trade (FLEGT) Voluntary Partnership Agreement (VPA) with the
European Union and which have been licensed for export by the producing country’s government. This
may also include timber and wood-derived products that have been independently verified as meeting all
the producing country’s requirements for a FLEGT licence where a VPA has been entered into but the
FLEGT licensing system is not fully operational, or equivalent evidence from a country that has not
entered into a VPA which demonstrates that all of the requirements equivalent to FLEGT-licensed timber
have been met.
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May 2014
Amendment - April 2022 29F
30F
Volume 1 Series 100
NATIONAL ALTERATIONS OF THE OVERSEEING

ORGANISATION
the works. OF WALES
2150NAW(05/14) The Checking
testing
(05/14) Bar
scheduled in Schedules
contract specific Appendix 1/5, including sampling and provision of the
1in contract
(05/14) The Contractor shall check the bar schedules and, make any corrections necessary. Checking shall be
specific Appendix 1/5 within an elapsed time from the taking of the respective samples which shall be
commenced
reasonable insufficiently in advanceunless
all the circumstances of ordering steel prescribed
otherwise reinforcement to allow
by the for corrections
Overseeing and approvals.
Organisation. The
The Contractor
Contractor shall be fully responsible for correctness of the schedules, and the Overseeing Organisation does not
accept any liability whatsoever for any errors therein. The schedules, corrected as necessary, shall be the basis of
admeasurement.
151NAW
(ii) trials Dimensional
(05/14)and Accuracy
demonstrations;
(iii) routine
1 (05/14) testing carriedany
Before commencing outpart
by manufacturers andContractor
of the works, the suppliers in compliance
shall check thatwith a specified standard
all co-ordinates, or
levels and
specification;
dimensions shown in the Contract Documents are correct. He shall check and satisfy himself that the various parts
fit satisfactorily
(iv) testingtogether and in relation to existing physical features. Checking shall be commenced sufficiently in
of plant.
advance of construction to allow for corrections. The Contractor shall be fully responsible for correctness and the
3 (05/14) Where
Overseeing requireddoes
Organisation in contract specific
not accept Appendix
any liability 1/5 test certificates
whatsoever and/or
for any errors product certification complying
therein.
with the provisions of the relevant standard or specification where applicable and certifying that the goods or
least four weeks
152NAW (05/14)prior to the incorporation
Agreement of the goodsInvolving
on Measurements or materialsComputer
in the works.
Equipment
1 (05/14) If applicable all measurements relating to the works which involve the use of computer equipment
(whether in the taking of the measurements or in the storage of results of the measurements) and will have a
bearing on valuations, payment and specification compliance shall, where practicable, be jointly undertaken by the
materials in the works. This information shall be in English.
Overseeing Organisation and Contractor’s staff. The results of the measurement, as produced by or stored in the
4respective Where required
(05/14) computer in contract
equipment, specific
shall be Appendix
complied to and 1/5 tests and
certified associated
as being correctsampling
by both shall be If
parties. undertaken
joint by
testing laboratories
measurement is not accredited in accordance
possible, independent withmeasuring
check BS EN ISO/IEC
shall be17025.
carriedThe
out accreditation
and certifyingshall be by UKAS or
counter-signatures
equivalent European
shall be attached accreditation
to the organisation
original measure and thewhich is party to a multi-lateral agreement (MLA) with UKAS or any
check-measure.
2 (05/14) If compatible computerised data-storage systems are employed by both the Overseeing Organisation and
Where UKAS or
the Contractor, equivalent
agreement onlaboratory accreditation
the correctness is required
of the data the results
can be based shall
on data betransferred
files reported onbetween
an official
theUKAS
parties or
in
equivalent
the form ofaccredited
computer laboratory
disks or bytest report
direct or certificate.
transfer. Counter-signatures must, however, be attached to printed copies of
the data which must be filed for record purposes.
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shall deliver these to the Overseeing Organisation as described in contract specific Appendix 1/6. Unless otherwise
stated in contract specific Appendix 1/6, the Contractor shall arrange for the sampling of such goods and materials
to be undertaken by qualified staff of testing laboratories holding UKAS or equivalent European Accreditation
activities. Following an initial period of sampling, the Contractor may apply to the Overseeing Organisation for a
Appendix 1/6.

W1F
W1F
Volume 1 Series 100

ORGANISATION
the works. OF NORTHERN IRELAND
2104NI TheStandards,
(05/14)
(05/14) Quality
testing scheduled Management
in contract and Acceptance
specific Appendix 1/5, including sampling and provision of the
(05/14) Standards
in contract specificand CE markings
Appendix 1/5 within an elapsed time from the taking of the respective samples which shall be
1 (12/14) Where there is a requirement in this specification for compliance with any part of a “British Standard”
or other technical specification, that requirement may be met by compliance with:
(a) a standard or code of practice of a national standards body or equivalent body of any EEA state or Turkey;
(b) any international standard recognised for use as a standard or code of practice by any EEA state or Turkey;
(c) a technical specification recognised for use as a standard by a public authority of any EEA state or Turkey;
(iii) orroutine testing carried out by manufacturers and suppliers in compliance with a specified standard or
specification;
(d) a European Technical Assessment issued in accordance with the procedure set out in regulation (EU) No
(iv) 305/2011
testing of plant.
3 (05/14)that
provided Where requiredstandard
the relevant in contract specific
imposes an Appendix
equivalent1/5 testofcertificates
level performance and/or
and product certification
safety provided for bycomplying
the
with
statedthe provisions
Standard of the relevant
or technical standard or specification where applicable and certifying that the goods or
specification.
“EEA State” means a state which is a contracting party to the agreement on an European Economic Area signed at
least four weeks prior to the incorporation of the goods or materials in the works.
Oporto on the 2nd of May 1992 as adjusted or amended.
2 (05/14)inElectrical
materials the works. equipment to whichshall
This information directives 2006/95/EC or 2004/108/EC apply and which are produced for
be in English.
conformity to the provisions of the applicable directives. Declarations of conformity required by the above
testing laboratories accredited in accordance with BS EN ISO/IEC 17025. The accreditation shall be by UKAS or
the equipment.
3 (05/14) Construction products which are produced for incorporation in a permanent manner in the works and are
covered by a harmonised European standard or European Technical Approval or Assessment must have the product
equivalent accredited laboratory test report or certificate.
performance required by the specification for the intended use declared under the Declaration of Performance and
5be CE Where
marked
(05/14) goods or materials
in accordance with theare accepted
relevant on the
British basis European
adopted of an equivalent standard,
standard quality
or European management
Technical Approvals
scheme, productand
or Assessments certification scheme
the regulation (EU)or No
product acceptance
305/2011. Unlessscheme as provided
otherwise describedforininthe
Clause 104, testing
specification, and
the declared
sampling
performanceas specified in or applicable
of the product shall meet tothesuch an equivalent
required standard
performance of allquality management
the essential scheme,required
characteristics product by the
certification
specification.scheme or product
Declarations acceptance required
of performance scheme isbyaccepted
the aboveandregulation
shall be substituted for those
shall be provided to specified in
the Overseeing
contract specific
Organisation Appendices
prior 1/5 and
to installation 1/6orrespectively.
or use procurement or supply of the product.
6 (05/14)
(05/14) The Management
Quality Contractor shall provide samples, which shall include source samples, of goods and materials and
4stated Unlessspecific
in contract
(05/14) otherwise indicated
Appendix in the
1/6, contract specific
Contractor Appendix
shall arrange1/24 or as
for the requiredofinsuch
sampling the goods
Conditions of
and materials
Contract,
to the Contractor
be undertaken shall staff
by qualified institute a quality
of testing management
laboratories system
holding complying
UKAS with BS
or equivalent EN ISOAccreditation
European 9001 and shall
prepare a Quality
Organisation Plan. ThetoContractor
accreditation BS EN ISO/IEC shall demonstrate compliance
17025 for such with
sampling. this requirement
These samples shalltobeinstitute a quality
supplied in
management
sufficient timesystem to the
for them Overseeing
to be tested forOrganisation, onethe
acceptability by acceptable method
Overseeing for this demonstration
Organisation, is to evidence
taking into account the
registration to
programme forBS
theEN ISO Production
works. 9001. samples shall be delivered in a condition which is representative of the
material’s
5 (05/14)state for the purpose
The Quality Plan shallof the test.
incorporate the requirements of contract specific Appendix 1/24 and the
7requirements
(05/14) TheofContractor
the qualityshall
management
provide forschemes listed
rates of in Appendix
sampling A applicable
specified in contractto the works
specific in accordance
Appendix with
1/6. These
sub-Clause
rates 8 of this
of sampling Clause.
shall apply at the outset of each of the respective activities and for the duration of each of the
activities.
The Quality Following
Plan shallanbeinitial periodtoofthe
submitted sampling, the Contractor
Overseeing Organisationmay applythe
within to period(s)
the Overseeing Organisation
stated in for a
contract specific
relaxation in these rates of sampling having demonstrated
Appendix 1/24, for acceptance, before any related work is commenced.to the Overseeing Organisation an acceptable level of
Appendix 1/6.

December --`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
N1
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Where(iv)anydetails of where
work, goods the goodstoare
or materials beincorporated into the
used in the works areworks.
the subject of the quality management schemes
listed in Appendix A, the Contractor shall require the supplier of such items to prepare a Quality Plan and the
Contractor shall submit it to the Overseeing Organisation. Such Quality Plans shall comply with the requirements
the works.
Quality Management
(05/14) Sampling and in Highway Works, see sub-Clause 8.
Testing
26 (05/14) Quality Plans shall indicate “hold points” as follows:
(05/14) The testing scheduled in contract specific Appendix 1/5, including sampling and provision of the
associated
Contractor’ssamples, shall
points be undertaken
where no further by theshall
work Contractor. The Contractor shall carry out each of the tests required
in contract
hold points:specific Appendix
proceed 1/5the
without within an elapsed
written approvaltime
of afrom the taking
designated of the
person of respective samples
the Contractor’s which shall who
management, be
reasonable in allshall
the circumstances unless otherwise
be named in the Quality Plan. prescribed by the Overseeing Organisation. The Contractor
Overseeing points where no further work shall
The following operations
Organisation’s are not the
proceed without included inapproval
written contract specific
of Appendix 1/5:
hold(i)
points:checking,
a designated
inspecting, examining, measuring (exceptOrganisation.
representative of the Overseeing in connection with testing);
The Contractor
(ii) trialsshall ensure the Quality Plans and associated quality documentation are made available to all
and demonstrations;
parties involved with the works.
(05/14) Quality Records
specification;
(iv) testing
7 (05/14) of plant.
For works, goods or materials other than those which are CE marked, the Contractor shall make
available contemporary
3 (05/14) Where required quality recordsspecific
in contract to the Overseeing
Appendix 1/5 Organisation whenand/or
test certificates requested. Thiscertification
product includes quality
complying
records
with the provisions of the relevant standard or specification where applicable and certifying that quality
such as those identified in BS EN ISO 9001 to demonstrate achievement of the required the goodsandorthe
effectiveness
materials meetofthe thespecified
quality system. The Contractor
requirements, shall require
shall be supplied any
to the member ofOrganisation
Overseeing the Contractor’s
by thesupply chain at
Contractor to
make available such contemporary quality records when requested. Following
least four weeks prior to the incorporation of the goods or materials in the works. a request copies of all quality
Where goods or materials
non-conforming are required
product/service to the to be CE marked
Overseeing or whereand
Organisation theshall
Contractor
requireproposes to use
any member ofCE
themarked goods
Contractor’s
or materials
chainthe Contractor shall supply the Overseeing Organisation withtothe
theCE marking The
information including
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supply to immediately report any non-conforming product/service Contractor. Contractor shall

any relevant instructions
immediately and safety
pass these reports to theinformation
OverseeingatOrganisation,
least four weeksand prior to theno
undertake incorporation of the
further related work goods
untilor
materials in the works. This information
remedial or other measures have been undertaken. shall be in English.
4 (05/14)
The Where
Contractor required
shall submitinthe
contract
qualityspecific
recordsAppendix
required by 1/5this
tests and associated
Specification, sampling in
as indicated shall be undertaken
Appendix by
H, to the
Overseeing accredited
Organisation. in accordance
No item of work shallwithbeBS EN ISO/IEC
considered 17025.until
complete Thethese
accreditation shallbeen
records have be byreceived
UKAS or by
equivalent European
the Overseeing accreditation organisation which is party to a multi-lateral agreement (MLA) with UKAS or any
Organisation.
Note: Quality terms used in this Clause are as BS EN ISO 9000.
(05/14) Quality
equivalent Management
accredited Schemes
laboratory test report or certificate.
85 (05/14) Where
Except goods or materials
as described are accepted
in sub-Clause 104.9,onwhere
the basis
anyof an equivalent
work, standard, to
goods or materials quality management
be used in the works
scheme,
are the subject of a quality management scheme listed in Appendix A, only work, goods or materialstesting
product certification scheme or product acceptance scheme as provided for in Clause 104, and
conforming
sampling
with such as specified
a scheme in or
shall beapplicable to such
used and the an equivalent
organisations standard
carrying quality
out such management
work scheme,registration
shall have current product to the
certification schemeThe
relevant scheme(s). or product acceptance
Contractor shall in scheme
each caseis accepted
submit toand
the shall be substituted
Overseeing for those
Organisation specified
a copy of the in
contract specific
certificate Appendices
of conformity 1/5 and
affirming 1/6 respectively.
compliance with the scheme.
69 (05/14) The WhereContractor
any work, shall provide
goods samples,towhich
or materials be usedshall include
in the works source samples,
are the subjectofofgoods andmanagement
a quality materials and
shall
scheme listed in Appendix A and for which the goods or materials are CE marked products in accordanceotherwise
deliver these to the Overseeing Organisation as described in contract specific Appendix 1/6. Unless with the
stated
relevant in standard(s)
exclusions 1/6, the Contractor
to mandatory requirementsshallasarrange
listed infor the sampling
Appendix of such goods and materials
A apply.
10 (05/14) Where specific training and competency requirements are identified in any quality management scheme
listed in Appendix
sufficient A, thetoContractor
time for them shall
be tested for provide copies
acceptability of Overseeing
by the the relevant Organisation,
training and/ortaking
competency assessments
into account the
certificates
programme for the works. Production samples shall be delivered in a condition which is representative of prior
and/or registration/skill cards of the workforce to the Overseeing Organisation for acceptance the to
the commencement of relevant work.
11
7 (05/14) The requirement for compliance with a registered quality management scheme listed in Appendix A
(05/14) The Contractor shall provide for rates of sampling specified in contract specific Appendix 1/6. These
shall be sampling
rates of satisfied by compliance
shall with
apply at the an equivalent
outset of each ofquality management
the respective scheme
activities and of
forany
theMember
duration State of of
of each thethe
European
activities. Following an initial period of sampling, the Contractor may apply to the Overseeing Organisation forthat
Economic Area or a State which is party to a relevant agreement with the European Union, provided a
the proposed
relaxation scheme
in these is designed
rates to ensure
of sampling havingindemonstrated
use levels of tosafety, performance
the Overseeing and fitness an
Organisation foracceptable
purpose equivalent
level of to
those provided
confidence for by the
in control. schemeatspecified.
Provided, The proposed
any subsequent time whenscheme will include
test results third
indicate theparty
needassessment
for improvedby control
bodies in
accredited
the opinion of the Overseeing Organisation, the Contractor samples at the rate specified in contract specific or
in accordance with BS EN ISO/IEC 17021 by the United Kingdom Accreditation Service (UKAS)
equivalent
Appendix 1/6. European Accreditation Organisation, which is party to a multi-lateral agreement (MLA) with UKAS or

N2
N2
Volume 1 Series 100
any equivalent
(iv) detailsInternational
of where the
Accreditation
goods are incorporated
Forum (IAF)into
MLA the signatory
works. with a scope which includes the relevant
standard(s). This sub-Clause applies also to works only in so far as the means of carrying out such works are
indivisibly associated with the goods or materials for which an alternative quality management scheme is proposed.
the works.
12 (05/14) Works, goods and materials, other than those covered by the Construction Products Regulation, falling
under the standards listed in Appendix B are required to have attestation or third party accreditation to demonstrate
reasonable
(i) in all the circumstances
Compliance unless
with a relevant otherwise
product mark prescribed by the Overseeing
scheme demonstrating Organisation.
compliance The Contractor
as described in sub-Clause
shall supply13tobelow;
the Overseeing Organisation, within 24 hours of the completion of each test, a copy of the results.
The (ii)
following operations are
Demonstration not includedasindescribed
of compliance contract specific Appendix
in sub-Clause 1/5:
13 below;
(i)
(iii) checking, inspecting,
Demonstration examining,
of compliance measuring
using (except
testing and in connection
calculation with testing);
as described in sub-Clause 14 below.
Where(ii)works,
trials and demonstrations;
goods or materials are covered by the Construction Products Regulation (EU) No. 305/2011 (CPR)
performance of the product given in the Declaration of Performance meeting the required performance of all the
specification;
essential characteristics given in the specification and evidence being provided that demonstrates the product meets
(iv) testingofofthe
the requirements plant.
specification for aspects other than those covered by the essential characteristics, where
such evidence meets the
3 (05/14) Where required requirements
in contract of options
specific (i) or (ii)1/5
Appendix above.
test certificates and/or product certification complying
with the provisions
13 (05/14) of the(i)
Where option relevant standard
or (ii) of or specification
sub-Clause where
12 is used the applicable
product andcertified
shall be certifying that the goods
as compliant withorthe
materials meetand
specification therelevant
specified requirements,
standard, shall beassupplied
or equivalent to in
described thesub-Clause
Overseeing1 Organisation
of this Clause,bybythe Contractor at
a Certification
least
Body.four weeks prior to the incorporation of the goods or materials in the works.
The Certification arebe
Body shall required to beinCE
accredited marked orwith
accordance where
BS the
ENContractor
45011 or BS proposes to use 17065
EN ISO/IEC CE marked
by thegoods
or materials
United the Contractor
Kingdom shallService
Accreditation supply (UKAS)
or equivalent withAccreditation
European the CE marking information
Organisation, including
which is party
any
to a relevant instructions
multi-lateral and(MLA)
agreement safety information
with UKAS at or least four weeksInternational
any equivalent prior to the incorporation
Accreditation of the goods
Forum (IAF)orMLA
materials
signatory in theaworks.
with This information
scope which includes theshall be instandard(s).
relevant English.
4Unless Wheredescribed
otherwise
(05/14) required in
incontract specific Appendix
the specification assessment1/5oftests and associated
the product shall besampling shall
carried out be undertaken
to the level of by
attestation accredited
as determined in theinrelevant
accordance withfor
standard BSthe
ENintended
ISO/IECuse 17025.
of theThe accreditation
product shall and
in the works be by UKAS
shall or
include
equivalent
confirmation European
that theaccreditation organisation
product provides, which is party
in use, adequate levelstoofa safety,
multi-lateral agreement
performance and(MLA)
fitness with UKAS or
for purpose. any
For
other equivalent
products coveredInternational
by the Low Accreditation Forum
Voltage Directive MLA signatory
(2006/95/EC) and with a scope that includes
the Electromagnetic BS EN ISO/IEC
Compatibility 17025.
Directive
(2004/108/EC)
Where UKAS orthe safety aspects
equivalent wouldaccreditation
laboratory be for aspects
is not covered
required the by the relevant
results shall be CE marking.
reported on an official UKAS or
equivalent accredited
The Contractor laboratory
shall provide test reportonorthe
information certificate.
product to the Overseeing Organisation for acceptance. This
information
5 (05/14) Where goods or materials are accepted details
shall include certification, attestation on the and
basisCertification Bodystandard,
of an equivalent details. quality management
scheme,
14 (05/14)product
Wherecertification
option (iii) scheme or product
of sub-Clause 12 isacceptance
used it shallscheme as providedthat
be demonstrated forthe
in Clause
product104, testing of
is capable and
sampling
performing asas
specified
requiredinusing
or applicable to such anorequivalent
tests, calculations standard
other means. Such quality
testing management
or other meansscheme, product
shall have a minimum
certification schemeasorthat
level of attestation product acceptance
determined by thescheme is standard
relevant accepted and
and be
shall be substituted
suitably extensivefor
to those specified
provide in on
information
contract specific
all relevant Appendices
parameters. 1/5shall
Testing and be
1/6carried
respectively.
out by laboratories accredited to UKAS or equivalent Accredited
Organisation
6 (05/14) The asContractor
described in sub-Clause
shall 105.4. which shall include source samples, of goods and materials and
provide samples,
shall deliverorthese
The testing othertomeans
shall include as described
confirmation in contract
that the product specific
provides, in Appendix 1/6.levels
use, adequate Unlessofotherwise
safety,
stated in contract
performance specificfor
and fitness Appendix
purpose.1/6,
Forthe Contractor
products shall
covered byarrange
the LowforVoltage
the sampling of such
Directive goods andand
(2006/95/EC) materials
the
to be undertaken Compatibility
Electromagnetic by qualified staff of testing
Directive laboratories the
(2004/108/EC) holding
safetyUKAS orwould
aspects equivalent
be forEuropean Accreditation
aspects not covered by the
relevant CE marking.
The Contractor shall provide information on the product to the Overseeing Organisation for acceptance. This
information shall include testing or calculation details and results, certification and attestation details.
(05/14) Product
7 (05/14) Acceptanceshall
The Contractor Schemes
provide for rates of sampling specified in contract specific Appendix 1/6. These
15 (05/14) Where there are references in the Specification to particular industry product acceptance schemes such
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as British Board of Agrément Certificates, Roads and Bridges Certificates, HAPAS certificates, CARES certificate
or equivalent scheme, these shall be taken as references to a product acceptance scheme that has the attributes given
in sub-Clause 16 below. The types of work, goods or materials listed in Appendix C are required to be certificated
by a product acceptance scheme prior to their inclusion in the works.
Appendix 1/6.
Amendment - May 2014 N3

9
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Volume 1 Series 100
16 (iv)
(05/14) details of where
The works, goodstheorgoods are incorporated
materials into the
shall be assessed works.
against a set of guidelines and criteria by a Certification
Body. Certification to confirm the products successfully meet the guidelines and criteria shall be issued by a
Certification Body. The Contractor shall provide information on the product to the Overseeing Organisation for
the works.
its compliance
(05/14) Sampling with
andtheTesting
criteria given below and accreditation details of the organisation issuing the certification.
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2The (05/14)
schemeTheshall meetscheduled
testing the following criteria.specific Appendix 1/5, including sampling and provision of the
in contract
associated
(a) samples, shall be undertaken
Product acceptance by the Contractor.
and certification specified inThe
thisContractor
sub-Clauseshall
shallcarry out each of
be structured andthe tests required
implemented to
in contract provide
specific assurance
Appendix to1/5the
within an elapsed
Overseeing time fromthat
Organisation the the
taking of thewhen
product, respective samples
supplied for itswhich shalluse
intended be
reasonable and
in allinstalled
the circumstances
or processed unless otherwise prescribed
post manufacture, by the with
in accordance Overseeing Organisation.instructions,
the manufacturer’s The Contractorwill
shall supplygive
to the Overseeing Organisation, within 24 hours
the performance and level of safety required by of the completion of each test, a copy of
specification and be fit for purpose. the results.
The (b)
following
Theoperations
organisation arecertifying
not included in contract
products specific
and issuing theAppendix
certificates1/5:
must be accredited to the relevant
(i) Certification
checking, inspecting, examining, measuring (except in connection withfortesting);
Body standard, BS EN 45011 or BS EN ISO/IEC 17065 product certification, or BS EN
(ii) istrials andtodemonstrations;
party a multi-lateral agreement (MLA) with UKAS or any equivalent International Accreditation
(iii) routine testingMLA
Forum (IAF) carriedsignatory with a scope which
out by manufacturers includes in
and suppliers thecompliance
relevant standard(s). This shall
with a specified include
standard or
accreditation
specification; to manage and execute a certification scheme as defined in this sub-Clause. Accreditation
must cover a scope of activity relevant to the construction, installation, maintenance and operation of
(iv) highway
testing ofinfrastructure.
plant.
3 (05/14)
(c) The Where required
scheme mustincover
contract specific Appendix 1/5 test certificates and/or product certification complying
as appropriate:
i. theManufacture
materials meet and installation
specified requirements, shallorbepost manufacture
supplied processing Organisation
to the Overseeing of those products forContractor
by the which a at
Declaration of Performance, and consequent
least four weeks prior to the incorporation of the goods or materials in the works. CE marking, has not been made on the basis of any
harmonised European Standard (hEN) or European Technical Assessment; or
or materialsii.the Contractor
Only the installation
shall supplyofthe a material
Overseeing or post manufacture
Organisation withprocessing where the
the CE marking manufacturer
information has
including
made a Declaration of Performance of the material (with consequent
any relevant instructions and safety information at least four weeks prior to the incorporation of the goods or CE marking); or
materials iniii.
the works.
ProductThis information not
characteristics shallincluded
be in English.
in the required essential characteristics of a hEN or in a
European Technical Assessment
4 (05/14) Where required in contract specific Appendix 1/5 if such characteristics provide additional
tests and associated protection
sampling shall for the by
be undertaken
consumer (e.g. road user).
equivalent
(d) European accreditation
The assessment organisation
and certification which is party
requirements for atoproduct
a multi-lateral agreement
certified under the(MLA)
schemewithmust UKAS
be or any
other equivalent International
developed ensuringAccreditation
due consideration ForumisMLA givensignatory with a scopeofthat
to the requirements theincludes
users of BS the EN ISO/IEC
product 17025.
and those
Where UKAS responsible for thelaboratory
or equivalent highwaysaccreditation
on which such products the
is required willresults
be used or installed.
shall be reported on an official UKAS or
equivalent
(e) The accredited
schemelaboratory
must havetest report or supervisory
a technical certificate. panel that provides technical oversight on the operation
5 (05/14) of the scheme
Where goods or and formallyare
materials consents
accepted to on
thethe issue of assessment
basis and certification
of an equivalent requirements
standard, quality management of the
scheme, product certification scheme or product acceptance scheme as provided for in Clause 104, testing and a
specialist groups developing the assessment and certification requirements. This panel must include
sampling asbalanced
specifiedrepresentation
in or applicable of key end an
to such users, recognized
equivalent industry
standard experts
quality and thosescheme,
management responsible for the
product
highways on which such products will be used or installed.
contract
(f) specific Appendices
The product 1/5 andmust
certification 1/6 respectively.
include requirements for the audit and quality control of the production
and installation processes
6 (05/14) The Contractor shall provide samples,for the product where
which necessary
shall include taking
source account
samples,ofofthe product
goods and having
materials its and
performance declared under a CE mark. Installer certification must include
shall deliver these to the Overseeing Organisation as described in contract specific Appendix 1/6. Unless otherwise requirements for on site
surveillance
stated in contract specificof Appendix
installation1/6,or post manufacturing
the Contractor shall processes.
arrange for the sampling of such goods and materials
to be(g)
undertaken
For everyby qualified
product itstaffhas of testing under
certified laboratories
a product holding UKAS or
certification equivalent
scheme, European Accreditation
an organisation must make open
Organisationandaccreditation to BS EN
publicly accessible ISO/IEC
details of the17025 for such
assessment andsampling. These
certification samples shall be supplied in
guidelines.
(h) Where
programme for thedifferent organisations
works. Production have certified
samples the same generic
shall be delivered form ofwhich
in a condition product they must be able
is representative of theto
demonstrate to the Overseeing
material’s state for the purpose of the test. Organisation equivalence of performance of products certified under the
7 (05/14) product.
The Contractor shall provide for rates of sampling specified in contract specific Appendix 1/6. These
i)
activities. FollowingTheancompetences
initial periodof oforganisations
sampling, the certifying
Contractor products shall to
may apply be the
as the competency
Overseeing requirements
Organisation for afor
Technical Assessment Bodies given in Regulation (EU) No 305/2011,
relaxation in these rates of sampling having demonstrated to the Overseeing Organisation an acceptable level of the Construction Products
Regulation,
confidence in control. Provided, Annex IV,subsequent
at any Table 2 with timethewhen
additions given in
test results Table 1/1.
indicate the need for improved control in
Appendix 1/6.

N4
N4
Volume 1 Series 100
Table
(iv)
(05/14) 1/1 of
details Competency additions
where the goods to Construction
are incorporated Product Regulation (EU) No. 305/2011
into the works.
Annex IV, (Table 2)
the works.
Competence Description of Competence Requirement
Samplingthe
7. Determining
(05/14) andspecific
Testing Understand and evaluate the A certification body shall have staff
installation or post manufacturing installation or post manufacturing with appropriate technical
control processes of the specific product in knowledge of the relationship
order to identify appropriate between the installation / post
measures ensuring consistent manufacturing processes and the
compliant delivery of the installed product characteristics related to
or post manufactured product. production control for installation or
The following operations are not included in contract specific Appendix 1/5: post manufacture.
8. Constructive
(i) engagement
checking, Be prepared
inspecting, examining, to engage
measuring Be able
(except in connection with to resolve differences in the
testing);
constructively with highway certified performance of products of
(ii) trials and demonstrations; infrastructure managers and other the same generic type and where
certifying bodies for resolution of
(iii) routine testing carried out by manufacturers and suppliers in compliance appropriate
with aagree a common
specified setorof
standard
specification; issues. guidelines for the assessment and
certification of such products.
(iv) testing of plant.
(05/14) European
3 (05/14) WhereTechnical
required inAssessment (ETA)Appendix 1/5 test certificates and/or product certification complying
contract specific
with(05/14)
17 the provisions of the relevant
The requirements standard
for works, or specification
goods or materials towhere applicable
be subject and certifying
to a product that the
certification goodsoror
scheme
materials
product acceptance scheme as discussed in sub- Clauses 12 to 16 above may alternatively be met by a product at
meet the specified requirements, shall be supplied to the Overseeing Organisation by the Contractor
least
beingfour weeks
attested priora European
using to the incorporation of the goods(ETA)
Technical Assessment or materials
issuedin
inthe works. with the procedure set out in
accordance
Regulation
Where goods305/2011, provided
or materials that thetorelevant
are required attestation
be CE marked imposes
or where theanContractor
equivalentproposes
level of safety,
to use CEperformance and
marked goods
fitness
or for purpose
materials providedshall
the Contractor for by the Specification.
supply the Overseeing Organisation with the CE marking information including
any
18 relevant instructions and safety information at least four weeks prior to the incorporation of the goods or
(05/14) Not used.
(05/14) Departmental
4 (05/14) Authorisation
Where required in contract specific Appendix 1/5 tests and associated sampling shall be undertaken by
testing laboratories accredited in accordance
19 (05/14) Departmental authorisation with BS
is required EN any
before ISO/IEC
traffic17025. Theincorporated
signs are accreditationinto
shall
thebeworks
by UKAS
whereor
equivalent European accreditation organisation which is party to a multi-lateral agreement (MLA) with UKAS
these are of a character and/or are to be used in circumstances which have not been prescribed in the Traffic Signs or any
other equivalent International Accreditation Forum MLA signatory with a scope that includes BS EN
Regulations (Northern Ireland) 1997, the Zebra, Pelican and Puffin Pedestrian Crossings Regulations (Northern ISO/IEC 17025.
Ireland) 2006 and
Where UKAS subsequentlaboratory
or equivalent amendingaccreditation
Regulations.isWhere thethe
required Contractor has designed
results shall partonofanthe
be reported worksUKAS
official for or
which such authorisation is required, application shall be
equivalent accredited laboratory test report or certificate. made to the Overseeing Organisation.
520 (05/14) TheWhere types of works,
goods goodsare
or materials or materials
accepted on which are required
the basis to have Type
of an equivalent Approval
standard, or Registration
quality managementprior
to their acceptance
scheme, for inclusion
product certification in theorworks
scheme productareacceptance
given in Appendix
scheme E, with the exception
as provided for in Clausethat 104,
products thatand
testing are
covered
sampling as specified in or applicable to such an equivalent standard quality management scheme, product their
by the Construction Products Regulation (EU) No. 305/2011 (CPR) do not have to be listed prior to
acceptance
certificationfor inclusion
scheme in the works.
or product For products
acceptance scheme is not coveredand
accepted by CPR
shall previously obtained
be substituted typespecified
for those approvalinor
registration
contract can be
specific used. The 1/5
Appendices Contractor
and 1/6 shall submit to the Overseeing Organisation a copy of the type approval/
respectively.
registration certificate. Where previously obtained type approval or registration is not available the Contractor shall
submit documentation to the Overseeing Organisation which demonstrates compliance with the relevant
Organisation
(05/14) accreditation
Provision to BS EN ISO/IEC 17025 for such sampling. These samples shall be supplied in
of Information
21 (05/14) Where
programme for theinformation and documentation
works. Production samples shallregarding works,
be delivered in agoods or materials
condition which isisrepresentative
required to beof submitted
the
to the Overseeing
material’s state forOrganisation
the purpose offorthe
acceptance
test. the Contractor shall submit such documentation in a timescale to
meet the requirements of the Contractor’s programme of works. The Contractor shall liaise with the Overseeing
7Organisation
(05/14) The Contractor shall provide for rates of sampling specified in contract specific Appendix 1/6. These
to ensure that adequate time is allocated for the Overseeing Organisation to undertake the required
rates of sampling
assessments shall applyThe
for acceptance. at the
timeoutset of each
allocated forofacceptance
the respective
shallactivities andthan
not be less for four
the duration
weeks. of each of the
22 (05/14) in
relaxation Unless
these otherwise specified,
rates of sampling two copies
having of all information
demonstrated and documentation,
to the Overseeing Organisationincluding validlevel of
an acceptable
certificates,in
confidence incontrol.
respect of work, goods
Provided, at anyorsubsequent
materials proposed
time whenbytesttheresults
Contractor shallthebeneed
indicate supplied to the Overseeing
for improved control in
Organisation
the opinion ofinthe English.
Overseeing Organisation, the Contractor samples at the rate specified in contract specific
Appendix 1/6.

9
N5
--`,,,`,`,,,`,,,,```,`

Volume 1 Series 100
23 (iv)
(05/14) details
Where of thewhere the goods
Contractor are incorporated
proposes into the works.
to use an equivalent standard, quality management scheme, product
certification scheme, industry product acceptance scheme, or type approval/registration to that specified the
Contractor shall provide relevant information to enable the Overseeing Organisation to ascertain whether or not the
the works.
proposal is equivalent to the specified requirement. The information provided by the Contractor shall provide full
disclosure
(05/14) and appropriate
Sampling evidence regarding the works, goods or materials concerned in order to fully
and Testing
demonstrate equivalent levels of safety, performance and fitness for purpose. For products within the scope of the
2Construction
(05/14) The testing scheduled
Products Regulationinthis
documentation would be1/5, includingDeclaration
the relevant sampling and provision of the
of Performance and
associated samples, shall be undertaken by the
CE mark for the intended specified use. Contractor. The Contractor shall carry out each of the tests required
drawings in the
shall supply format
to the detailedOrganisation,
Overseeing in contract specific
withinAppendix
24 hours of1/4,
theprepared by or
completion ofon behalf
each test,of the Contractor,
a copy shall
of the results.
be submitted for the Overseeing Organisation’s acceptance. The minimum period for submission of the drawings
The
priorfollowing operationsofare
to commencement thenot included
related worksin shall
contract specific
be as stated Appendix
in contract1/5:
specific Appendix 1/4. Such acceptance
shall(i)
in no checking,
way relieve the Contractor
inspecting, of his responsibilities
examining, measuring (except for in
theconnection
work underwiththe testing);
Contract.

112NI
(iii)(05/14) Setting
routine Out
testing carried out by manufacturers and suppliers in compliance with a specified standard or
1 (05/14) specification;
The Contractor shall, unless otherwise stated in contract specific Appendix 1/12, within 3 weeks of the
date (iv)
for commencement
testing of plant.of the works, carry out a check of the co-ordinates and levels of all permanent ground
markers and permanent bench marks described in contract specific Appendix 1/12 and shall supply the Overseeing
3 (05/14) Where
Organisation, required with
if requested, in contract specificand
their position Appendix
level in1/5 testthat
order certificates
they mayand/or productand
be checked certification complying
revised if necessary.
with
The Contractor shall identify and bring to the attention of the Overseeing Organisation any markers that areor
the provisions of the relevant standard or specification where applicable and certifying that the goods
materials
missing. The meetContractor
the specified
shallrequirements,
comply with shall be supplied
any specific to the Overseeing
requirements Organisation
for setting out described byinthecontract
Contractor at
specific
least four weeks
Appendix 1/12. prior to the incorporation of the goods or materials in the works.
Where
2 (05/14) goods
TheorContractor
materials are
shallrequired to be CE
keep updated marked or
schedules andwhere the Contractor
drawings of all benchproposes to use CE
marks (which shallmarked goods
be based on
or materials the Contractor shall supply the Overseeing Organisation with the CE marking
Ordnance Datum of Belfast Mean Sea Level) used in the setting out and shall make these available to the information including
any relevantOrganisation
Overseeing instructions and
when safety information at least four weeks prior to the incorporation of the goods or
required.
3 (05/14) The Contractor shall ensure that where necessary, in order to maintain his programme, lines and levels
4are set
(05/14) Where required in contract specific Appendix 1/5 tests and associated sampling shall be undertaken by
out in such time as to enable Statutory Undertakers’ apparatus and other publicly or privately owned services
or supplies accredited
to be installed, in accordance
altered or removed. with BS EN ISO/IEC 17025. The accreditation shall be by UKAS or
4 (05/14)
other The Contractor
equivalent shall
International survey and Forum
Accreditation record MLA
existing details with
signatory of items which
a scope thatheincludes
is required
BS ENto remove
ISO/IEC and
17025.
subsequently replace. The level of survey information to be recorded is described in contract specific Appendix
Where
1/12. UKAS or equivalent laboratory accreditation is required the results shall be reported on an official UKAS or
117NI
scheme,(05/14)
productTraffic Safety
certification and Management
scheme or product acceptance scheme as provided for in Clause 104, testing and
(05/14) General
1 (05/14) Unless otherwise stated in contract specific Appendix 1/17 the Contractor shall plan, design,
6programme, provide,
(05/14) The implement,
Contractor maintain
shall provide and remove
samples, whichall traffic
shall safetysource
include and management measures
samples, of goods andnecessary
materials for
and
the completion
shall deliver theseof the works.
to the This shall
Overseeing include undertaking
Organisation all in
as described necessary
contractliaison
specificwith the police
Appendix 1/6.and highway
Unless otherwise
authority
stated responsible
in contract for each
specific public1/6,
Appendix highway affected by
the Contractor thearrange
shall works both before
for the commencement
sampling of such goods andand
throughout
materials
thebe
to duration of thebyworks.
undertaken Thestaff
qualified traffic
of safety
testingand management
laboratories measures
holding UKASshall be in accordance
or equivalent European with the
Accreditation
requirements accreditation
Organisation and constraints to stated
BS ENinISO/IEC
contract 17025
specific
forAppendix 1/17 and
such sampling. the Contractor
These samples shallshall
betake into account
supplied in
the information
sufficient time for contained
them to in
becontract
tested forspecific Appendix
acceptability 1/18.
by the The trafficOrganisation,
Overseeing safety and management
taking into measures
account the shall be
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
in accordance
programme forwith ChapterProduction
the works. 8 of the Traffic Signs
samples Manual.
shall The Contractor
be delivered shall which
in a condition informisthe Overseeing Organisation
representative of the
of any details
material’s statethe
forContractor
the purposehasofagreed with the police and/or the highway authority.
the test.
72 (05/14) AllThetraffic safetyshall
Contractor and provide
management operations
for rates shall specified
of sampling be undertaken by a supplier
in contract specificregistered
Appendixto National
1/6. These
Highway
rates Sector Scheme
of sampling 12 with
shall apply a scope
at the outset of
of registration
each of the that includes
respective reference
activities andtofor
onethe
orduration
more of of
National
each of the
Highways Following
activities. Sector Schemes 12A/B,
an initial 12C
period of or 12D as appropriate
sampling, to the
the Contractor mayworks.
apply to the Overseeing Organisation for a
3 (05/14) The Contractor shall, unless otherwise stated in contract specific Appendix 1/17, after consultation with
the police and highway authorities concerned, prepare and submit traffic safety and management proposals within
the timescale described in contract specific Appendix 1/17 to the Overseeing Organisation. These shall show the
Appendix 1/6.

N6
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Volume 1 Series 100
proposed
(iv) traffic
detailssafety
of where
and management
the goods aremeasures
incorporated
including
into the
provision
works. of safety zones. If stated in contract specific
Appendix 1/17, the proposals shall include the provision of running lanes for the use of emergency vehicles within
the site. The Contractor shall make such changes to his proposals as may be necessary to meet the requirements of
the works.
the Contract. Thereafter the Contractor shall furnish and update such details and information as may be necessitated
by the Sampling
(05/14) works. and Testing
24 (05/14) If stated in contract specific Appendix 1/17, the Contractor shall undertake the highway maintenance
functions
associated samples, therein
described shall beand to the extent
undertaken there
by the described,
Contractor. The onContractor
the lengthsshall
of highway
carry outthere
eachspecified, until
of the tests the
required
issue of the appropriate certificate of completion.
reasonable in all the
5 (05/14) Traffic circumstances
signs shall comply unless
with otherwise prescribed
the appropriate Clausesby the Overseeing
in Series 1200 of Organisation. The Contractor
the Specification.
6 (05/14) Where a temporary speed limit at road works has been imposed and the works have been temporarily
The following
terminated, operations
with the removal are ofnottraffic
included in contractmeasures,
management specific Appendix
the Contractor1/5: shall ensure that the temporary speed
limit(i)signs checking,
are covered or taken down for the duration of the
inspecting, examining, measuring (except in connection cessation of the works. Where the temporary speed
with testing);
limit signs are covered, the covering material shall prevent the sign being visible through the cover in natural light
(ii) vehicle
and under trials and demonstrations;
headlamp or street lamp illumination at night, be non light reflective and securely fastened.
(iii) routine
7 (05/14) Where the testing carried
Contract out by manufacturers
provides that the Contractor and suppliers in compliance
shall not erect, maintainwith a specified
or reposition standard
traffic signs,orthe
Contractor specification;
shall not change in any manner the permanent or temporary traffic signs without instruction from the
Overseeing Organisation
(iv) testing of plant.and shall give such notice as is stated in contract specific Appendix 1/17 to indicate when
signs should be moved compatible with the progress of the works.
3 (05/14) Where required in contract specific Appendix 1/5 test certificates and/or product certification complying
8with(05/14) All trafficofsafety
the provisions and management
the relevant standard ormeasures necessitated
specification by the works
where applicable and shall be fully
certifying thatoperational
the goods or before
the Contractor commences any work, which affects the public highway or the use of
materials meet the specified requirements, shall be supplied to the Overseeing Organisation by the Contractor at it.
least four weeks
9 (05/14) Any areaprioroftohighway
the incorporation
which hasof the closed
been goods or materials
because in works
of the the works.
shall not be re-opened to traffic until
all appropriate traffic safety and management measures have
Where goods or materials are required to be CE marked or where the Contractor been completed andproposes
the highway is CE
to use in amarked
suitablegoods
condition for public use.
any
10 relevant instructions
(05/14) Where work isand safety
carried outinformation at least
on, or adjacent to afour weeksopen
highway priortototraffic
the incorporation
the Contractor of the
shallgoods or that
ensure
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vehicles and mobile plant under his control operating frequently or regularly on or adjacent to that highway in the
execution
4 (05/14)of the works
Where shallinbe
required conspicuous
contract specificand comply with
Appendix Section
1/5 tests and O5 Generalsampling
associated Vehicle Issues ofundertaken
shall be Chapter 8, Part
by
2testing
Operations, of the Traffic Signs Manual.
laboratories accredited in accordance with BS EN ISO/IEC 17025. The accreditation shall be by UKAS or
equivalent
11 (05/14) European accreditation
Where required organisation
in contract which is party
specific Appendix 1/17toorawhere
multi-lateral
required agreement (MLA) with
for the execution UKAS
of the works or the
any
other equivalent International Accreditation Forum MLA
Contractor shall provide temporary lighting in accordance with Clause 1405. signatory with a scope that includes BS EN ISO/IEC 17025.
Where
12 UKAS
(05/14) Whereor equivalent
required inlaboratory accreditation
contract specific Appendix is required the results
1/17 or where shallfor
required bethereported
executionon anof official
the works UKAS
the or
Contractor shall provide laboratory
Temporary testEmergency
report or certificate.
Telephones in accordance with Clause 1529.
135 (05/14) Where
(05/14) The goods orshall
Contractor materials
provide areand
accepted
suitablyon sign
the basis
pointsofof
anentry
equivalent
to and standard,
exit fromqualitythe site,management
for vehicles and
scheme,
plant engaged on the works. The Contractor shall ensure that when any vehicle or item of plant104,
product certification scheme or product acceptance scheme as provided for in Clause testing and
is reversing within
sampling
the site onasorspecified
adjacent into or applicable
a highway to such
open an equivalent
to traffic, it does sostandard
only underquality managementofscheme,
the supervision a personproduct
designated for
certification
the purpose of scheme or product
regulating trafficacceptance
within the siteschemewhoisshall
accepted and shall
be readily be substituted
distinguishable from forthe
those specified
remainder of in
the work
contract
force. specific Appendices 1/5 and 1/6 respectively.
614 (05/14)
(05/14) The
If anContractor
accident orshall provideoccurs
breakdown samples, on which shall include
a carriageway or hardsource samples,
shoulder openoftogoods
trafficand materials
within and
or in the
shall deliver these to the Overseeing Organisation as described in contract specific Appendix
vicinity of the site, the Contractor and operators of recovery vehicles provided in accordance with Clause 120 shall 1/6. Unless otherwise
stated in contractbyspecific
act as requested police Appendix
officers or1/6, theofficers
traffic Contractor shall
acting arrange
under theirfor the sampling
statutory powers.of such goods and materials
15 (05/14) Where work is carried out on or adjacent to a highway open to traffic the Contractor shall ensure that the
workforce and for
sufficient time the them
site supervisory
to be testedstaff at all times wear
for acceptability by thehigh visibility warning
Overseeing clothing
Organisation, complying
taking with BS
into account the EN
471. Clothing shall be to Table 1, Class 2 or 3 (Class 3 on motorways or other high
programme for the works. Production samples shall be delivered in a condition which is representative of thespeed roads) and shall comply
with the requirements of para 4.2.3(b).
material’s state for the purpose of the test. In addition on motorways or other high speed roads full length sleeves
meeting the requirements of para 4.2.4 shall be provided for coveralls and jackets. The colour of the clothing shall
7normally
(05/14)beThe Contractoryellow”
“fluorescent shall provide for rates of
or “fluorescent sampling specified
orange-red” complying inwith
contract
Tablespecific
2. The Appendix 1/6. These
retroreflective material
rates of sampling
used shall shall1as
be to Level apply at theatoutset
defined Tableof5.each of thecomplying
Clothing respectivewith activities
other and for the duration
specifications may be ofused
eachinof the
activities.
accordanceFollowing
with Clause an initial period
104 where theyof sampling, the Contractor
offer equivalent levels of may apply to in
performance thesoOverseeing Organisationgiven
far as the specification for a is
relaxation
not inconsistent with the basic health and safety requirements set out in Annex 2 of the Personal Protective of
in these rates of sampling having demonstrated to the Overseeing Organisation an acceptable level
confidence
Equipment in control.(89/686/EEC).
Directive Provided, at any Thesubsequent
Contractortime
shallwhen testthat
ensure results indicateinthe
the person needofforthe
charge improved
workforce control
is in
the opinion of the Overseeing Organisation, the Contractor samples at the rate specified
readily distinguishable from the person designated in sub-Clause 16 of this Clause and from the remainder of thein contract specific
Appendix
workforce.1/6.

9
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Volume 1 Series 100
(05/14) Traffic
(iv) Safety
details and Control
of where Officer
the goods are incorporated into the works.
These
16 details
(05/14) shall otherwise
Unless be provided to the
stated in Overseeing
contract specific Organisation
Appendix by1/17,
the Contractor
the Contractoruponshall
request and at
appoint completion of
a suitably
the works.
qualified Traffic Safety and Control Officer (TSCO) who shall make all arrangements necessary for traffic safety
and control including the provision and operation of breakdown recovery vehicles.
17 (05/14) The TSCO shall be experienced in the control of temporary traffic management operations and shall
2possess
(05/14) The testing
a National scheduled
Highway Sector in Scheme
contract (NHSS)
specific Appendix
12 Traffic 1/5,Safetyincluding
and Controlsampling and(2009)
Officer provision of the
Registration
associated
Card. samples, shall be undertaken by the Contractor. The Contractor shall carry out each of the tests required
18 (05/14) The
reasonable in allContractor shall provide
the circumstances unlesstheotherwise
prescribed by thewith the names
Overseeing and contactThe
Organisation. details of the
Contractor
TSCOsupply
shall and any nominated
to the Overseeing deputies. Unless otherwise
Organisation, within 24described
hours of the in contract
completion specific Appendix
of each 1/17 the
test, a copy TSCO
of the or a
results.
nominated deputy shall be on the site at all times when traffic management is in operation and shall be readily
The following
available to deal operations
with mattersare not included
related in contract
to traffic safety and specific Appendix
control including 1/5:breakdown recovery vehicles.
(i)
19 (05/14) checking, inspecting,
Without prejudice examining, 16
to sub-Clause measuring (except
above, whilst in connection
within the limits with testing); traffic management
of a temporary
scheme, the TSCO shall manage
(ii) trials and demonstrations; any traffic management related requests given by a Police Officer or Traffic
Officer. On Highways Agency roads the TSCO shall liaise with the Overseeing Organisation’s Regional Control
Centre(iii)on traffic
routinemanagement
testing carried out by
related manufacturers
matters includingand suppliers
requests in compliance with a specified standard or
and instructions.
specification;
20 (05/14) Unless otherwise stated in contract specific Appendix 1/17 the responsibilities of the Traffic Safety and
(iv) Officer
Control testing andofofplant.
his nominated deputies shall include the following:
3 (05/14) Where required withinthe
contract specific Appendixmobile 1/5 test certificates andand/or productothercertification complying
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a) Monitoring, assistance of sufficient personnel of sufficient suitable and
with the provisions of the relevant standard or specification
appropriate aids, the flow of traffic within the area of the site; where applicable and certifying that the goods or
leastb) Ensuring
four weeks priorthat, within
to the 5 minutes of
incorporation of the
notification
goods or of the occurrence
materials of an incident resulting in stationary
in the works.
vehicle(s) on a highway open to the public, the incident is reported to the vehicle recovery service when
vehicle recoveryare is required
in operation; to be CE marked or where the Contractor proposes to use CE marked goods
c)
any relevant Recording
instructions andandlogging
safetyallinformation
incidents and all movements
at least four weeksofprior recovery
to thevehicles and, when
incorporation of thecalled,
goodsall or
materials inmovements
the works. of theinformation
This emergency shall services.
be in English.
Where
4 (05/14) an “incident”
Where required is a shed load, vehicle
in contract specificbreakdown,
Appendixvehicle 1/5 testsabandonment
and associated or traffic
samplingaccident,
shall bewhether or notby
undertaken the
latter involves personal injury.
(05/14) Statutory Orders, Temporary Traffic Regulation Orders
21
Where (05/14)
UKAS Unless otherwise laboratory
or equivalent detailed inaccreditation
is required the 1/17
results theshall
Contractor shallon
be reported submit a formal
an official UKAS or
application to the appropriate authority
equivalent accredited laboratory test report or certificate.for any temporary traffic regulation orders or other statutory orders required
to be made or notices required to be published in connection with his traffic safety and management proposals. The
5Contractor
(05/14) Where goods with
shall comply or materials are accepted
any procedural on the basis
requirements given of in
ancontract
equivalent standard,
specific quality1/17.
Appendix management
22 (05/14)asThe
sampling Contractor
specified in or shall allow to
applicable forsuch
the notice periods standard
an equivalent required quality
for obtaining and implementation
management scheme, product of any
temporary
certification scheme or product acceptance scheme is accepted and shall be substituted for those specified in are to
traffic regulation orders or other statutory orders in the programme of works. Where applications
be made specific
contract to the Overseeing
Appendices Organisation
1/5 and 1/6 the notice periods required shall be as given in contract specific Appendix
respectively.
1/17.
23 (05/14)
shall deliverWherethese applications
to the Overseeing for temporary
Organisation trafficasregulation
described orders
in contractor other statutory
specific orders1/6.
Appendix are Unless
made by the
otherwise
Overseeing Organisation prior to the commencement of the works the Contractor
stated in contract specific Appendix 1/6, the Contractor shall arrange for the sampling of such goods and materials shall provide all necessary traffic
safety and management measures to implement the orders.
(05/14) Crossovers
24programme
(05/14) The for Contractor
the works. Production
shall design,samples constructshallandbemaintain,
deliveredorinifacontract
condition which Appendix
specific is representative
1/17 soofprovides,
the
shall construct and maintain, the central reserve crossovers described in contract specific Appendix 1/17 in
accordance
7 (05/14) The withContractor
the information stated therein.
shall provide for ratesUnless otherwise
of sampling described
specified in contract
in contract specific
specific Appendix
Appendix 1/6. 1/17,
Thesethe
Contractor shall remove those crossovers when no longer required and reinstate
rates of sampling shall apply at the outset of each of the respective activities and for the duration of each of the the central reserve to its original
condition.
relaxation
25 (05/14) in If these rates of sampling
the Contractor proposeshaving demonstrated
to construct to the Overseeing
central reserve crossovers Organisation
as part of his an acceptable
traffic safety andlevel of
confidence in control. Provided, at any subsequent time when test results
management proposals he shall submit such proposals to the Overseeing Organisation in advance, in accordance indicate the need for improved control in
the opinion of the Overseeing Organisation,
with the requirements of sub-Clause 3 of this Clause. the Contractor samples at the rate specified in contract specific
Appendix 1/6.

N8
N8
Volume 1 Series 100
(05/14) Driver
(iv) Information
details Signs
of where the goods are incorporated into the works.
These
26 details
(05/14) shallrequired
Where be provided to the Overseeing
specific Appendix by the
1/17, the Contractor
Contractor shallupon request
provide, andmaintain
erect, at completion
and of
the works.
remove Driver Information Signs to diagrams 7004 and 7005 of the Traffic Signs Regulations and (Northern
Ireland) 1997 in accordance with sub-Clause 27 of this Clause and Chapter 8 of the Traffic Signs Manual.
Information signs shall only be displayed within roadworks where they accurately reflect the reason for the
2inactivity.
associated
27 (05/14) samples,
Legends shall
shall be
be undertaken by the Contractor.
selected as appropriate The Contractor
from those shall
permitted and carry
listed inout each of
Chapter thethe
8 of tests required
Traffic
in contract specific Appendix 1/5 within an elapsed time from
Signs Manual unless stated otherwise in contract specific Appendix 1/17. the taking of the respective samples which shall be
Sign 7005
shall supplyshall indicate
to the how long
Overseeing delays are within
Organisation, possible.
24 This
hoursdate shall
of the be updated
completion ofby thetest,
each Contractor,
a copy of if the
necessary,
results.
until the restrictions are removed.
Sign 7004 shall be located within roadworks when part of the road is coned off, and the reason for this is not
(i) from
apparent checking, inspecting,for
the carriageway, examining,
any period measuring
exceeding(except in connection
30 minutes, withiftesting);
or one hour road capacity is maintained.
However, signs located within
(ii) trials and demonstrations; roadworks shall only be used where they can be located at least 50 metres beyond
the downstream end of a taper and in a position which does not prejudice traffic safety.
If needed, Information
specification;Signs shall be sited at the beginning and at one kilometre intervals through the works. They
shall not be placed where they may distract drivers negotiating traffic management provisions.
Signs shall either be sited for the duration of the works where it is safe and appropriate to do so or provision made
3 enable
to Where
(05/14)their use required in contract specific Appendix 1/5 test certificates and/or product certification complying
at short notice.
The Contractor
materials meet theshall providerequirements,
specified adequate storage
shallfacilities cleartoofthe
be supplied anyOverseeing
safety zone. Storage within
Organisation theContractor
by the central reserve
at
or in four
least frontweeks
of safety barriers
prior to the shall not be permitted.
incorporation of the goods or materials in the works.
WhereTemporary
(05/14) goods or materials
Automaticare required to be CESystem
Speed Camera marked(TASCAR)
or where the Contractor proposes to use CE marked goods
28 (05/14) Where
any relevant required
instructions andin safety
information 1/17,
at least four a Temporary
weeks prior to theAutomatic Speed of
incorporation Camera System
the goods or for
the Enforcement of Mandatory Speed Limits
materials in the works. This information shall be in English. at Roadworks (TASCAR) shall be provided in accordance with the
following requirements and those given in contract specific Appendix 1/27. The type of system and the number of
4speed(05/14) Where sites
monitoring required
and in contract
their specific
locations shallAppendix 1/5 tests
be as specified and associated
in contract specificsampling
Appendixshall 1/27.be undertaken by
29 The Contractor
(05/14) European
equivalent shall beorganisation
accreditation responsible which for theisdesign,
party toinstallation, commissioning,
a multi-lateral agreement (MLA) maintenance and or any
with UKAS
removal
other equivalent International Accreditation Forum MLA signatory with a scope that includes BS EN ISO/IEC(EES).
of the system. This shall be undertaken using a suitably qualified Enforcement Equipment Supplier 17025.
The EES shall make all arrangements necessary for the provision and operation of the TASCAR system. The
Where
ContractorUKAS shallorsupply
equivalent laboratory
evidence of the accreditation is required
EES qualifications to thethe results shall
Overseeing be reportedprior
Organisation on an toofficial
the UKAS or
commencement of the works. laboratory test report or certificate.
5The (05/14)
equipmentWhere goods
shall meetorthematerials are accepted
requirements on the basis Handbook
of the Speedmeter of an equivalent standard,
and have Homequality management
Office Type Approval
scheme, product certification scheme or product acceptance scheme as provided
(HOTA) for the purpose required. The installation, commissioning, operation and maintenance of the for in Clause 104, testing
systemandshall
sampling
be undertakenas specified in or applicable
in accordance to such an equivalent
with the requirements standard quality
of the equipment’s HOTA. management scheme, product
All equipment
contract specific and training necessary
Appendices 1/5 and 1/6to bring the sites into operation shall be provided and installed by the
respectively.
Contractor, this shall include, but not be limited to, all equipment, poles, housings and power supplies. The
6quantities
(05/14)ofThe Contractor
equipment shall provide
required shall besamples,
as specifiedwhich shall include
in contract source
specific samples,
Appendix of goods
1/27.The and materials
Contractor shall and
shall deliver these to the Overseeing Organisation as described in contract specific
ensure that the System is completely installed and fully operational from the time defined in contract specificAppendix 1/6. Unless otherwise
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
stated in contract
Appendix 1/27 and specific
that it Appendix
remains in1/6, the Contractor
operation shall arrange
for the duration of thefor the sampling
Contract of such goods
unless otherwise and materials
specified in
to be undertaken by qualified staff of testing laboratories
contract specific Appendix 1/27 and is removed on completion of the works. holding UKAS or equivalent European Accreditation
The Contractor
sufficient time for shall
themcommission
to be tested anyfornecessary thirdby
acceptability party
the certification of the system taking
Overseeing Organisation, and shall
intosupply
accountcopies
the of the
certification to the Overseeing Organisation.
material’s
30 (05/14)state
Unless forotherwise
the purpose of the test.
required by the equipment’s HOTA requirements, the equipment and ancillary items
shall
7 (05/14) The Contractor shall provideand
be compatible with all permanent for temporary installations
rates of sampling associated
specified with specific
in contract the works. Appendix 1/6. These
rates of sampling
31 (05/14) shall apply
The Contractor at the
shall, outset
liaise withofthe
each of the Enforcement
relevant respective activities
Authority and(EA)
for the duration ofhow
to determine eachthe
of system
the
activities. Following an initial period of sampling, the Contractor may apply to the Overseeing
for the scheme shall integrate with the EA’s existing facilities and operations. The Contractor shall comply with Organisation for athe
relaxation
Overseeing Organisation’s procedures with respect the liaison as described in contract specific Appendix 1/27.ofThe
in these rates of sampling having demonstrated to the Overseeing Organisation an acceptable level
confidence in control.
Contractor shall submitProvided,
details ofattheanysystem
subsequent
to the time when test
Overseeing results indicate
Organisation the need
four weeks in for improved
advance of itscontrol
operationin
the opinion
for approval. of the Overseeing Organisation, the Contractor samples at the rate specified in contract specific
Appendix 1/6.

9
N9
Volume 1 Series 100
32 (iv)
(05/14) details of whereequipment
The TASCAR the goodsshall
are incorporated into thedetection
consist of a HOTA works. and measuring device, and ancillary
equipment that allows day and night operation, If a trailer mounted system is supplied it shall be fitted with
retractable de-mountable wheels.
the works.
33 (05/14) The Contractor shall arrange for the provision of a mains electrical supply of adequate power capacity to
(05/14) Samplingofand
all components the Testing
system. Alternatively, he may provide an equivalent supply from a local electrical generator
or generators which shall
2 (05/14) The testing scheduledbe used in
only for this
contract purpose.
specific Such generator(s)
Appendix shallsampling
1/5, including have electric start mechanisms
and provision of the and
be adequately regulated as to voltage and frequency to suit the accuracy requirements of the
associated samples, shall be undertaken by the Contractor. The Contractor shall carry out each of the testsequipment provided
required
for TASCAR and be capable of running constantly for 48 hours without refuelling at an output
in contract specific Appendix 1/5 within an elapsed time from the taking of the respective samples which shallof not less than be
that
required by the equipment at 0.8 power factor, or equivalent output. All generators shall be housed
reasonable in all the circumstances unless otherwise prescribed by the Overseeing Organisation. The Contractor in vandal-proof
containers
shall supplyandto be
thesecurely locked.
Overseeing One set ofwithin
Organisation, keys shall be provided
24 hours to the EA. of
of the completion Generators
each test,may only
a copy ofbetheused when
results.
they will not adversely affect the equipment/systems operations or the equipments HOTA requirements.
34 (05/14) The housing and poles for the TASCAR equipment must be as required for the specific HOTA for that
(i)
equipment, checking,
and shall inspecting, examining, measuring
include security-locking mechanisms(except in connection
to prevent with testing);
unauthorised access or operation.
(ii) trials
35 (05/14) and demonstrations;
The Contractor shall install the poles/masts/cabinets or trailers required at each individual speed
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
monitoring
(iii) routine testing carried out shall
location, any installation be within highway
by manufacturers limits. in compliance with a specified standard or
and suppliers
36 (05/14) specification;
At completion of the works the Contractor shall remove all TASCAR equipment and reinstate ground as
described in contract
(iv) testing specific Appendix 1/27.
of plant.
37 (05/14) The
3 (05/14) Where Contractor
required shall ensurespecific
in contract that suitable access
Appendix arrangements
1/5 are and/or
test certificates in placeproduct
at eachcertification
speed monitoring site
complying
including vehicle hard standings, walkways and steps where necessary to allow for general
with the provisions of the relevant standard or specification where applicable and certifying that the goods ormaintenance and
servicing
materials of thethe
meet camera unit.requirements,
specified Where supplied, suitable
shall provisions
be supplied to theshall be madeOrganisation
Overseeing for installingbyand
therecovering
Contractor at
trailers.
38
Where(05/14) TheorContractor
goods materials areshall ensure to
required that
bethe
CEcamera
markedpoles are located
or where in accordance
the Contractor withtoroad
proposes restraint
use CE systems
marked goods
requirements detailed in TD 19/06.
any
39 relevant
(05/14) Theinstructions
Contractorand safety
shall information
ensure at least
that the site four weeks
reference number prior to the indicated
is clearly incorporation of the
on both thegoods or
installation
and on the road surface within the field of view of the camera(s). Site reference numbers should be agreed with the
EA.
40 (05/14) Any ductingaccredited in accordance
provision, withinstallation
loop or piezo BS EN ISO/IEC
shall be17025.
carriedTheoutaccreditation
in accordanceshall
withbethe
byrelevant
UKAS or
equivalent European
clauses of Series 500accreditation
and 1200 of organisation which is party to a multi-lateral agreement (MLA) with UKAS or any
the Specification.
41 (05/14) The Contractor shall be responsible for the commissioning of the TASCAR as a whole, including
Where
secondaryUKASand or
in equivalent laboratory
station checks. accreditation
The Contractor shall,is where
required the results
required shall
as part be reported
of the on an official
HOTA, provide UKAS or
a secondary
equivalent accredited laboratory
method of confirming test report or certificate.
the speed calculation.
542 (05/14) Where
(05/14) The goods or materials
commissioning of the are
TASCARaccepted on be
shall thecarried
basis ofout aninequivalent
the presencestandard,
of, andquality management
for acceptance by, the
scheme,
EA and shall be in accordance with any particular requirements in contract specific Appendix 1/27, testing
product certification scheme or product acceptance scheme as provided for in Clause 104, the and
sampling as specified
commissioning in orbe
shall only applicable
completetowhen sucheach
an equivalent standard
site, and where quality management
applicable, scheme,
the overall system product as
is accepted
certification scheme
being operational by or
theproduct
EA. The acceptance
Contractorscheme is accepted
shall give notice toand theshall be substituted
Overseeing for those
Organisation of specified
his intention in to
contract
carry outspecific
this work, Appendices 1/5 and 1/6
unless otherwise statedrespectively.
in contract specific Appendix 1/27 this shall be not less than four days
in
6 advance of the
(05/14) The intended shall
Contractor time for the commissioning.
provide samples, whichAn Evidential
shall Trail (ET)
include source whichofmeets
samples, goodsalland
thematerials
requirements
and
as stated in contract specific Appendix 1/27 including commissioning certificates
shall deliver these to the Overseeing Organisation as described in contract specific Appendix 1/6. Unless shall be provided by theotherwise
Contractor to the Overseeing
stated in contract Organisation
specific Appendix 1/6, theand shall include
Contractor shallone pair for
arrange of photographs
the samplingorofvideosuch images
goods andfor materials
acceptance by the EA as part of the commissioning and acceptance procedure of the
to be undertaken by qualified staff of testing laboratories holding UKAS or equivalent European Accreditation system. The Contractor shall
ensure that all relevant requirements of the Evidential Trails for Enforcement
Organisation accreditation to BS EN ISO/IEC 17025 for such sampling. These samples shall be supplied inSystems documents are achieved.
sufficient
43 (05/14)time for them
Cameras sitedtoon
bethe
tested for acceptability
nearside by the Overseeing
of the carriageway Organisation,
shall be installed taking into account
and commissioned prior to 24thehour
programme for the works. Production samples shall be delivered in a condition which
lane closures being put into operation. Cameras sited in the central reserve shall be installed and commissioned is representative of the not
later than 12 hours after installation of the contraflow. Both sets of cameras shall then remain in continuous
operation
7 (05/14)untilThe aContractor
Completion Certificate
shall provide for has rates
been of
issued for the
sampling whole of
specified inthe works.specific
contract At the Appendix
end of the 1/6.
period of
These
operation required under the Contract, the equipment shall remain the property of the Contractor.
activities.
44 (05/14)Following
Followingan initial period of
commissioning thesampling,
TASCARthe Contractor
Operator will may
be the apply
EA. toThetheContractor
shall provide for a
relaxation in these rates of sampling having demonstrated to the Overseeing Organisation
assistance to the EA for the repositioning of the speed monitoring equipment between the housings, or switching an acceptable level of of
confidence in control. Provided, at any subsequent time when test results indicate
detection equipment between zones and servicing as and when requested by the EA. Any repositioning during the need for improved control
thein
the opinion of the Overseeing Organisation, the Contractor samples at the rate specified
works that requires that the equipment parameters are changed must be supported by the issue of a calibration in contract specific
Appendix
certificate 1/6.
by the Contractor to the EA.

N10
N10
Volume 1 Series 100
45 (iv)
(05/14) details
All evidential
of wheremedia
the goods
from speed
are incorporated
monitoringinto
sitesthe
will
works.
remain the property of the EA. The scheme ET
documents shall be kept up to date by the Contractor.
46 works.
the (05/14) The Contractor shall provide and install all necessary speed limit signing in connection with the
operation of the TASCAR system, any signing used shall either be prescribed or where necessary authorised. The
(05/14) Sampling
Contractor and Testing
shall provide the EA, through the Overseeing Organisation, with a two hourly log showing the locations
of all the speed limit and speed limit
2 (05/14) The testing scheduled repeaterspecific
in contract signs relative
Appendixto existing marker sampling
1/5, including posts. A repeater sign shall
and provision be
of the
positioned such that one is visible in each photograph. Where there is a 24-hour CCTV system installed
associated samples, shall be undertaken by the Contractor. The Contractor shall carry out each of the tests required that is
monitoring ALL speed limit and repeater signs this log can be compiled remotely.
reasonable in all the
47 (05/14) Where circumstances
digital unless otherwise
HOTA equipment prescribed
is used, the by the
Contractor willOverseeing Organisation.
provide either The Contractor
the communications service
shall supply to the Overseeing Organisation, within 24 hours of the completion of each
to transfer data and control the device or appropriate media such as WORM (Write Once Read Many) test, a copy of the results.
drives, CDs,
memory sticks as appropriate, and in quantities required by the EA
The following operations are not included in contract specific Appendix 1/5: for the use of the equipment for the duration of
the works. If HOTA 35mm wet film systems are used, the film will be supplied to the EA by the Contractor,
(i) atchecking,
typically the rate ofinspecting, examining,
one film per measuring
day per live camera (except in connection
in operation, with testing);
plus ten which shall be supplied at the
specification;
3 (05/14) Where required in contract specific Appendix 1/5 test certificates and/or product certification complying
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
Appendix 1/6.
Amendment - May 2014 N11F

9
N11F
SERIES 200
SITE CLEARANCE
Contents
Clause Title Page
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
200 (02/16) General 2
201 (02/16) Clearing 2
(02/16) Existing Trees, Bushes
202
and Hedges 3F
203 (02/16) Explosives and Blasting 3F
204 (02/16) Hazardous Materials 3F

Volume 1 Series 200
Specification for Highway Works Site Clearance
SITE CLEARANCE
200 (02/16) General
1 (02/16) This Series is part of the Specification for Highway Works. Whilst this Series is particularly relevant to
the subject matter in its title it must be read in conjunction with the general requirements in Series 000 and 100 and
with all other Series relevant to the specification for the particular works to be undertaken.
201 (02/16) Clearing

1 (02/16) The Contractor shall demolish, break up and remove buildings and structures as described in contract
specific Appendix 2/1 and superficial obstructions on the site in the way of or otherwise affected by the permanent
works. The extent of any partial demolition of structures shall be as described in contract specific Appendix 2/1.
The Contractor shall clear each part of the site at times and to the extent indicated on the drawings. The Contractor
shall comply with the requirements of contract specific Appendix 2/6 with respect to ecological or other
environmental site clearance measures or restrictions.
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
The Contractor shall ensure that individual trees, shrubs and other features and areas stated on the drawings to be
preserved, are suitably identified and protected. The Contractor shall prepare a method statement describing the
approach for such works and their operation. This shall be submitted to the Overseeing Organisation for acceptance
prior to the commencement of site clearance works.
Should any trees, shrubs and other planting features and planting areas which it is intended to preserve be killed,
removed or damaged by the Contractor during the course of the works, they shall be replaced by the Contractor
with plants of the same species and equal in size to those killed, removed or damaged, all in accordance with Series
3000; or made good by arboricultural work in accordance with Clause 3010, or as directed by the Overseeing
Organisation; or replaced or made good to the satisfaction of the Overseeing Organisation. Such work shall be
carried out at the Contractor’s own expense.
2 (02/16) Where the line of an existing fence, hedge or wall is cut by the site boundary the severance shall be
made good unless otherwise described in contract specific Appendix 2/1; either by the continuation of the fence,
hedge or wall in a different direction, or by its termination. In the case of a strained wire or chain link fence a
straining post shall be installed and the fence re-strained.
3 (02/16) Underground structures, chambers and foundations described in contract specific Appendix 2/1 shall be
demolished to the depths prescribed, properly cleaned out, and filled. To permit free drainage, holes shall be made
at 500 mm centres over the whole area of slabs, basements, etc, which are not removed and which are liable to form
a barrier to water.
4 (02/16) Disused soil and surface water drains, sewers, cables and ducts together with any bed or haunch
or surround within 1 m of formation level shall be removed and over 1 m below formation shall be left unless
otherwise described in contract specific Appendix 2/2. The ends of existing drains and sewers no longer required
because of alterations to the drainage layout shall be sealed in accordance with Clause 506. All trenches shall be
backfilled in accordance with Clause 505 unless otherwise described in contract specific Appendix 2/2.
5 (02/16) The Contractor, subject to any instructions or contrary directions in accordance with the contract, shall
take all measures required by any Statutory Undertaker, the management of other publicly owned services, or
owners of privately owned services or supplies, for disconnection and proper sealing off of all redundant drains,
services and supplies.
6 (02/16) All materials arising from site clearance which are not required, or unacceptable for use in the
permanent works and not included in contract specific Appendix 2/3, shall become the property of the Contractor
and shall be disposed of by him.

Volume 1 Series 200
Specification for Highway Works Site Clearance
Materials included in contract specific Appendix 2/3 shall be carefully dismantled, taken up or taken down,
cleaned and retained for re-use, stacked, labeled and protected or loaded, and transported to store as described in
contract specific Appendix 2/3 and items damaged in this operation shall be replaced. All replacements shall be of
equivalent quality to the original materials.
When required in contract specific Appendix 2/3, voids left by items that have been removed shall be backfilled
immediately in accordance with the appropriate Clauses in Series 600.
7 (02/16) Topsoil excavated to enable parapet or boundary walls to be set back to new lines, or to be erected on
the boundaries of the site shall be reserved for re-use. After erection of the walls the topsoil shall be spread over the
disturbed ground, any surplus being disposed of as described in Clause 602.
8 (02/16) All existing road markings and road studs on carriageways open to traffic shall be removed as soon as
they become superfluous or a hazard to traffic and the carriageway reinstated in accordance with the requirements
of contract specific Appendix 2/3. Road markings shall be removed in accordance with Clause 1212.
9 (02/16) Existing tensioned safety barriers shall be detensioned to ensure safe removal.
202 (02/16) Existing Trees, Bushes and Hedges

1 (02/16) Unless otherwise required in contract specific Appendix 2/6 trees, bushes and hedges shall be uprooted
or cut down as near to ground level as possible. All felled timber shall be disposed of by the Contractor unless
otherwise described in contract specific Appendix 2/3.
2 (02/16) Stumps and roots from trees, bushes and hedges shall be grubbed up or blasted in accordance with
Clause 203 and disposed of by the Contractor. Holes left by removal of the stumps or roots shall, within one week,
be filled with acceptable material, as defined in Clause 601 and Table 6/1, and be compacted in compliance with
Clause 612 and Table 6/4.
3 (02/16) Unless otherwise required in contract specific Appendix 2/6 where shown on the drawings, existing
trees, bushes and hedges shall be cut back to the lines shown on the drawings in accordance with Clause 3010. For
the purposes of this sub-Clause, trees shall be defined as a woody plant greater than 2m in height and a bush shall
be defined as a woody plant of 2m height or less.
203 (02/16) Explosives and Blasting

1 (02/16) Blasting for site clearance shall comply with Clause 607 except that references in that Clause to contract
specific Appendix 6/3 shall be deleted and replaced by reference to contract specific Appendix 2/4 and such blasting
shall be confined to the locations and be within the limits stated therein.
204 (02/16) Hazardous Materials

--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
1 (02/16) The treatment of hazardous materials encountered in site clearance shall comply with any specific
requirements stated in contract specific Appendix 2/5 as well as relevant legislation and any other health and safety
measures.

SERIES 300
fencing
Contents
Clause Title Page
301 (05/01) General 2

302 Requirements for Temporary
and Permanent Fences 2
303 Temporary Fencing 2
304 (05/01) Timber Quality 2
305 (05/01) Fittings 3
306 (05/01) Permanent Fencing 3
307 Permanent Fencing for
Accommodation Works 4
308 Gates and Stiles 4
309 Removing and Re-erecting
Existing Fences and Gates 5
310 Not used 5
311 (05/01) Preservation of Timber 5
312 Painting of Timber Fences,
Gates, Stiles and Posts 6
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Volume 1 Series 300
Specification for Highway Works Fencing
fencing
301 (05/01) General (ii) Post and wire fencing as sub-Clause (i)
above but with no barbed wires.
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
1 Temporary and permanent fences shall comply with
this Series and the quality management schemes (iii) Cleft chestnut pale fencing type CW 120
detailed in Appendix A. complying with BS 1722 : Part 4 in
accordance with HCD Drawing Number H2.
2 (05/08) Organisations involved in fencing works for
highway schemes shall comply with this Series and the (iv) Wooden post and wire fence type C8/80/30
associated quality management schemes detailed in complying with BS 1722 : Part 2 in
Appendix A. accordance with HCD Drawing Number H2.
2 If temporary fencing is removed temporarily for the
execution of any part of the Works it shall be reinstated
302 Requirements for Temporary and as soon as possible and in the meantime the gap in the
Permanent Fences fencing shall be patrolled so that no unauthorised entry
1 (05/01) As soon as the Contractor is placed in on to adjoining land takes place and no stock escapes
possession of any part of the Site he shall immediately from the adjoining land.
erect fencing on the boundaries of the land as shown on 3 Unless otherwise described in Appendix 3/1, timber
the Drawings. In places where permanent fencing for temporary fencing need not have preservation
cannot be erected immediately or where none is treatment.
required, the Contractor shall erect, and when and
where necessary, re-erect and maintain, temporary
fencing and subsequently take down and remove as 304 (05/01) Timber Quality
necessary. The type of temporary fencing shall be
chosen by the Contractor, unless otherwise described in 1 (11/02) Timber for use in permanent works shall be
Appendix 3/1, and may be selected from the four either of appropriate natural durability or be treated
standard types for highway works described in with wood preservatives in compliance with
Clause 303, taking into account the usage of the Clause 311. Where natural durability is used as the
adjoining land. Unless otherwise described in criterion, the timber shall be of class 1 if used in ground
Appendix 3/1, the Contractor shall not use barbed wire contact (e.g. fence posts) and of class 2 or better if used
in areas accessible to the general public. Access shall be out of ground contact (e.g. fence rails) according to the
made in temporary fencing as necessary for the use of classification given in BS EN 350-1.
the occupiers of adjacent lands. 2 (05/08) If any sapwood is present in the timber,
2 Temporary fencing shall remain in position either irrespective of the natural durability of the heartwood,
until it is replaced by permanent fencing or until its the timber shall be treated with preservative
removal on completion of the Works, unless otherwise 3 (05/08) Unless otherwise described in this
described in Appendix 3/1. specification and in Appendix 3/1, timber for permanent
3 When concrete for post footings is required, it shall fencing shall comply with BS 1722-7, timber for field
comply with Clause 2602. gates and posts shall comply with BS 3470; and timber
for stiles, bridle gates and kissing gates shall comply
with BS 5709.
303 Temporary Fencing 4 (05/08) All timber for permanent fencing, field gates
and posts, stiles, bridle gates and kissing gates shall be
1 (05/01) Temporary fencing shall be appropriate to
of sawn timber conforming to BS 1722-7 Annex A. Non
the usage of the adjoining land and, unless otherwise
structural timber in environmental barriers shall comply
described in Appendix 3/1, may be selected from the
with the requirements of sub-Clause 2504.6. Structural
following types:
timber in environmental barriers shall be stress graded
(i) Post and wire fencing type SW 120 and marked to comply with BS EN 14081-1 and where
complying with BS 1722 : Part 2 in appropriate BS 4978, BS 5756 or BS EN 519 or other
accordance with HCD Drawing Number H1 grading rules accepted in BS 5268-2 and BS EN 1912.
with at least two of the wires being barbed.

Volume 1 Series 300
5 (05/08) For checking compliance with strength 3 Wire dropper fences for motorways shall be as
requirements, samples shall be taken by the shown on HCD Drawing Numbers H4, H5, H6 and H7.
manufacturer or supplier in accordance with the They shall comply with BS 1722 : Part 2 Sections 6 and
suggested sampling plan in Annex B of BS 1722-7. 7, with the following Clauses amended as below and
with any additional requirements described in
6 (05/08) All timber and wood contained in products
Appendix 3/1.
supplied or used for fences, including field gates and
posts, stiles, bridle gates, kissing gates, and On completion of the tensioning of the line wires all
environmental barriers shall comply with sustainability fittings, droppers and connections shall be painted with
criteria described in Clause 126. plastic paint of the same colour as the fence posts and
wire, within 24 hours of erection when required in
Appendix 3/1.
305 (05/01) Fittings
Clause 6.1.1 Delete text and insert:
1 (05/06) Bolts, screws and nuts shall comply with “High tensile wire, zinc and plastic coated,
BS EN ISO 4016, BS EN ISO 4018 and complying with Clause 2605, shall be used unless
BS EN ISO 4034, for BS EN ISO 898-1 property class otherwise stated in Appendix 3/1.”
4.6 or 4.8 unless otherwise described in Appendix 3/1.
Washers shall comply with BS 4320. Nails shall comply Appendix B, Clause B.2 Delete text and insert:
with BS 1202. Bolts washers and nails shall be “Steel posts and struts shall be galvanized and
galvanised to comply with BS EN ISO 1461 unless they plastic coated to comply with Clause 2604.”
are stainless steel.
Clause 4.4.4 Add:
“Only dowelled ends to straining and
306 (05/01) Permanent Fencing intermediate posts, and struts shall be used.
1 (11/06) Permanent fencing shall comply with this Turning posts shall be provided and fitted with
Clause and the additional requirements described in 225 mm x 150 mm x 3 mm thrust plates complying
Appendix 3/1. All permanent fencing, unless otherwise with Clause 2.4.2.2.
described in Appendix 3/1, shall be erected to present a As an alternative to being holed, a steel fillet may
flowing alignment both in plan and elevation following be welded to the straining post to allow for bolting
approximately the level of the ground and the the strut and post together.”
Contractor shall trim the ground along the line of the
Clause 4.6.6 Add:
fence when required in Appendix 3/1. Where the ground
is uneven or undulating the Contractor shall provide “Fence post rivets and wire vices shall be as
extra posts, stakes and ground anchors as necessary to described in Appendix 3/1.”
ensure that the bottom line wire in planting works
Clause 4.7 Delete text and insert:
fencing does not rise more than 50 mm above ground
level. The fencing shall be neatly and effectively joined “Concrete for surrounding the base of posts and
to existing hedges, fences and to other structures, to struts shall comply with Clause 2602.”
comply with HCD Drawing Number H36 and Chapter 8 Table 3. Add:
of TD 19 (DMRB 2.2.8), unless otherwise described in
Appendix 3/1. Planting works fencing shall be joined to Turning Posts
existing boundaries providing a secure joint capable of Length Section
withstanding entry by rabbits or larger animals. m CHS
2 Timber fencing for motorways shall be wooden mm x mm
post and rail fence with four rails type SPR 13/4 2.27 76.1 x 4.0
complying with BS 1722 : Part 7, to dimensions shown 2.72 88.9 x 4.0
on HCD Drawing Number H3. Both ends of posts and
rails shall be cross cut at right angles to the length of the 3.02 88.9 x 4.0
piece. The timber species and preservation treatment
shall comply with Clause 311 and any additional
stockproofing required shall be as described in
Appendix 3/1. Painting, if required in Appendix 3/1,
shall comply with Clause 312 and concrete surround to
posts, if required in Appendix 3/1, shall comply with
sub-Clause 302.3.
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Volume 1 Series 300
Clause 5.2.1 Delete paragraphs 2 to 5 and insert: the planting area and transfer them to cover
the whole of the ‘turned out’ portion of the
“All posts and struts shall be set in concrete and the
netting.
concrete surround shall be filled to within 75 mm
of the ground level.” (iv) The netting shall be buried vertically, to a
depth of 250 mm below existing ground
Clause 7.2.2 Add:
level. The excavation shall be backfilled and
“Turning posts and fittings shall be provided as rammed.
described in Appendix 3/1.”
Wire Mesh to Permanent or Existing Fencing
Clause 7.3.4 Amend 2nd sentence to read
6 Where required in Appendix 3/1, wire mesh shall
“The interval between a dropper and a post or
be attached to permanent or existing fencing in
between adjacent droppers, shall be as shown on
accordance with HCD Drawing Numbers H46, H47 and
HCD Drawing Numbers H4, H5 and H6”.
H48.
Planting Works Fencing 7 The Contractor shall check the condition of the
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4 Fencing for the protection of planted areas shall be lengths of existing fencing to which mesh is to be
one of the following types, required as described in attached before commencing work. Where there is
Appendix 3/1: damage to the existing fencing, the Contractor shall
report this to the Overseeing Organisation before
(i) Hexagonal wire netting fencing complying commencing attachment of the mesh.
with BS 1722 : Part 2 Section 8 and in
accordance with HCD Drawing Number Fenced Tree Guards
H39.
8 Where required in Appendix 3/1, fenced tree guards
(ii) Rectangular wire mesh and hexagonal wire shall be provided in accordance with HCD Drawing
netting fencing complying with Number H43.
BS 1722 : Part 2 Section 8 and in accordance
with HCD Drawing Number H40.
307 Permanent Fencing for Accommodation
(iii) Wooden post and four rail fencing type SPR
13/4 complying with BS 1722 : Part 7 and in
Works
accordance with HCD Drawing Number H3. 1 Permanent fencing shall be provided for
(iv) Wooden driven post fencing in accordance accommodation works and shall comply with this
with HCD Drawing Number H44. Series and the particular requirements described in
Appendix 1/15.
5 The ‘turned out’ portion of the hexagonal wire
netting of rabbit-proof fencing shall be treated in
accordance with one of the methods given below, as 308 Gates and Stiles
described in Appendix 3/1:
1 Field gates and posts shall comply with BS 3470
(i) 100 mm of netting buried vertically into the and Clauses 304 and 311. They shall be provided to the
ground beneath the fence, with a further dimensions shown on HCD Drawing Numbers H17 to
150 mm turned out towards the rabbit H22. Painting, if required in Appendix 3/1, shall
harbourage. The excavation shall be comply with Clause 312.
backfilled and rammed.
Fittings for field gates shall be as shown on HCD
(ii) 250 mm of netting turned out towards the Drawing Numbers H26-H33.
rabbit harbourage, laid flat to the ground
contours and pegged at 400 mm centres with 2 (05/01) Stiles, bridle gates, kissing gates and gates
300 mm long x 4 mm diameter galvanised in planting works fencing shall comply with BS 5709
wire pins bent hairpin pattern. and Clauses 304 and 311. They shall be provided to the
dimensions shown on HCD Drawing Numbers H23,
(iii) 50 mm of netting buried vertically into the H24, H25, H34, H35, H41 and H42.
ground beneath the fence, with a further
200 mm of netting turned out towards the 3 Concrete for post foundations shall comply with
rabbit harbourage and covered with turves. Clause 2602.
The Contractor shall cut and lift sections of 4 Any additional stockproofing required to gates and
turf at least 30 mm thick from the inside of stiles shall be as described in Appendix 3/1.
Amendment - November 2002 4

Volume 1 Series 300
5 (05/01) Where access gates are to be provided in a (ii) (05/08) For timber used out of ground contact
length of fencing that incorporates wildlife mesh, the the retention and penetration requirements of
underside of the gate shall include the measures the preservative shall be in accordance with
described in Appendix 3/1. the relevant provisions of BS 8417 (30 year
specification). Assessment for compliance
Badger Gates with these requirements shall be carried out
6 (05/04) Where required in Appendix 3/1, badger using the scheme described in (v) and (vi)
gates shall be provided in accordance with HCD below.
Drawing Number H45. Marine ply timber shall comply (iii) (05/08) For timber used in ground contact
with BS 1088-1 and BS 1088-2. where the preservative is a creosote
preservative complying with BS EN 13991,
the penetration and retention requirements
309 Removing and Re-erecting Existing shall be in accordance with the relevant
Fences and Gates provisions in BS 8417 (30 year specification)
with the exception of Douglas fir. Douglas
1 Where required in Appendix 2/3, existing fences, fir treated with creosote shall comply with
gates and stiles, with posts shall be carefully taken penetration class P8 of BS EN 351-1, i.e.
down, laid aside, removed or later re-erected in complete sapwood penetration, and the
compliance with Clauses 306, 307 and 308 as specified preservative retention in the analytical zone
in sub-Clause 201.6. shall be not less than 130 kg/m3. Assessment
2 (05/01) Fences, gates, stiles and posts which are to for compliance with these requirements shall
be re-erected shall have any existing paint removed and be carried out using the scheme described in
shall be prepared and treated to comply with (v) and (vi) below.
Clause 312. (iv) (05/08) For timber used in ground contact
3 (05/01) If any posts, rails or lengths of fencing are where the preservative is any other
removed to facilitate repairs or renewal of existing acceptable type of formulation, the
fences, the gap in the fencing shall be patrolled or penetration requirements for all timber
closed with appropriate temporary fencing in species shall be in accordance with the
accordance with Clause 303 together with any existing relevant provisions in BS 8417 (30 year
wildlife mesh attachments. specification). The preservative retention
shall be derived from BS8417 (30 years
specification) and 10 years ground contact
310 Not Used field test data (for example BS 7282),
interpreted according to the principles in
BS EN 599-1. Assessment for compliance
311 (05/01) Preservation of Timber with these requirements shall be carried out
using the scheme described in (v) and (vi)
1 Prior to preservation treatment and when the below.
moisture content is 28% or below, determined in
accordance with BS EN 13183-1 or BS EN 13183-2, (v) (05/08) To demonstrate that the required
the timber quality shall comply with Clause 304. penetration has been achieved, the sampling
scheme recommended in BS EN 351-1 for
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Defects unaffected by moisture content shall not be

accepted at any time. direct testing shall be followed. The number
of units to be sampled at random from the
2 (05/08) The preservation of timber shall be specified treated batch shall be determined using
in accordance with the system described in general inspection level II as defined in
BS EN 351-1 and shall comply with National Highways ISO 2859-1. Penetration shall be determined
Sector Schemes for Quality Management in Highway for each selected unit from sub samples (e.g.
Works: Sector Scheme 4 – preservative treatment of core borings) taken as recommended in
timber. BS EN 351-2. To determine whether the
(i) (05/08) Unless otherwise specified in treated batch has achieved the required
Appendix 3/1, the preservative used shall be penetration, an acceptable quality level
one which can be used in accordance with (AQL) of 10% for permeable timbers (e.g.
BS 8417 for use classes 3 and 4 for a desired Scots pine) and an AQL of 25% for resistant
service life of 30 years as described in (ii), timbers (e.g. Douglas fir) shall be used to
(iii) and (iv) below. establish pass/fail criteria from ISO 2859-1.

Volume 1 Series 300
A Certificate of Treatment showing the basis

of compliance with the specification shall
accompany each batch or part batch
delivered to site.
(vi) (05/08) Compliance with the retention
requirement within a batch of treated timber
shall be calculated from the chemical
analysis of the combined analytical zones of
the sub samples taken to determine
penetration. The retention shall be equal to
or greater than the appropriate value derived
as described in (ii), (iii) and (iv) above.
312 Painting of Timber Fences, Gates, Stiles

and Posts
General
1 Painting shall be carried out in accordance with the
recommendations in the Code of Practice BS 6150.
2 All timber fabricated into units before delivery to
the Site and which is required to be painted shall be
primed at the works.
Priming
3 (05/01) Surfaces of wood shall be clean and dry
before being primed. Priming paint shall comply with
either Type C primer to BS 7956 or ready mixed
aluminium priming paint complying with BS 4756.
Undercoats and Finishing Coats
4 After erection, all exposed primed surfaces shall be
painted with one coat of undercoat as described in
Appendix 3/1.
5 Two finishing coats of the colour and type
described in Appendix 3/1 shall be applied.
Coloured Wood-Stain
6 (05/01) Coloured wood-stains shall be applied as
described in Appendix 3/1.
Amendment - May 2008 6F

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SERIES 400
ROAD RESTRAINT SYSTEMS
(VEHICLE AND PEDESTRIAN)
Contents
Clause Title Page

400 (05/17) Road Restraint Systems General 2
VEHICLE RESTRAINT SYSTEMS
General Requirements
401 (05/17) Vehicle Restraint Systems
General 2
402 (05/17) Components for Maintenance
and Repair of Legacy Vehicle Restraint
Systems 7
Safety Barriers, Terminals, Transitions, Removable
Barrier Sections and Crash Cushions
403 (05/17) Installation of Safety Barriers
(except vehicle parapets), Terminals,
Transitions, Removable Barrier Sections
and Crash Cushions – Overall
Requirements 11
404 (05/17) Site Testing 14
405 (05/17) Temporary Safety Barriers 14
Vehicle Parapets
406 (05/17) General 15
407 (05/17) Anchorages and Attachment
Systems for Vehicle Parapets 16
408 (05/17) Amendments and Additions to
BS 6779 17
409 (05/17) Inspection and Testing of
Vehicle Parapet Posts 21
410 (05/17) Site Tests on Anchorages in
Drilled Holes for Vehicle Parapets 21
PEDESTRIAN RESTRAINT SYSTEMS
411 (05/17) Pedestrian Parapets and
Pedestrian Guardrails 22
ANTI-GLARE SCREENS
412 (05/17) Anti-glare Screens 23F
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Volume 1 Series 400
Specification for Highway Works Road Restraint Systems (Vehicle and Pedestrian)
ROAD RESTRAINT SYSTEMS (VEHICLE AND

PEDESTRIAN)
400 (05/17) Road Restraint Systems General
2 (05/17) Road restraint systems (RRS) shall be able to achieve the specified performance at the temperatures
described in the National Annex (NA) to BS EN 1991-1-5:2003 figures NA.1 and NA.2 and determined in
accordance with Figure 6.1 of BS EN 1991-1-5 and the NA. Additionally, the recommended differences in the note
to clause 6.1.6 of BS EN 1991-1-5 shall be taken into account to determine the most severe temperature effect,
assuming the rail of a parapet to be equivalent to a structural element in 6.1.6 (1) NOTE.
3 (03/20) Where RRS are required to be connected to other RRS, existing systems or new systems, they shall be
compatible with each other such that the required performance of each system is achieved and all other specified
conditions are met.
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VEHICLE RESTRAINT SYSTEMS
General Requirements
401 (05/17) Vehicle Restraint Systems General

1 (05/17) Vehicle restraint systems (VRS) shall conform to this Series and the requirements stated in contract
specific Appendix 4/1. VRS, other than the following, shall conform to BS EN 1317-5 and be CE marked:
• Maintenance of legacy systems, as described in sub-Clause 402.1;
• Transitions;
• Terminals;
• Barrier gates (Removable Barrier Sections); and
• Vehicle parapets and combined vehicle/pedestrian parapets constructed as bespoke.
These systems shall conform to the requirements stated in paragraphs (i) to (iv) below.
(i) Maintenance of legacy systems, as described in sub-Clause 402.1, shall conform to Clauses 402 and 406.
(ii) Transitions to and between safety barriers (including vehicle parapets) shall conform to the requirements
of DD ENV 1317-4.
(iii) Terminals shall conform to the requirements of DD ENV 1317-4.
(iv) Barrier gates (Removable Barrier Sections) shall conform to the requirements of DD ENV 1317-4.
(v) Vehicle parapets and combined vehicle / pedestrian parapets constructed as bespoke shall conform to
Clause 406.
2 (03/20) The minimum Performance Class Requirements (Containment Level, Impact Severity Level [ISL],
Working Width Class [W], Vehicle Intrusion [VI], Performance Level, Redirection Zone Class [Z], Permanent
Lateral Displacement Zone Class [D], Performance Class [P], Permanent Lateral Displacement Zone [D. y. x.], Exit
Box Class[Z] and other requirements such as the Length of Need (as defined in CD 377 (DMRB 2.2.8)), the Setback
(as defined in CD 377), the minimum height of parapets, requirement for pedestrian provision and the maximum
height of the road restraint that allows the required visibility shall be as described in contract specific Appendix 4/1.
Amendment – March 2020 2

Volume 1 Series 400
3 (03/20) Like-for-like renewal may be used where:

(i) localised sections need to be temporarily removed to gain access; or
(ii) where minor repair work is required; or
(iii) where the VRS is required to be replaced due to incident damage; or
(iv) where a length of less than 500 m in a section of safety fence between terminals needs to be dismantled
or replaced as part of planned maintenance and the remaining length is greater than 500 m and remains
unaltered.
(05/17) Acceptance of Proposals
4 (03/20) Details of the vehicle restraint systems proposed by the Contractor for both new installations or for
maintenance of existing systems shall be submitted to the Overseeing Organisation at least four weeks before
the commencement of vehicle restraint system work for acceptance with the following supporting information
demonstrating compliance with this specification, and the requirements set out in contract specific Appendix 4/1.
Where a Declaration of Performance is required to be submitted this is as required by the Construction Products
Regulation (EU No. 305/2011) (CPR) and the relevant harmonised standard.
(i) For Safety Barriers (excluding vehicle parapets)
(a) A Declaration of Performance demonstrating compliance with the contract requirements for the
essential characteristics, plus additional information as necessary to demonstrate that the chosen
system(s) meets the location specific design criteria as stated in the contract specific specification.
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(ii) For Vehicle Parapets

(a) A Declaration of Performance demonstrating compliance with the contract requirements for the
(b) When required in contract specific Appendix 4/1 the Contractor shall provide evidence that
demonstrates the following: that the declared performance was achieved in testing, in accordance
with BS EN 1317 Parts 1 and 2 and that the test vehicle did not in any way touch or take advantage
of structures which will not be present on the final bridge installation; that is, if the vehicle dropped
down behind the bridge installation, it did not touch soil or other supporting devices, or any other
feature.
(iii) For Crash Cushions
(a) Declaration of Performance demonstrating compliance with the contract requirements for the
(iv) For the maintenance and repair of Legacy Safety Barriers, as described in sub-Clause 402.1
(a) Documentation showing compliance with and operation of the Quality Management requirements
of Clause 104 and associated quality management schemes listed in Appendix A. This shall
include the quality plans required in sub-Clause 104.5 which shall make specific reference to the
management of the vehicle restraint operations and all associated operations. The documentation
shall identify quality management procedures for each vehicle restraint activity for each system
included in the works.
(b) For legacy systems documentation showing compliance with the Safety Barrier Systems Drawings
such as those detailed in the Non Proprietary Safety Barrier Systems Rev 1 drawings or outwith the
Highways England network guidance should be sort from the appropriate Overseeing Organisation.

Volume 1 Series 400
(v) For Vehicle Parapets and Combined Vehicle / Pedestrian Parapets constructed as bespoke.
(a) Documentation showing compliance with BS 6779-2 as amended by this Series and CD 377
(DMRB 2.2.8).
(vi) For Combined Vehicle/Pedestrian Parapets
(a) Declaration of Performance demonstrating vehicle containment achieves compliance with the
contract requirements for the essential characteristics, plus additional information as necessary to
demonstrate that the chosen system(s) meets the location specific design criteria as stated in the
contract specific specification.
(b) For maintenance of legacy systems as described in sub-Clause 402.1 documentation showing
compliance with BS 6779-1 as amended by this Series 400 and CD 377 (DMRB 2.2.8) for
pedestrian containment.
(c) For the pedestrian containment aspects documentation as per the requirements of sub-Clause 401.5.
Where such documentation has previously been submitted to the Overseeing Organisation and the
system has been listed as described in sub-Clause 104.20 further submission of this documentation
may not be necessary. Where the Contractor proposes to use such systems the Contractor shall
confirm the relaxation of these documentation requirements with the Overseeing Organisation.
(d) When required in contract specific Appendix 4/1 the Contractor shall provide evidence that
demonstrates the following: that the declared performance was achieved in testing, in accordance
with BS EN 1317 Parts 1 and 2 and that the test vehicle did not in any way touch or take advantage
of structures which will not be present on the final bridge installation; that is, if the vehicle dropped
down behind the bridge installation, it did not touch soil or other supporting devices, or any other
feature.
(vii) For Transitions between vehicle restraint systems
of Clause 104 and associated quality management schemes listed in Appendix A, as required in
sub-Clause 401.4 paragraph (iv)(a).
(b) Documentation demonstrating compliance with DD ENV 1317-4 and the contract performance
requirements.
(c) Documentation as per the requirements of sub-Clause 401.5. Where such documentation has
previously been submitted to the Overseeing Organisation and the system has been listed as
described in sub-Clause 104.20 further submission of this documentation may not be necessary.
Where the Contractor proposes to use such systems the Contractor shall confirm the relaxation of
these documentation requirements with the Overseeing Organisation.
(viii) For Terminals to vehicle restraint systems
of Clause 104 and associated quality management schemes listed in Appendix A, as required in
sub-Clause 401.4 paragraph (iv)(a).
(b) Documentation demonstrating compliance with DD ENV 1317-4 and the contract performance
requirements.
(c) Documentation as per the requirements of sub-Clause 401.5. Where such documentation has
previously been submitted to the Overseeing Organisation and the system has been listed as
described in sub-Clause 104.20 further submission of this documentation may not be necessary.
Where the Contractor proposes to use such systems the Contractor shall confirm the relaxation of
these documentation requirements with the Overseeing Organisation.
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Volume 1 Series 400
(ix) For motorcyclist protection systems

(a) Documentation to confirm compatibility with the associated VRS and to demonstrate compliance
with other specification requirements.
5 (03/20) Where specified in sub-Clause 401.4 the following information shall be provided to the Overseeing
Organisation. Where required the Contractor shall complete the proforma included in contract specific
Appendix 4/2.
(i) Test report in accordance with either BS EN1317-2, Annex A or BS EN 1317-3, Annex A or DD ENV
1317-4:2002, clause 7.8.
(ii) Video/high speed film of test annotated showing date, test number and performance class.
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(iii) Still photographs of complete installation including anchorage points.
(iv) Still photographs of vehicle before and after impact.
(v) Full drawings of tested items.
(vi) Certification from the manufacturer that the item tested complies with the drawings supplied.
(vii) Certificate from a test house accredited in accordance with the requirements of sub-Clause 105.4.
(05/17) Durability
6 (03/20) Safety barriers, vehicle parapets, terminals, transitions, removable barrier sections and crash cushions
shall conform to the following.
(i) All components shall be designed to achieve a serviceable life of not less than:
(a) 20 years for metal safety barriers, terminals, transitions, removable barrier sections and crash
cushions;
(b) 50 years for concrete safety barrier systems, except for temporary safety barriers where the
serviceable life shall be not less than 10 years;
(c) 30 years for metal vehicle parapets and metal components of combined metal and concrete vehicle
parapets; and
(d) 120 years for concrete vehicle parapets and concrete components of combined metal and concrete
vehicle parapets; and
(ii) For metal vehicle parapets and metal components of combined metal and concrete parapets the
serviceable life shall, except where stated in contract specific Appendix 4/1, be obtained without the
requirement for any maintenance other than that resulting from accidental damage. In addition metal
components of combined metal and concrete parapets shall be capable of replacement without damage
to the concrete components.
(05/17) Information Required to be Provided by the Contractor Prior to Installation
7 (03/20) The following information shall be provided by the Contractor to the Overseeing Organisation, all
documentation shall be in English.
For all proposed road restraint systems:
(i) Information as required in sub-Clause 401.4.
(ii) Installation drawings.
(iii) Manufacturer’s installation instructions or installation manual including foundation requirements and
test methods to verify their performance.

Volume 1 Series 400
(iv) Manufacturer’s repair and maintenance manual.

(v) For each organisation undertaking vehicle restraint system work certificate(s) of registration to the
relevant National Highways Sector Scheme(s) listed in Appendix A. The certificate(s) of registration
shall include in the scope of registration installation of the vehicle restraint system(s) being installed.
(vi) Where contract specific Appendix 4/1 specifies requirements for loads imposed by road restraint systems
on foundations or structures the nominal loads (direct forces, moments and co-existent shears) that will
be transferred from the barrier or parapet to the structure or foundation shall be provided.
(05/17) Information Required to be Provided by the Contractor After Installation
8 (03/20) The Contractor shall provide to the Overseeing Organisation as-built drawings which shall include
plans and details of the constructed system. The Contractor shall also provide to the Overseeing Organisation for
each proprietary system installed, a certificate certifying that it has been installed fully in accordance with the
manufacturer’s instructions.
(05/17) Marking
9 (03/20) All components of systems that fall within the scope of the Construction Products Regulation
(EU No. 305/2011) (CPR) shall be marked in accordance with the requirements of the CPR and the relevant
harmonised standard.
(05/17) Handling and Storage
10 (03/20) All components shall be protected from damage and handled and stacked in such a way that permanent
damage is not caused, particularly to threaded components. Means shall be provided to avoid damage to galvanized
coatings and any damage that does occur shall be repaired in accordance with BS EN ISO 1461.
(05/17) Installation Instructions
11 (03/20) The Contractor shall ensure that the installation instructions, or installation manual as required by BS
EN 1317-5, for a proposed system includes all the information necessary to install the road restraint system in the
locations shown on the drawings such that the system will meet its declared performance.
12 (03/20) Installation instructions shall be appropriate to the road restraint system being installed and its location.
The use of the system relative to different ground and other conditions of installation and use, including limitations
(e.g. permitted temperature range), shall be defined in the installation manual.
The installation manual shall also include the following information and any additional information appropriate to
the system proposed and its proposed location.
(i) Erection:
(a) assembly drawings, of the product tested, including tolerances, anchorages, end parts – where
relevant, installation height above pavement and/or ground levels, other installation details
appropriate to the installation for the specific locations including changes relevant to different set-
backs from the edge of carriageway, etc.;
(b) description of the installation works, including equipment and specific details for installation on a
curve, with minimum allowed radius on a convex curve and concave curve;
(c) procedures for installation (erection, assembly, foundations, anchorages and bolt torques when
relevant etc.);
(d) all tools required to perform a proper installation of the system;
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(e) ambient temperature and humidity at time of installation (if relevant) and how installation should
be adjusted for the ambient conditions at the time of installation;
(f) details of tensioning (if relevant);
(g) particular conditions applicable to the use of the product (e.g. provisions for use under certain
conditions);
(h) description of the soil, pavement and/or foundations characteristics and conditions suitable for the
system and information about conditions which can influence the behaviour of the product;
(i) details of any testing of the installation or other on installation specific testing; e.g. post push tests
to prove the proposed foundation system;
(j) any other relevant recycling information, details of toxic or dangerous materials present in the
works.
(ii) Maintenance and inspection:
(a) provisions for repair, inspection and maintenance, including indications for disassembling and
reassembling or reconstruction of damaged system;
(b) in service tolerances including for installation height.
(iii) The following information is applicable specifically to safety barriers:
(a) recommended range of length of the safety barrier (minimum / maximum), curve radius etc.;
(b) provisions for installing lengths above the minimum;
(c) recommended arrangements for dealing with exposed rail ends (e.g. flaring, terminals, etc.);
(d) recommended soils, slopes, possibility of plinth installation and specific instructions;
(e) recommended arrangements for drainage through and/or in front of the safety barrier;
(f) other safety barrier types which can easily be connected with the product.
(iv) The following information is applicable specifically to terminals:
safety barrier types which can be connected to the product.
(05/17) Further installation requirements
13 (03/20) All VRS shall be installed, refurbished, repaired and maintained by operatives that have been trained
under the relevant National Highway Sector Schemes listed in Appendix A or equivalent as stated in sub-
Clause 104.11. The Contractor shall, in accordance with sub-Clause 104.10, provide evidence to the Overseeing
Organisation to demonstrate that the operatives’ accreditation to the relevant scheme(s) is current and valid.
Any non-conformances with the relevant sector scheme shall be notified to the sector scheme Advisory Committee
Secretary. A copy of this shall be submitted to the Overseeing Organisation.
402 (05/17) Components for Maintenance and Repair of Legacy Vehicle Restraint Systems
1 (05/17) Legacy systems are VRS that are currently on the road network that are not CE marked. The
requirements given in this Series with respect to legacy systems are for the maintenance and repair of such systems.
All new VRS shall comply with the requirements of Clause 401.
2 (05/17) For the purpose of vehicle parapet requirements, this Clause shall also be read in conjunction with
Clause 406.
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(05/17) Materials
3 (03/20) Materials and fabrication of components and fittings shall be as described and detailed on the drawings
submitted by the Contractor, in compliance with Clause 104, sub-Clause 401.4 and other requirements of this Series.
It shall be demonstrated that the materials are within the limits of statistical variation for the specified material and
for the material of the prototype tested system. Materials significantly exceeding the original specified strength
shall not be accepted.
4 (05/17) Structural concrete, reinforcement, workmanship and other requirements shall conform to the relevant
requirements of Series 1700 and Appendices 17/1 to 17/5. Standardised prescribed concrete shall conform to Clause
2602 and contract specific Appendix 26/1.
(05/17) Protection Against Corrosion
5 (05/17) Protection against corrosion shall be as described in the manufacturer’s specification and the following:
(i) all steel components except stainless steel items, concrete foundation reinforcing rings and reinforcing
bars that will be permanently embedded in concrete shall be galvanized after shop fabrication as
described in Clause 1909; and
(ii) where required in contract specific Appendix 4/1, the surface preparation and protection against
corrosion of all steel vehicle parapets and steel components of combined metal and concrete vehicle
parapets shall comply with Series 1900.
(05/17) Tolerances
6 (05/17) Fabrication tolerances, including tolerance on hole diameters, shall be as shown and described on the
drawings submitted by the Contractor in accordance with sub-Clauses 401.3(iv) and 401.6. Components, which are
to be galvanized or metal coated, shall be measured before galvanizing or metal coating.
(05/17) Welding
7 (i) (03/20) General: Arc welding of ferritic steels shall conform to BS EN 1011-1 and BS EN 1011-2. Weld
symbols shown on the drawings, submitted by the Contractor in accordance with sub-Clause 401.4 and
401.7, shall be as described in BS EN ISO 2553. Welding shall not be used except as where detailed on
the drawings submitted by the Contractor in accordance with sub-Clause 401.4 and 401.7. Arc welding
of stainless steels shall conform to BS EN 1011-3. Arc welding of aluminium alloys shall conform to
BS EN 1011-1 and BS EN 1011-4.
(ii) Procedures: Written welding procedures shall be used with testing to BS EN ISO 15607, BS EN ISO
15609-1 and BS EN ISO 15614-1 for steel and BS EN ISO 15607, BS EN ISO 15609-1 and BS EN
ISO 15609-2 for aluminium alloys and shall apply to all production and repair procedures. These shall
be subject to re-approval after a period of seven years. When applying BS EN ISO 15607, BS EN ISO
15609-1 and BS EN ISO 15614-1, the welding consumables and procedures used shall be such that the
mechanical properties of deposited weld metal shall not be less than the respective minimum specified
values of the parent metal being welded. Weld testing shall be undertaken by an appropriate organisation
accredited in accordance with sub-Clause 105.4. Approval shall be by an Independent Inspecting
Authority using Registered Welding Engineers or Registered Welding Quality Engineers or equivalent.
Welding procedures shall be approved in accordance with BS EN ISO 15613. Pre-production test pieces
shall represent the main assembly types.
(iii) Welder Qualification: All welders shall hold certificates of approval to BS EN 287-1 and BS EN 1418
for steel and BS EN ISO 9606-2 for aluminium alloys. The tests shall include in addition an application
test on transverse butt welds in beams. Welders carrying out fillet welds only may be approved to BS
4872-1. Certificates of approval shall be by an Independent Inspecting Authority using Registered
Welding Engineers, Registered Welding Quality Engineers or Welding Inspectors certified by the
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Certification Scheme for Weldment Inspection Personnel (CSWIP) or equivalent. Weld testing shall be
undertaken by an appropriate organisation accredited in accordance with sub-Clause 105.4.
(iv) Production Inspection and Testing: The manufacturer shall provide suitable personnel to carry out
inspection of production welds in (a) to (c) below. Personnel conducting visual inspection shall be
certified by the Certification Scheme for Weldment Inspection Personnel (CSWIP) or equivalent at
a competency level appropriate to the type of weld inspected. Personnel conducting non-destructive
testing (NDT) shall be certified by the Certification Scheme for Weldment Inspection Personnel
(CSWIP) or equivalent appropriate to the equipment used and the weld groups inspected all in
accordance with BS EN ISO 9712. Evidence of training and qualification shall be retained and made
available for examination when required. The results of all weld inspections shall be recorded.
(a) Visual Inspection: All welded joints shall be subject to visual inspection in accordance with BS
EN ISO 17637 prior to any NDT and galvanizing. Weld surfaces shall be free of slag residues
and sharp edges. All surfaces shall be free of traces of weld splatter, arc strikes and contaminants.
The apparent throat dimensions of butt welds and the apparent leg length and apparent throat
dimensions of fillet welds, as measured by a welding gauge, taking into account any known lack of
fit, shall not be less than those specified, except that local shortfalls up to 1 mm may be accepted,
provided the average over any 50 mm length is not less than the specified dimension. All welds
to be free of cold lap. The surface of all welds shall be free from cracks, lack of fusion including
overlap, and slag. Isolated discontinuous porosity may be accepted provided it is not detrimental
to the galvanising process. Undercut shall not result in a section loss of more than 5% over any
50 mm length of joint, nor shall its depth exceed 0.5 mm or 10% of the thickness, whichever is
the less.
(b) Magnetic Particle Inspection (MPI) and Liquid Penetrant Inspection (LPI): MPI shall be applied
in accordance with BS EN ISO 9934-1 to joints selected in accordance with (d) below, where any
of the material thickness exceeds 20 mm. Notwithstanding the requirements of (d) below, MPI or
LPI in accordance with BS EN 571-1, shall be applied as appropriate where on visual inspection
the presence of cracking or lack of fusion may be suspected. To aid inspection, the profile of the
weld may be dressed by burr grinding provided that the specified throat size and leg length is still
maintained. The surface of the weld shall be free of cracks, lack of fusion and slag.
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(c) Ultrasonic Testing: All butt joints in material 8 mm thick or greater selected in accordance with (d)
below shall be ultrasonically tested in accordance with BS EN ISO 17640. The weld shall be free
of cracks. The height of buried slag, lack of fusion or lack of penetration shall not exceed 3 mm
and within 6 mm of the outer surface their individual lengths shall not exceed 10 mm. The resulting
net throat area loss over any 50 mm length of weld shall not exceed 5% of the specified throat area.
(d) Frequency of NDT: Joints shall be selected as follows:
All joints of each type up to a batch size of 10 components and 10% of additional components
thereafter. If non- conformances are found the scope of NDT shall be doubled. If further non-
conformances are found, the whole batch shall be tested.
(e) Reporting: Inspection records for production welds shall be retained by the manufacturer for three
years and those covering the production periods relating to the components supplied shall be made
available for examination.
(v) Destructive Testing: Copies of certified reports of destructive tests on components supplied under earlier
contracts with the Overseeing Organisation shall be provided.
(vi) Frequency of Destructive Testing: The Contractor shall supply components, or sample joints cut from
components, for destructive testing as selected on behalf of the Overseeing Organisation. The basis of
selection shall be as follows:

Volume 1 Series 400
(a) For batches of less than 100 beam assemblies with transverse butt welds, 1 sample joint shall be
supplied unless an identical sample joint from the same works has been destructively tested within
the previous four weeks. For batches exceeding 100 or more, 1 sample joint shall be supplied for
each subsequent sampling lot not exceeding 100.
(b) Welded adjuster brackets shall be supplied at a rate of 1 for each sampling lot not exceeding 300.
(c) Each type of post shall be supplied at a rate of 1 post for each sampling lot not exceeding 1000.
(d) Each type of surface mounted post shall be supplied at the rate of 1 post for each sampling lot not
exceeding 100.
(e) For batches of up to 150 vehicle parapet posts: No test required, provided that records certified by
a representative of the Overseeing Organisation are produced of successful testing carried out on
posts of the same weld group within the previous 3 months. If no satisfactory record is available,
one post to be tested.
For batches of 150 to 300 vehicle parapet posts: One post to be tested.
For batches exceeding 300 vehicle parapet posts: Two posts to be tested.
(f) Each type of anchor frame, vehicle parapet connection and connection piece shall be supplied at an
interval not exceeding 6 months for each manufacturer’s works.
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(g) For batches of up to 150 welded vehicle parapet splices, one splice shall be supplied for testing
unless successful testing has been carried out within the previous 3 months on a similar splice(s),
where the splice to be tested was selected by the Overseeing Organisation’s representative and the
welding is to be carried out by the same personnel. For batches greater than 150 welded vehicle
parapet splices, two splices shall be tested.
(h) Other welded components shall be supplied at an interval not exceeding 12 months for each
manufacturer’s works.
(vii) Acceptance Criteria: The acceptance criteria shall be as specified in sub-Clause 402.7(iv), except that
in sub-Clause 402.7(iv)(a), the throat and leg dimension of the weld shall apply to the true rather than
apparent dimension.
(viii) Non-conformance: In the event that there is a non-conformance arising from a deviation in materials,
preparation, assembly or welding procedure, the batch concerned shall be rejected and further
production of the components affected stopped until such time as the fault has been corrected. A minor
non-compliance shall only be accepted on the basis that further sampling and testing shows that the fault
is not repetitive and will not in that instance impair structural integrity. If the problem can be traced
to a particular manufacturing period, operator, piece of equipment or batch of material and if proper
traceability to individual batches of components can be assured, only those batches affected may be
subjected to rejection.
(ix) Test Report: The destruction test reports shall be retained by the Contractor and recorded in a register for
a period of three years. The destructive test samples shall be retained for a period of 18 months. These
shall be made available for examination on future contracts with the Overseeing Organisation.
(x) Remedial Work: Welds which do not conform to the Specification may be repaired to an approved
procedure as described in sub-Clause 402.7(ii). Welds in aluminium alloys shall not be repaired more
than once.

Volume 1 Series 400
(05/17) Marking
8 (05/17) All components, excluding fasteners, reinforcing rings and bars, shall be clearly and durably marked
with the manufacturer’s identification mark and digits indicating month and year of manufacture. In addition to the
marking requirements of BS EN ISO 898-1, fasteners shall be clearly marked with the following:
(i) safety barrier, terminal, transition, crash cushion manufacturer’s identification mark; and
(ii) fastener number as referenced on the manufacturer’s construction drawings.
(05/17) Workmanship and Testing
9 (05/17) All components shall be manufactured so as to permit the construction of the accepted systems within the
tolerances described in sub-Clauses 403.2 and 403.4 and in accordance with the accepted drawings submitted by the
Contractor. Changes in material properties outside those used in the type tests of the systems shall not be permitted.
10 (05/17) Unless otherwise indicated on the accepted drawings submitted by the Contractor to the Overseeing
Organisation, all fabrication of components shall be completed before the surface protection is applied.
11 (05/17) The Contractor shall provide the Overseeing Organisation with evidence that the manufacturer has
arranged for tensile tests to destruction to be carried out by a testing laboratory, accredited in accordance with sub-
Clause 105.4, annually and whenever the production technique is changed.
(05/17) Quality Management
12 (05/17) Parapet legacy system components used for repair and maintenance shall be manufactured by an
organisation registered to National Highways Sector Scheme 5A for the Manufacture of Parapets for Road Restraint
Systems. The Contractor shall submit a certificate of registration to the Overseeing Organisation. The scope of
registration shall include the components being installed.
(05/17) Safety Barriers, Terminals, Transitions, Removable Barrier Sections and Crash Cushions
403 (05/17) Installation of Safety Barriers (except vehicle parapets), Terminals, Transitions,
Removable Barrier Sections and Crash Cushions - Overall Requirements
(05/17) Layout
1 (05/17) The overall layout and location of safety barriers, terminals, transitions, removable barrier sections
(RBS) and crash cushions shall be as indicated on the contract drawings and described in contract specific
Appendix 4/1.
2 (05/17) All safety barriers, terminals, transitions and RBS shall be erected to present a flowing alignment. Unless
a requirement is given in the manufacturer’s installation instructions or installation manual, all safety barriers,
terminals and transitions shall be erected in accordance with the following:
(i) The overall alignment on plan shall not depart from the prescribed alignment by the more onerous
requirements of either:
(a) the manufacturer’s drawings; or
(b) more than ±30 mm, nor deviate in any 10 m length from the straight or required radius by more
than ±15 mm.
(ii) Vertical alignment – this shall be in accordance with the manufacturer’s installation instructions or
installation manual except for works in relation to existing legacy safety barrier systems where the
installation heights shall be as given on the installation drawings for those products.
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(05/17) Excavation for Concrete Foundations and Anchor Blocks

3 (05/17) Excavations for concrete foundations and anchor blocks shall be in accordance with the manufacturer’s
instructions or installation manual, or for legacy systems to the detailed drawings, submitted by the Contractor to
the Overseeing Organisation.
4 (05/17) Where the sides of the excavations cannot be maintained vertical until concrete is placed, suitable
permanent or temporary formwork shall be used. The formwork shall be installed immediately after excavation
and any lateral overbreak of the excavation shall be filled with concrete conforming to BS 8500-2 or the accepted
manufacturer’s instructions or installation manual submitted by the Contractor to the Overseeing Organisation
as appropriate.
5 (05/17) Impermeable plastic sheeting 500 gauge thick shall be laid at the base of an in-situ concrete foundation
located in filter drains.
(05/17) Concrete in Foundations and Anchor Blocks
6 (05/17) Concrete in foundations and anchor blocks shall be in accordance with the relevant Clauses of this
Series and the manufacturer’s instructions, or for maintenance and repair works related to existing legacy systems
to the Non-Proprietary Safety Barrier System Drawings Rev 1 submitted by the Contractor to the Overseeing
Organisation.
7 (05/17) The Contractor shall ensure that any concrete which constitutes part of the road restraint system has
reached the specified strength stated on the accepted drawings prior to any tensioning of the road restraint system
taking place.
(05/17) Beams
8 (03/20) Notwithstanding the manufacturing tolerances permitted for individual beams, the cumulative length
tolerance shall be such that beams and posts can be positioned in their prescribed location and the requirements of
sub-Clauses 403.1 and 403.2 can be met. With the exception of any special closure pieces necessary to complete
lengths of safety barriers, terminals, transitions or RBS, beam lengths shall not differ from those described on the
accepted drawings submitted by the Contractor in accordance with sub-Clause 401.4 and 401.7.
(05/17) Posts
9 (03/20) Where applicable, posts, foundations and post sockets shall be in accordance with the manufacturer’s
instructions, or for legacy systems to the detailed drawings, submitted by the Contractor in accordance with sub-
Clause 401.4 and 401.7.
10 (05/17) Where posts are mounted in cast in post sockets these shall be protected to prevent the collection of
detritus in the socket voids.
11 (05/17) When steel posts are driven into the ground this shall be carried out without damage to the post and the
protective coating. Any superficial damage to the galvanising shall be treated in accordance with BS EN ISO 1461
unless the manufacturer’s instructions require more comprehensive repairs.
(05/17) Cutting of components
12 (05/17) No drilling, cutting (including flame cutting) or welding of beams and posts shall be permitted after the
corrosion protection to the system has been applied.
13 (05/17) Special closure pieces shall be fabricated before corrosion protection is applied.
(05/17) Assembly
14 (05/17) Direct contact between dissimilar metals shall be avoided. Where necessary to prevent direct contact,
this shall be achieved by interposing a dielectric separator in accordance with the manufacturer’s instructions, or for
legacy systems to the detailed drawings, submitted by the Contractor.
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(05/17) Anchorages and Attachment Systems for Surface Mounted Posts

15 (05/17) Unless otherwise described in contract specific Appendix 4/1, the Contractor shall submit to the
Overseeing Organisation, at least 4 weeks before installation, well attested and documented evidence that proposed
anchorages and attachment systems in drilled holes, are capable of resisting the ultimate tensile loads resulting from
failure of the proposed safety barrier, terminal, transition, RBS or crash cushion system. Where the ultimate capacity
of a safety barrier, terminal, transition, RBS or crash cushion system, is governed by the failure of the attachment
system the evidence shall demonstrate that the anchorages in drilled holes, are capable of resisting the ultimate
tensile loads resulting from failure of the attached system. Anchorages of an expanding type, other than undercut
anchorages, shall not be permitted.
16 (05/17) Unless otherwise specifically indicated on the accepted manufacturer’s instructions or installation
manual submitted by the Contractor to the Overseeing Organisation, steel anchorages and attachment systems shall
be used for securing surface mounted posts to a concrete or steel base.
17 (05/17) Unless otherwise specifically indicated on the accepted manufacturer’s instructions or installation
manual submitted by the Contractor to the Overseeing Organisation, where surface mounted posts are to be installed
on a highway structure, the anchorages shall include an internally threaded component to receive the attachment
system. All parts of anchorages on bridge decks and other structures (where the anchorage is within 80mm of the
upper surface of the supporting concrete or where the anchorage parts are threaded to receive the holding down
bolt) shall be of stainless steel designation 1.4401, 1.4436, 1.4362 or 1.4462 to BS EN 10088-1. Holding down
bolts, studs and nuts on bridge decks and other structures shall be stainless steel grade A4-80 to BS EN ISO 3506-1
and BS EN ISO 3506-2. Washers on bridge decks and other structures shall conform to BS 4320 and be made from
stainless steel strip designation 1.4401 or 1.4436 to BS EN 10029, BS EN 10048, BS EN 10051and BS EN ISO
9445. Unless specifically indicated on the accepted manufacturer’s instructions submitted by the Contractor
to the Overseeing Organisation direct metal to metal contact between dissimilar materials within the attachment
system and anchorage shall be prevented by the use of non- conductive sleeves, washers or coatings to prevent
bimetallic corrosion.
18 (05/17) Unless specifically indicated on the accepted manufacturer’s instructions or installation manual
submitted by the Contractor to the Overseeing Organisation or where surface mounted posts are attached to a steel
base the base plate shall be bedded on mortar conforming with Clause 2601 and contract specific Appendix 26/2.
The bedding mortar shall have a minimum thickness of 10 mm and a maximum thickness of 30 mm. An additional
allowance may be made for longitudinal falls.
19 (05/17) For anchorages in drilled holes, each hole location shall be checked to ensure that the hole will be clear
of reinforcement before drilling is carried out. Where it is not possible to locate drilled holes without encountering
reinforcement, the Contractor shall provide a specialist’s report to the Overseeing Organisation on the consequences
of drilling through or cutting the reinforcement. No drilling or cutting shall take place without the prior written
acceptance of the Overseeing Organisation.
20 (05/17) Before installation of anchorages in drilled holes, each hole shall be sound, clean and dry and the
tolerance of the hole shall be within the values given by the anchorage manufacturer.
21 (05/17) Attachment systems shall be tightened to the specified torque and have not less than the minimum thread
engagement specified by the manufacturer of the system.
22 (05/17) Stainless steel bolts, screws and nuts shall conform to BS EN ISO 3506-1 and BS EN ISO 3506-2, Grade
A4-80. The dimensions and tolerances of the bolts, screws and nuts shall conform to BS EN ISO 4016, BS EN ISO
4018 and BS EN ISO 4034.
23 (05/17) Stainless steel washers shall conform to BS 4320 and be made from stainless steel strip designation
1.4401 or 1.4436 to BS EN 10029, BS EN 10048, BS EN 10051, and BS EN ISO 9445.
24 (05/17) Unless expressly prohibited by the manufacturer’s instructions or installation manual the threads of steel
anchorages shall be lined with grease having a high resistance to creep and being suitable for hot or cold smearing.
25 (05/17) Voids shall be sealed with a durable, non-structural and impermeable filler to prevent ingress of
moisture and deleterious substances. Sealing of voids in anchorages, attachment systems and base plates with a
non-structural impermeable durable filler is important to prevent water ingress and to avoid corrosion and damage.
Fillers may be derived from polymers or elastomers, but shall exclude acrylic or polyester based materials.
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404 (05/17) Site Testing for Contract Compliance

(05/17) Anchorages in Drilled Holes for Safety Barriers, Terminals, Transitions and Crash Cushions
1 (05/17) The Contractor shall carry out on-site tensile load tests on anchorages in drilled holes. For the purpose
of this sub-Clause the types of fixing referred to in clause 1 of BS 5080-1 shall include “anchorages”. Unless more
onerous or alternative testing is proposed in the manufacturer’s installation manual accepted by the Overseeing
Organisation the following testing methodology shall be applied.
(i) Where anchorages are tested they shall be loaded incrementally in tension in accordance with BS 5080-1
except that they shall be capable of resisting a test load equal to 10 per cent above the nominal tensile
load applied to the anchorage at failure of the safety barrier, terminal, transition or crash cushion system
in lieu of testing to failure.
(ii) The nominal tensile load shall be determined by the manufacturer of the safety barrier, terminal,
transition, RBS or crash cushion system. Where the failure of the attachment system (e.g., the holding
down bolt) is the prescribed failure mode of the safety barrier, terminal, transition, RBS or crash cushion
system, the test load shall be 90 per cent of the yield load of the attachment system. Incremental loads
shall be held for not less than half a minute and the test load for not less than five minutes. Readings
shall be taken immediately after applying load and at the end of the interval stated above.
(iii) The total movement of the anchorage shall not exceed 1.0 mm during the test. Any evidence of slip
during loading as demonstrated by a significant change in the slope of the load/extension curve, shall
constitute failure.
(iv) The testing frequency shall be in accordance with contract specific Appendix 1/5. In addition, testing
shall comply with any special requirements given in contract specific Appendix 4/1.
(05/17) Post Foundations
2 (05/17) The Contractor shall provide the test equipment and carry out loading tests on post foundations to
ascertain compliance with the manufacturer’s specification or installation manual for the proposed safety barrier,
terminal, transition, RBS and crash cushion system. The tests shall be carried out and the results submitted to the
Overseeing Organisation at least one week prior to installation of the relevant lengths of safety barrier, terminal,
transition, RBS and crash cushion system. The testing frequency shall be in accordance with contract specific
Appendix 1/5 or the manufacturer’s installation manual if this stipulates a more onerous testing regime.
3 (05/17) Where stated in contract specific Appendix 4/1, the Overseeing Organisation shall provide the test
equipment and carry out loading tests on post foundations installed by the Contractor for that purpose. The
Contractor shall make available a vehicle of not less than 5 tonnes for the Overseeing Organisation’s use while
carrying out the tests.
4 (05/17) The Contractor shall install test posts and foundations after completion of the finished ground.
5 (05/17) On completion of loading tests the Contractor shall remove the test posts and foundations and reinstate
the finished ground to meet the requirements of the Contract.
405 (05/17) Temporary Safety Barriers

1 (03/20) Where required in contract specific Appendix 4/1, the Contractor shall provide, install and maintain
temporary safety barriers, terminals and transitions, and on completion of the works, remove them to the
locations stated in contract specific Appendix 4/1. Temporary safety barriers shall meet the performance and other
requirements stated in contract specific Appendix 4/1. Temporary safety barriers shall provide suitable protection
for vulnerable features within the works areas.
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2 (05/17) Where temporary safety barriers, terminals and transitions are to be provided by the Overseeing
Organisation, the Contractor shall remove them from the location stated in contract specific Appendix 4/1 and
install and maintain them. On completion of the works, the Contractor shall remove the temporary safety barriers,
terminals and transitions to the locations stated in contract specific Appendix 4/1.
3 (03/20) Temporary crash cushions shall have a minimum containment class of N2 and impact severity level not
exceeding level B as defined by BS EN 1317. The Contractor shall provide evidence to demonstrate that the crash
cushion(s) have been tested and meet these criteria, suitable evidence would be a declaration of performance in
accordance with BS EN 1317-5.
(05/17) Vehicle Parapets (including Vehicle / Pedestrian Parapets)
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406 (05/17) General
1 (03/20) Unless otherwise described in contract specific Appendix 4/1, vehicle parapets shall be in accordance
with the following requirements except where these conflict with BS EN 1317-5 in which event BS EN 1317-5
shall take precedence:
(i) CD 377 (DMRB 2.2.8);
(ii) Clause 401, contract specific Appendix 1/5 and contract specific Appendix 4/1;
(iii) Clauses 407 to 410.
Legacy systems, as described in sub-Clause 402.1, shall be in accordance with Clause 402 and BS 6779-1.
Vehicle parapets and combined vehicle / pedestrian parapets constructed as bespoke in concrete shall be in
accordance with BS 6779-2.
2 (03/20) Unless otherwise stated in contract specific Appendix 4/1, metal parapets shall have a plinth upstand of
50mm high with a tolerance of -0/+50mm.
(05/17) Aesthetic Requirements
3 (03/20) Vehicle parapets shall comply with the aesthetic requirements given in contract specific Appendix 4/1.
(05/17) Layout
4 (03/20) The overall layout and location of vehicle parapets shall be as indicated on the contract drawings and
(05/17) Maintenance and Repair
5 (03/20) Components used for maintenance and repair of parapets shall match the performance characteristics of
the existing parapet and shall comply with the requirements stated in contract specific Appendix 4/1. Components
are to be of identical design, detail, specification and geometry to the parapet components originally installed
and are to be installed such that the completed repair is like for like. Except that in addition the requirements
and standards current at the time of manufacture of the original parapet shall apply, subject to such revisions
and modifications applicable to the parapet type during the period of original manufacture, the capacity of the
components shall be comparable to that of the original components as tested.
6 (03/20) The maintenance and/or repair of CE marked parapets shall be undertaken in accordance with the
manufacturer’s installation manual and requirements for the parapet using components which are identical in
design, specification and geometry to the parapet components originally installed.
7 (03/20) Steel parapets shall be galvanised, but not painted unless required for aesthetic reasons.

Volume 1 Series 400
(03/20) Masonry and Brickwork Facings

8 (03/20) Where reinforced concrete parapets are to be faced with masonry or brickwork the following minimum
requirements shall apply:
(i) fixings shall be spaced at not more than 450mm horizontally and 300mm vertically;
(ii) brick reinforcing mesh shall be incorporated into the bedding joints below those containing the fixings,
where this is not practical uncoursed work will not be used where detached masonry would cause a
hazard to the public and shall not be used on the front face to the parapet;
(iii) fixings and reinforcing mesh shall be stainless steel and shall not be placed in contact with carbon steel
reinforcement;
(iv) stone used on the front face shall be close jointed ashlar or smooth blocks with bricks having a smooth
surface; and the pointing is to be near flush.
9 (03/20) Where masonry on the front face of the parapet has an irregular surface finish, the plane through the
peaks shall be flat for straight vehicle parapets, and follow the nominal vehicle parapet curvature for curved vehicle
parapets.
Masonry on the front face of the parapet may have an irregular surface finish, but overall, the parapet should be
smooth faced.
Where it is impractical to provide reinforcing mesh, uncoursed work shall:
(i) only be permitted where there is a low probability of detached masonry presenting a hazard to the
public; and
(ii) not be permitted on the front face of the parapet.
(03/20) Stone and Precast Concrete Copings
10 (03/20) Stone and precast concrete copings shall be secured to the concrete backing by fixings capable of
resisting at the ultimate limit state a horizontal force of 33kN per metre of coping.
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407 (05/17) Anchorages and Attachment Systems for Vehicle Parapets

1 (03/20) Unless otherwise described in contract specific Appendix 4/1, the design, fabrication, and installation
of the anchorage and attachment system shall conform to the manufacturer’s drawings and specifications, the
requirements of BS EN 1317-1&2, this Series 400 and CD 377 (DMRB 2.2.8).
2 (03/20) Unless otherwise covered under the CE marked system’s Declaration of Performance and its supporting
documentation or described in contract specific Appendix 4/1, the Contractor shall submit to the Overseeing
Organisation, at least 4 weeks before installation, well attested and documented evidence that the proposed fixings,
including all cradles, anchorages and attachment systems, are capable of resisting the applied load effects resulting
from collision with the proposed vehicle parapet system. Where the ultimate capacity of a vehicle parapet system
is governed by the failure of the attachment system, the evidence shall demonstrate that anchorages in drilled holes
are capable of resisting the ultimate tensile loads resulting from the failure of the attachment system so that an
anchorage does not fail within the section embedded within the supporting structure and is able to be reused in the
event of the need to replace a parapet that has suffered collision damage.
3 (05/17) Anchorages of an expanding type shall not be permitted.
4 (05/17) ) Unless otherwise specifically indicated on the accepted manufacturer’s drawings submitted by the
Contractor to the Overseeing Organisation anchorages shall include an internally threaded component to receive the
attachment system.
5 (05/17) Where the anchorage is within 80mm of the upper surface of the supporting concrete or where the
anchorage part is threaded to receive the holding down bolt all parts of the anchorage shall be of stainless steel
designation 1.4401, 1.4436, 1.4362 or 1.4462 to BS EN 10088-1.

Volume 1 Series 400
6 (05/17) Holding down bolts, studs and nuts shall be in stainless steel grade A4-80 to BS EN ISO 3506-1 and BS
EN ISO 3506-2.
7 (05/17) Unless specifically indicated on the accepted manufacturer’s drawings submitted by the Contractor
to the Overseeing Organisation direct metal to metal contact between dissimilar materials within the attachment
system and anchorage shall be prevented by the use of non-conducting sleeves, washers or coatings to prevent
bimetallic corrosion.
8 (05/17) Unless specifically indicated in the manufacturer’s installation manual submitted by the Contractor and
accepted by the Overseeing Organisation, or where the vehicle parapet posts are attached to a steel base, the posts
shall be bedded on mortar complying with Clause 2601 and contract specific Appendix 26/2. The bedding mortar
shall have a minimum thickness of 10 mm and a maximum thickness of 30 mm. An additional allowance may be
made for longitudinal falls.
9 (05/17) For anchorages in drilled holes, each hole location shall be checked to ensure that the hole will be
clear of reinforcement before drilling is carried out. Where it is not possible to locate drilled holes without
encountering reinforcement, the Contractor shall provide a specialist’s report to the Overseeing Organisation on the
consequences of drilling through or cutting the reinforcement. No drilling or cutting shall take place without the
prior written acceptance of the Overseeing Organisation.
10 (05/17) Before installation of anchorages in drilled holes, each hole shall be sound, clean and dry and the
tolerance of the hole shall be within the values given by the anchorage manufacturer.
11 (05/17) Attachment systems shall be tightened to the torque given in the manufacturer’s installation manual and
have not less than the minimum thread engagement specified by the manufacturer of the system.
12 (05/17) Stainless steel bolts, screws and nuts shall comply with BS EN ISO 3506-1 and BS EN ISO 3506-2,
Grade A4-80. The dimensions and tolerances of the bolts, screws and nuts shall comply with BS EN ISO 4016,
BS EN ISO 4018 and BS EN ISO 4034.
13 (05/17) Stainless steel washers shall comply with BS 4320 and be made from stainless steel strip designation
1.4401 or 1.4436 to BS EN 10029, BS EN 10048, BS EN 10051 and BS EN ISO 9445.
14 (05/17) Unless expressly prohibited by the manufacturer’s drawings, and to facilitate removal of holding down
bolts for maintenance or repair, the threads of steel anchorages shall be coated with anti-seize compound having
a high resistance to creep, intended for use with the materials that form both component thread faces and being
suitable for hot or cold smearing.
15 (05/17) All voids in anchorages, attachment systems and base plates shall be filled with a non-setting passive
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filler to prevent the ingress of moisture.
408 (05/17) Amendments and Additions to BS 6779

1 (05/17) BS 6779-1: 1998 (Amd. No. 14290, 21 March 2003)
(i) Clause 2:
(a) clause 2.1: first paragraph, third line delete “71” and replace with “65”.
(ii) Clause 5:
(a) Table 1 – Designation of vehicle parapets, Item a), delete the existing text under “Designation” and
“Clause” and insert “As prescribed in BS EN 1317-1, BS EN 1317-2 and DD ENV 1317-4: 2002”.
(iii) Clause 6:
(a) clause 6.1 Levels of containment: delete “clause 6.1.1 to clause 6.1.3” and insert “As prescribed in
BS EN 1317-1, BS EN 1317-2 and DD ENV 1317-4: 2002”;
(b) clause 6.4.1 delete the “NOTE and following text”;
(c) clause 6.4.2: delete paragraphs “d) and e)”;

Volume 1 Series 400
(d) clause 6.5.1.4.1: delete “last paragraph of NOTE 2” (i.e. “Details of approved connections …..
proved in service”);
(e) clause 6.6.2: Main structure: Replace “Department of Transport Standard BD 37/88” with
“BS EN 1991-2 clause 4.7.3 and the National Annex to BS EN 1992-2”; and
(f) clause 6.6.5: End of Note 1, insert: “The tensile strength of concrete shall be ignored in the
calculation.”
(iv) Clause 7:
(a) clause 7.1.2: Notch toughness: Replace “Department of Transport Standard BD 13/90” with
“BD 13 (DMRB 1.3)”;
(b) Table 3 – Materials of construction for steel parapets: Delete and insert as follows
Delete Insert
BS 4848-2 BS EN 10210-2
BS 4848-4 BS EN 10056-1
BS 1387 BS EN 10255
BS 6363 BS EN 10219-2
BS EN 10113 BS EN 10025-1, BS EN 10025-3 and BS EN 10025-4
BS 1449-1 BS 1449-1.1
BS 1449-2 BS EN 10029, BS EN 10048, BS EN 10051, BS EN ISO 9445
BS 970-1 BS EN 10087
BS 970-3 BS EN 10277-1 to BS EN 10277-5 (inclusive) and BS EN 10278
BS EN 24016 BS EN ISO 4016
BS EN 20898-1 BS EN ISO 898-1
BS EN 20898-1 BS EN ISO 898-1
BS 6105 BS EN ISO 3506-1 and BS EN ISO 3506-2
BS 4395-1 BS EN 14399
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Volume 1 Series 400
(c) Table 4 – Materials of construction for aluminium alloy parapets:

Delete and insert as follows
Delete Insert
BS 1474:1987, BS EN 515, BS EN 573-3, BS EN 755-1 to BS EN 755-9 (inclusive), BS
alloys 6061, 6063, EN 12020-1 and BS EN 12020-2, alloys EN AW-6061, EN AW-6063, EN
6082, 6005A AW-6082, EN AW-6005A and EN AW-6060
and 6060
BS 1471:1972, BS EN 515, BS EN 573-3, BS EN 754-1, BS EN 754-2,
alloys 6061, 6063 BS EN 754-7 and BS EN 754-8, alloys EN AW-6061,
and 6082 EN AW-6063 and EN AW-6082
BS 4300/1:1967, BS EN 1592-1 to BS EN 1592-4 (inclusive), alloy EN AW-5251
alloy 5251
BS EN 485-1:1994 BS EN 485-1
BS 1490:1988, BS EN 1559-1, BS EN 1559-4, BS EN 1676 and BS EN 1706, alloys EN
alloys LM6 and AC-47000, EN AC-47100 and EN AC-47200
LM25
BS 1449-1 BS 1449-1.1
BS 1449-2: 1983, BS EN 10029, BS EN 10048, BS EN 10051,and BS EN ISO 9445,
Grades 316 S31, designation 1.4401 or 1.4436
and 316 S33
BS EN 20898-1 BS EN ISO 898-1
BS EN 20898-1 BS EN ISO 898-1
(v) Clause 8:
(a) clause 8.3.1, NOTE: delete last sentence.
(vi) Clause 9:
(a) clause 9.1.1, delete last sentence from first paragraph;
(b) clause 9.2, Table 8 – Values of fk and γm: delete and insert as follows
Delete Insert
BS 1449-2 BS EN 10029, BS EN 10048, BS EN 10051, and BS EN ISO 9445
BS 1490 BS EN 1559-1, BS EN 1559-4, BS EN 1676 and BS EN 1706
(c) clause 9.4.1.2, delete “Laminar defects” from title and clause text, insert “Internal discontinuities”;
(d) clause 9.4.2, Welding: delete sub-clauses 9.4.2.1 to 9.4.3.2.5 inclusive; and
(e) clause 9.4.4, delete whole text.
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Volume 1 Series 400
(vii) Clause 10:

(a) clause 10.1.1: delete last sentence as follows: “Currently approved systems as listed in Annex F are
exempt from this requirement.”; and
(b) clause 10.1.1: insert additional paragraph as follows
“The designer or manufacturer shall arrange for third party certification that the new vehicle parapet
design complies with the requirements of BS EN 1317-1, BS EN 1317-2 and Series 400 (MCHW
1.400). The certification shall be undertaken by a body or testing laboratory in any Member State
of the European Economic Area, offering suitable and satisfactory evidence of technical and
professional competence and independence. The Overseeing Organisation is likely to require to
examine the full record of testing.”
2 (05/17) BS 6779-2: 1991
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(i) Clause 0.2
Delete first sentence and replace with “The specification requirements are based upon the results of tests
on panels of 2.1 m and 3.0 m lengths and it is considered reasonable to extrapolate to include panel
lengths from 2.0 m to 3.5 m.”
(ii) Clause 5
(a) clause 5.2: NOTE 2, delete “British Rail” and insert “railway or tramway operator”.
(iii) Clause 6:
(a) clause 6.3: Main structure: Replace “Department of Transport Standard BD 37/88” with
“BS EN 1991-2 clause 4.7.3 and the National Annex to BS EN 1992-2”.
(iv) Table 2
Delete title of table and replace with “Table 2 — Equivalent static nominal loads for in situ and precast
concrete parapets applicable to panel lengths (L) 2.0 m to 3.5 m.
(v) Clause 7
(a) clause 7: delete “BS 5400-2” and insert “BS EN 1990 and BS EN 1991-1-7”.
(vi) Clause 10:
(a) clause 10.1 delete initial paragraph and replace with: “Concrete parapets are likely to be directly
affected by de-icing salts, traffic fumes and other corrosive elements: therefore they shall be
constructed in accordance with Specification for Highway Works Series 1700. In particular they
shall comply with the following:”
(b) clause 10.1 (a). Note: delete the note in its entirety;
(c) clauses 10.1(a), (b) and (c): delete and replace with
“(a) Concrete exposure classes shall be in accordance with BS 8500-1. The minimum allowable
concrete exposure classes shall be XC3 + XD3 + XF4. Exposure classes XS and XA shall be
suitable for the site conditions.
(b) The minimum grade of concrete shall be C32/40 as specified in BS 8500-1.
(c) The nominal cover to reinforcement shall be as specified in BS 8500-1 (see also 11.3.2).”;
(d) clause 10.1 d): delete “BS 6105” and insert “BS EN ISO 3506-1 and BS EN ISO 3506-2”, delete
“BS 729” and insert “BS EN ISO 1461”.

Volume 1 Series 400
(vii) Clause 11:

(a) clause 11.2.4: delete “BS 5400-3” and insert “BS EN 1993-1-1:2005, BS EN 1993-1-5:2006, BS
EN 1993-1-8, BS EN 1993-1-10 and BS EN 1993-2”;
(b) clause 11.3.5: delete “BS 6105” and insert “BS EN ISO 3506-1 and BS EN ISO 3506-2”, delete
“BS 1449-2” and insert “BS EN 10029, BS EN 10048, BS EN 10051 and BS EN ISO 9445”.
(viii) Table 4 – Values of fk and γm:
(a) Anchorage and attachment system
3rd column, delete BS 6105” and insert “BS EN ISO 3506-1 and BS EN ISO 3506-2”, delete
“BS 1449-2” and insert “BS EN 10029, BS EN 10048, BS EN 10051 and BS EN ISO 9445”.
(ix) Clause 12
(a) Delete “and shall not be less than 1.5 m” and replace with “and shall not be less than 2.0 m”.
(x) Clause 13:
(a) clause 13.2.1: delete “NOTE For more information on safety fences see BS 6579”; and
(b) clause 13.3.1: delete “NOTE 1 and NOTE 2” completely.
(xi) Figure 4:
(a) top right hand side, delete “Grade 316 S 33 to BS 1449: Part 2” and insert “designation 1.4401 or
1.4436 to BS EN 10029, BS EN 10048, BS EN 10051 and BS EN ISO 9445.
409 (05/17) Inspection and Testing of Vehicle Parapet Components

1 (05/17) Inspection and testing of vehicle parapet posts shall be carried out by the Contractor as per the
manufacturer’s installation manual.
2 (05/17) When required in contract specific Appendix 4/1 components of legacy systems shall comply with the
following.
(i) The components for parapet posts and all completed parapet posts shall conform to the acceptance
criteria described in clauses 9.4 and 9.5 of BS 6779-1.
(ii) The Contractor shall only supply vehicle parapet posts of a type which have certification for static
destructive testing in accordance with clause 9.4.3.2.6.3 of BS 6779-1.
410 (05/17) Site Tests on Anchorages in Drilled Holes for Vehicle Parapets for Contract
Compliance
1 (05/17) The Contractor shall carry out on-site tensile load tests on anchorages in drilled holes. For the purpose
of this sub-Clause the types of fixing referred to in clause 1 of BS 5080-1 shall include ‘anchorages’. Where
anchorages are tested they shall be loaded incrementally in tension in accordance with BS 5080-1 except that they
shall be capable of resisting a test load equal to 10 per cent above the nominal tensile load applied to the anchorage
at failure of the vehicle parapet in lieu of testing to failure. The nominal tensile load shall be determined by the
vehicle parapet manufacturer. Where the failure of the attachment system (e.g., the holding down bolt) is the
prescribed failure mode of the vehicle parapet, the test load shall be 90 per cent of the yield load of the attachment
system. Incremental loads shall be held for not less than half a minute and the test load for not less than five
minutes. Readings shall be taken immediately after applying load and at the end of the time intervals stated above.
2 (05/17) Unless specifically indicated on the accepted manufacturer’s instructions submitted by the Contractor
to the Overseeing Organisation the total movement of the anchorage shall not exceed 1.0mm during the test. Any
evidence of slip during loading up to the test load, as demonstrated by a significant change in the slope of the load/
extension curve, shall constitute failure.
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Volume 1 Series 400
3 (05/17) The Contractor shall test the anchorages at the frequency given in contract specific Appendix 1/5 and in
accordance with any requirements given in contract specific Appendix 4/1.
PEDESTRIAN RESTRAINT SYSTEMS

411 (05/17) Pedestrian Parapets and Pedestrian Guardrails
(05/17) General
1 (03/20) Pedestrian parapets and pedestrian guardrails shall conform to the requirements of this Clause, contract
specific Appendix 4/1, CD 377 (DMRB 2.2.8) and the following.
(i) Pedestrian parapets or guardrails assembled from factory manufactured parts and assembled on site:
(a) BS 7818.
(ii) Bespoke pedestrian parapets manufactured from concrete on site:
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(a) In Accordance with the loading described in BS 6399-1 Table 4 Class C5 (x) and BS EN 1992-2.
(05/17) Durability
2 (05/17) Pedestrian parapets and pedestrian guardrails shall conform to the following.
(i) All components of pedestrian parapets and guardrails shall be designed to achieve a serviceable life of
not less than:
(a) metal pedestrian parapets and metal components of combined metal and concrete pedestrian
parapets – 30 years;
(b) concrete pedestrian parapets and concrete components of combined metal and concrete pedestrian
parapets – 120 years; and
(c) pedestrian guardrails – 15 years.
(ii) For metal pedestrian parapets and pedestrian guardrails and metal components of combined metal and
concrete pedestrian parapets and pedestrian guardrails the serviceable life shall, except where stated in
contract specific Appendix 4/1, be obtained without the requirement for any maintenance other than that
resulting from accidental damage.
3 (05/17) Protection against corrosion for pedestrian parapets and pedestrian guardrails, shall be as described in
the manufacturer’s specification and the following:
(i) all components of steel pedestrian parapets and pedestrian guardrails, except stainless steel items, shall
be surface protected after shop fabrication as described in Clause 1909; and
(ii) where required in contract specific Appendix 4/1, the surface preparation and protection against
corrosion of all steel pedestrian parapets and steel components of combined metal and concrete
pedestrian parapets shall comply with Series 1900.
(05/17) Aesthetic Requirements
4 (05/17) The design of pedestrian parapets shall comply with the aesthetic requirements given in contract specific
Appendix 4/1.
(05/17) Information Required to be Provided by the Contractor Prior to Installation
5 (05/17) The following information shall be provided by the Contactor to the Overseeing Organisation for
acceptance. All documents shall be in English.
(i) Manufacturer’s specification.
(ii) Installation drawings.

Volume 1 Series 400
(iii) Manufacturer’s installation instructions or installation manual including foundation requirements and
test methods to verify their performance.
(iv) Manufacturer’s repair and maintenance manual.
(v) A certificate of registration to National Highways Sector Scheme 2A for the Design and/or Supply,
Installation and Repair of Fences for Infrastructure Works.
(05/17) Workmanship and Testing
6 (05/17) All components shall be manufactured so as to permit the construction of the accepted systems within
the tolerances described in sub-Clause 403.2 and in accordance with the manufacturer’s drawings.
7 (05/17) Unless otherwise indicated on the manufacturer’s drawings submitted by the Contractor to the
Overseeing Organisation, all fabrication of components shall be completed before the surface protection is applied.
8 (05/17) The Contractor shall provide the Overseeing Organisation with evidence that the manufacturer has
arranged for tensile tests to destruction and analysis of composition to be carried out by a testing laboratory,
accredited in accordance with sub-Clause 105.4, annually and whenever the source of material or the production
technique is changed.
The testing shall include at least the determination of the yield/proof strength of the material, ultimate strength and
the extension at break. It shall be demonstrated that the materials are within the limits of statistical variation for the
specified material and for the material of the prototype tested system. Materials significantly exceeding the original
specified strength shall not be accepted.
(05/17) Handling
9 (05/17) All components shall be protected from damage and handled and stacked in such a way that permanent
damage is not caused, particularly to threaded components. Means shall be provided to avoid damage to galvanized
coatings and any damage that does occur shall be repaired in accordance with BS EN ISO 1461.
(05/17) Information Required to be Provided by the Contractor After Installation
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10 (05/17) The Contractor shall provide to the Overseeing Organisation as-built drawings which shall include plans
and details of the constructed system.
ANTI-GLARE SCREENS
412 (05/17) Anti-glare Screens
1 (05/17) Anti-glare screen systems shall conform to BS EN 12676-1 and BS EN 12676-2 and the requirements
of contract specific Appendix 4/1. The Contractor shall supply the Declaration of Performance which shall
demonstrate that the anti-glare screen system meets the performance requirements stated in contract specific
Appendix 4/1. The Contractor shall provide information to the Overseeing Organisation in English to demonstrate
that the screens are compatible with the vehicle restraint system on which the screens are proposed to be mounted
and do not adversely affect the performance of the vehicle restraint system.
Amendment – May 2017 23F

SERIES 500 523 (02/20) Grassed Surface Water Channels 37

DRAINAGE AND SERVICE DUCTS 524 (02/20) Combined Surface
Contents Water Channel and Pipe (Concrete) 38

Clause Title Page 525 (02/20) Reservoir Pavements 39
500 Introduction 2 526 Maintenance Plans for
(02/20)
Soakaways39
501 (02/20) Pipes for Drainage and
Service Ducts 2
502 Excavation for Pipes and
(02/20) NATIONAL ALTERATIONS OF THE
Chambers5 OVERSEEING ORGANISATIONS OF
503 (02/20) Bedding, Laying and SCOTLAND, WALES AND NORTHERN
Surrounding of Pipes 6 IRELAND
504 (02/20) Jointing of Pipes 8 Northern Ireland
505 (02/20) Backfilling of Trenches 9 Clause Title Page
506 Connecting to Existing Drains
(02/20) 508NI (02/20) Gullies and Pipe Junctions N1
Chambers and Channels 11
507 (02/20) Chambers 11
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# denotes a Clause or Sample Contract Specific Appendix which
#508 (02/20) Gullies and Pipe Junctions 15
has a substitute National Clause or Sample Appendix for one or
509 (02/20) Testing and Cleaning 16 more of the Overseeing Organisations of Scotland, Wales or
Northern Ireland.
510 Surface Water Channels and
(02/20)
Drainage Channel Blocks 17
511 (02/20) Land Drains 17
512 (02/20) Backfilling to Pipe Bay and
Verges on Bridges 17
513 (02/20) Permeable Backing to Earth
Retaining Structures 18
514 (02/20) Fin Drains 18
515 (02/20) Narrow Filter Drains 23
516 (02/20) Combined
Drainage and Kerb
Systems25
517 (02/20) Linear Drainage Channel
Systems26
518 (02/20) ThermoplasticsStructured
Wall Pipes and Fittings 28
519 (02/20) Concrete Bagwork 33
520 (02/20) The
Cleaning of Existing
Drainage Systems 33
521 (02/20) Low Pressure High Volume
Jetting of Drainage Systems 35
522 (02/20) Vortex Separators 37

Volume 1 Series 500
Specification for Highway Works Drainage and Service Ducts
DRAINAGE AND SERVICE DUCTS

1 (02/20) This Series is part of the Specification for Highways Works. Whilst this Series is particularly relevant to
with other Series relevant to the specification of the particular works to be undertaken.
501 (02/20) Pipes for Drainage and for Service Ducts

(02/20) General
1 (02/20) Where the term drain is used in this Series it shall be deemed to include the terms sewer and piped
culvert.
The Contractor shall design the piped culverts listed in contract specific Appendix 1/10 in accordance with the
requirements of Clause 106 and this Series.
2 (02/20) All drains constructed of pipes as well as piped culverts up to and including 900mm internal diameter
shall comply with this Series and any additional requirements in contract specific Appendix 5/1. Drains
constructed using pipes exceeding 900mm internal diameter as well as box and piped culverts shall comply with
Series 2500. Unless otherwise described in contract specific Appendix 5/1 only one type of pipe shall be used
within any individual drain or service duct between consecutive chambers. The Contractor shall ensure that all
drainage materials are not subjected to any form of deterioration before installation into the works.
(02/20) Pipes for Drainage
3 (02/20) Pipes for drainage shall be selected from the alternatives in Table 5/1 titled Pipes for Drainage and shall
comply with Clause 104 and contract specific Appendix 5/1. The Contractor shall demonstrate the pipes selected
satisfy the hydraulic design of the system as described in contract specific Appendix 5/1. On completion of the
whole of the drainage works, the Contractor shall provide the Overseeing Organisation with a schedule showing
details of all pipe types used, including quality, joints and name of manufacturer. This will form the basis of a
declaration of performance for the drainage.
(02/20) Corrugated Steel Pipes
4 (02/20) Corrugated steel pipes shall be manufactured from either:
(i) bolted segmental plate pipes complying with sub-Clause 6 of this Clause and having plate thicknesses as
described in contract specific Appendix 5/1; or,
(ii) galvanized steel sheet suitable for lock seam fabrication complying with BS EN 10346 grade
DX51D + Z600, or aluminium coated steel sheet complying with AASHTO specification M274-87.
Corrugated steel pipes complying with (ii) above shall be manufactured from steel of minimum thickness 1.25mm
unless otherwise described in contract specific Appendix 5/1.
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5 (02/20) Where described in contract specific Appendix 5/1 corrugated steel pipes shall be provided with
additional protection of hot applied bitumen complying with BS EN 13808, BS EN 15322 or BS EN 14023 having
a minimum peak cohesion value of 1.0 J/cm2 by pendulum test in accordance with BS EN 13588.
6 (02/20) Bolted segmental plate pipes shall meet the following requirements:
(i) Steel for the plates shall comply with BS 1449: Part 1.1, Grade 3 or Grade 4, Condition HR;
(ii) After forming, the depth of the corrugations shall be within a tolerance of ±6% and the pitch of the
corrugations within a tolerance of ±4% of the nominal dimensions. Plates shall have a minimum lip of
45mm beyond each end crest. Cut edges shall be free from notches, gouges, rust or burrs;

Volume 1 Series 500
(iii) Bolts and nuts for connecting plates shall comply with BS EN ISO 4014, BS EN 4017 and
BS EN ISO 4032, for BS EN ISO 898-1 and BS EN 20898-2, ISO 898-2 property class 8.8, nominal
size M20; or with BS 4395: Part 2, nominal size M20; or with BS EN ISO 898-1 and BS EN 20898-2,
ISO 898-2 property class 10.9;
(iv) When all the plates have been assembled, the nuts shall be tightened against a domed washer.
The tightening shall be repeated if necessary to achieve the torque recommended by the manufacturer;
and,
(v) Steel plate shall be galvanized in compliance with Clause 1909. Plates shall be galvanized after forming
the corrugations and completing all necessary cutting, punching and drilling. Units in which the zinc
coating has been burned by welding or otherwise damaged in fabrication, transport or handling at site
shall be made good in compliance with Clauses 1907 and 1908. Bolts and nuts shall be galvanized in
compliance with Clause 1909.
TABLE 5/1: (03/20) Pipes for Drainage
Material Usage Standard Particular Requirements

Vitrified clay Foul drains BS EN 295
Surface water drains BS EN 295
Filter drains BS EN 295
Concrete (With Portland Foul & surface water drains BS 5911-1 and
cement or sulfate-resisting BS EN 1916
cement when required in (Ordinary reinforced or
contract specific Appendix 5/1. unreinforced)
Supersulfated cement shall not
be used) BS 5911-5
Surface water drains BS 5911-1
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Filter drains BS 5911-1

(Porous with ogee or
rebated joints)
BS 5911-1 Unperforated not exceeding
2m in length with open
joints or castellated rebated
joints with the total slot area
between castellations being
at least 1000mm² per metre
length of pipe
OR
Perforated with circular holes
not greater than 10mm nor
less than 3mm in diameter
Glass reinforced plastics (GRP) Foul & surface water drains BS EN 14364 Class to be as specified in
5/1
Iron Foul & surface water drains BS 437 (Cast iron)
BS EN 598 (Ductile
iron)

Volume 1 Series 500
TABLE 5/1: (02/20) Pipes for Drainage (continued)
Material Usage Standard Particular Requirements

Thermoplastics solid wall pipes and Foul & surface water drains BS 4660 or BS 5481 or See the UK national forward to the
fittings BS EN 1401 (PVC-U) relevant BS EN. The grade
BS EN 1852-1 (PP) appropriate for use without structural
Unplasticised polyvinyl-chloride
BS EN 12666-1 (PE) calculations shall be used i.e. SN8
(PVC-U)
for PP & PE and SN4 (SDR 41) for
Polypropylene (PP) PVC-U
Polyethylene (PE) Filter drains BS EN 13598 (BS 4660 Perforated with not less than
for cleaning eyes) or 1000mm2 of holes per metre length
BS EN 1401 (PVC-U) of pipe. The perforations shall not
BS EN 1852-1 (PP) reduce the pipe stiffness by more
BS EN 12666-1 (PE) than 5%. Circular perforations not
greater than 10mm nor less than
3mm in diameter or rectangular slots
not greater than 4mm nor less than
0.6mm in width
Thermoplastics structured wall pipe Surface water drains Clause 518 Unperforated with watertight joints
and fittings and with a pipe stiffness class, creep
ratio and impact resistance as
described in contract specific
Appendix 5/1
Filter drains Clause 518 Perforated with not less than
1000mm2 of holes per metre length
of pipe. The perforations shall not
reduce the pipe ring stiffness by
more than 5%. Circular perforations
3mm in diameter or rectangular slots
0.6mm in width
Subsoil field drains BS 4962 or
Clause 518
Corrugated steel Surface water drains, filter BS EN 10346 AASHTO
drains Designation: M27 4-87
(2012)
(02/20) Pipes for Service Ducts

7 (02/20) Pipes for service ducts, excluding those in use in highway communications installations, shall be
selected from the alternatives in Table 5/2 and shall comply with the standards and particular requirements therein.
Pipes for use in highway communications installations shall comply with Series 1500. Pipes for service ducts shall
have a smooth internal bore without any sharp edges to the ends of pipes, shall comply with contract specific
Appendix 5/2, and be of 100mm internal diameter unless otherwise described therein. Their alignment shall be
tested in accordance with sub-Clause 509.9.
The use of pipes and fittings other than those included in Table 5/2 shall be permitted provided that they hold
current Product Acceptance Scheme certification in accordance with sub-Clauses 104.15 and 104.16 stating that
they are a suitable alternative to those listed in Table 5/2.
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8 (02/20) Each duct shall be fitted with a pigmented, stranded polypropylene or equivalent rot-proof material draw
rope of 5kN breaking load and having a design life of not less than 20 years, the ends of which shall be either made
fast to marker blocks as shown on HCD Drawing Number I1 or secured inside chambers. The ends of a duct shall
be either sealed by removable stoppers immediately it has been laid, or terminated in chambers of the type specified
in contract specific Appendix 5/2.

Volume 1 Series 500
TABLE 5/2: (02/20) Pipes for Ducts
Material Standard Particular Requirements

Vitrified clay BS EN 295 Plain-ended, self-aligning flexible sleeve jointed with
internal ends radiused to 3mm minimum
Iron BS EN 598
(Ductile iron)
Glass reinforced plastics BS EN 14364 Class to be as specified in contract specific Appendix 5/2
Thermoplastics solid wall BS 4660 and BS EN 13598 When pipes BS 3506 (Class C) are used, joints shall
or comply with BS EN ISO 1452-1 to 5 as appropriate
BS 3506 (Class C) or
Unplasticised polyvinyl-chloride (PVC-U) BS EN 1401,
(PVC-U) BS EN ISO 1452-1 to 5 as
appropriate class PN10.
Polypropylene (PP) BS EN 1852-1 (PP)

Polyethylene (PE) BS EN 12666-1 (PE)
Thermoplastics single wall BS EN 61386-24 Ducts to BS EN 61386-24 shall be classified as normal
(Restricted to ducts buried a duty, corrugated have a degree of protection against ingress
minimum of 600mm below the of foreign objects classification rating of 3 or 4 and a
surface) degree of protection against ingress of water classification
rating of 7. Resistance to bending requirements shall be as
stated in contract specific Appendix 5/2.
Thermoplastics structured wall BS EN 61386-24 Ducts to BS EN 61386-24 shall be classified as normal
and Clause 518 duty, corrugated have a degree of protection against ingress
of foreign objects classification rating of 3 or 4 and a
degree of protection against ingress of water classification
rating of 7. Resistance to bending requirements shall be as
stated in contract specific Appendix 5/2
502 (02/20) Excavation for Pipes and Chambers

1 (02/20) Excavation shall comply with Clause 602 and with the following:
(i) soft spots existing below the bottom of an excavation shall be removed and the resulting voids backfilled
with Type 1 unbound mixture for subbase complying with Clause 803 or pipe bedding material
complying with Clause 503, both well compacted, or ST1 concrete in compliance to Clause 2602;
(ii) any additional excavation below the bottom of an excavation that is required because the Contractor
has allowed the bottom to become soft or otherwise unacceptable for the construction of the pipeline or
chambers shall be made good as described in sub-Clause 1(i) of this Clause; and,
(iii) any excavation greater than the net volume required for the permanent works below the level of any pipe
surround shall be made good as described in (i) above.
2 (02/20) Unless otherwise described in contract specific Appendix 5/1, all pipes in or under new embankments
shall be laid only when the embankment has been formed and compacted to formation level under paved areas, to
finished earthworks level in other areas, or to a level which will give a minimum cover of 1.2m to the pipes,
whichever is the lowest.

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Volume 1 Series 500
503 (02/20) Bedding, Laying and Surrounding of Pipes

1 (02/20) Immediately following the excavation of the trench, the pipes shall be laid and jointed on the pipe bed.
Pipes shall be laid so that each one is in contact with the bed throughout the length of its barrel. The pipes shall be
laid at the level and gradients shown on the drawings and schedules. The deviation in level from that specified at
any point shall not exceed 20mm and in addition the algebraic difference of the deviation in level at any two points
on each pipe shall not exceed 30mm. In the case of socketed or sleeve jointed pipes the bed shall be cut away and
removed at each socket or sleeve to give a clearance of at least 50mm, or 100mm for trenches in material
designated as hard material, so that the socket or sleeve does not bear on the bed. Pipes shall be laid on setting
blocks only where a concrete bed or cradle is used.
Pipes and fittings that show any sign of damage shall be excluded from the works. The pipes and fittings’ joint
surfaces and components shall be cleaned immediately before laying. Measures shall be taken to prevent soil or
other material from entering pipes, and to anchor each pipe to prevent movement before the work is complete.
2 (02/20) Pipes complying with BS 4962 which are corrugated coilable perforated pipes shall, unless otherwise
permitted in contract specific Appendix 5/1, be laid only by automatic single pass drain laying machines.
3 (02/20) Drainage pipe and bedding combinations shall be selected from the alternatives described in contract
specific Appendix 5/1. The granular material shall consist of natural and/or recycled coarse aggregate complying
with BS EN 13242 and have a declaration of performance for its intended use, the declaration of performance shall
demonstrate that the aggregate meets the specification.
Where recycled coarse aggregate is used in this Clause, it shall have been tested in accordance with Clause 710 and
shall not contain more than 1% ‘other’ materials (Class X). Pipe bedding, haunching and surrounding material
shall be as shown on HCD Drawing Numbers F1 and F2, and shall comply with the following:
(i) For pipes on beds shown on HCD Drawing Numbers F1 and F2 as Types B, F, S, I, J, L, K and M the
aggregate shall have:
(a) geometrical requirements in accordance with Table 5/3;
(b) a resistance to fragmentation in Category LA50 in accordance with BS EN 13242, clause 5.2 and
table 9;
(c) a water-soluble sulfate content of less than 0.2% category SS0.2 in accordance with BS EN 13242
when tested in accordance with BS EN 1744-1, clause 10; and,
(d) all other requirements in CategoryNR.
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(ii) For pipes on beds shown on HCD Drawing Number F1 as Types N and T the aggregate shall comply
with the geometrical requirements of either Table 5/3 or with Table 5/4, and with the fragmentation,
watersoluble sulfate content and other requirements of (i) above;
(iii) For pipes on beds shown on HCD Drawing Number F1 as Types A and Z concrete shall be ST4 and ST2
respectively, in compliance to Clause 2602. Backfilling shall not be carried out until after the concrete
has cured. The concrete bed or surround may extend to the sides of the trench. Class 8 material shall be
used to fill any voids formed;
(iv) Except for filter drains a further surround above the bed, haunch and surround described above shall be
provided to a height of 300mm above the top of the pipe consisting of Class 8 lower trench fill material
as described in Table 6/1 and in compliance with Series 600;
(v) Unless otherwise described in contract specific Appendix 5/1 the materials used for the bedding,
haunching and surrounding of filter drains shall comply with the appropriate bedding, haunching and
surrounding materials specified in sub- Clauses 503.3.(i) to 503.3.(iv) and with the requirements for
backfilling specified in sub-Clause 505.3; and,
(vi) Pipes shown on HCD Drawing Number F2 shall be laid with slots or perforations upwards where a
concrete bed is used. For other beds the slots or perforations shall be orientated as described in contract

Volume 1 Series 500
4 (02/20) Materials for bedding, haunching and surrounding pipes within 500mm, or any other distance described
in contract specific Appendix 5/1, of concrete, cement bound materials, other cementitious materials or stabilised
capping shall comply with the requirements stated in sub-Clause 601.16.
5 (02/20) Materials for bedding, haunching and surrounding pipes placed within 500mm, or any other distance
described in contract specific Appendix 5/1, of metallic structural elements shall comply with the requirements
stated in sub-Clause 601.17.
TABLE 5/3: (02/20) BS EN 13242, Coarse Aggregate for Pipe Bedding, Haunching and Surrounding Material
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BS EN 13242, Coarse aggregate
Category for general grading requirements GC80-20
Category for tolerances at mid-size sieves GTNR (no requirements)
Category for maximum values of fines content Natural aggregate – f1.5
Manufactured aggregate, recycled aggregate – f4
Nominal pipe diameter, mm Aggregate size, mm
Graded Single
Not exceeding 140 – 4/10
Exceeding 140 but not exceeding 400 2/14 or 4/20 4/10, 6/10 or 10/20
Exceeding 400 2/14, 4/20 or 4/40 4/10, 6/14, 10/20 or 20/40
TABLE 5/4: (02/20) BS EN 13242, Fine and All-in Aggregated for Pipe Bedding, Haunching and Surrounding
Material
BS EN 13242, Fine and all-in aggregate

Fine All-in
Category for general grading requirements Category GF80 Category GA80
Category for tolerances on manufacturer’s declared GTFNR GTANR
typical grading (no requirement) (no requirement)
Category for maximum values of fines content Natural aggregate – f3 Natural aggregate – f3
Manufactured aggregate, recycled Manufactured aggregate,

aggregate – f10 recycled aggregate – f12
Nominal pipe diameter, mm Aggregate size, mm
Fine All-in
Not exceeding 140 0/10
Exceeding 140 but not exceeding 400 0/1, 0/2, 0/4 or 0/6 0/10 or 0/20
Exceeding 400 0/10, 0/20 or 0/40
6 (02/20) Except where the pipeline is to be tested in compliance with Clause 509 before backfilling as specified
in contract specific Appendix 5/1, the completion of the bedding, haunching and surrounding of the pipes is to be
carried out immediately after jointing. The bed, haunch and surround shall be brought up equally on both sides of
the pipe ensuring that it is in contact with the underside of the pipe barrel and be carefully compacted in layers not
exceeding 150mm thickness ensuring full compaction next to the trench walls. Pipes shall be maintained to line
and level during the bedding, haunching and surrounding operations. Where pipelines are to be tested before being
covered the bedding haunching and surrounding material shall only be brought up sufficiently to support the
pipeline and the joints shall be left exposed until the test is completed satisfactorily.
7 (02/20) Duct construction shall comply with the requirements of contract specific Appendix 5/2.

Volume 1 Series 500
504 (02/20) Jointing of Pipes

1 (02/20) Rigid joints shall mean joints made solid by caulking the sockets, or bolting together flanges integral
with the pipes. Flexible joints shall mean joints made with deformable rings or gaskets held between pipe spigots
and sockets, sleeves or collars.
2 (02/20) Joints in surface water drains shall be watertight complying with Table 5/1 or partly watertight
complying with Table 5/1 as described in contract specific Appendix 5/1. Foul drains shall have watertight joints.
Filter drains shall have joints complying with Table 5/1. Ducts need not have watertight joints unless otherwise
3 (02/20) Watertight joints shall comply with Table 5/1, the manufacturer’s instructions and the following:
(i) Rigid joints shall be used only where permitted in contract specific Appendix 5/1. Spigots and
sockets of rigid joints jointed conventionally and the socket completely filled with mortar designation
(i) complying with Clause 2404, excluding lime; a fillet of mortar being worked around the socket
extending for a length of not less than 50mm from the face of the socket;
(ii) Joints in PVC-U pipes shall not be made with plastic solvent;
(iii) Flexible mechanical joints may be used with surface water pipes complying with BS EN 295;
(iv) Joints for cast iron pipes to BS 437 shall comply with BS EN 877 and have a declared performance that
meets the specification requirements; and,
(v) Joints in thermoplastics structured wall pipe shall comply with Clause 518.
4 (02/20) Partly watertight joints for surface water drains shall be tested in accordance with sub-Clause 509.9 and
shall be in accordance with Table 5/1. Push fit joints shall have a register to ensure that the pipe is fully pushed into
the joint.
Corrugated steel pipes of lock seam fabrication, not exceeding 900mm internal diameter, shall be joined in
accordance with the manufacturer’s instructions. Bolted segmental plate pipe arches or circular pipes, not
exceeding 900mm internal diameter, shall be joined in accordance with sub-Clause 501.6 (iv) and the
5 (02/20) Where a concrete bed, cradle, arch or surround is used with rigid pipes having flexible joints, joint filler
board complying with Clause 1015 shall be placed in contact with the end of the socket at a pipe joint and shall
extend through the full thickness of the concrete in contact with the pipe. Such joints in the concrete bed, haunch
or surround shall be at intervals not exceeding 5 metres except where the spacing of joints in the pipe exceeds
5 metres when they shall be at each pipe joint.
6 (02/20) Joints in pipes for filter drains shall comply with Table 5/1 and with the following:
(i) Non-porous and unperforated concrete and clay pipes with spigot and socket, rebated or ogee joints shall
be laid with unsealed joints and with a gap of 10mm between the end of the pipe and the inner end of the
socket or rebate. The pipes shall be supported by a jointing material within the sockets over the lower
third of the circumference so that there are no vertical steps between one pipe and another. Such pipes
shall only be used with Type B filter material as described in Clause 505;
(ii) The ends of perforated or porous concrete pipes with rebated joints and perforated clayware pipes with
rebated or with flexible sleeve joints shall be pushed tightly together;
(iii) Perforated or slotted thermoplastics pipes with spigots and sockets or sleeves may be dry-jointed or
jointed as described in sub-Clauses 3 and 4 of this Clause; and,
(iv) Other perforated pipes shall be jointed as unperforated pipes of the same material.
7 (02/20) Joints in pipes for service ducts shall comply with BS 4660, BS EN 13598-1 and with the following:
(i) Pipes for ducts shall be jointed so that no silt, grit, grout or concrete surround is able to enter the duct.
Pipes with push-fit joints shall have a register to ensure that the pipe is fully pushed into the joint.
(ii) Joints in pipes to BS 3506 shall comply with BS EN ISO 1452-1 to 5 as appropriate.
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Volume 1 Series 500
505 (02/20) Backfilling of Trenches

1 (02/20) Backfilling shall be undertaken immediately after the required operations preceding it have been
completed.
2 (02/20) Except where otherwise described in contract specific Appendix 5/1, trenches other than filter drain
trenches shall be backfilled above the pipe surround material described in Clause 503, with Class 1, 2, or 3 general
fill material complying with Series 600.
3 (02/20) Where detailed in contract specific Appendix 5/1 the bases of trenches formed on water soluble soils
shall be sealed with a waterproof geotextile membrane. The geotextile membrane shall be in accordance with
Clause 609.
4 (02/20) Each side of the waterproof geotextile membrane shall be protected by a layer of non-woven geotextile.
The non-woven geotextile shall be in accordance with Clause 609.
5 (02/20) Sub-base material for the upper layer of the drain shall consist of Type 1 material to Clause 803.
6 (02/20) Geotextile membranes used between the upper and lower section of combined surface and sub-surface
drains shall be in accordance with Clause 609.
7 (02/20) Use of lightweight aggregates as filter material shall be subject to the approval of the Overseeing
Organisation.
8 (02/20) Filter drains shall be backfilled as described in contract specific Appendix 5/1 with Type A, Type B or
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Type C filter material which shall consist of natural or recycled coarse aggregate complying with BS EN 13242 and
the following:
(i) for Type A and C, grading requirements for unbound mixtures in accordance with Table 5/5 and
BS EN 13285;
(ii) for Type B, geometrical requirements in accordance with Table 5/5 and BS EN 13242;
(iii) a resistance to fragmentation in Category LA50 in accordance with BS EN 13242, clause 5.2 and table 9;
(iv) a water-soluble sulfate content of less than 0.2% Category SS0.2 in accordance with BS EN 13242 when
tested in accordance with BS EN 1744-1, clause 10;
(v) all other requirements in CategoryNR
Where recycled coarse aggregate is used in accordance with this Clause, it shall have been tested in accordance
with Clause 710 and shall not contain more than 1% ‘other’ materials (Class X).
Filter materials, shall be tested for permeability in accordance with sub-Clause 509.8 and shall comply with
permeability requirements as described in contract specific Appendix 5/1.
Locations where Type A material is to be used shall be as specified in contract specific Appendix 5/1.

Volume 1 Series 500
TABLE 5/5: (02/20) Grading and Geometrical Requirements for Filter Drain Material
Type A Type B Type C

Standard BS EN 13285 BS EN 13242 BS EN 13285
Size, mm 0/20 20/40
Grading GE (with an additional GC80-20
sieve)
As described in
Oversize category OC80 –
contract specific
Category for tolerances at mid-size sieves – GTNR Appendix 5/1
(no requirement)
Category for maximum fines UF3 FNR
(no requirement)
Summary grading requirements
Sieve size, mm Percentage by mass passing
80 – 100
63 – 98 - 100
40 100 80 - 99
20 80 - 99 0 - 20
10 50 - 90 0-5
4 30 - 75 –
As described in
2 15 - 60 – contract specific
Appendix 5/1
0.500 0 - 35 –
0.125 0-4 –
0.063 0-3 –
% in size fraction
4/10 5 - 35 –
2/4 5 - 35 –
9 (02/20) Materials for backfilling trenches and filter drains placed within 500mm, or any other distance described
in contract specific Appendix 5/1, of concrete, cement bound materials, other cementitious mixtures or stabilised
capping shall comply with the requirements stated in sub-Clause 601.16.
10 (02/20) Materials for backfilling trenches and filter drains placed within 500mm, or any other distance described
in contract specific Appendix 5/1, of metallic structural elements shall comply with the requirements stated in
sub-Clause 601.17.
11 (02/20) Backfilling shall be deposited and compacted in compliance with Clause 612. Filter material for filter
drains shall be deposited in layers not exceeding 225mm loose depth; each layer being compacted in compliance
with Table 6/4 Method 3.
12 (02/20) Material shall be deposited in even layers and shall not be heaped in the trench before being spread.
Spreading and compaction shall be carried out evenly without dislodging, distorting or damaging the pipe. Power
rammers shall not be used within 300mm of any part of the pipe or joint.

10
Volume 1 Series 500
13 (02/20) Except in carriageways, other paved areas and locations described in contract specific Appendix 5/1,
backfill of trenches shall be brought up to ground level. Where topsoil is at the surface on the line of the trench the
upper section of the backfill shall be topsoil of the thickness described in contract specific Appendix 6/8, or of the
same thickness and quality of topsoil as the surrounding ground where no thickness is specified. For trenches in
carriageways or other paved areas the backfill shall be brought up to formation level, or sub-formation level where
capping is required, unless a lower level is described in contract specific Appendix 5/1. Sheeting and other
excavation supports shall be removed as the filling proceeds unless otherwise described in contract specific
Appendix 6/3.
14 (02/20) The position of service ducts shall be marked when the trenches are backfilled and permanent marker
blocks and location posts provided as described in contract specific Appendix 5/2.
(02/20) Bitumen Bound Shredded Tyres
15 (02/20) If the use of bitumen bound shredded tyres is proposed as a treatment to improve the stability of
combined surface and sub-surface drains then the specification is to be submitted to the Overseeing Organisation
for approval prior to use.
506 (02/20) Connecting to Existing Drains Chambers and Channels

1 (02/20) Where described in contract specific Appendix 5/1, existing drains shall be extended, connected and
jointed to new drains, chambers or channels. All such connections shall be made during the construction of the
new drain or other work and their positions recorded by the Contractor who shall provide to the Overseeing
Organisation a copy of the record of the connections made the previous day. Where pipe connections are made to
existing brick concrete or stone drains, chambers or channels, the pipes shall be well and tightly built into the
concrete, brick or masonry work and be so placed as to discharge at an angle not greater than 60° to the direction of
flow of the drain or channel and with the end of the pipe carefully cut to the necessary angle. Where the
connections are between pipe drains, special connecting pipes shall be laid and jointed as described in contract
2 (02/20) Before entering or breaking into an existing sewer or drain, the Contractor shall give notice of his
intention to do so to the authority responsible for the drainage system to which the connection is to be made.
3 (02/20) Unless otherwise stated in contract specific Appendix 2/2, existing drains no longer required shall, as
required by contract specific Appendix 5/1, be sealed with ST2 concrete, in compliance with Clause 2602, or
removed and replaced with general fill material complying with Clause 601 and Table 6/1 and compacted in
compliance with Clause 612, or grouted with a 1:10, cement: pfa mix. The grout shall use the minimum quantity of
water to ensure the fluidity necessary to render it capable of being pumped to the ends of the pipe and be in
accordance with the manufacturer’s instructions. It shall be used within one hour of mixing but when the mix
contains a retarding admixture this time may be extended in accordance with the manufacturer’s instructions. The
cement shall comply with BS EN 197-1 and the pulverised fuel ash (pfa) with BS 3892: Part 2, fineness to Zone B
and sulfate content not exceeding 1.5%.
507 (02/20) Chambers

1 (02/20) Chambers shall include manholes, catchpits, inspection chambers, draw pits and walled soakaways.
Chambers shall be of the type specified in contract specific Appendix 5/1, constructed in accordance with HCD
Drawing Numbers F3 to F12 and F25 to F27 as appropriate to that type. Chambers for use in highway
communications installations shall comply with Series 1500. All ST concrete referred to in this Clause shall comply
with Clause 2602, unless otherwise described in contract specific Appendix 5/1.
2 (02/20) Foundations to chambers shall be of ST4 concrete. Channels for chambers shall be formed and finished
smooth in the foundation concrete or constructed of preformed half circle channels, with sides benched in ST4
concrete, or mortar designation (i) complying with Clause 2404 excluding lime. Alternatively for inspection
chambers not exceeding 1.3 metres in depth to invert, complete plastics units or other units in equivalent material
surrounded by 150mm of ST4 concrete may be used.
Amendment – February 2020

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Volume 1 Series 500
3 (02/20) Brickwork shall comply with Series 2400 and be built with mortar designation (i) in English bond.
The joints of brickwork where exposed shall be finished as specified for unpointed joints in Clause 2412. The ends
of all pipes shall be neatly built into the brickwork and finished flush with mortar designation (i). Where precast
concrete adjusting units are used they shall conform to BS EN 1917 and BS 5911-3. Benching width for chambers
detailed on HCD drawing numbers F25 to F27 shall be 300mm for branch connection.
4 (02/20) Precast concrete chambers shall comply with BS 5911-3 and BS EN 1917 and the particular
requirements described in contract specific Appendix 5/1. Cast in situ concrete chambers shall be constructed of
ST4 concrete complying with Clause 2602 and the particular requirements described in contract specific
Appendix 5/1.
5 (02/20) Corrugated galvanized steel chambers shall comply with Clause 501 with in situ ST4 concrete inverts
and precast concrete cover slabs complying with BS 5911-3 and BS EN 1917 and the particular requirements
described in contract specific Appendix 5/1. They shall be surrounded with well graded granular material Class 6M
as described in Table 6/1 compacted in accordance with Clause 612.
6 (02/20) Where the depth of invert of chambers, excluding inspection chambers, exceeds 900mm below the
finished surface of the carriageway or the adjacent ground, chamber steps complying with BS EN 13101 shall be
built in accordance with relevant Series F-HCD Drawings. The steps shall have a declaration of performance for
their intended use within the permanent works. Threaded components shall be galvanised in compliance with
Clause 1909.
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7 (02/20) Excavation around chambers, except those described in sub-Clause 5 of this Clause, shall be backfilled
with general fill material as described in Table 6/1 and compacted in compliance with Clause 612. Where
mechanical compaction is impracticable, the excavation shall be backfilled with ST2 concrete. Where there are
precast concrete access shafts to precast concrete chambers, the shafts shall be surrounded by a minimum thickness
of 150mm of ST4 concrete, and the remaining excavation backfilled with general fill material as described in Table
6/1 compacted in compliance with Clause 612.
8 (02/20) Chambers for foul drains shall be tested for watertightness in accordance with Clause 509 and where
required in contract specific Appendix 5/1.
9 (02/20) Chamber covers, gratings and frames shall be as described in contract specific Appendix 5/1 and shall
comply with BS EN 124: 1994 and sub-Clauses 11 and 20 of this Clause. The cover shall be of suitable material,
design and construction to achieve the required in-service skid resistance potential determined by the accelerated
polish test method described in BS 9124. The Polished Skid Resistance Value (PSRV) shall be as stated in contract
specific Appendix 5/1. The Unpolished Skid Resistance Value (USRV) is not an acceptable alternative to
demonstrate in-service skid resistance.
10 (02/20) Class D 400 units and above shall incorporate a permanent non-rock feature either triangular point
suspension or machined faces. Where a cover is required to be seated in a frame the design life of the seating shall
match that of the frame. The seating shall not reduce the performance characteristics of the frame and cover.
11 (02/20) Bolts supplied for loosely coupling separate sections of covers and gratings shall be steel hexagon
headed, complying with the requirements of BS EN ISO 4016, BS EN ISO 4018 and BS EN ISO 4034 and be
galvanized in compliance with Clause 1909. They shall not be less than size M16 complete with hexagon nut and
shall be provided with means to prevent undue tightening of unit sections.
12 (02/20) Unless otherwise specified in contract specific Appendix 5/1, all covers, gratings and frames shall be
supplied in a fine cast (uncoated) condition. Where a coating is specified in contract specific Appendix 5/1, the
coating shall only be applied when the surfaces of the casting are clean, free from rust and dry.
13 (02/20) Requirements for special duty covers for use in carriageways shall be as described in contract specific
Appendix 5/1.
14 (02/20) Gratings for catchpit chambers shall have a minimum waterway area as described in contract specific
Appendix 5/1.

Volume 1 Series 500
15 (02/20) Two sets of lifting keys shall be delivered to the Overseeing Organisation for each type of cover
supplied. At least two keyways, as detailed on HCD Drawing No. F17, shall be provided in each complete cover,
one in each segment for segmental covers. A recess for a prising bar shall be incorporated in manhole covers unless
other means of loosening the cover from the frame are provided.
16 (02/20) Frames for chamber covers and gratings shall be set in cement mortar designation (i) complying with
Clause 2404 or a quick setting mortar of equivalent strength with a declaration of performance for its intended use.
The declaration of performance shall be submitted to the Overseeing Organisation.
17 (02/20) For all pipelines except those constructed with corrugated pipes the nearest joint to any chamber shall be
not more than 500mm from the inner face of the wall and shall not be restricted by any concrete. Between this and
the next joint, the length of the articulated pipe shall be in accordance with Table 5/6.
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TABLE 5/6: (02/20) Length of Articulated Pipe
Nominal Pipe Diameter (mm) Length of Pipe (mm)

450 and less 500 to 750
Greater than 450 750 to 1000
18 (02/20) Where the adjustment or replacement of existing frames and covers or gratings is required, the units
shall be taken up and re-fixed or removed and replaced with new units complying with sub-Clauses 9 to 15 of this
Clause, or as described in contract specific Appendix 5/1. On taking up or removal of the unit, any concrete or
mortar bedding shall be broken out and the surface prepared. Where existing frames and covers or gratings are to
be adjusted, the Contractor shall take up the unit and clean it so it is free from existing mortar, any debris, rust and
is dry before re-use. The adjusted or replaced units shall be laid on a mortar bed complying with sub-Clause 16 of
this Clause. The finished thickness of the mortar bed shall be between 10mm and 25mm. Where required in
contract specific Appendix 5/1, covers and gratings shall be bedded using a quick setting high strength mortar with
a declaration of performance for its intended use. The declaration of performance shall be provided to the
Overseeing Organisation before use. Unless otherwise described in contract specific Appendix 5/1, adjusted or
replaced frames and covers or gratings shall be set flush with the new or reinstated surface. Any additional
adjustments shall be by modifying the brickwork, or adjusting units in accordance with BS EN 1917 and
BS 5911- 3, in compliance with sub-Clause 507.3 or by using a frame of a suitable depth. On completion of the
works, each cover shall be lifted and the frame and seating cleaned.
19 (02/20) Unless otherwise specified in contract specific Appendix 5/1, chamber covers shall have the following
minimum clear opening requirements:
(i) rectangular frame 600mm, with a minimum diagonal measurement of 700mm;
(ii) circular frame minimum diameter of 700mm.
20 (02/20) Vents are not required in chamber covers unless otherwise stated in contract specific Appendix 5/1.
21 (02/20) Where stated in contract specific Appendix 5/1 the sealing of a cover within the frame is required.
22 (02/20) Access covers with a clear opening of greater than 1m shall comply with BS 9124.
23 (02/20) Where pins or circlips are used as part of the securing device these shall be of equal cross-sectional area.
24 (02/20) Chamber tops and gully tops shall be bedded upon material which has the following properties:
(i) non-shrinkable;
(ii) a minimum workable life of 15 minutes;
(iii) a compression strength that exceeds 30N/mm2 within 3 hours of placing; and,
(iv) a tensile strength that exceeds 5N/mm2 within three hours of placing.
25 (02/20) The bedding beneath the chamber top or gully top frame shall be free of voids.
26 (02/20) Packing materials shall not be used in the bedding of chamber tops and gully tops.

Volume 1 Series 500
27 (02/20) Seatings of covers within frames shall have been manufactured to ensure that, when trafficked, stability
and quietness are achieved in accordance with BS EN 124: 1994.
28 (02/20) The frame bearing area shall have the following properties:
(i) the nominal bearing pressure in relation to the test load in BS EN 124:1994;
(ii) frames have an overall minimum bedding width of 50mm of metal and a maximum overall bedding
width of 120mm of metal; and,
(iii) for openings with corners, the external corners of the frame are solid (unless test data are provided that
demonstrate the inclusion of holes does not reduce the structural integrity of the system) and may be
square, curved or chamfered but at no point shall the width be less than the minimum bedding width.
29 (02/20) The bedding flange shall have a minimum thickness of 5mm.
30 (02/20) Where vertical frame stiffening webs/gussets are provided, they shall be located adjacent to seatings.
31 (02/20) The tops of such triangular webs/ gussets shall be in accordance with BS 7903.
32 (02/20) There shall be no holes within the seating areas of the bedding flanges beneath the cover seatings.
33 (02/20) Any holes within flanges within the bedding area of the frame shall be minimal and not reduce the
specified bearing area of the frame.
(02/20) Placing of Frames and Covers
34 (02/20) The frame of chamber tops and gully tops shall be placed on the bedding material so that all webs of the
frame are fully supported by the frame supporting structure.
35 (02/20) The bedding surface shall permit a bedding thickness of between 10mm and 75mm.
36 (02/20) The webs of the frame shall not overhang the internal faces of the frame supporting structure.
37 (02/20) Any holes within the frame shall be infilled with bedding material and the flanges of the frame
enveloped by a minimum thickness of 10mm of the same material.
38 (02/20) Exposed surfaces of the bedding material around the outside of the chamber or gully top frame shall be
floated to fill any voids and remove loose fragments.
39 (02/20) The exposed surface of the bedding material inside the chamber shall be pointed to a smooth finish.
40 (02/20) Surround materials shall only be placed in contact with the frame once the bedding material has set.
(02/20) Placement of Cover Surround Materials
41 (02/20) Where a self-setting fill material is used this shall be placed no higher than 40mm below the finished
surface level.
(02/20) Securing Chamber Covers and Frames
42 (02/20) Chamber covers and frames shall be secured to ensure that they are not dislodged by a vehicle.
(02/20) Reinstatement Works
(02/20) Frame Supporting Structure

43 (02/20) Where rebuilding involves more than one course of brickwork or precast concrete cover frame seating
ring, an adjusting course shall be used to meet the specified finished surface level.
44 (02/20) Frame supporting structure reconstruction shall be engineering bricks in compliance with Clause 2400
(without holes or frogs) or adjusting units in accordance with BS EN 1917 and BS 5911-3, bedded on mortar that
achieves a compressive strength exceeding 20N/mm2 Class Md in accordance with BS EN 998 and Clause 2404
before loading.

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Volume 1 Series 500
(02/20) Re-bedding of Covers/Gully Gratings

45 (02/20) Mixing and placing of proprietary bedding materials shall be in accordance with the manufacturer’s
instructions.
46 (02/20) Site made mortar shall be in accordance with Clause 2404.
47 (02/20) Bedding layers greater than 50mm thick shall be placed in two stages.
48 (02/20) The first layer of the mortar shall be no thicker than 40mm.
(02/20) Reinstatement of Surrounding Flexible Carriageway
49 (02/20) There shall be no contact between any compaction device and the frame or cover to avoid damaging the
frame, cover or the bedding layer.
50 (02/20) The joint between the reinstated and existing materials shall be sealed with bituminous material in
compliance with clause 903.22.
#508 (02/20) Gullies and Pipe Junctions

1 (02/20) Gullies shall be trapped, untrapped or sumpless as described in contract specific Appendix 5/1 and be in
accordance with HCD Drawing Numbers F13 and F14. All ST concrete referred to in this Clause shall comply
with Clause 2602 unless otherwise described in contract specific Appendix 5/1.
2 (02/20) Gullies shall be constructed so that no part of the spout or trap has a cross-sectional area less than 2/3rd
that of the outlet. The depth of water seal in trapped gullies shall be not less than 50mm.
3 (02/20) Precast concrete gullies and cover slabs shall comply with BS 5911-6 and clay gullies with BS EN 295.
In situ concrete gullies shall be as described in contract specific Appendix 5/1 and constructed of ST4 concrete of
150mm minimum thickness, using permanent or removable shuttering.
4 When constructing an in situ sumpless gully, the pot shall not distort under pressure.
5 Where in situ concrete gullies are formed with permanent shuttering, such shuttering shall have current product
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acceptance scheme certification in accordance with sub-Clauses 104.15 and 104.16.

6 (02/20) Gully gratings, kerb type gully covers and frames shall comply with BS EN 124: 1994 and the following
and shall be of the classes and sizes described in contract specific Appendix 5/1.
7 (02/20) The upper surface of gully gratings shall be flat except where otherwise described in contract specific
Appendix 5/1. Slots in gratings or between gratings and frames shall not be orientated parallel to the direction of
traffic except where the slots are less than 150mm long or less than 20mm wide. Minimum waterway areas shall be
as specified in contract specific Appendix 5/1. Unless otherwise specified in contract specific Appendix 5/1, all
gratings and frames shall be supplied in a fine cast (uncoated) condition. Where a coating is specified in contract
specific Appendix 5/1, the coating shall only be applied when the surfaces of the casting are clean, free from rust
and dry. Frames shall be bedded on mortar complying with sub-Clause 507.21. Brickwork shall comply with
sub-Clause 507.3.
8 (02/20) Backfilling to precast gullies shall be carried out up to sub-formation level with general fill material
Class 1, as described in Table 6/1 compacted in compliance with Clause 612. Where mechanical compaction is
impracticable, the backfilling shall be in ST2 concrete. The remainder of the backfilling shall be in appropriate
capping and road pavement materials except that where mechanical compaction of capping or unbound mixture for
subbase is impracticable ST2 concrete shall be used.

Volume 1 Series 500
9 (02/20) Gully connection pipes shall be either flexible or rigid not exceeding 0.7m in length with flexible joints
for a distance of 2m from the gully and shall be in accordance with Clause 507 when entering chambers. Junction
pipes shall be manufactured of the same type and class of material as the remainder of the pipes in the run.
Junction pipes which are laid but not immediately connected, shall be fitted with temporary stoppers or seals and
the position of all such junctions shall be clearly defined by means of stakes or tracing wires properly marked or
labelled. Saddles may be used to form junctions only where permitted in contract specific Appendix 5/1. No
internal projections greater than 5 mm will be permitted. Saddles for plastics pipes shall be installed in accordance
with the manufacturer’s recommendations. Saddles with clay pipes shall be jointed with mortar designation (i)
complying with Clause 2404, excluding lime. Saddles and pipes shall be surrounded with ST2 concrete.
10 (02/20) Where the adjustment or replacement of existing frames and gratings is required, the units shall be taken
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up and re-fixed or removed and replaced with new units complying with sub-Clauses 4 and 5 of this Clause, or as
described in contract specific Appendix 5/1. On taking up or removal of the unit, any concrete or mortar bedding
shall be broken out and the surface prepared. Where existing frames and covers or gratings are to be adjusted, the
Contractor shall take up the unit and clean it so it is free from existing mortar, any debris, rust and is dry before
re-use. The adjusted or replaced units shall be laid at a level, unless otherwise described in contract specific
Appendix 5/1, 6 mm below the adjoining road surface on a mortar bed complying with sub-Clause 507.16. The
finished thickness of the mortar bed shall be between 10 mm and 25 mm. Where required in contract specific
Appendix 5/1, covers and gratings shall be bedded using a quick setting high strength mortar which shall have a
declaration of performance for its intended use, the declaration of performance shall be provided to the Overseeing
Organisation before use. Any additional adjustment shall be made by modifying the brickwork in compliance with
sub-Clause 507.3 or by using a frame of suitable depth. On completion of the works, each grating shall be lifted
and the frame and seating cleaned.
509 (02/20) Testing and Cleaning

1 (02/20) Drains required in contract specific Appendix 5/1 to have watertight joints shall be tested as described in
contract specific Appendix 1/5 in sections, e.g. between chambers, by means of the air test described in sub-Clause
2 of this Clause. If a pipeline is rejected because of a failed air test, as part of the rectification work, a water test as
described in sub-Clause 3 of this Clause may be carried out as an alternative compliance test. Before testing, the
ends of the pipeline to be tested, including those of short branches, shall be plugged and sealed.
2 (02/20) For the pipeline air test, air shall be pumped in by suitable means until a stable pressure of 100mm head
of water is indicated in a U-tube connected to the system. The air pressure shall not fall to less than 75mm head of
water during a period of 5 minutes without further pumping, after an initial period to allow stabilization. Drains
with traps shall be tested to 50mm head of water and the permissible loss shall then be no more than 13mm head of
water in 5 minutes without further pumping after the initial stabilising period.
3 (02/20) For the pipeline water test, the pipes shall be filled with water under a head of not less than 1.2m above
the crown of the pipe at the high end and not more than 6m above the pipe at the low end. Steeply graded pipelines
shall be tested in sections so that the above maximum is not exceeded. The test shall commence not less than two
hours after filling the test section at which time the level of water at the vertical feed pipe shall be made up to
produce the required 1.2m minimum test head. The loss of water over a 30 minute period shall be measured by
adding water at regular 10 minute intervals to restore the original water level and recording the amounts so added.
The drain will have passed the test if the volume of water added does not exceed one litre per hour per linear metre
of drain per metre of nominal internal diameter.
4 (02/20) All pipelines less than 350mm diameter, excluding service ducts shall be checked by drawing through
each completed length of pipe a spherical mandrel of a diameter 10% less than the nominal bore of the pipes being
tested.
5 (02/20) During the progress of the works all existing chambers, gullies and rodding eyes shall be kept clean and
free from obstruction. On completion of the whole of the works, all chambers, gullies and drains including verge/
surface water drains and filter drains but excluding all fin and narrow filter drains shall be flushed from end to end
with water and left free from obstructions and silt. Catchpit chambers shall be left clean and free from silt.

Volume 1 Series 500
Unless otherwise required in contract specific Appendix 90/1 (MCHW 5.9.3) all carrier, foul and filter drains but
excluding all fin and narrow filter drains shall be surveyed by Closed Circuit Television (CCTV) in accordance
with the relevant requirements of Series 9000 (MCHW 5.9, Parts 1 to 5). Further guidance is provided in sub-
Clauses NG 509.4 and NG 509.5.
6 (02/20) The pipes and filter material of filter drains shall at all times be left clean and free from silt and
obstruction.
7 (02/20) Where described in contract specific Appendix 1/5, samples of one or more partly watertight joints for
pipelines up to and including 900mm diameter shall be tested with a head of water kept level with the crown of the
pipe. The joint will not be accepted if the flow through the joint in litres per minute exceeds 20 times the square of
the nominal internal diameter of the pipe in metres.
8 (02/20) Permeability tests shall be as described in contract specific Appendix 5/1.
9 (02/20) Service ducts shall be checked by drawing a wooden mandrel, as shown on HCD Drawing Number I2,
through as the ducts are laid. Where a set has to be given to the line of ducts the wooden mandrel shall be replaced
by an iron mandrel 250mm long but of the same diameter as the wooden version.
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510 (02/20) Surface Water Channels and Drainage Channel Blocks
1 (02/20) Surface water channels and drainage channel blocks shall be constructed as described in contract
2 (02/20) Surface water channels shall comply with Clause 1103.
3 (02/20) Drainage channel blocks shall comply with Clause 1101. Pre-cast concrete channel blocks shall comply
with BS EN 1340. The declaration of performance shall be submitted to the Overseeing Organisation and it shall
demonstrate that the channel blocks meet the specification.
511 (02/20) Land Drains

1 (02/20) Existing land drains which are permanently severed by the works shall be located and connected into a
new drain, pipe or ditch all as described in contract specific Appendix 5/1. The lengths remaining within the works
shall be cleaned out from the new drain trench face as necessary. Any pipe disturbed by the works shall be re-laid
to ensure a free discharge into the new drain. Disused ends of intercepted land drains shall be adequately sealed
with ST2 concrete in compliance with Clause 2602.
2 (02/20) Where an existing land drain is exposed and severed by temporary trench excavation, the Contractor
shall mark the position of the drain and record it. The drain shall be diverted into an existing drain or watercourse.
Alternatively, the normal functioning of the drain shall be continued by the construction of a pipeline or channel
adequately supported across the excavation, until permanent restoration is made on the original line.
3 (02/20) The Contractor shall notify the Overseeing Organisation of any land drain which is blocked or is
otherwise defective when the drain is first exposed.
4 (02/20) Severed mole drains shall be led straight into new drains; alternatively they shall where required in
contract specific Appendix 5/1 be intercepted by the construction of a land drain. Where they have been disturbed
mole channels shall be cleaned out and filled locally with Type A filter material or as otherwise described in
512 (02/20) Backfilling to Pipe Bays and Verges on Bridges

1 (02/20) Unless otherwise described in contract specific Appendix 5/1, filling to pipe bays and verges on bridges
shall be well graded granular material not exceeding 20mm size containing not more than 3% of material passing
the 0.063mm sieve and with a uniformity coefficient of more than 5. It shall be laid and compacted in compliance
with sub-Clauses 505.11 and 12. The material shall meet the sulfate requirement described in sub-Clauses 503.4,
503.5, 505.9 and 505.10.

Volume 1 Series 500
513 (02/20) Permeable Backing to Earth Retaining Structures

1 (02/20) Unless otherwise described in contract specific Appendix 5/1, permeable backing shall consist of one of
the following materials except when the filling adjacent to the structure is selected cohesive material (Class 7A),
selected conditioned pulverised-fuel ash (Class 7B) or chalk:
(i) A minimum thickness of 300mm of granular material complying with the requirements of Clause 505
for Type A or Type C material and, in addition, satisfying the following criteria:
(a) Piping ratio, defined as
15 per cent size of the drainage material, <5
85 per cent size of the backfill material
(b) Permeability ratio, defined as
15 per cent size of the drainage material, <5
15 per cent size of the backfill material
where the per cent size of a material is the size of particle corresponding to the given per cent ordinate of the
particle size distribution graph.
(ii) Porous no-fines concrete, cast in situ 225mm thick complying with the requirements of Clause 2603.
(iii) Precast hollow concrete blocks complying with the BS EN 771-3 laid in stretcher bond with dry joints
in 225mm thick walling with holes vertical. The blocks shall have a declaration of performance for their
intended use which shall demonstrate that the blocks meet the specification.
2 (02/20) When the filling adjacent to the structure is selected cohesive material (Class 7A), selected conditioned
pulverised-fuel ash (Class 7B) or chalk, the permeable backing shall be a minimum thickness of 300mm of 0/4 or
0/2, CP or MP, sand complying with BS EN 12620 unless otherwise described in contract specific Appendix 5/1.
The sand shall have a declaration of performance for its intended use which shall demonstrate that it meets the
specification.
514 (02/20) Fin Drains

(02/20) General
1 (02/20) Fin drains shall comply with this Clause and the special requirements described in contract specific
Appendix 5/4.
The terms thickness, width, height and core shall have the meanings indicated on HCD Drawing Number F18
The term fin drain shall mean a planar geocomposite structure designed to perform the same function as a narrow
filter drain.
2 (02/20) Where fin drains are designed for lateral entry of water from one side only the requirements for flow
rates in sub-Clauses 4 and 5 of this Clause shall apply to the face or plane designed to admit or transmit water.
3 (02/20) The materials of which the drain is made shall be treated so that they are protected from the deleterious
effects of short term exposure to ultraviolet light, and shall be resistant to degradation by acids, alkalis, common
chemicals, bacteria, fungi and moulds occurring in soils and highway construction materials.
After exposure to ultraviolet light the Overseeing Organisation may require evidence that the materials still comply
with the requirements of this Clause. The drain shall be protected from damage and ultraviolet light and be labelled
to identify the grade and manufacturer or supplier. Where necessary, the side intended for entry of water and the
direction of in-plane flow shall be identified.
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Volume 1 Series 500
(02/20) Geotextile
4 (02/20) The geotextile shall:

(i) conform to BS EN 13252 and the details stated in contract specific Appendix 5/4, it shall have a
declaration of performance for its intended use, the declaration of performance shall demonstrate that
the geotextile meets the specification and shall be submitted to the Overseeing Organisation prior to the
commencement of fin drain work;
(ii) in both machine and cross-machine directions, sustain a tensile load of not less than 5.0kN/m at break
and have a minimum failure strain of 10% when determined in accordance with BS EN ISO 10319;
(iii) have a minimum static puncture resistance of 1200N when determined in accordance with
BS EN ISO 12236;
(iv) have a mean hole diameter < 40mm when tested to BS EN ISO 13433;
(v) have a size distribution of pore openings such that the apparent opening size O90 when determined in
accordance with BS EN ISO 12956 is as stated in contract specific Appendix 5/4; and,
(vi) have water permeability characteristics as stated in contract specific Appendix 5/4.
(02/20) Composite Drain
5 (02/20) Where a composite drain is installed in an existing drain the following steps shall be undertaken:
(i) removal of approximately 400mm depth of media from the drain;
(ii) positioning of a non-woven geotextile over the exposed media;
(iii) placement and compaction of sub-soil in compliance with Class 4 material (see Table 6/1) to form a
V-channel profile;
(iv) placement of 35mm to 50mm of topsoil.
The maximum depth from the top of the topsoil to the channel invert shall be 200mm.
To ensure the grass roots get air as well as water after compaction, the subsoil shall be non cohesive and have a
permeability in excess of 10-4m/s as tested in accordance with HA 41.
6 (02/20) The composite drain shall:
(i) have a flow rate through each face of the drain of more than 75% of the value specified in sub-Clause
4(v) of this Clause on the side or sides where inflow occurs. This value may be found by either:
(a) direct measurement of the composite drain using a modified version of BS 6906: Part 3; or,
(b) calculation based on the flow rate obtained by the standard test in BS 6906: Part 3 and the
percentage contact area of the drainage core obtained from sub-Clause 13 of this Clause or other
appropriate method;
(ii) have values of long term in-plane flow rates as stated in contract specific Appendix 5/4 when determined
in accordance with sub-Clauses 14 and 15 of this Clause. The values of hydraulic gradient and
minimum applied stresses shall be as given in Table 5/7.

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Volume 1 Series 500
TABLE 5/7: (02/20) Applied Stresses (kN/m²) and Hydraulic Gradient
HCD Drain Type 5 6 7 10

Sub-Clause 15:
Normal Stress 50 50 50 100
Shear Stress 10 10 10 10
Sub-Clause 16:
100 100 100 100
Normal Stress
Sub-Clause 16:
Hydraulic 0.1 1.0 1.0 0.1
Gradient 1.0 1.0
(02/20) Joints
7 (02/20) Fin drains shall be capable of being jointed longitudinally or laterally into pipe systems or chambers for
inflow and outflow purposes and be self jointing either directly or through purpose made attachment pieces for
forming continuous drain lengths. All such joints shall be formed so as to prevent the ingress of soil particles or
other extraneous material into the drain.
Fin drain joints transverse to the direction of flow shall have values of in-plane flow rates not less than that required
by sub-Clause 5(ii) of this Clause.
Fin drain joints parallel to the direction of flow and any exposed edges shall be protected from the ingress of soil by
a geotextile wrapping with a minimum overlap of 150mm.
(02/20) Pipes
8 (02/20) For drain Type 6 pipes shall be perforated or porous and comply with sub-Clause 501.3.
For drain Type 7 pipes shall be unperforated thermoplastics pipe complying with Clause 518 slotted longitudinally
along the top surface and stress relief treated (if required) in accordance with the system manufacturer’s
specification.
9 (02/20) Pipe joints shall comply with the requirements of the relevant British Standard for the pipe used or
Clause 518.
(02/20) Backfill and Surround Material
10 (02/20) Pipe surround material for drain Types 6 and 7 shall comply with sub-Clause 503.3(i) or 503.3(ii) or
Type A or C material complying with sub-Clause 505.3.
Where fin drains are installed in a trench backfill material shall be the original as-dug material from the trench
unless otherwise specified in contract specific Appendix 5/4.
(02/20) Dimensions
11 (02/20) Unless otherwise described in contract specific Appendix 5/4 the dimensions of the fin drain shall be as
shown on HCD Drawings F18 and F21. The pipe diameter shall be as stated in contract specific Appendix 5/4.
The drain slope angle (x), as shown on Drawing F19, shall be not greater than 15% from the vertical unless
otherwise stated in contract specific Appendix 5/4.
(02/20) Installation and Handling
12 (02/20) Installation of fin drains shall be as shown on HCD Drawing Numbers F19 to F21. Where fin drains are
assembled on site the assembly area shall be clean and dry and free of wind-borne pollutants. Any material which
becomes contaminated must be replaced. No geotextile or core material shall be exposed to daylight (or any source
of ultraviolet radiation) for a period exceeding a cumulative total of 50 hours. Any geotextile or core material
exposed to daylight (or any source of ultraviolet light) for a period exceeding a cumulative total of 50 hours shall
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be replaced unless it can be demonstrated that the materials of the drain still comply with the requirements of this
Clause.

Volume 1 Series 500
Where fin drains are laid in trench, the trench bottom shall be free of irregularities and to the required levels given
in contract specific Appendix 5/4. Rock and other hard protuberances shall be removed and any excess cut in the
trench bottom filled and compacted back to the required grade with suitable excavated or imported material.
The drain shall be laid with the appropriate face against the side of the trench adjacent to the carriageway and in the
appropriate direction. This side of the trench shall have walls sufficiently clean to enable the fin drain to come into
close contact with the wall when the trench is backfilled and compacted. Compaction shall be in accordance with
Clause 612. Fin drains installed as part of the works shall be protected from surface water, contamination, and
accidental damage during construction.
The fin drain, pipe surround and backfill shall be installed so as to cause no damage to the fin drain. Where any
damage does occur, the damaged materials shall be replaced by new material.
After the installation of the fin drain has been completed a marker tape shall be laid approximately 75mm above the
fin drain in the position shown on HCD Drawing Numbers F19 and F20. The tapes shall be green self-coloured
PVC or polythene plastic not less than 0.1mm thick and 150mm wide.
(02/20) Identification
13 (02/20) The Contractor shall obtain and make available the following information for each separate consignment
of fin drain delivered to site:
(i) geotextile declaration of performance;
(ii) core name, grade/number and mass per unit area;
(iii) names and addresses of system producer core and pipe manufacturers;
(iv) manufacturing characteristics and constituents of core. This shall include composition and type of
constituent filaments, threads, fibres, films, tapes and other components;
(v) consignment number and delivery date; and,
(vi) a copy of the site delivery note.
(02/20) Test Method for the Percentage Contact Area of Drainage Core
14 (i) (02/20) The test determines the area of one face of a drainage core which will be in contact with a geotextile
filter as a percentage;
(ii) The apparatus required is as follows:
(a) loading device able to apply a compressive load of at least 2kN and having a flat steel base;
(b) flat steel loading plate 200mm x 200mm;
(c) printers ink and roller (or pad);
(d) sheet of thin compressible rubber; and,
(e) planimeter.
(iii) The test procedure shall be as follows. Cut three representative test specimens 200mm x 200mm
(±2mm). Apply ink to one 200mm x 200mm face of a specimen and cover with a sheet of plain
paper and a thin compressible rubber sheet. Place the prepared specimen in to the loading device and
gradually apply the load of 2kN and maintain for 5 minutes. Release the load and remove the specimen
and separate it from the paper. Using the planimeter find the total area of the paper which has received
an imprint. Repeat for all specimens;

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Volume 1 Series 500
(iv) The percentage contact area =

total area of imprint x 100
area of test specimen
(v) The report shall include:
(a) a reference to this method;
(b) sample identification details;
(c) individual and mean percentage contact areas; and,
(d) details of any deviation from the specified test procedure.
(vi) Alternative methods of determining the percentage contact area may be employed with the prior
approval of the Overseeing Organisation.
(02/20) Test Method for Determining the Thickness of Fin Drains Under Specified Normal and Shear Stresses
15 (i) (02/20) The test determines the thickness of the fin drain under sustained normal and shear stresses. A long
term thickness (at 100,000 hours) is calculated by extrapolation and a short term equivalent normal load which
produces the long term thickness is determined.
(ii) The apparatus required is as follows:
(a) a suitable compression testing machine, which shall have a vertical travel at least the nominal
thickness of the specimen. It shall be capable of sustaining the necessary loads to within
1% accuracy for the duration of the test;
(b) the compression testing apparatus, which shall include a fixed base plate and parallel moveable
top plate with flat steel surface with sufficient friction to permit the development of the required
shear forces;
(c) a means of measuring the mean thickness of the specimen to an accuracy of 0.01mm.
As an alternative to (a) and (b), an appropriate inclined plane and kentledge system may be employed to
produce the normal and shear loads.
The test procedure shall be as follows:
(iii) Cut six representative specimens of minimum size 100mm x 100mm symmetrically about the core
design. Three specimens shall be tested in accordance with (v) below and three in accordance with (vi)
below;
(iv) The test specimen shall be placed symmetrically on the base plate and covered by the top plate. The
means of measuring thickness shall be attached and the initial thickness measured;
(v) Apply the load smoothly and as quickly as possible to the top plate. The full load (normal and shear)
shall be applied in less than 20 seconds and sustained for at least 1000 hours. The applied stresses shall
be those given in Table 5/7. At least four measurements of thickness shall be made during each unit
of logarithmic time after the first minute. Determine the long term thickness of the specimen as the
thickness of the specimen at 1000 hours reduced by 2T where T is the difference in thicknesses of the
specimen thickness recorded at 100 hours and 1000 hours. Repeat the test on the two other specimens.
The test specimens shall be maintained at a constant temperature of 20°C ± 2°C throughout the test
period.
(vi) Apply increasing increments of normal load to the specimen. Determine the short term equivalent load
which shall be the load which when applied for a period of 20±5 minutes produces a specimen thickness
equal (within an accuracy of ±0.05mm) to the long term thickness of the specimen obtained at (v) above.
Repeat the test on the other two specimens.

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Volume 1 Series 500
(vii) The report shall include:

(a) a reference to this method;
(b) sample identification details;
(c) the initial thickness of the sample;
(d) the applied load;
(e) the thickness of each sample at 100 and 1000 hours and the mean of the three results;
(f) a plot of percentage reduction in thickness against logarithmic time;
(g) the mean long term thickness;
(h) the mean short term equivalent load; and,
(i) any deviations from the specified test procedure.
(02/20) Determining In-plane Flow Under Compressive Loading
16 (02/20) In-plane flow shall be determined in accordance with BS 6906: Part 7 except that the following
conditions shall apply:
(i) the applied normal stress shall be the greater of the value given in Table 5/7 (for sub-Clause 16) or the
mean short term equivalent stress as determined in sub-Clause 15 (vi) of this Clause;
(ii) the sample shall be tested such that the measured flow (or flows) is in the same direction as the principal
flow (or flows) when the fin drain is in service;
(iii) the foam rubber option of the test procedure shall be used (details of the foam rubber to be used may be
obtained from the Overseeing Organisation); and,
(iv) the hydraulic transmissivity shall be reported for each of the hydraulic gradients employed.
(02/20) Test Methods
17 (02/20) Notwithstanding the requirements of sub-Clauses 14, 15 and 16 of this Clause, variations in the test
methods specified therein shall be made where deemed necessary by the British Board of Agrément (or equivalent)
following consultation with the manufacturer. All such variations shall be recorded in the report.
(02/20) Certification
18 (02/20) Fin drains and constituent materials, other than the geotextile and aggregates, shall have current product
acceptance scheme certification in accordance with sub-Clauses 104.15 and 104.16 certifying the appropriate
physical properties when tested in accordance with this Clause.
515 (02/20) Narrow Filter Drains

(02/20) General
1 (02/20) Narrow filter drains shall comply with this Clause and the special requirements described in contract
The term narrow filter drain refers to drain Types 8 or 9 indicated in the HCD Drawing Number F18. They consist
of a porous or perforated pipe laid in a narrow trench surrounded by granular material where the granular material
and/or the pipe is enclosed by a layer of geotextile filter. Narrow filter drains and fin drains perform the same
function.

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Volume 1 Series 500
(02/20) Materials
2 (02/20) The materials used in the drain shall be stored so that they are protected from the deleterious effects of
short term exposure to ultraviolet light, and shall be resistant to degradation by acids, alkalis, common chemicals,
bacteria, fungi and moulds occurring in soils and highway construction materials. After exposure to ultraviolet
light the Overseeing Organisation may require evidence that the materials still comply with the requirements of this
Clause. They shall be protected from damage and ultraviolet light and be labelled to identify the grade and
manufacturer or supplier.
3 (02/20) The geotextile used in narrow filter drains shall comply with all requirements of sub-Clause 514.4 for
geotextiles used in fin drains.
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For drain Type 8 the geotextile surround to the pipe shall consist of a prefabricated continuous close fitting sock.
Alternatively the pipe shall be firmly wrapped in a single layer of geotextile with an overlap of between 50 and
75mm and secured around the pipe in a manner so as to prevent the ingress of soil particles or other extraneous
material and without affecting the permeability of the wrapped material. Splices between lengths of sock or layer
shall have overlaps within these dimensions and be securely tied.
For drain Type 9 the geotextile surround to the granular material shall have a minimum overlap of 250mm
including 100mm down-tuck. Splicing of lengths of geotextile shall consist of minimum 600mm overlap secured
with pins or mechanical ties. Where an outlet pipe passes through the geotextile a separate piece of geotextile shall
be wrapped round the outlet pipe, flared against the geotextile in the filter drain and secured. Where drain lengths
are terminated at chambers, the geotextile shall be secured against the chamber walls by suitable means so as to
prevent the ingress of soil particles or other extraneous material into the drain.
4 (02/20) Pipes and fittings shall comply with sub- Clauses 514.8 and 514.9. Where coilable pipes are used they
shall be capable of being straightened so as to lie flat without restraint in the trench bottom before backfilling.
5 (02/20) The granular material used for trench infill shall comply with the requirements for non-plasticity, LA
category and sulfate content of sub-Clause 505.8 and have a grading within the limits of Table 5/8. The material
shall meet the permeability requirements described in contract specific Appendix 5/4.
TABLE 5/8: (02/20) Narrow Filter Drain: Trench Infill Grading Requirements
Type 8 Type 9
Standard BS EN 13242 BS EN 13242
Size, mm 1/20 10/40
Grading GC 80-20 GC 85-15
Aggregate Coarse Coarse
Category for tolerances at
as stated in contract specific Appendix 5/4 as stated in contract specific Appendix 5/4
mid-size sieves
Category for maximum fines f2 f2
Additional requirements d/8 d/80
0-3% passing by mass 0-3% passing by mass
(02/20) Dimensions
6 (02/20) Unless otherwise described in contract specific Appendix 5/4 the dimensions of the narrow filter drain
shall be as shown on HCD Drawing No. F18. The pipe diameter shall be as stated in contract specific Appendix
5/4. The drain slope angle (x), as shown on Drawing F20, shall be not greater than 15% from the vertical unless

Volume 1 Series 500

7 (02/20) Narrow filter drains shall be installed as shown on HCD Drawing Number F20. Before during and after
installation the geotextile shall be protected from contamination, damage and exposure to ultraviolet radiation in
accordance with sub-Clause 514.12.
(02/20) The excavated trench bottom shall be free of irregularities and to the required levels given in contract
specific Appendix 5/4. Rock and other hard protuberances shall be removed and any excess cut in the trench
bottom filled and compacted back to the required grade with suitable excavated or imported material. Drain Type 9
shall have trench walls sufficiently clean to enable the geotextile to come into close contact with the wall when the
granular material is placed inside it. The deposition and compaction of infill shall be in accordance with sub-
Clause 505.4 for filter drains.
(02/20) Narrowfilter drains installed as part of the works shall not be used for the disposal of surface water run-off
during construction. Narrow filter drains exposed to surface water ingress shall be temporarily protected.
(02/20) Marker tapes shall conform and be installed in accordance with sub-Clause 514.12.
8 (02/20) The Contractor shall obtain and make available the information required in sub-Clause 514.13 in respect
of the geotextile and pipe.
516 (02/20) Combined Drainage and Kerb Systems

(02/20) General
1 (02/20) Combined drainage and kerb systems listed in contract specific Appendix 1/10 shall be treated as
features to be designed by the Contractor. Combined drainage and kerb systems shall conform to BS EN 1433 and
to the special requirements in contract specific Appendix 5/5.
2 (02/20) Combined drainage and kerb systems shall be suitable for their intended use and place of installation in
the works and as stated in contract specific Appendix 5/1. The Contractor shall provide a declaration of
performance for each type of combined drainage and kerb system proposed to the Overseeing Organisation prior to
the commencement of drainage works. The declaration(s) of performance shall demonstrate that the system(s)
meet the requirements of the specification.
3 (02/20) Design flows given in contract specific Appendix 5/5 shall be accommodated without surcharge within
the main combined drainage and kerb section and beneath the underside of any inlet slot sections.
4 (02/20) Where applicable, the width and depth of combined drainage and kerb system units shall not exceed the
dimensions given in contract specific Appendix 5/5.
5 (02/20) When used adjacent to pervious surfacing materials, units shall incorporate side entry inlets to permit
drainage of water held within the pervious surfacing. Inlets shall comply with the requirements of contract specific
Appendix 5/5 and shall have the capacity to drain pervious surfacing.
(02/20) Classification
6 (02/20) Combined drainage and kerb systems, excluding in situ system, shall be classified as follows according
to their intended use and shall be as stated in contract specific Appendix 5/5:
(i) C 250:
(ii) D 400; and
(iii) where, exceptionally, combined kerb and drainage units have to be located in areas subjected to large
numbers of high speed heavy goods vehicles, Class E600 combined kerb and drainage units shall be
considered.

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(02/20) Water Tightness
7 (02/20) Joints between units comprising the system and between the channel and units, shall be designed to
avoid leakage of surface water. Joints between bridge deck waterproofing and component parts passing through the
waterproofing shall be watertight. Sealants shall be compatible with the waterproofing system.
8 (02/20) Combined drainage and kerb systems shall be laid and jointed in accordance with the manufacturer’s
instructions.
9 (02/20) Adjacent carriageway, footway, verge or central reserve to bedding, backing, surrounding or jointing of
combined drainage and kerb units shall be in accordance with the manufacturer’s instructions.
10 (02/20) Junctions, connecting pipes and other fittings comprising the combined drainage and kerb system shall
comply with sub-Clause 501.3 and shall be as described in contract specific Appendix 5/5. The combined drainage
and kerb system shall incorporate measures to enable rodding of the outfall pipework and adequate access for
jetting by water jetting equipment into the system.
(02/20) Cleaning
11 (02/20) Combined drainage and kerb systems shall be cleaned out by appropriate means and shall be left clean
and free from all obstruction. The completed combined drainage and kerb systems shall be surveyed in accordance
with the relevant requirements in contract specific Appendix 5/5.
517 (02/20) Linear Drainage Channel Systems

(02/20) General
1 (02/20) The linear drainage channel systems listed in contract specific Appendix 1/10 shall be treated as features
to be designed by the Contractor and shall conform with requirements stated in contract specific Appendices 1/10
and 5/6. In situ linear drainage channel systems shall conform, where applicable, to sub-Clauses 517.2 to 517.17.
Prefabricated, or manufactured, linear drainage channel systems shall conform to BS EN 1433.
2 (02/20) Linear drainage channel systems shall be suitable for their intended use and place of installation in the
works. The Contractor shall provide evidence of such suitability for the purpose to the Overseeing Organisation.
For prefabricated or manufactured linear drainage systems this shall be the declaration of performance. The
declaration of performance shall demonstrate that the linear drainage system meets the requirements of the
specification.
3 (02/20) Design flows given in contract specific Appendix 5/6 shall be accommodated without surcharge within
the main channel section and beneath the underside of any inlet slot sections.
4 (02/20) Where applicable, the width and depth of linear drainage channel system units shall not exceed the
dimensions given in contract specific Appendix 5/6.
5 (02/20) Dimensions of inlet slots shall comply with the following criteria:
(i) for prefabricated linear drainage channel systems they shall conform to BS EN 1433; and,
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(ii) for in situ linear drainage channel systems they shall conform to BS EN 1433.
6 (02/20) When used adjacent to porous asphalt surfacing materials, units shall also incorporate side entry inlets to
permit drainage of water held within the porous asphalt. Inlets shall comply with the requirements of contract
specific Appendix 5/6 and shall have the capacity to drain porous asphalt.
(02/20) Weathering Resistance
7 (02/20) Marking relating to the grade of weathering resistance for drainage channels made of concrete shall be
as stated in contract specific Appendix 5/6.

Volume 1 Series 500
(02/20) Classification
8 (02/20) Linear drainage channel systems shall be classified as follows according to their intended use and shall
be as stated in contract specific Appendix 5/6:
(i) C 250;
(ii) D 400; and
(iii) where, exceptionally, linear drainage channel systems have to be located in areas subjected to large
numbers of high speed heavy goods vehicles, Class E600 combined kerb and drainage units shall be
considered.
(02/20) Water Tightness
9 (02/20) Joints between units comprising the system and between adjacent construction and the system shall be
designed to avoid leakage of surface water. Where applicable, joints between bridge deck waterproofing and
component parts passing through the waterproofing shall be watertight. Sealants shall also be compatible with the
waterproofing system.
10 (02/20) Junctions, connecting pipes and other fittings comprising the linear drainage channel system shall
comply with sub-Clause 501.3 and shall be as described in contract specific Appendix 5/6. The linear drainage
channel system shall incorporate measures to enable rodding of the outfall pipework and adequate access for jetting
by water jetting equipment into the system.
(02/20) Cleaning
11 (02/20) The linear drainage channel systems shall be cleaned out by appropriate means and shall be left clean
and free from all obstruction on completion of the works. The completed linear drainage channel systems shall be
surveyed in accordance with requirements stated in contract specific Appendix 5/6.
(02/20) In Situ Systems
12 (02/20) In situ systems shall comply with the requirements of sub-Clauses 1103.1, 1103.3 and 1103.4. They
shall also comply with the requirements of sub-Clause 1103.2 except that the concrete shall be considered as plain
concrete within the terms of this sub-Clause, irrespective of the inclusion of reinforcement.
13 (02/20) In situ systems shall be slip formed except for sections at gullies which shall be hand formed. Full depth
joints shall be constructed at the interface at each side of gullies with a 25mm thick filler board complying with
Clause 1015 and sealed in accordance with Clauses 1016 and 1017.
14 (02/20) The central void may be formed by an inflated tube which is then removed, or by an in situ suitable pipe
or similar former fit for the purpose. At gully positions the inner former shall be pre-sleeved with a suitable pipe or
similar former fit for the purpose which shall be of sufficient length to overlap the two joints on either side of the
gully.
15 (02/20) The central void shall be checked in accordance with sub-Clause 509.4. Verification of slot widths shall
be determined by suitable templates.
16 (02/20) Reinforcement shall comply with Series 1700. Cover to reinforcement shall be not less than 75mm.
17 (02/20) Trial lengths and testing of in situ channels shall be undertaken in accordance with contract specific
Appendix 1/5 and clauses 6 and 8.6 of BS 5931 and the relevant paragraphs of clause 9 of BS EN 1433
respectively.

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Volume 1 Series 500
518 (02/20) Thermoplastics Structured Wall Pipes and Fittings

(02/20) General
1 (02/20) Thermoplastics structured wall pipe shall comply with this Clause and the special requirements
described in contract specific Appendix 5/1. The term structured wall pipe shall mean all types of smooth bore pipe
except solid wall homogeneous pipe. Typical forms of construction classified as structured wall pipes include:
single wall externally structured smooth bore, twin wall, foamed core and spirally wound.
The term fitting shall mean a product used in conjunction with the pipe to form the system but excluding gullies
manhole chambers, inspection chambers and access chambers.
(02/20) Materials
2 (02/20) The materials from which the pipe and fittings are made, shall be treated so that they are protected from
the deleterious effects of short term exposure to ultraviolet light, and shall be resistant to degradation by acids,
alkalis, common chemicals, bacteria, fungi and moulds occurring in soil, highway construction materials and
highway drainage systems. In addition, the materials from which the pipe and fittings are made, shall not
incorporate any additives in quantities sufficient to cause microbiological degradation or to impair the conformity
to the chemical, physical and mechanical properties or impact resistance requirements given in sub-Clause 5 of this
Clause. The specification of the raw material shall be agreed between the certification body, as defined in sub-
Clause 15 of this Clause, and the manufacturer and may incorporate re-processable and/or recyclable material.
The agreed specification shall incorporate tolerances for each of the relevant characteristics defined in the
appropriate clause of BS EN 13476. The Contractor shall submit to the Overseeing Organisation, prior to
commencement of the works, completed information sheets in accordance with contract specific Appendix 5/7.
(02/20) Dimensions
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3 (02/20) Systems for carrier drainage shall be between 150mm and 900mm nominal internal diameter. Pipes for
narrow filter drains shall be 110mm or 150mm nominal internal diameter. Pipes for service ducts shall have
nominal internal diameters of between 50mm and 150mm. Pipes for sub-soil drainage shall incorporate slots or
holes with a minimum cross sectional area of 1000mm2 per metre run of pipe.
The bore of the pipe and fittings shall be in accordance with the standard tolerances for nominal bores given in
BS EN 476.
(02/20) Appearance
4 (02/20) The system shall have a smooth bore and be free from any burs, flash or other inconsistencies that could
have a detrimental effect on the performance of the system. Pipes and fittings for drainage shall be externally
coloured either terracotta or black. The colour of ducting pipes shall be in accordance with National Joint Utilities
Group publication “Guidelines on the Positioning and Colour Coding of Utilities’ Apparatus”. Any variation in the
colour shall be described in contract specific Appendix 5/2.
(02/20) Structured Wall Pipe
5 (02/20) The structured wall pipe shall have the properties defined in Table 5/9.

Volume 1 Series 500
TABLE 5/9: (02/20) Requirements for Structured Wall Pipe
Property Relevant Standard Requirement

General BS EN ISO 2897-1, Dimensions to be specified
BS EN ISO 2897-2 and
BS ISO 11922-1
Ring stiffness BS EN ISO 9969 6 kN/m2 minimum. Lower stiffness values are
permitted if design calculations to BS EN 1295-1 (UK
national annex), based on site specific installation
conditions, indicate satisfactory performance.)
Creep Ratio BS EN ISO 9967 PVC-U – maximum 2.5
PP and PE – maximum 4.0
High volume low pressure WRc Jetting Test Minimum acceptable failure pressure 137 bar.
jetting Method
Longitudinal bending sub-Clause 518.11 Pipes with nominal diameters ≤ 350 mm to have a
difference in dimensions when measured in the vertical
axis of less than 5% of the pipe length and no local
permanent deformation occurs during the test.
Impact resistance at 0ºC BS EN 1411 with d25 Preliminary test – test 10 pieces as described in BS EN
striker of 1 kg 1411, dropping the striker from a height of 1m.
If any test pieces fail, subject the pipe to the full test
given in clause 7.3 of BS EN 1411 starting the striker
from a drop height of 400 mm. The mean minus 1.64
times the standard deviation must exceed 1m.
Impact resistance at 23ºC BS EN 1411 with Value to be derived from the same batch of pipe as used
striker as above in the impact resistance test at 0°C. The H50 (mean)
value - 10% to be used as the minimum value for
quality control testing. Alternatively the 0°C test can be
used as a QC test if the manufacturer chooses.
Rodding resistance sub-Clause 518.12 Pipes with nominal diameters ≤ 350 mm to have an
average failure energy >3 joules
Static friction coefficient TS 12-24 Pass
(ducts)
Creep at elevated BS EN ISO 9967 Test to be carried out at 45ºC, creep ratio to be less than
temperature(ducts) 2 times the values to BS EN ISO 9967.
Resistance to point loads sub-Clause 518.13 No perforation at 10% rod travel
(ducts)
Tensile strength of a seam BS EN 1979 BS EN 13476

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(02/20) Fittings
6 (02/20) The fittings for use with structured wall pipe shall have the properties defined in Table 5/10.
TABLE 5/10: (02/20) Requirements for Fittings

General BS EN ISO 2897-1, Dimensions to be specified
BS EN ISO 2897-2 and
BS EN ISO 11922-1
Ring stiffness (excluding couplers) ISO 13967 6kN/m2 minimum
Rodding resistance sub-Clause 518.12 Fittings with nominal diameters ≤ 350 mm to have an
average failure energy >3 joules
Strength and flexibility of BS EN 12256 BS EN 12256
fabricated fittings
Impact resistance (drop test) Drop Test to BS EN Fall height 1000mm at a temperature of 0ºC. Product less
12061: 1999 than ND 300 shall show ‘no damage’. Others may fail but
must be identified as ‘handle with care’
Watertightness of fabricated fittings BS EN 1053 0.5 bar for 1 minute
(02/20) Pipe and Fittings

7 (02/20) The pipe and fittings shall have the properties defined in Table 5/11.
TABLE 5/11: (02/20) Requirements of the Systems

Leaktightness of joints – diameter BS EN 1277 Method 4 Use default values from BS EN 1277
distortion (watertight joints) Condition B Temperature
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(23 ± 2)°C
Leaktightness of joints – angular BS EN 1277 Method 4 Use default values from BS EN 1277
deflection (watertight joints) Condition C Temperature
(23 ± 2)°C
Leakage rate from partially- sub-Clause 509.7 Less than 20 times the square of the ID of the pipe in
watertight joints metres shall flow through the joint in litres per minute
Resistance to wheel loads BS EN 1437 adapted Less than 5% deformation when loaded to 100 kN (for
to suit HA loading unequal branches only)
conditions
(02/20) Bedding, Backfill and Surround Material

8 (02/20) All systems shall be installed in accordance with the pipe and bedding combinations given in CD 533
(DMRB 4.2.5). Other combinations shall be supported by calculations in accordance with BS EN 1295-1 UK
National Annex. Bedding, backfill and surround materials are classified in Clause 503 and Clause 505.
9 (02/20) The bedding, surround and backfill shall be installed so as to cause no damage to the pipes and fittings.
Installation of the pipe and fittings, particularly, procedures for preparation and execution of jointing operations,
shall be in accordance with the manufacturer’s instructions.

Volume 1 Series 500
(02/20) Identification
10 (02/20) The Contractor shall maintain records with the following information for each separate consignment of
structured wall pipe or fittings delivered to Site:
(i) system name, ring stiffness grade/number and size;
(ii) name and address of the system manufacturer;
(iii) consignment number and delivery date; and,
(iv) a copy of the site delivery note.
(02/20) Test Method for Longitudinal Bending
11 (i) (02/20) The
test specimen shall be a six metre length of pipe or the maximum length available from the
manufacturer (if less than six metres);
(ii) The apparatus shall include:
(a) two level support blocks at least 250mm wide and of sufficient height to allow the pipe to sag over
its length without touching the ground; and,
(b) a means of measuring the vertical distance between the pipe at the centre of the span and a fixed
point of reference to an accuracy of ±0.5mm.
(iii) The test procedure shall be as follows:
(a) condition the specimen for at least 1 hour at 23°C ± 2°C;
(b) set the supports at a distance apart equal to the length of pipe minus 500mm;
(c) place the pipe symmetrically on the supports;
(d) measure the distance between the top of the supports and the fixed point of reference, in the
vertical axis through the centre line of the pipe;
(e) after a period of two minutes measure the distance between the underside of the pipe at mid span
and the fixed point of reference; and,
(f) record the difference in readings as a percentage of pipe length.
(02/20) Test Method for Rodding Resistance (Internal Puncture)
12 (i) (02/20) The test specimens shall be:
(a) twenty specimens cut from the structured wall pipe, each specimen to be 242mm to 246mm in
length and a quarter section of the circumference; or,
(b) twenty specimens cut from a number of identical fittings.
(a) a standard drop weight pipe testing apparatus capable of dropping a tup from a height of 1m;
(b) a 300g tup which can be varied in 30g multiples with a striker consisting a steel rod 18mm in
diameter with a 9mm hemispherical end; and,
(c) a 250mm x 250mm box containing dry Leighton Buzzard sand (Garside quarry) such that there is
at least 100mm of sand beneath the test specimen when bedded down.

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(iii) Procedure shall be as follows:

(a) mark the intended point on the inside of the pipe on the intersection of the centre lines. With
profiled pipes the point of impact shall be at the point nearest the intersection that mid way
between the ribs or in the middle of a hollow corrugation;
(b) alternatively mark the intended point of impact on the section of fitting;
(c) condition the test specimens in air at a temperature of 4°C ± 2°C for a period of at least one hour
before the test;
(d) locate the box under the drop tube of the impact apparatus;
(e) embed the specimen into the sand using a vibrator with the inner surface exposed and facing
upwards;
(f) locate the specimen such that the marked point of impact is under the centre line of the tup;
(g) drop the tup from a height of 1m on to the inner surface of the specimen within 10 seconds of
removing the specimen from the conditioning environment;
(h) examine the specimen for damage. Damage is defined as a puncture or crack of the inner layer.
Ductile bending or “whitening” is not considered to be damage;
(i) if the specimen exhibits no damage the next test shall be conducted with a tup of 30g greater mass.
If the specimen does exhibit damage the next test shall be conducted using a tup of 30g smaller
mass; and,
(j) after having completed the 20 strikes calculate the average of the energies where a pass
(no damage) was recorded and the average of the energies where a failure (damage) was recorded,
then calculate the average of the two averages.
(iv) The test report shall include:
(a) identification of the samples;
(b) the overall average; and,
(c) whether or not the specimens were damaged.
(02/20) Test Method for Resistance to Sharp Objects
13 (i) (02/20) Test specimens shall be three samples of duct each 300mm long.
(a) a compression testing machine;
(b) a 4.7mm diameter steel rod with an hemispherical end;
(c) and a 120° steel vee block at least 300mm long.
(iii) The test method shall be as follows:
(a) condition the test specimens for at least 1 hour at 23°C ± 2°C;
(b) insert the steel rod in the jaws of the moveable platen of the compression testing machine so that
the hemispherical end protrudes at least 15% of the nominal pipe diameter;
(c) position the specimen in the vee block and place directly below the steel rod, for twin-walled
pipe the specimen shall be positioned firstly so that the rod strikes on the corrugation or rib, and
secondly in the valley (where possible);
(d) set the machine to lower at a rate of 5mm/min; and,
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(e) allow the rod to travel into the pipe a distance equal to 10% of the nominal internal diameter of the
pipe (T10 mm) or until the pipe wall is perforated. When the outer skin of a twin wall pipe is perforated
before 10% is attained, the rod travel up to the point of failure shall be recorded (Tf mm) and the rod
allowed to travel to the inner wall. The rod travel shall be continued to a total of 10% (ie T10 - Tf) or
until complete penetration occurs.
(iv) For each test specimen: pipe size, reference, maximum load and rod travel shall be recorded.
14 (02/20) Notwithstanding the requirements of sub-Clauses 11, 12 and 13 of this Clause, variations in the test
methods specified therein shall be made where deemed necessary by the British Board of Agrément (or equivalent)
following consultation with the manufacturer and in agreement with the Overseeing Organisation. All such
variations shall be recorded in the report.
(02/20) Certification
15 (02/20) Pipes and fittings shall have current product acceptance scheme certification in accordance with sub-
Clauses 104.15 and 104.16 certifying the appropriate physical properties when tested in accordance with this
Clause.
519 (02/20) Concrete Bagwork

1 (02/20) ST4 concrete in compliance with Clause 2602 shall be used throughout. The concrete filling to the bags
shall have a low workability with a slump of 25mm.
2 (02/20) The bags shall be hessian sand bags complying with BS 1214. The size of the bags shall be such that
when filled, the dimensions shall be 450mm x 300mm x 150mm. The bags shall be placed in position and shaped
to the profile shown on the drawings by striking with a flat timber board until all faces are flat and all edges square.
3 (02/20) The finished exposed faces of the bagwork shall not be punctured or torn and no tucked ends shall be
visible.
4 (02/20) Each concrete bag is to be spiked to the one below and the bottom row spiked to the foundation with
10mm x 200mm mild steel dowel bars. Where the concrete bags have a concrete backing, alternate rows of bags
shall be spiked to the backing concrete with 10mm x 200mm mild steel dowel bars at 45 degrees to the horizontal
with one dowel per bag in the row.
5 (02/20) Where bagwork forms a headwall, headwall foundations are to be cast against the excavated face and
any overdig filled with ST4 concrete.
6 (02/20) Formed concrete surfaces shall be to Class F1 finish and unformed surfaces to Class U1 finish in
accordance with Clause 1708.
7 (02/20) Where bagwork is provided to protect watercourses, before placing the bags, the banks shall be cut into
horizontal steps to provide a suitable foundation and shall be covered in geotextile to the requirements of Clause
609. The bottom course of bags shall be at least 450mm below the stream bed and all succeeding courses shall be
horizontal and all vertical joints shall be staggered in alternate courses. Headers shall be placed at every third bag
in alternate courses.
8 (02/20) The bagwork shall be thoroughly soaked with water upon completion of the construction to saturate the
hessian bags.
520 (02/20) The Cleaning of Existing Drainage Systems

1 (02/20) Where stated in contract specific Appendix 5/1, the Contractor shall clean existing drainage systems in
accordance with this Clause.
2 (02/20) The Contractor shall take measures when clearing blocked drains to ensure that adjacent water courses
or groundwater via soakaways, will not be contaminated. Contamination includes mud or soil being washed or
flushed into streams as well as other more obvious contaminants including diesel fuel, oil and chemicals.
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Volume 1 Series 500
3 (02/20) Initial attempts to clear blocked drains prior to jetting, shall be undertaken by hand rodding and any
debris and silt removed by the operation shall be removed off site. The Contractor shall report any localised
blockages that cannot be cleared by rodding to the Overseeing Organisation.
4 (02/20) Where jetting is required in contract specific Appendix 5/1 the procedures stated in Clause 521 shall be
followed.
(02/20) Cleaning of Gullies, Catchpits, Soakaways and Oil Separators
5 (02/20) At each chamber all mud and vegetation in the vicinity of the chamber likely to impede the flow of
water shall be removed. After lifting the cover or grating the chamber shall be cleansed of all water, detritus, debris
and silt, refilled with clean water to the outlet level, and all covers and gratings replaced and evenly bedded.
6 (02/20) Cleaning of chambers shall be by mechanical means. The vehicle used to clean existing chambers shall
be equipped with a 125mm dia gulley arm with boom jets, an exhauster with a minimum output of 5.95cum/min
and minimum 5455 litres capacity. Sediment, detritus and liquor from the chamber shall not be permitted to
discharge into the outlet. This may be achieved either by plugging the outlet during cleaning, or by simultaneous
jetting and abstraction of liquor from the chamber using a tanker fitted with low pressure high volume water jets
around the boom.
7 (02/20) Gullies and chambers not cleaned for whatever reason, blocked connections and broken or cracked
covers, gratings or frames shall be marked to aid subsequent identification.
8 (02/20) Oil separators shall be refilled with uncontaminated water following the cleaning operation.
9 (02/20) The Contractor shall dispose of all surplus water, debris and arisings from the works off site at a licensed
tip.
(02/20) Cleaning or Testing of Piped Drainage Systems and Subway Drainage Channels
10 (02/20) Routine cleaning or testing of piped drainage systems and subway drainage channels shall be carried out
by rodding or low pressure high volume jetting in accordance with Clause 521.
11 (02/20) The location of any obstruction that cannot be removed by flushing shall be marked on the ground using
a wooden peg or other semi-permanent means and reported to the Overseeing Organisation using the Routine
Maintenance Manual System (RMMS) referencing system in Part 3, Chapter 3.7.
12 (02/20) All covers which have been removed for cleaning operations shall be replaced and evenly bedded.
13 (02/20) The Contractor shall report any damage and defects to the drainage system or components to the
Overseeing Organisation each day, or immediately if considered a safety hazard.
(02/20) Cleaning Kerb or Channel Offlet Pipes
14 (02/20) Where necessary all vegetation and debris shall be removed from around metal kerb weirs and the cover
lifted for cleaning.
15 (02/20) Offlets shall be cleaned such that all silt and loose obstructions are removed from the pipe. This shall be
achieved by rodding or by using lorry-mounted drain clearance equipment comprising combination pressure jetting
with high air flow suction equipment. The vehicle shall also be equipped with a hydraulically powered grid lifter.
16 (02/20) The Contractor shall ensure that each end of the offlet is free from vegetation or other obstructions
including any material expelled from the pipe. Where the invert of the outlet is below the invert of the ditch, the
bottom of the ditch shall be excavated until the invert of the pipe is exposed and the ditch invert regraded to
facilitate flow from the outlet.
17 (02/20) The location of any obstruction that cannot be removed shall be marked on the ground using a wooden
peg or other semi-permanent means and reported to the Overseeing Organisation.
18 (02/20) All covers lifted for cleaning operations shall be replaced and evenly bedded.

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Volume 1 Series 500
(02/20) Cleaning of Bridge Drainage Systems

19 (02/20) Cleaning of bridge bearing shelves, subway sumps, grit chambers and other bridge drainage systems
shall be carried out by one of the following methods:
(i) vacuum/air suction having the ability to remove materials from depths of up to 9.0m with a suction
facility capable of displacing 55m³/min of air at 95% vacuum;
(ii) low pressure high volume jetting in accordance with Clause 521; and,
(iii) sweeping.
20 (02/20) All adjacent surfaces of the structure shall be protected to prevent staining by arisings from the cleaning
operation. All arisings shall be taken off site.
21 (02/20) The Contractor shall report to the Overseeing Organisation any damage or defects to the bridge drainage
system.
521 (02/20) Low Pressure High Volume Jetting of Drainage Systems

1 (02/20) Where stated in contract specific Appendix 5/1, the Contractor shall clean existing drainage systems in
accordance with this Clause.
2 (02/20) The drainage systems to be cleaned shall be as detailed in the contract specific Appendix 5/1.
3 (02/20) The pipe material of the drainage systems to be cleaned shall be identified in contract specific
Appendix 5/1. Where the material is unknown and cannot be verified by either visual inspection, without recourse
to man-entry, or from drainage records, or damage to the pipeline is the suspected cause of a blockage, cleaning
shall proceed on the basis of use of the lowest pump pressure stated in Table 5/12.
4 (02/20) Where the cleaning forms part of the pre-cleansing works for the CCTV survey of drainage systems, the
works shall be detailed in contract specific Appendix 90/1 (see Model Contract Documents for CCTV Survey of
Highway Drainage, (MCHW 5.9.3)).
(02/20) Jetting of Piped Drainage Systems
5 (02/20) Cleaning shall take place from downstream of the blockage in an upstream direction. The pipe shall be
plugged below the jetting point to prevent contaminants flowing to the watercourse. The cleaning shall take place
from a chamber, although it may be necessary to make a temporary excavation into the pipeline in some
circumstances.
6 (02/20) Should the Contractor find that it is not possible to jet in an upstream direction, then the pipe shall be
plugged below the blockage and the jetter then used to “back jet” to a suction hose.
TABLE 5/12: (02/20) Maximum Recommended Pump Pressures
Material Maximum pump pressure (bar/psi)

Unknown/structurally damaged 80/1200
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Brick/masonry 100/1500
Plastics – Structural Wall 127/1900
Plastics – Solid Wall 127/1900
Concrete 340/5000
Clay 340/5000
7 (02/20) The Contractor shall select a jethead that is appropriate for delivering the maximum jetting pressure for
the pipe material and also the minimum volume of water for the appropriate pipe diameter stated in Table 5/13.
8 (02/20) The jet head shall be of a configuration such that the number and direction of jets are adequate to be
directed to the sides and soffit of the pipeline to prevent debris passing over the top of the jetting head.

Volume 1 Series 500
TABLE 5/13: (02/20) Minimum Jetting Flow Rates
Pipe Diameter Minimum jetting flows

<230 mm 156 l/m
450 mm 270 l/m
900 mm 300 l/m
1600 mm 342 l/m
9 (02/20) The Contractor shall provide suitable jetting equipment that shall include the provision of the following:
(i) operation at a maximum rate of 850 l/min at 150 bar/2250 psi;
(ii) liquid ring vacuum pump operating with air flows of 4000m3 per hour, with a working vacuum of not
less than 90%;
(iii) a minimum of 20m of 100mm diameter suction hose for cleaning pipes up to 300mm diameter and
150mm diameter suction hose for cleaning pipes of diameter greater than 300mm;
(iv) minimum of 150m of 25mm or 38mm diameter jetting hose and a capability of jetting up to 200m;
(v) automatic and continuous water recycling; and,
(vi) silt, sand and rubble to be de-watered prior to discharge at licensed tip.
10 (02/20) The Contractor shall ensure that no damage occurs to the manhole chamber or pipeline during insertion
of the jetting equipment.
11 (02/20) The jetting head shall be propelled through or over the blockage and then the hose pulled backwards
enabling the force of the jet to break up the blockage material. The minimum force necessary to penetrate the
blockage shall be used but the pump pressures should not exceed those stated in Table 5/12.
12 (02/20) The hose shall be rewound at a rate of between 100mm and 200mm per second.
13 (02/20) There is a possibility that damage may occur to certain pipe materials should the jetting head remain
stationary thus the Contractor must ensure that the jetting head never remains stationary for more than 60 seconds.
14 (02/20) Where the presence of perforated pipes and porous concrete pipes in piped highway drainage systems is
discovered during the course of the works, the Overseeing Organisation shall be notified immediately and the
cleaning operation suspended for that section of the works.
(02/20) Cleaning of Linear Drainage Systems
15 (02/20) Where possible the Contractor shall clear blockages in linear drainage channels and combined kerb
drainage units by rodding.
16 (02/20) Where silt removal is necessitated, the use of pressure jetting will result in the loss of pressure through
the grating, slot or drainage holes together with the escape of silt and debris, unless the apertures can be temporarily
covered. The application of pressure shall be regulated such that there is only sufficient to drive the jetting head
across the silt to access remote from the point of entry.
17 (02/20) If necessary the jetting head shall be changed for one that can deliver the highest volume of water at low
pressure. The water pressure shall be sufficient to agitate the silt.
18 (02/20) The nozzle shall be drawn back to the point of entry at a rate of between 100mm and 200mm per
second.
(02/20) Silt Removal
19 (02/20) Suitable measures such as stanks or stoppers shall be positioned downstream of the drainage system to
be cleaned to minimise the risk of sediment causing contamination of watercourses or soakaways.
20 (02/20) Wherever practical the Contractor shall use equipment to carry debris over a greater depth than one
atmosphere and with a capability to suck liquid.

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21 (02/20) All arisings from the cleaning process shall be disposed of in an environmentally sensitive manner in
accordance with current legislation.
(02/20) Health and Safety
22 (02/20) The use of high pressure water can result in serious internal injuries that may not be apparent at the skin
surface.
23 (02/20) The Contractor shall ensure that all hoses are free from damage and that the equipment is in full working
order.
24 (02/20) Where overhead electric cables are present, there is a potential danger from accidental strike by a jet of
water.
522 (02/20) Vortex Separators

1 (02/20) Vortex separators shall be installed in accordance with the manufacturer’s requirements and
2 (02/20) The formation level of the vortex separator shall be blinded with ST1 concrete in accordance with Series
2600.
3 (02/20) The thickness of the concrete blinding shall be in accordance with the manufacturer’s requirements and
4 (02/20) Vortex separators shall have no moving parts.
5 (02/20) Internal components of the vortex separator shall be constructed from stainless steel and/or
polyethylene.
523 (02/20) Grassed Surface Water Channels

1 (02/20) For grassed surface water drainage channels a Type 5 or 6 fin drain in accordance with Clause 514
incorporating a double cuspated central impermeable core shall be installed at the edge of the pavement
construction and in accordance with contract specific Appendix 5/3.
2 (02/20) The double cuspated central core shall be made from polyethylene or polypropylene and in accordance
with Clause 514.
3 (02/20) The grassed surface water channel construction shall comprise of graded subsoil, a layer of topsoil and
sub-surface drainage.
4 (02/20) Prior to placing subsoil, the formation shall be ripped to a depth exceeding 150mm to provide a key
between the existing ground and subsoil layer.
5 (02/20) The subsoil shall be non cohesive.
6 (02/20) The subsoil shall be free from stones larger than 50mm.
7 (02/20) Where an impermeable membrane is required, the subsoil shall be free from flints.
8 (02/20) Subsoil shall be placed in layers, not exceeding 100mm thick and compacted in accordance with Table
6/4 using a vibrating plate compactor Ref No. 4 Method 1 or Ref No. 2 Method 3.
9 (02/20) The subsoil shall be shaped to the required channel cross sectional and longitudinal profiles stated in the
10 (02/20) Where stated in the contract specific Appendix 5/3, biodegradable geosynthetic reinforcement shall be
placed between the subsoil and topsoil layers to provide support until the grass becomes established.
11 (02/20) Fixings used to hold a geosynthetic in place shall not pierce the impermeable liner.

37
Volume 1 Series 500
12 (02/20) The surface material shall be topsoil class 5B in accordance with BS 3882 in contract specific Appendix
6/8 and the following:
(i) the topsoil texture shall be a sandy loam or loamy sand;
(ii) the topsoil shall have a pH greater than 5.5;
(iii) the topsoil depth shall be between 35mm and 50mm once compacted.
13 (02/20) Topsoil shall be compacted in accordance with Table 6/4 using a vibrating plate compactor Ref No. 4
Method 1 or Ref No. 2 Method 3 but the number of passes shall be reduced to two.
14 (02/20) A grassed surface water channel shall be seeded or lined with turf in accordance with this Clause.
15 (02/20) The steps for seedbed or turfbed preparation shall be:
(i) application of seedbed fertiliser at a ratio of 10:15:10 for N:P2O5:K2O at 30 g/m2; and,
(ii) final raking or harrowing before seeding, hydroseeding or turfing in accordance with contract specific
Appendix 5/3.
16 (02/20) Where turf is used, it shall be placed immediately after compaction of the topsoil to minimise the risk of
soil fines being washed away by surface runoff.
17 (02/20) Where turf is used, an allowance shall be made for its thickness when defining the finished level of the
topsoil.
524 (02/20) Combined Surface Water Channel and Pipe (Concrete)

1 (02/20) Combined channel and pipe sections shall be constructed in accordance with Clause 1103 and contract
2 (02/20) Combined surface water channel and pipe sections shall be in accordance with contract specific
Appendix 5/3.
3 (02/20) The maximum pipe size for unreinforced mass concrete combined channel and pipe sections with a
loading class of C250 and D400 shall be 300mm (Dmax), with a minimum vertical cover (Umin) of D/2, and a
minimum horizontal cover (Hcmin) of D/2.
4 (02/20) The maximum pipe size for light mesh reinforced concrete combined channel and pipe sections with a
loading class of D400, shall be 400mm (Dmax), with a minimum vertical cover (Umin) of D/2, and a minimum
horizontal cover (Hcmin) of D/2.
5 (02/20) Light mesh reinforcement is a welded mesh made of steel bars compliant with BS 4483 and contract
6 (02/20) Light mesh reinforcement shall be placed horizontally in the base of the combined channel and pipe
block such that the bars run parallel and perpendicular to the line of the pipe.
7 (02/20) For light mesh reinforced concrete combined channel and pipe sections the minimum area of steel
perpendicular to the longitudinal centre-line of the pipe shall be in accordance with contract specific Appendix 5/3.
8 (02/20) The maximum pipe size for heavier mesh reinforced concrete combined channel and pipe sections with
a loading class of D400, shall be 500mm (Dmax), with minimum vertical cover (Umin) of D/2, and a minimum
horizontal cover (Hcmin) of D/2.
9 (02/20) Heavier mesh reinforcement is a welded mesh made of steel bars compliant with BS 4483 and contract
10 (02/20) Heavier mesh reinforcement shall be placed horizontally in the base of the combined channel and pipe
block such that the bars run parallel and perpendicular to the line of the pipe.
11 (02/20) For heavier mesh reinforced concrete combined channel and pipe sections the minimum area of steel
perpendicular to the longitudinal centre-line of the pipe shall be in accordance with contract specific Appendix 5/3.
12 (02/20) For mesh reinforced concrete combined channel and pipe sections the ends of the bars shall be left flat.
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Volume 1 Series 500
525 (02/20) Reservoir Pavements

1 (02/20) If the use of reservoir pavements is proposed then the specification shall be submitted to the Overseeing
Organisation for approval prior to construction.
526 (02/20) Maintenance Plans for Soakaways

1 (02/20) The commissioning phase for soakaways shall be as described in contract specific Appendix 5/8.
2 (02/20) The routine inspections required to determine the rate of accumulation of sediment in soakaways and
pre-discharge treatment devices shall be as described in contract specific Appendix 5/8.
3 (02/20) Based on the routine inspections and minimum monitoring requirements contained in contract specific
Appendix 5/8, an asset specific inspection and maintenance plan shall be created for each soakaway. The ‘initial
management plan’ shall be the starting point for the asset specific inspection and maintenance plan.
4 (02/20) The asset specific inspection and maintenance plan shall specify the frequency for future:
(i) removal of debris from the floor of chamber and sediment traps (minimum annual frequency);
(ii) checking observation wells/inspection tubes for clogging;
(iii) checking that the soakaway is emptying;
(iv) inspecting the area around the soakaway for ground settlement or sediment loss;
(v) removal and washing of exposed stones on the trench surface; and,
(vi) trimming any roots that may be causing blockages.
5 (02/20) The inspection and maintenance plan(s) shall be submitted to the Overseeing Organisation to the
timetable stated in contract specific Appendix 5/8.
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ORGANISATION OF NORTHERN IRELAND
508NI (02/20) Gullies and Pipe Junctions

1 (02/20) Gullies shall be trapped, untrapped or sumpless as described in contract specific Appendix 5/1 and be in
accordance with HCD Drawing Numbers F13 and F14. All ST concrete referred to in this Clause shall comply
with Clause 2602 unless otherwise described in contract specific Appendix 5/1.
2 (02/20) Gullies shall be constructed so that no part of the spout or trap has a cross-sectional area less than 2/3rd
that of the outlet. The depth of water seal in trapped gullies shall be not less than 50mm.
3 (02/20) Precast concrete gullies and cover slabs shall comply with BS 5911-6 and clay gullies with BS EN 295.
In situ concrete gullies shall be as described in contract specific Appendix 5/1 and constructed of ST4 concrete of
150mm minimum thickness, using permanent or removable shuttering. Where in situ concrete gullies are formed
with permanent shuttering, such shuttering shall have current product acceptance scheme certification in
accordance with sub-Clauses 104.15 and 104.16. Precast rectangular section gullies shall be as described in
4 (02/20) Gully gratings, kerb type gully covers and frames shall comply with BS EN 124: 1994 and the following
and shall be of the classes and sizes described in contract specific Appendix 5/1.
5 (02/20) The upper surface of gully gratings shall be flat except where otherwise described in contract specific
Appendix 5/1. Slots in gratings or between gratings and frames shall not be orientated parallel to the direction of
traffic except where the slots are less than 150mm long or less than 20mm wide. Minimum waterway areas shall be
as specified in contract specific Appendix 5/1. Unless otherwise specified in contract specific Appendix 5/1, all
gratings and frames shall be supplied in a fine cast (uncoated) condition. Where a coating is specified in contract
specific Appendix 5/1, the coating shall only be applied when the surfaces of the casting are clean, free from rust
and dry. Gully gratings shall be laid parallel to and 6 mm below the finished road surface. Hinged gratings shall be
orientated to close in the direction of traffic flow. Frames shall be bedded on mortar complying with sub-Clause
507.16. Brickwork shall comply with sub-Clause 507.3.
6 (02/20) Backfilling to precast gullies shall be carried out up to sub-formation level with general fill material
Class 1, as described in Table 6/1 compacted in compliance with Clause 612. Where mechanical compaction is
impracticable, the backfilling shall be in ST2 concrete. The remainder of backfilling around gully shall be strength
class C8/10 or ST2 concrete.
7 (02/20) Gully connection pipes shall be either flexible or rigid not exceeding 0.7m in length with flexible joints
for a distance of 2m from the gully and shall be in accordance with Clause 507 when entering chambers. Junction
pipes shall be manufactured of the same type and class of material as the remainder of the pipes in the run.
Junction pipes which are laid but not immediately connected, shall be fitted with temporary stoppers or seals and
the position of all such junctions shall be clearly defined by means of stakes or tracing wires properly marked or
labelled. Saddles may be used to form junctions only where permitted in contract specific Appendix 5/1. No
internal projections greater than 5mm will be permitted. Saddles for plastics pipes shall be installed in accordance
with the manufacturer’s recommendations. Saddles with clay pipes shall be jointed with mortar designation (i)
complying with Clause 2404, excluding lime. Saddles and pipes shall be surrounded with ST2 concrete.

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8 (02/20) Where the adjustment or replacement of existing frames and gratings is required, the units shall be taken
up and re-fixed or removed and replaced with new units complying with sub-Clauses 4 and 5 of this Clause, or as
described in contract specific Appendix 5/1. On taking up or removal of the unit, any concrete or mortar bedding
shall be broken out and the surface prepared. Where existing frames and covers or gratings are to be adjusted, the
Contractor shall take up the unit and clean it so it is free from existing mortar, any debris, rust and is dry before
re-use. The adjusted or replaced units shall be laid at a level, unless otherwise described in contract specific
Appendix 5/1, 6mm below the adjoining road surface on a mortar bed complying with sub-Clause 507.16. The
finished thickness of the mortar bed shall be between 10mm and 25mm. Where required in contract specific
Appendix 5/1, covers and gratings shall be bedded using a quick setting high strength mortar which shall have a
declaration of performance for its intended use, the declaration of performance shall be provided to the Overseeing
Organisation before use. Any additional adjustment shall be made by modifying the brickwork in compliance with
sub-Clause 507.3 or by using a frame of suitable depth. On completion of the works, each grating shall be lifted
and the frame and seating cleaned.

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SERIES 600
EARTHWORKS
Contents
Clause Title Page Clause Title Page
#601 (02/16) Classification, Definitions and 623 (02/16) Earthworks for Corrugated Steel
Uses of Earthworks Materials 3 Buried Structures 26
602 (02/16) General Requirements 6 624 (02/16) Ground Anchorages 27
603 (02/16) Forming of Cuttings and Cutting 625 (02/16) Crib Walling 27
Slopes 8 626 (02/16) Gabions 28
604 (02/16) Excavation for Foundations 9 627 (02/16) Swallow Holes and Other
605 (02/16) Special Requirements for Class 3 Naturally Occurring Cavities 28
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Material 9 628 (02/16) Disused Mine Workings 28
606 (02/16) Watercourses 10 629 (02/16) Instrumentation and Monitoring 28
#607 (02/16) Explosives and Blasting for 630 (02/16) Ground Improvement 29
Excavation 11
631 (02/16) Earthworks Materials Tests 30
608 (02/16) Construction of Fills 12
#632 (02/16) Determination of Moisture
609 (02/16) Geotextiles and Geotextile-related Condition Value (MCV) of Earthworks
Products Used to Separate Earthworks Materials30
Materials 14
633 (02/16) Determination of Undrained
610 (02/16) Fill to Structures 14 Shear Strength of Remoulded Cohesive
611 (02/16) Fill Above Structural Concrete Material30
Foundations 14 634 (02/16) Determination of Intact Lump
612 (02/16) Compaction of Fills 15 Dry Density (IDD) of Chalk 31
613 (02/16) Sub-formation and Capping 17 635 (02/16) Los Angeles and Other Tests for
Particle Soundness 31
614 (02/16) Cement Stabilisation to Form
Capping 19 636 (02/16) Determination of Effective
Angle of Internal Friction (j/) and
615 (02/16) Lime Stabilisation to Form Effective Cohesion (c/) of Earthworks
Capping 20 Materials31
616 (02/16) Preparation and Surface 637 (02/16) Determination of Resistivity (rs)
Treatment of Formation 22 to Assess Corrosivity of Soil, Rock or
Earthworks Materials 32
617 (02/16) Use of Sub-formation or
Formation by Construction Plant 23 638 (02/16) Determination of Redox
Potential (Eh) to Assess Corrosivity of
618 (02/16) Topsoiling 23 Earthworks Materials for Reinforced
619 (02/16) Earthwork Environmental Bunds 24 Soil and Anchored Earth Structures 33
620 (02/16) Landscape Areas 24 639 (02/16) Determination of Coefficient of

Friction and Adhesion Between Fill and
621 (02/16) Strengthened Embankments 24 Reinforcing Elements or Anchor Elements
622 (02/16) Earthworks for Reinforced Soil
for Reinforced Soil and Anchored Earth
Structures34
and Anchored Earth Structures 25

Clause Title Page

640 (02/16) Determination of Permeability
of Earthworks Materials 34
641 (02/16) Determination of Available
Lime Content of Lime for Lime Stabilised
Capping35
642 (02/16) Determination of the Constrained
Soil Modulus (M*) of Earthworks Materials
for Corrugated Steel Buried Structures 35
643 (02/16) Lime and Cement Stabilisation to
Form Capping 36
644 (02/16) Determination of Sulfate Content 38
(02/16) Tables 6/1 to 6/7 39
NATIONAL ALTERATIONS OF THE

OVERSEEING ORGANISATIONS OF
SCOTLAND, WALES AND NORTHERN
IRELAND
Scotland
Clause Title Page
601TS (02/16) Classification, Definitions
and Uses of Earthworks Materials S1
632TS (02/16) Determination of Moisture
Condition Value (MCV) of Earthworks
Materials in Scotland S4F
(02/16) Wales
(02/16) 601W (02/16) Classification, Definitions

and Uses of Earthworks Materials W1
Northern Ireland
601NI (02/16) Classification, Definitions
and Uses of Earthworks Materials N1
607NI (02/16) Explosives and Blasting for
Excavation N4

has a substitute National Clause or Sample Contract Specific
Appendix for one or more of the Overseeing Organisations of
Scotland, Wales or Northern Ireland.
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Volume 1 Series 600
Specification for Highway Works Earthworks
EARTHWORKS
#601 (02/16) Classification, Definitions and Uses of Earthworks Materials
(02/16) General
(02/16) General Classification
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1 (02/16) Earthworks materials shall fall into one or other of the following general classifications:
(i) acceptable material: material excavated from within the site or imported on to the site which meets the
requirements of Table 6/1 and contract specific Appendix 6/1 for acceptability for use in the permanent
works;
(ii) unacceptable material Class U1A as defined in sub-Clauses 2(i)(a) and 2(i)(b) of this Clause: material
excavated from within the site which, unless processed so that it meets the requirements of Table 6/1 and
contract specific Appendix 6/1, shall not be used in the permanent works;
(iii) unacceptable material Class U1B as defined in sub-Clause 2(ii)(a) of this Clause: material excavated
from within the site which, unless processed so that it meets the requirements of Table 6/1 and contract
specific Appendix 6/1, shall not be used in the permanent works; and
(iv) unacceptable material Class U2 as defined in sub-Clause 3(i) of this Clause: material excavated from
within the site which shall not be used in the permanent works.
(02/16) Unacceptable Materials
2 (02/16) Unacceptable material Classes U1A and U1B:
(i) unacceptable material Class U1A shall be:
(a) material which does not comply with the permitted constituents and material properties of Table
6/1 and contract specific Appendix 6/1 for acceptable material; and
(b) material, or constituents of materials, composed of the following unless otherwise described in
contract specific Appendix 6/1:
• peat, materials from swamps, marshes and bogs;
• logs, stumps and perishable material;
• materials in a frozen condition;
• clay having a liquid limit determined in accordance with BS 1377: Part 2, exceeding 90 or
plasticity index determined in accordance with BS 1377: Part 2, exceeding 65;
• material susceptible to spontaneous combustion except unburnt colliery spoil complying
with sub-Clause 15 of this Clause;
(ii) unacceptable material Class U1B shall be:
(a) contaminated materials, including controlled wastes (as defined in the Environmental Protection
Act 1990 Part IIA) whose level of contamination is above that given either in contract specific
Appendix 6/14 or in contract specific Appendix 6/15, but excluding all hazardous wastes (as
defined in the Hazardous Waste (England and Wales) Regulations 2005) and radioactive wastes (as
defined in the Radioactive Substances Act 1993).

Volume 1 Series 600
3 (02/16) Unacceptable material Class U2 shall be:

(i) hazardous waste (as defined in the Hazardous Waste (England and Wales) Regulations 2005) and
radioactive waste (as defined in the Radioactive Substances Act 1993).
4 (02/16) Where required in contract specific Appendix 6/1, unacceptable material (other than Class U2) shall be
processed by mechanical, chemical or other means to render the material acceptable for use in the permanent works
in accordance with the requirements of Table 6/1 and contract specific Appendix 6/1.
(02/16) Definitions
5 (02/16) Where source codes are referred to these shall be for materials from the sources listed in Table 6/7.
6 (02/16) Chalk shall mean:
(i) any porous material of natural origin composed essentially of calcium carbonate and identified as chalk
on the maps produced by the British Geological Survey;
(ii) material designated as Class 3 in contract specific Appendix 6/1.
7 (02/16) Argillaceous rock shall mean shales mudstones siltstones slates and micaceous schists composed of
particles of clay and silt and mica. It shall include unburnt colliery spoil. Where argillaceous rock is imported onto
the site, it shall be aggregate complying with BS EN 13242 from source codes P (natural aggregates described as
shale, siltstone or slate), or G2 (refuse from hard coal mining (black coal shale)).
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8 (02/16) Pulverised-fuel ash shall mean solid material extracted by electrostatic and mechanical means from the
flue gases of furnaces fired with pulverised bituminous coal. It shall have a maximum particle size of 3 mm. Where
pulverised-fuel ash is imported onto the site, it shall be aggregate complying with BS EN 13242 from source code
C1 (coal fly ash).
9 (02/16) Furnace bottom ash shall mean agglomerated pulverised-fuel ash obtained from the bottom of the power
station furnace and having particle size no larger than 10 mm. Where furnace bottom ash is imported onto the site,
it shall be aggregate complying with BS EN 13242 from source code C4 (coal bottom ash).
10 (02/16) Formation shall be the top surface of capping. Where no capping is required formation shall be the top
surface of earthworks at the underside of sub-base, unless otherwise shown on the drawings.
11 (02/16) Sub-formation shall be the top surface of earthworks at the underside of capping.
12 (02/16) Stabilisation shall mean the spreading of cement or lime or both on a layer of deposited or intact
granular or cohesive material, and the subsequent process of pulverising and mixing followed by appropriate
compaction to form the whole or a constituent layer of a capping.
13 (02/16) Where ‘recycled aggregate’ is used in this Series, the material shall be aggregate resulting from
the processing of inorganic or mineral material previously used in construction and shall have been tested in
accordance with Clause 710. It shall not contain more than 1% other materials (Class X), not more than 50% in
Class Ra (bituminous materials) and not more than 25% in Class Rg (crushed glass). Where ‘recycled aggregate’
is imported onto the site, it shall be aggregate complying with BS EN 13242 from source code A (construction and
demolition recycling industries).
Where ‘recycled aggregate except recycled asphalt’ is used in this Series, the aggregate shall have been tested in
Class Ra (bituminous materials) and not more than 5% in Class Rg (crushed glass). Where ‘recycled aggregate
except recycled asphalt’ is imported onto the site, it shall be aggregate complying with BS EN 13242 from source
codes A2 (crushed concrete) and/or A3 (crushed bricks, masonry).
14 (02/16) ‘As dug’ shall mean material that has been excavated, transported and placed without any processing.
Where imported material undergoes any processing, including cleaning and sorting, it will not be deemed ‘as dug’
and thus shall be aggregate complying with BS EN 13242.

Volume 1 Series 600
(02/16) Use of Fill Materials

15 (02/16) In addition to any grading requirements the maximum particle size of any fill material shall be no more
than two-thirds of the compacted layer thickness except that cobbles having an equivalent diameter of more than
150 mm shall not be deposited beneath verges or central reserves within 1.30 m of the finished surface.
16 (02/16) Materials placed within 500 mm, or any other distances described in the contract specific Appendix
6/3, of concrete, cement bound materials, other cementitious mixtures or stabilised capping forming part of the
permanent works shall conform to, as appropriate, the following requirements:
(i) Materials shall conform to the following criteria:
(a) Water-soluble sulfate (WS) content determined in accordance with BS EN 1744-1 clause 10 shall
not exceed 1500 mg of sulfate (as S04) per litre;
(b) Total sulfur (TS) content determined in accordance with BS EN 1744-1 clause 11 expressed as (S)
shall not exceed 1% for aggregates other than air cooled blast furnace slag or 2% for air cooled
blast furnace slag.
(ii) Materials shall conform to at least one of the following options:
(a) When described in accordance with BS EN 932-3 and BS EN 13242 Annex A, limestone, chalk,
dolomite, blast furnace slag, steel slag or crushed concrete are predominant
or
(b) The sulfide content of the material determined in accordance with BS EN 1744-1 Clause 13 is less
than 0.5% (as S04).
When determining WS, TS or sulfide content, at least five samples of each material shall be tested. The mean of
the highest two values shall be used for comparison with the limiting values. This shall also apply if six to nine
results are available. If ten or more results are available, the mean of the highest 20% of the results shall be used for
comparison with the limiting values.
17 (02/16) Material placed within 500mm, or any other distances described in the contract specific Appendix 6/3,
of metallic structural elements forming part of the permanent works shall conform, as appropriate, to the following
requirements:
not exceed 300 mg of sulfate (as S04) per litre; and
shall not exceed 1% for aggregates other than air cooled blast furnace slag or 2% for air cooled
blast furnace slag.
dolomite, blast furnace slag, steel slag or crushed concrete are predominant;
or
than 0.06% (as S04).
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The requirements in (i) and (ii) above shall not apply to metallic items protected by concrete or ancillary metallic
items such as the tops of chambers and gullies.

Volume 1 Series 600
18 (02/16) Unburnt colliery spoil may be used as general fill provided it is compacted in compliance with Clause
612 and complies with the requirements of contract specific Appendix 6/1.
19 (02/16) Pulverised-fuel ash shall not be placed within the dimension described in contract specific
Appendix 6/3, below sub-formation or formation.
20 (02/16) Where pulverised-fuel ash is used, the Contractor shall for each consignment, make available to the
Overseeing Organisation a record of the type and source from which it was obtained and a certificate of results of
tests showing that the material complies with the requirements of Table 6/1.
602 (02/16) General Requirements

1 (02/16) The Contractor shall employ only plant and working methods which are suited to the materials to be
handled and traversed. He shall be responsible for maintaining the nature of the acceptable material so that when it
is placed and compacted it remains acceptable in accordance with the contract. Acceptability shall be determined in
accordance with Table 6/1 and any special contract specific requirements in Appendix 6/1.
2 (02/16) Haulage of material to embankments or other areas of fill shall proceed only when sufficient spreading
and compaction plant is operating at the place of deposition to ensure compliance with Clause 612.
3 (02/16) No excavated acceptable material or unacceptable material required to be processed, other than surplus
to the requirements of the contract, shall be removed from the site unless indicated otherwise in contract specific
Appendix 6/1. Material which is unacceptable only by reason of being frozen shall be retained on site when in that
condition. Where the Contractor is permitted to remove acceptable material, or unacceptable material required to
be processed, from the site to suit his operational procedure, then he shall make good any consequent deficit of
material arising therefrom. Environmental requirements for processing of Class U1B material, in terms of limiting
values of contaminants or other requirements, shall be set out in contract specific Appendix 6/1 in the earthworks
Class for which the processed material is to be used.
4 (02/16) If any acceptable material or unacceptable material required to be processed is, where permitted by
contract specific Appendix 6/1, used by the Contractor for purposes other than for general fill, sufficient acceptable
fill material to occupy, after full compaction, a volume corresponding to that which the excavated material occupied
shall be provided by the Contractor.
5 (02/16) Acceptable material (other than Class 5A or any Class 5B material replacing Class 5A material in
accordance with sub-Clause 3 of this Clause) surplus to the total requirements of the permanent works and all
unacceptable material Class U1A not required to be processed shall, unless indicated otherwise in contract specific
Appendix 6/1, be run to spoil in tips provided by the Contractor. In the case of unacceptable material, Class U1B
and Class U2, the Contractor shall comply with any specific requirements for disposal described in contract specific
Appendix 6/2.
6 (02/16) Where the excavation reveals a combination of acceptable and unacceptable materials the Contractor
shall, unless indicated otherwise in contract specific Appendix 6/3, carry out the excavation in such a manner that
the acceptable materials are excavated separately for use in the permanent works without contamination by the
unacceptable materials. Unless otherwise described in the contract classes of fill material required to be deposited
separately shall be excavated separately without contamination by other Classes of material.
7 (02/16) The Contractor shall make his own arrangements for stockpiling of acceptable material, and
unacceptable material to be processed, and for the provision of sites for the purpose.
8 (02/16) The Contractor shall ensure that he does not adversely affect the stability of excavations or fills by his
methods of stockpiling materials, use of plant or siting of temporary buildings or structures.
9 (02/16) Existing topsoil material shall, except where it is to be left in place in the locations described in contract
specific Appendix 6/8, be stripped to depths as described in contract specific Appendix 6/8 for
Class 5A material from all areas of cutting and from all areas to be covered by embankment or by other areas of fill.
Where stated in contract specific Appendix 6/8 existing topsoil shall be stripped as turf in accordance with sub-
Clause 3005.13.
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Volume 1 Series 600
10 (02/16) Topsoil shall wherever practicable be used immediately after its stripping and if not shall be stored in
stockpiles of heights not exceeding 2 m or other heights stated in contract specific Appendix 6/8. Unless otherwise
stated in contract specific Appendix 6/8, topsoil shall not be stockpiled for more than two years. Topsoil shall not
be unnecessarily trafficked either before stripping or when in a stockpile. Stockpiles shall not be surcharged or
otherwise loaded and multiple handling shall be kept to a minimum.
11 (02/16) All Class 5A topsoil arising from the site, or any Class 5B material replacing Class 5A material in
accordance with sub-Clause 3 of this Clause, in excess of the requirements for topsoiling, shall be subject to the
requirements described in contract specific Appendix 6/8.
12 (02/16) Excavations for foundations and trenches shall be adequately supported at all times, and except where
otherwise described in contract specific Appendix 6/3, shall not be battered. Where excavations are permitted to be
battered they shall be benched as described in contract specific Appendix 6/3 prior to backfilling and compaction.
The additional work and materials shall be provided by the Contractor. Sheeting and other excavation supports
shall be removed as filling proceeds except where they are required in contract specific Appendix 6/3 to be left in
position.
13 (02/16) Excavations requiring backfilling shall remain open only for the minimum period necessary.
14 (02/16) Excavations requiring backfilling in existing paved or other surfaces, including those paved areas to be
reconstructed or repaired, shall be carried out and reinstated in compliance with Clause 706.
15 (02/16) The Contractor shall keep earthworks free of water including:
(i) arranging for the rapid removal of water:
(a) shed on to the earthworks;
(b) entering the earthworks from any source;
(ii) lowering and maintaining by appropriate measures, the water level in excavations, sufficiently to enable
the permanent works to be constructed.
16 (02/16) In carrying out the requirements of sub-Clause 15 of this Clause the Contractor shall:
(i) form and maintain cuttings, embankments and other areas of fill with appropriate falls and gradient and
sealed surfaces;
(ii) provide where necessary temporary watercourses, drains, pumping and the like;
(iii) discharge accumulated water and groundwater into the permanent outfalls of the drainage system where
practicable;
(iv) provide adequate means for trapping silt on temporary systems discharging into permanent drainage
systems.
17 (02/16) The Contractor shall carry out and maintain any groundwater lowering or other treatment required in
18 (02/16) Where materials are designated in the contract as either Class U1B or Class U2, the Contractor shall
carry out any special requirements for their handling described in contract specific Appendix 6/2. Where such
materials are encountered during the progress of the works, the Contractor shall make all necessary arrangements
for their safe handling and disposal after consultation with the appropriate environmental authority.
19 (02/16) Subject to the surface level tolerances given in Clause 613 and sub-Clause 616.1, material shall not be
frost susceptible if it is used within 450 mm of the designed final surface of a road or paved central reserve, or 350
mm if the annual frost index of the site is less than 50. Material shall be classified as
non-frost-susceptible if the mean heave is 15 mm or less, when tested in accordance with BS 812: Part 124 or BS
1924: Part 2 for lime stabilised capping, amended as given in sub-Clause 801.7.

7
Volume 1 Series 600
603 (02/16) Forming of Cuttings and Cutting Slopes

1 (02/16) Cuttings shall be excavated to the lines and levels described in contract specific Appendix 6/3.
2 (02/16) Cutting slopes or toes of cuttings shall only be undercut when required in the contract for trench or
other excavations. Such excavations shall be restricted in extent as described in contract specific Appendix 6/3 and
where they require backfilling shall remain open only for the minimum period necessary, so as to prevent risk to the
permanent works.
3 (02/16) Except where otherwise described in contract specific Appendix 6/3, the excavation of cuttings may
be halted at any stage providing at least 300 mm of material as a weather protection is left in place above the
formation or above the sub-formation, subject to the requirements of Clauses 613 and 616.
4 (02/16) Where pre-split blasting is required or permitted in contract specific Appendix 6/3, it shall comply with
Clause 607 and any other requirements in contract specific Appendix 6/3. Full details of the methods and arrangements
to be adopted shall be made available to the Overseeing Organisation before commencement of drilling operations.
5 (02/16) Final faces of cuttings which are not to receive topsoil shall:
(i) wherever possible be left without scars or damage from construction plant; and
(ii) to achieve a natural appearance, when the stratum permits and when pre-split blasting is not adopted,
have the face left irregular within tolerances given in contract specific Appendix 6/3; and
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(iii) have boulders or other rock fragments that can be moved by hand without tools, removed; and
(iv) where required in contract specific Appendix 6/3 have material that can be blown away by airline hose,
having pressures no greater than those stated therein, so removed; and
(v) have adequate access to enable inspection to be carried out to determine the extent of work required by
this sub-Clause.
6 (02/16) Where required in contract specific Appendix 6/3, faces of cuttings which are not required to receive
topsoil shall have one or more of the following measures carried out as appropriate:
(i) Isolated patches of soft, fragmented and insecure material shall each be excavated to a depth of at
least 200 mm unless other depths are stated in contract specific Appendix 6/3 and replaced as soon as
practicable with ST2 concrete to Clause 2602 well rammed into the cleaned out void.
(ii) Areas of cutting face requiring their surface to be made stable shall be trimmed back by a nominal
50 mm or other amount required in contract specific Appendix 6/3 and the resulting surface together
with an area of any surrounding intact material as detailed in contract specific Appendix 6/3, shall have
a suitable cement based grout or sprayed concrete, applied by pressure to form a total nominal thickness
of 40 mm unless the required thickness is stated in contract specific Appendix 6/3. Where required in
contract specific Appendix 6/3, reinforcement shall be fixed to the surface before application of the
concrete or grout. Weep holes using permanent formers shall be constructed to the requirements of
contract specific Appendix 6/3 and at the locations described in contract specific Appendix 6/3.
(iii) Soft or insecure material, interlayered with rock shall be excavated to the depth behind the face
described in contract specific Appendix 6/3. The resulting cavity shall be filled with ST2 concrete to
Clause 2602 or with masonry infill complying with the Series 2400 and provided with weep holes all in
accordance with requirements in contract specific Appendix 6/3.
(iv) Netting or other sheet covering as described in contract specific Appendix 6/3 or rock bolts as described
7 (02/16) Where required in contract specific Appendix 6/3, faces of cuttings which are to receive topsoil shall
have one or more of the following measures carried out as appropriate:
(i) Be benched to retain topsoil as described in contract specific Appendix 6/3.

Volume 1 Series 600
(ii) Be harrowed to a depth of 50 mm. Such harrowing shall be carried out immediately prior to topsoiling,
diagonally, at an angle between 5º to 45º to the line of the toe, measured on the plane of the slope.
(iii) Isolated patches of soft, fragmented or insecure material shall be excavated and either:
(a) filled by well ramming in a Class of fill with similar characteristics as the surrounding intact
material; or
(b) excavated and dealt with as described in sub-Clause 6(i) of this Clause.
(iv) Other areas required to be made stable shall be dealt with as stated in contract specific Appendix 6/3.
8 (02/16) The concrete, referred to in sub-Clauses 6(i) and 6(iii) of this Clause, permanently exposed on the face
of the cutting shall have surface features as nearly as possible matching those of the adjacent intact face. Such
concrete and the grout referred to in sub-Clause 6(ii) of this Clause shall have a consistent colour as nearly as
possible matching that of the adjacent intact face.
604 (02/16) Excavation for Foundations

1 (02/16) The bottom of all foundation excavations shall be formed to the lines and levels shown on the drawings.
Pockets of soft soil or loose rock shall be removed and the resulting voids and any natural voids shall be filled with
ST1 concrete to Clause 2602 (or other material as required by contract specific Appendix 6/3) except in excavations
for corrugated steel buried structures when Class 6K lower bedding fill material complying with Table 6/1 shall be
used.
After placing of any blinding concrete shown on the drawings, no trimming of the side faces of the excavation shall
be carried out for 24 hours.
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2 (02/16) The Contractor shall make good:

(i) any lateral overbreak of the excavation above the bottom of the foundation greater than the net volume
required for the permanent works with material of the same Class as used for fill above structural
concrete foundations to comply with Clause 611 (except that for corrugated steel buried structures Class
6K lower bedding material shall be used) or, where the excavation is too narrow to allow the compaction
of earthworks materials, with ST1 concrete to Clause 2602;
(ii) any additional excavation at or below the bottom of foundations, including that resulting from removal
of material which the Contractor has allowed to deteriorate, with ST1 concrete to Clause 2602 (or other
material required by contract specific Appendix 6/3) except that under corrugated steel buried structures
Class 6K lower bedding material shall be used.
3 (02/16) Class 6K lower bedding material referred to in this Clause shall be deposited and compacted in
compliance with Clauses 608 and 612 and Table 6/1.
605 (02/16) Special Requirements for Class 3 Material

1 (02/16) When contract specific Appendix 6/1 designates a material as Class 3 to be used or to remain intact in
the permanent works the following shall apply:
(i) No earthworks involving Class 3 material or trafficking of areas which consist of Class 3 material,
unless they are protected, shall be carried out during the periods described in contract specific Appendix
6/4.
(ii) Excavation of Class 3 material shall be by means of a face shovel, which shall excavate, swing and
unload without moving the chassis or undercarriage during one operating cycle, or by means of a similar
shovel-loading machine, so as to reduce the degradation of the material to a minimum.
(iii) When excavating Class 3 material the Contractor shall arrange his method of working so as to maintain
a working face of minimum height 3 m or other height required in contract specific Appendix 6/4

Volume 1 Series 600
within Class 3 material except that where the depth of the cutting is less than 3 m the full height of
Class 3 material shall form the working face excluding any protection required to the formation or sub-
formation.
(iv) Material other than chalk contained within the volume designated as Class 3 material in the contract
shall be excavated and deposited separately from chalk and not be mixed with it.
(v) Trafficking of areas of Class 3 material shall not be permitted by vehicles having a capacity when struck
of more than 15 m3 unless otherwise described in contract specific Appendix 6/4.
(vi) Class 3 material shall not be stockpiled or be subjected to multiple handling.
(vii) Class 3 material shall not, unless required in contract specific Appendix 6/4, be layered with other fill
material in the construction of embankments and other areas of fill.
(viii) When required in contract specific Appendix 6/4 embankments and other areas of fill constructed of
Class 3 material shall either:
(a) upon reaching a level 600 mm below sub-formation or, where there is no capping, a level 600 mm
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below formation, be left for a minimum of 4 weeks or other period stated in contract specific Appendix
6/4, before continuing filling which shall, in all cases, be continued in compliance with sub-Clause
608.9; or
(b) be continued above sub-formation or formation with a protective layer in accordance with
sub-Clause 608.9(ii) but which shall be of Class 3 material. Such material shall then be left for a
minimum of 4 weeks or other period stated in contract specific Appendix 6/4 before removal of the
protective layer and shall be immediately continued with the preparation of sub-formation or formation,
as appropriate, in accordance with Clauses 613 and 616.
(ix) Where temporary instability occurs in chalk during deposition or compaction due to excessive working
by plant or to inclement weather, the Contractor shall delay the further deposition of Class 3 material
until the chalk has recovered sufficient strength for work to proceed. A detailed record of the areas of
instability shall be made available to the Overseeing Organisation.
(x) At the end of each working day of filling, exposed Class 3 material laid that day shall, unless otherwise
stated in contract specific Appendix 6/4 be rolled with two passes of a smooth wheeled roller having a
mass per metre width of roll exceeding 2100 kg.
(xi) The other special requirements for Class 3 material described in sub-Clauses 613.11(i), 613.12(i),
616.1(ii) and 616.3 shall also apply, together with any other special requirements described in contract
specific Appendix 6/1 or contract specific Appendix 6/4.
606 (02/16) Watercourses

1 (02/16) The clearance and modification of existing, or the construction of new watercourses, including ditches,
streams, rivers, lagoons and ponds, shall be as described in contract specific Appendix 6/3 including any protection,
lining, revetment or other works and shall comply with sub-Clauses 2 to 4 of this Clause.
2 (02/16) Clearance of existing watercourses shall include the removal of vegetation, vegetable matter and
all other deposits within the watercourse profile. Materials resulting from this clearance shall be dealt with as
unacceptable material.
3 (02/16) New watercourses and cleared existing watercourses shall be maintained in a clear condition.
4 (02/16) Redundant watercourses shall, where required in contract specific Appendix 6/3, be drained and cleared
in accordance with sub-Clause 2 of this Clause and material outside the watercourse profile excavated and dealt
with as unacceptable material. The excavations shall be to the dimensions stated in the contract and the whole filled
with general or selected fills of the Class described in contract specific Appendix 6/3 complying with Table 6/1

Volume 1 Series 600
deposited and compacted in compliance with Clause 608 and 612. Where the surface is to remain exposed it shall
be topsoiled and seeded, or receive other treatment, all as described in contract specific Appendix 6/3.
#607 (02/16) Explosives and Blasting for Excavation

1 (02/16) Blasting for excavation shall not be employed unless permitted or required in contract specific Appendix
6/3 and such blasting shall be confined to the locations and to within the time limits stated therein.
2 (02/16) The Contractor shall:
(i) not carry out plaster shooting;
(ii) for each location where blasting is to be undertaken, give written notice to the Overseeing Organisation
of the programme of blasting, including trial explosions, at least 10 days before it commences and give
written notice of each blasting event as described in (v) below, at least 12 hours beforehand;
(iii) carry out trial explosions starting with reduced quantities of explosive in order to determine the size of
the actual explosive charges and their disposition, for use in the main blasting operations, so as not to
exceed the values for vibrational amplitude and vibrational peak particle velocity stated in (vi) below at
the positions described therein;
(iv) determine danger zones likely to be created by the blasting operations, including trial explosions, within
which blasted material may be projected and utilise suitable arrangements including temporary works, to
retain such projectiles and ensure that no injury or damage is caused to persons or property thereby;
(v) limit blasting to a small number of events during permitted hours per day, where an event shall comprise
a single explosion or a group of explosions each separated by a short time interval, the group lasting less
than a minute;
(vi) ensure that:
(a) structures and earthworks, existing or under construction, on and off the site, do not experience,
during blasting operations including trial explosions, a vibrational amplitude exceeding 0.2 mm
and a resultant peak particle velocity exceeding 50 mm per second, or other limits stated in contract
specific Appendix 6/3, at the same time or individually; and
(b) peak overpressures, of magnitude such as to endanger windows and glazed areas of structures, do
not occur.
(vii) where instrumentation and monitoring is appropriate:
(a) rigidly fix to structures and insert in earthworks described in (vi)(a) above, suitable instruments
to measure the vibrational amplitude and resultant vibrational peak particle velocity, and peak
overpressures, experienced during blasting operations including trial explosions;
(b) make available details of the proposed instrumentation within the site;
(c) unless otherwise stipulated in contract specific Appendix 6/3, make his own arrangements for installing
instruments on property off the site including negotiating with landowners and other interested parties;
(d) read such instruments and take measurements throughout the period of blasting operations,
including trial explosions;
(e) for instruments on structures or earthworks on the site and, where required in contract specific
Appendix 6/3, on property off the site, make available the results to the Overseeing Organisation at
the end of each day’s blasting.
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Volume 1 Series 600
(viii) take measurements of vibrational amplitude and peak particle velocity in each of three mutually
perpendicular planes and determine the peak value, taken as the maximum resultant calculated by vector
summation of the three components of amplitude and velocity respectively, measured as instantaneously
as the resolution of the recording instrument permits;
(ix) ensure that noise from blasting operations is controlled in accordance with Clause 109;
(x) use explosives in the quantities and in the manner recommended by the manufacturer;
(xi) store explosives in registered premises in a licensed store or magazine provided with a separate
compartment for detonators or use them under an Immediate Use Certificate issued by the police;
(xii) only permit explosives to be used or handled by or under the immediate control of a competent person
in accordance with the Construction (General Provisions) Regulations 1961 (Regulation 19) and
subsequent amending Regulations;
(xiii) ensure there is no unauthorised issue or improper use of explosives brought on the site and maintain a
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strict check on quantities issued and consumed;
(xiv) comply with the requirements of BS 6657 in respect of the use of electrical detonators in the vicinity
of static and mobile radio transmitters, including normal radio and television broadcasting stations and
radar units associated with aircraft movements, electricity generating plant and transmission lines.
608 (02/16) Construction of Fills

1 (02/16) All fills, including embankments, shall be constructed:
(i) in the locations described in contract specific Appendix 6/3 to the lines and levels stated therein;
(ii) of Classes of materials required or permitted in contract specific Appendix 6/1, complying with Table
6/1 with, unless otherwise described in the contract, only Class 6A material deposited into open water;
(iii) by depositing, as soon as practicable after excavation, in layers to meet the compaction requirements of
Clause 612 as required for each Class of material in Table 6/1, except that:
(a) material requiring end product compaction shall be deposited in layers not exceeding 250 mm
uncompacted thickness;
(b) material placed into open water shall be deposited by end tipping without compaction;
(c) material deposited in areas to receive dynamic compaction complying with Clause 630 shall be
deposited and compacted to the requirements therein.
(iv) to the requirements of this Clause and any other requirements for fill in this Series.
2 (02/16) Starter layers of Classes 6B, 6C or 6D materials as described in contract specific Appendix 6/3 shall
be deposited as the first layer or layers of fill above existing ground level or, if appropriate, above any ground
improvement required by contract specific Appendix 6/13. Starter layers below Class 2E pulverised-fuel ash
general fill shall be Class 6D material. Plant movement across starter layer material shall be restricted to that plant
which is necessary for its deposition, spreading and compaction in compliance with this Clause and Clause 612 and
any plant required to carry out any ground improvement beneath it if required by Clause 630. The Contractor shall
take all reasonable measures to prevent damage to the underlying strata, which may include use of lighter spreading
plant or a reduction of the number of passes of compaction plant.
3 (02/16) Coarse granular material Classes 1C and 6B shall, before compaction, be spread in layers by a crawler
tractor of not less than 15 tonnes total mass. After compaction each layer shall, if voids remain, be blinded with an
approved Class of granular material complying with Table 6/1 so that all surface voids are filled before the next
layer and before any capping or sub-base is constructed.
4 (02/16) Embankments and other areas of fill shall, unless otherwise required in the contract, be constructed
evenly over their full width and their fullest possible extent and the Contractor shall control and direct

Volume 1 Series 600
constructional plant and other vehicular traffic uniformly over them. Damage by constructional plant and other
vehicular traffic shall be made good by the Contractor with material having the same characteristics and strength as
the material had before it was damaged.
5 (02/16) Embankments and other areas of unsupported fills shall not be constructed with steeper side slopes, or to
greater widths than those described in contract specific Appendix 6/3, except to permit adequate compaction at the edges
before trimming back, or to obtain the final profile following any settlement of the fill and the underlying material.
However any oversteepening or increase in width shall not exceed any limits described in contract specific Appendix 6/3
and shall remain only for the minimum periods necessary consistent with the safety of the permanent works.
6 (02/16) Staged construction of fills and any controlled rates of filling, shall be carried out, in accordance with
any requirements described in contract specific Appendix 6/3 including installation of instrumentation and its
monitoring, in compliance with Clause 629.
7 (02/16) Where required in contract specific Appendix 6/3 the Contractor shall surcharge embankments or other areas
of fill, as described therein for the periods stated. If settlement of surcharged fill results in any surcharging material,
which is unacceptable for use in the fill being surcharged, lying below the formation or, where there is a capping, the sub-
formation, the Contractor shall remove this unacceptable material and dispose of it in accordance with Clause 602. He
shall then bring the resultant level up to formation or sub-formation, as appropriate, with acceptable material.
8 (02/16) Where pipes in embankments or in other areas of fill are permitted in contract specific Appendix 5/1 to
be constructed other than in a trench, the fill shall be brought up to and over them equally on both sides. The fill
shall be deposited in even layers and shall not be heaped above the pipe. Spreading and compaction shall be carried
out evenly without dislodging, distorting or damaging the pipe. Power rammers are not to be used within 300 mm
of any part of the pipe or joint.
9 (02/16) The last 600 mm depth of fill up to sub-formation level, or formation level as appropriate, shall,
unless otherwise required in the Contract, be carried out for the full width of embankments, or between the outer
extremities of the verges in other areas of fill, in a continuous operation. The Contractor shall then continue without
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delay to carry out either (i) or (ii) below:

(i) form the sub-formation or formation, all in accordance with Clauses 613 and 616, following
immediately either by:
(a) the construction of the full thickness of capping or sub-base as appropriate; or
(b) if permitted in contract specific Appendix 6/3, the construction of a lesser thickness of capping or
sub-base as described therein laid as a weather protection layer;
(ii) place an additional 300 mm minimum compacted thickness of material above sub-formation level or
formation level as appropriate for the full width of the filling to form a weather protection. This weather
protection shall be composed of the same material as the sub-formation or formation and compacted in
compliance with Table 6/1. The material shall be provided from the Contractor’s own resources and the
protection layer shall be constructed in a continuous operation. For stabilised capping, the protective
layer shall consist of unstabilised material.
10 (02/16) During construction of embankments and other fills, exposed sides of Classes 2E and 7B pulverised-fuel
ash material shall be protected against scour and erosion from any source.
11 (02/16) Completed slopes of Classes 2E and 7B fill material shall be covered immediately by Class 5 topsoil as
required in contract specific Appendix 6/8 or turf or other material, as required in contract specific Appendix 30/5.
12 (02/16) Whenever fill is to be deposited against the face of a natural slope, or sloping earthworks face including
embankments, cuttings, other fills and excavations, such faces shall be benched or otherwise shaped as required in
contract specific Appendix 6/3 immediately before placing the subsequent fill.
13 (02/16) All permanent faces of side slopes of embankments and other areas of fill formed in Classes 2 or 7
cohesive materials other than pulverised-fuel ash, shall, subsequent to any trimming operations, be re-worked and
sealed by tracking a tracked vehicle, suitable for the purpose, on the slope, or by other suitable methods.

Volume 1 Series 600
609 (02/16) Geotextiles and Geotextile-related Products Used to Separate Earthworks Materials
1 (02/16) Geotextiles and geotextile-related products shall conform to the requirements of the product standard
BS EN 13251 and other characteristics and locations as set out in contract specific Appendix 6/5. A Declaration of
Performance for each product stating compliance with BS EN 13251 and the required levels of performance stated
in contract specific Appendix 6/5 shall be submitted to the Overseeing Organisation prior to their placement in the
works.
610 (02/16) Fill to Structures

1 This Clause shall apply to fill to structures other than:
(i) fill for reinforced earth structures, including associated drainage layers;
(ii) fill for anchored earth structures including associated drainage layers;
(iii) fill for surround and bedding of corrugated steel buried structures;
(iv) fill above structural concrete foundations unless otherwise required in contract specific Appendix 6/6.
2 (02/16) Materials, as required or permitted in contract specific Appendix 6/6 of Classes 6N, 6P, 7A or 7B and
complying with Table 6/1 shall be used as fill to structures, in the locations described in contract specific Appendix
6/6.
3 (02/16) The Contractor shall compact, in compliance with Clause 612, end-product compaction, Class 6N, 6P,
7A and 7B material to satisfy the compaction requirements for those Classes as listed in Table 6/1, but subject to
the restrictions in sub-Clauses 4 and 5 of this Clause.
4 (02/16) Where fill to structures is required to the same level on more than one side of a structural element or
buried structure (except where Clause 623 applies) it shall be maintained at heights not differing by more than 250
mm after compaction on opposing sides of the structural element as filling proceeds.
5 (02/16) The Contractor shall restrict compaction plant used on fill to structures, within 2 m of a structure, to the
following items as described in sub-Clause 612.10 and listed in Table 6/4:
(i) vibratory roller having a mass per metre width of roll, as determined by sub-Clause 612.10, not
exceeding 1,300 kg with a total mass not exceeding 1,000 kg;
(ii) vibrating plate compactor having a mass not exceeding 1,000 kg;
(iii) vibro-tamper having a mass not exceeding 75 kg.
The compacted level of the fill within this zone shall not differ during construction from the compacted level of the
remainder of the adjoining fill to structures by more than 250 mm.
6 (02/16) Where required in contract specific Appendix 6/6, Class 6N, 6P and 7B material shall be shown, by
means of a trial utilising not less than 20 m3 of the material, deposited and compacted in accordance with this
Clause, to be stable, when it is trimmed to a slope of 1 vertical to 1½ horizontal, or other slope described in contract
611 (02/16) Fill Above Structural Concrete Foundations

1 (02/16) Fill deposited above structural concrete foundations shall be, as shown on the drawings:
(i) Class 6N, 6P, 7A or 7B selected fill material complying with Clause 610 including compaction
requirements;
(ii) Class 6M selected fill material, deposited and compacted in accordance with Clause 623, above the
foundation of arch profile corrugated steel buried structures;
(iii) another class of selected fill or general fill complying with Table 6/1 deposited and compacted in
compliance with Clauses 608 and 612 and in addition be subject to sub-Clauses 610.4 and 5.

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612 (02/16) Compaction of Fills

(02/16) General
1 (02/16) Except for dynamic compaction, which shall comply with Clause 630, and unless otherwise described in
contract specific Appendix 6/3, the Contractor shall carry out compaction in compliance with this Clause, as soon
as practicable after deposition, on all those Classes of fill in Table 6/1 which require to be compacted.
2 (02/16) Compaction shall be either method or end-product as required for the Class of fill in Table 6/1, using
plant appropriate to the Class of fill and the site conditions.
3 (02/16) The Contractor shall obtain permission from the Overseeing Organisation before carrying out
compaction outside normal working hours.
(02/16) Method Compaction
4 (02/16) Where method compaction is required to be adopted it shall comply with sub-Clauses 5 to 10 of this
Clause.
5 (02/16) Except as stated in sub-Clause 6 of this Clause, method compaction shall be undertaken using the plant
and methods in Table 6/4 appropriate to the compaction requirements as listed in Table 6/1 for the Class of material
being compacted.
6 (02/16) Plant and methods not included in Table 6/4 shall only be used providing the Contractor demonstrates
at site trials that a state of compaction is achieved by the alternative method equivalent to that obtained using the
specified method.
7 (02/16) Earthmoving plant shall not be accepted as compaction equipment nor shall the use of a lighter category
of plant to provide any preliminary compaction to assist the use of heavier plant be taken into account when
assessing the amount of compaction required for any layer.
8 (02/16) If more than one Class of material is being used in such a way that it is not practicable to define the
areas in which each Class occurs, the Contractor shall compact with plant operating as if only the material which
requires the greater compactive effort is being compacted.
9 (02/16) The Contractor or Overseeing Organisation may carry out field dry density tests as described in
sub-Clause 15 of this Clause on material compacted to method requirements at a frequency defined in contract
specific Appendix 6/3. If the results of field tests show densities which indicate the state of compaction to be
inadequate, then if this is due to failure of the Contractor to comply with the requirements of the contract, the
Contractor shall carry out such further work as is required to comply with the contract.
10 (02/16) For the purposes of Table 6/4 the following shall apply:
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(i) The minimum number of passes N is the minimum number of times that each point on the surface of
the layer being compacted shall be traversed by the item of compaction plant in its operating mode, or
struck by power rammers or falling weight compactors. D is the maximum depth of the compacted layer.
(ii) In column headed N # the number of passes shown is to be doubled for material Classes 1A, 1B, 2A,
2B, 2C and 2D when such materials occur within 600 mm of sub-formation (if capping is required) or
formation. Such extra compaction shall, unless otherwise described in contract specific Appendix 6/3,
either be carried out for the full width of the embankment or, in other areas of fill which are to receive a
pavement, between the outer extremities of the verges.
(iii) The compaction plant in Table 6/4 is categorised in terms of static mass. The mass per metre width of
roll is the total mass on the roll divided by the total roll width. Where a smooth wheeled roller has more
than one axle the category of the machine shall be determined on the basis of the axle giving the highest
value of mass per metre width.
(iv) A grid roller is a machine with a compacting roll or rolls constructed of heavy steel mesh of square
pattern.

Volume 1 Series 600
(v) A deadweight tamping roller is a machine with a roll or rolls from which ‘feet’ project and where the
projected end area of each ‘foot’ exceeds 0.01 m² and the sum of the areas of the feet exceeds 15% of
the area of the cylinder swept by the ends of the feet. The requirements for tamping rollers apply to
machines that have 2 rolls in tandem. If only one tamping roll traverses each point on the surface of the
layer on any one pass of the machine, the minimum number of passes shall be twice the number given in
Table 6/4 plus any further doubling required to satisfy (ii) above.
(vi) For pneumatic-tyred rollers the mass per wheel is the total mass of the roller divided by the number of
wheels. In assessing the number of passes of pneumatic-tyred rollers the effective width shall be the sum
of the widths of the individual wheel tracks together with the sum of the spacings between the wheel
tracks provided that each spacing does not exceed 230 mm. Where the spacings exceed 230 mm the
effective width shall be the sum of the widths of the individual wheel tracks only.
(vii) A vibratory tamping roller, which may be self-propelled or towed, is a machine having a means of
applying mechanical vibration to one or more rolls. The roll or rolls have projecting feet where the
height of each foot exceeds 10% of the radius of the roll drum, the projected end area of each foot
exceeds 0.1% of the roll drum surface area, and the sum of the areas of the feet exceeds 10% of the area
of the cylinder swept by the ends of the feet.
The requirements for the operation of vibratory tamping rollers shall be the same as those stated for
vibratory rollers in sub-Clause (viii) except that vibratory tamping rollers operating without vibration
will be classified as deadweight tamping rollers.
(viii) Vibratory rollers are self-propelled or towed smooth-wheeled rollers having means of applying
mechanical vibration to one or more rolls except that vibratory rollers employed for Method 5
compaction shall be single roll types.
Vibratory rollers operating without vibration will be classified as smooth-wheeled rollers.
The requirements for vibratory rollers are based on the use of the lowest gear on a self-propelled
machine with mechanical transmission and a speed of 1.5 to 2.5 km/h for a towed machine, or a self-
propelled machine with hydrostatic transmission. If higher gears or speeds are used an increased number
of passes shall be provided in proportion to the increase in speed of travel.
Where the mechanical vibration is applied to two rolls in tandem, the minimum number of passes shall be half
the number given in Table 6/4 for the appropriate mass per metre width of one vibrating roll but if one roll
differs in mass per metre width from the other the number of passes shall be calculated as for the roll with the
smallest value. Alternatively the minimum number of passes may be determined by treating the machine as
having a single vibrating roll with a mass per metre width equal to that of the roll with the higher value.
Vibratory rollers shall be operated with their vibratory mechanism operating only at the frequency of
vibration recommended by the manufacturers. Where more than one amplitude setting is available and/
or a range of frequencies is recommended, the machine shall be operated at the maximum amplitude
setting and at the maximum recommended frequency for that setting.
Vibratory rollers shall be equipped or provided with devices indicating the frequency at which the
mechanism is operating and the speed of travel. Both devices shall be capable of being read by an
inspector alongside the machine.
(ix) Vibrating-plate compactors are machines having a base-plate to which is attached a source of vibration
consisting of one or two eccentrically weighted shafts and:
(a) the mass per square metre of the base-plate of a vibrating-plate compactor is calculated by dividing
the total mass of the machine in its working condition by its area in contact with compacted material;
(b) vibrating-plate compactors shall be operated at the frequency of vibration recommended by the
manufacturers. They shall normally be operated at travelling speeds of less than 1 km/h but if higher speeds
are necessary the number of passes shall be increased in proportion to the increase in speed of travel.
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Volume 1 Series 600
(x) Vibro-tampers are machines in which an engine-driven reciprocating mechanism acts on a spring system
through which oscillations are set up in a base-plate.
(xi) Power rammers are machines which are actuated by explosions in an internal combustion cylinder, each
explosion being controlled manually by the operator.
(xii) Dropping weight compactors are machines in which a dead weight is dropped from a controlled
height using a hoist mechanism and they include self-propelled machines with mechanical traversing
mechanisms capable of compacting soil in trenches and close to structures.
(xiii) In the case of power rammers and dropping-weight compactors one pass will be considered as made
when the compacting shoe has made one strike on the area in question.
(xiv) For items marked * in the Method 3 column of Table 6/4 the roller shall be towed by track-laying
tractors. Self-propelled rollers are unsuitable.
(xv) Where combinations of different types or categories of plant are used, the following shall apply:
(a) the depth of layer shall be that for the type of plant requiring the least depth of layer; and
(b) the number of passes shall be that for the type of plant requiring the greatest number of passes.
(02/16) End-product Compaction
11 (02/16) Where end-product compaction is required it shall comply with sub-Clauses 12 to 15 of this Clause.
12 (02/16) The Contractor shall at least 7 days before commencement of end-product compaction make available
the following to the Overseeing Organisation:
(i) the values of maximum dry density and the optimum moisture content obtained in accordance with
BS 1377: Part 4 using the 2.5 kg rammer method or vibrating hammer method as appropriate for each of
the fills he intends to use which meet the requirements of the permitted Class or Classes (where within
any Class of material the fill contains material having different maximum dry densities and optimum
moisture contents the Class shall be further sub-divided, by extending the identification system, in order
to monitor the compacted density);
(ii) a graph of density plotted against moisture content from which each of the values in (i) above of
maximum dry density and optimum moisture content were determined and, for Class 7A material, a plot
of the 5% air voids curve for each sub-division.
13 (02/16) Once the information contained in sub-Clause 12 of this Clause has been made available to the
Overseeing Organisation it shall form the basis for compaction.
14 (02/16) Fill compacted to end-product requirements shall have a field dry density, measured in accordance with
sub-Clause 15 of this Clause, equal to or greater than the percentage given in Table 6/1 of the maximum dry density
for the relevant Class of fill previously made available to the Overseeing Organisation in accordance with sub-
Clause 12 of this Clause.
15 (02/16) The field dry density referred to in sub-Clause 14 of this Clause shall be measured in accordance with
BS 1377: Part 9, except that nuclear methods shall only be used where required or permitted in contract specific
Appendix 6/3. Where nuclear methods are used, the gauge shall be calibrated in accordance with BS 1377: Part 9.
613 (02/16) Sub-formation and Capping

1 (02/16) Capping shall be provided only in those locations, and to the extent, particularly stated in the contract
specific Appendix 6/7 to be constructed with capping. It shall comply with this Clause and in addition, for stabilised
capping, with Clauses 614, 615 and 643 as appropriate.
2 (02/16) Capping shall be constructed with Class 6F1, 6F2, 6F3, 6F4, 6F5, 6S, 9A, 9B, 9C, 9D, 9E or 9F material
as required or permitted in contract specific Appendix 6/7 and complying with Table 6/1.

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3 (02/16) Unless otherwise described in contract specific Appendix 6/7, capping shall either consist of one Class
of capping material throughout its depth laid in one or more layers of compacted thickness complying with Clause
612, or be formed of not more than two elements of different capping materials. Each element shall be formed of
one or more layers of the same capping material, each of compacted thickness complying with Clause 612. Class
9D or 9E stabilised capping material shall not be placed or constructed above
Class 6F granular capping material or Class 6S granular filter layer material.
4 (02/16) Where required in contract specific Appendix 6/7, before commencing the construction of capping in
the permanent works, the Contractor shall demonstrate the methods, equipment and materials he proposes to use by
constructing an area, or areas as appropriate, of capping on a typical prepared sub-formation to the same thickness as
required in the permanent works. The area of each capping construction demonstration shall be not less than 700 m².
5 (02/16) The materials placed during the demonstration may form part of the permanent works, provided they
meet the requirements of the contract, or be carried out elsewhere on the site where this is detailed in contract
specific Appendix 6/7. After completion of each demonstration area the Contractor shall within a period of not
greater than 5 days and before commencing the main construction of the appropriate capping in the permanent
works, carry out tests on each demonstration area and provide the Overseeing Organisation with records
substantiating compliance with the stipulated criteria of contract specific Appendix 6/7. Where required by contract
specific Appendix 6/7 the Contractor shall provide sheeting, to protect the demonstration area.
6 (02/16) The demonstration area shall, if it does not meet the requirements for the permanent works or is located
elsewhere on site, be removed and the area reinstated in accordance with contract specific Appendix 6/7.
7 (02/16) The methods and materials used in the accepted demonstration shall not be changed during the course of
the works without the construction of a further demonstration where such demonstrations are required by contract
8 (02/16) Unless otherwise stated in contract specific Appendix 6/7, the sub-formation shall have the same
longitudinal gradient, crossfall and surface level tolerances as the formation.
9 (02/16) The Contractor shall limit any unprotected area of sub-formation, which is to receive capping to suit the
output of the plant in use and the rate of deposition of capping.
10 (02/16) No unprotected sub-formation which is to receive capping shall remain continuously exposed to rain
causing degradation, nor be left uncovered overnight.
11 (02/16) In cuttings the Contractor shall, as permitted or required in contract specific Appendix 6/7 carry out one
of the following procedures:
(i) for Class 6F granular capping material or Class 6S granular filter layer material, excavate below
formation level to a depth to accept the capping, trim the surface to form the sub-formation and
immediately compact with one pass of a smooth-wheeled roller having a mass per m width of roll
not less than 2,100 kg or a vibratory roller having a mass per m width of roll not less than 700 kg or
a vibrating plate compactor having a mass per m² of not less than 1,400 kg, except that only smooth
wheeled rollers shall be used on Class 3 chalk material, and immediately deposit and compact above it a
capping in Class 6F granular capping material or Class 6S granular filter layer material; or
(ii) for Class 9A, 9B, 9C, 9D, 9E or 9F capping material construct the capping by stabilising the intact
material, providing it complies with Class 6E, 6R 7E, 7F, 7G or 7I material requirements, immediately
below formation to form Class 9A, 9B, 9C, 9D, 9E or 9F material, respectively; or
(iii) excavate below formation to sufficient depth to enable stabilisation of intact Class 6E, 6R, 7E, 7F, 7G
or 7I material to be carried out, to produce Class 9A, 9B, 9C, 9D 9E or 9F material forming the lower
element of the capping (after stabilisation of this element, the capping shall be completed by depositing
a further layer or layers of Class 6E, 6R 7E, 7F, 7G, or 7I material and stabilising it to form Class 9A,
9B, 9C, 9D, 9E or 9F capping or depositing and compacting Class 6F granular capping material to form
the upper element of the capping); or
(iv) excavate to sub-formation level and deposit material complying with Classes 6E, 6R, 7E, 7F, 7G, or 7I
to be stabilised to form a capping of Class 9A, 9B, 9C, 9D, 9E or 9F layers.

Volume 1 Series 600
Where a stabilised layer is directly overlain by Class 6F granular capping material the stabilised layer shall be
compacted as for a sub-formation in 11(i) above.
12 (02/16) On embankments and other areas of fill the Contractor shall, as permitted or required in contract specific
Appendix 6/7 carry out one of the following procedures:
(i) complete the embankment to form the sub-formation or remove any protection layer and trim the surface
to form the sub-formation, and in both cases compact with one pass of a smooth-wheeled roller having
a mass per m width of not less than 2,100 kg or a vibratory roller of not less than 700 kg per m width or
a vibrating plate compactor having a mass per m² of not less than 1,400 kg, (except that only smooth-
wheeled rollers shall be used on Class 3 chalk material) and immediately construct above it, in one or
more layers, Class 6F granular capping material or Class 6S granular filter layer material; or
(ii) construct the embankment to sufficient height and carry out stabilisation to form a capping of Class 9A,
9B, 9C, 9D, 9E or 9F material in one or more layers utilising where appropriate any protection layer
previously constructed; or
(iii) for multi-element capping, incorporating stabilised material, construct the embankment to sufficient
height to carry out the work described in 12(ii) above and immediately construct above it one or more
layers of Class 6F granular capping material.
Where a stabilised layer is directly overlain by Class 6F granular capping material the stabilised layer shall be
compacted as for a sub-formation in 12(i) above.
13 (02/16) For Class 6F3 material Optimum Moisture Content shall be determined according to BS 1377: Part 4
Method 3.7 (vibrating hammer test). Measurements of moisture content both for control purposes and for optimum
moisture content determination shall be according to BS 1377: Part 2 Method 3 (oven dry method) but using an
oven on a reduced temperature setting of 45 to 50°C.
14 (02/16) Filter layers constructed of Class 6S granular filter layer material shall be protected from damage
by traffic and construction plant. The Contractor shall so organise work that only the traffic directly engaged in
depositing, spreading and compacting the filter layer shall be permitted access to the surface of this layer. At no
time shall the Contractor permit the leading edge of the filter layer to extend more than 100 metres beyond the
leading edge of the succeeding layer of subbase.
614 (02/16) Cement Stabilisation to Form Capping

1 (02/16) Where capping is to consist of, either wholly or in part, cement stabilised material Class 9A, 9B or 9C,
this Clause shall apply to the construction of those parts which are stabilised with cement.
2 (02/16) Material to be stabilised with cement shall be Class 6E, Class 7F and Class 7G materials all complying
with Clause 601 and Table 6/1. Unless otherwise described in contract specific Appendix 6/7 cement shall be
Portland cement complying with BS EN 197-1 and requirements given in contract specific Appendix 6/7.
3 (02/16) Class 6E, 7F or 7G material to be stabilised shall have added to it, at any point, that quantity of cement
measured as a percentage of its dry weight as determined on the demonstration area, to meet the required bearing
ratio in contract specific Appendix 6/1, subject to a minimum of 2% cement.
4 (02/16) The appropriate quantity of cement shall be uniformly spread, by a suitable spreading machine, on top
of the layer to be processed. Using a collecting tray and balance the Contractor shall check the rate of spread of the
machine once for every 500 m² of cement spread.
5 (02/16) Unless indicated otherwise in contract specific Appendix 6/7, Class 6E, 7F or 7G material shall be
stabilised in a single layer if its compacted thickness is 250 mm or less. If its compacted thickness is greater, the
material shall be stabilised in layers not less than 130 mm and not more than 250 mm thick, including any cutting-
in required by sub-Clause 9 of this Clause.
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6 (02/16) The Contractor shall not carry out cement stabilisation when the shade temperature is below 3°C unless
on a rising thermometer above 0°C. Cement stabilisation shall not be carried out during periods of rain or when rain
is imminent. When cement is spread on material likely to cause premature hydration, processing in accordance with
sub-Clause 7 of this Clause shall follow immediately.
7 (02/16) Unless indicated otherwise by contract specific Appendix 6/7, Class 6E, 7F or 7G material forming the
layer to be stabilised shall be processed by pulverising and mixing in the cement by means of a sufficient number
of passes of a suitable mobile stabilising machine until 95% of the silt and clay fraction is reduced to particles or
lumps passing a BS 28 mm sieve after dry sieving and the pulverisation complies with Table 6/1.
8 (02/16) During processing, sufficient water shall be available in the material to hydrate the cement and enable
satisfactory mixing and compaction to be achieved. Any added water shall be through an integral spray-bar on the
stabilising machine. Any added water shall have a sulfate content not exceeding 1400 mg/l as SO4, when tested in
accordance with BS EN 1744-1 clause 10.
9 (02/16) The stabilising machine shall be equipped with a device for controlling the depth of processing which
shall be maintained at the correct setting at all times. An overlap of 150 mm shall be made between adjacent passes
of the stabilising machine. Where a subsequent layer of material is placed on a layer previously stabilised the tines
or blades of the stabilising machine shall be set so that they cut into the previously stabilised layer below by at least
20 mm.
10 (02/16) Each layer of Class 9A, 9B or 9C processed material shall be compacted as soon as possible after the
final pass of the stabilising machine. Compaction shall be completed within 2 hours following the mixing of the
cement into the material to be stabilised. Immediately before compaction Class 9B processed material shall have a
Moisture Condition Value (MCV) of not greater than 12 nor less than the figure stated in contract specific Appendix
6/1 for Class 9B cement stabilised material, both as determined in accordance with Clause 632. Water shall be
added if necessary in a uniform manner to enable this MCV requirement to be met. Any added water shall have a
sulfate content not exceeding 1400 mg/l as SO4 when tested in accordance with BS EN 1744-1 clause 10.
11 (02/16) The compaction of each layer of Class 9A or 9B material shall comply with Clause 612, Table 6/4
Method 6 or Method 7 respectively, except that if layers of Class 9A or 9B greater than 250 mm thickness are to be
constructed, the number of passes of the compaction plant shall be determined from the results of a demonstration
area as detailed in contract specific Appendix 6/7.
12 (02/16) The compaction of Class 9C material shall comply with Clause 612, end product compaction, to satisfy
the compaction requirements given in Table 6/1 of this Class.
13 (02/16) Class 9A, 9B and 9C materials shall be cured in accordance with Clause 1035. During periods when the
air temperature is forecast to drop below 3°C or when ground frost is forecast Class 9A, 9B and 9C material shall
be protected, to prevent freezing, for a period of 7 days from the time of completion of compaction. Such protection
shall be sealed to prevent the ingress of moisture.
14 (02/16) Class 9A, 9B and 9C materials shall not have other material deposited or compacted above them until
such time as the required bearing ratio in contract specific Appendix 6/1 has been achieved. The relaxation allowed
in sub-Clause 617.2 shall not apply before this time.
615 (02/16) Lime Stabilisation to Form Capping

1 (02/16) This Clause shall apply only to those capping materials which are to be stabilised with lime to form
material Class 9D.
2 (02/16) Material to be stabilised with lime shall be Class 7E material complying with Clause 601 and Table 6/1.
3 (02/16) The form of lime used for lime stabilisation shall be as required in contract specific Appendix 6/7,
the lime shall conform to BS EN 459-1 and meet the performance requirements stated in contract specific
Appendix 6/7. This shall be demonstrated by the Declaration of Performance. Unless otherwise stated in contract
specific Appendix 6/7 lime shall be either quicklime or hydrated lime conforming to BS EN 459-1. The particle size
distribution of all types of quicklime shown in Tables 1 and 8 of BS EN 459-1 shall be of designation P4 as shown
in Tables 5 and 12 of BS EN 459-1.

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Volume 1 Series 600
4 (02/16) The Contractor shall carry out testing of the lime as installed for available lime in accordance with
Clause 641 at weekly intervals unless otherwise required in contract specific Appendix 6/7 during periods when
lime stabilisation is carried out. The results shall be reported to the Overseeing Organisation. The available lime
shall meet the requirements stated in contract specific Appendix 6/7 and the values stated in the Declaration of
Performance.
5 (02/16) Class 7E material to be stabilised shall have added to it, at any point, the percentage of its dry weight
of lime, as determined on the demonstration area, to meet the required bearing ratio in contract specific Appendix
6/1, subject to a minimum of 2½% by weight of ‘available lime’ as a percentage of the dry weight of the Class 7E
material.
6 (02/16) Lime of quantity complying with sub-Clause 5 of this Clause shall be uniformly spread by a suitable
spreading machine on top of the layer to be stabilised. Using a collecting tray and balance the Contractor shall
check the rate of spread by weight, once for every 500 m² of lime spread or a different rate of testing for the rate of
spread as described in contract specific Appendix 6/7. At the same time the Contractor shall collect samples of lime
deposited on the tray and test them for available lime content in accordance with Clause 641.
7 (02/16) Unless indicated otherwise in contract specific Appendix 6/7, the material shall be stabilised in a single
layer if its compacted thickness is 250 mm or less. If its compacted thickness is greater, the material shall be
stabilised in layers not less than 130 mm and not more than 250 mm thick, including any cutting-in required by
8 (02/16) Unless indicated otherwise in contract specific Appendix 6/7 lime stabilisation shall be carried out only
during the months of March to September inclusive and when the shade temperature is not below 7°C. Only when
the specified bearing ratio is attainable at a shade temperature less than 7°C, may lime stabilisation be carried out at
such lower temperature. Lime stabilisation shall be suspended if rainfall will have an adverse effect on the material
being stabilised. The spreading of lime shall not be carried out in a manner or under conditions that will result in
lime being blown from the site onto adjacent land or property.
9 (02/16) Unless indicated otherwise in contract specific Appendix 6/7, the material forming the layers to be
stabilised shall be processed by pulverising and mixing in the lime by means of sufficient number of passes of a
suitable mobile stabilising machine until 95% of the Class 9D processed material passes a BS 28 mm sieve after
dry sieving and the pulverisation complies with Table 6/1.
10 (02/16) During processing sufficient water shall be available in the material to slake the quicklime (if used) and
to enable satisfactory mixing and compaction to be achieved. Any added water shall be through an integral spray-
bar on the stabilising machine. Any added water shall have a sulfate content not exceeding 1400 mg/l as SO4 when
tested in accordance with BS EN 1744-1 clause 10.
11 (02/16) The layer shall receive at least two passes of the stabilising machine to pulverise and mix the lime and
soil, after which the processing shall be interrupted by a period of not less than 24 hours and not greater than 72
hours, to enable the lime to react with the soil. Before this period commences the surface of the layer shall be
sealed with one pass of a smooth wheeled roller having a mass per metre width of roll of not less than 2700 kg or
a pneumatic tyred roller of not less than 1000 kg per wheel. At the end of this period the layer shall receive one
further pass of the stabilising machine or more if required to enable the material to comply with sub-Clauses 9 and
13 of this Clause, adding water uniformly if necessary. Any added water shall have a sulfate content not exceeding
1400 mg/l as SO4 when tested in accordance with BS EN 1744-1 clause 10.
12 (02/16) The stabilising machine shall be equipped with a device for controlling the depth of processing which shall
be maintained at the correct setting at all times. An overlap of 150 mm shall be made between adjacent passes of the
stabilising machine. Where a subsequent layer of material is placed on a layer previously stabilised the tines or blades
of the stabilising machine shall be set so that they cut into the previously stabilised layer below by at least 20 mm.
13 (02/16) Each layer of Class 9D processed material shall be compacted as soon as possible after the final pass of
the stabilising machine. Immediately before compaction the processed material shall have a Moisture Condition
Value (MCV) of not greater than nor less than the figures stated in contract specific Appendix 6/1, for Class 9D
lime stabilised material, both as determined in accordance with Clause 632.

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Volume 1 Series 600
14 (02/16) If there is a delay following the final pass and before commencement of compaction the surface shall be
sealed by not less than 2 passes of a smooth-wheeled roller having a mass per metre width of not less than 2,700 kg or
of a pneumatic tyred roller of not less than 1,000 kg mass per wheel. On recommencement and before compaction the
layer shall be re-processed without the addition of lime, by a sufficient number of passes of the stabilising machine to
meet the MCV requirements of sub-Clause 13 of this Clause adding water uniformly if necessary.
15 (02/16) The compaction of each layer shall comply with Clause 612, Table 6/4 Method 7 except that if layers
more than 250 mm thick are constructed the number of passes of the compaction plant shall be those determined
from results obtained on a demonstration area as detailed in contract specific Appendix 6/7.
16 (02/16) Class 9D material shall not have other material deposited or compacted above it until such time as the
required bearing ratio in contract specific Appendix 6/1 has been achieved. The relaxation allowed in sub-Clause
617.2 shall not apply before this time.
616 (02/16) Preparation and Surface Treatment of Formation

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1 (02/16) The formation shall, after completion of any subgrade drainage, and immediately before laying sub-
base on areas of completed formation, have a surface level tolerance within +20 mm and -30 mm, or other level of
tolerance defined in contract specific Appendix 6/7 relative to its designed level after completion of the following
operations as necessary:
(i) Any protection layer shall be removed and any soft or damaged areas shall be rectified by excavating
them and replacing with acceptable material having the same characteristics and strength as the
surrounding material. The surface of the formation shall be trimmed and immediately cleaned
free from mud and slurry which shall be dealt with as unacceptable material in accordance with
sub‑Clause #601.2.
(ii) The formation shall immediately be compacted, in addition to the compaction required for the fill.
This additional compaction shall for this purpose be assumed to be as for a layer of 250 mm finished
thickness compacted in compliance with Clause 612 and Table 6/4 Method 6 except for Class 3
materials where Method 4 shall be used. Immediately after the additional compaction the formation shall
be trimmed to achieve the tolerances of this sub-Clause.
2 (02/16) Where the tolerances in sub-Clause 1 of this Clause are exceeded, the Contractor shall determine the full
extent of the area which is out of tolerance and shall make good the formation as follows:
(i) if the surface is too high it shall be re-trimmed and re-compacted in compliance with Clause 612 and
sub-Clause 1 of this Clause;
(ii) if the surface is too low it shall be corrected by the addition of acceptable material complying with Table
6/1 having characteristics and strength matching the overlain material, deposited and compacted in
compliance with Clause 608 and 612 and sub-Clause 1 of this Clause. In cohesive materials Classes 2
and 7, where this low surface is less than 150 mm below formation, material shall be removed to a depth
of at least 150 mm below formation before the additional material is deposited and compacted.
3 (02/16) After trimming, or re-trimming if necessary, the formation shall be rolled with one pass of a
smoothwheeled roller having a mass per metre width of roll not less than 2100 kg or, except for Class 3 material,
a vibratory roller having a mass per metre width of vibrating roll of not less than 700 kg or a vibrating plate
compactor having a mass per m² under the base plate of not less than 1,400 kg.
4 (02/16) Where required in contract specific Appendix 6/7 or where the tolerances in sub-Clause 1 of this Clause
cannot be achieved in the preparation of formation in rock then one of the following shall be carried out so as to
achieve the above tolerances:
(i) the material shall be excavated below formation to the depth described in contract specific Appendix 6/7.
The excavated material shall be processed as described in contract specific Appendix 6/7 and re-
deposited and compacted in compliance with Clauses 608 and 612 and Table 6/4 Method 6 in compacted
layers not greater than 250 mm thick; or

Volume 1 Series 600
(ii) where the rock surface is tabular it shall be regulated by depositing and compacting cement bound
material as described in contract specific Appendix 6/7, complying with the 1000 Series, or ST1 concrete
to Clause 2602.
5 (02/16) The Contractor shall limit any areas of completed formation to suit the output of plant in use and the rate
of deposition of sub-base. No formation of cohesive material Classes 2 and 7 shall remain continuously exposed to
rain causing degradation or be left uncovered overnight.
6 (02/16) The preparation of formation on existing sub-base material shall be completed as described in contract
617 (02/16) Use of Sub-formation or Formation by Construction Plant

1 (02/16) Construction plant and other vehicular traffic (except that required for the construction of capping) shall
not be operated on the sub-formation, unless adequate protection, if necessary in addition to any weather protection,
is provided.
2 (02/16) Construction plant and other vehicular traffic (except for that required for preparation of the formation
in compliance with Clause 616) shall not be operated on the formation unless adequate protection, if necessary in
addition to any weather protection is provided.
3 (02/16) In addition to the requirements of sub-Clauses 1 and 2 of this Clause, the Contractor shall make
available to the Overseeing Organisation his proposals for the protection of the sub-formation or formation in
areas where they are within 300 mm of the existing ground level, after topsoil has been stripped, before using
construction plant or other vehicular traffic at or above sub-formation or formation.
618 (02/16) Topsoiling

1 (02/16) Topsoiling shall be carried out using Class 5 material complying with Table 6/1.
2 (02/16) Imported topsoil, Class 5B material, shall only be imported when required in contract specific Appendix
6/8, or contract specific Appendix 30/6.
3 (02/16) When required in contract specific Appendix 6/8 topsoil shall not be excavated from stockpiles, whether
on site or imported:
(i) which have been exposed to a cumulative rainfall exceeding 100 mm, or other figure stated in contract
specific Appendix 6/8, over the preceding 28 days measured at a point detailed in contract specific
Appendix 6/8; or
(ii) when heavy rain is falling; or
(iii) with a tracked vehicle; or
(iv) which have been stockpiled for more than 2 years; or
(v) which are frozen; or
(vi) in the case of topsoil which has been stockpiled for more than 6 months, unless the stockpile has been
treated with a total, non-residual herbicide as recently as is seasonally possible (allowing the period of
time recommended by the manufacturer to elapse prior to excavation).
4 (02/16) Topsoil shall:
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(i) be deposited and spread on the areas, to the thicknesses described in contract specific Appendix 6/8,
in layers not exceeding 150 mm. Each layer shall be firmed before spreading the next. The thickness
shall be reduced where necessary to allow for any subsequent turfing required in contract specific
Appendix 30/5 (it shall not be spread using a tracked vehicle, when so stipulated in contract specific
Appendix 6/8);

Volume 1 Series 600
(ii) have stones and other debris removed and disposed off site which have:
(a) dimensions greater than 100 mm equivalent diameter, unless otherwise permitted in contract
specific Appendix 6/8; and
(b) dimensions greater than 50 mm equivalent diameter which lie within 50 mm of the surface;
(iii) be graded to smooth contours, eliminating all mounds and depressions where water may collect;
(iv) not have stones or other debris protruding above the surface by more than 30 mm, and comply with the
further requirements of Clauses 3004 and 3005.
619 (02/16) Earthwork Environmental Bunds

1 (02/16) Earthwork environmental bunds shall be constructed in the locations described in contract specific
Appendix 6/9 with fill materials complying with the requirements therein and Clause 601 and Table 6/1. Deposition
shall be in accordance with Clause 608 and compaction with the requirements of Table 6/1 unless otherwise
described in contract specific Appendix 6/9 or the requirements of sub-Clauses 2 or 3 of this Clause apply.
2 (02/16) Earthwork environmental bunds formed of reinforced or anchored earth shall be constructed in
compliance with Clauses 2502 and 622.
3 (02/16) Earthwork environmental bunds formed of strengthened embankments shall be constructed in
4 (02/16) Where required in contract specific Appendix 6/9 earthwork environmental bunds shall be topsoiled in
accordance with Clause 618 and seeded, or turfed, all in accordance with Clause 3001 and Clause 3005.
620 (02/16) Landscape Areas

1 (02/16) Landscape areas shall be constructed in the locations shown in contract specific Appendix 6/9 with Class
4 material as described therein and complying with Table 6/1.
2 (02/16) Unless method compaction to Clause 612 is required in contract specific Appendix 6/9 the degree of
compaction of Class 4 material shall be sufficient to remove large voids and to produce a coherent mass whilst
preventing over-compaction and any build up of excess pore pressures.
3 (02/16) Following completion of filling of landscape areas, Class 4 material shall where required in contract
specific Appendix 6/9, be shaped as described therein.
4 (02/16) Class 4 material shall be deposited in landscape areas after any adjoining embankment or other area of
fill has been completed. Where permitted in contract specific Appendix 6/9 and provided the adjoining embankment
or other area of fill is always kept at least 1 m higher than the landscape area fill, construction of such landscape
area may proceed until completion.
5 (02/16) Landscape areas shall be topsoiled in accordance with Clause 618 and seeded or turfed in accordance
with Clause 3001 and Clause 3005 to the requirements of contract specific Appendix 30/5.
621 (02/16) Strengthened Embankments

1 (02/16) Strengthened embankments shall be constructed in the locations and to the details described in contract
specific Appendix 6/9 with fill materials and strengthening materials described therein.

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Volume 1 Series 600
622 (02/16) Earthworks for Reinforced Soil and Anchored Earth Structures
1 (02/16) The construction of earthworks for reinforced soil and anchored earth structures together with assembly
and erection of reinforcing and anchor elements and associated components shall be in compliance with this Clause
and Clause 2502.
2 (02/16) Excavation shall be carried out in compliance with Clause 604.
3 (02/16) Fill for reinforced soil structures shall, except for their associated drainage layers, be of Class 6I, 6J, 7B,
7C or 7D selected material complying with Table 6/1 as permitted in contract specific Appendix 6/1 together with
any other additional requirements therein. Where Class 7B conditioned pulverised-fuel ash is used for fill, only
non-metallic reinforcing elements shall be used and metallic fasteners shall be of stainless steel.
4 (02/16) Fill for anchored earth structures shall, except for their associated drainage layers, be of 6I or 6J selected
material complying with Table 6/1 as permitted in contract specific Appendix 6/1 together with any other additional
requirements therein.
5 (02/16) Drainage layers to reinforced soil and anchored earth structures shall be one of the following as
appropriate:
(i) Class 6H material complying with Table 6/1 and contract specific Appendix 6/1.
(ii) for use with Class 7B material, uncrushed, partially crushed or crushed gravel sand complying with
BS EN 12620, fines content category f3 and sizes 0/4(CP), 0/4(MP) or 0/2(MP) and, when in contact
with metallic components, with the properties listed in Table 6/3.
(iii) Type B filter drain material complying with Clause 505 for use only in horizontal drainage layers.
Vertical layers of drainage layer material shall be brought up at the same rate as the adjoining fill
material without mixing or contamination.
6 (02/16) In addition to the requirements of sub-Clauses 7 and 8 of this Clause, fill for reinforced soil and
anchored earth structures shall be deposited and compacted in compliance with Clauses 608 and 612 and Table
6/1, with method compaction for Classes 6H, 6I, 6J, 7C and 7D materials and end-product compaction for Class
7B material. Drainage layer material other than Class 6H shall be deposited in accordance with Clause 608 and
compacted as described in contract specific Appendix 6/3.
7 (02/16) Reinforced soil and anchored earth structures shall have:
(i) the deposition and compaction carried out so that all layers of reinforcing and anchor elements are fixed
at the required levels on top of compacted fill;
(ii) the deposition, spreading, levelling and compaction of the fill carried out generally in a direction parallel
to the facing and executed in stages to alternate with the placing and fixing of the reinforcing and anchor
elements and the facing elements;
(iii) the reinforcing and anchor elements kept as free as possible from damage or displacement during
deposition, spreading, levelling and compaction of the fill (also the programme of filling shall be
arranged so that no machines or vehicles run on the reinforcing or anchor elements);
(iv) all construction plant, and all other vehicles, having a mass exceeding 1,000 kg, kept at least 2 m away
from the back of the facing;
(v) within 2 m of the back of the facing, the plant used for compacting the fill restricted to the following
items as described in sub-Clause 612.10 and listed in Table 6/4:
(a) vibratory roller having a mass per metre width of roll not exceeding 1,300 kg with a total mass not
exceeding 1,000 kg;
(b) vibrating plate compactor having a mass not exceeding 1,000 kg;

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Volume 1 Series 600
(c) vibro tamper having a mass not exceeding 75 kg;

(vi) at the Contractor’s option, the reinforced soil and anchored earth fill beyond the 2 m zone referred to
in (v) above, raised in thicker layers than within the 2 m zone, providing this is compatible with the
arrangement of the reinforcing and anchor elements and the difference in compacted level does not
exceed 300 mm;
(vii) during construction of the reinforced soil or anchored earth structure the retained fill at the rear of
the structure, as defined in sub-Clause 8 of this Clause, maintained at the same level as the adjoining
reinforced soil or anchored earth fill;
(viii) if the retained material at the rear of the reinforced soil or anchored earth structure, as defined in
sub-Clause 8 of this Clause, is an existing earthwork or natural slope which requires supporting by
temporary shoring, this shoring shall be removed progressively as the work proceeds to prevent the
formation of voids.
8 (02/16) The rear of the reinforced soil or anchored earth structure is the position coinciding with the ends of the
reinforcing or anchor elements furthest from the facing units.
623 (02/16) Earthworks for Corrugated Steel Buried Structures

1 (02/16) The construction of earthworks for corrugated steel buried structures together with assembly and
erection of their components shall be in compliance with this Clause and Clause 2501.
2 (02/16) Excavation shall be carried out in compliance with Clause 604 and any additional requirements given in
3 (02/16) Fill for corrugated steel buried structures shall be of the following selected granular materials complying
with Table 6/1:
(i) Lower bedding material Class 6K;
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(ii) Upper bedding material Class 6L;

(iii) Surround material Class 6M.
and the overlying fill shall be one of the following:
(iv) Well graded, uniformly graded or coarse, granular material Class 6Q; or
(v) Wet, dry, stony or silty cohesive material and chalk Class 7H.
4 (02/16) In addition to the requirements of sub-Clauses 5 to 14 of this Clause, Class 6K, 6L and 6M materials
shall be deposited in compliance with Clause 608 and shall (except for Class 6L upper bedding material which shall
be uncompacted) be end-product compacted in compliance with Clause 612 and Table 6/1,
except that the compacted layers shall not exceed 150 mm thickness. The compaction and testing requirements for
Class 6K lower bedding and Class 6M surround materials shall also comply with any additional requirements given
5 (02/16) As far as possible, the Class 6K lower bedding material shall be shaped to fit the invert such that it
supports 20% of the circumference of circular structures or the whole of the portion of circumference occupied
by the bottom plates of multi-radii structures. In the case of structures of span less than 3 m where this cannot be
met and the structure is erected on a flat or partially preshaped bedding, care shall be taken to ensure that the lower
bedding material is properly placed and compacted under the haunches. A uniform layer of uncompacted Class 6L
upper bedding material shall be deposited before the placing of any part of the steel structure, over the whole width
of the shaped lower bedding material and shall be of sufficient depth to fill the corrugations of the underside of the
structure.
6 (02/16) Class 6M surround material shall be used for filling all excavations above the bedding, except those in
hard material for which Class 6K lower bedding material shall be used throughout. Additional requirements for
making good are given in Clause 604.

Volume 1 Series 600
7 (02/16) Class 6M surround material shall be deposited and compacted uniformly on either side of the structure.
The maximum difference in fill level on opposite sides of the structure shall be no more than 250mm at all times
unless otherwise permitted in contract specific Appendix 6/3.
8 (02/16) Class 6M surround material shall be deposited and compacted in accordance with sub-Clause 4 of this
Clause, above the concrete foundations of arch-profile corrugated steel buried structures.
9 (02/16) Class 6M surround material under the structure shall be well compacted by hand using a suitably sized
pole or length of rectangular timber between the corrugations, or by another suitable method.
10 (02/16) Plant for compaction of Class 6M surround material within 1 m of either side of the structure and up
to a height of 1 m, or one fifth of the span if greater, above the crown, shall be restricted to the following items, as
described in sub-Clause 612.10 and listed in Table 6/4:
(i) vibratory rollers having a mass per metre width of roll not exceeding 750 kg;
(ii) vibrating plate compactors having mass not exceeding 750 kg;
(iii) vibro-tampers.
11 (02/16) Fill placed above the level of the crown of the structure, including Class 6M surround material, shall
be deposited, spread and compacted in such a manner that any out of balance forces transmitted to the culvert are
kept to a minimum. This will require that trafficking by construction plant is not all in one direction and that the
compacted surface of the fill is kept as near horizontal as practicable.
12 (02/16) During all operations of filling, compaction, road pavement construction and of any other traffic
movements which affect the shape of the structure, the changes in the horizontal and vertical diameters of the
structure shall not exceed ± 5% for circular structures and ± 2% for structures of other cross-sections. The
longitudinal straightness over any 10 m length of the structure shall not deviate by more than 25 mm, and the
rotational displacement in any 10 m length of structure shall not be greater than 25 mm.
13 (02/16) Only that compaction plant described in sub-Clause 10 of this Clause, shall be used in the vicinity of
the structure unless the depth of compacted Class 6M surround material placed above the crown of the structure is
more than 1 m, or one fifth of the span, whichever is the greater. The structure shall not be subjected to a surcharge
greater than the depth of fill required in the contract and permitted depth of any protection layer given in contract
14 (02/16) No material shall be placed by tipping either onto the structure or within a distance on either side of the
structure of 2 m or half the span of the structure, whichever is the greater.
15 (02/16) Method compaction shall be used for the overlying fill (Classes 6Q and 7H) according to Clause 612;
the method used being that for the corresponding general fill in Table 6/1.
624 (02/16) Ground Anchorages

1 (02/16) The Contractor shall design the ground anchorages required as part of the permanent works and listed
in contract specific Appendix 1/10, in accordance with the design requirements described in contract specific
Appendix 6/10. The ground anchorages shall be installed and where required in contract specific Appendix 6/10
proof loaded, in accordance with the requirements therein.
2 (02/16) Ground anchorages not forming part of the permanent works will only be permitted where such
anchorage will not affect the permanent works.
625 (02/16) Crib Walling

1 (02/16) The Contractor shall design the crib walling listed in contract specific Appendix 1/10 in accordance
with the design specification and procedures in contract specific Appendix 6/10 and Design Manual for Roads and
Bridges document BD 68 (DMRB 2.1.3).

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Volume 1 Series 600
626 (02/16) Gabions

1 (02/16) Gabions shall be manufactured and constructed in compliance with this Clause and with requirements
stated in contract specific Appendix 6/10. Gabion units shall be assembled in accordance with the manufacturer’s
instructions.
2 (02/16) Unless otherwise stated in contract specific Appendix 6/10 they shall be filled with Class 6G material
complying with Table 6/1. The grading of fill shall be as described in Appendix 6/10, the maximum size of fill
material shall not exceed two thirds of the minimum dimension of the gabion compartment or 200mm whichever is
smaller and the minimum size of the fill material shall be not less than the size of the mesh opening.
Gabion units shall be filled to fully achieve the required minimum cage density and compaction of fill. At no point
before, during or after filling shall the cage be deformed by working methods or in use loading. The required cage
density shall be as stated in contract specific Appendix 6/10. Internal tie wires shall be inserted and units shall be
tensioned in accordance with the manufacturer’s instructions. Gabion units shall be constructed so as to maintain
tightness of mesh and shall be laced securely with wire, complying with sub-Clause 3 of this Clause.
3 (02/16) Gabion wire mesh units shall be woven steel wire conforming to BS EN 10223-3 or welded steel mesh
conforming to BS EN 10223-8. The Contractor shall submit documentary evidence to the Overseeing Organisation
to demonstrate compliance of the gabion units at least four weeks prior to the commencement of gabion work.
Documentation that demonstrates compliance with a product acceptance scheme as described in Clause 104 sub-
Clauses 15 and 16 can be supplied to meet this requirement where the scheme demonstrates that the gabion units
meet the level of performance required by the specification.
Unless otherwise stated in contract specific Appendix 6/10 the site environment level shall be High Aggressive:
C4; and the Assumed Working Life shall be 120 years or greater. Coating requirements for all wire shall be as
required by Tables 1 and A.1 of BS EN 10223-3 and BS EN 10223-8.
4 (02/16) Unless otherwise stated in contract specific Appendix 6/10 woven steel gabions shall be of mesh
designation 6x8 or 8x10 with minimum wire diameter of 2.7mm.
5 (02/16) Unless otherwise stated in contract specific Appendix 6/10 welded mesh shall be 3mm to 5mm diameter
bars with the mesh size 75mm x 75mm maximum.
627 (02/16) Swallow Holes and Other Naturally Occurring Cavities

1 (02/16) Infilled swallow holes and other naturally occurring cavities shall where required in contract specific
Appendix 6/11 be excavated, filled and capped as described in contract specific Appendix 6/11.
2 (02/16) Open swallow holes and other shallow cavities shall where required in contract specific
Appendix 6/11 be flushed, cleared of rubbish where to do so would not endanger operatives, and filled and capped
as described in contract specific Appendix 6/11.
628 (02/16) Disused Mine Workings

1 (02/16) Disused mine workings shall, where required in contract specific Appendix 6/11 be investigated,
inspected, monitored, cleared, flushed, filled, capped or have any other treatment carried out, all as described in
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629 (02/16) Instrumentation and Monitoring

1 (02/16) Instrumentation, other than that required in compliance with Clause 607, shall be as described in
contract specific Appendix 6/12 and shall be installed in the locations shown therein.
2 (02/16) Monitoring of instrumentation shall be carried out as required in the contract specific Appendix 6/12 and
the results supplied to the Overseeing Organisation as required therein.

Volume 1 Series 600
630 (02/16) Ground Improvement

(02/16) Dynamic Compaction
1 (02/16) Dynamic compaction, carried out to either method or end-product as required in contract specific
Appendix 6/13 and achieved by dropping a free-falling heavy mass (pounder) a number of times at pre-
determined spacings on the surface of the ground or fill, shall be applied to the areas described in contract specific
Appendix 6/13.
2 (02/16) Dynamic compaction shall be completed before the commencement of construction of any permanent
works, or work on the placement or diversion of Statutory Undertaker’s equipment, within that part of the site
defined in the contract specific Appendix 6/13 which contains the area to be dynamically compacted.
3 (02/16) The Contractor shall ensure that no damage or injury is caused to persons or property on or off the site
as a result of the dynamic compaction.
(02/16) Vibrated Stone Columns
4 (02/16) Vibrated stone columns in existing natural soils or fill by vibroreplacement or vibrodisplacement shall
be formed in the manner and in the areas described in contract specific Appendix 6/13.
5 (02/16) Unless otherwise described in contract specific Appendix 6/13, materials shall comply with sub‑Clause 8
of this Clause.
6 (02/16) The Contractor shall report immediately to the Overseeing Organisation any circumstance which
indicates that in the Contractor’s opinion the ground conditions differ from those expected from his interpretation
of the ground investigation reports.
7 (02/16) Columns shall be installed as shown on the drawings and within the permitted tolerances stated in
(02/16) Materials
8 (02/16) The material used to form the columns shall be clean, hard, inert material and shall be natural sand,
gravel, crushed rock other than argillaceous rocks, crushed hardcore, crushed concrete, crushed slag or well burnt
non-plastic shale. The material shall be appropriate to the ground conditions in which the stone columns are formed
and its use shall not be detrimental to any other work on site. The material shall be nominally single sized coarse
aggregate with a value of upper (D) sieve size in the range 10 mm to 40 mm or a graded material complying with
Clause 804 (Type 2 unbound mixtures for subbase) except the material passing the 0.425 mm sieve shall be non-
plastic when tested in accordance with BS1377: Part 2.
(02/16) Testing of Ground Treatment
9 (02/16) Testing of treated ground shall be undertaken for control purposes during the treatment and on
completion of the ground treatment. The performance criteria for treated ground are given in contract specific
Appendix 6/13.
10 (02/16) Improvement in treated ground shall be measured in accordance with the criteria stated in contract
(02/16) Types of Test
11 (02/16) The following tests or alternatives permitted in contract specific Appendix 6/13 shall be carried out at
the positions and frequency given in contract specific Appendix 6/13.
(02/16) Plate tests
12 (02/16) Plate bearing tests are loading tests carried out using a plate on treated ground. The test is described in
BS 1377: Part 9: 1990 Method 4.1.

Volume 1 Series 600
(02/16) Zone Tests

13 (02/16) Zone tests are loading tests carried out with a slab, intended to test bearing pressure over a wider and
deeper zone than in the plate tests. The test is described in BS 1377: Part 9: 1990 Method 4.2.
(02/16) Penetration Tests
14 (02/16) In granular soils the static cone (Dutch cone) penetration test, the standard penetration test (SPT) or
dynamic cone penetration tests shall be employed as described in contract specific Appendix 6/13.
(02/16) Trial Areas
15 (02/16) Trial areas are to be treated and tested where required in contract specific Appendix 6/13. Trial areas
which meet the performance requirements may form part of the permanent works.
16 (02/16) Equipment and materials used in trial areas shall be identical to those proposed for the permanent works.
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17 (02/16) Testing in trial areas shall be carried out as given in contract specific Appendix 6/13.
18 (02/16) Detailed reports shall be prepared for all testing as defined in Table 6/6.
(02/16) Records and Reports
19 (02/16) Complete records of plant, equipment and materials shall be maintained during all ground treatment
operations.
20 (02/16) Records shall be made available to the Overseeing Organisation including all information identified
in Table 6/6 and any other information required by contract specific Appendix 6/13. All records pertaining to a
particular day’s operations shall be made available to the Overseeing Organisation at the start of the following day’s
operations.
(02/16) Other Methods
21 (02/16) Other methods of ground improvement shall be carried out where required in contract specific Appendix
6/13 and as described therein.
631 (02/16) Earthworks Materials Tests

1 (02/16) Unless otherwise described in the contract sampling and testing of earthworks materials shall be carried
out in accordance with BS 1377: Part 1 to Part 9 inclusive.
#632 (02/16) Determination of Moisture Condition Value (MCV) of Earthworks Materials

1 (02/16) Where the Moisture Condition Value (MCV) is to be determined, the determination shall be carried out
in accordance with BS 1377: Part 4.
2 (02/16) The determination of the MCV/moisture content relation in accordance with BS 1377: Part 4 shall be
carried out when required in contract specific Appendix 6/1.
3 (02/16) Where permitted in contract specific Appendix 6/1 the rapid assessment procedure for material
acceptability also given in BS 1377: Part 4 may be used.
633 (02/16) Determination of Undrained Shear Strength of Remoulded Cohesive Material

1 (02/16) Where required in contract specific Appendix 6/1, the undrained shear strength of cohesive soil under
total stress conditions shall be determined from triaxial compression tests performed on remoulded specimens
and tested under conditions where the lateral pressure is maintained constant and there is no change in total

Volume 1 Series 600
water content of the specimens. Unless otherwise required in contract specific Appendix 6/1, the tests shall be in
accordance with BS 1377: Part 7 and the additional requirements of sub-Clauses 2 to 4 of this Clause.
2 (02/16) The specimens shall be prepared in accordance with BS 1377: Part 7 using remoulded material
compacted into a split mould of nominal diameter 100 mm and nominal height 200 mm. The soil shall be at its
natural moisture content and compacted in accordance with BS 1377: Part 1 using the 2.5 kg rammer method
described in BS 1377: Part 4.
3 (02/16) The specimens shall be tested at an operating cell pressure of 200 ± 10 kN/m² and an axial strain rate of
1% per minute. Where contract specific Appendix 6/1 requires c and ϕ to be determined, the test shall be modified
to enable Mohr circles to be plotted and c and ϕ reported.
4 (02/16) Where stated and described in contract specific Appendix 6/1, other tests may be used during
construction to supplement the test described above, provided the results have been correlated to ensure
compatibility.
634 (02/16) Determination of Intact Lump Dry Density (IDD) of Chalk

1 (02/16) The intact lump dry density (IDD) of chalk lumps shall be determined in accordance with
BS 1377: Part 2.
635 (02/16) Los Angeles and Other Tests for Particle Soundness
(02/16) Resistance to Fragmentation – Los Angeles Coefficient (LA)
1 (02/16) The value of Los Angeles coefficient shall be determined in accordance with BS EN 1097-2.
(02/16) Other Tests for Particle Soundness
2 (02/16) Where contract specific Appendix 6/1 requires magnesium sulfate soundness tests to be carried out,
they shall be carried out in accordance with BS EN 1367-2. Where contract specific Appendix 6/1 requires slake
durability, point load or other tests for soundness to be carried out, they shall be carried out in accordance with the
procedures given therein.
636 (02/16) Determination of Effective Angle of Internal Friction (ϕ/) and Effective Cohesion (c/)
of Earthworks Materials
1 (02/16) The effective angle of internal friction ϕ/ and effective cohesion c/ shall be determined by shear box
or triaxial tests as required in Table 6/1 and contract specific Appendix 6/1. Unless otherwise required in contract
specific Appendix 6/1, the tests shall be in accordance with the requirements in sub-Clauses 2 to 6 of this Clause.
(02/16) Shear Box Tests
2 (02/16) For Classes 6N, 6P, 6I and 6J granular materials, the tests shall be carried out in accordance with
BS 1377: Part 7 and the following:
(i) The plan size of the shear box shall be nominally 300 mm square.
(ii) Three samples shall be tested, each sample occupying the full depth of the shear box and shall be
compacted at the optimum moisture content to a dry density of 92% ± 2% of the maximum dry density
determined in accordance with BS 1377: Part 4 using the vibrating hammer method. The samples shall
not be immersed in water.
(iii) Each of the samples shall be subjected to a different normal stress equal to the maximum vertical
pressure in the fill at the base, quarter height and mid-height of the structure respectively. Each of the

Volume 1 Series 600
samples shall be sheared in a single stage test within one hour of compaction and the rate of shearing
shall be such that no pore water pressure is generated.
(iv) The values of c/ and ϕ/ reported shall be those corresponding to the maximum strength envelope.
3 (02/16) For Classes 7A, 7C and 7D cohesive materials, the tests shall be carried out in accordance with
BS 1377: Part 7 and the following:
(i) The shear boxes shall be nominally 300 mm square and nominally 60 mm square.
(ii) For the initial determination of fill properties three samples shall be tested in each size of shear box. The
samples shall occupy the full depth of the shear box and shall be compacted at the optimum moisture
content to a dry density of 92% ± 2% of the maximum dry density determined in accordance with BS
1377: Part 4 using the 4.5 kg rammer method. To allow the samples to soften, the shear box assembly
shall then be immersed in water for a minimum period of 24 hours.
(iii) Each of the three samples in a set shall be subjected to a different effective normal stress equal to
the maximum vertical pressure in the fill at the base, quarter height and mid-height of the structure
respectively. Normal stresses shall be applied to the softened sample for a minimum period of 24 hours
prior to shearing in a single stage test. The rate of shearing shall be such that no pore water pressure is
generated.
(iv) The values of c/ and ϕ/ reported shall be those corresponding to the maximum strength envelope.
(v) The test results obtained using the 300 mm square box shall be taken as the properties of the fill. The
initial test results obtained using the 60 mm square box shall be used for the subsequent quality control
of the fill.
4 (02/16) For Class 7B pulverised-fuel ash material, the procedure shall be as for sub-Clause 3 of this Clause
except that:
(i) The maximum dry density and optimum moisture content shall be determined in accordance with
BS 1377: Part 4 using the 2.5 kg rammer method.
(ii) An additional sample in each set shall be subjected to an effective normal stress equal to the maximum
vertical pressure in the fill at three quarters of the height of the structure or the lowest attainable normal
stress, whichever is the greater.
(iii) As soon as the shear box has been filled and the sample compacted, the normal stress shall be applied
and the sample immersed in water. This concurrent loading and immersion of the sample shall continue
for a period of 24 hours and the sample shall then be sheared without further delay.
(02/16) Triaxial Tests
5 (02/16) Where Class 7A cohesive fill to structures is to be tested by a consolidated drained triaxial test, the test
shall be in accordance with BS 1377: Part 8 using the sample size and preparation procedure in Clause 633 and the
requirements of contract specific Appendix 6/1.
637 (02/16) Determination of Resistivity (rs) to Assess Corrosivity of Soil, Rock or Earthworks
Materials
(02/16) Method of Test
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1 (02/16) Where the resistivity of the ground or of material to be used in the permanent works is required to be
determined, this shall be obtained by in situ tests as described in sub-Clause 2 of this Clause or, when required in
contract specific Appendix 6/1, by laboratory tests on samples in accordance with BS 1377: Part 3.

Volume 1 Series 600
(02/16) In Situ Resistivity Tests

2 (02/16) In situ resistivity shall be determined at the site of the structure or the cutting or the proposed borrow pit
or on stockpiles in accordance with BS 1377: Part 9 and the requirements of contract specific
Appendix 6/1.
3 (02/16) Details of the area and volume of material to be tested shall be made available to the Overseeing
Organisation together with the arrangement of electrodes in each test. The Overseeing Organisation shall be given
notice of the date, time and location of each test.
4 (02/16) At any test location, at each selected depth, two measurements shall be made such that the electrode
alignment for the second measurement is approximately at right angles to the electrode alignment for the first
measurement.
5 (02/16) At any test location, the first selected depth shall be no more than 1.5 m below the ground surface or
no more than 1.5 m below the upper surface of the material to be tested, whichever is appropriate. Following the
measurements at the first selected depth, further measurements shall be made at selected depths increasing by
approximately 2 m each time until measurements have been carried out on the full depth of ground or material to be
tested.
6 (02/16) Where the depth of material to be tested is too great to be tested from the surface within the confines of
the site, the Contractor shall undertake all necessary arrangements for testing such material, including subsequent
tests which may be required at a lower level following excavation. Details of his arrangements shall be made
available to the Overseeing Organisation.
638 (02/16) Determination of Redox Potential (Eh) to Assess Corrosivity of Earthworks Materials
for Reinforced Soil and Anchored Earth Structures
(02/16) Method of Test
1 (02/16) Where the redox potential of material to be incorporated into reinforced earth or anchored earth
structures is required to be determined, this shall be obtained by in situ tests as described in sub-Clauses 2 to 6 of
this Clause or, when required in contract specific Appendix 6/1, by laboratory tests on samples in accordance with
BS 1377: Part 3.
(02/16) In Situ Redox Potential Tests
2 (02/16) In situ redox potential shall be determined in undisturbed ground at the site of the cutting or the
proposed borrow pit or on stockpiles in accordance with BS 1377: Part 9 and the requirements of contract specific
Appendix 6/1.
3 (02/16) Details of the area and volume of material to be tested shall be made available to the Overseeing
Organisation together with the locations of the test pits.
4 (02/16) The Overseeing Organisation shall be given notice of the date, time and location of each test.
5 (02/16) At each test location the tests shall be carried out in a test pit not less than 600 mm square in plan
excavated to a depth given in contract specific Appendix 6/1.
6 (02/16) At each test location, a sample shall be taken from the base of the excavation and kept in a hermetically
sealed container for determining the pH value of the fill which shall be obtained in accordance with BS 1377:
Part 3.

Volume 1 Series 600
639 (02/16) Determination of Coefficient of Friction and Adhesion Between Fill and Reinforcing
Elements or Anchor Elements for Reinforced Soil and Anchored Earth Structures
(02/16) Reinforcing Elements
1 (02/16) The coefficient of friction and the adhesion shall be determined by tests carried out in a 300 mm size
shear box with the element material fixed at the top of the lower half of the box and the fill sample occupying the
top half only.
2 (02/16) The test shall be carried out following the procedure given in Clause 636 for the determination of the
effective angle of internal friction and effective cohesion of earthworks materials except that:
(i) The apparatus shall in addition include a steel block fitting closely inside the lower half of the shear box
and equal in height to it less the thickness of the reinforcing element material. (The flat toothed grid
fitting the bottom of the shear box is not required).
(ii) The preparation of test specimens shall be as follows:
Element material shall be cut to fit the interior plan shape of the shear box using a sufficient number of
strips of such material abutting to completely fill the interior plan area without overlap. They shall be
firmly fixed to the top of the steel block so that the top face of the material is flush with the top edge of
the lower half of the box and aligned so that shearing occurs in a direction parallel to the longitudinal
axis of a reinforcing element.
A sample of the fill material to be used in the permanent works, of sufficient size to carry out the tests,
and within the range of moisture contents permitted in Table 6/1 for such material, shall be sieved to
obtain a test sample passing the 20 mm BS sieve, of sufficient quantity after compaction to fill the top
half of the shear box. The top and bottom of the shear box shall be fixed together and the test sample
of the sieved fill materials immediately placed and compacted in the top half of the box as described in
Clause 636.
3 (02/16) The value of the coefficient of friction between the fill and the reinforcing element shall be obtained by
plotting the values of peak shear stress, obtained in the tests, against applied normal stress and by measuring the
slope of the resulting straight line graph. The adhesion between the fill and the reinforcement shall be obtained by
taking the shear stress corresponding with zero normal stress.
4 (02/16) The following additional information shall be recorded for each test:
(i) Normal stress applied (kN/m²).
(ii) Peak shear stress (kN/m²).
(iii) Strain at peak shear stress (%).
(iv) Moisture content of fill after test (Classes 7B, 7C and 7D).
(02/16) Anchor Elements
5 (02/16) Where required in contract specific Appendix 6/1, tests shall be carried out as described therein to assess
the interaction between the fill and the element.
640 (02/16) Determination of Permeability of Earthworks Materials

1 (02/16) Where required in Table 6/1 or contract specific Appendix 6/1 the permeability of earthworks materials
shall be determined as described in contract specific Appendix 6/1.

34
Volume 1 Series 600
641 (02/16) Determination of Available Lime Content of Lime for Lime Stabilised Capping
1 (02/16) Contract compliance testing shall be carried out by the Contractor to determine the available lime
content of lime as installed for lime or lime and cement stabilised capping. This compliance testing shall be carried
out in accordance with BS EN 459-2 except that the sample increments shall be taken from the collecting tray used
to check the rate of spread at intervals of one increment per 500 m per lane.
2 (02/16) The available lime content shall be determined as required by BS EN 459-2, it shall be reported and
categorised as required in BS EN 459-1.
642 (02/16) Determination of the Constrained Soil Modulus (M*) of Earthworks Materials for
Corrugated Steel Buried structures
(02/16) General
1 (02/16) When required in contract specific Appendix 6/1, the constrained soil modulus M* shall be determined
by one of the following methods:
(i) From plate loading tests in accordance with BS 1377: Part 9.
(ii) From the results of Standard Penetration resistance tests (SPT) on non-cohesive materials in accordance
with BS 1377: Part 9.
(iii) From the values of the coefficient of volume compressibility (mv) from one-dimensional consolidation
tests on undisturbed soil specimens of cohesive materials, in accordance with BS 1377: Part 5.
(02/16) Plate Loading Tests
2 (02/16) When testing compacted granular fill materials the test surface shall be prepared by either:
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(i) removing the surface layer carefully using hand tools to perform the test at a depth of 100 mm below the
surface; or
(ii) compacting the surface, after the required compaction has been applied, with two additional passes with
no vibration to remove the overstressing in the surface layer.
If necessary, the plate shall be bedded onto the fill using a small quantity of dry sand to remove
any slight unevenness of the surface of the fill. The field dry density and moisture content shall be
determined at the position of each plate loading test in accordance with Clause 612 and BS 1377: Part 2
or equivalent, respectively.
3 (02/16) When using the plate loading test to determine M* of the material existing on site a smooth surface shall
be prepared by careful hand excavation and the plate bedded onto the soil using either sand or quick setting gypsum
plaster depending on whether the soil is granular or cohesive.
4 (02/16) The loading test shall be carried out under a series of maintained loads. The maximum load shall be such
that the average pressure applied to the plate is in excess of 350 kN/m². The elastic modulus Es shall be determined
as the secant modulus between average pressures applied to the plate of 150 and 350 kN/m² in the first load cycle.
A value of Poisson’s ratio of 0.3 shall be assumed. A second load cycle testing shall also be conducted and the
results of this test compared with the first load cycle to check that the plate was seated satisfactorily during the first
load cycle. If the results of the first load cycle suggest that the plate was not seated satisfactorily, then the procedure
shall be repeated at a new location. Second load cycle results shall not be used to demonstrate the adequacy of the
material being tested.

Volume 1 Series 600
5 (02/16) The constrained soil modulus M* shall be determined from the elastic modulus Es using the equation:
(1 – v)Es
M* = (N/mm2)
(1 + v)(1 – 2v)
where v = Poisson’s ratio to be taken as 0.3
and Es = Elastic modulus of the soil (N/mm2)
(02/16) Standard Penetration resistance Tests
6 (02/16) The constrained soil modulus M* of non-cohesive materials existing on site shall be determined from
the relationship:
0.39N1.4
M* = (N/mm2)
γm
Where N = uncorrected SPT value and γm = 1.3
(02/16) One-dimensional Consolidation Tests
7 (02/16) The constrained soil modulus M* of undrained cohesive materials existing on site shall be determined
from the formula:
1
M* = (N/mm2)
mv
where mv (mm2/N) is the coefficient of volume compressibility
The value of mv to be used in the formula is that calculated from the test results for the loading increment in
the consolidation test corresponding to the in situ effective overburden pressure at the level of the crown of the
structure.
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(02/16) Number of Tests
8 (02/16) Three tests for M* shall be carried out on the soil occurring on each side of the structure, one of which is
to be at the level of the maximum span, unless otherwise described in contract specific Appendix 6/1.
643 (02/16) Lime and Cement Stabilisation to Form Capping

1 (02/16) Where capping is to consist of, either wholly or in part, lime and cement stabilised material Class 9E or
9F, this Clause shall apply to the construction of those parts which are stabilised with lime and cement.
2 (02/16) Material to be stabilised with lime and cement shall be Class 6R or 7I material all complying with
Clause 601 and Table 6/1.
3 (02/16) The form of lime used for lime and cement stabilisation shall be as required in contract specific
Appendix 6/7, the lime shall conform to BS EN 459-1 and meet the performance requirements stated in contract
specific Appendix 6/7. This shall be demonstrated by the Declaration of Performance. Unless otherwise stated in
contract specific Appendix 6/7 lime shall be either quicklime or hydrated lime conforming to BS EN 459-1. The
particle size distribution of all types of quicklime shown in Tables 1 and 8 of
BS EN 459-1 shall be of designation P4 as shown in Tables 5 and 12 of BS EN 459-1.
4 (02/16) The Contractor shall carry out testing of the lime as installed for available lime in accordance with
Clause 641 at weekly intervals unless otherwise required in contract specific Appendix 6/7 during periods when
lime and cement stabilisation is carried out. The results shall be reported to the Overseeing Organisation. The
available lime shall meet the requirements stated in contract specific Appendix 6/7 and the values stated in the
Declaration of Performance.

Volume 1 Series 600
5 (02/16) Cement for lime and cement stabilisation shall be Portland cement complying with Clause 1001, unless
6 (02/16) Classes 6R and 7I material to be stabilised shall have added to it, at any point, the percentage of its dry
weight of lime and cement as determined on the demonstration area, to meet the required bearing ratio in contract
specific Appendix 6/1, subject to a minimum of 1% by weight of ‘available lime’ and 2% cement as a percentage of
the dry weight of the 6R and 7I materials.
7 (02/16) The Contractor shall not carry out lime and cement stabilisation when the shade temperature is below
3°C unless on a rising thermometer above 0°C. Lime and cement stabilisation shall not be carried out during
periods of rain or when rain is imminent. When cement is spread on material likely to cause premature hydration,
processing in accordance with sub-Clause 16 of this Clause shall follow immediately.
8 (02/16) Lime of quantity complying with sub-Clause 6 of this Clause shall be uniformly spread by an approved
spreading machine on top of the layer to be stabilised. Using a collecting tray and balance the Contractor shall
check the rate of spread by weight, once for every 500 m2 of lime spread or a different rate of testing for the rate of
spread as described in contract specific Appendix 6/7. At the same time the Contractor shall collect samples of lime
deposited on the tray and test them for available lime content in accordance with Clause 641.
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9 (02/16) Unless indicated otherwise in contract specific Appendix 6/7, the material shall be stabilised in a single
layer if its compacted thickness is 250 mm or less. If its compacted thickness is greater, the material shall be
stabilised in layers not less than 130 mm and not more than 250 mm thick, including any cutting-in required by
10 (02/16) Unless indicated otherwise in contract specific Appendix 6/7, the material forming the layer to be
stabilised shall be processed by pulverising and mixing in the lime by means of sufficient number of passes of an
approved mobile stabilising machine until 95% of the Class 9E or 95% of the silt and clay fraction of Class 9F
processed material passes a BS 28 mm sieve after dry sieving and the pulverisation complies with Table 6/1.
11 (02/16) During processing sufficient water shall be available in the material to slake the quicklime (if used) and
to enable satisfactory mixing and compaction to be achieved. Any added water shall be through an integral spray-
bar on the stabilising machine. Any added water shall have a sulfate content not exceeding 1400 mg/l as SO4 when
12 (02/16) The layer shall receive at least two passes of the stabilising machine to pulverise and mix the lime
and soil, after which the processing shall be interrupted by a period of not less than 24 hours and not greater than
72 hours to enable the lime to react with the soil. Before this period commences the surface of the layer shall be
sealed with one pass of a smooth wheeled roller having a mass per metre width of roll of not less than 2700 kg or
a pneumatic tyred roller of not less than 1000 kg per wheel. At the end of this period the layer shall receive one
further pass of the stabilising machine or more if required to enable the material to comply with sub-Clauses 10 of
this Clause.
13 (02/16) The stabilising machine shall be equipped with a device for controlling the depth of processing which shall
be maintained at the correct setting at all times. An overlap of 150 mm shall be made between adjacent passes of the
stabilising machine. Where a subsequent layer of material is placed on a layer previously stabilised the tines or blades
of the stabilising machine shall be set so that they cut into the previously stabilised layer below by at least 20 mm.
14 (02/16) The appropriate quantity of cement shall be uniformly spread, by a suitable spreading machine, on top
of the layer previously processed with lime. Using a collecting tray and balance the Contractor shall check the rate
of spread of the machine once for every 500 m2 of cement spread.
15 (02/16) Unless indicated otherwise in contract specific Appendix 6/7, the material previously mixed with lime
shall be stabilised with cement in a single layer or in layers of the same compacted thickness as for the lime mixed
material layers, including any cutting-in required by sub-Clause 13 of this Clause.
16 (02/16) Unless indicated otherwise in contract specific Appendix 6/7, the material forming the layer to be
stabilised shall be processed by pulverising and mixing in the cement by means of a sufficient number of passes
of an approved mobile stabilising machine until 95% of the silt and clay fraction is reduced to particles or lumps
passing a BS 28 mm sieve after dry sieving and the pulverisation complies with Table 6/1.

Volume 1 Series 600
17 (02/16) During processing, sufficient water shall be available in the material to hydrate the cement and enable
satisfactory mixing and compaction to be achieved. Any added water shall be through an integral spray-bar on the
stabilising machine. Any added water shall have a sulfate content not exceeding 1400 mg/l as SO4 when tested in
accordance with BS EN 1774-1 clause 10.
18 (02/16) The stabilising machine shall be equipped with a device for controlling the depth of processing which
shall be maintained at the correct setting at all times. An overlap of 150 mm shall be made between adjacent passes
of the stabilising machine. Where a subsequent layer of material is placed on a layer previously stabilised the tines
or blades of the stabilising machine shall be set so that they cut into the previously stabilised layer below by at least
20 mm.
19 (02/16) Each layer of Class 9E or 9F processed material shall be compacted as soon as possible after the final
pass of the stabilising machine. Compaction shall be completed within 2 hours following the mixing of the cement
into the material to be stabilised. Immediately before compaction Class 9E processed material shall have a Moisture
Condition Value (MCV) of not greater than 12 nor less than the figure stated in contract specific Appendix 6/1 both
as determined in accordance with Clause 632. Water shall be added if necessary in a uniform manner to enable this
MCV requirement to be met. Any added water shall have a sulfate content not exceeding 1400 mg/l as SO4 when
20 (02/16) The compaction of each layer of Class 9E or 9F material shall comply with Clause 612, Table 6/4
Method 7, except that if layers of Class 9E or 9F greater than 250 mm thickness are to be constructed, the number
of passes of the compaction plant shall be determined from the results of a demonstration area as detailed in
21 (02/16) Class 9E and 9F materials shall be cured in accordance with Clause 1035. During periods when the
air temperature is forecast to drop below 3°C or when ground frost is forecast Class 9E and 9F material shall be
protected, to prevent freezing, for a period of 7 days from the time of completion of compaction. Such protection
shall be sealed to prevent the ingress of moisture.
22 (02/16) Class 9E and 9F materials shall not have other material deposited or compacted above them until such
time as the required bearing ratio in contract specific Appendix 6/1 has been achieved. The relaxation allowed in
sub-Clause 617.2 shall not apply before this time.
644 (02/16) Determination of Sulfate Content

1 (02/16) Where required in Table 6/1 or contract specific Appendix 6/1, the effects of water-soluble sulfate,
oxidisable sulfides and total potential sulfate shall be assessed in accordance with BS EN 1744-1 clauses 10, 11
and 13.
2 (02/16) Test results and limiting values for sulfate shall be given as SO4.
3 (02/16) At least five samples of each material shall be tested for WS, OS and TPS. The mean of the highest two
values shall be used for comparison with the limiting values. This also applies if six to nine results are available. If
ten or more results are available, the mean of the highest 20% of the results shall be used for comparison with the
limiting values.

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TABLE 6/1: (02/16) Acceptable Earthworks Materials: Classification and Compaction Requirements (See footnotes)

Class General Typical Use Permitted Constituents (All Subject to Material Properties Required for Acceptability (In Addition Compaction Class

Material Requirements of Clause 601 and contract to Requirements on Use of Fill Materials in Clause 601 and Requirements
Volume 1
Description specific Appendix 6/1) Testing in Clause 631) in Clause 612

Property (See Defined and Acceptable Limits Within:
Exceptions in Tested in
Previous Column) Accordance with: Lower Upper
G 1 A – Well graded General Fill Any material, or combination of materials, (i) grading BS 1377: Part 2 or Tab 6/2 Tab 6/2 Tab 6/4 1 A –
E granular other than material designated as Class 3 in the BS EN 13242 Method 2
material Contract. (Properties (i), (ii) and (iv) in next
N (ii) uniformity See Note 5 10 –
column, shall not apply to chalk). Recycled
coefficient
E aggregate.

R (iii) mc BS 1377: Part 2 App 6/1 App 6/1
Where material is imported onto site which is See Note 4
A not ‘as dug’ it shall be aggregate conforming
L to BS EN 13242 from one or more of the (iv) MCV Clause 632 App 6/1 App 6/1
following source codes, see Notes 8, 9, and 10: (v) IDD of chalk Clause 634 – App 6/1
G P (natural aggregates);
R A (construction and demolition recycling
A industries);
N B1 (municipal incinerator bottom ash
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U (MIBA));
L D2 (air cooled blast furnace slag)
A D3 (basic oxygen furnace slag)
R
D4 (electric arc furnace slag (EAF C))
F E (non ferrous steel industry

– except E2 molybdenum slag)
I
L G (mining and quarry industry)
L

39
Earthworks
Series 600
TABLE 6/1: (02/16) Acceptable Earthworks Materials: Classification and Compaction Requirements (See footnotes) (continued)


Volume 1

1 B – Uniformly General Fill Any material, or combination of materials, other (i) grading BS 1377: Part 2 or Tab 6/2 Tab 6/2 Tab 6/4 1 B –
graded granular than chalk. Recycled aggregate BS EN 13242 Method 3
material
Where material is imported onto site which is (ii) uniformity See Note 5 – 10
not ‘as dug’ it shall be aggregate conforming coefficient

to BS EN 13242 from one or more of the (iii) mc BS 1377: Part 2 App 6/1 App 6/1
following source codes, see Notes 8, 9, and 10:
See Note 4
P (natural aggregates – except chalk);
(iv) MCV Clause 632 App 6/1 App 6/1
A (construction and demolition recycling
G industries);
E B1 (municipal incinerator bottom ash
N (MIBA));
E C1 (coal fly ash)
R
C4 (coal bottom ash)
A
D3 (basic oxygen furnace slag)
G D4 (electric arc furnace slag (EAF C))
R
E (non ferrous steel industry
A – except E2 molybdenum slag)
N
F (foundry industry)
U
L G (mining and quarry industry)

A H1 (dredge spoil sand)
R 1 C – Coarse granular General Fill Any material, or combination of materials, (i) grading BS 1377: Part 2 or Tab 6/2 Tab 6/2 Tab 6/4 1 C –
material other than material designated as Class 3 in BS EN 13242 Method 5
the Contract. (Properties (i) and (ii) in next

F (ii) uniformity See Note 5 5 –
column, shall not apply to chalk). Recycled
I coefficient
aggregate
L (iii) Los Angeles Clause 635 – 50
Where material is imported onto site which is coefficient
L not ‘as dug’ it shall be aggregate conforming
to BS EN 13242 from one or more of the
P (natural aggregates);
industries);
D2 (air cooled blast furnace slag)
40
Earthworks
Series 600
G (mining and quarry industry)

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Volume 1

2 A – Wet cohesive General Fill Any material, or combination of materials, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 2 A –
material other than chalk. Method 1
(ii) plastic limit BS 1377: Part 2 – –
except for
(PL)
materials with
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
(iii) mc BS 1377: Part 2 PL -4% App 6/1 liquid limit

See Note 4 greater than
50, determined
(iv) MCV Clause 632 App 6/1 App 6/1
G by BS 1377:
E (v) Undrained Clause 633 App 6/1 App 6/1 Part 2, only
shear strength deadweight
N
of remoulded tamping or
E material vibratory
R tamping
A rollers or grid
rollers shall be
L used.
2 B – Dry cohesive General Fill Any material, or combination of materials, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 2 B –
C material other than chalk Method 2
(ii) plastic limit BS 1377: Part 2 – –
O (PL)
H
(iii) mc BS 1377: Part 2 App 6/1 PL -4%
E See Note 4
S (iv) MCV Clause 632 App 6/1 App 6/1
I
(v) undrained Clause 633 App 6/1 App 6/1
V shear strength
E of remoulded
material

F 2 C – Stony cohesive General Fill Any material, or combination of materials, (i) grading BS 1377: part 2 Tab 6/2 Tab 6/2 Tab 6/4 2 C –
material other than chalk Method 2
I (ii) plastic limit BS 1377: part 2 – –
L (PL)

L (iii) mc BS 1377: Part 2 App 6/1 App 6/1
See Note 4
(iv) MCV Clause 632 App 6/1 –
(v) Undrained Clause 633 App 6/1 –
shear strength
of remoulded
material
41
Earthworks
Series 600


Volume 1

G 2 D – Silty cohesive General Fill Any material, or combination of materials, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 2 D –
E material other than chalk Method 3
(ii) mc BS 1377: Part 2 App 6/1 App 6/1
N See Note 4

E (iii) MCV Clause 632 App 6/1 App 6/1

R (iv) undrained Clause 633 App 6/1 App 6/1
A shear strength
L of remoulded
material
2 E – Reclaimed General Fill Reclaimed material from lagoon or stockpile (i) mc BS 1377: Part 2 To enable compaction to End product 2 E –
C
pulverised fuel containing not more than 20% furnace See Note 4 Clause 612 95% of
O ash cohesive bottom ash maximum
(ii) bulk density BS 1377: Part 9 App 6/1 App 6/1
H material dry density
of BS 1377 :
E
Part 4 (2.5
S kg rammer
I method)
V
E
F
I
L
L
G 3 – – Chalk General Fill Chalk and associated materials all designated (i) mc BS 1377: Part 2 – App 6/1 Tab 6/4 3 – –

E as Class 3 in the Contract See Note 4 Method 4,
or Method
N (ii) IDD Clause 634 App 6/1 App 6/1
1 if required
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
in App 6/1.

C All types of
vibratory
H rollers of
A Categories
L over 1800 kg
shall not be
K
used
F
I
L
L
42
Earthworks
Series 600


Volume 1

L 4 – – Various Fill to See App 6/1 (i) grading BS 1377: Part 2 App 6/1 App 6/1 See Clause 4 – –
A landscape 620 and App
(ii) mc BS 1377: Part 2 – App 6/1
areas 6/1
N See Note 4
D (iii) MCV Clause 632 App 6/1 App 6/1

S
C
A
P
E
F
I
L
L
T 5 A – Topsoil, or turf, Topsoiling Topsoil or turf designated as Class 5A in the (i) grading Clause 618 – Clause 618 – 5 A –
O existing on site Contract
P 5 B – Imported topsoil Topsoiling General purpose grade complying with – – – – – 5 B –
BS 3882
S
O
I
L

43
Earthworks
Series 600
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Volume 1

6 A – Selected well Below water Natural gravel, natural sand, crushed gravel, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 No 6 A –
graded granular crushed rock other than argillaceous rock, (On-site) compaction
material crushed concrete, chalk, well burnt colliery
BS EN 933-2 Tab 6/5 Tab 6/5
spoil or any combination thereof. (Properties
(Imported onto
(i) and (ii) in next column, shall not apply to

site)

chalk.) Recycled aggregate
(ii) uniformity See Note 5 10 –
Where material is imported onto site which is
S not ‘as dug’ it shall be aggregate conforming (iii) SMC of chalk Clause 634 – 20%
E to BS EN 13242 from one or more of the index
L (iv) plasticity BS 1377: Part 2 Non-plastic
P (natural aggregates – except shale, siltstone index
E
or slate, see Note 7);
C
T industries);
E
G1 (red coal shale)
D
G3 (pre-selected all-in from quarrying/mining)
6 B – Selected Starter layer Natural gravel, natural sand, crushed gravel, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 6 B –
G
coarse granular crushed rock, crushed concrete, chalk, well (On-site) Method 5
R material burnt colliery spoil, slag or any combination
BS EN 933-2 Tab 6/5 Tab 6/5
A thereof. (Properties (ii) and (iii) in next
(Imported onto
N column, shall not apply to chalk.) Recycled
site)
aggregate
U (ii) plasticity BS 1377: Part 2 Non-plastic
L index
not ‘as dug’ it shall be aggregate conforming
A to BS EN 13242 from one or more of the (iii) Los Angeles Clause 635 – 50

R following source codes, see Notes 8, 9, and 10: coefficient
P (natural aggregates – except shale, siltstone (iv) mc BS 1377: Part 2 App 6/1 App 6/1
F or slate, see Note 7); See Note 4

I A (construction and demolition recycling
industries);
L
G1 (red coal shale)
44
Earthworks
Series 600
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--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---


Volume 1

S 6 C – Selected Starter layer Natural gravel, natural sand, crushed gravel, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 6 C –
E uniformly crushed rock other than argillaceous rock, (On-site) Method 3
graded granular crushed concrete, chalk, well burnt colliery
L BS EN 933-2 Tab 6/5 Tab 6/5
material spoil, slag or any combination thereof.
(Imported onto

E (Property (iii) in next column, shall not apply

site)
C to chalk.) Recycled aggregate
(ii) uniformity See Note 5 – 10
T Where material is imported onto site which is

coefficient
E not ‘as dug’ it shall be aggregate conforming
to BS EN 13242 from one or more of the (iii) plasticity BS 1377: Part 2 Non-plastic
D following source codes, see Notes 8, 9, and 10: index
P (natural aggregates – except shale, siltstone (iv) Los Angeles Clause 635 – 50
G or slate, see Note 7); coefficient
R A (construction and demolition recycling (v) mc BS 1377: Part 2 App 6/1 App 6/1
A industries); See Note 4
N D2 (air cooled blast furnace slag)
U D3 (basic oxygen furnace slag)
L D4 (electric arc furnace slag (EAF C))
A
G1 (red coal shale)
R
F
I
L
L

45
Earthworks
Series 600


Volume 1

S 6 D – Selected Starter Natural gravel, natural sand, crushed gravel, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 6 D –
E uniformly layer below crushed rock other than argillaceous rock, (On site) Method 4
graded granular pulverised crushed concrete, chalk, well burnt colliery
L BS EN 933-2 Tab 6/5 Tab 6/5
material fuel ash spoil, slag or any combination thereof.
Imported onto

E Recycled aggregate
site)

C Where material is imported onto site which is
(ii) uniformity See Note 5 – 10
T not ‘as dug’ it shall be aggregate conforming
coefficient
E to BS EN 13242 from one or more of the
following source codes, see Notes 8, 9, and 10: (iii) plasticity BS 1377: Part 2 Non-plastic
D index
P (natural aggregates – except shale, siltstone
or slate, see Note 7); (iv) mc BS 1377: Part 2 App 6/1 App 6/1
G See Note 4
R industries); (v) MCV Clause 632 App 6/1 App 6/1
A D2 (air cooled blast furnace slag)
N
U
L
A G1 (red coal shale)
R
F
I
L
L

46
Earthworks
Series 600
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Volume 1

6 E – Selected For Any material, or combination of materials, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Not applicable 6 E –
granular stabilisation other than unburnt colliery spoil and (On-site)
material (Class with cement argillaceous rock. (Properties (i), (ii) and (iii)
BS EN 933-2 Tab 6/5 Tab 6/5
9A) to form in next column, shall not apply to chalk.)
(Imported onto

capping Recycled aggregate

site)
Where material is imported onto site which is (ii) mc BS 1377: Part 2 – App 6/1
S
not ‘as dug’ it shall be aggregate conforming See Note 4

E to BS EN 13242 from one or more of the
L following source codes, see Notes 8, 9, and 10: (iii) liquid limit BS 1377: Part 2 – 45
E P (natural aggregates – except shale, siltstone (iv) plasticity BS 1377: Part 2 – 20
or slate, see Note 7); index
C
T A (construction and demolition recycling (v) organic matter BS 1377: Part 3 – App 6/1
E industries); (vi) water soluble BS EN 1744-1 – 3000 mg/l
D (WS) sulfate clause 10 as SO4
content
G (mining and quarry industry – except G2 (vii) oxidisable BS EN 1744-1 – 0.6% as
G (black coal shale)) sulfides (OS) clause 13 SO4
R content
A (viii) SMC of Clause 634 – 20%
N chalk
U 6 F 1 Selected Capping Any material, or combination of materials – (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 6 F 1
L granular including recycled aggregates with not more (On site materials Method 6
material (fine than 50% by mass of recycled bituminous only)
A
grading) planings and granulated asphalt, but excluding
R (ii) optimum mc BS 1377: Part 4 – –
materials contaminated with tar and tar-

(vibrating hammer
bitumen binders, unburnt colliery spoil,
method)
F argillaceous rock and chalk.
(iii) mc BS 1377: Part 2 Optimum Optimum
I Property (vi) in the next column shall not See Note 4 mc - 2% mc

L apply if the Class Ra (asphalt) content of any
recycled aggregate is 20% or less. (iv) Los Angeles Clause 635 – 60
L coefficient
Where material in this Class is imported onto
site it shall be classified as Class 6F4 and (v) Class Ra Clause 710 – 50%
comply with the requirements for that material. (asphalt) content
(vi) bitumen BS EN 12697-1 or – 2.0%
content BS EN 12697-39
47
Earthworks
Series 600
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Volume 1

6 F 2 Selected Capping Any material, or combination of materials - (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 6 F 2
granular including recycled aggregates with not more (On site materials Method 6
material (coarse than 50% by mass of recycled bituminous only)
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
S grading) planings and granulated asphalt, but excluding
(ii) optimum mc BS 1377: Part 4 –

materials contaminated with tar and tar-
(vibrating hammer

E bitumen binders, unburnt colliery spoil and
method)
L argillaceous rock.
E (iii) mc BS 1377: Part 2 Optimum Optimum

Property (i) in the next column shall not apply See Note 4 mc - 2% mc
C to chalk.
(iv) Los Angeles Clause 635 – 50
T Property (vi) in the next column shall not coefficient
E apply if the Class Ra (asphalt) content of any
recycled aggregate is 20% or less. (v) Class Ra Clause 710 – 50%
D (asphalt) content
Where material in this Class is imported onto
site it shall be classified as Class 6F5 and (vi) bitumen BS EN 12697-1 or – 2.0%
G content BS EN 12697-39
comply with the requirements for that material.
R
A 6 F 3 Selected Capping Any material, or combination of materials (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 6 F 3
N granular with not less than 50% by mass of recycled (On-site) Method 6
material bituminous planings and granulated asphalt, Maximum
U BS EN 933-2 Tab 6/5 Tab 6/5
but excluding materials contaminated with tar Compacted
L (Imported onto
and tar-bitumen binders, unburnt colliery spoil layer thickness
site)
A and argillaceous rock. shall be 200
(ii) optimum mc Clause 613 – – mm
R Where material is imported onto site which is
not ‘as dug’ it shall be aggregate conforming (iii) mc Clause 613 See Optimum Optimum
to BS EN 13242 from the following source Note 4 mc -2% mc
F
codes, see Notes 8, 9 and 10:

(iv) Class Ra Clause 710 50% –
I
A1 (reclaimed asphalt) (asphalt) content
L
A4 (mixed recycled aggregate) (v) bitumen BS EN 12697-1 or – 10%
L content BS EN 12697-39

Aggregates from source code A4 shall contain
at least 50% of constituents in Class Ra
(bituminous materials).
48
Earthworks
Series 600


Volume 1

6 F 4 Selected Capping Unbound mixture complying with BS EN (i) Size BS EN 13285 – Tab 6/5 Tab 6/5 Tab 6/4 6 F 4
granular 13285 containing aggregate conforming to BS designation and 0/31.5 and GE Method 6
material (fine EN 13242 from one or more of the following overall grading
S grading) – source codes, see Notes 8, 9 and 10: category

imported on to

E P (natural aggregates – except chalk, shale, (ii) Maximum BS EN 13285 – Tab 6/5 Tab 6/5
the Site
siltstone or slate, see Note 7) fines and oversize UF15 and OC75
L
categories
E A2 (crushed concrete)
(iii) Los Angeles BS EN 13242 – – 60
C A3 (crushed bricks, masonry) coefficient LA60
T
A4 (mixed recycled aggregate) (iv) Volume BS EN 13242 – –
E stability of blast – free from
B1 (municipal incinerator bottom ash (MIBA)) furnace slag dicalcium
D
D2 (air cooled blast furnace slag) silicate and iron
disintegration
G D3 (basic oxygen furnace slag)
(v) Volume BS EN 13242 – V5 – –
R stability of steel
A (BOF) and EAF)
G (mining and quarry industry – except G2 slag
N
(black coal shale))
U (vi) Other BS EN 13242 – – –
Aggregates from source code A4 shall contain aggregate CategoryNR (no
L
not more than 50% of constituents in Class Ra requirements requirement)
A (bituminous materials).
(vii) Laboratory BS EN 13285, – –
R
Property (x) in the next column shall not dry density and Clause 5.3 –
apply if the Class Ra (asphalt) content of any optimum water declared values
F recycled aggregate is 20% or less. content

I (viii) Water BS EN 1097-5 Optimum Optimum
L content wc – -2% wc
L (ix) Class Ra Clause 710 – 50%

(asphalt) content
(x) bitumen BS EN 12697-1 or – 2.0%
49
Earthworks
Series 600
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Volume 1

6 F 5 Selected Capping Unbound mixture complying with BS EN (i) Size BS EN 13285 – Tab 6/5 Tab 6/5 Tab 6/4 6 F 5
granular 13285 containing aggregate conforming to BS designation and 0/80 and GE Method 6
material (coarse EN 13242 from one or more of the following overall grading
grading) – source codes, see Notes 8, 9 and 10: category

imported on to
P (natural aggregates – except chalk, shale, (ii) Maximum BS EN 13285 – Tab 6/5 Tab 6/5

the Site
siltstone or slate, see Note 7) fines and oversize UF12 and OC75
categories
A2 (crushed concrete)
(iii) Los Angeles BS EN 13242 – – 50
A3 (crushed bricks, masonry) coefficient
S LA50
E A4 (mixed recycled aggregate) (iv) Volume BS EN 13242 – –
L B1 (municipal incinerator bottom ash (MIBA)) stability of blast – free from
furnace slag dicalcium
E D2 (air cooled blast furnace slag) silicate and iron
C disintegration
T (v) Volume stability BS EN 13242 – V5 – –
E of steel (BOF) and
D G (mining and quarry industry – except G2 EAF) slag
(black coal shale))
(vi) Other BS EN 13242 – – –
G Aggregates from source code A4 shall contain aggregate Category NR (no
not more than 50% of constituents in Class Ra requirements requirement)
R (bituminous materials).
(vii) Laboratory BS EN 13285, – –
A dry density and Clause 5.3 –
Property (x) in the next column shall not
N apply if the Class Ra (asphalt) content of any optimum water declared values
U recycled aggregate is 20% or less. content
L (viii) Water BS EN 1097-5 Optimum Optimum

A content wc – -2% wc
R (ix) Class Ra Clause 710 – 50%
(asphalt) content

F (x) bitumen BS EN 12697-1 or – 2.0%
I
L 6 G – Selected Gabion Natural gravel, crushed rock, crushed concrete (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 None 6 G –
granular filling or any combination thereof. None of these (On-site)
L material constituents shall include any argillaceous rock.
BS EN 933-2 Tab 6/5 Tab 6/5
Where material is imported onto site which is (Imported onto site)
not ‘as dug’ it shall be aggregate conforming (ii) Los Angeles Clause 635 – 50
to BS EN 13242 from one or more of the coefficient
following source codes, see Notes 8, 9 and 10:
A2 (crushed concrete).
50
Earthworks
Series 600
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Volume 1

6 H – Selected Drainage Natural gravel, natural sand, crushed gravel, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 6 H –
granular layer to crushed rock, crushed concrete, chalk, (On-site) Method 3
material reinforced well burnt colliery spoil or any structures
S BS EN 933-2 Tab 6/5 Tab 6/5
soil and combination thereof. None of these
(Imported onto

E anchored constituents shall include any argillaceous
site)

earth rock. (Properties (vi), (vii), (viii), (ix), (x),
L structures (xi) and (xii) in next column only apply when (ii) plasticity BS 1377: Part 2 Non-plastic
E metallic reinforcing or anchor elements, facing index

C units or fastenings are used.) (Properties (ii)
(iii) Los Angeles Clause 635 – 50
and (v) in next column shall not apply to
T coefficient
chalk.) Recycled aggregate except recycled
E asphalt. (iv) mc BS 1377: Part 2 App 6/1 App 6/1
D See Note 4
not ‘as dug’ it shall be aggregate conforming (v) MCV Clause 632 App 6/1 App 6/1
G to BS EN 13242 from one or more of the (vi) pH value BS 1377: Part 3 Tab 6/3 Tab 6/3
R (vii) chloride ion BS EN 1744-1 – Tab 6/3
A P (natural aggregates – except shale, siltstone content
N (viii) water BS EN 1744-1 – Tab 6/3
U A2 (crushed concrete) soluble (WS) clause 10
L sulfate content
A3 (crushed bricks, masonry)
A (ix) oxidisable BS EN 1744-1 – Tab 6/3
G1 (red coal shale) sulfides (OS) clause 13
R
content
(x) resistivity Clause 637 Tab 6/3 –
F
I (xi) redox Clause 638 Tab 6/3 –

potential
L
(xii) organic BS 1377: Part 3 – Tab 6/3
L content

(xiii) microbial Table 6/3 – Tab 6/3
activity index
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51
Earthworks
Series 600
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Volume 1

6 I – Selected well Fill to Natural gravel, natural sand, crushed gravel, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 6 I –
graded granular reinforced crushed rock, crushed concrete, slag, chalk, (On-site) Method 2
material soil and well burnt colliery spoil or any combination
BS EN 933-2 Tab 6/5 Tab 6/5
anchored thereof except that chalk shall not be combined
(Imported onto

earth with any other constituent. None of these
site)

structures constituents shall include any argillaceous
rock. (Properties (i), (ii) and (v) in next column (ii) uniformity See Note 5 10 –
S shall not apply to chalk.) (Properties (viii), coefficient

E (ix), (x), (xi), (xii), (xiii) and (xiv) only apply
(iii) SMC of chalk Clause 634 – 20%
when metallic reinforcing or anchor elements,
L facing units or fastenings are used.) Recycled (iv) mc BS 1377: Part 2 App 6/1 App 6/1
E aggregate except recycled asphalt. See Note 4
C Where material is imported onto site which is (v) MCV Clause 632 App 6/1 App 6/1
T not ‘as dug’ it shall be aggregate conforming (vi) effective Clause 636 App 6/1 –
E to BS EN 13242 from one or more of the angle of friction
following source codes, see Notes 8, 9 and 10: (j') and effective
D
P (natural aggregates – except shale, siltstone cohesion (c')
or slate, see Note 7); (vii) coefficient Clause 639 App 6/1 –
G
A2 (crushed concrete) of friction and
R adhesion (fill/
A A3 (crushed bricks, masonry) elements)
N D2 (air cooled blast furnace slag) (viii) pH value BS 1377: Part 3 Tab 6/3 Tab 6/3
U
G1 (red coal shale) (ix) chloride ion BS EN 1744-1 – Tab 6/3
L content
A (x) water soluble BS EN 1744-1 – Tab 6/3

R (WS) sulfate clause 10
content
F (xi) oxidisable BS EN 1744-1 – Tab 6/3
I sulfides (OS) clause 13

content
L
(xii) resistivity Clause 637 Tab 6/3 –
L
(xiii) redox Clause 638 Tab 6/3 –
potential
(xiv) organic BS 1377: Part 3 – Tab 6/3
content
(xv) microbial Table 6/3 – Tab 6/3
activity index
52
Earthworks
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Volume 1

6 J – Selected Fill to Natural gravel, natural sand, crushed (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 6 J –
uniformly reinforced gravel, crushed rock, crushed concrete, (On-site) Method 3
graded granular soil and slag, chalk, well burnt colliery spoil or any
BS EN 933-2 Tab 6/5 Tab 6/5
material anchored combination thereof, except that chalk shall
(Imported onto

earth not be combined with any other constituent.
site)

None of these constituents shall include any
argillaceous rock. (Properties (viii), (ix), (x), (ii) uniformity See Note 5 5 10
S (xi), (xii), (xiii) and (xiv) in next column only coefficient

E apply when metallic reinforcing or anchor
(iii) SMC of chalk Clause 634 – 20%
elements, facing units or fastenings are used.)
L (Properties (i), (ii) and (v) in next column shall (iv) mc BS 1377: Part 2 App 6/1 App 6/1
E not apply to chalk.) Recycled aggregate except See Note 4
C recycled asphalt.
(v) MCV Clause 632 App 6/1 App 6/1
T Where material is imported onto site which is (vi) effective Clause 636 App 6/1 –
E not ‘as dug’ it shall be aggregate conforming angle of friction
to BS EN 13242 from one or more of the (ϕ') and effective
D
following source codes, see Notes 8, 9 and 10: cohesion (c')
P (natural aggregates – except shale, siltstone (vii) coefficient Clause 639 App 6/1 –
G
or slate, see Note 7); of friction and
R adhesion (fill/
A elements)
N A3 (crushed bricks, masonry)
(viii) pH value BS 1377: Part 3 Tab 6/3 Tab 6/3
U D2 (air cooled blast furnace slag) (ix) chloride ion BS EN 1744-1 – Tab 6/3
L G1 (red coal shale). content
A (x) water soluble BS EN 1744-1 – Tab 6/3

R (WS) sulfate clause 10
content

content
L
(xii) resistivity Clause 637 Tab 6/3 –
L
potential
(xiv) organic BS 1377: Part 3 – Tab 6/3
content
(xv) microbial Table 6/3 – Tab 6/3
activity index
53
Earthworks
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Volume 1

6 K – Selected Lower Natural gravel, natural sand, crushed gravel, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 End product 6 K –
granular bedding for crushed rock, crushed concrete, well burnt (On-site) 90% of
material corrugated colliery spoil or any combination thereof. maximum dry
BS EN 933-2 Tab 6/5 Tab 6/5
steel buried None of these constituents shall include any density of BS
(Imported onto

structures argillaceous rock. Recycled aggregate except 1377: Part 4
site)

S recycled asphalt. (Vibrating
(ii) uniformity See Note 5 5 – hammer
E Where material is imported onto which is not coefficient method)

L ‘as dug’ site it shall be aggregate conforming
to BS EN 13242 from one or more of the (iii) plasticity BS 1377: Part 2 – 6
E following source codes,)see Notes 8, 9 and 10: index
C (iv) optimum mc BS 1377: Part 4 – –
T or slate, see Note 7); (vibrating hammer
E method)
D (v) mc BS 1377: Part 2 Optimum Optimum
A3 (crushed bricks, masonry) See Note 4 mc -2% mc +1%
G G1 (red coal shale) (vi) MCV Clause 632 App 6/1 App 6/1
R (vii) Los Angeles Clause 635 – 40
A coefficient
N (viii) resistivity Clause 637 2000 ohm –
cm
U
L (ix) water soluble BS EN 1744-1 – 300 mg/ l
(WS) sulfate clause 10 as SO4
A content
R
(x) oxidisable BS EN 1744-1 – 0.06% as

sulfides (OS) clause 13 SO4
F content
I (xi) chloride ion BS EN 1744-1 – 0.025%
L content

L (xii) pH value BS 1377: Part 3 6 9
(xiii) sulfide and Standard textbook – Rapid
hydrogen sulfide of qualitative blackening
inorganic analysis of lead
acetate
paper
54
Earthworks
Series 600
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---


Volume 1

--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
S 6 L – Selected Upper Natural gravel, natural sand, crushed gravel, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 6 L –
E uniformly bedding for crushed rock, crushed concrete, well burnt (On-site)
graded granular corrugated colliery spoil or any combination thereof.
L BS EN 933-2 Tab 6/5 Tab 6/5
material steel buried None of these constituents shall include any
(Imported onto

E structures argillaceous rock. Recycled aggregate except
site)

C recycled asphalt.
(ii) resistivity Clause 637 2000 ohm –
T
Where material is imported onto site which is cm

to BS EN 13242 from one or more of the (iii) water soluble BS EN 1744-1 – 300 mg/ l
D following source codes, see Notes 8, 9 and 10: (WS) sulfate clause 10 as SO4
content
G or slate, see Note 7); (iv) oxidisable BS EN 1744-1 – 0.06% as
R sulfides (OS) clause 13 SO4
A2 (crushed concrete) content
A
N A3 (crushed bricks, masonry) (v) chloride ion BS EN 1744-1 – 0.025%
content
U G1 (red coal shale)
L (vi) pH value BS 1377: Part 3 6 9
A (vii) sulfide and Standard textbook – Rapid
R
acetate
F paper
I
L
L

55
Earthworks
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Volume 1

--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
6 M – Selected Surround to Natural gravel, natural sand, crushed gravel, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 End product 6 M –
granular corrugated crushed rock, crushed concrete, well burnt (On-site) 90% of
material steel buried colliery spoil or any combination thereof. maximum dry
BS EN 933-2 Tab 6/5 Tab 6/5
structures None of these constituents shall include any density of BS
(Imported onto
argillaceous rock. Recycled aggregate except

1377: Part
site)

S recycled asphalt. 4 (Vibrating
E coefficient method)
L not ‘as dug’ it shall be aggregate conforming unless
to BS EN 13242 from one or more of the (iii) plasticity BS 1377: Part 2 – 6
E otherwise
following source codes, see Notes 8, 9 and 10: index
stated in App
C (iv) optimum mc BS 1377: Part 4 – – 6/1
T or slate, see Note 7); (vibrating hammer
E method)
D (v) mc BS 1377: Part 2 Optimum Optimum
A3 (crushed bricks, masonry) See Note 4 mc -2% mc +1%
G G1 (red coal shale). (vi) MCV Clause 632 App 6/1 App 6/1
R (vii) Los Angeles Clause 635 – 40
A coefficient
N (viii) resistivity Clause 637 2000 ohm –
cm
U
L (ix) water soluble BS EN 1744-1 – 300 mg/ l
A content
R
(x) oxidisable BS EN 1744-1 – 0.06% as
sulfides (OS) clause 13

SO4
F content
I (xi) chloride ion BS EN 1744-1 – 0.025%
L content

L (xii) pH value BS 1377: Part 3 6 9
(xiii) sulfide and Standard textbook – Rapid
acetate
paper
56
Earthworks
Series 600


Volume 1

S 6 N – Selected well Fill to Natural gravel, natural sand, crushed gravel, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 End product 6 N –
E graded granular structures crushed rock, crushed concrete, slag, well (On-site) 95% of
material burnt colliery spoil or any combination thereof. maximum dry
L BS EN 933-2 Tab 6/5 Tab 6/5
None of these constituents shall include any density of BS
(Imported onto

E argillaceous rock. Recycled aggregate except 1377: Part 4
site)

C recycled asphalt. (vibrating
T
Where material is imported onto site which is coefficient method)

to BS EN 13242 from one or more of the (iii) Los Angeles Clause 635 – 40
D following source codes, see Notes 8, 9 and 10: coefficient
P (natural aggregates – except shale, siltstone (iv) undrained Clause 633 App 6/1 –
G or slate, see Note 7); shear parameters
R (c and ϕ)
A (v) effective angle Clause 636 App 6/1 –
N A3 (crushed bricks, masonry) of internal friction
(ϕ') and effective
U D2 (air cooled blast furnace slag) cohesion (c')
L G1 (red coal shale). (vi) permeability Clause 640 App 6/1 –
A
(vii) mc BS 1377: Part 2 App 6/1 App 6/1
R
See Note 4
(viii) MCV Clause 632 App 6/1 App 6/1
F
(ix) slope stability Clause 610 App 6/6
I
test (where
L required in App
L 6/6)
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---

57
Earthworks
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Volume 1

6 P – Selected Fill to Natural gravel, natural sand, crushed gravel, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 End product 6 P –
S granular structures crushed rock, crushed concrete, slag, chalk, (On-site) 95% of
E material well burnt colliery spoil or any combination maximum dry
BS EN 933-2 Tab 6/5 Tab 6/5
L thereof. None of these constituents shall density of BS
(Imported onto

include any argillaceous rock. (Properties (i), 1377: Part
E site)

(ii) and (ix) in next column shall not apply to 4 (vibrating
C chalk.) Recycled aggregate except recycled (ii) uniformity See Note 5 5 – hammer
T asphalt. coefficient method)

E Where material is imported onto site which is (iii) IDD of chalk Clause 634 – App 6/1
D not ‘as dug’ it shall be aggregate conforming (iv) Los Angeles Clause 635 – 60
to BS EN 13242 from one or more of the coefficient
G (v) undrained Clause 633 App 6/1 –
P (natural aggregates – except shale, siltstone shear parameters
R or slate, see Note 7); (c and ϕ)
A
A2 (crushed concrete) (vi) effective angle Clause 636 App 6/1 –
N
of internal friction
U A3 (crushed bricks, masonry)
(ϕ') and effective
L D2 (air cooled blast furnace slag) cohesion (c')
A G1 (red coal shale). (vii) permeability Clause 640 App 6/1 –
R (viii) mc BS 1377: Part 2 App 6/1 App 6/1
See Note 4
F (ix) MCV Clause 632 App 6/1 App 6/1
I (x) slope stability Clause 610 App 6/6
L test (where

L required in App
6/6)

58
Earthworks
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Volume 1

S 6 Q – Selected Fill to Natural gravel, natural sand, crushed gravel, As for Class 1A, 1B or 1C with the End product 6 Q –
E granular structures crushed rock, crushed concrete, slag, chalk, addition of the following: 95% of
material well burnt colliery spoil or any combination maximum dry
L (i) water soluble BS EN 1744-1 – 300 mg/ l
thereof. None of these constituents shall density of BS

E include any argillaceous rock. (Properties (i), 1377: Part
content

C (ii) and (ix) in next column shall not apply to 4 (vibrating
chalk.) Recycled aggregate except recycled (ii) oxidisable BS EN 1744-1 – 0.06% as hammer
T
asphalt. sulfides (OS) clause 13 SO4 method)

E content
D not ‘as dug’ it shall be aggregate conforming (iii) chloride ion BS EN 1744-1 – 0.025%
to BS EN 13242 from one or more of the content
G following source codes, see Notes 8, 9 and 10: (iv) pH value BS 1377: Part 3 6 9
R P (natural aggregates – except shale, siltstone (v) sulfide and Standard textbook – Rapid
A or slate, see Note 7); hydrogen sulfide of qualitative blackening
N A2 (crushed concrete) inorganic analysis of lead
acetate
U A3 (crushed bricks, masonry) paper
L
A
R G1 (red coal shale).
F
I
L
L

59 --`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
Earthworks
Series 600


Volume 1

6 R – Selected For Any material, or combination of materials, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 6 R –
S granular stabilisation other than unburnt colliery spoil and (On-site)
material with lime argillaceous rock. (Properties (i), (ii) and (iii)
E BS EN 933-2 Tab 6/5 Tab 6/5
and cement in next column, shall not apply to chalk.)
L (Imported onto

to form
site)

E capping
C (Class 9F) (ii) mc BS 1377: Part 2 App 6/1 –
See Note 4
T
(iii) liquid limit BS 1377: Part 2 – 45
E
D (iv) plasticity BS 1377: Part 2 – 20
index
(v) organic matter BS 1377: Part 3 – App 6/1
G
R (vi) water soluble BS EN 1744-1 – 3000 mg/ l
A content
N
(vii) oxidisable BS EN 1744-1 – 0.6% as
U sulfides (OS) clause 13 SO4
L content
A (viii) IDD of chalk Clause 634 – App 6/1
R 6 S – Selected well Filter layer Crushed rock or sand. (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 – 6 S –
graded granular below (On-site)
material subbase Where material is imported onto site which is
F not ‘as dug’ it shall be aggregate conforming BS EN 933-2 Tab 6/5 Tab 6/5
I to BS EN 13242 from one or more of the (Imported onto
L following source codes, see Notes 8, 9 and 10: site)

L P (natural aggregates – except chalk, shale, (ii) plasticity BS 1377: Part 2 – Non-plastic
siltstone or slate, see Note 7). index

--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
60
Earthworks
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Volume 1

S 7 A – Selected Fill to Any material or combination of materials, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 End product: 7 A –
E cohesive structures other than argillaceous rock and materials 100% of
material designated as Class 3 in the Contract. If chalk maximum
L See Note 4
is used it shall form 100% of constituents. dry density

E (Properties (i) and (iii) shall not apply to (iii) MCV Clause 632 App 6/1 App 6/1 of BS 1377 :

C chalk.) (Properties (vii) and (viii) may be Part 4 (2.5
(iv) undrained Clause 633 App 6/1 App 6/1
increased to 54% and 31% respectively for kg rammer
T shear parameters
Lias Clay only and subject to the requirements method) or a

E (c and ϕ)
of contract specific Appendix 6/6) dry density
D (v) effective angle Clause 636 App 6/1 App 6/1 corresponding
of internal friction to 5% air
(ϕ') and effective voids at field
C cohesion (c') mc whichever
O is lower
(vi) IDD of chalk Clause 634 App 6/1 App 6/1
H
(vii) liquid limit BS 1377: Part 2 – 45
E
(viii) plasticity BS 1377: Part 2 – 25
S index
I
V
E
F
I
L
L

61
Earthworks
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Volume 1

S 7 B – Selected Fill to Conditioned material direct from power (i) mc BS 1377: Part 2 To enable compaction to End product: 7 B –
E conditioned structures station dust collection system and to which a See Note 4 Clause 612 95% of
pulverised fuel and to controlled quantity of water has been added maximum
L (ii) bulk density BS 1377: Part 9 App 6/1 App 6/1
ash cohesive reinforced dry density

E material soil (iii) undrained Clause 633 App 6/1 – of BS 1377 :

C shear parameters Part 4 (2.5
(c and ϕ) kg rammer
T
method)
E (iv) effective angle Clause 636 App 6/1 –
of internal friction
D (ϕ') and effective
cohesion (c')
C (v) coefficient Clause 639 App 6/1 –
O of friction and
adhesion (fill/
H
elements)
E
(vi) permeability Clause 640 App 6/1 –
S
I (vii) slope stability Clause 610 App 6/6
test (where
V required in App
E 6/6)
F
I
L
L

62
Earthworks
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Volume 1

7 C – Selected wet Fill to Any material, or combination of materials, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 7 C –
cohesive reinforced other than unburnt colliery spoil, argillaceous Method 1
S material soil rock and chalk. (Properties (viii), (ix), (x),
See Note 4
(xi) and (xii) in next column only apply when
E

metallic reinforcing elements, facing units or (iii) MCV Clause 632 App 6/1 App 6/1

L fastenings are used)
(iv) effective angle Clause 636 App 6/1 –
E of internal friction
C (ϕ') and effective

T cohesion (c')
E (v) coefficient Clause 639 App 6/1 –
D of friction and
adhesion (fill/
elements)
C
(vi) liquid limit BS 1377: Part 2 – 45
O
(vii) plasticity BS 1377: Part 2 – 25
H index
E
S
(ix) chloride ion BS EN 1744-1 – Tab 6/3
I content
V
(x) water soluble BS EN 1744-1 – Tab 6/3
E (WS) sulfate clause 10
content

content
L
L (xii) resistivity Clause 637 Tab 6/3 –
potential

--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
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Volume 1

7 D – Selected stony Fill to Any material, or combination of materials, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Tab 6/4 7 D –
cohesive reinforced other than unburnt colliery spoil, argillaceous Method 2
S material soil rock and chalk. (Properties (vi), (vii), (viii),
See Note 4
(ix), (x), (xi) and (xii) in next column only
E
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---

apply when metallic reinforcing elements, (iii) MCV Clause 632 App 6/1 App 6/1

L facing units or fastenings are used)
(iv) effective angle Clause 636 App 6/1 –
E of internal friction
C (ϕ') and effective

T cohesion (c')
E (v) coefficient Clause 639 App 6/1 –
D of friction and
adhesion (fill/
elements)
C
(vi) liquid limit BS 1377: Part 2 – 45
O
(vii) plasticity BS 1377: Part 2 – 25
H index
E
S
(ix) chloride ion BS EN 1744-1 – Tab 6/3
I content
V
(x) water soluble BS EN 1744-1 – Tab 6/3
E (WS) sulfate clause 10
content

content
L
L (xii) resistivity Clause 637 Tab 6/3 –
potential

64
Earthworks
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Volume 1

--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
7 E – Selected For Any material, or combination of materials, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Not applicable 7 E –
cohesive stabilisation other than unburnt colliery spoil
(ii) mc BS 1377: Part 2 – App 6/1
material with lime to
See Note 4
form capping

(Class 9D) (iii) MCV Clause 632 App 6/1 –

(iv) plasticity BS 1377: Part 2 10 –
index
S (v) organic matter BS 1377: Part 3 – App 6/1

E (vi) water soluble BS EN 1744-1 – App 6/1
L (WS) sulfate clause 10
E content
C (vii) oxidisable BS EN 1744-1 – App 6/1
T
content
E
(viii) total BS EN 1744-1 – App 6/1
D potential sulfate clause 11
(TS) content
C 7 F – Selected silty For Any material, or combination of materials, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Not applicable 7 F –
O cohesive stabilisation other than chalk, unburnt colliery spoil and
(ii) uniformity See Note 5 5 –
H material with cement argillaceous rock
coefficient
to form
E capping (iii) mc BS 1377: Part 2 App 6/1 App 6/1
S (Class 9B) See Note 4
I (iv) MCV Clause 632 App 6/1 App 6/1
V

(v) liquid limit BS 1377: Part 2 – 45
E
(vi) plasticity BS 1377: Part 2 – 20
index
F (vii) organic BS 1377: Part 3 – App 6/1

I matter
L (viii) water BS EN 1744-1 – App 6/1
L soluble (WS) clause 10
sulfate content
(ix) oxidisable BS EN 1744-1 – App 6/1
content
(x) total potential BS EN 1744-1 – App 6/1
sulfate (TS) clause 11
content
65
Earthworks
Series 600

--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---

Volume 1

7 G – Selected For Conditioned material direct from power (i) mc BS 1377: Part 2 App 6/1 App 6/1 7 G –
conditioned stabilisation station dust collection system and to which a See Note 4
pulverised fuel with cement controlled quantity of water has been added
(ii) water soluble BS EN 1744-1 – 3000 mg/l
ash cohesive to form

material capping
content

(Class 9C)
(iii) oxidisable BS EN 1744-1 – 0.6% as

S content
E (iv) total potential BS EN 1744-1 – 1.2% as
L sulfate (TS) clause 11 SO4
content
E
C 7 H – Wet, dry, stony Overlying As Class 2A, 2B, 2C, 2D general cohesive As for Class 2A, 2B, 2C, 2D or 3 with the addition of the following 7 H –
or silty cohesive fill for fill material or Class 3 chalk fill material,
T (i) water soluble BS EN 1744-1 – 300 mg/l as
material and corrugated except that argillaceous rock, slag, PFA or any
(WS) sulfate clause 10 SO4
E chalk steel buried combination thereof shall not be used
content
D structures
(ii) oxidisable BS EN 1744-1 – 0.06% as
C content
O (iii) chloride ion BS EN 1744-1 – 0.025%
H content
E (iv) pH value BS 1377: Part 3 6 9
S 7 I – Selected For Any material, or combination of materials, (i) grading BS 1377: Part 2 Tab 6/2 Tab 6/2 Not applicable 7 I –
I cohesive stabilisation other than unburnt colliery spoil
(ii) mc BS 1377: Part 2 – App 6/1
V material with lime

See Note 4
and cement
E to form (iii) MCV Clause 632 App 6/1 –
capping
(iv) plasticity BS 1377: Part 2 10 –
F (Class 9E)
index

I (v) organic matter BS 1377: Part 3 – App 6/1
L
(vi) water soluble BS EN 1744-1 – App 6/1
L (WS) sulfate clause 10
content
(vii) oxidisable BS EN 1744-1 – App 6/1
content
(viii) total BS EN 1744-1 – App 6/1
potential sulfate clause 11
(TS) content
66
Earthworks
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Volume 1

8 – – Class 1, Class Lower trench Any material; except no stones or lumps of (i) mc BS 1377: Part 2 App 6/1 App 6/1 Tab 6/4 8 – –
2 or Class 3 fill clay shall be retained on the 40mm test sieve. See Note 4
material Recycled aggregate
(ii) MCV Clause 632 App 6/1 App 6/1
M Where material is imported onto site which is

I not ‘as dug’ it shall be aggregate conforming

to BS EN 13242 from one or more of the
S
C
P (natural aggregates);
F industries)
I B1 (municipal incinerator bottom ash (MIBA))
L
L
G (mining and quarry industry).
S 9 A – Cement Capping Class 6E with addition of cement according to (i) pulverisation BS EN 13286-48 60% – Tab 6/4 9 A –
T stabilised well Clause 614 Method 6
(ii) bearing ratio BS EN 13286-47 App 6/1 –
graded granular
A
material (iii) mc BS EN 13286-2 App 6/1 App 6/1
B
9 B – Cement Capping Class 7F with addition of cement according to (i) pulverisation BS EN 13286-48 App 6/1 – Tab 6/4 9 B –
I
stabilised Clause 614 Method 7
L (ii) MCV Clause 632 App 6/1 12
silty cohesive
immediately
I material
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
before compaction
S

(iii) bearing ratio BS EN 13286-47 App 6/1 –
E
D (iv) mc BS EN 13286-2 App 6/1 App 6/1
9 C – Cement Capping Class 7G with addition of cement according to (i) pulverisation BS EN 13286-48 60% – End 9 C –
stabilised Clause 614 product 95%

M (ii) bearing ratio BS EN 13286-47 App 6/1 –
conditioned of maximum
A
pulverised fuel (iii) mc BS EN 13286-2 To enable compaction to dry density BS
T ash cohesive Clause 612 EN 13286-47
E material (2.5 kg rammer
R method)
I
A
L
S
67
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Volume 1

S 9 D – Lime stabilised Capping Class 7E with addition of lime according to (i) pulverisation BS EN 13286-48 30% – Tab 6/4 9 D –
T cohesive Clause 615 Method 7
material
A immediately
B before compaction

I (iii) bearing ratio BS EN 13286-47 App 6/1 –
L (iv) mc BS EN 13286-2 App 6/1 App 6/1
I
9 E – Lime and Capping Class 7I with addition of lime and cement (i) pulverisation BS EN 13286-48 30% – Tab 6/4 9 E –
S cement according to Clause 643 Method 7
E stabilised
immediately
D cohesive
before completion
material
(iii) bearing ratio BS EN 13286-47 App 6/1 –
M
(iv) mc BS EN 13286-2 App 6/1 App 6/1
A
T 9 F – Lime and Capping Class 6R with addition of lime and cement (i) pulverisation BS EN 13286-48 60% – Tab 6/4 9 F –
cement according to Clause 643 Method 6
E (ii) bearing ratio BS EN 13286-47 App 6/1 –
stabilised well
R graded granular (iii) mc BS EN 13286-2 App 6/1 App 6/1
I material See Note 4
A
L
S
Footnotes to Table 6/1

1 (02/16) App = contract specific Appendix

2 (02/16) Tab = Table
3 (02/16) Where in the Acceptable Limits column reference is made to App 6/1, only those properties having limits ascribed to them in contract specific Appendix 6/1 shall apply. Where contract
specific Appendix 6/1 gives limits for other properties not listed in this Table such limits shall also apply.

4 (02/16) Where BS 1377: Part 2 is specified for mc, this shall mean BS 1377: Part 2 where the material is a soil or BS EN 1097-5 where the material is required to conform to a harmonised European
Standard.
5 (02/16) Uniformity coefficient is defined as the ratio of the particle diameters D60 to D10 on the particle-size distribution curve, where:
D60 = particle diameter at which 60% of the soil by weight is finer
D10 = particle diameter at which 10% of the soil by weight is finer
6. (02/16) The limiting values for Class U1B material are given in contract specific Appendix 6/14 and contract specific Appendix 6/15.
7 (02/16) For works in Wales see sub-Clause 601.21W.
8 (02/16) Where material source codes are referenced these are as listed in Table 6/7.
9 (02/16) Where materials are required to be aggregates conforming to BS EN 13242 materials certificated as being compliant with BS EN 13285 are acceptable for use provided that they meet all the
specification requirements and the Declaration of Performance for constituent parts to BS EN 13242 are provided to the Overseeing Organisation.
68
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10 (02/16) Materials shall comply with the current Environmental Regulations at the time of use. Reference shall be made to Annex ZA (informative) of BS EN 13242.
TABLE 6/2: (02/17) Grading Requirements for Acceptable Earthworks Materials Other Than Classes 6F4, 6F5 and 6S

Percentage by Mass Passing the Size Shown
Volume 1
Class Size Size (mm) Size (microns) Size Class

(mm) BS Series BS Series (micr-
ons)
500 300 125 90 75 37.5 28 20 14 10 6.3 5 3.35 2 1.18 600 300 150 63 2
1A 100 95-100 <15 1A
1B 100 <15 1B
1C 100 10-95 0-25 15 1C

2A & 100 80- 15-100 2A &

--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
2B 100 2B
2C 100 15-80 15-80 2C

2D 100 80-100 0-20 2D
6A 100 0-100 0-85 0-45 0-5 6A
6B 100 0-10 6B
6C 100 0-100 0-100 0-35 0-10 0-2 6C
6D 100 89-100 60- 30-100 15-80 5-48 0-15 6D
100 except
0-20 for
crushed
rock
6E & 100 85-100 25- 10-100 <15 6E &
6R 100 6R
6F1 100 75-100 40-95 30-85 10-50 <15 6F1
6F2 100 80-100 65- 45-100 15-60 10-45 0-25 0-12 6F2
100

6F3 100 80-100 65- 45-100 15-60 10-45 0-25 0-12 6F3
100
6H 100 60-100 15-45 0-25 0-5 6H

6I & 100 85- 25- 15- 9-100 <15 6I & 6J
6J 100 100 100
6K 100 0-10 6K
6L 100 89-100 60- 30-100 15-100 5-70 0-15 6L
100 except
0-20 for
crushed
rock
69
Earthworks
Series 600
TABLE 6/2: (02/16) Grading Requirements for Acceptable Earthworks Materials (continued)

Volume 1
Class Size Size (mm) Size (microns) Size Class

(mm) BS Series BS Series (micr-
ons)
500 300 125 90 75 37.5 28 20 14 10 6.3 5 3.35 2 1.18 600 300 150 63 2
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
6M 100 0-10 6M
6N & 100 <15 6N &
6P 6P

6S 100 60- 30-90 4-45 0-16 6S

100
7A 100 15-100 7A
7C 100 85- 83- 80- 60-100 15-45 0-20 7C
100 100 100
7D 100 85- 40-90 15-79 15-75 15-45 0-20 7D
100
7E 100 95-100 15-100 7E
7F 100 15-100 7F
7I 100 95-100 15-100 7I

70
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TABLE 6/3: (02/16) Limits of Material Properties of Fill for Use With Metal Components in Reinforced Soil and Anchored Earth
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---

Structures for Class 6H, 6I, 6J, 7C and 7D Materials

Volume 1
Reinforcing Properties of Fill

Element pH Value Max Max Max Water Maximum Minimum Minimum Microbial
Material Chloride Organic Soluble (WS) Oxidisable Restivity Redox Activity Index
Ion Content Content Sulfate Sulfides Ohm.cm Potential
Min Max Content (OS) volts
% %
mg/l as SO4 Content
% as SO4

Galvanised 5 10 0.02 0.2 300 0.06 5000 0.40 )
Steel )
Stainless Steel 5 10 0.025 0.2 600 0.12 3000 0.35 ) Less than 5
)
)
NOTES:
1 (02/16) A method of calculating the Microbial Activity Index may be obtained by reference to TRRL Contractor Report 54 ‘Soil Corrosivity
Assessment’.
2 (02/16) The corrosion potential of frictional fill shall be assessed from resistivity, pH, chloride, water soluble sulfate and oxidisable sulfides tests. For
cohesive soil it will be necessary to test additionally for organic content. Should either organic content or sulfate be in excess of the specified levels, then
tests shall also be included for Redox Potential and Microbial Activity Index.
3 (02/16) The water soluble sulfate content and oxidisable sulfides content shall be determined in accordance with the methods described in BS EN
1744-1 clause 10, 11 and 13.
4 (02/16) Methods of test (except for Microbial Activity Index, water soluble sulfate content and oxidisable sulfides content) are given in BS 1377:

Part 3.

71
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TABLE 6/4: (02/16) Method Compaction for Earthworks Materials: Plant and Methods (Method 1 to Method 6)

(This Table is to be read in conjunction with sub-Clause 612.10)

Volume 1
Type of Compaction Ref Category Method 1 Method 2 Method 3 Method 4 Method 5 Method 6
Plant No. D N# D N# D N# D N D N N for N for N for
D = 110 mm D = 150 mm D = 250 mm
Smoothed wheeled roller Mass per metre width of roll:
(or vibratory roller 1 over 2100 kg up to 2700 kg 125 8 125 10 125 10* 175 4 unsuitable unsuitable unsuitable unsuitable
operating without
vibration) 2 over 2700 kg up to 5400 kg 125 6 125 8 125 8* 200 4 unsuitable 16 unsuitable unsuitable
3 over 5400 kg 150 4 150 8 unsuitable 300 4 unsuitable 8 16 unsuitable

Grid roller Mass per metre width of roll:
1 over 2700 kg up to 5400 kg 150 10 unsuitable 150 10 250 4 unsuitable unsuitable unsuitable unsuitable
2 over 5400 kg up to 8000 kg 150 8 125 12 unsuitable 325 4 unsuitable 20 unsuitable unsuitable
3 over 8000 kg 150 4 150 12 unsuitable 400 4 unsuitable 12 20 unsuitable
Deadweight tamping Mass per metre width of roll:
roller 1 over 4000 kg up to 6000 kg 225 4 150 12 250 4 350 4 unsuitable 12 20 unsuitable
2 over 6000 kg 300 5 200 12 300 3 400 4 unsuitable 8 12 20
Pneumatic-tyred Mass per wheel:
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
roller 1 over 1000 kg up to 1500 kg 125 6 unsuitable 150 10* 240 4 unsuitable unsuitable unsuitable unsuitable
2 over 1500 kg up to 2000 kg 150 5 unsuitable unsuitable 300 4 unsuitable unsuitable unsuitable unsuitable
3 over 2000 kg up to 2500 kg 175 4 125 12 unsuitable 350 4 unsuitable unsuitable unsuitable unsuitable
4 over 2500 kg up to 4000 kg 225 4 125 10 unsuitable 400 4 unsuitable unsuitable unsuitable unsuitable
5 over 4000 kg up to 6000 kg 300 4 125 10 unsuitable unsuitable unsuitable 12 unsuitable unsuitable
6 over 6000 kg up to 8000 kg 350 4 150 8 unsuitable unsuitable unsuitable 12 unsuitable unsuitable
7 over 8000 kg up to 12000 kg 400 4 150 8 unsuitable unsuitable unsuitable 10 16 unsuitable
8 over 12000 kg 450 4 175 6 unsuitable unsuitable unsuitable 8 12 unsuitable

Vibratory tamping roller Mass per metre width of a
vibrating roll:

1 over 700 kg up to 1300 kg 100 12 100 12 150 12 100 10 unsuitable unsuitable unsuitable unsuitable
2 over 1300 kg up to 1800 kg 125 12 125 12 175 12* 175 8 unsuitable 12 unsuitable unsuitable
3 over 1800 kg up to 2300 kg 150 12 150 12 200 12* unsuitable unsuitable 8 12 unsuitable
4 over 2300 kg up to 2900 kg 150 9 150 9 250 12* unsuitable 400 5 6 10 unsuitable
7 over 4300 kg up to 5000 kg 250 9 250 9 300 9* unsuitable 700 6 3 7 12
8 over 5000 kg 275 9 275 9 300 7* unsuitable 800 6 3 6 10
72
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TABLE 6/4: (02/16) Method Compaction for Earthworks Materials: Plant and Methods (Method 1 to Method 6)

(This Table is to be read in conjunction with sub-Clause 612.10) (Continued)

Volume 1
Type of Compaction Ref Category Method 1 Method 2 Method 3 Method 4 Method 5 Method 6
Plant No. D N# D N# D N# D N D N N for N for N for
D = 110 mm D = 150 mm D = 250 mm
Vibratory roller Mass per metre width of
vibratory roll:
1 over 270 kg up to 450 kg unsuitable 75 16 150 16 unsuitable unsuitable unsuitable unsuitable unsuitable
2 over 450 kg up to 700 kg unsuitable 75 12 150 12 unsuitable unsuitable unsuitable unsuitable unsuitable

3 over 700 kg up to 1300 kg 100 12 125 10 150 6 125 10 unsuitable 16 unsuitable unsuitable
4 over 1300 kg up to 1800 kg 125 8 150 8 200 10* 175 4 unsuitable 6 16 unsuitable
5 over 1800 kg up to 2300 kg 150 4 150 4 225 12* unsuitable unsuitable 4 6 12

10 over 5000 kg 275 4 275 4 300 4* unsuitable 800 5 2 3 6
Vibrating plate Mass per m2 of base plate:
compactor 1 over 880 kg up to 1100 kg unsuitable unsuitable 75 6 unsuitable unsuitable unsuitable unsuitable unsuitable
2 over 1100 kg up to 1200 kg unsuitable 75 10 100 6 75 10 unsuitable unsuitable unsuitable unsuitable
3 over 1200 kg up to 1400 kg unsuitable 75 6 150 6 150 8 unsuitable unsuitable unsuitable unsuitable
4 over 1400 kg up to 1800 kg 100 6 125 6 150 4 unsuitable unsuitable 8 unsuitable unsuitable
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
5 over 1800 kg up to 2100 kg 150 6 150 5 200 4 unsuitable unsuitable 5 8 unsuitable
6 over 2100 kg 200 6 200 5 250 4 unsuitable unsuitable 3 6 12

Vibro-tamper Mass:
1 over 50 kg up to 65 kg 100 3 100 3 150 3 125 3 unsuitable 4 8 unsuitable
2 over 65 kg up to 75 kg 125 3 125 3 200 3 150 3 unsuitable 3 6 12

3 over 75 kg up to 100 kg 150 3 150 3 225 3 175 3 unsuitable 2 4 10
4 over 100 kg 225 3 200 3 225 3 250 3 unsuitable 2 4 10
Power rammer Mass:
1 100 kg up to 500 kg 150 4 150 6 unsuitable 200 4 unsuitable 5 8 unsuitable
2 over 500 kg 275 8 275 12 unsuitable 400 4 unsuitable 5 8 14
Dropping-weight Mass of rammer over 500 kg
compactor weight drop:
1 over 1 m up to 2 m 600 4 600 8 450 8 unsuitable unsuitable unsuitable unsuitable unsuitable
2 over 2 m 600 2 600 8 unsuitable unsuitable unsuitable unsuitable unsuitable unsuitable
73
Earthworks
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Volume 1 Series 600
TABLE 6/4: (02/16) Method Compaction for Earthworks Materials: Plant and Methods
(Method 7) (This Table is to be read in conjunction with sub-Clause 612.10) (Continued)
Type of Compaction Plant Ref~ Category Method 7
No.
N for N for
D = 150 mm D = 250mm
Smooth wheeled roller Mass per metre width of roll:
(or vibratory roller 1 over 2100 kg up to 2700 kg unsuitable unsuitable
operating without 2 over 2700 kg up to 5400 kg unsuitable unsuitable
vibration) 3 over 5400 kg 12 unsuitable
Grid roller Mass per metre width of roll:
1 over 2700 kg up to 5400 kg unsuitable unsuitable
2 over 5400 kg up to 8000 kg 16 unsuitable
3 over 8000 kg 8 unsuitable
Deadweight tamping roller Mass per metre width of roll:
1 over 4000 kg up to 6000 kg 4 8
2 over 6000 kg 3 6
Pneumatic-tyred roller Mass per wheel:
5 over 4000 kg up to 6000 kg 4 16
6 over 6000 kg up to 8000 kg unsuitable 8
7 over 8000 kg up to 12000 kg unsuitable 4
8 over 12000 kg unsuitable 4
Vibratory tamping roller Mass per metre width of vibrating roll:
6 over 3600 kg up to 4300 kg 8 16
7 over 4300 kg up to 5000 kg 7 14
8 over 5000 kg 6 12
Vibratory roller Mass per metre width of vibrating roll:
10 over 5000 kg 6 12
Vibratory plate compactor Mass per m2 of base plate:
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---

Vibro-tamper Mass:
Power rammer Mass:
1 100 kg up to 500 kg 8 unsuitable
2 over 500 kg 6 10
Dropping weight compactor Mass of rammer over 500 kg height drop:
1 over 1 m up to 2 m unsuitable unsuitable
2 over 2 m unsuitable unsuitable

TABLE 6/5: (02/16) Imported Onto Site Grading Requirements for Class 6 Acceptable Earthworks Materials

Volume 1
Class Size Size (mm) Size (microns) Class

(mm) BS EN 933-2 Series BS EN 933-2 Series
500 300 125 80 63 40 31.5 20 16 10 8 6.3 4 2 1 500 250 125 63 0
6A 100 0-100 0-85 0-45 0-5 6A
6B 100 0-10 6B
6C 100 0-100 0-100 0-35 0-10 0-2 6C
6D 100 85-100 60-100 30-100 15-80 5-48 0-15 6D

except
0-20
for
crushed
rock
6E & 100 85-100 25-100 10-100 <15 6E &
6R 6R
6F3 100 75-99 50-90 30- 15-60 0-35 0-12 6F3
75
6F4 100 75-99 50-90 30-75 15-60 0-35 <15 6F4
6F5 100 75-99 50-90 30- 15-60 0-35 0-12 6F5
75
6H 100 60-100 15-45 0-25 0-5 6H
6I & 100 85-100 25-100 15-100 9-100 <15 6I &
6J 6J
6K 100 0-10 6K
6L 100 85-100 60-100 30-100 15-100 5-70 0-15 6L

except
0-20
for
crushed

rock
6M 100 0-10 6M
6N & 100 <15 6N &
6P 6P
6S 100 60-100 30-90 8-45 0-16 6S
75
Earthworks
Series 600
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Volume 1 Series 600
TABLE 6/6: (02/16) Records and Reports - Information Required

Ground Treatment In situ Testing
For each column/area treated: For each area tested:
Date Date
Contract title Contract Title
Area identification Area identification
Unique grid location Test position, co-ordinates and level
Ground level at commencement Method of test used
Material used All information required by appropriate British
Approximate column diameter Standard test procedure
Depth of penetration of each compaction point
Vibrator power consumption during operation
Jetting pressure (where applicable)
Duration of penetration
Duration of compaction
Obstructions and delays
Number and type of tests carried out
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Volume 1 Series 600
TABLE 6/7 (02/16) Material Sources and Source Codes for Imported Materials
This table is taken from BS EN 13242:2013 which was published on 31st May 2013 and subsequently withdrawn
on 10th January 2014. All other specification requirements which reference BS EN 13242 shall be taken as
reference to the version of that standard current at the Contract Reference Document Date unless otherwise detailed
in the contract specific specification.
Source Source Sub-Code Specific Material
Code
P Natural Aggregates P All petrographic types included in BS EN 932-3
A Construction and demolition recycling A1 Reclaimed asphalt
industries
A2 Crushed concrete
A3 Crushed bricks, masonry
A4 Mix of A1, A2 and A3
B Municipal solid waste incineration B1 Municipal incinerator bottom ash (excluding fly ash) (MIBA)
industry
B2 Municipal incinerator fly ash (MIFA)
C Coal Power Generation Industry C1 Coal fly ash
C2 Fluidised bed combustion fly ash (FBCFA)
C3 Boiler slag
C4 Coal bottom ash
C5 Fluidised bed combustion bottom ash (FBC bottom ash)
D Iron and steel industry D1 Granulated blast furnace slag (GBS)
D2 Air-cooled blast furnace slag (ABS)
D3 Basic oxygen furnace slag (converter slag, BOS)
D4 Electric arc furnace slag (from carbon steel production, EAF C)
D5 Electric arc furnace slag (from stainless/high alloy steel production,
EAF S)
D6 Ferrochromium slag
E Non ferrous steel industry E1 Copper slag
E2 Molybdenum slag
E3 Zinc slag
E4 Phosphorous slag
F Foundry industry F1 Foundry sand
F2 Foundry cupola furnace slag
G Mining and quarry industry G1 Red coal shale
G2 Refuse from hard coal mining (black coal shale)
G3 Pre-selected all-in from quarry/mining
G4 Spent oil shale
H Maintenance dredging works H1 Dredge spoil sand
H2 Dredge spoil clay
I Miscellaneous I1 Excavated soil
I2 Paper sludge ash
I3 Sewage sludge incineration ash (municipal)
I4 Biomass ash
I5 Crushed glass
I6 Expanded clay

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Volume 1 Series 600

ORGANISATION OF SCOTLAND
601TS (02/16) Classification, Definitions and Uses of Earthworks Materials
(02/16) General
works;
(iii) unacceptable material Class U1B as defined in sub-Clause 2(ii)(a) of this Clause: material excavated
(a) material which does not comply with the permitted constituents and material properties of
Table 6/1 and contract specific Appendix 6/1 for acceptable material; and
Appendix 6/14 or in contract specific Appendix 6/15, but excluding all special wastes (as defined in
the Special Waste Amendment (Scotland) Regulations 2004) and radioactive wastes (as defined in
the Radioactive Substances Act 1993).
Amendment – February 2016 S1

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Volume 1 Series 600

(i) special waste (as defined in the Special Waste Scotland (Amendment) Regulations 2004) and radioactive
waste (as defined in the Radioactive Substances Act 1993).
(02/16) Definitions
particles of clay and silt and mica. It shall include unburnt colliery spoil. Where argillaceous rock is imported onto
the site, it shall be aggregate complying with BS EN 13242 from source codes P (natural aggregates described as
shale, siltstone or slate), or G2 (refuse from hard coal mining (black coal shale)).
flue gases of furnaces fired with pulverised bituminous coal. It shall have a maximum particle size of
3 mm. Where pulverised-fuel ash is imported onto the site, it shall be aggregate complying with BS EN 13242 from
source code C1 (coal fly ash).
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---

Volume 1 Series 600

16 (02/16) Material placed within 500 mm, or any other distances described in contract specific Appendix 6/3, of
concrete, cement bound materials, other cementitious materials or stabilised capping forming part of the permanent
works shall conform to, as appropriate, the following requirements.
shall not exceed 1% for aggregates other than air cooled blast furnace slag or 2% for air cooled blast
furnace slag.
or
(b) The sulfide content of the mixture determined in accordance with BS EN 1744-1 Clause 13 is less
than 0.5% (as S04).
metallic structural elements forming part of the permanent works shall conform, as appropriate, to the following
requirements.
furnace slag.
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
or
than 0.06% (as S04).
When determining WS, TS or sulfide content, at least five samples of each material shall be tested. The mean of the
highest two values shall be used for comparison with the limiting values. This shall also applies apply if six to nine
The requirements in (i) and (ii) above shall not apply to metallic elements protected by concrete or ancillary
metallic items such as the tops of chambers and gullies.

Volume 1 Series 600
18 (02/16) Unburnt colliery spoil may be used as general fill provided it is compacted in compliance with
Clause 612 and complies with the requirements of contract specific Appendix 6/1.
19 (02/16) Pulverised-fuel ash shall not be placed within the dimension described in contract specific Appendix 6/3,
below sub-formation or formation.
632TS (02/16) Determination of Moisture Condition Value (MCV) of Earthworks Materials in

Scotland
1 (02/16) Where the Moisture Condition Value (MCV) is required in contract specific Appendix 6/1, the MCV
determination shall be carried out in accordance with TRL Report 273, Appendix A, Sections 1 to 3.
2 (02/16) Where the natural moisture content MCV is required in contract specific Appendix 6/1, the MCV
determination shall be carried out in accordance with TRL Report 273, Appendix A, Sections 1 to 3.
3 (02/16) Where the MCV of saturated materials is required in contract specific Appendix 6/1, the MCV
determination shall be carried out in accordance with TRL Report 273, Appendix A, Sections 1, 2 and 4.
4 (02/16) When required in contract specific Appendix 6/1, the determination of the MCV/moisture content
relation shall be carried out in accordance with TRL Report 273, Appendix A, Sections 1, 2 and 5.
5 (02/16) An alternative procedure is given in Appendix A, Sections 1, 2 and 6 of TRL Report 273. The rapid
assessment procedure for material acceptability may be used when permitted in contract specific Appendix 6/1.
6 (02/16) The Contractor shall provide, for each Moisture Condition Apparatus (MCA) to be used, a test certificate
to show that the MCA is functioning correctly. The tests for correct function shall be carried out as described in
Appendix D of TRL Report 273 and the results recorded on form MCA3 (TRL Report 273, Appendix B), or similar.
All equipment used shall be traceable to national standards.
7 (02/16) The Contractor shall provide, for each operator of the MCA, a certificate which shows the operator
has completed an appropriate course of training approved by the Overseeing Organisation. The Overseeing
Organisation shall be contacted for details of those organisations able to provide such training.
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
Amendment – February 2016 S4F

Volume 1 Series 600

ORGANISATION OF WALES
(02/16) 601W Classification, Definitions and Uses of Earthworks Materials
(02/16) General
works;
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
(v) unacceptable material Class U1B as defined in sub-Clause 2(ii)(a) of this Clause: material excavated
(vi) unacceptable material Class U2 as defined in sub-Clause 3(i) of this Clause: material excavated from
Appendix 6/14 or in contract specific Appendix 6/15, but excluding all hazardous wastes (as
Amendment – February 2016 W1

Volume 1 Series 600
defined in the Hazardous Waste (England and Wales) Regulations 2005) and radioactive wastes (as
defined in the Radioactive Substances Act 1993).
(i) hazardous waste (as defined in the Hazardous Waste (England and Wales) Regulations 2005) and
(02/16) Definitions
particles of clay silt and mica. It shall include unburnt colliery spoil. Where argillaceous rock is imported onto the
site, it shall be aggregate complying with BS EN 13242 from source codes P (natural aggregates described as shale,
siltstone or slate), or G2 (refuse from hard coal mining (black coal shale)). See sub‑Clause 21.
9 (02/16) Furnace bottom ash shall mean agglomerated pulverised-fuel ash obtained from the bottom of the
power station furnace and having particle size no larger than 10 mm. Where furnace bottom ash is imported
onto the site, it shall be aggregate complying with BS EN 13242 from source code C4 (coal bottom ash).
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,
Amendment – February 2016 W2

Volume 1 Series 600

16 (02/16) Materials placed within 500 mm, or any other distances described in the contract specific Appendix
permanent works shall conform to, as appropriate, the following requirements:
furnace slag.
or
than 0.5% (as S04).
17 (02/16) Material placed within 500mm, or any other distances described in the contract specific Appendix 6/3,
of metallic structural elements forming part of the permanent works shall conform, as appropriate, to the following
requirements:
furnace slag.
or
than 0.06% (as S04).
The requirements in (i) and (ii) above shall not apply to metallic items protected by concrete or ancillary metallic
items such as the tops of chambers and gullies.
Amendment – February 2016 --`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`--- W3

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21 (02/16) Where stated in contract specific Appendix 6/1 permissible options for fill materials shall include slate
or other argillaceous rock materials as stated.
Amendment – February 2016 W4F

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Volume 1 Series 600

601NI (02/16) Classification, Definitions and Uses of Earthworks Materials
(02/16) General
works;
(iii) unacceptable material Class U1B as defined in sub-Clause 2 (ii)(a) of this Clause: material excavated
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---

(a) contaminated materials, including controlled wastes (as defined in the Waste and Contaminated
Land (Northern Ireland) Order 1997 whose level of contamination is above that given either in
contract specific Appendix 6/14 or in contract specific Appendix 6/15, but excluding all hazardous
wastes (as defined in the Hazardous Waste Regulations (Northern Ireland) 2005) and radioactive
wastes (as defined in the Radioactive Substances Act 1993).
Amendment – February 2016 N1

Volume 1 Series 600

(i) hazardous waste (as defined in the Hazardous Waste Regulations (Northern Ireland) 2005) and
4 (02/16) Where required in contract specific Appendix 6/1 unacceptable material (other than Class U2) shall be
in accordance with the requirements of Table 6/1 and the contract specific Appendix 6/1.
(02/16) Definitions
on the maps produced by the Geological Survey of Northern Ireland;
particles of clay silt and mica. It shall include unburnt colliery spoil. Where argillaceous rock is imported onto the
site, it shall be aggregate complying with BS EN 13242 from source codes P (natural aggregates described as shale,
siltstone or slate), or G2 (refuse from hard coal mining (black coal shale)).
10 (02/16) Formation shall be the top surface of capping.
Where no capping is required formation shall be the top surface of earthworks at the underside of sub-base, unless
otherwise shown on the drawings.

N2
Volume 1 Series 600

16 (02/16) Materials placed within 500 mm, or any other distances described in contract specific Appendix 6/3, of
concrete, cement bound materials, other cementitious materials or stabilised capping forming part of the permanent
works shall conform to, as appropriate, the following requirements:
furnace slag.
(ii) Marerials shall conform to at least one of the following options:
or
than 0.5% (as S04).
metallic structural elements forming part of the permanent works shall conform, as appropriate, to the following
requirements.
furnace slag.
or
than 0.06% (as S04).
When determining WS, TS or sulfide content, at least five samples of each material shall be tested. The mean of the
highest two values shall be used for comparison with the limiting values. This shall also applies apply if six to nine
The requirements in (i) and (ii) above shall not apply to metallic elements protected by concrete or ancillary
metallic items such as the tops of chambers and gullies.

N3
Volume 1 Series 600
20 (02/16) Where pulverised-fuel ash is used, the Contractor shall for each consignment make available to the
607NI (02/16) Explosives and Blasting for Excavation

1 (02/16) Blasting for excavation shall not be employed unless permitted or required in contract specific Appendix
6/3 and such blasting shall be confined to the locations and to within the time limits stated therein.
(i) not carry out plaster shooting;
(ii) for each location where blasting is to be undertaken, provide written notice to the Overseeing
Organisation of the programme of blasting, including trial explosions, at least 10 days before it
commences and give written notice of each blasting event as described in (v) below, at least 12 hours
beforehand;
(iii) carry out trial explosions starting with reduced quantities of explosive in order to determine the size of
the actual explosive charges and their disposition, for use in the main blasting operations, so as not to
exceed the values for vibrational amplitude and vibrational peak particle velocity stated in (vi) below at
the positions described therein;
(iv) determine danger zones likely to be created by the blasting operations, including trial explosions, within
which blasted material may be projected and utilise suitable arrangements including temporary works, to
retain such projectiles and ensure that no injury or damage is caused to persons or property thereby;
(v) limit blasting to a small number of events during permitted hours per day, where an event shall comprise
a single explosion or a group of explosions each separated by a short time interval, the group lasting less
than a minute;
(vi) ensure that:
(a) structures and earthworks, existing or under construction, on and off the site, do not experience,
during blasting operations including trial explosions, a vibrational amplitude exceeding 0.2 mm
and a resultant peak particle velocity exceeding 50 mm per second, or other limits stated in contract
specific Appendix 6/3, at the same time or individually; and
(b) peak overpressures, of magnitude such as to endanger windows and glazed areas of structures, do
not occur;
(vii) where instrumentation and monitoring is appropriate:
(a) rigidly fix to structures and insert in earthworks described in (vi)(a) above, suitable instruments
to measure the vibrational amplitude and resultant vibrational peak particle velocity, and peak
overpressures, experienced during blasting operations including trial explosions;
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
(b) make available details of the proposed instrumentation within the site;
(c) unless otherwise stipulated in contract specific Appendix 6/3, make his own arrangements for
installing instruments on property off the site including negotiating with landowners and other
interested parties;

Volume 1 Series 600
(d) read such instruments and take measurements throughout the period of blasting operations,
including trial explosions;
(e) for instruments on structures or earthworks on the site and, where required in contract specific
Appendix 6/3, on property off the site, make available the results to the Overseeing Organisation at
the end of each day’s blasting;
(viii) take measurements of vibrational amplitude and peak particle velocity in each of three mutually
perpendicular planes and determine the peak value, taken as the maximum resultant calculated by vector
summation of the three components of amplitude and velocity respectively, measured as instantaneously
as the resolution of the recording instrument permits;
(ix) ensure that noise from blasting operations is controlled in accordance with Clause 109;
(x) use explosives in the quantities and in the manner recommended by the manufacturer;
(xi) store explosives in registered premises in a licensed store or magazine provided with a separate
compartment for detonators or use them under an Immediate Use Certificate issued by the police;
(xii) only permit explosives to be used or handled by or under the immediate control of a competent person in
accordance with the Construction (General Provisions) Northern Ireland Regulations 1963 (Regulation
19) and subsequent amending Regulations;
(xiii) ensure there is no unauthorised issue or improper use of explosives brought on the site and maintain a
strict check on quantities issued and consumed;
(xiv) comply with the requirements of BS 6657 in respect of the use of electrical detonators in the vicinity
of static and mobile radio transmitters, including normal radio and television broadcasting stations and
radar units associated with aircraft movements, electricity generating plant and transmission lines.
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Amendment – February 2016 N5F

SERIES 700
ROAD PAVEMENTS – GENERAL
Contents
700 (02/16) General 2 719 (02/16) Back-analysis of Falling Weight
Deflectometer (FWD) Measurements
701 (02/16) Pavement Construction 2
Made on Concrete Pavements Treated
#702 (02/16) Horizontal Alignments, Surface by Fractured Slab Techniques 34
Levels and Surface Regularity of
Pavement Courses 2
703 to 705 (02/16) Not used 5 NATIONAL ALTERATIONS OF THE
#706 (02/16) Excavation, Trimming and
Reinstatement of Existing Surfaces 5
IRELAND
707 (02/16) Breaking Up or Perforation of
Redundant Pavement 7 Northern Ireland
708 (02/16) Not used 7 702NI (02/16) Horizontal Alignments, Surface

Levels and Surface Regularity of
709 (02/16) Cold-milling (Planing) of Pavement CoursesN1
Bituminous Bound Flexible Pavement 7
706NI (02/16) Excavation, Trimming and
710 (02/16) Testing for Constituent Materials Reinstatement of Existing SurfacesN4
in Recycled Aggregate and Recycled
Concrete Aggregate 8
711 (02/16) Overband and Inlaid Crack Sealing # denotes a Clause or Sample Contract Specific Appendix which has a
Systems 8 substitute National Clause or Sample Contract Specific Appendix for one
or more of the Overseeing Organisations of Scotland, Wales or Northern
712 (02/16) Maintenance of Arrester Beds 9 Ireland.
713 (02/16) Saw-cut and Seal Bituminous

Overlays on Existing Jointed Concrete
Pavements 9
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714 (02/16) Preparation of Jointed Concrete
Pavements Prior to Overlaying and
Saw-cut and Seal of the Bituminous
Overlays 10
715 (02/16) Saw-cut, Crack and Seat Existing
Jointed Reinforced Concrete Pavements 11
716 (02/16) Cracking and Seating of Existing
Jointed Unreinforced Concrete Pavements
and Hydraulically Bound Mixture (HBM)
Bases 20
717 (02/16) Monitoring of Cracked and Seated
Jointed Unreinforced Concrete Pavements
and HBM Bases Using the Falling Weight
Deflectometer (FWD)28
718 (02/16) Monitoring of Saw-cut, Cracked
and Seated Jointed Reinforced Concrete
Pavements Using the Falling Weight
Deflectometer (FWD) 31

Volume 1 Series 700
Specification for Highway Works Road Pavements – General
ROAD PAVEMENTS – GENERAL

700 (02/16) General
701 (02/16) Pavement Construction

1 (02/16) Road pavements shall be constructed from one of the permitted options described in contract specific
Appendix 7/1 and in compliance with this Series and the appropriate Clauses of Series 800, 900 and 1000.
2 (02/16) The Contractor shall, in his choice of permitted materials for subbases and bases, have regard to the
nature of those materials and of the subgrade or any capping and the need to protect them from deterioration due
to the ingress of water, the adverse effects of weather and the use of constructional plant. The Contractor shall
programme the laying and compaction of the subbase and the subsequent pavement courses and take such other
steps as may be considered necessary, to afford protection to the base, subbase and subgrade.
#702 (02/16) Horizontal Alignments, Surface Levels and Surface Regularity of Pavement Courses
Horizontal Alignments
1 (02/16) Horizontal alignments shall be determined from one edge of the pavement surface as described in
contract specific Appendix 1/12. The edge of the pavement as constructed and all other parallel alignments shall
be correct within a tolerance of 25 mm therefrom, except for kerbs and channel blocks which shall be laid with
a smooth alignment within a tolerance of ±13 mm. Longitudinal road markings lateral tolerance shall be in
(02/16) Surface Levels of Pavement Courses
2 The design levels of pavement courses shall be calculated from the vertical profile, crossfalls and the pavement
course thicknesses described in contract specific Appendix 7/1. The level of any point on the constructed surface of
the pavement courses shall be the design level subject to the appropriate tolerances stated in Table 7/1.
TABLE 7/1: (02/16) Tolerances in Surface Levels of Pavement Courses
Road surfaces
— general ± 6 mm
— adjacent to a surface water channel* + 10 – 0 mm
Binder course * ± 6 mm
Base * ± 15 mm
Subbase under concrete pavement surface slabs laid full thickness in one
operation by machines with surface compaction ± 10 mm
Subbases other than above + 10 – 30 mm
* Where a surface water channel is laid before the adjacent road pavement layer the top of that layer, measured from
the top of the adjacent edge of the surface water channel, shall be to the tolerances given in Table 7/1.
3 (02/16) Notwithstanding the tolerances permitted in surface levels of pavement courses, the cumulative
tolerance shall not result in a reduction in thickness of the pavement, excluding the subbase, by more than 15 mm
from the specified thickness nor a reduction in the thickness of the bituminous surface course by more than 5 mm
from that specified.

2
Volume 1 Series 700
4 (02/16) For checking compliance with sub-Clause 2 of this Clause, measurements of the surface levels of all
courses will be taken on a grid of points located as described in contract specific Appendix 7/1. In any length of
pavement, compliance shall be deemed to be met for all surfaces, other than the final road surface, when not more
than one of ten consecutive measurements taken longitudinally or one in any transverse line, exceeds the tolerances
permitted in Table 7/1, provided that this one measurement shall not exceed by more than 5 mm the tolerance for
the course concerned. For the final road surface the tolerance given in Table 7/1 shall apply to any point on that
surface.
(02/16) Surface Regularity
5 (02/16) The longitudinal regularity of the surfaces of surface courses, binder courses and concrete slabs shall be
such that the number of surface irregularities is within the relevant limits stated in Table 7/2.
An irregularity is a variation of not less than 4 mm or not less 7 mm of the profile of the road surface as measured
by the rolling straight-edge set at 4 mm or 7 mm as appropriate, or equivalent apparatus capable of measuring
irregularities within the same magnitudes over a 3 m length. No irregularity exceeding 10 mm shall be permitted.
6 (02/16) Prior to checking any final road surface, binder course or top surface of base in pavements without
binder course for level, regularity or macrotexture depth, it shall be cleaned of loose or extraneous materials. These
operations shall be carried out without damaging the surface of the pavement, as soon as possible and within 3 days
of construction of the pavement.
7 (02/16) Compliance with Table 7/2 shall be checked by the rolling straight-edge along any line or lines parallel
to the edge of pavement on sections of 300 m at regular intervals as stated in contract specific Appendix 7/1,
whether or not it is constructed in shorter lengths. Sections shorter than 300 m forming part of a longer pavement
shall be assessed using the number of irregularities for a 300 m length pro-rata to the nearest whole number.
Where the total length of pavement is less than 300 m, the measurements shall be taken on 75 m lengths.
8 (02/16) Pavements shall be measured transversely for irregularities at regular intervals as stated in contract
specific Appendix 7/1, by a 3 m long straight-edge in accordance with BS 8420 placed at right angles to the centre
line of the road. The maximum allowable difference between the pavement surface and the straight-edge shall be
3 mm.
9 (02/16) A straight-edge 3 metres long, shall be used to check longitudinal surface regularity in the following
cases:
(i) for lengths of less than 75 m of surface course, binder course and concrete slabs;
(ii) where use of the rolling straight-edge or equivalent apparatus is impracticable;
(iii) for all lengths of subbase under concrete pavement slabs laid full thickness in one operation by machine
with surface compaction.
The maximum allowable difference between the surface and the underside of the straight-edge, when placed
parallel with, or at right angles to, the centre line of the road shall be:
for pavement surfaces 3 mm
for binder courses 6 mm
for subbases under concrete pavements (as in (iii) above) 10 mm

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Volume 1 Series 700
TABLE 7/2: (02/16) Maximum Permitted Number of Surface Irregularities

Surfaces of each lane Surfaces of each lane of Surfaces of lay-bys,
of carriageway, each bituminous binder courses service areas, and
hard strip and each for carriageway, hard associated bituminous
hard shoulder for each strip and hard shoulder binder courses for each
irregularity limit for each irregularity limit irregularity limit
Irregularity Limits 4 mm 7 mm 4 mm 7 mm 4 mm 7 mm
Length (m) 300 75 300 75 300 75 300 75 300 75 300 75
Category A* Roads 20 9 2 1 40 18 4 2 40 18 4 2
Category B* Roads 40 18 4 2 60 27 6 3 60 27 6 3
* The Category of each section of road is described in contract specific Appendix 7/1.
(02/16) Rectification
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10 (02/16) Where any pavement area does not comply with the specification for regularity, surface tolerance,
thickness, macrotexture depth, material properties or compaction, the full extent of the area which does not comply
with the specification shall be made good and the surface of the pavement course shall be rectified in the manner
described below:
(i) Unbound and hydraulically bound materials
The top 75 mm shall be scarified, reshaped with material added or removed as necessary, and re-
compacted. The area treated shall be not less than 20 m long and 2 m wide. For hydraulically bound
materials, all rectification shall be completed within 48 hours of the binder being added to the material.
(ii) Cement bound subbases and bases
The method of correction will depend on the period which has elapsed between detection of the error
and the time of mixing of the material. If this is less than 4 hours, the surface shall be scarified to a
depth of not less than 50 mm, surplus material removed or freshly mixed material added as necessary,
and re-compacted in accordance with the specification. If the period is 4 hours or more the full depth
of the layer shall be removed from the pavement and replaced with material in accordance with the
specification. In either case the area treated shall be at least 5 m long and the full width of the paving
laid in one operation. If the Contractor proposes rectification within 7 days of laying he shall comply
with Clause 1048. Alternatively, for subbases under concrete pavements the Contractor may make up
low areas to a level within the tolerances of this Clause with a 1:4 cement and sand mortar or with an
AC4 fine surface course complying with Clause 914.
(iii) Bituminous bases
With coated macadam or asphalt bases, the full depth of the top layer as laid shall be removed and be
replaced with fresh material laid and compacted in accordance with the specification. Any area so treated
shall be at least 5 m long and the full width of the paving laid in one operation. Alternatively for low
areas in bituminous bases, the Contractor may make up the level with additional binder course material.
(iv) Surface courses and binder courses
These shall have the full depth of the course removed and replaced with fresh material laid and
compacted in accordance with the specification.
The area rectified shall be the full width of the paving laid in one operation, and at least 5 m long if
binder course, or 15 m if surface course.
Where the number of surface irregularities exceeds the limits in Table 7/2, the area to be rectified shall
be 300 m or 75 m long as appropriate and the full width of the lanes affected, or such lesser length as
necessary to make the number of surface irregularities conform with the limits and shall be the full width
of the lanes affected.

Volume 1 Series 700
Checking of the surface course for compliance with this Clause shall be carried out as soon as possible
after completion of the surfacing and remedial works completed before the road is opened to traffic.
Where the macrotexture depth requirement is not met for:
(a) a section 1000 m in lane length; or
(b) the full lane length of a section less than 1000 m long as the balance of a complete scheme; or
(c) the full lane length of a scheme less than 1000 m long;
then sufficient 50 m lengths shall be replaced, starting with that length having the least macrotexture
depth, until the average requirement for the section length is complied with.
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A minimum length of 50 m and the full lane width shall be removed and replaced either:
(a) to the full depth of the surface course; or
(b) to a depth of 20 mm when replaced by the repave method process in compliance with Clause 926.
Areas to be removed shall be delineated both longitudinally and transversely by saw cutting prior to
the material being removed. Joints shall be formed either by coating the exposed sawn face with hot
bitumen or heating by a suitable heater. The heater shall raise the temperature of the full depth of the
course immediately before laying the new material to a figure within the range of minimum rolling
temperature and maximum temperature at any stage specified for the material and for a width of not less
than 75 mm.
(v) Concrete slabs
Concrete slabs shall be rectified by planing, grinding or bump cutting. Large depressions, which cannot
be dealt with in this way, shall be rectified by cutting out the surface and replacing by a thin bonded
surface repair complying with Clause 1032.
Retexturing of hardened concrete shall be carried out by sawing grooves in accordance with the
specification. Texturing of replaced surfaces shall be by brushing in accordance with the specification.
Where the slab cannot be rectified as above, the full depth of slab shall be removed and replaced with
a slab constructed in compliance with Clause 1033 to the extent required to obtain compliance with the
specification. Remedial works involving the placing of fresh concrete shall be completed in sufficient
time for the concrete strength to have developed as required in Clause 1048, before that section of
pavement is opened to traffic.
703 to 705 (02/16) Not used
706 (02/16) Excavation, Trimming and Reinstatement of Existing Surfaces

(02/16) General
1 (02/16) The Contractor shall not excavate pits, trenches or other openings in paved areas which have been
constructed as part of the permanent works in order to construct other parts of the works, including Statutory
Undertakers and other service works, except with the prior approval of the Overseeing Organisation.
2 (02/16) Where excavation and trimming of existing paved areas and highways not constructed as part of
the permanent works are required in contract specific Appendix 7/2, they shall be carried out and reinstated in
compliance with this Clause and with any additional requirements described in contract specific Appendix 7/2.
Excavations shall be carried out to the dimensions described in contract specific Appendix 7/2, or, if not so
described, to the minimum dimensions, subject to sub-Clause 3 of this Clause, necessary to carry out the work.

Volume 1 Series 700
(02/16) Excavations
3 (02/16) Excavations in existing pavements and other paved areas, except those described in sub-Clause 4 of
this Clause, including surfacing, base and subbase, shall be cut to neat lines to dimensions at least 75 mm greater
on each side than the dimensions of any further excavation below formation level. Excavations in capping shall be
taken at least 75 mm outside the dimensions of any excavation below. Road surfacing of bituminous material shall
be cut back by sawing or planing to a further 75 mm on each side. Planing shall be carried out in accordance with
Clause 709. Concrete surfacing and concrete bases, except CBM, shall be cut back by sawing by at least 300 mm
on each side to the level of any reinforcement in reinforced slabs and to the full depth of the slab in unreinforced
slabs.
If excavations are required to inspect the condition of lower layers, each layer shall be excavated separately and
cleaned of debris to permit inspection.
4 (02/16) Concrete blocks, clay pavers and precast concrete flags, kerbs and channels shall be lifted without
cutting, to the nearest joint satisfying sub-Clause 3 of this Clause and carefully stored for re-use or dealt with as
described in contract specific Appendix 2/3. In situ kerbs and channels shall be broken out to at least
150 mm beyond the excavation.
(02/16) Reinstatement of Paved Areas
5 (10/22) Reinstatement of paved areas shall be undertaken in accordance with the contract specific requirements
of Appendix 7/2.
6 (10/22) Immediately before bituminous layers are reinstated, the edges of the existing material shall be cleaned
of all loose material and be coated with an appropriate hot bituminous binder, or equivalent treatment
7 (10/22) Where joints in concrete slabs are affected by the excavation they shall be reinstated by cutting back to
at least 0.5 m on each side of a transverse joint and forming an expansion joint on one side of the excavation and a
contraction joint on the other and provide longitudinal joints where necessary in the same line before reinstatement
in compliance with Series 1000 to match the existing construction.
8 (10/22) The transverse regularity of the pavement surface shall be assessed for compliance with the
requirements of sub-Clause 702.8 at 3 m intervals using a straight-edge 3 metres long perpendicular to the centre
line of the road.
9 (10/22) The longitudinal regularity of the pavement surface shall be assessed for compliance with the
requirements of sub-Clause 702.9 at 3 m intervals using a straight-edge 3 metres long parallel to the centre line of
the road, including straddling the existing surface and new surface at start and end joints.
(02/16) Reinstatement of Other Areas
10 (10/22) Where the excavation affects grassed areas, unpaved footpaths, footways, verges and bridleways they
shall be reinstated to match the existing surface, after backfilling with acceptable material described in contract
specific Appendix 7/2 to a depth of not less than 150 mm below the finished surface.
(02/16) Junctions Between New Pavement Construction and Existing Pavement or Other Paved Areas
11 (10/22) Where new pavement construction abuts an existing bituminous pavement which has to be reduced in
level or overlaid to match alignment and levels, the existing surface shall be trimmed by the minimum amount of
cold-milling (planing) to a depth which will allow the specified thickness of new construction to be laid, the edge
being trimmed and treated in compliance with this Clause. Where the difference in level makes it necessary, a
regulating course as described in contract specific Appendix 7/1 and specified in Clause 907 shall be provided. The
locations of areas to be trimmed are given in contract specific Appendix 7/2.
12 (10/22) Junctions between concrete pavements and between concrete and bituminous pavements shall be
constructed as described in contract specific Appendix 7/2. Junctions in porous asphalt surfacing shall comply also
with Clause 938. Junctions between porous asphalt surfacing and other pavement surfaces shall be constructed as
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6
Volume 1 Series 700
(02/16) Compressed Air

13 (10/22) When compressed air is used to clean dust, dirt and debris from prepared faces of existing concrete or
bituminous pavements which are otherwise ready for reinstatement, only oil-free compressed air shall be used and
this shall be at a pressure of not less than 0.5 N/mm2.
707 (02/16) Breaking Up or Perforation of Redundant Pavement

1 Where redundant pavement construction is to be perforated or broken up, the pavement shall be treated as
708 (02/16) Not used
709 (02/16) Cold-milling (Planing) of Bituminous Bound Flexible Pavement

1 (02/16) Where cold-milling of bituminous bound flexible pavement is required, the area of carriageway to be
milled shall be removed by a suitable milling machine to the requirements specified in contract specific Appendix
7/9. The process shall be carried out so as not to produce excessive quantities of dust, which shall be minimised by
damping with water sprays.
2 (02/16) The cut edges shall be left neat, vertical and in straight lines. The Contractor shall brush and sweep the
milled surface by mechanical means to produce a clean and regular running surface with a groove depth not greater
than 10 mm, and with a uniform texture.
3 (02/16) Carriageways shall be milled to the tolerance of ± 6 mm. If the tolerances in this Clause are exceeded,
the full extent of the area which does not comply shall be rectified by further milling or by regulating with materials
in accordance with Clause 907.
4 (02/16) Existing ironwork shall not be disturbed by the milling action. Where necessary, surfacing in the vicinity
of ironwork and in small or irregular areas shall be cut out by pneumatic tools or other suitable methods and
removed.
5 (02/16) Where milling is carried out on a carriageway open to traffic, temporary ramping to ensure the safe
passage of vehicles shall be provided in accordance with the requirements of contract specific Appendix 1/17.
6 (02/16) If the milled surface profile varies by more than 10 mm, when measured transversely or longitudinally
by a 3 metre straight-edge, adjustments or replacements shall be made to the cutting teeth on the milling drum
before work continues. Any discontinuity between adjacent milling passes exceeding 10 mm, when measured
transversely by a 3 metre straight-edge, shall be rectified by further milling or regulating before placing bituminous
materials.
7 (02/16) Where milling is required over extensive areas, the Contractor shall programme the work to allow
removal of full lane widths unless this is impracticable. The Contractor shall notify his proposed programme of
milling to the Overseeing Organisation prior to commencement of the work.
8 (02/16) Immediately after milling, surplus materials shall be removed by a machine of suitable and efficient
design and the milled surface swept to remove all dust and loose debris.
9 (02/16) The material removed from the carriageway shall be removed from site, unless otherwise described
in contract specific Appendix 2/3. No stockpiling shall be allowed on site unless the material is to be used in the
works.
10 (02/16) Carriageways which are closed to traffic to permit milling shall be resurfaced after milling prior to
reopening the carriageway to traffic unless otherwise agreed by the Overseeing Organisation.
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Volume 1 Series 700
11 (02/16) When specified in contract specific Appendix 7/9, 48 hours prior to cold-milling the Contractor shall
carry out a sweep of the area(s) to locate any buried metalwork within the layer to be cold-milled. The sweep shall
be carried out with electronic detection equipment suitable for the purpose. The surface shall be clearly marked
above all objects to show their detected extent. The objects shall be referenced and their location and depth reported
to the Overseeing Organisation within 6 hours of discovery. Surfacing in the vicinity of such objects shall be
excavated using pneumatic tools or other suitable methods.
710 (02/16) Testing for Constituent Materials in Recycled Aggregate and Recycled Concrete
Aggregate
(02/16) Scope
1 (02/16) This Clause specifies the basic procedure and test methods for the examination of recycled aggregate
and recycled concrete aggregate for the purpose of identifying and quantifying constituent materials.
(02/16) Quality Control Procedure
2 (02/16) The quality control procedure shall be in accordance with the ‘Quality Protocol for the production of
aggregates from inert waste’ and the ‘Producers’ compliance checklist’ published by Waste and Resources Action
Programme (WRAP). The results of all quality control checks carried out by the Contractor shall be compiled
in accordance with the procedure set down in the above document and with those in this Clause. These shall be
delivered promptly to the Overseeing Organisation on request.
(02/16) Test Method
3 (02/16) The constituents of a sample of recycled aggregate shall be classified by hand-sorting the coarse
aggregate particles in accordance with BS EN 933-11. The test shall be carried out by a suitably trained laboratory
technician who has demonstrated competence in classifying the constituent classes in accordance with the test
method.
711 (02/16) Overband and Inlaid Crack Sealing Systems

1 (02/16) Overbanding and inlaid crack sealing systems shall have current HAPAS Roads and Bridges Certificates
or equivalent. If no HAPAS or equivalent certificates have been issued, then in the interim, only overbanding and
inlaid crack sealing systems approved by the Overseeing Organisation shall be used.
2 (02/16) A crack sealing system with a current HAPAS or equivalent certificate shall only be installed by a
contractor approved by the Certificate Holder as an Approved Installer for that system.
(02/16) Overbanding Crack Sealing Systems
3 (02/16) The installed width and nominal thickness of overbanding sealants applied on the road surface shall not
exceed 40 mm and 3 mm respectively.
(02/16) Inlaid Crack Sealing Systems
4 (02/16) The inlaid crack sealing system HAPAS Grade Classification, or equivalent, required for each location
shall be as specified in contract specific Appendix 7/11.
(02/16) Chippings
5 (02/16) The minimum polished stone value of the source aggregate for chippings applied to the surface of
overbanding and inlaid crack sealing systems, determined in accordance with BS EN 1097-8, shall be as specified

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Volume 1 Series 700
(02/16) Installation and Quality Control Procedures

6 (02/16) The installation and quality control procedures for overbanding and inlaid crack sealing systems shall
be in accordance with the HAPAS or equivalent Certificate for each system and the current Method Statement.
The results of all quality control checks carried out on site by the Contractor and quality assurance information
compiled in accordance with the requirements of the HAPAS Certificate, including results from surveillance visits
shall be made available to the Overseeing Organisation on request.
(02/16) Initial Skid Resistance
7 (02/16) The minimum wet Skid Resistance value of overbanding and inlaid crack sealing systems when
newly installed shall not be less than 60 when determined using the portable skid resistance tester (pendulum) in
accordance with BS EN 13036-4, except that for sealant widths less than 75 mm, the narrow slider shall be used
over the full 126 mm sliding length utilising the normal slider scale C.
712 (02/16) Maintenance of Arrester Beds

1 (02/16) The locations and maintenance requirements of arrester beds are given in contract specific Appendix
7/12. Generally the arrester beds comprise an area of ground excavated and replaced with a granular material and
having a paved approach.
2 (02/16) The Contractor shall provide advance signing indicating that an arrester bed is closed, and shall
temporarily cover the permanent signing while this work is carried out.
3 (02/16) The maintenance work shall comprise:
(i) clearance of debris, litter and weed growth from granular material and removal off site;
(ii) sweeping of loose granular material from channel or paved approach, replacement on bed and raking
over and levelling the granular material on bed.
4 (02/16) Where there is a series of arrester beds, the Contractor shall restrict access to only one bed at a time.
713 (02/16) Saw-cut and Seal Bituminous Overlays on Existing Jointed Concrete Pavements
(02/16) General
1 (02/16) Where shown on the drawings listed in contract specific Appendix 7/13, a bituminous overlay or inlay,
as specified in contract specific Appendix 7/1, shall be laid over the existing concrete pavement which has been
either treated or prepared as specified in Clause 714. The overlay or inlay shall then be saw-cut and sealed above
existing transverse joints.
2 (02/16) Prior to the commencement of any preparatory work under sub-Clause 3 of this Clause, any and all
existing bituminous binder course, surfacing and the like shall be removed from the area to be treated as defined in
sub-Clause 1 of this Clause. This requirement shall not apply to work to this Clause to correct reflection cracking
to existing bituminous surfacing exceeding 40 mm thickness in rigid composite pavements where so specified in
3 (02/16) Preparatory work to the existing concrete pavement including joints shall comply with Clause 714.
4 (02/16) Before any tack or bond coating commences, the Contractor shall ensure that there are adequate stable
accurate reference marks delineating all existing transverse pavement joints or saw-cuts and that they have been
clearly marked and agreed with the Overseeing Organisation for purposes of accurately locating the positions of
saw-cuts after overlaying to sub-Clause 5 of this Clause. The marking procedure and the nature and location of
offsets and the means of their establishment shall be agreed in advance with the Overseeing Organisation in a
method statement. The accuracy of such markings shall be compatible with the specified accuracy of subsequent
saw-cutting operations to this Clause.
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Volume 1 Series 700
(02/16) Bituminous Overlay Including Tack Coat and Bond Coat

5 (02/16) Bituminous overlay shall comply with contract specific Appendix 7/1 and the relevant Clauses of Series
900. For the purposes of this Clause, bituminous overlay shall include all specified regulating course, base, binder
course and surfacing. Tack or bond coating shall be as specified in contract specific Appendix 7/4.
(02/16) Saw-cutting of Grooves, Cleaning and Sealing
6 (02/16) Saw-cutting of grooves, cleaning, application of bond-breaker tape and sealing of grooves shall be
carried out in one continuous operation and shall be completed in its entirety before the surface is opened to site
traffic. This trafficking restriction shall not apply to Contractor’s vehicles and plant necessary to complete the
bituminous overlay.
(02/16) Saw-cutting of Grooves
7 (02/16) As soon as practicable following the completion of the bituminous overlay in a given area, transverse
saw-cutting of grooves shall be carried out at each of the pre-marked locations defined in sub-Clause 4 of this
Clause. The positions and dimensions of all such saw-cut grooves shall be to the tolerance specified in contract
specific Appendix 7/13. The cross-section of saw-cut grooves shall comply with Figure 7/1. The saw-cut groove
shall comprise both the sealant slot and the crack-initiation slot. The centre line of the crack-initiation slot in
the overlay shall be aligned with each existing joint in the underlying concrete pavement to within the tolerance
specified in contract specific Appendix 7/13.
(02/16) Sealing
8 (02/16) The area at saw-cut grooves in the bituminous overlay at which the sealing material is to be laid
shall have been thoroughly cleaned, and shall be dry and free from dust, detritus or other debris. The ambient
temperature and the temperature of the adjacent bituminous material shall be neither less than 5ºC nor greater than
50ºC. Suitable measures shall be taken to prevent the sealant from entering the crack-initiation slot.
9 (02/16) Sealing at saw-cut grooves shall not commence until the line, direction and dimensions of each saw-cut
groove has been verified by the Overseeing Organisation and the Contractor has received written agreement that
sealing may commence.
The saw-cut grooves shall be sealed to the requirements of Clause 1016 with a hot-applied material to Clause
1017. A sample of the proposed sealant together with the manufacturer’s certificate and recommendations for its
use shall be supplied to the Overseeing Organisation before any saw-cutting commences. The sealant shall fill the
sealant slot to the surface level within the tolerance stated in Figure 7/1. The sealant level and tolerance will be
verified within 24 hours of the application of the sealant.
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10 (02/16) The sealing processes shall be completed after the surfacing course has been completed and before the
surface is opened to traffic.
714 (02/16) Preparation of Jointed Concrete Pavements Prior to Overlaying and Saw-cut and
Seal of the Bituminous Overlays
(02/16) General
1 (02/16) Where specified in contract specific Appendix 7/14 and shown on the drawings, the existing jointed un-
reinforced or reinforced cementitious pavement shall be prepared in accordance with this Clause before receiving a
bituminous overlay which will then be saw-cut and sealed in accordance with Clause 713.
(02/16) Acceptance of the Main Work
2 (02/16) Once the preparation work to this Clause has been accepted by the Overseeing Organisation for a
specified portion of the total area, the bituminous overlay, including any tack or bond coating, may proceed.
Then the saw-cutting and sealing shall be carried out and accepted solely in accordance with the requirements of
Clause 713.

Volume 1 Series 700
FIGURE 7/1: (02/16) Detail of Saw-cut and Seal Groove with Sealant in Bituminous Overlay
(02/16) Checking and Repair of Joints

3 (02/16) All joints, arrises and temporary repairs shall be checked and repaired in accordance with contract
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(02/16) Removal of Debris, Brushing and Cleaning before Overlay
4 (02/16) Before work to this Clause commences, the area shall be cleared of all debris and detritus and then be
thoroughly brushed clean. Similar cleaning shall be carried out on completion of work to this Clause and prior to
tack or bond coating in preparation for overlaying with the specified bituminous material.
715 (02/16) Saw-cut, Crack and Seat Existing Jointed Reinforced Concrete Pavements
(02/16) General
1 (02/16) Where shown on the drawings listed in contract specific Appendix 7/15, the existing reinforced concrete
pavement layers shall be saw-cut and cracked and seated with plant and equipment to which the Overseeing
Organisation’s consent has been given, and shall comply with this Clause. The treated surface shall then be
prepared in accordance with Clause 920 and tack or bond coated in accordance with contract specific Appendix 7/4
prior to overlaying in the locations specified in contract specific Appendix 7/1.

Volume 1 Series 700
2 (02/16) Prior to the commencement of any saw-cutting operations, any existing asphalt overlay and surfacing
shall be removed from the area to be treated under this Clause to the full width of each lane up to the adjoining
longitudinal joint(s) unless directed otherwise by the Overseeing Organisation. Removal of any overlay shall be
completed ahead of the works at a distance of not less than 50 m from the saw-cutting operation. The Contractor
shall also ensure that adequate reference location marks based on the Overseeing Organisation’s chainage have
been clearly marked and agreed with the Overseeing Organisation for purposes of accurately recording progress
and the locations of changes to equipment settings.
3 (02/16) Before any of the main saw-cut and crack and seat work is commenced, a main trial shall be carried out
as specified in sub-Clause 21 of this Clause. After the main trial, the Contractor shall locate all bay joints, repair
joints and any existing transverse cracks and shall pre-plan and mark the positions of the intended transverse saw-
cuts using the transverse saw-cut spacing determined from the main trial. If the Contractor foresees any difficulty
in complying with this sub-Clause, he shall immediately inform the Overseeing Organisation and shall not proceed
with saw-cutting in such areas until he has received appropriate instructions from the Overseeing Organisation.
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4 (02/16) Unless directed otherwise by the Overseeing Organisation, cracking and seating operations shall not
take place unless there is adequate side restraint in place from the adjacent verge(s) and central reserve assisted by
any temporary works which may be necessary.
5 (02/16) Compliance with this Clause shall be assessed by (i) examining the concrete surface for spalling, (ii)
examining the depth and severity of cracking and the depth of saw-cuts by means of core extraction, (iii) measuring
the spacing of saw-cuts, and (iv) recording the number of passes of the seating roller. Where required in contract
specific Appendix 7/15, the effective stiffness modulus and/or joint efficiency of the cracked concrete layer or
layers will be calculated from Falling Weight Deflectometer (FWD) measurements. The Overseeing Organisation
may then instruct any variation required in the spacing of saw-cuts and/or method and pattern of cracking and/or
subsequently confirm or otherwise the thickness of overlay required.
6 (02/16) The sequence of operations shall be: (i) pre-planning and marking of the positions of intended transverse
saw-cuts, (ii) saw-cutting of the concrete pavement at the spacing and depths specified in contract specific
Appendix 7/15, (iii) verification of saw-cut depths, (iv) inducing transverse cracks, (v) extracting cores, and (vi)
seating. The observation of the surface crack pattern and examination of the cores shall be carried out in daylight
or under sufficient artificial light provided by the Contractor to the satisfaction of the Overseeing Organisation.
Where FWD measurements are specified in contract specific Appendix 7/15, these will follow the seating operation
and shall be made by the Contractor in accordance with Clause 718 unless stated otherwise in contract specific
Appendix 7/15. Processing and analysis of the FWD results shall be performed by the Contractor in accordance
with Clause 719 unless stated otherwise in contract specific Appendix 7/15. The road shall be neither overlaid nor
re-opened to highway traffic without the Overseeing Organisation’s written confirmation that his interpretation of
the FWD measurements is complete and that the condition of the treated pavement is in accordance with the design
requirements.
7 (02/16) If, for reasons other than those in sub-Clauses 27 and 28 of this Clause, it either (i) becomes necessary
for the Contractor to change any plant, equipment and/or method or (ii) the Contractor makes unplanned use of
different or additional plant, he shall carry out a Special Trial which shall be so named but otherwise shall be in
accordance with sub-Clauses 33 to 35 of this Clause.
(02/16) Saw-cutting of Concrete Pavement
8 (02/16) Transverse saw-cutting of the concrete pavement shall be carried out to comply with this Clause
including the particular requirements in contract specific Appendix 7/15.
9 (02/16) The position of all saw-cuts shall be clearly marked by the Contractor on the surface of the concrete
prior to cutting. The spacing of saw-cuts to be used for the main trial in sub-Clauses 21 to 24 of this Clause shall
be as specified in contract specific Appendix 7/15. No saw-cuts shall be made within the distance stated in contract
specific Appendix 7/15 from an existing transverse joint or crack. The saw-cuts shall be made at the marked
positions and shall be transverse to the longitudinal axis of the carriageway and within the tolerances specified in

Volume 1 Series 700
10 (02/16) The depth of all saw-cuts shall be measured from the top surface of the concrete pavement slab. The
minimum depth of saw-cuts shall be just sufficient to cut completely through the longitudinal steel reinforcement
but this depth shall in no circumstances exceed 50% of the nominal depth of the concrete pavement layer. When
such a saw-cut fails to fully cut through the reinforcing steel, the cracking operation shall not proceed within 5 m
of the incompletely cut bar. This fact shall be recorded by the Contractor who shall report it to the Overseeing
Organisation as soon as practicable. This report shall be confirmed within 18 hours. Saw-cutting shall also cease
immediately and not re-commence on the same slab until so instructed by the Overseeing Organisation. If there has
been any over-cutting, this shall be remedied in accordance with sub-Clause 31 of this Clause.
11 (02/16) Each saw-cut, and the carriageway surface adjacent to it, shall be thoroughly cleaned of the slurry
produced by sawing and any other detritus prior to cracking.
(02/16) Cracking
12 (02/16) Induced cracking of existing pavement layer or layers shall be carried out to comply with this Clause
13 (02/16) Transverse cracks at the positions of the saw-cuts shall be induced by suitable plant with a guillotine
action capable of delivering controlled variable pre-set impact loads to the concrete surface. The plant used to
crack the concrete pavement layer or layers shall be self-propelled and have all wheels fitted with rubber tyres.
The compressive strength of the existing concrete shall be provided by the Overseeing Organisation in contract
specific Appendix 7/15. The Contractor shall keep records of (i) the settings to his plant and equipment, (ii) the
chainage and (iii) the time at which each and every adjustment is made to the plant and equipment. Such records
shall be in accordance with the pro forma in contract specific Appendix 7/17 for the ‘Cracking Plant and Equipment
Progress Record’ and shall be available on demand for inspection by the Overseeing Organisation. Cracks shall be
induced in the concrete underlying the saw-cut by one strike of the impacting head of such plant. The Contractor
shall take suitable measures to ensure that the plant and impact head are of sufficient mass and geared to prevent
both head bounce and any associated surface damage arising therefrom. The impact force shall be adjustable to
achieve the cracking specified and the minimum force consistent with no damage to either the saw-cut or to the
adjoining concrete surface. Excessive impact forces which cause multiple cracking or shattering of the underside
of the concrete slab, or to the underlying or adjacent layers, shall not be permitted. If such damage does occur, the
Contractor shall carry out remedial measures in accordance with sub-Clause 31 of this Clause.
14 (02/16) The induced cracks shall extend from the bottom of the concrete slab to the base of the saw-cut and shall
be predominantly vertical. They shall extend the full width of each concrete bay. The generation of longitudinal
cracks is undesirable and those produced within the highway traffic wheel track zones of length greater than the
longitudinal spacing of the saw-cuts specified in contract specific Appendix 7/15 or derived from a Main Trial shall
constitute a failure under sub-Clause 31 of this Clause.
15 (02/16) Where the full width of any existing pavement layer cannot be cracked transversely with one pass of the
crack inducing plant further parallel passes shall be made as necessary so that all subsequent transverse cracks are
aligned with those from the preceding pass within the tolerances specified in contract specific Appendix 7/15.
16 (02/16) The Contractor shall adjust his equipment and methods so that (i) full depth fine vertical cracks in
the concrete layer or layers are obtained, (ii) shattering of the concrete at the surface and/or at the bottom of the
slab is avoided, and (iii) treated areas are rendered suitable for overlaying, to the satisfaction of the Overseeing
Organisation. The cracking operation shall not proceed more than 100 metres beyond the last accepted core in the
assessment under sub-Clause 29 of this Clause. Cracking shall not commence on a given saw-cut until it has been
cut over its entire width to the appropriate depth in accordance with this Clause.
(02/16) Coring
17 (02/16) The Contractor shall take cores in accordance with sub-Clauses 22, 29, 30 and 32 of this Clause and
with contract specific Appendix 7/15 at locations selected by the Overseeing Organisation. All holes from which
core samples have been extracted shall be filled with new hydraulically bound material equivalent to that in the
surrounding pavement and adequately compacted in layers each not exceeding 50 mm thickness.
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Volume 1 Series 700
(02/16) Seating
18 (02/16) Following cracking, all the cracked pavement layer shall be seated with a multi-wheeled pneumatic-
tyred roller with a weight of not less than 20 tonnes compliant with contract specific Appendix 7/15 and with
the number of passes specified in contract specific Appendix 7/15. The load including any ballast shall be
distributed uniformly over all the wheels. The drive gear shall provide a progressive, variable speed, forward and
reversing capability. Such compaction plant shall have articulating wheels on both front and rear axles. The wheel
arrangement shall provide an overlap of not less than 40 mm with the adjacent wheels. The internal pressure of
the tyres shall be adjustable to provide variable ground contact pressure (GCP). The Contractor shall certify in an
agreed form on a daily basis the exact extent of work completed under this sub-Clause and shall deliver each such
certificate to the Overseeing Organisation before noon the next day.
19 (02/16) Where voids under the pavement permit rocking at the ends of the slab(s) that is not remedied by the
seating operation under sub-Clause 18 of this Clause, this shall be deemed to be unstable seating. This shall require
additional parallel saw-cuts followed by cracking at suitable positions sufficient to enable stable seating to be
achieved to the satisfaction of the Overseeing Organisation.
20 (02/16) Once saw-cutting and cracking and seating and any remedial work under sub-Clause 31 of this Clause
have been completed, the pavement shall be prepared to Clause 920 before overlay.
(02/16) Main Trial Area
21 (02/16) The Contractor shall demonstrate that the plant, equipment and method that he proposes for the saw-
cut and cracking and seating of the existing concrete layer or layers are capable of producing the required depth of
saw-cut and required type of cracks. This shall be demonstrated by first executing a main trial over an area neither
less than 250 m2 nor greater than 420 m2 of existing pavement. The location and area of the trial shall be as directed
by the Overseeing Organisation, and shall include a length of the most heavily trafficked lane. The Contractor shall
demonstrate that the saw-cutting and cracking operation can achieve consistent compliance with this sub-Clause
and with sub-Clauses 8, 9, 10, 12, 13 and 22 of this Clause and with contract specific Appendix 7/15. If the road
pavement to be treated contains known areas where there are significant differences in the concrete thickness or
the concrete strength or in the conditions of the reinforcement or foundations, then a main trial shall be conducted
in each such area. The locations of pre-existing transverse cracks within the Main Trial shall be recorded by the
Contractor. The work on the main trial length shall proceed as follows:
(i) Saw-cutting and cracking shall proceed in stages as directed by the Overseeing Organisation. Each Stage
that is cracked and seated shall be assessed in accordance with sub-Clause 22 of this Clause.
(ii) Stage 1 of the main trial shall be on 1 no. slab. The Contractor shall set up his plant and equipment
and demonstrate that he can produce the required pattern and quality of saw-cuts and transverse cracks
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in accordance with this Clause including contract specific Appendix 7/15. This shall be assessed in
accordance with sub-Clause 22 of this Clause.
(iii) In Stage 2 and any subsequent Stage of the main trial, a length encompassed by 6 no. saw-cuts shall
be cracked starting from one end to produce transverse cracks at the saw-cut spacing stated in contract
specific Appendix 7/15. For each Stage, the settings of the cracking plant and equipment shall be
recorded in accordance with the pro forma in contract specific Appendix 7/17. The cracked pavement
shall then be seated in accordance with the method in sub-Clauses 18 and 22(v) of this Clause.
(iv) Seating: After cracking, the pavement shall be seated with the number of passes of the roller specified in
contract specific Appendix 7/15 as described in sub-Clause 18 of this Clause.
(02/16) Assessment of Main Trial
22 (02/16) Compliance with the saw-cutting and the cracking and seating requirements for the main trial shall be
assessed as follows:
(i) The depths of the saw-cutting shall be checked by the Contractor before cracking.
(ii) The spacing of transverse saw-cuts will be checked by the Contractor before cracking.

Volume 1 Series 700
(iii) The surface cracking patterns shall be checked by the Overseeing Organisation either before or after
seating by the Contractor.
(iv) The depth of the saw-cut and the depth and vertical direction of cracking shall be determined by coring
through the full depth of the concrete pavement layer or layers symmetrically at any transverse position
along the length of the saw-cut. Core diameter shall be in accordance with contract specific Appendix
7/15. In Stage 1 the Contractor may select the number and position of cores to be taken. In Stage 2
and in subsequent Stages of the main trial, the number of cores shall be in accordance with Table
7/3, with not less than one core taken from alternate saw-cuts. These shall be at locations selected by
the Overseeing Organisation. If the depth of saw-cut exceeds the specified depth, or if any shattering
or multiple cracking is present in the extracted core then it is deemed to require remedial work in
(v) The Contractor’s seating certificates required under sub-Clause 18 of this Clause will be checked by
the Overseeing Organisation. If the number of roller passes required for seating is not in accordance
with sub-Clause 18 of this Clause, the Contractor shall roll the entire area again in accordance with
sub-Clause 18 of this Clause with not less than the number of passes of the roller specified in contract
23 (02/16) Where required in contract specific Appendix 7/15, FWD testing of effective stiffness modulus shall be
performed before saw-cutting and after seating in Stage 2 and any subsequent Stages of the main trial. The FWD
testing shall be performed by the Contractor in accordance with Clause 718, unless stated otherwise in contract
specific Appendix 7/15, both (i) before cracking and (ii) after seating in accordance with this Clause. Unless stated
otherwise in contract specific Appendix 7/15, the Contractor shall perform the processing and analysis of the
FWD measurements in accordance with Clause 719 and will present the results to the Overseeing Organisation for
interpretation and instruction. The Contractor shall remove all debris from the cracked pavement in the main trial
lengths before FWD measurements are made. Saw-cutting of Stage 2 or subsequent Stages of the Main Trial shall
not commence until the Overseeing Organisation has interpreted the analysed FWD measurements undertaken
before cracking and has confirmed or otherwise the suitability of the area selected for the Main Trial.
(02/16) Consent to the Method and Acceptance of the Main Trial
24 (02/16) The Contractor shall not proceed with the main work until the Overseeing Organisation has given
its consent that the plant, equipment and methods used in the main trial length comply with the requirements in
Table 7/3. Consent to use the plant equipment and methods of saw-cutting and cracking and seating will be given
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by the Overseeing Organisation following a successful demonstration in the main trial that the saw-cutting and
the cracking and seating complies with the requirements of this Clause and that the effective stiffness modulus
of the cracked and seated pavement and/or underlying foundation derived from FWD testing meets the design
criteria. When consent by the Overseeing Organisation to the method has been given, the plant, equipment and
methods shall not be changed thereafter without the prior consent of the Overseeing Organisation except for normal
adjustment and maintenance of plant. Should it be necessary for the Contractor to otherwise change any plant,
equipment and/or method the Contractor may be required to carry out a further main trial Stage.
(02/16) Main Production Work
25 (02/16) The saw-cutting and cracking operation for the main production work shall proceed using the parameters
as determined from the Main Trial or from any relevant subsequent Saw-cutting and Cracking Re-Assessment
Trial. The seating operation shall be completed by rolling the pavement with the number of passes specified in
contract specific Appendix 7/15. The main work shall be assessed in accordance with sub-Clause 29 of this Clause.
As required in contract specific Appendix 7/15, the Contractor shall make allowance in his programme for FWD
measurements of effective stiffness modulus which will be made by the Contractor according to Clause 718 after
seating in accordance with this Clause, unless stated otherwise in contract specific Appendix 7/15. The Contractor
will perform the processing and analysis of the FWD measurements in accordance with Clause 719, unless stated
otherwise in contract specific Appendix 7/15, and will present the results to the Overseeing Organisation for
interpretation and instruction. The Contractor shall remove all debris from the cracked pavement before FWD
measurements are made.

Volume 1 Series 700
26 (02/16) The Contractor shall be responsible for the continuous observation of the operation. The location of
pre-existing transverse cracks shall be recorded by the Contractor. Should the results vary from those to which
consent was given in the main trial, or from any relevant subsequent Saw-cutting and Cracking Re-Assessment
Trail, with the consent of the Overseeing Organisation the Contractor shall adjust the plant and equipment and/or
saw-cut depth in order to produce the agreed results. The new settings of the plant and equipment shall be recorded
by the Contractor, together with the location at which it was changed. These particulars shall be delivered to the
Overseeing Organisation within 24 hours of the changes being completed. If the agreed surface crack pattern is not
restored within 20 m production cracking shall cease in accordance with sub-Clause 6 of this Clause. A Saw-cutting
and Cracking Re-Assessment Trial shall then be carried out in accordance with sub-Clauses 33 to 35 of this Clause
before any further production saw-cutting and cracking and seating work is executed.
27 (02/16) The depth of saw-cutting shall be measured before cracking. If the depth is not within the depth as
specified in contract specific Appendix 7/15 the saw-cutting shall cease. If the saw-cut is too shallow it shall be re-
cut until it is within tolerance. If the saw-cut is too deep it shall be deemed non-compliant under sub-Clause 22(iv)
of this Clause. The saw-cut depth shall be brought within tolerance for subsequent cuts.
28 (02/16) The depth of the saw-cutting and the depth and quality of the induced cracks shall be monitored
by inspection of extracted cores. If there has been any non-compliance with sub-Clause 22(iv) of this Clause,
production saw-cutting and cracking shall cease immediately. The extent of the area affected shall be determined as
specified in sub-Clause 32 of this Clause.
(02/16) Assessment of the Main Production Work
29 (02/16) Compliance with the saw-cutting and the cracking and seating requirements shall be assessed during the
main work in accordance with the following criteria:
(i) The spacing and depths of transverse saw-cuts will be monitored by the Overseeing Organisation.
(ii) The surface pattern of cracking of all areas that have been cracked and seated shall be checked by the
Contractor and will be monitored by the Overseeing Organisation.
(iii) The depth of saw-cut and the depth and the vertical direction of cracking through the full depth of the
concrete pavement layer or layers shall be determined symmetrically at the saw-cut position. Core
diameter shall be in accordance with contract specific Appendix 7/15. The minimum frequency for
coring of saw-cut and cracked and seated concrete is specified in contract specific Appendix 7/15.
(iv) The seating shall be assessed in accordance with sub-Clause 22(v) of this Clause.
(02/16) Acceptance of the Main Production Work
30 (02/16) The main work under this Clause shall be accepted when it complies fully with the requirements of this
clause and Table 7/3.
(02/16) Failure to Comply and Remedial Work
31 (02/16) The results of the saw-cut and crack and seat operations of any 5 m length of jointed reinforced concrete
shall be rejected if they fail to comply with any of the criteria in sub-Clause 28 of this Clause. If:
(i) shattering or multiple cracking of concrete material occurs within the extracted core; or
(ii) excessive spall damage is caused to be arrises of the saw-cuts; or
(iii) the length of any longitudinal cracks in the highway traffic wheel tracks are in excess of the spacing of
the induced transverse cracks; or
(iv) the spacing of the transverse saw-cuts is outside the tolerance specified in contract specific
Appendix 7/15; or
(v) the depth of the transverse saw-cuts is greater than the depth specified in contract specific
Appendix 7/15;

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Volume 1 Series 700
or any combination of these, then the following remedial measures shall be taken. The size of the affected area shall
be determined and the rejected section(s) shall be broken out, excavated to full depth and reinstated with equivalent
material, unless otherwise instructed by the Overseeing Organisation. The positions of the highway traffic wheel
tracks to which reference is made in this Clause shall be as defined in sub-Clause 903.21. If the number of roller
passes required for seating is less than the number of passes specified in contract specific Appendix 7/15 at each
and every point on the pavement, then the Contractor shall roll the entire area again with not less than the number
of passes of the roller specified in contract specific Appendix 7/15, unless otherwise instructed by the Overseeing
Organisation.
32 (02/16) The extent of shattering or multiple cracking or the extent to which the depth of the saw-cut is outside
the specified tolerance shall be determined by extracting and inspecting cores. Such cores shall be taken through a
saw-cut within the area between the position of the crack-inducing plant and the last core in which the saw-cutting
and cracking complied with the requirements of sub-Clause 29 of this Clause. The extent of longitudinal cracking
in the highway traffic wheel tracks shall be determined by visual inspection.
(02/16) Saw-cutting and Cracking Re-assessment Trial
33 (02/16) When in the opinion of the Overseeing Organisation the conditions so require, a saw-cut and cracking
re-assessment trial shall take place. The re-assessment trial described in this sub-Clause and in sub-Clauses 7, 26,
34 and 35 of this Clause shall require the Contractor to demonstrate that the plant, equipment and method to which
consent was given by the Overseeing Organisation for use in the main production work are capable of producing
the required effective stiffness modulus in the existing concrete layer or layers by executing this trial over an area
of neither less than 75 m2 nor greater than 120 m2 of existing pavement. The location of the trial shall be as directed
by the Overseeing Organisation. The saw-cut spacing(s) shall be as directed by the Overseeing Organisation within
the tolerances specified in contract specific Appendix 7/15. The Contractor shall demonstrate that the saw-cutting
and the cracking operations can achieve consistent compliance with sub-Clause 29 of this Clause. The saw-cutting
and cracking re-assessment trial length shall be seated with the number of roller passes specified in contract specific
Appendix 7/15.
Where FWD measurements are required by contract specific Appendix 7/15 the Contractor shall make programme
allowance for these which shall be made by the Contractor according to Clause 718 before sawing and after
cracking in accordance with this Clause, unless stated otherwise in contract specific Appendix 7/15. Unless stated
otherwise in contract specific Appendix 7/16, the Contractor shall perform the processing and analysis of the FWD
measurements in accordance with Clause 719 and shall present the results to the Overseeing Organisation for
interpretation and instruction. The Contractor shall remove debris from the cracked pavement in the re-assessment
trial length before FWD measurements are made. The production cracking re-assessment trial length shall be seated
with the number of passes of the roller specified in contract specific Appendix 7/15.
(02/16) Assessment of Saw-cutting and Cracking Re-assessment Trial
34 (02/16) Compliance with the saw-cutting and cracking and seating requirements for the saw-cutting and
cracking re-assessment trial shall be assessed in accordance with sub-Clauses 22 and 23 above.
(02/16) Consent
to Use the Method and Acceptance of the Saw-cutting and Cracking
Re-assessment Trial
35 (02/16) The Contractor shall not resume the main work until the Overseeing Organisation has given its consent
that the plant, equipment and methods used in the saw-cutting and cracking re-assessment trial comply with the
requirements given in Table 7/3.
Consent to the plant equipment and methods will be given by the Overseeing Organisation following a successful
demonstration in the saw-cutting and cracking re-assessment trial that the saw-cutting and cracking and seating
complies with the requirements of this Clause. When consent to the method by the Overseeing Organisation has
been given, the plant, equipment and methods shall not be changed thereafter without the prior consent of the
Overseeing Organisation except for normal adjustment and maintenance of plant. Should it be necessary for the
Contractor to otherwise change any plant, equipment and/or method the Contractor shall carry out a further saw-
cutting and cracking re-assessment trial.

TABLE 7/3: (02/16) Saw-cut, Crack and Seat Existing Jointed Reinforced Concrete Pavements – Assessment Criteria for Acceptance of Trials and
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for the Main Production Work

Volume 1
TYPE OF TRIAL OR CRITERIA

WORK CATEGORY Transverse Crack quality and extent Coring to determine depth of Seating FWD monitoring (where required)
spacings and depths of saw-cut and severity, depth and [not part of the assessment of
saw-cuts vertical direction of cracking Contractor’s work]
1 2 3 4 5

Main trial Stage 1 (i) As specified in contract (i) No longitudinal crack (i) Cores shall be taken through (i) Monitored by the Contractor; None required.
specific Appendix 7/15; length > saw-cut spacing; saw-cuts at locations chosen by the
(ii) Roll with the number of passes May be done for/ by the Overseeing
Contractor.
(ii) Checked by the (ii) Monitored by the of the roller specified in contract Organisation at his request.
Contractor. Contractor. specific Appendix 7/15.
Main trial Stage 2 and (i) As specified in contract (i) No wheeltrack (i) Cores shall be taken at locations (i) Monitored by the Overseeing The Contractor to either:
subsequent stages specific Appendix 7/15; longitudinal crack length > chosen by the Overseeing Organisation;
(a) Determine and record the minimum
saw-cut spacing; Organisation;
(ii) Monitored by the (ii) Roll with the number of passes effective stiffness modulus from FWD
Overseeing Organisation. (ii) Monitored by the (ii) Not less than 5 cores in each of the roller specified in contract measurements and core details provided
Overseeing Organisation. Stage with not less than 1 core per specific Appendix 7/15. by the Contractor; or
alternate transverse saw-cut.
(b) Determine vertical movement at
joints before and after treatment.
Acceptance of main (i) Required tolerance on (i) Crack pattern complies (i) No multiple cracks or shattering (i) Certification by the Contractor The Contractor to either:
trial Stage 2 and transverse spacing and depth with (i) above. within the core; that each point has been rolled
(a) Produce a record of the measured
subsequent stages of saw-cutting achieved. with the number of passes of the
(ii) Cores shall have a single crack effective stiffness modulus for (i)
roller specified in contract specific
from the bottom of the saw-cut to the the concrete pavement and (ii) the
Appendix 7/15.
full depth of the concrete; foundation combination after the saw-
cutting and cracking and/or seating; or

(iii) Cracks shall be predominantly
vertical; (b) Produce a record of measurements of
vertical movement at joints before and
(iv) Depths of saw-cut to be within
after treatment.

specified tolerances;
(v) Depth of each saw-cut > depth to
bottom of local transverse steel.
Main production work (i) As specified in contract (i) No wheeltrack (i) Cores shall be taken at locations (i) Roll each point with the The Contractor to either:
specific Appendix 7/15; longitudinal crack length > chosen by the Overseeing number of passes of the roller
(a) Determine and record the effective
saw-cut spacing: Organisation; specified in contract specific
(ii) Monitored by the stiffness modulus from FWD
Appendix 7/15.
Contractor. (ii) Monitored by the (ii) Not less than 1 core per area measurements and core details provided
Contractor. specified in contract specific (ii) Monitored by the Contractor. by the Contractor on every 5 m length
Appendix 7/15; after cracking and/or seating; or
(iii) Monitored by the Contractor. (b) Determine the vertical movement at
joints after treatment.
18
Series 700
Road Pavements – General
TABLE 7/3: (02/16) Saw-cut, Crack and Seat Existing Jointed Reinforced Concrete Pavements - Assessment

Criteria for Acceptance of Trials and for the Main Production Work (continued)
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Volume 1

WORK CATEGORY Transverse Crack quality and extent Coring to determine depth of Seating FWD monitoring (where required)
spacings and depths of saw-cut and severity, depth and [not part of the assessment of
saw-cuts vertical direction of cracking Contractor’s work]
1 2 3 4 5

Acceptance of the main (i) Required tolerance on (i) Crack pattern complies (i) No multiple cracks or shattering (i) Certification by the Contractor (i) Not required for compliance
production work transverse spacing of saw- with (i) above. within the core; that each point has been rolled monitoring;
cutting achieved. with not less than the number

(ii) Cores shall have a single crack (ii) Required for confirmation of
of passes specified in contract
from the bottom of the saw-cut to the structural design.
full depth of the concrete;
vertical; (iv) Depths of saw-cut to be
within specified tolerances;
(v) Depth of each
saw- cut > depth to bottom of local
transverse steel.
Saw-cutting and (i) Saw-cut spacing as (i) No wheeltrack (i) Cores shall be taken at locations (i) Roll each point with not < the The Contractor to either:
cracking re-assessment specified by the Overseeing longitudinal crack length > chosen by the Overseeing number of passes of the roller
(a) Determine and record the minimum
trial Organisation to the tolerance transverse crack spacing; Organisation; specified in contract specific
effective stiffness modulus on every
specified in contract specific Appendix 7/15;
(ii) Monitored by the (ii) Not less than 5 cores with 5 m length after seating from FWD
Appendix 7/15;
Overseeing Organisation. not less than 1 core per alternate (ii) Monitored by the Overseeing measurements and core details provided
(ii) Monitored by the transverse saw-cut; Organisation. by the Contractor; or
(iii) Monitored by the Overseeing (b) Determine vertical movement at

Organisation. joints before and after treatment.
Acceptance of a saw- (i) Required tolerance on (i) Crack pattern complies (i) No multiple cracks or shattering (i) Certification by the Contractor The Contractor to either:
cutting and cracking transverse saw-cutting with (i) above. within the core; that each point has been rolled
(a) Produce a record of the measured
re-assessment trial achieved. with not less than the number

(ii) Cores shall have a single crack to effective stiffness modulus for (i)
of passes specified in contract
the full depth of the concrete; the concrete pavement and (ii) the
foundation combination both before, and
after the saw-cutting and cracking and/
vertical;
or seating; or
(iv) Depths of saw-cut to be within
(b) Produce a record of measurements of
specified tolerances;
vertical movement at joints before and
(v) Depth of each saw- cut > depth to after treatment.
bottom of local transverse steel.
19
Series 700
Volume 1 Series 700
716 (02/16) Cracking and Seating of Existing Jointed Unreinforced Concrete Pavements and
Hydraulically Bound Mixture (HBM) Bases
(02/16) General
1 (02/16) Where shown on the drawings listed in contract specific Appendix 7/16, the existing unreinforced
hydraulically bound pavement layer or layers shall be cracked and seated with plant and equipment to which the
Overseeing Organisation’s consent has been given, and shall comply with this Clause. The treated surface shall
be then be prepared in accordance with Clause 920 and tack or bond coated in accordance with contract specific
Appendix 7/4 prior to overlaying where specified in contract specific Appendix 7/1.
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2 (02/16) Prior to the commencement of any operations to induce cracks, any existing asphalt overlay and
surfacing shall be removed from the area to be treated for the full width of each lane up to the adjacent longitudinal
joints unless directed otherwise by the Overseeing Organisation. Removal of any overlay shall be completed ahead
of the works at a distance of not less than 50 m from the cracking operation. The Contractor shall also ensure
that adequate reference marks based on the Overseeing Organisation’s chainage have been clearly marked and
agreed with the Overseeing Organisation for purposes of accurately recording progress and locations of changes to
equipment settings.
3 (02/16) Before any of the main crack and seat work is commenced, a main trial shall be carried out in
accordance with sub-Clauses 17 to 20 of this Clause. After the main trial, the Contractor shall locate all bay joints
and repair joints, or existing cracks in the concrete pavement or HBM, and shall pre-plan and mark the positions of
the intended induced cracks at these locations using the transverse crack spacing determined from the main trial.
If the Contractor foresees any difficulty in complying with this sub-Clause, he shall immediately draw this to the
attention of the Overseeing Organisation and shall not proceed with cracking in such areas until he has received
appropriate instructions from the Overseeing Organisation.
4 (02/16) Cracking and seating operations shall not take place unless there is adequate side restraint in place from
the adjacent verge(s) and central reserve assisted by any temporary works which may be necessary. All cracking
and seating operations shall be completed before the commencement of any excavation which, in the opinion of the
Overseeing Organisation, would remove adequate side restraint in the adjacent verge(s) and/or central reserve.
5 (02/16) Compliance with this Clause shall be assessed by (i) examining the generated crack pattern on the
surface of the jointed concrete or HBM base layer, (ii) examining the depth and severity of cracking by means of
core extraction, (iii) measuring the spacing of the induced cracks, and (iv) recording the number of passes of the
seating roller. The effective stiffness modulus of the cracked hydraulically bound layer or layers and underlaying
foundation will be calculated from Falling Weight Deflectometer (FWD) measurements. The Overseeing
Organisation may then instruct any variation required in the method and pattern of cracking or subsequently
confirm or otherwise the thickness of overlay required.
6 (02/16) The sequence of operations for the main production work shall be: (i) where necessary, pre-planning
and marking of the positions of induced transverse cracks, (ii) application of clean water to assist examination
of the crack pattern, (iii) inducing transverse cracks, (iv) observation of the surface crack pattern, (v) extracting
cores and (vi) seating. The observation of the surface crack pattern and examination of the cores shall be carried
out in daylight or under sufficient artificial light provided by the Contractor to the satisfaction of the Overseeing
Organisation. FWD measurements will follow the seating operation and shall be performed by the Contractor in
accordance with Clause 717 unless stated otherwise in contract specific Appendix 7/16. Processing and analysis
of the FWD results shall be performed by the Contractor in accordance with Clause 719 unless stated otherwise
in contract specific Appendix 7/16. The road shall be neither overlaid nor re-opened to highway traffic without the
Overseeing Organisation’s written confirmation that the Overseeing Organisation has completed its interpretation
of the FWD measurements and that the condition of the treated pavement is in accordance with the design
requirements.
7 (02/16) Once the main crack and seat operation has commenced, its efficacy shall be kept under review by the
Contractor in accordance with sub-Clauses 21 to 25 of this Clause. If, due to variations in the strength or other
physical characteristics of the hydraulically bound pavement layer or of the foundation or otherwise, the crack
pattern varies from that confirmed in the main trial, the equipment shall be adjusted as described in sub-Clauses
10 and 22 of this Clause to produce the required crack pattern. If the crack pattern obtained in the main trial is not

Volume 1 Series 700
re-established within 4 bays for jointed unreinforced concrete pavements, or within 20 m for HBM bases, then
production cracking shall stop immediately. The Contractor shall report such circumstances to the Overseeing
Organisation orally within 1 hour and confirm it in writing within 2 hours. A production cracking re-assessment
trial shall then be carried out in accordance with sub-Clauses 28 to 30 of this Clause before any further cracking
and seating work is executed at the relevant area.
8 (02/16) If, for reasons other than those in sub-Clause 22 of this Clause, it either (i) becomes necessary for the
Contractor to change any plant, equipment and/or method or (ii) the Contractor makes unplanned use of different
or additional plant, he shall carry out a Special Trial which shall be so named but otherwise shall be in accordance
with sub-Clauses 28 to 30 of this Clause.
(02/16) Cracking
9 (02/16) Induced cracking of existing pavement layer or layers shall be carried out to comply with this Clause
10 (02/16) Transverse cracks at the required spacing shall be induced by suitable plant with a guillotine
action capable of delivering variable pre-set impact loads to the concrete surface. The plant used to crack the
hydraulically bound pavement layer or layers shall be self-propelled and have all wheels fitted with rubber tyres.
The compressive strength of the existing concrete shall be provided by the Overseeing Organisation in contract
specific Appendix 7/16. The required spacing of cracks for the main trial in sub-Clauses 17 to 20 of this Clause
shall be as specified in contract specific Appendix 7/16. The required spacing thereafter shall be as confirmed by
the Overseeing Organisation on completion of the main trial. The Contractor shall keep records of (i) the settings
to his plant and equipment, (ii) the crack spacing, (iii) the chainage and (iv) the time at which each and every
adjustment is made to the plant and equipment. Such records shall be in accordance with the pro forma in contract
specific Appendix 7/17 for the ‘Cracking Plant and Equipment Progress Record’ and shall be available on demand
for inspection by the Overseeing Organisation. Cracks shall be induced by one strike of the impacting head of such
plant without producing undue surface shatter. The plant and impact head shall be of sufficient mass and geared
to prevent both head bounce and any associated surface damage arising therefrom. The impact force shall be
adjustable to achieve the cracking specified using the minimum force consistent with no surface shatter. Excessive
impact forces which cause multiple cracking or shattering of the underside of the concrete slab, or to the underlying
or adjacent layers shall not be permitted. If such damage does occur, the Contractor shall carry out remedial
measures in accordance with sub-Clauses 26 or 27 of this Clause, as appropriate.
11 (02/16) The induced cracks shall be predominantly vertical and shall be transverse to the direction of the
road. They shall extend the full width of each concrete bay or the lane width of a HBM base. The generation of
longitudinal cracks is undesirable and those produced within the highway traffic wheel track zones of length greater
than the spacing of the induced transverse cracks shall constitute a failure under Clause 26 of this Clause.
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12 (02/16) Where the full width of any existing pavement layer cannot be cracked transversely with one pass of the
crack inducing plant further parallel passes shall be made as necessary so that all subsequent transverse cracks are
aligned with those from the preceding pass within the tolerances specified in contract specific Appendix 7/16.
13 (02/16) The Contractor shall be responsible for (i) adjusting his equipment and methods so that the requisite
crack pattern is maintained, (ii) producing full depth fine vertical cracks in the hydraulically bound layer or layers,
and (iii) rendering treated areas suitable for overlaying, to the satisfaction of the Overseeing Organisation. For
all trials and for all production cracking operations the Contractor shall provide clean water and shall saturate
the surface area of the pavement which is to be cracked. The surface shall be allowed to dry naturally or shall be
dried artificially so that it becomes surface dry before visual inspection is made of the induced crack pattern. The
cracking operation shall not proceed more than 100 metres beyond the last accepted core in the assessment under
(02/16) Coring
14 (02/16) The Contractor shall take cores in accordance with sub-Clauses 18, 23, 24, and 27 of this Clause and
with contract specific Appendix 7/16 at locations selected by the Overseeing Organisation. All holes from which
core samples have been extracted shall be filled with new hydraulically bound material equivalent to that in the
surrounding pavement and adequately compacted in layers each not exceeding 50 mm thickness.

Volume 1 Series 700
(02/16) Seating
15 (02/16) Following cracking, all of the cracked pavement layer shall be seated with a multi-wheeled pneumatic-
tyred roller with a weight specified in contract specific Appendix 7/16 and with the number of passes specified in
contract specific Appendix 7/16. The load including any ballast shall be distributed uniformly over all the wheels.
The drive gear shall provide a progressive, variable speed, forward and reversing capability. Such compaction plant
shall have articulating wheels on both front and rear axles. The wheel arrangement shall provide an overlap of not
less than 40 mm with the adjacent wheels. The internal pressure of the tyres shall be adjustable to provide variable
ground contact pressure (GCP). The Contractor shall certify in an agreed form on a daily basis the exact extent of
work completed under this sub-Clause and shall deliver each such certificate to the Overseeing Organisation before
noon the next day.
16 (02/16) Once cracking and seating and any remedial work under sub-Clause 26 of this Clause have been
completed, the pavement shall be prepared to Clause 920 before overlay.
(02/16) Main Trial
17 (02/16) The Contractor shall demonstrate that the plant, equipment and method that he proposes for the cracking
and seating of the existing hydraulically bound layer or layers are capable of producing the required type and
pattern of cracks. This shall be demonstrated by first executing a main trial over an area of neither less than 250 m2
nor greater than 420 m2 of existing pavement. The location of the trial shall be as directed by the Overseeing
Organisation and shall include a length of the most heavily trafficked lane. The Contractor shall demonstrate that
the cracking operation can achieve consistent compliance with this sub-Clause and with sub-Clauses 10 and 18
of this Clause and with contract specific Appendix 7/16. If the road pavement to be treated contains known areas
where there are differences in the concrete thickness or strength or in the foundation conditions, then a main trial
shall be conducted in each such area. The locations of pre-existing transverse cracks within the area of the Main
Trial shall be recorded by the Contractor. The work on the main trial length shall proceed as follows:
(i) Cracking shall proceed in stages as directed by the Overseeing Organisation in groups of four to six bays
in jointed concrete pavements, or in lengths of 20 m for HBM bases. Each group that is cracked and
seated shall be assessed in accordance with sub-Clause 18 of this Clause.
(ii) In Stage 1 of the main trial the Contractor shall set up his plant and equipment and demonstrate that
he can produce the required pattern and quality of transverse cracks in accordance with this Clause
including contract specific Appendix 7/16. This shall be assessed in accordance with sub-Clause 18 of
this Clause.
(iii) In Stage 2 and each subsequent Stage of the main trial, a group of four bays in jointed concrete
pavements, or a length of 20 m for HBM bases, shall be cracked starting from one end to produce
transverse cracks at each of the spacings stated in item 5(i) of contract specific Appendix 7/16. For each
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Stage, the settings of the cracking plant and equipment shall be recorded in accordance with the pro
forma in contract specific Appendix 7/17.
(iv) Seating: After cracking in both Stage 1 and Stage 2, the pavement shall be seated with the number
of roller passes specified in contract specific Appendix 7/16 and as described in sub-Clause 15 of
this Clause.
(02/16) Assessment of Main Trial
18 (02/16) Compliance with the cracking and seating requirements for the main trial shall be assessed as follows:
(i) The surface pattern of cracking shall be checked before seating but after applying clean water and
allowing to dry as specified in sub-Clause 13 of this Clause.
(ii) In Stage 1 of the main trial, the induced crack pattern shall be inspected by the Contractor. In Stage
2 and in subsequent Stages, visual inspection of the crack pattern shall be made by the Overseeing
Organisation.

Volume 1 Series 700
(iii) In Stage 2 and in subsequent Stages of the main trial, the spacing of transverse cracks will be monitored
by the Overseeing Organisation.
(iv) The depth and the vertical direction of cracking shall be determined by coring through the full depth of
the hydraulically bound pavement layer symmetrically at the crack position. Core diameter shall be in
accordance with contract specific Appendix 7/16. In Stage 2 and in subsequent Stages of the main trial,
the number of cores shall be in accordance with Table 7/4. In cases where cracks are not visible in the
surface, the locations of cores will be generally within the impact points and transversely in line with the
impact points. If any shattering or multiple cracking is present in the extracted core then there is deemed
to have been ‘shattering failure’.
(v) The Contractor’s certificates required under sub-Clause 15 of this Clause will be checked by the
Overseeing Organisation. If the number of roller passes required for seating is not in accordance with
sub-Clause 15 of this Clause, the Contractor shall roll again the entire area in accordance with sub-
Clause 15 of this Clause and with not less than the number of roller passes specified in contract specific
Appendix 7/16.
19 (02/16) The Contractor shall make allowance in his programme for the undertaking of FWD measurements
which will be performed by the Contractor in accordance with Clause 717, unless stated otherwise in contract
specific Appendix 7/16, both (i) before cracking and (ii) after seating in accordance with this Clause. Unless
stated otherwise in contract specific Appendix 7/16, the Contractor shall perform the processing and analysis of
the FWD measurements in accordance with Clause 719 and shall present them to the Overseeing Organisation for
interpretation and instruction. The Contractor shall remove all debris from the cracked pavement in the main trial
lengths before FWD measurements are made. Cracking of Stage 2 or subsequent Stages of the Main Trial shall not
commence until the Overseeing Organisation has interpreted the analysed FWD measurements undertaken before
cracking and has confirmed or otherwise the suitability of the area selected for the Main Trial.
(02/16) Consent to the Method and Acceptance of the Main Trial
20 (02/16) The Contractor shall not proceed with the main crack and seat work until the Overseeing Organisation
has given its consent that the plant, equipment and methods used in the main trial length comply with the
requirements in Table 7/4. Consent to the plant equipment and methods of cracking and seating will be given by
the Overseeing Organisation following a successful demonstration in the main trial that the cracking and seating
complies with the requirements of this Clause and that the effective stiffness modulus of the cracked and seated
pavement and/or underlying foundation derived from FWD testing meets the design criteria. When consent by the
Overseeing Organisation to the method has been given, the plant, equipment and methods shall not be changed
thereafter without the prior consent of the Overseeing Organisation except for normal adjustment and maintenance
of plant. Should it be necessary for the Contractor to otherwise change any plant, equipment and/or method the
Contractor may be required to carry out a further main trial Stage.
(02/16) Main Production Work
21 (02/16) The cracking operation for the main production work shall proceed at the crack spacing determined
after the main trial, or from any relevant subsequent production cracking re-assessment trial. The seating operation
shall be completed by rolling the pavement for the number of passes specified in contract specific Appendix 7/16.
The main production work shall be assessed in accordance with sub-Clause 24 of this Clause. The Contractor shall
make allowance in his programme for FWD measurements which will be made by the Contractor according to
Clause 717 after seating in accordance with this Clause, unless stated otherwise in contract specific Appendix 7/16.
The Contractor will perform the processing and analysis of the FWD measurements in accordance with Clause
719, unless stated otherwise in contract specific Appendix 7/16, and will present the results to the Overseeing
Organisation for interpretation and instruction. The Contractor shall remove all debris from the cracked pavement
before FWD measurements are made.
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22 (02/16) The surface pattern of cracking shall be checked after applying water as specified in sub-Clause
13 of this Clause. The Contractor shall be responsible for the continuous observation of the crack pattern. The
location of pre-existing transverse cracks shall be recorded by the Contractor. If without the prior agreement
of the Overseeing Organisation the crack spacing on the main work is shorter than that specified following the

Volume 1 Series 700
main trial, the Contractor shall so notify the Overseeing Organisation in not less than 2 hours. Should the crack
pattern vary from that to which consent was given in the main trial, or from any relevant subsequent production
cracking re-assessment trial, with the consent of the Overseeing Organisation the Contractor shall adjust the plant
and equipment in order to produce the agreed crack pattern. The new settings of the plant and equipment shall
be recorded by the Contractor, together with the chainage at which the settings were changed. These particulars
shall be delivered to the Overseeing Organisation within not more than 24 hours of the changes being completed.
If the agreed crack pattern is not restored within 4 bays in jointed concrete pavements or within 20 m in HBM
bases production cracking shall cease in accordance with sub-Clause 7 of this Clause. A production cracking re-
assessment trial shall then be carried out in accordance with sub-Clauses 28 to 30 of this Clause before any further
production cracking and seating work is executed.
23 (02/16) The depth and quality of the induced cracks shall be monitored by inspection of extracted cores. If there
has been ‘shattering failure’ in accordance with sub-Clause 18(iv) of this Clause, production cracking shall cease
immediately. The extent of the area affected shall be determined as specified in sub-Clause 27 of this Clause.
(02/16) Assessment of the Main Production Work
24 (02/16) Compliance with the cracking and seating requirements shall be assessed during the main work in
accordance with the following criteria:
(i) The spacing of transverse cracks shall be checked by the Contractor and will be monitored by the
(ii) The surface pattern of cracking of all areas that have been cracked shall be checked after applying water
as specified in sub-Clause 13 of this Clause.
(iii) The depth and the vertical direction of cracking shall be determined through the full depth of the
hydraulically bound pavement layer or layers symmetrically at the crack position. Core diameter shall
be in accordance with contract specific Appendix 7/16. Not less than one core shall be extracted in every
300 m2 of cracked concrete at locations selected by the Overseeing Organisation. In cases where cracks
are not visible in the surface, the locations of cores will be generally in line with the impact points.
(iv) The seating shall be assessed in accordance with sub-Clause 18(v) of this Clause.
(02/16) Acceptance of the Main Production Work
25 (02/16) The main production work under this Clause shall be accepted when it complies fully with the
requirements of this Clause and with Table 7/4.
(02/16) Failure to Comply and Remedial Work
26 (02/16) The results of the crack and seat operations for any jointed unreinforced concrete slab, or any 5 m length
of HBM base, shall be rejected if it fails to comply with any of the criteria in sub-Clause 23 of this Clause. If:
(i) shattering or multiple cracking of hydraulically bound material occurs within the extracted core; or
(ii) the length of any longitudinal cracks in the highway traffic wheel track zones are in excess of the
specified crack spacing of the induced transverse cracks;
(iii) the transverse crack spacing determined for the particular portion of the work is outside the tolerance
specified in contract specific Appendix 7/16;
or any combination of these, then the following remedial measures shall be taken. The size of the affected area shall
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be determined and the rejected section(s) shall be broken out, excavated to full depth and reinstated with equivalent
material, unless otherwise instructed by the Overseeing Organisation. The positions of the wheel track zones to
which reference is made in this Clause shall be as defined in sub-Clause 903.21.

TABLE 7/4: (02/16) Saw-cut, Crack and Seat of Existing Jointed Unreinforced Concrete Pavements and CBM Bases – Assessment Criteria for

Acceptance of Trials and for the Main Production Work

Volume 1

WORK CATEGORY Surface crack pattern Transverse crack spacing Coring to determine severity, Seating FWD monitoring required by
depth and vertical direction of contract specific Appendix 7/16
cracking
[Not part of the assessment of
Contractor’s work]

5

1 2 3 4
Main trial Stage 1 (i) Fine (i.e. < 0.5mm wide); As specified in contract specific Cores shall be taken at locations (i) Monitored by the Contractor; None required.
Appendix 7/16. chosen by the Contractor.

(ii) In a transverse direction; (ii) Roll with the number of passes May be done by the Contractor if
of the roller specified in contract desired.
(iii) No wheeltrack longitudinal
crack length > transverse crack
spacing;
(iv) Monitored by the
Contractor.
Main trial Stage 2 and (i) Fine (i.e. < 0.5mm wide); (i) Each stage at one crack (i) Cores shall be taken at locations (i) Monitored by the Overseeing Unless stated otherwise in contract
subsequent stages spacing as specified in contract chosen by the Overseeing Organisation; specific Appendix 7/16 the Contractor
(ii) In a transverse direction;
specific Appendix 7/16; Organisation; to determine and record the minimum
(ii) Roll with the number of passes
(iii) No longitudinal crack effective stiffness modulus from
(ii) Monitored by the (ii) Not less than 5 cores in each of the roller specified in contract
length > transverse crack FWD measurements and core details
Overseeing Organisation. Stage with not less than 1 core from specific Appendix 7/16.
spacing; provided by the Contractor.
each bay or from a 5m length in
(iv) Monitored by the HBM bases, as appropriate.
Acceptance of main (i) Crack pattern complies with (i) Required tolerance on (i) No multiple cracks or shattering Certification by the Contractor Unless stated otherwise in contract
trial Stage 2 and (i) to (iii) above. transverse crack spacing within the core; that each point has been rolled specific Appendix 7/16 the Contractor

subsequent stages achieved. with not < the number of passes to produce a record of the measured
(ii) Cores shall have a single crack
of the roller specified in contract effective stiffness moduli for (i)
to the full depth of the concrete;
specific Appendix 7/16. the concrete pavement and (ii) the
(iii) Cracks shall be predominantly foundation both before, and after

vertical. cracking and/or seating.
Main production work (i) Fine (i.e. < 0.5mm wide); (i) Crack spacing determined (i) Cores shall be taken at locations (i) Monitored by the Contractor; Unless stated otherwise in contract
from the main trial or from chosen by the Overseeing specific Appendix 7/16 the Contractor
(ii) In a transverse direction; (ii) Roll each point with not <
the re-assessment trial, as Organisation; to determine and record the effective
the number of passes of the roller
(iii) No wheeltrack longitudinal appropriate, to the tolerance stiffness modulus from FWD
(ii) Not less than 1 core every 300sq specified in contract specific
crack length > transverse crack specified in contract specific measurements and core details
m; Appendix 7/16.
spacing; Appendix 7/16; provided by the Contractor on every
(iii) Monitored by the Contractor. bay or 5 m length of HBM base after
(iv) Monitored by the (ii) Monitored by the
cracking and/or seating.
Contractor. Contractor.
25
Series 700
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TABLE 7/4: (02/16) Saw-cut, Crack and Seat of Existing Jointed Unreinforced Concrete Pavements and CBM Bases – Assessment Criteria for

Acceptance of Trials and for the Main Production Work (continued)

Volume 1
WORK CATEGORY Surface crack pattern Transverse crack spacing Coring to determine severity, Seating FWD monitoring required by
depth and vertical direction of contract specific Appendix 7/16
cracking
[Not part of the assessment of
Contractor’s work]

1 2 3 4

Acceptance of the main (i) Crack pattern complies with (i) Required tolerance on (i) No multiple cracks or shattering (i) Certification by the Contractor (i) Not required for compliance
production work (i) to (iii) above. transverse crack spacing within the core; that each point has been rolled monitoring;
achieved; with not < the number of passes

(ii) Cores shall have a single crack (ii) Required for confirmation of
of the roller specified in contract
to the full depth of the hydraulically structural design.
bound layer;
vertical.
Production cracking (i) Fine (i.e. < 0.5mm wide); (i) Crack spacing as specified (i) Cores shall be taken at locations (i) Monitored by the Overseeing Unless stated otherwise in contract
re-assessment trial by the Overseeing Organisation chosen by the Overseeing Organisation; specific Appendix 7/16 the Contractor
(ii) In a transverse direction;
to the tolerance specified in Organisation; to determine and record the minimum
(ii) Roll each point with not <
(iii) No wheeltrack longitudinal contract specific Appendix effective stiffness modulus on every
(ii) Not less than 5 cores with not the number of passes of the roller
crack length > transverse crack 7/16; bay or 5 m length of HBM base
less than 1 core from each bay specified in contract specific
spacing; after cracking and/or seating from
(ii) Monitored by the or 5m length in HBM bases, as Appendix 7/16.
FWD measurements and core details
(iv) Monitored by the Overseeing Organisation. appropriate;
provided by the Contractor.
(iii) Monitored by the Overseeing
Organisation.
Acceptance of a (i) Crack pattern complies with (i) Required tolerance on (i) No multiple cracks or shattering (i) Certification by the Contractor Unless stated otherwise in contract
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production cracking (i) to (iii) above. transverse crack spacing within the core; that each point has been rolled specific Appendix 7/16 the Contractor

re-assessment trial achieved. with not < the number of passes to produce a record of the measured
(ii) Cores shall have a single crack
of the roller specified in contract effective stiffness moduli for (i)
to the full depth of the hydraulically
specific Appendix 7/16. the concrete pavement and (ii) the
bound layer;
foundation combination both before,

(iii) Cracks shall be predominantly and after cracking and seating.
vertical.
26
Series 700
Volume 1 Series 700
If the number of roller passes required for seating is less than the specified minimum at each and every point on
the pavement, or less than such other increased number of passes which has been specified by the Overseeing
Organisation following a trial or otherwise then the Contractor shall roll the entire area again with not less than
the number of passes specified in contract specific Appendix 7/16, unless otherwise instructed by the Overseeing
Organisation.
27 (02/16) The extent of shattering or multiple cracking shall be determined by extracting and inspecting cores.
Such cores shall be taken at the location of induced transverse cracks within the area between the position of the
crack-inducing plant and the last core in which the cracking complied with the requirements of sub-Clause 25 of
this Clause. The extent of longitudinal cracking in the wheel track zones shall be determined by visual inspection.
(02/16) Production Cracking Re-assessment Trial
28 (02/16) When in the opinion of the Overseeing Organisation, the conditions so require, a Production Re-
assessment Trial shall take place. The Production Cracking Re-assessment Trial described in this sub-Clause and
in sub-Clauses 7, 22, 29 and 30 of this Clause shall require the Contractor to demonstrate that the plant, equipment
and method to which consent was given by the Overseeing Organisation for use in the main work are capable of
producing the required type and pattern of cracks in the existing hydraulically bound layer or layers by executing
this trial over an area of neither less than 75 m2 nor greater than 120 m2 of existing pavement. The location of
the trial shall be as directed by the Overseeing Organisation. The crack spacing(s) shall be as directed by the
Overseeing Organisation within the tolerances specified in contract specific Appendix 7/16. The Contractor shall
demonstrate that the cracking operation can achieve consistent compliance with sub-Clause 29 of this Clause.
The Contractor shall make programme allowance for FWD measurements which shall be made by the Contractor
according to Clause 717 before cracking and after seating in accordance with this Clause unless stated otherwise
in contract specific Appendix 7/16. Unless stated otherwise in contract specific Appendix 7/16 the Contractor shall
perform the processing and analysis of the FWD measurements in accordance with Clause 719 and shall present
the results to the Overseeing Organisation for interpretation and instruction. The Contractor shall remove all debris
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from the cracked pavement in the re-assessment trial length before FWD measurements are made. The production
cracking re-assessment trial length shall be seated with the number of passes of the roller specified in contract
(02/16) Assessment of Production Cracking Re-assessment Trial
29 (02/16) Compliance with the cracking and seating requirements for the production cracking re-assessment trial
shall be assessed in accordance with sub-Clauses 24 and 25 above.
(02/16) Consent to the Method and Acceptance of the Production Cracking Re-assessment Trial
30 (02/16) The Contractor shall not resume the main work until the Overseeing Organisation has given its consent
that the plant, equipment and methods used in the production cracking re-assessment trial comply with the
requirements given in Table 7/4.
Consent to the plant equipment and methods will be given by the Overseeing Organisation following a successful
demonstration in the Production Cracking Re-assessment Trial that the cracking and seating complies with the
requirements of this Clause. When consent to the method has been given by the Overseeing Organisation, the plant,
equipment and methods shall not be changed thereafter without the prior consent of the Overseeing Organisation
except for normal adjustment and maintenance of plant. Should it be necessary for the Contractor to otherwise
change any plant, equipment and/or method the Contractor shall carry out a further Production Cracking Re-
assessment Trial.

Volume 1 Series 700
717 (02/16) Monitoring of Cracked and Seated Jointed Unreinforced Concrete Pavements and
HBM Bases using the Falling Weight Deflectometer (FWD)
(02/16) General
1 (02/16) This Clause specifies the procedures to be followed when the Falling Weight Deflectometer (FWD) is
to be used to acquire the measurements required to determine the load-spreading properties of cracked and seated
concrete as required by Clause 716. Specifically, the FWD shall be used to validate whether the effective stiffness
modulus of the cracked and seated hydraulically bound layer or layers exceeds the threshold value determined from
the structural design calculations. The type of equipment is specified together with the procedures for its use on
site and the parameters to be used to acquire the deflection data. The effective stiffness moduli of the cracked and
seated hydraulically bound layer or layers and of the underlying foundation shall be calculated by the Contractor
using back-analysis of the FWD measurements obtained by the Contractor in accordance with Clause 719.
2 (02/16) FWD measurements shall be made on the surface of the concrete after the removal of any existing
asphalt overlay or surfacing from the area to be tested. Removal of overlay shall be completed ahead of the FWD
testing at a distance of not less than 100 m from the FWD equipment. The cracking and seating operation shall
be completed ahead of the FWD testing at a distance of not less than 100 m from the FWD equipment in order to
minimise the effect of pavement vibration. FWD measurements shall follow the seating operation. The Contractor
shall ensure that a sufficient frequency of clearly-marked locational reference markers have been put in place to
the satisfaction of the Overseeing Organisation for the purpose of accurately recording the locations of the FWD
measurements and therefore correlating the results with the settings used by the cracking plant.
3 (02/16) The Overseeing Organisation will use the effective stiffness moduli obtained from the main trial in
accordance with Clause 719 in conjunction with the other criteria specified in sub-Clause 17 of Clause 716 to
determine the required transverse crack spacing to be used in the main production work.
4 (02/16) The Overseeing Organisation may instruct any variation required in the method and pattern of cracking
or subsequently confirm or otherwise the suitability of the proposed thickness of overlay required as a result of the
effective stiffness modulus of the cracked and seated hydraulically bound layer or layers determined from FWD
measurements.
5 (02/16) The road shall be neither overlaid nor re-opened to highway traffic without the Overseeing
Organisation’s written confirmation that the FWD measurements have been assessed and any required remedial
action taken.
(02/16) Measuring Equipment
6 (02/16) Any FWD used to monitor the effectiveness of the cracking and seating operation as specified in this
Clause and in Clause 716 shall have the current appropriate certification before it can be used on the Overseeing
Organisation’s network.
7 (02/16) Evidence of a satisfactory absolute calibration by the equipment manufacturer and consistency checks
by the operator shall be provided as required by the Overseeing Organisation. The absolute calibration of the
deflection sensors, load cell and system processor shall be carried out annually. Consistency checks of the dynamic
response of the machine as a whole should take place at intervals of six weeks or less during periods of operation
and after any major service involving replacement parts.
8 (02/16) For the monitoring of the crack and seat operation on jointed unreinforced concrete pavements and on
HBM bases, the load level shall be set at 50kN ± 10%. The load pulse shall be applied through a 300mm diameter
plate and have a rise time from start of pulse to peak of between 5 and 15 milliseconds. Most FWDs have a 60 Hz
smoothing filter option which has been shown to improve the agreement between machines. Where available the
smoothing filter shall be activated. Deflections shall be measured to a resolution of at least 1 micron over the range
0-2mm by a minimum of 7 sensors situated at radii up to a distance of 2.25m from the centre of the loading plate at
positions shown in Table 7/5. While more than 7 geophones can be fitted to an FWD, Clause 719 requires that the
data input to the approved back-analysis software program shall contain measurements only from the geophones
located at the positions shown in Table 7/5.
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Volume 1 Series 700
(02/16) Operation on Site

9 (02/16) FWD testing shall not be performed while standing water is present on the surface to be tested.
10 (02/16) The Contractor shall ensure that there is no detritus on the road surface prior to the FWD testing. Care
shall be taken to ensure that the whole area of the FWD loading plate is in contact with the pavement surface. A
minimum of 3 drops, plus a small initial drop for settling the load plate, should be made at each test point. The
Contractor shall make checks for machine consistency during the survey and before analysis.
TABLE 7/5: (02/16) Deflection Sensor Positions for Monitoring Cracking and Seating
Type of Pavement Distance (mm) from Centre of Loading Plate Geophone number
d1 d2 d3 d4 d5 d6 d7
Jointed unreinforced
concrete or HBM base 0 300 600 900 1,350 1,800 2,250
11 (02/16) During FWD testing, it is essential for subsequent analysis that the deflection values (for d1 to d7)
decrease as the distance from the applied load increases. Should the deflection measured by a geophone of a higher
number (see Table 7/5) be greater than the deflection measured by a geophone of lower number, then the FWD
shall be moved forwards or backwards by a small distance and the measurement cycle repeated. If it is not possible
to obtain a decreasing deflection bowl after two shifts of position, then the measurement should be discarded
and the Overseeing Organisation informed of the location of the test position for possible further investigation.
Measurements of pavement temperature at 100 mm depth should be recorded at no less than hourly intervals.
(02/16) Main Trial Area Testing
12 (02/16) In Stage 2 and subsequent Stages of a Main Trial, FWD measurements shall be made both before and
after cracking to determine the reduction in the effective stiffness modulus of the concrete produced by the cracking
and seating operation. Stage 2 and subsequent Stages shall consist of an area as described in sub-Clause 17 of
Clause 716. The area of concrete to be tested shall be adequately marked to enable FWD testing to be performed on
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the same locations both before and after cracking and seating.
13 (02/16) On jointed concrete pavements, FWD measurements shall be made along the centre line of the bays. For
each crack spacing specified in contract specific Appendix 7/15, the location of the centre of the loading plate for
the first measurement shall be 1 m beyond the transverse joint at the start of a bay with all the geophones located
within the bay. Subsequent measurements shall be made at intervals of 0.5 m along the centre line of the slab up
to and including the centre of the slab. Test positions coincident with transverse cracks shall be omitted and the
location of the crack recorded by the Contractor. For each measurement, the location of the FWD loading plate
shall be adequately recorded so that the position of each measurement can be clearly identified.
14 (02/16) On HBM bases, FWD measurements shall be made along the centre line of each traffic lane unless this
alignment coincides with a longitudinal shrinkage or construction crack, in which case the measuring line shall
be shifted towards the nearside wheelpath until the FWD test plate is not located within 0.5 m of a longitudinal
crack. The location of the centre of the loading plate for the first measurement shall be 1m past the start of the test
area for the Stage. Subsequent measurements shall be made at intervals of 1 m along the centre line of the lane
until the outer geophone d7 (see Table 7/5) is outside the other end of the test area for the Stage. Test positions
coincident with transverse cracks shall be omitted and the location of the crack recorded by the Contractor. For
each measurement, the location of the FWD loading plate shall be adequately recorded such that the position of
each measurement can be clearly identified.
15 (02/16) After completion of the FWD measurements on the Main Trial, the deflection data and layer thickness
details derived from cores taken in accordance with Clause 716, and supplemented by Ground Penetrating Radar
(GPR) measurements when required by contract specific Appendix 7/16, shall be used by the Contractor to
calculate effective stiffness moduli of the pavement layers in accordance with Clause 719. The moduli values
shall be supplied to the Overseeing Organisation who will determine the required transverse crack spacing to
be used in the main production with reference to the other criteria specified in sub-Clause 17 of Clause 716. For
jointed unreinforced concrete pavements, the analysis will also provide the location on each bay where FWD
measurements shall be made following production cracking and seating in the main works.

Volume 1 Series 700
(02/16) Consent to the Results of the FWD Measurements on the Main Trial
16 (02/16) The Contractor shall not proceed with the main production cracking works until the Overseeing
Organisation has specified the transverse crack spacing and given its consent that the effective stiffness modulus of
the cracked and seated concrete exceeds the threshold value required by the structural design.
17 (02/16) Consent to the plant, equipment and methods will be given by the Overseeing Organisation following a
successful demonstration in the main trial that the cracking and seating complies with the requirements of Clause
716 and this Clause. When consent by the Overseeing Organisation to the method has been given, the plant,
change any plant, equipment and/or method, the Contractor shall carry out a further main trial Stage.
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(02/16) Main Production Work Testing
18 (02/16) The cracking operation for the main production work shall proceed at the crack spacing determined from
the main trial, or from any relevant subsequent production cracking re-assessment trial. The main production work
shall be assessed in accordance with sub-Clause 24 of Clause 716 with reference to sub-Clause 21 of this Clause.
19 (02/16) FWD measurements shall be made along the centre line of every bay of jointed concrete pavement after
cracking and seating at the bay location determined by the Overseeing Organisation from the results of the main
trial. For HBM bases, the FWD measurements shall be made every 5 m along the centre line of each traffic lane,
and shifting by 0.5 m where necessary to avoid the location of pre-existing transverse cracks.
20 (02/16) If the crack characteristics or patterns vary from those to which consent was given in the main trial, or
from any relevant subsequent production cracking re-assessment trial and are not restored within 4 bays in jointed
concrete pavements or within 20 m in HBM bases, production cracking shall cease in accordance with sub-Clause 7
of Clause 716. A production cracking re-assessment trial shall then be carried out in accordance with sub-Clause 28
of Clause 716 before any further production cracking and seating work is executed.
21 (02/16) After completion of the FWD measurements on the Main Production Work, the deflection data and layer
thickness details derived from cores taken in accordance with Clause 716, and supplemented by Ground Penetrating
Radar (GPR) measurements when required by contract specific Appendix 7/16, shall be used by the Contractor to
calculate effective stiffness moduli of the pavement layers in accordance with Clause 719. The moduli values shall
be supplied to the Overseeing Organisation within 24 hours of the cracking operations.
(02/16) Acceptance of the Main Production Work Testing
22 (02/16) The effective stiffness moduli of the cracked and seated concrete calculated in accordance with Clause
719 from the FWD measurements collected in accordance with this Clause shall be assessed by the Overseeing
Organisation in conjunction with the other criteria specified in sub-Clause 24 of Clause 716. The Overseeing
Organisation shall instruct or otherwise on any remedial actions that may be required. The road shall be neither
overlaid nor re-opened to highway traffic without the Overseeing Organisation’s written confirmation that he has
completed his interpretation of the FWD measurements and that all required remedial actions have been completed.
23 (02/16) Should a production cracking re-assessment trial be required for the reasons specified in sub-Clause 7
of Clause 716, then FWD measurements will be required for assessment of the trial. These measurements shall be
made by the Contractor in accordance with sub-Clauses 12 to 17 of this Clause both before and after cracking and
seating.
24 (02/16) After completion of the FWD measurements on the re-assessment trial, the deflection data and layer
thickness details derived from cores taken in accordance with Clause 716 shall be used by the Contractor to
calculate effective stiffness moduli of the pavement layers in accordance with Clause 719. The Overseeing
Organisation will use these moduli values, in conjunction with the other criteria specified in sub-Clause 18
of Clause 716, to determine the transverse crack spacing to be used in the main production work. For jointed

Volume 1 Series 700
unreinforced concrete pavements, the analysis will also provide the location on individual bays where FWD
measurements will be made following cracking and seating in the main works.
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25 (02/16) The Contractor shall not resume the main crack and seat works until the Overseeing Organisation has
given his consent that the plant, equipment and methods used in the production cracking re-assessment trial comply
with the requirements given in Table 7/4 of Clause 716 and sub-Clauses 23 and 24 of this Clause.
718 (02/16) Monitoring of Saw-cut, Cracked and Seated Jointed Reinforced Concrete Pavements
Using the Falling Weight Deflectometer (FWD)
(02/16) General
1 (02/16) This Clause specifies the procedures to be followed when the Falling Weight Deflectometer (FWD) is
to be used to acquire the measurements used to determine the load-spreading properties of saw-cut, cracked and
seated reinforced concrete as required by Clause 715. Specifically, the FWD shall be used to validate whether the
effective stiffness modulus of the saw-cut, cracked and seated hydraulically bound layer or layers exceeds the
threshold value determined from the structural design calculations. The type of equipment is specified together with
the procedures for its use on site and the parameters required to acquire the deflection data. The effective stiffness
moduli of the saw-cut, cracked and seated hydraulically bound layer or layers and of the underlying foundation
shall be calculated by the Contractor using back-analysis of the FWD measurements obtained by the Contractor in
2 (02/16) FWD measurements shall be made on the surface of the concrete after the removal of any existing
asphalt overlay or surfacing from the area to be tested. Removal of overlay shall be completed ahead of the FWD
testing at a distance of not less than 100 m from the FWD equipment. The cracking and seating operation shall also
be completed ahead of the FWD testing at a distance of not less than 100 m from the FWD equipment in order to
minimise the effect of pavement vibration. FWD measurements shall follow the seating operation. The Contractor
shall ensure that a sufficient frequency of clearly-marked locational reference markers have been put in place to
the satisfaction of the Overseeing Organisation for the purpose of accurately recording the locations of the FWD
measurements and therefore correlating the results with the settings used by the cracking plant.
3 (02/16) The Overseeing Organisation will use the effective stiffness moduli obtained from the main trial in
accordance with Clause 719 in conjunction with the other criteria specified in sub-Clause 21 of Clause 715 to
determine the required transverse crack spacing to be used in the main production work.
4 (02/16) The Overseeing Organisation may instruct any variation required in the method and pattern of saw-
cutting and/or cracking or subsequently confirm or otherwise the suitability of the proposed thickness of overlay
required, as a result of the effective stiffness modulus of the saw-cut, cracked and seated hydraulically bound layer
or layers determined from FWD measurements.
5 (02/16) The road shall be neither overlaid nor re-opened to highway traffic without the Overseeing
Organisation’s written confirmation that the FWD measurements have been assessed and any required remedial
action taken.
(02/16) Measuring Equipment
6 (02/16) Any FWD used to monitor the effectiveness of the saw-cut, cracking and seating operation as specified
in this Clause and in Clause 715, shall have the current appropriate certification before it can be used on the
Overseeing Organisation’s network.
7 (02/16) Evidence of a satisfactory absolute calibration by the equipment manufacturer and consistency checks
by the operator shall be provided as required by the Overseeing Organisation. The absolute calibration of the
deflection sensors, load cell and system processor shall be carried out annually. Consistency checks of the dynamic
response of the machine as a whole should take place at intervals of six weeks or less during periods of operation
and after any major service involving replacement parts.

Volume 1 Series 700
8 (02/16) For the monitoring of the saw-cut, crack and seat operation, the load level shall be set at 50kN ± 10%.
The load pulse shall be applied through a 300 mm diameter plate and have a rise time from start of pulse to peak
of between 5 and 15 milliseconds. Most FWDs have a 60 Hz smoothing filter option which has been shown to
improve the agreement between machines. Where available the smoothing filter shall be activated. Deflections
shall be measured to a resolution of at least 1 micron over the range 0-2 mm by a minimum of 7 sensors situated
at radii up to a distance of 2.25m from the centre of the loading plate at positions shown in Table 7/6. While more
than 7 geophones can be fitted to an FWD, Clause 719 requires that the data input to the approved back-analysis
software program shall contain measurements only from the geophones located at the positions shown in Table 7/6.
TABLE 7/6: (02/16) Deflection Sensor Positions for Monitoring Cracking and Seating
Type of Pavement Distance (mm) from Centre of Loading Plate
Inner >>>> Outer
Geophone number
d1 d2 d3 d4 d5 d6 d7
Jointed reinforced concrete 0 300 600 900 1,350 1,800 2,250
(02/16) Operation on site

9 (02/16) FWD testing shall not be performed while standing water is present on the surface to be tested.
10 (02/16) The Contractor shall ensure that there is no detritus on the road surface prior to the FWD testing. Care
shall be taken to ensure that the whole area of the FWD loading plate is in contact with the pavement surface. A
minimum of 3 drops, plus a small initial drop for settling the load plate, should be made at each test point. The
Contractor shall make checks for machine consistency during the survey and before analysis.
11 (02/16) During FWD testing, it is essential for subsequent analysis that the deflection values for d1 to d7 reduce
as the distance from the applied load increases. Should the deflection measured by a geophone of a higher number
(see Table 7/6) be greater than the deflection measured by a geophone of a lower number, then the FWD shall
be moved forwards or backwards by a small distance and the measurement cycle repeated. If it is not possible to
obtain a decreasing deflection bowl after two shifts of position, then the measurement should be discarded and the
location of the test position noted for further investigation by the Overseeing Organisation.
(02/16) Main Trial Area Testing
12 (02/16) In Stage 2 and subsequent Stages of the Main Trial, the Contractor shall make FWD measurements both
before saw-cutting and then after cracking and seating, in order to determine the reduction in the effective stiffness
modulus of the concrete produced by the saw-cut, cracking and seating operation. Stage 2 and subsequent Stages,
shall consist of an area as described in sub-clause 21 of Clause 715. The area of concrete to be tested shall be
adequately marked to enable FWD testing to be performed on the same locations both before saw-cutting and after
cracking.
13 (02/16) FWD measurements shall be made along the centre line of the reinforced slabs. For each saw-cut
spacing, the location of the centre of the loading plate for the first measurement shall be at the midpoint between
the first two saw-cuts. Subsequent measurements shall be made directly on the saw-cuts and at the midpoint
between adjacent saw-cuts. Test positions coincident with transverse cracks should be omitted and the location of
the crack recorded by the Contractor. The location of the FWD loading plate shall be adequately recorded so that
the location of each measurement can be clearly identified.
14 (02/16) After completion of the FWD measurements on the main trial, the deflection data and layer thickness
details derived from cores taken in accordance with Clause 715, and supplemented by Ground Penetrating Radar
(GPR) measurements when required by contract specific Appendix 7/15, shall be used by the Contractor to
be supplied to the Overseeing Organisation who will determine the required transverse saw-cut spacing to be used
in the main production work with reference to the other criteria specified in sub-Clause 21 of Clause 715.

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Volume 1 Series 700
(02/16) Consent to the Results of the FWD Measurements on the Main Trial
15 (02/16) The Contractor shall not proceed with the main saw-cut, crack and seat works until the Overseeing
Organisation has specified the transverse saw-cut spacing and given its consent that the effective stiffness modulus
of the cracked and seated concrete exceeds the threshold value required by the structural design.
16 (02/16) Consent to the plant, equipment and methods will be given by the Overseeing Organisation following a
successful demonstration in the main trial that the saw-cut, cracking and seating complies with the requirements of
Clause 715 and this Clause. When consent by the Overseeing Organisation to the method has been given, the plant,
change any plant, equipment and/or method the Contractor shall carry out a further main trial Stage.
(02/16) Main Production Work Testing
17 (02/16) The cracking operation for the main production work shall proceed using the saw-cut spacing
determined from the main trial, or from any relevant subsequent production cracking re-assessment trial. The main
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production work shall be assessed in accordance with sub-Clause 29 of Clause 715 with reference to sub-Clause 23
of this Clause.
18 (02/16) FWD measurements shall be made every 5 m along the centre line of the slabs in each traffic lane, and
shifting by 0.5 m where necessary to avoid the location of pre-existing transverse cracks.
19 (02/16) If the crack characteristics or patterns vary from those to which consent was given in the main trial, or
from any relevant subsequent production cracking re-assessment trial and are not restored within 20 m, production
cracking shall cease in accordance with sub-Clause 6 of Clause 715. A production cracking re-assessment trial shall
then be carried out in accordance with sub-Clause 33 of Clause 715 before any further production saw-cut and
cracking and seating work is executed.
20 (02/16) After completion of the FWD measurements on the Main Production Work, the deflection data and layer
thickness details derived from cores taken in accordance with Clause 715, and supplemented by Ground Penetrating
Radar (GPR) measurements when required by contract specific Appendix 7/15, shall be used by the Contractor to
be supplied to the Overseeing Organisation within 24 hours of the cracking operations.
(02/16) Assessment of the Main Production Work Testing
21 (02/16) The effective stiffness moduli of the cracked and seated concrete calculated by the Contractor in
accordance with Clause 719 from the FWD measurements collected in accordance with this Clause shall be
assessed by the Overseeing Organisation in conjunction with the other criteria specified in sub-Clause 29 of
Clause 715. The Overseeing Organisation shall instruct or otherwise on any remedial actions that may be required.
The road shall be neither overlaid nor re-opened to highway traffic without the Overseeing Organisation’s written
confirmation that he has completed his interpretation of the FWD measurements and that all required remedial
actions have been completed.
22 (02/16) Should a production cracking re-assessment trial be required as specified in sub-Clause 33 of Clause
715, then FWD measurements will be required for assessment of the trial. These measurements shall be made by
the Contractor in accordance with sub-Clauses 12 to 16 of this Clause both before saw-cutting and after cracking
and seating.
23 (02/16) After completion of the FWD measurements on the re-assessment trial, the deflection data and layer
thickness details derived from cores taken in accordance with Clause 715 shall be used by the Contractor to
calculate effective stiffness moduli of the pavement layers in accordance with Clause 719. The Overseeing
Organisation will use these moduli values, in conjunction with the other criteria specified in sub-Clause 21 of
Clause 715, to determine the transverse crack spacing to be used in the main production work.

Volume 1 Series 700
24 (02/16) The Contractor shall not resume the main saw-cut, crack and seat works until the Overseeing
Organisation has given its consent that the plant, equipment and methods used in the production cracking re-
assessment trial comply with the requirements given in Table 7/3 of Clause 715 and sub-Clauses 15 and 16 of this
Clause.
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719 (02/16) Back-analysis of Falling Weight Deflectometer (FWD) Measurements Made on
Concrete Pavements Treated by Fractured Slab Techniques
(02/16) General
1 (02/16) For the purposes of this Clause, ‘Fractured Slab’ techniques shall comprise the following:
(i) Crack and seat of jointed unreinforced concrete pavements and HBM bases in accordance with Clause
716.
(ii) Saw-cut and crack and seat of jointed reinforced concrete pavements in accordance with Clause 715.
2 (02/16) The Contractor shall produce the FWD deflection measurements to be used in this Clause in accordance
with Clause 717 for crack and seat or Clause 718 for saw-cut, crack and seat.
3 (02/16) The effective stiffness modulus of the fractured concrete, together with that of the foundation, shall be
derived from the back-analysis of FWD deflection bowl measurements by means of a recognised analysis package.
Highways England recognises the MODULUS-HA computer program, any alternative package proposed must be
proven to provide the same output values as MODULUS-HA. MODULUS-HA or an approved equivalent shall
be used for all back-analysis of FWD measurements performed in accordance with Clause 717 for crack and seat
or Clause 718 for saw-cut, crack and seat. Detailed instructions for the use of this program are contained in its
accompanying MODULUS-HA User Guide.
4 (02/16) The back-analysis procedure to be used utilises a two-layer model and, therefore, only the thickness
of the bound layers is required. The unbound layers are modelled as a single layer of infinite depth. Thickness
information for the bound layers is obtained from core samples obtained from the assessment of the cracking
operations in accordance with Clause 715 or Clause 716, and may be supplemented by Ground Penetrating Radar
measurements when required by contract specific Appendix 7/16 for crack and seat or contract specific Appendix
7/15 for saw-cut, crack and seat.
5 (02/16) The pavement deflection data to be back-analysed shall be divided into uniform sections with similar
total thicknesses of hydraulically bound material for the purposes of back-analysis. The mean total thickness of
hydraulically bound material present shall be calculated for each section. The measured bound-layer thicknesses
within a uniform section should lie within ±5 per cent of the bound-layer thickness used for that section.
6 (02/16) The Overseeing Organisation may instruct any variation required in the method and pattern of cracking
or subsequently confirm or otherwise the suitability of the proposed thickness of overlay required as a result
of the effective stiffness modulus of the fractured hydraulically bound layer or layers determined from FWD
measurements.
7 (02/16) Following submission of the electronic tables and graphs produced in accordance with sub-Clauses 11
and 12 of this Clause, the Contractor shall allow the period of time set out in contract specific Appendix 7/19 for
the Overseeing Organisation to carry out his assessment and interpretation of the results.
8 (02/16) The pavement shall be neither overlaid nor re-opened to highway traffic without the Overseeing
Organisation’s written confirmation that he has completed his assessment of the FWD measurements and that any
required remedial action has been completed.

Volume 1 Series 700
(02/16) Processing and Back-analysis Using MODULUS-HA

9 (02/16) The Contractor shall use MODULUS-HA or an approved equivalent to create .OUT files with the
required format from standard .F20 or .FWD output files in accordance with Chapter 3 of the MODULUS-HA
User’s Guide. Deflection measurements from a maximum of seven geophones shall be used. The additional
parameters required by MODULUS-HA or an approved equivalent shall be as specified in contract specific
Appendix 7/19. If the FWD deflection measurement data is not output in .F20 or .FWD file formats then the
Contractor shall produce suitable .OUT files containing the measured FWD data with the required structure by an
alternative method of his own devising.
10 (02/16) Following production of a suitable .OUT file, the Contractor shall back-analyse the FWD deflection
data obtained from a length of pavement defined in accordance with sub-Clause 5 of this Clause. The back-analysis
shall be performed in accordance with the procedure set out in Chapter 4 of the MODULUS-HA Users Guide.
The additional parameters required by MODULUS-HA or an approved equivalent shall be as specified in contract
11 (02/16) The Contractor shall save the back-analysed data as an ASCII data file in accordance with the procedure
set out in Chapter 5 of the MODULUS-HA Users Guide. The structure of the data contained within the output data
files shall be as specified in Appendix F of the MODULUS-HA Users Guide.
12 (02/16) The Contractor shall compile and present the back-analysed data created by MODULUS-HA or an
approved equivalent to the Overseeing Organisation in tabulated form in accordance with the electronic spreadsheet
format specified in contract specific Appendix 7/19. For each FWD test point, the presented data shall include, as a
minimum, the:
(i) Station identification; eg carriageway, lane and chainage.
(ii) Magnitude of the applied load (in kN).
(iii) Absolute measured deflections at each geophone position (in microns).
(iv) Back-analysed effective stiffness modulus of the hydraulically bound layer (in MPa).
(v) Back-analysed effective stiffness modulus of the foundation layer (in MPa).
(vi) Calculated thickness of hydraulically bound material used in the back-analysis (in mm).
(vii) Root Mean Square Deviation (RMS).
(viii) Absolute Mean Deviation (AMD) (in microns).
(ix) Estimated depth to a stiff layer (bedrock) (in mm).
The tabulated data shall also contain the actual measured core thicknesses and their locations relative to the FWD
test positions.
(02/16) Back-analysis and Presentation of Results of FWD Monitoring of Main Trial
13 (02/16) The Contractor shall back-analyse and present the results of his FWD testing of the Main Trial carried
out in accordance with Clause 717 for crack and seat or Clause 718 for saw-cut, crack and seat in accordance with
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sub-Clauses 9 to 11 of this Clause. The results shall also be presented graphically. The layout of the graphs shall
display the relationships specified in contract specific Appendix 7/19 in a format acceptable to the Overseeing
Organisation.
(02/16) Back-analysis and Presentation of Results of FWD Monitoring of Main Production Works
14 (02/16) The Contractor shall back-analyse and present the results of his FWD testing of the Main Production
Works carried out in accordance with Clause 717 for crack and seat or Clause 718 for saw-cut, crack and seat in
accordance with sub-Clauses 9 to 11 of this Clause. The results shall also be presented graphically. The layout of
the graphs shall display the relationships specified in contract specific Appendix 7/19 in a format acceptable to the

Volume 1 Series 700
(02/16) Back-analysis and Presentation of Results of FWD Monitoring of Production Cracking Reassessment
Trials
15 (02/16) The Contractor shall back-analyse and present the results of his FWD testing of any Production
Cracking Reassessment Trial carried out in accordance with Clause 717 for crack and seat or Clause 718 for
saw-cut, crack and seat in accordance with sub-Clauses 9 to 11 of this Clause. The results shall also be presented
graphically. The layout of the graphs shall display the relationships specified in contract specific Appendix 7/19 in a
format acceptable to the Overseeing Organisation.
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Volume 1 Series 700

702NI (02/16) Horizontal Alignments, Surface Levels and Surface Regularity of Pavement
Courses
(02/16) Horizontal Alignments
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1 (02/16) Horizontal alignments shall be determined from one edge of the pavement surface as described in
contract specific Appendix 1/12. The edge of the pavement as constructed and all other parallel alignments shall
be correct within a tolerance of ± 25 mm therefrom, except for kerbs and channel blocks which shall be laid with
a smooth alignment within a tolerance of ± 13 mm. Longitudinal road markings lateral tolerances shall be in
accordance with sub-Clause 1212.20NI.
(02/16) Surface Levels of Pavement Courses
2 (02/16) The design levels of pavement courses shall be calculated from the vertical profile, crossfalls and the
pavement course thicknesses described in contract specific Appendix 7/1. The level of any point on the constructed
surface of the pavement courses shall be the design level subject to the appropriate tolerances stated in Table 7/1NI.
TABLE 7/1NI: (02/16) Tolerances in Surface Levels of Pavement Courses
Road surfaces
– general ± 6 mm
– adjacent to a surface water channel* + 10 – 0 mm
Binder course * ± 6 mm
Top surface of base in pavements without binder course * ± 8 mm
Base * ± 15 mm
Subbase under concrete pavement surface slabs laid full thickness in one
operation by machines with surface compaction ± 10 mm
Subbases other than above + 10 – 30 mm
* Where a surface water channel is laid before the adjacent road pavement layer the top of that layer, measured
from the top of the adjacent edge of the surface water channel, shall be to the tolerances given in Table 7/1NI
3 (02/16) Notwithstanding the tolerances permitted in surface levels of pavement courses, the cumulative
tolerance shall not result in a reduction in thickness of the pavement, excluding the subbase and filter layer, by
more than 15 mm from the specified thickness nor a reduction in the thickness of the bituminous surface course by
more than 5 mm from that specified.
4 (02/16) For checking compliance with sub-Clause 2 of this Clause, measurements of the surface levels of all
courses will be taken on a grid of points located as described in contract specific Appendix 7/1. In any length of
pavement, compliance shall be deemed to be met for all surfaces, other than the final road surface, when not more
than one of ten consecutive measurements taken longitudinally or one in any transverse line, exceeds the tolerances
permitted in Table 7/1NI, provided that this one measurement shall not exceed by more than 5 mm the tolerance for
the course concerned. For the final road surface the tolerance given in Table 7/1NI shall apply to any point on that
surface.
(02/16) Surface Regularity
5 (02/16) The longitudinal regularity of the surfaces of surface courses, binder courses and concrete slabs shall be
such that the number of surface irregularities is within the relevant limits stated in Table 7/2NI.

Volume 1 Series 700
An irregularity is a variation of not less than 4 mm or not less 7 mm of the profile of the road surface as measured
by the rolling straight-edge set at 4 mm or 7 mm as appropriate, or equivalent apparatus capable of measuring
irregularities within the same magnitudes over a 3 m length. No irregularity exceeding 10 mm shall be permitted.
6 (02/16) Prior to checking any final road surface, binder course or top surface of base in pavements without
binder course for level, regularity or macrotexture depth, it shall be cleaned of loose or extraneous materials. These
operations shall be carried out without damaging the surface of the pavement, as soon as possible and within 3 days
of construction of the pavement.
7 (02/16) Compliance with Table 7/2NI shall be checked by the rolling straight-edge along any line or lines
parallel to the edge of pavement on sections of 300 m at regular intervals as stated in contract specific Appendix
7/1, whether or not it is constructed in shorter lengths. Sections shorter than 300 m forming part of a longer
pavement shall be assessed using the number of irregularities for a 300 m length pro-rata to the nearest whole
number.
Where the total length of pavement is less than 300 m, the measurements shall be taken on 75 m lengths.
8 (02/16) Pavements shall be measured transversely for irregularities at regular intervals as stated in contract
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specific Appendix 7/1, by a 3 m long straight-edge to BS 8420 placed at right angles to the centre line of the road.
The maximum allowable difference between the pavement surface and the straight-edge shall be 3 mm.
cases:
(i) for lengths of less than 75 m of surface course, binder course and concrete slabs;
(ii) where use of the rolling straight-edge or equivalent apparatus is impracticable;
(iii) for all lengths of subbase under concrete pavement slabs laid full thickness in one operation by machine
with surface compaction.
The maximum allowable difference between the surface and the underside of the straight-edge, when placed
parallel with, or at right angles to, the centre line of the road shall be:
for pavement surfaces 3 mm
for binder courses 6 mm
for subbases under concrete pavements (as in (iii) above) 10 mm
TABLE 7/2NI: (02/16) Maximum Permitted Number of Surface Irregularities
Surfaces of each lane of Surfaces of each lane of Surfaces of lay-bys, service
carriageway, each hard strip bituminous binder courses for areas, and associated
and each hard shoulder for carriageway, hard strip and bituminous binder courses for
each irregularity limit hard shoulder for each each irregularity limit
irregularity limit
Irregularity Limits 4 mm 7 mm 4 mm 7 mm 4 mm 7 mm
Length (m) 300 75 300 75 300 75 300 75 300 75 300 75
Category A* Roads 20 9 2 1 40 18 4 2 40 18 4 2
Category B* Roads 40 18 4 2 60 27 6 3 60 27 6 3
* The Category of each section of road is described in contract specific Appendix 7/1.
10 (02/16) Where any pavement area does not comply with the specification for regularity, surface tolerance,
thickness, macrotexture depth, material properties or compaction, the full extent of the area which does not comply
with the specification shall be made good and the surface of the pavement course shall be rectified in the manner
described below:

Volume 1 Series 700
(i) Unbound and Hydraulically bound materials

The top 75 mm shall be scarified, reshaped with material added or removed as necessary, and re-
compacted. The area treated shall be not less than 30 m long and 2 m wide or such area as necessary to
obtain compliance with the specification.
(ii) Cement bound subbases and bases
The method of correction will depend on the period which has elapsed between detection of the error
and the time of mixing of the material. If this is less than 4 hours, the surface shall be scarified to a
depth of not less than 50 mm, surplus material removed or freshly mixed material added as necessary,
and re-compacted in accordance with the specification. If the period is 4 hours or more the full depth
of the layer shall be removed from the pavement and replaced with material in accordance with the
specification. In either case the area treated shall be at least 5 m long and the full width of the paving
laid in one operation. If the Contractor proposes rectification within 7 days of laying he shall comply
with Clause 1048. Alternatively, for subbases under concrete pavements the Contractor may make up
low areas to a level within the tolerances of this Clause with a 1:4 cement and sand mortar or with an
AC4 fine surface course complying with Clause 914.
(iii) Bituminous bases
With coated macadam or asphalt bases, the full depth of the top layer as laid shall be removed and be
replaced with fresh material laid and compacted in accordance with the specification. Any area so treated
shall be at least 5 m long and the full width of the paving laid in one operation. Alternatively for low
areas in bituminous bases, the Contractor may make up the level with additional binder course material.
(iv) Surface courses, binder courses
These shall have the full depth of the course removed and replaced with fresh material laid and
compacted in accordance with the specification.
The area rectified shall be the full width of the paving laid in one operation, and at least 5 m long if
binder course or base on pavements without binder course, or 15 m if surface course.
Where the number of surface irregularities exceeds the limits in Table 7/2NI, the area to be rectified
shall be 300 m or 75 m long as appropriate and the full width of the lanes affected, or such lesser area as
necessary to make the number of surface irregularities conform with the limits.
Checking of the surface course for compliance with this Clause shall be carried out as soon as possible
after completion of the surfacing and remedial works completed before the road is opened to traffic.
Where the macrotexture depth requirement is not met for:
(a) a section 1000 m in lane length; or
(b) the full lane length of a section less than 1000 m long as the balance of a complete scheme; or
(c) the full lane length of a scheme less than 1000 m long;
then sufficient 50 m lengths shall be replaced, starting with that length having the least macrotexture
depth, until the average requirement for the section length is complied with.
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A minimum length of 50 m and the full lane width shall be removed and replaced either:
(a) to the full depth of the surface course; or
(b) to a depth of 20 mm when replaced by the repave method process in compliance with Clause 926.
Areas to be removed shall be delineated both longitudinally and transversely by saw cutting prior to
the material being removed. Joints shall be formed either by coating the exposed sawn face with hot
bitumen or heating by suitable heater. The heater shall raise the temperature of the full depth of the course
immediately before laying the new material to a figure within the range of minimum rolling temperature
and maximum temperature at any stage specified for the material and for a width of not less than 75 mm.

Volume 1 Series 700
(v) Concrete slabs

Concrete slabs shall be rectified by planing, grinding or bump cutting. Large depressions, which cannot
be dealt with in this way, shall be rectified by cutting out the surface and replacing by a thin bonded
surface repair complying with Clause 1032.
Retexturing of hardened concrete shall be carried out by sawing grooves in accordance with the
specification. Texturing of replaced surfaces shall be by brushing in accordance with the specification.
Where the slab cannot be rectified as above, the full depth of slab shall be removed and replaced with
a slab constructed in compliance with Clause 1033 to the extent required to obtain compliance with the
specification. Remedial works involving the placing of fresh concrete shall be completed in sufficient
time for the concrete strength to have developed as required in Clause 1048, before that section of
pavement is opened to traffic.
706NI (02/16) Excavation, Trimming and Reinstatement of Existing Surfaces

(02/16) General
1 (02/16) The Contractor shall not excavate pits, trenches or other openings in paved areas which have been
constructed as part of the permanent works in order to construct other parts of the works, including Statutory
Undertakers and other service works except with the prior approval of the Overseeing Organisation.
2 (02/16) Where excavation and trimming of existing paved areas and highways not constructed as part of
the permanent works are required in contract specific Appendix 7/2, they shall be carried out and reinstated in
compliance with this Clause and with any additional requirements described in contract specific Appendix 7/2.
Excavations shall be carried out to the dimensions described in contract specific Appendix 7/2, or, if not so
described, to the minimum dimensions, subject to sub-Clause 3 of this Clause, necessary to carry out the work.
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(02/16) Excavations
3 (02/16) Excavations in existing pavements and other paved areas, except those described in sub-Clause 4 of
this Clause, including surfacing, base and subbase, shall be cut to neat lines to dimensions at least 75 mm greater
on each side than the dimensions of any further excavation below formation level. Excavations in capping shall
be taken at least 75 mm outside the dimensions of any excavation below. Road surfacing of bituminous material
shall be cut back by sawing or planing to a further 75 mm on each side. Planing shall be carried out in accordance
with Clause 709. Concrete surfacing and concrete roadbases, except CBM, shall be cut back by sawing by at
least 300 mm on each side to the level of any reinforcement in reinforced slabs and to the full depth of the slab in
unreinforced slabs.
If excavations are required to inspect the condition of lower layers, each layer shall be excavated separately and
cleaned of debris to permit inspection.
4 (02/16) Concrete blocks, clay pavers and precast concrete flags, kerbs and channels shall be lifted without
cutting, to the nearest joint satisfying sub-Clause 3 of this Clause and carefully stored for re-use or dealt with as
described in contract specific Appendix 2/3. In situ kerbs and channels shall be broken out to at least 150 mm
beyond the excavation.
5 (02/16) All excavations shall be carried out in compliance with the specification and adequately supported at all
times. Support shall be withdrawn as backfilling proceeds.
(02/16) Backfilling
6 (02/16) Backfilling of excavations shall be carried out as quickly as possible after completion of the work for
which the excavation is required, to formation or sub-formation, in compliance with the appropriate Clauses in
Series 500, 600, 1200, 1300 and 1400 or as otherwise described in contract specific Appendix 7/2 using fill material
and compaction described therein.

Volume 1 Series 700
(02/16) Reinstatement of Paved Areas

7 (02/16) The layers of capping and pavement and other paved area materials shall be reinstated consecutively,
as soon as possible, in compliance with the appropriate Clauses in the 600, 700, 800, 900, 1000 and 1100 Series,
to match the thicknesses and constituents of the existing material or as otherwise described in contract specific
Appendix 7/2. They shall be laid and compacted in compliance with the appropriate Clauses in the above Series
within the tolerances given in Table 7/1.
To allow for settlement in backfill under concrete pavements, temporary repairs to the pavement shall be carried
out using bituminous materials. Alternatively, foamed concrete shall be used up to the base of the slab and the slab
reinstated as soon as possible. The reinstatement of the concrete slab shall be carried out as described in contract
8 (02/16) Block and flag paving and precast and in situ kerbs and channels shall be reinstated in compliance with
Series 1100 to match the existing construction.
9 (02/16) Where settlement of the reinstatement occurs, the surface level shall be brought to correct levels and
surface regularity. Where an existing pavement has been trimmed for a new pavement to abut it, regulating layers
for changes in crossfall or level shall comply with the requirements for the appropriate subbase, base or surface
layer.
10 (02/16) Immediately before bituminous layers are reinstated, the edges of the existing material shall be cleaned
of all loose material and be coated with an appropriate hot bituminous binder or equivalent treatment.
11 (10/22) Where joints in concrete slabs are affected by the excavation they shall be reinstated by cutting back to
at least 0.5 m on each side of a transverse joint and forming an expansion joint on one side of the excavation and a
contraction joint on the other and provide longitudinal joints where necessary in the same line before reinstatement
in compliance with Series 1000 to match the existing construction.
12 (10/22) The transverse regularity of the pavement surface shall be assessed for compliance with the
requirements of sub-Clause 702.8NI at 3 m intervals using a straight-edge 3 metres long perpendicular to the centre
line of the road.
13 (10/22) The longitudinal regularity of the pavement surface shall be assessed for compliance with the
requirements of sub-Clause 702.9NI at 3 m intervals using a straight-edge 3 metres long parallel to the centre line
of the road, including straddling the existing surface and new surface at start and end joints.
(02/16) Reinstatement of Unpaved Areas and Other Surfaced Highways
14 (10/22) Where the excavation affects verges, grassed areas, footpaths and bridleways they shall be reinstated to
match the existing surface, after backfilling in compliance with sub-Clause 6 of this Clause to a depth of 150 mm
below the existing surface. The reinstatement shall be completed by topsoil and seeding or turfing in compliance
with the specification, in both cases re-using any topsoil or turves cut and stored for re-use, or, when surfaced, with
material matching the existing foundation and surface.
15 (10/22) Levels between existing and newly constructed footpaths, footways, verges and bridleways shall be
matched by removing the minimum area of existing material necessary, to enable the total thickness of surfacing
material to be laid abutting the existing surface. Where settlement of the reinstatement occurs the levels shall be
brought up to existing levels.
Surfaces may be left proud of the adjacent existing surfaces by an amount not exceeding 50 mm, adequately
ramped to avoid sharp changes in level, to cater for subsequent settlement.
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Amendment – October 2022 N5

Volume 1 Series 700
(02/16) Junctions Between New Pavement Construction and Existing Pavement or Other Paved Areas
16 (10/22) Where new pavement construction abuts an existing bituminous pavement which has to be reduced in
level or overlaid to match alignment and levels, the existing surface shall be trimmed by the minimum amount of
cold-milling (planing) to a depth which will allow the specified thickness of new construction to be laid, the edge
being trimmed and treated in compliance with this Clause. Where the difference in level makes it necessary, a
regulating course as described in contract specific Appendix 7/1 and specified in Clause 907 shall be provided. The
locations to be trimmed are given in contract specific Appendix 7/2.
17 (10/22) Junctions between concrete pavements and between concrete and bituminous pavements shall be
constructed as described in contract specific Appendix 7/2. Junctions in porous asphalt shall comply also with
Clause 938. Junctions between porous asphalt surfacing and other pavement surfaces shall be constructed as
(02/16) Compressed Air
18 (10/22) When compressed air is used to clean dust, dirt and debris from prepared faces of existing concrete or
bituminous pavements which are otherwise ready for reinstatement, only oil-free compressed air shall be used and
this shall be at a pressure of not less than 0.5 N/mm2.
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Amendment – October 2022 N6F

SERIES 800
ROAD PAVEMENTS —
UNBOUND, CEMENT AND
OTHER HYDRAULICALLY
BOUND MIXTURES
Contents
801 (02/16) General Requirements for 821 (11/21) Cement Bound Granular
Unbound Mixtures 3 Mixtures A (CBGM A) 26
802 (02/16) Transport, Laying, Compaction 822 (11/21) Cement Bound Granular
and Trafficking of Unbound Mixtures 7 Mixtures B (CBGM B) 27
803 (02/16) Type 1 Unbound Mixtures 11 823 (11/21) Cement Bound Granular
Mixtures C (CBGM C) 27
804 (02/16) Type 2 Unbound Mixtures 13
824 to 829 (02/16) Not Used 27
805 (02/16) Type 3 (open graded) Unbound
Mixtures 14 (11/21) Fly Ash Bound Mixture 1
830
(FABM 1) and Hydraulic Road Binder
806 (02/16) Category B (close graded)
Bound Mixture 1 (HRBBM1) 27
Unbound Mixtures 15
(11/21) Slag Bound Mixture B2 (SBM B2),
831
807 (02/16) Type 4 (asphalt arisings)
Fly Ash Bound Mixture 2 (FABM 2) and
Unbound Mixtures 16 Hydraulic Road Binder Bound Mixture 2
808 & 809 (02/16) Not Used17 (HRBBM 2) 28
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(02/16) Cement and Other Hydraulically Bound Mixtures (11/21) Slag Bound Mixture B3 (SBM B3),
832
Fly Ash Bound Mixture 3 (FABM 3) and
810 (02/16) General Requirements for Cement Hydraulic Road Binder Bound Mixture 3
and Other Hydraulically Bound Mixtures 17 (HRBBM 3) 28
811 (02/16) Binder Constituents 19 833 (02/16) Not Used 29
812 (02/16) Storage of Constituents 20 834 (11/21) Fly Ash Bound Mixture 5
813 (02/16) General Requirements for (FABM 5) 29
Production and Layer Construction 20 835 (11/21) Slag Bound Mixtures B1-1,
814 (02/16) Mix-in-Plant Method of B1-2, B1-3 and B1-4 (SBM B1) 29
Construction Using Batching by Mass 23 836 to 839 (02/16) Not Used 29
815 (02/16) Mix-in-Plant Method of (11/21) Soil Treated by Cement (SC),
840
Construction Using Volume Batching 23 Soil Treated by Slag (SS), Soil Treated
816 (02/16) Mix-in-Place Method of by Fly Ash (SFA) and Soil Treated by
Construction 24 Hydraulic Road Binder (SHRB) 29
817 (02/16) Method Statement and 841 to 869 (02/16) Not Used 31
Demonstration Area 24 870 (02/16) Testing, Control and Checking
818 (02/16) Induced Cracking of HBM 25 of HBM 31
819 (02/16) Not Used 25 871 (02/16) Determination of the Coefficient of

Linear Thermal Expansion 35
820 (02/16) Aggregates 25
872 to 879 (02/16) Not Used 36
Amendment – November 2021 1

Clause Title Page

880 (02/16) Laboratory Mixture Design
Procedure 36
881 (03/20) Laboratory Stiffness Testing 37
882 (03/20) Determination of the Construction
Subgrade Surface Modulus 37
883 (03/20) Demonstration Area for
Performance Foundation Designs 38
884 (03/20) Permanent Works Performance
Assessment for Performance Foundations 40
885 (03/20) Top of Foundation Performance
Assessment 41
886 (03/20) Wheelpath Deformation
Measurement 42F
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Volume 1 Series 800
Specification for Highway Works Road Pavements – Unbound, Cement and
Other Hydraulically Bound Mixtures
ROAD PAVEMENTS – UNBOUND, CEMENT AND

OTHER HYDRAULICALLY BOUND MIXTURES
801 (02/16) General Requirements for Unbound Mixtures

(11/21) Unbound Mixtures for Subbase
the subject matter in its title it shall be read in conjunction with the general requirements in Series 000 and 100 and
2 (11/21) Unbound mixtures shall be made and constructed to conform to BS EN 13285, the requirement
categories in Table 8/1 and Clauses 802 to 807.
TABLE 8/1: (11/21) Mixture and Grading Requirement Categories for Unbound Mixtures
Unbound mixture Type 1 Type 2 Type 3 Category B Type 4

(open graded) (close graded) (asphalt arisings)
Clause 803 804 805 806 807

Standard BS EN 13285 Categories for unbound mixture properties
Mixture requirement
category
1) Designation 0/31,5 or 0/20 0/31,5 0/40 0/31,5 0/31,5
2) Maximum fines UF9 or UF12 UF9 UF5 UF9 UF9
3) Oversize OC75 OC75 OC80 OC80 OC75
Grading requirement
category GP GE GO GB GP
1) Overall grading
3 (11/21) The permitted alternatives for each part of the permanent works shall be as described in contract specific
Appendix 7/1.
4 (11/21) The properties of aggregates used in unbound mixtures shall comply with the selected requirements of
BS EN 13242 listed in Table 8/2.
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3
Volume 1 Series 800
TABLE 8/2: (11/21) Requirements for Aggregates Used in Unbound Mixtures
Unbound mixture Type 1 Type 2 Type 3 Category B Type 4

(open graded) (close graded) (asphalt
arisings)
Clause 803 804 805 806 807
Standard BS EN 13285 Categories for unbound mixture properties
Crushed, or broken and totally
rounded particles – crushed
rock, crushed manufactured C90/3 C90/3 C90/3 C90/3
and crushed recycled
aggregates (see NOTE 1)
Crushed, or broken and totally CNR

rounded particles - crushed C50/10
(no Not permitted Not permitted
gravel – see NOTE 2
requirement)
Resistance to fragmentation –
Los Angeles test LA LA LA LA
50 50 30 50
Resistance to wear – micro- MDENR (no requirement).

Deval test The supplier shall state the value for the aggregate used.
Resistance to freezing and
thawing – magnesium sulfate MS35
soundness
Water absorption WA24NR (no requirement).
The supplier shall state the value for the aggregate used.
Volume stability of blast Free from dicalcium silicate and iron disintegration.
furnace slags
Volume stability of steel (BOF
V5 V5 Not permitted V5
and EAF) slags
All other BS EN 13242
Category NR (no requirement).
aggregate requirements
NOTES:
1. BS EN 13242 assumes that crushed rock aggregates comply with category C90/3 without further testing.
2. Where permitted by contract specific Appendix 7/1.
5 (11/21) Where recycled coarse aggregate or recycled concrete aggregate is used in unbound mixtures complying
with Clauses 802 to 807 as appropriate, it shall have been tested in accordance with Clause 710.
6 (11/21) Recycled coarse aggregate and recycled concrete aggregate used in unbound mixtures in accordance
with Clauses 803, 804 and 807 shall also comply with the requirements of Table 8/3.
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Volume 1 Series 800
TABLE 8/3 (11/21) Requirements for Recycled Coarse Aggregate and Recycled Concrete Aggregate Used in
Type 1, Type 2 and Type 4 Unbound Mixtures
Unbound Mixture Type 1 Type 2 Type 4 (asphalt

arisings)
Clause 803 804 807
Component Identified by Clause 710 Maximum Permitted Content (% by mass)
Asphalt (Class Ra) 50 50 100
Glass (Class Rg) 25
Other materials (Class X), including wood,
1
plastic and metal
Floating Materials ≤ 5 cm3/kg
7 (11/21) The unbound mixture shall satisfy the minimum surface modulus requirement of contract specific
Appendix 7/1 when tested in accordance with Procedure A in Clause 885.
8 (11/21) The mixture shall be tested at the density and moisture content likely to develop in equilibrium field
conditions which will be taken as being the density relating to the uniform air voids content of 5% and the value of
optimum water content declared when tested as required by BS EN 13285.
(11/21) Limitations to Use
(11/21) Water-soluble sulphate

9 (11/21) Unbound mixtures placed within 500 mm, or any other distances described in contract specific Appendix
permanent works shall conform to requirements A and B below:
A Mixtures shall conform to the following two criteria:
(i) Water-soluble sulfate (WS) content determined in accordance with BS EN 1744-1 clause
10 not to exceed 1500 mg of sulfate (as SO4) per litre;
(ii) Total sulfur (TS) content determined in accordance with BS EN 1744-1 clause 11
expressed as (S) not to exceed 1% for aggregates other than air cooled blast furnace slag or
2% for air cooled blast furnace slag.
B Mixtures shall conform to at least one of the following two options:
(i) When described in accordance with BS EN 932-3 and BS EN 13242 Annex A, limestone,
chalk, dolomite, blast furnace slag, steel slag or crushed concrete are predominant; or
(ii) The sulfide content of the mixture determined in accordance with BS EN 1744-1 clause 13
is less than 0.5% (as SO4).
10 (11/21) When determining WS, TS or sulfide content, at least five samples of each material shall be tested. The
mean of the highest two values to be used for comparison with the limiting values. This also applies if six to nine
results are available. If ten or more results are available, the mean of the highest 20% of the results to be used for
comparison with the limiting values. The pH of the mixture shall be reported.
11 (11/21) Unbound mixtures placed within 500mm, or any other distances described in contract specific
Appendix 7/1, of metallic structural elements forming part of the permanent works shall conform to requirements
C and D below.

5
Volume 1 Series 800
C Mixtures shall conform to the following two criteria:

(i) Water-soluble sulfate (WS) content determined in accordance with BS EN 1744-1 clause
10 to not exceed 300 mg of sulfate (as SO4) per litre;
(ii) Total sulfur (TS) content determined in accordance with BS EN 1744-1 clause 11
expressed as (S) to not exceed 1% for aggregates other than air cooled blast furnace slag or
2% for air cooled blast furnace slag.
D Mixtures shall conform to at least one of the following two options:
(i) When described in accordance with BS EN 932-3 and BS EN 13242 Annex A, limestone,
chalk, dolomite, blast furnace slag, steel slag or crushed concrete are predominant;
or
(ii) The sulfide content of the mixture determined in accordance with BS EN 1744-1 clause 13
is less than 0.06% (as SO4).
12 (11/21) When determining WS, TS or sulfide content, at least five samples of each material shall be tested. The
mean of the highest two values to be used for comparison with the limiting values. This also applies if six to nine
results are available. If ten or more results are available, the mean of the highest 20% of the results to be used for
comparison with the limiting values. The pH of the mixture to be reported.
13 (11/21) The requirements in (i) and (ii) above shall not apply to metallic items protected by concrete and
ancillary metallic items such as the tops of chambers and gullies.
(11/21) Frost Heave
14 (11/21) Subject to the tolerances given in Table 7/1 and unless otherwise stated in contract specific Appendix
7/1, material shall not be frost susceptible if it is used within 450 mm of the designed final surface of a road or
paved central reserve, or 350 mm if the Mean Annual Frost Index (MAFI) of the site is less than 50.
15 (11/21) Material shall be classified as non-frost-susceptible if the mean heave is 15 mm or less, when tested in
accordance with BS 812-124. Comparator specimens in accordance with Annex B of BS 812-124 will be used.
(11/21) Aluminium Particles
16 (11/21) Mixtures containing manufactured aggregates, other than air-cooled blast furnace slag and steel slag,
covered with less than 150 mm asphalt shall meet the requirements of Table 8/4.
TABLE 8/4 (11/21) Requirements for mixtures containing manufactured aggregates
Constituent Requirement Test procedure

Aluminium particles None retained on 14 mm sieve Clause 801.17 – 18
17 (11/21) The following test procedure shall be followed.
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(i) Obtain test portion in accordance with BS EN 932-1 1997, with a minimum mass of 10 kg.
(ii) Pass the test portion over a 14 mm test sieve conforming to BS EN 933-2 1999, discard particles passing
the 14 mm sieve.
(iii) Spread particles retained on the 14 mm sieve onto a clean flat surface.
(iv) Separate by hand any aluminium particles and agglomerated particles that contain a portion of
aluminium.
(a) Discard non-aluminium particles and agglomerated particles that do not contain a portion
of aluminium.
(b) Place any aluminium particles in a tray.

Volume 1 Series 800
(v) Separate the aluminium fraction from any agglomerated particles.

(a) Add any non-separated agglomerated particles to the tray.
(b) Discard any resulting non-aluminium fraction.
(c) Re-pass any resulting aluminium fraction over the 14 mm sieve and discard particles
passing the 14 mm sieve.
(d) Add any resulting aluminium fraction retained on the 14 mm sieve to the tray.
(vi) The particles in the tray are classified as aluminium particles retained on 14 mm sieve.
18 (11/21) The test report shall include the following information:
(i) reference to this Clause;
(ii) name and location of the sample source;
(iii) date of sampling;
(iv) mass of test portion (kg);
(v) date of test;
(vi) number of aluminium particles retained on 14 mm sieve;
(vii) description of any retained particles.
802 (02/16) Transport, Laying, Compaction and Trafficking of Unbound Mixtures

(02/16) Transporting
1 (02/16) Unbound mixtures shall be protected from drying out and segregation both during transit to the point
where it is to be laid and whilst awaiting tipping.
(02/16) Laying
2 (11/21) Unbound mixtures in a frozen condition shall not be incorporated in the works but may be used, if
acceptable, when thawed.
3 (11/21) Unbound mixtures shall not be laid on any surface which is frozen or covered with ice.
4 (11/21) All unbound mixtures shall be placed and spread evenly.
5 (11/21) Spreading shall be undertaken either concurrently with placing or without delay.
6 (11/21) Unbound mixtures shall be spread using a paving machine or a suitable spreader box and operated with
a mechanism which levels off the material to an even depth.
7 (11/21) Except where otherwise stated in contract specific Appendix 7/1, material up to 225 mm compacted
thickness shall be spread in one layer so that after compaction the total thickness is as specified.
8 (11/21) Material of compacted thickness greater than 225 mm shall be laid in two or more layers and the
minimum compacted thickness of any such layer to be 110 mm.
9 (11/21) Where the layers of unbound mixtures are of unequal thickness, the lowest layer shall be the thickest
layer.
(02/16) Compaction
10 (11/21) Compaction shall be completed after the mixture has been spread and in accordance with the
requirements for the individual mixtures.

7
Volume 1 Series 800
11 (11/21) Full compaction shall be obtained over the full area including in the vicinity of both longitudinal and
transverse joints.
12 (11/21) Compaction of unbound mixtures shall be carried out by a method specified in Table 8/5, unless it is
demonstrated at site trials that a state of compaction achieved by an alternative method is equivalent to or better
than that using the specified method.
13 (11/21) The surface of any layer of material shall on completion of compaction and immediately before
overlaying, be well closed, free from movement under construction plant and from ridges, cracks, loose material,
pot holes, ruts or other defects.
14 (11/21) All loose, segregated or otherwise defective areas shall be removed to the full thickness of the layer, and
new material laid and compacted.
15 (11/21) For the purposes of Table 8/5 the following shall apply:
(i) The number of passes is the number of times that each point on the surface of the layer being compacted
is traversed by the item of compaction plant in its operating mode (or struck, in the case of power
rammers).
(ii) The compaction plant in Table 8/5 is categorised in terms of static mass. The mass per metre width of
roll is the total mass on the roll divided by the total roll width. Where a smooth-wheeled roller has more
than one axle, the category of the machine is determined on the basis of the axle giving the highest value
of mass per metre width.
(iii) For pneumatic-tyred rollers the mass per wheel is the total mass of the roller divided by the number of
wheels. In assessing the number of passes of pneumatic-tyred rollers the effective width is the sum of
the widths of the individual wheel tracks together with the sum of the spacings between the wheel tracks
provided that each spacing does not exceed 230 mm. Where the spacings exceed 230 mm the effective
width is the sum of the widths of the individual wheel tracks only.
(iv) Vibratory rollers are self-propelled or towed smooth-wheeled rollers having means of applying
mechanical vibration to one or more rolls:
(a) The requirements for vibratory rollers are based on the use of the lowest gear on a self-
propelled machine with mechanical transmission and a speed of 1.5-2.5 km/h for a towed
machine or a self-propelled machine with hydrostatic transmission. If higher gears or
speeds are used an increased number of passes need to be provided in proportion to the
increase in speed of travel.
(b) Where the mechanical vibration is applied to two rolls in tandem, the minimum number of
passes is half the number given in Table 8/5 for the appropriate mass per metre width of
one vibrating roll but if one roll differs in mass per metre width from the other, the number
of passes to be calculated as for the roll with the smaller value. Alternatively the minimum
number of passes may be determined by treating the machine as having a single vibrating
roll with a mass per metre width equal to that of the roll with the higher value.
(c) Vibratory rollers operating without vibration are to be classified as smooth-wheeled rollers.
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(d) Vibratory rollers are to be operated with their vibratory mechanism operating at the
frequency of vibration recommended by the manufacturer. All such rollers to be equipped,
or provided with devices indicating the frequency at which the mechanism is operating
and the speed of travel. Both devices to be capable of being safely read by an inspector
alongside the machine.

Volume 1 Series 800
(v) Vibrating-plate compactors are machines having a base-plate to which is attached a source of vibration
consisting of one or two eccentrically-weighted shafts:
(a) The mass per square metre of base-plate of a vibrating-plate compactor is calculated by
dividing the total mass of the machine in its working condition by its area in contact with
compacted material.
(b) Vibrating-plate compactors re to be operated at the frequency of vibration recommended
by the manufacturer. They will normally be operated at travelling speeds of less than
1 km/h but if higher speeds are necessary, the number of passes are tol be increased in
proportion to the increase in speed of travel.
(vi) Vibro-tampers are machines in which an engine driven reciprocating mechanism acts on a spring system,
through which oscillations are set up in a base-plate.
(vii) Power rammers are machines which are actuated by explosions in an internal combustion cylinder; each
explosion being controlled manually by the operator. One pass of a power rammer is considered to have
been made when the compacting shoe has made one strike on the area in question.
(viii) Combinations of different types of plant or different categories of the same plant will be permitted;
in which case the number of passes for each is to be such proportion of the appropriate number in
Table 3.15 (8/5) as will together produce the same total compactive effort as any one operated singly.
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Volume 1 Series 800
TABLE 8/5: (11/21) Compaction Requirements for Unbound Mixtures
Number of passes for layers not exceeding the

Type of Compaction Plant Category following compacted thicknesses:
110 mm 150 mm 225 mm
Smooth-wheeled roller (or Mass per metre width of roll:
vibratory roller operating over 2700 kg up to 5400 kg 16 unsuitable unsuitable
without vibration) over 5400 g 8 16 unsuitable
Mass per wheel:
over 4000 kg up to 6000 kg 12 unsuitable unsuitable
Pneumatic-tyred roller over 6000 kg up to 8000 kg 12 unsuitable unsuitable
over 8000 kg up to 12000 kg 10 16 unsuitable
over 12000 kg 8 12 unsuitable
Mass per metre width of vibrating
roll:
over 700 kg up to 1300 kg 16 unsuitable unsuitable
over 1800 kg up to 2300 kg 4 6 10
Vibratory roller
over 2300 kg up to 2900 kg 3 5 9
over 2900 kg up to 3600 kg 3 5 8
over 3600 kg up to 4300 kg 2 4 7
over 4300 kg up to 5000 kg 2 4 6
over 5000 kg 2 3 5
Mass per square metre of base plate:
over 1400 kg/m² up to 1800 kg/m² 8 unsuitable unsuitable
Vibrating-plate compactor
over 1800 kg/m² up to 2100 kg/m² 5 8 unsuitable
over 2100 kg/m² 3 6 10
Mass:
Vibro-tamper
over 65 kg up to 75 kg 3 6 10
over 75 kg 2 4 8
Mass:
Power rammer 100 kg-500 kg 5 8 unsuitable
over 500 kg 5 12 12
(02/16) Use of Surfaces by Construction Plant and Other Traffic

16 (11/21) Construction plant and other traffic used on pavements under construction shall be suitable in relation to
the material, condition and thickness of the courses it traverses so that damage is not caused to the subgrade or the
pavement courses already constructed.
17 (11/21) The wheels or tracks of plant moving over the various pavement courses shall be kept free from
deleterious materials.
18 (11/21) Where it is proposed to use the unbound mixture layers for construction plant these layers shall be
improved to accommodate the method of construction and the type of plant and vehicles which are to be used, in
order to avoid damage to the laid layer(s), any capping and the subgrade.
19 (11/21) Any permanent thickening shall be across the whole width of the pavement.
20 (11/21) Temporary thickening shall not impede drainage of any layer or the subgrade.

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Volume 1 Series 800
(02/16) Trafficking Trial
21 (11/21) When required by contract specific Appendix 7/1, a Trafficking Trial shall be undertaken incorporating
the unbound mixture proposed for use in the permanent works.
22 (11/21) A trial area shall be constructed, trafficked and assessed in accordance with the procedure described in
sub-Clauses 25 to 29 of this Clause.
23 (11/21) The mean vertical deformation after 1000 equivalent standard axles shall be less than 30 mm when
measured in accordance with the procedure stated in sub-Clause 31 to 33 of this Clause.
24 (11/21) Proposals for trafficking trials shall be submitted to the Overseeing Organisation for review and
acceptance five days in advance of construction.
(02/16) Trial Procedure
25 (11/21) The trial area shall be located on a formation prepared in accordance with the specification. The trial
area may be located so that it can be incorporated within the permanent works if the resistance to wheel track
rutting is demonstrated to comply with sub-Clause 19 of this Clause.
26 (11/21) The trial area shall be at least 60 m long, and of sufficient width that when trafficked, the wheel paths of
the test vehicle are at least 1 m from either edge of the top of the unbound mixture layer.
27 (11/21) The unbound mixture layer shall be compacted to the thickness specified in contract specific Appendix
7/1.
28 (11/21) The formation shall extend for a further 1 m either side of the unbound mixture layer.
29 (11/21) A sufficient run off/run on area shall be constructed at each end of the trial area of the same width, and
compacted to the same level, as the trial area, to ensure correct tracking by the test vehicle and minimise dynamic
effects of the vehicle bouncing on its springs. Suitable guidance is to be given to assist the driver in maintaining
the same track in each pass and to achieve channelled trafficking. Examples of suitable guides would be a string or
painted line.
(02/16) Mixtures
30 (11/21) The unbound mixture used in the trial shall be transported, laid and compacted using the equipment
proposed for use in the works.
31 (11/21) Maximum vertical deformation shall be measured in both wheel tracks using optical or laser levels at
pre-determined monitoring points on five transverse lines spaced equally along the length of the trial bay.
32 (11/21) The transverse lines at the ends of the trial area shall be at least 5 m from the run off/run on areas.
33 (11/21) The average deformation of the two wheel tracks after 1000 standard axles shall be recorded.
(02/16) Reporting and Acceptance of Trafficking Trial Area
34 (11/21) A report on the Trafficking Trial, stating how the use of the unbound mixture was validated shall be
provided.
35 (11/21) The main construction of the permanent works shall not start until the Trafficking Trial area has been
accepted by the Overseeing Organisation.
803 (11/21) Type 1 Unbound Mixtures

1 (11/21) Type 1 unbound mixture shall be made from crushed rock, crushed slag, crushed concrete, recycled
aggregates, manufactured aggregates, or well burnt non-plastic shale and may contain up to 10% by mass of natural
sand that passes the 4 mm test sieve. Where permitted by contract specific Appendix 7/1, crushed gravel complying
with sub-Clause 803.7 may be used.

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Volume 1 Series 800
2 (11/21) The mixture shall meet the requirements of BS EN 13285 and Table 8/1. The grading requirements for
the mixture are summarised in Tables 8/6a or 8/6b. Table 8/6b shall only be used for trench reinstatements and
narrow widenings less than 1 m.
Table 8/6a (11/21) Summary Grading Requirements for Type 1 and Type 4 Unbound Mixtures
Percentage by mass passing

Sieve size, mm Tolerance on the
Overall grading Supplier declared
supplier declared
range value grading range
value
63 100 - -
31.5 75 – 99 - -
16 43 – 81 54 – 72 ±15
8 23 – 66 33 – 52 ±15
4 12 – 53 21 – 38 ±15
2 6 – 42 14 – 27 ±13
1 3 – 32 9 – 20 ±10
0.063 0–9 - -
Grading of individual batches – differences in values passing selected sieves
Retained sieve size, Passing sieve size, Percentage by mass passing
mm mm Not less than Not more than
8 16 7 30
4 8 7 30
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Volume 1 Series 800
Table 8/6b (11/21) Summary Grading Requirements for Type 1 F Unbound Mixtures (0/20)

supplier declared
value
40 100 - -
20 75 – 99 - -
10 43 – 81 54 – 72 ±15
4 23 – 66 33 – 52 ±15
2 12 – 53 21 – 38 ±15
1 6 – 42 14 – 27 ±13
0.5 3 – 32 9 – 20 ±10
0.063 0 – 12 - -
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4 10 7 30
2 4 7 30
3 (11/21) The properties of aggregates used in the mixture shall be in accordance with BS EN 13242 and the
requirements of Table 8/2.
4 (11/21) The size fraction of the unbound mixture passing the 0.425 mm size test sieve shall be non-plastic as
defined by BS 1377-2 and tested in compliance therewith.
5 (11/21) Mixtures containing recycled coarse aggregate, or recycled concrete aggregate, shall meet the
requirements of sub-Clause 801.5 and 801.6.
6 (11/21) The mixture shall be transported, laid and compacted without drying out or segregation.
7 (11/21) All mixtures shall meet the minimum surface modulus requirement in sub-Clause 801.7.
804 (02/16) Type 2 Unbound Mixtures

1 (11/21) Type 2 unbound mixture shall be made from natural sands, gravels, crushed rock, crushed slag, crushed
concrete, recycled aggregates, manufactured aggregates or well burnt non-plastic shale.
2 (11/21) The mixture shall comply with BS EN 13285 and the requirements of Table 8/1. The grading
requirements for the mixture are summarised in Table 8/7.

Volume 1 Series 800
TABLE 8/7 (11/21) Summary Grading Requirements for Type 2 Unbound Mixtures
Sieve size, mm
Supplier declared value Tolerance on the supplier
Overall grading range
grading range declared value
63 100
31.5 75 – 99
16 50 – 90
8 30 – 75 No requirement No requirement
4 15 – 60
1 0 – 35
0.063 0–9
Retained sieve size, mm Passing sieve size, mm
Not less than Not more than
8 16 5 35
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4 8 5 35
3 (02/16) The properties of aggregates used in the mixture shall be in accordance with BS EN 13242 and
the requirements of Table 8/2.
4 (02/16) The size fraction of the unbound mixture passing the 0.425 mm size test sieve when tested in
compliance with BS 1377-2 shall have a plasticity index of less than 6.
5 (11/21) Where the mixture contains recycled coarse aggregate or recycled concrete aggregate, it shall
comply with sub-Clause 801.5 and 801.6.
6 (11/21) All mixtures shall meet the minimum surface modulus requirement in sub-Clause 801.7.
7 (02/16) The mixture shall be transported, laid and compacted without drying out or segregation, at a moisture
content within the range 1% above to 2% below the declared value of optimum water content when tested as
required by BS EN 13285.
805 (02/16) Type 3 (open graded) Unbound Mixtures

1 (11/21) Type 3 (open graded) unbound mixture shall be made from crushed rock, crushed blast furnace slag,
manufactured aggregates or recycled concrete aggregate. When tested in accordance with Clause 710, recycled
concrete aggregate used in Type 3 (open graded) unbound mixtures shall not contain more than 5% asphalt
(Class Ra) and not more than 1% other materials (Class X).

Volume 1 Series 800
TABLE 8/8: (11/21) Summary Grading Requirements for Type 3 (open graded) Unbound Mixtures
Sieve size, mm Supplier declared value Tolerance on the supplier

Overall grading range
grading range declared value
80 100 - -
40 80 – 99 - -
20 50 – 78 58 – 70 ±8
10 31 – 60 39 – 51 ±8
4 18 – 46 26 – 38 ±8
2 10 – 35 17 – 28 ±7
1 6 – 26 11 – 21 ±5
0.500 0 – 20 5 – 15 ±5
0.063 0–5 - -
10 20 10 25
4 10 10 25
2 4 7 20
1 2 4 15
806 (02/16) Category B (close graded) Unbound Mixtures

1 (11/21) Category B (close graded) unbound mixture shall be made from crushed rock, crushed blast furnace
slag, manufactured aggregates or recycled concrete aggregate. When tested in accordance with Clause 710,
recycled concrete aggregate used in Category B (close graded) unbound mixtures shall not contain more than 5%
asphalt (Class Ra) and not more than 1% other materials (Class X).

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Volume 1 Series 800
Table 8/9 (11/21) Summary Grading Requirements for Category B (close graded) Unbound Mixtures

supplier declared
value
80 100 - -
40 80 – 99 - -
20 55 – 85 63 – 77 ±8
10 35 – 68 43 – 60 ±8
4 22 – 60 30 – 52 ±8
2 16 – 47 23 – 40 ±7
1 9 – 40 14 – 35 ±5
0.5 5 – 35 10 – 30 ±5
0.063 0–9 - -
10 16 10 25
4 8 10 25
2 4 7 20
1 2 4 15
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807 (02/16) Type 4 (asphalt arisings) Unbound Mixtures
1 (11/21) Type 4 unbound mixture shall be made from recycled aggregates containing asphalt arisings, and may
contain crushed rock, crushed slag, manufactured aggregates, crushed concrete or well burnt non-plastic shale and
up to 10% by mass of natural sand that passes the 4 mm size test sieve.
2 (02/16) Asphalt arisings shall be either asphalt road planings or granulated asphalt, but excluding materials
contaminated with tar or tar-bitumen binders. Asphalt planings are defined as materials derived from the asphalt
layers of the pavement using a mobile machine fitted with milling cutters. Granulated asphalt is defined as asphalt
bound material recycled from roads under reconstruction or surplus asphalt material destined for bound pavement
layers, but unused, which has been granulated.
3 (11/21) Type 4 unbound mixture shall have an asphalt (Class Ra) content greater than 50% when tested in
4 (11/21) The recovered bitumen content of the asphalt shall be not more than 10% when tested in accordance
with BS EN 12697-1.
5 (11/21) Type 4 unbound mixture shall comply with BS EN 13285 and the requirements of Table 8/1. The
grading requirements for the mixture are summarised in 8/6a.

Volume 1 Series 800
8 (11/21) Where the mixture contains recycled coarse aggregate or recycled concrete aggregate, it shall comply
with sub-Clause 801.5 and 801.6.
9 (11/21) The mixture shall be transported, laid and compacted without drying out or segregation, at a moisture
content within the range 1% above to 2% below the declared value of optimum water content when tested as
required by BS EN 13285. The moisture content to be determined by oven drying at a reduced temperature setting
of 45ºC to 50ºC.
10 (11/21) Where required by contract specific Appendix 7/1, Type 4 unbound mixtures shall be assessed using a
trafficking trial complying with sub-Clause 802.21.
808 and 809 (02/16) Not Used
(02/16) Cement and Other Hydraulically Bound Mixtures
810 (02/16) General Requirements for Cement and Other Hydraulically Bound Mixtures
1 (11/21) Cement and other hydraulically bound mixtures (HBM) shall be produced, constructed and tested in
accordance with the following Clauses.
2 (11/21) The permitted alternatives for each part of the works shall be as described in contract specific
Appendix 7/1.
3 (11/21) Attributes shall be deemed to have a “No requirement” classification unless stated otherwise.
4 (11/21) The terms listed below in Table 8/10 shall apply to the HBM Clauses of this specification.
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Volume 1 Series 800
TABLE 8/10 (11/21) Hydraulically Bound Mixture Terminology
ASS air cooled steel slag

CBGM cement bound granular mixture
CBR Californian Bearing Ratio
CFA cement treated fly ash
E modulus of elasticity
FA fly ash (also known as ‘pulverized fuel ash’)
FABGM fly ash bound granular mixture
Gvxx volumetric expansion category
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GBS granulated blast furnace slag
GGBS ground granulated blast furnace slag
HBM hydraulically bound mixture
HBGM hydraulically bound granular mixture
HRB hydraulic road binder (factory blended hydraulic binder for road use)
HRBBGM hydraulic road binder bound granular mixture
HSS hydraulically stabilised soils
IBI immediate bearing index
Immxx immersion category
IPIxx immediate bearing index category
LA Los Angeles coefficient
LFA lime treated fly ash
MCV moisture condition value
NR no requirement
OWC optimum water content
PTR pneumatic tyred roller
Pulvxx pulverisation category
Rc compressive strength
Rt direct tensile strength
Rit indirect tensile strength
Rt’E method of performance classification based on the combination Rt and E. Classes of Rt,E are
designated T0 to T5, in BS EN 14227, where T designates Rt,E and the number indicates the
performance class
SBGM slag bound granular mixture
t time (hours) at constant temperature in defining maturity for calculating the construction period
TºC ambient air temperature in defining maturity for calculating construction period
Wxx water content category
5 (11/21) HBM shall be tested in accordance with Clause 870 and the test methods specified in the following
Clauses.
6 (11/21) Before work commences, a method statement shall be submitted that includes:
(i) the information detailed in the ‘Designation and Description’ clause of the relevant BS EN Standard for
the specified HBM, confirming compliance with the requirements of this Series and contract specific
Appendix 7/1;
(ii) target proportions of constituents, including water;

Volume 1 Series 800
(iii) mixture design details and results, in accordance with Clause 880;
(iv) method statement for the demonstration area and the main works, in accordance with Clause 817.
7 (11/21) The coefficient of linear expansion of the mixture shall be determined in accordance with Clause 871.
811 (02/16) Binder Constituents

1 (11/21) Binder constituents, other than lime, shall comply with BS EN 14227.
2 (11/21) Lime shall comply with BS EN 459-1
3 (11/21) Quicklime shall have a grading that complies with BS EN 459-1 – Category P2.
4 (11/21) The minimum binder content shall be those given in Table 8/11.
TABLE 8/11 (11/21) Minimum Binder or Binder Constituent Additions for HBM
Binder or binder constituent Application Minimum addition for mix-in- Minimum addition for mix-in-
plant method of construction plant method of construction
using batching by mass using volume batching and for
mix-in-place construction
(by dry mass of mixture) (by dry mass of mixture)

Lime (quicklime or hydrated when used with another binder 1.5% 2%
lime) constituent
when used as the only binder 3% 4%
in Fly Ash Bound Granular
Mixture (FABGM) 5
Cement when used with another binder 2% 3%
constituent
constituent in Cement Bound
Granular Mixtures (CBGM)
constituent in Hydraulically
Stabilised Soils (HSS)
Ground granulated blast furnace when used with cement 2% 3%
slag (GGBS)
when used with lime 3% 4%
Air-cooled steel slag (ASS) when used with GBS (see Note) 2.5% 3%
Dry fly ash (FA) when used with cement 4% 5%
when used with lime 5% 6%
Granulated blast furnace slag when used with lime 6% 8%
(GBS)
when used with ASS (see Note) 2.5% 3%
Wet (conditioned) fly ash (FA) All applications 6% 8%
Hydraulic road binder All applications 3% 4%
NOTE: When GBS and ASS are used in combination, the sum of the two shall be not less than 11%.
5 (11/21) The mixture proportions used for production shall be based on a laboratory mixture design procedure in

19
Volume 1 Series 800
812 (02/16) Storage of Constituents

1 (11/21) Aggregates shall be stored on a firm and clean substrate avoiding contamination with other constituents.
2 (11/21) Fine aggregate shall be stored at the production location for at least 24 hours before use.
3 (11/21) Lime, cement, GGBS, HRB and dry FA shall be stored in silos.
4 (11/21) Wet (conditioned) FA shall have no agglomerations greater than 10 mm size. This is to be determined by
sieving samples through a 10 mm size test sieve using not more than 10 seconds of gentle agitation by hand.
5 (11/21) Wet fly ash shall be stored at the source or at the production location for at least 72 hours before use, and
have a minimum water content of 10%.
6 (11/21) GBS and ASS shall be stored as specified in sub-Clause 812.1 and used within 3 months of delivery to
the production location.
813 (02/16) General Requirements for Production and Layer Construction

1 (11/21) HBM shall be produced and laid using one of the following methods:
(i) mix-in-plant method of construction using batching by mass, in accordance with Clause 814;
(ii) mix-in-plant method of construction using volume batching, in accordance with Clause 815;
(iii) mix-in-place method of construction, in accordance with Clause 816.
2 (11/21) Construction of layers, including multiple lift layers, and any reworking and reuse, shall be completed
within the lesser of 8 hours, the construction period specified in Table 8/12 or the mixture setting time.
3 (11/21) The time shall be measured from the addition event defined in Table 8/12 to completion of compaction.
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4 (11/21) The construction period, in degree hours, shall be the summation of the products of the average air
temperature above 3ºC (T ºC) and time for each period (t hours): i.e. construction period limit =Σ(T.t). The air
temperature during the interval, t, which cannot fluctuate by more than 4ºC.

Volume 1 Series 800
Table 8/12 (11/21) Construction Period for HBM Layers

Binder Addition event defining the start Maximum construction period
time for calculating maximum (ºC hours)
construction period
Cement, cement with FA or cement Addition of cement 35
with GGBS
Lime with GBS or FA Addition of lime 1,600
Lime and gypsum for FABGM 5 Addition of lime and gypsum 70
GBS + ASS Addition of ASS and GBS 3,000
Lime with GGBS Addition of GGBS 200 if GGBS added after lime 1,600
if GGBS added before lime
HRB Addition of HRB Workability Period at 20°C

determined in accordance with BS
EN 13286-45 multiplied by 17
5 (11/21) Mixtures used in base layers shall be batched by mass and paver laid in a single lift.
6 (11/21) Construction of bases by methods other than a paver shall only be permitted in confined spaces where it
is impracticable for a paver to operate.
7 (11/21) When quicklime is used, full hydration shall be complete prior to final compaction.
8 (11/21) Laying shall be carried out in a way that avoids segregation and drying of the surface.
9 (11/21) Temporary intermediate surfaces within a multiple lift layer shall be sprayed with water to prevent
surface drying.
10 (11/21) The minimum compacted lift thickness in a multiple lift layer shall be 150 mm.
11 (11/21) Making-up of level after initial compaction shall not be permitted for single lift working or the
uppermost lift of multiple lift working.
12 (11/21) The edge of previously compacted HBM or other material shall be vertical and straight before fresh
HBM is laid against it.
13 (11/21) Compaction of HBM layers, including the intermediate lifts of multiple lift working, shall be completed
without drying out and before setting of any part of the layer.
14 (11/21) Compaction of HBM layers shall meet the requirements for density in Clause 870.
15 (11/21) Compaction of HBM, other than FABGM 5, shall be carried out by vibrating roller and/or pneumatic-
tyred roller (PTR).
16 (11/21) Where vibrating roller compaction is used on mixtures specified in Clauses 830 to 835 it shall be
followed by at least 8 passes of a PTR with a wheel loading of not less than 30kN.
17 (11/21) Only PTR compaction with a wheel loading of not less than 30kN shall be applied to FABGM 5.
18 (11/21) On completion of compaction the surface shall be closed, free from ridges, cracks, loose material,
visible voids, ruts, shear planes and other defects.
19 (11/21) All defective areas shall be rectified within the time period specified in sub-Clause 813.2.
20 (11/21) If rectification is not completed within the specified time period, the defective area shall be removed to
the full thickness of the layer, and new mixture laid and compacted.

21
Volume 1 Series 800
(11/21) Cold and Wet Weather Working

21 (11/21) During cold weather the following shall apply:
(i) the temperature of HBM is not be less than 5ºC at the time of laying;
(ii) HBM is not to be laid on a frozen surface;
(iii) laying of HBM ceases when the air temperature falls below 3ºC;
(iv) laying of HBM does not resume until the rising air temperature reaches 3ºC;
(v) the laying of HBM using binders containing less than 3% of CEM 1 cement, by dry mass of mixture, is
restricted in use to the period from 1 May to 30 September.
22 (11/21) In the case of heavy or persistent rain, production shall cease and any laid material shall be compacted
immediately.
(11/21) Curing, Protection and Trafficking
23 (11/21) On completion of compaction the layer shall be cured to prevent loss of moisture by either a bitumen
emulsion spray or a mist/fog/light spray of water.
24 (11/21) Where an application of a bitumen emulsion spray is used it shall be to Class C40B4, of the National
Foreword to BS EN 13808 to produce an even and complete coverage of at least 0.2 kg/m2 of residual bitumen.
Before bitumen spraying commences, the surface is to be free of all loose material and standing water. The bitumen
curing membrane is to be protected from any damage until the construction of the overlaying layer.
25 (11/21) Where a mist/fog/light spray of water is applied it shall be sufficient to keep the surface continuously
wet until the specified strength of the HBM has been developed or the layer is overlaid.
26 (11/21) Trafficking of HBM layers shall be permitted as shown in Table 8/13.
TABLE 8/13 (11/21) Trafficking of HBM Layers
HBM Designation Clause reference Trafficking

CBGM 5, 1 and 2 821, 822 and 823 Sub-Clause 29
SBGM 1 and 2
FABGM 1 and 2 830, 831 and 835 Not restricted
HRBBGM 1 and 2
SBGM 3, FABGM 3 and Not restricted provided that the IBI requirement of sub-
832
HRBBGM 3 Clause 832.6 is satisfied
Not permitted for 7 days unless overlaid by at least 150mm
FABGM 5 with cement 834
of bound material within the construction period.
Only the minimum amount of traffic required to construct
FABGM 5 with lime 834
the next layer is permitted.
Not restricted provided that the IPI requirements of Table
8/15 are satisfied.
For mixtures containing cohesive soil or chalk, the test

HSS 840
specimens made at the same time as the specimens required
in Clause 870 but cured under the same conditions as the in-
situ treated soil shall also have achieved an average strength
of at least Class C0.8/1.0.

22
Volume 1 Series 800
27 (11/21) Should any HBM layer exhibit signs of damage, trafficking shall cease immediately.
28 (11/21) Trafficking of a layer exhibiting signs of damage shall only be resumed once the layer has gained
sufficient stability to resist damage.
29 (11/21) CBGM shall not be trafficked for 7 days unless the layer complies with the following:
(i) the layer is compacted by both vibrating roller and PTR in accordance with sub-Clause 813.11 to comply
with the requirements of sub-Clause 813.12;
(ii) the mixture contains at least 50% by mass of coarse aggregate complying with BS EN 13242, Category
C90/3 for ‘crushed or broken particles’;
(iii) test specimens made at the same time as the specimens required in Clause 870 but cured under the same
conditions as the in-situ CBGM have achieved an average strength of at least Class C3/4.
30 (11/21) Surface contamination shall be removed prior to overlaying.
31 (11/21) Reworking and re-compaction of the layer shall only be permitted within the construction period set out
in Table 8/12.
32 (11/21) Reworking shall only be permitted when the water content requirements of the reworked material are
maintained within the limits stated in the method statement.
33 (11/21) Before overlaying, any loose material shall be removed and replaced to the full depth of the layer if not
within the construction period set out in Table 8/12.
34 (11/21) Daily record sheets complying with sub-Clause 817.4 shall be compiled by start of work on the next
working day and submitted to the overseeing organisation detailing:
(i) spread rate/batching record results;
(ii) depth measurements;
(iii) density test measurements;
(iv) sample and test locations;
(v) construction period records showing the time(s) of mixing, water addition, completion of compaction
and application of curing membrane.
814 (02/16) Mix-in-Plant Method of Construction Using Batching by Mass

1 (02/16) The HBM shall be produced in a stationary mixing plant that batches by mass and mixes in a
forced- action mixer, allowing sufficient time in the mixer to produce a homogenous mixture.
2 (02/16) The mixing plant shall have an automated surveillance and data collection system.
3 (11/21) HBM shall be transported directly to the point where it is to be laid and protected from the weather
during transit and whilst awaiting tipping.
815 (02/16) Mix-in-Plant Method of Construction Using Volume Batching

1 (02/16) The HBM shall be produced in a stationary mixing plant that batches by volume and mixes in a forced
action mixer, allowing sufficient time in the mixer to produce a homogenous mixture.
2 (11/21) HBM shall be transported directly to the point where it is to be laid and protected from the weather
during transit and whilst awaiting tipping.
3 (02/16) Dispensing accuracy shall be verified by reconciliation between constituent deliveries and the area and
depth of completed layer for each 5000 m2 of work, or part thereof, during each day’s operations.
Amendment – November 2021

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23
Volume 1 Series 800
816 (02/16) Mix-in-Place Method of Construction

1 (11/21) Mixed-in-place HBM shall be produced by an in-situ pulverizing-mixing process with the added mixing
water injected directly into the mixture during the mixing process.
2 (11/21) The pulverizing-mixing process shall be repeated until a homogenous mixture is produced. When binder
constituents are dispensed onto the surface to be pulverized-mixed, the rate of spread to be confirmed by site checks
carried out in accordance with Clause 870. For each group of 5 readings the mean rate of spread of material to be
within ±10% of the stated target rate and each individual value to be within ±15% of the mean value of the group of
5 readings.
3 (02/16) The accuracy of the system used to dispense binder constituents shall be verified by reconciliation
between constituent deliveries and the area and depth of completed layer for each 5000 m2 of work, or part thereof,
during each day’s operations.
4 (11/21) Mixing of fresh material shall have a minimum overlap of 200 mm with previously mixed material.
5 (11/21) Where lime is used to granulate cohesive soils it shall be added and mixed with the soil using at least
two passes of the pulverizer-mixer between 24 and 96 hours before the subsequent addition of cement, FA, HRB or
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GGBS. The surface of the layer to be sealed by rolling immediately after adding and mixing lime the MCV during
this period, known as the mellowing period, to comply with Clause 840.
817 (02/16) Method Statement and Demonstration Area

(02/16) Method Statement
1 (11/21) At least 10 days prior to constructing the demonstration area specified in sub-Clause 817.5, a full
method statement shall be provided which details:
(i) the operatives;
(ii) plant;
(iii) materials and procedures for the construction of demonstration area(s) and of the works;
(iv) procedures for induced cracking, if required by contract specific Appendix 7/1;
(v) procedures to be applied during inclement weather, plant breakdowns and other unscheduled events;
(vi) the intended mixture proportions with supporting data from trial mix results and/or historic records to
justify the proportions;
(vii) the water content (or MCV) limits;
(viii) spread rates for all stages of the work (if applicable);
(ix) a sample record sheet for the submission of the data required by sub-Clause 813.34.
2 (11/21) Where multiple lift working is used, the method statement shall detail:
(i) the methods used to assure that bond between the individual lifts is achieved;
(ii) the procedures to be used to confirm that bond has been achieved in the demonstration area and in the
works.
(02/16) Demonstration Area
3 (11/21) Prior to the commencement of the main works a demonstration area shall be constructed of at least
800 m2 conforming to the submitted method statement. The demonstration area to include a transverse end of- day
joint and (if appropriate) multiple lift working. The demonstration area may be accepted into the permanent
works. A demonstration area may not be required where documentary evidence of similar work carried out to this
specification during the previous 6 months is provided.

Volume 1 Series 800
4 (11/21) Where multiple lift working is used, the demonstration area shall confirm the effectiveness of the
procedures used to assure that bond between the individual lifts can be achieved.
5 (11/21) Where induced cracking is required, the demonstration area shall include crack induction at the specified
spacing. The effectiveness of the procedure used to be checked within 28 days of construction, by recovering four
evenly spaced 150 mm diameter cores from the line of the induced cracks and assessing each core for compliance
with sub-Clause 818.3.
6 (11/21) The mixture constituents, proportions, laying and compaction plant and construction procedures used for
the demonstration area shall not be changed unless a further demonstration area is laid.
818 (02/16) Induced Cracking of HBM

1 (11/21) Where required by contract specific Appendix 7/1, transverse cracks shall be formed at the specified
spacing with a tolerance of ± 150 mm.
2 (11/21) Where the pavement is made up of two or more layers of HBM with induced cracks, the cracks in the
overlying HBM layer shall align with the induced cracks in the layer below with a tolerance of ± 100 mm.
3 (11/21) Cracks shall be induced in fresh material after initial compaction.
4 (11/21) The transverse cracks shall be induced by grooving the fresh material to form straight vertical grooves
not more than 20 mm wide, to a depth of between one half and two thirds of the layer thickness over the full width
of the pavement.
5 (11/21) Bitumen emulsion shall be poured or sprayed into the grooves prior to final compaction, to form a crack
inducing membrane.
6 (11/21) The bitumen emulsion shall comply with Class C40B4, as specified in the National Foreword to
BS EN 13808.
7 (11/21) During final compaction of the mixture, the surface of the groove shall be fully closed throughout its full
length.
8 (11/21) The bitumen in the groove shall be fully encased and remain continuous, with not less than 70% of the
sides of the groove coated with bitumen.
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9 (11/21) Where required by contract specific Appendix 7/1, longitudinal cracks shall be induced using the
procedure specified in sub-Clause 818.4
819 (02/16) Not Used
820 (02/16) Aggregates

1 (11/21) Aggregates used in HBGM shall comply with BS EN 13242 and Table 8/14.
2 (11/21) Where recycled coarse aggregate or recycled concrete aggregate is used in HBGM, it shall also be tested
in accordance with Clause 710 and comply with the additional requirements for the proportion of the components
listed in Table 8/14.
3 (11/21) An existing pavement layer that is to be used to produce HBGM shall be tested to confirm compliance

Volume 1 Series 800
TABLE 8/14: (11/21) Aggregate Requirements for HBGM
Clause reference 821 822 823 830 831 832 835

HBM designation CBGM 5 CBGM 1 CBGM 2 FABGM 1 SBGM 2, SBGM B3, SBGM 1
HRBBGM 1 FABGM 2 FABGM 3
HRBBGM 2 HRBBGM 3
Categories for aggregate properties, BS EN 13242
Crushed or broken particles CNR CNR C90/3 or C50/30, CNR C90/3 or
and totally rounded particles (Note 1) unless otherwise specified as specified in contract specific (Note 1) C50/30 as
in coarse aggregate in contract specific Appendix 7/1 (Note 2) specified
Appendix 7/1 in contract
specific
Appendix
7/1
Resistance to fragmentation LA50 LA50
of coarse aggregate or or
LA60 LA60
LANR as specified LA50 as specified LA50 LANR LA50
in contract in contract
specific specific
Appendix 7/1 Appendix 7/1
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Acid-soluble sulfate content Air-cooled blast-furnace slag – AS1,0
Other aggregates – AS0,8

Total sulfur content Air-cooled blast-furnace slag – S2
Other aggregates – S1
Other requirements, BS 1377-2
Fines quality Non-
NR NR
Non-plastic (Note 3) plastic
(Note 1) (Note 1)
(Note 3)
Proportion of components, Clause 710
Maximum glass content
40 40 40 40 40 40 40
(ClassRgG)
Maximum impurities
5 3 3 3 3 5 3
content (Class X)
NOTES:
1. The suffix NR denotes that the ‘No requirement’ category applies.
2. CNR if FABGM 1 contains at least 3% CEM 1 cement by dry mass of the mixture and trafficking is prevented for 7 days.
3. The size fraction of the aggregate passing the 0.425 mm size test sieve shall be non-plastic as defined by and tested in compliance with
BS 1377-2.
821 (11/21) Cement Bound Granular Mixtures 5 (CBGM 5)

1 (11/21) Cement bound granular mixtures 5 (CBGM 5) shall comply with BS EN 14227-1 and have binder
constituent proportions complying with the requirements of Clause 811.
2 (11/21) Aggregate shall comply with the requirements of Clause 820 and have a mixture grading complying
with the requirements of BS EN 14227-1 Table 3.
3 (02/16) The strength after immersion shall be at least 80% of the non-immersed strength, when tested in
accordance with the laboratory mixture design requirements specified in Clause 880.
4 (02/16) The method of construction shall be in accordance with Clause 813 and either Clause 814, Clause 815 or
Clause 816.

Volume 1 Series 800
5 (02/16) The laboratory mechanical performance shall comply with the requirements of contract specific
Appendix 7/1, when sampled and tested in accordance with Clause 870.

1 (11/21) Cement bound granular mixtures 1 (CBGM 1) shall comply with BS EN 14227-1, and have binder
2 (11/21) Aggregates shall comply with the requirements of Clause 820 and be either a 0/31.5 mm, a 0/20 mm or
a 0/14 mm mixture with a grading complying with the requirements of BS EN 14227-1 Figure 1, 2 and 3 using the
G1 limits.
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4 (02/16) The method of construction shall be in accordance with Clause 813 and Clause 814.

1 (11/21) Cement bound granular mixtures 2 (CBGM 2) shall comply with BS EN 14227-1, and have binder
2 (11/21) Aggregates shall comply with the requirements of Clause 820 and be either a 0/20 mm, a 0/14 mm or a
0/10 mm mixture with a grading complying with the requirements of BS EN 14227-1 Figures 4, 5 and 6 using the
G1 limits.
3 (11/21) The compacity of the mixture shall be at least 0.8, when calculated in accordance with BS EN 14227-2,
Annex C.
4 (11/21) The maximum dry density value used for the calculation shall be determined in accordance with
BS EN 13286-50, using the modified Proctor (4.5 kg rammer) procedure from BS EN 13286-2.
6 (11/21) The method of construction shall be in accordance with Clause 813 and Clause 814.
824 to 829 (02/16) Not Used
830 (11/21) Fly Ash Bound Granular Mixture 1 (FABGM 1) and Hydraulic Road Binder Bound
Granular Mixture 1 (HRBBGM 1)
1 (11/21) The mixture shall comply with the requirements of BS EN 14227-3 for Fly Ash Bound Granular
Mixture 1 (FABGM 1) or the requirements of BS EN 14227-5 for Hydraulic Road Binder Bound Granular
Mixture 1 (HRBBGM 1) and have binder constituent proportions complying with the requirements of Clause 811.
2 (02/16) Aggregate shall comply with the requirements of Clause 820.
3 (11/21) FABGM 1 shall be a 0/31.5 mm mixture with a grading complying with the requirements of
BS EN 14227-3 Figure 1.

Volume 1 Series 800
4 (11/21) HRBBGM 1 shall be a 0/31.5 mm mixture with a grading complying with the requirements of
BS EN 14227-5 Figure 1.
6 (11/21) The method of construction shall comply with Clause 813 and Clause 814.
7 (11/21) The laboratory mechanical performance shall comply with the contract specific requirements of
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831 (11/21) Slag Bound Granular Mixture 2 (SBGM 2), Fly Ash Bound Granular Mixture 2
(FABGM 2) and Hydraulic Road Binder Bound Granular Mixture 2 (HRBBGM 2)
1 (11/21) The mixture shall comply with the requirements of BS EN 14227-2 for Slag Bound Granular
Mixture 2 (SBGM 2), the requirements of BS EN 14227-3 for Fly Ash Bound Granular Mixture 2 (FABGM 2) or
the requirements of BS EN 14227-5 for Hydraulic Road Binder Bound Granular Mixture 2 (HRBBGM 2) and have
binder constituent proportions complying with the requirements of Clause 811.
2 (02/16) Aggregate shall comply with Clause 820.
3 (11/21) SBGM 2 shall be a 0/20 mm, a 0/14 mm or a 0/10 mm mixture with a grading complying with the
requirements of BS EN 14227-2 Figure 4, 5 and 6 using the G1 or G2 limits.
4 (11/21) FABGM 2 shall be a 0/20 mm, a 0/14 mm or a 0/10 mm mixture with a grading complying with the
5 (11/21) HRBBGM 2 shall be a 0/20 mm, a 0/14 mm or a 0/10 mm mixture with a grading complying with the
7 (02/16) The method of construction shall be in accordance with Clauses 814 and 813.
832 (11/21) Slag Bound Granular Mixture 3 (SBGM 3), Fly Ash Bound Granular Mixture 3
(FABGM 3) and Hydraulic Road Binder Bound Granular Mixture 3 (HRBBGM 3)
1 (11/21) The mixture shall comply with the requirements of BS EN 14227-2 for Slag Bound Granular
Mixture 3 (SBGM 3), the requirements of BS EN 14227-3 for Fly Ash Bound Granular Mixture 3 (FABGM 3) or
the requirements of BS EN 14227-5 for Hydraulic Road Binder Bound Granular Mixture 3 (HRBBGM 3) and have
2 (02/16) Aggregate shall comply with the requirements of Clause 820.
3 (11/21) The mixture grading shall comply with the requirements of BS EN 14227-2 Table 3 for SBGM 3,
the requirements of BS EN 14227-3 Table 2 for FABGM 3 or the requirements of BS EN 14227-5 Table 2 for
HRBBGM 3.
Clause 816.

Volume 1 Series 800
7 (11/21) The mixture design procedures specified in Clause 880 shall include the determination of the immediate
bearing at the target water and binder content.
8 (11/21) The mixture shall comply with Immediate Bearing Index Category IPI40.
9 (11/21) The requirements of Clause 832.8 shall not apply if the mixture contains at least 3% cement by mass of
the dry mixture and traffic is not permitted to use the layer for the first 7 days.
833 (02/16) Not Used
834 (11/21) Fly Ash Bound Granular Mixture 5 (FABGM 5)

1 (11/21) The mixture shall comply with BS EN 14227-3 for Fly Ash Bound Granular Mixture 5 (FABGM 5), and
have binder constituent proportions complying with the requirements of Clause 811.
3 (11/21) For lime-treated fly ash mixtures with gypsum added as an additional constituent, the method of
construction shall be in accordance with Clause 813 and 814.
4 (11/21) For other mixtures, the method of construction permitted shall comply with Clause 813 and either
Clause 814, Clause 815 or Clause 816.
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835 (11/21) Slag Bound Granular Mixture 1 (SBGM 1)

1 (11/21) Slag Bound Granular Mixture 1 (SBGM 1) shall comply with BS EN 14227-2 and have binder
2 (11/21) Aggregates shall comply with the requirements of Clause 820 and be a 0/31.5 mm mixture with a
grading complying with the requirements of BS EN 14227-2 Figure 1.
4 (11/21) The method of construction shall be in accordance with Clause 813 and 814.
836 to 839 (02/16) Not Used
840 (11/21) Hydraulically Stabilised Soils (HSS)

1 (11/21) Hydraulically Stabilised Soils (HSS) shall comply with BS EN 14227-15 and the requirements from
Table 8/15, and have binder constituent proportions complying with the requirements of Clause 811.
2 (11/21) A minimum of 95% of the soil shall pass the 63 mm size test sieve when tested in accordance with
BS EN 933-1.
3 (11/21) The maximum particle size of the soil shall not exceed 25% of the layer depth.

Volume 1 Series 800
4 (11/21) When tested in accordance with BS EN 1744-1 clause 10, soil with a total potential sulfate (TPS)
content less than 0.25% sulfate (as SO4) shall be deemed suitable for treatment, if the laboratory mixture design
procedure confirms that the mixture complies with the ‘resistance to water’ requirements specified in Table 8/15.
Clause 816.
TABLE 8/15 (11/21) Requirements for Hydraulically Stabilised Soils (HSS)
Requirement Category
Mixture parameter Cohesive soil mixtures BS EN 14227-15
Non-cohesive soil mixtures reference and chalk
mixtures
Minimum water content W0,9
WNR
(Expressed as a proportion of the optimum water W1,0 Table 2
(Note 1)
content, determined in accordance with for mixtures containing quicklime
BS EN 13286-4, Vibrating hammer method)
Degree of Pulverization (Determined in
PulvNR (Note 1) Pulv60 Table 3
accordance with BS EN 13286-48)
Immediate Bearing Index (Note 2) IPI40 IPI15 Table 4
(Determined in accordance with Clause 880) (Note 3)

Moisture Condition Value MCV8/12
MCVNR
at final mixing and Table 5
(Note 1)
(Determined in accordance with BS EN 13286-46) compaction (Note 4)
Laboratory mechanical performance
Table 7 for Rc
Rc or Rt,E,
(Compressive strength or tensile strength and as specified in contract specific Appendix 7/1
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Figure 1 for Rt,E

modulus of elasticity)
Resistance to water – strength after immersion
I0,8 Table 8
(Ri/R ratio, determined in accordance with Clause
880)
Resistance to water – volumetric swelling NR
BS 14227-15 clause
GV5
9.1.4
(Determined in accordance with BS EN 13286-49) (Note 1)
NOTES:
1. The suffix NR denotes that the ‘No requirement’ category applies.
2. Where HSS is not to be trafficked within 7 days, IPINR may be used.
3. IPI25 where the mixture is not subject to direct trafficking.
4. For cohesive soil mixtures, the requirement also applies during the mellowing period.

Volume 1 Series 800
841 to 869 (02/16) Not Used
870 (02/16) Testing, Control and Checking of HBM

(11/21) General
1 (11/21) Tests, controls and checks shall be carried out in accordance with the requirements in Table 8/16 and the
following sub-Clauses at locations stated in contract specific Appendix 1/5.
2 (11/21) Where a test reference is shown in Table 8/16, the testing shall be carried out in compliance
with the requirements of Clause 105 and be undertaken by an organisation accredited in accordance with
BS EN ISO/ IEC 17025 for the test method.
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Volume 1 Series 800
TABLE 8/16 (11/21) Requirements for Testing, Control and Checking of HBM
Test/control/check Test frequency Test reference
Water content of aggregate or soil sources on 3 per 1000 m2 BS 1924-1, Clause 7.1
site
Grading of aggregate or soil sources on site 1 per 1000 m2 Aggregates:
BS EN 1097-5
Soils: BS 1924-1,
clause 7.1
Plasticity of aggregate or soil sources on site 1 per 1000 m2 BS 1924-1, clause 7.3
Constituents sourced off-site Aggregates – Declaration of performance determined in
accordance with 104.3
BS EN 13242, Annex C.
Cement – Declaration of performance determined in accordance

with BS EN 197-1, National Annex NB.
Slag – Declaration of performance determined in accordance

with the requirements of BS EN 14227-2, Clause 5.
Fly ash – Declaration of performance determined in accordance

with the requirements of BS EN 14227-4.
Other constituents – certificates to be provided weekly to confirm

compliance with the specification agreed as part of the factory
production control system for the mixture.
Batching records for ‘mix-in-plant’ method of Continuously using the automated surveillance and data
construction using batching by mass collection system
Batching records for ‘mix-in-plant’ method Dispensing accuracy shall be verified by reconciliation between
of construction using batching by volume and constituent deliveries and the area and depth of completed layer
mix-in-place for each 5000m2 of work, or part thereof, during each day’s
operation
Spread checks for ‘mix-in-place’ method 1 determination per 1000 m2 but not less than 4 per day
of construction at each stage of the mixing
process (sub-Clause 870.3)
Mixture grading, including binder 1 per 1000 m2 but not less than 3 per day BS EN 933-1
Water content at final compaction 1 per 1000 m2 but not less than 3 per day BS 1924-2, clause 1.3
MCV at mixing and final compaction and, 3 per 1000 m2 but not less than 4 per day BS EN 13286-46
in the case of cohesive mixtures, during the
mellowing period
Pulverization (cohesive mixtures only) 2 per 1000 m2 but not less than 4 per day BS EN 13286-48
Depth of mixing for ‘mix-in-place’ method 5 per 1000 m2 but not less than 4 per day -
of construction at each stage of the mixing
process (sub-Clause 870.4)
In-situ wet density 5 per 1000 m2 or part thereof laid each day Sub-Clause 870.5
(measured at the locations detailed in sub-Clause 870.8)
Laboratory mechanical performance 5 per 1000 m2 or part thereof laid each day BS 9227 Table 5
(with test specimens prepared from a bulk sample taken from
each of the locations detailed in sub-Clause 870.8)
Strength after immersion in water Laboratory mixture design procedure As required by Clause
880

32
Volume 1 Series 800
(11/21) Sampling
3 (11/21) Sampling shall be in accordance with BS 1924-1. Where a bulk sample of HBM is taken from a layer,
it shall be taken from the full depth of the layer, used without further mixing, and not combined with other bulk
samples.
Spread Checks for the Mix-in-Place Method of Construction
4 (11/21) The rate of spread of added constituents shall be determined by weighing the amount of material
retained on five trays (or mats) of known area laid in the path of the spreading machine.
5 (11/21) The trays (or mats) shall be positioned at points equally spaced along a diagonal bisecting line the area
of coverage so as to assess the full width of discharge from the spreading machine.
(11/21) Depth of Mixing for the Mix-in-Place Method of Construction
6 (11/21) The depth of mixing shall be checked by excavation and inspection on completion of each stage of the
pulverizing-mixing process.
7 (11/21) The depth of mixing shall be referenced to the design levels for the pavement by precise leveling of
the stabilized soil interface to ensure that the level at the underside of the stabilized layer is in accordance with the
specified requirements.
(11/21) Standardisation of Nuclear Density Gauges and Measurement of In-situ Wet Density
8 (11/21) Where Nuclear Density Gauges cannot be used a correlation shall be established for each alternative
measuring device used.
9 (11/21) The in-situ wet density of a compacted mixture shall be measured using a calibrated nuclear density
gauge in accordance with BS 1924-2 and the following sub-Clauses, except that each test will consist of at least 3
measurements at 120 degrees to each other using the same source rod hole and the density taken as the average of
the higher 2 results.
10 (11/21) The operation, warming-up period if any, and standardisation of the gauge shall be carried out in
compliance with the manufacturer’s recommendations.
11 (11/21) The gauge shall be calibrated in accordance with BS 1924 immediately prior to the construction of the
demonstration area and at least once every 28 days thereafter.
12 (11/21) The gauge shall be used in the direct transmission mode of operation with the source rod lowered to
within 25 mm of the bottom surface of the layer.
13 (11/21) The in-situ wet density shall be determined within two hours of completing compaction.
14 (11/21) The in-situ wet density of a subbase layer shall be taken as the average value of five determinations
equally spaced along a line that bisects each 1000 m2 or part thereof laid each day.
15 (11/21) The first and fifth positions shall be located 300 mm from the edges of the laid area.
16 (11/21) For a subbase layer, the average in-situ wet density of the area specified in sub-Clause 870.14 shall be
not less than 95% of the average wet density of the test specimens taken to determine the laboratory mechanical
performance of the same area.
17 (11/21) For a base layer, the average in-situ wet density of the area specified in sub-Clause 870.14 shall be
not less than 95% of the wet density of the HBM at its optimum moisture content, measured using the vibrating
hammer method detailed in BS EN 13286-4.
18 (11/21) The result of each single determination of in-situ wet density shall be not less than 92% of the wet
density of the HBM at its optimum moisture content.

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Volume 1 Series 800
(11/21) Laboratory Mechanical Performance

19 (11/21) A bulk sample of HBM shall be taken from each of the locations in sub-Clause 870.14, after the in-situ
wet density has been determined.
20 (11/21) The sample shall be tested in accordance with Table 8/17
TABLE 8/17 (11/21) Laboratory Mechanical Performance Testing Requirements for HBM
Clause Mixture Curing regime Curing temperature Test method Age at test
GBGM 5,
821, 822 & 823 BS EN 14227-1 20°C
CBGM 1 and CBGM 2
RC –
SBGM, HRBBGM BS EN 13286-41
830, 831, 832 & 835 and FABGM, (except BS EN 13286-51 40°C
FABGM 5)
FABGM 5 treated with 28 days

BS EN 13286-51 40°C
lime Rit – (see Note)
834
FABGM 5 treated with BS EN 13286-41
BS EN 13286-51 20°C
cement
BS EN 14227-15,
HSS with not less than
20°C EC –
840 3% cement
Annex A BS EN 13286-43
Other HSS BS EN 13286-51 40°C
NOTE:
For site control purposes, HBM may be assessed on the basis of 7 days strength (or other agreed age) where the Contractor so requests,
provided that a robust correlation is established between 7 days and 28 days strength using representative samples of the aggregates and
binder used in the works.
21 (11/21) Test specimens used to determine laboratory mechanical performance shall be made using vibratory
hammer compaction, in accordance with BS EN 13286-51.
22 (11/21) Where cubes are used for the determination of compressive strength, the specimens shall be 150 mm
size.
23 (11/21) Compliance of the area specified in sub-Clause 870.14 shall be determined using the results for test
specimens that are cured and tested in accordance with Table 8/16 using compression or indirect tensile testing
appropriate to the class of mechanical performance specified in contract specific Appendix 7/1.
24 (11/21) Assessment shall be made using the following criteria which supersede any reference to ‘characteristic
strength’ in BS EN14227-1.
(i) Compressive strength: The requirement specified in contract specific Appendix 7/1 will be satisfied if
the average compressive strength of the group of specimens in Table 8/16 is equal to or greater than
the minimum for the specified Rc class and no individual test result is less than 67% of the minimum
strength requirement for the Rc class.
(ii) Indirect tensile strength: The requirement specified in contract specific Appendix 7/1 will be satisfied
if the average indirect tensile strength of the group of specimens in Table 8/16 is equal to or greater
than the minimum requirement and no individual result is less than 67% of the minimum requirement
appropriate to the E value determined during the laboratory mixture design procedure specified in
Clause 880.

34
Volume 1 Series 800
871 (02/16) Determination of the Coefficient of Linear Thermal Expansion

(02/16) Scope
1 (11/21) The test method described in this Clause shall be used to determine the coefficient of linear thermal
expansion of HBM within the normal range of temperature for pavement layers.
2 (11/21) The test method shall be carried out using hardened specimens.
(02/16) Apparatus
3 (11/21) The following apparatus shall be used:

(i) A water bath with sufficient capacity to accommodate three test specimens and capable of maintaining
predetermined temperatures between 15ºC and 60ºC.
(ii) A device capable of measuring linear dimensions of not less than 275 mm to an accuracy of ± 0.002 mm,
with a known temperature correction factor.
(iii) Vibrating hammer compaction apparatus capable of producing 150 mm diameter cylindrical test
specimens, in accordance with BS EN 13286-51. The apparatus to be suitably modified to manufacture
300 mm long test specimens.
(02/16) Test procedure
4 (11/21) The following test procedure shall be followed.
(i) Compact three 150 mm diameter test specimens, 300 mm in length, in accordance with BS EN 13286-51
but using six layers, each with a nominal depth of 50 mm.
(ii) Mark each specimen with 3 pairs of permanent reference points, aligned longitudinally. One of each pair
to be at opposite ends of the specimen. Each pair to be located at 120º around the circumference of the
specimens, aligned parallel to the axis, and not more than 30 mm from each end of the specimen.
(iii) Cure the specimens using the procedure specified for the determination of mechanical laboratory
performance in Table 8/17.
(iv) Saturate the test specimens, either at atmospheric pressure or under vacuum, until the increase in the
surface dried mass of each specimen, determined using two readings taken at least 24 hours apart, is less
than 1%.
(v) Immerse the specimens in the water bath at a constant temperature (T1), maintained to an accuracy of
± 2ºC, for 24 ± 2 hours. Then measure the length (L1) of each test specimen at the locations defined by
the three pairs of reference points. Repeat the measurement of length every 24 hours, until the change in
length between successive measurements is less than 0.004 mm.
(vi) Raise the temperature of the water bath by at least 30ºC and record the temperature (T2). T2 not to
exceed 55ºC. Maintain the temperature at T2 ± 2ºC for 24 ± 2 hours and measure the length (L2) using
the procedure in (5).
(vii) Lower the temperature of the water bath by at least 30ºC and record the temperature (T3). Maintain the
temperature at T3 ± 2ºC for 24 ± 2 hours and measure the final length (L3) using the procedure in (5).
(02/16) Calculations
5 (11/21) The Coefficient of Linear Thermal Expansion (CLE) shall be calculated as follows:
(i) For each pair of reference points for the heating sequence calculate: CLE´ = (L2 – L1) / (T2 – T1), giving
9 results in total.
(ii) Reject the highest and lowest results and record the mean value of CLE´ for the remaining 7 results.

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Volume 1 Series 800
(iii) For each pair of reference points for the cooling sequence calculate: CLE´´ = (L2 – L3) / (T2 – T3),
giving 9 results in total.
(iv) Reject the highest and lowest results and record the mean value of CLE´´ for the remaining 7 results.
(v) Calculate: CLE = 0.5 ((Mean value of CLE´) + (Mean value of CLE´´)).
(vi) Check that the mean values of CLE´ and CLE´´ lie in the range 0.95CLE to 1.05CLE. If the mean values lie
outside this range, repeat the procedure in sub-Clause 871.4.
(02/16) Reporting of Results
6 (11/21) The value of CLE using units of m.10-6/ºC, expressed to the nearest whole number shall be reported.
872 to 879 (02/16) Not used

880 (02/16) Laboratory Mixture Design Procedure
1 (11/21) Prior to the commencement of the work or any change in mixture constituents, the target proportions of
the constituents, including water, for the specified HBM, based on the mixture design procedure described in this
Clause shall be determined.
2 (02/16) The mixture design procedure shall determine the properties of the HBM at a minimum of 3 values of
binder contents, and a minimum of 2 values of water content for each value of binder content.
(02/16) Immediate Stability
3 (11/21) When required, the mixture design procedure shall include the determination of the immediate bearing
index (IBI) at the selected design water and binder content, measured in accordance with BS EN 13286-47.
4 (11/21) The IBI value shall be taken as the average value for a set of 3 test specimens.
(02/16) Resistance to Water – Strength After Immersion
5 (11/21) The strength after immersion in water shall be assessed by comparing the average strength and condition
of:
(i) 3 specimens initially cured in a sealed condition for 14 days at the test temperature; and then removed
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from their moulds and immersed in aerated water for 14 days at the same test temperature.
(ii) 3 specimens cured in sealed condition for 28 days at the same test temperature.
6 (11/21) The immersed specimens shall be unconfined and have water in contact with all surfaces. On completion
of the immersion stage of the test the specimens to show no signs of cracking or swelling.
7 (11/21) For mixtures containing less than 3% by dry mass of the mixture of cement, the test temperature shall be
(40 ± 2)ºC.
8 (11/21) For mixtures containing 3% or more cement, the test temperature shall be (20 ± 2)ºC.
(02/16) Resistance to Frost Heave
9 (11/21) HBM shall be deemed resistant to frost heave where the compressive strength class is C3/4 or greater or
Rit is greater than 0.25 MPa, when cured in accordance with Table 8/17.

Volume 1 Series 800
881 (03/20) Laboratory Stiffness Testing

(03/20) Scope
1 (11/21) The test methods described in this Clause shall determine the stiffness values for use within a
performance foundation design.
(03/20) Cement and Other Hydraulically Bound Mixtures
2 (03/20) The mean modulus of elasticity in compression (Ec) of hydraulically bound mixtures shall be
determined in accordance with BS EN 13286-43.
3 (11/21) Specimens shall be:
(i) manufactured in accordance BS 1924-2 7.2.2 with a 2:1 height diameter ratio; and
(ii) cured in accordance with Table 8/17.
882 (03/20) Determination of the Construction Subgrade Surface Modulus

(03/20) Scope
1 (03/20) The test methods described in this Clause shall be used for the determination of the subgrade surface
modulus of the foundation prior to the commencement of construction of the overlying layers.
(03/20) Procedure
2 (03/20) The construction subgrade surface modulus shall be determined in accordance with this Clause at
intervals suitable for the type of subgrade material and its condition, with a maximum spacing of 60 m along each
lane of prepared subgrade and staggered to the mid-point between adjacent lanes, see Figure 8/1.
FIGURE 8/1: (03/20) Subgrade Surface Modulus Test Locations
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3 (03/20) At least 10 tests shall be carried out for each prepared foundation area.
4 (03/20) The measurement of the construction subgrade surface modulus shall be taken at formation level or at
sub-formation level if capping is part of the foundation design.
5 (03/20) The test site shall be free from standing water, ice and snow.

Volume 1 Series 800
6 (03/20) Where the construction subgrade surface modulus is found to be less than the design subgrade modulus,
the area shall either be improved or the foundation redesigned in accordance with CD 225 (DMRB).
(03/20) Construction Subgrade Surface Modulus Measurement
7 (03/20) The subgrade surface modulus shall be determined using one of the following devices:
(i) Dynamic Cone Penetrometer (DCP);
(ii) Falling Weight Deflectometer (FWD); or
(iii) Lightweight Deflectometer (LWD).
(03/20) Dynamic Cone Penetrometer (DCP) Testing
8 (03/20) Dynamic Cone Penetrometer (DCP) testing shall be undertaken following the procedure outlined within
CS 229 (DMRB).
9 (03/20) Result expressed as mm/blow shall be converted to a California Bearing Ratio (CBR) value, expressed
as a percentage, using the following relationship:
EQUATION 8/1: (03/20) DCP (mm/blow) to CBR Relationship
Log10 (CBR) = 2.48 – 1.057 * Log10 (mm/blow)
10 (03/20) The CBR value obtained in sub-Clauses 883.6 to 883.8 shall then be converted to surface modulus (E)
using the following equation:
EQUATION 8/2: (03/20) CBR to Subgrade Surface Modulus Equation
E = 17.6(CBR)0.64 MPa
(03/20) Falling Weight Deflectometer (FWD) Testing
11 (03/20) FWD testing shall be undertaken using a calibrated FWD in accordance with BS 1924-2.
(03/20) Lightweight Deflectometer Testing (LWD)
12 (03/20) LWD testing shall be undertaken using a calibrated LWD in accordance with BS 1924-2.
13 (03/20) In accordance with BS 1924-2, an LWD device shall only be used with a site-specific correlation versus
a FWD or if it has an annual correlation certificate.
14 (03/20) Testing shall either be undertaken to:
(i) Procedure A – the standard target stress as per BS 1924-2; or
(ii) Procedure B – a range of target stresses centred around 100 KPa to determine stress dependency.
883 (03/20) Demonstration Area for Performance Foundation Designs

(03/20) Scope
1 (03/20) The procedure described in this Clause is to demonstrate the adequacy of performance of a foundation
design together with the methods used to construct the foundation prior to the commencement of the permanent
works.
2 (03/20) Demonstration areas are required for performance design foundations and when specified in contract

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Volume 1 Series 800
(03/20) Demonstration Area for Performance Foundations

3 (03/20) For each foundation area, a demonstration area shall be prepared using the same methods, materials,
thickness and compaction as proposed for the permanent works. Each demonstration area shall be not less than
400 m² and not less than 60 m long. For foundations constructed using HBM to Clause 810, the demonstration area
shall comply with the requirements of Clause 817.
4 (03/20) The demonstration area shall have a sufficient and suitable run off/run on area as outlined in Clause
802.15 to ensure the trafficking trial can be undertaken.
5 (03/20) The materials placed in the demonstration area may form part of the permanent works, provided that
they meet the requirements of the permanent works.
(03/20) Procedure
6 (03/20) Measure subgrade surface modulus in accordance with Clause 882 and confirm that the value is greater
to or higher than the design subgrade surface modulus value.
7 (03/20) If the measured subgrade surface modulus is lower than the design subgrade modulus, a foundation
redesign is required.
8 (03/20) Where the measured subgrade surface modulus is greater than design subgrade surface modulus, an
adjustment factor should be applied to the measurements of foundation surface modulus values in this clause using
Equation 8/3.
EQUATION 8/3: (03/20) Foundation Surface Modulus Adjustment
#$
# $ ! ' %
#$
&("
Notes:
1 EF (adjusted) Adjusted foundation surface modulus.
2 EF Measured foundation surface modulus.
3 ES (measured) Measured subgrade surface modulus.
4 ES (design) Design subgrade surface modulus.
9 (03/20) Construct foundation as proposed for permanent works.
10 (11/21) Measure foundation surface modulus in accordance with Clause 885 to confirm the foundation surface
modulus requirements for the foundation are in accordance with the requirements of Table 8/18.
11 (03/20) Undertake trafficking trial in accordance with sub-Clause 883.16.
12 (03/20) Repeat measurement of foundation surface modulus in accordance with Clause 885 to confirm the
foundation surface modulus requirements for the foundation are in accordance with the requirements of Table 6/1.
13 (03/20) Where the completed demonstration area meets all of the specification requirements, the methods,
materials and thicknesses used shall not be changed for the construction of the main works without an additional
demonstration area being constructed.
14 (03/20) Where the demonstration area fails to meet all of the specification requirements, the design and
construction practices shall be reviewed, and the demonstration area reconstructed until the specification
requirements have been met.

Volume 1 Series 800
15 (03/20) Records of the performance test results for each construction stage, referenced to the following
condition details shall be stored and presented on request to the Overseeing Organisation in a digital spreadsheet
format:
(i) Subgrade surface modulus value immediately before foundation construction;
(ii) Date and time of mixing (for stabilised and slow-setting materials);
(iii) Date and time of placing and compaction;
(iv) Date of performance testing;
(v) Values of surface modulus recorded;
(vi) Values of material properties including density and layer thickness;
(vii) Weather conditions including temperature; and
(viii) Sampling and testing records in the demonstration area.
(03/20) Trafficking Trials
16 (03/20) The Contractor shall undertake a controlled trafficking trial on top of the constructed foundation in the
demonstration area.
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(03/20) Trial Procedure

17 (03/20) Mark out intended running track for the vehicle to ensure same wheelpath is followed in each pass.
18 (03/20) Using a heavy goods vehicle, undertake a number of passes of the demonstration area along the marked
out running track to achieve a number of passes equivalent to 1000 standard axles.
19 (03/20) At 10 metre intervals and where instructed by the Overseeing Organisation, measure vertical
deformation in the wheelpath in accordance with Clause 886 using a straight edge with a length of at least 2 m.
20 (03/20) The wheelpath deformation shall not exceed the limits in Clause 886 along any section of trial length.
884 (03/20) Permanent Works Performance Assessment for Performance Foundations

(03/20) Scope
1 (03/20) This Clause outlines the performance testing required when constructing a performance foundation in
addition to other compliance testing outlined in the specification.
(03/20) Information Required
2 (03/20) For each foundation area, records of the performance test results for each construction stage, referenced
to the following condition details shall be stored and presented on request to the Overseeing Organisation in a
digital spreadsheet format:
(i) Subgrade surface modulus value immediately before foundation construction;
(ii) Date and time of mixing (for stabilised and slow-setting materials);
(iii) Date and time of placing and compaction;
(iv) Date of performance testing;
(v) Values of foundation surface modulus recorded;
(vi) Values of material properties including density and layer thickness;
(vii) Weather conditions including temperature; and
(viii) Sampling and testing records.

Volume 1 Series 800
(03/20) Performance Assessment
3 (03/20) Within 48 hours prior to construction of the overlying pavement layers, the foundation surface modulus
shall be tested in accordance with Clause 885 at 20 m intervals along each lane, staggered by 10 m between
adjacent lanes. Tests shall coincide with subgrade surface modulus and density tests where appropriate.
4 (11/21) The foundation surface modulus values achieved shall meet or exceed that detailed in Table 8/18 for the
corresponding material and foundation class.
5 (11/21) A foundation containing unbound materials that fails to comply with the performance requirements
detailed in Table 8/18 when the recorded moisture content is in excess of that in the demonstration area, may be
re- tested for compliance when the foundation moisture content has reduced to that in the demonstration area.
6 (11/21) Where surface modulus performance values do not meet the requirements detailed in Table 8/18 the
foundation is required to be re-designed. Where detailed in contract specific Appendix 1/10 the Contractor shall
redesign the foundation in accordance with CD 225 (DMRB), and another demonstration area constructed.
7 (03/20) Ruts that develop under construction traffic, measured in accordance with this Clause, shall nowhere
exceed the limits in Clause 886.
885 (03/20) Top of Foundation Performance Assessment

(03/20) Scope
1 (03/20) The procedure described in this clause is for establishing the foundation surface modulus of newly
constructed performance foundations.
(03/20) Foundation Surface Modulus Measurement
2 (03/20) The foundation surface modulus shall be measured using either:
(i) FWD; and
(ii) LWD based on a site-specific correlation versus an FWD.
3 (03/20) FWD testing shall be undertaken using a calibrated FWD in accordance with BS 1924-2.
4 (03/20) LWD testing shall be undertaken using a calibrated LWD in accordance with BS 1924-2 and requires a
site-specific correlation versus a FWD undertaken in the performance foundation demonstration area.
5 (03/20) The site specific correlation for an LWD shall be established in accordance with BS 1924-2.
6 (03/20) Where a Lightweight Deflectometer is being used, testing shall either be undertaken to:
(i) Procedure A – the standard target stress as per BS 1924-2; or
(ii) Procedure B – a range of target stresses centred around 100 kPa specified in order to determine stress
dependency.
7 (11/21) Table 8/18 gives the mean foundation surface modulus and minimum foundation surface modulus
values, for each foundation class, and for different categories of materials, that shall be met at the top of foundation
level immediately prior to the construction of the overlying pavement layers.

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Volume 1 Series 800
TABLE 8/18 (11/21) Foundation Surface Modulus Requirements
Foundation Class Class 1 Class 2 Class 3 Class 4

Unbound mixtures 40 80 N/A N/A
Mean of 5 foundation surface modulus tests
Fast-setting mixtures 50 100 300 600
(MPa)
Slow-setting mixtures 40 80 150 300
Unbound mixtures 30 50 N/A N/A
Minimum of any foundation surface modulus
Fast-setting mixtures 30 50 150 300
test (MPa)
Slow-setting mixtures 30 50 75 150
886 (03/20) Wheelpath Deformation Measurement

(03/20) Scope
1 (03/20) This procedure shall be used at the top of a pavement foundation to measure and provide limitations to
deformation in the foundation under construction trafficking.
(03/20) Procedure
2 (03/20) Apparatus required:

(i) Straight edge with a minimum length of 2 m;
(ii) Two identical blocks; and
(iii) Ruler.
3 (03/20) The straight edge shall be placed transverse to the rut and raised clear from the rut by two identical
blocks. The blocks shall be placed on undisturbed material outside the wheel path. The amount of deformation shall
be the difference of the foundation (A) and the height of the blocks (B), see Figure 8/2.
FIGURE 8/2: (03/20) Wheelpath Deformation
4 (03/20) Ruts that develop under construction traffic, measured in accordance with this Clause, shall nowhere
exceed the following limits:
(i) All bound surfaces – 10 mm;
(ii) < 250 mm design thickness of granular material – 30 mm; and
(iii) ≥ 250 mm design thickness of granular material – 40 mm.

42F
SERIES 900
ROAD PAVEMENTS – BITUMINOUS BOUND
MATERIALS
Contents
Clause Title Page
Clause Title Page
922 (05/18) Surface Dressing: Design, 23
900 (05/18) General 3 Application and End Product
Performance
901 (05/18) Bituminous Mixtures 3
923 (05/18) Cold Applied Ultra-Thin 26
902 (05/18) Reclaimed Asphalt 5 Surfacing
903 (05/18) Placing and Compaction
924 (05/18) High Friction Surfaces 29
of Bituminous Mixtures 6
925 (05/18) Testing of Bituminous Mixtures 30
904 (05/18) Hot Rolled Asphalt Base 9
926 (05/18) In Situ Recycling: The Repave 30
905 (05/18) Hot Rolled Asphalt Binder 9 Process
Course (Recipe Mixtures)
927 & 928 (05/18) Not Used 31
906 (05/18) Dense Base and Binder Course 10
Asphalt Concrete with Paving Grade 929 (05/18) Dense Base and Binder Course 31
Bitumen (Recipe Mixtures) Asphalt Concrete (Design Mixtures)
907 (05/18) Regulating Course 10 930 (05/18) EME2 Base and Binder Course 32
Asphalt Concrete
# 908 (07/21) Warm Mix Asphalt 10
931 to 935 (07/19) Not Used 36
909 (05/18) 6 mm Dense Asphalt Concrete 12
Surface Course 936 (07/19) Geosynthetics and Steel Meshes:36
Installation and End Product Performance
910 (05/18) Hot Rolled Asphalt Surface 12
Course (Recipe Mixtures) 937 (05/18) Stone Mastic Asphalt (SMA) 38
Binder Course and Regulating Course
#911 (05/18) Hot Rolled Asphalt Surface 13
Course (Design Mixtures) 938 (05/18) Porous Asphalt 40
912 (05/18) Close Graded Asphalt Concrete 13 939 to 941 (05/18) Not Used 40
Surface Course
#942 (05/18) Thin Surface Course Systems 40
913 (05/18) Not Used 14
943 (05/18) Hot Rolled Asphalt Surface 47
914 (05/18) Fine Graded Asphalt Concrete 14 Course and Binder Course (Performance-
Surface Course Related Design Mixtures)
915 (05/18) Coated Chippings for Application 14 944 (05/18) Not Used 48
to Hot Rolled Asphalt Surfacings
945 (05/18) Weather Conditions for Laying 48
916 & 917 (05/18) Not Used 14 of Bituminous Mixtures
918 (05/18) Slurry Surfacing Incorporating 14 946 (05/18) Local Repairs 49
Microsurfacing
947 (05/18) In Situ Cold Recycled Bound 51
919 (05/18) Surface Dressing: Recipe 18 Material
Specification
948 (05/18) Ex Situ Cold Recycled Bound 59
920 (05/18) Bond Coats, Tack Coats and 20 Material
Other Bituminous Sprays
949 (05/18) Not Used 65
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921 (05/18) Surface Macrotexture of 22

Bituminous Surface Courses 950 (05/18) Surface Preservation Systems 65
Amendment – July 2021 1

Clause Title Page

951 (05/18) Torque Bond Test 65
952 & 953 (05/18) Not Used 66
954 (05/18) Method for Laboratory 66
Determination of Interface Properties
Using the Modified Leutner Shear Test
955 (05/18) Ageing Profile Test Using a 71
Modified Rolling Thin Film Oven Test
(MRTFOT)
956 & 957 (05/18) Not Used 81
958 (05/18) Modified Binder Storage 81
Stability Test

IRELAND
Clause Title Page
Scotland
908TS (07/21) Warm Mix Asphalt (WMA) S1
911TS (07/21) Hot Rolled Asphalt Surface S2
Course (Design Mixtures)
942TS (07/21) Stone Mastic Asphalt Surface S3F
Course (TS2010)
Wales
908WG (07/21) Warm Mix Asphalt (WMA) W1
911WG (07/21) Hot Rolled Asphalt Surface W1
Course (Design Mixtures)
942WG (07/21) Welsh Government Procedure W2F
and Advice Guidance (PAG) 112/20 –
Stone Mastic Asphalt Specification
Northern Ireland
908NI (07/21) Warm Mix Asphalt (WMA) N1F
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has a substitute National Clause or Sample Contract Specific
Appendix for one or more of the Overseeing Organisations of
Scotland, Wales or Northern Ireland.

Volume 1 Series 900
Specification for Highway Works Road Pavements – Bituminous Bound Materials
ROAD PAVEMENTS – BITUMINOUS BOUND

MATERIALS
900 (05/18) General
901 (05/18) Bituminous Pavement Mixtures

(05/18) General
1 (07/21) This Clause gives general requirements for production of bituminous mixtures, as well as the
properties of the aggregates and bitumen used in plant-produced mixtures. These requirements shall apply to all
plant produced bituminous mixtures unless otherwise specified in contract specific Appendix 7/1 or where other
requirements are given in specific Clauses in this Series.
2 (07/21) Asphalt mix formulations produced and supplied in accordance with BS EN 13108 shall be CE marked.
3 (07/21) The Contractor shall submit the Declaration of Performance which demonstrates that the asphalt mix
formulation provides the performance required by the specification.
(05/18) Aggregates for Bituminous Mixtures
4 (07/21) Natural, recycled unbound and manufactured (artificial) aggregates shall be clean, hard and durable
and comply with BS EN 13043 and be CE marked and have a declared performance which demonstrates that the
aggregate meets the requirements of the specification.
5 (07/21) Where recycled coarse aggregate or recycled concrete aggregate is used in bituminous mixtures, it shall
have been tested in accordance with Clause 710.
6 (07/21) The content of other materials (Class X) including wood, plastic and metal shall not exceed 1% by mass.
7 (07/21) Reclaimed asphalt shall comply with Clause 902.
8 (07/21) The use of aggregate derived as a by-product during the extraction of china clay is permitted. It shall
comply with the requirements of this Clause, BS EN 13043 and the examples of the relevant annex of PD 6691.
(05/18) Crushed Slate Aggregate
9 (07/21) The use of crushed slate aggregate is only permitted in base and binder course layers. It shall not be used
in surface layers.
10 (07/21) Crushed slate aggregate shall comply with the requirements of this Clause, BS EN 13043 and the
examples of the relevant annex of PD 6691.
11 (07/21) The flakiness category of crushed slate aggregate shall be approved by the Overseeing Organisation.
12 (07/21) Mixtures of crushed slate aggregate with coarse aggregate of a different geological type shall not be
permitted.
(05/18) Resistance to Fragmentation (Hardness)
13 (07/21) When tested in accordance with clause 4.2.2 of BS EN 13043 and unless otherwise stated in contract
specific Appendix 7/1 the resistance to fragmentation of the coarse aggregates for bituminous mixtures shall meet
the following criteria:
(i) ≤ LA30 for natural aggregates and ≤ LA50 for blast furnace slag; or
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Volume 1 Series 900
(ii) for aggregates greater than LA30 but less than LA35, where evidence can be presented to the Overseeing
Organisation of previous satisfactory use of the source in asphalt.
(05/18) Resistance to Freezing and Thawing (Durability)
14 (07/21) When required in contract specific Appendix 1/5, the resistance of the coarse aggregate to freezing and
thawing shall be declared.
15 (07/21) The freezing and thawing (soundness) category, as defined in BS EN 13043 clause 4.2.9.2, shall be
MS25 unless otherwise specified in contract specific Appendix 7/1.
16 (07/21) The water absorption value of the coarse aggregate shall be determined in accordance with
BS EN 13043 clause 4.2.9.1.
17 (07/21) If the water absorption value of the coarse aggregate is greater than WA242, the soundness test shall be
carried out on the material delivered to site. The requirements for water absorption do not apply to blast furnace
slag aggregate.
(05/18) Cleanliness
18 (07/21) Unless otherwise specified in contract specific Appendix 7/1, the proportion of coarse and fine
aggregates for bituminous mixtures passing the 0.063 mm test sieve (fines content) shall not exceed the limits
stated in BSI PD 6691 Annex B, Annex C and Annex D, when tested in accordance with the washing and sieving
method of BS EN 933-1.
(05/18) Resistance to Polishing and Surface Abrasion
19 (07/21) When specified in the appropriate Clause or contract specific Appendix 7/1, the aggregate shall conform
to the required declared PSV category in accordance with BS EN 13043 clause 4.2.3 and BSI PD 6682-2 clause
4.3.2.
20 (07/21) The resistance to surface abrasion of coarse aggregate used in surface courses in accordance with
BS EN 13043 clause 4.2.3 and BSI PD 6682-2 clause 3.3.3, shall conform to category AAV10 unless otherwise
specified in the appropriate Clause or in contract specific Appendix 7/1.
(05/18) Chemical Requirements
(05/18) Dicalcium Silicate Disintegration

21 (07/21) Air-cooled blast furnace slag aggregates shall be free from iron dicalcium silicate disintegration as
defined in BS EN 13043:2002, clause 4.3.4.1.
(05/18) Iron Disintegration
22 (07/21) Air-cooled blast furnace slag aggregates shall be free from iron disintegration as defined in
BS EN 13043:2002, clause 4.3.4.2.
(05/18) Volume Stability
23 (07/21) The volume stability category of steel slag aggregates as defined in BS EN 13043, clause 4.3.4.3 shall
not exceed V10.
(05/18) Bitumen
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24 (07/21) Paving grade bitumen shall comply with BS EN 12591.

25 (07/21) Polymer modified bitumen shall comply with BS EN 14023.

Volume 1 Series 900
(05/18) Asphalt Durability – Base and Binder Course

26 (07/21) The water sensitivity of base and binder course mixtures designed in accordance with Clause 929 and
to be used on trunk roads including motorways shall be determined by testing in accordance with Method A of
BS EN 12697‑12.
27 (07/21) The minimum Indirect Tensile Strength Ratio (ITSR) shall be ITSRmin70.
28 (07/21) Mixtures that include 2% hydrated lime filler are deemed to result in mixtures which satisfy water
sensitivity requirements and testing is not required. Hydrated lime filler shall be Ca(OH)2 in the form of hydrated
lime, type CL 90-S.
902 (05/18) Reclaimed Asphalt

1 (05/18) The requirements of this clause apply to all bituminous mixtures containing reclaimed asphalt.
2 (05/18) Reclaimed asphalt may be used in the production of bituminous surface course, binder course,
regulating course and base. Unless otherwise specified in contract specific Appendix 7/1, the use of reclaimed
asphalt shall be in accordance with:
(i) Clause 942 for surface course mixtures specified in Clause 942;
(ii) BSI PD 6691, B.2.4.4 for Asphalt Concrete mixtures (macadams);
(iii) BSI PD 6691, C.2.3.4 for Hot Rolled Asphalt mixtures;
(iv) BSI PD 6691, D.2.2.3 for Stone Mastic Asphalt mixtures.
Other recycled materials shall only be used in bituminous mixtures with the approval of the Overseeing
Organisation. The mixed material shall comply with the requirements of all the relevant Clauses in this Series.
(05/18) Reclaimed Feedstock
3 (05/18) All reclaimed material shall be pre-treated before use such that it is homogeneously mixed and the
maximum particle size does not exceed 32 mm.
(05/18) Properties of Binder
4 (05/18) The fresh bitumen added to the mixture shall not be more than two grades softer than the nominal
grade for the mixture given in Table 12 of BSI PD 6691. Checks on the penetration of the binder recovered
from the reclaimed asphalt, together with a calculation of the properties of the combined binder, shall be
carried out in accordance with the relevant parts of BS EN 13108. When more than 10% of reclaimed asphalt is
incorporated in a mixture, tests on binder recovered from the mixture shall be carried out following the example in
BSI PD 6691 13.3.6.2. The results shall be within the limits set out in BSI PD 6691 13.3.6.2.
(05/18) Mixed materials containing more than 25% reclaimed asphalt
5 (05/18) When more than 25% of reclaimed asphalt is incorporated in a designed base or binder course
mixture, cores taken to assess compliance with Clause 929.12 or Clause 930.14 shall also be tested for stiffness
in accordance with BS EN 12697-26 (ITSM method 20°C). The frequency of testing shall be agreed with the
Overseeing Organisation prior to the commencement of works and shall comply with the requirements of contract
specific Appendices 1/5 and 1/6.
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6 (05/18) The stiffness of the mixture shall comply with the appropriate category from Table 9/1.
TABLE 9/1: (05/18) Stiffness Categories for Designed Base and Binder Course Mixtures
Incorporating Greater than 25% Reclaimed Asphalt
Nominal binder grade of mixture Stiffness category
(Smin)
10/20 5500
15/25 5500
30/45 2800
40/60 1800
903 (05/18) Placing and Compaction of Bituminous Mixtures

(05/18) General
1 (05/18) This Clause gives general requirements for the placing and compaction of bituminous mixtures, which
are complementary and additional to the requirements of BS 594987. These requirements and the requirements
of BS 594987 apply to all bituminous mixtures, unless otherwise specified in the other Clauses in this Series or in
2 (07/21) Bituminous pavements shall be laid by organisations registered to and operating in compliance with
BS EN ISO 9001 ‘National Highways Sector Scheme 16 for the Laying of Asphalt Mixes’ or equivalent listed in
Appendix A and constructed using the materials specified in contract specific Appendix 7/1.
3 (07/21) There shall be full interlayer bonding between bituminous layers. This may be achieved by keeping the
surface of the bituminous layers clean and uncontaminated, and by excluding moisture.
4 (07/21) Unless agreed with the Overseeing Organisation, the only traffic permitted to run on the surface of
bituminous material to be overlaid shall be that engaged in laying and compacting the next course or, where a
binder course is to be blinded or surface dressed, that is engaged on such surface treatment.
5 (07/21) If full interlayer bonding cannot be achieved due to surfaces becoming contaminated, the surfaces shall
be made good by cleaning and, if this proves impracticable, by rectification in compliance with Clause 702.
6 (07/21) Prior to placing bituminous material on any new or existing bound substrate, a bond coat or shall be
applied in accordance with Clauses 920 or 942, as appropriate.
7 (07/21) Before work commences, the Contractor shall submit a method statement to the Overseeing
Organisation that includes:
(i) laying and compaction procedures for each layer – including paving speed and paved width; size, type
and number of rollers; number of roller passes; and laying and compaction temperatures;
(ii) the joint formation procedures for each layer – including the location of longitudinal and transverse
joints; and the method(s) of treating upstanding edges.
(05/18) Transporting
8 (07/21) Bituminous mixtures shall be transported in accordance with the requirements of BS 594987 and shall
remain covered whilst awaiting tipping.
(05/18) Laying
9 (07/21) Bituminous mixtures shall be laid in accordance with the requirements of BS 594987 and
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sub- Clauses 10 to 19 of this Clause.

Volume 1 Series 900
10 (07/21) Surfacings specified under Clause 942 shall also be laid in accordance with the additional requirements
of that Clause.
11 (07/21) Wherever practicable, bituminous mixtures shall be spread, levelled and tamped by a self-propelled
paving machine.
12 (07/21) Where the rate of delivery of material to the paver is intermittent for any reason, and the temperature of
the material falls below that recommended by the manufacturer for laying, the cold material shall be removed and a
perpendicular joint formed in accordance with Clause 903.35 before laying recommences.
13 (07/21) Hand placing of bituminous mixtures shall be restricted to the following circumstances:
(i) for laying regulating courses of irregular shape and varying thickness;
(ii) in confined spaces where it is impracticable for a paver to operate;
(iii) for footways;
(iv) at the approaches to expansion joints at bridges, viaducts or other structures; and
(v) for laying mastic asphalt.
14 (07/21) Hand-raking of surface course material or the addition of such material by hand-spreading to the paved
area, for adjustment of level, shall be restricted to the following circumstances:
(i) at the edges of the layers of material and at gullies, manholes and other ironwork; and
(ii) at the approaches to expansion joints at bridges, viaducts or other structures.
15 (07/21) The method of laying shall be such that the finished mat is free from dragging, tearing and segregation
of the material.
16 (07/21) When laying mixtures from more than one source, the mixtures shall have equivalent laying and
compaction characteristics so that surface evenness is not compromised.
17 (07/21) When paving adjacent to an expansion joint of a structure, the joint or joint cavity shall be kept clear of
material.
18 (07/21) When laying binder course or surface course, the paver shall be taken out of use whilst laying the
remainder of the pavement up to the joint and the corresponding area beyond it.
19 (07/21) When paving directly onto bridge deck waterproofing systems, any special requirements which apply to
that system shall be complied with.
(05/18) Compaction
20 (07/21) The compaction of bituminous mixtures shall be in accordance with BS 594987 and the requirements
for specific mixtures in:
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(i) Clause 929 for dense base and binder course asphalt concrete (design mixtures);
(ii) Clause 930 for EME2 mixtures; and
(iii) Clause 942 for thin surface course systems.
21 (07/21) Except where otherwise specified, rollers shall comply with the general requirements of BS 594987.
22 (07/21) The minimum mass of deadweight smooth wheeled rollers shall be 8 tonnes.
23 (07/21) Multi-wheeled pneumatic tyred rollers and vibratory rollers shall only be used if they are capable of
achieving at least the standard of compaction of an 8-tonnes deadweight roller.
24 (07/21) Where compaction is to be determined in accordance with Clauses 929 and 930, the requirements to
prove the performance of rollers do not apply. In such cases, the Contractor is permitted use any plant to achieve
the specified level of compaction and shall carry out compaction at temperatures above the minimum specified
rolling temperature.
25 (07/21) Vibratory rollers shall not be used in vibrating mode on bridge decks.

Volume 1 Series 900
(05/18) Chippings
26 (07/21) The application of coated chippings to areas of surface course shall be by a mechanical spreader capable
of distributing chippings to an even rate of spread.
27 (07/21) Addition of chippings by hand operation shall only be permitted in the following circumstances:
(i) in confined spaces, where it is impracticable for a chipping spreader to operate;
(ii) as a temporary expedient, when adjustments have to be made to the spreader distribution mechanism;
(iii) when hand laying of the surface course is permitted; and
(iv) to correct uneven distribution of chippings.
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28 (07/21) Chippings shall be applied uniformly and rolled into the surface so they are effectively held and provide
the initial macrotexture depth specified in Clause 921.
(05/18) Joints
29 (07/21) For new, widened and realigned pavement construction, all longitudinal joints in all layers shall be
situated outside wheel track zones.
30 (07/21) For the purposes of this Clause, for a 3.65m wide lane, the wheel track zones shall be taken to be
between 0.5m and 1.1m and between 2.55m and 3.15m from the centre of the nearside lane markings for each
traffic lane (or, in the absence of lane markings, lane edges).
31 (07/21) Where the lane width is other than 3.65m then each wheel track zone shall be taken to be 0.6m wide
with the inside edges of the wheel track offset from the centre of the lane by 0.72m.
32 (07/21) Where an existing road pavement is resurfaced, joints in the surface course shall coincide with either the
lane edge, the lane marking, or the middle of a traffic lane, whichever is appropriate.
33 (07/21) Joints shall not coincide with the wheel path.
34 (07/21) Stepping of all joints shall be offset by 300mm from parallel joints in the layer beneath.
35 (07/21) Where indicated on the drawings, or in contract specific Appendix 7/1, that the requirements of 300mm
steps and prohibition of joints in wheel track zones cannot be met, for example due to new lane configuration, the
joints shall be offset as close as practicable to 300mm but not less than 150mm and only if the layer above is less
than 150mm thick.
36 (07/21) Unless otherwise specified in contract specific Appendix 7/1, the faces of all cold upstanding edges,
including previously laid asphalt, against which bituminous mixtures are to be laid to form joints shall be treated
with one of the following:
(i) hot bituminous binder with a penetration value of not less than 40/60;
(ii) hot elastomeric polymer-modified bituminous binder complying with BS EN 14023 with a penetration
Class 4; and
(iii) cold applied thixotropic bituminous compound of similar bitumen or polymer-modified bitumen grade;
or
(iv) polymer-modified adhesive bitumen strip with a minimum thickness of 2mm.
37 (07/21) This operation shall be done so that the binder adheres to both the cold and the warm upstanding edges
when the asphalt is placed.
38 (07/21) Unless otherwise specified in contract specific Appendix 7/1, joints in binder courses and bases shall be
compacted such that the air voids content measured from core pairs whose centres are not more than 100mm from
the final joint is not greater than 2% above the maximum permitted limit for core pairs in the body of the mat.
39 (07/21) The air voids content shall be calculated in accordance with BS EN 12697-8 using the relevant bulk and
maximum densities defined in Appendix B of BS EN 13108-20 for the relevant mixture type.

Volume 1 Series 900
40 (07/21) Within 24 hours of the joint being formed, a sealant shall be applied to the top surface of all base and
binder course joints such that there is not less than 0.50 kg/m2 of residual bitumen 75mm either side of the joint,
41 (07/21) The sealant, which may contain mineral filler to BS EN 13043, shall be one of the following:
(i) hot elastomeric polymer-modified bituminous binder complying with BS EN 14023 with a penetration
Class 4;
(ii) bitumen emulsion with a cohesion by pendulum of Class 4 or above in accordance with BS EN 13808;
or
(iii) slurry surfacing complying with Clause 918.
(05/18) Regulating Course
42 (07/21) Regulating course material shall be produced and laid in accordance with the requirements of Clause
907.
(05/18) Use of Surfaces by Traffic
43 (07/21) Where a new bituminous layer other than the surface course is to be opened to highway traffic as a
temporary running surface it shall either:
(i) be surface dressed in accordance with Clause 919 using chippings of category not less than PSV50,
unless otherwise specified in contract specific Appendix 7/1; or
(ii) contain a coarse aggregate of category of not less than PSV50, unless otherwise specified in contract
44 (07/21) Construction plant and traffic shall not be permitted to damage the subgrade or the pavement courses
already constructed.
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45 (07/21) Temporary running surfaces used by construction traffic shall be kept free of deleterious materials.
904 (05/18) Hot Rolled Asphalt Base

1 (05/18) Hot Rolled Asphalt base recipe mixes shall conform to BS EN 13108-4, the detailed requirements of
the example in BSI PD 6691 Annex C and requirements specified in contract specific Appendix 7/1. The mixture
designation shall be one of the following:
(i) HRA 60/32 base 40/60.
(ii) HRA 60/32 base 30/45.
(iii) HRA 60/20 base 40/60.
(iv) HRA 60/20 base 30/45.
905 (05/18) Hot Rolled Asphalt Binder Course (Recipe Mixtures)

1 (05/18) Hot Rolled Asphalt binder course recipe mixes shall conform to BS EN 13108-4, the example in
BSI PD 6691 Annex C and requirements specified in contract specific Appendix 7/1. The mixture designation shall
be one of the following:
(i) HRA 60/32 bin 40/60.
(ii) HRA 60/32 bin 30/45.
(iii) HRA 60/20 bin 40/60.
(iv) HRA 60/20 bin 30/45.

Volume 1 Series 900
906 (05/18) Dense Base and Binder Course Asphalt Concrete (Recipe Mixtures)
1 (05/18) Dense base and binder course asphalt concrete (formerly macadam) recipe mixtures shall be asphalt
concrete conforming to BS EN 13108-1, the detailed requirements from BSI PD 6691 Annex B and requirements
specified in contract specific Appendix 7/1. The mixture designation shall be one of the following:
(i) AC 32 dense base 40/60 rec.
(ii) AC 32 dense base 100/150 rec.
(iii) AC 32 dense base 160/220 rec.
(iv) AC 32 dense bin 40/60 rec.
(v) AC 32 dense bin 100/150 rec.
(vi) AC 32 dense bin 160/220 rec.
(vii) AC 20 dense bin 40/60 rec.
(viii) AC 20 dense bin 100/150 rec.
(ix) AC 20 dense bin 160/220 rec.
907 (05/18) Regulating Course

1 (05/18) Regulating courses, which may consist of one or more layers of a bituminous material, shall have their
finished surfaces laid to achieve the appropriate tolerances for horizontal alignments, surface levels and surface
regularity for pavement layers, in accordance with Clause 702.
2 (05/18) Unless otherwise specified in contract specific Appendix 7/1, stone mastic asphalt complying with
Clause 937, or base or binder course asphalt concrete complying with Clause 929 or hot rolled asphalt complying
with Clause 943, shall be used for regulating courses immediately below surface courses. Bituminous mixtures for
regulating courses shall meet the requirements for the appropriate material, as specified above.
3 (05/18) Where the total depth of a regulating course exceeds 150 mm then the course shall be laid so that each
regulating layer has a compacted thickness of between 75 mm and 150 mm.
908 (07/21) Warm Mix Asphalt (WMA)

(07/21) WMA General
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1 (07/21) WMAs shall be installed in accordance with the producer’s instructions.

(07/21) WMA Permitted Mixtures
2 (07/21) Mixtures produced as Warm Mix Asphalts shall fulfil the requirements given in:
(i) Clause 906 for Dense Base and Binder Course Asphalt Concrete with Paving Grade Bitumen (Recipe
Mixtures);
(ii) Clause 912 for Close Graded Asphalt Concrete Surface Course;
(iii) Clause 929 for Dense Base and Binder Course Asphalt Concrete (Design Mixtures);
(iv) Clause 930 for EME2 Base and Binder Course Asphalt Concrete;
(v) Clause 937 for Stone Mastic Asphalt (SMA) Binder Course and Regulating Course;
(vi) Clause 942 for Thin Surface Course Systems; and
(vii) Clause 901 and Clause 903 and contract specific Appendix 7/1.

Volume 1 Series 900
3 (07/21) Warm mixtures conforming to Clause 942 shall have Product Acceptance Scheme certification for their
installation in compliance with sub-Clause 104.16 and Clause 942 to demonstrate their performance.
4 (07/21) For the purposes of traceability, the mixture designation shall include a reference to the use of warm mix
technologies e.g AC20 bin HDM 40/60 "W".
(07/21) WMA Production Temperatures
5 (07/21) The maximum production temperatures, when measured in accordance with BS EN 12697-13, shall be
in accordance with Table 9/1A and the material's Declaration of Performance and not compromise the efficacy of
the binder, additives or process.
Table 9/1A (07/21) Maximum production temperatures for WMAs incorporating paving grade
binders, hard paving grade binders or Polymer Modified Binders
Binder grade Maximum Temperature (°C)
(at any stage)
Paving grade conforming to BS EN 12591 150
Hard paving grade conforming to BS EN 13924-1 160
Documented and declared by
Polymer Modified Binder conforming to BS EN 14023
the producer
(07/21) Water Sensitivity

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6 (07/21) Unless otherwise stated in contract specific Appendix 7/1, the water sensitivity expressed as an Indirect
Tensile Strength Ratio or Compression strength ratio shall be in accordance with Table 9/1B and contract specific
Appendix 7/1 and be declared on the Declaration of Performance.
7 (07/21) Designated WMA mixtures in Table 9/1B which include 2% hydrated lime filler aggregate are deemed
to result in mixtures which satisfy water sensitivity requirements and testing is not required. Hydrated lime filler
shall be Ca(OH)2 in the form of hydrated lime, type CL 90-S.
Table 9/1B (07/21) Minimum Water Sensitivity Values for Warm Mix Asphalts
Material Clause and Description SHW ITSRmin BS EN 12697 12
Clause Test Method
Dense Base and Binder Course Asphalt Concrete
929
(Design Mixtures)
Stone Mastic Asphalt (SMA) Binder Course and 80 A
937
Regulating Course
Thin Surface Course Systems 942
EME2 Base and Binder Course Asphalt Concrete 930 See sub-clause 930.21 B
(07/21) WMA Installation
8 (07/21) Mixtures produced as WMA shall comply with the requirements in Clause 903, contract specific
Appendix 7/1, Table 9/1C and the producer's recommendations and not compromise the efficacy of the WMA
binder, additives or process.

Volume 1 Series 900
Table 9/1C (07/21) Minimum Rolling Temperatures for WMAs Incorporating Paving Grade
Binders, Hard Paving Grade Binders or Polymer Modified Binders
Binder grade Minimum Temperature (°C) (immediately
prior to rolling)
Polymer Modified Binder conforming to BS EN 14023 Documented and declared by the producer
(07/21) WMA Carbon Footprint (Reduction) Measurement
9 (07/21) The Contractor shall report CO2 emissions for asphalt using the calculation tool detailed at: https:// www.
gov.uk/government/publications/carbon-tool.
10 (07/21) A cradle-to-gate carbon footprint analysis shall be submitted by the Contractor to the Overseeing
Organisation and for Highways England contracts by email to: aspect@highwaysengland.co.uk for each WMA
mixture in accordance with sub-Clause 9.
11 (07/21) The carbon footprint analysis shall be conducted in accordance with TRL PPR 575 – Protocol for the
calculation of whole life cycle greenhouse gas emissions generated by asphalt, covering Steps 1 to 5 of the asphalt
life cycle, from ‘raw material acquisition’ to ‘road component production’.
12 (07/21) The carbon footprint shall be stated in kgCO2e per tonne of the warm mixture and broken down into
totals for Steps 1-3, Step 4 and Step 5.
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909 (05/18) 6 mm Dense Asphalt Concrete Surface Course

1 (05/18) 6 mm dense asphalt concrete (formerly macadam) surface course shall be asphalt concrete conforming
to BS EN13108-1, the example in BSI PD 6691 Annex B and requirements specified in contract specific
Appendix 7/1. The mixture designation shall be one of the following:
(i) AC 6 dense surf 100/150.
(ii) AC 6 dense surf 70/100.
(05/18) Coarse Aggregate
2 (05/18) To ensure adequate resistance to polishing and abrasion, the coarse aggregate shall have a minimum
declared PSV as specified in contract specific Appendix 7/1, in accordance with BS EN 13043:2002, clause 4.2.3.
and BSI PD 6682-2, and shall have a maximum declared AAV, as specified in contract specific Appendix 7/1, in
accordance with BS EN 13043:2002, clause 4.2.4 and BSI PD 6682-2.
910 (05/18) Hot Rolled Asphalt Surface Course (Recipe Mixtures)

1 (05/18) Hot Rolled Asphalt surface course recipe mixtures shall conform to BS EN 13108-4, the example
of BSI PD 6691 Annex C, and the requirements specified in contract specific Appendix 7/1. Unless otherwise
specified in contract specific Appendix 7/1, the mixture designation shall be one of the following:
(i) HRA 0/2 F surf 40/60.
(ii) HRA 15/10 F surf 40/60.
(iii) HRA 30/10 F surf 40/60.
(iv) HRA 30/14 F surf 40/60.
(v) HRA 35/14 F surf 40/60.

Volume 1 Series 900
When the mixture designation is not specified in contract specific Appendix 7/1, the mixture selected by the
Contractor shall be notified to the Overseeing Organisation prior to its use in the works.
2 (05/18) The resistance to polishing of the coarse aggregate for chipped mixtures shall be category PSV44 as
defined in BS EN 13043:2002, clause 4.2.3. For unchipped mixtures, the coarse aggregate shall have a minimum
declared PSV and a maximum AAV as specified in contract specific Appendix 7/1.
(05/18) Coated Chippings
3 (05/18) When required, coated chippings shall be either 14/20 mm or 8/14 mm, as specified in contract specific
Appendix 7/1 and comply with Clause 915.
#911 (05/18) Hot Rolled Asphalt Surface Course (Design Mixtures)

1 (05/18) Hot Rolled Asphalt surface course design mixes shall conform to BS EN 13108-4, the example of
(i) HRA 0/2 F surf xx/yy des.
(ii) HRA 30/14 F surf xx/yy des.
(iii) HRA 35/14 F surf xx/yy des.
(iv) HRA 55/10 F surf xx/yy des.
(v) HRA 55/14 F surf xx/yy des.
(vi) HRA 0/2 C surf xx/yy des.
(vii) HRA 30/14 C surf xx/yy des.
(viii) HRA 35/14 C surf xx/yy des.
(ix) HRA 55/10 C surf xx/yy des.
(x) HRA 55/14 C surf xx/yy des.
Unless otherwise specified in contract specific Appendix 7/1, the grade of bitumen required (xx/yy) shall be 40/60.
declared PSV and a maximum AAV as specified in contract specific Appendix 7/1.
3 (05/18) When required, coated chippings shall be either 14/20 mm or 8/14 mm in accordance with
BSI PD 6682-2, as specified in contract specific Appendix 7/1. Coated chippings shall also comply with
Clause 915.
912 (05/18) Close Graded Asphalt Concrete Surface Course

1 (05/18) Close graded asphalt concrete (formerly macadam) surface course recipe mixes shall be asphalt concrete
conforming to BS EN 13108-1, the example of BSI PD 6691 Annex B and requirements specified in contract
specific Appendix 7/1. The mixture designation shall be one of the following:
(i) AC 10 close surf 100/150.
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(ii) AC 10 close surf 70/100.

(iii) AC 14 close surf 100/150.
(iv) AC 14 close surf 70/100.
declared PSV and a maximum AAV, as specified in contract specific Appendix 7/1.
913 (05/18) Not Used
914 (05/18) Fine Graded Asphalt Concrete Surface Course

1 (05/18) Fine graded asphalt concrete (formerly macadam) surface course recipe mixes shall be asphalt concrete
conforming to BS EN 13108-1, the example of BSI PD 6691 Annex B and requirements specified in contract
(i) AC 4 fine surf 160/220.
(ii) AC 4 fine surf 250/330.
915 (05/18) Coated Chippings for Application to Hot Rolled Asphalt Surfacings
1 (05/18) Coated chippings for rolling into the surface of hot rolled asphalt shall conform to BS EN 13108-4, the
example in BSI PD 6691 Annex C clause C.2.8 and requirements specified in contract specific Appendix 7/1.
3 (05/18) The shape of the chippings shall comply with category FI20 as defined in BS EN 13043:2002
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clause 4.1.6.
916 & 917 (05/18) Not used
918 (05/18) Slurry Surfacing Incorporating Microsurfacing

1 (05/18) The Contractor shall be responsible for the design of the Slurry Surfacing, choice of materials,
techniques and processes based on site and traffic data specified in contract specific Appendix 7/7 and the schedule
of constraints on site availability in contract specific Appendix 1/13.
(i) Provide a Design Proposal to achieve the performance requirements in terms of texture and maximum
levels of defects as set out in this Clause and in contract specific Appendix 7/7 ensuring that the Slurry
Surfacing has an initial stability such that it is capable of withstanding the normal traffic for the site
when first opened.
(ii) State the Estimated Design Life of the Slurry Surfacing in the Design Proposal.

Volume 1 Series 900
(iii) Provide a Quality Plan.

(iv) Carry out the Slurry Surfacing in accordance with the manufacturers installation instructions and the
Design Proposal to the thickness and tolerances specified in contract specific Appendix 7/7.
3 (05/18) The Contractor shall guarantee the design, materials and workmanship against defects and against
failure to meet the end performance requirements for a period of two years, or as otherwise specified in contract
specific Appendix 7/7, from the date of completion of the work. The Contractor shall rectify any defects identified
during the guarantee period.
(05/18) The System
4 (05/18) The proposed Slurry Surfacing shall comply with BS EN 12273 and it shall be CE marked. The
Contractor shall provide the declaration of performance and installation information as required in this Clause and
The declaration of performance shall demonstrate that the system meets the requirements of the specification and
provides performance categories for all of the items identified in this Clause and in contract specific Appendix 7/7.
(05/18) Aggregates
5 (05/18) The aggregate shall be crushed rock, slag, gravel or calcined bauxite, complying with this specification.
The coarse aggregate shall have a minimum declared PSV and a maximum AAV as specified in contract specific
Appendix 7/7. In the Design Proposal the Contractor shall provide the declaration of performance for the aggregate
which shall demonstrate that the aggregate shall meet the requirements of the specification including the properties
detailed in contract specific Appendix 7/7. The grading and binder content shall not differ from the proposed target
values by more than the tolerances detailed in the Design Proposal.
(05/18) Binder
6 (05/18) The Contractor shall provide, with his Design Proposal, the declaration of performance for the binder
which shall demonstrate that the binder shall meet the requirements of the specification including the properties
detailed in contract specific Appendix 7/7.
Contract compliance testing shall be carried out by the Contractor as detailed in contract specific Appendix
1/5. The recovery of the binder shall be carried out in accordance with Clause 955. The test to determine Vialit
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Pendulum Cohesion shall be carried out in accordance with BS EN 13588. The Contractor shall provide rheological
product identification data for modified binders in accordance with BS EN 14770.
(05/18) Coloured Materials
7 (05/18) Where required in contract specific Appendix 7/7 a coloured slurry surfacing shall be provided. All
coloured slurry surfacings shall be approved by the Overseeing Organisation. They shall conform in all respects
with the requirements of this Clause.
(05/18) Equipment
8 (05/18) The mixing machine shall be capable of uniform application and the provision of a continuous surface
without ridges or segregation.
(05/18) Health and Safety
9 (05/18) Health and Safety information and safe handling guidance shall be provided by the Contractor to the
(05/18) Layer Thickness
10 (05/18) When required, the minimum and/or maximum thickness of the Slurry Surfacing shall be as specified in

Volume 1 Series 900
(05/18) Preparation
11 (05/18) Any necessary remedial works to the road surface and structure shall be completed either prior to the
commencement of works, or as part of the contract and agreed as acceptable by the Overseeing Organisation and
the Contractor before Slurry Surfacing commences.
12 (05/18) Street furniture, and where specified in contract specific Appendix 7/7, road markings and kerbs, shall
be masked using self-adhesive masking material or other material firmly secured against the passage of the spreader
box or the tools used for hand laying. Any packed mud or other deposits on the road surface shall be removed, all
organic growth shall be removed by suitable means, and the road surface shall be swept free of all loose material.
13 (05/18) A bond coat complying with Clause 920 shall be applied prior to the Slurry Surfacing with or without
grit or chippings in order to seal the existing substrate and to enhance the bond to the existing road surface unless
the Contractor can demonstrate that sufficient bond will be developed without its use. This treatment shall be in
accordance with the Contractor’s method statement contained within his Design Proposal.
(05/18) Traffic Safety and Management
14 (05/18) Traffic Safety and Management shall be strictly in accordance with the requirements of Series 100 and
the site specific requirements specified in contract specific Appendix 1/17 and the constraints described in contract
(05/18) Mixing
15 (05/18) The Slurry Surfacing shall be mixed in a continuous flow mixing machine and discharged directly into
the spreader box. Where the material is to be hand laid the Slurry Surfacing may be mixed in a batch mixer or
supplied to site pre-mixed in suitable containers. The Quality Plan shall detail the precautions to be taken to achieve
a homogeneous mixture.
(05/18) Application
16 (05/18) Application restrictions to be observed in the event of adverse weather shall be as specified in this
Clause, the Contractor’s Method Statement and any additional requirements specified in contract specific
Appendix 7/7.
17 (05/18) Transverse joints shall be formed with spreading starting and finishing on a protective strip not less
than 100 mm wide at each end of the lane length or area being treated or such other method as defined in the
Contractor’s Method Statement to produce an equivalent standard. Transverse joints shall be formed such that there
shall be no ridges or bare strips.
18 (05/18) Unless otherwise agreed with the Overseeing Organisation, longitudinal joints, where the material is laid
on a road, shall coincide with lane markings. Longitudinal joints shall be formed such that there shall be no ridges
or bare strips.
19 (05/18) Handwork around street furniture and other ironwork shall meet the same performance requirements and
form a homogeneous surface with the rest of the treated carriageway.
20 (05/18) Footways and other confined areas may be spread by hand using squeegees and brooms. Kerb edges
and other areas not being treated shall be suitably masked with self-adhesive masking material. Footways shall
be finished by dragging a dampened broom transversely over the footway under its own weight or other method
producing a similar macrotexture or as stated in contract specific Appendix 7/7.
21 (05/18) All voids, cracks and surface irregularities shall be completely filled. Spreading shall not be undertaken
on carriageways when the temperature falls below 4°C or when standing water is present on the surface. In warm
dry weather, the surface immediately ahead of the spreading, shall be slightly damped by mist water spray applied
mechanically, or for hand laying by a hand operated pressure sprayer, unless otherwise agreed by the Overseeing
Organisation.
22 (05/18) The finished Slurry Surfacing shall have a uniform surface macrotexture throughout the work, without
variations of macrotexture within the lane width, or from area to area.
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Volume 1 Series 900
23 (05/18) The finished surface shall be free from blow holes and surface irregularities due to scraping, scabbing,
score marks, dragging, droppings, excess overlapping or badly aligned longitudinal or transverse joints, damage by
rain or frost, or other defects which remain 24 hours after laying. Slurry Surfacing which does not comply with this
Clause or is non-uniform in surface macrotexture or colour, 24 hours after laying shall be rectified by removal and
replacement, or superimposed if this is impractical, with fresh material in compliance with this Clause. Areas so
treated shall be not less than 5 m long and not less than one lane wide (or the full width if less than a lane wide). All
areas being worked on shall be kept free of traffic until the material has set sufficiently to carry the traffic.
24 (05/18) The Contractor shall record the amount of Slurry Surfacing used and the area covered for each run or
section completed.
25 (05/18) The Contractor shall facilitate duplicate or joint testing by the Overseeing Organisation if required.
(05/18) Aftercare
26 (05/18) Masking shall be removed after the Slurry Surfacing has been applied, without damage to the edge of
the surfacing, and before opening the road or footway to traffic. The ironwork shall be reset, if necessary, within
48 hours of application of the Slurry Surfacing.
27 (05/18) The Contractor shall remove surplus aggregate from the treated areas using a method stated in the
Quality Plan. The Contractor shall monitor the Slurry Surfacing closely for a minimum period of 2 hours and
if necessary the lane shall be swept again. The monitoring shall continue until the Slurry Surfacing has reached
sufficient stability to carry unrestricted traffic. If there are signs of distress the Contractor shall reinstate traffic
safety and management procedures or other such remedial action where necessary in order to prevent further
damage.
28 (05/18) Further operations to remove subsequently loosened aggregate shall be carried out over the next
48 hours. The areas treated and adjacent side roads, footways and paved areas shall be kept substantially free of
loose aggregate for a period of 30 days after completion of the work.
(05/18) As Built Manual
29 (05/18) Not more than 30 days after completion of the work the Contractor shall provide a record of the progress
of the work in the form of an As Built Manual incorporating all relevant information, including all contract
compliance test results, volumes of Slurry Surfacing used and areas covered with calculated thickness, record of
traffic control carried out, weather information, unforeseen problems, a list of complaints, if any, from the general
public or road users and any other information that the Overseeing Organisation may reasonably require to be
included.
(05/18) Performance Standards for Slurry Surfacing During the Guarantee Period
(05/18) Surface Macrotexture

30 (05/18) The Contractor is responsible for maintaining the surface macrotexture requirements set out in contract
specific Appendix 7/7 throughout the guarantee period.
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The definitive test is the volumetric patch technique measured in accordance with BS EN 13036-1 except that
10 individual measurements shall be made on the nearside (inside) wheel-track of the most heavily trafficked lane
or for low traffic category sites the track carrying the most stress. The average macrotexture depth of each lane
kilometre, or the complete carriageway lane where this is less than 1,000 metres, shall be as specified in contract
specific Appendix 7/7. The average of each set of 10 individual measurements shall be not less than 80% of the
minimum permitted.
(05/18) Surface Profile
31 (05/18) The surface profile of the slurry surfacing, when measured in accordance with Series 700, shall meet the
requirements specified in contract specific Appendix 7/7 for both transverse and longitudinal profile.

Volume 1 Series 900
(05/18) Defects
32 (05/18) When the extent of area and linear defects is monitored using the visual method of assessment in
accordance with BS EN 12274-8 the Slurry Surfacing shall have less than the permitted maximum level of defects
33 (05/18) Coloured materials shall retain their colour throughout the guarantee period to the level stated in the
34 (05/18) Any section failing to meet the required standard as specified in contract specific Appendix 7/7 shall be
subject to remedial action by the Contractor.
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919 (05/18) Surface Dressing: Recipe Specification

(i) Carry out the Surface Dressing in accordance with the design described in contract specific
Appendix 7/21 subject to the schedule of constraints on site availability set out in contract specific
Appendix 1/13. The supply and application of Surface Dressing to road surfaces shall be undertaken by
organisations registered to the National Highways Sector Scheme 13 for The Supply and Application of
Surface Treatments to Road Surfaces listed in Appendix A.
(ii) Be responsible for the choice of materials, techniques and processes subject to the requirements
described in contract specific Appendix 7/21. The tolerances permitted for this work shall be as specified
(iii) Provide a Quality Plan, which may be subject to audit by the Overseeing Organisation with respect to
the method of executing the work.
(iv) Guarantee the materials and workmanship against defects and against failure to meet the specification
for a period of one year, or as otherwise described in contract specific Appendix 7/21, from the date of
completion of the work.
(05/18) Materials and Equipment – Binder
2 (05/18) The binder shall be of the type and grade specified in the contract specific Appendix 7/21, complying
with BS EN13808 and be CE marked.
3 (05/18) The Contractor shall provide a Binder Data Sheet giving details of the properties specified in contract
specific Appendix 7/21 for each binder proposed. Contract compliance testing shall be carried out as detailed
in contract specific Appendix 1/5. The test to determine the Vialit Pendulum Cohesion shall be carried out in
accordance with BS EN 13588. The Contractor shall provide rheological product identification data for modified
binders in accordance with BS EN 14770. Health and Safety information and a safe handling guide from the
manufacturer shall be provided together with details of any weather restrictions placed upon the use of the binder.
4 (05/18) The binder sprayer shall be capable of uniform application at the designed rate of spread over a variable
or fixed width sufficient to allow a full lane width to be produced in a single pass. Before spraying begins the
Contractor shall provide the Overseeing Organisation with a test certificate showing test results for rate of spread
and accuracy of spread of binder carried out in accordance with the test methods in BS EN 12272-1 issued by an
appropriate organisation accredited in accordance with sub-Clause 105.4 for those tests demonstrating that the
binder sprayer has been tested, using the binder to be used in the Contract, not more than six weeks before the
commencement of the work, and that it complies with the requirements set out in contract specific Appendix 7/21.
(05/18) Materials and Equipment – Chippings
5 (05/18) The chippings shall be crushed rock, slag, gravel or calcined bauxite complying with BS EN 13043:2002,
and shall be CE marked and be of the size specified in contract specific Appendix 7/21. In his proposals, the
Contractor shall state the source and characteristics of chippings to be used and the coating, if any. The coarse

Volume 1 Series 900
aggregate shall have a minimum declared PSV and a maximum AAV as specified in contract specific Appendix 7/21.
The shape of the chipping shall comply with category FI20 as defined in BS EN 13043:2002, clause 4.1.6. Contract
compliance testing shall be carried out as required and at the frequency specified in contract specific Appendix 1/5.
6 (05/18) The chipping spreader shall have controlled metering and be capable of variable or fixed width application
to match the binder sprayer. Before a spreader is used, the Contractor shall provide to the Overseeing Organisation a
test certificate showing test results for rate of spread and accuracy of spread of chippings in accordance with the test
methods in BS EN 12272-1 issued by an appropriate organisation, accredited in accordance with sub-Clause 105.4 for
those tests, or tests carried out under his own quality management scheme demonstrating that the chipping spreader
has been tested, using chippings similar to those to be used in the Contract, not more than six weeks before the
commencement of the work, and that it complies with the requirements set out in contract specific Appendix 7/21.
(05/18) Preparation
7 (05/18) Any necessary remedial works to the road surface and structure shall be completed either prior to
commencement of the works, or as part of the contract and agreed as acceptable by the Overseeing Organisation
and the Contractor before Surface Dressing commences.
8 (05/18) Before binder is applied, street furniture shall be masked using self-adhesive masking material. Oil, sand
or similar materials shall not be used. Any packed mud or other deposits on the road surface shall be removed, and
the road surface shall be swept free of all loose material.
9 (05/18) Traffic Safety and Management shall be in accordance with the requirements of Series 100 and the site
specific requirements specified in contract specific Appendix 1/17 and the constraints described in contract specific
Appendix 1/13.
(05/18) Application
10 (05/18) Binder shall be applied to the road surface at the rates specified in the design. The Contractor shall mark
out areas where an adjusted binder rate is needed, because of localised conditions and note such changes in the As
Built Manual. Application restrictions to be observed in the event of adverse weather shall be as specified below
together with any additional limitations set out in contract specific Appendix 7/21.
(i) When there is precipitation.
(ii) When there is free water on the surface.
(iii) When the air temperature is at or below the values given in Table 9/2.
(iv) For emulsion binders when the relative humidity exceeds 80%.
(v) When the road surface temperature exceeds 35°C for roads carrying over 200 cv/lane/day or 40°C below
that traffic level.
TABLE 9/2: (05/18) Air Temperature for Spraying

Binder Uncoated chippings Coated chippings
Minimum °C Minimum °C
Bitumen emulsion 10 –
All modified binders and fluxed binders Manufacturer’s Manufacturer’s
recommendation recommendation
11 (05/18) Transverse joints shall be formed with spraying starting and finishing on a protective strip not less than
1 metre wide at each end of the lane length being treated. Transverse joints shall be of binder overlap only and not
wider than 100 mm. There shall be no ridges or bare strips.
Longitudinal joints shall coincide with lane markings. Longitudinal joints shall be of binder overlap only while
ensuring that the proposed rate of spread is achieved across the joint. For quartering (using a part of the spraybar)
the overlap may be extended to a maximum of 300 mm. There shall be no ridges or bare strips.

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Volume 1 Series 900
12 (05/18) The Contractor shall carry out the tests for rates of spread and accuracy of application of binder and
chippings in accordance with the test methods in BS EN 12272-1 at the frequency specified in contract specific
Appendix 1/5 and report the results verbally to the Overseeing Organisation within 24 hours of carrying out
the test and confirm in writing within 7 days. The Contractor shall facilitate duplicate testing by the Overseeing
Organisation if required.
13 (05/18) Rolling shall be performed by rubber coated vibratory steel rollers and/or pneumatic tyred rollers as
specified in Clause 903. The rollers shall have fully operating sprinkler systems, spraying water or other release
agent onto the drum or tyres, so that if the chippings start to move under the roller exposing binder the sprinklers
are available immediately.
(05/18) Aftercare
14 (05/18) Masking shall be removed after the Surface Dressing has been applied and before opening the road to
unrestricted traffic. The Contractor shall remove surplus chippings from the road by suction sweeping before it is
opened to unrestricted traffic.
15 (05/18) The Contractor shall monitor the Surface Dressing closely for a minimum period of 2 hours, or as
specified in contract specific Appendix 7/21, after the road is opened to traffic. The Contractor shall reinstate traffic
safety and management procedures or institute other remedial action where necessary, such as dusting, if there are
signs of distress, such as turning of the chippings, in order to prevent further damage to the Surface Dressing.
16 (05/18) Further operations to remove subsequently loosened chippings shall be carried out over the next
48 hours. The road, and adjacent side roads, footways and paved areas, shall be kept substantially free of loose
chippings for a period of 30 days after completion of the work.
17 (05/18) Any defects arising from deficiencies in the materials, workmanship and aftercare manifest during or at
the end of the maintenance period shall be rectified by the Contractor at his own expense.
18 (05/18) Not more than 30 days after completion of the work the Contractor shall provide a record of the
progress of the work in the form of an As Built Manual incorporating all relevant information, including all test
results; variations to the design and those necessitated by localised site conditions; weather information; unforeseen
problems; a list of complaints, if any, from the general public or road users; and any such other information that the
Overseeing Organisation may reasonably require to be included.
920 (05/18) Bond Coats, Tack Coats and Other Bituminous Sprays
1 (05/18) Bond coats and tack coats used in conjunction with bituminous mixtures, other than those covered by
Clause 942, shall be in accordance with this Clause and the requirements specified in contract specific Appendix 7/1
and 7/4.
(05/18) Bond Coats
2 (05/18) Bond coats for bituminous mixtures shall be cationic polymer modified bitumen emulsions complying
with BS EN 13808 or polymer modified bitumen complying with BS EN 14023 with a minimum peak cohesion
value of 1.0 J/cm2 when tested in accordance with BS EN 13588. They shall be CE marked and the Contractor shall
submit the declaration of performance to the Overseeing Organisation prior to their application. The declaration of
performance shall demonstrate that the bond coat meets the requirements of the specification.
(05/18) Tack Coats
3 (05/18) Tack coats for bituminous mixtures shall be unmodified bitumen emulsion complying with
BS EN 13808. They shall be CE marked and the Contractor shall submit the declaration of performance to the
Overseeing Organisation prior to their application. The declaration of performance shall demonstrate that the tack
coat meets the requirements of the specification.
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Volume 1 Series 900
(05/18) Bituminous Sprays

4 (05/18) Bituminous sprays used to facilitate sealing and curing shall consist of either bitumen emulsion
complying with BS EN 13808 or paving grade bitumen complying with BS EN 12591. They shall be CE marked
and the Contractor shall submit the declaration of performance to the Overseeing Organisation prior to their
application. The declaration of performance shall demonstrate that the spray meets the requirements of the
specification.
(05/18) Product Information
5 (05/18) For bond coats, tack coats and bituminous sprays the Contractor shall provide the information specified
in contract specific Appendix 7/4 and supply a copy to the Overseeing Organisation prior to the application of the
product.
(05/18) Preparation
6 (05/18) The Contractor shall comply with any limitations on area availability and timing or other constraints
for the work as specified in contract specific Appendix 1/13. Before spraying is commenced, the surface shall be
free of all loose material and standing water and shall comply with any requirements specified in contract specific
Appendix 7/4. When specified in contract specific Appendix 7/4, street furniture, ironwork and drop-kerbs shall be
masked using self-adhesive masking material before application starts and removed on completion of the works.
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(05/18) Application
7 (05/18) Application shall be by metered mechanical spraying equipment, spray tanker or spraying device
integral with the paving machine. The spraying equipment used shall not cause permanent deformation in the
surface. For small or inaccessible areas, application may be by hand held sprayer with the agreement of the
8 (05/18) The target rates of spread of bond coats or tack coats below bituminous mixtures shall be in accordance
with BS 594987, clause 5.5. For other applications, unmodified bitumen emulsions shall be sprayed at the rate of
spread specified in BS 434-2 or as stated in contract specific Appendix 7/4.
(05/18) Accuracy of Application
9 (05/18) Spray application shall be uniform. Before spraying begins, the Contractor shall provide the Overseeing
Organisation with a test certificate showing the results for rate of spread and accuracy of spread. These tests shall
be carried out in accordance with BS EN 12272-1 by an appropriate organisation, accredited in accordance with
sub-Clause 105.4 for those tests. The certificate shall demonstrate that the spraying device has been tested, using
the product to be used in the contract, not more than six weeks before commencement of the work. The tolerance
on the specified rate of spread shall not exceed ±20% and the coefficient of variation of the transverse distribution
shall not exceed 15%. During the works the Contractor shall repeat the tests for rate of spread and accuracy of
application at the frequency specified in contract specific Appendix 1/5. The results shall be reported verbally to the
Overseeing Organisation within 24 hours of carrying out a test and in writing within 7 days. Where application is
by hand held sprayer, the rate of spread shall be measured by calculating the volume applied per square metre and
evenness shall be visually assessed.
(05/18) Joints
10 (05/18) There shall be no bare strips or areas having less than the minimum permitted rate of spread. Transverse
joints shall have an overlap not wider than 300 mm. Longitudinal joints shall have an overlap to ensure that the
minimum permitted rate of spread is achieved across the joint. For quartering (using part of the spraybar) the
longitudinal joint overlap width may be extended to a maximum of 300 mm. Paver integral sprayers shall provide
a wet edge to ensure spray overlap under adjacent overlays such that the minimum permitted rate of spread is
achieved across the longitudinal joint. Where the longitudinal spray overlap causes the effective rate of spread to be
increased by more than 50% of the specified rate, then the width of overlap shall not be greater than 100 mm and
shall be outside the location of the wheel tracks for the lane.

Volume 1 Series 900
(05/18) Overlaying Concrete Surfaces

11 (05/18) The Contractor shall submit evidence of the suitability of the bond or tack coats he intends to use when
overlaying concrete surfaces to the Overseeing Organisation prior to the commencement of the work.
(05/18) Blinding Material for Bituminous Sprays
12 (05/18) When specified in contract specific Appendix 7/4, blinding material shall consist of hard clean crushed
fine aggregate or slag fine aggregate or sand containing not more than 15% by mass retained on a 6.3 mm sieve. It
shall be distributed over the sprayed area and left. Blinding used on cementitious materials shall be light in colour
to minimise solar gain. All loose material on a sprayed surface including non-adhered blinding material shall be
removed prior to the application of an overlay.
(05/18) Chipping to Prevent Binder Pickup
13 (05/18) When chippings are used to prevent tack or bond coat pickup on vehicle tyres, they shall consist of hard,
clean aggregate 2/4 mm or 2/6 mm Gc 85/35. The rate of application of aggregate shall be the minimum necessary
and shall be distributed by metered mechanical means. Bond coat shall be visible after aggregate application to
ensure bond is still achieved between the pavement layers.
921 (05/18) Surface Macrotexture of Bituminous Surface Courses

1 (05/18) Surface macrotexture of bituminous surface courses other than those covered by Clause 942, shall be
in accordance with this Clause where unless otherwise specified in contract specific Appendix 7/1. Initial surface
macrotexture for bituminous surface courses shall be measured using the volumetric patch method described in
BS EN 13036-1.
2 (05/18) Texture depth shall be measured by 10 individual measurements taken at approximately 5 m spacing
along a diagonal line across the lane width. Unless otherwise specified in contract specific Appendix 7/1, at least
one set of 10 measurements shall be made for each 250 m section of carriageway lane. The average texture depth
for each set of 10 individual measurements and the average texture depth of each 1,000 m section (or complete
carriageway lane where this is less than 1,000 m) shall not be less than the appropriate values shown in Table 9/3,
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Volume 1 Series 900
TABLE 9/3: (05/18) Requirements for Initial Texture Depth for Materials Other Than Those
Covered by Clause 942
Road Type Surfacing Type Average per 1,000 m Average for a set
section, mm of 10
Minimum Maximum Measurements,
mm (minimum)
High speed roads Cold applied ultra thin surface 1.5 2.0 1.2
Posted speed limit ≥ 50 miles/ course systems to Clause 923
hr (80 km/hr) Chipped hot rolled asphalt, 1.5 2.0 1.2
and all other surfacings:
Lower speed roads Cold applied ultra thin surface 1.5 2.0 1.2
Posted speed limit ≤ 40 miles/ course systems to Clause 923
hr (65 km/hr) Chipped hot rolled asphalt, 1.2 1.7 1.0
and all other surfacings:
Roundabouts on high speed Chipped hot rolled asphalt, 1.2 1.7 1.0
roads and all other surfacings:
Posted speed limit ≥ 50 miles/
hr (80 km/hr)
Roundabouts on lower speed Chipped hot rolled asphalt, 1.0 1.5 0.9
roads and all other surfacings
Posted speed limit ≤ 40 miles/
hr (65 km/hr)
922 (05/18) Surface Dressing: Design, Application and End Product Performance
1 (05/18) The Contractor shall be responsible for the design of the Surface Dressing, choice of materials,
techniques and processes based on site and traffic data specified in contract specific Appendix 7/3 and the schedule
of constraints on site availability in contract specific Appendix 1/13.
(i) Provide a Design Proposal to achieve the performance requirements in terms of macrotexture and
maximum levels of defects as set out in this Clause and in contract specific Appendix 7/3 ensuring that
the Surface Dressing has an initial stability such that it is capable of withstanding the normal traffic for
the site when first opened.
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(ii) State the Estimated Design Life of the Surface Dressing in the Design Proposal.
(iii) Provide a Quality Plan.
(iv) Carry out the Surface Dressing in accordance with BS EN 12271 and the Design Proposal to the
tolerances specified in contract specific Appendix 7/3.
3 (05/18) The Contractor shall guarantee the design, materials and workmanship against defects and against
failure to meet the end product performance requirements for a period of two years, or as otherwise specified in
contract specific Appendix 7/3, from the date of completion of the work. The Contractor shall rectify any defects
identified during the guarantee period.
(05/18) The System
4 (05/18) The proposed Surface Dressing shall comply with BS EN 12271 and it shall be CE marked. The
Contractor shall provide the declaration of performance and installation information as required in this Clause and

Volume 1 Series 900
The declaration of performance shall demonstrate that the system meets the requirements of the specification and
provides performance categories for all of the items identified in this Clause and contract specific Appendix 7/3.
(05/18) Materials and Equipment – Binder
5 (05/18) The binder shall be bitumen emulsion complying with BS EN 13808 and be CE marked and comply
with requirements stated in contract specific Appendix 7/3.
6 (05/18) The Contractor shall provide, with his Design Proposal, the declaration of performance for the binder
which shall demonstrate that the binder shall meet the requirements of the specification including the properties
Contract compliance testing shall be carried out as detailed in contract specific Appendix 1/5. The recovery of the
binder shall be carried out in accordance with Clause 955. The test to determine Vialit Pendulum Cohesion shall
be carried out in accordance with BS EN 13588. The Contractor shall provide rheological product identification
data for modified binders in accordance with BS EN 14770. The data provided shall be not more than 6 months old
and obtained on samples of binder representative of binder manufactured and supplied using the same source and
processes as the proposed binder. Health and Safety information and a safe handling guide from the manufacturer
shall be provided together with details of any weather restrictions placed upon use of the binder.
7 (05/18) The binder application shall be uniform and for motorways, trunk roads and heavily trafficked and
highly stressed roads, shall be of sufficient width to allow a full lane to be dressed in a single pass. Before spraying
begins, the Contractor shall provide the Overseeing Organisation with a test certificate showing test results for
rate of spread and accuracy of spread of binder carried out in accordance with the test methods in BS EN 12272- 1
and issued by, an appropriate organisation, accredited in accordance with sub-Clause 105.4 for those tests,
demonstrating that the binder sprayer has been tested, using the binder to be used in the Contract, not more than
six weeks before the commencement of the work, and that it complies with the requirements set out in contract
(05/18) Materials and Equipment – Chippings
8 (05/18) The chippings shall be crushed rock, slag, gravel or calcined bauxite complying with the general
requirements of BS EN 13043:2002. The aggregate shall have a minimum declared PSV and a maximum AAV as
specified in contract specific Appendix 7/3.
9 (05/18) Chipping spreaders shall have controlled metering and be capable of variable or fixed width application
to match the binder sprayer. Before a spreader is used, the Contractor shall provide the Overseeing Organisation
with a test certificate showing test results for rate of spread and accuracy of spread of chippings carried out in
accordance with the test methods in BS EN 12272-1, and issued by an appropriate organisation, accredited in
accordance with sub-Clause 105.4 for those tests, demonstrating that the chipping spreader has been tested, using
chippings similar to those to be used in the Contract, not more than six weeks before the commencement of the
work, and that it complies with the requirements set out in contract specific Appendix 7/3.
(05/18) Preparation
10 (05/18) Any necessary remedial works to the road surface and structure shall be completed prior to or as part of
the contract and agreed as acceptable by the Overseeing Organisation and the Contractor before Surface Dressing
commences.
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11 (05/18) Before binder is applied, street furniture shall be masked using self-adhesive masking material. Oil, sand
or similar materials shall not be used. Any packed mud or other deposits on the road surface shall be removed, and
the road surface shall be swept free of all loose material.
(05/18) Traffic Safety and Management
12 (05/18) Traffic Safety and Management shall be in accordance with the requirements of Series 100 and the
site specific requirements specified in contract Appendix 1/17 and the constraints described in contract specific
Appendix 1/13.

Volume 1 Series 900
(05/18) Application
13 (05/18) Restrictions to be observed in the event of adverse weather shall be as specified in contract specific
Appendix 7/3. Transverse joints shall be formed with spraying starting and finishing on a protective strip not less
than 1 metre wide at each end of the lane length being treated. Transverse joints shall be of binder overlap only
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and not wider than 100 mm. There shall be no ridges or bare strips. Longitudinal joints shall coincide with lane
markings. Longitudinal joints shall be of binder overlap only, while ensuring that the proposed rate of spread is
achieved across the joint, for quartering (using a part of the spraybar) the overlap may be extended to a maximum
of 300 mm. There shall be no ridges or bare strips.
14 (05/18) The Contractor shall carry out the tests for rates of spread and accuracy of application of binder and
chippings in accordance with the test methods in BS EN 12272-1 at the frequency specified in contract specific
Appendix 1/5 and report the results verbally to the Overseeing Organisation within twenty-four hours of carrying
out the test and confirm in writing within seven days. The Contractor shall facilitate duplicate testing by the
Overseeing Organisation if required.
(05/18) Aftercare
15 (05/18) Masking shall be removed after the Surface Dressing has been applied and before opening the road to
unrestricted traffic. The time period before unrestricted traffic may use the Surface Dressing shall not exceed that
specified in contract specific Appendix 7/3. The Contractor shall remove surplus chippings from the road by suction
sweeping before it is opened to unrestricted traffic.
16 (05/18) The Contractor shall monitor the Surface Dressing closely for a minimum period of 2 hours, or as
specified in contract specific Appendix 7/3, after the road is opened to traffic. The Contractor shall reinstate traffic
safety and management procedures or institute other such remedial action where necessary, such as dusting, if there
are signs of distress, such as turning of the chippings, in order to prevent further damage to the Surface Dressing.
48 hours. The road, and adjacent side roads, footways and paved areas, shall be kept substantially free of loose
chippings for a period of 30 days after completion of the work.
of the work in the form of an As Built Manual incorporating all relevant information, including: all contract
compliance test results; variations to the Design Proposal and those necessitated by localised site conditions; a
record of traffic control carried out; weather information; unforeseen problems; a list of complaints, if any, from the
general public or road users; and any other information that the Overseeing Organisation may reasonably require to
be included.
(05/18) Performance Standards During the Guarantee Period
(05/18) Surface Macrotexture

19 (05/18) The Contractor is responsible for maintaining the surface macrotexture requirements set out in contract
specific Appendix 7/3 throughout the guarantee period.
The definitive test is the volumetric patch technique measured in accordance with BS EN 13036-1 except that
10 individual measurements shall be made on the nearside (inside) wheel-track of the most heavily trafficked
lane. The average macrotexture depth of each lane kilometre, or the complete carriageway lane where this is less
than 1,000 metres, shall be as specified in contract specific Appendix 7/3. The average of each set of 10 individual
measurements shall be not less than 80% of the minimum permitted.
The Overseeing Organisation will use the TRAffic-speed Condition Survey (TRACS) or other suitable equipment
to determine the Sensor Measured Texture Depth (SMTD) for trunk roads including motorways and other highly
trafficked or highly stressed roads. Measurements of SMTD shall be made in the nearside and offside wheel-tracks
of all lanes. For other roads where road closure is less critical the volumetric patch technique or other measuring
device such as the Mini Texture Meter may be used.

Volume 1 Series 900
The SMTD or results from other devices shall be calibrated for the particular Surface Dressing product design and
condition against volumetric patch values to provide the Volumetric Patch Equivalent value. The macrotexture
depths will be measured after 11 months and before 13 months and additionally for two year guarantee period
contracts after 22 months and before 24 months unless otherwise specified in contract specific Appendix 7/3. When
required, the Contractor shall design the Surface Dressing to limit the maximum macrotexture after four weeks
trafficking to that specified in contract specific Appendix 7/3 and the macrotexture depths will be measured, for this
purpose, between three weeks and five weeks after completion of the Works.
(05/18) Defects
20 (05/18) The extent of chipping loss or other defects will be monitored using a visual method of assessment. The
performance standard is that any section of the works shall be deemed as having failed if the areas of defects do not
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comply with the classes specified in contract specific Appendix 7/3. If there is a failed section, the Contractor shall
agree remedial measures with the Overseeing Organisation and undertake the remedial measures.
In the event that the Contractor and Overseeing Organisation are unable to reach agreement on whether a section
has failed by qualitative visual assessment described in BS EN 12272-2, the level of defects shall be determined in
accordance with the quantitative test methods in BS EN 12272-2. Any section failing to meet the required standard
as specified in contract specific Appendix 7/3 shall be subject to remedial action by the Contractor after agreement
of the Overseeing Organisation.
923 (05/18) Cold Applied Ultra Thin Surfacing

(05/18) General
1 (05/18) The Cold Applied Ultra Thin Surfacing shall meet the product performance requirements under the
combinations of traffic level and site classification specified in contract specific Appendix 7/1 and it shall meet the
following criteria.
(i) Where the product falls under the scope of a harmonised European standard under the Construction
Products Regulation the Cold Applied Ultra Thin Surfacing shall have a declaration of performance and
be CE marked in accordance with the relevant British adopted European standard.
(ii) Where the product does not fall under the scope of a harmonised European standard under the
Construction Products Regulation it shall either:
(a) have a declaration of performance and be CE marked in accordance with a European Technical
Assessment; or
(b) be certified under a product acceptance scheme as detailed in sub-Clauses 104.15 and 104.16 such
as HAPAS certification.
The Contractor shall supply the certification or declaration of performance to the Overseeing Organisation, it shall
demonstrate that the Cold Applied Ultra Thin Surfacing shall meet the requirements of the specification.
The installation of the surfacing shall be certified under a product acceptance scheme as detailed in sub-Clauses
104.15 and 104.16 such as HAPAS certification.
2 (05/18) Cold Applied Ultra Thin Surfacing systems that are supplied in accordance with sub-Clause 1 paragraph
(ii) (b) shall be produced and installed by organisations that are registered to the National Highways Sector Scheme
13 for The Supply and Application of Surface Treatments to Road Surfaces, as listed in Appendix A.
(05/18) Documentation, Test Certificates and Material Samples
3 (05/18) The Contractor shall supply a Quality Plan and Installation Method Statement to the Overseeing
Organisation.
4 (05/18) Test certificates stating the properties of the aggregate to be used shall be supplied to the Overseeing
Organisation unless the values are declared in the Declaration of Performance under the CE mark.

Volume 1 Series 900
5 (05/18) The details of the component materials and their relative proportions and/or spread rates for use in the
permanent works shall be notified to the Overseeing Organisation. The component materials listed shall include, as
appropriate, coarse aggregates, fine aggregates, filler, additives (including fibres), binder, modifier and bond coat,
and shall be subdivided into layers if applied.
6 (05/18) When required in contract specific Appendix 1/6, samples of aggregate, bond coat or binder, modified
or unmodified bitumen from either the spray bar or storage tank or mixed bituminous materials from the pavement
surface or other suitable sampling point shall be supplied to the Overseeing Organisation.
(05/18) Aggregates
7 (05/18) Coarse aggregate shall be crushed rock or steel slag complying with Clause 901 when tested in
accordance with the procedures of BS EN 13043:2002. The coarse aggregate shall additionally have the following
properties.
(i) Polished Stone Value (PSV) – as specified in contract specific Appendix 7/1 – BS EN 13043:2002;
(ii) Aggregate Abrasion Value (AAV) – as specified in contract specific Appendix 7/1 – BS EN 13043:2002;
(iii) Los Angeles Coefficient (LA) – not greater than LA30. – BS EN 13043:2002;
(iv) Flakiness Index (FI) – not more than FI20. – BS EN 13043:2002.
(05/18) Performance Levels
8 (05/18) Cold Applied Ultra Thin Surfacing is permitted on Site Categories B, C, D, E, F and G as defined in
Table 9/4.
TABLE 9/4: (05/18) Site Stress Level Classification

Site Category Site Definition Stress Level
A Motorway (main line) 1
B Dual carriageway (all purpose) non-event sections 1
C Single carriageway non-event sections 1
D Dual carriageway (all purpose) minor junctions 1
E Single carriageway minor junctions 1
F Approaches to and across major junctions (all limbs) 2
G Gradient >5%, longer than 50 m (Dual downhill; single uphill 2
and downhill)
H1 Bend (not subject to 40 mph or lower speed limit) radius 100 – 2
250 m
H2 Bend (not subject to 40 mph or lower speed limit) radius <100 m 3
L Roundabout 3
J Approach to roundabout 4
K Approach to traffic signals, pedestrian crossing, railway level 4
crossing and similar
9 (05/18) The road/tyre noise level of the cold applied ultra thin surface shall be as specified in contract specific
Appendix 7/1, as defined in Table 9/5.
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27
Volume 1 Series 900
TABLE 9/5: (05/18) Road/Tyre Noise Levels

Level Road Surface Influence
RSI
0 +1.2 dB(A)
NR No requirement
10 (05/18) The minimum and/or maximum compacted thickness of the Cold Applied Ultra Thin Surfacing system
shall be as specified in contract specific Appendix 7/1. The installed layer thickness must not be less than the
permitted minimum thickness stated in the HAPAS certificate or equivalent certification for a particular system.
(05/18) Surface Preparation
11 (05/18) When required in contract specific Appendix 7/1, a site inspection shall be undertaken prior to the main
works jointly by representatives of the Overseeing Organisation and the Contractor to agree suitable preparation
works (e.g. patching).
12 (05/18) Surface preparation shall be in accordance with BS 594987, clause 5.1 and 5.3, and the Installation
Method Statement provided in accordance with sub-Clause 4.
(05/18) Transportation
13 (05/18) Transportation of the Cold Applied Ultra Thin Surfacing and/or its components shall be in accordance
with the Installation Method Statement provided in accordance with sub-Clause 4.
(05/18) Sweeping and early life monitoring of Cold Applied Ultra Thin Surfacings
14 (05/18) Sweeping of newly laid Cold Applied Ultra Thin Surfacing shall be in accordance with the HAPAS or
equivalent certification and the Installation Method Statement.
15 (05/18) Notwithstanding the above, suction sweeping shall be undertaken immediately before the newly laid
Cold Applied Ultra Thin Surfacing is opened to traffic.
16 (05/18) The installation shall be monitored closely for a minimum period of 2 hours after the road is opened to
traffic. Traffic safety and management procedures shall be reinstated or other such remedial actions instigated, if
there are signs of distress in the surfacing, such as turning of the chippings, in order to prevent further damage to
the installation.
17 (05/18) Where detailed in contract specific Appendix 1/17 a mandatory speed limit shall be implemented during
installation and for a period of 5 days after installation.
48 hours. The road, and adjacent side roads, footways and paved areas shall be kept substantially free of loose
chippings for a period of 30 days after completion of the surfacing work.
(05/18) Surface Macrotexture – Untrafficked
19 (05/18) The macrotexture depth of the cold applied ultra thin surfacing after compaction has been completed and
before opening to traffic shall be in accordance with Clause 921.
(05/18) Surface Macrotexture – Performance Guarantee
20 (05/18) For a period of two years from the date of opening to traffic the average macrotexture, measured using
the volumetric patch technique described in BS EN 13036-1, will be maintained above an average per 1000m of
1.0 mm, unless otherwise specified in contract specific Appendix 7/1.

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Volume 1 Series 900
21 (05/18) Where measurement is necessary to demonstrate compliance during the guarantee period, the
macrotexture shall be measured in accordance with BS EN 13036-1 in the most heavily trafficked lane at 10 m
intervals. The average value of a set of 10 individual measurements taken along the centre of the most heavily worn
wheel-track shall not be less than the appropriate value stated in contract specific Appendix 7/1.
(05/18) Surfacing Integrity – Performance Guarantee
22 (05/18) Unless otherwise stated in contract specific Appendix 7/1 a guarantee shall be provided for the integrity
of the surfacing and the workmanship for a period of five years from the date of opening to traffic.
23 (05/18) The five-year guarantee shall include for defects such as fretting, ravelling, stripping and loss of
chippings. Replacement of the surfacing or other remedial measures agreed with the Overseeing Organisation shall
be executed if the surfacing is in a “Suspect”, “Poor” or “Bad” condition as defined in Appendix A of TRL Report
TRL674 – “Durability of thin surfacing systems, Part 4, Final report after nine years monitoring, TRL report 674”.
924 (05/18) High Friction Surfaces

1 (05/18) High friction surfacing systems shall have current HAPAS certificate or equivalent product acceptance
scheme certification as described in sub-Clauses 104.15 and 104.16.
2 (05/18) High friction surfacing shall be installed in accordance with the requirements of the HAPAS or
equivalent product acceptance scheme certification.
3 (05/18) The high friction surfacing system HAPAS or equivalent product acceptance scheme certification Type
Classification required for each location shall be as specified in contract specific Appendix 7/1.
(05/18) Aggregate
4 (05/18) Aggregate used in high friction surfacing systems shall have the minimum declared PSV category
specified in contract specific Appendix 7/1 in accordance with BS EN 13043:2002, clause 4.2.3. The resistance
to abrasion of coarse aggregate shall have the maximum AAV specified in contract specific Appendix 7/1 in
accordance with BS EN 13043:2002, clause 4.2.4. The Contractor shall provide, before work commences, the
declaration of performance for the aggregate to the Overseeing Organisation. The declaration of performance shall
demonstrate that the aggregate shall meet the requirements of the specification.
(05/18) Installation and Quality Control Procedures
5 (05/18) The installation and quality control procedures shall be in accordance with the HAPAS or equivalent
product acceptance scheme certification for each system and the current method statement. The results of all quality
control checks carried out on site by the Contractor and quality management information compiled in accordance
with the requirements of the Certificate, including results from surveillance visits, shall be made available to the
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Overseeing Organisation on request.

(05/18) System Coverage
6 (05/18) For each location where high friction surfacing is applied, the total quantities of each system component
used, the measured area of the surface treated and the calculated coverage rate in kg/m2 shall be reported to the
Overseeing Organisation within three days of completion at that location. For systems in which aggregate is
broadcast over a film of binder applied to the surface, the calculated coverage rate shall be that of the binder film
and shall not include the mass of the aggregate.
(05/18) Guarantee
7 (05/18) The Contractor shall guarantee the high friction surfacing materials and workmanship for a period of
two years from the date of opening the surfacing to traffic. This guarantee shall cover failure to meet the minimum
requirements set out in Table 4 of the HAPAS document ‘Guideline Document for the Assessment and Certification
of High Friction Surfaces for Highways’.

Volume 1 Series 900
925 (05/18) Testing of Bituminous Mixtures

1 (05/18) The contract compliance sampling and testing of bituminous mixtures shall comply with BS EN 12697,
except where otherwise specified in this Series.
2 (05/18) Additional testing shall be carried out as specified in contract specific Appendices 7/1, 1/5 and 1/6.
926 (05/18) In Situ Recycling: The Repave Process

1 (05/18) Where milling is required, it shall be carried out in accordance with Clause 709, and as described in
(05/18) Heating and Scarifying
2 (05/18) Surfaces to be treated shall be heated by plant with heating surfaces insulated and fully enclosed. The
heated-width of surfacing shall exceed the scarified width by at least 75 mm on each side, except against the edge
of the carriageway or kerb face. When new surfacing material is spilt onto the road surface it shall be removed
before the existing surface is heated and scarified. Areas of unscarified material shall not exceed 50 mm x 50 mm.
3 (05/18) The depth of scarification shall be such that the bottom of the scarified layer is parallel to and below the
finished road surface level by the thickness of surface course material specified in contract specific Appendix 7/5.
A tolerance of ± 6 mm is permissible.
4 (05/18) Where ironwork and other obstructions occur, these shall be suitably protected or removed and the void
covered. Surface dressings and large areas of road markings shall be removed by milling, planing, scarifying or
similar.
5 (05/18) The heated surface shall be evenly scarified to comply with the requirements of sub-Clause 3 of this
Clause. When ironwork is left in place or raised, the adjacent areas shall be scarified by other means, with the
material either left in place or removed, prior to passage of the machine. If ironwork needs to be re-levelled, on
completion of work, the new surface course material shall be used to make good the road surface for a maximum
width of 200 mm around the ironwork.
6 (05/18) During the reheating process the surface temperature of the road shall not exceed 200°C for more than
5 minutes.
(05/18) New Surfacing
7 (05/18) New surface course shall conform to Clauses 910, 911, 923, 942 or 943, as described in contract specific
Appendix 7/5.
8 (05/18) The new surfacing material shall be laid on, and compacted with the re-profiled surfacing, which shall
be at a temperature within the range of 70°C to 150°C.
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Volume 1 Series 900
927 & 928 (05/18) Not Used
929 (05/18) Dense Base and Binder Course Asphalt Concrete (Design Mixtures)
1 (05/18) Designed dense base and binder course asphalt concrete (formerly macadams), including HDM and
HMB, shall be asphalt concrete conforming to BS EN 13108-1, the example of BSI PD 6691 Annex B for the
selected mixture, and requirements specified in contract specific Appendix 7/1. The mixture designation shall be
one of the following:
(i) AC 32 HDM base 40/60 des.
(ii) AC 32 dense base 40/60 des.
(iii) AC 32 HMB base 30/45 des.
(iv) AC 20 HDM bin 40/60 des.
(v) AC 32 HDM bin 40/60 des.
(vi) AC 20 dense bin 40/60 des.
(vii) AC 32 dense bin 40/60 des.
(viii) AC 20 HMB bin 30/45 des.
(ix) AC 32 HMB bin 30/45 des.
2 (05/18) The volumetric properties of mixtures shall follow the example in BSI PD 6691, clause B.3.2 for
designed base mixtures and BSI PD 6691, clause B.3.3 for designed binder course mixtures.
3 (05/18) When specified in contract specific Appendix 7/1, the volumetric properties of the mixture shall be
monitored by determining the void content of cores compacted to refusal. Core pairs and samples of loose mix
shall be taken every 500 lane metres and tested in accordance with BS 594987, clauses C.2.1, C.2.2, C.3, C.4.1 and
C.4.2. If the mean air void content at refusal of any three consecutive pairs of cores falls below 0.5%, the mixture
target composition shall be reviewed and the type test revalidated in accordance with BS 594987, Annex C.
(05/18) Deformation Resistance
4 (05/18) The resistance to permanent deformation of the mixture shall be in accordance with the appropriate class
selected from Table D.2 of PD 6691, as specified in contract specific Appendix 7/1.
5 (05/18) When specified in contract specific Appendix 7/1, the resistance to permanent deformation of material
laid in the permanent works shall be monitored by testing in accordance with clauses D 3.1, 3.2 and 3.3 of
BS 594987 Annex D. Six cores shall be taken from the first kilometre length of material from each mixing plant
and thereafter one further core from each subsequent lane kilometre. Results shall be assessed on successive rolling
means of sets of six consecutive results and shall be deemed to conform if the mean is no greater than the specified
value and individual values not more than 50% greater than the specified value.
(05/18) Stiffness
6 (05/18) Stiffness of the mixture shall be assessed in accordance with BS 594987, Annex E.
Mixtures with 40/60 grade binder shall conform to category Smin 1800 as defined in BS EN 13108-1, clause 5.4.2.
Mixtures with 30/45 grade binder shall conform to category Smin 2800 as defined in BS EN 13108-1, clause 5.4.2.
(05/18) Compaction Control for the Permanent Works
7 (05/18) Compaction shall be controlled and monitored in accordance with the general requirements of
BS 594987 9.5.1 and the specific requirements of this Clause.
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Volume 1 Series 900
8 (05/18) Compaction shall be continuously assessed using an indirect density gauge in accordance with
BS 594987 9.4.2 with readings taken at 20 m intervals in alternate wheel-tracks. Gauge readings shall also be
taken at each core location specified in sub-Clauses 12 and 14. Each gauge shall be individually calibrated on each
mixture from each mixing plant and the calibrations shall be continually checked and updated based on correlations
between gauge readings and core densities at the same locations.
9 (05/18) For each location, the in situ void content shall be determined in accordance with BS EN 12697-8 using
the bulk density from the gauge reading and a maximum density taken from the mixture type testing data and
updated with values from testing in accordance with sub-Clause 12.
10 (05/18) The average in situ void content calculated from any six consecutive indirect gauge readings shall not
exceed 7%.
11 (05/18) In the event of a failure to meet the requirements in sub-Clause 10, cores shall be taken at each location
and void contents determined as described in sub-Clause 12 and the evaluation of the extent of any non-conformity
shall be based on these. If it is necessary to remove and replace any material to restore conformity this shall be in
lengths not less than 15 m unless otherwise agreed by the Overseeing Organisation.
12 (05/18) For the material from each mixing plant, a pair of cores shall be taken from every 1,000 linear metres
laid and the void content shall be determined in accordance with BS 594987, clause 9.5.1.3.
13 (05/18) The average in situ air voids for each core pair shall not exceed 7%.
14 (05/18) For the material from each mixing plant a pair of cores shall be taken every 250 linear metres laid,
centred 100 mm from the final joint position at any unsupported edge and the air void shall be determined in
accordance with BS 594987, clause 9.5.1.3.
15 (05/18) The average in situ void content for each of these pairs shall not exceed 9%.
16 (05/18) In the event of non-conformity with sub-Clauses 13 or 15 then density readings with indirect gauges
and, if necessary, further cores shall be taken to establish the extent. If it is necessary to remove and replace any
material to restore conformity, this shall be in lengths not less than 15 m unless otherwise agreed by the Overseeing
Organisation.
17 (05/18) Each core extracted shall be examined for evidence of excessive voids below the depth to which the
indirect density gauge penetrates. If excessive voids are observed, further cores shall be taken to determine its
extent.
18 (05/18) Two copies of the final indirect density test results obtained and their correlation with in situ air void
contents shall be passed to the Overseeing Organisation within 72 hours.
(07/21) Warm Mix Asphalt (WMA)
19 (07/21) Mixtures to be produced as WMAs shall comply with Clause 908.
930 (05/18) EME2 Base and Binder Course Asphalt Concrete

1 (05/18) EME2 base and binder course asphalt concrete shall conform to BS EN 13108-1, the example in
BSI PD 6691 Annex B for the selected mixture, the requirements of this Clause and those specified in contract
(i) AC 10 EME2 bin/base 10/20 des.
(ii) AC 10 EME2 bin/base 15/25 des.
(iii) AC 14 EME2 bin/base 10/20 des.
(iv) AC 14 EME2 bin/base 15/25 des.
(v) AC 20 EME2 bin/base 10/20 des.
(vi) AC 20 EME2 bin/base 15/25 des.

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Volume 1 Series 900
2 (05/18) The binder shall be Hard Paving Grade Bitumen in accordance with BS EN 13924 and the requirements
specified in Tables 9/6, 9/7 and 9/8.
3 (05/18) EME2 mixtures, otherwise conforming to BS EN 13108-1 and the example in BSI PD 6691 Annex B,
but using alternative paving grade bitumens or polymer modified paving grade bitumens, shall not be used without
prior approval by the Overseeing Organisation.
TABLE 9/6: (05/18) Initial Binder Characteristics, as Supplied

Characteristic Test Method Unit Hard Grade Binders for EME2 FPC
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10/20 pen 15/25 pen Test
frequency
Penetration at 25°C EN 1426 0.1mm 10 - 20 15 - 25 D
Softening Point EN 1427 °C 63 – 73 60 – 70 W
Target value Target value
71 max(1) 68 max(1)
Penetration Index, max EN 13924 – +0.7 +0.7 W
Annex A Target Value Target Value
+0.5 max(1) +0.5 max(1)
Fraass breaking point, max EN 12593 °C Target mean(2) Target mean(2) Q
0 max 0 max
Range -15 to +5 Range -15 to +5
Viscosity at 135°C, min EN 12595 mm2/S 1,100 900 A
Flash point, minimum EN 12592 °C 245 245 A
Solubility, minimum EN 12592 %(m/m) 99.0 99.0 A
Notes:
(1) Target max value based on a rolling mean of the last 6 consecutive results in FPC.
(2) Target max value based on a rolling mean of the last 3 consecutive results in FPC.
All tests to be carried out on sub-samples of a single bulk sample of binder.
Minimum test frequency : D = Daily, W = Weekly, Q = Quarterly, A = Annually.
(Indicated frequencies apply only if product is in regular supply.)

Volume 1 Series 900
TABLE 9/7: (05/18) Binder Characteristics, After Short-term Ageing to EN 12607-1 (RTFOT)
Characteristic Test Method Unit Hard Grade Binders for EME2 FPC
10/20 pen 15/25 pen Test frequency
Change of mass, max % 0.5 0.5 A
Retained Pen 25°C EN 1426 % 65 (1) 65(1) Q
Increase in Softening Point, EN 1427 °C 8 8 A
maximum
Notes:
(1) Target minimum value based on a rolling mean of the last 3 consecutive results in FPC.
Minimum test frequency : A = Annually, Q = Quarterly.
TABLE 9/8: (05/18) Binder Characteristics to be Reported

Characteristic Test Method Unit Binder FPC frequency
for EME2 AS STA LTA
Brookfield Viscosity EN 13302 °C TBR A
T 200cP
T 2000cP °C TBR A
T 5000cP °C TBR A
G* and Phase Angle BS EN 14770 Pa, degrees TBR A A A
VET temperature, G’=G”, at 0.4 °C TBR A A A
Hz
G* at the VET temperature Pa TBR A A A
G’ and G” Mastercurves 80°C to Graphical Output TBR A A A
0°C Graphical
G” and Phase Angle at 15°C, 10Hz Output Pa, degrees TBR A A A
and 20°C, 1Hz
T S=300 MPa, by BBR BS EN 14771 °C TBR A A A
T m=0.3, by BBR °C TBR A A A
Pendulum Cohesion, min BS EN 13588 J/cm2 TBR A A A
Fraass breaking point, min EN 12593 °C TBR A
Notes:
AS = As Supplied; STA = After EN 12607-1 (RTFOT) * LTA = After PAV85 *
* An ageing profile determined in accordance with clause 955 is an acceptable alternative to STA and PAV85.
Minimum test frequency : A = Annually.
4 (05/18) The properties of mixtures shall follow the example in BSI PD 6691 Annex B, clause 3.4.1 to
clause 3.4.7 inclusive.
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Volume 1 Series 900
5 (05/18) A separate assessment shall be made of the conformity of soluble binder content analysis results of
EME2 mixtures using the principles of the ‘mean of four results’ approach used in BS EN 13108-21. Binder
content shall be assessed on a continuous basis by taking the mean value of the previous four analysis results. This
will give a ‘rolling mean binder content’. In addition to the analysis results meeting all of the standard conformity
requirements of EN 13108-21, this rolling mean binder content shall comply with the target composition ± 0.3%.
(05/18) Compaction
6 (05/18) EME2 shall be delivered to site at a temperature which enables laying with a minimum paver-out
temperature of 140°C.
7 (05/18) EME2 mixtures shall be compacted with either:
(i) steel rollers exceeding 8 tonnes, provided compaction is speedily undertaken. Any vibration shall be
switched off when traversing compacted material to avoid micro-cracking the cooling surface;
(ii) pneumatic tyred rollers (PTR’s) weighted at a minimum of 1.0 tonne per wheel, finishing with wide steel
non-vibrating rollers and 3-point rollers.
8 (05/18) Compaction shall be substantially completed before the temperature falls below 120°C. Limited rolling
without vibration may be carried out below this temperature to improve the finish.
(05/18) Compaction Control for the Permanent Works
9 (05/18) Compaction shall be controlled and monitored in accordance with the general requirements of
BS 594987 9.5.1 and the specific requirements of this Clause.
10 (05/18) Compaction shall be continuously assessed using an indirect density gauge in accordance with
BS 594987 9.4.2 with readings taken at 20 m intervals in alternate wheel-tracks. Gauge readings shall also be
taken at each core location specified in sub-Clauses 13 and 14. Each gauge shall be individually calibrated on each
mixture from each mixing plant and the calibrations shall be continually checked and updated based on correlations
between gauge readings and core densities at the same locations.
11 (05/18) For each location, determine the in situ void content in accordance with BS EN 12697-8 using the bulk
density from the gauge reading and a maximum density taken from the mixture type testing data and updated with
values from testing in accordance with sub-Clauses 13 and 14.
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exceed 6%.
13 (05/18) In the event of a failure to meet the requirements in sub-Clause 12, cores shall be taken and void
contents determined in accordance with BS 594987, clause 9.5.1.3 and the evaluation of the extent of any
non conformity shall be based on these. If it is necessary to remove and replace any material to restore conformity
this shall be in lengths not less than 15 m unless otherwise agreed by the Overseeing Organisation.
14 (05/18) For the material from each mixing plant a pair of cores shall be taken from the wheel-tracks every
1,000 metres laid and the void content shall be determined in accordance with BS 594987, clause 9.5.1.3.
15 (05/18) The average in situ air voids for each core pair shall not exceed 6%.
16 (05/18) For the material from each mixing plant a pair of cores shall be taken every 250 metres laid, centred
100mm from the final joint position at any unsupported edge and the air void shall be determined in accordance
with BS 594987, clause 9.5.1.3.
17 (05/18) The average in situ void content for each of these pairs shall not exceed 8%
18 (05/18) In the event of non-conformity with sub-Clauses 15 or 17 then density readings with indirect gauges
and, if necessary, further cores shall be taken to establish the extent. If it is necessary to remove and replace any
material to restore conformity this shall be in lengths not less than 15 m unless otherwise agreed by the Overseeing
Organisation.

Volume 1 Series 900
19 (05/18) Each core extracted shall be examined for evidence of excessive voids below the depth to which the
indirect density gauge penetrates. If excessive voids are observed, further cores shall be taken to determine its
extent.
20 (05/18) Two copies of the final indirect density test results obtained and their correlation with in situ air void
contents shall be passed to the Overseeing Organisation within 72 hours of the material being laid.
21 (07/21) The minimum water sensitivity when tested in accordance with Method B of BS EN 12697-12 shall be
i/Cmin75. This requirement is also deemed to satisfy the requirement for mixtures produced as warm mix asphalts as
specified in Clause 908.
931 to 935 (07/19) Not Used
936 (07/19) Geosynthetics and Steel Meshes: Installation and End Product Performance
1 (07/21) Systems that are intended to suppress reflection cracking in asphalt surfacing by use of an interlayer
shall have Product Acceptance Scheme certification in compliance with sub-Clause 104.16 to demonstrate their
performance. Systems without Product Acceptance Scheme certification in compliance with sub- Clause 104.16
shall not be used without prior approval by the Overseeing Organisation.
2 (07/19) The Contractor shall be responsible for the installation of geosynthetic or steel mesh systems, observing
site and process constraints presented by the site and traffic data specified in contract specific Appendix 7/1.
(i) work in accordance with the design provided to achieve the performance requirements in terms of
control of reflection cracking as set out in this Clause and in contract specific Appendix 7/1;
(ii) ensure that the geosynthetic or steel mesh has initial bond such that it is capable of withstanding
construction traffic, and remains fully adhered to the substrate and the asphalt overlay with no
separation.
(07/19) Materials and Equipment
4 (07/21) The geosynthetic or steel mesh shall be manufactured to the requirements of BS EN 15381.
5 (07/19) The installation of the geosynthetic or steel mesh shall be carried out by a purpose built mechanical
applicator where it is possible to do so. Hand-laying may be required in locations such as tight radius bends and on --`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
small restricted sites.

(07/19) Bond Coats
6 (07/19) Systems requiring hot bitumen bond coats for installation shall use paving grade bitumen produced in
accordance with BS EN 12591 or use hot modified bitumen in accordance with BS EN 14023.
7 (07/19) Bitumen emulsion bond coats produced in accordance with BS EN 13808 may be used as an alternative
to using hot bitumen.
8 (07/21) Bond coats shall be installed in accordance with the following criteria:
(i) A bond coat shall be applied directly beneath the geosynthetic in accordance with the minimum
application rates given in BS 594987. Higher application rates may be specified on a product specific
basis. (Note: in some cases this bond coat may be part of a composite system including a geosynthetic.)

Volume 1 Series 900
(ii) The bond coat shall be sprayed through a calibrated spray bar at the agreed rate appropriate to the
specific project. The calibrated spray bar shall be in good working order and shall be certified showing
that it has been tested within the last twelve months to conform to BS 1707.
(iii) The rate and accuracy of the distribution of the bond coat shall be checked at the commencement of
the work by means of a carpet tile test carried out in accordance with BS EN12272-1. This test shall be
repeated for each binder distributor used during the course of the work.
(iv) Where bitumen emulsions are used, evidence shall be provided by the Contractor that the emulsion will
“break” within the time limits likely to be encountered during normal maintenance working windows.
(v) Systems requiring slurry surfacing bond coats for installation shall use a slurry surfacing system
complying with the requirements in BS EN 12273.
9 (07/19) Systems requiring a levelling or regulating course shall be laid in accordance with the requirements of
Clause 907.
(07/19) Surface Preparation
10 (07/21) The surface to receive the geosynthetic or steel mesh shall be free of surface defects so as not to
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compromise the performance of the product system to be applied.

11 (07/19) Before binder is applied, ironwork shall be masked. Any planings or asphalt deposits on the surface shall
be removed and the receiving surface shall be swept free of all loose material.
(07/19) Application
12 (07/19) Installation shall be carried out using appropriate mechanical equipment that is designed specifically to
lay the material under tension. Installation shall be planned and carried out such that there is continuity of works
and other surfacing operations are not impeded.
13 (07/19) The Contractor’s quality plan shall determine the weather conditions under which the geosynthetic
or steel mesh can be installed. Transverse and longitudinal overlaps shall be in accordance with the Contractor’s
quality plan. The Contractor shall measure and record the bond condition as stipulated in the quality plan and refer
to the RSTA ADEPT Code of Practice for Geosynthetics and Steel Meshes.
14 (07/19) A geosynthetic or steel mesh interlayer shall be placed sufficiently deep within the bound layers so that
it is not removed when the surface course is replaced. If a surface course is to be placed directly on a geosynthetic,
approval by the Overseeing Organisation (a Departure from Standard) will be needed.
(07/19) Aftercare
15 (07/19) Masking shall be removed after the geosynthetic or steel mesh has been installed and before the
surfacing operation commences. The geosynthetic or steel mesh shall be overlaid in the same shift, or as soon as is
practically possible.
16 (07/19) The Contractor shall undertake remedial action where necessary, which may include nailing, patching,
cutting or dusting if there are signs of distress, such as separation, turning damage, bleeding or pickup of the
geosynthetic or steel mesh in order to prevent further damage to the System.
of the work in the form of an ‘as built’ manual incorporating all relevant information, including:
(i) the product name;
(ii) all test results;

Volume 1 Series 900
(iii) a pre-treatment crack map. Where geosynthetics are applied over a new longitudinal joint, a drawing
showing the location of the joint shall be submitted. (Note: If a pre-treatment crack map is not
provided, all cracks appearing within 5 years will be seen as ‘excessive’ and require remedial measures
(see sub- Clause 936.19).
(iv) variations to the design proposal and those necessitated by local conditions (which need to be agreed
prior to installation);
(v) a record of installation control carried out;
(vi) weather information;
(vii) unforeseen problems encountered;
(viii) a list of complaints, if any, from the general public or road users;
(ix) any other information that the Overseeing Organisation may reasonably require to be included, as
previously agreed.
Records are to be sent to Highways England using the PavementInnovationsDevelopment@highwaysengland.co.uk
email address.
(07/19) Defects
18 (07/19) The surface course shall not have more than 10% of the reflection cracking that was present before the
installation of the geosynthetic or steel mesh, for a minimum period of 5 years. The amount of cracking shall be
expressed as a length per 100m for each 100m length. The length of cracking before treatment shall be taken from
the visual survey produced as part of the pavement investigation used for scheme identification.
19 (07/19) Replacement of the surfacing or other remedial measures agreed with the Overseeing Organisation shall
be carried out if reflection cracking appears within the first 5 years.
20 (07/19) For the period of the guarantee, the geosynthetic or steel mesh shall meet the performance requirements
stated in this Clause and contract specific Appendix 7/1.
21 (07/19) The guarantee shall exclude defects arising from accidental damage or damage caused by settlement or
subsidence on which the surfacing material has been laid.
22 (07/19) The reappearance of reflection cracking shall be confirmed by comparing locations of cracking with
visual survey records carried out as part of the investigation prior to maintenance treatment design and coring
through the cracks. This will identify whether cracking in the ‘new’ surface appears over existing cracks lower in
the pavement structure. Note that reflection cracking may be ‘top-down’ or ‘bottom-up’.
937 (05/18) Stone Mastic Asphalt (SMA) Binder Course and Regulating Course
(05/18) General
1 (05/18) Stone Mastic Asphalt binder course and regulating course shall conform to BS EN13108-5, the example
from BSI PD 6691 Annex D for the selected mixture, the requirements of this Clause and those specified in contract
(i) SMA 6 bin 40/60.
(ii) SMA 6 bin 70/100.
(iii) SMA 6 bin 100/150.
(iv) SMA 6 bin PMB.
(v) SMA 10 bin 40/60.
(vi) SMA 10 bin 70/100.
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38
Volume 1 Series 900
(vii) SMA 10 bin 100/150.

(viii) SMA 10 bin PMB.
(ix) SMA 14 bin 40/60.
(x) SMA 14 bin 70/100.
(xi) SMA 14 bin 100/150.
(xii) SMA 14 bin PMB.
(xiii) SMA 20 bin 40/60.
(xiv) SMA 20 bin 70/100.
(xv) SMA 20 bin 100/150.
(xvi) SMA 20 bin PMB.
(05/18) Binder Modification
2 (05/18) Polymer modified bitumens shall comply with BS EN 14023. The Contractor shall provide the
declaration of performance for the polymer modified bitumen to the Overseeing Organisation. The declaration
of performance shall demonstrate that the binder meets the requirements of the specification including the
3 (05/18) For premixed binders not covered by BS EN 12591 or BS EN 14023 the Contractor shall provide data
sheets giving details of the properties of the modified binders or additives proposed, including those specified in
contract specific Appendix 7/1. These shall include rheological data for pre-blended polymer modified binders in
accordance with BS EN 14770 and cohesion in accordance with BS EN 13588.
selected from Table D.7 of BSI PD 6691 as specified in contract specific Appendix 7/1.
5 (05/18) When specified in contract specific Appendix 7/1 the resistance to permanent deformation of material
laid in the permanent works shall be monitored by testing in accordance with BS 594987, clause G 3.1, 3.2 and 3.3.
Six cores shall be taken from the first kilometre length of material from each mixing plant and thereafter one further
core from each subsequent lane kilometre. Results shall be assessed on successive rolling means of sets of six
consecutive results and shall be deemed to conform if the mean is no greater than the specified value and individual
values not more than 50% greater than the specified value.
(05/18) Compaction control for Permanent Works
6 (05/18) Compaction shall be controlled by monitoring density and air void content in accordance with
BS 594987, clause 9.5.3 and the requirements of this Clause.
7 (05/18) Density shall be continuously assessed using an indirect density gauge in accordance with BS 594987,
clause 9.4.2, with readings taken at 50 m intervals in the centre of the mat. Gauge readings shall also be taken at
each core location specified in BS 594987, clause 9.5.3.2.1 and at the location of cores required by sub-Clause 11.
Each gauge shall be individually calibrated on each mixture from each mixing plant and the calibrations shall be
continually checked and updated based on correlations between gauge readings and core densities at the same
locations.
8 (05/18) For each location, the in situ void content shall be determined in accordance with EN 12697-8 using the
bulk density from the indirect gauge reading and a maximum density taken from the mixture type testing data and
updated with values from testing in accordance with sub-Clause 8.
exceed 5%, or for regulating course less than 30 mm in thickness, shall not exceed 7%.

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Volume 1 Series 900
10 (05/18) In the event of a failure to meet the requirements in sub-Clause 10, cores shall be taken at each location
and void contents determined. Testing of cores shall be carried out in accordance with BS 594987 section 9.5.3 and
assessment of conformity shall be in accordance with BS 594987, clause 9.5.3.6.1
11 (05/18) In the event of non-conformity with the requirements of sub-Clause 11 then density readings with
indirect gauges and if necessary, further cores shall be taken to establish the extent of the non-conformity. If it is
necessary to remove and replace any material to restore conformity this shall be in lengths not less than 15 m unless
otherwise agreed by the Overseeing Organisation.
12 (05/18) If the density readings taken with the indirect density gauge indicate that the air voids content may be
less than 2%, one 200 mm diameter core shall be cut at that chainage and the resistance to permanent deformation
checked in accordance with sub-Clause 6.
(05/18) Bond Coat
13 (05/18) Where the thickness of the stone mastic asphalt is less than 20 mm, polymer modified bond coats shall
be used.
938 (05/18) Porous Asphalt

1 (05/18) Porous asphalt shall conform to BS EN 13108-7, as specified in contract specific Appendix 7/1.
939 to 941 (05/18) Not Used
#942 (05/18) Thin Surface Course Systems

(05/18) General
1 (05/18) Thin surface course systems shall be provided and installed in accordance with the requirements stated
in this Clause and those given in contract specific Appendix 7/1.
2 (05/18) Thin surface course systems specified under this Clause shall be between 20mm and 50mm thick.
(05/18) Overall Performance Requirements
3 (05/18) The Contractor shall guarantee the installed thin surface course for a period of 5 years from the date of
opening to traffic. For the period of the guarantee the thin surface course shall meet the performance requirements
stated in this Clause and contract specific Appendix 7/1. The guarantee shall exclude defects arising from
accidental damage or damage caused by settlement, subsidence or failure of the underlying carriageway on which
the surfacing material has been laid. Replacement of the surfacing or other remedial measures agreed with the
Overseeing Organisation shall be executed if the surfacing is in a “Suspect”, “Poor” or “Bad” condition as defined
in Appendix A of TRL Report TRL674 – “Durability of thin surfacing systems, Part 4, Final report after nine years
monitoring, TRL report 674”.
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4 (05/18) The Contractor shall demonstrate that the ‘as installed’ thin surface course system can meet the
requirements of the specification. This shall be demonstrated by the system meeting the stated material
requirements and by having undergone a System Installation Performance Trial (SIPT) to cover the aspects of the
installation not covered by the material’s declaration of performance. The SIPT shall comply with the requirements
of sub-Clauses 23 to 43 of this Clause. An acceptable approach for the SIPT would be to use a scheme in
accordance with sub-Clause 104.16. The Contractor shall submit details of the SIPT for the systems to be used in
the contract as required in sub-Clause 28 to the Overseeing Organisation for acceptance.

Volume 1 Series 900
(05/18) Material Requirements

5 (05/18) The thin surface course mixture shall comply with BS EN 13108-1, BS EN 13108-2 or BS EN 13108-5.
It shall be CE marked and the Contractor shall submit the declaration of performance for the material to
the Overseeing Organisation. The declaration of performance shall demonstrate that the material meets the
requirements of the specification.
6 (05/18) The coarse aggregate shall be crushed rock or steel slag complying with Clause 901 and
BS EN 13043:2002. The Contractor shall submit the declaration of performance for the aggregate to the Overseeing
Organisation. The declaration of performance shall demonstrate that the aggregate meets the requirements of the
specification. The resistance to polishing and abrasion, PSV and AAV, shall be as specified in contract specific
Appendix 7/1.
The aggregate resistance to fragmentation and flakiness Index shall be as follows:
(i) Resistance to fragmentation: Los Angeles Coefficient (LA) – not greater than LA30;
(ii) Flakiness Index (FI) – not greater than FI20.
The maximum aggregate size shall be as given in Table 9/9
TABLE 9/9: (05/18) Maximum Aggregate Size

Site Definition Maximum Aggregate Size
Roundabouts 10mm
Bends < 250m radius 10mm
Junctions where turning radius movements 10mm
<250m
All other sites 14mm
7 (05/18) The minimum target design binder contents shall be in accordance with Table 9/10 and contract specific
Appendix 7/1.
TABLE 9/10: (05/18) Minimum design binder content

Minimum target design binder content (Bmin)
Maximum Mixture types: EN13108, Parts 1 Mixture types: EN 13108 Part 5 (SMA –
aggregate size (D) and 2 (AC & BBTM with PMB to paving grade bitumen to BS EN 12591
BS EN 14023) and fibresSMA)
14 5.0 6.0
10 5.2 6.2
6 5.4 Not used
8 (05/18) The resistance to permanent deformation shall be as specified in contract specific Appendix 7/1. The
resistance to permanent deformation of mixtures conforming to BS EN 13108 Parts 1 and 5 shall be in accordance
with the appropriate class selected from Table B.4 or D.2 respectively of PD 6691.
9 (05/18) The water sensitivity shall be as specified in contract specific Appendix 7/1. The water sensitivity of
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mixtures conforming with BS EN 13108 Parts 1, 2 and 5 shall conform to, at least, category ITSRmin70.
10 (05/18) Where required in contract specific Appendix 7/1 the design void content shall be Vmin1 to Vmax5%
11 (05/18) Contract compliance testing of the mixture shall be carried out as required in contract specific
Appendix 1/5 and samples supplied as detailed in contract specific Appendix 1/6.

Volume 1 Series 900
(05/18) Installation Requirements: General

12 (05/18) The Contractor shall provide an Installation Method Statement to the Overseeing Organisation. It
shall include the SIPT method statement as described in sub-Clause 26 of this Clause, all installation instructions
relevant to the system being used, details as specified in this Clause and details to meet the requirements of Clause
903.
13 (05/18) The design thickness of the thin surface course system shall be as specified in the contract specific
Appendix 7/1 within the minimum and maximum design thickness permitted in Table 9/11. The installed layer
thickness must not be less than the permitted minimum thickness, nor greater than the permitted maximum
thickness, stated in the Installation Method Statement.
TABLE 9/11: (05/18) Design Target Layer Thickness.

Nominal Aggregate Design target thickness, mm
size, mm Minimum Maximum
6 20 30
10 25 40
14 35 50
14 (05/18) Where required in the Installation Method Statement or in contract specific Appendix 7/1, to achieve
final pavement levels and/or thicknesses the existing substrate surface shall be strengthened or regulated in
15 (05/18) Where the existing substrate surface is regulated in accordance with Clause 907, evidence that the
deformation resistance of the regulating material will meet the specification shall be submitted by the Contractor to
the Overseeing Organisation. Where the combined thickness of the regulating material and the thin surface course
is more than 20 mm, evidence of the deformation resistance of the combined layers shall be provided.
16 (05/18) Surface preparation including the removal of road markings, cleaning and drying, resetting of ironwork
and road studs shall be in accordance with BS 594987 and the Installation Method Statement.
17 (05/18) Where required in the Installation Method Statement a bond coat or tack coat shall be applied. It shall be
in accordance with the Installation Method Statement. Unless otherwise stated in the Installation Method Statement
is shall also comply with Clause 920 and BS 594987. A calibrated mechanised method of application shall be used
unless otherwise agreed with the Overseeing Organisation.
18 (05/18) Transportation of the thin surface course material shall be in accordance with the System Installation
Method Statement and Clause 903.
(05/18) Installation Requirements: Surface Macrotexture – Untrafficked
19 (05/18) The surface macrotexture depth of the thin surface course system shall be measured in accordance
with BS EN 13036-1. Unless otherwise stated in contract specific Appendix 7/1 the macrotexture of the installed
surfacing shall comply with the relevant section of Table 9/12 or Table 9/13.
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Volume 1 Series 900
TABLE 9/12: (05/18) Requirements for Initial Texture Depth for Trunk Roads including
Motorways for Thin Surface Course Systems
Average per 1,000 m Average for a set of
Road Type Surfacing Type section, mm 10 Measurements,
Minimum Maximum mm (minimum)
Upper (D) aggregate size of 14mm 1.3 1.8 1.0
High speed roads Upper (D) aggregate size of 10mm 1.1 1.6 0.9
Upper (D) aggregate size of 14mm or
Lower speed roads 1.0 1.5 0.9
less:
Roundabouts on
high speed roads
Roundabouts on Upper (D) aggregate size of 10mm 1.0 1.5 0.9
lower speed roads Upper (D) aggregate size of 6mm 1.0 1.5 0.9
High Speed Roads are those with a posted speed limit ≥ 50 miles/h (80 km/h)
Lower Speed Roads are those with a posted speed limit ≤ 40 miles/h (65 km/h)
TABLE 9/13: (05/18) Requirements for Initial Texture Depth for Roads other than Trunk Roads
and Motorways for Thin Surface Course Systems
Road Posted traffic speed Average per 1,000 m section, mm Average for a set of
Classification 10 Measurements,
Minimum Maximum Initial
initial (mm) (mm) mm (minimum)
A ≥ 50mph 1.0 1.5 0.9
A All other traffic speeds 0.8 1.3 0.7
B,C,U All traffic speeds 0.8 1.3 0.7
(05/18) Installation Requirements: Macrotexture – Trafficked
20 (05/18) For a period of two years from the date of opening to traffic the average macrotexture, measured using
the volumetric patch technique in accordance with BS EN 13036-1, will be maintained above the levels given in
contract specific Appendix 7/1 and Table 9/14. The measurements shall be in the most heavily trafficked lane at
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Volume 1 Series 900
TABLE 9/14: (05/18) Retained Surface Macrotexture Requirements

Surfacing Type Average texture depth per
1,000m section, mm*
Systems with an upper (D) aggregate size of 14mm laid on motorway 0.9
trunk and high speed A roads
Systems with an upper (D) aggregate size of 10mm laid on motorway 0.8
Systems with an upper (D) aggregate size of 6mm laid on motorway 0.7 **
Systems with all aggregate sizes laid on non-trunk low speed A, and all 0.6
B, C and U classification roads
* or the complete carriageway lane where this is less than 1,000 m.
** verification of high speed friction performance required
(05/18) Installation Requirements: Torque Bond
21 (05/18) The bond strength between a thin surfacing system and its substrate shall be ≥ 400 kPa, measured in
(05/18) Installation Requirements: Noise
22 (05/18) The thin surface course system shall have the road/tyre noise characteristics as required in contract
(05/18) System Installation Performance Trial (SIPT) Requirements
23 (05/18) The thin surface course used in the SIPT shall meet the performance requirements of the thin surface
course to be supplied under the contract. This shall be demonstrated by the assessments and testing undertaken for
the SIPT.
24 (05/18) The installed thin surface course system shall be assessed, tested and certified by a Certification Body
using one or more trial areas of surfacing. The Certification Body shall be accredited to BS EN 45011 by UKAS or
equivalent European Accreditation organisation which is party to a multi-lateral agreement (MLA) with UKAS or
any equivalent International Accreditation Forum MLA signatory with a scope that includes relevant standard(s) or
scheme(s).
25 (05/18) The area of surfacing for the SIPT shall be a minimum of 200 metres in length and 3.5 metres in width.
26 (05/18) A SIPT method statement shall be prepared. The SIPT shall demonstrate, and enable verification of,
the installation procedures given in the SIPT method statement. This will include the correct application rates
of the bond (or tack) coat, application method of bond coat, paving speed of mixed material, joint formation,
laying temperatures, methods of verification to be used on site, maintenance and repair techniques, aftercare, and
frequency of testing and acceptable variations within the specified limits.
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27 (05/18) A SIPT inspection protocol shall be prepared. It shall demonstrate qualitatively and quantitatively the
applicability of the SIPT for the system in order to satisfy the performance requirements.
28 (05/18) The SIPT method statement, SIPT inspection protocols, all inspection and testing results and the SIPT
certification shall be submitted to the Overseeing Organisation along with the Installation Method Statement.
29 (05/18) The SIPT shall include the following to be undertaken by the Certification Body:
(i) verification that the system installation trial has been undertaken in accordance with the SIPT method
statement and the stated protocols;
(ii) assessment of the visual condition of the completed system at the times stated in sub-Clause 30;
(iii) assessment of the data from the site performance tests detailed in sub-Clause 30.

Volume 1 Series 900
The assessments shall be undertaken by an assessment team that includes a lead assessor with experience in
pavement inspections and a minimum of two additional suitably experienced persons to comprise an inspection
panel for the visual condition of the SIPT installation and interim inspections.
30 (05/18) The installed performance characteristics of the trail area shall meet the criteria stated in Table 9/15 at
the times and intervals stated.
TABLE 9/15: (05/18) Installed Performance characteristics

Characteristic Performance Requirements Time(s) at which the performance
characteristic shall be determined or
measured
Visual inspection Good or Excellent At opening to traffic.
As defined in sub-Clause 32 Good or Excellent 12 months after opening to traffic.
Good or Excellent 24 months after opening to traffic
Surface macrotexture depth Contract specific Appendix 7/1 or At opening to traffic.
(BS EN 13036-1:2010) Table 9/12 or 9/13
Appendix 7/1 and Table 9/14 12 months after opening to traffic.
Appendix 7/1 and Table 9/14 24 months after opening to traffic

Torque Bond ≥ 400 kPa Between 28 and 56 days after
installation.
Road/Tyre Noise level Table 9/17 Between 12 and 24 months after opening
to traffic.
Void Content (Voluntary Sub-Clause 34 Between 0 and 24 months after opening
assessment and declaration) to traffic.
31 (05/18) Defects identified during the visual inspections shall be recorded. The defects to be recorded are
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those described in TRL 674. The assessment of defects shall be summarised as a Performance Band as listed in
Table 9/16.
TABLE 9/16: (05/18) Site Installation Performance Trial visual inspection requirement
Performance Band Description
Excellent No discernible fault
Good No significant fault
Moderate Some defects but insufficient for serious problem
Acceptable Several defects but would usually be just acceptable
Suspect Seriously defective but still serviceable in the short term
Poor Requires remedial treatment
Bad Requires immediate remedial treatment
32 (05/18) The torque bond strength between the thin surface course and its substrate shall be established in
accordance with Clause 951. This shall be established between 28 and 56 days after the SIPT is installed.
33 (05/18) The void content of the proposed mixture when evaluated for the SIPT shall be Vmin2 to Vmax6% from
the average of 6 cores.

Volume 1 Series 900
(05/18) Noise
34 (05/18) Where noise characteristics for the thin surface course systems are specified in contract specific
Appendix 7/1 the SIPT shall include the assessment and measurement of noise characteristics as described in
sub- Clauses 34 to 43 of this Clause. The declared level shall be 0 to 3 or ‘NR’ as given in Table 9/17.

Level Equivalence to Traditional Surfacing Materials Road Surface Influence
RSI
3 Very quiet surfacing material -3.5 dB(A)
2 Quieter than HRA surfacing materials -2.5 dB(A)
1 Equivalent to HRA surfacing materials -0.5 dB(A)
0 Noisier than HRA Surfacing Materials +1.2 dB(A)
NR No requirement No requirement
35 (05/18) The influence of the road surface on traffic noise using the statistical pass-by method shall be established
at the SIPT site between 12 and 24 months after opening to traffic in accordance with ISO 11819-1: 2002,
Sections 7 and 8.
36 (05/18) Acoustic measurements shall only be carried out when the road surface is dry and the meteorological
condition specified in ISO 11819-1: 2002, Section 11 are met.
37 (05/18) The air and surface temperatures shall be monitored in accordance with the procedure described in
ISO 11819-1: 2002, clause 8.5. The road surface temperature, T surface, must be within 5°C to 50°C during
acoustic measurements. The air temperature, T air, must be within 5°C to 30°C.
38 (05/18) The test location road speed category shall be classified as either Medium or High as defined in
ISO 11819-1: 2002, clause 3.3. Not less than two test locations shall be selected for each road speed category,
which may be at the same site, provided the locations are at least 100 m apart or on different carriageways.
Each test location shall be representative in terms of road speed category and traffic level. Each of the test sites
selected must meet the requirements of ISO 11819-1: 2002 Section 6 and ISO/CD 11819-2: 2000. The road must
be essentially straight, or bends with a radius of curvature greater than 500 m for medium-speed, and 1000 m for
high- speed road categories. The crossfall of the test lane at the test site must not exceed 4%.
39 (05/18) The apparatus described in ISO 11819-1: 2002 Section 5 are used. The frequency range of between
100 and 5000 Hz (centre frequencies of the one-third octave bands) should be covered.
40 (05/18) The macrotexture of the road surface used for the noise assessment shall be measured in the nearside
wheel-track along the whole length of test material in accordance BS EN 13036-1:2010. The macrotexture depth of
the nearside wheel-track in front of a test location must be within 10 per cent of the average macrotexture measured
along the site.
41 (05/18) The microphone location at each measurement site shall be recorded accurately and marked with
appropriate methods such that the position can be readily identified for a period of at least two years.
42 (05/18) When sufficient vehicle pass-bys’ have been measured, a linear regression analysis shall be performed
in accordance with ISO 11819-1: 2002, clause 9.1. In the case of the high-speed road category, measurements must
not be taken of vehicles travelling at speeds of less than 60 km/h in accordance with AFNOR Standard S31-119.
43 (05/18) For each category of vehicle defined in Table 9/18, the Vehicle Sound Level, Lveh, shall be calculated
as the ordinate sound level of the regression line at the reference speed for the category of road. All levels shall be
calculated to two decimal places and rounded to one decimal place.
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Volume 1 Series 900
TABLE 9/18: (05/18) Reference speeds (km•h-1) for different road speed categories
Vehicle Road speed category (km·h-1)
category Medium High
L 80 110
H1 70 90
H2 70 90
Category L vehicles — light vehicles including passenger cars and car derived vans, excluding vehicles towing
trailers.
Category H1 vehicles — commercial trucks with 2 axles and greater than 3.5 tonnes.
Category H2 vehicles — commercial trucks with more than 2 axles and greater than 3.5 tonnes.
44 (07/21) Mixtures to be produced as WMAs shall comply with the requirements of this Clause and Clause 908.
943 (05/18) Hot Rolled Asphalt Surface Course and Binder Course (Performance-Related Design
Mixtures)
1 (05/18) HRA Performance Related surface course shall conform to BS EN 13108-4 and follow the example
from BSI PD 6691 Annex C section C.2.5.1.4, the requirements of this Clause and those specified in contract
specific Appendix 7.1.
This mixture can be laid at lower layers within special pavement types, e.g bridge decks, when it is unchipped.
2 (05/18) The nominal thickness of the hot rolled asphalt surface course layer shall be either 45 mm or 50 mm
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(05/18) Binder and Binder Modification
3 (05/18) Bitumen processed during refining to provide a binder with enhanced properties without the addition of
a modifier, shall have a HAPAS certificate or equivalent product acceptance scheme certification.
4 (05/18) For binders that do not comply with Clause 901 and without HAPAS or equivalent product acceptance
scheme certification, the Contractor shall provide data sheets giving details of the properties of modified binders,
whether the modifier is pre-blended with bitumen, the bitumen is modified during refinery processing or modified
by addition into the asphalt mixer, including those specified in contract specific Appendix 7/1. These shall include
rheological data in accordance with BS EN 14770 and cohesion in accordance with BS EN 13588. Binders that do
not comply with Clause 901 or sub-Clause 3 of this Clause shall not be used without the approval of the Overseeing
Organisation.
5 (05/18) Coarse aggregate shall be crushed rock or slag complying with BS EN 13043:2002 and Clause 901.
The resistance to polishing of the coarse aggregate for surface course shall comply with category PSV44 in
accordance with BS EN 13043:2002, clause 4.2.3.
selected from Table C.3 of BSI PD 6691, as specified in contract specific Appendix 7/1.

Volume 1 Series 900
(05/18) Coated Chippings for Surface Course

7 (05/18) When required, coated chippings shall be 14/20 mm or 8/14 mm size as specified in contract specific
Appendix 7/1 and comply with Clause 915.
(05/18) Surface Macrotexture for Surface Course
8 (05/18) The surface macrotexture shall comply with Clause 921.
(05/18) Compaction Control Procedures
9 (05/18) Control testing for compaction and resistance to permanent deformation shall be carried out in
accordance with BS 594987 section 9.5.2.
10 (05/18) When specified in the contract specific Appendix 7/1, the resistance to permanent deformation of
material laid in the permanent works shall be monitored by testing in accordance with clause F.3 of BS 594987
Annex F. Six cores shall be taken from the first kilometre length of material from each mixing plant and thereafter
one further core from each subsequent lane kilometre. Results shall be assessed on successive rolling means of sets
of six consecutive results and shall be deemed to conform if the mean is no greater than the specified value and
individual values not more than 50% greater than the specified value.
(05/18) Trafficking Newly Laid Surfacing
11 (05/18) The Contractor shall ensure the pavement material has adequately cooled and hardened before the road
is opened to traffic. Unless otherwise agreed by the Overseeing Organisation, the road shall not be opened to traffic
if its surface temperature exceeds 25°C unless the maximum temperature within the mat has fallen below 35°C.
944 (05/18) Not Used
945 (05/18) Weather Conditions for Laying of Hot Bituminous Mixtures

1 (05/18) The Contractor shall take account of the weather conditions when planning his working methods.
The Contractor’s working methods shall comply with all weather-related requirements of BS 594987 and any
additional requirements of this Clause. When laying is to be undertaken during winter (October to April) and/or
night time (9 p.m. to 6 a.m.), the contractor shall work to a Quality Plan that allows for the specific issues raised by
winter and/or night time working.
2 (05/18) Hot bituminous materials laid less than 50 mm thick, other than those supplied to Clause 942, shall be
laid within the wind speed and temperature constraints of Figure 9/1.
(05/18) Thin Surface Course Systems
3 (05/18) The weather conditions for laying thin surface course systems shall comply with those identified as
being acceptable in the Installation Method Statement as required in Clause 942.
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Volume 1 Series 900
(05/18) Hot Rolled Asphalt With Pre-coated Chippings

4 (05/18) Hot rolled asphalt surface course mixtures incorporating 35% coarse aggregate with pre-coated
chippings shall be laid 50 mm thick, within the following constraints of delivery temperature, wind speed and air
temperature.
Air temperature (minimum): 0°C
40 km/h (at 2 m height)
Wind speed (maximum at any air temperature): or
50 km/h (at 10 m height)
Minimum delivery temperature of materials: 155°C.
(05/18) Wind Speed
5 (05/18) When measurements are required for assessment, wind speed shall be measured by anemometer
positioned near the laying site to accurately reflect conditions at the laying site. The anemometer shall be fitted with
a digital accumulative device.
FIGURE 9/1: (05/18) Wind Speed and Air Temperature Laying Restrictions for Layers Less Than
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50 mm Thick
946 (05/18) Local Repairs

(05/18) General
1 (05/18) Local repair is defined as the reinstatement of surface course, and binder course and base if necessary,
over a relatively small area.
2 (05/18) Areas of defectiveness greater than 1m2 shall be repaired by inset replacement over a length and width
in accordance with sub-Clause 702.10(iv) and sub-Clause 903.21. Areas of defectiveness up to 1m2 in surface area
may be repaired using an inset patch. The repair technique used shall be as given in Table 9/19.

Volume 1 Series 900
TABLE 9/19: (05/18) Repair Technique

Size ( approx m2) Application Repair technique
Individual pothole or road stud
Up to 1.0 hole. Discrete area of local Inset patch
defectiveness
Replacement for minimum length of 5m
In excess of 1.0 or several or 15m in accordance with sub-Clause
closely adjacent areas less Wide area of local defectiveness. 702.10 (iv). Full lane width or less where
than 1.0 practicable, joints to comply with sub-
Clause 903.21.
(05/18) Inset Patch Repair for Areas ≤ 1.0m2 – Preparation
3 (05/18) The edges of the repair shall be saw-cut or planed in a neat rectangular shape in sound surfacing at a
distance of at least 0.25m beyond the defective area. The saw-cut or planed opening shall have vertical straight
edges and extend for the full depth of surface course. For repairs that extend into the binder course and/or base
these lower layers may be removed by the use of a mechanical breaker. An offset stepped detail for the binder and
base layers shall be used to ensure that vertical joints do not pass through more than one layer at the same location.
A minimum horizontal step of 100mm shall be provided at all layer interfaces.
4 (05/18) All existing material within the saw-cut perimeter of the repair area shall be removed and the base
and sides of the cavity thoroughly cleansed of all loose material and moisture to provide clean and dry surfaces
throughout.
5 The prepared vertical joints and the base of the cavity shall be treated in accordance with sub-Clause 903.22.
(05/18) Inset Patch Repair for Areas ≤ 1.0m2 – Repair Materials
6 (05/18) Repair materials shall comply with the specification requirements stated in contract specific
Appendix 7/1. Unless otherwise stated in contract specific Appendix 7/1 repair materials shall be consistent with,
and compatible to, the surrounding materials.
7 (05/18) Repair materials for patches in hot rolled asphalt surfacing shall be in accordance with Clause 911.
(05/18) Inset Patch Repair for Areas ≤ 1.0m2 – Construction
8 (05/18) Construction of the repair should commence at the edges and progress inwards with particular care
for full compaction especially in the vicinity of the vertical joint faces. All construction layers shall be laid and
compacted such that on completion each layer shall be at the same level as the adjacent course.
9 (05/18) The repair material must be compacted using rollers, vibrating plates and/or tampers as appropriate for
the size of the repair. The corners of the repair are the most vulnerable to distress and particular care must be taken
to achieve full compaction in these areas.
(05/18) Repair Areas >1.0m2
10 (05/18) Large areas shall only be repaired with materials installed using full scale self-propelled paving
machinery. The extent of the repair area shall be as described in sub-Clause 702.10(iv) with appropriate
longitudinal and transverse joints in accordance with sub-Clause 903.21.
11 (05/18) Repairs to large areas in Thin Surface Course Systems shall be undertaken in accordance with the
instructions stated in contract specific Appendix 7/1.
12 (05/18) Repair materials shall comply with the specification requirements stated in contract specific
Appendix 7/1. Unless otherwise stated in contract specific Appendix 7/1 repair materials shall be consistent with,
and compatible to, the surrounding materials.
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13 (05/18) Areas exceeding 1m2 in existing hot rolled asphalt surfacing shall be repaired using hot rolled asphalt
material in accordance with Clause 911.

Volume 1 Series 900
14 (05/18) Placing and compaction shall be in accordance with Clause 903 and BS594987 with use of bond coat in
(05/18) Proprietary Materials and Techniques for Repairs ≤ 1.0m2
15 (05/18) Evidence from laboratory evaluation shall be provided by the Contractor to the Overseeing Organisation
to demonstrate that the proprietary repair materials and/or techniques comply with the following performance
criteria:
• Stiffness: ≥1 GPa after 28 days when tested in accordance with BS EN 12697-26 (ITSM method 20°C)
• Resistance to permanent deformation: Classification No. 1 as defined in Table D.2 of BSI PD 6691
16 (05/18) Data from a representative area of the material and/or technique, for a local repair >2m2 in size, must be
provided to demonstrate that the finished surface to be trafficked complies with the following:
• The initial surface texture shall be not less than 0.9mm when measured using the volumetric patch
method described in BS EN 13036-1
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• The minimum wet Skid Resistance value shall not be less than 60 when determined using the portable
skid resistance tester (pendulum) in accordance with BS EN 13036-4.
947 (05/18) In Situ Cold Recycled Bitumen Bound Material

(05/18) Scope
1 (05/18) In situ cold recycled bitumen bound material shall be designed and produced to form the foundation or
main structural layer of the road pavement. The primary aggregate source shall be obtained by cold pulverisation
of all, or part, of the existing road structure. The primary binder (stabilising agent) shall be a foamed bitumen, with
cement or lime as an adhesion agent. The aggregate grading may be adjusted by the addition of a filler. Lime may
also be used to modify any cohesive sub-grade soil incorporated in the pulverised layer.
2 (05/18) Prior to commencing the pulverisation and stabilisation works, the Contractor shall demonstrate, to the
satisfaction of the Overseeing Organisation, using the results of mix design procedures described in sub-Clauses 58
to 65 of this Clause, that the existing pavement materials in the sections of the works defined in contract specific
Appendix 7/18 are capable of being recycled by pulverisation to form the primary aggregate component of an in
situ cold recycled bitumen bound material which can meet the specified end-product performance requirements.
(05/18) Component Materials
(05/18) Aggregates and Fillers

3 (05/18) The pulverised pavement material and any supplementary aggregate and/or filler shall normally be
granular material with not less than 5% and not more than 20% passing the 0.063 mm sieve (Zone A graded
material). Approval for use of pulverised granular material containing up to 35% passing the 0.063 mm sieve
(Zone B graded material) shall require confirmation by the Overseeing Organisation, subject to the results of the
mixture design procedures described in sub-Clauses 58 to 65 of this Clause.
4 (05/18) The pulverised granular material shall contain not more than 2% of organic matter as determined in
accordance with BS 1377-3 clause 3.
(05/18) Bitumen Binder
5 (05/18) The primary binder shall be foamed bitumen. The base bitumen shall comply with BS EN 12591 and
shall be 100/150 penetration grade.
6 (05/18) Other than foaming agent(s), bitumen modifiers shall not be used unless approved by the Overseeing
Organisation for special purposes or conditions.

Volume 1 Series 900
7 (05/18) The binder shall be transported to the site in tankers capable of maintaining the required temperature and
a homogeneous binder consistency and transferred to the stabilising plant in a controlled and uniform manner.
8 (05/18) The foaming of the bitumen shall be carried out within the spraybar system of the recycling machine
and immediately mixed with the pulverised aggregate, at which point the foamed bitumen shall have a volume of
not less than 10 times the volume of the base penetration grade bitumen.
(05/18) Cement, Filler Aggregate and Lime
9 (05/18) The constituents and required quality standards of hydraulic cement, filler aggregate and lime delivered
to site shall be certified by the supplier, whose manufacturing and delivery processes shall be implemented using
quality management systems in accordance with the BS EN ISO 9001 and certified by an accredited body.
10 (05/18) Hydraulic cement as a filler aggregate or adhesion agent shall be cement, blast furnace slag cement or
PFA cement, in accordance with sub-Clause 1001.3.
11 (05/18) PFA, used as a filler aggregate, shall be in accordance with BS EN 450-1.
12 (05/18) Lime for lime stabilisation (or as a modifier for plastic fines) shall, as required in contract specific
Appendix 7/18, be either quicklime or hydrated lime, complying with sub-Clause 615.3.
(05/18) Water
13 (05/18) Water for moisture content control of the pulverised granular material, shall normally be obtained from
a water company supply and used without testing. Water from an alternative source shall comply with BS EN 1008
and be approved by the Overseeing Organisation.
(05/18) Pulverisation and Stabilisation
14 (05/18) The Contractor shall satisfy the Overseeing Organisation that the plant used for pulverisation is
capable of uniformly pulverising the existing road structure in a single pass, to the depth stated in contract specific
Appendix 7/18. The plant used for stabilisation shall be capable of uniformly mixing controlled amounts of water
and binder agent(s) into the full depth of pulverised layer. For either operation, the plant shall be equipped with a
means of controlling the depth of processing to ±15 mm of the required depth.
15 (05/18) The plant used for stabilisation shall be equipped with a spraybar system within the mixing chamber
capable of producing and uniformly distributing foamed bitumen binder at a monitored and controlled rate. An
accessible sampling jet shall also be fitted that produces foamed bitumen having the same characteristics as that
produced by the main spraybar. Flow rate meters for measuring the supply rate of hot bitumen and other liquid
additives to the mixture shall be capable of recording the correct rate of flow during all states of pipeline flow
(i.e. fully or partially charged). Evidence confirming the capabilities of the plant and the calibration of flow meters,
shall be submitted to and approved by the Overseeing Organisation prior to the stabilisation works commencing.
16 (05/18) The material shall be pulverised and stabilised in a single layer if its compacted thickness is 300 mm
or less. If the compacted thickness is greater than 300 mm, the material shall be pulverised and stabilised in
the minimum number of layers between 100 mm and 300 mm thick. Where more than one layer is required,
the Contractor shall satisfy the Overseeing Organisation that the lower layer has achieved adequate stability in
accordance with sub-Clause 31 of this Clause before proceeding with the overlying layer.
(05/18) Pulverisation Process
17 (05/18) Pulverisation of the existing road structure shall be carried out in a systematic pattern, to the required
depth, to ensure that all parts of the existing road designated in contract specific Appendix 7/18 are included in the
works. An overlap of at least 150 mm shall be made between adjacent passes of the machine. Any material missed
along hard edges or around obstructions shall be excavated and placed in the path of subsequent passes of the
machine until a uniform fully pulverised aggregate is obtained. The pulverised material shall not be contaminated
by material drawn in from the verges.
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18 (05/18) All longitudinal and transverse joints shall be clean cut and vertical. Where work continues adjacent
to previously recycled material, transverse joints shall be reformed a minimum 0.5 m into the previously treated
construction. Where a layer of material for stabilisation is placed over a layer previously stabilised, the depth
of pulverisation/stabilisation of the upper layer shall be set to cut into the underlying stabilised layer by at least
20 mm.
19 (05/18) Excess pulverised material shall be removed by the grader and/or excavator for use elsewhere on site
or transported to stockpile at locations given in contract specific Appendix 7/18. The surface of the layer shall be
graded nominally to the required profile and provisionally compacted.
20 (05/18) Moisture content of the pulverised aggregate immediately prior to stabilisation shall be measured
in accordance with BS EN 1097-5 using the high temperature method. The moisture content shall be uniform
throughout the layer within the range ±2% of the optimum moisture content for the unstabilised aggregate
including any designed proportion of filler, determined in accordance with BS EN 13286-2.
21 (05/18) If the moisture content of the unstabilised pulverised aggregate fails to meet the specified moisture
content range, corrective action shall be taken either by aeration to reduce the moisture content or by controlled
addition of water to increase the moisture content.
22 (05/18) Aeration of the affected area shall be achieved by full depth passes of the recycling machine to disturb
and loosen the material and assist the evaporation of excess moisture. The material shall be kept in a loose
condition until subsequent moisture content tests show that the treated material has reached the required moisture
content range. The layer shall be re-graded nominally to the required profile and provisionally compacted in
preparation for stabilisation.
23 (05/18) An increase in moisture content of the affected area shall be achieved by the addition of water through
an adjustable spraybar system in conjunction with full depth passes of the recycling machine to achieve a uniform
distribution of the water throughout the layer. Increments of water shall be added and mixed in until subsequent
moisture content tests show that the material has reached the required moisture content range. The layer shall be
re-graded nominally to the required profile and provisionally compacted in preparation for stabilisation.
(05/18) Stabilisation Process
24 (05/18) Stabilisation shall not be carried out during or after periods of rainfall where the duration and intensity
are likely to cause the stabilised mixture to exceed the specified moisture content criteria and compromise the
stability of the layer under compaction (as defined in sub-Clause 31 of this Clause). Stabilisation of frozen
materials shall not be permitted.
25 (05/18) Prior to stabilisation, pulverised materials within 100 mm of restricted hard edges such as kerbs and
channels, or around obstructions such as gullies, shall be removed and spread uniformly over the remaining full
width of the pulverised material.
26 (05/18) Immediately prior to stabilisation, any filler and/or adhesion agent shall be spread uniformly over the
full width of the layer using a mechanical spreader capable of distributing the material(s) in a uniform controlled
manner. The rate of spread of these materials shall be calculated to achieve the mixture composition determined
in accordance with sub-Clauses 58 to 65 of this Clause and monitored as the spreading operation proceeds in
27 (05/18) The stabilisation shall be carried out to the required depth in a systematic pattern similar to that used for
the pulverisation process, with an overlap of at least 150 mm between adjacent passes of the machine. The bitumen
binder shall be introduced as a foamed bitumen and distributed through the spraybar system directly into the rotor
and mixing box of the stabiliser. The binder shall be supplied to the spraybar of the recycling machine by pumped
pipeline from on-board tanks or from a tanker moving in tandem with the recycling machine. The rate of supply of
the bitumen and any foaming agent, calculated to achieve the target binder content determined in accordance with
sub-Clauses 58 to 65, shall be controlled and monitored as described in sub-Clause 36 of this Clause.
28 (05/18) The layer of stabilised material shall be graded to level and compacted within two hours of the final pass
of the stabilising plant, unless a curing or “maturing” period of aeration is required. Any furrow formed by prior
excavation of edge materials shall be re-filled by grading the adjacent stabilised material into the space using a
minimum amount of re-working.
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29 (05/18) The compaction of each layer shall be carried out using compaction plant approved by the Overseeing
Organisation, until such time as the in-situ density complies with sub-Clauses 40 and 41 of this Clause and the
stabilised layer provides a stable and dense surface. Any open or segregated surface area shall be blinded using dry
crushed rock fines.
30 (05/18) The stability of the layer under compaction shall be deemed adequate if the finished surface does not
shove, rut or exhibit transverse cracking under the load of subsequent construction traffic.
31 (05/18) Where required by the Overseeing Organisation the stability of a layer in any area shall be assessed
after a curing period of at least 24 hours by channelled trafficking using a rigid three-axle tipper truck loaded to a
gross mass of 24 tonnes (assumed equivalent to three standard axles). The vertical deformation shall be measured
in all wheel-tracks at monitoring points on each of 5 transverse sections set 1 m apart after 5, 15, 30 and 40 passes
of the truck. The mean vertical deformations at the above trafficking increments shall be plotted against the
respective number of truck passes and the mean vertical deformation corresponding to 100 standard axles shall be
interpolated. The layer shall be deemed acceptable if the mean vertical deformation corresponding to 100 standard
axles is less than 10 mm.
32 (05/18) On completion of compaction the surface shall be sealed using a sprayed membrane of Class K1–70
bitumen emulsion complying with Clause 920. The bitumen emulsion shall be sprayed at the rate stated in contract
specific Appendix 7/18. Where the surface is opened to traffic, the sealing membrane shall be blinded with fine
aggregate or sand applied at a rate of 5.5 to 7.0 kg/m2.
(05/18) Process Control
33 (05/18) The condition or quality of the pulverised material or stabilised mixture shall be assessed for
specification compliance on the basis of each 800 m2 area of the works or part thereof, completed in the same
working day.
34 (05/18) The moisture content specified in sub-Clause 20 of this Clause shall be monitored using test specimens
extracted from three bulk samples of pulverised aggregate taken from points evenly spaced along a diagonal
bisecting the assessment area. The bulk samples shall comprise material taken from the full depth of the pulverised
layer. The depth of pulverisation relative to the designed road level shall be measured and recorded at each
point. The samples shall also be tested to determine the particle (or “lump”) size distribution in accordance with
BS EN 933-1 (or by an amended method to obtain an early assessment of grading, provided correlation with the
standard test method can be demonstrated). Where appropriate, the residue of the three samples shall be combined
to form one bulk sample and the bitumen content of the pulverised aggregate determined in accordance with
BS EN 12697-1. If any adjustment of moisture content is carried out prior to stabilisation, subsequent samples shall
be taken and further moisture content tests completed.
35 (05/18) The rate of spread of cement, filler, hydrated lime or quicklime shall be measured by weighing the
amount of material retained on each of five trays or mats of known area laid in the path of the spreading machine.
The trays shall be positioned approximately at points equally spaced along a diagonal bisecting the area of
coverage. The mean rate of spread and percentage addition of the material shall be determined and recorded for
each assessment area.
36 (05/18) The rate of supply of bitumen binder and any other fluids to the stabilising plant shall be set and
continuously monitored using the appropriate flow rate meters on the stabilising plant. As a check at the start of
each work period, the rate of supply of bitumen shall be determined from before and after dip measurements of
the storage/delivery tanks, related to an area of stabilisation of not more than 250 m2. The calculated supply rate of
bitumen for each test area shall be recorded.
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37 (05/18) As directed by the Overseeing Organisation, where lime has been used to modify a cohesive soil
component of the pulverised aggregate, the acceptability of the modified materials shall be tested in accordance

Volume 1 Series 900
38 (05/18) After stabilisation, prior to final compaction of the stabilised mixture, five samples of the stabilised
material shall be obtained. Each sample shall be taken from a point equally spaced along a diagonal bisecting the
area under consideration. The location of each sampling point shall be recorded. Each sample shall comprise at
least 40 kg of material taken from the full depth of the layer. The depth of stabilisation relative to the designed
road level shall be measured and recorded at each point. Where appropriate and as directed by the Overseeing
Organisation, the depth measurements shall be made using a stringline stretched between points of known level.
39 (05/18) In the field, each sample of the stabilised material shall be mixed in a tray and sufficient representative
material taken to produce a 150 mm cube specimen, made in accordance with the relevant Clauses of Series 800.
The refusal density for each cube sample shall be determined to the nearest 10 kg/m3. The remainder of each
sample shall be retained in a sealed condition for subsequent testing on site or in the laboratory, as described in
sub- Clauses 42, 43 and 46 of this Clause.
40 (05/18) After trimming and final compaction of the stabilised layer, the in-situ bulk density shall be measured at
50 m intervals per lane, including points close to the material sampling points, using an indirect density gauge in
direct transmission mode, to a depth within 25 mm of the total layer thickness. The meter readings shall be verified
periodically in accordance with BS EN 13286-2.
41 (05/18) The in-situ bulk density values obtained shall be compared with the refusal density value obtained from
the cube specimens at the respective sampling points. The average in-situ bulk density of each set of five values
shall be at least 95% of the cube refusal density, with no individual in-situ density value less than 93% of the
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respective refusal density.

42 (05/18) Either on site or immediately on arrival at the laboratory, each of the five samples shall be tested for
moisture content in accordance with BS 1377-2.
43 (05/18) Either on site or within 24 hours of arrival at the laboratory, one 150 mm diameter by 75 mm to 100 mm
high cylinder test specimen (briquette specimen) shall be manufactured from each of the five samples, compacted
in a PRD mould to a target density of the average in-situ bulk density measured in the field. The final density of
each briquette specimen shall be measured and using the respective moisture content values, the dry density values
shall be determined.
44 (05/18) The curing history of the five briquette specimens prior to testing shall be recorded, which shall, as soon
as possible after manufacture, include a period of 72 hours at a nominal temperature of 60ºC. Immediately before
testing, each briquette specimen shall be conditioned in air for a minimum period of 12 hours at 20ºC and then
tested in accordance with BS EN 12697-26 (ITSM method) to determine the Indirect Tensile Stiffness Modulus
(ITSM) of the material. After removal from the test apparatus, each briquette shall be immersed in water at 20°C
for a minimum period of 24 hours, then re-tested to determine the ITSM of the material in a saturated state.
45 (05/18) The air voids content of each briquette shall be determined in accordance with BS 598-104 except
that the maximum density for the partially coated product, used in the air voids content calculation, shall be
standardised using the maximum density determined for a fully coated laboratory prepared specimen. A sample
of loose pulverised aggregate obtained prior to the addition of foamed bitumen shall be dried to constant mass
at 50°C. Sufficient hot penetration grade bitumen shall then be added in increments to the dried aggregate in a
mechanical mixer until the mixture is visually fully coated (using of the order 4% of added bitumen). The coated
specimen shall be tested to determine maximum density as specified in BS EN 12697-5.
46 (05/18) The residue of the five samples of stabilised material shall be combined to form one bulk sample. From
this bulk sample, four sub-samples shall be obtained. Three sub-samples shall be tested to determine the particle
size distribution and one sub-sample to determine bitumen content in accordance with BS EN 12697-1. The added
bitumen content shall be the measured bitumen content of the stabilised mixture, less the bitumen content of the
pulverised aggregate prior to stabilisation.
47 (05/18) The specification compliance criteria for the process control tests shall be as described in Table 9/20.

Volume 1 Series 900
(05/18) End Product Performance of In Situ Cold Recycled Bitumen Bound Material
48 (05/18) The end-product performance of the in situ cold recycled bitumen bound material shall be assessed on
the basis of measurements carried out in areas of 800 m2 or part thereof completed each working day which match
the areas defined in sub-Clause 33 of this Clause.
49 (05/18) Within 24 hours of completion, the as-installed performance of the stabilised layer shall be evaluated
using a dynamic plate loading or penetrometer technique to determine values of elastic modulus at points on a
nominal grid pattern as described in contract specific Appendix 7/18. The elastic modulus at each point and the
mean elastic modulus for the assessment area shall comply with the minimum standards stated in contract specific
Appendix 7/18. Additionally, before proceeding with construction of the overlying pavement, the valuation process
shall be repeated to demonstrate that the elastic modulus value at all points and that of the mean value have
increased over the respective as-installed values by not less than the percentage values stated in contract specific
Appendix 7/18. Where these criteria are not met, the full extent of the non-compliant material shall be determined
and appropriate remedial measures implemented. Remedial action shall comprise either a delay in construction to
allow further curing and stiffening of the layer to occur or a repeat of all or part of the recycling process, followed
by re-evaluation, until a compliant material is achieved.
50 (05/18) Within 270 days of completion of the surfacing works, a Falling Weight Deflectometer survey shall be
carried out and analysed in general accordance with HD 29 (DMRB 7.3.2). In particular, the measurements shall
be taken on the finished road surface in the nearside wheel path, at a uniform and maximum spacing of 10 m. The
survey shall be carried out during a period when the pavement temperature at a depth of 50 mm is within the range
15 to 25ºC. The FWD results shall be analysed using a linear elastic FWD back analysis computer program, with
the pavement modelled as a two layer system. Layer 1 shall represent the combined design thickness of the bound
materials (i.e. the combined recycled material and overlying surfacing materials) and layer 2 shall represent the
unbound foundation layer of infinite depth. End product performance shall be defined in terms of the calculated
stiffness of layer 1, uncorrected for temperature. Compliance shall be achieved when the rolling mean of 10 results
is not less than the figure specified in contract specific Appendix 7/18 and no individual result is less than 85% of
the figure specified.
51 (05/18) In the event that the layer 1 stiffness requirement of sub-Clause 50 of this Clause are not met, the full
extent of the non-compliant material shall be determined by further investigation involving coring and laboratory
testing. For each area of non-compliance, cores shall be extracted through the full depth of the stabilised layer at
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locations directed by the Overseeing Organisation, at a minimum rate of one x 150 mm diameter core per 75 m2.
TABLE 9/20: (05/18) Compliance Criteria for Process Control Tests on In Situ Cold Recycled
Bound Material
Material property or characteristic Individual results Mean from test set
Relative in-situ density 93% Minimum 95% Minimum
Aggregate grading In accordance with sub-Clause 3 of this Clause
Added bitumen content Target1 = 0.6% N/A
Moisture content Optimum ± 3% Optimum ± 2%
Layer thickness (site measurement) ± 25 mm of specified ± 15 mm of specified
Cement content (site rate of spread measurement) Target ± 2% Target ± 1%
Indirect Tensile Stiffness Modulus (ITSM) – 2000 MPa minimum 2500 MPa minimum
dry specimens
ITSM – water saturated specimens 1500 MPa minimum 2000 MPa minimum
Percentage air voids content 12% maximum 9% maximum
Note: subject to the absolute minimum added bitumen content has stated contract specific Appendix 7/18.

Volume 1 Series 900
52 (05/18) The Contractor shall be responsible for extraction of the cores with the minimum of force or disruption.
Air flush coring shall be allowed for materials that are disturbed by water flush coring. After extraction, each core
shall be labelled and photographed and, prior to testing, shall be stored in sealed polythene bags, in a uniformly
supported position, at a temperature of 20°C ± 5°C. The thickness of recycled layer shall be measured and
recorded.
53 (05/18) Reinstatement of all core holes shall be completed before opening the area to traffic.
54 (05/18) If, at any of the prescribed core locations, it is not possible to extract an intact core of suitable size or
condition for the end-product performance testing, using a maximum of three attempts in an area of 1.5 m radius,
the material in the vicinity shall be deemed not to comply with the end-product performance specification.
55 (05/18) In the laboratory, each of the cores extracted successfully shall be trimmed to remove surfacing
materials and any underlying material prior to cutting into core test specimens between 75 mm and 100 mm high.
Where possible, three test specimens shall be obtained from each core, one from the upper part, one from the centre
and the other from the lower part.
56 (05/18) All core test specimens thus obtained shall be tested in accordance with the standards described in
Table 9/21.
TABLE 9/21: (05/18) Testing Standards for Core Specimens of In Situ Cold Recycled Bound
Material
Test Standard
Bulk density BS EN 12697-6 and sub-Clause 39 of this Clause
Air voids content BS EN 12697-8 and sub-Clause 45 of this Clause
Indirect Tensile Stiffness Modulus BS EN 12697-26
57 (05/18) The results obtained shall be used for assessing the expected performance of the stabilised material in
the Works, in relation to the known performance of BS specified base materials. The stabilised material in the trial
area shall be deemed acceptable if the compliance criteria described in Table 9/22 are met.
TABLE 9/22: (05/18) Compliance Criteria for In Situ Cold Recycled Bound Material – Core
Specimens from the Works
Material property or characteristic Individual cores Mean from core set
Core density relative to refusal density 93% minimum 95% minimum
Air voids content 9% maximum 7% maximum
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Layer thickness (from core measurement) ± 25mm of specified ± 15mm of specified

Indirect Tensile Stiffness Modulus – dry 2000 MPa minimum 2500 MPa minimum
(05/18) Mixture Design and Characterisation
58 (05/18) Mixture design and characterisation of in situ cold recycled bitumen bound material for each site, or
section of site, including details of filler, binder, adhesion and/or stabilising agent(s) and their quantities, shall be
submitted to the Overseeing Organisation at least one week prior to commencement of the recycling works. Where
the site investigation has identified significant variation of existing pavement materials between different sections
of the site, a mix design shall be submitted for each section of the site. The proposed plan area and depth of the
different sections, covered by each mixture design, shall be approved by the Overseeing Organisation.
59 (05/18) The testing standards used for the mixture design of the recycled bitumen bound mixture shall be those
listed in Table 9/23.

Volume 1 Series 900
TABLE 9/23: (05/18) Testing Standards for the Design and Characterisation of In Situ Cold
Recycled Bound Material
Test Standard
Moisture content BS 1377-2
Bulk density BS EN 12697-6
Air voids content BS EN 12697-8 and sub-Clause 45 of this Clause
Grading and Binder Content BS EN 12697-2
Indirect Tensile Stiffness Modulus BS EN 12697-26
60 (05/18) The aggregate used in the design and characterisation process shall be obtained from the appropriate
section of the works and shall be representative in terms of component material proportions, of the pavement
layers to be pulverised. The laboratory manufactured aggregate shall be pulverised or crushed such that it closely
replicates the nature and grading of the pulverised aggregate and that the aggregate particle size distribution shall
comply with sub-Clause 3 of this Clause.
61 (05/18) The laboratory prepared aggregate shall be thoroughly mixed with measured proportions of the bitumen
binder and adhesion agent(s) to produce at least three trial mixtures with different added bitumen contents. The
penetration reference of the bitumen and the type of the adhesion agent(s) used in the trial mixtures shall be the
same as those used in the finished works.
62 (05/18) The different added bitumen contents of the trial mixtures shall be set at increments of between 0.5%
and 1.0% in the range 3.0% to 6.0%, with appropriate allowance made for residual binder in any crushed asphalt
component. From each trial mixture, four 150 mm diameter x 75 mm to 100 mm high, cylinder test specimens
(briquette specimens) shall be compacted to refusal by vibratory compaction in a cylindrical metal mould, using
the compaction mould assembly and vibratory hammer described in BS EN 12697-32. The bulk density of each
cylinder shall be determined.
63 (05/18) The briquette specimens shall be cured for a period of 72 hours at a nominal temperature of 60ºC.
Following this, the briquette specimens shall be conditioned in air for a minimum period of 12 hours at 20°C and
then immediately tested in accordance with BS EN 12697-26 to determine the ITSM. After further conditioning of
the briquettes, immersed in water at 20°C for a minimum period of 24 hours, the ITSM tests shall be repeated on
each specimen.
64 (05/18) The characteristics of the mixture to be used in the works, including any added water, shall be
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determined using the optimum ITSM (dry) values. If peak conditions are not clearly displayed then plateau
characteristics shall be accepted and the lowest added bitumen content for which all the criteria defined in Table
9/24 are met, shall be used in the works subject to a minimum of 4.0% for mixtures containing only pulverised
unbound or cement bound aggregate and 3.0% for mixtures containing only pulverised bitumen bound materials.
65 (05/18) On the basis of the foregoing test results, the contractor shall declare details of the Job Standard
Mixture(s) for the works, setting out target aggregate grading and type, added water content, adhesion agents and
binder content, together with tolerances. The method of compaction shall be described such that the material to be
utilised in the works meets the mixture.

Volume 1 Series 900
TABLE 9/24: (05/18) Acceptable Design and Characteristic Requirements for In Situ Cold
Recycled Bound Material
Property or characteristic Individual specimens Mean from test set
Moisture content N/A Optimum ± 2%
Indirect Tensile Stiffness Modulus (dry) 2000 MPa 2500 MPa
Indirect Tensile Stiffness Modulus (wet) 1500 MPa 2000 MPa
Bitumen content N/A Target ± 0.5%
Particle size distribution N/A Zone A or Zone B
Air voids content 9% maximum 7% maximum
948 (05/18) Ex Situ Cold Recycled Bound Material

(05/18) General
1 (05/18) Ex situ cold recycled bound material (CRBM) comprises base and binder courses produced in a fixed
or mobile mixing plant from graded aggregate processed from arisings from the excavation of roads and similar
sources, blended if necessary with other aggregate and bound with cementitious, hydraulic or bituminous binders,
separately or in combination. This Clause covers four generic material families: Quick Hydraulic (QH), Slow
Hydraulic (SH), Quick Visco-Elastic (QVE) and Slow Visco-Elastic (SVE). The primary binder of these families of
materials shall be as follows:
QH: Cement as the main component and excluding bituminous binders.
SH: Hydraulic binders (e.g. PFA/lime and GBS/lime) excluding bituminous and Portland Cement;
QVE: Bituminous binder as the main component but also including Portland Cement.
SVE: Bituminous binder as main component but excluding Portland Cement.
2 (05/18) Ex situ CRBM shall be designed to achieve the specified level of the appropriate end performance
property
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(05/18) Quality Assurance

3 (05/18) Ex situ CRBM shall be produced in plants that have a UKAS accredited BS EN ISO 9001 Quality
Management System. The BS EN ISO 9001 Certificate scope shall include this activity.
(05/18) Sourcing of Aggregate
4 (05/18) The quality plan shall contain details of all aggregates to be used in the CRBM. Aggregate may include:
(i) asphalt, concrete or granular material planed or excavated from a road or other paved area;
(ii) primary, secondary or recycled aggregate from other sources;
(iii) fillers from primary or secondary sources (e.g. PFA).
5 (05/18) The processed aggregate including added filler shall not contain deleterious material that adversely
affects the performance of the mixture.
(05/18) Processing of Aggregate
6 (05/18) The quality plan shall describe how, in particular, highway arisings are to be processed, crushed,
screened and stocked to enable consistent production of the CRBM in line with the Job Standard mixture.

Volume 1 Series 900
(05/18) Binders and Other Constituents

7 (05/18) The bitumen and other constituents shall conform to the following standards:
(i) Bitumen emulsion shall conform to BS EN 13808 and be used in accordance with BS 434-2.
(ii) Cement shall conform to BS EN 197-1.
(iii) Bitumen used for foaming shall conform to BS EN 12591 and shall be grade 160/220 or harder.
(iv) Granulated blast furnace slag (GBS) shall comply with EN 14227-2.
(v) Ground granulated blast furnace slag (GGBS) shall comply with BS EN 14227-2.
(vi) Lime shall comply with BS EN 14227-11.
(vii) Fly ash (PFA) used as either as filler or pozzolan, shall comply with BS EN 14227‑4.
(viii) Un-weathered 0/4mm Basic Oxygen Slag (BOS) slag fines used in SH material as activator/accelerator
to the GBS shall comply with BS 6463 Part 102.
8 (05/18) Subject to approval, other constituents including setting and hardening agents may be used to enhance
the performance of the mixture. Water shall not contain material that adversely affects the performance of the
mixture.
(05/18) Job Standard Mixture
9 (05/18) The composition of the job standard mixture shall be declared as follows:
(i) Source, origin and proportion of all aggregate constituents.
(ii) Combined target grading, including mineral binders and tolerances.
(iii) Source, origin and proportion of all binders.
(iv) Target moisture content.
10 (05/18) The grading of the job standard mixture, i.e. the aggregate together with the other constituents including
hydraulic binders, shall comply with one of the zones in Table 9/25.
11 (05/18) Use of Zone B or C graded material shall be permitted only when the results of a full mix design
showing compliance with the required 28 day performance properties are available or when evidence can be
provided of satisfactory achievement of the performance requirements on an earlier contract with a similar
composition.
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60
Volume 1 Series 900
TABLE 9/25: (05/18) Particle Size Distribution of Mixture for Cold Recycling
Sieve (mm) Percentage by mass passing
Zone A Zone B Zone C
40 100 100 100
31,5 100 100 86-100
20 100 100 65-100
14 85-100 85-100 52-100
10 68-100 68-100 44-100
4 38-74 38-94 26-74
2 26-58 26-84 18-58
0,5 13-38 13-64 8-38
0,250 9-28 9-51 5-28
0,063 5-21 5-38 3-21
The binder addition shall comply with Table 9/26.
TABLE 9/26: (05/18) Minimum Binder Contents for Ex Situ Construction by Family and Binder
Type
Family OPC Lime PFA GBS GGBS Bitumen*

QH 3% – – – – –
2% – 4% –
2% – 3% –
2% – 2% –
SH – 2% 8% – – –
– 2% 6% – –
2% – – 4%
– 1% – 10% – –
– – – 10% – –
QVE 1% – ** – – 3%
SVE – 1.5%*** ** – – 3%
* foamed or emulsion (residual)
** PFA may be added as filler
***lime may be added for ‘breaking’ and adhesion purposes, and, if PFA included as filler, will contribute to
strength
(05/18) Mixture Design Validation
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12 (05/18) When a mix design validation is required it shall be carried out on aggregates and binders representative
of those to be used on the works. The validation may be carried out on CRBM mixed either in the laboratory or on
a pilot basis on a full scale plant.
13 (05/18) The target mixture shall comply with sub-Clauses 5 and 6.
14 (05/18) A preliminary exercise shall be undertaken to establish a target grading and suitable moisture content.

Volume 1 Series 900
15 (05/18) Representative samples of the mixture shall be taken and from these 150 mm diameter cylindrical
specimens shall be produced in accordance with sub-Clause 14. These specimens shall be 150 mm high for
hydraulic bound mixtures and 70-75 mm high for visco-elastic bound mixtures. The time between mixing and
specimen production shall be in accordance with the setting times given in Table 9/29.
16 (05/18) The density of each specimen shall be measured and using the respective moisture content values, the
dry density values shall be determined. The cylindrical specimens shall be conditioned and tested. The conditioning
and testing regime shall be agreed with the Overseeing Organisation and the measured characteristics shall
demonstrate compliance with the requirements of Table 9/27.
17 (05/18) The performance properties of the conditioned specimens shall be declared. The results shall be
considered as indicative only, as the compliance criteria apply only to the specimens prepared during the execution
of the works.
TABLE 9/27: (05/18) Mix Design and End Product Requirements

Property or Characteristic All Materials Mean from Test Set
QVE and SVE Materials (360 days*)
Class B1 1900 MPa
Class B2 2500 MPa
Indirect Tensile Stiffness Modulus
Class B3 3100 MPa
Class B4 4700 MPa
QH and SH Materials (360 days*)
*Note: 360 days in situ or cured in accordance with sub clause 15.
(05/18) Trafficking Trial
18 (05/18) When specified in contract specific Appendix 7/1 a trafficking trial shall be undertaken to demonstrate
that the CRBM is not prone to excessive rutting in its early life.
19 (05/18) A trial area shall be laid using the materials and plant to be used in the main works and on a foundation
typical of that in the main works. The trial area shall be left to cure for 24 hours and shall then be subjected to
controlled trafficking. The trafficking shall be performed by a heavy goods vehicle with an axle configuration and
loading typical of that to be encountered in the construction phase. The number of passes shall equate to the total
expected amount of traffic to be carried during construction, with a default value equivalent to 100 standard axles.
20 (05/18) The measured rutting in the trafficking trial shall be less than 10 mm or that specified in contract specific
Appendix 7/1.
(05/18) Process Control
21 (05/18) Production of the ex situ CRBM shall be subject to process control detailed in the quality plan and
meeting the following requirements:
(i) There shall be a description of the plant and the production process, preferably including a flow diagram,
detailing how material is to be produced in accordance with this specification.
(ii) Calibration schedules for all parts of the plant involved in determining mix consistency shall be
provided. These shall be accompanied by calibration records.
(iii) Details of transportation shall be provided. These shall include the location of the mixing plant and the
expected average time between mixing and laying. The Contractor shall record the duration between
mixing and the completion of compaction at the site during the execution of the works.
(iv) Measures to avoid problems caused by extreme weather. In particular, production shall not proceed if the
feedstock is frozen or excessively wet.
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Volume 1 Series 900
(05/18) Inspection and Test

22 (05/18) There shall be a schedule of inspection and test frequencies to be made during production of CRBM.
This shall comply with the minimum frequencies in Table 9/28.
TABLE 9/28: (05/18) Minimum Frequencies for Inspection and Test

Item Inspection Test
Aggregate stockpiles Daily Grading and moisture content Before production and weekly
Binders On receipt Supplier data
Combined grading of mixture Continual Daily
Moisture content of mixture Continual Daily
(05/18) Laying
23 (05/18) A written procedure for the laying of the ex situ CRBM shall be provided.
24 (05/18) The plant used for placing ex situ processed material shall be capable of laying the material without
significant segregation, evenly and to the required thickness across at least one lane width.
25 (05/18) A method for the making of longitudinal and transverse joints, appropriate to the type of CRBM being
laid shall be provided.
(05/18) Compaction
26 (05/18) The compaction of each layer shall be carried out to a defined rolling pattern, to achieve the required
in situ density and until the recycled layer provides a stable and dense tight surface. The stability of the layer after
compaction shall be deemed adequate if the finished surface does not shove, rut or exhibit transverse cracking
under the load of subsequent traffic. Open edges shall be protected from traffic.
27 (05/18) After trimming and final compaction of the recycled layer, the in situ bulk density shall be measured
using an indirect density gauge in direct transmission mode, to a depth within 25 mm of the total layer thickness.
The meter readings shall be verified periodically in accordance with BS EN 13286-2.
28 (05/18) The in situ bulk density values obtained shall be compared with the refusal density value of the Job
Standard Mix or of the refusal density of a specimen representative of the day’s production. The average in situ
bulk density of each set of five values shall be at least 95% of the refusal density, with no individual in situ density
value being less than 93% of the respective refusal density.
(05/18) Sealing
29 (05/18) When specified in contract specific Appendix 7/1, the surface shall be sealed using a sprayed membrane
of Class C40B4 bitumen emulsion complying with Clause 920. The bitumen emulsion shall be sprayed at a rate
1 to 1.5 l/m2 to achieve a uniform and continuous seal to the surface of the layer. Where the surface is opened to
traffic, the sealing membrane shall be blinded with fine aggregate or sand applied at a rate of 5.5 to 7.0 kg/m2.
(05/18) End Product Testing
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30 (05/18) The end product testing of the ex situ CRBM shall be assessed on the basis of representative specimens
made up in accordance with the schedule in contract specific Appendix 7/1.
31 (05/18) Representative samples of the ex situ CRBM shall be taken either at the mixing plant or from site.
150 mm diameter cylindrical test specimens shall be manufactured in sets of six by compacting to refusal in
accordance with BS 598 Part 104. The height of the test specimens and the time period after mixing during which
compaction must be completed shall be in accordance with Table 9/29.

Volume 1 Series 900
TABLE 9/29: (05/18) Setting Times of Cold Recycled Families

Family Setting time under normal Sample dimensions prepared to a target density
temperature conditions Diameter (mm) Height (mm)
QH 2 hours 150 150
SH 24 hours* 150 150
QVE 2 hours 150 75
SVE 24 hours* 150 75
* can be longer depending on material composition
(05/18) Conditioning and Testing of Samples
32 (05/18) Prior to testing, specimens shall be conditioned in a controlled environment, sealed to keep the moisture
in, as described in this clause. The purpose of this conditioning is to simulate the likely curing over the first year in
the road.
33 (05/18) Immediately after compaction, the cylindrical specimens, in their moulds shall be double wrapped in
cling-film plastic using two separate sheets; each of which shall be sufficient to cover the entire circumference of
the cylinder and the two ends of the specimen. Once wrapped in cling-film the sample shall be placed in a sealed
plastic bag. Care shall be taken when handling the specimens not to damage the plastic bag or the underlying
cling- film layer. The specimens should be stored in air or water at a temperature within 2°C of the nominal
conditioning temperature.
34 (05/18) The following conditioning regimes shall apply:
(i) QH specimens shall be conditioned for a period of 28 days at a temperature of 20+2°C.
(ii) SH and QVE specimens shall be conditioned for a period of 28 days at a temperature of 40+2°C.
(05/18) End Product Criteria
35 (05/18) The minimum specification compliance criteria for the process control tests shall be as described in
Table 9/30.
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TABLE 9/30: (05/18) End Product Criteria
Material property or characteristic Individual results Mean from test set of six specimens
Particle Size Distribution Zone –
Moisture content ±2% –
Relative In situ density 93% minimum 95% minimum
Layer thickness ±25 mm of specified ±15mm of specified
Indirect Tensile Stiffness Modulus or N/A Relevant value from Table 9/27 less 5%
Indirect Tensile Test
In the event of test specimens failing to achieve the required indirect tensile test results, compliance shall be
determined by the testing of cores extracted by dry coring after one year. The results shall be compared with the
criteria in Table 9/27.

Volume 1 Series 900
949 (05/18) Not Used
950 (05/18) Surface Preservation Systems

1 (05/18) Systems that are intended to extend the life of existing asphalt surfacing by the application of a
proprietary liquid coating shall have HAPAS or equivalent product acceptance scheme certification to demonstrate
their performance. Preservation systems without HAPAS or equivalent certification shall not be used without prior
approval by the Overseeing Organisation.
951 (05/18) Torque Bond Test

1 (05/18) The bond strength between a thin surfacing system and its substrate, which may be bituminous or
cementitious, shall be established between 28 and 56 days after the SIPT is installed by measuring the peak
shearing torque at a known temperature.
2 (05/18) Six evenly spaced, 100±5 mm diameter cores shall be cut to a depth of 20 mm below the thin surfacing
layer to be tested, along a diagonal line across the lane width from a 100 m length of the installation. The surface to
be tested must be clean and dry.
3 (05/18) A metal plate of mild steel having a diameter of 95±5 mm and a thickness of 14±2 mm, incorporating
a fitting to enable it to be coupled to a torque meter shall be secured to the surface of the core using a suitable
bonding agent, taking care to ensure that the plate is parallel to the surface.
4 (05/18) When the bonding agent has developed sufficient strength, (ie. failure should not occur within the
adhesive) a torque meter, fitted with a fiducial reading gauge, calibrated over a range of 0-350 Nm with a scale
readable to at least 10 Nm, shall be fitted to the metal plate, using adapters and extension rods as appropriate.
5 (05/18) Torque shall be applied to the core at a steady rate so that the torque wrench sweeps an angle of
90° within 30±15 seconds. Care must be taken to ensure that the torque is applied parallel to the core surface
within ± 10°. Torque is applied to the plate until failure of the bond occurs or a torque of 300 Nm is exceeded.
6 (05/18) The value of torque at failure shall be recorded in Newton metres (M). The bond interface temperature
shall be measured and recorded immediately after failure, using a thermometer readable to a temperature of 0.1ºC
and accurate to 0.5ºC.
7 (05/18) The core diameter shall be measured and recorded at two locations approximately 90° apart using
callipers and the mean value, D, recorded to an accuracy of 1 mm.
8 (05/18) The bond strength is calculated for each specimen using the following formula:
12M x 106
τ =
π D3
where:
τ : inter-layer bond strength in kiloPascals (kPa),
M : peak value of applied shearing torque in Newton metres (Nm),
D : diameter of core in millimetres (mm)
9 (05/18) The arithmetic mean of the inter-layer bond strength, τ, for the six specimens shall be calculated and
shall be greater than or equal to 400 kPa.
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10 (05/18) The test report shall include the name of organisation carrying out the test, description of materials
(system and substrate), date of test, peak torque at failure (Nm), inter-layer bond strength (kPa), (individual and
mean values), time to failure (seconds), diameter of core (mm), depth of Bond interface (mm), temperature of the
bond interface at test (ºC), identification of site or scheme, core location, age of the installation/specimen at the
time of test, nature of the bond interface, mode of failure.
952 & 953 (05/18) Not used
954 (05/18) Method for Laboratory Determination of Interface Properties Using the Modified
Leutner Shear Test
(05/18) Scope
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1 (05/18) This Clause specifies a laboratory test method to assess the bonding between adjacent asphalt pavement
layers using cylindrical samples. It is also appropriate for asphalt applied to concrete.
(05/18) Terms and Definitions
2 (05/18) For the purposes of this Clause the terms and definitions given in BS 6100 shall apply, together with the
following:
(i) Peak Shear Stress: The maximum value of shear stress, determined as the maximum force divided by
the initial cross sectional area of a specimen when tested as described in this Clause.
(ii) Displacement at Peak Shear Stress: The displacement at the maximum value of shear stress of a
specimen when tested as described in this Clause.
(iii) Shear Stiffness Modulus: The peak shear stress divided by the displacement at the peak shear stress of
a specimen when tested as described in this Clause.
(05/18) Principle of Test
3 (05/18) Cylindrical test specimens of nominal 150 mm diameter shall be subjected to direct shear loading at
20°C using the modified Leutner shear test. The maximum shear stress (in MPa) at the interface between layers
shall be determined.
(05/18) Test Apparatus and Materials
4 (05/18) The following test apparatus and materials shall be used:
(i) Shear test apparatus, as shown in Figure 9/2, composed of a base body (A) on which are fixed the
sample support (B) and the lower shear ring (D). The upper shear ring (C) is attached to the upper
body (E), which is movable along the guiding bars (F). The gap between shear rings (C and D) is 5 mm.
(ii) Loading frame capable of achieving a constant vertical displacement rate of 50.0 ± 2 mm per minute and
a maximum load of at least 50kN.
(iii) Data logging system to record load and displacement during the test.
(iv) Metal extension, as shown in Figure 9/3.
(v) Stiff adhesive, such as epoxy resin, with sufficient strength to avoid failure within the adhesive or at the
adhesive/asphalt material interface.

Volume 1 Series 900
(05/18) Sample Preparation

5 (05/18) Test specimens shall be cores of 150 ± 2 mm diameter; the minimum thickness of the layers above
and below the interface to be tested shall be 15 mm and 60 mm respectively. Specimens shall be cored from
an in-service pavement or from a slab manufactured using a laboratory roller compactor in accordance with
BS EN 12697-35 and BS EN 12697-33. If the thickness of the layer above the interface is between 15 and 30 mm,
a metal extension shall be glued on top of the layer above the interface.
(05/18) Procedure
6 (05/18) The diameter and thickness of the specimen shall be determined to the nearest mm.
7 (05/18) The specimen shall be placed into a suitable temperature controlled conditioning environment at
20 ± 0.5°C for a minimum of 5 hours.
8 (05/18) The appropriate shear rings, to form a loose fit around the specimen (for example, 151 mm diameter
shear rings for a 150 mm diameter specimen), shall be selected and attached to the Leutner test frame.
9 (05/18) The specimen shall be placed into the test apparatus and the interface aligned, (Figure 9/2 (G)), between
the upper and lower shear rings (Figure 9/2 (C and D)). If a metal extension is used, the specimen shall be placed
into the test apparatus so that the direction of the grooves is perpendicular to the direction of the applied shear load.
10 (05/18) Tighten the sample support using a suitable spanner.
11 (05/18) The test apparatus shall be placed into the loading frame and adjusted until the upper shear ring
(Figure 9/2 (C)) nearly touches the specimen.
12 (05/18) Start the data logging system (to record load and displacement) and commence shear loading. The
loading rate shall be 50.0 ± 2 mm per minute.
13 (05/18) Record the load (F) to the nearest 0.1 kN and the displacement (δ) to the nearest 0.1 mm.
14 (05/18) Stop the shear loading when the test frame reaches its limit of 7 mm displacement. The length of time
between removal of the specimen from the temperature controlled conditioning environment and completion of
testing shall not exceed 15 minutes.
15 (05/18) After the test has been completed, the apparatus shall be dismantled and the specimen removed.
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16 (05/18) Both sections of the specimen shall be observed (especially the interface) for any visual cracks and
unusual appearance (i.e. crushed aggregates on edges). Record any comments as necessary.
(05/18) Calculation and Expression of Results
17 (05/18) Calculate the shear stress as follows:
Where:
τ = shear stress in (MPa)
F = load (in kN)
r = initial radius of specimen (in mm)

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18 (05/18) Produce a shear stress versus shear displacement graph (an example is shown in Figure 9/4) using the
recorded data.
19 (05/18) Determine the following parameters from the graph:
(i) τ max = peak shear stress, MPa, expressed to the nearest 0.1
(ii) δ max = displacement at peak shear stress, mm, expressed to the nearest 0.1
(iii) k = shear stiffness modulus = τ max/ δ max, MPa/mm, expressed to the nearest 0.1
(05/18) Test Report
20 (05/18) The test report shall contain not less than the following information:
(i) A reference to this test method and test conditions.
(ii) Material descriptions for both layers.
(iii) Type and amount of tack (bond) coat (if known).
(iv) For each specimen tested, report:
– specimen diameter, expressed to the nearest mm
– layer thicknesses, expressed to the nearest mm
– maximum load (F), expressed to the nearest 0.1 kN
– peak shear stress (τ max), expressed to the nearest 0.1 MPa
– displacement at peak shear stress(δ max), expressed to the nearest 0.1 mm
– shear stiffness modulus (k), expressed to the nearest 0.1 MPa/mm
– any cracks or other damage.
(v) The test temperature, expressed to the nearest 0.5°C
(vi) The use (or otherwise) of a metal extension.

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A – base body
B – sample support
C – upper shear ring
D – lower shear ring
E – upper body
F – guiding bar
G – specimen interface
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FIGURE 9/2: (05/18) Schematic Diagram of the Modified Leutner Shear Test apparatus
FIGURE 9/3: (05/18) Schematic Drawing of the Metal Extension
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FIGURE 9/4: (05/18) Example of Shear Stress vs Displacement Data Plot
955 (05/18) Ageing Profile Test Using a Modified Rolling Thin Film Oven Test (MRTFOT)
(05/18) Scope
1 (05/18) This Clause specifies the procedure for obtaining samples of ‘Aged Binder’ after various stages of
conditioning. In this way, a plot of binder properties providing an ‘Ageing Profile’ may be accomplished in a short
time using the Modified Rolling Thin Film Oven Test (MRTFOT) to simulate ageing in road materials over many
years in service.
The MRTFOT utilises the Rolling Thin Film Oven (ASTM 2872) specified in BS EN 12607-1.
The method is suitable for generating small quantities of binder for rheological testing
The ‘Ageing Profile’ is generated by determining the rheological properties of complex shear (stiffness) modulus
G* and phase angle δ of samples taken from the oven at intervals throughout the test period, typically one day.
Other properties such as durability of cohesion may also be assessed.
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Three protocols are used depending on the type of binder and its use:
(i) a method to simulate ageing of polymer modified binder or paving grade bitumen used in the
manufacture of asphalt;
(ii) a method to remove the water phase and volatile flux from polymer modified bituminous emulsions and
simulate ageing and;
(iii) a method to test the potential for preservatives to reduce the ageing rate of bitumen.
The ‘Ageing Profile’ in terms of rheological characteristics provides ‘Product Identification’ and this is essential to
ensure consistency and to enable proprietary binders to be identified.

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(05/18) Warning
2 (05/18) The use of this test method can involve hazardous materials, operations and equipment. This Clause
does not purport to address all of the safety problems associated with the use of the test method. It is the
responsibility of the user of these test methods to establish appropriate safety and health practices and determine
the applicability of regulatory limitations prior to use.
(05/18) Asphalt Binders
3 (05/18) Binders used to manufacture hot mixed asphalt (asphalt binders) are first subjected to a ‘Short-term
Ageing Test’ to simulate the effects of manufacture, transport and laying. In this respect, the test described in this
Clause has been shown to be equivalent to BS EN 12607-1. The binder is continually stirred by rotating stainless
steel screws in sample cans to obtain a homogeneous sample; the procedure also benefits from a faster oxidation
rate (rapid ageing), because of the increased exposure to the jetted air stream and, therefore, a shorter test duration.
The binder samples are then aged at a lower temperature and samples removed at intervals and tested to obtain an
‘Ageing Profile’. This is particularly useful for asphalt, because different air void contents and binder contents in a
road pavement result in different ageing rates.
The ‘Long-term Aged’ binder sample, where the characteristics are equivalent to those obtained after 65 hours
using the Pressure Ageing Vessel PAV85 Test, is obtained after 7 hours; therefore, the test may be carried out in one
day. PAV85 is detailed in BS EN 14769.
Binders used for manufacturing ‘Warm Asphalt’ are mixed at much lower temperatures than for hot mixed asphalt
and they do not need the same high temperature protocol for ‘Short-term Ageing’; this part of the procedure is
therefore amended for these binders. All the ageing is done at the lower temperature.
(05/18) Bituminous Emulsion Binders
4 (05/18) Bitumen and polymer modified bituminous emulsions are first subjected to a ‘Rapid Recovery Test’
which removes any water phase and volatile oils to produce a ‘Recovered Binder’. The ‘Recovered Binder’ has
similar properties to that produced from other evaporative tests, but is achieved over a shorter period and the
use of nitrogen, replacing air, reduces risks associated with volatile oils in the oven. The ‘Recovered Binder’ in
rheological terms is equivalent to that recovered using BS EN 13074‑1.
The ‘Ageing Profile’ is provided by continuing the ageing of the ‘Recovered Binder’ in the MRTFO at a higher
temperature, replacing the nitrogen gas with air and removing samples after specified periods for testing. A
‘Stabilised Binder’, equivalent in rheological terms to that produced using BS EN 13074-2, may be obtained from
the ‘Ageing Profile’ Plot for a particular emulsion. Fluxed and vegetal fluxed binders where volatile oils are thought
to be present may also be tested using this protocol.
(05/18) Preservatives
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5 (05/18) 40/60 penetration grade bitumen, used as a control, is subjected to ‘Short-term Ageing’ in the MRTFOT
followed by an extended period at a lower temperature to simulate the ageing of the bitumen in a road pavement.
This aged bitumen control is then cooled to ambient and treated with the preservative. Most of the volatile oils are
then removed by conditioning the samples in the MRTFOT using a nitrogen blanket. The aged bitumen, treated by
preservative, is then subjected to further ageing with the MRTFOT. The properties of the aged bitumen, after action
of the preservative, are assessed by an ‘Ageing Profile’ using rheology and compared with the ‘Ageing Profile’ of
the control bitumen.
(05/18) Definitions
6 (05/18) For the purposes of the procedures specified in this Clause the following definitions apply:
(i) Laboratory Sample: sample of bituminous binder intended for laboratory tests. It may be a spot
sample, a composite sample or a part thereof (a divided sample) as described in BS EN 58.
(ii) Test Sample: sample of bituminous binder produced by treatment or subdivision of a laboratory sample
for individual test (BS EN 58).

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(iii) Recovered Binder: material remaining after removal of water or flux from a polymer modified
or unmodified bituminous emulsion or fluxed binder in the presence of nitrogen, equivalent to the
recovered binder using BS EN 13074-1.
(iv) Aged Binder: material remaining after the Ageing protocol.
(v) Short-term Aged Binder: material obtained during the MRTFOT which is equivalent to that provided
by BS EN 12607-1(RTFOT)
(vi) Long-term Aged Binder: material obtained during the MRTFOT which is equivalent to that provided
by BS EN 14769
(vii) Ageing Profile: graphical plot of performance-related results from samples tested during the ageing
protocol of this method. Performance-related testing is carried out using a Dynamic Shear Rheometer
(DSR), providing G* and phase angle data at a determined temperature and frequency.
(05/18) Test Apparatus (common to all protocols)
7 (05/18) The following test apparatus shall be used:
(i) RTFOT apparatus to BS EN 12607-1.
(ii) Eight identifiable sample cans with threaded screw top lids (or other fixing system) manufactured
from aluminium and coated on all internal surfaces with polytetrafluoroethylene (PTFE) with internal
dimensions and aperture diameter (L2) as shown below:
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The taper in the throat (from L2 aperture to lid top) is 45 ± 5°

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FIGURE 9/5: (05/18) Sample Can and Lid (both with threads)
(iii) Eight screws manufactured from high quality stainless steel (surgical quality) complying with BS
EN 10088-3, designation 1.4404 to a ‘fine machined finish’. All screws shall have dimensions: diameter
12.2 ± 0.2mm, length 120 ± 0.5mm and have between 18 and 19 turns with a pitch of 6 ± 0.2mm. The
depth of cut shall be 2 ± 0.2mm with a semi-circular profile – see Figure 9/6. At one end, the screw shall
have an unthreaded shank 10 ±0.5mm long and 7.5 ± 0.5mm diameter, ending in a 45° cone, truncated
to give a flat end at the apex 1.5 to 2.0mm diameter. The minimum weight of a screw shall be 70g.
The direction of screw shall be such that the binder sample is drawn to the closed end of the sample
can bottle when the can containing the screw is rotated in the carousel. If the RTFO carousel rotates
anticlockwise, viewed from the front, screws with a right-hand thread are required and if the carousel
rotates clockwise, screws with a left hand thread are required.
Dimension a = 1.5mm to 2mm
FIGURE 9/6 (05/18) Screw with Right-handed Thread (for anti-clockwise rotating carousel)
(iv) A spatula for removing the binder from the sample cans (a flat blade with a square end has been found
suitable).
(v) A balance accurate to 0.05g.
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(vi) A timer capable of timing 100 minutes, accurate to 1 second in five minutes and, for the MRTFOT, a
timer capable of timing 25 hours to the same accuracy.
(vii) Nitrogen gas supply (for Rapid Recovery Test and preservative test).
(viii) Air supply, clean dry air (for MRTFOT).
(ix) An oven to pre-heat the sample cans and the binder to the required temperature.
(05/18) Principle of the Ageing Profile Test for Polymer Modified and Unmodified Bituminous Binders for
Asphalts
8 (05/18) A thin film of binder is rotated in aluminium sample cans with screw top lids, both coated internally
with PTFE (replacing glass bottles), using the Rolling Thin Film Oven Test (RTFOT) apparatus, as described
in BS EN 12607-1. Special screws are used to disturb the binder and maintain a homogenous material during
‘Ageing’. Air is jetted over the film of binder for a much longer period than in the conventional test and a lower
temperature used in order to simulate the ‘ageing’ of the binder in the road after application. The screws accelerate
the process, and are necessary to maintain a homogeneous sample, especially when testing polymer modified
binders, which tend to form a skin and may phase separate in static ageing tests.
The initial conditioning test is to simulate the changes to the properties of the binder caused by the high
temperatures during manufacture, transport and laying, termed ‘Short-term Ageing’.
Further ageing is carried out at a reduced temperature and samples removed after set periods and tested, so that an
‘Ageing Profile’ may be plotted.
(05/18) Test Procedure for Determining the Ageing Profile of Hot Mixed Polymer Modified and Unmodified
Bituminous Binders for Asphalts
9 (05/18) Obtain a sample in accordance with BS EN 58. Stir the sample thoroughly to ensure it is completely
homogenized. If sub-samples are taken these shall have a minimum volume of 250ml. Ensure that the RTFO is
level so that the horizontal axes of the sample cans when in position in the carousel are level. Pre-heat the oven to
163 ± 1°C, 1h is generally sufficient. For binders used to manufacture warm mixed asphalts, substitute 135°C for
163°C throughout the test procedure.
Insert a stainless steel screw into each of the sample cans with the tapered end of the screw towards the aperture of
the container and record the mass of each assembly to 0.1g. Heat the sample cans and the stainless steel screws to
163 ± 1°C for 90 ± 10 min.
Heat the sample to 170 ± 3°C. Thoroughly stir the sample to ensure homogeneity immediately prior to decanting
into the sample cans.
Pour 19.0 ± 0.5g of the sample into a preheated sample can and record the mass with lid. Immediately after
weighing, roll the sample cans to ensure distribution of the binder on the walls of the can.
Mount the sample can in the carousel of the RTFO. Repeat for the remaining sample cans. Close the door of the
RTFO between mounting each sample can in the carousel. The period between weighing the first sample can with
binder and mounting of all the sample cans and the start of the rotation of the carousel shall not exceed 20 minutes.
When the carousel is fully loaded, rotate the carriage assembly at a speed of 15.0 ± 0.2min-1. Start the flow of air at
a set rate of 4000 ± 200ml/min. Start the timer. Maintain the samples in the oven and the air flowing for 45 ± 1min
from the time the test temperature reaches 163 ± 1°C.
If the test temperature of 163°C is not reached within the first 15 minutes, discontinue the test.
After 45 ± 1min, sample cans (minimum 2) may be removed for testing and to determine mass loss, if required.
This is the Short-term Aged binder, equivalent to RTFOT, BS EN 12607-1.
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To continue the Ageing Profile test, maintain the temperature at 163°C for a further 15 minutes, with the carousel
rotating in the air flow, then reduce the temperature of the oven to 135 ± 1°C. Note the time the RTFO takes to
reach 135°C. Once the temperature has been achieved, continue to rotate the samples in the air supply and remove
sample cans to obtain samples of aged binder as required for testing after three periods:
2h ± 10min; termed Aged2 Binder
6h ± 10min; termed Aged6 Binder: this is the Long-term Aged Binder, equivalent to PAV85.
Other periods may be used either for convenience or to allow other degrees of ageing to be investigated.
TABLE 9/31 (05/18) Summary of Sampling Times

Stage Gas RTFO Time Sampling Cumulative
Temperature time
Ageing Air 163°C 45min RTFOT Equivalent 45mins
Air 163°C 15min None 1h 00min
Air 135°C 2h Aged2 test samples 3h 00min
Air 135°C 6h Aged6 test samples (equivalent to PAV85) 7h 00min
For binders used to manufacture ‘Warm Asphalt’, ‘Short Term Ageing’ at 163°C is not required, therefore, replace
163ºC by 135ºC in Table 9/31 and report in addition Aged1 result (ageing at 135°C after a cumulative time of
1h ± 5min).
(05/18) Handling of the Aged Binder
10 (05/18) If the binder is to be tested immediately, remove a sample can from the carousel, extract the screw using
a small spatula and set the screw aside for cleaning. Place the sample can(s) in an oven preheated to the softening
point of the binder plus 100°C (if known), or 170°C if the properties of the binder are unknown, for 20 ± 5min.
Place the containers on their sides in an oven. This allows the binder to drain to one side of the container, which is
more easily removed with the spatula.
At the end of 20 ± 5min, remove the sample can from the oven, unscrew the lid and, using the spatula, scrape the
aged binder from the sample can and prepare the test samples in accordance with the relevant test method. Warming
the spatula to the same temperature as the binder facilitates removal of the binder.
If the aged binder from more than one sample can is needed to produce a test sample, combine the aged binder
from the sample cans and re-heat. Re-heating for testing shall be in accordance with BS EN 12594, ensuring that
aged binder is heated for no longer than is absolutely necessary. The binder shall be thoroughly homogenized by
stirring after heating and before being used for testing, while taking care not to entrain any air.
If the binder is not to be tested immediately, remove a sample can from the RTFO, extract the screw using a small
spatula and set the screw aside for cleaning. Unscrew the lid and, using the spatula, scrape the aged binder from the
sample can and place on a silicon sheet. The binder shall be sealed and stored at between 0°C to 5°C. The sample
shall be re-heated in accordance with BS EN 12594 and homogenised immediately before testing.
If the aged samples are to be transferred to another laboratory for testing, they shall not be subjected to
temperatures greater than ambient after ageing and before testing, and the delay before testing shall not exceed
120 hours.
The thermal history of the sample shall be recorded.

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(05/18) Principle of the Ageing Profile Test for Polymer Modified or Unmodified Bituminous Emulsions or
Fluxed Binders
11 (05/18) A thin film of binder is rotated in aluminium sample cans with screw top lids, both coated internally with
PTFE (replacing glass bottles), using the RTFOT apparatus, as described in BS EN 12607-1, to evaporate water
from bituminous emulsions and/or the light solvent or highly volatile fraction from fluxed or other binders. Special
screws are used to disturb the binder and maintain a homogenous material during breaking and/or curing. Nitrogen
gas instead of air is jetted over the film of bituminous binder at a lower temperature in order to minimize ageing
effects and simulate the condition of the binder soon after application. The first part of the process is carried out
with the RTFO set at 85°C to prevent frothing of the binder. The temperature is then increased to 135°C to drive off
any remaining water and/or solvent to provide the ‘Recovered Binder’, which is equivalent to the recovered binder
obtained from BS EN 13074‑1. The ‘Ageing Profile’ is provided by continuing the ageing of the binder in the
RTFO at 135°C, replacing the nitrogen gas with air and removing samples after specified periods for testing.
(05/18) Test Procedure for Recovery and Ageing of Bituminous Emulsion and Fluxed Binders
12 (05/18) Obtain a sample in accordance with BS EN 58. Stir the sample thoroughly to ensure it is completely
homogenized. The temperature of the binder sample shall not be less than 70% of the normal application
temperature in degrees Celsius and shall be recorded (for example, high binder content surface dressing emulsion
may require a minimum of 60°C, or a polymer modified fluxed binder, 130°C). The sample history if known shall
be recorded; this is important, as some ageing may have occurred. If sub-samples are taken these shall have a
minimum volume of 250ml. Ensure that the oven is level so that the horizontal axes of the sample cans, when in
position in the carriage, are level. Pre-heat the oven to 85 ± 1°C, 1h is generally sufficient.
Insert a stainless steel screw into each of the sample cans with the tapered end of the screw towards the aperture of
the container and record the mass of each assembly to 0.1g. Heat the sample cans, lids and the stainless steel screws
to 85 ± 1°C for 90 ± 10min.
Heat the sample to the application temperature of the binder, or, if this is not known, to 60 ± 3°C. Thoroughly stir
the sample to ensure homogeneity immediately prior to decanting into the sample cans, taking care to minimise
loss of water content and/or any volatile oil. Some cut-back binders and other binders such as primers having low
flash points are not suitable for this test. If there is any doubt concerning the volatile nature of the sample for test, a
suitable flash point test must be carried out before proceeding with the ‘Ageing Profile test’ or heating to 60°C.
Pour 19.0 ± 0.5g of the sample into a preheated sample can and record the mass. Immediately after weighing, roll
the containers to ensure distribution of the binder round the bottle.
When the carousel is fully loaded, rotate the carriage assembly at a speed of 15.0 ± 0.2min-1. Start the flow of
nitrogen at a set rate of 4000 ± 200ml/min. Start the timer. Maintain the samples in the oven and the nitrogen
flowing for 75 ± 1min from the time the test temperature reaches 85°C. At this stage there may still be residual
water in emulsion binders, especially those with high polymer contents.
If the test temperature of 85°C is not reached within the first 10 minutes, discontinue the test.
Increase the temperature of the oven to 135 ± 1°C. Note the time the RTFO takes to reach 135°C. Once the
temperature has been achieved, continue to rotate the carousel for a further 30 ± 1min at 135°C. At the end of
the 30 minutes, turn off the nitrogen. If required, sample cans may be removed and the samples may be used for
testing or determination of mass loss. This is the ‘Recovered Binder’ and is equivalent to that obtained using
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BS EN 13074-1.
The Ageing Profile can be determined by maintaining the RTFO at 135°C and switching to an air supply set at
4000 ± 200ml/min.

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Rotate the samples in the air supply and remove sample cans to obtain samples of aged binder as required for
testing after three periods:
5h ± 10min; termed Aged5 Binder, and
22h ± 10min, termed Aged22 Binder
Other periods may be used either for convenience or to allow different degrees of ageing to be investigated. Long-
term Ageing equivalent to PAV85 has been found to occur at 22 hours. It takes longer to achieve than with asphalt
binder, because there is no short-term ageing at 163°C. The PAV85 ageing period is not thought to be relevant
for emulsion binders used in most road applications. If samples at 22 hours are not required to simulate PAV85, a
combined sample from three sample cans may be useful at 3 and 5 hours, or another aged sample from two cans,
say at 4 hours, may be obtained for test to enhance the ‘Ageing Profile’
TABLE 9/32 (05/18) Summary of Sampling Times

Stage Gas RTFO Time Sampling Cumulative
Temperature time
Nitrogen 85°C 75±1min none 1h 15min
Recovery Nitrogen Ramp to 135°C 20min approx none 1h 35min
Nitrogen 135°C 30±1min ‘Recovered binder’ test samples 2h 05min
Ageing Air 135°C 5h Aged5 test samples 7h 05min
Air 135°C 22h (optional) Aged22 test samples 24h 05min
(05/18) Handling of the Recovered Binder

a small spatula and set the screw aside for cleaning. Immediately transfer the sample can (s) to an oven and heat
until at the required test temperature. Place the containers on their sides in an oven. This allows the binder to drain
to one side of the container, which is more easily removed with the spatula.
Unscrew the lid of the sample can and, using the spatula, scrape the recovered binder from the sample can and
place in the test apparatus. Warming the spatula to 135°C facilitates removal of the binder.
If the recovered binder from more than one sample can is needed to produce a test sample, combine the recovered
binder from the sample cans and re-heat. Re-heating for testing shall be in accordance with BS EN 12594, ensuring
that recovered binder is heated for no longer than is absolutely necessary. The recovered binder shall be thoroughly
homogenized by stirring after heating and before being used for testing, while taking care not to entrain any air.
If the recovered binder is not to be tested immediately, remove a sample can from the RTFO, extract the screw
using a small spatula and set the screw aside for cleaning. Unscrew the lid and, using the spatula, scrape the
recovered binder from the sample can and place on a silicon sheet. The binder shall be sealed and stored at between
0°C to 5°C. The sample shall be re-heated in accordance with BS EN 12594 and homogenised immediately before
testing.
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If the recovered samples are to be transferred to another laboratory for testing, they shall not be subjected to
temperatures greater than ambient after recovery and before testing, and the delay before testing shall not exceed
120 hours.

Volume 1 Series 900
(05/18) Handling of the Aged Binder

a small spatula and set the screw aside for cleaning. Place the sample can (s) in an oven preheated to the softening
point of the binder plus 100°C (if known), or 170°C if the properties of the binder are unknown, for 20 ± 5min.
Place the sample cans on their sides in an oven. This allows the binder to drain to one side of the sample can, which
is more easily removed with the spatula.
At the end of 20 ± 5min, remove the sample can from the oven, unscrew the lid and, using the spatula, scrape the
aged binder from the sample can and prepare the test samples in accordance with the relevant test method. Warming
If the aged binder from more than one sample can is needed to produce a test sample, combine the aged binder
from the containers and re-heat. Re-heating for testing shall be in accordance with BS EN 12594, ensuring that
aged binder is heated for no longer than is absolutely necessary. The binder shall be thoroughly homogenized by
stirring after heating and before being used for testing, while taking care not to entrain any air.
If the binder is not to be tested immediately, remove a sample can from the RTFO, extract the screw using a small
spatula, and set the screw aside for cleaning. Unscrew the lid and, using the spatula, scrape the aged binder from
the sample can and place on a silicon sheet. The binder shall be sealed and stored at between 0°C to 5°C. The
sample shall be re-heated in accordance with BS EN 12594 and homogenised immediately before testing.
120 hours.
(05/18) Principle of Assessing the Action of Preservatives using the MRTFOT
15 (05/18) A thin film of 40/60 penetration grade binder is rotated in aluminium sample cans, coated internally
with PTFE (replacing glass bottles), using the Rolling Thin Film Oven Test (RTFOT) apparatus, as described
in BS EN 12607-1. Special screws are used to disturb the binder and maintain a homogenous material during
conditioning. The bitumen is subjected to ‘Short-term Ageing’ followed by an extended period in the RTFO to
simulate the ageing of the bitumen in a road pavement. The properties of the ‘Long-term Aged’ bitumen may be
determined at this stage. The aged bitumen control in the remaining samples is then cooled to ambient, treated
with the preservative and left for 24 hours. Most of the remaining highly volatile oils are subsequently removed
by conditioning the samples in the RTFO using a nitrogen blanket. The aged bitumen, treated by preservative, is
then subjected to further ageing with the Modified RTFO. The properties of the aged bitumen, after action of the
preservative, are assessed by an ‘Ageing Profile’ test, using rheology values of complex shear (stiffness) modulus
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G* and phase angle δ, in accordance with BS EN 14770. Cohesion durability may also be determined.
(05/18) Test Procedure for Determining the ‘Ageing Profile’ of Aged Paving Grade Bitumen as a Control
Treated with a Preservative
16 (05/18) Obtain a sample of 40/60 paving grade binder in accordance with BS EN 58. Stir the sample thoroughly
to ensure it is completely homogenized. If sub-samples are taken these shall have a minimum volume of 250ml.
Ensure that the RTFO is level so that the horizontal axes of the sample cans when in position in the carousel are
level. Pre-heat the oven to 163 ± 1°C, 1h is generally sufficient.
Insert a weighed stainless steel screw into each of the sample cans with the tapered end of the screw towards the
aperture of the can lid; record the mass of each assembly to 0.1g. Heat the sample cans, lids and the stainless steel
screws to 163 ± 1°C for 90 ± 10min.
Heat the sample to the maximum storage temperature of the binder. Thoroughly stir the sample to ensure
homogeneity immediately prior to decanting into the sample cans.
Pour 19.0 ± 0.5g of the sample into a preheated sample can and record the mass. Immediately after weighing, roll
the sample can on the bench to ensure distribution of the binder round the walls of the can.

Volume 1 Series 900
When the carousel is fully loaded, rotate the carriage assembly at a speed of 15.0 ± 0.2min-1. Start the flow of air at
a set rate of 4000 ± 200ml/min. Start the timer. Maintain the samples in the oven and the air flowing for 45 ± 1min
from the time the test temperature reaches 163°C.
If the test temperature of 163°C is not reached within the first 10minutes, discontinue the test.
After 45± 1min at 163 ± 1°C, sample cans (minimum 2) shall be removed for testing and to determine mass loss.
This is the ‘Short-term Aged Binder’.
Reduce the temperature of the oven to 135 ± 1°C. Note the time the RTFO takes to reach 135°C. Once this
temperature has been achieved, continue to rotate the samples in the air supply for 240 ± 10min. At the end of this
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period, remove the sample cans from the RTFO and determine their mass loss.
Remove the screws and weigh to determine the mass of binder retained on each identified screw.
A quantity of binder shall be removed from each sample can, which shall be:
8 ± 1g, less the mass of binder retained on the particular screw removed.
It may be necessary to warm the sample cans to facilitate the removal of the screws and binder.
After removing the binder, lay the sample cans on their sides and allow them to cool to ambient temperature.
Add 10 ± 0.5g of preservative to each sample container and swill the preservative around the sample container for
approximately 15 seconds. Determine the mass of each sample can.
The sample cans with the binder and preservative are stored on their sides, with the pooled binder at the bottom,
in a ventilated fume cupboard at ambient temperature for 24 hours. This process allows any very low flashpoint
volatile oil to safely evaporate and consequently reduce the amount of hydrocarbon solvent within the sample can.
Pre-heat the oven to 50 ± 1°C, and transfer the sample cans from the fume cupboard to the RTFO carousel. Start the
carousel and jet nitrogen at 4000 ± 200ml/min over the sample cans for 120 ± 10min.
Identify and weigh eight clean screws and heat the screws to 135°C.
After 2 hours, the RTFO temperature is raised from 50°C to 135°C and air jetted at 4000 ± 200ml/min substituted
for the nitrogen supply. Note the time when the oven achieves 135°C.
When the RTFO has reached 135°C, stop the carousel and add a preheated screw to each sample can, with
the tapered end of the screw towards the aperture/lid of the sample can (and noting which screw is added to
which sample can). Restart the carousel and continue the conditioning of the samples at 135°C in air jetted at
4000 ± 200ml/min for 120 ± 10 min.
Remove the sample cans from the RTFO to obtain samples of aged binder as required for testing and determine the
mass of each sample can.
The control bitumen may be substituted with a binder recovered from a road or from a laboratory aged sample,
in which case the ‘Short-term Ageing’ and subsequent ageing protocol are not carried out, because the binder
will already have been aged and heated. In this case, the recovered binder sample is heated in accordance with
BS EN 12594 and 11 ± 0.5g added to heated cans (135°C) which are then rolled to achieve a film around the walls.
After this, they are cooled, 10 ± 0.5g preservative added and the preservative treated samples subjected to the same
Ageing Profile protocol as described above.
(05/18) Handling of the Preservative Treated Aged Bitumen
17 (05/18) If the binder is to be tested immediately, remove a container from the carousel, extract the screw using
a small spatula and set the screw aside for cleaning. Place the sample can (s) in an oven preheated to 140°C for
20 ± 5min. Place the containers on their sides in the oven. This allows the binder to drain to one side of the
container, which is more easily removed with the spatula.

Volume 1 Series 900
At the end of 20 ± 5min, remove the container from the oven, unscrew the lid and, using the spatula, scrape the
aged binder from the container and prepare the test samples in accordance with the relevant test method. Warming
If the aged binder from more than one container is needed to produce a test sample, combine the aged binder from
the containers and re-heat. Re-heating for testing shall be in accordance with BS EN 12594, ensuring that aged
binder is heated for no longer than is absolutely necessary. The binder shall be thoroughly homogenized by stirring
after heating and before being used for testing, while taking care not to entrain any air.
If the binder is not to be tested immediately, remove a container from the RTFO, extract the screw using a small
spatula and set the screw aside for cleaning. Unscrew the lid and, using the spatula, scrape the aged binder from the
container and place on a silicone sheet. The binder shall be sealed and stored at between 0°C to 5°C. The sample
shall be re-heated in accordance with BS EN 12594 and homogenised immediately before testing.
120 hours.
(05/18) Report
18 (05/18) Sample description (e.g. type, age/condition and source).
The Ageing Profile test procedure adopted for the work.
The change in mass of the sample from each stage of the recovery and /or ageing protocol shall be plotted to
develop an Ageing Profile for mass change.
Similarly, results of tests (for example G* using BS EN 14770), carried out after each stage of recovery and /or
ageing protocol, shall be plotted to develop an Ageing Profile for that property. These results shall include:
• A plot of G* (0.4Hz) over a range of temperatures between 0°C and 60°C
• A plot of phase angle (0.4Hz) over a range of temperatures between 0°C and 60°C
• G* and phase angle at 0.4Hz and 25°C
• Temperature (0.4Hz) where the phase angle is 45 degrees (Viscous Elastic Transition (VET)
temperature)
• G* (0.4Hz) at the VET temperature where phase angle is 45 degrees
For Clause 930 hard grade binder samples and other samples where they are considered to have a softening point
above 60°C the temperature range shall be increased to 80°C.
The thermal history of the samples, if they are not tested immediately, shall be reported.
956 & 957 (05/18) Not used
958 (05/18) Modified Binder Storage Stability Test

(05/18) Scope
1 (05/18) This test determines the susceptibility of a preblended modified binder to separation or instability during
prolonged storage at high temperature.
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Volume 1 Series 900
(05/18) Summary of Method

2 (05/18) A sample of modified binder shall be contained in a closed vessel of specific dimensions and shall be
maintained at 160 ± 2°C for 7 days ± 2 hours. A binder sample shall then be taken from the top and bottom thirds of
the vessel and both samples shall be tested for compliance with the binder specification.
(05/18) Apparatus
3 (05/18) The apparatus shall consist of:

(i) Cylinder, made of heat resistant glass, 190 ± 30 mm long and 65 ± 5 mm internal diameter having a
removable lid, flush fitting to exclude air when the cylinder is filled with binder, and provided with
three drain valves, one at the base, the other two spaced equally down the side of the cylinder, to allow
the sample to be divided into three equal portions as in sub-Clause 4 (vii) of the procedure.
Alternatively, a thin-wall sheet metal tube or similar vessel such as a 500 ml beverage can, of similar
dimensions to the glass cylinder, and having a similarly removable lid, fitted either with or without
drain-valves.
(ii) Oven, electrically heated, fan assisted, and capable of maintaining a temperature of 160 ± 2 °C, having
interior dimensions not less than 330 mm from the top of the heating element to the top of the chamber
and not less than 305 mm in width and depth.
(iii) Tube holder, made of metal, that will hold either the glass cylinder or sheet metal can, in a vertical
position, such that the base of the cylinder or can is not in direct contact with the oven floor.
(iv) Apparatus for determining the penetration and softening point of bitumen in accordance with
BS EN 1426 and BS EN 1427.
(v) Transfer dishes (3), made of metal, each of a capacity sufficient to hold at least one-third of the test
sample.
(05/18) Test Procedure
4 (05/18) The procedure shall be as follows:
(i) The bulk sample of modified binder shall be obtained by sampling in accordance with BS EN 58.
(ii) Place the bulk sample of modified binder and the glass cylinder (or metal tube or equivalent vessel) in
the preheated oven at 160 ± 2°C for a period not exceeding 3.75 ± 0.25 hours.
(iii) Remove the bulk sample from the oven and thoroughly mix by stirring to ensure obtaining a
representative test sample.
(iv) Remove the glass cylinder (or metal tube or equivalent vessel) from the oven and completely fill with
the modified binder test sample to allow no air space when the lid is fitted.
(v) Support the filled cylinder in a vertical position in the holder and transfer to the oven which shall be
controlled at a temperature of 160 ± 2°C and allow to stand undisturbed for a period of 168 ± 2 hours.
(vi) If a vessel having drain-valves has been used for the test proceed using Method A below, otherwise
proceed using Method B.
(vii) Method A
(a) Remove the glass cylinder (or alternative approved vessel) from the oven, keeping the cylinder
vertical.
(b) Open the uppermost drain-valve and run off the top third portion of the test sample into a transfer
dish for testing.

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Volume 1 Series 900
(c) Open the middle drain-valve and run off the middle third portion of the test sample into a suitable
container and discard.
(d) Open the lower drain-valve and run off the bottom third portion of the test sample into a transfer
dish for testing.
(viii) Method B
(a) Remove the tube or vessel containing the test sample from the oven and allow it to cool at room
temperature for 2 ± 0.25 hours whilst maintaining the vessel vertical in the holder.
(b) When the vessel of modified binder has cooled to ambient temperature, remove it from the
tube holder and make two cuts through the vessel and the sample at positions one-third and
two- thirds of the length from, and parallel, to the base.
(c) Retain the top and bottom thirds of the test sample for further testing and discard the middle third.
(ix) Determine the penetrations and softening points of the top and bottom thirds of the test sample, in
accordance with BS EN 1426 and BS EN 1427.
(05/18) Reporting
5 (05/18) For both the top and bottom thirds of the test sample the following shall be reported:
(i) The penetration, to BS EN 1426.
(ii) The softening point, to BS EN 1427.
(iii) Whether Method A or Method B was used.
(iv) The location and date of obtaining the bulk sample, and the dates of test.
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83F
Volume 1 Series 900

908TS (07/21) Warm Mix Asphalt (WMA)

(07/21) WMA General
1 (07/21) WMAs shall be installed in accordance with the producer’s instructions.
(07/21) WMA Permitted Mixtures
2 (07/21) Mixtures produced as Warm Mix Asphalts shall fulfil the requirements given in:
(iii) Clause 906 for Dense Base and Binder Course Asphalt Concrete with Paving Grade Bitumen
(Recipe Mixtures);
(iv) Clause 912 for Close Graded Asphalt Concrete Surface Course;
(iii) Clause 929 for Dense Base and Binder Course Asphalt Concrete (Design Mixtures);
(iv) Clause 930 for EME2 Base and Binder Course Asphalt Concrete;
(v) Clause 937 for Stone Mastic Asphalt (SMA) Binder Course and Regulating Course;
(vi) Clause 942TS for Thin Surface Course Systems; and
(vii) Clause 901 and Clause 903 and contract specific Appendix 7/1.
3 (07/21) Warm mixtures conforming to Clause 942TS shall have Product Acceptance Scheme certification for
their installation in compliance with sub-Clause 104.16 and Clause 942TS to demonstrate their performance.
4 (07/21) For the purposes of traceability, the mixture designation shall include a reference to the use of warm mix
technologies e.g AC20 bin HDM 40/60 "W".
(07/21) WMA Production Temperatures
5 (07/21) The maximum production temperatures, when measured in accordance with BS EN 12697-13, shall be
in accordance with Table 9/1A and the material's Declaration of Performance and not compromise the efficacy of
the binder, additives or process.
Table 9/1A TS (07/21) Maximum production temperatures for WMAs incorporating paving grade
binders, hard paving grade binders or Polymer Modified Binders
Maximum Temperature (°C)
Binder grade
(at any stage)
Documented and declared by
Polymer Modified Binder conforming to BS EN 14023
the producer
(07/21) Water Sensitivity
6 (07/21) Unless otherwise stated in contract specific Appendix 7/1, the water sensitivity expressed as an Indirect
Tensile Strength Ratio or Compression strength ratio shall be in accordance with Table 9/1B and contract specific
Appendix 7/1 and be declared on the Declaration of Performance.

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S1
Volume 1 Series 900
7 (07/21) Designated WMA mixtures in Table 9/1B which include 2% hydrated lime filler aggregate are deemed
to result in mixtures which satisfy water sensitivity requirements and testing is not required. Hydrated lime filler
shall be Ca(OH)2 in the form of hydrated lime, type CL 90-S.
Table 9/1B TS (07/21) Minimum Water Sensitivity Values for Warm Mix Asphalts
BS EN 12697
Material Clause and Description SHW Clause ITSRmin
12 Test Method
Dense Base and Binder Course Asphalt Concrete
929
(Design Mixtures)
Stone Mastic Asphalt (SMA) Binder Course and 80 A
937
Regulating Course
Thin Surface Course Systems 942
See sub-clause
EME2 Base and Binder Course Asphalt Concrete 930 B
930.21
(07/21) WMA Installation
8 (07/21) Mixtures produced as WMA shall comply with the requirements in Clause 903, contract specific
Appendix 7/1, Table 9/1C and the producer's recommendations and not compromise the efficacy of the WMA
binder, additives or process.
Table 9/1C TS (07/21) Minimum Rolling Temperatures for WMAs Incorporating Paving Grade
Binders, Hard Paving Grade Binders or Polymer Modified Binders
Minimum Temperature (°C) (immediately prior to
Binder grade
rolling)
Polymer Modified Binder conforming to BS EN 14023 Documented and declared by the producer
911TS (07/21) Hot Rolled Asphalt Surface Course (Design Mixtures)

1 (05/18) Hot Rolled Asphalt surface course design mixes shall conform to BS EN 13108-4, the example in
(i) HRA 0/2 F surf xx/yy des
(ii) HRA 30/14 F surf xx/yy des
(iii) HRA 35/14 F surf xx/yy des
(iv) HRA 55/10 F surf xx/yy des
(v) HRA 55/14 F surf xx/yy des
(vi) HRA 0/2 C surf xx/yy des

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S2
Volume 1 Series 900
(vii) HRA 30/14 C surf xx/yy des

(viii) HRA 35/14 C surf xx/yy des
(ix) HRA 55/10 C surf xx/yy des
(x) HRA 55/14 C surf xx/yy des
declared PSV and a maximum declared AAV as specified in contract specific Appendix 7/1.
3 (05/18) When required, coated chippings shall be either 14/20 mm or 8/14 mm size in accordance with
Clause 915.
(05/18) Marshall Stability and Flow
4 (05/18) When required, the Marshall stability and flow of the mixture at the target binder content shall be as
specified in contract specific Appendix 7/1. Stability and flow values shall be determined in accordance with the
procedures in BS 594987, Annex H.
942TS (07/21) Stone Mastic Asphalt Surface Course

1 (07/21) SMA TS2010 specification shall be as per Chapter 2 of TS2010 Surface Course Specification &
Guidance Issue 4 (November 2018), or subsequent issue, available from Transport Scotland Asset Management
Branch.
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Amendment – July 2021 S3F

Volume 1 Series 900

908WG (07/21) Warm Mix Asphalt (WMA)
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1 (07/21) Warm Mix Asphalt shall not be used.
911WG (07/21) Hot Rolled Asphalt Surface Course (Design Mixtures)

1 (05/18) Hot Rolled Asphalt surface course design mixes shall conform to BS EN 13108-4, the example in
(i) HRA 0/2 F surf xx/yy des
(ii) HRA 30/14 F surf xx/yy des
(iii) HRA 35/14 F surf xx/yy des
(iv) HRA 55/10 F surf xx/yy des
(v) HRA 55/14 F surf xx/yy des
(vi) HRA 0/2 C surf xx/yy des
(vii) HRA 30/14 C surf xx/yy des
(viii) HRA 35/14 C surf xx/yy des
(ix) HRA 55/10 C surf xx/yy des
(x) HRA 55/14 C surf xx/yy des
declared PSV and a maximum declared AAV as specified in contract specific Appendix 7/1.
3 (05/18) When required, coated chippings shall be either 14/20 mm or 8/14 mm size in accordance with
Clause 915.
(05/18) Marshall Stability and Flow
4 (05/18) When required, the Marshall stability and flow of the mixture at the target binder content shall be as
specified in contract specific Appendix 7/1. Stability and flow values shall be determined in accordance with the
procedures in BS 594987, Annex H.
Amendment – July 2021 W1

Volume 1 Series 900
942WG (07/21) Welsh Government Procedure and Advice Guidance (PAG) 112/20 – Stone Mastic
Asphalt Specification.
1 (07/21) WG Stone Mastic Asphalt (SMA) surface course shall be as specified in PAG 112/20 issue 02 or any
subsequent issue, available via:
https://gov.wales/sites/default/files/publications/2020-09/procedure-and-advice-guidance-pag-112-20-stone-mastic-
asphalt-specification.pdf
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Amendment – July 2021 W2F

Volume 1 Series 900

908NI (07/21) Warm Mix Asphalt (WMA)

1 (07/21) Warm Mix Asphalt shall not be used without prior approval from the Overseeing Organisation.
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Amendment – July 2021 N1F

SERIES 1000
ROAD PAVEMENTS – CONCRETE
MATERIALS
Contents
1000 General 2 1028 (02/16) Trial Length 30
(02/16) Strength Classes of Concrete and
1001 (01/20) Texturing of Hardened
1029
Constituent Materials for Pavement Layers 2 Concrete by Transverse Grooves 32
1002 (02/16) Air Content 7 1030 (01/20) Lower Strength Concrete 32
1003 (02/16) Density 7 (02/16) Measurement of Macrotexture
1031
Depth – Volumetric Patch Technique 34
1004 (02/16) Pavement Concrete Strength 8
1032 to 1038 (11/21) Not Used 34
1005 (02/16) Consistence (Workability) 9
(02/16) Summary of Rates for Sampling
1039
1006 (02/16) Not Used 9
and Testing Concrete for Pavement
(02/16) Separation and Waterproof
1007 Layers 34
Membranes 9
1040 to 1042 (02/16) Not Used 35
1008 (02/16) Steel Reinforcement 9
1043 (02/16) Foamed Concrete 35
1009 (02/16) Transverse Joints 11
(02/16) Pavements with an Exposed
1044
1010 (02/16) Longitudinal Joints 12 Aggregate Concrete Surface 35
1011 (02/16) Dowel Bars 13 (02/16) Weather Conditions for Laying
1045
1012 (02/16) Tie Bars 14 of Cementitious Materials 39
1013 (02/16) Joint Grooves 16 1046 to 1047 (02/16) Not Used 39
(02/16) Groove Formers and Bottom

1014 (02/16) Use of Surfaces by Traffic and
1048
Crack Inducers 16 Construction Plant 39
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1015 (02/16) Joint Filler Board 17 1049 to 1050 (01/20) Not Used40
(02/16) Preparation and Sealing of Joint

1016 (01/20) Roller Compacted Concrete Mixtures40
Grooves 18 1051 (01/20) General Requirements for Roller
1017 (02/16) Joint Seals 20 Compacted Concrete (RCC) mixtures40
(02/16) Joints at Manhole and Gully Slabs

1018 21 1052 (01/20) RCC Constituents41
1019 (02/16) Inspection of Dowel Bars 22 1053 (01/20) Storage of RCC Constituents42
(02/16) Side Forms, Rails and Guide Wires 22

1020 1054 (01/20) General Requirements for
Production and Layer Construction
1021 to 1022 (02/16) Not Used 23 of RCC42
1023 (02/16) Transport and Delivery 23 1055 (01/20) Production of Roller Compacted
1024 (02/16) Construction by Machine 23 Mixtures44
(02/16) Construction by Small Paving

1025 1056 (01/20) Method Statement and Trial
Machines or Hand Guided Methods 26 Length of RCC45
(02/16) Finished Surface Requirements

1026 26 1057 (01/20) Induced Cracking of RCC45
1027 (02/16) Curing 30 1058 (01/20) Roller Compacted Concrete

Mixtures46

Clause Title Page

1059 (01/20) Testing, Control and Checking
of RCC47
1060 (01/20) Laboratory Mixture Design
Procedure 49
(11/21) Maintenance of Concrete Pavements
1080 (11/21) Early Strength Concrete for Slab

Replacement50
1081 (11/21) Bay Replacement50
1082 (11/21) Full Depth Repairs51
1083 (11/21) Thin Bonded Repairs52
1084 (11/21) Shallow Repairs – Early Strength

Concrete52
1085 (11/21) Shallow Repairs – Polymeric Materials
53
1086 (11/21) Not Used54
1087 (11/21) Overlays to Concrete Pavements –

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Asphalt54
1088 (11/21) Grouting Under Slabs54
1089 (11/21) Not Used 55
1090 (11/21) Crack Sealing55
1091 (11/21) Crack Stitching56
1092 (11/21) Longitudinal Diamond Grinding56
1093 (11/21) Fine Milling58F

Volume 1 Series 1000
Specification for Highway Works Road Pavements – Concrete Materials
ROAD PAVEMENTS – CONCRETE MATERIALS

1000 (02/16) General
2 (01/20) The Contractor shall undertake the testing of concrete pavements as detailed in the Clauses of this Series
unless detailed otherwise in contract specific Appendices 1/5, 1/6 or 7/1.
1001 (02/16) Strength Classes of Concrete and Constituent Materials for Pavement Layers
1 (02/16) Concrete in rigid or rigid composite pavements shall be one of the classes given in Table 10/1, in
accordance with the pavement design alternatives permitted in contract specific Appendix 7/1.
2 (02/16) Unless otherwise specified in contract specific Appendix 7/1 concrete shall conform with the
requirements of BS EN 13877-2 and the requirements of this Series. The constituents of the concrete shall conform
with BS EN 206 and BS 8500-1 and BS 8500-2 and BS EN 13877-1 and the requirements of this Series.
TABLE 10/1: (01/20) Pavement Layers — Concrete Strength Classes
Pavement Layer BS EN 206, BS 8500-2, BS EN 13877-2 BS 8500-1 BS Clause

Designed Standardised Designated EN 13877-1
Concrete Prescribed Concrete
Concrete
(i) Surface slabs: C40/50** C32/40**

Unreinforced concrete (URC)
Jointed reinforced concrete (JRC) 1001 to
Continuously reinforced concrete pavement (CRCP) 1039 and
1044
(ii) Continuously reinforced concrete base (CRCB) C40/50** C32/40**
(iii) CRCP and CRCB ground beam anchorages * C25/30
(iv) Lower Strength concrete 4) For bases or sub-bases ST4 GEN 3 C16/20
as required in contract
(v) Lower Strength concrete 3) specific Appendix 7/1 ST3 GEN 2 C12/15
1030
(vi) Lower Strength concrete 2) ST2 GEN 1 C8/10
(vii) Lower Strength concrete 1) ST1 GEN 0 C6/8
NOTE: * Cores shall not be taken from ground beam anchorages. ** Minimum permitted concrete class.
(02/16) Cement
3 (01/20) The general term ‘cement’ in this Series means any of the materials in (i) or the combinations in (ii)
below:
(i) Cements Complying with:
(a) Portland cement CEM I BS EN 197-1
(b) Portland-slag cement CEM II/A-S and CEM II/B-S BS EN 197-1
(c) Blastfurnace cement CEM III/A and CEM III/B BS EN 197-1
(d) Portland-fly ash cement CEM II/A-V and CEM II/B-V BS EN 197-1
(e) Pozzolanic cement CEM IV/A BS EN 197-1
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Amendment – January 2020 3

(ii) Combinations
(a) Portland cement CEM I with ground granulated blastfurnace slag BS EN 197-1
(ggbs) for use with Portland cement CEM I BS EN 15167-1 and
BS EN 15167-2
(b) Portland cement CEM I with fly ash (fa) for use as a cementitious BS EN 197-1
component in structural concrete BS EN 450-1 and
BS EN 450-2
(c) Portland cement CEM I with pozzolanic additive having current BS EN 197-1
certification complying with a product acceptance scheme as
described in sub-Clauses 104.15 and 104.16.
(iii) In each cubic metre of fully compacted concrete the cement content shall be in accordance with
Table 10/2. For 20 mm maximum size aggregate add 20 kg/m3, and for < 20mm maximum size add
40 kg/m3.
(iv) When used, the proportion of silica fume to CEM I shall be 10 ± 1%.
(v) For materials required to comply with BS EN 197-1 and/or BS EN 450-1 the Contractor shall
submit the relevant material declarations of performance to the Overseeing Organisation prior to
the inclusion of the materials into the works. The declarations of performance shall demonstrate
that the materials meet the requirements for the specification.
TABLE 10/2: (01/20) Minimum Cement or Combination Contents with 40 mm Maximum Aggregate
Class (BS 8500-1) C40/50 C32/40 C32/40 C25/30 C16/20 C12/15 C8/10 C6/8
In surface slabs In at least

overlaid by 30 the top
mm minimum 50 mm of
thin surface surface
course system slabs
complying with
Cement Clause 942
Min. Portland cement Ref BS8500-1 320 320 280 180 160 130 120
CEM I, BS EN 197-1
(kg/m3)
Min. other cements 340 340 300 180 160 130 120
or combinations
permitted in sub-
Clauses 3(i) and 3(ii)
(kg/m3)
For mixtures pre-blended or mixed on site
Maximum proportion 50 50 35 65 65 65 65 65
of ggbs (%)
Max/min. proportion 35/15 35/15 25/15 35/15 35/15 50/0 50/0 50/0
of fa (%)
Min. CEM I content 220 220 255 200 160 – – –

(kg/m3)
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4
(02/16) Water
4 (01/20) Water from a water company supply may be used without testing. Water from other sources may be
used if it conforms to BS EN 1008. The water content shall be the minimum required to provide the specified
consistence for full compaction of the concrete to the required density, as determined by trial concrete mixes or
other means, and the maximum free water/cement ratio shall be 0.45 for strength classes C32/40 and C25/30 and
0.60 for strength classes C16/20 and C12/15. The requirements for standardised prescribed concrete shall be in
accordance with BS EN 206 and BS 8500-2.
(02/16) Admixtures
5 (01/20) Concrete in at least the top 50 mm of surface slabs shall incorporate an air-entraining admixture
complying with BS EN 934-2, except:
(i) for pavements with an exposed aggregate concrete surface constructed to Clause 1044 where at least the
top 40 mm of the surface slab shall be air entrained;
or
(ii) for surface slabs of pavements with at least a class C40/50 concrete;
(iii) for surface slabs of pavements with a class C32/40 concrete which are to be overlaid by a 30 mm
minimum thickness thin surface course system complying with Clause 942; and
(iv) for surface slabs of pavements with a class C35/45 concrete which are to be overlaid by a 20 mm
minimum thickness thin surface course system complying with Clause 942.
Plasticisers or water reducing admixtures shall comply with BS EN 934-2. Admixtures containing calcium chloride
shall not be used.
The Contractor shall submit the declaration of performance for each admixture to the Overseeing Organisation
prior to the incorporation of the admixture into the works. The declaration of performance shall demonstrate that
the admixture meets the specification requirements.
(02/16) Aggregate
6 (01/20) Aggregates for all pavement concrete, including Lower Strength, shall comply with BS EN 12620.
Crushed concrete, which complies with the quality and grading requirements of BS EN 12620 and Table 2
of BS 8500-2, may also be used in all pavement concretes except aggregate concrete surface complying with
Clause 1044. Alternatively, coarse aggregate may be crushed air-cooled blastfurnace slag complying with
BS EN 12620 and shall be Category FI50 or FI35 for concrete of classes C16/20 to C25/30 and over class C25/30,
respectively. FA when used as part of the aggregate shall comply with BS EN 450. Once the appropriate gradings
have been determined they shall not be varied without the approval of the Overseeing Organisation. Irrespective of
source, the aggregate will be considered suitable if:
(i) the resistance to freezing and thawing complies with BS EN 12620 clause 5.7.1 for pavement and Lower
Strength concrete;
and
(ii) the resistance to fragmentation complies with category LA35 of BS EN 12620 clause 5.2 for concrete
surface slabs and LA40 of BS EN 12620, clause 5.2 for concrete bases and Lower Strength concrete.
The Contractor shall submit the declaration of performance for each aggregate to the Overseeing Organisation prior
to the incorporation of the aggregate into the works. The declaration of performance shall demonstrate that the
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aggregate meets the specification requirements.

The water absorption (WA) of the coarse aggregate shall be determined and declared in accordance with
BS EN 12620. Where recycled coarse aggregate or recycled concrete aggregate is used in this Series, it shall
comply with the limits specified in Table 2 of BS 8500-2 and the constituents shall be declared.

7 (02/16) The maximum size of coarse aggregate (D) shall not exceed 40 mm. When the spacing between
longitudinal reinforcement is less than 90 mm, the maximum size of coarse aggregate (D) shall not exceed 20 mm.
8 (02/16) Sand (i.e. fine aggregate) containing more than 25% by mass of acid-soluble material as determined in
accordance with BS EN 196-2, in either the fraction retained on, or the fraction passing the 0.500 mm sieve, shall
not be used in the top 50 mm of surface slabs. This requirement will not apply for pavements with an exposed
aggregate concrete surface constructed to Clause 1044 or if it can be shown that the sand (ie fine aggregate)
retained on, or the fraction passing the 0.500 mm sieve, contains less than 25 per cent by weight of calcium
carbonate.
9 (01/20) The water absorption of flint coarse aggregate containing white flints for use in concrete surface slabs,
when determined in accordance with BS EN 1097-6 shall not exceed:
3.5% for any separate nominal size fraction;
2.0% for the total combination of coarse aggregates in the proportions to be used in the concrete.
Contract compliance tests shall be carried out during stockpiling or paving, once a week, or at a lesser rate when
authorised by the Overseeing Organisation.
(02/16) Source of Recycled Aggregates
10 (02/16) Where recycled coarse aggregate or recycled concrete aggregate is used, only crushed concrete resulting
from reclamation or processing of concrete previously used in construction which originates from appropriate
identified structures with a known history of use shall be used.
(02/16) Chloride Content
11 (01/20) The chloride ion content of the aggregate to be used in concrete shall be as stated in BS EN 206. The
chloride class of reinforced concrete or concrete containing embedded metal shall be Cl 0,40 and unreinforced
concrete shall be Cl 1,0. The water soluble chloride content of the aggregates shall be determined in accordance
with BS EN 12620 and declared. The acid soluble chloride content of recycled aggregates shall be determined in
accordance with BS EN 12620 and declared.
(02/16) Chemical Requirement
12 (01/20) Acid-soluble sulfate
Acid-soluble sulfate content of the aggregates and filler aggregates for concrete pavements, including Lower
Strength, shall comply with BS EN 12620, clause 6.3.1 and shall be Category AS1,0 for air-cooled blast furnace slag
and for other aggregates Category AS0,8.
13 (02/16) Total sulfur
Total sulfur content of recycled coarse aggregates, recycled concrete aggregates, aggregates and filler aggregates,
shall comply with BS EN 12620, clause 6.3.2.
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1002 (02/16) Air Content

1 (01/20) In the top 50mm concrete requiring air entrainment to satisfy Clause 1001.5 shall meet the requirement
for exposure class XF4 in BS EN 206. With the exception of concrete class C40/50 as defined in BS8500 this
shall be achieved by the use of an air-entraining agent. The minimum quantity of air in air-entrained concrete as a
percentage of the volume of the concrete shall be as in Table 10/3:
TABLE 10/3: (01/20) Minimum Air Contents
Maximum aggregate size Minimum air content Maximum air content

mm % %
20 3.5 6.5
40 3 5.5
2 (02/16) The air content shall be determined at the point of delivery to the paving plant by the pressure gauge
method in accordance with BS EN 12350-7, at the rate of one determination per 300 m² of slab or at least 6 times
per day, whichever is the greater, in conjunction with tests for consistence and strength. For areas less than 300 m²
the rate shall be at least one determination to each 20 m length of slab or less constructed at any one time or at
least 3 times per day. If the air content is outside the specified limits in BS EN 206 the Contractor shall remove the
concrete from the works.
3 (02/16) The air-entraining agent shall be added at the mixer, by an apparatus capable of dispensing the
correct dose within the tolerance for admixtures given in BS EN 206, to ensure uniform distribution of the agent
throughout the batch during mixing.
1003 (02/16) Density

(01/20) The Permanent Works
1 (01/20) With the exception of the trial length, the density shall be measured by non-destructive methods.
2 (01/20) A correlation shall be established for each mix and each measuring device and shall be established
from the trial length where cores have been taken. The correlation established shall be provided to the Overseeing
Organisation before commencement of the permanent works. The device chosen shall achieve a repeatability of at
least 90%.
3 (01/20) The concrete density measured by the device shall not be less than 95% of the average density of at least
six fully compacted saturated moulded specimens made from the same mix in the trail area and tested at the same
age.
4 (01/20) The density shall be measured routinely at a distance of 0.8 to 1.2m from the edge of the slab and at the
rate shown in Table 10/12.
5 (01/20) If a non-compliance in an area is indicated then cores shall be taken as required in the trial area. Density
measurements shall be taken at the locations at which material is placed that has been sampled for cube testing.
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(01/20) The Trial Length

6 (01/20) In the trial length as required in Clause 1028 the density of a saturated core cut from the full depth of
the concrete pavement shall not be less than 95% of the average density of at least six fully compacted saturated
moulded specimens made from the same concrete and tested at the same age.
7 (01/20) The density of the concrete pavement shall be determined in accordance with BS EN 13877-2. The
density of a saturated core cut from the full depth of the concrete pavement shall be determined in accordance with
BS EN 12390-7. The determination of the saturated density of the fully compacted moulded specimens shall be in
accordance with BS EN 12350-1, BS EN 12390-1 and BS EN 12390-2.

8 (01/20) The core shall have an average diameter of at least four times the nominal maximum aggregate size, and
in any case not less than 100 mm diameter. Where different concrete mixes are used in separate layers, the density
of each layer shall be separately determined by splitting or cutting the cores between the layers.
9 (01/20) Cores shall be taken at the rate given in Clause 1028 for the trial. If the density of any core is below the
minimum required, the concrete across the whole width of the slab constructed at the time relating to that core shall
be removed. In unreinforced concrete the whole slab length between joints shall be removed. For reinforced slabs,
in order to determine the limit of the defective area of concrete which shall be removed, additional cores shall be
taken at 5 m intervals on each side of any defective core until concrete of satisfactory density is found. Defective
areas shall be made good with new material in accordance with the specification.
10 (01/20) In calculating the density, allowance shall be made for any steel in the cores.
11 (01/20) Core holes shall be reinstated with compacted concrete with mix proportions of 1 part of Portland
cement CEM I: 2 parts of sand: 2 parts of 10 mm single sized coarse aggregate by mass.
1004 (02/16) Pavement Concrete Strength

1 (01/20) A trial length shall be constructed in accordance with Clause 1028.
2 (01/20) Concrete cores of 150mm diameter shall be taken from the trial length, cured and tested in accordance
with BS EN 12504-1 with the exception that the core shall be cured under water at 20°C ±2°C from as soon as
practically possible. A minimum of 9 cubes and 6 cores taken and at a minimum of 3 locations shall be taken from
the trial length. For each set of 6 cores, three shall be tested at 7 days and three at 28 days
3 (01/20) The end preparation of the core shall be by grinding and the height/diameter (h/d) ratio of the tested
specimen shall be between 1 and 2.
4 (01/20) The ratio of core density to non-destructive density measurement taken within 1m of the core location
shall be determined from the trial length as described in Clause 1003.
5 (01/20) If multi-layer construction is being used the cores shall be tested for adequacy of bond between layer in
accordance with BS EN 13877-2 with fv=1mPa at 7 days.
6 (01/20) Once a satisfactory trial construction has been achieved strength monitoring of the main construction
will be by the use of cubes cast at the rate of a set of 3 cubes for every 400 m2 of concrete laid. A minimum of
6 sets of cubes shall be taken each day with each set being from a different delivery of concrete.
7 (01/20) If the 7-day cube strength fails to conform with the requirements of BS EN 206 table B1 sampling and
testing for, and compliance with the specified characteristic core strength of designed concretes shall be undertaken
by compressive strength testing in accordance with BS EN 13877-2 on cores cut from the full depth of the slab.
8 (01/20) The strength of the concrete slab shall be evaluated in accordance with BS EN 206 (Annex B – Identity
Testing: Table B.1).
9 (01/20) To assess the time for use of a concrete slab by traffic, the strength development rate may be
predetermined by cubes stored at 20°C made from trial concrete mixes and maturity meters placed in the
pavement. Alternatively, pairs of cubes may be made for each 400 m² or less and stored alongside the pavement
in containers or in such a way that their sides are well insulated. If thermal insulation is used for accelerated curing
the cubes shall be similarly insulated. Pairs of cubes shall be tested at the intervals specified in contract specific
Appendix 7/1.
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1005 (02/16) Consistence (Workability)

1 (01/20) The consistence shall be determined by the Degree of Compactibility (Compaction Index) test in
accordance with BS EN 12350-4, or the Vebe test in accordance with BS EN 12350-3. Alternatively for concrete
class C16/20 or below, consistence may be determined by the slump test in accordance with BS EN 12350-2. The
sampling for all concrete classes shall be undertaken in accordance with BS EN 12350-1 and the rate of testing in
accordance with Table 17 of BS EN 206. Consistence shall be carried out at the point of placing, in conjunction
with tests for strength and any tests for air content. The consistence shall be maintained at the optimum within the
limits specified in BS EN 206.
2 (02/16) If any determination of consistence gives a result outside the tolerance, a further test shall be made
immediately on the next available load of concrete. The average of the two consecutive results and the difference
between them shall be calculated. If the average is not within the tolerance or the difference is greater than 0.1 for
CI or 20 mm for slump, or 6 seconds for Vebe, subsequent samples shall be taken from the delivery vehicles, which
shall not be allowed to discharge into the works until compliance with the specification has been established.
1006 (02/16) Not Used
1007 (02/16) Separation and Waterproof Membranes

1 (01/20) Over a bound sub-base a waterproof membrane shall be provided, which shall be a bituminous spray
in accordance with Clause 920. Where a bituminous spray has been used to cure cement-bound material or low
strength concrete then only those areas, which have been damaged or degraded, shall be resprayed after making
good.
1008 (02/16) Steel Reinforcement

(02/16) General
1 (01/20) Reinforcement shall comply with any of the following standards and shall be cut and bent in accordance
with BS 8666. The reinforcement materials shall be obtained from an organisation which has current, valid product
acceptance scheme certification, such as CARES certification, in accordance with sub-Clause 104.16. Re-bending
of carbon steel bars and fabric reinforcement on site shall not be permitted:
Hot Rolled and Cold Worked Carbon Steel Bars
(i) BS EN 10080 and BS 4449 (Grade B500B or B500C).
Steel Wires
(ii) BS EN 10080 and BS 4482 (Ribbed Grade B500).
Steel Fabric
(iii) BS EN 10080 and BS 4483 (Grade B500A, B500B or B500C). Steel fabric reinforcement shall have
a minimum nominal bar size of 6 mm (8 mm for Grade B500A). Steel fabric reinforcement shall be
delivered to site in flat mats or pre-bent.
2 (02/16) For hot rolled and cold worked carbon steel bars, and for steel fabric reinforcement, the bond property
requirements for BS 4449 shall be complied with based on the surface geometry requirements of that standard.
For steel wire, the bond property requirements of BS 4482 shall be complied with based on the surface geometry
requirements of that standard.
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3 (01/20) Spacing of bars shall not be less than twice the maximum size of aggregate used. Laps in longitudinal
bars shall be not less than 35 bar diameters or 450 mm whichever is greater. In continuously reinforced concrete
slabs (CRCP or CRCB), only one third of the laps may be in any one transverse section, except in single bay
width construction where half the laps may be in any one transverse section. There shall be a minimum of 1.2 m
longitudinally between groups of transverse laps or laps in prefabricated reinforcement sheets.
4 (02/16) Laps in any transverse reinforcement shall be a minimum of 300 mm. Where prefabricated
reinforcement sheets are used and longitudinal and transverse laps would coincide, no lap is required in the
transverse bars within the lap of the longitudinal reinforcement. These transverse bars may be cropped or fabricated
shorter so that the requirements for cover are met. Alternatively, prefabricated sheets incorporating splices (ie flying
ends) may be used to provide nesting of reinforcement in both directions at lap positions. The lengths of the laps
shall be the minimum values previously stated.
5 (01/20) If the reinforcement is positioned prior to concreting, it shall be fixed on chairs conforming with the
requirements of BS 7973 and retained in position at the required depth below the finished surface and distance from
the edge of the slab so as to ensure that the required cover is achieved. Reinforcement assembled on site shall be
tied, or firmly fixed, at sufficient intersections to provide sufficient rigidity to ensure that the reinforcement remains
in the correct position during construction of the slab.
6 (02/16) Alternatively, when a reinforced concrete slab (JRC, CRCP or CRCB) is constructed in two layers, the
reinforcement in the form of prefabricated sheets may be placed on or into the bottom layer which shall be spread
and compacted to such a level that it will support the reinforcement without distortion at the required position in
the slab. The sheets shall be tied together at overlaps and after the second layer has been spread and compacted, the
reinforcement shall have the required cover.
7 (02/16) When a reinforced concrete slab is constructed at maximum width as in Clause 1010 the transverse
reinforcement in the centre of each slab width shall be a minimum of 12 mm nominal diameter bars at 600 mm
centres. This reinforcement shall be at least 600 mm longer than one third of the width of the slab and be lapped to
other transverse reinforcement bars or sheets, or be continuous across the whole width of each slab.
(02/16) Jointed Reinforced Concrete Slabs
8 (02/16) The reinforcement shall be so placed that after compaction of the concrete, the cover below the finished
surface of the slab is 50 ± 10 mm for slabs less than 200 mm thick, 60 ± 10 mm for slabs 200 mm or more but
less than 270 mm thick, 70 ± 20 mm for slabs 270 mm thick or more. The negative vertical tolerance shall not be
permitted beneath road stud recesses. Where traffic signal detector loops are to be installed, the minimum cover
to the reinforcement from the surface shall be 100 mm. The vertical cover between any longitudinal joint groove
forming strip and any reinforcement or tie bars shall be a minimum of 30 mm. Any transverse bars shall be at right
angles to the longitudinal axis of the carriageway.
Any transverse reinforcement shall terminate at 125 ± 25 mm from the edges of the slab and longitudinal joints,
where tie bars as in Clause 1012 are used. No longitudinal bars shall lie within 100 mm of a longitudinal joint.
The reinforcement shall terminate 300 mm ± 50 mm from any transverse joint, excluding emergency construction
joints.
(02/16) Continuously Reinforced Concrete Slabs (CRCP or CRCB)
9 (01/20) The reinforcement shall be Grade B500B or B500C deformed steel bars with the diameters and spacings
10 (02/16) The reinforcement shall consist of bars assembled on site, or of prefabricated sheets. Except where
otherwise shown on the drawings the longitudinal bars shall be parallel to the centre-line of the road.
11 (01/20) The reinforcement shall be positioned so that, after compaction of the concrete, it shall be at the mid
depth of the specified thickness of the slab ±25 mm. No longitudinal bar shall lie within 100 mm of a longitudinal
joint. Reinforcement longitudinal bars shall be placed immediately above any transverse bars, which shall be at
right angles to the longitudinal axis of the carriageway. Any transverse reinforcement shall terminate 125 ± 25 mm
from the edges of the slab and longitudinal joints where tie bars as in Clause 1012 are used.
Amendment – January 2020

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10
1009 (02/16) Transverse Joints

(02/16) General
1 (02/16) Transverse joints shall be provided in unreinforced and jointed reinforced concrete slabs and shall be
contraction, expansion or warping joints at the spacings described in contract specific Appendix 7/1, such that for
unreinforced concrete slabs the length/width ratio shall be not greater than 2.0. The spacings may be increased by
20% if limestone coarse aggregate is used throughout the depth of the slab.
2 (02/16) Joints in the surface slab and sub-base shall be staggered so that they are not coincident vertically and
are at least 1 m apart.
3 (02/16) Transverse joints shall be straight within the following tolerances along the intended line of the
joint, which is the straight line transverse to the longitudinal axis of the carriageway, except at road junctions or
roundabouts where the positions shall be as shown on the drawings.
(i) deviations of the filler board or bottom crack inducer from the intended line of the joint shall be not
greater than ± 10 mm;
(ii) the best fit straight line through the joint groove as constructed shall be not more than 25 mm from the
intended line of the joint;
(iii) deviations of the joint groove from the best fit straight line of the joint shall be not greater than 10 mm.
4 (02/16) Transverse joints on each side of a longitudinal joint shall be in line with each other and of the same
type and width. The position of the joints relative to manholes and gullies shall be in accordance with Clause 1018.
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5 (02/16) Concrete pavement layers shall be isolated from fixed structures by expansion joints, or earthworks
or a granular layer over the structure, or by bridge-type expansion joints, or by lengths of fully flexible pavement
construction. End of pavement surface slabs shall have a transition bay as shown on the drawings, leading into the
fully flexible construction.
6 (02/16) Transverse joints shall have a sealing groove which shall be sealed in compliance with Clause 1016.
(02/16) Contraction Joints
7 (02/16) Contraction joints shall consist of:
(i) a sawn joint groove complying with Clause 1013;
(ii) dowel bars complying with Clause 1011;
(iii) a sealing groove complying with Clause 1016.
(02/16) Expansion Joints
8 (02/16) Expansion joints shall consist of:
(i) a joint filler board complying with Clause 1015;
(ii) dowel bars complying with Clause 1011;
9 (02/16) The filler board shall be positioned vertically within the prefabricated joint assemblies along the line of
the joint within the tolerances given in sub-Clause 3 of this Clause, and at such depth below the surface as will not
impede the passage of the finishing beams on the paving machines. The joint filler board together with the sealing
groove shall provide a complete separation of adjacent slabs and any spaces around dowel bars and between the
sub-base and the filler board shall be packed with a suitable compressible material after fixing the joint assembly.

(02/16) Warping Joints

10 (02/16) Warping joints shall consist of:
(i) a sawn joint groove complying with Clause 1013;
(ii) tie bars complying with Clause 1012;
(02/16) Construction Joints
11 (02/16) Construction joints made at the end of a working day in unreinforced concrete slabs and jointed
reinforced concrete slabs shall be contraction joints. In the event of mechanical breakdown of the concreting
machinery, or at the onset of adverse weather, emergency joints may be formed.
12 (02/16) Emergency joints in unreinforced concrete slabs shall be contraction joints not less than 2.5 m from the
preceding or succeeding joint position.
13 (02/16) Emergency joints in jointed reinforced concrete slabs shall be not less than 2.5 m from the preceding
or succeeding joint position. The stop end formwork shall be sufficiently rigid to ensure that dowel bars, tie bars
or reinforcement will be held in position in compliance with the specification, and placed in such a position that it
permits the longitudinal reinforcement to project through the joint for a distance of at least 750 mm.
14 (02/16) Construction joints in continuously reinforced concrete slabs (CRCP and CRCB) at end of day or in
an emergency shall not be constructed within 1.5 m of any lap in the longitudinal reinforcement. The stop end
formwork shall be sufficiently rigid to ensure that the longitudinal reinforcement and the tie bars as required in
sub‑Clause 1012.7 which project through the joint are held in the correct position.
1010 (02/16) Longitudinal Joints

(02/16) General
1 (02/16) Sawn or wet-formed longitudinal joints shall be provided in surface slabs between or at the centre
of traffic lanes within the allowable positions as shown on the drawings, so that bay widths are not greater than
4.2 m (or 5.0 m with limestone aggregate) for unreinforced slabs, or 6 m (or 7.6 m with limestone aggregate) for
reinforced concrete surface slabs with transverse reinforcement as in sub-Clause 1008.7. Longitudinal joints shall
be provided in CRCB between lanes or at the centre of lanes, within a tolerance of ± 150 mm so that bay widths are
not greater than 6 m (or 7.6 m with limestone aggregate).
Joints in the surface slab, base or sub-base shall be staggered so that they are not coincident vertically and are at
least 300 mm apart.
2 (02/16) Wet-formed longitudinal joints shall consist of wet-formed joint grooves complying with Clause 1013,
a bottom crack inducer complying with Clause 1014 and tie bars complying with Clause 1012, except where
transverse reinforcement is permitted in lieu.
3 (02/16) Longitudinal joints shall be constructed within the following tolerances:
(i) deviations of the bottom crack inducer from the intended line of the joint, parallel to the axis of the road
shall be not greater than ± 13 mm;
(ii) the joint groove shall be located vertically above the bottom crack inducers within a horizontal tolerance
of ± 25 mm;
(iii) the best fit line along the constructed joint groove, shall be not more than 25 mm from the intended line
of the joint;
(iv) deviations of the joint groove from the best fit line of the joint shall be not greater than 10 mm.
4 (02/16) Sawn longitudinal joints shall consist of joint grooves complying with Clause 1013.

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12
5 (02/16) Tie bars may be replaced by continuous transverse reinforcement across the joints in continuously
reinforced concrete slabs which are constructed in more than one lane width in one operation, provided that the
transverse reinforcement is a minimum of 12 mm diameter bars at 600 mm centres. The transverse reinforcement in
these circumstances shall be protected by suitable bituminous paint or equivalent coating for a distance of at least
75 mm either side of the joint.
(02/16) Longitudinal Construction Joints
6 (02/16) Longitudinal construction joints between separate slabs shall have tie bars as in Clause 1012 with a joint
groove as in Clause 1013. Alternatively, if split forms are used, the transverse reinforcement, if 12 mm diameter
or more, may be continued across the joint for a minimum of 500 mm or 30 times the diameter of the transverse
reinforcement bars, whichever is the greater. The transverse reinforcement in these circumstances shall be protected
by suitable bituminous paint or equivalent coating for a distance of at least 75 mm either side of the joint. A joint
sealing groove is not required in construction joints in continuously reinforced concrete bases. Where the edge of
the concrete slab is damaged it shall be made good before the adjacent slab is constructed.
1011 (02/16) Dowel Bars

1 (01/20) Dowel bars shall meet the requirements of BS EN 13877-3 with a minimum tensile strength of 250MPa
and shall be free from oil, dirt, loose rust and scale. They shall be straight, free of burrs and other irregularities
and the sliding ends sawn cleanly with no protrusions outside the normal diameter of the bar. For expansion joints,
dowel bars shall be 25 mm diameter at 300 mm spacing and 600 mm long for slabs up to 239 mm thick and 32 mm
diameter for thicker slabs. For contraction joints, dowels shall be 20 mm diameter at 300 mm spacing and 400 mm
long for slabs up to 239 mm thick, and 25 mm diameter at 300 mm spacing and 600 mm long for thicker slabs.
The Contractor shall submit the declaration of performance for the dowel bars to the Overseeing Organisation prior
to the incorporation of the dowel bars into the works. The declaration of performance shall demonstrate that the
dowel bars meet the specification requirements.
2 (02/16) Dowel bars shall be supported on cradles in prefabricated joint assemblies positioned prior to
construction of the slab. For contraction joints, as an alternative to prefabricated assemblies, dowel bars may be
mechanically inserted with vibration into the concrete by a method which ensures full recompaction of the concrete
around the dowel bars and the surface finished by a diagonal finishing beam, or a longitudinal oscillating float
travelling across the slab.
3 (02/16) Dowel bars shall be positioned at mid-depth from the surface level of the slab ± 20 mm. They shall be
aligned parallel to the finished surface of the slab, to the centre line of the carriageway and to each other within the
following tolerances:
(i) for bars supported on cradles prior to construction of the slab and for inserted bars in two layer
construction prior to placing the top layer:
(a) all bars in a joint shall be within ± 3 mm per 300 mm length of bar;
(b) two thirds of the bars shall be within ± 2 mm per 300 mm length of bar;
(c) no bar shall differ in alignment from an adjoining bar by more than 3 mm per 300 mm length of
bar in either the horizontal or vertical plane;
(ii) for all bars, after construction of the slab:
(a) twice the tolerances for alignment as in (i) above;
(b) equally positioned about the intended line of the joint within a tolerance of 25 mm.
4 (02/16) Cradles supporting dowel bars shall not extend across the line of the joint.
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13
5 (02/16) Dowel bars, supported on cradles in assemblies, when subjected to a load of 110 N applied at either end
and in either the vertical or horizontal direction (upwards and downwards and both directions horizontally) shall
not deflect more than the following limits:
(i) two thirds of the number of bars of any assembly tested shall not deflect more than 2 mm per 300 mm
length of bar;
(ii) the remainder of the bars in that assembly shall not deflect more than 3 mm per 300 mm length of bar.
6 (02/16) The assembly of dowel bars and supporting cradles, including the joint filler board in the case of
expansion joints shall have the following degree of rigidity when fixed in position:
(i) For expansion joints the deflection of the top edge of the filler board shall be not greater than
13 mm, when a load of 1.3 kN is applied perpendicular to the vertical face of the joint filler board and
distributed over a length of 600 mm by means of a bar or timber packing, at mid depth and midway
between individual fixings, or 300 mm from either end of any length of filler board, if a continuous
fixing is used. The residual deflection after removal of the load shall be not more than 3 mm.
(ii) The joint assembly fixings to the sub-base shall not fail under the 1.3 kN load applied for testing the
rigidity of the assembly but shall fail before the load reaches 2.6 kN.
(iii) The fixings for contraction joints shall not fail under a 1.3 kN load and shall fail before the load reaches
2.6 kN when applied over a length of 600 mm by means of a bar or timber packing placed as near to the
level of the line of fixings as practicable.
(iv) Failure of the fixings shall be deemed to be when there is displacement of the assemblies by more than
3 mm with any form of fixing, under the test load. The displacement shall be measured at the nearest
part of the assembly to the centre of the bar or timber packing.
7 (01/20) Dowel bars shall be covered by a flexible polymeric corrosion resistant coating, bonded onto the
previously cleaned bar. The coating shall be smooth and free of indentations. During coating, the bar shall be
supported at each end. Minimum thickness shall be 0.3 mm. The coating shall also be able to withstand 250 hours
immersion in a salt fog cabinet complying with BS EN ISO 7253, without showing any visible crazing or corrosion
of the protected bar. The coated bar shall comply with the following pull out test:
(i) Four bars shall be taken at random from stock and without any special preparation shall be coated as
required in this Clause. The dowel bars which have been coated shall be cast centrally into concrete
specimens 150 x 150 x 450 mm, made of the same concrete mix proportions to be used in the pavement,
but with a maximum aggregate size of 20 mm and cured in accordance with BS EN 12390-2. At 7 days
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a tensile load shall be applied to achieve a movement of the bar of at least 0.25 mm. The average bond
stress to achieve this movement shall be not greater than 0.89 N/mm2.
8 (02/16) For expansion joints, a closely fitting cap 100 mm long consisting of waterproofed cardboard or suitable
synthetic material shall be placed over one end of each dowel bar. An expansion space 10 mm greater than the
thickness of the joint filler board shall be formed between the end of the cap and the end of the dowel bar.
1012 (02/16) Tie Bars

1 (02/16) Tie bars in transverse or longitudinal joints shall conform to Clause 1008, in accordance with the
requirements given below and Table 10/5.
2 (01/20) Tie bars for use across joints shall have corrosion protection in the form of a flexible polymeric
corrosion resistant coating, bonded centrally onto 200 mm of the previously cleaned centre section of the bars.
Where tie bars are to be cranked for construction joints and later straightened, the coating shall be shown to be
capable of being straightened through 90 degrees without cracking.
The coating for both straight and cranked bars after straightening shall be able to withstand 250 hours immersion in
a salt fog cabinet complying with BS EN ISO 7253, without showing any visible crazing or cracking, or corrosion
of the protected part of the bar.

3 (02/16) Tie bars in warping joints and wet-formed longitudinal joints shall be made up into rigid assemblies with
adequate supports and fixings to remain firmly in position during the construction of the slab.
4 (02/16) Alternatively, tie bars at longitudinal joints may be mechanically inserted by vibration from above using
a method which ensures recompaction of the concrete around the tie bars.
5 (02/16) At longitudinal construction joints, tie bars may be adequately fixed to side forms or inserted into the side
of the slab by a method which ensures recompaction of the concrete around the tie bars and adequate bond.
6 (02/16) Tie bars in warping joints shall be positioned from the top surface of the slab within +20, -10 mm of the
mid depth of the slab.
Tie bars in other joints shall be positioned and remain within the middle third of the slab depth, approximately
parallel to the surface and approximately perpendicular to the line of the joint, with the centre of each bar on the
intended line of the joints within a tolerance of ± 50 mm, and with a minimum cover of 30 mm below any top crack
inducer of joint groove for slabs 200 mm thick or more, or 20 mm for slabs up to 200 mm thick.
7 (02/16) At transverse construction joints in continuously reinforced concrete, tie bars shall be 1.5 m long
and of the same Grade and size as the longitudinal reinforcement, and shall be fixed at twice the normal spacing
midway between the longitudinal reinforcement bars so that 750 mm ± 50 mm extends each side of the joint
at the same level as the longitudinal reinforcement and be tied to the transverse reinforcement. Where paving
from a construction joint is not resumed within 5 days, an extra longitudinal reinforcement bar 8 m long shall be
lapped and tied to each tie bar. These extra bars may be combined with the tie bars. Where the spacing between
longitudinal reinforcement and the extra 8 m long bars is less than 90 mm, the nominal size of aggregate shall be
20 mm for a sufficient number of concrete batches to complete that section of pavement.
TABLE 10/5: (01/20) Tie Bar Details
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Joints Diameter Grade of Steel Length Spacing
mm mm mm
Transverse construction joints in As for main Grade B500B or 1500 Twice the spacing of
continuously reinforced concrete reinforcement B500C main reinforcement
Emergency construction joints in jointed 12 Grade B500B or 1000 600
reinforced concrete slabs other than at B500C
contraction or expansion joints 750 600
Warping joints 12 Grade B500B or 1000 300

B500C
750 600
Longitudinal 12 Grade B500B or 1000 600
}
All joints, except where B500C
Transverse reinforcement 750 600
is permitted in lieu
or 16 Grade B500B or 600 600
B500C
or 20 Grade B500B or 500 600
B500C
Transition from rigid to flexible 20 Grade B500B or 1000 300
construction B500C
NOTE: The transverse reinforcement may be continued across the joint in reinforced concrete if the bars are of a minimum nominal diameter
of 12 mm and the bars are protected from corrosion and the cover is as required in this Clause.
8 (02/16) Where tie bars are used in longitudinal joints in continuously reinforced concrete they shall be placed at
the same level as the transverse reinforcement and tied to the longitudinal reinforcement.

1013 (02/16) Joint Grooves

(02/16) General
1 (02/16) Transverse contraction or warping joint grooves shall be sawn in the hardened concrete.
2 (02/16) Transverse joint grooves which are initially constructed less than the full width of the slab shall be
completed by sawing through to the edge of the slab and across longitudinal joints as soon as any forms have been
removed and before an induced crack develops at the joint.
(02/16) Sawn Transverse and Longitudinal Joint Grooves
3 (02/16) Sawing shall be undertaken as soon as possible after the concrete has hardened sufficiently to enable a
sharp edged groove to be produced without disrupting the concrete and before random cracks develop in the slab.
The grooves shall be between 1/4 and 1/3 of the specified depth of the slab and of any convenient width not less
than 3 mm. The sealing groove may be sawn to the required width later. Expansion joint sealing grooves shall be
sealed as soon as practical after sawing.
(02/16) Wet-formed Longitudinal Joint Grooves
4 (02/16) When slabs are constructed in more than one lane width in one operation a joint groove shall be formed
by inserting a groove former ahead of the finishing beams from dispenser. The concrete so displaced shall be
recompacted by a vibrating compactor or similar device, at least 300 mm wide operating symmetrically along the
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line of the joint. After finishing the concrete, the groove forming strip shall be in the correct position and alignment,
within 10° of the vertical, and to sufficient depth below the surface to allow for the passage of the finishing beam
within the range 0-3 mm below the finished level of the slab. Groove forming strips in wet-formed longitudinal
joint grooves shall be left in place.
(02/16) Construction Joint Grooves in Surface Slabs
5 (02/16) The grooves shall be formed by fixing a groove-former or strip or cork seal along the top edge of the
slab already constructed, before concreting the adjacent slab. Where the edge of the concrete is damaged it shall
be ground or made good before fixing the groove forming strip. Alternatively the subsequent slab may be placed
adjacent to the first and a sealing groove sawn later in the hardened concrete to the minimum depth required in
Table 10/6 or to the manufacturer’s instructions if greater, and to sufficient width to eliminate minor spalling of the
joint arris, up to a maximum of 25 mm for longitudinal joints and 40 mm for transverse joints. The joint shall be
sealed in compliance with Clause 1016.
1014 (02/16) Groove Formers and Bottom Crack Inducers

(02/16) General
1 (02/16) Except where joint grooves are sawn, a bottom crack inducer shall be provided at each longitudinal joint
position.
2 (02/16) The bottom crack inducer shall be triangular or inverted Y-shaped fillet, with a base width not less than
the height, made of timber or rigid synthetic material. It shall be firmly fixed to the sub-base so as to remain in
position during the whole process of constructing the slab.
3 (02/16) The combined depth of groove formers and bottom crack inducers shall be between 1/4 and 1/3 of the
depth of the slab and the difference between the depth of the groove former and the height of the bottom crack
inducer shall not be greater than 20 mm.
(02/16) Longitudinal Joints
4 (02/16) Groove forming sealing strips for wet-formed longitudinal joints shall be of firm compressible strips of
ethylene vinyl acetate foam of minimum density 90 kg/m3, or synthetic rubber, or equivalent material. They shall
have a minimum thickness of 5 mm and shall be sufficiently rigid to remain vertical and straight in the concrete
without curving or stretching. They shall be inserted continuously along the joint.

(02/16) CRCP Universal Beam Anchorage Transverse Joint

5 (02/16) One side of the beam shall be separated from the CRCP slab by an expansion joint filler board against
the vertical face and ethylene vinyl acetate foam in accordance with HCD Drawing C20.
1015 (02/16) Joint Filler Board

1 (01/20) Joint filler board for expansion joints and manhole and gully slab joints shall be 25 mm thick unless
otherwise shown in the drawings, within a tolerance of ± 1.5 mm. It shall be a firm compressible material or a bonded
combination of compressible and rigid materials of sufficient rigidity to resist deformation during the passage of the
concrete paving plant. The depth of the joint filler board for manhole and gully slabs shall be the full depth of the
slab less the depth of the sealing groove. In expansion joints, the filler board shall have a ridged top as shown on the
drawings, except where a sealing groove former is indicated on the drawings.
Holes for dowel bars shall be accurately bored or punched out to form a sliding fit for the sheathed dowel bar.
2 (01/20) The joint filler board shall meet the requirements given when tested in accordance with the procedures
in the following sub-Clauses:
(i) Weathering Test
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(a) Three specimens, each 115 mm square ± 2.5 mm, shall be placed in a ventilated drying oven
maintained at a temperature of 55°C ± 5°C for 7 days, after which they shall immediately be
immersed in water at room temperature of between 16°C and 21°C for 24 hours. They shall then be
subjected to five cycles of freezing and thawing in the following manner.
(b) The specimens shall be placed in a watertight weathering test pan having a ribbed bottom and a
fitted slotted lid designed to hold the three specimens vertically on edge. The pan shall be filled
with water to half the depth of the specimens and then frozen to minus 7°C or below, for at least
four hours after the initial freezing of the water. The pan shall then be placed in a water bath
maintained at 18°C to 38°C without disturbing the specimens and shall remain there for one hour
after thawing has completed. The pan and specimens shall then be returned to the refrigerator
and freezing and thawing shall be repeated in precisely the same manner until five cycles of the
process have been completed. The specimens shall be removed from the pan and air dried at room
temperature for 48 hours before examination.
(c) The material shall be deemed to have passed the weathering test if the specimens show no signs of
disintegration or shrinkage.
(ii) Compression and Recovery Test
(a) Two of the specimens which pass the weathering test, and two new specimens, each trimmed
to 100 mm square ± 0.5 mm, maintained at room temperature and humidity for 24 hours, shall
be subjected to three applications of load at 24 hour intervals in a compression test machine
complying with BS EN ISO 7500-1, with auxiliary platens 100 mm2, minimum 13 mm thick.
During each application of load each specimen shall be compressed to 50% of its original thickness
at a rate of strain of 1.3 mm per minute. The load required to achieve this amount of compression
shall be:
• not less than 0.7 N/mm2 nor more than 10 N/mm2 for material to be used in pavements; and
• not less than 0.7 N/mm2 and not more than 0.4 N/mm2 for material to be used in bridge joints.
The load shall be released immediately the required degree of compression is reached and after the
third application a recovery period of 30 minutes shall be allowed after which the thickness of the
specimen shall be measured.

(b) This thickness, expressed as a percentage of the original thickness, is the ‘recovery’ value of the
specimen. The thicknesses shall be measured to an accuracy of 25 micron. The two new specimens
shall be weighed before and after testing. The difference in mass shall be determined with an
accuracy of 0.1% and shall be expressed as a percentage of the original mass of the specimen.
(c) The material shall be deemed to have passed the test if all four specimens have recovery values of
at least 70% and the two new specimens have not suffered a reduction of mass in excess of 1%.
(iii) Extrusion Test
(a) The third sample which passes the weathering test shall be trimmed to 100 mm square ± 0.5 mm
and be subjected to the following extrusion test.
(b) The extrusion mould shall be 100 mm x 100 mm (+ 0.5 mm, - 0) internally, of sufficient depth
to test the sample as received, open on one side only and fixed rigidly to a base plate. The mould
shall be provided with a closely fitting pressure plate which shall fit without binding, and with
an accurate horizontal measuring dial gauge or measuring device accurate to 25 microns. The
specimen shall be mounted in the extrusion mould and loaded once as described in the compression
and recovery test. The extrusion at the open side of the mould shall be measured with the gauge
when the specimen is compressed to 50% of its original thickness and before release of the load.
(c) The material shall be deemed to have passed the test if the extrusion of the free edge does not
exceed 6 mm.
1016 (02/16) Preparation and Sealing of Joint Grooves

(02/16) General
1 (02/16) All transverse joints in surface slabs, except for construction joints in CRCP shall be sealed using one
of the joint seals described in Clause 1017. Additionally longitudinal joints which are sawn or widened, shall be
sealed.
(02/16) Preparation of Joint Grooves for Sealing
2 (02/16) Joint grooves shall be prepared in accordance with BS 5212 : Part 2 and sub-Clauses 3 to 8 of this
Clause.
3 (02/16) That part of the groove former used to form the sealing groove or any temporary seal shall be removed
cleanly without damaging the joint arrises to a minimum depth of 25 mm where compression seals are used or
otherwise to such depth as will provide an applied seal to the dimensions shown in Table 10/6, after allowing
for any necessary caulking material described in sub-Clause 6 of this Clause. If joint grooves are not initially
constructed to provide the minimum dimensions for the joint seals as given in Table 10/6, they shall be widened
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by sawing. Joint grooves formed by tapered formers need not be widened. The sealing grooves shall be cleaned
out immediately after sawing using high pressure water jets, to remove all slurry from the joint, before the slurry
hardens.
4 (02/16) If rough arrises develop when grooves are made they shall be ground to provide a chamfer
approximately 5 mm wide. If the groove is at an angle up to 10° from the perpendicular to the surface, the
overhanging edge of the sealing groove shall be sawn or ground perpendicular. If spalling occurs or the angle
of the former is greater than 10° the joint sealing groove shall be sawn wider and perpendicular to the surface to
encompass the defects up to a maximum width, including any chamfer, of 40 mm for transverse joints and 25 mm
for longitudinal joints. If the spalling cannot be so eliminated then the arris shall be repaired by suitable thin
bonded arris repair using cementitious materials as specified in Clause 1032.
5 (02/16) For applied sealants the sides of the joint sealing groove shall be scoured by dry abrasive blasting.
This shall not be carried out before the characteristic compressive strength of the concrete is expected to reach
15 N/mm². When compression seals are used, the sides of the groove may be ground or wire brushed.

6 (02/16) For hot and cold applied sealants, compressible caulking material, debonding strip or tape or cord
compatible with the sealant, of a suitable size to fill the width of the sealing groove, shall be firmly packed or
stuck in the bottom of the sealing groove to such a depth so as to provide the correct depth of seal as described in
Table 10/6 with the top of the seal at the correct depth below the surface of the concrete.
7 (02/16) All grooves shall be cleaned of any dirt or loose material by air blasting with filtered, oil-free
compressed air. The groove shall be clean and dry at the time of priming and sealing.
8 (02/16) For applied sealants the joint grooves shall be primed with the relevant primer for the hot or cold applied
sealant in accordance with the manufacturer’s recommendations and with BS 5212 : Part 2, except that when
necessary the joint grooves may be primed and sealed earlier than 14 days after construction, as soon as the grooves
have been grit-blasted and cleaned.
TABLE 10/6: (01/20) Dimensions of Applied Joint Seals
Type and Spacing of Joints (m) Minimum Minimum Depth of Seal (Note 1) Impregnated Depth of
Width Foam Seal Below
Cold Applied Hot Applied Compression the Concrete
Strips Surface
mm mm mm mm mm
Contraction
15 and under 13 (Note 2) 13 15 30 5±2
Over 15 to 20 20 15 30 30 5±2
Over 20 to 25 30 20 25 40 5±2
Expansion 30 20 25 40 7±2
Transverse Warping 10 10 13 30 5±2
Longitudinal Joints (if sealed) 10 10 13 30 0 to 5
Gully and Manhole Slabs 20 15 20 30 0 to 3
NOTE (1): The depth of seal is that part in contact with the vertical face of the joint groove. The depth of seal below the surface shall be
taken at the centre of an applied seal relative to a short straight edge, 150 mm long, placed centrally across the joint within 7 days of sealing.
NOTE (2): For cork seals other than in construction joints, grooves shall be 20 mm width, 50 mm depth.
(02/16) Sealing with Applied Sealants

9 (02/16) Sealing shall be carried out continuously along the full length of joint in any one rip, except for remedial
areas. When hot or cold applied sealants are used the sealant shall be applied within the minimum and maximum
drying times of the primer recommended by the manufacturer. Priming and sealing with applied sealants shall
not be carried out when the naturally occurring temperature in the joint groove to be sealed is below 10°C except
between 8°C and 10°C it may be carried out when the temperature is rising.
10 (02/16) Hot-applied sealants shall be prepared and applied in accordance with the manufacturer’s instructions.
11 (02/16) The components of cold-applied sealants shall be thoroughly mixed in the correct proportions in
accordance with the manufacturer’s instructions. As soon as possible after mixing and within the worklife of the
sealant, the material shall be dispensed into the joint, or applied using a caulking gun, to the correct level below
the concrete surface. The tack-free time shall be achieved within 3 hours for machine dispensed material, or within
12 hours for hand applied material.
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(02/16) Testing of Applied Sealants

12 (01/20) No additional testing of sealants is required provided a declaration of performance for cold-applied
sealants in accordance with BS EN 14188-2 or for. BS EN 14188-1 has been provided to the Overseeing
Organisation.
(02/16) Sealing with Compression Seals
13 (02/16) When compression seals are used, the widths of the seal shall be selected in relation to the width of the
sealing groove, the bay lengths and manufacturer’s recommendations so that the estimated maximum width of the
joint opening shall be not more than 70% of the original width of the seal, the estimated maximum width being
calculated on the basis of a movement of 4 mm per 10 m run of slab. The maximum calculated width of sealing
groove shall be 30 mm. The depth of groove shall be such that the contact face of the seal with the side of the
groove shall be not less than 20 mm and that the top of the seal shall be a minimum of 3 mm below the surface of
the concrete.
14 (02/16) Compression seals shall be inserted into the grooves without prior extension or rotation and, where
recommended by the manufacturer, with a lubricant adhesive which is compatible with the seal and the concrete.
The adhesive shall be applied to both sides of the sealing groove or the seal, or to both. The seal shall be positioned
with its axis perpendicular to the concrete surface. Excess adhesive on top of the seal shall be removed to prevent
adhesion of the top faces of the seal under compression. Except when compression seals are used in longitudinal
joints the transverse joint seal shall be continuous across the slab and the longitudinal joint groove forming
strips shall be cut to the required depth after the concrete has hardened for the transverse seal to be inserted. If
compression seals are used in longitudinal joints where the grooves have been sawn after construction of the slab
they shall be continuous across transverse joints, with the transverse seals butted and fixed to the longitudinal seals
with adhesive.
1017 (02/16) Joint Seals

1 (01/20) Joint seals shall consist of hot or cold applied sealants or compression seals complying with this Clause.
The colour of the joint seal material shall comply with the requirements of contract specific Appendix 7/2.
For hot-applied and cold applied sealants the Contractor shall submit the declaration of performance for each
sealant to the Overseeing Organisation prior to the incorporation of the sealant into the works. The declaration of
performance shall demonstrate that the sealant meets the specification requirements.
(02/16) Hot-applied Sealants
2 (01/20) Hot-applied sealants shall be Type N1 or Type F1 or Type F2, as stated in contract specific
Appendix 7/1, and conforming to BS EN 14188-1.
3 (02/16) For joints between concrete surface slabs and bituminous surfacing, hot applied Type N1 sealants
conforming to BS EN 14188-1 shall be used. Alternatively polymer modified bitumen sealing strips may be used
and shall be applied in accordance with the manufacturer’s instructions. Hot-applied Type N1 sealants may be used
in joints in asphalt kerbs laid on concrete pavements.
(02/16) Cold-applied Sealants
4 (01/20) Cold-applied sealants shall be Type N conforming to BS EN 14188-2 except that Type F shall be used
for lay-bys and hardstandings.
5 (02/16) For joints in kerbs and joints other than in pavements, seals may be any of the pavement sealants if
they have the suitable characteristics for the application, or gunning grade cold applied plasticised bituminous
rubber sealant or gunning grades of two part polysulphide-based sealants complying with BS 4254 may be used.
Alternatively, polyurethane-based sealing compounds may be used provided their performance is not inferior to
BS 4254 material.

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20
(02/16) Compression Seals

6 (01/20) Compression seals shall be pre-compressed neoprene impregnated expanding foam sealing strip having
current product acceptance scheme certification in accordance with sub-Clauses 104.15 and 104.16 such as HAPAS
certification, or rubber seals made of polychloroprene elastomers complying with BS 2752 and conforming with
the requirements of ASTM Standard D2628-91. Seals of butadiene-acrylonitrile or other synthetic rubbers may be
used if certificates are produced to show that they conform to the performance requirements of ASTM Standard
D2628- 91 for oven ageing, oil and ozone resistance, low temperature stiffening and recovery. Seals made of
ethylene vinyl acetate in microcellular form and other synthetic materials may be used in longitudinal joints and
in structures if test certificates are produced to show adequate resistance to heat ageing when tested in accordance
with BS EN ISO 2440 and resistance to fuel oils. The compression set of any seal shall not be greater than
15% when the specimen is subjected to a 25% compression in accordance with BS EN ISO 1856. When immersed
in standard oils for 48 hours at 25°C in accordance with BS ISO 1817, the volume change shall not be greater
than 5%.
7 (02/16) Compression seals shall be shaped so that they will remain compressed at all times in accordance with
Clause 1016 and shall have a minimum of 20 mm contact face with the sides of the sealing groove. If lubricant-
adhesive is used, it shall be compatible with the seal and the concrete and shall be resistant to abrasion, oxidization,
fuels and salt.
1018 (02/16) Joints at Manhole and Gully Slabs

1 (02/16) Manhole covers, gullies and their frames shall be isolated from the pavement slabs and be contained in
separate small slabs, which shall be larger than the exterior of the manhole and gully shafts, including any concrete
surround less than 150 mm below the underside of the sub-base layer. The joint around the manhole or gully slab
shall be vertical and incorporate joint filler board as in Clause 1015 but without dowel bars and tie bars.
2 (02/16) Gully slabs in unreinforced concrete slabs shall be adjacent to or straddle a transverse joint, extending
the gully slab as necessary to a maximum of 2 m. Where this is impractical, an extra tied warping joint shall be
provided adjacent to or within the gully slab and at least 2 m from the next transverse joint. If the edge of an
isolator slab is within 1 m of any longitudinal joint the isolator slab shall be extended to that joint.
3 (02/16) Manhole slabs in unreinforced concrete slabs shall be adjacent to or straddle transverse or longitudinal
joints. If the manhole is within the middle third of the bay length a warping joint shall be constructed on one side of
the manhole slab across the whole width of the bay to the nearest longitudinal joint.
4 (02/16) Reinforcement as shown on the drawings shall be placed in the main concrete slabs in the corners
between the manhole and gully slabs and the transverse or longitudinal joints. Extra reinforcement as described in
the Contract shall be placed in reinforced concrete slabs around the manhole or gully slabs.
5 (02/16) Manhole and gully slabs shall have square corners, at all corners which are not adjacent to a transverse
or longitudinal joint in the main slab.
6 (01/20) Reinforcement as shown on the drawings shall be placed in the gully or manhole slab and concrete
Class C32/40 shall be placed by hand in the space between the main slab and the manhole frame. The concrete shall
be fully compacted and finished in compliance with Clause 1025.
7 (02/16) A sealing groove shall be made directly above the joint filler board and sealed in compliance with
Clause 1016.
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1019 (02/16) Inspection of Dowel Bars

1 (02/16) Compliance with Clause 1011 for the position and alignment of dowel bars at contraction and expansion
joints shall be checked by measurement relative to the side form or guide wires.
2 (01/20) When the slab has been constructed, the position and alignment of dowel bars and any filler board shall
be measured after carefully exposing them across the whole width of the slab. When the joint is an expansion joint
the top of the filler board shall first be exposed sufficiently in the plastic concrete to permit measurement of any
lateral or vertical displacement of the board. During the course of normal working these measurements shall be
carried out at a rate of one joint per 1500 m length of slab or one per 5 days whichever occurs the sooner. For small
areas the rate shall be one joint for up to each 100 joints. For trial lengths measurements shall be carried out at two
consecutive joints.
3 (02/16) If the position or alignment of the bars in a single joint in the slab is unsatisfactory then the next two
joints shall be inspected. If only the one joint of the three is defective, the rate of checking shall be increased to one
joint per day until compliance is being achieved. In the event of non-compliance in two or more successive joints,
the Contractor shall revert to the construction of trial lengths and make any necessary alterations to the concrete
mix, paving plant or methods until the dowel bar position and alignment is satisfactory.
4 (02/16) After the dowel bars have been examined, the remainder of the concrete shall be removed 500 mm on
each side of the line of the joint, and reinstated to the requirements of the specification. Alternatively if the dowels
are examined in the penultimate joint of a day’s work that joint shall be made a construction joint for the next day’s
work and the remainder of the concrete in the last slab may be discarded.
1020 (02/16) Side Forms, Rails and Guide Wires

(02/16) Side Forms and Rails
1 (01/20) All side forms and rails shall be made of steel or timber and be sufficiently robust and rigid to support
the weight and pressure caused by the paving equipment. Side forms for use with wheeled paving machines shall
incorporate metal rails firmly fixed at a constant height below the top of the forms.
2 (02/16) The forms shall be secured by using not less than three pins for each 3 m length having one pin fixed at
each side of every joint. Forms shall be tightly joined together by a locked joint, free from play or movement in any
direction. Forms shall be cleaned and oiled immediately before each use. The rails or running surface shall be kept
clean in front of the wheels of any paving machines. The forms shall be straight within a tolerance of 3 mm in 3 m.
3 (02/16) The forms shall be bedded on low moisture content cement mortar or concrete class C6/8 and set to
the pavement surface level as shown on the drawings within a tolerance of ± 3 mm. The bedding shall not extend
under the slab. There shall be no vertical step between the ends of adjacent forms greater than 3 mm. The horizontal
alignment for forms shall be to the required alignment of the pavement edge as shown on the drawings within a
tolerance of ± 10 mm. The Contractor shall ensure that the forms are set to the correct profile immediately prior to
concreting. The mortar or concrete bedding shall be broken out after use.
4 (02/16) Side forms shall not be removed earlier than 6 hours after the completion of the construction of the slab.
Care shall be taken to prevent damage to the concrete and any projecting tie bars during the removal of the forms.
If the removal of forms results in any damage to the concrete the period of 6 hours shall be increased to that which
is necessary to avoid further damage and the Contractor shall make good the damaged areas.
(02/16) Guide Wires
5 (01/20) Unless a laser or electronically controlled level system capable of meeting the vertical and horizontal
tolerances stated below is used, a guide wire shall be provided along each side of the slab to be constructed by
slip form paving plant. Each guide wire shall be at a constant height above and parallel to the required edges of
the slab as shown on the drawings, within a vertical tolerance of ± 3 mm. Additionally one of the wires shall be at
a constant horizontal distance from the required edge of the pavement as shown in the drawings within a lateral
tolerance of ± 10 mm.

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6 (02/16) The guide wires shall be supported from stakes not more than 8 m apart by connectors capable of fine
horizontal and vertical adjustment. The guide wire shall be tensioned on the stakes so that a 500 gramme weight
shall produce a deflection of not more than 20 mm when suspended at the mid-point between any pair of stakes.
The ends of the guide wires shall be anchored to fixing points which shall be not closer to the edge of the slab than
the row of stakes and in no circumstances shall a guide wire be anchored to a stake.
7 (02/16) The stakes shall be positioned and the connectors maintained at their correct height and alignment from
1200 hours on the day before concreting takes place until 36 hours after the concrete has been finished. The guide
wire shall be erected and tensioned on the connectors at any section for at least two hours before concreting that
section.
1021 to 1022 (02/16) Not Used
1023 (02/16) Transport and Delivery

1 (02/16) The number of delivery vehicles provided shall be sufficient to ensure a constant supply of concrete to
enable the paving plant to proceed continuously.
1024 (02/16) Construction by Machine
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1 (02/16) The concrete slab shall be constructed in a continuous process by either slip-form or by fixed
form paving plant in accordance with this Clause or by small paving machines or hand guided methods as in
Clause 1025.
2 (01/20) The slab may be constructed in either one or two layers. In two layer construction the thickness of the
top layer shall be not less than 40 mm or twice the maximum size of the coarse aggregate, whichever is the greater,
and shall be at least 15 mm thicker than the depth of the groove former, if used.
(02/16) Construction by Fixed Form Paving Machines
3 (02/16) A fixed form paving train shall consist of separate, powered machines which spread, compact and finish
the concrete in a continuous operation.
4 (02/16) Concrete shall be discharged without segregation into a hopper spreader which is equipped with
the means of controlling its rate of deposition on to the sub-base or on to the lower layer. The concrete shall be
spread in each layer without segregation and to a uniform uncompacted density over the whole area of the slab.
The deposited concrete shall be struck off to the necessary level by the underside of the hopper as it is traversed
across the spreading machine. The machine shall be capable of being rapidly adjusted for changes in average and
differential surcharge necessitated by changes in slab thickness or crossfall. When the slab is constructed in two
layers, the spreading of the concrete in the top layer shall follow the completion of the bottom layer within the
times given in Table 10/7.

TABLE 10/7: (01/20) Maximum Working Times
Temperature of concrete at discharge Reinforced concrete slabs constructed in All other concrete slabs
from the delivery vehicle two layers, without retarding admixtures
Mixing first Between layers Mixing first Between layers in
Time is function of degree hours see layer to finishing layer to finishing two layer work
RCC concrete concrete
Not more than 25°C hours 3 hours half hour 3 hours 1.5 hours
Exceeding 25°C hours but not exceeding 2 hours half hour 2 hours 1 hour
30°C hours
Exceeding 30°C hours Unacceptable for – Unacceptable for –
paving paving
5 (02/16) Prior to being compacted, the surface level of each loose spread layer shall be adjusted to the correct
surcharge by means of rotating strike-off blades or a screw device.
6 (02/16) The concrete shall be compacted by vibration or by a combination of vibration and mechanical tamping
so as to comply with Clause 1003 throughout the full depth of the slab. Poker vibrators shall be used in each layer
adjacent to the side forms and the edge of a previously constructed slab.
7 (02/16) The initial regulation and finish to the surface of the slab shall be effected by means of a beam
oscillating transversely or obliquely to the longitudinal axis of the pavement. This beam shall be readily adjustable
for both height and tilt.
8 (02/16) Joint grooves shall be constructed in compliance with Clause 1013. When grooves are wet-formed, the
concrete shall be re-compacted around the former by a hand held vibrating plate compactor drawn along or on each
side of the joint, prior to the final regulation of the surface by a longitudinal oscillating float.
9 (02/16) The regulation and finishing of the surface of the slab shall be carried out by a machine which
incorporates twin oblique oscillating finishing beams which shall be readily adjustable for both height and tilt. The
beams shall weigh not less than 170 kg/m, be of rectangular section and span the full width of the slab. The leading
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beam shall be vibrated. The beams shall be supported on a carriage, the level of which shall be controlled by the
average level of not less than four points evenly spaced over at least 3.5 m of the supporting rail, beam, or slab, on
each side of the slab that is being constructed. Except for CRCB slabs, the final regulation of the surface of the slab
shall be provided by a longitudinal oscillating float, travelling across the slab. After the final regulation and before
the macrotexture is applied, any excess concrete on top of the joint groove former, where present, shall be removed.
Additionally the longitudinal oscillating float shall complete the traverse of the slab in both directions within the
length of the float and shall have a total longitudinal stroke of 200 mm to 300 mm.
10 (02/16) The longitudinal oscillating float shall have a minimum length of 3 m and a minimum constant width of
250 mm with a maximum weight of 10 kg/m. The edges of the float shall be curved or chamfered.
11 (02/16) A minimum length of 500 mm of longitudinal oscillating float shall be within the length of the machine
tracks or wheels.
12 (02/16) When a concrete slab is constructed in more than one width, flanged wheels on the paving machines
shall not be run directly on the surface of any completed part of the slab. The second or subsequent slabs shall be
constructed either by supporting machines with flanged wheels on flat-bottom section rails weighing not less than
15 kg/m laid on the surface of the completed slab, or by replacing the flanged wheels on that side of the machines
by smooth flangeless wheels. Before flangeless wheels or rails are used, the surface regularity of the slab over
which they are to pass shall comply with Clause 702 and its surface shall be thoroughly cleaned and brushed to
remove all extraneous matter. Flangeless wheels or rails shall be positioned sufficiently far from the edge of the
slab to avoid damage to that edge.
(02/16) Construction by Slip-form Paving Machine
13 (02/16) A slip-form paving train shall consist of powered machines which spread, compact and finish the
concrete in a continuous operation.

14 (02/16) The slip-form paving machine shall compact the concrete by internal vibration and shape it between
sliding side forms or over fixed side forms by means of either a conforming plate or by vibrating and oscillating
finishing beams.
15 (02/16) The concrete shall be deposited without segregation in front of the slip-form paver across its whole
width and to a height which at all times is in excess of the required surcharge. The deposited concrete shall be
struck off to the necessary average and differential surcharge by means of a strike-off plate or a screw auger device
extending across the whole width of the slab. The equipment for striking off the concrete shall be capable of being
rapidly adjusted for changes of the average and differential surcharge necessitated by changes in slab thickness or
crossfall.
16 (02/16) The level of the conforming plate and finishing beams shall be controlled automatically from the guide
wires by sensors attached at the four corners of the slip form paving machine. The alignment of the paver shall be
controlled automatically from the guide wire by at least one sensor attached to the paver. The alignment and level
of ancillary machines for finishing, texturing and curing of the concrete shall be automatically controlled relative to
the guide wire or to the surface and edge of the slab.
17 (02/16) Slip-form paving machines shall have vibration of variable output, with a maximum energy output of
not less than 2.5 kW per metre width of slab per 300 mm depth of slab for a laying speed of up to 1.5 m per minute
or pro rata for higher speeds. The machines shall be of sufficient mass to provide adequate reaction on the traction
units to maintain forward movements during the placing of concrete in all situations.
18 (02/16) Except for CRCB slabs, the final regulation of the surface slab shall be provided by a longitudinal
oscillating float travelling across the slab. The longitudinal float shall comply with the requirements of
sub-Clauses 9, 10 and 11 of this Clause. Additionally, the longitudinal float shall either be a separate machine
closely following a slip-form paver or alternatively it shall be attached to a slip-form paver in such a manner that it
functions effectively and does not adversely affect the performance of the paver or the surface of the slab.
19 (02/16) Joint grooves shall be constructed in compliance with Clause 1013. Where grooves are wet-formed
the concrete shall be compacted around the former by a separate vibrating plate compactor with twin plates. The
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groove former shall be compacted to the correct level by a vibrating pan which may be included with the transverse
joint finishing beam. Final finishing shall be carried out in accordance with sub-Clause 18 of this Clause. Any
excess concrete on top of the groove former shall be removed before the surface is macrotextured.
20 (02/16) Where a concrete slab is constructed in more than one width or where the edge needs to be matched
for one level to another section of surface slab, and the surface levels at the edges are not achieved, the slab shall
be supported by separate side forms placed before or after the paver to ensure that edge levels meet the required
tolerances.
(02/16) General
21 (01/20) While the concrete is still plastic its surface shall be treated to comply with the macrotexture
requirements specified in Clause 1026. The surface and edges of surface slabs and CRC bases shall be cured in
compliance with Clause 1027. Lower Strength concrete bases and subbases shall be cured in compliance with
Clause 1030.
22 (01/20) The spreading, compacting and finishing of the concrete shall be carried out as rapidly as possible
and the paving operation shall be so arranged as to ensure that the time between the mixing of the first batch of
concrete in any transverse section of the slab and the application of the sprayed curing membrane to the surface
of that section shall not exceed those given in Table 10/7. This working time is a function of degree hours see
sub- Clause 1054.3.
23 (02/16) Each bay in jointed concrete surface slabs shall be consecutively numbered near the verge, next to a
transverse joint while the concrete is plastic. In continuously reinforced concrete pavement the slab shall be marked
with the chainage at intervals not greater than 50 m apart.

1025 (02/16) Construction by Small Paving Machines or Hand Guided Methods

1 (01/20) As an alternative to fixed form or slip-form paving trains, the concrete slab may be constructed using
parts of trains, small paving machines, truss type finishing beams, roller beams or hand guided methods. Hand
tamping beams may only be used for short lengths or infill bays or tapers. Reinforcement, dowel bars and tie bars
shall be supported in position in accordance with Clauses 1008, 1011 and 1012 respectively, except where two
layer construction is used and reinforcement is placed on the bottom layer.
2 (01/20) The concrete shall be spread uniformly without segregation or varying amounts of pre-compaction,
by conveyor, chute, blade or auger. The concrete shall be struck off by a screed or auger so that the average and
differential surcharge is sufficient for the surface of the slab to be at the correct levels after compaction of the
concrete.
3 (02/16) The concrete shall be compacted by vibrating finishing beams across the slab and with vibrating pokers
adjacent to the side forms or the edge of a previously constructed slab. In addition, internal poker vibration shall be
used for slabs thicker than 200 mm and may be used for lesser thicknesses. When used, the pokers shall be at points
not more than 500 mm apart over the whole area of the slab, or drawn continuously across the slab in front of the
finishing beams.
4 (02/16) The finishing beams shall be metal with a contact face at least 50 mm wide. They shall be rigid or
supported by a frame or truss without sag across the width of slab being paved. The beams shall be supported on
rails or forms or an adjacent slab and shall be moved forward at a steady speed of 0.5 m to 2 m per minute whilst
vibrating, to compact the concrete and to produce a smooth surface finished to the correct crossfalls, crowns and
levels relative to the top of the forms or adjacent slab.
5 (02/16) Joint grooves shall be constructed in compliance with Clause 1013. Any irregularities at wet-formed
joint grooves shall be rectified by means of a vibrating float at least 1.0 m wide drawn along the line of the joint.
The whole area of the slab shall be regulated by two passes of a scraping straight edge not less than 1.8 m wide or
by a further application of a twin vibrating finishing beam. Any excess concrete on top of the groove former shall
be removed before the surface is macrotextured.
6 (02/16) The surface shall be brush-textured as described in Clause 1026.
7 (02/16) The surface shall be cured in compliance with Clause 1027, within the time to completion given in
Table 10/7.
1026 (02/16) Finished Surface Requirements

(02/16) Macrotexture of Running Surfaces
1 (01/20) The macrotexture of running surfaces for pavement widening, partial reconstruction and repair
shall comply with sub-Clauses 2 to 6 of this Clause, other pavements shall comply with sub-Clause 2 and
sub- Clauses 7 to 27 of this Clause.
2 (01/20) The finished surface of the pavement shall comply with the requirements of Clause 702. Where a
pavement area does not comply with the specification in any respect the full extent of the surface which does not
comply shall be rectified in accordance with Clause 702.
(02/16) Brush Finish Macrotexture
3 (02/16) After the final regulation of the surface of the slab and before the application of the curing membrane,
the surface of concrete slabs to be used as running surfaces shall be brush-macrotextured in a direction at right
angles to the longitudinal axis of the carriageway. The macrotexture shall be applied evenly across the slab in one
direction by a brush not less than 450 mm wide. The macrotexture shall be uniform both along and across the slab.

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4 (02/16) The macrotexture depth shall be determined by the volumetric patch technique as described in
BS EN 13036-1. Tests shall be taken within 100 m of commencement of paving and thereafter at least once for
each day’s paving at the times after construction as given below and in the following manner: 10 individual
measurements of the macrotexture depth shall be taken at least 2 m apart anywhere along a diagonal line across a
lane width between points 50 m apart along the pavement. No measurement shall be taken within 300 mm of the
longitudinal edges of a concrete slab constructed in one pass.
5 (02/16) Macrotexture depths shall be as required in Table 10/8.
6 (02/16) Where the required macrotexture depth is found to be deficient the Contractor shall make good the
texture across the full lane width over lengths necessary to comply with the requirements of Table 10/9, by
retexturing the hardened concrete surface as described in Clause 1029. Failure to achieve a satisfactory minimum
macrotexture depth by random grooving shall result in the removal of the full thickness of the slab to the extent
required to permit reconstruction of the slab in accordance with the specification. If the macrotexture depth is
excessive the surface shall be planed or ground or otherwise treated over lengths necessary to comply with the
requirements of Table 10/8. The treatment shall not affect the requirements of Clause 702 in respect of surface
levels or surface regularity.
TABLE 10/8: (01/20) Macrotexture Depths
Time of Test Required Macrotexture Depth (mm)

Specified value Tolerance
(i) Between 24 hours and 7 days after An average of 10 measurements 1.00 +0.25
the construction of the slab or until the -0.10
slab is first used by vehicles
(ii) Not later than 6 weeks before the An average of 10 measurements 1.00 +0.25
road is opened to public traffic -0.10
(02/16) Performance Characteristics of Concrete Road Surfaces

7 (01/20) The surface macrotexture shall meet the performance requirements stated in Table 10/8.
8 (01/20) The Contractor shall demonstrate that the ‘as installed’ concrete pavement can meet the requirements of
the specification. This shall be demonstrated by the system meeting the stated material requirements and by having
undergone a System Installation Performance Trial (SIPT) for the surface finish. The SIPT shall comply with the
requirements of sub-Clauses 9 to 27 of this Clause and the requirements of sub-Clause 104.16. The Contractor shall
submit details of the SIPT for the systems to be used in the contract as required in sub-Clause 15 to the Overseeing
Organisation for acceptance.
With respect to the requirements of this Clause ‘the system’ shall be the combination of materials, equipment and
working methods to be used in the works. The SIPT shall have been undertaken with the same materials, equipment
and working methods.
(01/20) System Installation Performance Trial (SIPT) Requirements
9 (01/20) The surface finish used in the SIPT shall meet the performance requirements of the surface course to be
supplied under the contract. The SIPT shall demonstrate, and enable verification of, the performance of the road
surface.
10 (01/20) The SIPT shall be undertaken during daylight hours and shall be a minimum of 200 metres in length and
3.5 metres wide.
11 (01/20) The system shall be assessed, tested and certified by a Certification Body using one or more trial
areas of pavement. The Certification Body shall be accredited to BS EN 45011 by UKAS or equivalent European
Accreditation organisation which is party to a multi-lateral agreement (MLA) with UKAS or any equivalent
International Accreditation Forum MLA signatory with a scope that includes relevant standard(s) or scheme(s).
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12 (01/20) The average locked wheel friction of the SIPT road surface macrotexture depth of the surface shall
be measured in accordance with ASTM E274/E274M – 11, at a speed of 90 km/hr rather than 40 mph in the test
method, using a tyre that complies with ASTM E524 – 08.
13 (01/20) A SIPT method statement shall be prepared. The SIPT shall demonstrate, and enable verification of, the
installation procedures given in the SIPT method statement. This will include working methods and equipment, any
limitations, aftercare, testing methods and frequency of testing.
14 (01/20) A SIPT inspection protocol shall be prepared. It shall demonstrate qualitatively and quantitatively the
applicability of the SIPT for the system in order to satisfy the performance requirements.
15 (01/20) The SIPT method statement, SIPT inspection protocols, all inspection and testing results and the SIPT
certification shall be submitted to the Overseeing Organisation prior to the commencement of concrete pavement
construction.
16 (01/20) The SIPT shall include the following to be undertaken by the Certification Body:
(i) verification that the system installation trial has been undertaken in accordance with the SIPT method
statement;
(ii) assessment of the data from the site performance tests detailed in sub-Clause 17
17 (01/20) The installed performance of the system over the two-year trial period shall be assessed at the intervals
specified in Table 10/9. Data relating to properties in Table 10/9 shall be provided to the Overseeing Organisation
TABLE 10/9: (01/20) Installed Performance Characteristics
Property Frequency Requirement

Average locked wheel friction (L- Initial, 12 and 24 months >0.3 L-Fn90
Fn90) measured at 90km/hr. by
Pavement Friction Tester
Noise (Voluntary assessment and Between 12 and 24 months Table 10/11
declaration)
(02/16) Noise
18 (01/20) Where noise characteristics for the surface are specified in contract specific Appendix 7/1 the SIPT shall
include the assessment and measurement of the road/tyre noise levels. The road/tyre noise level of the concrete
shall be assessed as detailed in sub-Clauses 19 to 27 of this Clause, and declared as NR, 0, 1, 2 or 3 as described
in Table 10/10. If the SIPT site conditions are not appropriate for testing an alternative site shall be selected and
nominated.
Level Equivalence to Traditional Surfacing Materials Road Surface Influence

RSI
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3 Very quiet surfacing material -3.5 dB(A)

2 Quieter than HRA surfacing materials -2.5 dB(A)
1 Equivalent to HRA surfacing materials -0.5 dB(A)
0 Noisier than HRA Surfacing materials +1.2 dB(A)
NR No requirement No requirement
19 (01/20) The influence of the road surface on traffic noise using the statistical pass-by method shall
be established at the SIPT site between 12 and 24 months after opening to traffic in accordance with
ISO 11819- 1: 2002, Sections 7 and 8.

20 (01/20) Acoustic measurements shall only be carried out when the road surface is dry and the meteorological
conditions specified in ISO 11819-1: 2002, Section 11 are met.
21 (01/20) The air and surface temperatures are monitored in accordance with the procedure described in
ISO 11819-1: 2002, Clause 8.5. The road surface temperature, T surface, must be within 5°C to 50°C during
acoustic measurements. The air temperature, T air, must be within 5°C to 30°C.
22 (01/20) The test location road speed category shall be classified as either Medium or High as defined in
ISO 11819-1: 2002, clause 3.3. Not less than two test locations are selected for each road speed category, which
may be at the same site, provided the locations are at least 100 m apart or on different carriageways. Each test
location shall be representative in terms of road speed category and traffic level. Each of the test sites selected must
meet the requirements of ISO 11819-1: 2002 Section 6 and ISO/CD 11819-2: 2000. The road must be essentially
straight, or bends with a radius of curvature greater than 500 m for medium-speed, and 1000 m for high-speed road
categories. The crossfall of the test lane at the test site must not exceed 4%.
23 (01/20) The apparatus described in ISO 11819-1: 2002 Section 5 are used. The frequency range of between
100 and 5000 Hz (centre frequencies of the one-third octave bands) should be covered.
24 (01/20) The macrotexture of the road surface used for the noise assessment shall be measured in the nearside
wheel-track along the whole length of test material in accordance BS EN 13036-1: 2010. The macrotexture depth of
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the nearside wheel-track in front of a test location must be within 10 per cent of the average macrotexture measured
along the site.
25 (01/20) The microphone location at each measurement site shall be recorded accurately and marked with
appropriate methods such that the position can be readily identified for a period of at least two years.
26 (01/20) When sufficient vehicle pass-bys’ have been measured, a linear regression analysis shall be performed
in accordance with ISO 11819-1: 2002, Clause 9.1. In the case of the high-speed road category, measurements must
not be taken of vehicles travelling at speeds of less than 60 km/h in accordance with AFNOR Standard S31-119.
27 (01/20) For each category of vehicle defined in Table 10/11, the Vehicle Sound Level, Lveh, shall be
calculated as the ordinate sound level of the regression line at the reference speed for the category of road. All
levels shall be calculated to two decimal places and rounded to one decimal place.
TABLE 10/11: (02/16) Reference speeds (km•h-1) for different road speed categories
Vehicle category Road speed category (km·h-1)

Medium High
L 80 110
H1 70 90
H2 70 90
Category L vehicles — light vehicles including passenger cars and car derived vans, excluding vehicles towing trailers.
Category H1 vehicles — commercial trucks with 2 axles and greater than 3.5 tonnes.
Category H2 vehicles — commercial trucks with more than 2 axles and greater than 3.5 tonnes.
(02/16) Texture of Concrete Bases

28 (01/20) The surface of wet-laid concrete bases (prior to the application of a bituminous overlay) shall be
roughened before the application of any curing compound by brushing with a wire brush or stiff broom to achieve
min 0.5 mm texture depth.

1027 (02/16) Curing

1 (01/20) Immediately after the surface treatment described in Clause 1026, the surface and exposed edges of the
surface shall be cured, without disturbance, for a minimum period of 7 days, by the application of a resin based
aluminised curing compound, or polythene sheeting or a sprayed plastic film which hardens into a peelable plastic
sheet and which shall be removed before road marking and opening to traffic. Where the concrete is to receive a
thin surfacing overlay, the surface and exposed edges shall be cured for a minimum of 7 days by the application of
a curing agent. If the concrete is to be overlaid by bituminous surfacing the curing agent shall be compatible with
the bond coat and installation requirements for the thin surfacing in accordance with Series 900.
2 (02/16) Resin based aluminised curing compound shall contain sufficient flake aluminium in finely divided
dispersion to produce a complete coverage of the sprayed surface with a metallic finish. The compound shall
become stable and impervious to evaporation of water from the concrete surface within 60 minutes of application
and shall have an efficiency index of 90% when tested as described in BS 7542.
3 (02/16) The curing compound shall not react chemically with the concrete to be cured and shall not crack, peel
or disintegrate within three weeks after application.
4 (02/16) Prior to application, the contents of any containers shall be thoroughly agitated. The curing compound
shall be mechanically applied using a fine spray on to the surface at a rate of at least 0.22 1/m². For the sides of
slip‑formed slabs or when the side forms are removed within 24 hours and for small areas where mechanical
application cannot be used, the compound shall be sprayed by hand lance at a rate of at least 0.27 1/m². The rate of
spread shall be checked during construction of each trial length and for each 1000 m² of treated slab.
5 (02/16) The mechanical sprayer shall incorporate an efficient mechanical device for continuous agitation and
mixing of the compound in its container during spraying.
6 (02/16) Continuously reinforced concrete bases shall be cured in accordance with this Clause. Immediately prior
to laying the bituminous surfacing or upper base, a cationic bituminous tack coat shall be applied in accordance
with Clause 920 at a rate between 0.35 l/m² to 0.55 l/m².
7 (01/20) To achieve high early strength for early use by vehicles, insulation blankets as described in Clause 1045
may be used for accelerated curing.
1028 (02/16) Trial Length

(02/16) General
1 (01/20) Except in rapid construction projects and unless otherwise described in contract specific Appendix 7/1,
at least 2 weeks prior to the construction of the trial length of surface slabs or CRCB the Contractor shall submit a
detailed description of the proposed constituent materials, concrete proportions, plant, equipment and construction
methods to the Overseeing Organisation. No trials of new constituent materials, plant, equipment or construction
methods; nor any development of them shall be permitted either during the construction of the trial length or in any
subsequent paving work, unless they form part of further satisfactory trials.
2 (02/16) Unless otherwise described in contract specific Appendix 7/1, the Contractor shall demonstrate the
constituent materials, concrete proportions, plant, equipment and methods of construction that are proposed
for concrete paving, by first constructing a trial length of slab, at least 150 m but not more than 300 m long for
mechanised construction, and at least 30 m long for hand guided methods. The concrete proportions decided
by trial concrete mixes may be adjusted during the trial but shall not be changed once the trial length has been
satisfactorily completed unless the Contractor lays a further trial area to assess the suitability of the proposed
changes.
3 (02/16) The trial length shall be constructed in two parts over a period comprising at least part of two separate
working days, with a minimum of 75 m constructed each day when mechanised paving plant is used and a
minimum of 15 m on each day for hand guided methods. The trial length shall be constructed at a similar rate to
that which is proposed for the main construction in the permanent works.

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4 (02/16) At least two transverse joints and one longitudinal joint of each type that are proposed for unreinforced
concrete slabs and jointed reinforced concrete slabs in the main construction in the permanent works shall be
constructed and assessed in the trial length. If in the trial length expansion joints are not demonstrated, the first
2 expansion joints and at least the first 150 m of longitudinal construction joint for mechanised paving, or 30 m for
hand guided method of construction laid in the main construction in the permanent works, shall be considered the
trial length for these joints. One construction joint shall be demonstrated in each trial length of CRCP or CRCB.
(02/16) Assessment
5 (02/16) The trial length shall comply for strength and density with the specification in all respects, with the
following additions and exceptions:
(02/16) Surface Levels and Irregularity
(i) In checking for compliance with Table 7/1 the levels shall be taken at intervals of not more than
2.5 m along any line or lines parallel to the longitudinal centre line of the trial length.
(ii) The maximum number of permitted irregularities of pavement surfaces shall comply with the
requirements of Table 7/2 for 300 m lengths. Shorter trial lengths shall be assessed pro-rata based on
values for a 300 m length.
(02/16) Joints
(iii) At least 3 cores of minimum diameter 100 mm shall be taken from the slab at joints to check the lateral
and vertical location of joint grooves and bottom crack inducers.
(iv) Alignment of dowel bars shall be inspected as described in Clause 1019 in any two consecutive
transverse joints. If the position or alignment of the dowel bars at one of these joints does not comply
with Clause 1011 but if that joint remains the only one that does not comply after the next 3 consecutive
joints of the same type have been inspected then the method of placing dowels shall be deemed to be
satisfactory. In order to check sufficient joints for dowel bar alignment without extending the trial length
unduly, the Contractor may construct joints at more frequent joint intervals than the normal spacing
required in contract specific Appendix 7/1.
(v) If there are deficiencies in the first expansion joint that is constructed as a trial the next expansion joint
shall be a trial joint. Should this also be deficient further trial expansion joints shall be made as part of a
trial length. Deficient expansion joints shall not form part of the permanent works.
(02/16) Position of Reinforcement and Tie Bars
(vi) Compliance with Clause 1008 for the position of steel reinforcement and Clause 1012 for the position
and alignment of tie bars shall be checked by drilling additional cores from the slab unless they can be
determined from cores taken for density assessment.
(02/16) Completion of Trial
6 (02/16) The Contractor shall not proceed with normal working unless the trial length complies with the
specification and any earlier defective trial lengths have been removed, unless they can be remedied to comply with
the specification.
7 (02/16) After satisfactory completion of the trial length, the constituent materials, concrete proportions,
plant, equipment and construction methods shall not thereafter be changed, except for normal adjustments and
maintenance of plant, unless the Contractor lays a further trial length as described in this Clause to demonstrate that
the changes will not adversely affect the permanent works or agrees the changes with the Overseeing Organisation.
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(02/16) Rejection and Further Trials

8 (02/16) Trial lengths which do not comply with the specification, with the exception of areas within the
pavement surface which can be remedied in accordance with Clause 1029, shall be removed and the Contractor
shall construct a further trial length.
1029 (02/16) Texturing of Hardened Concrete

1 (01/20) Worn, rain damaged or inadequately textured surface slabs shall be macrotextured by sawing grooves in
the hardened concrete surface at right angles to the longitudinal axis of the pavement with machines using diamond
or other abrasive cutting discs. This produces a high noise surface and shall only be carried out with the agreement
2 (02/16) Grooves shall be irregularly spaced and shall be not less than 2 mm and not more than 5 mm wide.
The sequence of distances between groove centres in mm 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, 55. A tolerance of ± 3 mm shall be allowed on each of the
spacings. The minimum width of grooving head shall be 500 mm and a head not providing a complete sequence of
spacings shall use the number of spacings appropriate to its width commencing at the start of the sequence.
3 (02/16) Groove depths shall be measured using a tyre tread depth gauge and measurements shall be taken as
follows:
(i) At 10 locations at least 2 m apart along a diagonal line across a lane width between points 50 m apart
longitudinally. No measurement shall be taken within 300 mm of the longitudinal edge of a slab.
(ii) At each of the 10 locations the depth of 10 adjacent grooves shall be measured.
(iii) Where a grooved area is less than 50 m in length the locations where measurements are taken shall be as
(i) but the number shall be proportional to the requirements for 50 m.
(iv) The average of each set of 10 measurements shall be not less than 3 mm, nor greater than 7 mm.
4 (02/16) 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.
1030 (01/20) Lower Strength Concrete

(02/16) Grades and Constituents
1 (01/20) The strength for Lower Strength concrete shall be as described in Clause 1001 with the following
constituents:
(i) cements as described in sub-Clause 1001.3 and water/cement ratio as described in sub-Clause 1001.4;
(ii) aggregate shall be in accordance with sub-Clause 1001.6.
(02/16) Consistence (Workability)
2 (02/16) Consistence shall comply with Clause 1005.
(02/16) Placing
3 (01/20) Lower Strength concrete shall be spread uniformly, without segregation and without varying degrees
of pre-compaction. The concrete shall be struck off to a level so that the surcharge is sufficient to ensure that after
compaction the surface is at the required level.

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32
(02/16) Compaction
4 (01/20) The spread Lower Strength concrete shall be compacted using internal or external vibration, or a
combination of both to meet the required density. Compaction and finishing to level shall be completed within the
times given in Table 10/7.
(02/16) Joints
5 (02/16) At transverse and longitudinal construction joints between two separately constructed slabs, the
previously laid slab end or edge shall present a vertical face before construction of subsequent slabs.
6 (01/20) Longitudinal joints in Lower Strength concrete shall be staggered by at least 300 mm from the position
of longitudinal joints in any superimposed concrete slab, and by 1m for transverse joints.
(02/16) Curing
7 (01/20) The surface shall be cured, without disturbance, for a minimum period of 7 days, by the application of
a resin based aluminised curing compound, or polythene sheeting or a sprayed plastic film which hardens into a
peelable plastic sheet.
(02/16) Sampling for Testing
8 (02/16) Sampling shall be as specified in Clause 1003.
(02/16) Density
9 (02/16) The density shall be determined as required in Clause 1003.
(02/16) Strength
10 (02/16) The strength shall be determined as in Clause 1004.
(02/16) Trial Concrete Mixes
11 (02/16) Trial concrete mixes shall conform with BS 8500-2 for designed concretes for strength class C12/15 and
above or CC14 and above, unless recent data relating entirely to the proposed concrete, satisfies the requirements of
the specification.
(02/16) Trial Length
12 (01/20) At least 10 days before the start of the main Lower Strength concrete works a trial length of at least
400 m2 for mechanised construction and 30 m for hand-guided methods shall be constructed. The trial length shall
be laid to assess the suitability of the proposed material, plant, equipment and construction methods to meet the
requirements of the specification. The main construction in the permanent works shall not start unless the trial
length complies with the specification. If any trial length does not conform to the specification another trial length
shall be constructed. Trial lengths not complying shall be removed unless they can be rectified to comply with the
specification.
13 (02/16) After satisfactory completion of the trial, the material, plant, equipment and construction methods shall
not be changed unless the Contractor lays a further trial length to assess the suitability of the proposed changes or
agrees the changes with the Overseeing Organisation.
(02/16) Surface Finish
14 (01/20) The surface of the Lower Strength concrete after compaction and finishing and before overlaying shall
be free from ridges, loose material, pot holes, ruts or other defects.
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1031 (02/16) Measurement of Macrotexture Depth – Volumetric Patch Technique

1 (01/20) For repairs and widening of existing concrete pavements only the macrotexture depth of the road surface
will be determined using the method described and the equipment specified in BS EN 13036-1.
1032 to 1038 (11/21) Not Used
1039 (02/16) Summary of Rates for Sampling and Testing Concrete for Pavement Layers
1 (02/16) Unless otherwise stated in contract specific Appendix 1/5, Table 10/12 summarises the minimum rates of
sampling and testing of specimens to the specification.
2 (02/16) Samples for testing shall be taken at the point of placing or from the relevant pavement layer.
TABLE 10/12: (01/20) Rates for Sampling and Testing Concrete for Pavement Layers
Clause Test Rate (the greater number shall be used)
1002 Air content a) Main slab 1 per 300 m2 or 6 per day
b) Slabs less than 300 m² 1 per 20 m length or 3 per day
1003 Density a) Trial length

A minimum of 3 cores at a rate of 1 core per 1000 m2 sets of
3 cubes for every 400m2 of concrete laid
b) Main Slab
1004 Strength a) Main slab 3 cubes per 400m2 not less than 6 sets per day. 1 to be tested
at 7 days and 2 at 28 days.
b) Trial length At least 9 cubes, 3 to be tested 7 days and 6 at 28 days
1005 Consistence a) Main Slab – Initial 50 m3 3 samples

– Subsequently 1 per 150 m3 or 1 per production day
b) Slabs less than 150 m3 3 samples in the first 50 m3 then 1 more
1019 Inspection of dowel a) Main slab 1 joint per 1500 m length or 1 joint per 5 days whichever is
alignment the sooner
b) Slabs less than 1500 m in length At a rate of one joint for up to each 100 joints
c) Trial lengths 2 consecutive joints. If one defective, inspect next

3 consecutive joints
1026 Macrotexture depth Each lane width One within 100 m of commencement of paving and
thereafter at least one set of 10 measurements per day’s work.
1030 Lower Strength As in Clause 1003 and 1004

concrete
In situ density A minimum of 3 cores at a rate of 1 core per 1000 m2
Strength a) Main slab 3 cubes per 600m2 not less than 6 sets per day
At least 6 cubes, half to be tested 7 days and half at 28 days
b) Trial length 3 cubes per 600m2 not less than 6 sets per day
At least 6 cubes, half to be tested 7 days and half at 28 days
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1040 to 1042 (02/16) Not Used
1043 (02/16) Foamed Concrete

1 (02/16) Foamed concrete used in reinstatements shall comply with the requirements of the “Specification for the
Reinstatement of Openings in Highways” issued by the Highway Authorities and Utilities Committee.
2 (02/16) Foamed concrete used for backfilling excavations, including trench reinstatement, under road pavements
shall have the following compressive strengths:
(i) A minimum cube compressive strength of 4 N/mm2 at an age of 7 days.
(ii) A maximum cube compressive strength of 10 N/mm2 at an age of 7 days.
(The compressive strength shall be determined by testing foamed concrete cubes which have been made in
accordance with BS EN 12390-1 except that the foamed concrete shall be placed in the mould without any tamping
or vibration other than gently rocking the mould on a firm base. The test cubes shall be cured in accordance with
BS EN 12390-2 and tested for compressive strength in accordance with BS EN 12390-3.
3 (02/16) All aggregate used in foamed concrete shall pass a 6.3 mm sieve and shall comply with the MP and
FP grading limits given in BS EN 12620. Larger size aggregate may be used provided it can be shown to be
practicable.
4 (02/16) After placing, foamed concrete shall not be tamped, or otherwise compacted.
5 (02/16) Reinstatement of the sub-base and base over the foamed concrete shall not be carried out until the
foamed concrete has attained sufficient strength to allow compaction of the sub-base and base material.
1044 (02/16) Pavements with an Exposed Aggregate Concrete Surface

(02/16) General
1 (01/20) Pavements with an exposed aggregate concrete surface shall comply with all the requirements of this
Series except Clause 1026 and where otherwise specified in this Clause.
2 (02/16) The Contractor shall complete contract specific Appendix 10/1 and submit this with his tender
documents. If after acceptance the Contractor wishes to change the proposals contained in contract specific
Appendix 10/1 this change shall only be with the consent of the Overseeing Organisation.
3 (02/16) The concrete slab shall be laid in either a single layer or in two layers as stated in contract specific
Appendix 10/1. If laid in two layers the surface layer shall be laid monolithically with the lower layer.
4 (02/16) The Contractor shall carry out trials, as specified in sub-Clauses 31 to 39 of this Clause, to demonstrate
that the materials, concrete proportions and methods for exposing the aggregate will meet the requirements of this
Clause.
(02/16) Quality of Concrete in the Slab
5 (02/16) The surface layer concrete shall comply with the following requirements:
(i) The surface layer shall be not less than 40 mm thick. The coarse aggregate shall comply with the size
requirements of contract specific Appendix 7/1.
(ii) For 6.3/10 mm coarse aggregate or 4/8 mm coarse aggregate as required in contract specific Appendix
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7/1, the amount of aggregate retained on the 10 mm sieve and 8 mm sieve respectively shall not exceed
3% by mass. The aggregate passing the 6.3 mm sieve and 4 mm sieve respectively shall not exceed 10%
by mass.
(iii) The fine aggregate grading shall comply with the 0/2 (FP) or 0/1 (FP) grading in BS EN 12620 except
that not less than 99% of the mass of the material shall pass the 2 mm sieve.

(iv) The coarse aggregate shall comprise at least 60% by mass of the oven dry constituents of the concrete.
(v) The polished stone value (PSV) and the aggregate abrasion value (AAV) of the coarse aggregate
determined in accordance with BS EN 1097-8 shall be as specified in contract specific Appendix 7/1.
The Category of flakiness index of the aggregate is FI15.
(vi) Hardness and durability of the coarse aggregate shall be as described in sub-Clause 901.2.
(vii) The type of cement used in the concrete shall be limited to Class 42.5N/42.5R Portland cement CEM I
complying with BS EN 197-1. The minimum cement content of the concrete shall be 375 kg/m³ and the
maximum free water/cement ratio shall be 0.40.
(viii) The air content, density and strength requirements shall be as required in Clauses 1002, 1003 and 1004
respectively.
(02/16) General Construction Requirements
6 (02/16) The concrete paving equipment shall comply with contract specific Appendix 10/1 as completed by the
Contractor and submitted at Tender stage for approval by the Overseeing Organisation before the work commences.
The general construction requirements shall be in accordance with the requirements of this Series except where
otherwise stated in this Clause:
(i) The concrete carriageway paving operation shall be undertaken as not less than a single lane width of
construction using either slip-form paving machines or fixed form paving machines.
(ii) The concrete surface layer shall be fed, spread, compacted, regulated and finished using equipment with
elements to obtain the required uniform distribution and bonded embedment of the selected aggregate in
the finished road surface.
(iii) The spread concrete shall be compacted in such a manner that base layer concrete is not drawn into the
surfacing and selected aggregate is uniformly present in the finished road surface.
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(iv) The surface layer shall be compacted and shaped to line and level by a combination of either internal
vibration and fixed conforming plate or vibrating conforming plate.
(v) The final regulation of the surface layer shall be provided by a transverse finishing screed in advance
of a longitudinal oscillating float in accordance with Clause 1024, travelling across the slab before the
application of a retarder complying with BS EN 934-2.
(02/16) Finished Surface Requirements
7 (02/16) The finished surface of the pavement shall comply with the requirements of Clause 702. Where
a pavement area does not comply with the specification for regularity, surface tolerance, thickness, material
properties or compaction or contains surface depressions, the full extent of the surface which does not comply
with the specification shall be rectified by cutting out the full depth of the slab. It shall be replaced with a new
slab complying with the procedures set out in Clause 1033 to the extent required to obtain compliance with the
specification.
(02/16) Production of an Exposed Aggregate Surface
8 (02/16) In order to obtain a suitable exposed aggregate surface the main requirement shall be the removal of the
surface mortar from the top of the slab to produce an exposed aggregate finish. This objective may be achieved by
the application of a suitable cement set retarder which is sprayed on the surface of the fresh concrete immediately
after it has been levelled and finished. Retarded mortar shall be removed by wet or dry brushing as stated in
contract specific Appendix 10/1, generally no sooner than when the surface concrete has reached a maturity of
16 hours at 20°C or after a suitable interval determined by trial, to achieve the requirements of sub-Clause 27 of
this Clause.

(02/16) Retarder
9 (02/16) The composition and viscosity of the retarder shall be such that it can be spread at an adequate and
uniform rate over the surface of the concrete slab in order to ensure adequate aggregate exposure during the
subsequent brushing operation.
10 (02/16) The retarder shall contain a pigment in sufficient quantity to give an even uniform colour after it has
been sprayed on to the slab surface. The pigment shall be fully degraded by exposure to ultra-violet light without
leaving any residue that is detrimental to the surface of the concrete.
11 (02/16) The chemical composition of the retarder and of the curing compound shall be such that they do not
react adversely following the application of the curing compound to the exposed aggregate surface.
12 (02/16) The Contractor shall use the retarder which he has nominated in contract specific Appendix 10/1.
This shall be of a type and composition to satisfy the requirements of this Clause.
(02/16) Application of the Retarder
13 (02/16) The retarder shall be spread evenly on to the surface of the wet concrete slab as soon as practicable
after the surface layer has been levelled and finished, by a spray bar over the full width of the slab in one pass. To
achieve this uniformity of spread, the spraying system shall consist of a spray bar, provided with nozzles, mounted
on a machine spanning the slab. Temporary works materials and equipment shall be chosen in order to permit
inspection to ensure adequate coverage of retarder immediately after spraying and before protection of the surface.
14 (02/16) Before commencing work, the level of the spray bar, the rate of delivery of the retarder from the nozzles
of the spray bar, and the forward speed of the spraying machine shall be adjusted to achieve the required rate of
spread. Means shall be provided and steps shall be taken to avoid excess retarder flowing on the surface of the slab.
15 (02/16) Back-up spraying equipment shall be available on the site at all times for use in case of a breakdown of
the spraying machine.
(02/16) Protection of the Surface after the Application of the Retarder
16 (02/16) The finished surface of the pavement concrete after application of retarder shall be protected against
precipitation, moisture loss, contamination and dispersal of the retarder by air movements as stated in contract
specific Appendix 10/1. This protection shall be applied immediately after the application of the retarder.
17 (02/16) Where waterproof sheeting is used it shall be laid onto the surface of the concrete immediately after the
retarder has been sprayed. It shall be retained in position until immediately prior to exposing of the aggregate.
18 (02/16) The protection system shall not adversely affect either the finish, the line or the level of the concrete
surface or the even distribution of the retarder in any way. Where sheeting is used, any air bubbling or blistering
shall be prevented.
(02/16) Exposing the Aggregate Surface
19 (02/16) Brushing equipment shall be used to expose the concrete surface aggregate. Where the brushing
equipment runs on the slab the concrete shall have gained sufficient strength to avoid any damage to the concrete.
20 (02/16) Removal of the protection system shall take place as brushing proceeds. If waterproof sheeting is used
as a protection system it shall be maintained in position until immediately in advance of the brushing operation.
21 (02/16) The Contractor shall complete the process of exposing the aggregate before the retarder becomes
ineffective. Failure to do so shall entail the remedial measures specified in sub-Clauses 29 and 30 of this Clause.
(02/16) Brushing System
22 (02/16) Sufficient brushing capability shall always be maintained on site to complete the exposure of the
aggregate before the retarder becomes ineffective. An adequate back-up brushing facility shall be available on the
site at all times for use in case of a breakdown of the brushing equipment.

37
23 (02/16) The brushing equipment nominated by the Contractor in contract specific Appendix 10/1 shall be used to
produce an even macrotexture on the surface of the slab. Brushing shall be carried out in the longitudinal direction
of the concrete slab.
24 (02/16) The brushing equipment shall be capable of maintaining an adequate brush rotational speed which in
conjunction with the forward working speed is sufficient to remove the surface mortar. Adequate dust suppression
and collection measures shall be in operation at all times.
25 (02/16) When complying with the requirements of sub-Clause 19 of this Clause, the wheels of any brushing
equipment which may run on the slab shall be fitted with tyres with a shallow tread pattern and a low inflation
pressure and be sufficiently wide to avoid damage to the concrete.
(02/16) Protection of the Surface Layer After Exposure of the Aggregate
26 (02/16) Within one hour of completing exposure of the aggregate the surface shall be dampened with water.
A curing compound shall be applied to the entire exposed aggregate surface of the slab in accordance with
Clause 1027. In wet weather the curing compound shall be applied as soon as practicable after the rain stops. The
surface may, alternatively, be covered by hessian provided it is maintained in a wet condition at all times during the
curing period of the concrete.
(02/16) Surface Macrotexture Depth and Remedial Measures
27 (02/16) The texture depth of the surface of the concrete shall be measured using a volumetric patch technique
described in BS EN 13036-1. The average macrotexture depth of each 1000 m section of carriageway lane, or each
carriageway lane where less than 1000 m, shall comply with the requirements of contract specific Appendix 7/1.
Any individual result shall be neither greater than the maximum, nor be less than the minimum value of
macrotexture depth stated in contract specific Appendix 7/1.
28 (02/16) During brushing, initial interim spot check measurements of the surface macrotexture depth shall be
made as soon as it is considered that the required texture depth has been reached. This shall continue until the
specified macrotexture depth has been achieved.
29 (02/16) In the event that it is not possible to achieve the specified minimum macrotexture depth by further
exposure, the Contractor shall treat the surface in accordance with Clause 1029 to achieve the specified
macrotexture depth. This treatment shall not be applied until the concrete has reached an age of 28 days and shall
not affect the requirements of sub-Clauses 702.2 to 702.4 and 702.5 to 702.9.
30 (02/16) Failure to achieve a satisfactory minimum macrotexture depth by mechanical means shall result in
removal of the full thickness of the slab to the extent required to permit reconstruction of the slab in accordance
with the specification. Where the maximum macrotexture depth is exceeded suitable remedial measures shall be
employed.
(02/16) Preliminary Trials
31 (02/16) The Contractor shall carry out preliminary trials to demonstrate to the Overseeing Organisation, not less
than one month prior to the commencement of the trial length referred to in sub-Clauses 37 to 39 of this Clause, the
materials, concrete proportions and methods for achieving the macrotexture depth requirements defined in contract
32 (02/16) Preliminary trial panels shall be constructed off-line incorporating a top surface of exposed aggregate
concrete similar to that specified for the permanent works. These panels shall be 20 m long and not less than
100 mm deep, and the maximum intended paving width. They shall be used to enable the Contractor to determine
the required application rate of the retarder and the amount of brushing required to achieve the specified
macrotexture depth.
33 (02/16) The trial panels may alternatively be constructed on-site, but in this case, they may only form part of the
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permanent works if they meet all the requirements of the specification, otherwise they shall be removed after they
have served their purpose.

34 (02/16) The surface macrotexture depth shall be determined by volumetric patch technique at approximately
2 m spacings along a diagonal line across each trial panel, and shall follow the procedure described in
BS EN 13036-1.
35 (02/16) The average value of each set of 10 individual measurements shall be taken as the resulting
macrotexture depth which shall be assessed against the specification.
36 (02/16) The materials including all the aggregates, plant and equipment used in the preliminary trials shall be
equivalent to that which will be used in the Trial Length.
37 (02/16) In addition to the requirements of Clause 1028, the macrotexture depth shall be tested for compliance in
accordance with sub-Clauses 38 and 39 of this Clause.
38 (02/16) Macrotexture depth shall be assessed by the volumetric patch technique for each 50 m length of the trial
length and for each lane, and shall follow the procedure in BS EN 13036-1.
39 (02/16) During the construction of the Trial Length, spot checks shall be made as soon as it is considered that
the required macrotexture depth has been reached. Should the texture depth be found to be inadequate, further
exposure of the aggregate shall be undertaken until the specified macrotexture depth has been achieved. Where the
macrotexture depth is not achieved, and the trial was intended to form part of the running surface of the permanent
works, the remedial measures described in sub-Clauses 29 and 30 of this Clause shall apply.
1045 (02/16) Weather Conditions for Laying of Cementitious Materials

1 (01/20) Road pavement materials in a frozen condition shall not be incorporated in the works.
2 (02/16) Road pavement materials shall not be laid on any surface which is frozen or covered with ice.
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3 (01/20) The temperature of concrete in any pavement layer shall not be less than 5ºC at the point of delivery.
These materials shall not be laid when the air temperature falls below 3ºC and laying shall not be resumed until
the rising air temperature reaches 3ºC unless all surfaces of the concrete slabs are protected by thermal insulation
blankets laid immediately after placing and finishing the concrete. The insulation shall be placed before the
temperature of the concrete surface has dropped below 2ºC. It shall be retained for a minimum of 3 days or until
the concrete is assessed to have reached 50% of the specified characteristic 5 N/mm2 compressive strength based on
testing of samples cured adjacent to the placed concrete provided the air temperature is above 0ºC and rising at that
time. Thermal insulation blankets shall be closed cell polyethylene foam sheets, minimum 10 mm thick with a ‘U’
value of 4 watts/m ºC (or K value of 0.04 watts/m Kelvin) or suitable material with an equivalent or lower thermal
conductivity. They shall be sufficiently robust and capable of being held in place against variations in wind and
weather conditions for the necessary curing time.
1046 to 1047 (02/16) Not Used
1048 (02/16) Use of Surfaces by Traffic and Construction Plant

1 (02/16) Construction plant and traffic used on pavements under construction shall be suitable in relation to the
material, condition and thickness of the courses it traverses so that damage is not caused to the subgrade or the
pavement courses already constructed. The wheels or tracks of plant moving over the various pavement courses
shall be kept free from deleterious materials.
2 (02/16) Concrete slabs may be used by traffic when the cube compressive strength is assessed to have reached
25 N/mm2 for pavement surface slabs, or 20 N/mm2 for bases with asphalt surfacing. The method of assessing the
time when this strength is reached shall be as described in Clause 1004.
3 (02/16) In the absence of test data establishing compliance with sub-Clause 2 of this Clause, no vehicle with an
axle loading greater than 2 tonnes shall run on concrete slabs within a period of 14 days after placing the concrete.

Vehicles with rubber tyres with an axle loading less than 2 tonnes, or wheels or tracks of concreting plant, shall
not use any part of a newly constructed pavement within 7 days. The above periods before traffic may run on the
pavement shall be increased if the 7 day cube strength is below that required in the specification. These periods
shall be extended by one day for each night on which the temperature of the layer falls to 0ºC or below.
1049 to 1050 (01/20) Not Used
(01/20) Roller Compacted Concrete Mixtures
1051 (01/20) General Requirements for Roller Compacted Mixtures

1 (01/20) Roller Compacted Concrete (RCC) shall be produced, constructed and tested in accordance with
Clauses 1051 to 1060. Unless otherwise specified in Clauses 1051 to 1060 the works shall conform to the
requirements of this Series.
2 (01/20) The terms listed below shall apply to the RCC Clauses of this specification:
RCC Roller Compacted Concrete
FA fly ash (also known as ‘pulverized fuel ash’)
Gvxx volumetric expansion category
IBI immediate bearing index
Immxx immersion category
IBIxx immediate bearing index category
LA Los Angeles coefficient
NR no requirement
OWC optimum water content
PTR Pneumatic tyred roller
Rc compressive strength
t time (hours) at constant temperature in defining maturity for calculating the construction period
TºC ambient air temperature in defining maturity for calculating construction period
3 (01/20) The strength class for RCC shall be a minimum mean strength C40/50 in accordance with
sub- Clauses 1059.9 to 1059.13.
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4 (01/20) RCC shall be tested in accordance with contract specific Appendix 1/5, Clause 1059 and the test
methods specified in the following Clauses.
5 (01/20) Before work commences, the Contractor shall submit a statement to the Overseeing Organisation that
includes:
(i) the information detailed in the ‘Designation and Description’ clause of the relevant BS EN Standard
for the specified RCC, confirming compliance with the requirements of this Series and contract specific
Appendix 7/1;
(ii) target proportions of constituents, including optimum moisture content;
(iii) mixture design details and results, in accordance with Clause 1060.
(iv) Method statement for the trial length and the main works, in accordance with Clause 1056.

1052 (01/20) RCC Constituents

(01/20) Cement and combinations
1 (01/20) The permitted cement and combinations and the required minimum cement content or combination
content are listed in Table 10/13. RCC mixture proportions used for production shall be based on a laboratory
mixture design procedure in Clause 1060.
TABLE 10/13: (01/20) Minimum Cement or Combination Content for RCC
Cement and combinations Minimum Cement or Combination

Content
(a) Portland cement CEM I conforming to BS EN 197-1 270 kg/m3
(b) Portland-slag cement CEM II/A-S and CEM II/B-S conforming 270 kg/m3
to BS EN 197-1
(c) Portland-fly ash cement CEM II/A-V and CEM II/B-V

conforming to BS EN 197-1
(d) Pozzolanic cement CEM IV/A (V) conforming to BS EN 197-1
See NOTE 1
(f) A BS 8500-2 combination of Portland cement CEM I 270 kg/m3
conforming to BS EN 197-1 with not more than 35% fly-ash for use
as a cementitious component in structural concrete conforming to
BS EN 450-1 (SEE NOTE 2)
NOTE 1:
CEM II/A-V has a maximum siliceous fly ash content of 20%
CEM II/B-V has a maximum siliceous fly ash content of 35%
CEM IV/A (V) has a maximum siliceous fly ash content of 35%
NOTE 2: Siliceous fly ash conforming to EN 14227-4 may be used where it meets the BS 8500-2:2015 Annex A
compressive strength requirements.
For materials required to comply with BS EN 197-1 and/or BS EN 450-1 the Contractor shall submit the relevant
material declarations of performance to the Overseeing Organisation prior to the inclusion of the materials into
the works. The declarations of performance shall demonstrate that the materials meet the requirements for the
specification.
(01/20) Aggregates
2 (01/20) The aggregates used in RCC shall comply with BS EN 13242 and have declared values for the
requirements listed in Table 10/14. The Contractor shall submit the declaration of performance for the aggregate to
the Overseeing Organisation prior to the inclusion of the aggregate in the works. The declaration of performance
shall demonstrate that the aggregate meets the requirements for the specification.

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TABLE 10/14: (01/20) Aggregate Requirements for RCC
Reference Declared Values for aggregate properties

Crushed or broken particles in coarse and fine C100/0 (crushed gravels, manufactured and recycled
aggregate aggregates are not permitted)
Resistance to fragmentation of coarse LA35 or as specified in contract specific Appendix 7/1
aggregate
Magnesium sulfate MS18
Total sulphur content S1 (Where the Contractor is able to provide evidence
of mixture stability over an extended period then the
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Overseeing Organisation may consider the use of higher
limits.)
Acid-soluble sulfate content AS0.2 (Where the Contractor is able to provide evidence
of mixture stability over an extended period then the
Overseeing Organisation may consider the use of higher
limits.)
Fines quality Aggregate passing 425 µm shall be non-plastic as defined by
and tested in compliance with BS 1377-2
1053 (01/20) Storage of RCC Constituents

1 (01/20) Aggregates shall be stored on a firm and clean substrate avoiding contamination with other constituents.
2 (01/20) Cement, and dry FA shall be stored in silos.
3 (01/20) Wet (conditioned) to BS EN 450-1 FA shall have no agglomerations greater than 10 mm size.
4 (01/20) Wet (conditioned) FA shall be stored at the source or at the production location for at least 72 hours
before use, and have a minimum water content of 10%.
1054 (01/20) General Requirements for Production and Layer Construction

(01/20) Production
1 (01/20) RCC shall be produced by the mix-in-plant method using batching by mass, in accordance with
Clause1055. RCC shall be produced in plants which operate a production control quality management system
which follows the guidance in BS EN 14227-1 Annex B.
(01/20) Layer Construction
2 (01/20) Construction of layers and any reworking and reuse shall be completed within the maximum
construction period specified of 30 °C hours. The time shall be measured from the addition of binder to completion
of compaction.
3 (01/20) The construction period, in degree hours, shall be the summation of the products of the average air
temperature above 3ºC (T ºC) and time for each period (t hours): i.e. construction period limit =Σ(T.t). If the air
temperature during the interval, t, fluctuates by more than 4ºC, interval t shall be re-calculated.
4 (01/20) Mixtures shall be batched by mass and paver laid in a single lift. The mixture must be placed using a
paver with a high compaction screed used in accordance with the method demonstrated on the Trial Length. The
paver must be capable of attaining the thickness, lines and grades indicated on the plan, and produce consistent
compaction and compliance with surface level tolerance.

5 (01/20) Laying shall be carried out in a way that avoids segregation and drying of the surface. Curing shall
be undertaken in accordance with sub-Clause 1054.19 as soon as practicable, and the curing compound shall be
applied prior to drying of the surface.
6 (01/20) Compaction of RCC shall be carried out by rollers to achieve the design compaction as demonstrated in
the installation trial.
7 (01/20) The minimum compacted thickness shall be 150 mm.
8 (01/20) Making-up of level after initial compaction is not permitted.
9 (01/20) The edge of hardened RCC material shall be vertical and straight before fresh RCC material is laid
against it within the permitted construction period in sub-Clauses 1054.2 and 1054.3. To ensure adequate bond
between wet joints compaction shall be completed before drying and within the permitted construction period in
sub-Clauses 1054.2 and 1054.3.
10 (01/20) Compaction of RCC layers by a method proven in the Trial Length (or by previous satisfactory
experience on similar projects) to provide the required density and finished profile shall be completed without
drying out and before setting of any part of the layer. Testing, controls and checking of RCC shall be carried out in
accordance with the requirements in Clause 1059.
11 (01/20) On completion of compaction the surface shall be closed, free from ridges, cracks, loose material,
visible voids, ruts, shear planes and other defects.
12 (01/20) Reworking and re-compaction of the layer to achieve the required surface finish shall only be
permitted within the construction period set out in sub-Clauses 1054.2 and 1054.3 and only when the water
content requirements of the reworked material are maintained within the limits stated in the method statement.
If rectification is not completed within the specified time period the defective area shall be removed to the full
thickness of the layer and new mixture machine laid and compacted. The minimum length of full depth replacement
shall be 15m and full width of a traffic lane.
13 (01/20) The exposed uncompacted edges of the longitudinal and transverse day joints shall be cut back to a
minimum 1.5 times the layer thickness.
14 (01/20) Transverse and longitudinal day joints shall be formed before commencing further work by sawing
vertically to the full depth.
15 (01/20) Unless otherwise specified in contract specific Appendix 7/1, all longitudinal joints shall be formed
outside wheel path zones.
16 (01/20) Longitudinal day joints shall be subject to density testing procedures 300mm from the edge. The density
shall be within 95% of that measured for the relevant test section.
17 (01/20) During cold weather:
(i) the temperature of RCC shall not be less than 5ºC at the time of laying;
(ii) RCC shall not be laid on a frozen surface;
(iii) laying of RCC shall cease when the air temperature falls below 3ºC, and laying shall not be resumed
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until the rising air temperature reaches 3ºC.

18 (01/20) In the case of heavy or persistent rain, production shall cease and any laid material shall be compacted
immediately. The above also applies for light rain that results in any roller pick up and/or ponding of water on the
uncompacted RCC.

(01/20) Curing, Protection and Use of Surfaces by Traffic and Construction Plant
19 (01/20) On completion of compaction the layer shall be cured to prevent loss of water by the following.
(i) Application of a bitumen emulsion spray complying with Class C40B4, as specified in the National
Foreword to BS EN 13808 to produce an even and complete coverage of at least 0.2 kg/m2 of residual
bitumen. Before spraying commences, the surface shall be free of all loose material and standing water.
The curing membrane shall be protected from any damage until the construction of the overlaying layer.
(ii) Application shall be by metered mechanical spraying equipment, spray tanker or spraying device to
ensure consistent and adequate cover rate. The machine spread rate shall be calibrated using the method
in BS 594987. The spraying equipment used shall not cause permanent deformation in the surface. For
small or inaccessible areas, application may be by hand held sprayer.
20 (01/20) RCC shall not be trafficked within 7 days of laying unless test specimens made at the time of
construction as required in Clause 1059 and cured under the same conditions as the in-situ RCC achieve 20 N/mm2.
21 (01/20) Should the RCC when trafficked exhibit signs of damage, trafficking shall cease immediately and shall
only resume once the layer has gained sufficient stability to resist damage.
22 (01/20) Surface contamination shall be avoided as far as is practicable and any unavoidable contamination shall
be removed prior to overlaying.
23 (01/20) Before overlaying the finished pavement, high spots shall be removed by fine milling, grinding or bump
cutting. Milling, grinding or bump cutting shall only be carried out after 7 days or when the material has achieved
a strength of 20 N/mm2. No visible damage shall be evident to the upper section of the layer. Damage can include
delamination, cracking and/or spalling of the surface.
24 (01/20) Depressions which exceed the permitted level tolerances under Clause 702 shall be removed and
replaced to the full depth of the layer. Any loose material shall be removed and replaced to the full depth of the
layer. The minimum length of the full depth replacement shall be 15m and full width of a traffic lane.
(01/20) Daily Records
25 (01/20) Daily record sheets shall be included in the Health and Safety file at the completion of the works and
shall include the following information:
(i) suppliers’ details including name/company name and address;
(ii) mixing plant production batch record results (to include: date of production, aggregate content, cement
content, added water, time of completion of mixing, vehicle identification);
(iii) records that demonstrate that the constructed layer is within the permitted tolerances;
(iv) density test measurements;
(v) sample and test locations;
(vi) site construction period records showing the time(s) of arrival, vehicle identification, time(s) of
completion of compaction and time(s) of application of curing membrane;
(vii) construction period calculated in accordance with sub-Clauses 1054.2 and 1054.3;
(viii) weather records at point of laying.
1055 (01/20) Production of Roller Compacted Concrete Mixtures

1 (01/20) The RCC shall be produced in a static mixing plant that batches by mass and mixes in a forced-action
mixer, to produce a homogenous mixture.

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2 (01/20) The mixing plant shall have an automated recording and data collection system.
3 (01/20) A minimum of two aggregate fractions shall be used each with a separate feed hopper.
4 (01/20) RCC shall be transported directly to the point where it is to be laid. RCC shall be protected from the
weather during transit and whilst awaiting tipping.
5 (01/20) Results of routine compressive strength testing and moisture content of aggregate, during normal
production shall be used by the Contractor to make any necessary prudent adjustments to the mix design. The
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Contractor shall inform the Overseeing Organisation of any changes made to the mix design when the change is
implemented.
1056 (01/20) Method Statement and Trial Length

(01/20) Method Statement
1 (01/20) At least 10 days prior to constructing the trial length specified in sub-Clauses 1056.4 to 1056.6 and when
a trafficking trial is required sub-Clauses 1056.8 to 1056.10, the Contractor shall provide a full method statement
to the Overseeing Organisation. The statement shall detail the operatives, plant, materials and procedures for
the construction of the trial length(s) and of the works. The statement shall also include procedures for induced
cracking, and the procedures to be applied during inclement weather, plant breakdowns and other unscheduled
events.
2 (01/20) The method statement shall include the intended mixture proportions with supporting data from trial mix
results carried out in accordance with Clause 1060 and/or historic records to justify the proportions.
3 (01/20) The method statement shall include a sample record sheet for the submission of the data required by
sub-Clause 1054.25
(01/20) Trial length
4 (01/20) Prior to the commencement of the main works, the Contractor shall construct a trial length of at least
800 m2 conforming to the submitted method statement. The trial length shall include a longitudinal joint, transverse
end-of-day joint and a trafficking trial included should immediate trafficking be required. The trial length may be
accepted into the permanent works where the work meets the specified requirements. Where the Contractor can
produce documentary evidence of similar work carried out to this specification during the previous 6 months, the
Overseeing Organisation may allow the works to proceed without the trial length.
5 (01/20) The trial length shall include crack induction at the spacing specified in Clause 1057.1. The effectiveness
of the crack induction procedure used shall be checked within 28 days of construction, by recovering four evenly
spaced 150 mm diameter cores from the line of the induced cracks and assessing each core for compliance with
Clause 1057.1.
6 (01/20) The depth of the crack induction shall be measured versus the requirements of Clause 1057.2. Should
the average depth of the induced cracks be less than the specified depth, then a further demonstration shall be
completed with a revised method to verify compliant full width sections of RCC. Non-compliant sections shall be
removed.
7 (01/20) The mixture constituents, proportions, laying and compaction plant and construction procedures used for
the trial length shall not be changed unless the Contractor lays a further trial length or the changes are agreed by the
8 (01/20) The method statement shall include the proposed method by which the density compliance shall be
achieved.
1057 (01/20) Induced Cracking of RCC

1 (01/20) Transverse cracks shall be induced at 2.5 m longitudinal spacing with a tolerance of ± 300 mm.

2 (01/20) Cracks shall be induced in fresh material after initial compaction. The transverse cracks shall be
induced by grooving the fresh material to form straight vertical grooves not more than 20 mm wide, to a depth of
between one quarter and one third of the layer thickness over the full width of the pavement. Bitumen emulsion
shall be poured or sprayed into the grooves prior to final compaction, to form a crack inducing membrane. The
bitumen emulsion shall comply with Class C40, as specified in the National Annexes to BS EN 13808. During final
compaction of the mixture, the surface of the groove shall be fully closed throughout its full length. The bitumen in
the groove shall be fully encased and remain continuous. The plant and methodology shall be approved as part of
the Method Statement and Methodology trial under Clause 1056.
3 (01/20) The depth of bitumen emulsion membrane in the compacted layer shall be sufficient to reduce the
effective cross-sectional area of the layer by between one quarter and one third, and shall be a minimum depth
specified in the method statement based on the requirements of sub-Clause 1057.2. The effectiveness of the
procedure shall be checked as part of the trial length as described in Clause 1056.
4 (01/20) Longitudinal cracks shall be induced, using the procedure specified in sub-Clause 1057.2, under
each lane line and the edge line between the nearside lane and a hardshoulder. A longitudinal induced crack is
not required between the nearside lane and a 1 metre hard strip. Unless otherwise specified in contract specific
Appendix 7/1, longitudinal joints in all layers shall be situated outside wheel track zones.
5 (01/20) Saw cutting of the hardened RCC as an alternative to induced cracking is not permitted.
1058 (01/20) Roller Compacted Concrete Mixtures

1 (01/20) With the exception of mixture grading RCC mixtures shall comply with BS EN 14227-1, and have
2 (01/20) Aggregates shall comply with the requirements of Clause 1052 and shall have a grading that complies
with a grading envelope in Table 10/15 for a 0/14 or 0/20 aggregate mixture. The aggregate gradings in Table 10/15
exclude the binder constituent proportion.
Table 10/15: (01/20) Aggregate Grading for RCC Mixtures (Excluding binders)
Sieve Percenatge passing by mass

mm minimum maximum minimum maximum
0/14 0/20
31.5 100 100 100 100
20 100 100 90 100
14 86 100 78 94
10 72 95 62 86
8 68 90 56 80
4 52 74 38 59
2 41 61 28 48
1 30 50 19 39
0.5 20 37 15 31
0.25 11 26 9 23
0.125 6 15 6 15
0.063 2 10 2 10
3 (01/20) The mixture strength after immersion shall be at least 80% of the non-immersed strength, when tested in

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4 (01/20) The method of construction shall be in accordance with Clause 1054.

5 (01/20) The laboratory performance of the mix shall comply with the requirement of contract specific
1059 (01/20) Testing, Control and Checking of RCC

(01/20) General
1 (01/20) Tests, controls and checks shall be carried out in accordance with the requirements in Table 10/16 and
the following sub-Clauses at locations stated in contract specific Appendix 1/5. Testing shall be carried out in
compliance with the requirements of Clause 1055 and be undertaken by an organisation accredited in accordance
with BS EN ISO/IEC 17025 for the test method.
(01/20) Sampling
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2 (01/20) Sampling shall be in accordance with BS 1924-1. Where a bulk sample of RCC is taken from a layer,
it shall be taken from the full depth of the layer, used without further mixing, and not combined with other bulk
samples.
(01/20) Measurement of In-situ Wet Density
3 (01/20) With the exception of a trial length the normal method for determining density shall be by
non- destructive methods.
4 (01/20) A correlation shall be established for each mix and each measuring device from the trial length.
5 (11/21) The density shall be measured routinely at a distance of 0.8 to 1.2m from the edge of the slab if a spot
measurement process is chosen with a minimum frequency of five readings per laid area of 1000 m2.
6 (01/20) Density measurements shall be taken at the locations at which material is placed that has been sampled
for cube testing.
7 (01/20) The average in-situ wet density of an area 1000 m2 specified in sub-Clause 1059.6 shall be not less than
95% of the average wet density of the test specimens taken to determine the laboratory mechanical performance of
the same area.
8 (01/20) The result of each single determination of in-situ wet density shall be not less than 92% of the wet
density of the RCC cube made with the sample from the same location.
(01/20) Laboratory Mechanical Performance
9 (01/20) A bulk sample of RCC shall be taken from each location specified for the determination of in-situ wet
density, as sub-Clause 1059.5
10 (01/20) For conformity assessment the 28 day strength shall be determined in accordance with BS EN 13286-41
on specimens made from each bulk sample in accordance with BS EN 13286-51, using vibratory compaction.
The minimum-mean average strength of RCC shall be C40/50, which shall be
a) 40 MPa as determined from 150mm diameter 2:1 cylinder specimens, or
b) 50 MPa where determined for either 150mm cubes or 150mm diameter 1:1 cylinder
11 (01/20) The requirement specified in contract specific Appendix 7/1 shall be deemed to be satisfied if the
average compressive strength of the group of specimens is equal to or greater than C40/50 and no individual test
result is less than C27/34N/mm2.

TABLE 10/16: (01/20) Requirements for Testing, Control and Checking of RCC
Test/control/check Test frequency Test reference

Constituents Aggregates – BS EN 13242 Declaration of –
performance to be submitted for each aggregate
used prior to the commencement of RCC work.
Cement – Declaration of performance to be

submitted prior to the commencement of RCC
work.
Slag – Certificates to be provided weekly

to confirm the declared values required by
BS EN 14227-2, Clause 5.
Fly ash – Certificates to be provided weekly to

confirm compliance with the requirements of
BS EN 14227-4.
Other constituents (that do not fall under the

scope of the Construction Products Regulation)
– certificates to be provided weekly to confirm
compliance with the specification agreed as part
of the factory production control system for the
mixture.
Batching records for Continuously using the automated surveillance and –
‘mix-in-plant’ method of data collection system
construction using batching
by mass
Aggregate grading Not less than 2 per day BS EN 933-1
Water content at final Not less than 2 per day BS 1924-2, Clause 1.3
compaction
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In-situ wet density 1 per 1000 m2 or part thereof laid each day Sub-Clause 1059.5
(measured at the locations detailed in
sub- Clause 1059.5)
Laboratory mechanical 1 per 1000 m2 or part thereof laid each day As required by Table 10/17
performance (with test specimens prepared from a bulk sample
taken from each of the locations detailed in
sub- Clause 1059.5)
Strength after immersion in Laboratory mixture design procedure Sub-Clause 1060.7
water

Table 10/17: (11/21) Laboratory Mechanical Performance Testing Requirements for RCC
Clause Mixture Curing regime Curing Test method Age at test

temperature
28 days
or other age
BS EN 12390 RC – agreed by the
1059.5 RCC 20°C
Water at 20ºC BS EN 13286-41 Overseeing
Organisation
(see Note)
NOTE:
For laboratory mechanical performance the requirement specified in contract specific Appendix 7/1 shall be deemed to be satisfied if the
average 28 day compressive strength of the group of specimens is equal to or greater than C40/50 and no individual test result is less than
C27/34N/mm2. Alternatively, RCC may be assessed on the basis of 7 day strength (or other agreed age) provided that a robust correlation
is established between the 7 day and 28 day strength, using representative samples of the aggregates and cement used in the works.
12 (01/20) Compliance of the area specified in sub-Clause 1059.5 shall be assessed using the results for test
specimens that are cured and tested in accordance with Table 10/17 using compression testing to the class of
mechanical performance specified in contract specific Appendix 7/1.
For the purposes of this specification, any reference to ‘characteristic strength’ in BS EN 14227-1 shall be
superseded by the requirements of this sub-Clause.
1060 (01/20) Laboratory Mixture Design Procedure

1 (01/20) Prior to the commencement of the work or any change in mixture constituents, the Contractor shall
determine the target proportions of the constituents, including water, for the specified RCC, based on the mixture
design procedure described in this Clause.
2 (01/20) The mixture design procedure shall determine the properties of the RCC at a minimum of 3 values of
binder contents, and a minimum of 2 values of water content for each value of binder content.
3 (01/20) The optimum water content (owc) and maximum bulk density of the mixture shall be determined using
the vibrating hammer method detailed in BS EN 13286-4.
4 (01/20) RCC mixtures shall be classified in accordance with BS EN 14227-1 by compressive strength with
specimens manufactured in accordance with EN 13286-41, at the age of 28 days.
5 (01/20) In order to establish strength development characteristics, compressive strength shall be reported at
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7 and 28 days.
6 (01/20) The strength after immersion in water shall be assessed in accordance with sub-Clause 1060.7. The test
temperature shall be (20 ± 2) °C.
(01/20) Resistance to Water – Strength After Immersion
7 (01/20) The strength after immersion in water shall be assessed by comparing the average strength and condition
of:
(i) 3 specimens initially cured in a sealed condition for 14 days at the test temperature; and then removed
from their moulds and immersed in aerated water for 14 days at the same test temperature;
(ii) 3 specimens cured in a sealed condition for 28 days at the same test temperature; and then removed from
their moulds and immersed in aerated water for 14 days at the same test temperature.
The immersed specimens shall be unconfined and have water in contact with all surfaces. On completion of the
immersion stage of the test the specimens shall show no signs of cracking or swelling.

8 (01/20) The test temperature shall be (20 ± 2) ºC.

(11/21) Maintenance of Concrete Pavements
1080 (11/21) Early Strength Concrete for Slab Replacement

(11/21) General
1 (11/21) Early strength concrete shall conform to the requirements of contract specific Appendix 7/1 or either:
(i) BS 8500-2 and BS EN 206 and meet the requirements of sub-Clauses 1001.3 for cement, 1001.6 to
1001.9 for aggregate, 1001.12 chloride class, 1001.13 acid soluble sulfate and 1001.14 for total sulfur.
Or
(ii) Proprietary concrete conforming to BS 8500-2 and alternative materials shall be certified in accordance
with sub-Clauses 104.15 and 104.16 of the specification. The certification shall include the assessment
of a 2-year trial installation that demonstrates defect free performance and a declaration of the traffic
levels to which the product has been assessed. Defects to be assessed shall include: Surface Texture
Retention, Cracking, Spalling and Loss of Material.
2 (11/21) The minimum strength class shall be C40/50 and maximum free water content (w/c) 0.45.
3 (11/21) The concrete shall not be air entrained.
4 (11/21) Early strength concrete shall be designed to achieve a minimum compressive strength of 25 MPa at
4 hours or earlier.
5 (11/21) The requirements of Clause 1004 shall not apply to this Clause.
(11/21) In situ strength
6 (11/21) The development of in situ concrete strength shall be based on the relationship of compressive strength
to maturity. Detailed estimates of the development of concrete properties may be based on one of the following:
(i) maturity calculation from temperature measurements taken at a maximum depth of 75 mm below the
surface;
(ii) maturity calculation based on the daily average air temperature;
(iii) non-destructive technologies to monitor strength gain.
(11/21) Preparation
7 (11/21) Grout for new dowel and tie bars shall be set before the slab is poured.
1081 (11/21) Bay Replacement

1 (11/21) Where individual bays are to be replaced they shall match the design thickness of the original concrete
including reinforcement if originally included as described in contract specific Appendix 7/23
2 (11/21) The replacement bay shall be connected to the surrounding concrete with new dowel and tie bars at
transverse and longitudinal joints in accordance with Clause 1011.
3 (11/21) Grooves shall be formed in accordance with Clause 1013.
4 (11/21) A surface texture as specified in Clause 1026 shall be applied and a curing compound as specified in
Clause 1027.
5 (11/21) Joints surrounding the new bay shall be sealed as specified in Clause 1016.

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1082 (11/21) Full Depth Repairs

(11/21) General
1 (11/21) Full depth repairs shall be repairs which will require full depth reinstatement of the concrete slab
in-accordance with this Clause and as described in contract specific Appendix 7/24. Repairs may also require
reinstatement of subbase.
2 (11/21) Full width repairs to jointed pavements (JUC and URC) shall be repairs over the full width of a bay or
bays. Part width repairs shall be repairs over part of the width of a bay or bays. A bay shall be that portion of the
concrete pavement bounded by adjacent longitudinal and transverse joints.
3 (11/21) For continuously reinforced concrete slabs (CRCP or CRCB) the edge of the repair shall be not less than
0.5 m from the nearest crack and not less than 3 m from a transverse construction joint at ground beam anchorages.
Where this and the provisions of sub-Clause 3 of this Clause would otherwise require a longitudinal repair joint
within 1 m of the existing longitudinal joint or edge, the repair shall be extended to align with that longitudinal
joint or edge.
(11/21) Part Width Repairs
4 (11/21) Providing all the following criteria are met, part width repairs may be carried out in accordance with
sub-Clause 3 of this Clause:
(i) the transverse width of the repair shall not exceed 45% of the width of the slab under repair; and
(ii) the longitudinal joint which would be formed by the repair shall not occur within the wheel track; and
(iii) the minimum transverse width of the repair shall not be less than 1.0 m.
5 (11/21) If the criteria in sub-Clause 4 and those in sub-Clause 3 of this Clause cannot be met, a full-width repair
shall be made in-accordance with this Clause.
(11/21) Full Width Repairs
6 (11/21) For full width repairs the following criteria shall apply unless otherwise specified in contract specific
Appendix 7/24:
(i) Repair lengths which do not replace an existing transverse joint shall be constructed with two transverse
contraction joints and the longitudinal joint shall have tie bars in repair lengths which are greater than
1 metre.
(ii) Repair lengths which replace a single existing transverse joint shall be constructed with two transverse
joints: one expansion and one contraction. The new expansion joint shall be formed at the end which
will have the shortest longitudinal distance between this joint and the joint in the adjacent lane(s). The
longitudinal joint(s) between the existing joint(s) and the new expansion joint shall be constructed
without tie bars and shall have 5 mm thick compressible foam within the joint for the full depth of the
concrete slab. The longitudinal joint between the new contraction joint and the joint in the adjacent
bay(s) shall be constructed with tie bars where the exposed length so permits.
(iii) Repair lengths which replace more than one existing transverse joint shall be constructed with transverse
joints to match expansion and contraction joints in the adjacent bay(s). Where the repair length does
not replace an existing expansion joint, one end joint shall be formed as an expansion joint. Except for
the end joints all transverse joints shall be formed to coincide with the existing transverse joints. Where
one end joint is an expansion joint, the longitudinal joint(s) between the existing joint(s) and the new
expansion joint shall be constructed without tie bars and shall have 5 mm thick compressible foam
within the joint for the full depth of the concrete slab. All other longitudinal joints shall be constructed
with tie bars.
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(11/21) Repair Work

7 (11/21) Any replacement dowels and tie bars shall comply with the requirements of Clauses 1011 and 1012
respectively. Epoxy mortar shall be to the manufacturer’s recommendation for this specific application. Where
repairs straddle a movement joint with an adjacent slab, tie bars shall be omitted and the joint between the slabs
debonded to ensure that movement patterns are not restricted.
8 (11/21) A surface texture as specified in Clause 1026 shall be applied and cured as specified in Clause 1027.
1083 (11/21) Thin Bonded Repairs

(11/21) General
1 (11/21) Thin bonded repairs shall be as described in contract specific Appendix 7/25
(11/21) Materials
2 (11/21) Cement mortar shall be used for depths less than 20 mm and fine concrete for greater depths. Resin
mortar may be used for patch repairs where insufficient time for adequate curing of a cementitious mortar exists.
3 (11/21) The cements, aggregates, admixtures and water shall comply with Clause 1001. Mortars or fine concrete
shall be within the limits of 0/4 (CP), 0/4 (MP), 0/2 (MP) or 0/2 (F/P) of BS EN 12620. Coarse aggregate for fine
concrete shall be (4/10) single sized aggregate complying with BS EN 12620. All aggregates shall be of the same
type as the aggregate in the original concrete, so that they have the same thermal properties. Filler and aggregate
for resin mortars shall be prepacked in the correct proportions and mixed with the resin all in accordance with the
4 (11/21) The proportions of cement, admixtures, additives to water and aggregates shall be sufficient to provide
high early strength mortar or fine concrete or concrete complying with Clauses 1001, 1003 and 1004. For cement
mortar the fine aggregate to cement ratio shall not be greater than 3. For resin mortar the fine aggregate content
shall be in accordance with the manufacturer’s requirements in the range between 7 and 11 to 1 of resin. Early
strength concrete shall have a design compressive strength of 25 MPa at 4 hours or earlier. For thin bonded repairs
using early strength concrete, air entrainment is not required.
1084 (11/21) Shallow Repairs – Early Strength Concrete

(11/21) General
1 (11/21) The maximum depth of repair to a concrete slab shall not exceed 33% of slab thickness and be as
described in contract specific Appendix 7/26
2 (11/21) The maximum aggregate size in the concrete shall not exceed the thickness of the repair divided by 2.5.
3 (11/21) The repair shall not span an existing crack or joint.
4 (11/21) Early strength concrete shall conform to the requirements of contract specific Appendix 7/1 or either.
(i) BS 8500-2 and BS EN 206 and meet the requirements of sub-Clauses 1001.3 for cement, 1001.6 to
1001.9 for aggregate, 1001.12 chloride class, 1001.13 acid soluble sulfate and 1001.14 for total sulfur.
Or
(ii) Proprietary concrete conforming to BS 8500-2 and alternative materials shall be certified in accordance
with sub-Clauses 104.15 and 104.16 of the specification. The certification shall include the assessment
of a 2-year trial installation that demonstrates defect free performance and a declaration of the traffic
levels to which the product has been assessed. Defects to be assessed shall include: Surface Texture
retention, Cracking, Spalling and Loss of Material.

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52
5 (11/21) The minimum strength class shall be C40/50 and maximum free w/c 0.45.
6 (11/21) The concrete shall not be air entrained.
7 (11/21) The requirements of Clause 1004 shall not apply to this Clause.
(11/21) In situ strength
8 (11/21) Early strength concrete shall have a design strength of 25 MPa at 4 hours.
9 (11/21) The method to determine the minimum strength of the concrete may be based on the relationship of
compressive strength to maturity. Detailed estimates of the development of concrete properties may be based on
one of the following:
(i) maturity calculation from temperature measurements taken at a maximum depth of 75 mm below the
surface;
(ii) maturity calculation based on the daily average air temperature; and
(iii) temperature-matched curing.
1085 (11/21) Shallow Repairs – Polymeric Materials

1 (11/21) The maximum depth of repair of a concrete slab shall not exceed 33% of slab thickness and as described
2 (11/21) All polymeric repair materials used for shallow repairs shall be certified in accordance with sub-Clauses
104.15 and 104.16 of the specification for use at declared traffic levels.
3 (11/21) All polymeric repair materials shall undergo an independently verified SIPT (System Installation
Performance Trial).
4 (11/21) The SIPT shall determine that the following requirements are met:
(i) Repair to remain intact, un-cracked and visibly bonded to surrounding concrete for a period of two
years;
(ii) A statement as to the maximum traffic level for which the material has been assessed;
(iii) A statement as to the maximum repair thickness to which the material has been assessed.
(iv) The polymeric repair material to retain after 2 years a minimum Skid Resistance Value (SRV) of 60
when measured in accordance with BS 7976; and
(v) The difference in surface level between the material and the concrete to either side to be no more than
5mm at the time of installation and after 2 years.
5 (11/21) The manufacture’s guidance shall be followed with regards to preferred aggregate size which will be
related to width and depth of repair.
6 (11/21) A primer shall be used if recommended by the manufacturer.
7 (11/21) The maximum thickness of the repair shall not exceed the product manufacturer’s recommendation.
8 (11/21) The minimum SRV before opening to traffic shall be 60 when measured in accordance with BS 7976.

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1086 (11/21) Not Used
1087 (11/21) Overlays to Concrete Pavements - Asphalt

1 (11/21) If the existing concrete pavement is unsound (as defined in CD 227 (DMRB)) it shall be repaired or
strengthened prior to the installation of an asphalt overlay that is less than 150mm thick as described in contract
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2 (11/21) A bond coat complying with Clause 920 shall be applied to the concrete surface at a minimum of
0.35 kg/m2 of residual binder.
3 (11/21) If an asphalt overlay between 25 mm and 100 mm thick is placed upon a jointed concrete pavement
without any systems intended to supress reflective cracking, then the overlay shall be saw cut and sealed in line
with joints in the concrete below in accordance with Clause 713 as described in contract specific Appendix 7/14 .
4 (11/21) The minimum length of any patch shall be 15m in accordance with Clause 946.
5 (11/21) Bond coat shall be fully broken before application of asphalt overlay in accordance with BS 594987.
1088 (11/21) Grouting Under Slabs

(11/21) General
1 (11/21) Under slab grouting consists of the insertion of a flowable material under pressure or vacuum beneath a
concrete slab to fill voids and restore full support.
2 (11/21) Under slab grouting shall be as described in contract specific Appendix 7/28
3 (11/21) A detailed investigation shall be conducted by the Contractor in accordance with CS 229 (DMRB) prior
to undertaking under slab grouting to accurately detect the presence of voiding and loss of support unless otherwise
instructed in the contract specific Appendix 7/28.
(11/21) Under Slab Grouting Application
4 (11/21) The material chosen for under slab grouting shall consist of a polymeric or cement based grout.
5 (11/21) The grout shall be able to penetrate the in situ voids while having the strength and durability to
withstand pressures caused by traffic, moisture and temperature changes.
6 (11/21) The Contractor shall determine the optimal method and locations of grout insertion holes, which will
form the basis of a grouting insertion plan.
7 (11/21) The grout insertion plan shall identify the following:
(i) the flowability of the grout material being used,
(ii) the pavement construction type;
(iii) transverse joint spacing (jointed pavements);
(iv) size and shape of the detected void;
(v) location of cracks and joints near the void;
(vi) the location of wheel track zones; and
(vii) the adjacent pavement conditions.
8 (11/21) The grouting insertion plan that shall be submitted to the Overseeing Organisation, when requested, in
advance of the works commencing.
9 (11/21) Grout insertion holes shall be drilled to avoid any services using a method that produces clean holes
with no surface spalling or breakouts on the underside of the slab.

10 (11/21) Upon completion of the grouting, any surplus grout shall be removed from the surface of the slab and
the holes cleaned out and made good with resin or cementitious mortar. Any resin grout which cannot be removed
from the surface of the slab may be blinded with calcined bauxite if this can be done before the grout has gelled.
11 (11/21) Prior to the carriageway being trafficked, the minimum curing period as defined by the product
manufacturer shall elapse.
(11/21) End Performance
12 (11/21) A Falling Weight Deflectometer (FWD) survey shall be conducted by the Contractor upon completion of
treatment at transverse joint locations in accordance with CS 229 (DMRB). The under-slab grouting shall achieve:
(i) Load Transfer Efficiency of ≥75% on 90% of all joints treated; and
(ii) Void Intercept ≤15 on 90% of all joints treated.
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13 (11/21) Steps between existing and grouted slabs shall not exceed 5 mm upon completion of treatment in the
wheel track zones as measured by a 2 m straight edge and wedge.
1089 (11/21) Not Used
1090 (11/21) Crack Sealing

1 (11/21) Crack sealing shall be carried out as described in contract specific Appendix 7/11 using a polymeric
compound designed for the purposes of flexibly sealing cracks in concrete road pavements, certified in accordance
with sub-Clauses 104.15 and 104.16 of the specification for use at the declared traffic levels.
2 (11/21) Only inlaid systems are permitted.
3 (11/21) Minimum inlay thickness shall be in accordance with the manufacturer’s requirements.
4 (11/21) The Contractor shall declare the minimum time between installation of repair material and trafficking.
5 (11/21) The Contractor shall declare any limiting ambient temperature or road temperature or weather conditions
for the installation of the sealant.
6 (11/21) The sealing product shall be installed in accordance with the manufacturer’s instructions.
7 (11/21) Crack sealing materials shall undergo an independently verified SIPT (System Installation Performance
Trial) as part of the certification requirements in sub-Clause 1.
8 (11/21) The SIPT shall determine that the following requirements are met:
(i) repair to remain intact, un-cracked and visibly bonded to surrounding concrete for a period of two years;
(ii) a statement as to the maximum traffic level for which the seal has been assessed;
(iii) a statement as to which orientation cracks (transverse, longitudinal or diagonal) the seal has been
assessed for;
(iv) the sealant to retain after 2 years a minimum Skid Resistance Value (SRV) of 60;
(v) the difference in surface level between the sealant and the concrete to either side to be no more than
5 mm (increased to 10 mm if ambient temperatures less than 10°C) at the time of installation and after
2 years.

1091 (11/21) Crack Stitching

1 (11/21) Stitched crack repairs shall be as described in contract specific Appendix 7/29 and be either:
(i) Type 1 - Staple Tie Bar Repair; or
(ii) Type 2 - Diagonal Tie Bar Repair.
2 (11/21) For Type 1 crack repairs, slots 25 - 30 mm wide by 470 mm long at 600 mm centres and at right angles
to the line of the crack shall be chased out to a depth such that, when bedded, the tie bars lie between ⅓ and ½ of
the depth of the slab below the surface.
3 (11/21) For Type 2 crack repairs drilling points shall be at a distance from the crack equivalent to the depth of
the slab, at 600 mm intervals along the crack with alternate points on opposite sides of the crack.
1092 (11/21) Longitudinal Diamond Grinding

(11/21) General
1 (11/21) This specification provides requirements for the longitudinal diamond grinding (LDG) of a Pavement
Quality Concrete surface to restore texture, skid resistance and ride quality on structurally sound (as defined in
CD 227 (DMRB)) concrete pavements and as described in contract specific Appendix 7/30.
(11/21) Preparation
2 (11/21) Where concrete repairs are required they shall be undertaken in accordance with Clauses 1082 to 1091
of the specification and contract specific Appendices appropriate to the repairs required prior to the application of
LDG.
3 (11/21) Any transverse steps between adjacent slabs shall be reduced to a maximum of 10 mm prior to the
application of LDG by grouting under slabs to Clause 1089.
4 (11/21) Where the joint and loops seals are no longer effective or are damaged they shall be replaced prior
to the diamond grinding as described in contract specific Appendix 7/30 and installed in a recessed condition in
(11/21) Equipment
5 (11/21) Grinding shall be accomplished using diamond blades mounted on a self-propelled machine designed
specifically for diamond grinding of the pavement.
6 (11/21) The equipment shall weigh a minimum of 16,000 kg including the grinding head and be of a size that
will grind a strip at least 1200 mm wide in a single pass.
7 (11/21) The effective wheel base of the machine shall be no less than 3.6 m. The effective wheel base is defined
as the distance from the front wheel assembly transverse pivot point to the transverse pivot point of the profile/
depth control/ground drive wheels.
8 (11/21) Diamond grinding equipment uses diamond blades mounted in series on a cutting head. The width of the
cutting head shall be at least 1200 mm.
9 (11/21) The spacing of the diamond blades shall be selected based on the hardness of the aggregates in the
existing concrete, as described in contract specific Appendix 7/30, to achieve the required end performance and the
profile shown in Figure 10/1.

(11/21) Figure 10/1 Schematic of grinding surface texture
10 (11/21) The maximum depth of the grooves shall be 5 mm.

11 (11/21) The width of the grooves shall be between 2 mm and 4 mm.
12 (11/21) The spacing of the grooves (land area) shall be between 1.75 mm and 3.25 mm.
13 (11/21) The machine shall be fitted with a speed control device that automatically adjusts forward travel speed
to maintain a constant load on the cutting drum.
14 (11/21) The equipment shall have a positive means of vacuuming the grinding residue from the pavement
surface leaving the surface in a clean, near dry condition.
(11/21) Longitudinal Diamond Grinding Operation
15 (11/21) The direction of grinding shall be the direction of flow of traffic
16 (11/21) The equipment shall grind the pavement to the specified depth. Use of the equipment shall not be so
destructive such that it causes excessive ravelling, aggregate fracture, spalling, or disturbance or damage to the
transverse or longitudinal joints.
17 (11/21) The grinding shall produce a uniform finished surface.
18 (11/21) Grinding shall be accomplished in a manner that eliminates joint or crack faults so there is no more than
a 5mm differential between the adjacent sides of the joints and cracks.
19 (11/21) Transitioning shall be provided to auxiliary or ramp lanes as required from the mainline edge to
maintain or provide continuity of drainage and acceptable ride quality and skidding resistance characteristics.
20 (11/21) Grinding shall be performed continuously along a traffic lane to produce a uniform homogeneous finish.
(11/21) Performance Requirements
21 (11/21) Longitudinal Diamond Grinding shall achieve a minimum road/tyre noise reduction of 3 dBA when
compared with the surface before treatment as measured by Proximity (CPX) method averaged over 100m, as
standardised in ISO 11819-2. The Contractor shall provide this testing prior to treatment and within 3 months of
completion of treatment.
22 (11/21) Longitudinal Diamond Grinding shall achieve a ride quality improvement so that all the treated surface
meets a minimum of category 2 for 10m and 30m enhanced longitudinal profile variance (eLPV) as defined in
DMRB CS 230 Table E/1.8a, E1.8b or table E/1.8c as appropriate to be measured within 12 months of installation
by network surveys.
23 (11/21) Longitudinal Diamond Grinding shall achieve a minimum SCRIM measured skid resistance equivalent
to the investigatory level for the site as defined in CS 228 (DMRB) to be measured within 12 months of installation
by network surveys.
24 (11/21) The finished surface of the treated pavement shall comply with the requirements of sub-Clauses 702.5 to
702.9.
25 (11/21) A minimum of 95 percent of any 20m2 section of pavement surface shall be textured.
26 (11/21) Failure to meet the performance requirements will require re-treatment of the areas not achieving the
requirements.

57
1093 (11/21) Fine Milling

(11/21) General
1 (11/21) This specification provides requirements for the fine milling (FM) of a Pavement Quality Concrete
surface to restore texture and skid resistance on structurally sound (as defined in CD 227 (DMRB)) concrete
pavements and as described in contract specific Appendix 7/31.
(11/21) Preparation
2 (11/21) Where concrete repairs are required they shall be undertaken in accordance with Clauses 1082 to 1091
of the specification and contract specific Appendices appropriate to the repairs required prior to the application of
FM.
3 (11/21) Any transverse steps between adjacent slabs shall be reduced to a maximum of 20 mm prior to the
application of FM.
4 (11/21) Where the joint and loops seals are no longer effective or are damaged they shall be replaced after FM
and installed in a recessed condition in compliance with Clause 1017.
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(11/21) Equipment
5 (11/21) FM shall be accomplished using a planing machine fitted with diamond tip picks at a maximum spacing
of 6 mm.
6 (11/21) FM shall be performed continuously along a traffic lane to produce a uniform homogeneous finish.
(11/21) Performance Requirements
7 (11/21) Surface macro-texture of the textured surface shall be measured using the volumetric patch method
described in BS EN 13036-1.
8 (11/21) Texture depth shall be measured by 10 individual measurements taken at approximately 5 m spacing
along a diagonal line across the lane width. Unless otherwise specified in contract specific Appendix 7/31, at least
one set of 10 measurements shall be made for each 250 m section of carriageway lane. The average texture depth
for each set of 10 individual measurements and the average texture depth of each 1,000 m section (or complete
carriageway lane where this is less than 1,000 m) shall be a minimum of 0.7mm and a maximum of 1.2mm unless
otherwise specified in contract specific Appendix 7/31
9 (11/21) Fine Milling shall achieve a minimum SCRIM measured skid resistance equivalent to the investigatory
level for the site as defined in CS 228 (DMRB) to be measured within 12 months of installation by network
surveys.
10 (11/21) The finished surface of the treated pavement shall comply with the requirements of sub-Clauses 702.5 to
702.9.
11 (11/21) A minimum of 95 percent of any 20m2 section of pavement surface shall be textured.
Amendment – November 2021 58F

SERIES 1100
KERBS, FOOTWAYS, CYCLEWAYS AND
PAVED AREAS
Contents
1100 (02/21) Kerbs, Footways, Cycleways 1118 (02/21) Polymeric Kerbs, Islands and
and Paved Areas General 2 Lane Separators 15
1101 (02/21) Precast Concrete and Natural 1119 (02/21) Footways, Cycleways and Paved
Stone Kerbs, Channels, Edgings and Areas – Natural Stone Setts 16F
Quadrants2
1102 (02/21) In-Situ Asphalt Kerbs 4
1103 In-Situ Concrete Kerbs, Channels and
Edge Details 4
1104 (02/21) Footways, Cycleways and
Paved Areas – Precast Concrete Flags
and Natural Stone Slabs 6
1105 (02/21) Footways, Cycleways and Paved
Areas – Bituminous Mixtures 7
Areas – In-situ Concrete 7
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Areas – Concrete Block Paving 7

Areas – Clay Pavers 8
1109 (02/21) Grass Concrete Paving 9
1110 (02/21) Access Steps 9
1111 Installation of Unbound and
(02/21)
Hydraulically Bound Mixtures 11
1112 (02/21) Not Used 11
1113 (02/21) End Product Specification for
Compaction of Bituminous Layers 11
1114 Horizontal Alignments and
(02/21)
Surface Levels of Pavement Courses
and Formation 12
1115 (02/21) Surface Regularity of
Bituminous Surfaced Footways,
Cycleways and Paved Areas 13
1116 (02/21) Rectification of Bituminous
Surfaces of Footways, Cycleways or
Paved Areas 14
Areas – Permeable Block Paving 14

Specification for Highway Works Kerbs, Footways, Cycleways and Paved Areas
KERBS, FOOTWAYS, CYCLEWAYS AND PAVED

AREAS
1100 (02/21) Kerbs, Footways, Cycleways and Paved Areas General
2 (02/21) The term cycleways in this Series shall exclude those that are of integral construction with the vehicle
carriageway. Cycle lanes are not included.
1101 (02/21) Precast Concrete and Natural Stone Kerbs, Channels, Edgings and Quadrants
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1 (02/21) Precast concrete kerbs, channels, edgings and quadrants shall conform to BS EN 1340 and meet the
minimum required performance/class in Table 11/1.
Table 11/1 (02/21) Minimum Requirements for Precast Concrete Kerbs, Channels, Edgings and Quadrants
Property Minimum Required Performance/Class when tested in accordance with BS

EN 1340
Bending Strength Class 2
Slip/Skid Resistance Unpolished skid resistance value (USRV) of 45
Durability (Bending Strength) Class 2
Weathering Resistance Class 3
Abrasion Class 4
2 (02/21) Natural stone kerbs, channels, edgings and quadrants shall conform to BS EN 1343 with coarse textured
surfaces and meet the minimum required performance/class in Table 11/2.
Table 11/2 (02/21) Minimum Requirements for Natural Stone Kerbs, Channels, Edging and Quadrants
Property Minimum required performance/class for natural stone when tested in

accordance with BS EN 1343
Flexural strength Value from BS EN 1343
Slip/skid resistance Unpolished skid resistance value (USRV) of 45
Durability (retained flexural 98% after 56 cycles+
strength)
Weathering resistance (retained 98% after 25 cycles with de-icing salt
flexural strength)
Water absorption (max) 0.3% or 0.2% as described in contract specific Appendix 11/1
3 (02/21) The dimensions and type designations of precast concrete kerbs, channels, edgings and quadrants shall
be as detailed in contract specific Appendix 11/1.
4 (02/21) Precast concrete kerbs, channels, edgings and quadrants shall be laid and bedded in accordance with
BS 7533-6 for raised kerbs and quadrants or in accordance with BS 7533-4 for flush kerbs and channels as detailed
in contract specific Appendix 11/1, either:
(i) on a race of fresh concrete;
(ii) bedded onto a mortar race on top of an edge beam of hardened concrete class C25/30;

(iii) onto a mortar bedding on a carriageway base; or,

(iv) suitably bedded on the surface layer of the road pavement
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5 (02/21) All precast units laid on a mortar bed or bedded onto plastic concrete shall be backed with fresh
concrete. The backing is shown in BS 7533-7 Annex D.
6 (02/21) Concrete for bedding on a race and backing shall be strength class C6/8 or standardised prescribed
concrete ST1 to Clause 2602.
7 (02/21) Concrete for mortar bedding shall be C.4 Type A to BS 7533-7.
8 (02/21) Precast concrete kerbs, which are to be bonded to the pavement surface shall be bonded using a
proprietary synthetic resin compound or with a proprietary modified strengthened mortar.
9 (02/21) Proprietary synthetic resin compounds and proprietary modified strengthened mortars shall be
specifically designed for this purpose, resilient and compatible with the pavement materials.
10 (02/21) Proprietary bonding materials shall be used in accordance with the manufacturer’s recommendations for
this specific application.
11 (02/21) Precast concrete kerbs to be bonded to the pavement surface shall not be less than 100 mm in width at
the base.
12 (02/21) The height of precast concrete kerbs to be bonded to the pavement surface shall not exceed their width.
13 (02/21) Precast concrete kerbs bonded to the pavement surface shall be bonded to the pavement surface over
their full width.
14 (02/21) The back of precast concrete kerbs bonded to the pavement surface shall not be less than 100 mm from
the unsupported pavement edge.
15 (02/21) Precast concrete kerbs bonded to the pavement surface shall be capable of withstanding a static push-off
load of 10 kN/m applied parallel to the pavement surface at right angles to the kerb.
(02/21) Joints
16 (02/21) Joints shall be provided in kerbs, channels, edgings and backing, which are laid on or adjacent to
concrete pavements to coincide with the pavement transverse contraction and expansion joints.
17 (02/21) Joints in kerbs, channels, edgings and backing coinciding with joints in concrete pavements shall be the
same width as the joint sealing grooves of the pavement.
18 (02/21) Joints in kerbs, channels, edgings and backing coinciding with joints in concrete pavements shall be
caulked and sealed as detailed in Clauses 1016 and 1017.
19 (02/21) Concrete foundations to kerbs, channels and edgings laid adjacent to a concrete pavement shall be
provided with joint filler board complying with Clause 1015 placed vertically through the full extent of the concrete
foundation at positions coinciding with the pavement joints.
20 (02/21) At expansion joints in bridge decks, the kerb joints shall be as detailed in contract specific
Appendix 11/1.
(02/21) Geometry
21 (02/21) For curves of radius 15 m or less, kerbs of appropriate radius shall be used as per BS EN 1340.
(02/21) Surface Levels and Horizontal Alignments
22 (02/21) The surface level of units of kerb, channel, edging and quadrant shall not deviate from the design
level ± 6 mm, nor the longitudinal surface regularity deviate more than 3 mm when checked with a 3 m straight
edge.
23 (02/21) Horizontal alignment of kerbs shall meet the requirements of Clause 702.

1102 (02/21) In-Situ Asphalt Kerbs

1 (02/21) The materials for, and making and placing of in-situ asphalt kerbs shall meet the requirements of
BS 5931. In addition, in-situ asphalt kerbs shall be laid by a machine capable of producing a dense, smooth-
surfaced kerb to true line and level.
2 (02/21) A bond coat shall be applied to the receiving surface prior to the kerb laying operation unless kerb
formation is integral part of the creation of the asphalt surface and a hot joint is achieved.
3 (02/21) The bond coat shall meet the requirements of and be applied in accordance with Clause 920 including
surface preparation.
4 (02/21) In situ tensile bond testing shall be carried out in accordance with Type 3 specimen protocol to
BS EN 13596.
5 (02/21) The in-situ tensile bond between the kerb, the bond coat and the substrate shall not be less than 0.5 MPa
when tested at 23°C during dry weather conditions.
6 (02/21) Kerbs shall be constructed to the dimensions detailed in contract specific Appendix 11/1 with a width of
not less than 500 mm if applied to an existing cold asphalt surface.
(02/21) Joints
7 (02/21) Joints shall be provided in kerbs which are laid on or adjacent to concrete pavements to coincide with
the pavement transverse contraction and expansion joints.
8 (02/21) Joints in kerbs coinciding with joints in concrete pavements shall be the same width as the joint sealing
grooves of the pavement.
9 (02/21) All joints shall be caulked and sealed in compliance with Clauses 1016 and 1017.
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Appendix 11/1.
11 (02/21) Prior to commencing the installation process, a trial length of not less than 15 m of the type of the in-situ
asphalt kerb detail shall be formed in accordance with BS 5931.
1103 (02/21) In-Situ Concrete Kerbs, Channels and Edge Details

1 (02/21) In-situ concrete kerbs, channels and edge details shall be formed in accordance with BS 5931.
2 (02/21) The machine used shall be capable of forming dense kerbs or surface water channels or edge details with
regular sides, arises and chamfers, finished to a fine surface free from blow holes and dragging and constructed to
the dimensions detailed in contract specific Appendix 11/1.
3 (02/21) The concrete shall be cured by one of the methods specified in Clause 1027.
4 (02/21) In-situ concrete kerbs, channels and edge details shall be designed to meet the requirements of
Table 11/3.

Table 11/3 (02/21) Minimum Requirements for Test Specimens of In-Situ Concrete Kerbs, Channels and Edge
Details
Property Minimum required performance/class when tested in accordance with BS

EN 1340
Bending strength Class 2
Durability (bending strength) Class 2
Weathering resistance Class 3
Abrasion Class 4
(02/21) Testing Requirements

5 (02/21) For each 500 linear metres laid or 4 days production, a set of specimens prepared in accordance with
BS EN 1340 from the supplied material shall be tested to meet the requirements of Table 11/3 by a laboratory
accredited in accordance with Clause 105.
6 (02/21) Kerbs, channels and edge details shall be capable of withstanding a static push-off load of 10 kN/m
applied parallel to the pavement surface at right angles to the kerb.
(02/21) Surface Levels and Horizontal Alignments
7 (02/21) The longitudinal surface regularity shall not deviate by more than 5 mm when measured with a 3 m
straight edge.
8 (02/21) For kerbs, channels and edge details constructed before the adjacent road pavement surface, the surface
level adjacent to the future road surface shall not deviate from the design level by more than ±5 mm.
9 (02/21) For kerbs, channels and edge details constructed after the adjacent road pavement surface, the surface
level shall not deviate from the finished level of the adjacent pavement surface by more than +0-10 mm.
(02/21) Joints
10 (02/21) Joints shall be provided in in-situ concrete kerbs, channels, and edgings, which are laid on or adjacent to
concrete pavements to coincide with the pavement transverse contraction and expansion joints.
11 (02/21) Joints in kerbs, channels and edgings coinciding with joints in concrete pavements shall be the same
width as the joint sealing grooves of the pavement.
12 (02/21) Joints in kerbs, channels and edgings with joints in concrete pavements shall be caulked and sealed as
detailed in Clauses 1016 and 1017.
13 (02/21) Concrete foundations to kerbs, channels and edgings laid adjacent to a concrete pavement shall be
provided with joint filler board complying with Clause 1015 placed vertically through the full extent of the concrete
foundation at positions coinciding with the pavement joints.
Appendix 11/1.
(02/21) Trial length
15 (02/21) Prior to commencing the installation process, a trial length of a minimum length of 15 m of the type of
the in-situ concrete kerb, channel or edge detail shall be formed in accordance with BS 5931 to demonstrate
compliance with the requirements.

5
1104 (02/21) Footways, Cycleways and Paved Areas – Precast Concrete Flags and Natural Stone
Slabs
(02/21) Precast Concrete Flags
1 (02/21) Precast concrete flags shall conform to BS EN 1339 and the requirements of Table 11/4.
Table 11/4 (02/21) Minimum Requirements for Precast Concrete Flags
Property Minimum required performance/class when tested in accordance with

BS EN 1339
Bending strength Class 2
Slip resistance (for pedestrian use only) Unpolished slip resistance value (USRV) of 40
Skid resistance (for vehicle use) Unpolished skid resistance value (USRV) of 45
Durability (characteristic bending Class 2
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strength)
Abrasion resistance Class 4
2 (02/21) Type designations and thicknesses shall be as detailed in contract specific Appendix 11/1.
(02/21) Natural Stone Slabs
3 (02/21) Natural stone slabs shall conform to BS EN 1341 and the requirements of Table 11/5
Table 11/5 (02/21) Minimum Requirements for Natural Stone Slabs
Property Minimum required performance/class for natural stone slabs when

tested in accordance with BS EN 1341
Flexural strength Value from BS EN 1341 Annex
Durability (flexural strength) 98% retained after 56 cycles
Weathering resistance (flexural strength) 98% retained after 25 cycles with de-icing salts
Water absorption (maximum) 0.3%
4 (02/21) Type designations, thicknesses and performance class for flexural strength of natural stone slabs shall be
as detailed in contract specific Appendix 11/1.
(02/21) Installation Requirements
5 (02/21) Precast concrete flags and natural stone slabs shall be laid in accordance with BS 7533-4 with a
minimum mortar thickness of 25 mm.
6 (02/21) The foundation and base material shall be as detailed in contract specific Appendix 11/1.
7 (02/21) The laying course and jointing material type (e.g. sand or mortar) shall be as detailed in contract specific
Appendix 11/1.
8 (02/21) The required cross falls and bond shall be as detailed in contract specific Appendix 11/1 with joints at
right angles to the kerb.
9 (02/21) On circular work where the radius is 15 m or less, precast concrete flags and natural stone slabs shall be
radially cut on both edges to the required line.
10 (02/21) Surface tolerances for footways, cycleways and paved areas surfaced with precast concrete flags and
natural stone slabs shall meet those provided in Clause 1114.
11 (02/21) The surface regularity for footways, cycleways and paved areas surfaced with precast concrete flags and
natural stone slabs shall meet those provided in Clause 1115.

1105 (02/21) Footways, Cycleways and Paved Areas – Bituminous Mixtures

1 (02/21) Bituminous mixtures used in surface course and binder course for footways, cycleways and paved areas
shall be constructed using the materials and layer thicknesses detailed in contract specific Appendix 11/1.
2 (02/21) The foundation shall be as detailed in contract specific Appendix 11/1.
3 (02/21) Bituminous mixtures shall be made in accordance with Series 900.
4 (02/21) Bituminous mixtures shall be laid and compacted in accordance with BS 594987.
5 (02/21) Compaction of bituminous mixtures shall meet the end product specification requirements specified in
Clause 1113.
6 (02/21) Surface tolerances for bituminous surfaced footways, cycleways and paved areas shall meet those
provided in Clause 1114.
8 (02/21) The surface regularity of bituminous surfaced footways, cycleways and paved areas shall meet those
1106 (02/21) Footways, Cycleways and Paved Areas – In-situ Concrete

1 (02/21) In-situ concrete for footways, cycleways and paved areas shall be constructed using the materials and
layer thicknesses detailed in contract specific Appendix 11/1.
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2 (02/21) In-situ concrete for footways, cycleways and paved areas shall be made, laid and cured in accordance
with Series 1000.
3 (02/21) The foundation shall be as detailed in contract specific Appendix 11/1.
4 (02/21) The surface finish shall be as detailed in contract specific Appendix 11/1.
5 (02/21) Joint details shall be as detailed in contract specific Appendix 11/1.
6 (02/21) Maximum joint spacing shall be as detailed in contract specific Appendix 11/1.
7 (02/21) Surface tolerances for concrete surfaced footways, cycleways and paved areas shall meet those provided
in Clause 1114.
8 (02/21) The surface regularity of concrete surfaced footways, cycleways and paved areas shall meet those
1107 (02/21) Footways, Cycleways and Paved Areas – Concrete Block Paving
1 (02/21) Precast concrete paving blocks shall be chamfered and conform to BS EN 1338, meeting required
performance/class in Table 11/6.

Table 11/6 (02/21) Requirements for Concrete Block Paving

EN 1338
Tensile splitting strength The characteristic tensile splitting strength T shall not be less than 3.6
MPa. None of the individual results shall be less than 2.9 MPa, nor have
a failure load less than 250 N/mm of splitting length
Durability – strength Not less than the characteristic tensile splitting strength
Durability – slip/skid resistance Not less than the initial slip/skid resistance
Abrasion resistance Class 4
2 (02/21) The shapes, dimensions and colours of precast concrete paving blocks shall be as detailed in contract
3 (02/21) Precast concrete paving blocks shall be laid in accordance with BS 7533-3 or BS 7533-9 as applicable.
4 (02/21) The foundation and base layers shall be as detailed in contract specific Appendix 11/1.
5 (02/21) The laying course and jointing material type (e.g. sand or mortar) course shall be as detailed in contract
6 (02/21) The layout of blocks and details at edges, chamber covers, gullies and other openings shall be as detailed
7 (02/21) Surface tolerances for footways, cycleways and paved areas surfaced with precast concrete paving
blocks shall meet those provided in Clause 1114.
8 (02/21) The surface regularity for footways, cycleways and paved areas surfaced with precast concrete paving
blocks shall meet those provided Clause 1115.
1108 (02/21) Footways, Cycleways and Paved Areas – Clay Pavers

1 (02/21) Clay pavers shall conform to BS EN 1344 with chamfers meeting the minimum required performance/
class in Table 11/7.
Table 11/7 (02/21) Requirements for Clay Pavers

EN 1344
Transverse breaking load Class T4
Freeze/thaw resistance Class FP100 (freeze thaw resistant)
Abrasion resistance Class A2
2 (02/21) The shapes, dimensions and colours of clay pavers shall be as detailed in contract specific
Appendix 11/1.
3 (02/21) Clay pavers shall be laid in accordance with BS 7533-3 or BS 7533-9 as applicable, with tolerances as
detailed in Clause 1114.
5 (02/21) The laying course and jointing material type (e.g. sand or mortar) course shall be as detailed contract

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8
6 (02/21) The layout of pavers and details at edges, chamber covers, gullies and other openings shall be as detailed
7 (02/21) Surface tolerances for footways, cycleways and paved areas surfaced with clay pavers shall meet those
8 (02/21) The surface regularity for footways, cycleways and paved areas surfaced with clay pavers shall meet
those provided in Clause 1115
1109 (02/21) Grass Concrete Paving

1 (02/21) Grass concrete paving shall consist of a reinforced perforated in-situ concrete slab or a precast panel
system in accordance with contract specific Appendix 11/1.
2 (02/21) Perforations shall be formed in in-situ grass concrete paving as detailed in contract specific
Appendix 11/1.
3 (02/21) Precast concrete panels shall conform to the shape, dimensions and colour detailed in contract specific
Appendix 11/1.
4 (02/21) The concrete used to form the precast panels shall have a minimum compressive strength class of
C28/35 to BS 8500-1.
5 (02/21) The precast panels, when tested in accordance with BS EN 1339, shall have a minimum characteristic
bending strength class of 3.
6 (02/21) The water absorption when tested in accordance with BS EN 1339 shall meet the requirements of class 2
of table 4.1.
7 (02/21) The layout of precast panels and details at edges, chamber covers, gullies and other openings shall be as
8 (02/21) Grass concrete paving shall be laid on a bed of Type 1 unbound mixture conforming to Clause 803, laid
in accordance with Clause 802, as detailed in contract specific Appendix 11/1.
9 (02/21) In addition, panels shall be bedded on a layer of sand conforming to 0/4 Fine Aggregate.
10 (02/21) Perforations shall be filled to 30mm below the top surface with soil meeting the requirements of sub-
Clauses 3004.8 to 3004.11.
11 (02/21) The soil shall be seeded with grass meeting the requirements of Clause 3005.
1110 (02/21) Access Steps

1 (02/21) Access steps shall be provided when identified in contract specific Appendix 11/2 and where identified
in contract specific Appendix 1/10 the Contractor shall undertake the design of the access steps or access steps
elements.
2 (02/21) The access steps shall meet the requirements of BS EN ISO 14122-1 and BS EN ISO 14122-3, contract
specific Appendix 11/2 and the performance requirements described hereafter.
3 (02/21) For the purpose of this Clause the term ‘access steps’ shall mean access steps provided for highway
maintenance purposes to communication cabinets and other roadside items and includes landings and guardrails.
4 (02/21) For the purpose of this Clause the term ‘machinery’ referred to under BS EN ISO 14122-1 and
BS EN ISO 14122-3 shall mean communication cabinets and other roadside items.
5 (02/21) The alignment and location for access steps shall enable the safe access to and egress from any
communication cabinet and other roadside items.
6 (02/21) The steps shall be located, where possible, such that they will not require removal for access to services
or supplies including motorway communication systems.

9
(02/21) Durability
7 (02/21) The access steps shall achieve a serviceable life to the requirements of contract specific Appendix 11/2.
8 (02/21) The serviceable life shall be obtained without the requirement for any maintenance other than that
resulting from accidental damage and routine maintenance.
(02/21) Materials for Construction In-situ
9 (02/21) Material for in-situ construction of access steps shall conform to BS EN ISO 14122-3 section 4 and
10 (02/21) All components of the steps shall be resistant to theft, tampering and fire.
11 (02/21) Where two or more materials are used they shall be compatible and include measures to avoid galvanic
action and avoid differential movement.
12 (02/21) Materials shall be able to resist corrosion provoked by the surrounding atmosphere and ground
conditions to achieve its serviceable life.
13 (02/21) Materials listed in Table 11/8 shall meet the detailed requirements listed in Table 11/8.
Table 11/8 (02/21) Access Step Materials
Material Requirements
General Detailed
Paving slabs of flags Clause 1104 -
Engineering bricks BS EN 771-1 Class B
Compressive strength ≥ 75 N/mm2
Water absorption (% by mass) ≤ 7.0
Freeze/thaw resistance category F2
Active soluble salts content category S2
Mortar BS EN 1996-2 Durability designation M or S
BS EN 998-2
Bedding sand BS EN 12620 Designation 0/4 mm
Precast concrete edgings Clause 1101 -
Concrete landings Series 1700 Exposure class:
reinforced – XC3 or XC4, XD3, XF2
BS 8500 unreinforced – XF2
Minimum strength class C25/30 or greater
Maximum aggregate size – 20 mm
Ancillary concrete Clause 2602 Bedding and backing to precast concrete
edgings ST2
Backing to steps ST2
Fill material Series 600, Table 6/1 Class 1 general fill
Galvanised steel guardrails BS EN 10255 -
(02/21) Modular and Preformed Steps

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14 (02/21) Preformed concrete steps shall comply to BS EN 14843.

15 (02/21) Preformed stairs shall conform to BS 4592.

(02/21) Particular Access Step Criteria

16 (02/21) Unless otherwise stated in contract specific Appendix 11/2 the design of access steps shall conform to
the requirements of Table 11/9.
Table 11/9 (02/21) Access Step Criteria
Item Standard Requirement

Steps Minimum clear width 800mm
Steps Maximum protrusion above ground: Step rise height + 50mm
Steps BS EN ISO 14122-3 At least one guardrail unless the width of the steps is greater or equal
to 1200 mm when two guardrails are required
Steps BS EN ISO 14122-3 A rise and going which achieves the safety requirements formulae of
the standard
Steps Maximum pitch 45 degrees
Steps A change in horizontal direction of not less than 30 degrees after a the
lesser of a maximum of 16 steps or a climbing height of 6 m, utilising
a landing
Steps Step goings and landings shall be solid
Drainage No areas of standing water on the steps
Risers Open risers not permitted
Knee rails Required on all landings and steps
(02/21) Environment Requirements

17 (02/21) The access steps shall conform to the environmental requirements stated in contract specific
Appendix 11/2.
18 (02/21) The access steps shall have a non-intrusive appearance and be suitable for the location.
19 (02/21) The alignment of the steps shall minimise the impact on the environmental assets in the soft estate.
1111 (02/21) Installation of Unbound and Hydraulically Bound Mixtures

1 (02/21) Installation of unbound and hydraulically bound mixtures for footways, cycleways and paved areas shall
be in accordance with Series 800.
1112 (02/21) Not Used

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1113 (02/21) End Product Specification for Compaction of Bituminous Layers

1 (02/21) The end product compaction of the bituminous surface layers shall be determined by the air voids
content to satisfy the requirements in Table 11/10.
Table 11/10 (02/21) Air Voids Content Limits
Material Average of 6 density gauge Mean of core pairs maximum in-situ air
consecutive readings void content
Dense asphalt concrete binder Maximum 7% Maximum 9%
course and 14 mm close graded
asphalt concrete surface course
used as a binder course
Other asphalt materials Maximum 6% Maximum 8%
2 (02/21) Air voids content shall be monitored by a correlated density gauge operated in accordance with
BS 594987 at 20 m spacings.
3 (02/21) The average in-situ void content calculated from any six consecutive gauge readings shall not exceed
the values in Table 11/10.
4 (02/21) For the material from each mixing plant, one pair of 100 mm nominal diameter cores shall be taken
from every 500 linear metres laid and the void content determined in accordance with sub-Clause 6.
5 (02/21) The average in-situ void content of a pair of cores shall not exceed the values in Table 11/10.
6 (02/21) The in-situ air voids content shall be calculated in accordance with BS EN 12697-8.
7 (02/21) When the material contains applied chippings the air voids content shall be calculated from the whole
layer including chippings.
8 (02/21) The maximum density ρmax shall be determined to BS EN 12697-5 using Procedure A in water using
sampled material or the core pairs.
9 (02/21) The bulk density ρ shall be determined to BS EN 12697-6 using the procedure specified by
BS EN 13108-20 for the material type.
10 (02/21) Where these requirements for the air voids content are not met a minimum length of 15 m for the full
depth and width, of the defective material shall be removed and replaced with fresh material laid and compacted to
this specification.
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1114 (02/21) Horizontal Alignments and Surface Levels of Pavement Courses and Formation
1 (02/21) The design levels of pavement courses shall be calculated from the vertical profile and crossfalls
2 (02/21) The level of any point on the constructed surface of the pavement courses shall be the design level
subject to the appropriate tolerances stated in Table 11/11.
3 (02/21) Compliance with sub-Clause 1 of this Clause shall be checked by taking measurements of the surface
levels of all courses on a grid of points located as detailed in Appendix 11/1.
Table 11/11 (02/21) Construction Tolerances for Footways, Cycleways and Paved Areas
Parameter Tolerance
General tolerance requirements relevant to all paved area types
Horizontal alignment accuracy Requirements for horizontal alignments including
edge strips shall be as Clause 702.
Kerbs and edging strips (vertical tolerance) including Requirements as Clause 1101.
combined kerb and drainage systems
Formation level Subgrade surface within +10 mm to -30 mm of design
level.
Subbase thickness Not more than 10 mm less than specified in contract
Surface course level tolerance Within +5 mm or -0 mm of the adjacent kerb, edging
strip or any ironwork.
Specific tolerance requirements for bituminous paved area types
Subbase surface level Where the footway, cycleway or paved area is
surfaced in bituminous material the compacted
subbase surface shall be within +10 mm and –20 mm
of its design level. Where segmental surfacing or in-
situ concrete is used the subbase shall be within ± 10
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mm of its design level.

Binder course The compacted binder course level shall be within
+/-10 mm of the design level.
Bituminous thickness The total thickness of bituminous material shall not
be more than 5 mm less than specified.
Specific tolerance requirements for block/slab paved area types
Tolerance requirements other than those above shall be as detailed in the British Standard referenced in the
relevant Clause above.
4 (02/21) For footways, cycleways and paved areas excluding those with flexible surfacing, the maximum
allowable difference between the surface and the underside of a 1 m straight edge and wedge complying with
BS 8420 when placed parallel with, or perpendicular to, the footway/cycleway shall be 3 mm.

1115 (02/21) Surface Regularity of Bituminous Surfaced Footways, Cycleways and Paved Areas
1 (02/21) The longitudinal regularity of the completed surface of the footway/cycleway surface course shall meet
the limits stated in Table 11/12.
Table 11/12 (02/21) Maximum Permitted Number of Surface Irregularities
Irregularity Limits 4 mm 7 mm
Length (m) 300 75 300 75
Permitted number of surface 60 27 6 3
irregularities
Additional requirement No more than 5 irregularities shall be permitted in any 5 m
Additional requirement No irregularity exceeding 10 mm
2 (02/21) Compliance with Table 11/12 shall be checked by a rolling straight edge along any line or lines parallel
to the edge of the footway/cycleway on sections of 300 m at regular intervals as stated in contract specific
Appendix 11/1.
3 (02/21) Sections shorter than 300 m forming part of a longer pavement shall be assessed using the number of
irregularities for a 300 m length pro-rata to the nearest whole number.
4 (02/21) Where the total length of pavement is less than 300 m, the measurements shall be taken on 75 m lengths.
cases only:
(i) for lengths of less than 75 m; and
(ii) where the use of the rolling straight-edge or equivalent apparatus is impracticable.
6 (02/21) The maximum allowable difference between the surface and the underside of the straight edge, when
placed parallel to, the footway/cycleway shall be 3 mm.
7 (02/21) The footway/cycleway surface shall be checked for transverse surface regularity using a 1 m straight
edge and wedge complying with BS 8420 placed at right angles to the centre line.
8 (02/21) The maximum transverse deviation of the footway/cycleway surface shall be 3 mm.
1116 (02/21) Rectification of Bituminous Surfaces of Footways, Cycleways or Paved Areas

1 (02/21) Where bituminous surfaced footways, cycleways, or paved areas do not comply with the Specification
for regularity, surface tolerance, thickness, material property or compaction, the full extent of the area which does
not comply with the Specification shall be removed and replaced with fresh material laid and compacted in
accordance with the Specification.
2 (02/21) The area rectified shall be the full width of the footway/cycleway, and at least 5 m long if binder course,
or 15 m if surface course.
3 (02/21) Where the number of surface irregularities exceeds the limits in Table 11/12, the area to be rectified
shall be a minimum of 75 m long and the full width of the footway/cycleway.
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1117 (02/21) Footways, Cycleways and Paved Areas – Permeable Block Paving
1 (02/21) Permeable block paving shall be constructed with concrete block paving complying with the
requirements of Clause 1107 or clay pavers complying with the requirements of Clause 1108.
2 (02/21) Permeable block paving shall be laid in accordance with BS 7533-3.
3 (02/21) The laying course and foundation layers shall be as detailed in contract specific Appendix 11/1.

4 (02/21) The layout of pavers and details at edges, chamber covers, gullies and other openings shall be as detailed
1118 (02/21) Polymeric Kerbs, Islands and Lane Separators

1 (02/21) Polymeric kerbs, islands and lane separators shall be manufactured from recycled plastomeric or
elastomeric materials processed with functional additives and the Contractor shall supply to the Overseeing
Organisation the results of testing carried out at production stage by a laboratory meeting the requirements of
Clause 105. The testing shall demonstrate that the kerbs, islands and/or lane separators meet the specification
requirements.
2 (02/21) The type designations of polymeric kerbs, islands and lane separators shall meet the description in
3 (02/21) The product shall meet the performance requirements in Table 11/13.
Table 11/13 (02/21) Minimum Requirements for Polymeric Kerbs, Islands and Lane Separators
Property Test method Minimum required performance/class

Bending Strength BS EN 1340 2.8 MPa
Slip/skid resistance BS EN 1340 Unpolished skid resistance value
(USRV) of 45
Abrasion BS EN 1340 Class 4
Resistance to impact damage See Note 1 BS EN 1317-2 Acceleration severity index (ASI) ≤ 1.9,
Weathering resistance – resistance to UV BS EN 14836 Maintain the above properties after test
light specimens are subjected to artificial
weathering. See Note 2.
Weathering resistance – resistance to BS EN 1340 Class 3
freeze- thaw with de-icing salts
Note 1 Resistance to impact damage from heavy goods vehicles at angles and speed to direction of traffic as
detailed in Table 1 of BS EN 1317-2. Damage can include scuffing, gouging and deep penetration.
Note 2 The following properties are to be determined after the artificial weathering: breaking strength; abrasion;
and slip/skid resistance.
4 (02/21) Kerbs shall not be less than 100 mm in width at the base.
5 (02/21) The height of the kerbs above the road surface shall not exceed their width.
6 (02/21) Lane separators shall not be less than 500 mm in width at the base.
7 (02/21) The height of lane separators shall not exceed their width.
(02/21) Installation
8 (02/21) Polymeric kerbs, islands and lane separators shall be secured to the road surface in accordance with the
manufacture’s installation instructions.
9 (02/21) The materials used for Polymeric kerbs, islands and lane separators shall withstand temperatures of
60°C for a period of 24 hours, without incurring damage to their integrity and functionality.
10 (02/21) The fixing system shall resist impacts from 44 t vehicles at impact angles between 10° to 90° at 80km/h
without the kerb being displaced from the surface.

15
1119 (02/21) Footways, Cycleways and Paved Areas – Natural Stone Setts
1 (02/21) Natural stone setts shall conform to BS EN 1342 with chamfers and meeting the performance/class in
Table 11/14.
Table 11/14 (02/21) Minimum Requirements for Natural Stone Setts
Property Minimum required performance/class for natural stone setts when

tested in accordance with BS EN 1342
Compressive strength 130 MPa in accordance with BS EN 1926
Durability (retained compressive 98% after 56 cycles
strength)
Weathering resistance (retained 98% after 25 cycles with de-icing salts
compressive strength)
Water absorption 0.3%
2 (02/21) The shapes, dimensions and colours of natural stone setts shall be as detailed in contract specific
Appendix 11/1.
4 (02/21) The laying and jointing of natural stone setts in either bound or unbound construction shall be in
accordance with BS 7533-7.
5 (02/21) Natural stone setts, in either bound or unbound construction, shall be laid in accordance with BS 7533-7
as detailed in contract specific Appendix 11/1.
6 (02/21) The layout of units and details at edges, chamber covers, gullies and other openings shall be as detailed
7 (02/21) Surface tolerances for footways, cycleways and paved areas surfaced with natural stone shall meet those
8 (02/21) The surface regularity for footways, cycleways and paved areas surfaced with natural stone shall meet
those provided in Clause 1115.

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SERIES 1200
TRAFFIC SIGNS
Contents
Clause Title Page OVERSEEING ORGANISATIONS OF
#1201 Regulations, Sign Classification IRELAND
and Standards 2
1202 General Requirements for
Permanent Traffic Signs 2 Clause Title Page
1203 Foundations for Permanent
Traffic Signs and Signals 3 Wales
1204 Posts for Permanent Traffic Signs 3
1201NAW (05/01) Regulations, Sign
1205 Sign Plates for Permanent Traffic Classification and Standards W1
Signs 3
1206 Faces for Permanent Traffic Signs 4 Northern Ireland
1207 Construction and Assembly of 1201NI (05/01) Regulations, Sign
Permanent Traffic Signs 4 Classification and Standards N1
1208 Location and Erection of 1212NI (05/01) Road Markings N1
Permanent Traffic Signs 5
1213NI (05/01) Road Studs N3
1209 Covering of Permanent Traffic
Signs 5
1210 Permanent Bollards 6
1211 Permanent Marker Posts 6
#1212 (05/01) Road Markings 6 # denotes a Clause or Sample Appendix which has a substitute
National Clause or Sample Appendix for one or more of the
#1213 (05/01) Road Studs 8 Overseeing Organisations of Scotland, Wales or Northern Ireland.
1214 Traffic Cones, Traffic Cylinders,
Flat Traffic Delineators and Other
Traffic Delineators 9
1215 Road Danger Lamps and High
Intensity Flashing Beacons 12
1216 Temporary Traffic Signs 12
1217 Traffic Signals 13
1218 Detector Loops 14
1219 Controlled and Un-controlled
Crossings 14
1220 Traffic Signs on Gantries 15
1221 Preparation and Finish of Metal
and Other Surfaces 15
Amendment - May 2004

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1
Specification for Highway Works Traffic Signs
TRAFFIC SIGNS
#1201 Regulations, Sign Classification and specially authorised by the Secretary of

Standards State, or any part thereof, designed to remain
in position at the completion of the
Regulations Permanent Works or a traffic cone, cylinder
or other traffic delineator to be retained by
1 (08/03) Subject to paragraphs 2 and 3 below, all the Employer;
traffic signs used (including retroreflecting road studs
(ii) prescribed temporary traffic signs. Any of
and road markings), whether permanent or temporary,
shall be of the size, shape, colour and type prescribed the traffic signs defined in the Regulations,
for that use in The Traffic Signs Regulations and or specially authorised by the Secretary of
General Directions 2002 (Statutory Instrument 2002 State, or any part thereof, described in
No. 3113), including Working Drawings for Traffic Appendix 12/1 which, unless otherwise
described in Appendix 12/1, comply with the
Sign Design and Manufacture (Volumes 1, 2 and 3), the
requirements of a permanent traffic sign but
Zebra, Pelican and Puffin Pedestrian Crossings
Regulations and General Directions 1997 (Statutory which will not remain in position at the
Instrument 1997 No. 2400) and subsequent amending completion of the Permanent Works;
Regulations. Other relevant requirements are contained (iii) temporary traffic signs. Any of the traffic
in the above Regulations and General Directions. signs defined in the Regulations, or specially
2 Signs that are not prescribed in Regulations need to authorised by the Secretary of State, or any
be specially authorised by the Secretary of State. Where part thereof, designed by the Contractor, in
the Contractor proposes to use non-prescribed compliance with Clause 1216 which will not
remain in position at the completion of the
temporary traffic signs, he shall obtain the agreement of
Permanent Works.
the Overseeing Organisation to their intended design
and location. Where the Contractor proposes to use
prescribed temporary traffic signs, he shall obtain the 1202 General Requirements for Permanent
agreement of the police and the highway authority to
Traffic Signs
their intended location. The Contractor shall obtain
authorisation and approval from the Overseeing 1 (05/01) Materials for permanent traffic signs and
Organisation for the use of the signs at the specific their construction, assembly, location and erection shall
locations proposed. comply with this Series, Series 1400 and the
3 Signs that are changeable by means other than the requirements described in Appendix 12/1. The
purely mechanical require statutory type approval for manufacture and installation of traffic signs shall be in
their construction and operating mechanisms by the accordance with the quality management scheme
Secretary of State. This requirement is in addition to the described in Appendix A.
need for the design of the sign to be prescribed or 2 Each complete traffic sign or part thereof shall be
specially authorised. The Contractor’s proposal for capable of passing the tests in BS 873 : Part 1.
signs that require statutory type approval shall include
the reference numbers of any approval already issued in 3 Sign panels of internally illuminated signs and
respect of that equipment. The signs shall not be luminaire face panels shall, unless otherwise described
installed until appropriate approval or confirmation of in Appendix 12/1, comply with impact Category 1 of
existing approval, by the Overseeing Organisation has BS 873 : Part 5.
been obtained. 4 All lit traffic signs shall comply with Category 1
luminance of BS 873 : Part 5 unless otherwise
Sign Classification described in Appendix 12/1.
4 For the purposes of the Contract the following 5 Before the commencement of fabrication of any
classifications apply: traffic sign, unless otherwise stated in Appendix 12/1,
the Contractor shall submit for the Overseeing
(i) permanent traffic signs. Any of the traffic
signs prescribed in the Regulations, or
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2
Organisation’s approval: 8 Reinstatement of existing surfaces above

foundations shall comply with Clause 706.
(i) fabrication drawings for ‘directional
informatory’ and ‘informatory’ signs as
required in Appendix 1/4; 1204 Posts for Permanent Traffic Signs
(ii) the information about ‘warning’, ‘regulatory’
and other traffic signs required in 1 Posts for permanent traffic signs shall be as
Appendix 12/1. described in Appendix 12/1 and shall comply with
BS 873 : Part 7, the surface protection requirements of
6 All traffic sign housings shall be provided with BS 873 : Part 6 and with the following:
vandal and weather resistant locks. Keys, in the
quantities stated in Appendix 12/1, shall be provided to (i) steel posts shall be tubular or
(08/03)
the Overseeing Organisation. Types of lock shall be rectangular hollow section complying with
kept to a minimum. BS EN 10 210, joists, universal beams or
columns complying with BS 4-1, and shall
7 The backs of traffic signs shall have a location be manufactured from steel complying with
identifying mark as described in Appendix 12/1. grade S275 JO or S275 J2;
8 Traffic signs shall be carefully handled to prevent (ii) aluminium posts shall be of tubular or
damage, transported and stored in accordance with the rectangular hollow section;
sign face manufacturer’s instructions.
(iii) concrete for reinforced or prestressed
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concrete posts shall comply with Series 1700
1203 Foundations for Permanent Traffic and Appendix 12/1.
Signs and Signals 2 Posts shall not protrude above the top of the sign
unless supporting an external luminaire, in which case
1 The type and size of foundations for permanent
the protrusion shall be kept to a minimum.
traffic signs and signals shall be as described in, and
unless otherwise stated therein shall comply with, this 3 Internally illuminated posts for pedestrian crossing
Clause. beacons shall comply with this Clause and where
appropriate with BS 873 : Part 7.
2 All excavations for foundations shall be carried out
in compliance with Clause 604 and shall be cleared of 4 Signs erected on a single post shall be positioned
all loose material before placing of concrete and so that the post is in the centre of the sign, unless
backfilling. otherwise described in Appendix 12/1.
3 Unless otherwise described in Appendix 12/1 5 Compartments for electrical equipment shall be as
traffic signs and signals supported by a single post described in Appendix 12/1 and, wherever practicable,
placed in the ground shall have the post installed access doors shall be on the side of the compartment
centrally in 300 mm diameter or square holes filled in furthest from approaching traffic. In the case of signs
compliance with Clause 2602 with mix ST2 concrete to supported by more than one post, such compartment
within 150 mm of the ground surface. shall be on the post furthest from the carriageway
unless otherwise described in Appendix 12/1.
4 Unless otherwise described in Appendix 12/1, posts
shall be supported for a minimum of 3 days after 6 Flange plates shall have holes or slots as described
placing the concrete and backfilling shall not take place in Appendix 12/1 to accommodate the attachment
until at least 48 hours after placing. system.
5 For traffic signals and illuminated signs provision
shall be made for cable entry through the foundation by 1205 Sign Plates for Permanent Traffic Signs
means of ducting as described in Appendix 12/1.
6 Where pockets are formed in concrete foundations 1 All permanent sign plates shall comply with
their plan dimensions shall be sufficiently larger than BS 873 : Part 6, and with this Clause.
those of the post to allow for positioning and bedding of 2 Plate signs not exceeding 1.2 m in height and 2.4 m
the post and backfilling of the pocket. width shall be made of a single sheet. Where more than
7 All backfilling of foundations shall comply with one sheet is used to make up a sign, the number of
Clause 611 except that where pipes or buried cables are sheets shall be kept to a reasonable minimum and the
installed it shall comply with Clauses 505 and 1421 separate sheets shall be rectangular and of comparable
respectively. size and shape.
Amendment - August 2003 3

3 (05/05) Extruded plank signs up to 4.8 m wide shall accordance with the sheeting manufacturer’s
have no vertical joints. Above this size, joints in instructions.
extruded planks shall preferably be positioned at a
7 Screen processed letters, numerals, symbols and
vertical support; if not, then the vertical joints in
borders shall be screen printed with materials in
adjacent planks shall not be less than 1.0 m apart and
accordance with the sheeting manufacturer’s
only one joint per extruded plank is permitted.
instructions. Any inks, pastes and finishing coats used
4 (05/05) Fabricated plank signs up to 4.8 m wide shall be compatible with the sheeting material or the
shall have no vertical joints, but each plank may be face panel of internally illuminated signs.
constructed from a maximum of two pieces of sub-
8 Sheeting materials including letters, numerals,
strate material, producing one split line. Split lines shall
symbols and borders shall be fully adhered and there
be lined up vertically or horizontally. Above 4.8 m
shall be no air bubbles, creases, cracks or other
wide, joints in the stiffening extrusions of adjacent
blemishes. Where the sheeting manufacturer requires
planks shall preferably be positioned at a vertical
the assembled materials to be provided with a coat of
support; if not, then the vertical joints in the stiffening
clear lacquer, it shall be uniform and continuous. All
extrusions of adjacent planks shall not be less than
lacquer shall be applied at the time of fabrication of the
1.0 m apart and only one such joint per fabricated plank
sign face and shall be of a type specified or supplied by
shall then be permitted.
the sheeting manufacturer.
5 Where top and bottom light spill screens are
required in Appendix 12/1, these shall extend for the
whole width of the sign and be fabricated out of the 1207 Construction and Assembly of
same material as the sign plate. Permanent Traffic Signs
6 Top and bottom light spill screens shall be
considered as part of the sign plate and any stiffeners General
and mounting fittings shall be designed to 1 Construction and assembly of traffic signs shall
accommodate the combined size. comply with BS 873 : Part 6 and with this Clause.
2 All sign plates and planks, frames, purlins, posts
1206 Faces for Permanent Traffic Signs and other components shall be de-burred prior to
assembly.
1 Faces for permanent traffic signs shall be as
described in Appendix 12/1. They shall comply with 3 Where framing and stiffening are not an integral
BS 873 : Part 6 and with this Clause. part of the sign plate their joints shall be welded or
joined with suitable brackets utilising nuts, bolts and
2 All plastics sheeting shall be fixed in accordance washers.
with the sheeting manufacturer’s instructions.
4 Where purlins are adopted they shall be attached to
3 Only vertical and horizontal joints shall be each vertical member of the sign frame and the sign
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permitted and all joints in plastics sheeting shall be stiffening and framing shall be continuous in the
overlapped by not less than 6 mm. The overlap in the vertical direction. Purlins shall be spaced equally apart.
horizontal joints shall be from the top. Butt joints in Connections shall be made at every point where a purlin
plastics sheeting shall not be used, except between crosses a post.
individual planks or in electro cutable overlay film, or
as recommended by the sheeting manufacturer. 5 Where purlins are not adopted the sign stiffening
and framing shall be continuous in the horizontal
4 All materials comprising the sign face, including direction.
the background, border and legends shall be carefully
matched for colour at the time of sign fabrication to 6 Rivets and other devices used for fixing sheet sign
provide uniform appearance both by day and night. The plates to their stiffeners or framework, or in the
sheeting manufacturer’s recommendations on colour construction of housings, shall be of a material
matching methods shall be observed. compatible with the materials being joined. Spacing of
rivets or other fixing devices shall be uniform and shall
5 Letters, numerals, symbols and borders shall be not exceed 150 mm around the outside edge of any
clear cut, sharp edged and without cracks. sheet or section of sheet, and shall not exceed 300 mm
6 Any cut-out letters, numerals, symbols and borders on cross braces. Hollow rivets shall not be used. Where
shall be of material compatible with the sheeting to sign plates need to be stiffened this shall be achieved in
which they are applied. They shall be applied in a manner such that the sign face material is not
punctured or otherwise damaged to accommodate the
stiffening.
7 An additional washer of neoprene, nylon or other 1208 Location and Erection of Permanent
suitable material shall be used between the sign face Traffic Signs
and any metal nuts, bolts, washers and screws to protect
it from corrosive or other damaging effects. 1 The approximate location of each traffic sign is
described in Appendix 12/1. All traffic signs shall have
8 Where supports to traffic signs, including external their exact location determined and recorded in
lighting luminaires, are required to have flange plates compliance with Clause 1403.
these shall be secured by anchorages and attachment
systems complying with Series 1300. The bolts shall be 2 All posts shall be erected plumb and where two or
lightly greased before final installation and they and more posts are provided for any one sign, the faces of
their anchorages shall be installed so as to achieve the the posts shall be lined up.
loadings, torque settings and other requirements 3 Signs erected on two posts shall have each post
described in Appendix 12/1. positioned so that the distance from the centre of the
9 Sheet and plank signs shall be connected to posts post to the edge of the sign plate is 300 mm unless
by an appropriate method. Banding systems shall be of otherwise described in Appendix 12/1.
stainless steel complying with AISI Grade 201. 4 Any pockets formed in concrete foundations to
10 Plank signs shall be assembled in accordance with receive the posts shall be cleaned out immediately prior
the manufacturer’s instructions. to erection. The posts shall be placed centrally in the
pockets and be bedded on mortar designation (i)
11 Where ferrous components are permitted any complying with Clause 2404 and, unless otherwise
drilling of them shall be completed before the described in Appendix 12/1, the pockets shall be filled
application of any finish. up to finished foundation level with mix ST5 concrete.
12 Any hole drilled in plates with plastics sheeting to 5 Traffic signs mounted on posts, except those on
accommodate a rivet or bolt shall immediately prior to gantries, shall be erected to have their face plumb and
the insertion of the rivet or bolt have a clear lacquer, be orientated in relation to the carriageway in
recommended by the plastics sheeting manufacturer, accordance with Chapter 1 of the Traffic Signs Manual.
applied to its edge to prevent the ingress of moisture.
The surfaces of rivets or bolts exposed on the sign face 6 Traffic signs mounted on gantries shall be erected
shall be covered by a suitable material of a colour to as described in Appendix 12/6 and all other traffic signs
match that part of the face. shall be erected as described in Appendix 12/1.
13 (05/01) Prior to fitting any sign to any lighting 7 The site records required by Clause 1402, shall
column, the Contractor shall ensure that the sign is include daily records for non-lit traffic signs.
included in the technical approval of the lighting 8 No traffic sign shall be dismantled, resited or
column in accordance with the Technical Approval removed without the prior approval of the Overseeing
Scheme adopted by the Overseeing Organisation and Organisation.
with Standard BD 26. No holes shall be drilled in the
lighting column except those whose location and size
are included in the technical approval. 1209 Covering of Permanent Traffic Signs
14 Traffic signs to be erected on road lighting columns 1 Where it is required in Appendix 12/1 that
shall have fixings compatible with the column cross- permanent traffic signs be blanked-out or have an
section and finish. Wiring shall be contained in external alternative message, the method to be adopted shall
conduit complying with BS 4568. Conduits shall be comply with the following, unless otherwise described
affixed to concrete lighting columns with stainless steel in Appendix 12/1:
banding systems complying with AISI Grade 201.
Conduits shall be affixed to other lighting columns with (i) for plate signs: A cover plate compatible
stainless steel clamps which shall be screwed with with the plate sign’s material, or a covering
stainless steel screws into tapped holes in the lighting of a suitable, opaque, non damaging
column. Alternatively permanent cabling shall be material, or, for covering periods of up to
placed on the inside of the lighting column and shall one year, a self adhesive plastic film to
exit via a bushed drilled hole. support the temporary sign face sheeting;
(ii) for other traffic signs: A covering of a
Variable Message Traffic Signs suitable, opaque, non damaging material.
15 Variable message traffic signs shall comply with
this Clause.
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5
2 Cover plates shall be suitably fixed to give a 10 mm Distance Marker Posts

minimum air gap between the sign face and cover plate.
The fixing method shall not cause damage or staining to 2 Distance marker posts shall be made from plastics,
the sign face. Any holes remaining in the finished sign timber, or other materials described in Appendix 12/2.
face after removal of the plate shall be filled with a Hazard Marker Posts
suitable material, of a colour to match that part of the
face. 3 Hazard marker posts shall comply with
3 Where self adhesive plastic film is used it shall be BS 873 : Part 2. Post construction and colour and type
compatible with the sign face materials and be applied of reflective marker shall be as described in
and removed in compliance with the manufacturer’s Appendix 12/2.
instructions.
4 Any loose covering used must be sufficiently
#1212 (05/01) Road Markings
opaque to prevent reflection from and legibility of the General
covered sign and be securely fastened to the back of the
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sign. Under no circumstances shall tape or other 1 (08/03) Road markings shall be white or yellow
adhesive material be applied to the face of the sign. (Classes Y1 and Y2) complying with BS EN 1436 Table
Sufficient space shall be left between the covering and 6, as appropriate except where an alternative shade has
the face to permit air flow over the sign. been specified in Appendix 12/3. The markings shall
consist of continuous or intermittent lines, letters,
5 Traffic signs which are to be covered shall not be
figures, arrows or symbols and comply with sub-
erected on trafficked highways without the covering in
Clauses 2 to 12 of this Clause.
place.
6 Removal of any covering shall be carried out with Statutory requirements controlling road markings are
the minimum disturbance to traffic. contained in The Traffic Signs Regulations and General
Directions 2002 (Statutory Instrument 2002 No. 3113)
7 Irrespective of any requirement in Appendix 12/1 and subsequent amending Regulations.
to cover signs, any traffic sign erected at such a time
that its legend does not relate either wholly or in part to Permanent Road Markings
the traffic movement and route in operation, shall have
its sign face securely covered with one of the materials 2 (11/07) Permanent road markings shall be one of the
in sub-Clause 1 of this Clause until such time as its following materials and comply with the colour,
legend is applicable. location and material type requirements described in
Appendix 12/3:
1210 Permanent Bollards (i) thermoplastic road marking material or paint
1 Permanent bollards shall be as described in in accordance with BS EN 1871;
Appendix 12/1 and shall comply with appropriate (ii) permanent preformed road markings in
Clauses of this Series. accordance with BS EN 1790;
2 Internally illuminated bollards and, unless (iii) other materials as described in
otherwise described in Appendix 12/1 reflective-only Appendix 12/3.
bollards, shall be secured by stainless steel holding
down bolts, nuts and washers. Holding down bolts and They shall be also tested in road trials to the Roll-over
anchorages cast into the foundation shall be capable of class P5 in accordance with the procedure stated in
complying with the performance requirements of BS EN 1824 to demonstrate compliance with the
BS 873 : Part 3 when tested as described therein. performance requirements as stated in sub-Clauses 3 to
6. The test report shall give particulars of the quality
3 All bolts shall be lightly greased before final and quantity of the material, including drop on glass
installation and tightening to the bollard manufacturer’s beads laid at the test site for future reference and
torque setting. comparison purposes should such a need arise.
1211 Permanent Marker Posts 3 Road markings shall have the following road
performance as defined in BS EN 1436 for the period of
General the functional life starting from the date of application
or when the road is trafficked, whichever is later. The
1 Permanent marker posts shall be constructed to the materials to be used shall be to the same mix, material
dimensions and be installed in the locations and by quality, quantity and rate of application as used on the
methods described in Appendix 12/2 and shall comply test site.
with this Series and sub-Clauses 2 and 3 of this Clause.
Property BS EN 1436 Requirement Value 7 The pavement shall be prepared in accordance with
Reference the following:
Colour Table 6 1. White x, y co-ordinates (i) Where the marking is to be applied on
given concrete carriageways, the transverse
2. Yellow x, y co-ordinates texturing shall be freed from all traces of
Class Y1, Y2 given curing compound by wire brushing or other
Luminance Table 5 1. Class B2 0.3 approved means. Prior to the application of
Factor 2. Class B1 0.2 the thermoplastic material a tack coat
Skid Table 7 1. Class S1 45 compatible with the road surface and the
Resistance 2. Class S1 45 marking material shall be applied in
Retroreflect- Table 2 Class 1. Class R2 100 accordance with the manufacturer’s
ivity of RL for dry 2. Class R1 80 instructions.
markings (ii) On surface dressed carriageways, all loose
* Note: 1 = White, 2 = Yellow chippings where the marking is to be applied
shall be removed prior to application.
4 (11/07) The width tolerances and thickness for
screed, spray, preformed and extruded white or yellow 8 The application of permanent road markings shall
lines shall be in accordance with The Traffic Signs be in accordance with the Sector Scheme described in
Regulations and General Direction 2002. With the Appendix A. Road marking materials shall only be
exception of the road markings listed in Regulation 32 applied to surfaces which are clean and dry. Markings
(2) of The Traffic Signs Regulations and General shall be free from raggedness at their edges and shall be
Directions, in no case shall any materials be laid more uniform and free from streaks. Longitudinal road
than 6 mm thick. Unless specified, all white markings markings shall be laid to a regular alignment.
shall be reflectorised with glass beads in accordance Raised Rib Road Markings
with BS EN 1423 and BS EN 1424 by incorporation
(apart from preformed markings) into the road marking 9 Raised Rib Road Markings shall only be used on
mixture and to the wet surface of the marking. The glass motorways with full width hardshoulders or all-purpose
beads shall not have more than 1,000 ppm of Arsenic roads (both single and dual carriageway) with at least
Trioxide, 200 ppm of Lead and 1,000 ppm of Antimony. 1 metre wide hardstrips. They shall comply with
The Contractor shall supply test certificates showing sub-Clauses 1, 2(i), 3, 5, 6, 7 and 8 of this Clause.
compliance with these requirements. 10 Raised Rib Road Markings shall be white lines
5 Where there is requirement for improved visibility which are continuous over the sections where they are
in wet conditions at night, products showing the specified in Appendix 12/3. Where specified in
following performance in addition to that stated in Appendix 12/3 gaps shall be provided for drainage
sub-Clause 3 shall be used. purposes.
11 (08/03) Raised Rib Road Markings shall be in
Property BS EN 1436 Requirement Value accordance with The Traffic Signs Regulations and
Reference General Directions 2002 (Statutory Instrument 2002
Retroreflect- Table 3 Class RW3 50 No. 3113), Diagrams 1012.2 and 1012.3, as appropriate.
ivity Spacing of the transverse raised ribs shall be 500 mm or
250 mm as specified in Appendix 12/3.
12 Raised Rib Road Markings shall not be used
6 Where there is a requirement for improved skid adjacent to hatched areas or central reserve crossings
resistance as referred to in Appendix 12/3 products except as prescribed for use with diagrams 1040.3,
showing the following performance in addition to that 1040.5 and 1042.
stated in sub-Clause 3 shall be used. Temporary Road Markings
13 Temporary road markings shall only be adopted
Property BS EN 1436 Requirement Value
with the prior approval of the Overseeing Organisation.
Reference
They shall comply with sub-Clauses 1 to 8 of this
Skid Table 7 Class S3 55 Clause or if required to be removable, be constructed
Resistance only from a proprietary preformed road marking
material complying with BS EN 1790.
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7
14 When temporary road markings are used on Longitudinal Road Markings Lateral
(05/04)
surfaces that will continue to be used by public traffic Tolerances
after their removal, any shadow trace remaining after
their removal shall be permanently obliterated. 20 (05/04) For longitudinal road markings, the lateral
Preformed materials shall not be used for this tolerance shall be within ± 25mm from the designed
obliteration. position. Any discontinuities between road markings
shall be replaced with a smooth taper from one road
15 Temporary road markings constructed from a marking to the other. The length of the transition shall
proprietary preformed road marking material shall only be derived from table below. All road markings shall
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be adopted in locations and on types of road surface as comply with the dimensions, angles and proportions
described in Appendix 12/3 and shall comply with any stated in the Traffic Signs Regulations and General
other requirement therein. The marking material shall Directions 2002 (Statutory Instrument 2002 No.3113)
be new and together with any primer shall be stored and and any subsequent amending Regulations.
installed in accordance with the manufacturer’s
instructions and within the recommended shelf life.
16 Temporary preformed road markings shall only be Speed Limit (mph) Taper
applied to surfaces that are clean and dry. Upon removal 30 1 in 40
they shall be disposed of off Site and if any making
40 1 in 40
good is necessary to the road surface it shall be
satisfactorily carried out before the road is opened to 50 1 in 45
traffic. 60 1 in 50
70 1 in 55
Road Markings on Porous Asphalt Surfacing
17 Spray paint, thermoplastic applied by machine
screed, spray or extrusion or preformed road markings #1213 (05/01) Road Studs
shall be used for carriageway markings on porous
asphalt surfacing. Manual screeding shall not be Retroreflecting Road Studs
permitted except for directional arrows and similar 1 (08/03) Statutory requirements controlling
markings. retroreflecting road studs (both permanent and
Removal of Road Markings tempoarary) are contained in the Traffic Signs
Regulations and General Directions 2002 (Statutory
18 (05/08) The removal of road markings on surfaces Instrument 2002 No. 3113) regulations 31, 32 and
that will continue to be used by traffic shall be directions 57 and 58, the Traffic Signs (Amendment)
undertaken in a manner that will avoid damage to the General Directions 2003 (Statutory Instrument 2002
surface. No. 393) and any subsequent amending Regulations and
General Directions.
The removal of temporary road markings shall comply
with sub-Clauses 14 and 15 of this Clause. 2 (08/03) All retroreflecting road studs shall be
installed in accordance with the manufacturer’s
For bituminous running surfaces, the removal of
instructions and with the Sector Scheme described in
permanent road markings shall be by mechanical means
Appendix A.
or forced air abrasive (shot blasting) only. Hot
Compressed Air (HCA) lance shall be permitted on 3 (05/05) Retroreflecting road studs and components
other types of running surfaces. In all cases the which are not within the scope of BS EN 1463-1, but
Contractor shall submit details of the proposed method which have statutory type approval by the Secretary of
for the Overseeing Organisation’s consent. State under direction 58 of the Traffic Signs Regulations
and General Directions 2002 (Statutory Instrument
Masking of Road Markings 2002 No. 3113), and any subsequent amending General
19 (11/07) When black masking materials are required Directions can be incorporated into the Works.
to cover existing permanent road markings, they shall 4 (05/05) Not used.
comply with BS 7962. The total thickness of original
and masking materials shall not exceed 6 mm.

(05/05) Permanent Retroreflecting Road Studs stated in Appendix 12/4. The width of the top of the
blade shall be 45 ± 10 mm. Other dimensions shall be
5 (08/03) Permanent retroreflecting road studs shall be in accordance with Diagram 7102 of TSRGD 2002 or
installed in the locations and to any other requirements the Traffic Signs Regulations (Northern Ireland) 1997
as described in Appendix 12/3. as appropriate.
Temporary Retroreflecting Road Studs 5 FTD bases shall be so designed that they will stack
without binding and without causing damage to the
6 (08/03) Temporary retroreflecting road studs shall retroreflective surfaces. Additionally the blades and
not be used for a second application. Adhesive used for their attachment to the base or fixing shall be so
the temporary retroreflecting road studs shall be designed that the blade’s face presents throughout its
removed from the carriageway on completion of the design life a plane to the approaching traffic no more
Works. than 12.5° from the vertical.
Non retroreflecting Road Studs 6 FTD bases may be coloured red, black, grey or
brown. They may have a 100 mm wide white reflective
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7 All non retroreflecting road studs shall be installed line placed on one edge of the base provided:
in accordance with the manufacturer’s instructions in
(i) the edge of the base where the white line is
locations, and complying with any other requirements,
to be attached comprises a sloping surface
which is at an angle to the road surface of no
Retroreflecting Road Studs on Porous Asphalt more than 60° and is of such dimensions
Surfacing either to fully accommodate the 100 mm
wide white line or, where the angle between
8 (05/05) The edges of recesses for inset the road surface and the sloping surface
retroreflecting road studs in porous asphalt surfacing exceeds 30°, to accommodate at least 80 mm
shall be milled when the material has cooled to ambient of the width of the white line, the excess
temperature. Care shall be exercised when removing (maximum 20 mm) being returned onto the
porous asphalt to form the recess to prevent damage top surface of the base;
occurring to the cut edges and to prevent detritus (ii) the material from which the base is
clogging the porous asphalt surfacing. Surface applied manufactured allows proper adhesion or
road studs shall not be applied if there is evidence of attachment of the white reflective line to
moisture present on the surface of porous asphalt, nor prevent it becoming detached during normal
shall inset road studs be installed if moisture is present use;
in the recess after milling of the asphalt.
(iii) the coverage of white reflective material is
maintained at more than 70% of the area
1214 Traffic Cones, Traffic Cylinders, Flat treated.
Traffic Delineators and Other Traffic 7 (05/01) The white reflective strip material shall
Delineators comply with BS EN 1436 and BS EN 1871 or
BS EN 1790 as appropriate. Additionally when tested
General using a portable retroreflectometer the white line shall
have a coefficient of retroreflectance of Class R2 or
1 (05/05) Traffic cones and traffic cylinders,
better to Table 2 of BS EN 1436.
hereinafter termed cones and cylinders, shall comply
with Designation 1 or Designation 2 of BS EN 13422. 8 (08/03) FTD blades shall be coloured red and white
Cones shall be to Category A. as indicated in Diagram 7102 of TSRGD 2002 or the
Traffic Signs Regulations (Northern Ireland) 1997 as
2 Flat Traffic Delineators, hereinafter termed FTDs,
appropriate.
shall comply with sub-Clauses 3 to 17 of this Clause.
9 The white portions of the FTD blades shall comply
3 An FTD shall comprise a flat blade fixed to a base.
with the chromaticity co-ordinates and luminance factor
The flat blade may incorporate stiffeners provided that
given in BS 873 : Part 6.
they do not encroach into the white retroreflective area.
10 (05/05) The red portions of the FTD shall comply
4 (08/03) FTDs shall be constructed of rubber or
with the chromaticity co-ordinates and luminance factor
plastic materials. It shall be possible to insert and
for traffic cones given in BS EN 13422 when measured
remove blades without requiring a special tool. The
in accordance with BS 873 : Part 1.
height of the FTD shall be 750 mm or 1000 mm as

11 That part of the blade coloured white shall Permanent Cones, Cylinders, FTDs and Other
comprise retroreflective material, complying with the Delineators
requirements for Class 1 or Class 2 as specified in
BS 873 : Part 6, which shall be securely applied or 20 (05/01) Where required in Appendix 1/5 the
attached to the blade to prevent it becoming detached Contractor shall arrange for the tests described in sub-
during normal use. Clauses 22 to 56 of this Clause, for cones, cylinders,
FTDs and other delineators, to be carried out at a
12 The red portions may also be retroreflective. UKAS approved testing laboratory. The numbers to be
13 (05/05) The minimum mass of the FTD including tested, as given in Appendix 1/5, are to be selected at
any ballast recommended by the manufacturer shall random from the batch to be supplied under the
comply with the mass of a traffic cone as defined in Contract. Failure of any test will result in rejection of
BS EN 13422. the batch.
14 FTDs shall be clearly and durably marked with the Temporary Cones, Cylinders, FTDs and Other
following information in the following order: Delineators
(a) the name, trade mark or other means of
21 The Contractor shall submit to the Overseeing
identification of the manufacturer or vendor;
Organisation certification substantiating that at least 1
(b) the title and date of this document, ie. in every 500 of any batch of cones, cylinders, FTDs and
Specification for Highway Works, with delineators to be used in the Temporary Works have
appropriate date. passed the tests described in sub-Clauses 22 to 56 of
this Clause as appropriate.
The marking shall be in characters legible at a normal
reading distance such that the total area of the marking
Testing
does not exceed 30 cm². Additionally the legend
‘DUAL CARRIAGEWAY AND MOTORWAY USE 22 (05/05) Cones and cylinders shall be tested in
ONLY’ shall be applied to the lowermost red portion of compliance with BS EN 13422.
the blade, using block capitals of minimum height 15
mm, in such a location that it can be clearly seen when 23 FTDs shall be tested in compliance with
the FTD is in position. sub-Clauses 24 to 55 of this Clause.
15 All markings shall be sufficiently durable to last 24 Test procedures shall be carried out on each size of
the expected life of the FTD to which they are applied FTD and each method of attachment between blade and
and in no case less than 5 years. base.
16 When checked by inspection and by rubbing 25 When tested in accordance with sub-Clauses 31 to
lightly, first for 15 seconds with a piece of cloth soaked 38 of this Clause with the exception of the white
in water and then for 15 seconds with a piece of cloth retroreflective material, no part of the FTD shall crack,
split or deform.
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soaked in petroleum spirit, followed by 15 seconds with
a piece of cloth soaked in diesel oil, the marking shall 26 When samples with retroreflective portions
still be legible. attached are tested in accordance with sub-Clauses 31
17 FTDs shall be supplied with the following to 38 of this Clause the coefficient of luminous
information: intensity, R (as defined in Publication CIE No 54;
Retroreflection, definition and measurement), after
(a) instructions for ballasting (if required); testing shall be not less than 80% of the value previous
(b) instructions for fixing blades to bases. to the test.
18 Other traffic delineators hereinafter termed 27 When tested in accordance with sub-Clauses 39 to
delineators shall be as described in Appendix 12/4. 43 of this Clause, no part of the FTD with the exception
of white retroreflective material, shall crack, fracture or
19 The Contractor shall submit to the Overseeing split and any ballast or ballast container shall not have
Organisation a copy of a test certificate confirming that become displaced within the base or separated from it.
samples of the identical type of cone, cylinder, FTD or Any ballast container as either an integral part of the
delineator as those to be used in the Works and supplied base or enclosed within it shall not have been damaged
as permanent cones, cylinders, FTDs or delineators to the extent that ballast is discharged. Caps or bungs to
under the Contract, have been tested and found to ballast containers shall not have been forced from their
comply with sub-Clauses 1 to 18 of this Clause. sockets or other fixings.

28 When tested in accordance with sub-Clauses 44 to water at 20 ± 5°C for 10 minutes. After draining for 10
49 of this Clause, no part of the FTD with the exception minutes the coefficient of luminous intensity, R, shall
of white retroreflective material shall crack, fracture or be measured in accordance with sub-Clause 34 of this
split. Bases shall remain in contact with the reference Clause.
surface.
38 The sample shall be examined and any damage,
29 When tested in accordance with sub-Clauses 50 to percentage change in the coefficient of luminous
55 of this Clause, no part of the FTD with the exception intensity, or any detachment of a blade from its base
of the white retroreflective material shall crack, fracture shall be reported.
or split. Bases shall remain in contact with the reference
surface. Drop Test
30 Throughout the tests in sub-Clauses 31 to 38, 44 to 39 FTDs requiring the addition of ballast shall be
49, and 50 to 55 of this Clause, the blade shall remain ballasted as instructed by the manufacturer.
fixed in position. On completion of the testing in
accordance with sub-Clauses 44 to 49 and 50 to 55 of 40 The FTD shall be conditioned for a period of not
this Clause the residual deflection of the top of the less than 2 hours at a temperature of 32 ± 2°C.
blade in any horizontal direction, measured 30 seconds 41 Within 1 minute after conditioning the FTD shall
to 60 seconds after completion of the tests, shall be not be suspended with its normal vertical axis horizontal
more than 12.5% of the height of the FTD. The height (any cap or bung to a ballast container forming an
of the FTD, H, is as measured from the reference integral part of the FTD shall be positioned uppermost)
surface. and with its lowest part 1500 ± 5 mm above a solid
horizontal surface and dropped once vertically from rest
Low Temperature Impact Test onto the solid surface.
31 The test shall be conducted using a steel ball swung 42 The test detailed in sub-Clause 41 shall be repeated
on a pendulum. The apparatus shall be as shown in after conditioning at a temperature of -16 ± 2°C.
HCD Drawing Number K3. The steel ball shall have a 43 Any damage observed shall be reported.
mass of 0.9 ± 0.045 kg and be suspended by one or two
steel pendulum wires of not more than 1 mm diameter Bending Test
so that the pendulum radius is 1750 ± 10 mm. The point
of impact shall be vertically beneath the centre of radius 44 The test shall be carried out on specimens with and
of the pendulum and at a height on the specimen of H/2 without retroreflective portions attached.
± 10 mm where H is the height of a FTD above the 45 The blade shall be fixed to the base in accordance
reference surface. with the manufacturer’s instructions. The blade and its
32 FTDs shall be fixed to the reference surface using base shall be conditioned for a period of not less than 2
the base. hours at a temperature of -16 ± 2°C. Within 1 minute
after conditioning, the blade shall be bent over about its
33 The test shall be carried out on specimens with and base line by applying a force to the face of the blade at
without retroreflective portions attached. a point on its vertical centre line H/2 ± 10 mm from the
34 For samples with retroreflective portions attached, top, so that the top edge touches the reference surface
or a surface coplanar with it as indicated in the HCD
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the coefficient of luminous intensity, R, of every such

face at an observation angle of 20° and at an entrance Drawing Number K3. H is the height of the FTD. When
angle normal to the face of the blade prior to the the top edge of the blade touches the reference surface
conditioning shall be determined; the definitions of the bending force shall be removed immediately.
observation angle and entrance angle being those given 46 From 30 seconds to 60 seconds after completion
in BS 873 : Part 1. the maximum residual horizontal deflection of the top
35 All test samples shall be conditioned for a period of the blade shall be measured from the vertical axis
of not less than 2 hours at a temperature of -16 ± 2°C. passing through the centre of the base of the blade and
Impact testing shall be carried out within 60 seconds perpendicular to the reference surface.
after conditioning. 47 The test shall be repeated in the opposite direction.
36 Impact shall be made in ambient conditions of not 48 The procedure in sub-Clauses 45 to 47 of this
greater than 20°C. Clause shall be repeated at a temperature of 32 ± 2°C.
37 Within 1 hour of impacting, samples shall be
immersed with retroreflective portions attached, in

49 The deflections, any damage observed, any Organisation prior to installation, and comply with sub-
detachment of the blade from its base, and any Clauses 2 to 6 of this Clause.
movement of the base shall be reported.
Temporary traffic signs shall comply with The Traffic
Fatigue Test Signs Regulations and General Directions 2002, or The
Traffic Sign (Welsh and English Language Provisions)
50 The test shall be carried out on specimens with and Regulations and General Directions 1985, or The
without retroreflective portions attached. This test is to Traffic Signs Regulations (Northern Ireland) 1997 as
be carried out on a different specimen to that or those appropriate, and be designed in accordance with
tested in sub-Clauses 31 to 38 and 44 to 49 of this Clause. Working Drawings for Traffic Sign Design and
51 The blade shall be fixed to the base in accordance Manufacture (Volumes 1, 2 and 3) and where
with the manufacturer’s instructions. The test shall be appropriate Local Transport Notes 1/94 and Chapter 7
carried out after conditioning the blade and its base for and any other relevant Chapters of the Traffic Signs
a period of not less than 2 hours at a temperature of -16 Manual.
± 2°C. 2 (05/01) Temporary traffic signs shall be constructed
52 By applying a force to the face of blade at a point as follows:
on its vertical centre line H/2 ± 10 mm from the top, the (i) plate signs and internally illuminated signs:
top of the blade shall be oscillated as indicated in the
HCD Drawing Number K3 at a frequency of 60 (a) (11/06) the coefficient of retroreflection
oscillations per minute to 90 oscillations per minute at of the material for the faces of signs
an amplitude of H/4 for 10 minutes with the reference used for Standard and Relaxation works,
surface held in a horizontal position. H is the height of as defined in Chapter 8 (Part 1 Design)
the FTD. One oscillation is the movement from the of the Traffic Signs Manual, and any
upright position to the maximum amplitude in one amendment thereto including the
direction, then to the maximum amplitude in the amendments specified in
opposite direction and then the return to the upright sub-Clause 117.8, shall be as given in
position. BS 873 : Part 6 for Class 1 material;
53 From 30 seconds to 60 seconds after completion (b) where the sign is to be erected for less
the maximum residual horizontal deflection of the top than 6 months, it shall, unless
of the blade shall be measured from the vertical axis Appendix 12/1 requires it to be
passing through the centre of the base of the blade and constructed to a similar standard as a
perpendicular to the reference surface. permanent sign, be either a portable sign
complying with BS 873: Part 2 or a
54 The procedure in sub-Clauses 51 to 53 of this fixed short life sign complying with
Clause shall be repeated at a temperature of 32 ± 2°C. sub-Clause 3 of this Clause;
55 The deflection, any damage observed and any (c) where the sign is to be erected for
detachment of the blade from its base shall be reported. periods of 6 months or more, or where
56 Other traffic delineators shall be tested in Appendix 12/1 requires it to be
compliance with Appendix 12/4. constructed to the standard for a
permanent sign, it shall comply with the
requirements for permanent traffic
1215 Road Danger Lamps and High Intensity signs;
Flashing Beacons (d) in addition to either (b) or (c) above,
1 (05/05) Road danger lamps and high intensity electrical work related to temporary
flashing beacons shall be used in accordance with traffic signs shall comply with the Series
Regulations 55 and 54 respectively of TSRGD 2002, or 1400 except Clauses 1402, 1410 and
Regulations 44 and 43 respectively of the Traffic Signs 1425;
Regulations (Northern Ireland) 1997 as appropriate. (ii) bollards and marker posts shall comply with
Clauses 1210 and 1211;
1216 Temporary Traffic Signs (iii) road studs:
(a) temporary retroreflecting road studs
1 (08/03) Temporary traffic signs shall be designed by
shall comply with Clause 1213 and only
the Contractor, comply with Clause 1201, satisfy
be installed for periods of up to 3
Clause 117, have the consent of the Overseeing
months and thereupon be replaced;

12
(b) (05/05) if permanent retroreflecting road (ii) construction:

studs are used for temporary purposes
(a) sign plates shall be constructed on
they shall comply with Clause 1213;
similar principles to those required for
(iv) road markings, cones, cylinders and permanent signs, although stiffening
delineators, road danger lamps and high may be omitted provided the sign plate
intensity flashing beacons shall comply with passes the bending test given in
Clauses 1212, 1214 and 1215 as appropriate; BS 873 : Part 1;
(v) portable traffic signals and haul route (b) stiffening frames constructed of timber
crossing signals shall, where relevant, members shall be jointed so that they
comply with Clause 1217; withstand adverse weather conditions;
(vi) any other signal, lamp, barrier or device shall (c) mounting posts constructed of timber
be suitable for its intended purpose and shall have dimensions that are sufficient
where relevant shall comply with appropriate to withstand the estimated loading on
British Standards. the sign;
3 Fixed short life signs shall be constructed as (d) fixing of signs to the stiffening frame
follows: where required, and to the mounting
posts shall be by screwing, nailing or
(i) materials:
gluing;
(a) sign plates may be constructed of
(e) timber sign plates, stiffening frames and
materials to the standard for a
mounting posts shall be preserved with
permanent sign, or alternatively shall be
copper/chrome/arsenic (CCA)
constructed of timber, hardboard,
complying with BS 4072. The sign plate
plywood or chipboard;
face shall be finished to comply with
(b) stiffening frames for sign plates BS 873 : Part 6.
constructed of timber, hardboard,
4 Erection of temporary traffic signs mounted on
plywood or chipboard, shall be
posts shall comply with Clause 1208.
constructed of timber, mild steel or
aluminium sections; 5 Any temporary covering of temporary traffic signs
shall comply with Clause 1209. Any temporary
(c) mounting posts shall be constructed of
covering of road studs and road markings shall comply
steel, cast iron, aluminium alloy,
with any requirements described in Appendix 12/3.
reinforced or prestressed concrete or
timber; 6 Removal of temporary traffic signs shall be carried
out as soon as they become superfluous or a hazard to
(d) fittings for signs made of materials to
traffic. Methods of removal shall ensure the minimum
the standard for a permanent sign shall
disturbance to traffic consistent with safety. Making
be similar to those used for permanent
good shall be carried out immediately after removal of
signs. For signs made of timber,
the traffic sign.
hardboard, plywood or chipboard,
fittings shall be of steel, stainless steel, 7 Posts shall not protrude above the top of the sign
or brass wood screws, or wire nails. unless supporting an external luminaire, in which case
Adhesives may be used for fixing the protrusion shall be kept to a minimum.
provided they are weatherproof and are
not affected by variations in
temperature; 1217 Traffic Signals
(e) sign plates constructed of timber,
General
hardboard, plywood or chipboard shall
be sealed or otherwise treated to ensure 1 Traffic signals shall comprise road junction signals,
that the final finish will provide a pelican and puffin pedestrian crossing signals, haul
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satisfactory appearance and will not route signals and wig-wag signals and shall be of the
deteriorate during the period the sign is type described in Appendix 12/5.
expected to be in use;
2 (05/01) Traffic signals shall comply with sub-
Clauses 3 to 15 of this Clause and the requirements
described in Appendix 12/5. The installation and

maintenance of traffic signals shall be in accordance equipment cabinet shall be a protective conductor and
with the quality management scheme described in shall bond the earth terminal at the post to the main
Appendix A. earth terminal.
3 (05/01) Traffic signal equipment shall comply with 11 Cable testing shall be in accordance with
BS 505 : 1971 (AMD 1990, 1976) as amended by Clause 1424. Tests (a), (b), (c), (e), (f), (g), (h) and (j)
Specification TR 0102. It shall consist of control as defined in sub-Clause 1424.2 shall be conducted and
equipment including detector loops of a type which has all measurements recorded.
received statutory type approval by the Secretary of
State in accordance with the procedure described in Telecommunications Carrier Interface
Specification TRG 0500. Traffic signal equipment with
such statutory type approval shall be deemed valid for 12 Where a connection interface to the plant of a
use in Northern Ireland. They shall be maintained and telecommunications carrier is specified in
serviced as described in Appendix 12/5. Appendix 12/5 the installation shall comply with the
rules and regulations of that carrier.
4 All traffic safety and management measures
associated with work on traffic signals shall comply Posts
with Clause 117, and any work entailing the switching
off of existing signals shall not be carried out until the 13 Posts for traffic signals shall be installed in
highway authority has been informed and until agreed compliance with Clause 1203 and in the locations
alternative traffic management measures are in specified in Appendix 12/5.
operation to safeguard and control vehicles using the
highway. Signal Heads
14 All backing boards shall have a border of Class 1
Controllers retroreflective material (white). Pressure sensitive
5 Controllers shall be provided and installed as material shall normally be supplied but vacuum applied
described in Appendix 12/5. The cabinet shall be material may be used in accordance with the
mounted on a foundation, with or without an adjacent manufacturer’s process. Application of pressure
inspection chamber as described in Appendix 12/5. The sensitive material shall take place only on dry surfaces.
foundation shall make provision for the entry of the An ambient temperature of 15°C minimum is
appropriate number of cable ducts. recommended for satisfactory adhesion. The material
shall have a 50 mm width throughout. Where the
6 Traffic signal controllers shall, in addition to any continuous border bridges each backing board/signal
testing carried out in compliance with Clause 1424 be head a distinct cut edge shall be made to avoid any
tested before delivery to Site and again after installation subsequent stretching/ shrinkage of dissimilar surfaces.
but before commissioning, to ensure they comply with The finished border shall be of a neat appearance and
the specification in Appendix 12/5. not made up of short lengths of cuttings.
Cabling and Electrical Requirements Road Markings
7 Traffic signal equipment on each post shall be 15 Road markings associated with traffic signals shall
connected to the controller in accordance with the comply with Clause 1212.
requirements described in Appendix 12/5.
8 The installation shall comply with BS 7671
Regulations for Electrical Installations (IEE Wiring 1218 Detector Loops
Regulations) and the rules and regulations of the 1 The installation and testing of detector loops shall
electricity supplier which provides the supply. be in accordance with Specification MCH 1540.
9 (05/01) Cables shall be PVC insulated and sheathed
600/1000 V grade with steel wire armouring to BS 6346
and shall be installed in ducts in compliance with 1219 Controlled and Un-controlled Crossings
Clause 1421 and terminated in compliance with 1 The location of controlled and un-controlled
Clause 1423. Reinstatement shall be in compliance with crossings shall be as described in Appendix 12/5.
Clause # 706. Details shall be as described in Appendix 12/5.
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10 Earthing of all posts, pushbutton boxes and the 2 (05/01) Surfacing of Zebra crossing areas shall be
controller cabinet shall comply with Clause 1420. One laid with materials and to methods specified in
conductor in each cable between a post and the Appendix 12/5. The finished surfacing shall have a

minimum skid resistance Class of S3 when tested in BS 873 : Part 7. Painting shall comply with Series 1900
compliance with BS EN 1436. and be as described in Appendix 19/2.
3 (05/01) Non retroreflecting road studs shall comply
Aluminium or Aluminium Alloy Posts and Post
with Clause 1213.
Housings
4 Road markings shall be white and comply with
Clause 1212 for permanent markings and be of the 5 (05/01) Aluminium or aluminium alloy posts and
material described in Appendix 12/5. post housings shall, unless otherwise required in
Appendix 19/2, be left unpainted, except for the
5 Traffic signals, related control and other equipment bituminous coating required by BS 873 : Part 7 below
where incorporated in controlled crossings together ground level. A matt appearance shall be achieved in
with installation and reinstatement shall comply with accordance with sub-Clause 6(ii) of this Clause.
Clause 1217 for permanent traffic signals.
Aluminium or Aluminium Alloy Sign Plates,
Framework and Stiffening and Luminaire Housings
1220 Traffic Signs on Gantries
6 (05/01) Backs of aluminium or aluminium alloy
1 Where traffic signs (including signals) are erected sheet and planks forming plate signs and external parts
on gantries the signs shall comply with the of luminaire housings and other permanently exposed
requirements of the relevant Clauses of this Series. components shall, to prevent specular reflection, be
2 Fabricated steel gantries shall be constructed to the dulled using a method to be agreed by the Overseeing
requirements described in Appendix 12/6, and to Organisation or be coated with either paint or plastics
comply with Series 1800. Reinforced or prestressed as follows:
concrete gantries shall be as described in (i) plastics coating, and pre-treatment before its
Appendix 12/6 and shall comply with Series 1700.
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application, shall be in compliance with

BS 873 : Part 6;
1221 Preparation and Finish of Metal and (ii) surfaces to be painted shall be lightly
Other Surfaces abraded in accordance with sub-Clauses
1903.5 and 1903.6 or degreased and etch
General primed with primer detailed in Standard
BD35, Item No. 14. Except for etch primed
1 Permanent traffic signs and, where specified in surfaces, all surfaces shall be immediately
Appendix 12/1 prescribed temporary traffic signs shall cleaned in accordance with sub-Clause
be prepared, protected against corrosion and finished in 1903.9. All surfaces, including etch primed
compliance with BS 873 : Part 6 and with surfaces, shall be applied with one coat of
sub-Clauses 2 to 9 of this Clause. matt polyurethane paint to Standard BD35,
Item No. 168, and colour as described in
Faces Appendix19/2. The paint application shall
comply with the appropriate recoat times
2 Faces of sign plates shall be prepared to receive (over etch primer) as detailed in the paint
sign face materials in compliance with BS 873 : Part 6 manufacturer’s data sheet and Clauses in
and to the recommendations of the sign face material Series 1900.
manufacturer following completion of any preparation
and finish in sub-Clauses 3 and 6 of this Clause. Internally Housed Electrical Components and
Ancillary Equipment
Steel Sign Plates, Purlins, Frames and Fittings
7 Ferrous steel shall be finished inside and out by
3 Steel sign plates, frames and fittings and purlins galvanizing, electro-plating or zinc or aluminium spray
shall be prepared and protected in compliance with all in accordance with Series 1900, or other equivalent
BS 873 : Part 6 and be as described in Appendix 12/1. preparation and finish. Aluminium and other metals
Preparation to clean steel 2nd Quality and painting of shall unless otherwise required in Appendix 14/4 be left
surfaces shall comply with Series 1900. untreated.
Steel Posts and Post Housings
4 (05/01) Steel posts and post housings shall be
prepared and protected in compliance with

Stainless Steel Components

8 (05/01) Unless otherwise required in
Appendix 19/2 stainless steel shall be left untreated
except where the component is visible against the sign
face when it shall be covered by a suitable material, of a
colour to match that part of the face.
Cast Iron and Cast Steel Components

9 (05/01) External surfaces shall be prepared and
protected as described in Appendix 19/2. Cabinets and
feeder pillars shall have final coats of paint applied on
Site after final installation including the fitting of any
internal apparatus required as part of the Permanent
Works. Internal surfaces shall unless otherwise
specified in Appendix 19/2 receive the same treatment
as for external surfaces except that final paint coats
shall be applied before internal components are
installed.
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1201NAW (05/01) Regulations, Sign Sign Classification

Classification and Standards
4 For the purposes of the Contract the following
classifications apply:
Regulations
(i) (02/03) permanent traffic signs. Any of the
1 (08/03) Subject to paragraphs 2 and 3 below, all traffic signs prescribed in the Regulations, or
traffic signs used (including retroreflecting road studs specially authorised by the Welsh Assembly
and road markings), whether permanent or temporary, Government, or any part thereof, designed to
shall be of the size, shape, colour and type prescribed remain in position at the completion of the
for that use in The Traffic Signs Regulations and Permanent Works or a traffic cone, cylinder
General Directions 2002 (Statutory Instrument 2002 or other traffic delineator to be retained by
No. 3113), The Traffic Signs (Welsh and English the Employer;
Language Provisions) Regulations and General
Directions 1985 (Statutory Instrument 1985 No. 713), (ii) (02/03) prescribed temporary traffic signs.
the Zebra, Pelican and Puffin Pedestrian Crossings Any of the traffic signs defined in the
Regulations and General Directions 1997 (Statutory Regulations, or specially authorised by
Instrument 1997 No. 2400) and subsequent amending the Welsh Assembly Government, or any
Regulations. Other relevant requirements are contained part thereof, described in Appendix 12/1
in the above Regulations and General Directions, apart which, unless otherwise described in
from bilingual sign layouts which shall be as stated in Appendix 12/1, comply with the
Appendix 12/1. requirements of a permanent traffic sign but
which will not remain in position at the
2 (02/03) Signs that are not prescribed in Regulations completion of the Permanent Works;
need to be specially authorised by the Welsh Assembly
Government. Where the Contractor proposes to use (iii) (02/03) temporary traffic signs. Any of the
non-prescribed temporary traffic signs, he shall obtain traffic signs defined in the Regulations, or
the agreement of the Overseeing Organisation to their specially authorised by the Welsh Assembly
intended design and location. Where the Contractor Government, or any part thereof, designed
proposes to use prescribed temporary traffic signs, he by the Contractor, in compliance with
shall obtain the agreement of the police and the Clause 1216 which will not remain in
highway authority to their intended location. The position at the completion of the Permanent
Contractor shall obtain authorisation and approval from Works.
the Overseeing Organisation for the use of the signs at
the specific locations proposed.
3 (02/03) Signs that are changeable by means other
than the purely mechanical require statutory type
approval for their construction and operating
mechanisms by the Welsh Assembly Government. This
requirement is in addition to the need for the design of
the sign to be prescribed or specially authorised. The
Contractor’s proposal for signs that require statutory
type approval shall include the reference numbers of
any approval already issued in respect of that
equipment. The signs shall not be installed until
appropriate approval or confirmation of existing
approval, by the Overseeing Organisation has been
obtained.
Amendment - August 2003 --`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---

W1F

1201NI (05/01) Regulations, Sign Classification or specifically authorised by the Overseeing

and Standards Organisation, or any part thereof, described
in Appendix 12/1 which, unless otherwise
1 (11/06) Subject to sub-Clauses 2 and 3 below, all described in Appendix 12/1, comply with the
traffic signs used (including retroreflecting road studs requirements of a permanent traffic sign but
and road markings) whether permanent or temporary, which will not remain in position at the
shall be the size, shape, colour and type prescribed for completion of the Permanent Works;
that use in The Traffic Signs Regulations (Northern
Ireland) 1997, the Zebra, Pelican and Puffin Pedestrian (iii) temporary traffic signs. Any of the traffic
Crossings Regulations (Northern Ireland) 2006, and signs defined in the Regulations, or
subsequent amending Regulations. specifically authorised by the Overseeing
Organisation, or any part thereof, designed
2 Signs that are not prescribed in Regulations need to by the Contractor in compliance with Clause
be specially authorised by the Overseeing Organisation. 1216 which will not remain in position at the
Where the Contractor proposes to use non-prescribed completion of the Permanent Works.
temporary traffic signs, he shall obtain the agreement of
the Overseeing Organisation to their intended design
and location. Where the Contractor proposes to use 1212NI (05/01) Road Markings
prescribed temporary traffic signs, he shall obtain the
agreement of the police and the highway authority to General
their intended location. The Contractor shall obtain
authorisation and approval from the Overseeing 1 Road markings shall be white or yellow (Classes
Organisation for the use of the signs at the specific Y1 and Y2) complying with BS EN 1436 Table 6, as
locations proposed. appropriate except where an alternative shade has been
specified in Appendix 12/3. The markings shall consist
3 Signs that are changeable by means other than the
of continuous or intermittent lines, letters, figures,
purely mechanical require type approval by the
arrows or symbols and comply with sub-Clauses 2 to 12
Overseeing Organisation. This requirement is in
of this Clause.
addition to the need for the design of the sign to be
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prescribed or authorised. The Contractor’s proposal for Statutory requirements controlling road markings are
signs that require type approval shall include the contained in The Traffic Signs Regulations (Northern
reference numbers of any approval already issued in Ireland) 1997 and subsequent amending Regulations.
respect of that equipment. The signs shall not be
installed until appropriate approval or confirmation of Permanent Road Markings
existing approval, by the Overseeing Organisation, has
2 (11/07) Permanent road markings shall be one of the
been obtained.
following materials and comply with the colour,
Sign Classification location and material type requirements described in
Appendix 12/3:
4 For the purpose of the Contract the following (i) thermoplastic road marking material or paint
classifications apply: in accordance with BS EN 1871;
(i) permanent traffic signs. Any of the traffic (ii) permanent preformed road markings in
signs prescribed in the Regulations, or accordance with BS EN 1790;
specifically authorised by the Overseeing
Organisation, or any part thereof, designed (iii) other materials as described in
to remain in position at the completion of the Appendix 12/3.
Permanent Works or a traffic cone, cylinder They shall be also tested in road trials to the Roll-over
or other traffic delineator to be retained by class of P5 in accordance with procedure stated in
the Employer; BS EN 1824 to demonstrate compliance with the
(ii) prescribed temporary traffic signs. Any of performance requirements as stated in sub-Clauses 3 to
the traffic signs defined in the Regulations, 6. The test report shall give particulars of the quality
Amendment - November 2007 N1

and quantity of the material, including drop on glass 6 Where there is a requirement for improved skid
beads laid at the test site for future reference and resistance as referred to in Appendix 12/3, products
comparison purposes should such a need arise. showing the following performance in addition to that
stated in sub clause 3 shall be used.
3 Road marking shall have the following road
performance as defined in BS EN 1436 for the period of
Property BS EN 1436 Requirement Value
the functional life starting from the date of application Reference
or when the road is trafficked, whichever is later. The
materials to be used shall be to the same mix, material Skid Table 7 Class S3 55
quality, quantity and rate of application as used on the Resistance
test site.
Property BS EN 1436 Requirement* Value 7 The pavement shall be prepared in accordance with
Reference the following:
Colour Table 6 1. White x, y co-ordinates (i) where the marking is to be applied on

given concrete carriageways, the transverse
2. Yellow Class x, y co-ordinates texturing shall be freed from all traces of
Y1, Y2 given curing compound by wire brushing or other
approved means. Prior to the application of
Luminance Table 5 1. Class B2 0.3 the thermoplastic material a tack coat
Factor 2. Class B1 0.2
compatible with the road surface and the
Skid Table 7 1. Class S1 45 marking material shall be applied in
Resistance 2. Class S1 45 accordance with the manufacturer’s
instructions;
Retroreflect- Table 2 Class 1. Class R2 100
ivity of RL for dry 2. Class R1 80 (ii) on surface dressed carriageways, all loose
chippings where the marking is to be applied
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markings
shall be removed prior to application.
* Note: 1 = White, 2 = Yellow 8 The application of permanent road markings shall
4 (11/07) The width tolerances and thickness for be in accordance with the Sector Scheme described in
screed, spray, preformed and extrusion white or yellow Appendix A. Road marking materials shall only be
lines shall be in accordance with the Traffic Signs applied to surfaces which are clean and dry. Markings
Regulations (Northern Ireland) 1997. With the shall be free from raggedness at their edges and shall be
exception of the road markings listed in Regulation 29 uniform and free from streaks. Longitudinal road
(2) of The Traffic Signs Regulations (Northern Ireland), markings shall be laid to a regular alignment.
in no case shall any materials be laid more than 5 mm
thick. Unless otherwise specified, all white markings Raised Rib Road Markings
shall be reflectorised with glass beads in accordance 9 Raised Rib Road Markings shall only be used on
with BS EN 1423 and BS EN 1424 by incorporation motorways with full width hardshoulders or all-purpose
(apart from preformed markings) into the road marking roads (both single and dual carriageway) with at least 1
mixture and to the wet surface of the marking. The metre wide hardstrips. They shall comply with sub-
glass beads shall not have more than 1,000 ppm of Clauses 1, 2(i), 3, 5, 6, 7 and 8 of this Clause.
Arsenic Trioxide, 200 ppm of Lead and 1,000 ppm of
Antimony. The Contractor shall supply test certificates 10 Raised Rib Road Markings shall be white lines
showing compliance with these requirements. which are continuous over the sections where they are
specified in Appendix 12/3. Where specified in
5 Where there is requirement for improved visibility Appendix 12/3 gaps shall be provided for drainage
in wet conditions at night, products showing the purposes.
following performance in addition to that stated in sub-
Clause 3 shall be used. 11 Raised Rib Road Markings shall be in accordance
with The Traffic Signs Regulations (Northern Ireland)
Property BS EN 1436 Requirement Value 1997, Diagrams 1012.2 and 1012.3, as appropriate.
Reference Spacing of the transverse raised ribs shall be 500 mm or
250 mm as specified in Appendix 12/3.
Retroreflect- Table 3 Class RW3 50
ivity 12 Raised Rib Road Markings shall not be used
adjacent to hatched areas or central reserve crossings

except as prescribed for use with diagrams 1040.3, Masking of Road Markings
1040.5 and 1042.
19 (11/07) When black masking materials are required
Temporary Road Markings to cover existing permanent road markings, they shall
comply with BS 7962. The total thickness of original
13 Temporary road markings shall only be adopted and masking materials shall not exceed 6 mm.
with the prior approval of the Overseeing Organisation.
They shall comply with sub-Clauses 1 to 8 of this (05/04) Longitudinal Road Markings Lateral
Clause or if required to be removable, be constructed Tolerances
only from a proprietary preformed road marking
material complying with BS EN 1790. 20 (05/04) For longitudinal road markings, the lateral
tolerance shall be within ± 25 mm from the designed
14 When temporary road markings are used on position. Any discontinuities between road markings
surfaces that will continue to be used by public traffic shall be replaced with a smooth taper from one road
after their removal, any shadow trace remaining after marking to the other. The length of the transition shall
their removal shall be permanently obliterated. be derived from table below. All road markings shall
Preformed materials shall not be used for this comply with the dimensions, angles and proportions
obliteration. stated in the Traffic Signs Regulations (Northern
15 Temporary road markings constructed from a Ireland) 1997 and any subsequent amending
proprietary preformed road marking material shall only Regulations.
be adopted in locations and on types of road surface as
described in Appendix 12/3 and shall comply with any Speed Limit (mph) Taper
other requirement therein. The marking material shall
be new and together with any primer shall be stored and 30 1 in 40
installed in accordance with the manufacturer’s 40 1 in 40
instructions and within the recommended shelf life.
50 1 in 45
16 Temporary preformed road markings shall only be
applied to surfaces that are clean and dry. Upon 60 1 in 50
removal they shall be disposed of off Site and if any 70 1 in 55
making good is necessary to the road surface it shall be
satisfactorily carried out before the road is opened to
traffic. 1213NI (05/01) Road Studs
Road Markings on Porous Asphalt Surfacing Retroreflecting Road Studs
17 Spray paint, thermoplastic applied by machine 1 Statutory requirements controlling retroreflecting
screed, spray or extrusion. or preformed road markings road studs are contained in The Traffic Signs
shall be used for carriageway markings on porous Regulations (Northern Ireland) 1997 and subsequent
asphalt surfacing. Manual screeding shall not be amending Regulations.
permitted except for directional arrows and similar
markings. 2 All retroreflecting road studs shall comply with
BS EN 1463-1 and 1463-2, and shall be installed in
Removal of Road Markings accordance with the manufacturer’s instructions and the
Sector Scheme described in Appendix A.
18 The removal of road markings on surfaces that will
3 Retroreflecting road studs and components which
continue to be used by traffic shall be undertaken in a
do not fall into a category of BS EN 1463, but which
manner that will avoid damage to the surface.
have type approval of the Overseeing Organisation can
The removal of temporary road markings shall comply be incorporated into the Works. They shall be installed
with sub-Clauses 14 and 15 of this Clause. in accordance with the manufacturer’s instructions.
The removal of permanent road markings shall be by 4 The Contractor shall submit details of the
mechanical means only. The Contractor shall submit retroreflecting road studs he proposes to use in the
details of the system he proposes to use to the Works to the Overseeing Organisation for approval.
Overseeing Organisation for approval.

--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---

Permanent Retroreflecting Road Studs

5 Permanent retroreflecting road studs shall be
installed in the locations and to any other requirements
as described in Appendix 12/3.
Temporary Retroreflecting Road Studs

6 Temporary retroreflecting road studs shall be of the
fluorescent green-yellow type to BS EN 1463-1 and
shall be appropriate for the situation concerned. They
shall not be used for a second application.
Adhesive used for the temporary retroreflecting road
studs shall be removed from the carriageway on
completion of the Works.
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
Non retroreflecting Road Studs
7 All non retroreflecting road studs shall be installed
in accordance with the manufacturer’s instructions in
locations, and complying with any other requirements,
Retroreflecting Road Studs on Porous Asphalt

Surfacing
8 (05/05) The edges of recesses for inset
retroreflecting road studs in porous asphalt surfacing
shall be milled when the material has cooled to ambient
temperature. Care shall be exercised when removing
porous asphalt to form the recess to prevent damage
occurring to the cut edges and to prevent detritus
clogging the porous asphalt surfacing. Surface applied
road studs shall not be applied if there is evidence of
moisture present on the surface of porous asphalt, nor
shall inset road studs be installed if moisture is present
in the recess after milling of the asphalt.
Amendment - November 2007 N4F

SERIES 1300
(11/03) ROAD LIGHTING COLUMNS AND
BRACKETS, CCTV MASTS AND
CANTILEVER MASTS
Contents
Clause Title Page

#1301 (05/01) General 2 OVERSEEING ORGANISATIONS OF
1302 (11/03) Design of Lighting Columns, SCOTLAND, WALES AND NORTHERN
Brackets, CCTV Masts, Cantilever Masts, IRELAND
Foundations, Anchorages and Attachment
Systems 2
1303 (05/01) Data Sheets 3 Northern Ireland
1304 (05/01) Identification and Location Markings 3
1301NI (05/01) General N1
1305 Installation of Foundations, Anchorages
and Attachment Systems 3 1308NI (05/01) Handling, Transport and Erection N1
1306 Site Tests on Anchorages in Drilled Holes 4
# denotes a Clause or Sample Appendix which has a substitute
1307 Materials and Surface Finishes 5
National Clause or Sample Appendix for one or more of the
#1308 (05/01) Handling, Transport and Erection 5 Overseeing Organisations of Scotland, Wales or Northern Ireland.

BS 5649-2: 1978 (AMD 3136, 1979)
for Lighting Columns 5
BS EN 40-5 and BS EN 40-6 for
Lighting Columns and Brackets, CCTV
Masts and Cantilever Masts 6
BS 5649-5 for Lighting Columns, CCTV
Masts and Cantilever Masts 10
1312 (11/03) Attachments to Lighting Columns,
CCTV Masts and Cantilever Masts 11
1313 (05/01) Laminated Glass Fibre Reinforced
Plastic (GFRP) Lighting Columns 11
1314 Brackets for Laminated GFRP Lighting
Columns 12

1
Specification for Highway Works Road Lighting Columns and Brackets, CCTV Masts and Cantilever Masts
ROAD LIGHTING COLUMNS AND BRACKETS,

(11/03)
CCTV MASTS AND CANTILEVER MASTS
#1301 (05/01) General The Contractor shall where required design:

1 (11/03) This Series shall apply to the design, supply (i) anchorages and attachment systems for
and installation of lighting columns and brackets and columns and masts with flange plates to
CCTV masts and cantilever masts for traffic signals foundation or bridge deck;
and/or speed cameras (hereafter called cantilever masts) (ii) foundations for columns and masts with
within the following dimensional limitations: flange plates;
(i) For steel, aluminium and concrete lighting as described in Appendices 13/1, 13/4 and 13/7.
columns:
3 (05/06) Lighting columns and brackets, CCTV masts
(a) post top columns not exceeding 20 m and cantilever masts shall be supplied and installed in
nominal height; compliance with the relevant requirements of
(b) columns with brackets not exceeding BS EN 40-1, BS EN 40-3-1, BS EN 40-3-2,
18 m nominal height; BS EN 40-4, BS EN 40-5, BS EN 40-6 and BS 5649-2,
BS 5649-5 and BS 5649-7 together with the
(c) bracket projections not exceeding 0.25 x amendments and additions stated in Clauses 1309, 1310
nominal height or 3 m whichever is the and 1311 and all the other requirements of this Series.
lesser.
4 Brackets for lighting columns shall include wall
(ii) For glass fibre reinforced plastic lighting
mounted brackets and fixtures.
columns:
5 Temporary lighting on temporary diversions for
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(a) columns not exceeding 10 m nominal
traffic, and crossovers, shall comply with this Series.
height;
6 (11/03) Where lighting columns, CCTV masts and
(b) bracket projections not exceeding 1.5 m.
cantilever masts are to be in the vicinity of overhead
(iii) For steel CCTV masts: power lines the Contractor shall ensure that the
(a) post top masts not exceeding 25 m appropriate Electricity Authorities are notified and give
nominal height. written agreement to the specific clearances to be
provided and that warning notices as described in
(iv) (11/03) For steel cantilever masts: Appendices 13/1, 13/4 and 13/7 are permanently fixed
(a) nominal height not exceeding 8.5 m; to these columns prior to erection.
(b) cantilever projection not exceeding 7 (11/03) Headroom over the carriageway for
8.5 m. cantilever mast shall be in accordance with the
requirements of paragraph 3.2 of Standard BD 88
Where nominal height is taken as the distance between (DMRB 2.2.13).
of the underside of the flange plate and the highest
point of the mast (see Figure 1 of BD 88
(DMRB 2.2.13)). 1302 (11/03) Design of Lighting Columns,
2 (11/03) The Contractor shall propose lighting Brackets, CCTV Masts, Cantilever Masts,
columns and brackets, CCTV masts and cantilever Foundations, Anchorages and Attachment
masts which have been designed by the manufacturer. Systems
The manufacture, supply and verification of lighting
columns and bracket arms shall comply with the quality 1 (11/03) Lighting columns, brackets, CCTV masts,
management scheme described in Appendix A. cantilever masts, the foundations of both planted
columns and columns and masts with flange plates, and
The Contractor shall design foundations for planted the anchorages and attachment systems for columns and
lighting columns and cantilever masts in accordance masts with flange plates shall be designed to comply
with BD 26 Chapter 8 (DMRB 2.2.1) or of BD 88/03 with the requirements of Standards BD 26 (DMRB
Chapter 8 (DMRB 2.2.13) using the soil type 2.2.1), BD 83 (DMRB 2.2.11), BD 88 (DMRB 2.2.13)
information as described in Appendices 13/1 and 13/7. and the technical approval scheme adopted by the

The Contractor shall submit to the Overseeing It shall be located either within the base compartment
Organisation a copy of the design and check certificates or, except in the case of hard stamping, immediately
for lighting columns, brackets, CCTV masts, cantilever above or below the door. It shall not be located on the
masts and foundations. The design of the foundations door.
shall be appropriate to the soil types encountered on All hard stamping shall be made only in a secondary
site, as identified in Appendices 13/1, 13/4 and 13/7. member of the column/mast and shall be done in a
manner, which will not induce any stresses in the
Aesthetic Requirements
material of the main member of the column/mast.
2 (11/04) The aesthetic design of lighting columns, 3 The bracket identification mark shall be permanent
luminaires including those with bracket arms, CCTV and legible and be:
masts and cantilever masts shall be submitted by the
Contractor to the Overseeing Organisation. The design (i) hard stamped; or
of lighting columns and luminaires including those with (ii) formed in the material of the bracket on an
bracket arms shall comply with the general advice given external face only.
in BS 5489-1 for the appearance of lighting installations
The mark shall be located either on the luminaire spigot
by day and by night both from the viewpoint of the road
or on the underside of the bracket adjacent to the
and from the surrounding neighbourhood.
column shaft or wall or pole mounting plate.
4 Alternatively the bracket identification mark shall
1303 (05/01) Data Sheets be hard stamped or formed in a detachable label
supplied fixed to the bracket. This label shall be moved
1 (11/03) The Contractor shall complete the details in from its temporary position and fixed on erection to a
Appendices 13/2, 13/5 and 13/8 in accordance with the suitably provided hole next to the label on the column.
instructions given in Appendices 13/3, 13/6 and 13/9.
The Contractor shall provide the Overseeing 5 (11/03) In addition, location marks for inspection
Organisation with triplicate copies of the completed and maintenance purposes shall be applied to each
Data Sheets for each type of column and bracket, column as described in Appendices 13/1, 13/4 and 13/7.
CCTV mast and cantilever mast not later than the date
stated in Appendices 13/1, 13/4 and 13/7. 1305 Installation of Foundations, Anchorages
2 (11/03) The columns and brackets, CCTV masts and and Attachment Systems
cantilever masts shall not be ordered or erected until the
Overseeing Organisation has notified its acceptance of (11/03) Planted Lighting Columns and Cantilever
the completed Data Sheet in writing to the Contractor. Masts
1 (11/03) A layer of ST4 concrete 75 mm thick,
1304 (05/01) Identification and Location complying with Clause 2602 shall be placed and
Markings compacted in the bottom of the excavation up to the
base of the column or mast post.
1 (11/03) All lighting columns and brackets, CCTV
masts and cantilever masts shall carry unique 2 The cable entry slot shall be temporarily plugged
identification marks which indicate the name of the as necessary in order to prevent any ingress of concrete
manufacturer, year of manufacture, the unique product or filling material during the concreting and backfilling
code and other relevant information, to enable details of operations.
the lighting column and bracket, CCTV masts and 3 (11/03) The hole into which the lighting column or
cantilever masts to be determined by reference to the cantilever mast is placed shall be backfilled as follows:
appropriate Lighting Column and Bracket, CCTV masts
and cantilever masts Data Sheets. (i) in the case of metal and glass fibre
reinforced plastic columns with concrete or
2 The column and mast identification marks shall be other material described in Appendix 13/1;
permanent, legible and clearly visible and be:
(ii) in the case of concrete columns with
(i) on a permanent fixed label; or concrete or earth fill complying with
(ii) hard stamped; or sub-Clause 5 of this Clause or other material
described in Appendix 13/1;
(iii) formed in the material of the column/mast on
an external face only. (iii) (11/03) in the case of cantilever masts with
concrete or other material described in
Appendix 13/7.

3
4 (11/03) Concrete backfill shall be ST5 concrete 11 For anchorages in drilled holes the hole location
complying with Clause 2602, well compacted by shall be checked to ensure that the hole will be clear of
vibration over the full planting depth of the column/ reinforcement before drilling is carried out.
mast post. A duct equal in size to the width of the cable
12 Before installation of anchorages in drilled holes,
entry hole, shall be formed through the concrete filling
the hole shall be sound, clean and dry and the tolerance
using a suitable preformed lining tube capable of
of the hole shall be within the values given by the
retaining its cross-sectional shape during compaction.
anchorage manufacturer.
The concrete shall be placed 10 mm above ground level
adjacent to the column/mast post and taper to ground 13 The threads of steel anchorages shall be lined with
level 100 mm from the column/mast post face. grease having a high resistance to creep and being
suitable for hot or cold smearing. The grease shall
5 (11/03) Earth backfill shall be Class 8 material
provide protection to the threads for a minimum of
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
complying with Clause 601, Table 6/1 unless otherwise
either 18 months under cover or 6 months exposed on
described in Appendices 13/1 and 13/7. The material
Site.
shall be placed in 150 mm thick layers and shall be well
rammed and compacted in order to provide full lateral 14 (11/04) Attachment systems shall be tightened to the
support to the planting depth of the column/mast post. appropriate torque and have the minimum thread
If the backfilling is disturbed for any reason it shall be engagement calculated in accordance with the
reinstated in compliance with this Clause. A duct equal requirements of BS 6779-1: 1998 (Amd. No. 14290,
in size to the width of the cable entry hole, shall be 21 March 2003) sub-Clause 6.6.4.
made through the backfill material using a suitable 15 All voids in anchorages, attachment systems and
preformed lining tube capable of retaining its cross- flange plates shall be filled with a non-setting passive
sectional shape during compaction. filler to prevent the collection of water.
(11/03) Columns, CCTV Masts and Cantilever Masts
with Flange Plates 1306 Site Tests on Anchorages in Drilled
6 (05/01) Concrete in the foundations shall comply Holes
with Series 1700. 1 (11/04) The Contractor shall carry out site tests on
7 (11/03) The bedding mortar between the underside anchorages in drilled holes. For the purpose of this
of the column/mast flange plate and the top of the sub-Clause the types of fixing referred to in clause 1 of
concrete base shall comply with Clause 2601. The BS 5080-1 shall include “anchorages”. Where
bearing stresses in any bedding mortar under the flange anchorages are tested they shall be loaded
plates shall not exceed 20 N/mm2. incrementally in tension in accordance with BS 5080-1
except that they shall be capable of resisting a test load
8 (11/03) A cable duct, 75 mm diameter, shall be
equal to 10 per cent above the nominal tensile load to
provided through the foundation or bridge component
be resisted by the anchorage in lieu of testing to failure.
as described in Appendices 13/1, 13/4 and 13/7.
The tensile load shall be determined in accordance with
9 (11/03) Steel anchorages and attachment systems the criteria given in sub-Clauses 8.15 to 8.18 of
shall be used and the anchorage shall include an Standard BD 26 (DMRB 2.2.1), Chapter 7 of Standard
internally threaded component to receive the attachment BD 83 (DMRB 2.2.11) and Chapter 9 of BD 88
system, i.e. holding down bolt. (DMRB 2.2.13). Incremental loads shall be held for not
less than half a minute and the test load for not less than
10 (11/03) Where anchorages in drilled holes are to be
five minutes. Readings shall be taken immediately after
used, the Contractor shall, unless otherwise described in
applying load and at the end of the time intervals stated
Appendices 13/1, 13/4 or 13/7, submit to the
above.
Overseeing Organisation at least 4 weeks before
installation well attested and documented evidence that 2 (11/03) The total movement of the anchorage shall
the proposed anchorage is: not exceed 1.0 mm during the test. Any evidence of slip
during loading up to the test load, as demonstrated by a
(i) capable of complying with the test
significant change in the slope of the load/extension
requirements specified in Clause 1306; and
curve, shall constitute failure.
(ii) capable of resisting pulsating loading.
3 The Contractor shall test anchorages selected on
Anchorages in drilled holes of an expanding type shall behalf of the Overseeing Organisation at the testing
not be used. frequency in accordance with Appendix 1/5.

1307 Materials and Surface Finishes 4 (11/03) Columns and masts shall be installed in
accordance with the manufacturer’s recommendations.
1 (11/05) All steel fixings including doors, door The door shall face the direction described in
hinges, chains and locks shall be stainless steel to Appendices 13/1, 13/4 and 13/7.
BS EN 10029, BS 970-1 or BS EN ISO 3506-1 and
BS EN ISO 3506-2 as appropriate or steel to 5 Wall mounted lighting brackets and fixtures shall
BS EN 10025-1, BS EN 10025-2 or BS EN 40-5 and be fixed as described in Appendix 13/1.
BS EN 40-6 as amended in Clause 1310, galvanized in
compliance with Series 1900.
2 Where different metals are in contact, BS 5649-2 : 1978 (AMD 3136, 1979) for
consideration shall be given to the necessary measures Lighting Columns
to avoid galvanic corrosion.
(11/03) Page 5 - Clause 3
3 (11/03) The surface preparation and protection of
steel lighting columns, brackets and wall mountings, Delete Note “Lantern fixing angle 5° or 15°” and
steel CCTV masts and steel cantilever masts, mountings Insert Note “Lantern fixing angle 3°, 5° or 15°”.
and housings shall comply with Appendix 19/1 and the
relevant Clauses in Series 1900. In the Table insert additional bracket projections w of
“0.5 m, 1.0 m, 1.5 m and 2.5 m”.
4 (11/03) The exterior and interior surfaces of the
intended planted depth of an aluminium alloy lighting (11/03) Page 6 - Clause 4
column shaft and a length of 250 mm above the ground Figure 4
level shall be coated with a non-porous electrically
insulating bitumen with a minimum layer thickness of Delete cable entry slot width dimension “50 mm” and
250 microns. The coating shall only be applied after Insert cable entry slot width dimension “X”.
degreasing and after an approved preliminary treatment
in order to ensure adhesion. Insert additional note as follows:
5 The underside of an aluminium alloy flange plate “5) Cable entry slot width dimension “X” shall be
shall be treated before erection with bituminous paint either 75 mm or 50 mm as described in
complying with BS 3416 or BS 6949. Appendix 13/1.”
(11/03) Page 8 - Clause 6
6 The finish to concrete lighting columns and
brackets shall be Class F3 in compliance with Delete existing Tables and replace by the following:
Clause 1708.
h sa) a d1a) d2
#1308 (05/01) Handling, Transport and m min min min
Erection
≤5 8 200 M12 13
1 (11/03) Lighting columns and brackets, CCTV masts ≤12 10 300 M16 17
and cantilever masts shall be handled, transported and
stored in such a way as to avoid any structural damage ≤20 15 300 M24 26
--`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---
or damage to the surface protection system. Any 400

damage incurred shall be made good in such a way that
the structural performance and durability of the item Delete ‘1’ from Figure 7 and ‘c’ from Figure 8.
shall be in no way reduced.
Insert additional notes as follows:
and cantilever masts shall be stored clear of the ground “2 Unless otherwise described in Appendix 13/1
in such a way that contact with cement, groundwater, circumferential slotted holes shall be used instead of
soil or ash or other deleterious material is prevented and round holes in the flange plates in order to allow ± 5° of
that water does not accumulate on any surfaces or rotational adjustment.
inside sections. Suitable packings shall be placed 3 Where slotted holes are required in the flange plate to
between the columns/masts to allow a free passage of allow for rotational adjustment of the column then the
air and dispersion of water. flange plate sizes shall be increased to give a suitable
3 All rivets, bolts, nuts, washers, screws, small plates edge distance.
and small articles generally shall be suitably packed and
identified. All such items shall be stored under cover.

4 The distance from the edge of the hole or slot to the 1310 (11/04) Amendments and Additions to
edge of the plate shall be not less than d2. BS EN 40-5 and BS EN 40-6 for Lighting
5 Washers complying with BS 4320 shall be used Columns and Brackets, CCTV Masts and
between the holding down fastener and the flange Cantilever Masts
plate.” 1310.1 For Lighting Columns and Brackets:
(11/04) Page 9 - Clause 7 (11/04) BS EN 40-5 and BS EN 40-6 shall apply subject
Delete existing Table for post top lanterns and replace to the following amendments and additions:
by the following: (11/05) Page 6 - Clause 4 (BS EN 40-5)
Delete the last five lines in sub-Clause 4.1 and replace
d1b) l1 with “The steel shall be equivalent to or better than
60.3 70 BS EN 10025-1, BS EN 10025-2, Grade S275 JR or
100 BS EN 10210, Grade S275 JOH”.
76.1 76 (11/05) Page 6 - Clause 4 (BS EN 40-5 and BS EN 40-6)
100 Delete sub-Clause 4.2 and replace with: “The steel used
101.6 250 for foundation bolts shall be equivalent to or better than
BS EN 10025-2, BS EN 10025-2, Grade S275 JR.”
108.0 250
(11/04) Page 6 - Clause 5 (BS EN 40-5 and BS EN 40-6)
Delete existing Table for side entry lanterns and replace (11/04) replace
“prEN 40-2” with “BS 5649-2 : 1978
by the following: (AMD 3136, 1979)”
(11/04) Page 6 - Clause 6 (BS EN 40-5 and BS EN 40-6)
d2b) l2 (11/04) replace “prEN 40-3-3” with “BS 5649-7”
33.7 80 (11/04) Pages 6 and 7 - Clause 7 (BS EN 40-5 and
42.4 110 BS EN 40-6)
400 (11/03) Delete sub-Clauses 7.1, 7.2 and 7.3 and insert the
48.3 110 following:
60.3 110 “7.1.Steel and Aluminium Lighting Columns
250 (11/03) 7.1.1 General. Arc welding of ferritic steels shall
400 comply with BS EN 1011-1 and BS EN 1011-2,
Welding - Recommendations for welding of metallic
(11/04) Page 9 - Note b materials. Arc welding of stainless steels shall comply
with BS 4677. Arc welding of aluminium alloys shall
Delete “ISO 64 : 1974” and insert “ISO 4200”
comply with BS EN 1011-1 and BS EN 1011-4.
(11/03) Page 10 - Clause 8
(11/05) 7.1.2Procedures. Written welding procedures
8.7 Column cross-section shall be used with testing to BS EN ISO 15607,
BS EN ISO 15609-1 and BS EN ISO 15614-1 for steel
Insert additional sub-Clause as follows:
and BS EN ISO 15607, BS EN ISO 15609-1 and
“8.7.1.3 Material thickness tolerance BS EN ISO 15609-2 for aluminium alloys and shall
(+ unspecified, - 5%)”. apply to all production and repair procedures. These
8.7.2.2 Deviation in shape shall be subject to reapproval after a period of seven
years. When applying BS EN ISO 15607,
Delete content of entire sub-Clause and insert the BS EN ISO 15609-1 and BS EN ISO 15614-1 the
following: welding consumables and procedures used for steel
“Cross-section dimensional tolerances ± 5% with a shall be such that the mechanical properties of
maximum of ± 10 mm.” deposited weld metal will not be less than the
respective minimum specified values of the parent
8.8.2 Diameter of lantern connection (ungalvanised) metal being welded. Weld testing shall be undertaken
(11/04) Delete “ISO 64 : 1974” and insert “ISO 4200” by an appropriate organisation accredited in accordance
with sub-Clauses 105.3 and 105.4. Approval shall be by
an Independent Inspecting Authority using Registered

6
Welding Engineers, Registered Welding Quality angle shall not be less than 110°. The surface of all
Engineers or equivalent. Welding procedures shall be welds shall be free from cracks, lack of fusion including
approved in accordance with BS EN ISO 15613. overlap, and slag. Isolated discontinuous porosity may
Pre-production test pieces shall represent the main be accepted provided it is not detrimental to the
assembly types. galvanizing process. Undercut shall not result in a
section loss of more than 5% over any 50 mm length of
(11/05) 7.1.3 Welder Qualification. All welders shall be
joint, nor shall its depth exceed 0.5 mm or 10% of the
approved to BS EN 287-1 for steel and
thickness, whichever is the less.
BS EN ISO 9606-2 for aluminium alloys. The tests
shall include in addition an application test (11/03) 7.1.4.3 Magnetic Particle Inspection (MPI) and
representative of the ‘main structural’ joints on which Liquid Penetrant Inspection. MPI shall be applied in
the welder is to be approved to work. The main accordance with BS EN ISO 9934-1 to joints in steel
structural joints shall include, where relevant, the lighting columns selected in accordance with 7.1.4.5,
flange plate joint, the base compartment to shaft joint, where any of the material thickness exceeds 20 mm.
the door reinforcement, any intermediate column joint, Liquid penetrant inspection in accordance with
the column to bracket joint and the column seam weld. BS EN 571-1 shall be applied to transverse welds in
Welders shall be subject to reapproval in accordance aluminium columns selected in accordance with 7.1.4.5.
with BS EN 287-1 and BS EN ISO 9606-2. Weld testing Notwithstanding the requirements of 7.1.4.5, one of the
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shall be undertaken by an appropriate organisation above methods shall be applied as appropriate where on
accredited in accordance with sub-Clauses 105.3 and visual inspection the presence of cracking or lack of
105.4. Approval shall be by an Independent Inspecting fusion may be suspected. To aid inspection the profile
Authority using Registered Welding Engineers, of the weld may be dressed by burr grinding provided
Registered Welding Quality Engineers or Welding that the specified throat size and leg length is still
Inspectors certified by the Certification Scheme for maintained. The surface of the weld shall be free of
Weldment Inspection Personnel (CSWIP) or equivalent. cracks, lack of fusion and slag.
Test results shall be kept current and made available for
(11/04) 7.1.4.4Ultrasonic Testing. All butt joints selected
review on request.
in accordance with 7.1.4.5 shall be ultrasonically tested
7.1.4 Inspection and Non-Destructive Testing in accordance with BS EN 1714 where the column shaft
is 8 mm thick or greater. The weld shall be free of
(11/03) 7.1.4.1Inspection Personnel. The manufacturer
cracks. The height of buried slag, lack of fusion or lack
shall provide suitable personnel to carry out inspection
of penetration shall not exceed 3 mm. Within 6 mm of
of production welds as required in 7.1.4.2 to 7.1.4.4.
the outer surface, their individual length shall not
Personnel conducting visual inspection shall have a
exceed 5 mm. The resulting net throat area loss over
nationally recognised certificate of competence
any 50 mm length of weld shall not exceed 5%.
appropriate to the type of welding being inspected.
Personnel conducting non-destructive testing (NDT) 7.1.4.5 Frequency of Testing. Joints for MPI, liquid
shall be certified according to a nationally recognised penetrant inspection or ultrasonic testing shall be
certification scheme appropriate to the equipment used selected as follows:
and the weld groups inspected all in accordance with
10% of lighting columns of each type shall be
BS EN 473. Evidence of training and qualification shall
inspected. The sample shall include all variations
be retained and made available for examination when
in joint geometry, material thickness and weld size
required. The results of all weld inspections shall be
covered by the basic type, that are within the scope
recorded.
of 7.1.4.3 and 7.1.4.4. If non-conformances are
(11/04) 7.1.4.2 Visual Inspection. All welds shall be found the scope of MPI, liquid penetrant inspection
subject to visual inspection in accordance with and ultrasonic testing shall be doubled. If further
BS EN 970 prior to any NDT and galvanizing. Weld non-conformances are found, the whole batch shall
surfaces shall be free of slag residues and sharp edges. be tested.
All surfaces shall be free of traces of weld spatter, arc
7.1.4.6 Reporting. Inspection records for production
strikes and contaminants. The apparent throat
welds shall be retained by the manufacturer for seven
dimensions of butt welds and the apparent leg length
years and those covering the production periods relating
and apparent throat dimensions of fillet welds, as
to the lighting columns supplied shall be made available
measured by a welding gauge and taking into account
for examination.
any known lack of fit, shall not be less than those
specified, except that local shortfalls up to 0.5 mm may 7.1.5 Destructive Testing. Copies of certified reports of
be accepted provided the average over any 50 mm destructive tests on lighting columns supplied under
length is not less than the specified dimension. The toe earlier contracts with the Overseeing Organisation shall
be made available for examination.
The Contractor shall supply sample joints cut from Page 12 sub-Clause 13.6.1 (BS EN 40-5 and
(11/04)
complete lighting columns for destructive testing as BS EN 40-6)
selected on behalf of the Overseeing Organisation. The
(11/04) In the first paragraph delete “in 7.2”
sample joints shall be cut from the column, extension
piece, bracket and welded anchorage where relevant. In third paragraph delete “13.6.3” and add “ 7.1.4.2,
The basis of selection shall be as follows: 7.1.4.3, 7.1.4.4 and 7.1.4.5”
a) For orders of 1 to 10 lighting columns - one (11/04) Pages 12 and 13 Clause 13 (BS EN 40-5 and
complete lighting column for each type, BS EN 40-6)
unless destructive testing has been carried Delete sub-Clauses 13.6.2, 13.6.3 and 13.6.4
out within the last year on a lighting column
of that type. The manufacture, supply and (11/04) Pages 13, 14 and 15 Clause 14 (BS EN 40-5 and
verification of lighting columns and bracket BS EN 40-6)
arms shall comply with the quality Delete sub-Clauses 14.5.1, 14.5.2, 14.5.3 and 14.5.4
management scheme described in
Appendix A.
1310.2 For CCTV Masts and Cantilever
(11/03)
b) For orders of 11 to 300 lighting columns - Masts:
one complete lighting column for each type
unless destructive testing has been carried (11/04) BS EN 40-5 applies subject to the following
out within the last month on a lighting amendments:
column of that type where the lighting Page 6 - Clause 4
column to be tested was also selected on
(11/05) Delete the last five lines in sub-Clause 4.1 and
behalf of the Overseeing Organisation.
replace with: “The steel shall be equivalent to or better
c) For orders exceeding 300 lighting columns - than BS EN 10025-1, BS EN 10025-2, Grade S275 JR
two complete lighting columns for each type. or BS EN 10210, Grade S275 JOH”.
Acceptance criteria shall be as specified in 7.1.4, except (11/05) Delete sub-Clause 4.2 and replace with: “The
that in 7.1.4.2 the throat and leg dimension shall apply steel used for foundation bolts shall be equivalent to or
to the true rather than the apparent dimension. better than BS EN 10025-1, BS EN 10025-2, Grade
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In the event that there is a non-conformance arising S275 JR”.
from a serious deviation in materials, preparation, Page 7 - Clause 7
assembly, or welding procedure, the batch concerned
Delete sub-Clauses 7.1, 7.2 and 7.3 and insert the
shall be rejected and further production of the columns
affected stopped until such time as the fault has been following:
corrected. A minor non-conformance shall only be (11/03) “7.1.Steel CCTV masts and Cantilever masts
accepted on the basis that further sampling and testing
7.1.1 General. Arc welding of ferritic steels shall
(11/04)
shows that fault is not repetitive and in the view of the
comply with BS EN 1011-1 and BS EN 1011-2. Arc
Overseeing Organisation will not in that instance impair
welding of stainless steels shall comply with
structural integrity.
BS EN 1011-3.
If the problem can be traced to a particular
(11/05)7.1.2 Procedures. Written welding procedures
manufacturing period, operator, piece of equipment or
shall be used with testing to BS EN ISO 15607,
batch of materials and if proper traceability to
BS EN ISO 15609-1 and BS EN ISO 15614-1 for steel
individual batches of components can be assured, only
and shall apply to all production and repair procedures.
those batches affected may be subject to rejection.
These shall be subject to reapproval after a period of
The destructive test reports shall be retained by the seven years. When applying BS EN ISO 15607,
manufacturer and recorded in a register for a period of BS EN ISO 15609-1 and BS EN ISO 15614-1 the
two years. The destructive test specimens shall be welding consumables and procedures used for steel
retained for a period of 12 months. These shall be made shall be such that the mechanical properties of
available for examination on future contracts with the deposited weld metal will not be less than the
Overseeing Organisation. respective minimum specified values of the parent
metal being welded. Weld testing shall be undertaken
7.1.6 Remedial Work. Welds which do not comply with
by an appropriate organisation accredited in accordance
the Specification may be repaired to an approved
with sub-Clauses 105.3 and 105.4. Approval shall be by
procedure, as described in 7.1.2.”
an Independent Inspecting Authority using Registered
Welding Engineers, Registered Welding Quality

Engineers or equivalent. Welding procedures shall be galvanizing process. Undercut shall not result in a
approved in accordance with BS EN ISO 15613. section loss of more than 5% over any 50 mm length of
Pre-production test pieces shall represent the main joint, nor shall its depth exceed 0.5 mm or 10% of the
assembly types. thickness, whichever is the less.
(11/05)7.1.3 Welder Qualification. All welders shall be (11/03)7.1.4.3 Magnetic Particle Inspection (MPI) and
approved to BS EN 287-1. The tests shall include in Liquid Penetrant Inspection. MPI shall be applied in
addition an application test representative of the ‘main accordance with BS EN ISO 9934-1 to joints in steel
structural’ joints on which the welder is to be approved CCTV masts and cantilever masts selected in
to work. The main structural joints shall include, where accordance with 7.1.4.5, where any of the material
relevant, the flange plate joint, the base compartment to thickness exceeds 20 mm. Liquid Penetrant Inspection
shaft joint, the door reinforcement, any intermediate in accordance with BS 571-1 shall be applied to
mast joint, the mast to bracket joint and the mast seam transverse joints in masts selected in accordance with
weld. Welders shall be subject to reapproval in 7.1.4.5. Notwithstanding the requirements of 7.1.4.5,
accordance with BS EN 287-1. Weld testing shall be one of the above methods shall be applied as
undertaken by an appropriate organisation accredited in appropriate where on visual inspection the presence of
accordance with sub-Clauses 105.3 and 105.4. Approval cracking or lack of fusion may be suspected. To aid
shall be by an Independent Inspecting Authority using inspection the profile of the weld may be dressed by
Registered Welding Engineers, Registered Welding burr grinding provided that the specified throat size and
Quality Engineers or Welding Inspectors certified by leg length is still maintained. The surface of the weld
the Certification Scheme for Weldment Inspection shall be free of cracks, lack of fusion and slag.
Personnel (CSWIP) or equivalent. Test results shall be
7.1.4.4 Ultrasonic Testing. All butt joints selected in
kept current and made available for review on request.
accordance with 7.1.4.5 shall be ultrasonically tested in
7.1.4 Inspection and Non-Destructive Testing accordance with BS EN 1714 where the mast shaft is
8 mm thick or greater. The weld shall be free of cracks.
(11/03) 7.1.4.1 Inspection Personnel. The manufacturer
The height of buried slag, lack of fusion or lack of
shall provide suitable personnel to carry out inspection
penetration shall not exceed 3 mm. Within 6 mm of the
of production welds as required in 7.1.4.2 to 7.1.4.4.
outer surface, their individual length shall not exceed
Personnel conducting visual inspection shall have a
5 mm. The resulting net throat area loss over any
nationally recognised certificate of competence
50 mm length of weld shall not exceed 5%.
appropriate to the type of welding being inspected.
Personnel conducting non-destructive testing (NDT) (11/03)7.1.4.5 Frequency of Testing. Joints for MPI,
shall be certified according to a nationally recognised liquid penetrant inspection or ultrasonic testing shall be
certification scheme appropriate to the equipment used selected as follows:
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and the weld groups inspected all in accordance with
10% of CCTV masts of each type shall be
BS EN 473. Evidence of training and qualification shall
inspected, except for orders of 1 to 10 masts, in
be retained and made available for examination when
which case 50% shall be inspected. The sample
required. The results of all weld inspections shall be
shall include all variations in joint geometry,
recorded.
material thickness and weld size covered by the
(11/04) 7.1.4.2 Visual Inspection. All welds shall be basic type, that are within the scope of 7.1.4.3 and
subject to visual inspection in accordance with 7.1.4.4. If non-conformances are found the scope of
BS EN 970 prior to any NDT and galvanizing. Weld MPI, liquid penetrant inspection and ultrasonic
surfaces shall be free of slag residues and sharp edges. testing shall be doubled. If further non-
All surfaces shall be free of traces of weld spatter, arc conformances are found, the whole batch shall be
strikes and contaminants. The apparent throat tested.
dimensions of butt welds and the apparent leg length
(11/03)7.1.4.6 Reporting. Inspection records for
and apparent throat dimensions of fillet welds, as
production welds shall be retained by the manufacturer
measured by a welding gauge and taking into account
for seven years and those covering the production
any known lack of fit, shall not be less than those
periods relating to the CCTV masts and/or cantilever
specified, except that local shortfalls up to 0.5 mm may
masts supplied shall be made available for examination.
be accepted provided the average over any 50 mm
length is not less than the specified dimension. The toe (11/03)7.1.5 Destructive Testing. Copies of certified
angle shall not be less than 110°. The surface of all reports of destructive tests on CCTV masts and/or
welds shall be free from cracks, lack of fusion including cantilever masts supplied under earlier contracts with
overlap, and slag. Isolated discontinuous porosity may the Overseeing Organisation shall be made available for
be accepted provided it is not detrimental to the examination.

The Contractor shall supply sample joints cut from Page 12 sub-Clause 13.6.1
complete CCTV masts and/or cantilever masts for
In first paragraph delete “7.2”and add “7.1.2”
destructive testing as selected on behalf of the
Overseeing Organisation. The sample joints shall be cut In third paragraph delete “ 13.6.3” and add “7.1.4.2,
from the mast, extension piece, bracket and welded 7.1.4.3, 7.1.4.4 and 7.1.4.5”
anchorage where relevant. The basis of selection shall Page 13 Clause 13
be as follows:
Delete sub-Clauses 13.6.2, 13.6.3 and 13.6.4
a) For orders of 1 to 10 CCTV masts
(11/03)
and/or cantilever masts - no requirement. Page 15 Clause 14
b) (11/03)For orders of 11 to 300 CCTV masts Delete sub-Clauses 14.5.1, 14.5.2, 14.5.3 and 14.5.4
and/or cantilever masts - one complete
CCTV mast and/or cantilever mast for each
type unless destructive testing has been 1311 (11/04) Amendments and Additions to
carried out within the last month on a CCTV BS 5649-5 for Lighting Columns, CCTV
mast and/or cantilever mast of that type Masts and Cantilever Masts
where the CCTV mast and/or cantilever 1311.1 (11/03) For Lighting Columns, CCTV Masts
mast to be tested was also selected on behalf and Cantilever Masts:
Page 3
c) (11/03)For orders exceeding 300 CCTV
masts and/or cantilever masts - two complete 3.2, after paragraph 2
CCTV masts and/or cantilever masts for Insert additional paragraphs as follows:
each type.
(11/04) “The door arrangement shall be such that it can
Acceptance criteria shall be as specified in 7.1.4, except be opened by releasing a single threaded locking
that in 7.1.4.2 the throat and leg dimension shall apply fastener. The fastener shall be of stainless steel to
to the true rather than the apparent dimension. BS EN ISO 3506-1 and BS EN ISO 3506-2 or BS 970-1
In the event that there is a non-conformance arising with the dimensions given in HCD Drawing Number
from a serious deviation in materials, preparation, K1.
assembly, or welding procedure, the batch concerned When the door is secured the fastener head shall be
shall be rejected and further production of the masts completely recessed into the door in a circular recess as
affected stopped until such time as the fault has been indicated in HCD Drawing Number K1.
corrected. A minor non-conformance shall only be
accepted on the basis that further sampling and testing Six door keys as shown on HCD Drawing Number K1,
shows that fault is not repetitive and in the view of the or for alternative vandal resistant locks approved by the
Overseeing Organisation will not in that instance impair Overseeing Organisation shall be supplied to the
structural integrity. Overseeing Organisation.
If the problem can be traced to a particular The locking fastener shall be suitable for opening with
manufacturing period, operator, piece of equipment or the standard key detailed in HCD Drawing Number
batch of materials and if proper traceability to K1.”
individual batches of components can be assured, only 1311.2 For Lighting Columns:
those batches affected may be subject to rejection.
Page 3
The destructive test reports shall be retained by the
manufacturer and recorded in a register for a period of 3.4, after paragraph 2
two years. The destructive test specimens shall be Insert additional paragraph as follows:
retained for a period of 12 months. These shall be made
available for examination on future contracts with the “Where a cable entry slot width of 75 mm is provided,
Overseeing Organisation. the minimum size of cableway from the cable entry slot
to the base compartment shall be 75 mm”
(11/03) 7.1.6 Remedial Work. Welds which do not
comply with the Specification may be repaired to an After Page 3
approved procedure, as described in 7.1.2.” Insert “HCD Drawing Number K1.”

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1312 (11/03) Attachments to Lighting Columns, 9 All accelerators, catalysts and hardeners shall be
CCTV Masts and Cantilever Masts used in accordance with the resin manufacturer’s
instructions.
1 Attachments to lighting columns and CCTV masts
shall be by means of circumferential clamps of stainless Testing of GFRP Laminates
steel complying with AISI Grade 201 or other suitable
material which shall not damage the column or its 10 The properties of the laminates shall be verified by
protective coating. testing as described in sub-Clauses 13 to 18 of this
Clause. Any material failing any of the tests listed shall
2 (11/03) Attachments to cantilever masts shall be in be rejected. Such tests shall, unless otherwise described
accordance with Chapter 7 of BD 88 (DMRB 2.2.13). in Appendix 13/1, be carried out on samples
representing the batch of columns to be supplied under
the Contract.
1313 (05/01) Laminated Glass Fibre Reinforced
Plastic (GFRP) Lighting Columns 11 Two types of samples shall be provided for the
tests:
Manufacture of GFRP Laminates (i) Samples from a specially prepared flat
1 The columns shall be produced either by hand lay- laminate for type tests or where changes in
up or mechanical moulding technique. The mechanical raw materials or manufacturing techniques
manufacture shall be carried out either by filament are proposed. These shall comprise tests for
colour fastness, electric strength, water
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winding, centrifugal casting, compression moulding,

resin injection or any other appropriate method absorption and impact strength.
accepted by the Overseeing Organisation. (ii) (11/03) Samples cut from complete columns
2 An exterior resin rich layer of at least 0.25 mm to be used for quality control purposes, to be
thickness shall be provided to ensure adequate carried out at a frequency of one in each fifty
protection of the reinforcing fibres against adverse production columns. Each column for tests
effects of the weather and possible chemical attack. will be selected on a random basis and will
be examined by visual inspection and for
3 Columns containing bubbles, cracks, holes, pits or loss on ignition.
other voids each greater than 7 mm² in area shall be
rejected. 12 A flat laminate sample 300 mm ± 10 mm square by
3 mm + 0.5 mm/-0.0 mm thick shall be prepared by
4 (11/04) The dimension and tolerances shall be those hand lay-up method using the same curing conditions
given in BS 5649-2 for seamless metal columns. The resin and reinforcement systems as used for production
outer surface shall have a smooth uniform taper along columns. The total glass fibre content shall not exceed
its total length. 40% by weight.
Materials for GFRP Laminates 13 (05/06) The colour fastness test shall be conducted
in accordance with ‘BS EN ISO 877, BS 2782-5 :
5 The fibre reinforced plastic shall be in the form of Method 550B’ and the results assessed by Method
laminate made of thermosetting resin, fibre 552A. Material with a colour change assessed greater
reinforcement (mainly glass fibre), catalyst system and than moderate will not be accepted.
filler.
14 (11/05) The electric strength test shall be carried out
6 The resins used shall conform to the appropriate in accordance with ‘BS EN 60243-2, IEC 60243-2’.
British Standards. Polyester resins shall be based on The electric strength shall be not less than 10 kV/mm.
isophthalic acid and conform to BS 3532, Type B.
15 (11/03) The water absorption test shall be carried out
7 Any fillers and pigments incorporated in the resin in accordance with BS EN ISO 62. The absorption of
shall form part of the total resin system and shall be water shall be not greater than 50 milligrammes.
subject to acceptance of the Overseeing Organisation.
16 (11/05) The impact strength test shall be carried out
8 (11/04) Fibre reinforcement shall conform to the in accordance with ‘BS EN ISO 179-2,
appropriate British Standards. Where glass fibre is used BS 2782-3: Method 359B’. The impact resistance shall
as the base for mat or chopped fibre it shall conform to be at least 30 kJ/m².
BS EN 14020-1, BS EN 14020-2 and BS EN 14020-3
17 (11/04) The loss on ignition tests shall be carried out
and shall be treated with an appropriate finish
in accordance with BS 2782-10 : Method 1002. The
compatible with the resin system used.
loss on ignition on samples taken at random throughout
the length of a column shall not exceed 60% after
subtracting the amount allowed for non combustible 8 The flexural stress at a deflection of 10 mm carried
fillers. The percentage of glass fibre remaining out on a specimen shall be in the range of
following ignition shall be at least 40% by weight. 24 to 30 MPa. The method of testing shall be in
accordance with the polyurethane foam manufacturer’s
18 Samples cut randomly throughout the length of a
instructions.
column shall be visually inspected to confirm that there
are no delaminations or voids greater than specified in 9 The tests specified in sub-Clauses 6, 7 and 8 of this
sub-Clause 3 of this Clause and that the laminate is Clause shall each be carried out on two specimens and,
fully densified and includes the required number of unless otherwise stated in Appendix 13/1, the results
laminations. shall be representative of the batch of columns to be
supplied.
1314 Brackets for Laminated GFRP Lighting 10 Evidence of quality control including results of
Columns tests similar to those required in sub-Clauses 6, 7 and 8
of this Clause shall be made available when required by
the Overseeing Organisation.
General
11 Tests specified in sub-Clauses 6, 7 and 8 of this
1 Brackets shall consist of a galvanized steel tube Clause shall be carried out when changes in raw
assembly with an external self-skinning rigid materials or manufacturing techniques are proposed.
polyurethane foam moulding. For quality control purposes testing shall be carried out
in accordance with sub-Clause 3 of this Clause on each
Materials production batch of brackets which are to be fitted to
2 (11/04) The steel tube assembly shall comply with
columns.
BS EN 40-1 and BS 5649 and the requirements of this
Series.
3 (11/03) The rigid polyurethane foam shall be
moulded in accordance with the manufacturer’s
instructions to give a bulk density within the range of
500 ±50 kg/m3, when in the form of a test sheet in
accordance with sub-Clause 5 of this Clause. The
surface shall be free from obvious defects such as
voiding, pitting or cracking. It shall have a surface
hardness of at least D/30/1 when measured in
accordance with BS EN ISO 868.
4 The polyurethane moulding shall be primed with a
two part polyurethane primer and finished with a two
part polyurethane top coating all in accordance with the
Testing of Polyurethane Foam

5 Properties of foam shall be verified by testing using
specimens cut from moulded test sheets of 10 mm
nominal thickness using the same material as in the
manufacture of the bracket arms.
6 The apparent bulk density of a specimen shall be
determined and be within the range of 500 ± 50 kg/m3.
The method of testing shall be in accordance with the
polyurethane foam manufacturer’s instructions.
7 (11/05) The impact strength of a specimen shall be
determined in accordance with ‘BS EN ISO 179-2,
BS 2782-3: Method 359B’ and shall be at least
6.0 kJ/m².
Amendment - November 2005 12F

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1301NI (05/01) General The Contractor shall, where required, design:

1 (11/03) This Series shall apply to the design, supply (i) anchorages and attachment systems for
and installation of lighting columns and brackets and columns and masts with flange plates to
CCTV masts and cantilever masts for traffic signals foundation or bridge deck;
and/or speed cameras (hereafter called cantilever masts) (ii) foundations for columns and masts with
within the following dimensional limitations: flange plates;
(i) For steel, aluminium and concrete lighting as described in Appendices 13/1, 13/4 and 13/7.
columns:
(a) post top columns not exceeding 20 m and cantilever masts shall be supplied and installed in
nominal height; compliance with the relevant requirements of
(b) columns with brackets not exceeding BS EN 40-1, BS EN 40-3-1, BS EN 40-3-2,
18 m nominal height; BS EN 40-4, BS EN 40- 5, BS EN 40-6 and BS 5649-2,
BS 5649-5 and BS 5649-7 together with the
(c) bracket projections not exceeding 0.25 x amendments and additions stated in Clauses 1309, 1310
nominal height or 3 m whichever is the and 1311 and all the other requirements of this Series.
lesser.
4 Brackets shall include wall and wood pole mounted
(ii) For glass fibre reinforced plastic lighting brackets and fixtures.
columns:
5 Temporary lighting on temporary diversions for
(a) columns not exceeding 10 m nominal traffic, and crossovers, shall comply with this Series.
height;
6 (11/03) Where lighting columns, CCTV masts and
(b) bracket projections not exceeding 1.5 m. cantilever masts are to be in the vicinity of overhead
(iii) For steel CCTV masts: power lines the Contractor shall ensure that the
appropriate Electricity Authorities are notified and give
(a) post top masts not exceeding 25 m written agreement to the specific clearances to be
nominal height. provided and that warning notices as described in
(iv) (11/03) For steel cantilever masts: Appendices 13/1, 13/4 and 13/7 are permanently fixed
to these columns prior to erection.
(a) nominal height not exceeding 8.5 m;
7 (11/03) Headroom over carriageway for cantilever
(b) cantilever projection not exceeding
masts shall be in accordance with the requirements of
8.5 m.
paragraph 3.2 of Standard BD 88 (DMRB 2.2.13).
Where nominal hieght is taken as the distance between
of the underside of the flange plate and the highest
point of the mast (see Figure 1 of BD 88 (DMRB 1308NI (05/01) Handling, Transport and
2.2.13)). Erection
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2 (11/03) The Contractor shall propose lighting 1 (11/03) Lighting columns and brackets, CCTV masts
columns and brackets, CCTV masts and cantilever and cantilever masts shall be handled, transported and
masts which have been designed by the manufacturer. stored in such a way as to avoid any structural damage
The manufacture, supply and verification of lighting or damage to the surface protection system. Any
columns and bracket arms shall comply with the quality damage incurred shall be made good in such a way that
management scheme described in Appendix A. the structural performance and durability of the item
The Contractor shall design foundations for planted shall be in no way reduced.
lighting columns and cantilever masts in accordance 2 (11/03) Lighting columns and brackets, CCTV masts
with BD 26 Chapter 8 (DMRB 2.2.1) or of BD 88/03 and cantilever masts shall be stored clear of the ground
Chapter 8 (DMRB 2.2.13) using the soil type in such a way that contact with cement, groundwater,
information as described in Appendices 13/1 and 13/7. soil or ash or other deleterious material is prevented and

that water does not accumulate on any surfaces or

inside sections. Suitable packings shall be placed
between the columns/masts to allow a free passage of
air and dispersion of water.
3 All rivets, bolts, nuts, washers, screws, small plates
and small articles generally shall be suitably packed and
identified. All such items shall be stored under cover.
4 (11/03) Columns and masts shall be installed in
accordance with the manufacturer’s recommendations.
The door shall face the direction described in
Appendices 13/1, 13/4 and 13/7.
5 Wall and wood pole mounted lighting brackets and
fixtures shall be fixed as described in Appendix 13/1.
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Amendment - November 2003 N2F

SERIES 1400
ELECTRICAL WORK FOR ROAD
LIGHTING AND TRAFFIC SIGNS
Contents
Clause Title Page OVERSEEING ORGANISATIONS OF
#1401 General 2 IRELAND
1402 Site Records 2
1403 Location of Lighting Units and
Feeder Pillars 3 Northern Ireland
1404 Change of Lighting Clause Title Page
Arrangements 3
1405 Temporary Lighting 3 1401NI General N1
1406 Radio Interference 3
1407 Luminaires 3
1408 Lamps 3
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1409 Photo-electric Control Units
(PECUs) 4 # denotes a Clause or Sample Appendix which has a substitute
1410 Shorting Plugs (Dummy PECUs) 4 National Clause or Sample Appendix for one or more of the
Overseeing Organisations of Scotland, Wales or Northern Ireland.
1411 Time Switches 4
1412 Ballasts 4
1413 Ignitors for Discharge Lamps 4
1414 Starters for Fluorescent Lamps 4
1415 Capacitators 5
1416 Cut-outs, Fuse Holders, Fuses
and Miniature Circuit Breakers
(MCBs) 5
1417 Base Compartment Fixing
Arrangements 5
1418 Feeder Pillars 5
1419 Wiring 5
1420 Earthing 6
1421 Underground and Ducted Cable 6
1422 Cable Joints 8
1423 Armoured Cable Terminations 8
1424 Inspection and Testing to be
Carried Out by the Contractor 8
1425 Preparation and Finish of Metal
and Other Surfaces 9

Specification for Highway Works Electrical Work for Road Lighting and Traffic Signs
ELECTRICAL WORK FOR ROAD LIGHTING AND

TRAFFIC SIGNS
#1401 General (ii) A Lit Sign Unit shall consist of a traffic sign
requiring an electricity supply and Electrical
1 (05/01) Materials equipment and workmanship Equipment and wiring as in (i) above.
required under the Contract shall comply with BS 7671
Regulations for Electrical Installations (IEE Wiring (iii) The term Lighting Unit applies to both Road
Regulations) and the rules and regulations of the Lighting Units and Lit Sign Units.
electricity supplier who provides the supply. The (iv) Electrical Equipment for Lighting Units shall
installation and maintenance of electrical apparatus and consist of the following as described in the
cabling for road lighting and traffic signs shall comply Contract: luminaires, photo-electric control
with the quality management scheme detailed in units (PECUs), shorting plugs, lamps, time
Appendix A. The Contractor shall take into account switches, ballasts, ignitors, starters,
Engineering Recommendation G.39/1 ‘Model Code of capacitors, cut-outs, fuses, fuse holders and
Practice covering Electrical Safety in the Planning miniature circuit breakers (MCBs).
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Installation, Commissioning and Maintenance of Public
Lighting and Other Street Furniture’. Other relevant (v) The network is the electrical distribution
requirements are contained in the Electricity at Work system installed by the Contractor from the
Regulations, 1989. electricity supplier’s interface to the
Lighting Units.
The Contractor shall employ only competent personnel
each of whom holds a “Competent Persons 3 (05/01) Each network shall operate on a single phase
Authorisation Certificate” in accordance with the model 230V -6% to +10% or three phase 400V - 6% to +10%.
form in Appendix B of the above document G.39/1, but 4 The Contractor shall provide facilities for the
modified as specified below, which has been duly electricity supplier for service connections and
completed by the Contractor and authorised by a commissioning of the network.
designated responsible person in the Authority or
company as defined in Clause 2 of G.39/1, all in 5 A dedicated feeder pillar shall be provided for the
accordance with Clause 10 of G.39/1. The form of Overseeing Organisation’s network. Supplies provided
certificate as specified above shall be modified on page to electrical equipment and lighting units for third
B2 of G.39/1 by insertion of the following after the parties shall not be connected to the Overseeing
space for ‘Name and Address of Employer’: Organisation’s network. Where required, and described
in Appendix 14/2, electrical isolation pillars shall be
“Name of Authority or provided on the network at the maintenance boundaries
Company……………………………………” between the Overseeing Organisation and third parties,
In addition to the requirements of sub-Clauses 10.2 and with the prior agreement of the Overseeing
10.3 of G.39/1, each Competent Person as defined in Organisation.
G.39/1, Clause 2, shall be provided by the Contractor
with not less than one copy of the above certificate,
1402 Site Records
duly completed and signed as Approved, and such
certificate(s) shall be retained and be available at all 1 In accordance with the requirements of the
times for inspection on the Works on request by the Electricity at Work Regulations the Contractor shall, on
Overseeing Organisation. A suitable Work Allocation the completion of the electrical work, provide a set of
Record shall be kept by the Contractor to enable works as-installed drawings or transparencies showing as a
to be identified with the operatives and supervisors minimum the position and identification mark
responsible for those works. (including luminaire type, modification status, lamp
2 The following definitions shall apply: setting, lamp type and serial numbers) of equipment
requiring electrical connections, ducts, underground
(i) A Road Lighting Unit shall consist of the cables and joints and the type and depth of cables. The
following as described in the Contract: Contractor shall also supply test certificates and
column, bracket, wall mounting, Electrical Operation and Maintenance manuals. Any additional
Equipment as defined in (iv) below and requirements for records shall be as described in
wiring excluding electrical supply cable. Appendix 14/1.
2 Locational measurements shall be taken of the 1406 Radio Interference

underground equipment to the nearest 100 mm from the
nearest edge of the carriageway or fence line. Offsets to 1 (11/03) Electrical equipment shall be installed so
cables and ducts shall be recorded at 20 m intervals that levels of radio interference given in
along their line. Offsets shall be defined longitudinally BS EN 55014-1 are not exceeded.
by distance from a permanent highway feature, a
marker post or other suitable point.
1407 Luminaires
3 The Contractor shall keep a daily record of the
work in sufficient detail, including the type and drum 1 Where described in Appendix 14/4, luminaires
number of underground cables, to enable site records to fitted with integral control gear shall have a fuse holder
be completed. A copy of the daily record shall be adjacent to the terminal block with a cartridge fuse
provided by the Contractor on the next working day for protecting each set of control gear.
retention and use by the Overseeing Organisation. 2 Luminaires for road lighting shall:
4 (05/01) The Contractor shall supply to the (i) (05/05) comply with BS EN 60598-2-3, and
Overseeing Organisation one master and two prints of be as described in Appendix 14/4;
the ‘as-built’ drawings of power supply arrangements
for road lighting and traffic signal installations (ii) be fitted in accordance with manufacturers’
immediately upon completion of the installation work. instructions with no gap between the
luminaire and the shoulder of any bracket
arm;
1403 Location of Lighting Units and Feeder (iii) (05/06) forthe luminaire optical system (lamp
Pillars housing) have degree of protection rating
1 The position of Lighting Units and feeder pillars is IP 54 to BS EN 60529 unless a higher rating
described in Appendix 14/2. The exact location will be is specified in Appendix 14/4;
agreed on site before commencement of any associated (iv) (05/06) forthe luminaire control gear housing
ground work. The Contractor shall be responsible for have a degree of protection rating IP 43 to
recording the actual location. BS EN 60529 unless a higher rate is
2 In cases where the location of an item has been specified in Appendix 14/4;
determined as indicated above and it is impossible (v) (05/06) befitted with a PECU socket located
because of underground obstruction to install the item in the canopy unless otherwise specified in
then any excavation shall be backfilled and reinstated to Appendix 14/4;
its original condition.
(vi) (05/06) meetthe structural design and
aesthetic approval requirements of Clause
1404 Change of Lighting Arrangements 1302.
3 (05/06) Traffic sign luminaires shall comply with
1 (05/01) No Lighting Unit shall be switched on or off, BS 873-5, Appendix 12/1 and the following:
dismantled, resited, replaced or removed without prior
approval of the Overseeing Organisation. (i) External lighting luminaires shall be
correctly positioned to meet the luminance
requirements of the sign.
1405 Temporary Lighting (05/06) Mean sign luminance shall be
(ii)
1 The standard of temporary Lighting Units shall Category 1 of BS 873-5 unless otherwise
conform to the Clauses in this Series and stated in Appendix 12/1.
Appendix 14/3. (iii) (05/06) Impact
strength shall be Category 1 of
2 The Contractor shall ensure that any temporary BS 873-5 unless otherwise stated in
lighting he provides does not cause glare to traffic using Appendix 12/1.
any highway nor annoyance to occupants of
surrounding property.
1408 Lamps
1 Lamps shall be compatible with the luminaires
used.
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2 (05/01) The initial luminous flux of a lamp 1410 Shorting Plugs (Dummy PECUs)
multiplied by the lamp flux maintenance factor for the
projected lamp life shall be taken as its light output for 1 Shorting plugs shall:
road lighting design. (i) be interchangeable with PECUs;
3 Lamps shall not be fitted until columns, brackets (ii) have the line and load terminals permanently
and sign posts have been erected and the luminaires connected internally; and
have been installed.
(iii) be clearly distinguishable from PECUs.
Lamps for Road Lighting
4 (05/01) Low pressure and high pressure sodium 1411 Time Switches
vapour lamps shall comply with BS EN 62035.
1 Time switches shall:
(i) be electrically or electronically driven;
1409 Photo-electric Control Units (PECUs)
(ii) have an electrically wound spring or battery
1 Photo-electric control units (PECUs) shall comply reserve of not less than 12 hours unless
with BS 5972. They shall have differential switch on - otherwise described in Appendix 14/4;
switch off levels as described in Appendix 14/4. They (iii) be equipped with a solar dial suitable for the
shall be designed where possible so that in the event of geographic location or equivalent means of
a fault occurring in the unit they cause the load to be setting and seasonal adjustment;
switched ‘on’.
(iv) have 2 switched on/off periods per 24 hours;
2 PECUs shall:
(v) be capable of switching a 10 A inductive
(i) be secured as appropriate to the: load current at the specified operating
(a) road lighting luminaire canopy; voltage of the network.
(b) top of pole located close to feeder pillar;
(c) top of sign post; 1412 Ballasts
(d) internally illuminated sign housing; or 1 (05/06) Unless otherwise specified in
(e) luminaire of externally illuminated sign; Appendix 14/4 ballasts shall comply with
BS EN 61347-1, BS EN 61347-2-1, BS EN 61347-2-8,
(ii) include a delay device to prevent the lamp BS EN 61347-2-9 and BS EN 60921 or BS EN 60923
being switched in response to transient as appropriate and be tap selected to the specified
changes in light conditions; operating voltage of the network.
(iii) be indelibly marked with the (a) 2 The terminals shall be indelibly marked to indicate
manufacturer’s identification mark (b) model all wiring connections and operating voltages.
number and (c) switch on level;
(iv) be provided with a gasket or grommet to
maintain the IP protection rating of the 1413 Ignitors for Discharge Lamps
luminaire; 1 Unless otherwise specified in Appendix 14/4,
(v) be installed to the manufacturer’s ignitors shall not be incorporated in the lamps.
instructions. 2 Ignitor, lamp and ballast shall be mutually
3 Where luminaires are a pair mounted on twin arm compatible.
brackets, unless otherwise specified in Appendix 14/4,
one luminaire shall be fitted with a PECU to control
both luminaires and the other luminaire shall be fitted 1414 Starters for Fluorescent Lamps
with a shorting plug. The luminaire to be fitted with the 1 Starters shall comply with BS EN 60155 and shall
shorting plug shall be as described in Appendix 14/4. be incorporated in the electrical equipment where
4 Where described in Appendix 14/4, circuits shall applicable.
be group switched as specified therein.
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1415 Capacitors 1418 Feeder Pillars

1 Capacitors shall comply with BS EN 61048 and 1 Feeder pillars shall be constructed in the materials
BS EN 61049 and be supplied complete with fixing described in Appendix 14/4. They shall comply with
clips, discharge resistors, and either sealed-in cable tails IP 34 of BS EN 60529. They shall include a full size
or shrouded terminals. back board of varnished marine plywood at least 15 mm
thick or other suitable non-hygroscopic material.
2 Capacitors shall correct the lamp circuit power
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Alternatively a purpose-designed equipment mounting
factor to not less than 0.85 lagging.
system may be used. The entry for cables shall be via
the root.
1416 Cut-outs, Fuse Holders, Fuses and 2 (05/01) The distribution MCBs or fuse boards shall
Miniature Circuit Breakers (MCBs) have sufficient spare capacity to accommodate at least
one extra circuit. (One three phase spare way on a three
1 Cut-outs, fuse holders and MCBs shall have phase distribution unit and one single phase spare way
moulded drip-proof housings to IP 31 or above. on a single phase distribution unit). There shall be at
2 Cut-outs shall be double pole and comply with least 25% usable spare space on the back board.
BS 7654. 3 (05/06) The feeder pillar shall be fitted with a
3 Terminals shall be sufficient for the conductors as suitably rated 1 to 3-phase and neutral switch fuse to
described in Appendix 14/4. They shall be clearly BS EN 60947-3 as appropriate for the supply cable.
labelled to differentiate circuits and phases. 4 (05/06) The pillar doors shall be fitted with tamper-
4 When fuse holders are intended to be used as proof locks, all locks being identical in pattern and two
isolating devices, special tools or protective measures sets of keys shall be provided. All hinges and locks
shall not be necessary to extract them. shall be of stainless steel unless otherwise stated in
Appendix 14/4.
5 (05/06) Fuse links shall comply with the
requirements of either BS EN 60269-1, 5 (05/06) Distribution boards shall be provided with
BS EN 60269-2, BS 646/BS 2950, or BS 1361. They an external earth, phase barriered and colour coded.
shall be of high breaking capacity type and be of a They shall be fitted with the same number of live and
value specified in Appendix 14/4 to protect the circuit. neutral bus bar terminals as there are outgoing circuits
plus at least one spare way.
6 (05/06) Miniature circuit breakers shall be in
accordance with BS EN 60898 and BS EN 60947-2 for 6 (05/06) Circuit details and labelling shall be
use on the specified operating voltage of the network at provided in each feeder pillar as described in
single or three phase as appropriate. Their short circuit Appendix 14/4.
current rating and type shall be as described in 7 (05/06) The main earthing terminal in each feeder
Appendix 14/4. Thermal or magnetic excess current pillar shall be connected to earth as described in
tripping devices shall be provided with a mechanism to Appendix 14/4.
ensure that the contact cannot be held closed against a
fault. 8 (05/06) Unless otherwise stated in Appendix 14/4,
feeder pillars shall be mounted on a 150 mm thick
7 (05/05) Where MCBs are intended to be used as foundation of ST2 concrete in compliance with
isolating devices, a ‘lock off’ facility shall be provided. Clause 2602. After completion of the cabling the feeder
pillar base shall be filled to 25 mm below the door with
1417 Base Compartment Fixing rounded coarse aggregate conforming with Table 2 of
Arrangements BS EN 12620, 4/14 aggregate with a grading category
of GC90/15.
1 Electrical equipment described in Clauses 1411 to
1416 installed within the base compartment of columns 9 (05/06) A durable warning sign indicating ‘Danger
or posts shall be positioned as described in 415 Volts’ or ‘Danger 240 Volts’ as appropriate, shall be
Appendix 14/4 and Appendix 14/5 and fixed in fixed to the front of the pillar where applicable.
accordance with manufacturers’ instructions with
corrosion resistant fixing screws. 1419 Wiring
1 All wiring and installation of components within
the column, post or Lit Sign Unit shall be as described
in Appendix 14/4 and Appendix 14/5.

2 (05/01) Wiring between the terminal block in the conductors shall be terminated in accordance with
luminaire and the components in the base of the column manufacturers’ instructions in correctly sized purpose
or sign unit shall be PVC or XLPE insulated and made lugs. Such connections shall be made with non-
sheathed single, multi-core or composite cable to ferrous nuts, bolts and washers.
BS 6004 of 300/500 volt grade. Phase and neutral
2 A circuit protective conductor shall connect the
copper conductors shall be not less than 2.5 mm² in
earth terminal on each luminaire to the main earth
cross-sectional area except that where the vertical
terminal associated with the service cut-out unit.
unsupported length does not exceed 6 metres their
cross-sectional area may be reduced to 1.5 mm². Cable 3 A separate circuit protective conductor of not less
types and sizes shall be selected to ensure that the than 2.5 mm² cross-sectional area shall connect all
operation of the lighting systems shall not be adversely metal enclosures of all electrical components to the
affected. main earth terminal.
3 Where electronic ignitors are used with remote 4 All extraneous conductive parts, as described in
control gear, single core cable shall be used. BS 7671, and including doors to feeder pillars, lighting
columns and lit sign units, shall be bonded to the main
4 The final connection between equipment mounted
earth terminal using an equipotential bonding conductor
in the base compartment and the cut out shall be made
of 6 mm² cross-sectional area when the lighting unit is
using PVC or XLPE insulated and sheathed single core
directly serviced by a TN-C-S supply. Earth electrodes
cable of a minimum cross-sectional area of 2.5 mm².
shall be installed where necessary.
5 All cables shall be correctly colour coded
5 All street lighting and other electrically supplied
throughout their length and labelled appropriately at the
street furniture shall be earthed and bonded in
feeder pillar and the cut-out.
compliance with BS 7430.
6 Unsupported lengths of cable shall be kept to a
minimum and shall not be allowed to come into contact
with components by their freedom of movement. Where 1421 Underground and Ducted Cable
there is more than one cable they shall be secured
1 (05/06) Cables shall have XLPE insulation and
together at one metre intervals throughout the
sheathing material coloured in accordance with
unsupported length. Vertical cables within posts or
National Joint Utilities Group publication “Guidelines
columns shall be adequately supported along their
on the positioning and colour coding of utilities’
length at the top of the cable run.
apparatus”. The identification of the conductors by
7 On double bracket columns the wiring shall colour shall be as per Table 51 of BS 7671 and every
connect PECU sockets in series, unless otherwise core shall be identifiable by colour throughout its
specified in Appendix 14/4. length. The sheathing material shall be appropriate to
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8 Wiring shall wherever possible be housed inside the ground conditions in which it will be laid. In ground
columns, wall brackets and posts or stiffening members. that is liable at any time to become waterlogged, then
Where it is external it shall be as described in the sheathing material shall have an ASTM F1249-1
Appendix 14/4. Connections between conduit and sign tested maximum permeability of 2.0 g.d-1-2, 90% R.H,
housings, switchboxes and other components shall be 1mm. The cables shall be 600/1000 V grade with steel
waterproof and be smooth internally. wire or aluminium strip armouring to BS 6346 or
BS 5467 and all conductors shall be of equal cross-
9 All unused cores in cables shall be cut to a sectional area. The Contractor shall provide to the
minimum length, long enough to connect to the furthest Overseeing Organisation evidence that each cable
working-off point within the unit and shall be cut to length delivered to Site has been tested at the place of
equal length. The ends of the cores shall be tied manufacture and complies with the testing requirements
together and sealed with self-amalgamating waterproof of BS 6346 or BS 5467 according to the cable used.
jointing tape. The unused cores shall be coiled and
strapped in a suitable unobtrusive position. 2 (05/06) Service ducts shall be self coloured in
accordance with National Joint Utilities Group
publication “Guidelines on the positioning and colour
1420 Earthing coding of utilities’ apparatus” and shall comply with
Series 500 and Appendix 5/2.
1 Circuit protective and equipotential conductors
3 Cable covers for protection of underground cables
shall be installed as shown on the Drawings and shall
shall comply with BS 2484 and shall be installed as
be green/yellow PVC or XLPE insulated or sleeved.
described in Appendix 14/4. When cable covers are
Where bolted connections are required, these
installed, marker tapes are not required.

4 Cable trenches shall be excavated to the lines deposited to a thickness of 175 mm prior to further
described in Appendix 14/4 and in accordance with backfilling in compliance with sub-Clause 16 of this
Clause 602. The depth of excavation shall be such that Clause.
cables laid under verges, footways or open ground shall
14 A yellow, self-coloured PVC or polythene plastic
have a minimum cover of 500 mm and under
tape for cable marking, not less than 0.1 mm thick and
carriageways of 750 mm or 300 mm below formation
150 mm wide with the wording “Street Lighting Cables
whichever is the greater depth.
Below” printed in black along the full length so as to
5 Cables shall be laid without sharp bends and kinks occupy not less than 75% of its available length and
and in accordance with any particular requirements in occurring at least at 1 m intervals, shall be laid
Appendix 14/4. If required, additional protection and approximately 250 mm above any power supply cable.
support shall be provided as described in Where several cables are laid in one trench, only one
Appendix 14/4. line of marker tape need be installed.
6 (11/03) Where cables are laid across or within 15 Where cables are required to be laid in ducts the
500 mm of filter drains they shall be contained within a Contractor shall swab through the duct prior to drawing
duct. The duct shall be surrounded with 50 mm of ST2 in the cables and a further draw rope. On completion of
concrete in compliance with Clause 2602. cabling, ducts shall be left with a draw rope in place
and re-sealed with split plugs, or suitable alternative
7 Cables following the same route shall unless
material, to adequately seal the ducts against the ingress
otherwise described in Appendix 14/4 occupy the same
of foreign matter. Where cables are laid in troughs they
trench with a clearance of 50 mm between the outer
shall be covered with sand, or equivalent material,
sheath of the cables.
passing a 2 mm BS sieve up to the level of the cover.
8 Power supply cables, other than those associated
16 Backfilling to cable trenches shall comply with
solely with the communications system, shall not be
Clause 602 and to prevent damage by the ingress of
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installed within 500 mm of signal or communication
foreign matter shall whenever practical be undertaken
cables, within 300 mm of telecommunication cables or
immediately after the specified operations preceding it
within 300 mm of HV cables, unless otherwise
have been completed. The Contractor shall backfill
above the cable marking tape, duct or trough with Class
9 Cables shall only be laid when the ambient 1, 2 or 3 material complying with Table 6/1 and
temperature is above 0°C, and the cable has been stored compacted to the requirements therein, except that he
at a temperature greater than 0°C for the previous 24 shall:
hours.
(i) spread and compact the material evenly
10 Cables shall not be bent to an internal radius of less without dislodging, disturbing or damaging
than 12 times the external diameter of the cable or less cables, ducts or troughs; and
than the radius recommended by the manufacturer,
(ii) not use power rammers within 300 mm of
whichever is greater.
cables, ducts or troughs.
11 Sufficient length of cable shall be allowed for its
17 Where described in Appendix 2/2, buried cables
termination. When termination does not proceed
shall be taken up and removed by the Contractor.
immediately following the installation of the cable, its
Conductors shall be disconnected from the equipment
end shall be sealed against the ingress of moisture. If
in which they are terminated, the terminal screws and
such cable ends are buried, their positions shall be
glands retightened, and the cable withdrawn clear of the
marked with a permanent marker block consisting of a
equipment.
300 mm square x 225 mm deep precast concrete block
having a mark as described in Appendix 14/4 indented 18 Unused cores in cables shall be dealt with as
into its top surface and recorded on the site records. described in sub-Clause 1419.9.
12 When duct or trough alignments differ from those 19 Unless ducts terminate at cabinets or mounting
of the trench the transition from one to the other shall posts or columns, their ends shall be marked as
not exceed 1:30 horizontally or vertically. described in Appendix 5/2, with marker blocks
complying with sub-Clause 11 of this Clause and
13 Cables laid in trench shall, unless otherwise
location posts so that their location can be clearly
specified in Appendix 14/4, be both bedded on and
identified without exploratory excavation.
covered by a 100 mm thickness of lightly compacted
graded sand or equivalent material passing a 2 mm BS
sieve. Class 8 material complying with Table 6/1 and
compacted to the requirements therein shall then be

1422 Cable Joints 1424 Inspection and Testing to be Carried

Out by the Contractor
1 (05/06) Joints shall be made using jointing kits
complying with BS 6910-1 which shall be installed in 1 Every Lighting Unit and network, on completion
compliance with BS 6910-2. and before being energised, shall be inspected and
2 Prior to any cable laying, the Contractor shall tested to verify that the requirements of BS 7671 have
provide evidence to the Overseeing Organisation of the been met. The method of testing shall be such that no
jointer’s competence in the use of the adopted cable danger to persons or property or damage to equipment
joint kit. A record shall be kept to enable cable joints to can occur even if the circuit tested is defective.
be identified with the jointer responsible for the work. 2 The following tests shall be carried out in the
3 Cable joints shall be made where described in sequence indicated below and recorded on a Schedule,
Appendix 14/4. Additional joints shall not be provided in an appropriate format, which shall be submitted to
on cables in duct or trough. Approval is required from the Overseeing Organisation immediately after
the Overseeing Organisation for additional joints using completion of all the tests, including those on Lighting
other fixing methods. Units, within each network:
4 Jointing shall only be carried out when all (i) For Lighting Units (b), (d), (f), (g) apply.
materials to be used in the jointing are free from visible (ii) For networks (a), (b), (c), (e), (f), (g), (h), (j)
signs of moisture and joints shall be left protected from apply.
the weather during the curing period.
Standard methods of testing are given in BS 7671.
5 Joints shall be adequately supported at all times.
(a) Cable sheath insulation test.
Backfilling shall not take place until the joint is fully
completed in accordance with the manufacturer’s (b) Continuity of protective conductors
instructions including curing times, and is in a fit including main and supplementary
condition to withstand any stresses which may be equipotential bonding.
imposed upon it. (c) Earth electrode resistance.
6 Where described in Appendix 14/4, a cable joint (d) Insulation resistance at a test voltage of
marker block, as described in sub-Clause 1421.11 shall 500 V to be not less than 1.0 M ohm.
be placed over the cable joint and reference
measurements taken from nearby permanent features. (e) Insulation resistance at a test voltage of
500 V to be not less than 6 M ohm.
7 All cable jointing shall be made under the
protection of a specialist jointing tent. (f) Insulation of the site-built assemblies.
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(g) Polarity, including the continuity of circuit
conductors.
1423 Armoured Cable Terminations
(h) Earth fault loop impedance at every cut-out.
1 (11/05) Cables shall be individually terminated and
existing cables re-terminated, and secured at switches, (j) Operation of residual current devices.
cut-outs and other electrical apparatus by means of an 3 The cable sheath insulation test shall be carried out
armour securing clamp or an aluminium compression using an insulation tester. The insulation resistance test
type gland complying with ‘BS 6121-1, BS EN 50262’ of 1000 V, direct current, shall be applied and
and a gland plate, all as described in Appendix 14/4. maintained for not less than one minute between the
2 The armour securing clamp or compression gland continuous cable armouring or earth conductor and the
and plate assembly shall incorporate at least one non- general mass of earth. The measured insulation
ferrous earthing terminal. resistance shall not fall below 1.0 M ohm for the full
duration of the test. The cable sheath insulation test
3 All glands shall be shrouded overall with PVC shall be carried out after the cable has been laid and the
sleeves and the conductor shall be terminated with trench backfilled, but before jointing has taken place.
cable lugs.
4 Voltage readings shall be taken at each feeder pillar
4 An anti-oxidant mastic or paste protective coating and at the terminals of the last current-using equipment
shall be applied to all aluminium conductor terminals on each circuit, with all equipment energised.
where they are exposed to the atmosphere.
5 The Contractor shall give not less than 7 days’
5 Phase connections shall be clearly indicated by a notice to the Overseeing Organisation of his intention to
suitable colour marking system. carry out any of the tests specified and the Overseeing

Organisation shall be given the opportunity to witness

such tests.
6 The Contractor shall furnish the Overseeing
Organisation with two copies of a certificate verifying
compliance with BS 7671 upon satisfactory completion
of the inspection and tests.
7 (11/03) The Contractor shall ensure that all test
instruments have been calibrated and adjusted in
accordance with BS EN ISO 9001 and come complete
with calibration certificates to verify that
BS EN ISO 9001 has been complied with.
1425 Preparation and Finish of Metal and

Other Surfaces
1 Electrical components and ancillary equipment
shall be prepared and finished in compliance with sub-
Clauses 1221.7 and 9.
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1401NI General (ii) A Lit Sign Unit shall consist of a traffic sign
requiring an electricity supply and Electrical
1 (05/01) Materials equipment and workmanship Equipment and wiring as in (i) above.
required under the Contract shall comply with BS 7671
Regulations for Electrical Installations (the IEE Wiring (iii) The term Lighting Unit applies to both Road
Regulations) and the rules and regulations of the Lighting Units and Lit Sign Units.
electricity supplier who provides the supply. The
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(iv) Electrical Equipment for Lighting Units shall

installation and maintenance of electrical apparatus and consist of the following as described in the
cabling for road lighting and traffic signs shall comply Contract: luminaires, photo-electric control
with the quality management scheme detailed in units (PECUs), shorting plugs, lamps, time
Appendix A. The Contractor shall take into account switches, ballasts, ignitors, starters,
Engineering Recommendation G.39/1 ‘Model Code of capacitors, cut-outs, fuses, fuse holders and
Practice covering Electrical Safety in the Planning, miniature circuit breakers (MCBs).
Installation, Commissioning and Maintenance of Public
Lighting and Other Street Furniture’. Other relevant (v) The network is the electrical distribution
requirements are contained in the Electricity at Work system installed by the Contractor from the
Regulations (Northern Ireland) 1991. electricity supplier’s interface to the
Lighting Units.
The Contractor shall employ only competent personnel
each of whom holds a “Competent Persons 3 (05/01) Each network shall operate on a single phase
Authorisation Certificate” in accordance with the model 230V - 6% to +10% or three phase 400V - 6% to +10%.
form in Appendix B of the above document G.39/1, but 4 The Contractor shall provide facilities for the
modified as specified below, which has been duly electricity supplier for service connections and
completed by the Contractor and authorised by a commissioning of the network.
designated responsible person in the Authority or
company as defined in Clause 2 of G.39/1, all in
accordance with Clause 10 of G.39/1. The form of
certificate as specified above shall be modified on page
B2 of G.39/1 by insertion of the following after the
space for ‘Name and Address of Employer’:
“Name of Authority or
Company………………………………………”
In addition to the requirements of sub-Clauses 10.2 and
10.3 of G.39/1, each Competent Person as defined in
G.39/1, Clause 2, shall be provided by the Contractor
with not less than one copy of the above certificate,
duly completed and signed as Approved, and such
certificate(s) shall be retained and be available at all
times for inspection on the Works on request by the
Overseeing Organisation. A suitable Work Allocation
Record shall be kept by the Contractor to enable works
to be identified with the operatives and supervisors
responsible for those works.
2 The following definitions shall apply:
(i) A Road Lighting Unit shall consist of the
following as described in the Contract:
column, bracket, wall mounting, Electrical
Equipment as defined in (iv) below and
wiring excluding electrical supply cable.
Amendment - May 2001 N1F

SERIES 1500
HIGHWAY COMMUNICATIONS
Contents
1501 (02/17) Introduction 2 1527 (02/17) Cable Installation at Transmission
Stations 20
1502 (02/17) General Requirements 3
1528 (02/17) Modifications to Equipment and
1503 (02/17) aterials Equipment and
M Circuitry associated with Existing
Workmanship 4 Cabinets 20
1504 (02/17) Site Records 4 1529 (02/17) Temporary Emergency Telephones 21
1505 (02/17) Provision of Cabinets, Cables and
1530 (02/17) Cable Ducts General 22
Ancillary Items 6
1531 (02/17) Installation of Ducts General 24
1506 (02/17) Cables 6
1532 (02/17) Chambers for Highway
1507 (02/17) Cable Installation 6 Communications Cables 26
1508 (02/17) I nstallation of Cabinets and 1533 (02/17) Proving and Testing of Ducts 29
Signal Posts 9
1534 (02/17) Closed Circuit Television 29
1509 (02/17) Gantries for Motorway Signals 10
1535 (02/17) Provision of the Telecommunications
1510 (02/17) Installation of Telephones 11 Services 29
1511 (02/17) Marker Tape 11 1536 (02/17) Electricity Connections 30
1512 (02/17) Installation of Ancillary Items 12
1513 (02/17) Jointing and Termination of
Multi-pair Communications NATIONAL ALTERATIONS OF THE
Cables 12 OVERSEEING ORGANISATIONS OF
1514 (02/17) Cable Connectors 13
IRELAND
1515 (02/17) Terminationof Optical Fibre
Communication Cables 14 Contract specific Additional Requirements (A) and
1516 (02/17) Termination and Jointing of Power Substitute Requirements (S) may be included for
Supply Cables for Communications 14 contracts where the Overseeing Organisation is not
Highways England (or its successor). Where required,
1517 (02/17) Earthing, Bonding and Lightning these will be issued by:
Protection 15
Scotland
1518 (02/17) Cable Testing 15 Transport Scotland, 8th Floor, Buchanan House,
1519 (02/17) Labelling and Numbering 16 58 Port Dundas Road, Glasgow, G4 0HF.
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1520 (02/17) Not Used Wales

1521 (02/17)Removal and Re-siting of Existing The Welsh Government, Transport Department,
Equipment 17 Cathays Park, Cardiff, CF10 3NQ.
1522 (02/17) Enforcement and Other Systems 18 Northern Ireland

Director of Engineering, The Department for
1523 (02/17) Detector Systems 18 Infrastructure, Clarence Court, 10 – 18 Adelaide Street,
1524 (02/17) Trial Pits 18 Belfast BT2 8GB.
1525 (02/17) Safeguardingthe Existing Highway The Overseeing Organisation may also issue an initial
Communications Network 19 list of Alternative Requirements/Departures.
1526 (02/17) The Inspection and Testing of
Electrical Installations 20

Specification for Highway Works Highway Communications
HIGHWAY COMMUNICATIONS
1 (02/17) Where this document contains specification requirements, it must be read in conjunction with the general
requirements in Series 000 and 100 and with all other Series relevant to the specification for the particular works to
be undertaken.
Where this document contains design requirements, it must be read in conjunction with the general requirements
in GD 01 (DMRB 0.0.2), GD 02 (DMRB 0.2.1) and GD 04 (DMRB 0.2.4) and with all other DMRB documents
relevant to the design for the particular works to be undertaken.
Where this document contains technology requirements that fall within the scope of the TSS Plans Registry, it must
be read in conjunction with the general requirements in TR 1000, TR 1100 and TR 2130, and with all other TSSR
Documents relevant to the particular works to be undertaken.
2 (02/17) Where there is a requirement in this document for compliance with any part of a “British Standard”,
technical specification or quality mark, that requirement may be met by compliance with GD 01.
Where there is a requirement in this document for compliance with any part of a “British Standard”, technical
specification or quality mark, that requirement may be met by compliance with Series 100 of the specification.
Where there is a requirement in this document for compliance with any part of a “British Standard”, technical
specification or quality mark, that requirement may be met by compliance with TR 1000.
3 (02/17) A safety risk assessment shall be carried out in accordance with GD 04.
4 (02/17) Where the design falls within the scope of the Equality Act, an equality impact assessment shall be
carried out by the designer.
5 (02/17) Where a product falls within the scope of a harmonised standard, the contractor shall provide the
declaration of performance and manufacturer’s installation instructions for the product as part of the safety file.
6 (02/17) Series 1500 applies to the Strategic Road Network i.e. both to all purpose trunk roads and motorways.
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7 (02/17) Unless otherwise stated in contract specific Appendix 15/1 a Telecommunications Services Provider is
responsible for the highway communications transmission network from a Service Delivery Point (SDP) where
roadside technology interface with that network to the SDP in the Overseeing Organisation’s central facilities such
as the Regional Control Centres.
Where the Contractor is responsible for the highway communications transmission network the requirements
placed on the Contractor shall be as set out within amended or substitute Clauses to this 1500 Series with detail of
the works contained in contract specific Appendices 15/1 and 15/2.
The Contractor is responsible for all cabling, termination and linking downstream or otherwise termed beyond the
SDP where such cabling is required by the installation but not directly linked to the SDP.
The Contractor shall install all communications infrastructure, comprising but not limited to ducts, chambers,
hard-standings, transmission station bases, cabinet bases (including any cast-in frames that may be provided by
the Telecommunications Services Provider) access infrastructure and protection infrastructure as stated in contract
With exception of cables and equipment provided by the Telecommunications Services Provider the Contractor
shall supply and install all cables, cable terminations and equipment as stated in contract specific Appendix 15/1.
This shall include all power cabling and local communications cables that are installed beyond the SDP and any
other local cables required by the installed equipment and systems.
8 (02/17) The telecommunications services and all related equipment necessary to provide the telecommunications
services shall be as scheduled in contract specific Appendix 15/1. These shall be installed by the
Telecommunications Services Provider into infrastructure constructed by the Contractor unless the contract specific
Appendix 15/1 defines otherwise.

1502 (02/17) General Requirements
1 (02/17) The Contractor is responsible for the supply of all equipment except that scheduled in contract specific
Appendix 15/1 as to be supplied by the Overseeing Organisation.
The procurement responsibilities in respect of the telecommunications services to be provided by the
Telecommunications Services Provider shall be as set out within the contract. Details of the telecommunications
services to be provided by the Telecommunications Services Provider and any specific instructions relating to the
provision of the telecommunications services shall be as stated in contract specific Appendix 15/1. The Contractor
shall comply with the requirements of the Telecommunications Services Provider as stated in contract specific
Appendix 15/3.
The Contractor shall confirm and amend as appropriate with the Telecommunications Services Provider details of
the telecommunications services contained in the contract specific Appendix 15/1.
The Contractor shall establish and maintain a programme of interfacing, liaison, planning and co-ordination
with the Telecommunications Services Provider, taking account of the requirements within contract specific
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Appendix 15/3, throughout the period of performing the works as necessary to permit the Telecommunication
Services Provider to provide the telecommunications services.
2 (02/17) In response to requirements set out in contract specific Appendix 15/3, the Contractor shall contribute
to and provide support to the Telecommunications Services Provider in the establishment, joint periodic review
and update of an interface agreement, comprising a memorandum of understanding between the Contractor and
the Telecommunications Services Provider. This interface agreement covering the period of the works shall as a
minimum capture the joint requirements in respect of:
(i) the scope and geographic coverage of the interface agreement;
(ii) a description of the contractual and operational interfaces including current and future plans;
(iii) contacts and roles/responsibilities, including fault reporting, handling and escalation;
(iv) requirements in respect of meetings and written and electronic communications;
(v) requirements in respect of authorisations and the provision of notices;
(vi) specific access boundaries and access protocols;
(vii) definition of responsibilities for maintenance, including any shared maintenance responsibilities;
(viii) the booking and provision of temporary traffic management;
(ix) a schedule and details of special requirements including references to site-specific special requirements
such as site health and safety requirements and permits to work;
(x) any additional requirements within contract specific Appendix 15/3.
3 (02/17) The Contractor shall organise all operations and works so that the highways communications installation,
the provision of services by the Telecommunications Services Provider is completed, tested and the test results
accepted by the Overseeing Organisation or in accordance with contract specific Appendix 15/3 by the date or dates
specified in contract specific Appendix 1/13. The Contractor shall allow time in the programme for any remedial
works, repairs and retesting which may be required to be completed satisfactorily before the date or dates specified
The Contractor shall include within the programme key dates, as appropriate to the work relating to the
Telecommunications Services Provider’s activities including any sectional completion. This programme shall
include dates for:
(i) installation and removal of telecommunications bypasses;
(ii) de-activation and re-activation of existing telecommunications services;
(iii) removal of existing telecommunications equipment and infrastructure;

(iv) setting out of telecommunications infrastructure at site prior to the start of construction activities;
(v) completion of telecommunications infrastructure, including periods for inspection and acceptance;
(vi) the availability of cabinets for the installation of cabling or equipment;
(vii) installation of the Contractor’s cables;
(viii) installation of the Telecommunications Services Provider’s cabinets, cables and equipment, based on
information provided by the Telecommunications Services Provider;
(ix) activation of new telecommunications services;
(x) provision of temporary traffic management by the Contractor for the Telecommunications Services
Provider;
(xi) dates for any additional activity types including notice and mobilisation periods and constraints
regarding the Telecommunications Services Provider’s activities contained within contract specific
Appendix 15/3.
4 (02/17) The location of existing buried services and infrastructure shall be detected, confirmed, marked on the
ground and protected in accordance with the relevant special requirements contained in the contract documents
and any additional requirements detailed in contract specific Appendix 15/1 and contract specific Appendix 15/3 in
the case of buried services and infrastructure owned, operated or maintained by the Telecommunications Services
Provider.
In respect of buried services and infrastructure owned, operated or maintained by the Telecommunications
Services Provider, the Contractor shall arrange for the location and marking of buried services and infrastructure
and shall subsequently comply with the requirements for excavation in the proximity of such buried services and
infrastructure in accordance with contract specific Appendix 15/3.
The location of buried cables shall be detected, confirmed and protected in accordance with the relevant “special
requirements of (name of statutory undertaker)” or similar notice or instruction issued by a statutory undertaker and
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any additional requirements determined by the Telecommunications Services Provider in accordance with contract
5 (02/17) Prior to the start of telecommunications infrastructure construction activities, the Contractor shall comply
with any requirements of the Telecommunications Services Provider contained in contract specific Appendix 15/3,
in respect of the setting out of communications infrastructure that will be handed over upon the completion of the
works for the Telecommunications Services Provider to maintain.
6 (02/17) Mitigation methods to prevent metal theft shall be contained in contract specific Appendix 15/1 as agreed
with the Overseeing Organisation.
1503 (02/17) Materials Equipment and Workmanship

1 (02/17) All Electrical works shall comply with BS 7671 ‘Requirements for Electrical Installations, IET wiring
Regulations’ and the rules and regulations of the electricity Distribution Network Operator (DNO).
1504 (02/17) Site Records

1 (02/17) The Contractor shall keep a record, on drawings or as specified in contract specific Appendix 15/1, of
all work carried out as it proceeds. Copies shall be kept available for the use of the Overseeing Organisation and
during the Contract at intervals shown in the programme.
The compilation of records, drawings and other information specified in contract specific Appendix 15/1 including
timing of submissions shall be co-ordinated with and reflect the requirements of the Telecommunications Services
Provider as specified in contract specific Appendix 15/3.

Upon completion of the works, the Contractor shall produce record drawings in accordance with MCH1652 and
contract specific Appendix 15/3 which shall be issued to the Overseeing Organisation and the Telecommunications
Services Provider for record purposes. The following information shall be recorded on the drawings:
(i) Duct locations including depth, number and size of ducts and duct material.
(ii) Cable chamber locations including type, depth, incoming and outgoing ducts, sub-ducts, type of
chamber cover and details of cable joints within.
(iii) Cabinet positions and type.
(iv) Cabinet, cabinet function and cable chamber references.
(v) Other than those cables installed by the Telecommunications Services Provider the cable routes
including cable lengths. Additionally, within a ducted network, the number and type of cable allocated to
each duct and the length of each cable, unless the Telecommunication Services Provider is to provide the
cable route.
(vi) Other than those cables installed by the Telecommunications Services Provider, the cable size, type and
drum number.
(vii) Power supply installations.
(viii) SDP interfaces with Telecommunications Services Provider.
(ix) Signals.
(x) Telephones.
(xi) Sheath repair and cable joint positions.
(xii) Any additional requirements stated in contract specific Appendix 15/1 and contract specific
Appendix 15/3.
The drawings shall be submitted for the approval of the Overseeing Organisation at weekly intervals during the
contract.
2 (02/17) Position measurements (both horizontal and vertical) shall be taken of the underground equipment to the
nearest 100 mm. The interval and method of recording including any datum shall be agreed with the Overseeing
Organisation and shall be in accordance with the requirements of contract specific Appendix 15/1.
3 (02/17) The Contractor shall keep records of the work in sufficient detail including type and drum number of
installed cables to enable site records to be completed. A copy of the records shall be provided by the Contractor for
retention and use by the Overseeing Organisation.
4 (02/17) The Contractor shall keep record sheets for ducts, sub-ducts and chambers which shall indicate details of
all cables installed by the Contractor, ironwork, and plugs or seals installed and tests undertaken.
5 (02/17) For all cables installed by the Contractor each drum of cable delivered to the site will have quality
inspection certificates attached to each side flange in accordance with the relevant cable specification and shall
be CE marked. The Contractor shall ensure that the certificate relates to the cable to which it is attached. The
certificate shall be given to the Overseeing Organisation prior to the installation of cable.
6 (02/17) The Contractor shall produce handover records in accordance with MCH1349.
7 (02/17) Record information shall include details of any test equipment used to produce test results. For each set
of results, details of the test equipment manufacturer, model, serial number and confirmation that the test equipment
is within its calibration period as recommended by the manufacturer at the time of performing the test.
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1505 (02/17) Provision of Cabinets, Cables and Ancillary Items

1 (02/17) Cabinets, cables and ancillary items including cabinet bases, cabinet fittings, equipment mounting posts,
and similar items may be supplied by the Overseeing Organisation or the Telecommunications Services Provider
to the Contractor. These along with the organisation responsible for delivery, installation and maintenance will be
listed in contract specific Appendix 15/1.
2 (02/17) The Contractor shall supply a programme of required delivery dates and other information in accordance
with the Overseeing Organisation’s requirements given in contract specific Appendix 15/1.
The notice period required for this programme of required equipment and delivery dates is given in contract
This programme shall be reviewed and revised by the Contractor to suit the progress of the works and any revised
programme and associated schedule of equipment submitted to the Overseeing Organisation in accordance with
their requirements given in contract specific Appendix 15/1.
3 (02/17) The Contractor shall provide a dry and heated store to ensure that the equipment is stored in the manner
recommended by the manufacturer as described in contract specific Appendix 15/1.
4 (02/17) The Contractor shall be responsible for examining the equipment and cable from the Overseeing
Organisation and shall report any defects within five working days to the Overseeing Organisation.
5 (02/17) On completion of the works all unused Overseeing Organisation equipment, cables and cable drums shall
be set aside. The ownership status of these items from this point and any instructions for the Contractor to deliver
these items to the Overseeing Organisation or make them available for collection by the Overseeing Organisation
shall be as set out in contract specific Appendix 15/1.
1506 (02/17) Cables
1 (02/17) Communications cables installed by the Contractor shall meet the requirements of TRH2583 or as
2 (02/17) Power cables for communications systems shall meet the requirements of TRH2583 or as detailed in
3 (02/17) On receipt and at various stages before laying armoured cables the Contractor shall ensure that no
damage has been sustained by the cable which will compromise the integrity of the sheath. The Contractor shall
also determine that the quantity is sufficient based on the optimum cut lengths and based on the drum quantities and
also ensuring minimum wastage. The location in the ground of cable lengths by reference to their drum numbers
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shall be kept with the daily records.

4 (02/17) The cable end shall be cut/ terminated and the ends sealed to prevent the ingress of water to IPX7.
1507 (02/17) Cable Installation
1 (02/17) The approximate location of roadside technology, cabinets, SDPs, Contractor installed cables, ducts and
trenches are described in contract specific Appendix 15/1 and contract specific Appendix 15/2. The Contractor and,
as appropriate, the Overseeing Organisation or Telecommunications Services Provider shall agree the exact location
of these items before commencement of any associated works, including groundworks.
2 (02/17) Cables shall be stored and laid in accordance with manufacturer’s written instructions. Cable occupancy
for multiple cables installed in the same duct shall allow for installation and future cable replacement. The cross
sectional area of all cables shall not exceed 60% of the inner cross sectional area of the duct or as stated in contract
3 (02/17) Sufficient length of cable shall be allowed for its correct termination. When termination does not proceed
immediately following the installation of the cable, the cable ends shall be sealed against the ingress of water to
IPX7.

4 (02/17) The schedule of existing and new ducts is contained in contract specific Appendix 15/2.
The Contractor shall verify that all ducts are prepared and proven suitable for cable installation in accordance with
Clause 1533 prior to the drawing in of cable including where the Telecommunications Services Provider’s cables
are to be installed by the Telecommunications Services Provider.
Requirements for the preparation and proving of new or existing ducts and sub-ducts for the installation of cables
by the Telecommunications Services Provider are specified in contract specific Appendix 15/3.
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The requirement for the Contractor to install certain cables prior to the installation of cables by the
Telecommunications Services Provider is specified in contract specific Appendix 15/3.
On completion of the cable installation a draw cord in accordance with sub-Clause 1530.11 shall remain secured in
each duct.
Where specified in contract specific Appendix 15/2 or as determined by survey, including surveying using CCTV,
during construction works, existing ducts may be considered by the Contractor or Telecommunications Services
Provider as unsuitable to install new cables. An unsuitable duct in this context shall be determined through the
failure of a mandrel test in accordance with Manual of Contract Documents for Highway Works Volume 3 –
Highway Construction Details or the presence of visible sharp edges or discontinuities along the length of the duct.
In such circumstances the existing duct may be sleeved or sub-ducted with a single High-density polyethylene
(HDPE) continuous sub-duct acting as a sleeve for the installation of multiple cables or multiple HDPE continuous
sub-ducts in accordance with sub-Clause 1530.3, with one sub-duct for each cable. The diameter of each cable
including pulling arrangement shall not exceed 70% of the cross sectional area of the inner diameter of the
sub-duct. Sub-ducts shall be retained within the chamber at each end of the continuous run of sub-ducts using
a clamping plate or duct plug or other proprietary duct sealing system that can easily be removed (excluding
expanding foam) that retains the sub-duct(s) to the outer duct at each chamber.
5 (02/17) No cable shall be left exposed at the end of any work period. Any cable stolen and/or vandalised shall be
replaced in its entirety at the Contractor’s expense.
6 (02/17) Shall any damage occur to a cable during installation, however slight, the Contractor shall identify
and record the damage and report it to the Overseeing Organisation. The damage shall be repaired with cable
accessories meeting BS EN 50393 in accordance with the manufacturer’s instructions and at the Contractor’s
expense.
7 (02/17) Every cable shall be temporarily or permanently labelled immediately following its installation.
Temporarily labels shall be subsequently replaced with a permanent label prior to the completion of the works.
8 (02/17) Cables shall be handled and installed in accordance with the manufacturer’s instructions. The installation
of cables shall not damage the cable being installed, existing cables in the duct or the duct itself. Where permitted
by the manufacturer, a biodegradable lubricant may be used.
9 (02/17) Unless specifically identified in contract specific Appendix 15/1 and agreed by the owner of the service
duct, sharing of individual service ducts for power and data services shall not be permitted.
10 (02/17) Where cables pass through intermediate chambers, the Contractor shall, immediately after installation,
label each cable with the destination of the cable (joint chamber or equipment reference as appropriate) 150 mm
from the entry and exit points of the chamber.
11 (02/17) The Contractor shall take account of the requirements of the Telecommunications Services Provider as
specified in contract specific Appendix 15/3 when determining the order of the installation of cables within ducts
and sub-ducts.
12 (02/17) The sections of optical fibre cables that are visible inside chambers shall additionally be marked at
intervals of 500 mm along their length inside each chamber. The marking shall be 25 mm wide, yellow PVC
adhesive tape or alternative fit for the purpose.
13 (02/17) Cables shall not be bent to an internal radius less than the manufacturer’s recommendations, taking
account of the tensile load present in the cable during installation.

14 (02/17) Cables shall be secured to the chamber walls using fixings recommended by the manufacturer and
kept within the permitted bend radius. Cable management shall be laid such that it maximises the available
space, allowing for future cabling of the remaining ducts. The Contractor shall provide cable management
fixings to chambers in accordance with the Telecommunications Services Provider as stated in contract specific
Appendix 15/3.
15 (02/17) On completion of cabling within chambers, including cabling installed by the Telecommunications
Services Provider, the ducts shall be re-sealed with purpose made mechanical duct plugs or other proprietary duct
sealing system that can easily be removed (excluding expanding foam) installed in compliance with sub-Clause
1530.14. The locations and responsibility for the provision and installation of duct plugs or duct sealing systems
other than by the Contractor shall be as stated in contract specific Appendix 15/2. The cables shall be looped around
within the chambers and secured to the cable support steelwork.
16 (02/17) Unless stated otherwise in contract specific Appendix 15/1, all types of cable installed on gantries shall
be provided with continuous protection against mechanical damage or vandalism, from ground level to a point a
minimum of 3.5 m above the adjacent ground level within a covered cable tray or by other means.
Other means shall be as specified in contract specific Appendix 15/1.
In addition, cables installed on gantries in those areas that are accessible from walkways or ladders, shall be
protected from mechanical damage or vandalism by the provision of covered cable tray or other means unless
stated otherwise in contract specific Appendix 15/1.
Where specified in contract specific Appendix 15/1, cables shall also be protected against environmental damage
e.g. through prolonged exposure to ultraviolet radiation.
Where cables are to be installed across gantries by the Telecommunications Services Provider then the Contractor
shall be responsible for the final design and installation of the cable management and cable containment solution to
satisfy any requirements in respect of design proving and testing, as specified in contract specific Appendix 15/3.
17 (02/17) The depth of excavation shall be such that directly buried cables laid under verges, footways or open
ground shall have a minimum cover of 500 mm and under carriageways of 750 mm, or 300 mm below formation,
whichever is the greater depth. Trench detail does not apply to cables laid under carriageways or below formation.
For trenches requiring topsoiling, grass seeding and/or turfing shall be as described in Clauses 618 & 3005, and
shall be placed in the top 150 mm of the cable trench unless otherwise specified in contract specific Appendix 15/2.
With the agreement of the Overseeing Organisation, where minimum cover cannot be achieved, cables can be laid
in accordance with contract specific Appendix 15/3.
18 (02/17) Cables laid in trenches shall be both bedded on and covered by a 75 mm thickness of sand complying
with sub-Clause 503.3 (ii) Class 1C material complying with Table 6/1 and compacted to those requirements. An
additional 100 mm of sand shall be deposited to reach a total cover thickness of 175 mm prior to final backfilling.
Cables shall be laid in sand bedding and surround material in accordance with Clause 503 to a depth of 150 mm.
Class 1C material in accordance with Clause 602 and Table 6/1 shall be laid on top of the sand to a depth of
175 mm. Class 8 material in accordance with Clause 602 and Table 6/1 shall be laid on top of the Class 1C material
to a depth of 150 mm. Where shared ownership of cables applies in the one trench, the requirements of contract
specific Appendix 15/3 shall take precedence.
19 (02/17) Backfilling shall be in accordance with Clause 602 with material Class 8 complying with Table 6/1 and
compacted to the requirements therein. The material shall be spread and compacted evenly without dislodging,
disturbing or damaging cables, ducts or troughs. Vibrating compaction equipment shall not be used within 300 mm
of cables, ducts or troughs. For trenches requiring topsoiling, grass seeding and/or turfing shall be as described
in Clauses 618 & 3005, and shall be placed in the top 150 mm of the cable trench unless otherwise specified in
20 (02/17) Cable marker tape complying with Clause 1511 shall be laid in the cable trench. Where several cables
are laid in one trench one line of marker tape shall be installed for each 600 mm of trench width.

8
21 (02/17) Before installing any cables the ducts shall be free from foreign matter and detritus. When cables are
required to be laid in ducts the Contractor shall swab through the duct prior to drawing in the cables and a further
draw cord. The ducts shall be sealed with a draw cord in place following cabling, and resealed with split plugs, or
other proprietary duct sealing system that can easily be removed (excluding expanding foam), to adequately seal
the ducts against the ingress of foreign matter.
22 (02/17) Where cables are installed in existing troughs they shall either, as defined in contract specific
Appendix 15/2, be installed in sub-ducts suitably retaining in position or be covered with sand up to the level
underside or seating of the cover, whichever is the lower. The sand shall pass as 2 mm size test sieve as specified in
BS EN 933-2.
23 (02/17) The Telecommunications Services Provider’s use of armoured communications cables shall be limited
by design rules where specified in contract specific Appendix 15/3. Unless otherwise stated in contract specific
Appendix 15/2, longitudinal armoured cables that are to be installed by the Telecommunications Services Provider
shall be installed within sacrificial ducting installed by the Contractor. Longitudinal cables shall generally be run
parallel to the fence line or edge of the hardshoulder.
Transverse cables shall run at right angles to the carriageway. Subject to the approval of the Overseeing
Organisation transverse cables installed diagonally with respect to the carriageway may be accepted.
24 (02/17) All armoured communications cables exceeding 50 metres in length shall be provided with buried
loops to allow for re-termination following a cabinet knockdown. These loops shall be installed at each end of the
cable immediately adjacent to the entry and exit ducts at cabinet locations and the location included on the record
drawings.
25 (02/17) When duct or trough alignments differ from those of the trench the transition from one to the other shall
not exceed 1:30 horizontally or vertically.
26 (02/17) When more than one cable is laid in a trench they shall be accommodated in one horizontal layer in
order to locate them in the future. This applies to both communications and power cables as long as the power
cables are associated solely with communications equipment.
27 (02/17) The minimum separation between cables shall be such that safety and heat transfer, as defined in BS
7671 or interference, as defined in BS EN 50174-3, from adjacent cables will not affect the cable or the safety
and functionality of the equipment the cable is connecting (both communications and power) and as stated in
Appendix 15/3. The separation between a cable and the wall of the trench shall be such that the cable shall not be
damaged during infill or future ground movement.
28 (02/17) Following completion of work unused cable ends shall be sealed according to the manufacturer’s
written instructions to comply with IPX7.
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29 (02/17) Installed cables including any cable joints shall have a design life of not less than 30 years unless
1508 (02/17) Installation of Cabinets and Signal Posts

1 (02/17) Where described in contract specific Appendix 15/1, the Contractor shall construct hard-standing areas
and foundations incorporating plinths for cabinets and signal posts. Plinths shall make allowance for ducts to enter
cabinets from beneath.
Hard-standing areas shall be constructed; these shall extend at least 600 mm plus the depth of any raised plinth away
from each opening within a face of a cabinet or 900 mm in respect of signal posts, fence line cabinets and gantry
cable interfaces to the ducted network requiring access for maintenance. Individual hard-standing areas within
groups of cabinets and posts shall be interconnected by paths of minimum 600 mm width. Hard-standing areas shall
be continuous between opposing cabinet or post doors where the spacing between the door faces is up to 1.8 m.

Hard-standing areas shall be constructed such that any water drains away from cabinet plinths. Cabinet plinths shall
be constructed and cabinets installed such that cabinet doors shall be capable of opening and closing without being
fouled by the paved area or each other. The cabinets and signal posts shall be mounted on plinths using the fixings
provided. Plinths shall be constructed such that the orientation of the cabinets shall allow the hinged doors to open
towards the carriageway unless otherwise required by space or fouling constraints.
The Contractor shall construct hard-standing areas and foundations incorporating plinths for cabinets for use by the
Telecommunications Services Provider as described in contract specific Appendix 15/1.
The responsibilities for the provision of cast-in frames, erection of cabinets, labelling, installation of cables and
sealing of cabinet bases and ducts shall be as described in contract specific Appendix 15/1.
The orientation, spacing and clearance around cabinets and cabinet doors shall comply with the Telecommunication
Services Provider in contract specific Appendix 15/3.
2 (02/17) After the completion of all cable terminations and testing, the cabinet bases and ducts shall be sealed so
that the ingress protection (IP) rating of the cabinet, rodent protection and ability to add and replace cables without
damage, is maintained following the manufacturer’s guidelines.
3 (02/17) The Contractor shall keep the interior of cabinets free from moisture and debris. The Contractor shall
ensure, prior to the installation of equipment that for cabinets requiring power for environmental conditioning
that power is applied to the cabinets and is subsequently maintained and that the cabinets are clean and dry.
Subsequently the Contractor shall ensure that the doors of each cabinet are closed and properly secured after the
installation of equipment in the cabinet and after the completion of any other work.
4 (02/17) Entry/exit ducts to cabinets on a ducted network shall be sealed using duct plugs in compliance with
sub-Clause 1530.14 or other proprietary duct sealing system that can easily be removed, to prevent the ingress
of water and soil, gravel etc. The use of expanding foam is prohibited. The locations and responsibility for the
provision and installation of sealing systems other than by the Contractor shall be as stated in contract specific
Appendix 15/2.
5 (02/17) Where cabinets are situated in groups they shall be located in a consistent sequence as described in
6 (02/17) The Contractor shall install additional security measures to deter unauthorised access to cabinets,
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including cabinets operated and maintained by the Telecommunications Services Provider as detailed in contract
7 (02/17) The Contractor shall install secure cabinets for enforcement systems as detailed in contract specific
Appendix 15/1.
8 (02/17) When installing a sign in an area where a concrete safety barrier is present it is permissible to install
signal posts on top of the concrete safety barrier providing the mounting height as required by the Traffic Signs
Regulations and General Directions (TSRGD) is maintained and the access door is accessible as defined in contract
9 (02/17) Where power or communications interface cabinets are installed within the Overseeing Organisation’s
boundary fence line to permit access by a third party to the interface, the cabinet and the associated
communications infrastructure shall be wholly contained within the Overseeing Organisation’s land.
1509 (02/17) Gantries for Motorway Signals

1 (02/17) Details of cables and electrical equipment for traffic signs including variable message signs and matrix
signals on gantries are given in contract specific Appendix 15/1.

1510 (02/17) Installation of Telephones

1 (02/17) The Contractor shall construct a hard standing area and install the telephone base as described in contract
specific Appendix 15/1. Access for disabled users shall be provided.
2 (02/17) An area of hard standing shall be provided adjacent to the telephone. It shall be suitable to allow a person
in a wheelchair to access the telephone.
3 (02/17) A further hard standing, where required, in accordance with Clause 803 of sufficient working area shall
be installed behind the telephone to provide a flat level surface for maintenance purposes.
4 (02/17) Where not protected by a safety barrier, the telephone holding down arrangements shall pass the
requirements of EN 12767:2000 when tested in accordance with speed class 35 and 100, non-energy absorbing
structures occupant safety level 3.
5 (02/17) Spare cabling as stated in contract specific Appendix 15/1 shall be provided at ERT locations to allow
for ERT knockdowns. A cable re-make loop should be retained in the cable pit moulding or nearby underground
chamber.
Unless otherwise stated where new cable is being installed, a minimum 5 m length re-make loop of unhindered
cable shall be retained in the cable pit moulding.
6 (02/17) Each telephone column, instrument module and header module shall be orientated such that:
(i) locations where the telephone site is not protected by safety barrier the instrument module door is on the
downstream of traffic side of the unit, meaning that the road user is facing oncoming traffic while using
the telephone;
(ii) locations where a safety barrier is present, that the instrument module door faces the kerb to allow the
road user to access the telephone.
7 (02/17) Where telephones are installed on existing highways they shall be covered with purpose made “Not in
Use” covers until they have been commissioned and are available for use by the public. Where solar panel powered
telephones are used the bag used shall ensure that it does not prevent the charging of the telephone.
8 (02/17) Telephones shall be aligned within ±1° of the vertical.
9 (02/17) The Telecommunications Services Provider SDP shall be within the telephone column or instrument
module or as agreed by the Overseeing Organisation as defined in the contract specific Appendix 15/1.
10 (02/17) An under-plinth duct shall be used for all wired plinth installations. In ducted systems, a suitable
proprietary sealed joint shall be used to connect the under-plinth duct to the ducted network. The under-plinth duct
shall also be sealed against water ingress, by suitable means, at its junction with the cable pit moulding. Duct to
extend minimum of 200 mm beyond edge of plinth (for sites without existing ducts).
1511 (02/17) Marker Tape

1 (02/17) All cables and ducts installed underground shall have their position indicated by the use of marker tape
in accordance with BS EN 12613 that is detectable from above ground. Marker tape shall be buried in the trench
above the cable/duct.
2 (02/17) The wording on the marker tape shall read “CAUTION COMMUNICATIONS/ POWER CABLES
BELOW”. The marker tape shall be compliant to EN 12613.
3 (02/17) Marker tape shall be yellow in colour, with wording in black.

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1512 (02/17) Installation of Ancillary Items

1 (02/17) Unless otherwise specified in contract specific Appendix 15/1, all boxes shall be mounted onto the
baseboards or frames of cabinets, the knockouts for cable access removed as necessary and holes bushed or fitted
with cable glands. Termination frames shall be fitted within the boxes where appropriate.
2 (02/17) Distributors shall be mounted onto the baseboards of posts. Distributors and electrical switches shall be
mounted at the gantry or as described in contract specific Appendix 15/1.
3 (02/17) Power switchgear and protective devices shall be installed in power supply cabinets and other locations
4 (02/17) The Contractor shall provide and install connectors for the termination of cables as detailed in contract
specific Appendix 15/1. All terminations and link cabling from the Telecommunication Services Provider’s SDP to
the equipment installed within the cabinet shall be the responsibility of the Contractor.
5 (02/17) Where the Telecommunications Services Provider’s active equipment is installed in a cabinet a minimum
of two separately protected circuit ways from the main distribution point within the cabinet shall be provided for
the sole use by the Telecommunications Services Provider. Sufficient spare cable terminations and entry points to
allow the fitting of 20 mm cable glands or the provision of outlet sockets to IEC 60320 Part 2-2 sheet F shall be
provided to permit the Telecommunications Services Provider to make connections to the power supply. Unless
stated otherwise in contract specific Appendix 15/1, protection devices on each of the circuit ways shall be 6A, type
B miniature circuit breakers that meet the relevant essential requirements for overcurrent protection under the Low
Voltage Directive.
1513 (02/17) Jointing and Termination of Multi-pair Communications Cables

1 (02/17) Unless described otherwise in contract specific Appendix 15/1, jointing and termination of multi-pair
communications cables up to the SDP shall be undertaken by the Telecommunications Services Provider. The
Contractor shall be responsible for jointing and termination of multi-pair communications cables beyond the SDP,
including detector systems and cables to gantry mounted equipment. The Contractor shall provide space and fixing
points to accommodate the Telecommunications Services Provider’s terminations, including terminations up to the
SDP.
2 (02/17) Cable joints provided by the Contractor (except within in-road detector systems) will only be permitted
at the locations described in contract specific Appendix 15/1. Where cable joints house a SDP then these joints shall
be located and readily accessible as determined by the Contractor’s consultation with both the Telecommunications
Services Provider and the Overseeing Organisation’s Technology Maintenance Services Provider. The
responsibility for providing the cable joint that houses an SDP shall be the Telecommunications Services Provider
3 (02/17) Cable joints in road detector systems shall comply with Clause 1218.
4 (02/17) All jointing and termination shall be carried out in accordance with manufacturer’s instructions. All cable
conductors shall be protected from strain prior to their termination. Cables shall be dressed neatly in accordance to
the manufacturer’s instructions.
5 (02/17) The Contractor shall ensure that the lay of the cable is maintained up to the termination position without
exerting undue stress on the conductors and terminals. All conductor pairs shall be identified by means of a
numbered plastic sleeve, collar or other method as agreed with the Overseeing Organisation.
6 (02/17) Termination of cable using insulation displacement connectors shall be undertaken in accordance with
the manufacturer’s instructions using any specialist tools necessary. The Contractor shall provide the requisite tools.

7 (02/17) Within cabinets, links shall be terminated in terminal blocks complying with sub-Clause 1514.2. The
conductors shall be secured in terminals in accordance with the manufacturer’s written instructions. Links shall
be tied and supported and of sufficient length to facilitate routine maintenance and allow for subsequent re-
terminations. The correct pairing shall be maintained at all times. The Contractor shall clearly identify links by
using collets at either end.
8 (02/17) Where the Contractor is required as scheduled in contract specific Appendix 15/1 to terminate cables into
cabinets containing operational circuitry, the Contractor shall give two weeks’ notice (or as specified in contract
specific Appendix 15/3, whichever is the longer) to allow the opportunity for a representative of the Overseeing
Organisation’s Technology Maintenance Services Provider to attend each site to oversee all work within the cabinet
for which the Contractor is responsible.
(i) The Contractor shall also comply with the Telecommunications Services Provider’s requirements for
notification and attendance by the Telecommunications Services Provider where necessary in accordance
with the requirements specified in contract specific Appendix 15/3. This work shall not compromise
operational system(s).
9 (02/17) For cable joints installed by the Contractor, Cable Joint Enclosures (CJE) shall be installed in
chambers and Above Ground Joints (AGJ) or other cable joint type in cabinets, as described in contract specific
Appendix 15/1. If cable joints are to be located in the same chamber as a Telecommunications Services Provider’s
cable joints then the accommodation requirements shall be as per contract specific Appendix 15/3.
10 (02/17) At rural post mounted signal sites or other locations where the accommodation of a suitable SDP
connection is not possible or readily accessible within the equipment housing, the Contractor shall provide
sufficient space within a segregated compartment for the Telecommunications Services Provider to install a CJE to
house an SDP and to facilitate the isolation and testing of RS485 and other communication circuits.
11 (02/17) Cable continuity kits to ensure the integrity of protective and screening conductors shall be installed
on every cable except in the case of screening conductors where specified otherwise in contract specific
Appendix 15/1.
12 (02/17) Links shall be installed and connected within cabinets and connection boxes with jumper leads installed
between connection boxes wherever two are installed within one cabinet; using as appropriate the insulated
conductors of multi-pair cable with its outer sheath, armour and inner sheath removed. The leads shall be of
sufficient length to facilitate routine maintenance and allow for several subsequent re-terminations and shall not
obstruct any accessory in the connection box. The Contractor shall maintain multi-pair colour coding so that colour
code duplication does not occur. The correct pairing shall be maintained at all times.
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1514 (02/17) Cable Connectors
1 (02/17) Where shown on the contract specific drawings, cables shall be terminated using insulation displacement
connectors that are designed to accommodate the conductor and outer insulation sizes of the cables being
terminated and the number of conductors terminated into a single terminal.
2 (02/17) Unless otherwise shown on the contract specific drawings the Contractor shall use terminal blocks that
meet the relevant essential requirements for copper conductors under the Low Voltage Directive with an impulse
withstand voltage rating of at least 6kV. Terminals shall employ either screw-type or screw-less-type clamping
arrangements to retain individual conductors without any direct screw to conductor contact. Terminal blocks shall
be compatible with the stranding and size of conductors being terminated and shall incorporate or be fitted with
indelible identification labels to uniquely identify each terminal way.
3 (02/17) The requirements for ethernet and optical patch cords shall be as detailed in contract specific
Appendix 15/1.

1515 (02/17) Termination of Optical Fibre Communication Cables

1 (02/17) Unless otherwise stated in contract specific Appendix 15/1, the Telecommunications Services Provider
shall be responsible for the termination of optical fibre cables up to the SDP and the Contractor shall be responsible
for the termination of optical fibre cables beyond the SDP. Sub-Clauses 1515.2 to 4 give the requirements where the
Contractor is required to execute optical fibre cable jointing.
2 (02/17) The Contractor shall be responsible for the safe disposal of any optical fibre cable waste created by the
Contractor.
3 (02/17) Cables shall be terminated in such a way to prevent damage due to the occurrence of moisture to IPX7.
The fibres shall be fusion spliced and protected from mechanical strain.
4 (02/17) Copper conductors in composite optical fibre cables shall be secured in terminals in accordance with the
manufacturer’s recommendations.
1516 (02/17) Termination and Jointing of Power Supply Cables for Communications
1 (02/17) The method and responsibility of the termination of power supply cables for communications shall be
2 (02/17) Cable joints in power cables shall be made where described in contract specific Appendix 15/1.
Additional joints shall not be permitted to overcome inaccuracies in measurement, or cable damage. Cable joints
shall not be situated in a duct or trough. Heat-shrink or cold-shrink type joints shall not be used.
3 (02/17) Cables greater in size than 25 mm2 shall not be terminated within cabinets, unless the cabinet is
specifically designed to terminate a large sized cable as identified in contract specific Appendix 15/1.
As specified in contract specific Appendix 15/1 or on the cable schematic contract specific drawings the cable shall
be jointed to a length of 10 mm2 or 25 mm2 cable manufactured to specification TRH 2583 part 3. The 10 mm2 or
25 mm2 cable shall be terminated within the cabinet. An underground cable reduction joint shall be installed at the
change in cable size. Within a ducted cable network the cable joint shall be made in the adjacent chamber or for a
direct buried network near to the cabinet cable entry duct. The type of chamber shall be as shown on the contract
specific drawings. Details of the reduction joint shall be displayed within the cabinet where the jointed cable is
terminated.
4 (02/17) Power supply cable joints including reduction joints for cables of cross section greater than 50 mm2 are
not permitted within chambers containing longitudinal below ground cable joints. Power supply cable joints for
cables of cross section greater than 50 mm2 shall be housed in separate chambers as shown on the contract specific
drawings. Details of the locations of chambers that will contain power supply cable joints are provided in contract
Power cables shall be supported and routed in a manner that does not impede access to the telecommunications
infrastructure nor create a hazard when using the access steps where present.
5 (02/17) Joints shall be made using a suitable jointing system in which all components are mutually compatible
and adequate for the type of cables to be jointed. Joints shall be installed in accordance with the manufacturer’s
written instructions.
6 (02/17) Jointing shall only be carried out when all the materials used in the joint are free from visible signs
of moisture. Joints shall be protected from water, frost, direct sunlight and extremes of temperature during the
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curing period for the joint materials in accordance with the manufacturer’s instructions. Joints shall be adequately
supported at all times. Backfilling shall comply with this specification and shall not take place until the joint is
completely cured and able to withstand any stresses which may be imposed on it.
7 (02/17) Where a new power supply is being provided to existing equipment or an existing power supply is
modified which will result in a disruption to or the loss of existing facilities (signals, CCTV etc.) written authority
shall be obtained by the Contractor from the Overseeing Organisation and Telecommunications Services Provider
(as appropriate), who will advise their individual stakeholders of the anticipated duration, so that the effects of the

power supply disruption can be assessed. The Contractor shall provide at least two weeks’ notice in writing of all
planned disruptions to the Overseeing Organisation and take into account any other notice periods that are in place
as stated in contract specific Appendix 15/1. The Contractor shall undertake all necessary preparatory work to
ensure that the period of disruption is minimised.
8 (02/17) Where described in contract specific Appendix 15/1 at each existing gantry the Contractor shall carry out
tests to confirm that the lighting supply and the communications power supply are fed from the same phase. Where
tests show the two supplies are not in phase the Contractor shall isolate the lighting power supply, at the power
isolation cabinet, from the mains supply and carry out the remedial works necessary to bring both supplies into the
same phase as agreed with the Overseeing Organisation.
9 (02/17) Cable joint markers complying with the requirements of duct end markers, sub-Clause 501.8, but with
the letters ‘CJ’ replacing the letter ‘D’, shall be provided and installed to indicate the position of below ground
joints. Alternatively, the letters ‘CJ’ can be added to the chamber label described in sub-Clause 1532.15. Temporary
markers shall be provided if necessary to ensure the accurate positioning of permanent markers, alternatively an
active marker may be provided.
1517 (02/17) Earthing, Bonding and Lightning Protection

1 (02/17) Lightning protection and power supply earthing, and the labelling of such earthing arrangements, shall
be provided for all metalwork including gantries and cantilever structures in accordance with BS EN 62305,
BS 7430 and BS 7671. Specific lightning protection and earthing requirements are defined in contract specific
Appendix 15/1.
2 (02/17) The area of gland plates or boxes which will come in contact with a cable gland shall be cleaned of all
paint and corrosion before a cable gland is fitted. Once the gland is fitted, exposed metalwork of gland plates or
boxes shall be suitably treated to protect against corrosion.
3 (02/17) All connections to bolted fixtures shall be made through crimped type lugs.
4 (02/17) Adjacent cabinets less than two metres distant shall be effectively equipotentially bonded together in
accordance with BS 7671.
5 (02/17) Lightning protection for gantries and other structures, such as camera masts, shall be provided as
described in contract specific Appendix 15/1. Gantry lightning protection system components shall comply with
BS EN 62561.
6 (02/17) Unless otherwise stated in contract specific Appendix 15/1, the Telecommunications Services Provider
shall provide lightning protection components to protect the telecommunications services delivered to the SDP.
7 (02/17) The Contractor shall provide space and fixing points to accommodate the Telecommunications Services
Provider’s lightning protection components.
8 (02/17) The Contractor shall provide suitable earthing point or earthing arrangements in accordance with
contract specific Appendix 15/3 for use by the Telecommunications Services Provider to provide earthing for the
Telecommunications Services Provider’s lightning protection components.
1518 (02/17) Cable Testing

1 (02/17) The Contractor shall undertake tests on cables as detailed in contract specific Appendix 1/5. The
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Telecommunications Services Provider shall undertake tests on all cables installed by the Telecommunications
Services Provider.
2 (02/17) All cables shall be tested by the Contractor post installation in accordance with specification MCG 1022
(for armoured or non-armoured copper cables), or to the manufacturer’s specifications for continuity and insulation,
as appropriate. The cable sections and scope of tests shall be as described in contract specific Appendix 15/1.

3 (02/17) Three copies of all cable test results shall be supplied to the Overseeing Organisation on the completion
of each test.
4 (02/17) All test instruments requiring calibration shall have a current calibration certificate, copies of which shall
be available at the time of testing.
5 (02/17) The Contractor shall give at least two weeks’ advance notice, in writing, to the Overseeing Organisation
of any cable testing.
6 (02/17) In the event of the Contractor opening up a trench or drawing further cables through a duct after cables
have been installed and tested, then all cables in the trench or duct shall be retested. Any damage identified by this
test shall be rectified by the Contractor and the cables then re-tested.
7 (02/17) After testing, the Contractor shall locate and expose any damaged outer sheath and shall report all
such damage to the Overseeing Organisation. The Overseeing Organisation shall be informed prior to the
commencement of any operation to expose damaged cable and shall be allowed to be in attendance during the
operation. The Contractor will be informed by the Overseeing Organisation whether a sheath repair shall be
permitted. For cables installed on behalf of the Telecommunications Services Provider the criteria to determine
whether a cable sheath repair is permitted or other action required shall be as defined in contract specific
Appendix 15/3. Should sheath repairs be permitted the Contractor shall provide and install cable joint markers
complying with sub-Clause 1516.9.
8 (02/17) No tests shall be carried out until the cable trench has been backfilled and the ground above the cable
reinstated and the cable ends have been installed, unterminated, in the respective termination cabinets.
1519 (02/17) Labelling and Numbering

1 (02/17) Gantries, Cable Joint Enclosures (CJE), Above Ground Joints (AGJ), cable chambers, cabinets, signal
posts and telephones shall be numbered and cables shall be labelled, in accordance with the details described in
2 (02/17) Labels shall be as specified in contract specific Appendix 15/1. Labels shall be fitted so as not to
compromise the IP rating of the cabinet or enclosure. The label material and fixing method shall be capable of
lasting the design life of the equipment it is fitted to.
3 (02/17) The Contractor shall reference individual telecommunications services in correspondence and site
records using the telecommunications service and SDP labelling information as provided and installed by the
Telecommunications Services Provider and as stated in contract specific Appendix 15/3.
4 (02/17) Cables shall not be left unlabelled at any time, temporary labelling may be applied to facilitate testing
and termination prior to the implementation of permanent labelling.
5 (02/17) All cabinets and enclosures containing power distribution and control equipment shall be labelled to
indicate the source of supply, destination and user where this is a third party (e.g. Telecommunications Services
Provider), circuit arrangements and test details in accordance with regulations. Refer to contract specific
Appendix 15/1 for examples of such labels.
6 (02/17) Where the Contractor carries out modification work to existing cabinets, new labels shall be fitted in
accordance with contract specific Appendix 15/1.
7 (02/17) The Contractor shall submit to the Overseeing Organisation for acceptance proposals for cabinet labels.
The Contractor shall allow seven working days for acceptance of the proposals.
8 (02/17) Cabinets, enclosures and distribution equipment containing power shall be fitted with warning labels, as
per the requirements in BS 7671.
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9 (02/17) The Contractor shall refer to TSRGD for proportions and forms of numbers and letters for all external
labels. External cabinet identification labels shall contain details of marker post number, carriageway designation
letter and internal equipment, or cabinet function identification. Cabinet identification references shall be consistent
across a scheme and with references used within record information and drawings. Text shall be upper case

and readable when standing adjacent to the cabinet. Cabinet labels shall be installed on the side of the cabinets
facing the carriageway. At Electrical Interface (EI) locations, the label shall be fitted on each cabinet door due to
orientation of the cabinet in the fence line.
10 (02/17) External labels for post 75 signal posts and target boards shall have numbers and upper case letters. The
label shall be fitted as near to the bottom of the post as possible and viewed from the carriageway. The label can be
fitted to the door if the signal obscures the bottom of the post e.g. when an Advanced Motorway Indicator (AMI) is
fitted.
11 (02/17) External labels for gantries shall be fitted to each gantry leg facing traffic 2 m above road level.
12 (02/17) For telephone installations although the door may face the carriageway or downstream of the traffic
direction, depending on installation, the header module shall always be oriented so that external labels face
upstream and downstream.
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13 (02/17) All cables shall be clearly and unambiguously marked to show details of cable destinations. At CJEs the
cable shall be marked immediately adjacent to the CJE. At AGJs the cable shall be marked immediately prior to the
glanding of the cable before its entry into the terminal housing.
14 (02/17) Where the Overseeing Organisation’s cables are terminated into cabinets or locations for which the
Telecommunications Services Provider is solely responsible for maintaining then the Contractor shall identify the
Overseeing Organisation’s cables in accordance with the requirements in contract specific Appendix 15/3.
1520 (02/17) Not Used
1521 (02/17) Removal and Re-siting of Existing Equipment

1 (02/17) Existing communications equipment and infrastructure shall be removed or re-sited where required in the
works, as detailed in contract specific Appendix 15/1. No equipment shall be removed or cables disconnected or cut
until agreed by either the Overseeing Organisation or Telecommunications Services Provider (as appropriate).
The Contractor shall co-ordinate and schedule the deactivation of telecommunications services, re-siting of
equipment, re-activation of telecommunications services and removal of telecommunications services and
associated equipment and infrastructure as identified in contract specific Appendix 15/1 in accordance with a
programme agreed with the Telecommunications Services Provider as and in compliance with the requirements of
2 (02/17) Existing highway communications equipment, as detailed in contract specific Appendix 15/1, shall
be removed in a manner that would enable its reuse and stored by the Contractor as directed by the Overseeing
Organisation.
Existing equipment operated by the Telecommunications Services Provider shall be removed by the
Telecommunications Services Provider. Cables and other infrastructure maintained by the Telecommunications
Services Provider shall, as scheduled in contract specific Appendix 15/1, be removed or broken out and disposed of
by the Contractor in compliance with Clause 201.
3 (02/17) Where the Telecommunications Services Provider is required to attend site and remove equipment no
longer required or that requires re-siting, the notice period set out in contract specific Appendix 15/3 shall be given
by the Contractor to the Telecommunications Services Provider.
4 (02/17) Conductors shall be disconnected from the equipment in which they are terminated, the terminal screws
and glands re-tightened and the cable withdrawn clear of the equipment.
5 (02/17) Items of equipment to be re-sited shall be unbolted from their plinths or supports together with their
holding down bolts, stored, and re-sited as described in contract specific Appendix 15/1. Plinths and concrete
foundations shall be broken out and disposed of in compliance with Clause 201.

6 (02/17) Cables, including those to be removed, shall be located and marked at ground level by the
Telecommunications Services Provider where these are maintained by the Telecommunications Services Provider
or the Contractor in respect of other cables throughout their routes. The marking shall clearly distinguish the
cables to be removed from other cables. The Contractor or Telecommunications Services Provider (as appropriate)
shall also excavate trial holes to expose these cables at the pre-determined locations detailed in contract specific
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Appendix 15/2 together with the method of cable removal.
Where described in contract specific Appendix 15/2 the Contractor or Telecommunications Services Provider
(as appropriate) shall excavate that part of the cable route carefully by hand. Where the cable to be removed is
sharing a trench with other existing cables, on completion of removal, all stones and contaminated material shall
be removed from the cable trench, clean sand and warning tape shall be provided and installed and the cable trench
shall then be reinstated in compliance with Clause 1507; the Contractor or Telecommunications Services Provider
(as appropriate) shall then remove and dispose of all unsuitable and surplus material in compliance with Clause
201.
Cable in ducts shall be carefully withdrawn. The Contractor or Telecommunications Services Provider (as
appropriate) shall also fulfil the requirements for removal of duct seal, re-sealing and re-roping. Cables in
troughs shall be carefully segregated and lifted out. The Contractor or Telecommunications Services Provider (as
appropriate) shall also remove all trough lids, all debris from troughs and all sand from troughs. On completion the
Contractor or Telecommunications Services Provider (as appropriate) shall provide and install clean sand, reinstate
all trough lids, and provide and install new trough lids to replace any breakages caused during the preceding
operation.
7 (02/17) The sites of cabinets, plinths and cable trenches shall be reinstated to the level of the surrounding ground
8 (02/17) The disposal of any waste shall be in accordance to the Contractor’s waste management plan.
1522 (02/17) Enforcement and Other Systems

1 (02/17) Secure equipment cabinets required for enforcement systems shall be installed in accordance with Clause
1508.
2 (02/17) The Contractor shall construct foundations for enforcement system camera masts as described in contract
3 (02/17) Mountings, cable tray and other ancillary items for enforcement system equipment shall be installed as
1523 (02/17) Detector Systems

1 (02/17) The installation of detector systems shall comply with the requirements of contract specific
Appendix 15/1.
2 (02/17) Where detector loops are specified, detector loop installation and testing shall comply with Clause 1218.
Other detection systems shall comply with the installation requirements detailed in contract specific Appendix 15/1.
3 (02/17) Any cabinet equipped for detector system use shall be installed in accordance with Clause 1508.
4 (02/17) Loop feeder cables shall be terminated as described in contract specific Appendix 15/1. The loop feeders
shall be terminated in terminals complying with Clause 1514, secured to the equipment frame. Each feeder shall
have 500 mm of cable coiled in the bottom of the cabinet to allow subsequent re-terminations. Each feeder shall be
individually identified by means of a label.
1524 (02/17) Trial Pits

1 (02/17) Trial pits shall be excavated as described in contract specific Appendix 15/1.

1525 (02/17) Safeguarding the Existing Highway Communications Network

1 (02/17) The highway communications network forms part of the national network operated by the
Telecommunications Services Provider and consequently any damage to equipment or infrastructure within the
works area, including power supplies to the Telecommunications Services Provider’s equipment cabinets, can
have severe consequences to the system as a whole. The Contractor shall co-ordinate with the Telecommunications
Services Provider a programme of works that supports the installation by the Telecommunications Services
Provider of measures to maintain service continuity throughout the affected area (there may be more than one
affected areas within the works boundary) and to implement temporary communications arrangements that allow
the Contract to complete each phase of the works whilst minimising the disruption to the national communications
network and local communications services. The requirements for implementing measures to maintain service
continuity and for giving notice to the Telecommunications Services Provider to implement these measures and
other temporary communications services are specified in contract specific Appendix 15/3. Any provisional
agreements in respect of network bypass cables shall be scheduled in contract specific Appendix 15/1.
2 (02/17) Telecommunications services to be suspended (de-activated pending activation at a later date), re-
located or removed by the Telecommunications Services Provider shall be as scheduled against location and
equipment type in contract specific Appendix 15/1. Telecommunications services to be maintained using temporary
arrangements are to be implemented by the Telecommunications Services Provider. In each case the Contractor
shall give notice for service suspension, re-location, service removal and the implementation of temporary
communications arrangements in accordance with contract specific Appendix 15/3.
3 (02/17) The Contractor shall give at least three weeks’ written notice of the proposed change to the network,
which shall have been identified in advance in the Contractor’s programme. Any such proposal shall be subject to
the agreement of the Overseeing Organisation and the Telecommunications Services Provider.
4 (02/17) The Contractor shall allow representatives of the Overseeing Organisation and the Telecommunications
Services Provider access to all equipment within the works which has been identified as operational. The
Contractor shall comply with the Telecommunications Services Provider’s requirements for access to install,
maintain and remove operational equipment and telecommunications bypasses as specified in contract specific
Appendix 15/3.
5 (02/17) The Contractor shall recognise the importance of the need for the Telecommunications Services Provider
to gain access for the maintenance and repair of temporary communications arrangements, particularly those that
support the national communications network. The Contractor shall accommodate and prioritise requests made
by the Telecommunications Services Provider to enable the repair of temporary communications arrangements to
restore the Telecommunications Services Provider’s services.
6 (02/17) Areas within the works boundary where the nature of the works performed has a potential impact upon
the integrity of the national communications network and local telecommunications services shall be jointly
identified and agreed between the Contractor, the Overseeing Organisation and the Telecommunications Services
Provider. Measures to maintain service continuity throughout the affected areas, including any routes for the
implementation of network bypass cables and to implement temporary communications arrangements shall be
agreed between the Contractor, the Overseeing Organisation and the Telecommunications Services Provider.
7 (02/17) The Contractor shall be responsible for the provision of cable protection for network bypass cables and
other temporary communications cables. The requirements for protection shall be as detailed in contract specific
Appendix 15/3. The locations for the installation of cable protection and the measures to be applied over the entire
length of network bypass cables shall be agreed with the Telecommunications Services Provider, taking account of
the following.
(i) The risk of damage due to construction work activities, including plant crossings.
(ii) The risk of damage due to vandalism or theft, e.g. close exposure to public footpaths or known areas of
vandal damage/theft.
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(iii) The close proximity to running traffic lanes and where the cables can only be located at a low level
where they directly face running traffic, e.g. close proximity to running traffic with cables installed near
to ground level – risk of damage by stones or other debris.
(iv) The installation of protection infrastructure at carriageway crossings on over-bridges or gantries where
this enables cable installation without the need to implement significant lane closures.
All of the above requirements shall apply to the full extent of network bypass cables and other temporary cabling
including where they extend beyond the works boundary.
8 (02/17) Where, in accordance with criteria set out within contract specific Appendix 15/3, construction works
are to be performed in close proximity to the Telecommunications Services Provider’s buried services and
infrastructure, then the Contractor shall provide notice to the Telecommunications Services Provider to attend site
during periods of relevant construction work. The Contractor shall provide construction method statements and a
programme of these works to the Telecommunications Services Provider. No construction works in close proximity
to the Telecommunications Services Provider’s buried services and infrastructure shall be performed by the
Contractor without either:
(i) the attendance at site by the Telecommunications Services Provider; or
(ii) the written consent of the Telecommunications Services Provider.
1526 (02/17) The Inspection and Testing of Electrical Installations

1 (02/17) The Contractor shall carry out the inspection and testing of electrical installations in accordance with
BS 7671. The Contractor shall provide inspection and completion certificates to the Overseeing Organisation in
accordance with BS 7671 and to notice periods determined in contract specific Appendix 15/3.
2 (02/17) Where the inspection/ tests show that an existing electrical installation or earthing arrangement is not
determined as safe in accordance with the requirements of BS 7671, the Contractor shall immediately notify the
Overseeing Organisation giving full details of non-compliance. The Contractor shall not undertake any work on
such an installation until written instructions have been issued by the Overseeing Organisation.
3 (02/17) Electrical inspection records, test results and electrical installation certificates shall form part of the
records produced in compliance with Clause 1504.
4 (02/17) In the case where the Telecommunications Services provider shares power with the Overseeing
Organisation the Telecommunications Services Provider shall, unless specified otherwise within contract specific
Appendix 15/1, be responsible for the inspection and testing of the electrical installation from the point that the
supply becomes for the sole use of the Telecommunications Services Provider.
1527 (02/17) Cable Installation at Transmission Stations

1 (02/17) Cables shall be installed into and terminated within transmission station buildings and transmission
cabinets by the Telecommunications Services Provider.
2 (02/17) Unless detailed otherwise in contract specific Appendix 15/1 work shall not be undertaken
in transmission station buildings or transmission cabinets by the Contractor without the approval of the
Telecommunications Services Provider. The work shall be identified in the Contractor’s programme and agreed
with the Telecommunications Services Provider. The Contractor shall comply with the requirements for access to
transmission stations and transmission cabinets to perform work as specified in contract specific Appendix 15/3.
The Contractor shall ensure that no unplanned disruption occurs to any operational systems.
1528 (02/17) Modifications to Equipment and Circuitry associated with Existing Cabinets
1 (02/17) The Contractor shall carry out modifications to equipment and circuitry associated with existing cabinets

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20
2 (02/17) The Contractor shall, prior to laying any cable to the cabinets, locate (including, as appropriate,
scheduling the Telecommunications Services Provider to attend site and to mark buried services and infrastructure)
the position of all cabling exposing all cables that are not in ducts by careful hand excavation and identify the type,
size and designation of each cable.
3 (02/17) Where appropriate the Contractor shall undertake the following:
(i) remove, retain for re-use, and reinstall the cabinet duct seals and base pea gravel;
(ii) remove and re-lay any hard-standing;
(iii) excavate to expose cable, remake loop and excavate cable routes;
(iv) reroute cable to gain sufficient lengths for the proposed modification;
(v) reinstate cable trenches;
(vi) break open and re-seal resin filled base;
(vii) disconnect and reconnect, undo existing gland and re-gland, including the provision of new ducts seals,
gland assemblies and cable termination ancillaries where required;
(viii) withdraw and reinstall cables at cabinet base.
4 (02/17) Any work required to operational circuitry shall be undertaken by a representative of the Overseeing
Organisation or Telecommunications Services Provider (as appropriate). The Contractor shall give at least two
weeks’ written notice and take into account any other notice periods that are in place as stated in contract specific
Appendix 15/1 of the need for such work and shall, in respect of work to be performed by the Telecommunications
Services Provider, comply with the requirements stated within contract specific Appendix 15/3.
1529 (02/17) Temporary Emergency Telephones

1 (02/17) Where described in contract specific Appendix 15/1, Temporary Emergency Telephones shall be installed
for use by the public when it would otherwise be necessary for the public to cross either a live traffic lane or
the works to use the nearest working Emergency Roadside Telephone. When not in use Temporary Emergency
Telephones shall either be removed or covered up. The direction of Temporary Emergency Telephones shall be
indicated in a manner agreed by the Overseeing Organisation at 100 metre intervals. The location and orientation of
Temporary Emergency Telephones shall be agreed with the Overseeing Organisation.
2 (02/17) When Temporary Emergency Telephones are required they shall be supplied by the Overseeing
Organisation or the Contractor as stated and detailed in contract specific Appendix 15/1.
The use of Global System for Mobile Communications (GSM) or other wirelessly connected Temporary
Emergency Telephones may be agreed by the Overseeing Organisation as detailed in contract specific
Appendix 15/1.
3 (02/17) Locations for cable for Temporary Emergency Telephones shall be identified by the Contractor and the
Telecommunications Services Provider. Providing the location of a Temporary Emergency Telephone is within
close proximity (within 100 metre and on the same side of the carriageway) of an existing Emergency Roadside
Telephone location, the Telecommunications Services Provider shall be responsible for the installation and
termination of temporary cables to support local telecommunications services in accordance with the requirements
stated in contract specific Appendix 15/3. The Contractor shall be responsible for the additional cost of works
performed by the Telecommunications Services Provider where the location of any Temporary Emergency
Telephone is not in close proximity of an existing Emergency Roadside Telephone.
4 (02/17) The Contractor shall give at least two weeks’ written notice of the need for connections and
disconnections from the live communications network by the Overseeing Organisation or Telecommunications
Services Provider and, shall in respect of work to be performed by the Telecommunications Services Provider,
comply with the requirements stated within contract specific Appendix 15/3.

21
5 (02/17) The Contractor shall install, place in position, maintain, cover up, uncover, reposition, re-cable and
remove Temporary Emergency Telephones and associated work as necessitated by the progress of the works, and
upon completion of the works return them to the Overseeing Organisation.
6 (02/17) Maintenance of Temporary Emergency Telephones connected onto the network shall only be undertaken
by a representative of the Overseeing Organisation or Telecommunications Services Provider (as appropriate).
The Contractor shall allow full access arrangements to representatives of the Overseeing Organisation and the
Telecommunications Services Provider.
1530 (02/17) Cable Ducts General

1 (02/17) The term cable duct is used in this Series to describe the ducts, sub-ducts or conduits used for installing
the highway communications cable network. The ducts shall comply with this Series and any other requirements
described in contract specific Appendix 15/2. The Contractor shall be responsible for ensuring that all components
used within the duct are compatible with each other and with existing ducts.
2 (02/17) With the exception of the cases listed in this sub-Clause below, cable ducts shall comply with the general
essential requirements for cable management systems and for buried conduit systems under the Low Voltage
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Directive with a type 450N compression and impact resistance rating. The specification of cable ducts for the
following cases shall be listed in the contract specific Appendix 15/2 in respect of:
(i) ducts in transverse crossings installed using trenchless installation techniques;
(ii) ducts located within or adjacent to filter drains, refer to sub-Clause1531.13;
(iii) ducts specified by the Telecommunications Services Provider in accordance of the Telecommunications
Services Provider’s standards for communications infrastructure (“The Telecommunications Services
Provider’s Duct Standards”), to meet the Telecommunications Services Provider’s requirements in
3 (02/17) Sub-ducts shall be either:
(i) continuous HDPE sub-ducts with a Standard Dimension Ratio (SDR) of 11 or less installed between
chambers, individual sub-ducts may be joined by low external profile mechanical or welded couplers,
welded couplers shall not present an internal bead of sub-duct material that locally reduces the internal
diameter of the sub-duct either by more than 3% or has a bead height of greater than 2 mm; or
(ii) sectional HDPE or uPVC sub-ducts pre-installed into HDPE or uPVC outer main ducts as a modular
arrangement using internal spacers and keyed coupler and duct sealing arrangements to prevent
misalignment of sub-ducts and to preserve their colour coding between chambers, outer main duct and
inner sub-duct seals to provide protection to at least IP47 for the sub-duct; or
(iii) continuous or sectional HDPE sub-ducts moulded directly within an outer main duct with keyed coupler
arrangements and duct sealing to prevent misalignment of sub-ducts, outer main duct and inner sub-duct
seals to provide protection to at least IP47 for the sub-duct, individual sub-ducts, where exposed, shall
be uniquely identifiable within chambers.
4 (02/17) For cable ducts identified in contract specific Appendix 15/2 to be handed over to the
Telecommunications Services Provider upon completion of the works, the Contractor shall be free to elect whether
the ducts to be handed over comply with the Overseeing Organisations standards or whether the ducts comply
with The Telecommunications Services Provider’s duct standards. Whichever duct standards are used the standard
shall be applied consistently throughout the works. Chambers shall be positioned at all locations where there is a
change to a ducting standard and the ducting systems are not directly compatible by the application of standard duct
couplers to achieve a smooth and ridge free internal bore.

Where the Contractor elects to use The Telecommunications Services Provider’s duct standards then The
Telecommunications Services Provider’s duct standards shall in the case of a change or conflict in requirements
have precedence over requirements stated in Clauses 1530, 1531, 1532 and 1533, otherwise the requirements of
these Clauses remain.
5 (02/17) The internal bore shall be smooth and even throughout the length of the duct and the duct joints to ensure
the outer sheath of the cable is not damaged during installation.
6 (02/17) The use of ducts that are designed to be laid to a small bend radius and do not present a smooth bore for
the installation of cables shall not be used as ducts for longitudinal cable routes. Use of such ducts shall only be
permitted to avoid unforeseen obstacles within local ducts routes. Two sections of such ducts, each up to 3 m in
length, separated by at least 6 m shall be permitted in a local duct route.
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7 (02/17) With the exception of ducts in transverse crossings installed using trenchless installation techniques
and unless otherwise described in contract specific Appendix 15/2 the sizes of the ducts shall be as shown on the
contract specific drawings. The internal diameter of standard sized ducts shall be 150 mm, 100 mm or 50 mm.
Non-standard sized ducts may be used where a duct is used to sleeve an existing duct or sub-ducts are installed.
8 (02/17) Ducts shall not be bent to internal radius less than the manufacturer’s requirements.
The internal radius of installed ducts shall be such that the performance of the cable and duct is safeguarded
following cable pulling.
9 (02/17) With the exception of ducts in transverse crossings installed using trenchless techniques and sub-ducts,
the external wall of the ducts shall be self-coloured purple in accordance with National Joint Utilities Group
publication “Guidelines on the Positioning and Colour Coding of Utilities’ Apparatus”.
10 (02/17) The materials from which the duct and fittings are made shall be treated so that they are protected from
the deleterious effects of short term exposure to ultra violet light and shall be resistant to degradation by acids,
alkalis, common chemicals, bacteria, fungi and moulds occurring in soils. The Contractor shall protect the duct and
fittings on site in accordance with the manufacturer’s written instructions.
11 (02/17) Each duct shall be fitted with a pigmented, rot-proof material draw cord of 5kN breaking load and
having a design life of not less than 30 years, the ends of which shall be made fast within the chambers to which the
duct is terminated. Draw cords shall be secured within a chamber. Draw cords shall not be knotted within ducts.
12 (02/17) Ducts in transverse crossings installed without a sleeve using directional drilling techniques conforming
to the requirements of Series 8000 shall consist of four 100 mm internal diameter Medium Density Polyethylene
(PE 80) pipes conforming to BS EN 12201‑2 and any other requirements described in contract specific
Appendix 15/2.
(i) Where stated in contract specific Appendix 15/2, the number of ducts may be reduced. The pipe bores
shall be smooth and even, and terminated in a chamber at each end.
13 (02/17) The ducts shall be securely bundled together and installed through the crossing with a minimum cover
above the top of the combined bundle of eight times the reamed diameter of the bored hole. Each duct shall be
tested after installation in accordance with the requirements of Clause 1533.
14 (02/17) The duct network shall be protected against the ingress of water to IPX7, and gases. This shall be
achieved by the ducts having suitable joints and plugs or other proprietary duct sealing system that can easily be
removed (excluding expanding foam) at the entry to all chambers and cabinets. In addition the Telecommunications
Services Provider’s requirements for duct plugs, sealing systems and sealing of ducts shall be as stated in contract
15 (02/17) The minimum longitudinal duct provision is one communications duct of at least 100 mm diameter
fitted with four sub-ducts complying with sub-Clause 1530.3 and of a sub-duct size to accommodate the
Telecommunications Services Provider’s cables. Ducts for local communications cables may either be incorporated
as sub-ducts within a single longitudinal duct or as separate local ducts. Local ducts and separate ducts for power
cables installed in the same trench as ducts for longitudinal communications cables need not be continuous
throughout the duct network.

16 (02/17) The Contractor shall provide and install in the end of every duct and sub-duct and at every point
of entry to chambers re-usable duct plugs or other proprietary duct sealing system that can easily be removed,
excluding expanding foam, to achieve ingress protection rating of IP47 on completion of mandrel and air pressure
tests. When cable is installed within the ducts, the sealing system will be replaced with a plug pre-formed with the
appropriate cable port configuration or other proprietary duct sealing system that can easily be removed, excluding
expanding foam, to maintain the ingress protection rating of IP47 after cable installation. The responsibility for the
provision and installation of duct plugs or duct sealing systems shall be as stated in contract specific Appendix 15/2.
17 (02/17) After installation ducting shall not cause damage to cables when they are drawn through. Ducts shall
be supplied with purpose made spacers and strapping in accordance with the manufacturer’s requirements. The
strapping shall bind the ducts tightly in the specified formation during installation, backfilling and for the whole life
of the duct. Strapping shall be spaced longitudinally to ensure a duct separation of no more than 50 mm.
1531 (02/17) Installation of Ducts General

1 (02/17) Ducts shall be laid at the levels and lines shown on the contract specific drawings and schedules
contained in contract specific Appendix 15/2. Longitudinal ducts shall generally be run parallel to the edge of the
adjacent carriageway unless otherwise shown on the contract specific drawings. Transverse ducts shall cross at right
angles to the carriageway unless otherwise shown on the contract specific drawings. Transverse duct crossings of
existing carriageways shall be installed in accordance with the requirements of Series 8000 (MCHW 5.8.2). The
exact location of the ducts shall be agreed with the Overseeing Organisation before the commencement of any
associated works. Excavations shall comply with Clauses 502 and 602. Immediately following the excavation of
the trench, the ducts shall be jointed and laid on the bedding material or prepared trench where the standard of duct
installation does not require the duct to be laid on a bedding material. The deviation in level from that specified at
any point shall not exceed 50 mm.
2 (02/17) Ducts and fittings shall be examined for damage and the joint surfaces and components shall be cleaned
immediately before laying. Measures shall be taken to prevent soil or other material from entering ducts, and to
anchor each duct to prevent movement before the work is complete.
3 (02/17) Ducts, other than those in structures using conduits, shall be installed in trenches. The trenches and the
fill shall be such that compaction, either during installation or after by use, e.g. a vehicle, shall not crush or damage
the ducting; or distort its route such that pulling a cable through will damage the cabling.
The bed and surround for ducts shall be granular material to Clause 503.3. This shall provide a minimum depth
of cover to the uppermost duct of 50 mm. The minimum cover depth of overall backfill in non-hardened verges
shall be 600 mm in respect of longitudinal ducts and 350 mm in respect of local ducts, the balance comprising of
Class 8 material in accordance with Clause 602 and Table 6/1. Alternative installations or where minimum cover
cannot be achieved shall be as stated in contract specific Appendix 15/3 subject to agreement with the Overseeing
Organisation and Telecommunications Services Provider.
4 (02/17) Transverse crossing ducts shall be installed in granular material to Clause 503.3(i). For shallow
transverse crossing ducts with between 750 mm and 1200 mm cover the fill above the ducts shall be replaced with
ST2 concrete to Clause 2602, a minimum depth of 150 mm above the ducts. Backfill shall be in accordance with
Clause 505.
5 (02/17) For installation of transverse ducts on existing highways, a line and level drainage survey shall be
conducted in order to determine the appropriate depths of the ducts to avoid groundwater.
6 (02/17) Duct joints shall have the following characteristics:
(i) The joint and duct shall be free from burrs and other irregularities that may cause damage to cables
when they are drawn through the duct.
(ii) The joint shall hold and maintain the ducts in axial alignment during installation and afterwards when
subjected to foreseeable ground movement in accordance with the manufacturer’s written instructions.
Requirements for duct joints are defined in contract specific Appendix 15/2.

24
(iii) The joint shall not compromise the duct network protection of ingress protection rating IP47.
7 (02/17) Cable duct configurations, and any alternative or additional requirements for bedding, haunching,
surround, backfilling, surfacing or reinstatement shall be as in contract specific Appendix 15/2.
8 (02/17) Backfilling shall be undertaken immediately after the required operations preceding it have been
completed.
9 (02/17) Trenches for the cable ducts shown shall be backfilled with Class 8 lower trench fill material,
as described in sub-Clause 3 of this Clause and sub-Clause 1507.19.
10 (02/17) For duct trenches requiring topsoiling, grass seeding and/or turfing shall be as described in Clauses
618 & 3005, and shall be placed in the top 150 mm of the cable duct trench unless otherwise specified in contract
11 (02/17) In order to prevent damage from other works, all trenched ducts shall have marker tape laid within the
trench excavation at a depth of 150 mm or at the Class 8 topsoil interface whichever is the greater depth.
12 (02/17) Prior to the interruption or extension of the cable duct network the Contractor shall confirm the
operational and future status of cables within the duct route to be interrupted. Where there is a requirement to
permanently remove or pull back cables within a duct route the Contractor shall liaise with the Telecommunications
Services Provider and co-ordinate the works with them.
The Contractor shall comply with Telecommunications Services Provider’s requirements for interruption or
extension of the cable duct network as detailed in contract specific Appendix 15/3.
Following the completion of the works necessitating the interruption of a duct route, chambers shall be installed at
the interface to the new section of duct. Chambers shall be installed at each end of the new duct route and at any
intermediate transition points where any of the following conditions are met:
(i) the new duct section is routed through a structure; or
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(ii) the new duct section includes a change of direction, horizontal axis and/or a step change in the vertical
axis, of the duct route that would otherwise impede the continuous pulling of cables through the
completed duct route; or
(iii) the total length of the new duct section includes more than ten intermediate duct joints or a distance of
>50 m whichever is the greater; or
(iv) where there is a change of ducting standard or duct types that cannot be directly mated to each other.
Where the above criterion is not met then new sections of duct may be mated with existing ducts without installing
new chambers.
New sections of duct installed between chambers shall be tested and proved in accordance with Clause 1533.
Existing duct mated directly to a section of new ducting shall be cleaned and swabbed prior to the installation of
new cables or re-installation of old cables. There shall be no need to air pressure test existing sections of duct.
13 (02/17) Ducts shall be provided for armoured or unarmoured cables that are laid across or within 500 mm of
filter drains. The ducts shall be surrounded with 150 mm of ST2 concrete in compliance with Clause 2602. Where
a duct crosses the filter drain it may be necessary to provide additional drainage capacity or other measures to
compensate for the volume occupied by the duct and associated concrete surround. The Contractor shall provide
the Overseeing Organisation with details of the proposed arrangements for additional capacity or other measures
for acceptance. This shall be clearly identified in the Contractor’s programme of works. In the event that a duct
route coincides with the line of a filter drain an alternative duct line shall be determined. Any damage caused by
the Contractor to any drain shall be satisfactorily repaired and reinstated at no cost to the Overseeing Organisation.
It shall be the responsibility of the Contractor to identify to the Overseeing Organisation any existing damage to
drains prior to the commencement of works.

14 (02/17) Where cables are subsequently to be laid by the Telecommunications Services Provider, the Contractor
shall lay sacrificial ducting along the cable route leaving cable pulling pits at intermediate locations in accordance
with the Telecommunications Services Provider’s requirements in contract specific Appendix 15/3. Details of
sacrificial duct routes, lengths, number, type and depth of sacrificial ducting, the requirements for reinstatement and
locations of intermediate cable pulling pits shall be as specified in contract specific Appendix 15/2.
1532 (02/17) Chambers for Highway Communications Cables

1 (02/17) Chambers shall be constructed of materials of sufficient strength for the purpose. The walls, base and
top shall be of sufficient strength to prevent collapse and settlement for the local soil conditions, depth of chamber,
number of ducts passing through the wall, weight of cover and frame and any additional force, for example a
vehicle, that may be applied to the top of the chamber. In addition to these requirements, plastic chambers shall be
installed to manufacture’s requirements.
Chambers shall be as detailed in the schedule in contract specific Appendix 15/2 and the Telecommunications
Services Providers requirements in contract specific Appendix 15/3. Chambers may be designated by type (size and
usage) by a letter (A to E).
2 (02/17) Chambers shall:
(i) be used solely for highway communications cables, including power cables used for highway
communications;
(ii) be located at the interface point to duct sections installed through a structure or under a carriageway;
(iii) be located where a section of duct includes a change of direction, horizontal axis and/or a step change in
the vertical axis, of the duct route that would otherwise impede the continuous pulling of cables through
the completed duct route.
3 (02/17) The exact location, size and usage of these chambers shall be agreed with the Overseeing Organisation
and the Telecommunications Services Provider (as appropriate) on site prior to the commencement of any
associated works.
4 (02/17) Brickwork chambers shall comply with the Series 2400 and be built with mortar designation in English
bond. The joints of brickwork where exposed shall be finished as specified for un-pointed joints in Clause
2412. The ends of all ducts shall be neatly built into the brickwork and finished flush with mortar designation to
prevent the ingress of water. The walls of the chambers shall be 225 mm in thickness and shall be treated with
waterproofing material to prevent the ingress of moisture.
5 (02/17) Precast concrete chambers shall comply with BS 5911-3 Concrete Pipes and Ancillary Concrete
Products – Specification for Unreinforced and Reinforced Concrete Manholes and Soak-a-ways and BS EN 1917
Concrete Manholes and Inspection Chambers, Unreinforced, Steel Fibre and Reinforced. Cast in situ chambers
shall be constructed of ST4 concrete complying with Clause 2602 unless otherwise described in contract specific
Appendix 15/2.
6 (02/17) Chambers may be constructed from plastic units that comply with the requirements of BS 5834-4.
Where plastic chambers are comprised of multiple sections, all sections shall be sealed in accordance with the
manufacturer’s requirements to prevent the ingress of water throughout the intended design life of the chamber. The
foundation and backfill for plastic chambers is location specific and shall be as described in Appendix 15/2.
7 (02/17) The design of the chamber shall allow sufficient access for a person to enter and exit the chamber, access
to the ducting, and provide a safe working environment appropriate to the needs and purpose of the chamber that
would allow industry standard interchangeability. The design of the chamber shall take into account all hazards that
could occur as a result of a confined space.
Where steps are required for entry and exit from the chamber these shall conform to BS EN 13101. Hinged covers
shall allow safe access without the cover unintentionally closing. Access shall be possible by a single person.
The dimensions for chamber cover openings and chamber length and breadth shall be described in Appendix 15/2.
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Where the depth of chambers exceeds 900 mm below the finished surface of the carriageway or the adjacent
ground, manhole steps complying with BS EN 13101 shall be included.
8 (02/17) Chamber covers, gratings and frames shall be as described in contract specific Appendix 15/2 and shall
comply with BS EN 124:1994. Chambers containing a joint shall be equipped with 2 x 100 mm access ports to
chambers for the installation of network bypass (interrupter) cables. Reinforced concrete cover slabs shall be
installed at the top of the chamber on all sides to provide suitable support for the chamber covers to be installed.
Where access ports are required for temporary interrupter cables these shall be agreed by the Telecommunications
Services Provider as stated in contract specific Appendix 15/2.
9 (02/17) Where required by contract specific Appendix 15/2, lockable chamber covers or other measures to deter
unauthorised access to chambers shall be provided. Where the telecommunications infrastructure is provided
for the operation and maintenance of the Telecommunications Services Provider lockable covers shall also meet
requirements in contract specific Appendix 15/3. The Contractor shall supply four sets of keys for each type
of locking system to the Overseeing Organisation and four sets of keys for each type of locking system to the
Telecommunications Services Provider.
10 (02/17) Four sets of chamber cover lifting keys as described in contract specific Appendix 15/2 shall be
delivered to the Overseeing Organisation and to the Telecommunications Services Provider for each type of cover
supplied.
(i) Additionally, a suitable cover lifter shall be delivered for each type of cover to the Overseeing
Organisation or Telecommunications Services Provider, as appropriate, where the mass of an individual
cover exceeds manual handling regulations or as stated in contract specific Appendix 15/2.
(ii) The quantities of cover lifters, required for compliance with manual handling regulations, shall be as
stated in contract specific Appendix 15/2.
11 (02/17) Frames for chamber covers gratings shall be set in cement mortar complying with Clause 2404 or a
suitable proprietary quick setting mortar of equivalent strength.
12 (02/17) The chamber shall contain a sump to allow water to collect and drain away such that no water shall
collect in the bottom of the chamber. The size of the sump and position shall not affect the integrity of the structure
or be too large to prevent a person to be able to stand and work from the bottom of the chamber.
The sump shall feed to a soakaway or highway drainage system that shall allow water entering the chamber to
collect and drain away. The sump and soakaway capacity, or sump and drainage system shall be based on the
location of the site including its varying water table throughout the year.
The sump shall be of sufficient size to fit a pump and shall be as agreed with the Telecommunication Services
Provider and stated in contract specific Appendix 15/3.
Details of the drainage system shall be shown in contract specific Appendix 15/2.
13 (02/17) Chambers shall be clearly identified by the legend “HIGHWAY COMMUNICATIONS”, on each cover.
Where covers have a concrete infill, a non-corrodible plate showing the above information shall be cast into the
concrete flush with the concrete surface.
14 (02/17) All chambers shall be referenced to their longitudinal position along the carriageway with an accuracy
of ±1 m. The measurement point for each chamber will be the centre of the chamber cover. The longitudinal
position of the chamber, and where used the chamber reference number, shall be clearly displayed on the chamber
apron or on a concrete block placed immediately adjacent to the cover. The longitudinal position shall be in the
form of an address comprising the marker post reference, offset to the marker post, carriageway identification and
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chamber reference.
15 Where required in contract specific Appendix 15/3 Technology Performance Management Services (TPMS)
barcode label mounting plates shall be provided.

16 (02/17) Where detailed in contract specific Appendix 15/2, stub ducts shall be incorporated into the chamber
construction. Ducts shall be as described in Clause 1530 and are either to be plugged in accordance with sub-
Clause 1530.14 or proprietary inserts or other proprietary duct sealing system that can easily be removed,
excluding expanding foam. Details of sealing system shall be supplied by the Contractor for acceptance of the
Telecommunications Services Provider as defined in the Contractors programme of works.
17 (02/17) Where a Chamber, installed as part of a cross carriageway duct crossing, does not lie on the line of the
longitudinal network, a second chamber shall be constructed on the line of the longitudinal network under and
connected to the cross carriageway duct crossing chamber by means of a 4-way duct.
18 (02/17) Where the water table is within 2 m of the ground surface, or the ground is poorly drained, the chambers
shall be surrounded by a minimum thickness of 150 mm ST4 concrete to reduce the potential for water ingress,
detrimental deformity or movement. Specific requirements will be defined in contract specific Appendix 15/2.
19 (02/17) To accommodate the form of construction used for the chamber the spacing between local ducts
entering the chamber shall be within 100 mm of one another.
20 (02/17) Chambers shall be constructed so that their covers are raised 50 mm above the level of the adjacent
ground and the in-situ concrete hard-standing area surrounding chambers laid to falls to the adjacent ground level
to prevent ponding of water over and adjacent to the chambers. The fall shall be formed of a 150 mm minimum
deep layer of ST4 concrete to Clause 2602 with a U2 surface finish. In order to maintain long term stability
reinforcement shall be applied. The raised covers shall not cause a trip hazard.
21 (02/17) Where type A chambers are required for telecommunications cable joints, cable joint bearer systems
will be installed within the chamber. The cable brackets shall be equipped with two CJE cable bearers, but shall be
capable of supporting an additional bracket for a third CJE if required. Where more than three CJEs are required, an
additional type A chamber shall be provided. Where power cables enter a chamber equipped for CJEs, these cables
shall be installed in such a way that the extraction of the CJE from the chamber for maintenance is not impeded by
the power cables. Specific requirements for cable bearers will be defined in contract specific Appendix 15/2.
22 (02/17) All ducts shall enter the chamber wall perpendicularly such that the drawing of cables through the ducts
shall not cause any damage to the cables, and shall be sealed to prevent the ingress of water unless otherwise stated
23 (02/17) Type B chambers shall not be used for the housing of CJEs, where power cable reduction joints are
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required, or where power cable size exceeds 70 mm2.

24 (02/17) For type A chambers, longitudinal sub-duct ducts may be continuous through the chamber where no
access to the cables within is required.
25 (02/17) For type B chambers, longitudinal ducts may be continuous through the chamber where no access to the
cables within is required.
26 (02/17) The maximum depth of type B chambers shall be 1300 mm, measured from the underside of the
chamber cover and the base of the chamber. Where the depth of transverse ducts dictates a greater depth than
1300 mm, the use of a more suitable chamber, such as a type A chamber shall be considered.
27 (02/17) Type C chambers shall not be used for the housing of CJEs, where power cable reduction joints are
required, where power cable size exceeds 25 mm2 or as an interface to equipment cabinets.
28 (02/17) The chamber size shall be selected to ensure that cable minimum bend radii and maximum cable tension
parameters during installation according to TRH 2583 or the cable manufacturer’s written specification are not
exceeded.
29 (02/17) The chamber shall have a design life of not less than 30 years unless otherwise stated in contract
30 (02/17) The chamber shall have an area of hard-standing around it to allow for safe working and lifting of
covers. It shall be flush with the finished ground level. The hardstanding, cover and frame shall be sufficient for
the loading that might be placed on it including any vehicles, and have life span of a minimum of 30 years unless

1533 (02/17) Proving and Testing of Ducts

1 (02/17) Longitudinal and cross carriageway cable ducts shall be proved by drawing a mandrel of 150 mm length
through each as the ducts are laid. Local ducts from chambers to cabinets shall be proved by drawing through each
completed length of duct a spherical mandrel. The mandrel will have a diameter of 10% less than the internal bore
of the duct. On the successful completion of each mandrel test the Contractor shall certify compliance of the duct
and immediately seal the duct in accordance with sub-Clause 1530.14.
2 (02/17) Longitudinal and cross carriageway cable ducts within a ducted non-armoured cable network shall be
tested in chamber-to-chamber sections by means of the air test described in sub-Clause 1533.3. On the successful
completion of each test the Contractor shall certify compliance of the duct and immediately seal the duct in
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3 (02/17) To undertake the test, air shall be pumped in by suitable means until a stable pressure of 100 mm head
of water is indicated in a U-tube connected to the system. The air pressure shall not fall to less than 75 mm head of
water during a period of five minutes without further pumping, after an initial period to allow for stabilization.
4 (02/17) Continuous sections of ducts and sub-ducts, including sub-ducts jointed as part of a modular inner and
outer duct arrangement, shall be tested and proven by blowing a close fitting foam plug or similar arrangement that
tests the integrity of the duct in respect of diameter and air-tightness in a single operation. There is no requirement
to additionally test the outer main duct that houses a sub-duct. The design and dimension of the foam plug shall
inhibit the progression of the foam plug within the duct where the diameter of the duct has suffered deformity or
presents a discontinuity in size that is outside of the duct manufacturer’s written specifications.
5 (02/17) No testing and proving of sacrificial ducts shall be required prior to the installation of armoured cables.
The Contractor shall satisfy themselves that the sacrificial duct is fit for purpose and the Telecommunications
Services Provider (where applicable) will be able to correctly install the armoured cable.
6 (02/17) The Contractor shall comply with any additional or amended requirements in respect of the proving and
testing of ducts as contained within contract specific Appendix 15/3.
7 (02/17) A register of mandrel and air test certificates shall be maintained by the Contractor as appropriate and
handed to the Overseeing Organisation and Telecommunications Services Provider on the successful completion of
the ducting work.
1534 (02/17) Closed Circuit Television

1 (02/17) Unless specified otherwise in contract specific Appendix 15/1 the camera and outstation equipment for
closed circuit television (CCTV) shall be provided by the Contractor in accordance with specifications MCE2135,
Pan tilt zoom cameras, MCE2241, fixed cameras, and MCE2536.
2 (02/17) The provision of cabinets and ancillary items for CCTV shall be as described in contract specific
Appendix 15/1.
3 (02/17) The Contractor shall install and commission CCTV equipment in accordance with the requirements
4 (02/17) The provision of masts shall be as scheduled in Series 1300 contract specific Appendices.
1535 (02/17) Provision of the Telecommunications Services

1 (02/17) In the case where the Contractor provides the telecommunications services, the requirements in respect
of the telecommunications services shall be contained in contract specific Appendix 15/1.
2 (02/17) In the case where the Telecommunications Services Provider provides the communications infrastructure,
the requirements in respect of communications infrastructure to support the provision of the telecommunications
services shall be contained in contract specific Appendices 15/1, 15/2 and 15/3.

3 (02/17) In the case where the Telecommunications Services Provider provides the telecommunications services
the Contractor, in addition to the requirements specified elsewhere in this 1500 Series, shall comply with the
Telecommunications Services Provider’s requirements detailed in contract specific Appendix 15/3 in respect of the
following.
(i) Designs for Telecommunications Services including authorised changes to designs and departures from
the Telecommunication Services Provider’s standards.
(ii) The confirmation of accommodation requirements for the installation of the Telecommunications
Services Provider’s equipment within the Overseeing Organisation’s cabinets including the allocation
of space and power supply load allocation, total power dissipation, and power supply distribution
arrangements within the Overseeing Organisation’s cabinets.
(iii) Changes or additions to the telecommunications services contained in contract specific Appendix 15/1
and the processes relating to any changes or additions to the telecommunications services including any
associated change control, design, ordering and notification periods.
(iv) The provision and updating of service configuration information related to the telecommunications
services, including geographic, IP, URL or other electronic address information as appropriate to the
telecommunications service and/or the roadside and central control system technologies.
(v) The Telecommunications Services Provider’s process related to the activation and deactivation of
telecommunications services, including methods of notification offered by the Telecommunications
Services Provider and associated notification periods as part of any request for the activation and
deactivation of telecommunications services.
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(vi) The inspection, witnessing and acceptance criteria with respect to the installation of communications
infrastructure and cabinets provided by the Contractor and associated pre-installation requirements of
the Telecommunications Services Provider.
(vii) The processes, including notification, reporting and periods for remedial actions associated with any
defects and remedial works that result from the Telecommunications Services Provider’s inspection,
witnessing and acceptance activities with respect to the installation of communications infrastructure
and cabinets.
(viii) The provision of copies of electrical test certificates prior to the Telecommunications Services Provider’s
connection to the Contractor’s or Overseeing Organisation’s power supplies.
1536 (02/17) Electricity Connections

1 (02/17) The type of electricity connection, whether an exit point with standard Distribution Network Operator
(DNO) single or a more secure dual feed (i.e. incoming feeds from two primary sub stations) shall be agreed with
the Overseeing Organisation and shall be as stated in contract specific Appendix 15/1.
2 (02/17) The Contractor shall record all equipment that is connected and disconnected from the roadside
electricity supply during the works with a date and time of the connection/disconnection. They shall provide this
information to the Overseeing Organisation within five working days of the connection/disconnection or as agreed
3 (02/17) The Contractor shall provide infrastructure for the electricity DNO for electricity connections to roadside
technology and infrastructure.
4 (02/17) The Contractor shall provide the required total load requirements and equipment types to the DNO. The
information shall be sufficient for the DNO to provide the correct supply capacity and phase, single and multiple, at
an exit point.
5 (02/17) The Contractor shall provide the DNO the information required for both metered and unmetered exit
points. Equipment to be connected to unmetered exit points must possess an Unmetered Supplies User Group
(UMSUG) charge code.

6 (02/17) For any equipment without charge codes, the Contractor shall request one from UMSUG at Elexon.
7 (02/17) The Contractor shall agree with the DNO and Overseeing Organisation access requirements for meter
reading and maintenance.
8 (02/17) The electricity supplier shall fit the supply meter. This shall remain in their ownership.
9 (02/17) In the case of a DNO offer for a three phase supply capacity at an exit point being slightly above the
DNO single phase limit, then discussions shall be started with the DNO to ascertain whether a single phase supply
could be offered.
10 (02/17) Where the provision of three phase supply is the only viable means of obtaining an exit point, the
Contractor shall:
(i) clarify the responsibility for balancing the load with the DNO;
(ii) comply with any DNO requirements for balancing the load across the three phases;
(iii) in the case of double span gantries that require equipment to be fed from separate phases the Contractor
shall ensure the risk of receiving shock at 400V is eliminated;
(iv) in areas where equipment fed from separate phases are within reach of each other, clear warning
labelling shall be provided to BS7671 section 514.10.1;
(v) the Contractor shall ensure a switch is available to isolate both sides of a double span gantry.
11 (02/17) The Contractor shall ensure electricity connections provided by the DNO to be a Protective Multiple
Earthing (PME) termination (TN-C-S) including the provision of a customer earth terminal.
In the case where the DNO will not provide a PME terra terra (TT) termination the Contractor shall ensure that
additional protective equipment is installed.
If a PME (TN-C-S) is not offered in the proposed location, the DNO may agree to a PME termination in the
following circumstances:
(i) the 609 EI cab is installed in an enclosed area fenced off from public access;
(ii) installation a Class II 609 EI cabinet.
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SERIES 1600
PILING AND EMBEDDED RETAINING
WALLS
Contents
Clause Title Page
1601 General Requirements for Piling

and Embedded Retaining Walls 2
1602 Precast Reinforced and Prestressed
Concrete Piles and Precast
Reinforced Concrete Segmental
Piles 3
1603 Bored Cast-in-Place Piles 10
1604 Bored Piles Constructed Using
Continuous Flight Augers and
Concrete or Grout Injection
Through Hollow Auger Stems 15
1605 Driven Cast-in-Place Piles 18
1606 Steel Bearing Piles 20
1607 Reduction of Friction on Piles 24
1608 Non-Destructive Methods for
Testing Piles 25
1609 Static Load Testing of Piles 27
1610 Diaphragm Walls 33
1611 Hard/Hard Secant Pile Walls 36
1612 Hard/Soft Secant Pile Walls 39
1613 Contiguous Bored Pile Walls 40
1614 King Post Walls 41
1615 Steel Sheet Piles 42
1616 Integrity Testing of Wall 44
Elements
1617 Instrumentation of Piles 44
and Embedded Walls
1618 Support Fluid 48
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March 1998 1
Specification for Highway Works Piling and Embedded Retaining Walls
PILING AND EMBEDDED RETAINING WALLS
1601 General Requirements for Piling and 13 “Raking pile”: a pile installed at an inclination to
Embedded Retaining Walls the vertical.
14 “Reaction system”: the arrangement of the
Definitions kentledge, piles, anchorages or spread foundations that
1 “Allowable pile capacity”: a capacity which takes provide a resistance against which the pile is tested.
into account the pile’s bearing capacity, the materials 15 “Pile settlement”: the axial movement at the top of
from which the pile is made, the required load factor, the pile. The value of pile settlement specified for a
settlement, pile spacing, downdrag, the overall bearing given load refers to the value reached at the end of the
capacity of the ground beneath the piles and other first cycle of loading. Where piles are to be loaded and
relevant factors. unloaded through a number of cycles settlement shall
2 “Commencing surface”: the level at which the be the cumulative vertical movement.
piling equipment first enters the ground. 16 “Specified Working Load (SWL)”: the specified
load on the head of the pile as stated in the relevant
3 “Compression pile”: a pile which is designed to
resist an axial force such as would cause it to penetrate Appendix.
further into the ground. 17 “Tension pile”: a pile which is designed to resist an
axial force such as would tend to cause it to be
4 “Constant rate of penetration (CRP) test”: a test in
which the pile is made to penetrate the ground at a extracted from the ground.
constant controlled speed, while the force applied at the 18 “Test pile”: any pile to which a test load is, or is to
top of the pile to maintain the rate of penetration is be, applied.
continuously measured.
19 “Ultimate bearing capacity”: the maximum
5 “Constant rate of uplift (CRU) test”: a test in resistance offered by the pile when the strength of the
which the pile is made to lift out of the ground at a soil is fully mobilised.
constant controlled speed, while the force applied at the
20 “Working pile”: one of the piles forming the
top of the pile to maintain the rate of extraction is
foundation of a structure.
continuously measured.
21 “Embedded retaining wall”: retaining wall with
6 “Cut-off level”: the level to which the pile is
shuttering provided either by the surrounding ground
trimmed.
(ie. cast against an excavated soil face) or sheet piles
7 “Design Verification Load (DVL)”: a load which inserted into the ground.
will be substituted for the Specified Working Load for
22 “Embedded retaining wall element”: an individual
the purpose of a test.
component utilised in a particular embedded retaining
8 “Kentledge”: dead load used in a loading test. walling system eg. diaphragm wall panel, or primary or
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secondary pile in a secant wall which can be

9 “Load factor”: the ratio between the pile’s ultimate
bearing capacity and maximum safe bearing capacity. constructed in isolation.
10 “Maintained load test”: a loading test in which General

each increment of load is held constant either for a
defined period of time or until the rate of movement 23 (11/03) Piles and embedded retaining walls shall be
(settlement or uplift) falls to a specified value. constructed from one of the permitted options described
in Appendix 16/1 and in compliance with this Series
11 “Preliminary pile”: a pile installed before the and appropriate Clauses of Series 1700, 1800, and 1900
commencement of the main piling works or specific unless otherwise described in Appendix 16/1.
part of the Works.
12 “Proof load”: a load applied to a selected working Layout, design and construction
pile to confirm that it is suitable for the load at the 24 Where applicable Appendices 1/10 and 1/11 in
settlement specified. Series 100 list structures and elements which the

Contractor has to design in accordance with the Where required in Appendix 16/1, the Contractor shall
Specification and relevant Appendices 16/1 to 16/18. submit his planned sequence and timing for driving or
Where required in Appendix 16/1, the Contractor shall boring piles, or for installing wall elements having
also submit design calculations, details of materials to regard to the avoidance of damage to adjacent piles or
be used, and a schedule of dimensions. wall elements.
Pile tolerances Temporary support

25 Piles shall be installed within the following 30 The Contractor shall ensure that where required,
maximum permitted tolerances: any permanently free-standing piles are temporarily
braced or stayed immediately after driving to prevent
Position: 75 mm in any direction at commencing
loosening of the piles in the ground and to ensure that
level.
no damage resulting from oscillation, vibration or
Verticality: 1 in 75 deviation from the vertical movement can occur.
Rake: 1 in 25 deviation from the specified
Ordering of piles
rake for piles raking up to 1:6 and 1 in
15 for piles raking more than 1:6. 31 The Contractor shall ensure that the piles are
No method of forcible correction will be permitted available in time for incorporation in the Works. All
unless it can be proved that the integrity, durability and piles and production facilities shall be made available
performance of the piles will not be adversely affected. for inspection at any time. Piles shall be examined by
the Contractor at the time of delivery and any faulty
Piling method units replaced. Where required in Appendix 16/1, the
records of testing of the concrete and steel used in the
26 Where required in Appendix 16/1, the Contractor piles shall be provided.
shall supply all relevant details of the method of piling,
the plant and monitoring equipment he plans to adopt. Testing of materials shall be in accordance with
Alternative piling methods may be used provided that Appendix 1/5. For steel piles the Contractor shall
they satisfy the requirements of the Specification. submit details of all preliminary test results at least 5
working days prior to ordering piles for the main works
Records other than temporary works.
27 The Contractor shall keep records as indicated by

an asterisk in Table 16/1 for the installation of each 1602 Precast Reinforced and Prestressed
pile, or for each element in embedded retaining walls, Concrete Piles and Precast Reinforced
or as listed in Clause 1615 for sheet pile walls. The Concrete Segmental Piles
signed records will form a record of the work. Copies of
these records shall be provided where required in Materials and components
Appendix 16/1.
Any unexpected driving or boring conditions shall be Steel and iron components
noted in the records.
1 (11/05) In the manufacture of precast concrete piles
Damage and jointed precast concrete segmental piles, fabricated
steel components shall comply with BS EN 10025-1
and BS EN 10025-2, Grades S275 or S355, cast steel
Damage criteria for adjacent structures or services components with BS 3100, grade A (A1, A2 or A3) and
28 Damage criteria for adjacent structures or services ductile iron components with BS EN 1563 material
are given in Appendix 16/1. Where required in designation symbol EN-GJS-350-22, EN-GJS-400-15,
Appendix 16/1, the Contractor shall submit his plans EN-GJS-400-10.
for making surveys and monitoring movements or
vibration before the commencement of the piling works. Pile joints for segmental piles
2 The joints shall be close-fitting face to face and the
Damage to piles or completed wall elements locking method shall be such as to hold the faces in
29 The Contractor shall ensure that during the course intimate contact. Where required in Appendix 16/2,
of the work, displacement or damage which would details of the design, manufacture and tests of the
impair either performance or durability does not occur jointing system shall be submitted prior to the
to completed piles or wall elements. commencement of the piling works.

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A jointed pile shall be capable of withstanding the same Pile toes

driving stresses as a single unjointed pile of the same
cross-sectional dimensions and materials. 3 Pile toes shall be constructed so as to ensure that
damage is not caused to the pile during installation.
The welding of a joint to main reinforcement in lieu of
a lapped connection with projecting bars affixed to the Pile head reinforcement
joint shall not be permitted.
4 Pile heads shall be so reinforced or banded as to
Each pile joint shall be square to the axis of the pile prevent bursting of the pile under driving.
within a tolerance of 1 in 150. The centroid of the pile
joint shall lie within 5 mm of the true axis of the pile
element.
TABLE 16/1: Records to be kept (indicated by an asterisk)
Data Driven Driven Driven Bored Continuous

precast segmental cast-in- cast-in- flight
concrete concrete place place auger
and piles concrete concrete concrete or
steel piles piles grout
bearing piles
piles
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Contract * * * * *
Pile reference number (location) * * * * *
Pile type * * * * *
Nominal cross-sectional dimensions or diameter * * * * *
Nominal diameter of underream/base - - - * -
Length of preformed pile * * - - -
Standing groundwater level from direct observation - - * * *
or given site investigation data
Date and time of driving, redriving or boring * * * * *
Date of concreting - - * * *
Ground level at pile position at commencement of * * * * *
installation of pile (commencing surface)
Working level on which piling base machine stands * * * * *
Depth from ground level at pile position to pile toe * * * * *
Toe level * * * * *
Pile head level as constructed * * * * *
Pile cut-off level * * * * *
Length of temporary casing - - * * -
Length of permanent casing - - * * -
Type, weight, drop and mechanical condition of hammer * * * - -
and equivalent information for other equipment
Number and type of packing used and type and * * * - -
conditions of dolly used during driving of the pile
Set of pile or pile tube in millimetres per 10 blows or * * * - -
number of blows per 25 mm of penetration
Temporary compression of ground and pile * * * - -
Driving resistance taken at 0.25 m intervals * * * - -
Soil samples taken and in situ tests carried out during * * * * *
pile formation or adjacent to pile position
Length and details of and cover to reinforcement - - * * *
Concrete mix - - * * *
Volume of concrete supplied to pile where this is - - * * *
practical
All information regarding obstructions delays * * * * *
and other interruptions to the sequence of work
Pile forming equipment including rig no. * * * * *
Description of ground excavated - - - * *
Depth from commencing surface to changes - - - * *
in strata and to standing ground water and any
fluctuations
March 1998 4
TABLE 16/1: Records to be kept (cont'd)
Data Driven Driven Driven Bored Continuous

precast segmental cast-in- cast-in- flight
concrete concrete place place auger
and piles concrete concrete concrete or
steel piles piles grout
bearing piles
piles
Depth to average levels of concrete surface before and - - - * -

after withdrawing temporary lining
Type, torque, assessed efficiency of motor - - - - *
Depth to concrete surface after every concrete load - - * * *
For raking piles, angle of rake * * * * -
Support fluid tests - - - * *
Monitoring information referred to in Clause 1604 - - - - *
sub-Clause 15
Level of top of reinforcement cage, as constructed - - * * *
Contract * * * * *
Element reference number (location) * * * * *
Element type * * * * *
Nominal cross-sectional dimensions * * * * *
Top and bottom of guidewall level (as appropriate) * * * - -
Length of preformed element (as appropriate) * - - - *
Groundwater level from direct observation * * * * *
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Date and time of excavation * * * * *
Date of concreting * * * * *
Details of material samples taken * * * * *
Ground level at element position at commencement of * * * * *
element installation (commencing surface)
Working level on which base machine stands * * * * *
Depth from ground level or guide wall, as appropriate, * * * * *
at element position to element toe
Toe level * * * * *
Element head level as constructed * * * * *
Element cut-off level * * * * *
Stop end details * - - - -
Length of temporary casing (as appropriate) - * * * *
Length of permanent casing (as appropriate) - - * * *
Soil samples taken and in situ tests carried out during * * * * *
element formation or adjacent to element position
Tests on support fluid (as appropriate) * * * * *
Length and details of steel reinforcement (as appropriate) * * * * *
Concrete mix or grout (as appropriate) * * * * *
Volume of concrete supplied to element * * * * *
Graph of top of concrete or grout level vs volume placed * * * * *
by batch (as appropriate)
All information regarding obstructions, delays and other * * * * *
interruptions to the sequence of work
As constructed positional records vertical * * * * *
and horizontal, as required
Movements of ground and structures and * * * * *
services as specified
NOTES
1. All levels shall be relative to the Datum specified in Appendix 1/12.
2. All times shall be given in 24-hour format.
March 1998 5
Tolerances in pile dimensions Formwork

5 The cross-sectional dimensions of the pile shall be 8 If a pile is constructed with a shaped point or shoe,
not less than those specified and shall not exceed them then the end of the pile shall be symmetrical about the
by more than 6 mm. Each face of a pile shall not longitudinal axis of the pile. Holes for handling or
deviate by more than 6 mm from any straight line 3 m pitching, where provided in the pile, shall be lined with
long joining two points on that face, nor shall the centre steel tubes; alternatively, inserts may be cast in.
of area of the pile at any cross-section along its length
Formwork shall be robust, clean and so constructed as
deviate by more than 1/500 of the pile length from a
to prevent loss of grout or aggregate from the wet
line joining the centres of area at the ends of the pile.
concrete and ensure the production of uniform pile
Where a pile is less than 3 m long the permitted
sections, free from defects. The piles shall be removed
deviation from straightness shall be reduced below 6
from the formwork in such a manner that damage to the
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mm on a pro rata basis in accordance with actual length.
pile is prevented.
The head of a pile element or the end of the pile upon
which the hammer acts shall be square to the pile axis Concrete
within a tolerance of 1 in 150.
General
Reinforcement for precast reinforced and
prestressed concrete piles 9 Cement materials, aggregates, admixtures and
water shall be in accordance with Series 1700.
6 (11/03) Steel reinforcement shall be as described in
Appendix 16/2 and in accordance with Series 1700. The method of placing and compacting the concrete
shall be such as to ensure that the concrete in its final
The main longitudinal reinforcing bars in piles not position is dense and homogeneous.
exceeding 12 m in length shall be in one continuous
length. In piles more than 12 m long, joints will be Protecting and curing concrete
permitted in main longitudinal bars so that the number
of joints is minimised. Joints in reinforcement shall be 10 Immediately after compaction, concrete shall be
such that the full strength of the bar is effective across adequately protected from the harmful effects of the
the joint. weather, including wind, rain, rapid temperature
changes and freezing. Curing and accelerated curing
Lap or splice joints shall be provided with link bars shall comply with Clause 1710.
designed to resist eccentric forces. Reinforcement shall
be incorporated for lifting and handling purposes. Piles shall not be removed from formwork until a
sufficient pile concrete strength has been achieved to
Spacers shall be designed and manufactured using allow the pile to be handled without damage.
durable materials which shall not lead to corrosion of
the reinforcement or spalling of the concrete cover. Prestressing
Where required in Appendix 16/2, details of the means
by which the Contractor plans to ensure the correct General
cover to and position of the reinforcement shall be
submitted. 11 Prestressing operations shall be carried out only
under the direction of an experienced and competent
Reinforcement for precast reinforced concrete supervisor. All personnel operating the stressing
segmental piles equipment shall have been trained in its use.
7 (11/03) Steel reinforcement shall be as described in The extensions and total forces, including allowance for
Appendix 16/2 and in accordance with Series 1700. losses, shall be calculated before stressing commences.
The main longitudinal reinforcing bars shall be in one Stressing of tendons and transfer of prestress shall be
continuous length. Reinforcement shall be incorporated carried out at a gradual and steady rate. The force in the
for lifting and handling purposes. tendons shall be obtained from readings on a recently
calibrated load cell or pressure gauge incorporated in
Spacers shall be designed and manufactured using the equipment. The extension of the tendons under the
durable materials which shall not lead to corrosion of total forces shall be within 5% of the calculated
the reinforcement or spalling of the concrete cover. extension.
by which the Contractor plans to ensure the correct
submitted.

Concrete strength c) (11/03) Grout shall have a water/cement ratio

as low as possible consistent with the
12 The Contractor shall cast sufficient cubes, cured in necessary consistence, and the water cement
the same manner as the piles, to be able to demonstrate ratio shall not exceed 0.40.
by testing two cubes at a time, with appropriate
intervals between pairs of cubes, that the necessary in d) Grout shall not bleed in excess of 2% after 3
situ strength of the concrete has been reached. hours, or a maximum of 4%, when measured
at 18°C in a covered glass cylinder
Concrete in the piles shall not be stressed until two test approximately 100 mm in diameter with a
cubes attain the necessary strength. height of grout of approximately 100 mm, and
the water shall be reabsorbed after 24 hours.
Records
13 The Contractor shall keep detailed records of times Testing works grout
of tensioning, measured extensions, pressure gauge 17 (11/03) Cube strength testing shall be carried out in
readings or load cell readings and the amount of pull-in accordance with BS EN 12390-1. A sample shall consist
at each anchorage. The Contractor shall also check the of a set of six 100 mm cubes. Three cubes shall be
cover to reinforcement of each pile and shall ensure it is tested at seven days and the remaining three at 28 days
at least that specified. Copies of these records shall be after casting.
provided where required in Appendix 16/2.
Batching grout
Post-tensioned piles
18 The weighing and water-dispensing mechanisms
14 Apart from the requirement for ducts and vents in shall be maintained at all times to within the limits of
post-tensioned piles to be grouted after the transfer of accuracy described in BS 1305.
prestress, the requirements for pre-stressed piles apply.
The weights of each component of the mix shall be
Grouting procedure within 2% of the respective weights per batch.
15 Grout shall be mixed for a minimum of 2 minutes Mixing grout

and until a uniform consistency is obtained.
19 Cement grouts shall be mechanically mixed using:
Ducts shall not be grouted when the air temperature in
the shade is lower than 3°C. a) high speed colloidal mixer
(minimum speed = 1000 revs/minute); or
Before grouting is started all ducts shall be thoroughly
cleaned by means of compressed air which shall be free b) paddle mixer
of oils. (minimum speed = 150 revs/minute)
Grout shall be injected near the lowest point in the duct or other suitable mixer subject to satisfactory evidence
in one continuous operation and allowed to flow from of performance.
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the outlet until the consistency is equivalent to that of The grout shall be mixed on site until a homogenous
the grout being injected. grout is obtained and shall be kept in continuous
Vents in ducts shall be provided in accordance with movement until it is used. It shall be used within 30
Clause 1711. minutes from the start of mixing. Following mixing the
grout shall be passed through a 5 mm aperture sieve and
Grout shall be remixed if lumps are retained.
16 Grout for prestressing shall have the following Transporting grout

properties:
20 Grout shall be transported from the mixer to the
a) (11/03) Thedesign and consistence of grout to position of the pile in such a manner that segregation of
be used in the formation of piles shall produce the mix does not occur.
a mix which is suitable for pumping.
b) (11/03) Grout shall consist only of Portland Placing grout in cold weather
cement CEM I to BS EN 197-1, water and
21 Grout shall have a minimum temperature of 5°C
admixtures. Admixtures are only to be used in
when placed. No frozen material or material containing
accordance with the Manufacturer’s
ice shall be used for making grout. All plant and
instructions and shall comply with
equipment used in the transporting and placing of grout
Clause 1703.
shall be free of ice that could enter the grout.
Records the pile has attained the strength to resist driving

stresses, whichever is the greater.
22 The Contractor shall keep records of grouting,
including the date, the proportions of the grout and any Leaders and trestles
admixtures used, the pressure, details of interruption
and topping up required. Copies of these records shall 27 At all stages during driving and until incorporation
be provided where required in Appendix 16/2. into the structure the pile shall be adequately supported
and restrained by means of leaders, trestles, temporary
Pile quality supports or other guide arrangements to maintain
position and alignment and to prevent damage to the
23 A certificate of quality from the pile manufacturer pile.
shall be provided where required in Appendix 16/2
stating that the requirements of this Specification have Performance of driving equipment
been fulfilled during manufacture.
28 Where required in Appendix 16/2, the Contractor
Marking of piles shall provide information on the efficiency and energy
of the driving equipment including when followers are
24 (11/03) Each pile shall be marked in such a manner used. Where required in Appendix 16/2, (or 16/6 as
that it can be identified with the records of manufacture appropriate), dynamic evaluation and analysis shall be
which shall state the date of casting, the cement type, provided.
concrete strength class, element length, the prestressing
Where a drop hammer is used, the mass of the hammer
force where appropriate and any other relevant data. On
shall be at least half that of the pile or pile segment. For
delivery the piles shall be accompanied by records of
other types of hammer the energy delivered to the pile
manufacture. Lifting positions shall be marked on each
per blow shall be at least equivalent to that of a drop
pile in accordance with the requirements of design.
hammer of the stated mass. Drop hammers shall not be
Handling, transportation and storage of piles used from floating craft in such a manner as to cause
instability of the craft or damage to the pile.
25 The method and sequence of lifting, handling,
transporting and storing piles shall be such as to avoid Length of piles
shock loading and to ensure that the piles are not 29 The length of pile to be driven in any position shall
damaged. Only designed lifting and support points shall be as specified in Appendix 16/2. During the execution
be used. During transport and storage, piles shall be of the Works any amendments to the scheduled lengths
appropriately supported under the marked lifting points shall be recorded by the Contractor and a full statement
or fully supported along their length. of the reasons included in the pile record.
All piles within a stack shall be in groups of the same
Driving procedure and redrive checks
length. Packing of uniform thickness shall be provided
between piles at the lifting points. 30 The driving procedure shall be such as to avoid
Concrete shall at no time be subjected to loading, damage to the piles.
including its own weight, which will induce a The Contractor shall comply with all the particular
compressive stress in it exceeding 0.33 of its strength at requirements of Appendix 16/2 on driving resistances
the time of loading or of the specified strength, and characteristics.
whichever is the lesser. For this purpose an assessment
of the strength of the concrete and of the stresses The driving of each pile shall be continuous until the
produced by the loads shall be carried out. depth or set as required by the design has been reached.
In the event of unavoidable interruption to driving, the
A pile shall be rejected when the width of any pile may be redriven provided it can subsequently be
transverse crack exceeds the value given in Table 1 of driven to the designed depth and/or resistance or set
BS 5400 : Part 4. The measurement shall be made with without damage. A follower shall not be used unless the
the pile in its working attitude. set is revised where applicable in order to take into
account reduction in the effectiveness of the hammer
Driving piles blow.
Strength of piles Driving records shall be made for every pile. This
record shall contain the weight and fall of the hammer
26 Piles shall not be driven until the concrete cubes or ram and the number of blows for each 0.25 m of
have achieved the specified characteristic strength or penetration, unless otherwise specified in
Appendix 16/2, (or 16/5 or 16/6 as appropriate).

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Any unexpected change in driving characteristics shall throughout the period of the piling work and the results
be included in the pile record. recorded.
If preliminary piles are not installed the Contractor
Set
shall commence installation of working piles taking
31 The set and temporary compression shall be measures to reduce or eliminate uplift until it can be
measured and recorded for each pile at the completion established by site measurements that such measures
of driving unless otherwise stated in Appendix 16/2, (or are no longer necessary. Thereafter checks on uplift
16/6 as appropriate). shall be made by the Contractor at least once a week
and the results recorded.
When a set is being measured, the following
requirements shall be met. If a static load test shows that a pile which uplifted
more than the maximum permitted amount due to any
(a) The exposed part of the pile shall be in good pile driven within a radius of eight pile diameters does
condition without damage or distortion. not comply with the requirements of the Specification
(b) The helmet, dolly and any packing shall be in all such piles that may have been uplifted shall be
sound condition. redriven.
(c) The hammer blow shall be in line with the If records and measurements show that piles have been
pile axis and the impact surfaces shall be flat laterally displaced so as to be outside the permitted
and at right angles to the pile and hammer tolerance or damaged the measures the Contractor plans
axis. to adopt to enable the piles to comply with the
Specification shall be provided in accordance with
(d) The hammer shall be in good condition,
Appendix 16/2.
delivering adequate energy per blow, and
operating correctly. Laterally displaced piles shall not be corrected by
forcible correction at the heads.
(e) The temporary compression of the pile shall
be recorded if required in Appendix 16/2, (or Preboring
16/6 as appropriate).
The set shall be recorded either as the penetration in 33 If preboring is specified, the diameter and depth of
millimetres per 10 blows or as the number of blows prebore shall be as stipulated in Appendix 16/2.
required to produce a penetration of 25 mm. Other means to ease pile drivability may be used
provided the completed piles meet the requirements of
Driving sequence and risen piles the Specification.
32 Piles shall be driven in a sequence to minimise any Repair and lengthening of piles
detrimental effects of heave and lateral displacement of
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the ground. The sequence and method of piling

Repair of damaged pile heads
including preboring shall limit uplift and lateral
movement so that the final position of each pile is 34 If it is necessary to repair the head of a pile before
within the specified tolerances. At all times the it has been driven to its final level, the Contractor shall
deflections of each pile from its axis as driven shall not carry out such repair in a way which allows the pile-
be such as to cause damage or impair durability of the driving to be completed without further damage. If the
piles or any structures or services. driving of a pile has been completed but the level of
The maximum permitted uplift of each pile due to any sound concrete of the pile is below the required cut-off
one pile driven within a pile centre to centre radius of level, the pile shall be made good to the cut-off level, or
eight pile diameters is 3 mm or such figure as shall be the pile cap or substructure may be locally deepened, so
specified unless it can be demonstrated by static load that the completed foundation will safely withstand the
testing that uplift exceeding this amount does not affect specified working load.
the ability of the pile to meet the requirements of this
Specification. Lengthening of precast reinforced and prestressed
concrete piles
Even if during the installation of preliminary piles
uplift is shown to be within the permitted maximum and 35 Any provision for lengthening piles incorporated at
the preliminary piles tested meet the requirements of the time of manufacture shall be designed by the
the Specification, checks of uplift on working piles Contractor to resist all stresses to which it may be
shall be made by the Contractor at least once a week subjected.
March 1998 9
If no provision for lengthening piles was incorporated Casings

at the time of manufacture, any method for lengthening
shall be such that the extended pile including any joints 4 (11/03) Temporary casings shall be of quality of
is capable of taking safely the stresses during driving material, length and thickness adequate for the purpose
and under load. of preventing water and unstable soil from entering the
pile excavations. A short length of temporary casing
Lengthening of segmental piles shall be provided for all piles to provide an upstand of
at least 1 m above surrounding ground level for safety
36 Where piles are driven to depths exceeding those and to prevent contamination of the concrete in the
expected, leaving insufficient projection for penetration bore.
into the following works, the piles shall be extended or
Temporary casings shall maintain the excavations to
replaced so that the completed piles are capable of
their full dimensions and ensure that piles are
meeting the requirements of the Specification.
completed to their full cross-sectional dimensions.
Driving repaired or lengthened piles The use of a vibrator to insert and withdraw temporary
casings is subject to compliance with Clause 109
37 Repaired or lengthened piles shall not be driven (Control of Noise and Vibration) and sub-Clause
until cubes for the added concrete have reached the 1601.28 and to the method not causing disturbance of
specified characteristic strength of the concrete of the the ground which would adversely affect the
pile. construction or the capacity of piles.
Cutting off pile heads Temporary casings shall be free from significant
distortion. They shall be of uniform cross-section
38 When the driving of a pile has satisfied the throughout each continuous length. During concreting,
Specification requirements the concrete at the head of they shall be free from internal projections and
the pile shall be cut off to the level specified. encrusted concrete which might adversely affect the
Reinforcing bars projecting above this level shall be as proper formation of piles.
specified.
Where piles are bored under water or support fluid in
Care shall be taken to avoid shattering or otherwise an unlined state, the insertion of a full-length loosely
damaging the rest of the pile. Any cracked or defective fitting casing to the bottom of the bore prior to placing
concrete shall be cut away and the pile repaired to concrete will not be permitted.
provide a full and sound section to cut-off level.
If required, permanent casings shall be specified in
Appendix 16/3.
1603 Bored Cast-in-Place Piles
Stability of pile bore
Support fluid 5 Where boring takes place through unstable water-
1 Where support fluid is used to maintain the bearing strata, the process of excavation and the support
stability of the excavation it shall be in accordance with fluid and depth of temporary casing where employed
Clause 1618. shall be such that soil from outside the area of the pile
is not drawn into the pile section and cavities are not
Diameter of piles created outside the temporary casing as it is advanced.
Where a support fluid is used for maintaining the
2 The diameter of a pile shall be not less than the
stability of a bore, an adequate temporary casing shall
specified diameter.
be used in conjunction with the support fluid so as to
The auger width shall be checked as necessary and ensure stability of the strata near ground level until
recorded for each pile to ensure the specified diameter concrete has been placed. During construction the level
is achieved. A tolerance of +5% -0 on the auger width is of drilling fluid in the pile excavation shall be
permissible. maintained within the cased or stable bore so that it is
not less than 2 m above the level of external standing
Boring groundwater at all times, unless stated otherwise in
Appendix 16/3.
Boring near recently cast piles
Pumping from pile bores
3 Piles shall be bored in an order and in such a
manner that no damage is sustained by previously 6 Pumping from pile bores shall not be permitted
formed piles. unless the bore has been sealed against further water
Amendment - November 2003 --`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`--- 10

entry by casing or unless the soil is stable and will Cleanliness of pile bases
allow pumping to take place without ground
disturbance below or around the pile. 10 On completion of boring loose, disturbed or
softened soil shall be removed from the bore using
Continuity of construction appropriate methods, which shall be designed to clean
while at the same time minimizing ground disturbance
7 The pile shall be bored and the concrete shall be below the pile bases. Water or support fluid shall be
placed without such delay as would lead to impairment maintained at such levels throughout and following the
of the performance of the pile. cleaning operation that stability of the bore is
The time period during which each pile is excavated preserved. At all times when the pile head is
and the concrete is placed shall not exceed 12 hours. unattended, the bore shall be clearly marked and fenced
The time period shall start when excavation below the off so as not to cause a safety hazard.
temporary lining tubes commences. Where the
Reinforcement
construction sequence is such that the time period of 12
hours will be exceeded even if no delays are taken into 11 (11/03) Steel reinforcement shall be as described in
account, a realistic time period during which the pile is Appendix 16/3 and in accordance with Series 1700.
excavated and concrete placed shall be stated in the Where steel sections are used for reinforcement, they
Contractor’s method statement. The Contractor shall shall be in accordance with Series 1800.
advise on the likely effect of this extended pile
construction period on the performance and capacity of The number of joints in longitudinal steel bars shall be
the pile. kept to a minimum. Joints in steel reinforcement shall
be such that the full strength of each bar is effective
Enlarged pile bases across the joint and shall be made so that there is no
detrimental displacement of the reinforcement during
8 A mechanically formed enlarged base shall be no the construction of the pile. Reinforcement shall be
smaller than the dimensions specified and shall be maintained in its correct position during concreting of
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concentric with the pile shaft to within a tolerance of the pile, to allow a vertical tolerance of +150/-50 mm
10% of the shaft diameter. The sloping surface of the on the level of the reinforcement projecting above the
frustum forming the enlargement shall make an angle to final cut off level. Where reinforcement is made up into
the axis of the pile of not more than 35°. cages, they shall be sufficiently rigid to enable them to
At the specified diameter of the underream at the be handled, placed and concreted without damage. If
perimeter of the base there shall be a minimum height the cage is to be welded together, welding shall be
of 150 mm. carried out to the requirements of BS 7123.
Unless otherwise specified, reinforcement shall extend
Inspection to the base of the pile or to at least 3 m below the
bottom of the temporary casing, whichever is the lesser.
9 Each pile bore which does not contain standing
water or support fluid shall be inspected from the Spacers shall be designed and manufactured using
ground surface prior to concrete being placed in it to durable materials which shall not lead to corrosion of
ensure the base is clean. Adequate means of lighting, the reinforcement or spalling of the concrete cover.
measuring tapes and a means of measuring verticality Where required in Appendix 16/3, details of the means
shall be used. For piles of 750 mm diameter or larger by which the Contractor plans to ensure the correct
and where manned inspection of the pile base is cover to and position of the reinforcement shall be
specified in Appendix 16/3, equipment shall be submitted.
provided by the Contractor to enable his representatives
to descend into the bore for the purpose of inspection. Concrete
The Contractor shall provide all necessary facilities to
enable an inspection of any pile excavation to be made General
including facilities to check the depth, verticality and
position. The full requirements of BS 8008 shall be 12 (11/03) Cement materials, aggregates, admixtures
followed. and water shall be in accordance with Series 1700.
The Contractor shall designate a Supervisor to The consistence and method of placing of the concrete
supervise each inspection. The Supervisor shall have a shall be such that a continuous monolithic concrete or
copy of BS 8008 and shall ensure that every person grout shaft of the full cross-section is formed. Concrete
involved in the descent of piles is familiar with its shall be transported from the mixer to the position of
requirements. the pile in such a manner that segregation of the
concrete constituents does not occur.
The concrete shall be placed without such interruption Placing concrete under water or support fluid
as would allow the previously placed batch to have
achieved a stiffness which prevents proper 16 (11/03) Before placing concrete, measures shall be
amalgamation of the two concrete batches. taken in accordance with sub-Clause 1603.10 to ensure
there is no accumulation of silt or other material at the
The Contractor shall take all precautions in the design base of the boring, and the Contractor shall ensure that
of the concrete mix and placing of the concrete to avoid heavily contaminated support fluid, which could impair
arching of the concrete. No soil, liquid, or other foreign the free flow of concrete from the tremie pipe, has not
matter shall be permitted to contaminate the concrete. accumulated in the bottom of the hole.
(11/03) Consistence of concrete A sample of support fluid shall be taken from the top
and bottom of the boring using an appropriate device.
13 Consistence measured at the time of discharge into The fluid shall be prepared, sampled and tested as
the pile bore shall be in accordance with the limits stated in the Contractor’s submission. If tests show the
shown in Table 16/2 fluid does not comply with the limits stated by the
Contractor for the particular type of support fluid, the
Compaction fluid shall be wholly or partly replaced as appropriate
before concrete is placed.
14 Internal vibrators shall not be used to compact
concrete. Concrete to be placed under water or support fluid shall
be placed by tremie in one continuous operation and
Placing concrete in dry borings shall not be discharged freely into the water or support
fluid. Pumping of concrete may be used where
15 Measures shall be taken to ensure that the appropriate. The bottom end of the tremie must be
structural strength of the concrete placed in all piles is square to the axis of the tremie and its circumference
not impaired through grout loss, segregation or must be continuous. The tremie must be fully charged
bleeding. with concrete before it is lifted off the base of the pile.
The method of placing shall be such as to ensure that The concrete shall be of high consistence and cement
the concrete or grout in its final position is dense and content in accordance with Series 1700 and Table 16/2
homogeneous. Concrete shall be introduced into the mix C.
pile via a hopper and suitable length of rigid delivery
tube to ensure that the concrete falls vertically and The concrete shall be placed in a manner that shall not
centrally down the shaft. The tube shall be at least 3 m cause segregation of the constituents of concrete mix.
long.
TABLE 16/2: (11/03) Piling Mix Consistence
Piling mix Consistence Typical conditions of use

Consistence (The concrete and aggregate size must be
compatible with the reinforcement spacing)
Flow class Range Slump class
mm Range
mm
A Not S2-S4 Placed into water-free unlined or permanently lined bore of

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applicable 600 mm diameter or over, or where casting level lies below

temporary casing; reinforcement spaced at 100 mm centres or
greater, leaving ample room for free movement of concrete
between bars.
B F3-F4 *S3-S5b** Where reinforcement is spaced at less than 100 mm centres;
where cut-off level of concrete is within temporary casing;
where pile bore is water-free and the diameter is less than
600mm.
C F4-F5 *S4 or more Where concrete is to be placed by tremie under water or
support fluid or by pumping or by continuous flight auger.
Notes: 1. (11/03) *The slump test method is not suited to these very high consistence and the flow test is to be preferred.
2. (11/03) **The test method may lack sensitivity with this class.

The depths to the surface of the concrete shall be TABLE 16/4: Casting Tolerance above Cut-off Level
measured and the length of the tremie tubes recorded at for Piles cast in Dry Bores within Permanent Lining
regular intervals corresponding to the placing of each tubes or Permanent casings, or where their Cut-off
batch of concrete. The depths measured and volumes Levels are in Stable Ground below the Base of any
placed shall be plotted immediately on a graph and Casing used
compared with the theoretical relationship of depth
against volume. Cut-off distance below Casting tolerance above
commencing surface, H, m+ cut-off level, m
The hopper and pipe of the tremie shall be clean and
0.15 - 10.00 0.3 + H/10
watertight throughout. The pipe shall extend to the base
of the bore and a sliding plug or barrier shall be placed + Beyond H = 10 m, the casting tolerance applying to H = 10 m
in the pipe to prevent direct contact between the first shall apply.
charge of concrete in the tremie and the water or
support fluid. The pipe shall at all times penetrate the TABLE 16/5: Casting Tolerance above Cut-off Level
concrete which has previously been placed with a for Piles cast under Water or Support Fluid*
minimum embedment of 3 m and shall not be
withdrawn from the concrete until completion of Cut-off distance below Casting tolerance above
concreting. A sufficient quantity of concrete shall be commencing surface, H, m+ cut-off level, m
maintained within the pipe to ensure that the pressure 0.15 - 10.00 1.0 + H/12 + C/8
from it exceeds that from the water or support fluid. where C = length of
The internal diameter of the pipe of the tremie shall be temporary casing below the
commencing surface*
not less than the greater of 150 mm or six times the
maximum aggregate size. It shall be so designed that + Beyond H = 10 m, the casting tolerance applying to H = 10 m
external projections are minimized, allowing the tremie shall apply.
* In cases where a pile is cast so that the cut-off is within a
to pass within reinforcing cages without causing permanent lining tube, the appropriate tolerance is given by
damage. The internal face of the pipe of the tremie shall deletion of the casing term C/8 in the table.
be free from projections. The concrete level within a temporary casing in a dry
Extraction of casing bore may be topped up where necessary during the
course of casing extraction so that the base of the
(11/03) Consistence of concrete casing is always below the concrete surface until the
casting of the pile has been completed.
17 (11/03) Temporary casings shall be extracted while
the concrete within them remains sufficient consistence Adequate precautions shall be taken in all cases where
to ensure that the concrete is not lifted. During excess heads of water or support fluid could occur as
extraction the motion of the casing shall be maintained the casing is withdrawn because of the displacement of
in an axial direction relative to the pile. water or fluid by the concrete as it flows into its final
position against the walls of the pile bore. Where two or
Concrete level more discontinuous lengths of casing (double casing)
are used in the construction the Contractor’s method of
18 When the casing is being extracted, a sufficient working shall produce piles to their full designed cross-
quantity of concrete shall be maintained within it to sections. The depth to the average levels of the concrete
ensure that pressure from external water, support fluid surface of the pile shall be measured before and after
or soil is exceeded and that the pile is neither reduced in each temporary casing is removed. These measurements
section nor contaminated. shall be recorded on the pile record.
TABLE 16/3: Casting Tolerance above Cut-off Level
for Piles cast in Dry Bores using Temporary Casing Pile head casting level tolerances
and without the use of Permanent Lining 19 For piles cast in dry bores using temporary casing
and without the use of a permanent casing, piles heads
Cut-off distance below Casting tolerance above
commencing surface, H, m+ cut-off level, m shall be cast to a level above the specified cut-off so
that, after trimming, a sound concrete connection with
0.15 - 10.00 0.3 + H/12+C/8 the pile can be made. The casting level shall be above
where C = length of
temporary casing below the the cut-off level and within the tolerance shown in
commencing surface* Table 16/3, but shall not be above the commencing
surface level. No pile shall be cast with its cut-off level
+ Beyond H = 10 m, the casting tolerance applying to H = 10 m
shall apply. below standing water level unless appropriate measures
* If H is greater than C, then this tolerance is no longer applicable
and the tolerances in Table 16/4 will apply.

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are taken to prevent inflow of water causing segregation Where the word “concrete” is used elsewhere in this
of the concrete as temporary casing is extracted. Clause then “grout” shall be read in its place. In
particular sub-Clauses 14 to 18 shall also apply to
For piles cast in dry bores within permanent lining
grout, except the requirement for grout consistence
tubes or permanent casings to where their cut-off levels
shall be that in Clause 1602, sub-Clause 16.
are in stable ground below the base of any casing used,
pile heads shall be cast to a level above the specified
Pressure grouting
cut-off so that, after trimming, a sound concrete
connection with the pile can be made. The casting level
shall be above the cut-off level and within the tolerance Grouting of piles
shown in Table 16/4, but shall not be above the 23 Where bases or sides of piles are to be pressure
commencing surface level. grouted, as detailed in Appendix 16/3, the Contractor
For piles cast under water or support fluid, the pile shall construct the piles with grout tubes and any other
heads shall be cast to a level above the specified cut-off necessary equipment pre-installed so that piles may
so that, after trimming to remove all debris and subsequently be grouted.
contaminated concrete, a sound concrete connection
with the pile can be made. The casting level shall be Method of grouting
above the cut-off level and within the tolerance shown 24 The method of grouting shall be such that the
in Table 16/5, but shall not be above the commencing completed pile meets the requirements of the
surface level. Cut-off levels may be specified below the Specification for load-settlement behaviour and that
standing groundwater level, and where this condition during grouting pile uplift is within the limits specified.
applies the borehole fluid level shall not be reduced Where required in Appendix 16/3, the Contractor shall
below the standing groundwater level until the concrete submit full descriptions of the equipment, materials and
has set. methods that he plans to use before commencing
Where either support fluid or water is mixed in the grouting. The method statement shall comprise at least
ground by the drilling equipment to assist with the the following information:
installation of temporary casings the casting level shall i) Details of specialist contractor for grouting (if
be coincident with the commencing surface. applicable), names of key personnel and their
curricula vitae and previous experience on
Temporary backfilling above pile casting level
similar types of work.
20 After each pile has been cast, any empty bore ii) Details of grout pump, mixer, agitator and any
remaining shall be carefully backfilled as soon as other equipment used for mixing and injection
possible with inert spoil. of grout.
Cutting off pile heads iii) Full details of grout to be used, including
admixtures.
21 When cutting off and trimming piles to the
specified cut-off level, the Contractor shall take care to iv) Method of quality control on grout, including
avoid shattering or otherwise damaging the rest of the details of number of cubes taken and checks
pile. Any cracked or defective concrete shall be cut on density, flow and bleed of the grout.
away and the pile repaired in a manner to provide a full v) (11/03) Method of measuring grout take, which
and sound section at the cut-off level. shall be automatic and include a physical
method of checking grout take at the end of
Grout injection of each circuit.
22 (11/03) The use of grout containing fine aggregate is vi) (11/03) Method of measuring grout pressures
permitted in place of concrete specified elsewhere in which shall include a continuous record.
this Clause. The requirements of Clause 1602, sub- Calibration certificates for pressure gauges.
Clauses 15 to 22 shall apply. The sand shall be in vii) Typical record sheet for grouting, which shall
accordance with the limits of 0/4 (CP) or 0/2 (MP) of include records of grout take, grout pressure,
BS EN 12620. residual pressure, times of grouting and pile
The moisture content of aggregates shall be measured uplift for each grouting circuit. Typical
immediately before mixing and as frequently thereafter continuous records of grout pressure and pile
as is necessary to maintain consistency of the mix. uplift shall also be included.
Allowance shall be made for the aggregate moisture
when assessing batch weights.

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viii) Target minimum, maximum and residual grout The records shall comprise the following information:
pressures for each grout injection.
a) Pile number.
ix) Method of grout injection, including full
b) Date.
details of any packers. Target grout volumes
for each injection. c) Leakage test on grout pipes.
x) Method of measuring friction losses in the d) Grout mix.
tubes/packers. e) Continuous records of grout pressure and pile
uplift to the same timescale. The records shall
Grout tubes
be annotated at regular intervals with physical
25 The grouting tubes shall be tested to determine any measurements from pressure gauges and dial
grout leakage in joints under pressure prior to gauges including times of such measurements.
installation into the piles. The grout tubes must be Circuit number and pile number are also to be
capable of withstanding the pressures to which they will included.
be subjected. f) For each circuit the peak and residual grout
Robust threaded caps shall be provided to protect the pressures including times and sequence of
top of the grouting tubes during concreting and grouting.
afterwards. g) The total pile uplift and the uplift after each
The grouting tubes shall be flushed with water after circuit is grouted.
each grouting operation. h) For each circuit the physical and automatic
If the target volumes or grout pressures are not measurements for grout volume injected and
achieved, or the specified uplift is not achieved, then derived injected volumes. The total grout
the pile shall be regrouted within 24 hours. volume.
The Contractor shall provide an engineer to monitor i) All tests made on grout.
grout pressures and grout takes.
Pile uplift 1604 Bored Piles Constructed Using

Continuous Flight Augers and Concrete or
26 During base grouting, the pile uplift shall be not Grout Injection Through Hollow Auger Stems
less than 0.2 mm and shall not exceed 2.0 mm.
The Contractor shall provide an engineer to monitor the Diameter of piles
uplift of the piles during grouting.
The pile uplift shall be monitored with an appropriate specified diameter.
level reading off a graduated scale attached to the pile
The cutting head width shall be checked as necessary
head and by a dial gauge attached to a reference frame.
and recorded for each pile to ensure the specified
A continuous record of pile uplift shall be made using a
diameter is achieved and that the width is greater than
displacement transducer also attached to the reference
the diameter of the following flight. A tolerance of
frame. The accuracy of measurement shall be a
+5% -0 on the cutting head width is permissible.
minimum of 0.1 mm for each monitoring device.
The design of the reference frame shall be made Boring
available on request.
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Grout testing Boring near recently cast piles
27 Close control of the mixing of the grout shall be 2 Piles shall be formed in an order and in such a
carried out. The Contractor shall provide and maintain manner that no damage is sustained by previously
on site all test facilities required to test and control the formed piles.
grout mixes.
Removal of augers from the ground
Records
3 The auger shall not be extracted from the ground
28 In accordance with Appendix 16/3, the Contractor during the boring or construction of a pile in such a way
shall provide duplicate copies of all grouting records that an open unsupported bore or inflow of water into
for each pile within 24 hours of the completion of
grouting that pile.
March 1998 15
the pile section would result. As the auger is withdrawn pressure. Care shall be taken to ensure that the auger is
from the ground it shall be cleaned of all rising. lifted only the minimum distance necessary to initiate
the flow of concrete or grout, and that water inflow and
Suitability of boring equipment soil movement at the base of the auger are minimized.
The technique and equipment used to initiate and
4 The piles shall be bored using equipment capable maintain the concrete or grout flow shall be such that a
of penetrating the ground without drawing surrounding pile of the full specified cross-section is obtained from
soils laterally into the pile bore. the maximum depth of boring to the final pile cut-off
The Contractor shall record the fact if flighting of soil level.
up the auger is excessive.
Rate of supply of concrete or grout
The verticality of the auger shall be checked at the
commencement of boring. Should it deviate during 10 The concrete or grout shall be supplied to the pile
boring so that the pile verticality is outside the specified at a sufficient rate during auger withdrawal to ensure
tolerance the fact shall be recorded on the pile record. that a continuous monolithic shaft of at least the full
specified cross-section is formed, free from debris or
Sealing the base of the auger any segregated concrete or grout.
5 The base of the auger stem shall be fitted with a Completion of concreting or grouting of piles
suitable means of sealing it against ingress of water and
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soil during boring. 11 If the concrete or grout placing in any pile cannot
Depth of piles be completed in the normal manner, then the pile shall
be rebored to a safe level below the position of
6 Any failure of a pile to reach the required depth, as interruption in supply before the concrete or grout has
given in Appendix 16/4, shall be recorded by the achieved initial set and before further concrete or grout
Contractor and a full statement of the reasons included is injected. The method statement shall set out the
in the pile record. procedure.
Placing of concrete or grout Casting level of pile head
(11/03) Mix design and consistence; concrete 12 Concrete or grout shall be cast to the commencing
surface level in all cases. The pile position shall be
7 (11/03) Where not otherwise stated in this section, clearly marked and fenced off so as not to cause a
the concrete shall comply with Series 1700. The design safety hazard.
and consistence of concrete to be used in the formation
of a pile shall produce a concrete mix which is suitable (11/03) Mix design and consistence; grout
for pumping. It shall have a slump classs S4 or greater
or flow classes F4 to F5 and a minimum cement content 13 (11/03) Where not otherwise stated in this section,
of 340 kg/m³. The concrete shall be designed so that the grout shall comply with Clause 1602 sub-Clauses
segregation does not occur during the placing process, 15 to 22 with the exception that sand may be used. The
and bleeding of the concrete shall be minimized. sand shall be in accordance with the limits of 0/4 (CP)
or 0/2 (MP) of BS EN 12620.
The consistence of concrete mixes shall be measured by
the method described in Appendix 16/4. The moisture content of aggregates shall be measured
immediately before mixing and as frequently thereafter
Equipment for supply of concrete or grout to piles as is necessary to maintain consistency of the mix.
Allowance shall be made for the aggregate moisture
8 Grout or concrete shall be supplied to the pile content when assessing batch weights.
through suitable concrete pump, tubing and the hollow
The procedure for monitoring the suitability of grout
auger stem. All pipe fitments and connections shall be
throughout the Works shall be established prior to
so constructed that grout does not leak during the
commencement of the Works.
injection process.
Reinforcement
Commencement of concrete or grout supply to each
pile 14 (11/03) Steel reinforcement shall be as described in
Appendix 16/4 and in accordance with Series 1700.
9 At the beginning of concrete or grout placing the
Where steel sections are used for reinforcement, they
sealing device at the base of the auger stem shall be
shall be in accordance with Series 1800.
removed by the application of concrete or grout

All reinforcement shall be placed with the minimum shall be calibrated at the frequency specified below or
delay after the completion of the concreting or grouting at any time where there is reason to suspect
operation. It shall be fabricated in cages or bundles of malfunction.
bars fixed securely to permit it to be placed in the
Depth shall be calibrated once a week. At full auger
correct position and to the depth specified through the
length the tolerance is ± 0.1 m.
concrete or grout of the pile. Suitable spacers shall be
provided to maintain the specified concrete or grout Concrete flow rate shall be calibrated once during the
cover to steel. progress of the works by passing a known volume of
concrete through the flow meter. The tolerance on flow
The transverse reinforcement of any reinforcing cage
is ± 5%.
shall meet the design requirements and shall maintain
the longitudinal bars in position when the cage is The pressure transducer shall have a calibration
inserted into the wet concrete or grout. certificate. The tolerance on pressure shall be stated in
bars.
Longitudinal main steel reinforcement shall be
continuous over the specified length. Where joints are The automated monitoring system must be operational
necessary, no more than one joint shall be used and then at the start of every pile. The following information
only if the reinforcement cage length exceeds 12 m. shall be recorded during the construction of each pile:
Joints in steel reinforcement shall be such that the full
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i) the incremental time of auger penetration
strength of each bar is effective across the joint and during boring
shall be made so that there is no detrimental
displacement of the reinforcement during placing in the ii) final depth of the bore
pile. At the joint bars shall be welded to the requirement iii) time for each 0.5 m increment of auger
of BS 7123 or joined together in a suitable manner. extraction during concreting
Reinforcement shall be placed and maintained in iv) the volume of concrete or grout pumped for
position to provide the specified projection of each 0.5 m increment of auger extraction
reinforcement above the final cut-off level. A vertical during concreting
tolerance of +150/-50 mm on the level of reinforcement
projecting above the final cut-off level shall be met. v) total volume of concrete or grout for
completion of the pile
The Contractor shall provide such additional
reinforcement as he may require to suit his method of vi) the time at the start and end of boring,
placing the reinforcing steel cage. concreting and insertion of the reinforcement
cage and any time intervals for delays or
Monitoring system for pile construction stoppages
15 An automated system shall be provided for vii) relative concrete pressure during concreting
monitoring the construction of the piles. It shall provide viii) the direction of rotation of the auger during
the operator with information on the depth of the auger concreting
tip, flow of concrete and relative pressure of concrete as
If the number of auger revolutions relative to auger
a minimum. In addition the automatic monitoring
penetration becomes abnormally high at any stage
equipment shall monitor continuously with depth the
during boring, the fact shall be recorded, as shall the
following parameters.
occurrence of excessive flighting.
a) During boring:
The rig operator shall be competent and experienced in
i) auger penetration rate the construction of continuous flight auger piles and a
b) During concreting: full time supervisor shall be devoted to pile
construction. Where required in Appendix 16/4, details
i) rate of extraction of the auger of their relevant experience shall be submitted prior to
ii) relative injection pressure of concrete or work commencing.
grout In accordance with Appendix 16/4, the Contractor shall
iii) rate of supply of concrete or grout submit proposals on how he shall complete a pile in the
event of failure of all or part of the rig instrumentation
Equipment used for monitoring shall be calibrated at system prior to work commencing. This proposal shall
the start of the piling works and calibration certificates include the recording of the depth at which failure
issued before commencing piling. After the occurred, the time for auger extraction during
commencement of works, the monitoring equipment concreting, and the total volume of concrete or grout
March 1998 17
delivered. Any pile which was subject to an base and the materials to be used shall be included in
instrumentation failure during construction shall be the Contractor’s method statement.
integrity tested in accordance with Clause 1608.
Driving piles
The monitoring results must be available immediately
on completion of every pile.
Piling near recently cast piles
Cutting off pile heads 6 Casings shall not be driven or piles formed so close
16 When cutting off and trimming piles to the to other piles which have recently been cast and which
specified cut-off level, the Contractor shall take care to contain workable or unset concrete that a flow of
avoid shattering or otherwise damaging the rest of the concrete could be induced from or damage caused to
pile. Any laitence, or contaminated, cracked or any of the piles.
defective concrete shall be cut away and the pile made
good in a manner to provide a full and sound section up Performance of driving equipment
to the cut-off level. 7 Where required in Appendix 16/5, the Contractor
shall provide information on the efficiency and energy
of the driving equipment including when followers are
1605 Driven Cast-in-Place Piles used. Where required in Appendix 16/5, dynamic
evaluation and analysis shall be provided.
Materials
Drop hammers shall not be used from floating craft in
Permanent casings such a manner as to cause instability of the craft or
damage to the pile.
1 Permanent casings shall be as specified in
Appendix 16/5. Where a permanent casing is to be Length of piles
made from a series of short sections it shall be
8 The length of pile to be driven in any position shall
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watertight. The dimensions and quality of the casing

be as specified in Appendix 16/5. During the execution
shall be adequate to withstand the stresses caused by
of the Works any amendments to the scheduled lengths
handling and driving without damage or distortion.
shall be recorded by the Contractor and a full statement
Pile shoes of the reasons included in the pile record.
2 Pile shoes shall be manufactured from durable Driving procedure and redrive checks
material capable of withstanding the stresses caused by
9 Driving procedure and redrive checks shall be in
driving without damage, and shall be designed to give a
watertight joint during construction.
Set
Diameter of piles
10 The set shall be measured and recorded for each
pile at the completion of driving unless otherwise stated
specified diameter.
in Appendix 16/5.
Temporary casings When a set is being measured, the following
requirements shall be met.
4 Temporary casings shall be free from significant
distortion. They shall be of uniform external cross- (a) The exposed part of the pile casing shall be in
section throughout each continuous length and shall be good condition, without damage or distortion.
of sufficient strength to withstand driving and ground (b) The dolly, helmet and packing, if any, shall be
forces without deformation. During concreting they in sound condition.
shall be free from internal projections and encrusted
concrete which might prevent the proper formation of (c) The hammer blow shall be in line with the
piles. pile axis and the impact surfaces shall be flat
and at right angles to the pile and hammer
Enlarged pile bases axis.
5 Where the Contractor wishes to form a pile with an (d) The hammer shall be in good condition,
enlarged base or where such a base is specified in delivering adequate energy per blow, and
Appendix 16/5, details of the method of forming the operating correctly.
March 1998 18
The set shall be recorded either as the penetration in Inspection and remedial work
millimetres per 10 blows or as the number of blows
required to produce a penetration of 25 mm. 16 Prior to placing concrete in a pile casing, the
Contractor shall check that the casing is undamaged,
Driving sequence and risen piles and free from water or other foreign matter. In the event
of water or foreign matter having entered the pile
11 Requirements for the driving sequence and risen casing, the casing shall be withdrawn, repaired if
piles shall be in accordance with sub-Clause 1602.32. necessary and redriven, or other action taken to
Laterally displaced piles shall not be corrected by continue the construction of the pile to meet the
forceable correction at the heads. requirements of the Specification.
Preboring Reinforcement
12 If preboring is specified the pile casing shall be 17 (11/03) Steel reinforcement shall be as described in
pitched after preboring to the depth and diameter Appendix 16/5 and in accordance with Series 1700.
stipulated in Appendix 16/5. The number of joints in longitudinal steel bars shall be
Other means to ease pile driveability may be used kept to a minimum. The full strength of each bar shall
provided the completed piles meet their specified be effective across each joint, which shall be made so
requirements. that there is no detrimental displacement of the
reinforcement during the construction of the pile.
Internal drop hammer Reinforcement shall be maintained in its correct
position during concreting of the pile to allow a vertical
13 (11/03) Where a casing for a pile without an tolerance of +150/-50 mm on the level of the
enlarged base is to be driven by an internal drop reinforcement projecting above the final cut-off level to
hammer, a plug consisting of concrete strength class be met. Where reinforcement is made up into cages,
C16/20 with a water/cement ratio not exceeding 0.25 they shall be sufficiently rigid to enable them to be
shall be placed in the pile. This plug shall have a placed, handled and concreted without damage. If the
compacted height of not less than 2½ times the cage is to be welded together, welding shall be carried
diameter of the pile. Fresh concrete shall be added to out to the requirements of BS 7123.
ensure that this height of driving plug is maintained in
Spacers shall be designed and manufactured using
the casing throughout the period of driving, and in any
durable materials which shall not lead to corrosion of
event a plug of fresh concrete shall be added after 1½
the reinforcement or spalling of the concrete cover.
hours of normal driving or after 45 minutes of hard
driving, or, should the pile-driving be interrupted for 30
minutes or longer, fresh concrete shall be added prior to
driving being resumed.
submitted.
Repair of damaged pile heads and extending of piles
Concrete
to the cut-off level
14 (11/03) When repairing or extending the head of a General
pile, the head shall be cut off square at sound concrete,
and all loose particles shall be removed by wire- 18 (11/03) Cement materials, aggregates, admixtures
brushing, followed by washing with water. and water shall be in accordance with Series 1700.
If the level of sound concrete of the pile is below the The consistence and method of placing of the concrete
cut-off level, the pile shall be extended to the cut-off shall be such that a continuous monolithic concrete
level with concrete of a strength class not inferior to shaft of the full cross-section is formed. Concrete shall
that of the concrete of the pile so that it will safely be transported from the mixer to the position of the pile
withstand the specified working load. in such a manner that segregation of the constituents of
concrete mix does not occur.
Lengthening of permanent pile casings during The concrete shall be placed without such interruption
construction as would allow the previously placed batch to have
hardened.
15 The lengthening of permanent steel pile casings by
adding an additional length of steel casing during The Contractor shall take all precautions in the design
construction shall be carried out in accordance with of the concrete mix and placing of the concrete to avoid
Clause 1606. arching of the concrete in the casing. No spoil, liquid or

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other foreign matter shall be permitted to contaminate Concrete casting tolerances

the concrete.
25 For piles constructed without the use of a rigid
(11/03) Consistence of concrete permanent lining, pile concrete shall be cast to the
commencing surface level.
19 (11/03) Consistence measured at the time of
Where piles are constructed inside rigid permanent
discharge into the pile casing shall be in accordance
lining tubes or permanent casings, pile heads shall be
with the requirement shown in Table 16/2, except that
cast to a level above the specified cut-off so that, after
these standards shall not apply to piling systems which
trimming, a sound concrete connection with the pile can
use semi-dry concrete and employ special means for its
be made. In this case the tolerance of casting above the
compaction. The concrete shall be of the consistence
cut-off level shall be determined according to
specified when in its final position and until all
Table 16/4.
construction procedures in forming the pile have been
completed.
Temporary backfilling above pile casting level
Compaction 26 After each pile has been cast, any hole remaining
shall be protected and shall be carefully backfilled as
soon as possible with appropriate materials.
concrete cast-in-place.
Cutting off pile heads
Placing concrete
27 When cutting off and trimming piles to the
21 (11/03) Measures shall be taken as necessary in all
specified cut-off level, the Contractor shall take care to
piles to ensure that the structural strength of the placed
avoid shattering or otherwise damaging the rest of the
concrete is not impaired through grout loss, segregation,
pile. Any cracked or defective concrete shall be cut
or bleeding.
away and the pile repaired to provide a full and sound
Extraction of casing section to the cut-off level.
(11/03) Consistence of concrete 1606 Steel Bearing Piles

22 (11/03) Temporary casings shall be extracted while
the concrete within them remains sufficiently workable Materials
to ensure that the concrete is not lifted. Should a semi-
1 (11/05) Steel for bearing piles shall be in accordance
dry concrete mix have been used, the Contractor shall
with Series 1800.
ensure the concrete shall not lift during extraction of the
casing. Cast steel shoes shall be of steel to BS EN 10293,
Grade A1.
Concrete level
Strengthening of piles
23 When the casing is being extracted, a sufficient
quantity of concrete shall be maintained within it to 2 (11/03) The strengthening to the toe of a pile in lieu
ensure that pressure from external water or soil is of a shoe or the strengthening of the head of a pile shall
exceeded and that the pile is neither reduced in section be made using material of the same strength class as the
nor contaminated. pile.
Concrete shall be topped up as necessary while the Manufacturing tolerances
casing is extracted until the required head of concrete to
complete the pile in a sound and proper manner has 3 All piles shall be of the type and cross-sectional
been provided. No concrete is to be placed once the dimensions as designed. For standard rolled sections the
bottom of the casing has been lifted above the top of the dimensional tolerances and weight shall comply with
concrete. the relevant standard. Length tolerance of H-section
steel bearing piles shall be ± 50 mm in accordance with
Vibrating extractors BS EN 10034. The tolerance on length of other steel
bearing piles shall be -0 and +75 mm unless otherwise
24 The use of vibrating casing extractors will be
specified. For proprietary sections the dimensional
permitted subject to Clause 109 and Clause 1601 sub-
tolerances shall comply with the manufacturer’s
Clause 28.
standards. The rolling or manufacturing tolerances for
proprietary sections shall be such that the actual weight

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of section does not differ from the theoretical weight by Welding

more than +4% or -2.5%. The rolling or manufacturing
tolerances for steel tubular piles shall be such that the 7 (11/03) All welding shall be to BS EN 1011-1 and
actual weight of section does not differ from the BS EN 1011-2 and when appropriate shall be in
theoretical weight by more than ± 5%. The rolling or accordance with Clause 1801.
proprietary tolerances for H-section steel bearing piles For a tubular pile where the load will be compressive
shall be such that the actual weight of the section does and non-reversible and will be carried by the wall of the
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not differ from the theoretical weight by more than ± pile or by a concrete core, the welding shall be to
2.5%. BS EN 1011-1 and BS EN 1011-2 or BS 6265.
Straightness of sections Welders’ qualifications

4 For standard rolled sections the deviation from 8 (11/05) Only welders who are qualified to
straightness shall be within the compliance provisions BS EN 287-1 or who have attained a similar standard,
of BS EN 10034. When two or more rolled sections are shall be employed on the Works. Proof of welders’
joined by butt-jointing, the deviation from straightness proficiency shall be made available on request.
shall not exceed 1/600 of the overall length of the pile.
For proprietary sections made up from rolled sections Welding procedures
and for tubular piles, the deviation from straightness on 9 (11/05) All welding procedures shall have been
any longitudinal face shall not exceed 1/600 of the qualified to BS EN ISO 15607, BS EN ISO 15609-1,
length of the pile nor 5 mm in any 3 m length. BS EN ISO 15613 and BS EN ISO 15614-1 and the
Contractor shall make available full details of the
Fabrication of piles welding procedures and electrodes, with drawings and
5 For tubular piles where the load will be carried by schedules as may be necessary. Tests shall be
the wall of the pile, and if the pile will be subject to undertaken as may be required by the relevant British
loads that induce reversal of stress during or after Standard or as may be required in Appendix 16/6.
construction, the external diameter at any section as
measured by using a steel tape on the circumference Manufacturing processes
shall not differ from the theoretical diameter by more
than ± 1%. Welded tube piles
The ends of all tubular piles as manufactured shall be 10 Where required in Appendix 16/6, the Contractor
within a tolerance on ovality of ± 1% as measured by a shall submit details of the manufacturing and welding
ring gauge for a distance of 100 mm at each end of the procedures before commencement of manufacture.
pile length.
Welded box piles and proprietary sections
The root edges or root faces of lengths of piles that are
to be shop butt-welded shall not differ by more than 11 Welded box piles or proprietary sections made up
25% of the thickness of pile walls not exceeding 12 mm from two or more hot-rolled sections shall be welded in
thick or by more than 3 mm for piles where the wall is accordance with the manufacturer’s standards.
thicker than 12 mm. When piles of unequal wall
thickness are to be butt-welded, the thickness of the Non-destructive testing of welds
thinner material shall be the criterion.
12 During production of welded tube piles, one
Pile lengths shall be set up so that the differences in radiograph or ultrasonic test of a length of
dimensions are matched as evenly as possible. approximately 300 mm shall be made at each end of a
length as manufactured at the mill to provide a spot
Matching of pile lengths check on weld quality. In addition, on a spirally welded
6 Longitudinal seam welds and spiral seam welds of tube pile, a further check shall be made on welded
lengths of tubular piles forming a complete pile shall joints between strip lengths.
whenever possible be evenly staggered at the butt, but All the circumferential welds shall be fully
if, in order to obtain a satisfactory match of the ends of radiographed or ultrasonically tested by the method
piles or the specified straightness, the longitudinal specified in Appendix 16/6.
seams or spiral seams are brought closely to one
Results shall be made available within 10 days of
alignment at the joint then they shall be staggered by at
completion of the tests.
least 100 mm.

If the results of any weld test do not conform to the Standards for site butt welds
specified requirements, two additional specimens from
the same length of pile shall be tested. In the case of 16 Welds shall comply with the requirements of the
failure of one or both of these additional tests, the weld quality standards for site butt welds, given in
length of pile covered by the tests shall be rejected. Series 1800.
Standards for welds Protection during welding
13 Longitudinal welds in tubular piles. For piles of 17 All work associated with welding shall be
longitudinal or spiral weld manufacture where the load protected from the weather so that the quality of work
will be carried by the wall of the pile, and if the pile meets the requirements of the Specification.
will be subject to loads which induce reversal of stress
during or after construction other than driving stresses, Coating piles for protection against corrosion
the standard for interpretation of non-destructive testing
shall be the American Petroleum Institute Specification Durability of coatings
5L. The maximum permissible height of weld 18 Where coatings are specified they shall be provided
reinforcement shall not exceed 3.2 mm for wall in accordance with Appendix 16/6.
thicknesses not exceeding 12.7 mm and 4.8 mm for wall
thicknesses greater than 12.7 mm. Definition
Longitudinal welds in proprietary box piles and
19 The term ‘coating’ shall include the primer and the
proprietary sections. Longitudinal welds joining the
coats specified.
constituent parts of the box or proprietary section shall
be in accordance with the manufacturer’s specification.
Specialist labour
Circumferential welds. For circumferential welds in
tubular piles the same maximum height of weld 20 The preparation of surfaces and the application of
reinforcement as specified above for longitudinal welds the coats to form the coating shall be carried out by
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in tubular piles shall apply, the standard for specialist labour having experience in the preparation of
interpretation of non-destructive testing shall be the the surface and the application of the coating specified.
American Petroleum Institute Specification 5L.
Protection during coating
Site-welded butt splices 21 All work associated with surface preparation and
coating shall be undertaken inside a waterproof
Support and alignment structure.
14 When lengths of pile are to be butt-spliced on site,
Surface preparation
adequate facilities shall be provided for supporting and
aligning them prior to welding such that the specified 22 All surfaces to be coated shall be clean and dry and
straightness criterion can be achieved. prepared as follows:
Weld tests Degreasing with detergent wash compatible with the

coating shall be carried out where necessary.
15 Weld tests shall be performed by radiographic or
All surfaces shall be blast cleaned to Sa 2.5 of BS 7079
ultrasonic methods as specified. Provided that
Part A1. Blast-cleaning shall be done after fabrication.
satisfactory results are being obtained, one test of a
Unless an instantaneous-recovery blasting machine is
length of 300 mm shall be made for 10% or more of the
used, the cleaned steel surface shall be air-blasted with
number of welded splices in the case where the load
clean dry air and vacuum-cleaned or otherwise freed
will be carried by the wall or section of the pile. Where
from abrasive residues and dust immediately after
the load will be carried by the concrete core of a pile
cleaning.
the number of tests will be as specified in
Appendix 16/6, but will not normally exceed 10% of Application and type of primer
the number of butt splices.
Results shall be made available within 10 days of 23 Within 4 hours after surface preparation, before
completion of the tests. visible deterioration takes place, the surface shall be
coated with an appropriate primer or the specified
Any defective weld shall be cut out, replaced and coating. No coating shall be applied to a metal surface
reinspected. which is not thoroughly dry.

The primer shall be compatible with the specified When specified, the completed coating shall be checked
coating and shall be such that if subsequent welding or for adhesion by means of an adhesion test to
cutting is to be carried out it shall not emit noxious ‘BS EN ISO 2409, BS 3900-E6’, carried out on 10% of
fumes or be detrimental to the welding. the piles. The adhesion of any completed coating shall
not be worse than Classification 2. If adhesion tests on
Control of humidity during coating the initial batch are satisfactory, then on further batches
1% of the piles shall be tested. Adhesion tests shall not
24 No coating shall be applied when the surface metal be carried out until seven days after coating. On
temperature is less than 3°C above the dewpoint completion of testing the test area shall be made good
temperature or when the humidity could have an to the standard specified in Appendix 16/6. Areas where
adverse effect on the coat. the adhesion is defective shall be repaired and
When heating or ventilation is used to secure suitable reinspected.
conditions to allow coating to proceed, care shall be
taken to ensure the heating or ventilation of a local Marking, handling and storage of piles
surface does not have an adverse effect on adjacent
surfaces or work already done. Marking of piles
Parts to be welded 28 Each pile shall be clearly numbered and its length
shown near the pile head using white paint. In addition,
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25 The coating within 200 mm of a weld shall be before being driven, each pile shall be graduated along
applied after welding. The method of application shall its length at intervals of 250 mm.
comply with the manufacturer’s recommendations.
Handling and storage of piles
Thickness, number and colour of coats
29 All piles within a stack shall be in groups of the
26 The nominal thickness of the finished coating and same length and on appropriate supports. All operations
if necessary of each coat shall be as specified. The such as handling, transporting and pitching of piles
average coat or finished coating thickness shall be equal shall be carried out in a manner such that no damage
to or greater than the specified nominal thickness. In no occurs to piles and their coatings.
case shall any coat or finished coating be less than 75%
of the nominal thickness. Each coat shall be applied Driving of piles
after an interval that ensures the proper hardening or
curing of the previous coat. Leaders and trestles
Where more than one coat is applied to a surface, each 30 At all stages during driving and until incorporation
coat shall, if possible, be of a different colour from the in the structure the free length of the pile shall be
previous coat. The colour sequence and final coating adequately supported and restrained by means of
colour shall be established prior to application of leaders, trestles, temporary supports or other guide
coatings. arrangements to maintain position and alignment and to
prevent buckling. In marine works, lengths which
Inspection of coatings remain unsupported after driving shall be adequately
restrained until incorporated into the Permanent Works.
27 (11/05) The finished coating shall be generally
These constraint arrangements shall be such that no
smooth, of dense and uniform texture and free from
damage occurs to piles or their coatings.
sharp protuberances or pin-holes. Excessive sags,
dimpling or curtaining shall be retreated. Performance of driving equipment
Any coat damaged by subsequent processes or which
31 Performance of driving equipment shall be in
has deteriorated to an extent such that proper adhesion
accordance with sub-Clause 1602.28 of this
of the coating is in doubt shall be removed, and the
Specification.
surface shall be cleaned to the original standard and
recoated to provide the specified number of coats. Length of piles
The completed coating shall be checked for thickness 32 The length of pile to be driven and any additional
by a magnetic thickness gauge. Areas where the lengths of pile to be added during driving shall be as
thickness is less than that specified shall receive specified in Appendix 16/6. During the execution of the
additional treatment. Works any amendments to the scheduled lengths shall
be recorded by the Contractor and a full statement of
the reasons included in the pile record.

Driving procedure and redrive checks Pre-applied bituminous or other friction-reducing

coating materials
33 Driving procedure and redrive checks shall be in
General
Set 2 Where a proprietary product is used, the process of
cleaning pile surfaces, and the conditions and methods
34 Requirements for set shall be in accordance with
of application shall conform with the manufacturer’s
sub-Clause 1602.31.
current instructions. All materials shall conform with
Driving sequence and risen piles the manufacturer’s specification, which shall be made
available before any coating is applied.
35 Requirements for driving sequence and risen piles
shall be in accordance with sub-Clause 1602.32. Protection from damage
Laterally displaced piles shall not be corrected by 3 Where a friction-reducing material has been
forceable correction at the heads, unless the Contractor applied to a preformed pile prior to installation, it shall
can demonstrate that the integrity, durability and be protected from damage during handling and
performance of the piles has not been adversely transportation. In the event of damage to the coating, it
affected. shall be made good on site to the same specification as
the original coating prior to the pile being driven.
Preboring
Where bituminous materials are involved, precautions
36 If preboring is specified the pile shall be pitched shall be taken as necessary in hot weather to prevent
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after preboring to the depth and diameter stipulated in excessive flow or displacement of the coating. The
Appendix 16/6. coated piles shall be adequately protected against direct
sunlight and, if stacked, they shall be separated to
Other means to ease pile drivability may be used
prevent their coatings sticking together.
provided the completed piles meet the requirements of
the Specification. Pile driving
Preparation of pile heads 4 In the case of applied coatings, the piles shall not
be driven when the air temperature is such that the
37 If a steel structure is to be welded to piles, the piles
coating will crack, flake or otherwise be damaged prior
shall be cut square and to within ± 5 mm of the levels
to entry into the ground. Where bituminous materials
specified. If pile heads are to be encased in concrete
are involved, driving shall be carried out while the
they shall be cut to within ± 20 mm of the levels
temperature is at or above 5°C or as called for in the
specified, and protective coatings shall be removed
from the surfaces of the pile heads down to a level 100
mm above the soffit of the concrete. Pre-applied low-friction sleeving
5 Where required in Appendix 16/7, detailed design
1607 Reduction of Friction on Piles of the pre-applied low-friction sleeving shall be
submitted prior to driving the piles. All materials shall
General conform with the manufacturer’s specification, which
shall be made available before the material is used.
1 Where the particular method of reducing friction is
not specified, the Contractor shall provide full details of Formed-in-place low-friction surround
the method which he plans to employ. The Contractor
shall ensure that any product used will be compatible 6 Where required in Appendix 16/7, detailed design
with the ground conditions into which it will be of the formed-in-place low-friction surround shall be
installed. Particular requirements are detailed in submitted prior to driving or forming the piles. All
Appendix 16/7. materials shall conform with the manufacturer’s
specification, which shall be made available before the
material is used.
Pre-installed low-friction sleeving

7 Where required in Appendix 16/7, detailed design
of the pre-installed low-friction sleeving shall be
March 1998 24
submitted prior to driving or forming the piles. All Where required in Appendix 16/8, the Contractor shall
materials shall conform with the manufacturer’s submit the name of the specialist integrity testing firm,
specification, which shall be made available before the a description of the test equipment, a test method
material is used. statement and a programme for executing the specified
tests prior to commencement of the Works.
Inspection
Interpretation of tests
8 Where required in Appendix 16/7, piles shall be
partially exposed or extracted. Where significant 5 The interpretation of tests shall be carried out by
damage to the coating is found to have occurred the competent and experienced persons.
Contractor shall prepare a method statement for the
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The Contractor shall give all available details of the
repair or replacement of the coating prior to carrying
ground conditions, pile dimensions and construction
out the work.
method to the specialist firm before the commencement
of integrity testing in order to facilitate interpretation of
1608 Non-Destructive Methods for Testing the tests.
Piles Report
Integrity testing of piles 6 Preliminary results of the tests shall be made
available within 24 hours of carrying out the tests.
Method of testing The test results and findings shall be recorded and made
1 Where integrity testing is called for, the method to available within 10 days of the completion of each
be adopted shall be one of the following, as specified: phase of testing.
(a) impulse method; The report shall contain a summary of the method of
interpretation including all assumptions, calibrations,
(b) Sonic Echo, Frequency Response or Transient corrections, algorithms and derivations used in the
Dynamic steady state vibration method; analyses. If the results are presented in a graphical
(c) sonic logging method. form, the same scales shall be used consistently
throughout the report. The units on all scales shall be
Other methods may be considered subject to clearly marked.
satisfactory evidence of performance. Particular
requirements are detailed in Appendix 16/8. Anomalous results
Age of piles at time of testing 7 In the event that any anomaly in the acoustic signal
is found in the results indicating a possible defect in the
2 In the case of cast-in-place concrete piles, integrity pile the Contractor shall demonstrate that the pile is
tests shall not be carried out until the number of days satisfactory for its intended use or shall carry out
specified in Appendix 16/8 have elapsed since pile remedial works to make it so. Sonic logging tubes shall
casting. be grouted up after the Contractor has demonstrated
that the pile is satisfactory.
Preparation of pile heads
3 Where the method of testing requires the Dynamic pile-testing
positioning of sensing equipment on the pile head, the
head shall be broken down to expose sound concrete General
and shall be clean, free from water, laitence, loose 8 Particular requirements are detailed in Appendix
concrete, overspilled concrete and blinding concrete 16/8.
and shall be readily accessible for the purpose of
testing. Measuring instruments
Specialist Sub-contractor 9 Current calibration certificates shall be made
available for all instruments and monitoring equipment
4 The testing shall be carried out by a specialist firm, before testing commences.
subject to demonstration of satisfactory performance on
other similar contracts before the commencement of
testing.
March 1998 25
Hammer (c) pile identification number and location

10 The hammer and all other equipment used shall be (d) length of pile below commencing surface
capable of delivering an impact force sufficient to (e) total pile length, including projection above
mobilize the equivalent specified dynamic test load commencing surface at time of test
without damaging the pile.
(f) length of pile from instrumentation position to
Preparation of the pile head toe
(g) hammer type, drop and other relevant details
11 The preparation of the pile head for the application
of the dynamic test load shall involve trimming the (h) blow selected for analysis
head, cleaning and building up the pile using materials
(i) test load achieved (ie. total mobilised deduced
which will at the time of testing safely withstand the
static load)
impact stresses. The impact surface shall be flat and at
right angles to the pile axis. Where pile preparation (j) pile head movement at equivalent Design
requires drilling holes or welding, this preparation shall Verification Load
not adversely affect the performance of the pile when in (k) pile head movement at equivalent Design
service. Verification Load plus 50% of Specified
Working Load
Interpretation of tests
(l) pile head movement at maximum applied test
12 The interpretation of the tests shall be carried out load
by competent and experienced persons.
(m) permanent residual movement of pile head
The Contractor shall give all available details of the after each blow
ground conditions, pile dimensions and construction
method to the specialist firm carrying out the testing in (n) temporary compression.
order to facilitate interpretation of tests. For all piles tested the following information shall be
provided for typical blows:
Time of testing
(a) date of pile installation
13 The time between the completion of installation
(b) date of test
and testing for a preformed pile shall be more than 12
hours, and in the case of a cast-in-place pile shall be (c) pile identification number and location
such that the pile is not damaged under the impact (d) length of pile below commencing surface
stresses.
(e) total pile length, including projection above
Measurement of set commencing surface at time of test
14 If specified, the permanent penetration per blow (f) length of pile from instrumentation position to
and temporary compression of the pile and soil system toe
shall be measured independently of the instruments (g) hammer type, drop and other relevant details
being used to record the dynamic test data from a fixed
reference point unaffected by the piling operations. (h) permanent set per blow
(i) maximum force at pile head
Results
(j) maximum velocity at pile head
15 Initial results shall be made available within 24 (k) maximum downward energy imparted to the
hours of the completion of a test. These shall include: pile
(a) the maximum force applied to the pile head (l) dynamic soil resistance mobilised during the
(b) the maximum pile head velocity blow
(c) the maximum energy imparted to the pile. (m) static soil resistance mobilised during the
blow assuming that soil damping is
Subsequently a full report shall be made available,
proportional to pile velocity
within 10 days of the completion of testing, including:
(n) magnitude and location of possible pile
(a) date of pile installation
damage.
(b) date of test
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March 1998 26
Where required in Appendix 16/8, an analysis of concrete used for building up a working pile. If a
measurements from selected blows shall be carried out concrete pile is extended or capped for the purpose of
using a numerical model of the pile and soil to provide testing, a further four cubes shall be made from the
the following information. corresponding batch of concrete. The cubes shall be
made and tested in accordance with BS EN ISO 12390-2.
(a) Magnitude and distribution of mobilised static
soil resistance The pile test shall not be started until the strength of the
cubes taken from the pile exceeds twice the average
(b) Magnitude and distribution of soil stiffness
direct stress in any pile section under the maximum
and damping
required test load, and the strength of the cubes taken
(c) Deduced static load deflection behaviour of from the cap exceeds twice the average stress at any
the pile at the head and toe point in the cap under the same load.
(d) Assumptions made in the analysis
Preparation of working pile to be tested
(e) Limitations of the method.
6 If a test is required on a working pile the
Contractor shall cut down or otherwise prepare the pile
1609 Static Load Testing of Piles for testing in accordance with Appendix 16/9 and sub-
Clauses 13 and 14.
General
Cut-off level
1 The design and construction of the load application
system shall be satisfactory for the required test. These 7 The cut-off level for a preliminary test pile shall be
details shall be made available prior to the as specified in Appendix 16/9.
commencement of testing. Particular requirements are Where the cut-off level of working piles is below the
detailed in Appendix 16/9. ground level at the time of pile installation and where it
is required to carry out a proof test from that
Construction of a pile to be tested installation level, either allowance shall be made in the
determination of the design verification load for friction
Notice of construction which may be developed between the cut-off level and
the existing ground level, or the pile may be sleeved
2 The Contractor shall give at least 48 hours notice appropriately or otherwise protected to eliminate
of the commencement of construction of any friction which develops over the extended length.
preliminary pile which is to be test-loaded.
Supervision
Method of construction
8 The setting-up of pile testing equipment shall be
3 Each preliminary test pile shall be constructed in a carried out under competent supervision and the
manner similar to that to be used for the construction of equipment shall be checked to ensure that the setting-up
the working piles, and by the use of similar equipment is satisfactory before the commencement of load
and materials. Extra reinforcement and concrete of application.
increased strength will be permitted in the shafts of
preliminary piles where necessary for carrying out the All tests shall be carried out only under the direction of
testing. an experienced and competent supervisor conversant
with the test equipment and test procedure. All
Boring or driving record personnel operating the test equipment shall have been
trained in its use.
4 For each preliminary pile which is to be tested a
detailed record of the conditions experienced during Safety precautions
boring, or of the progress during driving, shall be made
available daily, not later than noon on the next working General
day. Where soil samples are required to be taken or in
situ tests to be made, the Contractor shall present the 9 Design, erection and dismantling of the pile test
results without delay. reaction system and the application of load shall be
carried out according to the requirements of the various
Concrete test cubes applicable statutory regulations concerned with lifting
and handling heavy equipment and shall safeguard
5 (11/03) Four test cubes shall be made from the operatives and others who may from time to time be in
concrete used in the preliminary test pile and from the the vicinity of a test from all avoidable hazards.
27
Kentledge The maximum test load expressed as a reading on the

gauge in use shall be displayed and all operators shall
10 Where kentledge is used the Contractor shall be made aware of this limit.
construct the foundations for the kentledge and any
cribwork, beams or other supporting structure in such a Pile head for compression test
manner that there will not be differential settlement,
bending or deflection of an amount that constitutes a 13 For a pile that is tested in compression, the pile
hazard to safety or impairs the efficiency of the head or cap shall be formed to give a plane surface
operation. The kentledge shall be adequately bonded, which is normal to the axis of the pile, sufficiently large
tied or otherwise held together to prevent it becoming to accommodate the loading and settlement measuring
unstable because of deflection of the supports or for any equipment and adequately reinforced or protected to
other reason. prevent damage from the concentrated application of
load from the loading equipment.
The weight of kentledge for each test shall be greater
than the maximum test load for that test, and if the Any pile cap shall be concentric with the test pile; the
weight is estimated from the density and volume of the joint between the cap and the pile shall have a strength
constituent materials an adequate factor of safety equivalent to that of the pile.
against error shall be allowed. Additional kentledge Sufficient clear space shall be made under and around
required shall be determined taking into account the any part of the cap projecting beyond the section of the
accuracy of positioning of the centre of gravity of the pile so that, at the maximum expected settlement, load
stack. is not transmitted to the ground by the cap.
Tension piles, reaction piles and ground anchorages Pile connection for tension test
11 Where tension piles, reaction piles or ground 14 For a pile that is tested in tension, means shall be
anchorages are used to provide the necessary load provided for transmitting the test load axially without
reaction, they shall be so designed that they will resist inducing moments in the pile. The connection between
the forces applied to them safely and without excessive the pile and the loading equipment shall be constructed
deformation which could cause a safety hazard during in such a manner as to provide a strength equal to the
the work. Such piles or anchorages shall be placed in maximum load which is to be applied to the pile during
the specified positions, and bars, tendons or links shall the test, with an appropriate factor of safety on the
be aligned to give a stable reaction in the direction structural design.
required. Any welding employed to extend or to fix
anchorages to a reaction frame shall be carried out so Reaction systems
that the full strength of the system is adequate and
unimpaired. Compression tests
Testing equipment 15 Compression tests shall be carried out using
kentledge, tension piles or specially constructed
12 (11/03) In all cases the Contractor shall ensure that
anchorages. Kentledge shall not be used for tests on
when the hydraulic jack and load-measuring device are
raking piles.
mounted on the pile head the whole system will be
stable up to the maximum load to be applied. Where kentledge is to be used, it shall be supported on
cribwork and positioned so that the centre of gravity of
If in the course of carrying out a test any unforeseen
the load is as close as possible to the axis of the pile.
occurrence should take place, further loading shall not
The bearing pressure under supporting cribs shall be
be applied until a proper engineering assessment of the
such as to ensure stability of the kentledge stack.
condition has been made and steps have been taken to
rectify any fault. Reading of gauges shall, however, be Tension tests
continued where possible and if it is safe to do so.
Where an inadequacy in any part of the system might 16 Tension tests may be carried out using compression
constitute a hazard, means shall be provided to enable piles, rafts or grillages constructed on the ground to
the test to be controlled from a position clear of the provide the necessary reaction. In all cases the resultant
kentledge stack or test frame. force of the reaction system shall be coaxial with the
test pile.
The hydraulic jack, pump, hoses, pipes, couplings and
other apparatus to be operated under hydraulic pressure Where inclined piles or reactions are specified or their
shall be capable of withstanding a pressure of 1½ times use is planned by the Contractor, full details shall be
the maximum pressure used in the test without leaking. made available prior to the commencement of testing.

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Working piles Care of piles

17 If the Contractor plans to use working piles as 20 The method employed in the installation of the
reaction piles, he shall notify his intention prior to reaction system shall be such as to prevent damage to
commencement of work. Working reaction piles shall any test pile or working pile.
not uplift by more than half their specified permissable
settlement at working load. The integrity of all working Equipment for applying load
piles used as reaction piles shall be checked on
completion of static load testing. 21 The equipment used for applying load shall consist
of a hydraulic ram or jack. The jacking system shall be
Where working piles are used as reaction piles their arranged in conjunction with the reaction system to
movement shall be measured and recorded to within an deliver an axial load to the test pile and maintain it
accuracy of ± 0.5 mm. constant when required. The complete system shall be
capable of safely transferring the maximum load
Spacing required for the test. The length of stroke of a ram shall
be sufficient to cater for deflection of the reaction
18 Where kentledge is used for loading vertical piles
system under load plus a deflection of the pile head up
in compression, the distance from the edge of the test
to 15% of the pile shaft diameter unless otherwise
pile to the nearest part of the crib supporting the
specified in Appendix 16/9.
kentledge stack in contact with the ground shall be not
less than 1.3 m.
Measurement of load
The centre-to-centre spacing of vertical reaction piles,
including working piles used as reaction piles, from a 22 The test load shall be measured by a single load
test pile shall be not less than three times the diameter cell or proving ring calibrated in divisions not
of the test pile or the reaction piles or 2 m whichever is exceeding 1% of the maximum load to be applied. If an
the greatest. Where a pile to be tested has an enlarged electronic transducer is used each reading shall be
base, the same criterion shall apply with regard to the immediately stored magnetically so that in case of
pile shaft, with the additional requirement that no power failure the readings are not lost.
surface of a reaction pile shall be closer to the base of The load cell or proving ring shall be calibrated
the test pile than one half of the enlarged base diameter. immediately prior to the test and a certificate of
Where vertical reaction piles penetrate deeper than the calibration shall be made available.
test pile, the centre-to-centre spacing of the reaction
piles from the test pile shall be not less than five times All increments of load shall be maintained to within 1%
the diameter of the test pile or the reaction piles of the specified load.
whichever is the greatest unless the base capacity of the A spherical seating of appropriate size shall be used to
test pile is less than 20% of the total ultimate capacity. avoid eccentric loading. Care shall be taken to avoid
Where ground anchorages are used to provide a test any risk of buckling of the load application and
reaction for loading in compression, no section of fixed measuring system. Load measuring and application
anchor length transferring load to the ground shall be devices shall be short in axial length in order to secure
closer to the test pile than three times the diameter of stability. The Contractor shall ensure that axial loading
the test pile. Where the pile to be tested has an enlarged is maintained.
base the same criterion shall apply with regard to the
Control of loading
pile shaft, with the additional requirement that no
section of the fixed anchor transferring load to the 23 The loading equipment shall enable the load to be
ground shall be closer to the pile base than a distance increased or decreased smoothly or to be held constant
equal to the base diameter. at any required value.
Adequate reaction Measuring pile head movement
19 The reaction frame support system shall be
adequate to transmit the maximum test load in a safe Maintained load test
manner without excessive movement or influence on 24 In a maintained load test, movement of the pile
the test pile. Calculations shall be provided when head shall be measured by the method in sub-Clause 26
required to justify the design of the reaction system. and by one of the methods in sub-Clauses 27, 28 and 29
in the case of vertical piles, or by one of the methods in
sub-Clauses 27, 28 and 29 in the case of the raking
piles, as required.
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29
CRP and CRU test Reference wires and scales

25 In a constant rate of penetration (CRP) or a 28 Two parallel reference wires, one on either side of
constant rate of uplift (CRU) test the method in sub- the pile, shall be held under constant tension at right
Clause 26 shall be used. Check-levelling of the angles to the test pile axis between supports formed as
reference frame or the pile head shall not be required. in the method in sub-Clause 27. The wires shall be
The dial gauge shall be graduated in divisions of 0.02 positioned against scales fixed to the test pile head in an
mm or less. axial direction and the movements of the scales relative
to the wires shall be determined.
Optical levelling method
Check observations of any movements of the supports
26 An optical levelling method by reference to a of the wires shall be made and a check shall be made on
remote datum may be used. the movement of the pile head at appropriate time
intervals. Readings shall be taken to within an accuracy
Where a level and staff are used, the level and scale of of 0.5 mm.
the staff shall be chosen to enable readings to be made
to within an accuracy of 0.5 mm. A scale attached to the Other methods
pile or pile cap may be used instead of a levelling staff.
At least two reliable independent datum points shall be 29 Where appropriate the Contractor may use an
established. Each datum point shall be so situated as to alternative method of measuring the movement of the
permit a single setting-up position of the level for all test pile head. The method shall be accurate to within
readings. 0.5 mm of the pile head movement.
No datum point shall be located where it can be
Protection of testing equipment
affected by the test loading or other operations on or off
the Site.
Protection from weather
Reference beams and dial gauges 30 Throughout the test period all equipment for
27 An independent reference beam or beams shall be measuring load and movement and beams shall be
set up to enable measurement of the movement of the protected from adverse effects of sun, wind and
pile to be made to the required accuracy. The supports precipitation. Temperature reading shall be taken at the
for a beam shall be founded in such a manner and at start, end and at the maximum load of each loading
such a distance from the test pile and reaction system cycle.
that movements of the ground do not cause movement
of the reference beam or beams which will affect the Prevention of disturbance
accuracy of the test. The supports of the beam or beams 31 Construction activity and persons who are not
shall be at least three test pile diameters or 2 m from the involved in the testing process shall be kept at a
centre of the test pile, whichever distance is the greater. sufficient distance from the test to avoid disturbance to
The beam must be free to move horizontally at one end. the measuring apparatus. Full records shall be kept of
Check observations of any movements of the reference any unavoidable activity and its effects.
beam or beams shall be made and a check shall be made
of the movement of the pile head relative to a remote Notice of test
reference datum at the start and end and at maximum 32 The Contractor shall give at least 24 hours notice
load for each loading cycle. of the commencement of the test. No load shall be
The measurement of pile movement shall be made by applied to the test pile before the commencement of the
four dial gauges rigidly mounted on the reference beam specified test procedure.
or beams, bearing on prepared flat surfaces fixed to the
pile cap or head and normal to the pile axis. Test procedure
Alternatively, the gauges may be fixed to the pile and
bear on prepared surfaces on the reference beam or Proof load test procedure (working compression
beams. The dial gauges shall be placed equidistant from piles)
the pile axis and from each other. The dial gauges shall
enable readings to be made to an accuracy of at least 33 The maximum load which shall be applied in a
0.1 mm and have a stem travel of at least 25 mm. proof test shall normally be the sum of the design
Machined spacer blocks may be used to extend the verification load (DVL) plus 50% of the specified
range of reading. Equivalent electrical displacement- working load (SWL). The loading and unloading shall
measuring devices may be substituted.
March 1998 --`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`--- 30
TABLE 16/6: Minimum Loading Times for Pile Test accordance with the requirements specified in
Appendix 16/9 and either the extended proof load test
Load* Minimum Time of Holding Load procedure or the constant rate of penetration testing
25% DVL 30 minutes procedure given below. A normal proof load test will
50% DVL 30 minutes constitute the first stage of such a preliminary test
75% DVL 30 minutes
100% DVL 6 hours
unless otherwise specified.
75% DVL 10 minutes
50% DVL 10 minutes Extended proof load test procedure
25% DVL 10 minutes
0 1 hour Where verification of the required minimum load factor
100% DVL 1 hour is called for, the loading procedure may be carried out
100% DVL + 25% SWL 1 hour as a continuation of the proof load testing procedure
100% DVL + 50% SWL 6 hours given in sub-Clause 33.
100% DVL + 25% SWL 10 minutes
100% DVL 10 minutes Following the completion of the proof load test, the
75% DVL 10 minutes load shall be restored in two stages (DVL, DVL + 50%
50% DVL 10 minutes SWL), and shall subsequently be increased by stages of
25% DVL 10 minutes 25% of the specified working load or other specified
0 1 hour
amount until the maximum specified load for the test is
*SWL denotes specified working load; DVL denotes design reached. Following each application of an increment of
verification load.be carried out in stages as shown in Table 16/6. load, the load shall be maintained at the specified value
for not less than 30 minutes and until the additional
Any particular requirements given in Appendix 16/9 measured settlement in a period of 30 minutes is less
shall be complied with. than 0.5% of the current cumulative settlement which
has occurred since the start of the current load
Following each application of an increment of load, the increment, subject to a minimum settlement rate of 0.05
load shall be maintained at the specified value for not mm in 30 minutes. The rate of settlement shall be
less than the period shown in Table 16/6 and until the calculated from the slope of the line obtained by
measured rate of settlement in a period of 30 minutes is plotting values of settlement versus time and drawing a
less than 0.5% of the current cumulative settlement smooth curve through the points. Reduction of load at
which has occurred, subject to a minimum settlement the end of the test shall be gradual as required by sub-
rate of 0.05 mm in 30 minutes. The rate of settlement Clause 36 and the final recovery of the pile head shall
shall be calculated from the slope of the line obtained be recorded.
by plotting values of settlement versus time and
drawing a smooth curve through the points. Permissible settlement at the load corresponding to the
required minimum factor of safety called for in the
Each stage of unloading shall proceed after the expiry design will not normally be specified. (The
of the period shown in Table 16/6. mobilization of ultimate load for compression piles
For any period when the load is constant, time and normally involves settlements of at least 10% of the
settlement shall be recorded immediately on reaching pile base diameter in clay and more in granular soils.
the load, at not more than five minute intervals up to 15 The settlement of piles bearing on rock requires special
minutes, at approximately 15 minutes intervals up to consideration, and failure of pile materials may precede
one hour, at 30 minute intervals between one hour and failure of the rock).
four hours, and 1 hour intervals between four hours and
12 hours after the application of the increment of load. Constant rate of penetration (CRP) testing
procedure
Where the methods of measuring pile head movement
given in sub-Clauses 26, 28 and 29 are used, the periods The rate of movement of the pile head shall be
of time for which loads must be held constant to maintained constant in so far as is practicable and shall
achieve the specified rates of settlement shall be be approximately 0.01 mm/s for piles in predominantly
extended as necessary to take into account the lower cohesive soils and 0.02 mm/s for piles in predominantly
levels of accuracy available from these methods and to cohesionless soils.
allow correct assessment of the settlement rate.
Readings of loads, penetration and time shall be made
simultaneously at regular intervals; the interval chosen
Test procedure for preliminary compression piles
shall be such that a curve of load versus penetration can
34 The procedure to be adopted for carrying out be plotted without ambiguity.
preliminary load tests on compression piles shall be in
March 1998 31
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Loading shall be continued until one of the following (a) (11/03) General
results is obtained: Site location
Contract identification
a) the maximum required test load as specified
Proposed structure
in accordance with Appendix 16/9 is reached
Main contractor
b) a constant or reducing load has been recorded Piling contractor
for an interval of penetration of 10 mm Client/Overseeing Organisation
c) a total movement of the pile base equal to Date and time of test
10% of the base diameter, or any other greater
value of movement specified in Appendix (b) (11/03) Pile details
16/9, has been reached. All types of pile
Identification (number and location)
The load shall then be reduced in five approximately Specified working load (SWL)
equal stages to zero load, penetration and load at each Design verification load (DVL)
stage and at zero load being recorded. Commencing surface level at pile position
Head level at which test load was applied
Testing of piles designed to carry load in tension Type of pile
35 The testing of piles designed to carry load in Vertical or raking, compression or tension
tension shall follow the same procedure as specified in Shape and size of cross-section of pile, and
sub-Clauses 33 and 34. position of any change in cross-section
Shoe or base details
The rate of movement of the pile head shall be Head details
maintained at approximately 0.005 mm/s in so far as is Length in ground
practicable. Level of toe
Dimensions of any permanent casing
Presentation of results
Concrete Piles
Concrete mix/strength class
Results to be submitted
Aggregate type and source
36 During the progress of a test, all records taken shall Cement type and cement replacement and type
be available for inspection. where used
Admixtures
Results shall be made available as follows: Slump class
a) a preliminary copy of the test records, unless Cube test results for pile and cap
otherwise directed, within 24 hours of the Date of casting of precast pile
completion of the test, which shall show Reinforcement
i) for a test by maintained load: for each Steel piles
stage of loading, the period for which the Steel quality
load was held, the load and the maximum Coating
pile movement at the end of the stage Filling or core materials - type and quality
ii) for a CRP or CRU test: the maximum (c) Installation details
load reached and a graph of load against All piles
penetration or load against uplift Dates and times of boring, driving and
b) the completed schedule of recorded data as concreting of test pile
prescribed in sub-Clause 37 within 10 days of Difficulties and delays encountered
the completion of the test. Date and time of casting concrete pile cap
Bored piles
Schedule of recorded data
Type of equipment used and method of boring
37 The Contractor shall provide information about the Temporary casing - diameter, type and length
test pile in accordance with the following schedule Full log of pile borehole
where applicable. Method of placing concrete
Volume of concrete placed

32
Driven preformed and driven cast-in-place the test pile location. Measuring and other demountable
piles equipment shall be stored in a safe manner so that it is
Method of support of hammer and pile available for further tests, if required, or removed from
Driven length of pile or temporary casing at site.
final set
Temporary tension piles and ground anchorages shall be
Hammer type, and size or weight
cut off below ground level, and off-cut materials
Dolly and packing, type and condition
removed from the Site. The ground shall be made good
Driving log (depth, hammer drop, blows per
to the original commencing surface level.
250 mm, interruptions or breaks in driving)
Final set in number of blows to produce Preliminary test pile head
penetration of 25 mm
Redrive check, time interval and set in number 39 Unless otherwise specified, the head of each
of blows to produce penetration of 25 mm preliminary test pile shall be cut off below ground level,
At final set and at redrive set, for a off-cut material shall be removed from the Site and the
drophammer or for a single acting hammer the ground made good to the original commencing surface
length of the drop or stroke, for a diesel level.
hammer the length of the stroke and the blows
per minute, for a double acting hammer the Proof test pile head
operating pressure and the number of blows per
minute. 40 On completion of a test on a proof pile, the test pile
Condition of pile head or temporary casing head shall be prepared as specified and left in a state
after driving ready for incorporation into the Permanent Works.
Use of a follower
Use of preboring
1610 Diaphragm Walls
Use of jetting
Lengthening
Method of placing concrete Guide walls
(d) Test procedure 1 The design and construction of the guide walls
shall be the responsibility of the Contractor and shall
Mass of kentledge take into account the actual site and ground conditions
Tension pile, ground anchorage or compression and the equipment to be used on site to ensure stability
pile details and avoid undercutting. Guide walls shall be
Plan of test arrangement showing position and constructed in reinforced concrete or other suitable
distances of kentledge supports, rafts, tension materials. The minimum depth of guide wall shall be
or compression pile or ground anchorages, and 1.0 m.
supports to pile movement reference system
Jack capacity Materials
Method of load measurement
Method(s) of penetration or uplift measurement Concrete : supply, mixing and testing
Calibration certificates
Temperature readings 2 Cement materials, aggregates, admixtures and
(e) Test results water shall be in accordance with Series 1700.
In tabular form Steel reinforcement : supply, fixing and welding

In graphical form: load plotted against pile
head movement, load plotted against time 3 (11/03) Steel reinforcement shall be as described in
Ambient temperature records during test Appendix 16/10 and in accordance with Series 1700.
Where steel sections are used for reinforcement, they
Completion of a test shall be in accordance with Series 1800.
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Removal of test equipment Support fluid
38 On completion of a test all measuring equipment 4 Bentonite and/or alternative fluid support
and load application devices shall be dismantled and materials, admixtures, mixing and testing and clean
checked. All other test equipment, including kentledge, water shall be in accordance with Clause 1618.
beams and supporting structures shall be removed from

Dimensions of panels shall be maintained in its correct position during

concreting of the panel. Where it is made up into cages,
5 The thickness of a panel shall be not less than the they shall be sufficiently rigid to enable them to be
specified thickness. The length of panel may be varied handled, placed and concreted without damage. If the
to suit an individual Contractor’s equipment but any cage is to be welded together, welding shall be carried
upper limits on length because of geological or other out to the requirements of BS 7123.
external factors shall be specified in Appendix 16/10.
Within these constraints the Contractor shall be Spacers shall be designed and manufactured using
responsible for selecting panel dimensions which durable materials which shall not lead to corrosion of
ensure stability and that movements remain within the the reinforcement or spalling of the concrete cover.
criteria set in Appendices 16/1 and 16/10. Where required in Appendix 16/10, details of the means
Excavation cover to and position of the reinforcement shall be
submitted.
Excavation near recently cast panel The minimum projecting bond lengths required by
Appendix 16/10 shall be observed.
6 Panels shall not be excavated so close to other
panels which have recently been cast and which contain The Contractor shall prepare reinforcement detail
workable or unset concrete that a flow of concrete or construction drawings for each panel and these shall be
instability could be induced from or damage caused to made available.
any panel. The Contractor’s sequence of construction
shall be submitted prior to work commencing in Placing concrete
General
Stability of the excavation 10 (11/03) The consistence and method of placing of
7 Support fluid for maintaining the stability of an the concrete shall be such that a continuous monolithic
excavation shall be in accordance with Clause 1618 of concrete panel of the full cross-section is formed, and
this Specification. A suitable guide wall shall be used in that the concrete in its final position is dense and
conjunction with the method to ensure stability of the homogenous. Concrete shall be transported from the
strata near ground level until concrete has been placed. mixer to the position of the wall in such a manner that
During construction the level of support fluid in the segregation of the concrete mix does not occur.
excavation shall be maintained within the guide wall or Before commencement of concreting of a panel, the
stable ground so that it is not less than 1.5 m above the Contractor shall satisfy himself that the supplier will
level of external standing groundwater at all times. have available sufficient quantity of concrete to
In the event of a loss of support fluid from an construct the panel in one continuous operation.
excavation, the Contractor shall include a full statement The concrete shall be placed without such interruption
of the reasons in the pile record. as would allow the previously placed batch to have
achieved a stiffness which prevents proper
Cleanliness of base amalgamation of the two concrete batches.
8 Prior to placing steel or concrete the Contractor No spoil, liquid or other foreign matter shall be allowed
shall clean the base of the excavation of as much loose, to contaminate the concrete.
disturbed and remoulded materials as practical and in
accordance with the method of construction and shall (11/03) Consistence of concrete
wholly or partly remove and replace support fluid while
maintaining the fluid head if it does not comply with 11 (11/03) The concrete consistence shall be
determined using the slump or flow classes in
the Contractor’s stated limits for support fluid prior to
accordance with BS EN 12390-2 and BS EN 12390-5
concreting.
respectively. The slump or flow classes for concrete
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Steel reinforcement placed through support fluid using a tremie pipe shall
be class S4 or greater or classes F4 to F5 respectively or
9 The number of joints in longitudinal steel bars shall as specified in Appendix 16/10.
be kept to a minimum. Joints in steel reinforcement
shall be such that the full strength of each bar is Compaction
effective across the joint and shall be made so that there
is no detrimental displacement of the reinforcement
concrete within a cast in place panel.
during the construction of the panel. Reinforcement
Placing concrete each 1.0 m that the cut-off level is below the top of the
guide wall shall be permitted unless otherwise stated in
13 The concrete shall be placed through a tremie pipe Appendix 16/10.
in one continuous operation. Where two or more pipes
are used in the same panel simultaneously, care shall be The exposed wall face and the ends of panels shall be
taken to ensure that the concrete level at each pipe vertical within a tolerance of 1:120 for walls
position is maintained nearly equal. constructed using grabs. A tolerance of 1:200 may be
specified if there is a special need and an expectation of
The hopper and pipe of the tremie shall be clean and reverse circulation cutters being used. An additional
watertight throughout. The pipe shall extend to the base tolerance of 100 mm will be allowed for concrete
of the panel and a sliding plug or barrier shall be placed protrusions resulting from cavities formed by overbreak
in the pipe to prevent direct contact between the first in the ground. Where very soft clay layers or peat
charge of concrete in the tremie and the support fluid. layers are anticipated or obstructions are to be removed
The pipe shall at all times penetrate the concrete which during trench excavation, an additional overbreak
has previously been placed with a minimum embedment tolerance shall be stated in Appendix 16/10.
of 3 m and shall not be withdrawn from the concrete
until completion of concreting. At all times a sufficient Recesses
quantity of concrete shall be maintained within the pipe
16 Where recesses are to be formed by inserts in the
to ensure that the pressure from it exceeds that from the
wall, the vertical tolerance shall be that of sub-Clause
support fluid and workable concrete above the tremie
17 and the horizontal tolerance shall be that of sub-
base. The internal diameter of the pipe of the tremie
Clause 17 plus the horizontal tolerance resulting from
shall be not less than the greater of 150 mm or six times
sub-Clause 15.
the maximum aggregate size. It shall be so designed
that external projections are minimised, allowing the Steel reinforcement
tremie to pass within reinforcing cages without causing
damage. The internal face of the pipe of the tremie shall 17 The longitudinal tolerance of the cage head at the
be free from projections. top of the guide wall measured along the excavation
The depth of the surface of the concrete shall be shall be ± 75 mm.
measured and the embedded length of the tremie pipe The vertical tolerance of the cage head measured
recorded at regular intervals corresponding to each relative to the guide wall shall be +150/-50 mm. The
batch of concrete. The depths measured and volumes reinforcement shall be maintained in position during
placed shall be plotted immediately on a graph and concreting of a panel.
compared with the theoretical relationship of depth
against volume. Temporary stop-ends in diaphragm panels
Tolerances 18 Temporary stop-ends shall be of the length,

thickness and quality of material adequate for the
Guide wall purpose of preventing water and soil from entering the
panel excavations.
14 The finished face of the guide wall towards the Each temporary stop-end shall be straight and true
excavation and on the side of the excavation nearest to throughout. The external surface shall be clean and free
any subsequent main excavation shall be vertical to from distortions that may affect panel integrity during
within a tolerance of 1 in 200 and the top edge of the removal of the temporary stop-end.
wall shall represent the reference line. There shall be no
ridges or abrupt changes on the face and its variation Stop-ends shall be rigid and adequately restrained to
from its specified position shall not exceed ± 15 mm in prevent horizontal movement during concreting.
3 m.
Concrete level
The minimum clear distance between the guide walls
shall be the specified diaphragm wall thickness plus 25 19 If the cut off level for the panel is less than 1 m
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mm and the maximum distance shall be the specified below the top level of the guide walls, uncontaminated
diaphragm wall thickness plus 50 mm. concrete shall be brought to the top of the guide walls.
If the cut off level is greater than 1m below the top
Diaphragm wall level of the guide walls, concrete shall be brought to
1 m above the cut off level specified, with a tolerance
15 At cut-off level the maximum deviation of the of ±150 mm. An additional tolerance of + 150 mm over
centre line of each panel from the specified position the above tolerances shall be permitted for each 1.0 m
shall be 15 mm and an additional tolerance of 8 mm for
March 1998 35
of depth by which the cut off level is below the top of Materials
the guide wall.
Where more than one tremie pipe is used the concrete Concrete : supply, mixing and testing
shall be brought up to 1000 mm above the cut off level 2 Cement materials, aggregates, admixtures and
specified with a tolerance of ± 250 mm. water shall be in accordance with Series 1700.
Temporary backfilling above panel casting level Steel reinforcement : supply, fixing and welding
20 After each panel has been cast, it shall be 3 (11/03) Steel reinforcement shall be as described in
protected and shall be carefully backfilled as soon as Appendix 16/11 and in accordance with Series 1700.
possible, with material in accordance with Appendix Where steel sections are used for reinforcement, they
16/10. All panels shall be clearly marked and fenced off shall be in accordance with Series 1800.
so as not to cause a safety hazard.
Support fluid
Water retention
4 Where support fluid is used to maintain the
21 The complete retaining wall shall be considered to stability of the pile bore it shall be in accordance with
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have satisfactory water retaining properties if overall Clause 1618.
the leakage of water per square metre of exposed wall
does not exceed the volume stated in Appendix 16/10. Boring
The Contractor shall be responsible for the repair of any
joint, defect or panel where on exposure of the wall Boring near recently cast piles
visible water leaks are found. Any leak which results in
water flow emanating from the surface of the retaining 5 Piles shall not be bored so close to other piles
wall shall be sealed. which have recently been cast and which contain
workable or partially set concrete that a flow of
Instrumentation concrete or instability could be induced or damage
caused to any installed piles. The Contractor’s sequence
22 Movement of the wall, the surrounding ground and
of construction shall be submitted prior to work
existing structures shall be monitored in accordance
commencing in accordance with Clause 1601.
with Appendix 16/10 and Clause 1617.
Stability of bore
Preparation of wall surfaces
6 Temporary casing shall be used in unstable ground
23 All surfaces buried or constructed as buried during
with or without support fluid to maintain the stability of
execution of the Works but which subsequently are to
the bore unless continuous flight augers are used. The
be partially or totally uncovered as part of the
casing shall extend to the full depth of each bore or to
construction shall be cleaned, trimmed of all detritus
the depth to which the minimum overlap has to be
and obstructions to the appropriate line and level as
provided. The process of advancing the bore and the
described in Appendix 16/10 (or 16/11, 16/12, 16/13 as
temporary casing shall be such that soil is not drawn
appropriate).
into the bore from outside the area of the pile and
cavities are not created outside the temporary casing.
1611 Hard/Hard Secant Pile Walls
Cleanliness of pile base
Guide walls 7 Prior to placing steel or concrete, the Contractor
shall remove from the base of the pile as much loose
1 The design and construction of guide walls, if the disturbed and remoulded materials as practical and in
use of guide walls is specified in Appendix 16/11 or is accordance with the method of construction.
required by the Contractor, shall be the responsibility of
the Contractor and shall take into account the actual site Cleaning of support fluid
and ground conditions and the equipment to be used on
site to ensure stability and avoid undercutting as 8 Prior to placing steel or concrete, any support fluid
appropriate. Guide walls shall be constructed in including water shall be wholly or partly removed and
reinforced concrete (or other suitable materials). The replaced while maintaining the fluid head if it does not
minimum depth of guide wall shall be 0.5 m, and the comply with the Contractor’s stated limits for support
minimum shoulder width shall be 0.3 m for walls in fluid prior to concreting.
reinforced concrete.

Steel reinforcement so that free discharge from the delivery pipe can be
observed to be taking place, and reinforcement placed
9 The number of joints in longitudinal steel bars shall after concreting.
be kept to a minimum. Joints in steel reinforcement
shall be such that the full strength of each bar is No spoil, liquid or other foreign matter shall be allowed
effective across the joint and shall be made so that there to contaminate the concrete.
is no detrimental displacement during the construction
of the pile. Reinforcement shall be maintained in its (11/03) Consistence of concrete
correct position during concreting of the pile or wall 11 (11/03) The concrete consistence shall be
element. Where reinforcement is made up into cages, determined using the slump or flow classes in
they shall be sufficiently rigid to enable them to be accordance with BS EN 12350-2 and BS EN 12350-5
handled, placed and concreted without damage. If the respectively. The slump or flow shall be measured at
cage is to be welded together, welding shall be carried the time of discharge into the pile boring and shall be in
out to the requirements of BS 7123. accordance with the limits shown in Table 16/2, or as
Spacers shall be designed and manufactured using specified in Appendix 16/11 (and 16/12, 16/13 or 16/14
durable materials which shall not lead to corrosion of as appropriate).
the reinforcement or spalling of the concrete cover.
Where required in Appendix 16/11, details of the means Compaction
concrete.
submitted.
The minimum projecting bond lengths required by Placing concrete in dry boreholes
Appendix 16/11 (and 16/12, 16/13 or 16/14 as
appropriate) shall be maintained. 13 (11/03) The concrete shall be placed through a
hopper attached to a length of tremie pipe and in such a
For continuous flight auger piles steel reinforcement way that the flow is directed and does not hit
cages shall be inserted into the pile shaft immediately reinforcing bars or the side of the bore.
after completion of concreting. The method of insertion
of reinforcement cages shall avoid distortion or damage The tremie pipe shall be at least 3 m long.
to the steel reinforcement and ensure accurate
Placing concrete under water or support fluid
positioning of the cage within the pile shaft.
14 Concrete to be placed under water or support fluid
Placing and compacting concrete shall be placed through a tremie pipe in one continuous
General operation.
The hopper and pipe of the tremie shall be clean and
10 (11/03) The consistence and method of placing of watertight throughout. The pipe shall extend to the base
the concrete shall be such that a continuous monolithic of the boring and a sliding plug or barrier shall be
concrete shaft of the full cross section is formed, and placed in the pipe to prevent direct contact between the
that the concrete in its final position is dense and first charge of concrete in the pipe of the tremie and the
homogenous. Concrete shall be transported from the water or support fluid. The pipe shall at all times
mixer to the position of the pile in such a manner that it penetrate the concrete which has previously been
does not cause segregation of the constituents of the placed with a minimum penetration of 3 m and shall not
concrete mix. be withdrawn from the concrete until completion of
Before commencement of concreting of a pile, the concreting.
Contractor shall satisfy himself that the Supplier will At all times a sufficient quantity of concrete shall be
have available a sufficient quantity of concrete to maintained within the tremie pipe to ensure that the
construct the pile in one continuous operation. pressure from it exceeds that from the water or support
Each batch of concrete in a pile shall be placed before fluid and workable concrete above the tremie base.
the previous batch has achieved a stiffness which The internal diameter of the pipe of the tremie shall be
prevents proper amalgamation of the two concrete not less than the greater of 150 mm or six times the
batches. Removal of temporary casings, when used, maximum aggregate size. It shall be so designed that
shall be completed before the concrete within the casing external projections are minimised, allowing the tremie
loses its consistence. to pass through reinforcing cages without causing
For continuous flight auger piles injection of concrete
shall continue up to the commencing surface or above
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damage. The internal face of the pipe of the tremie shall An additional tolerance of 100 mm will be allowed for
be free from projections. concrete protrusions resulting from cavities formed by
overbreak in the ground. Where very soft clay layers or
The depths to the surface of the concrete shall be
peat layers are anticipated or obstructions are to be
measured and the embedded length of the tremie pipe
removed prior to or during boring, an additional
recorded at regular intervals corresponding to the
overbreak tolerance shall be stated in Appendix 16/11.
placing of each load of concrete. The depth measured
and volumes of concrete placed shall be plotted
Recesses
immediately on a graph and compared with the
theoretical relationship of depth against volume. 18 If recesses in the form of box outs are to be formed
The foregoing is not applicable to piles constructed within a pile shaft, the vertical tolerance shall be in
using continuous flight augers. For such piles the full accordance with sub-Clause 19 and rotational tolerance
monitoring requirements of Clause 1604 shall be met. shall be 10 degrees.
Time period for excavation and placing concrete Steel reinforcement
15 The time period after a pile is excavated and before 19 A vertical tolerance of +150 mm/-50 mm shall
the concrete is placed shall not exceed 12 hours unless generally be permitted on the level of steel projecting
otherwise specified in Appendix 16/11 (and 16/12, from a pile cut off, except where a pile is constructed to
16/13 or 16/14 as appropriate). a higher level for reasons associated with ground
conditions, or technique (continuous flight auger),
If temporary casing is used, this period shall start when where additional steel projection may be necessary.
excavation below the temporary casing commences.
Concrete level
Tolerances
20 No pile shall be cast with its final cut off level
Guide wall below standing water level unless the Contractor’s
method of construction includes measures to prevent
16 The finished face of each guide wall towards the inflow of water that may cause segregation of the
excavation shall be vertical to a tolerance of 1 in 200 concrete as temporary casing is withdrawn. The
and shall represent the reference line. There shall be no standing water level will be treated as the cut off level
ridges on the face and the centre line of the guide wall for the purpose of calculating casting level.
shall not deviate from its specified position by more
For piles cast in dry bores using temporary casing, and
than ± 15 mm in 3 m.
for piles cast under water the casting level shall be
The minimum clear distance between the guide walls above the cut off level and within the tolerances shown
shall be the pile diameter plus 25 mm and the maximum in Table 16/7 except for continuous flight auger piles
distance shall be the pile diameter plus 50 mm. which shall be cast to ground level.
Secant piles Backfilling of empty bore

17 At cut-off level the maximum permitted deviation 21 Where concrete is not brought to the top of the
of the pile centre from the centre point shown on the guide wall, the empty pile bore shall be backfilled as
setting out drawings shall be 25 mm in any direction soon as possible with material in accordance with
except that an additional tolerance of 5 mm shall be Appendix 16/11 (and 16/12 or 16/13 as appropriate).
permitted for each 1.0 m that the cut-off level is below Prior to backfilling the bore shall be clearly marked and
the top of the guide wall unless otherwise specified in fenced off so as not to cause a safety hazard.
Appendix 16/11.
Water retention
In the case of construction by continuous flight augers
the additional tolerance shall be 8 mm for each 1.0 m 22 The completed retaining wall shall be considered to
below top of guide wall. have satisfactory water retaining properties if the
The exposed face of the pile shall be vertical within a leakage of water per square metre of exposed wall does
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tolerance of 1:200 for secant walls constructed with not exceed the volume specified in Appendix 16/11 or
temporary casings and 1:120 for secant walls 16/12. The Contractor shall be responsible for the repair
constructed with continuous flight augers in any of any joint, defect or pile where on exposure of the
direction. wall visible water leaks are found. Any leak which
results in water flow emanating from the surface of the
retaining wall shall be sealed.
March 1998 38
TABLE 16/7: Casting Tolerance Above Cut Off Trial concrete mixes shall be prepared for each mix
Levels for Specified Conditions unless there are existing data showing that the concrete
mix proportions and method of manufacture will
Cut off Level Below Casting Tolerance Condition produce hardened material of the strength, permeability,
Commencing Above Cut off shrinkage properties and durability required, having
Surface, H, m* Level, m
adequate consistence for compaction by the method to
0.15 to any depth 0.3 + H/10 Permanent casing and be used in placing. The performance requirements are
dry bore set out in Appendix 16/12. Limits on consistence and
time for placement are included. The requirements for
0.15 - 10.00 0.3 + H/12 + C/8 Piles cast in dry bore testing will be set out in Appendix 16/12.
using temporary casing
Where a trial concrete mix is required after
0.15 - 10.00 1.0 + H/12 + C/8 Pile cast under water or commencement of the works the above procedure shall
Where C = length support fluid be adopted.
of temporary
casing below the The consistence of each batch of a trial concrete mix
commencing shall be determined by the method as specified in
surface Appendix 16/12.
* Beyond H = 10 m, the casting tolerance applying to H = 10 m Trial concrete mix proportions shall be regarded as
shall apply. satisfactory if the compliance requirements set out in
Appendix 16/12 are met.
Instrumentation
No variations outside the limits set out in the
23 Movement of the wall, the surrounding ground and proportions shall be made nor in the original source of
existing structures shall be monitored in accordance the materials without demonstrating compliance with
with Appendix 16/11 (and 16/12 or 16/13 as this Specification.
appropriate) and Clause 1617.
Self hardening concrete mixes shall be checked for
Preparation of wall surfaces compliance with the mix proportions. Cylindrical
samples shall be made at the rate of four samples for
24 Preparation of wall surfaces shall be in accordance each 50 m3 of self hardening slurry or part thereof in
with sub-Clause 1610.23. each day’s work. Testing will be made in accordance
with the requirements of Appendix 16/12. The results
shall comply with Appendix 16/12.
1612 Hard/Soft Secant Pile Walls
The Contractor shall keep a detailed record of the
results of all tests on self hardening mixes and their
Guide walls
ingredients. Each test shall be clearly identified with the
1 The design and construction of guide walls shall be pile to which it relates and the date it was carried out.
in accordance with Appendix 16/12 and sub-Clause
1611.1. Boring
Materials General
4 Boring near recently cast piles, cleanliness of pile
General
base, and cleaning of support fluid shall be in
2 (11/03) Concrete, steel reinforcement and support accordance with sub-Clauses 1611.5, 7 and 8.
fluid shall be in accordance with sub-Clauses 1611.2, 3
and 4 and as described in Appendix 16/12. Stability of bore
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5 Temporary casing shall be used in unstable ground

Self hardening slurry mixes
3 (11/03) The Contractor shall submit details for the the bore unless continuous flight augers are used. The
self hardening slurry mix (soft pile) proportions to be process of advancing the bore and the temporary casing
used as required by Clause 1601. shall be such that soil is not drawn into the bore from
outside the area of the pile and cavities are not created
Cement materials, aggregates (if used), admixtures and outside the temporary casing.
water shall be in accordance with Series 1700.

Steel reinforcement Time period for excavation and placing self

hardening mix
6 (11/03) Steel reinforcement shall be in accordance
with sub-Clause 1611.9 and as described in 11 (11/03) The time period after a pile is excavated and
Appendix 16/12. before the self hardening concrete mix is placed shall
not exceed 12 hours unless otherwise specified in
Placing and compacting concrete Appendix 16/12. If temporary casing is used, this
period shall start when excavation below the temporary
7 Placing and compacting concrete shall be in casing commences.
accordance with sub-Clauses 1611.10 to 15 inclusive.
Tolerances
Placing and compacting self hardening slurry mixes
General
General
12 Guide wall, recesses and steel reinforcement
8 The method of placing and the workability of a self tolerances shall be in accordance with sub-Clauses
hardening slurry mix shall be such that a continuous 1611.16, 18 and 19.
monolithic shaft of the full cross section is formed and
that it shall be homogeneous in its final position. Secant piles
Before commencing the filling of the pile the
13 At cut-off level the maximum permitted deviation
Contractor shall plan and reasonably demonstrate that a
of the pile centre from the centre point shown on the
sufficient quantity of self hardening mix is available to
setting out drawings shall be 25 mm in any direction
construct the pile in one continuous operation.
except that an additional tolerance of 10 mm shall be
Removal of temporary casing, when used, shall be permitted for each 1.0 m that the cut-off level is below
completed before the self hardening mix within the the top of the guide wall unless otherwise specified in
casing loses its workability. Appendix 16/12.
For continuous flight auger piles injection of self The exposed face of the pile shall be vertical within a
hardening mix shall continue up to the commencing tolerance of 1:100 in any direction.
surface or above so that free discharge from the
An additional tolerance of 100 mm will be allowed for
delivery pipe can be observed to be taking place.
concrete protrusions resulting from cavities formed by
No spoil, liquid or other foreign matter shall be allowed overbreak in the ground. Where very soft clay layers or
to contaminate the mix. peat layers are anticipated or obstructions are to be
(11/03) Consistence of self hardening concrete mix overbreak tolerance will be stated in Appendix 16/12.
9 (11/03) Self hardening concretes shall be coherent General
and of a consistence such that when in its final position
and after all constructional procedures in forming the 14 Concrete level, backfilling of empty bore, water
pile have been completed it shall remain sufficient retention, instrumentation and preparation of wall
consistence. surfaces shall be in accordance with sub-Clauses
1611.20, 21, 22, 23 and 24.
(11/03) Placing self hardening concrete
10 (11/03) The self hardening concrete mix shall be 1613 Contiguous Bored Pile Walls
placed using methods appropriate to the composition of
the concrete mix. These may include placing through a
Guide walls
hopper attached to a length of tremie pipe and tremie
methods in which case placement shall be in 1 The design and construction of guide walls shall be
accordance with sub-Clauses 1611.14 and 15. Other self in accordance with Appendix 16/13 and sub-Clause
hardening concrete mixes use proprietary methods 1611.1.
which shall be set out by the Contractor in his method
of construction. Continuous flight auger piles shall use Materials
an appropriate pump which shall be kept charged
continuously throughout pile construction. 2 (11/03) Concrete, steel reinforcement and support
fluid shall be in accordance with sub-Clauses 1611, 2, 3
and 4 and as described in Appendix 16/13.

40
Boring General
9 Concrete level, backfilling of empty bore,
General
instrumentation and preparation of wall surfaces shall
3 Boring near recently cast piles, cleanliness of pile be in accordance with sub-Clauses 1611.20, 21,
base and cleaning of support fluid shall be in 23 and 24.
accordance with sub-Clauses 1611.5, 7 and 8.
Stability of bore 1614 King Post Walls

4 Temporary casings shall be used in unstable ground Materials
the bore unless continuous flight augers are used. The General
process of advancing the bore and the temporary casing
shall be such that soil is not drawn into the bore from 1 (11/03) Concrete, steel reinforcement and support
outside the area of the pile and cavities are not created fluid shall be in accordance with sub-Clauses 1611.2, 3
outside the temporary casing. and 4 and as described in Appendix 16/14.
Temporary casings shall be extracted immediately on
Structural steelwork
completion of concreting.
2 Structural steelwork shall be in accordance with
Steel reinforcement Series 1800.
5 Steel reinforcement shall be in accordance with
Boring
sub-Clause 1611.9.
Placing and compacting concrete General
6 Placing and compacting concrete shall be in 3 Boring near recently cast piles, cleanliness of pile
accordance with sub-Clauses 1611.10 to 15 inclusive. base, and cleaning of support fluid shall be in
Tolerances
Stability of bore
General 4 Temporary casings shall be used in unstable soils
7 Guide wall, recesses and steel reinforcement with or without support fluid to maintain the stability of
tolerances shall be in accordance with sub-Clauses the bore unless continuous flight augers are used. Care
1611.16, 18 and 19. shall be taken not to undermine or destabilise ground by
boring too far ahead of the temporary casing.
Contiguous piles Temporary casings shall be extracted immediately on
completion of concreting.
8 At cut-off level the maximum permitted deviation
The method of construction shall be submitted in
of the pile centre from the centre point shown on the
setting out drawings shall be 50 mm in any direction
except that an additional tolerance of 13 mm shall be Placement of King Post members
permitted for each 1.0 m that the cut-off level is below
working level or top of the guide wall unless otherwise 5 The method of handling and placing King Post
specified in Appendix 16/13. members shall be set out in the Contractor’s method of
construction, submitted in accordance with Clause 1601.
The exposed face of the pile shall be vertical within a
tolerance of 1:75 in any direction for contiguous walls. In appropriate conditions, the member may be plunged
into concrete already placed in the pile bore
An additional tolerance of 100 mm will be allowed for immediately after the concrete placement and before the
concrete protrusions resulting from cavities formed by concrete has achieved its initial set. Guides or hole
overbreak in the ground. Where very soft clay layers or spacers shall be used so that the specified tolerances of
peat layers are anticipated or obstructions are to be the King Post member are achieved.
overbreak tolerance shall be stated in Appendix 16/13. Where the King Post member is installed prior to
concreting, the Contractor shall ensure that it is not
disturbed, displaced or disoriented during concreting.
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Steel reinforcement 1615 Steel Sheet Piles

6 (11/03) Steel reinforcement shall be in accordance
General
with sub-Clause 1611.9 and as described in
Appendix 16/14. 1 Only new piles shall be used for permanent works.
Piles shall be carefully examined by the Contractor at
Placing and compacting concrete the time of delivery and damaged piles repaired or
replaced. The records of testing of the steel used in the
General piles shall be made available.
7 Placing and compacting concrete shall be in Materials
accordance with sub-Clauses 1611.10 to 15 inclusive.
The method of placing concrete shall avoid disturbance
Standard sheet piles
of King Post members.
2 Unless specified otherwise, all steel for sheet piles
Tolerances shall be manufactured to BS EN 10248 Grade S270GP
8 The required tolerances depend on the application or S355GP.
and are set out in Appendix 16/14.
Fabricated sheet piles
Concrete level 3 All fabricated piles eg. corners, junctions, box
9 No pile shall be cast with its final concreted level sections, high modulus sections, shall be fabricated and
below standing water level unless the Contractor’s supplied to the sheet pile manufacturer’s
method of construction includes measures to prevent recommendations.
inflow of water that may cause segregation of the
Storage
concrete as the temporary casing is withdrawn. The
standing water level will be treated as the cut off level 4 If sheet piles of different grade steel are stored on
for the purpose of calculating tolerance. site, each pile shall be clearly marked as to its grade and
For piles cast in dry bores using temporary casing and piles of different grade shall be stored separately.
for piles cast under water or support fluid the casting
level above cut off level shall be within the casing Clutch sealant
tolerance above the cut off level shown in Table 16/7. 5 If specified in Appendix 16/15, the Contractor shall
apply a clutch sealant to the piles prior to pitching in
Backfilling accordance with the manufacturer’s recommendations.
10 The concrete will usually be below the working
level and the pile bore containing the King Post Pile handling and driving
member shall be backfilled once the concrete has
sufficient strength or after such time as specified in Pile handling
Appendix 16/14.
6 When assembling piles before pitching the
The backfill material in accordance with Appendix Contractor shall ensure that the interlocks are clean and
16/14 shall be evenly placed on either side of the King free from distortion. All storage, handling, transporting
Post member to avoid uneven loading. Prior to and pitching of piles shall be carried out in such a way
backfilling, bores shall be clearly marked and fenced that no significant damage occurs to piles and their
off so as not to cause a safety hazard. coatings.
Instrumentation Pile installation and extraction

11 Movement of the wall, the surrounding ground and 7 (11/03) In the event of a Contractor’s design he shall
existing structures shall be monitored in accordance demonstrate that the sheet piles can be installed
with Appendix 16/14 and Clause 1617. adequately to the correct depths through the reported or
anticipated soil conditions.
The Contractor shall give at least 24 hours notice before
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the commencement of driving.

The piles shall be guided and held in position by
temporary gates with each pile properly interlocked

with its neighbour. Piles shall not by-pass one another welded, then these shall be designed in accordance with
in place of interlocking. the guidelines given in BS EN 1011-1 and BS EN 1011-2
and the manufacturer’s recommendations. Weld metal
Where sheet piles are driven in panels, the end piles to
shall not encroach within the interlock areas so as to
each panel shall be driven in advance of the general run
interfere with the interlocking of the piles.
of piles. After allowing for initial penetration, no pile in
the panel shall be driven to an excessive lead in
Piling records
comparison with the toe level of the panel in general
and where hard driving is encountered this lead shall 8 The following records shall be kept where
not exceed 1 m. appropriate:
At all stages during driving the free length of the sheet (a) pile reference number or location
pile shall be adequately supported and restrained. The
Contractor shall ensure that the sheet panels are driven (b) pile type and grade of steel
without significant damage or declutching, where (c) pile length
possible.
(d) type of hammer
The selection of driving and extracting plant shall be
(e) date of driving
made having due regard to the ground conditions and
pile type. The sheet piles shall be driven to the specified (f) commencing surface level
level and/or resistance or if hard driving is experienced, (g) depth driven
to practical refusal (which shall be defined as when the
rate of penetration is below 100 mm per minute when (h) length of offcuts
hammering continuously or 12 blows per 25 mm (i) length of pile extensions
movement when using the appropriate equipment), or
when visible damage to the pile occurs. Practical (j) if required, the measurement of driving
refusal for pile extraction shall be defined generally as resistance at appropriate depths.
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when the rate of extraction of a pile is below 100 mm (k) all information regarding interruptions,
per minute when back-hammering or pulling (with unexpected changes in driving characteristics,
equipment normally capable of withdrawing a pile) obstructions and times taken in overcoming
continuously (after an initial effort of 10 minutes), or them.
when damage to the pile head occurs. If the piles have
not penetrated to the levels specified in Appendix Positional and alignment tolerance
16/15, or have encountered obstructions, a full
statement of the reasons shall be recorded by the 9 Unless deflected by obstructions, sheet piles shall
Contractor and included in the pile record. be installed within the following tolerances:
If required in Appendix 16/15, the Contractor shall In plan ±75 mm of the given sheet pile line at
install the sheet piles using a vibrationless jacking commencing surface.
system. Vertical 1 in 75
Pile driving hammers shall be correctly positioned on Level ±50 mm of required top level
the pile so that the hammer will be aligned as near to
the axis of the pile as is practically possible. Freely Pile line dimensions shall be based on the nominal size
suspended piling hammers shall be equipped with of piles. Creep or shrinkage of the pile lines shall not
correctly adjusted leg guides and inserts. Where a exceed the manufacturer’s rolling tolerances.
hammer is mounted in a rigid leader, the leader shall be
stable. The anvil block or driving plate shall be of Welding
sufficient size to cover as much as possible of the cross
section of the pile. Welders qualification
Piles previously driven shall not be used until the 10 (11/05) Only welders who are qualified to
Contractor can demonstrate that they can meet all the BS EN 287-1 or who have attained a similar standard,
requirements of the Specification. shall be employed on the Works. Proof of welder’s
proficiency shall be made available on request.
The Contractor may provide each pile in more than one
length. Spliced joints shall be designed to cater for the
Welding standard
combined effects of bearing, shear and bending stresses
imposed upon the sheet piles. Splices shall be located to 11 (11/03) For manual metal arc and semi-automatic
avoid maximum stress positions. If splices are to be welding of carbon and carbon manganese steels,

welding of piles and steel framework shall be carried construction method to the specialist firm before the
out in accordance with BS EN 1011-1 and commencement of testing in order to facilitate
BS EN 1011-2. Defective welds shall be cut out and interpretation of the tests.
replaced. Where steel piles are to be spliced by butt
welding the interlocks shall not be welded unless a Report
sealing weld is required.
6 The requirements of sub-Clause 1608.6 shall apply.
Durability and protection
Anomalous results
12 Protective coating shall be applied, if specified,
following the procedures set out in Clause 1606. 7 In the event that any anomaly in the acoustic signal
is found in the results indicating a possible defect in the
Preparation of pile heads wall element the Contractor shall demonstrate that the
wall element is satisfactory for its intended use or shall
13 If a steel structure is to be welded to piles, the piles carry out remedial works to make it so. Sonic logging
shall be cut square and to within ± 5 mm of the levels tubes shall be grouted up after the Contractor has
specified. If pile heads are to be encased in concrete demonstrated that the wall element is satisfactory.
they shall be cut to within ± 20 mm of the levels
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specified, and protective coatings shall be removed
from the surfaces of the pile heads down to a level 100 1617 Instrumentation for Piles and
mm above the soffit of the concrete. Embedded Walls
General
1616 Integrity Testing of Wall Elements
1 All materials and work shall be in accordance with
Method of testing this Clause and Appendix 16/17.
1 Where integrity-testing of wall elements is Type of instrumentation

specified the sonic logging method normally shall be
used. Other methods may be considered subject to 2 Where the installation of instrumentation is called
satisfactory evidence of performance. for, the type of instrumentation shall be one of the
following, as specified in Appendix 16/17.
Age of wall elements at time of testing a) extensometer (rod or magnetic)
2 Integrity tests shall not be carried out until the b) inclinometer
number of days specified in Appendix 16/16 have c) load cell
elapsed since casting of the wall element.
d) pressure cell
Preparation of heads or tops of wall elements e) strain gauge (to be attached to steel or precast
3 Where the method of testing requires the concrete or embedded in cast in situ concrete).
positioning of sensing equipment on the wall element Other methods may be considered subject to
head or top, it shall be broken down to expose sound satisfactory evidence of performance. All equipment
concrete and shall be clean, free from water, laitence, used shall be suitable for its specified purpose.
loose concrete, overspilled concrete and blinding
concrete and shall be readily accessible for the purpose The instrumentation shall be robust and shall be a
of testing. proprietary system supplied by a reputable supplier.
Where required in Appendix 16/17, the Contractor shall
Specialist Sub-contractor submit details of the Supplier, the instrumentation and
curricula vitae for the staff who will install the
4 The requirements of sub-Clause 1608.4 shall apply. instrumentation on site, monitor it and analyse the
readings. The Contractor shall also submit details of
Interpretation of tests projects where the Specialist Instrumentation
Contractor has successfully installed and monitored the
5 The interpretation of tests shall be carried out by
specified type of instrumentation.
competent and experienced persons.
The Contractor shall give all available details of the
ground conditions, element dimensions and

Extensometers The inclinometer readout equipment shall comprise a

uniaxial or biaxial torpedo complete with operating
3 The instrumentation shall be securely attached to cable, cable reel, grip, carrying case, cartridge readout
the reinforcement cage so that no component is unit and battery charger. The torpedo shall be fully
displaced during placing of the reinforcement cage or waterproof, stainless steel and incorporate two robust
concreting. During concreting, the tubing shall be force servo accelerators aligned at right angles to each
adequately covered at both ends to prevent the ingress other. The torpedo shall be fitted with two orthogonal
of concrete. Compression or extension couplings shall pairs of centre sprung wheels and shall have a gauge
be installed as necessary for the movement range length of 0.5 m and be capable of negotiating a tube
specified in Appendix 16/17. curvature of 3 m. The cable shall be of an appropriate
The system will be such that the anchor and reference length. The readout unit shall have an alphanumeric
blocks shall be securely cast into the pile concrete. The LCD and rechargeable battery with sufficient power for
rod shall be made of fibreglass or similar material so 20 hours continuous use. The Contractor shall supply a
that it will not corrode or distort nor change its length calibration frame for checking the readout equipment.
due to heat or water changes. Alternatively a string of electrolevels may be used.
The top of the rod shall incorporate a range adjuster Sufficient electrolevels shall be incorporated to provide
with a travel of 25 mm. an accurate deformation profile.
If direct measurements are specified the displacement The “azimuth deviation” shall be recorded for each
measuring device shall consist of a rechargeable digital inclinometer access tube and shall be taken into account
dial gauge with 240 V. mains battery charger or when processing the data. Where azimuth correction is
analogue dial gauge. The orientation of the dial gauge necessary, the Contractor shall make available details of
relative to the top of the tube shall be constant for every the method used.
reading. If remote reading is specified the readings shall Readings shall be taken for the full length of each
be made by a linear potentiometer or other suitable inclinometer access tube for faces A, B, C and D. The
device, securely held in place. top wheel of the torpedo will travel up face A first
followed by faces B, C and D when using a uniaxial
Inclinometers torpedo. With a biaxial torpedo, only faces A and B are
4 (11/03) The access tubing shall be securely attached travelled.
to the reinforcement cage so that no component is If a full set of readings cannot be obtained due to
displaced during placing of the reinforcement cage or accumulation of debris in the access tubes, the
concreting. During concreting, the tubing shall be Contractor shall flush the tubes with water to remove
adequately covered at both ends to prevent the ingress the debris until readings can be taken.
of concrete. Alternatively, a nominal 100 mm steel duct
sealed at the lower end and fitted with a removable The readings shall be taken in increments of 0.5 m
screw cap at the upper end, shall be attached to the starting from the base of the access tube. All readings
reinforcement cage. The inclinometer access tube can shall be recorded and reported to the nearest 0.1 mm.
then be installed afterwards using a cementitious grout The readings are considered to be sufficiently accurate
containing a non-shrink admixture. only if the “face errors” in the A/B plane and the C/D
plane are less than 1.5 mm.
The system shall consist of 60 mm nominal diameter
corrosion-proof access tubing which shall have four The datum readings to be used in the calculations for
longitudinal internal keyways on two orthogonal axes. each inclinometer shall be made available.
The keyways shall be continuous over the length of the The data shall be processed assuming a fixed base. The
access tubing so that the wheels of the torpedoes can surveyed cumulative horizontal movement of the top of
pass freely along it. For embedded walls, the keyways the access tube shall be reported to an accuracy of
shall be oriented so that one set are parallel to the face 0.5 mm. When required, the data shall also be
of the wall. The coupling between sections of the access processed assuming a specified offset at the top of the
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tube shall ensure that the correct alignment of keyways access tube.
is maintained through a joint. Jointing rivets to connect
the tube sections shall be located midway between The processed data for faces A, B, C and D shall be
keyways. Sealing mastic shall be applied to each rivet tabulated to show the following:
head and to the points where the tubing enters a a) deviations and face errors
coupling. All joints shall be sealed by liberally
wrapping with a fabric tape impregnated with a b) mean deviation
waterproofing compound. This procedure shall also be c) change in mean deviation
carried out for the end-caps.
d) cumulative mean deviation Strain gauges

e) displacement profiles.
General
Items (c) and (e) shall also be presented graphically to
show the deviation or displacement plotted against 7 The strain gauges shall have a response time of 10
depth. seconds or less. The monitoring systems shall provide a
stable signal and any temperature or cable length or
Load cells other effects on the signal shall be included in the
permissible tolerance. The strain gauges and cabling
5 (11/03) The loads to be measured may be either shall be compatible with their intended position within
compressive or tensile, as specified in Appendix a pile and shall be unaffected by the presence of water
16/17. The load cells shall have a response time of two or fluid concrete. They shall be sufficiently strong to
seconds or less in response to monotonically increasing withstand additional loading due to placing of the
or decreasing loading. reinforcing cage and concreting or pile driving.
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The monitoring system shall provide a stable signal and
any temperature or cable length or other effects on the Strain gauges attached to steel or precast concrete
load signal shall be included in the permissible piles
tolerance. If a hydraulic or pneumatic system is used it
8 The strain gauges shall be securely attached to a
shall be rated for and have been tested to twice the
mounting plate welded to the steel for steel piles, or
anticipated maximum pressure. The load cells and
securely attached to the reinforced concrete for precast
cabling shall be compatible with their intended position
concrete piles. The welding procedures of Clause 1606
within a pile and shall be unaffected by the presence of
shall be followed. The method of attachment shall be
water or fluid concrete. They shall be sufficiently
sufficiently strong so the gauge is not displaced, nor the
strong to withstand additional loading due to placing of
wires or cables damaged by driving.
the reinforcement cage and concreting.
As the cell will give a direct reading of load, it shall be Strain gauges embedded in concrete
positioned so that all the load passes through it without
any eccentricity. The loading system shall be safe and 9 Strain gauges for cast in situ piles shall be either
stable. the embedment variety or shall be securely attached to
reinforcement bars or to ‘sister’ bars which shall be
Pressure cells attached to the reinforcement cage. The methods of
attachment shall be such that the gauge is not displaced,
6 The pressure cells shall have a response time of 2 nor the wires or cables damaged by placing of the
seconds or less in response to monotonically increasing reinforcement, concreting, driving or other processes.
or decreasing loading.
Readings
The monitoring system shall provide a stable signal and
any temperature or cable length or other effects on the
pressure signal shall be included in the permissible General
tolerance. If a hydraulic oil, pneumatic or mercury- 10 Readings shall be reported in terms of the basic
based system is used it shall be rated for and have been property measured (eg. volts, hertz, mm of Mercury)
tested to twice the anticipated maximum pressure. The and shall be converted to SI or derivative units by
pressure cells and cabling shall be compatible with their means of a calibration constant. The calibration
intended position within a pile and shall be unaffected constant and the range over which it is applicable shall
by the presence of water or fluid concrete. They shall be clearly stated.
be sufficiently strong to withstand additional loading
due to placing of the reinforcement cage and Readings shall be taken at the times or time intervals
concreting. specified in Appendix 16/17.
If the pressure cell is to be placed against concrete on Calibration and data checking
one or both sides, it shall be provided with a mercury
filled re-pressurising tube to ensure that no gap occurs 11 The instrumentation shall be calibrated prior to
between the hardened concrete and the pressure cell. incorporation into the works and a certificate of
calibration shall be made available. For strain gauges a
calibration constant can be provided if evidence is
available showing that the variation in calibration
constant will not vary maximum readings outside the
specified tolerance.
The instrumentation shall be calibrated so that its g) the calibration constants or equations that are
behaviour has been monitored over the range specified being applied and the dates they were
in Appendix 16/17. The Contractor shall demonstrate determined
that the type of instrumentation can provide a stable,
h) a table comparing the specified results with
reproducible and repeatable calibration.
any previous readings and with the base
All data shall be checked by the Contractor for errors readings
prior to submission. If erroneous data are discovered
i) (11/03) a graph showing variation of load or
(eg. face errors for inclinometer readings greater than
pressure or vertical movement or strain with
1.5 mm), the Contractor shall take a second set of
time or horizontal movement with depth. Key
readings immediately. If the errors are repeated, the
dates shall be marked with a brief explanation
Contractor shall determine the cause of the error. Both
of their significance.
sets of readings shall be processed and submitted,
together with the reasons for the errors and details of Columns of numbers shall be clearly labelled together
remedial works. The Contractor shall rectify any faults with units. Numbers shall not be reported to a greater
found in the instrumentation system for the duration of accuracy than is appropriate. Graph axes shall be linear
the specified monitoring period. and clearly labelled together with units.
All computer data files and calculation sheets used in Specialist Instrumentation Contractor
processing the data shall be preserved until the end of
the contract. They shall be made available for 14 The installation, monitoring and analysis shall be
inspection on request. carried out by a specialist Contractor, subject to
demonstration of satisfactory performance before the
Tolerances commencement of monitoring.
The staff carrying out the monitoring and interpretation
12 For load or pressure, a tolerance of ± 1% of the
of the results shall be competent and experienced with
range specified in Appendix 16/17 is permissible. For
the type of instrumentation used.
strain, a tolerance of ± 2 x 10-6 is permissible. For
displacement, a tolerance of ± 0.1 mm is permissible. Monitoring equipment
Except where explicitly specified in Appendix 15 (11/03) The monitoring equipment shall become the
16/17, no instrumentation device, tubing or cable shall property of the Overseeing Organisation, if so specified
be placed in the concrete cover zone. in Appendix 16/17. Monitoring shall be carried out
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either directly at the pile head, or remotely from a

Report monitoring cabin as specified in Appendix 16/17.
13 The results shall be made available within five The monitoring equipment shall be appropriate for the
working days of the completion of each phase of situation in which it is to be used. The manufacturer’s
testing. guidelines for its use shall be followed. Where it has
not been possible to follow the manufacturer’s
The report shall contain the following:
guidelines, the fact shall be reported together with the
a) the date and time of each reading reason and details of the alternative procedure.
b) the weather The monitoring equipment shall remain on site for the
c) the name of the person who made the reading duration of the monitoring programme, except when
on site and the name of the person who necessary for it to be calibrated, after which it shall be
analysed the readings together with their returned to site. The same monitoring equipment shall
company affiliations be used at each position. Where this is not possible the
fact shall be reported together with the reason.
d) the pile or wall element reference number and
the depth and identity number of the Protection
instrumentation 16 Terminal boxes at the head of the pile shall be
e) any damage to the instrumentation or protected by a lockable robust steel cap. The pile head
difficulties in reading shall then be fenced off with clearly visible barriers
which shall be maintained for the duration of the
f) the condition of the pile (eg. if the reading is monitoring programme.
being made during a load test, the stage of the
test; if a wall is being excavated alongside, the Any cable running along the ground shall be clearly
depth of the excavation, etc) marked and adequately protected to prevent the cable
posing a safety hazard or becoming damaged.

Surveying ii) results of representative laboratory or field

mixing trials with the support fluid to
17 The pile or element head terminal (top of access demonstrate compliance with the
tubing or as specified in Appendix 16/17) shall be Specification.
surveyed, if specified in Appendix 16/17. The level will
be determined to an accuracy of 1 mm relative to the iii) details of the tests to be used for monitoring
datum specified in Appendix 16/17. The grid the support fluid during the works and the
coordinates will be determined to an accuracy of ± 2 compliance values for these tests, presented in
mm relative to the grid specified in Appendix 16/17. the form of Table 16/8.
Other measurements shall be to the specified accuracy.
Materials
1618 Support Fluid Water

3 (11/03) If water for the Works is not available from a
General requirements
water company’s supply, the Contractor shall ensure
1 Where a support fluid is used for maintaining the that the water complies with the guidance given in
stability of an excavation the properties and use of the BS EN 1008. Water from the sea or tidal rivers shall not
fluid shall be such that the following requirements are be used.
achieved: When required in Appendix 16/18, the Contractor shall
i) continuous support of the excavation arrange for tests of the water for the Works to be carried
out in accordance with the specified schedule before
ii) solid particles are kept in suspension and during the progress of the work. The frequency of
iii) the fluid can be easily displaced during testing shall be as stated in Appendix 16/18.
concreting
Additives to the water
iv) the fluid does not coat the reinforcement to
such an extent that the bond between the 4 All solid additives shall be stored in separate
concrete and reinforcement is impaired waterproof stores with a raised floor or in waterproof
v) the fluid shall not cause pollution of the silos which shall not allow the material to become
ground and groundwater before, during or contaminated.
after use. Additives shall generally be used in accordance with
Where required in Appendix 16/18, details of the type the manufacturer’s recommendations unless
of support fluid, manufacturer’s certificates for the demonstrated otherwise. Bentonite shall be of a quality
constituents and mix proportions shall be submitted. that shall accord with Publication 163 “Drilling Fluid
Materials” of the Engineering Equipment and Material
Support fluids shall be in accordance with Appendix Users Association.
16/18 and this Clause, except where there may be a
conflict of requirements, in which case those in Mixing of support fluid
Appendix 16/18 shall take precedence.
5 The constituents of the fluid shall be mixed
Evidence of suitability of support fluid thoroughly to produce a homogeneous mix. The
temperature of the water used in mixing, and of the
2 The Contractor shall make available details of the support fluid at the time of commencing concrete
properties and use of the support fluid to demonstrate it placement shall not be less than 5°C.
will meet the specified requirements. These details shall
be prepared at least 21 days prior to the commencement Compliance testing of support fluid
of work and shall include:
6 The Contractor shall carry out testing of the
i) (11/03) evidence from previous work with this support fluid in accordance with his regime and this
support fluid and justification for its Specification to demonstrate compliance with his limits
suitability for these ground conditions and for each test. The Contractor shall establish a suitably
method of construction. Particular issues, equipped and properly maintained site laboratory for
which shall be addressed, are the types and this sole purpose and provide skilled staff and all
sources of the support fluid constituents, time necessary apparatus to undertake the sampling and
of construction of the piles, ambient testing.
temperature, soil and groundwater chemistry.

48
Each batch of freshly prepared or reconditioned slurry

shall be proven by sampling and testing to be within the
compliance values before the batch is used in
excavations. Details of the method, frequency and
locations for sampling and testing slurry from the
excavations shall be prepared at least 21 days prior to
the commencement of work. At least one sample
immediately prior to placing steel and concrete shall be
taken and tested from the base of the excavation and
one from the top.
If tests show the support fluid does not comply with the
Specification it shall be replaced.
Spillage and disposal of support fluid

7 All reasonable steps shall be taken to prevent the
spillage of support fluid on the site in areas outside the
immediate vicinity of boring. Discarded fluid shall be
removed from the site without undue delay. Any
disposal of fluid shall comply with the requirements of
current legislation and all relevant authorities.
TABLE 16/8: Test and Compliance Values for Support Fluid
Compliance Values Measured at 20°C
Property to be Test Method and Specification for test Freshly Mixed Fluid Sample from bore
Measured Apparatus prior to placing steel
and concrete
Density Mud balance
Rheological properties
- over appropriate range
of shear rates and
temperature
(a) Plastic viscosity Fann viscometer
(b)Yield stress Fann viscometer
(c) Consistency index, K Fann viscometer
(d)Flow index, n Fann viscometer
(e) Marsh cone viscosity Marsh cone
(f) Gel strength - for Fann viscometer
appropriate range of
times
Sand Content Sand Screen Set
Fluid loss - for Fluid loss test

appropriate range of
temperatures times and
pressures
Filtercake thickness Fluid loss test
pH Electrical pH meter to
BS 3145, range pH
7 to 14
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March 1998 49
49F
SERIES 1700
STRUCTURAL CONCRETE
Contents
1701 (12/14) Concrete – General 2 1726 (12/14) Stainless Steel Dowels – Materials 33
1702 (12/14) Concrete – Constituent Materials 2 1727 (12/14) Inspection and Testing of Structures
and Components 34
1703 (12/14) Concrete – Exposure Classes 4
1728 (12/14) Geometrical Tolerances 34
1704 (12/14) Concrete – General Requirements 4
1729 (03/20) Post-Installed Anchors and
1705 (12/14) Concrete – Requirements for
Reinforcing Bar Connections 37
Designed Concrete 5
1706 (12/14) Concrete – Production 5
1707 (12/14) Concrete – Conformity and
Identity Testing 6
1708 (12/14) Concrete – Surface Finish 6
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1709 (03/20) Concrete – Surface Protection 8
Systems
1710 (12/14) Concrete – Construction General 15
1711 (12/14) Concrete – Grouting and Duct
Systems For Post-tensioned Tendons 23
1712 (12/14) Reinforcement – Materials 27
1713 (12/14) Carbon Steel Reinforcement
and Stainless Steel Reinforcement –
Bar Schedule Dimensions – Cutting
and Bending 28
1714 (12/14) Reinforcement – Fixing 28
1715 (12/14) Reinforcement – Surface Condition 29
1716 (12/14) Reinforcement – Laps and Joints 29
1717 (12/14) Reinforcement – Welding 29
1718 (12/14) Prestressing Tendons – Materials 30
1719 (12/14) Prestressing Tendons – Handling
and Storage 30
1720 (12/14) Prestressing Tendons – Surface
Condition 30
1721 (12/14) Prestressing Tendons – Straightness 30
1722 (12/14) Prestressing Tendons – Cutting 31
1723 (12/14) Prestressing Tendons – Positioning
of Tendons, Sheaths and Duct Formers 31
1724 (12/14) Prestressing Tendons – Tensioning 31
1725 (12/14) Prestressing Tendons – Protection
and Bond 33

Specification for Highway Works Structural Concrete
STRUCTURAL CONCRETE
1701 (12/14) Concrete – General
(12/14) Specification of Concrete
the subject matter in its title, it must be read in conjunction with the general requirements in Series 000 and 100 and
with all other Series relevant to the Specification for the particular works to be undertaken.
2 (12/14) Concrete shall conform to the requirements of BS 8500 Parts 1 and 2. Unless otherwise described in
contract specific Appendix 17/4, concrete shall be specified as designed concrete. The contract specific
requirements for the structural concrete in the permanent works are given in contract specific Appendix 17/1.
(12/14) Designed Concrete
3 (12/14) The specification for designed concrete defined in BS 8500-1 shall be as described in this Specification
and contract specific Appendix 17/1 and shall contain:
(a) the basic requirements given in 4.3.2 of BS 8500-1;
(b) the additional requirements given in 4.3.3 of BS 8500-1 where described in this Specification and
(12/14) Implementation of BS EN 13670
4. (12/14) The execution of concrete structures shall be in accordance with BS EN 13670 as complemented by this
Specification. The provisions of this Specification apply to both in situ and precast concrete, unless noted
otherwise.
(12/14) Execution Class
5. (12/14) The works shall be built in accordance with Execution Class 3 as defined in BS EN 13670 unless
(12/14) Inspection Requirements
6. (12/14) Inspection for materials and products and inspection for execution of works, as well as documentation of
inspection, shall be in accordance with BS EN 13670 as complemented by this Specification. Requirements for the
inspection and testing of structures are given in contract specific Appendix 17/4. Where described in Appendix 17/4
inspection of concrete works shall be executed by an organisation independent of the Contractor.
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1702 (12/14) Concrete – Constituent Materials

(12/14) Cement and combinations
1 (12/14) Cement types as defined in BS 8500 (see Table A.6 of BS 8500-1 or Table 1 of BS 8500-2) shall
comprise one of the following, unless otherwise described in contract specific Appendix 17/4:
EM I, CEM II/A-S, CEM II/A-L, CEM II/A-LL, CEM II/A-D, CEM II/B-S, CEM II/A-V, CEM II/B-V, CEM
C
III/A, CEM III/B, CEM IV/B and sulfate-resisting Portland cements CEM I-SR 0 and CEM I-SR 3 conforming
to BS EN 197-1.
Combinations as defined in BS 8500 shall comprise one of the following, unless otherwise described in contract
specific Appendix 17/4:
CIIA-S, CIIB-S, CIIA-L, CIIA-LL, CIIA-V, CIIB-V, CIIIA, CIIIB and CIVB-V.
Amendment – December 2014 2

Cements shall conform to BS EN 197-1. Evidence of compliance with the harmonised part of BS EN 197-1 with
respect to product performance shall be demonstrated by CE marking and a Declaration of Performance where the
declared performance for the essential characteristics given in Annex ZA of that Standard is equal or greater than
the performance level required for the intended use of the cement.
Ground granulated blastfurnace slag, fly ash and silica fume shall conform to BS EN 15167-1, BS EN 450-1 and
BS EN 13263-1, respectively. Evidence of compliance with the harmonised part of those Standards with respect to
product performance shall be demonstrated by CE marking and a Declaration of Performance where the declared
performance for the essential characteristics given in Annex ZA of those Standards is equal or greater than the
performance level required for the intended use of the constituent.
Limestone fines shall conform to BS 7979.
(12/14) Aggregates
2 (12/14) Unless otherwise specified in contract specific Appendix 17/4, aggregates shall conform to BS EN
12620 (for normal and heavy weight aggregates) and BS EN 13055-1 (for lightweight aggregates) and to the
requirements of 4.3 of BS 8500-2 except that recycled concrete aggregate (RCA) and recycled aggregate (RA) shall
not be used. Where the use of RCA or RA is proposed, it shall be subject to the approval of the Overseeing
Organisation through its Departure from Standard processes.
Evidence of compliance with the harmonised part of BS EN 12620 and BS EN 13055-1 with respect to product
performance shall be demonstrated by CE marking and a Declaration of Performance where the declared
performance for the essential characteristics given in Annex ZA of that Standard is equal or greater than the
performance level required for the intended use of the aggregate, with the System of Assessment and Verification of
Consistency of Performance (AVCP) as defined in PD 6682-1 and PD 6682-4 for aggregates conforming to BS EN
12620 and BS EN 13055-1, respectively.
The flakiness index of the coarse aggregate when determined by the method described in BS EN 933-3 shall not
exceed FI35 except when natural, uncrushed aggregates are used for concrete of strength classes lower than C32/40,
when the flakiness index shall not exceed FI50. No flakiness index limit is required for strength class C12/15
concrete or below.
When required, the resistance to fragmentation of the coarse aggregate, determined in terms of the Los Angeles
coefficient as specified in BS EN 1097-2 and declared in accordance with the relevant category specified in Table
16 of BS EN 12620, shall meet the requirements for LA40. Aggregates with LA coefficient values above 40 may
also perform satisfactorily in normal concrete but their strength performance shall be established in concrete trials
before use.
Chloride levels of aggregate shall be established from testing using the Volhard reference method in BS EN 1744-1,
or other method calibrated against this reference method. Where the aggregate chloride level has been established
as minimal, that is less than the detection level of 0.002%, typical for land based materials, then this value may be
used. Where there is a significant chloride level, the value shall be established as set out in 5.2.7 of BS EN 206-1.
Aggregates shall be selected as to satisfy the requirements in sub-Clause 1704.5 for the control of alkali-silica
reaction.
(12/14) Admixtures and Pigments
3 (03/20) Admixtures shall conform to BS EN 934-2 and shall comply with 4.5 of BS 8500-2 and the
requirements of Clause 5 of BS EN 206-1 unless otherwise described in contract specific Appendix 17/4. Evidence
of compliance with the harmonised part of BS EN 934-2 with respect to product performance shall be demonstrated
by CE marking and a Declaration of Performance where the declared performance for the essential characteristics
given in Annex ZA of that Standard is equal or greater than the performance level required for the intended use of
the admixture. Where a specified coloured concrete requires a pigment, the pigment shall conform to BS EN 12878.
In all cases the Contractor shall record the following information, which shall be subsequently supplied to the
Overseeing Organisation in accordance with the requirements of CG 302 ‘As built, Operational and Maintenance
Records for Highway Structures’ (DMRB 3.2.1):
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3
(a) the detrimental effects caused by adding a greater or lesser quantity of admixture or pigment;
(b) the chemical name(s) of the main active ingredient(s);
(c) whether or not the admixture leads to the entrainment of air.
(12/14) Fibres for concrete
4 (12/14) The use of fibres for concrete is not covered by this Specification. Where their use is proposed, it shall
be subject to the approval of the Overseeing Organisation through its Departure from Standard processes.
1703 (12/14) Concrete – Exposure Classes

(12/14) Selection of Exposure Classes
1 (12/14) The exposure classes shall be as described in contract specific Appendix 17/1.
1704 (12/14) Concrete – General Requirements

(12/14) Compressive Strength Class of Concrete
1 (12/14) The compressive strength classes of concrete shall be as described in contract specific Appendix 17/1.
(12/14) Minimum Cement Content and Maximum Water/Cement Ratio
2 (12/14) The cement content shall be not less than, and the water/cement ratio shall be not greater than, the
values described in contract specific Appendix 17/1.
(12/14) Maximum Cement Content
3 (12/14) The cement content shall not exceed 550 kg/m3 unless otherwise described in contract specific Appendix
17/1.
(12/14) Maximum Chloride Content
4 (12/14) The chloride content class shall conform to the following requirements:
TABLE 17/1: (12/14) Chloride content classes
Type or use of concrete Chloride Maximum total chloride content expressed as %

content of chloride ion by mass of cement (inclusive of
class ggbs or fly ash when these are used as cement)
Prestressed concrete, heat-cured Cl 0,10 0.10%

concrete containing embedded metal
Concrete containing embedded metal Cl 0,20 0.20%

and made with sulfate-resisting
Portland cements CEM I-SR 0 and
CEM I-SR 3 conforming to BS EN
197-1
Concrete containing embedded metal Cl 0,30 0.30%

and made with other permitted cements

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(12/14) Control of Alkali-Silica Reaction

5 (12/14) The provisions given in 5.2 of BS 8500-2 shall be applied to minimize damaging alkali-silica reaction.
Extremely reactive aggregates, comprising those aggregates containing detectable quantities of opal, glass and
calcined flint, shall not be used alone or in combination with other aggregates. The definition of rock types shall be
as in BS EN 932-3.
(12/14) Buried Concrete Exposed to Sulfates
6 (12/14) Choice of concrete and additional protective measures (APMs) shall comply with the requirements of
BS 8500-1 for the design chemical (DC) class described in contract specific Appendix 17/1.
(12/14) Early Thermal Cracking
7 (12/14) The execution of concrete structures shall conform to the assumptions made in the design to control
early thermal cracking and described in contract specific Appendix 17/1, unless otherwise agreed with the
(12/14) Cover to Reinforcement
8 (12/14) The Contractor shall provide certificates of compliance with respect to cover to reinforcement and
detailed records of measured covers to the Overseeing Organisation before concrete is placed.
1705 (12/14) Concrete – Requirements for Designed Concrete

(12/14) Conformity Criteria
1 (12/14) The conformity criteria for a concrete shall be in accordance with BS EN 206-1 and BS 8500.
(12/14) Suitability of Proposed Constituent Material Proportions
2 (03/20) The Contractor shall record, prior to the supply of any designed concrete, the following information
which shall be subsequently supplied to the Overseeing Organisation in accordance with the requirements of
CG 302:
(i) the nature and source of each material;
(ii) either:
(a) appropriate existing data as evidence of satisfactory previous performance for target mean strength,
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current margin, consistence and water/cement ratio; or
(b) full details of initial tests carried out in accordance with Annex A of BS EN 206-1;
(iii) the quantities of each constituent material per cubic metre of fully compacted concrete.
Assessment of the concrete in accordance with this sub-Clause shall be carried out for each different source of
material and for any change in the quantities of each constituent material (except for changes in cement content of
not more than 20 kg/m3 and pro-rata changes in aggregate contents where a single assessment is required).
1706 (12/14) Concrete – Production

(12/14) Production Control
1 (12/14) All concrete produced shall be subject to production control, as specified in Clause 9 of BS EN 206-1
and Clause 13 of BS 8500-2, and in accordance with the requirements of Clause 104.

(12/14) Consistence At Delivery

2 (12/14) In general water or admixtures shall not be added to concrete delivered to site following initial mixing in
accordance with the mix design. Water or admixtures may only be added in special circumstances under the
direction of the concrete producer and used to bring the consistence to the specified value provided that the limiting
values, permitted by the Specification, are not exceeded. The quantity of any additional water or admixture added
to the mix shall be recorded on the delivery ticket in all cases along with name of the organisation and person
authorising the additions and the record of sub-Clause 1705.2 shall be amended accordingly.
(12/14) Self-Compacting Concrete (SCC)
3 (12/14) The use of SCC is not covered by this Specification. Where the use of SCC is proposed, it shall be
subject to the approval of the Overseeing Organisation through its Departure from Standards processes.
1707 (12/14) Concrete – Conformity and Identity Testing

(12/14) General
1 (12/14) Sampling and testing of fresh and of hardened concrete shall comply with BS EN 206-1 unless
otherwise described in contract specific Appendix 17/4, and shall be as scheduled in contract specific Appendices
1/5 and/or 1/6 as appropriate, in accordance with Clause 105.
(12/14) Identity Testing
2 (12/14) Where identity testing for compressive strength is required, as described in contract specific Appendix
17/4, it shall be in accordance with the requirements given in Annex B of BS EN 206-1 and Annex B of BS 8500-1.
Where identity testing for slump, flow, air content and density on individual batches of concrete is required, as
described in contract specific Appendix 17/4, it shall be in accordance with Annex B of BS 8500-1. Identity testing
shall be as scheduled in contract specific Appendix 1/5 and/or 1/6.
1708 (12/14) Concrete – Surface Finish

(12/14) Trial Panels
1 (12/14) When required in contract specific Appendix 17/3 and before commencing concrete works the
Contractor shall prepare a trial panel of a suitable size that will demonstrate that the required surface finish can be
achieved by the methods proposed.
The panel of concrete shall contain reinforcement representative of the reinforcement sizes and spacings in the
sections of the permanent works the panel represents and shall be filled with the concrete proposed for the works
the trial panel relates to compacted by the method to be used in the works. As soon as practicable after compaction,
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the formwork shall be removed to check that the required surface finish and compaction has been achieved.
Reference panels have also been produced showing typical Class F2 and F4 surface finishes made with local
materials in each region of the UK and they can be viewed at various sites throughout the UK.
(12/14) Control of Colour
2 (12/14) When stated in contract specific Appendix 17/1 each constituent material shall be obtained 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 sand (i.e. fine aggregate), shall be maintained constant. The same type of formwork
facing material, surface finish and surface treatments shall be used in formwork throughout similar exposed areas.

(12/14) Release Agents
3 (12/14) Release agents for the formwork shall enable the formwork to be removed without damage to the
concrete surface. Where a concrete surface is to be permanently exposed, only one agent shall be used throughout
the entire area. Release agents shall be applied evenly and shall not be permitted to come into contact with
reinforcement, prestressing tendons and anchorages; contamination from release agents shall be removed from such
areas.
Where the concrete is to receive an applied finish, or surface impregnation, release agents shall be compatible with
the particular material and any associated process.
(12/14) Surface Finishes for Concrete
4 (i) (12/14) Formed Surfaces – Classes of Finish
Formwork as described in sub-Clause 1710.2 shall be capable of producing the following finishes where required
in the works:
Class F1. A dense finish with no grout or mortar loss with the specified cover to embedded metal and achieving
the specified dimensional tolerances.
Class F2. As the requirements of F1 and the irregularities in the finish shall be no greater than those obtained
from the use of wrought thicknessed square edged boards arranged in a uniform pattern. The finish is intended
to be left as struck but imperfections such as fins and surface discolouration shall be made good.
Class F3. As the requirements of F1 and the resulting finish shall be smooth and of uniform texture and
appearance. The formwork lining shall leave no stain on the concrete and shall be so joined and fixed to its
backing that it imparts no blemishes. It shall be of the same type and obtained from only one source throughout
any one structure. The Contractor shall make good any imperfections in the finish. Internal ties and embedded
metal parts shall not be used.
Class F4. The requirements for Class F4 are as for Class F3 except that internal ties and embedded metal parts
shall be permitted. The ties shall be positioned only in rebates or in other positions as described in contract
Class F5. The resulting finish shall be smooth and of uniform texture. Any blemishes and imperfections, such
as discolouration and fins, shall be made good. Provision for the embedment of metal parts in the permanent
works on a regular spacing, shall be allowed.
Other Classes. The finishes shall comply with the specific requirements described in contract specific
Appendix 17/3.
Permanently exposed concrete surfaces to all Classes of finish other than F1 shall be protected from rust marks
and stains of all kinds.
Unless otherwise described in contract specific Appendix 17/3, all formwork joints for all classes of finish
other than F1 shall form a regular pattern with horizontal and vertical lines continuous throughout each
structure and all construction joints shall coincide with these horizontal or vertical lines.
(ii) (12/14) Unformed Surfaces – Classes of Finish
Class U1 finish. The concrete shall be levelled and screeded to produce a uniform surface to the profile shown
on the drawings. No further work shall be applied to the surface unless it is used as a first stage for another
class of finish.
Class U2 finish. After the concrete has hardened sufficiently, the Class U1 finish shall be floated by hand or
machine sufficiently only to produce a uniform surface free from screed marks.
Class U3 finish. When the moisture has disappeared and the concrete has hardened sufficiently to prevent
laitance from being worked to the surface, a Class U1 finish shall be steel-trowelled under firm pressure to
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produce a dense, smooth uniform surface free from trowel marks.

Class U4 finish. The concrete shall be levelled and screeded to produce a uniform surface. When the concrete
has sufficiently hardened and the bleed water evaporated the surface shall be trowelled to produce a hard dense
surface free from screed marks and exposed aggregate. Finally the surface shall be lightly textured with a
wooden float or equivalent. Alternatively the concrete shall be levelled, screeded and floated to produce a
uniform surface and immediately before the waterproofing operation this surface shall receive surface
preparation by water jetting or grit blasting to provide a lightly textured finish. The finished surface shall not
deviate from the required profile by more than 10 mm over a 3 m gauge length or have any abrupt irregularities
more than 3 mm.
Class U5 finish. The concrete shall be levelled and screeded to produce a uniform finish. When the concrete
has sufficiently hardened to prevent laitance being worked to the surface it shall be floated to produce a surface
free from screed marks and exposed aggregate. Finally the surface shall be textured to suit the requirements of
the particular waterproofing and surfacing system. The accuracy of the finished surface shall be such that it
does not deviate from the required profile by more than 5 mm over a 3 m gauge length or have any abrupt
irregularities.
Other Classes. The finishes shall comply with the specific requirements described in contract specific
Appendix 17/3.
1709 (03/20) Concrete – Surface Protection Systems

(03/20) General Requirements
1 (i)
(03/20) The structural concrete elements receiving surface protection systems shall be as specified in
(ii) The Contractor shall submit details of the surface protection system products to the Overseeing
Organisation for acceptance at least 4 weeks prior to commencing the surface protection works.
(iii) Special requirements or constraints to the application of surface protection systems shall be as detailed
(iv) The Contractor shall include details of the surface protection system and its application in the quality
plan and method statement submitted to the Overseeing Organisation in accordance with Clause 104 and
as specified in contract specific Appendix 1/24.
(v) Contaminated materials, protective sheeting or masking that have come into contact with surface
protection system products shall be disposed of at an appropriate disposal facility.
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(vi) Surface protection system products used in combination with other surface protection system products
shall be compatible with each other and applied in complementary combinations.
(vii) Surface protection systems shall be clear and colourless following application to the concrete substrate.
(03/20) Supply, Storage and Disposal of Surface Protection Systems
2 (i) (03/20) The Contractor shall implement processes for delivery, handling, disposal and spillage of
surface protection systems such that all safety, environmental and specification requirements are met.
Details of these processes shall be included in the quality plan and method statement as required in
sub-Clause 1709.1(iv) and shall include the requirements of paragraphs (ii) to (x) of this sub-Clause.
(ii) Surface protection system products shall be delivered to site in individual sealed containers or in a bulk
container. Product and container markings shall be examined upon delivery to site to ensure they are
within the manufacturer’s stated use by dates for the duration of the works.
(iii) The delivery dates for surface protection system products shall be recorded.
(iv) Surface protection system products shall be stored in a controlled environment in accordance with the
manufacturer’s recommendations and BS EN 1504-10.
(v) Quantities of surface protection system products used for the works shall be monitored on site.

(vi) Containers shall remain sealed until their contents are required for use.
(vii) The contents of any opened containers shall be used within the time limits in accordance with the
(viii) Any unused content of opened containers exceeding the time limits in accordance with the
manufacturer’s instructions must be disposed of in accordance with the Control of Substances
Hazardous to Health Regulations (COSHH).
(ix) If spillages of surface protection system products occur, the Contractor shall take immediate action to
limit the extent of the spillage in accordance with the manufacturer’s instructions.
(x) The Contractor shall inform the Overseeing Organisation and relevant responsible authorities of the
spillage without delay.
(03/20) Surface Protection Systems – Substrate Preparation
3 (i) (03/20) The concrete substrate shall be cleaned and prepared in accordance with the manufacturer’s
instructions and BS EN 1504-10.
(ii) The concrete substrate shall be free from defects prior to the application of the surface protection
system.
(iii) Where concrete repairs to defects are to be undertaken these shall be executed, prior to the application of
the surface protection system, in accordance with Series 5700.
(iv) The concrete substrate shall be free from contaminants, such as dust, dirt, oil and laitance, which might
affect the adhesion of the surface protection system to the substrate.
(v) Where hydrophobic impregnation products are to be applied, artificial drying of the concrete surface
shall not be permitted.
(vi) Where there is delay between cleaning and the application of the surface protection system, the cleaned
substrate shall be protected from further contamination.
(03/20) Hydrophobic Impregnation – General
4 (i) (03/20) Hydrophobic impregnation products shall conform to BS EN 1504 parts 1, 2, 8, 9 and 10.
(ii) Hydrophobic impregnation shall protect the concrete substrate against diffusion of chloride ions.
(03/20) Hydrophobic Impregnation – Materials
5 (i) (03/20) The performance requirements for hydrophobic impregnation shall be as specified in contract
specific Appendix 17/2. The performance requirements for specific performance characteristics of
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Table 3 of BS EN 1504-2 shall be in accordance with Table 17/2.

TABLE 17/2 (03/20) Performance Requirements for Hydrophobic Impregnation

BS EN Performance Test Method Requirements
1504-2 Characteristics
Table 3 ref
17 Loss of mass due to BS EN 13581 The loss of mass of the surface of the impregnated
freeze-thaw specimen must occur at least 20 cycles later than that of
the non-impregnated specimen
19 Depth of penetration Specified in Table 3 of class II: ≥10mm
BS EN 1504-2
23 Water absorption and BS EN 13580 Absorption ratio (after immersion in alkali solution)
resistance to alkali test <10%
25 Diffusion of chloride ions Subject to national standards Sub-Clause 1709.6(vi).
and national regulations: test
detailed in sub-Clause 1709.6
(ii) Evidence of compliance with the harmonised part of BS EN 1504-2 with respect to product performance
shall be demonstrated by CE marking and a Declaration of Performance where the declared performance
for the essential characteristics given in Annex ZA of that Standard is equal or greater than the
performance level required for the intended use of the product and the specification.
(03/20) Hydrophobic Impregnation – Test to Determine Resistance to Diffusion of Chloride Ions
6 (i) (03/20) Principle of test. The chloride profiles of treated and untreated concrete slabs shall be compared
after ponding the top surface of the slabs with salt solution fortnightly for 15 cycles.
(ii) Casting of test specimens. The test specimens shall be 450mm x 450mm x 100mm deep, and shall be
cast upside down with an insert in the base of the mould which forms a recess for treatment and
subsequent ponding, as shown in Figure 17/1. Four specimens shall be cast in accordance with
BS EN 1766 using Type C concrete as specified in that Standard. The specimens shall be cured in their
moulds under damp hessian for 24 hours and then demoulded. Thereafter the specimens shall be cured
under damp hessian for a further 6 days and then air-cured in the laboratory.

Figure 17/1 (03/20) Details of Test Specimen

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(iii) Treatment of the specimens. The top surface of two of the specimens shall be treated with the
hydrophobic impregnation product at least 28 days after casting, and the other two shall be used as
untreated control specimens. The specimens shall be treated in a fume cupboard to avoid cross
contamination of the untreated specimens. After treatment, the specimens shall be kept in the fume
cupboard with the fan turned off for a minimum of 48 hours before being moved into the laboratory.
The volume or weight of hydrophobic impregnation product required to cover the treated surface of the
specimens shall be calculated, and the product shall be applied to the specimens in accordance with the
manufacturer’s instructions and with the following:
(a) When liquid hydrophobic impregnation products are used, the required volume or weight of
product shall be poured over the test surface of each specimen, and spread with the base of a small
beaker to ensure that the whole surface is completely wetted.
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(b) When cream or gel hydrophobic impregnation products are used, they shall be applied using a
small roller. The roller shall first be charged with the product and weighed. The product shall then
be applied uniformly to the test surface by passing the roller over the surface. The roller shall then
be weighed to establish the amount of product that has been applied. If required, additional product
can be applied with further passes of the roller until the target application rate is achieved. Trials on
spare specimens shall be carried out to establish how much product is required to achieve the
specified application rate.
(iv) Ponding the specimens. The treated and untreated specimens shall be stored on a level surface in a
laboratory maintained at a temperature between 10°C and 25°C and ponded fortnightly for 15 cycles.
For each ponding cycle, one litre of 5% sodium chloride solution by weight shall be poured into the
recessed test area of each slab. The solution will dry off after a few days and the next cycle shall
commence 14 days after the first application of the salt solution.
(v) Chloride profiles. After 15 cycles, a single 50mm diameter core with a minimum depth of 60mm shall
be removed from the ponded surface of each slab. The cores shall be removed a minimum of 100mm
from the edges of the slabs. Dust samples shall be obtained by sawing the cores at depths of 5mm,
10mm and 15mm from the ponded surface and then grinding the slices to produce dust samples. For
each increment, the dust samples from the treated and untreated pairs of slabs shall be combined to form
a single sample. The chloride concentration of each of the dust samples shall be determined in
accordance with BS 1881 Part 124.
(vi) Requirement. For each increment, the percentage reduction (PR) in chloride ion concentration in the
treated slabs (Ct) compared with the chloride ion concentration in the untreated slab (Cu), given by
PR (%) = 100*(Cu-Ct)/Cu, shall be calculated. In order for the hydrophobic impregnation product to be
acceptable for use, the percentage reduction in chloride ion concentration shall be greater than 75% for
the 0-5mm increment, and greater than 90% for the 5-10mm and 10-15mm increments.
(03/20) Hydrophobic Impregnation – Testing
7 (i) (03/20) When transparent liquid hydrophobic impregnation products are used, the Contractor shall
demonstrate that they have not been contaminated by the following procedure, and as specified in
(a) The refractive index of the hydrophobic impregnation product shall be tested as follows:
• collect samples from each of the newly opened containers and from the spraying nozzle;
• measure the refractive index of three samples from each of the containers and the spray nozzle
using a portable refractometer;
• record the ambient temperature;
• correct the refractive index measurements to the temperature stated in the manufacturer’s product
specification.

(b) The measured value for each batch of the hydrophobic impregnation product shall comply with the
following:
• value stated in the manufacturer’s product information;
• within a limit of 0.003 units of each other.
(ii) Before the commencement of the works the Contractor shall demonstrate by procedure trials the
suitability of the proposed product, the method of working and the competence of the proposed
operatives executing the application as follows, and as specified in contract specific Appendix 17/2:
(a) construct small trial concrete panels on both vertical and horizontal surfaces replicating substrate
on site, with minimum dimensions 3m x 3m;
(b) the operative shall apply the hydrophobic impregnation product to the trial panels in accordance
with the method statement;
(c) the proposed rate of application shall achieve saturation (for liquids) or result in an evenly applied
material over the concrete surface (for gels and creams).
(03/20) Hydrophobic Impregnation – Application
8 (i) (03/20) Protective measures to prevent contamination of watercourses and damage to humans, animals,
vegetation and vehicles from the hydrophobic impregnation shall be implemented prior to the
application of the product.
(ii) Where hydrophobic impregnation is applied on structures over or adjacent to roads or railways,
protective sheeting or complete encapsulation, as well as safety measures shall be implemented.
(iii) Elastomeric bearings, painted steel surfaces, bituminous materials and joint sealants shall be protected
during the application of hydrophobic impregnation, with the protective measures maintained in
positions and good condition.
(iv) Hydrophobic impregnation shall not be applied until the concrete surface has been dry for 24 hours.
(v) The hydrophobic impregnation product shall be applied in accordance with the manufacturers’
instructions and safety information and the method statement.
(vi) Each application of the hydrophobic impregnation product on the face of a structural element shall be
executed in a single continuous operation.
(vii) Unless otherwise stated by the manufacturer’s instructions, hydrophobic impregnation shall be carried
out not less than 7 days after the concrete has been placed, or 3 days after concrete repairs have been
completed on a structural element.
(viii) Unless otherwise stated by the manufacturer’s instructions, hydrophobic impregnation shall not be
carried out in the following conditions:
(a) when the shade temperature is below 5°C;
(b) when the temperature of the concrete surface is lower than 5°C or greater than 25°C;
(c) when the shade temperature is less than 3°C above dew point;
(d) when the wind speed is in excess of 8 km/hr, unless the working area is fully encapsulated.
(ix) The treated concrete substrate shall be protected from rain and spray during application and for at least
six hours after completion or in accordance with the manufacturer’s instructions, whichever is the later.
(03/20) Anti-Graffiti Coatings – General
9 (i) (03/20) Anti-graffiti coatings shall conform to BS EN 1504 parts 1, 2, 8, 9 and 10.
(ii) Anti-graffiti coatings shall allow graffiti on treated areas of concrete structures to be removed without
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damage to the concrete substrate.

(iii) Anti-graffiti coatings shall not noticeably change the appearance of the substrate to which they are
applied.

(03/20) Anti-Graffiti Coatings – Materials

10 (i) (03/20) The performance requirements for anti-graffiti coatings shall be as specified in contract specific
Appendix 17/2. The performance requirements for specific performance characteristics of Table 5 of
BS EN 1504-2 shall be in accordance with Table 17/3.
TABLE 17/3 (03/20) Performance Requirements for Anti-graffiti Coatings
Table 5 ref
7 Permeability to BS EN ISO 7783-1 class I sD < 5m (permeable to water vapour)
water vapour BS EN ISO 7783-2
15 Adhesion strength BS EN 1542 Average [N/mm2]
by pull-off test Crack-bridging Rigid systemsc
or flexible
systems
without ≥ 0.8 (0.5)b ≥1.0 (0.7)b

trafficking
b
The value in brackets is the lowest accepted value of any reading
c
Rigid coatings are coatings with shore D ≥ 60 according to BS EN ISO 868
(03/20) Anti-Graffiti Coatings – Testing
11 (03/20) The Contractor shall demonstrate by procedure trials the suitability of the proposed product, the method
of working and the competence of the proposed operatives executing the application of the anti-graffiti
coating as follows, and as specified in contract specific Appendix 17/2:
(i) construct small trial concrete panels replicating substrate on site, with minimum dimensions 3m x 3m;
(ii) the operative shall apply the anti-graffiti coating to the trial panels in accordance with the method
statement;
(iii) the appearance of the trial panel following application of the anti-graffiti coating shall not have been
noticeably altered;
(iv) graffiti shall be applied to the treated trial panels and allowed to cure;
(v) once the graffiti is cured, cleaning of the trial panels shall be undertaken to demonstrate the removal of
graffiti without damage to the concrete substrate.
(03/20) Anti-Graffiti Coatings – Application
12 (i) (03/20) Application of the anti-graffiti coating shall be in accordance with the manufacturer’s instructions.
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(ii) Where repairs to the concrete are carried out prior to the application of the coating, the subsequently
applied coating shall be compatible with the concrete substrate, the repair materials used and any other
surface protection system product applied.
(iii) Finished surfaces shall be protected to prevent early and irreparable defacement in accordance with the
manufacturer’s instructions, or for five days after application of the final coat, whichever is the later.

(03/20) Anti-Carbonation Coatings – General

13 (i) (03/20) Anti-carbonation coatings shall conform to BS EN 1504 parts 1, 2, 8, 9 and 10.
(ii) Anti-carbonation coatings shall protect the concrete structure against carbon dioxide ingress and the
consequential carbonation of the substrate.
(03/20) Anti-Carbonation Coatings – Materials
14 (i) (03/20) The performance requirements for anti-carbonation coatings shall be as specified in contract
specific Appendix 17/2. The performance requirements for specific performance characteristics of
Table 5 of BS EN 1504-2 shall be in accordance with Table 17/4.
TABLE 17/4 (03/20) Performance Requirements for Anti-Carbonation Coatings
Table 5 ref
6 Permeability to CO2 BS EN 1062-6 Permeability to CO2 SD > 50m
(Conditioning of the
samples before testing
should be in accordance
with BS EN 1062-11
4.3)
7 Permeability to water BS EN ISO 7783-1 class I sD < 5m (permeable to water vapour)
vapour BS EN ISO 7783-2
8 Capillary absorption and BS EN 1062-3 w < 0.1[kg/m²] h0.5
permeability to water
15 Adhesion strength by BS EN 1542 Average [N/mm2]
pull-off test Crack-bridging or Rigid systemsc
flexible systems
without ≥ 0.8 (0.5)b ≥1.0 (0.7)b
trafficking
with trafficking ≥1.5 (1.0)b ≥2.0 (1.5)b
9 Adhesion after thermal BS EN 13687-1 and After thermal cycling
compatibility BS EN 13687-2 a) no bubbles, cracks and delamination
For outside application
b) pull of test results
with de-icing salt influence
Average [N/mm2]
Crack-bridging or Rigid systemsc
flexible systems
without ≥ 0.8 (0.5)b ≥1.0 (0.7)b
trafficking
with trafficking ≥1.5 (1.0)b ≥2.0 (1.5)b
13 Crack bridging ability BS EN 1062-7 The required classes and the test conditions are given in
Tables 6 and 7 of BS EN 1504-2
20 Artificial weathering BS EN 1062-11 After 2000 hours of artificial weathering:
no blistering according to BS EN ISO 4628-2
no cracking according to BS EN ISO 4628-4
no flaking according to BS EN ISO 4628-5
Slight colour change, loss of gloss and chalking
may be acceptable, but shall be described.
b
The value in brackets is the lowest accepted value of any reading
c
Rigid coatings are coatings with shore D ≥ 60 according to BS EN ISO 868
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(03/20) Anti-Carbonation Coatings – Application
15 (i) (03/20) Application of the anti-carbonation coating shall be in accordance with the manufacturer’s
instructions.
(ii) Where repairs to the concrete are carried out prior to the application of the coating, the subsequently
applied coating shall be compatible with the concrete substrate, the repair materials used and any other
surface protection system product applied.
(03/20) Surface Protection Systems – Records
16 (03/20) Following the application of the surface protection system, a comprehensive record shall be prepared
by the Contractor, subsequently supplied to the Overseeing Organisation in accordance with the requirements of
CG 302 (DMRB 3.2.1), incorporating the following information as a minimum:
(i) As-built records showing extents of the surface protection systems application;
(ii) all relevant technical literature relating to the surface protection system products used;
(iii) application method;
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(iv) contract compliance test findings;

(v) amount of materials used;
(vi) number of applications;
(vii) coverage rate;
(viii) weather conditions;
(ix) maintenance requirements;
(x) removal requirements.
1710 (12/14) Concrete – Construction General

(12/14) Construction Joints
1 (12/14) The position of construction joints shall be as shown on the drawings and at additional positions
determined by the Contractor in accordance with the requirements of contract specific Appendix 17/4. When
concrete is placed in vertical members, walls, columns and the like, the lifts of concrete shall finish level or, in
sloping members, at right angles to the axis of the members, and the joint lines shall match features of the finished
work, if possible, or be formed by grout checks. Kickers shall be constructed integrally with the lift of concrete
below.
Concreting shall be carried out continuously up to construction joints.
Unless interface shear calculations in accordance with BS EN 1992-2 (Clause 6.2.5 of BS EN 1992-1-1) show that
a non-prepared surface between concrete cast at different times is sufficient for structural purposes, construction
joints shall be prepared in either of the following ways:
(i) When the concrete is self-supporting but still sufficiently green, the formwork shall be removed, as
necessary to expose the construction joint, subject to the requirements of sub-Clause 5 of this Clause.
The concrete surface shall be sprayed with a fine spray of water or brushed with a stiff brush, just
sufficiently to remove the outer mortar skin and expose the larger aggregate without disturbing it.
Alternatively where this preparation proves impracticable the hardened surface skin and laitance shall be
removed by grit blasting or a needle gun. Hardened surfaces shall not be hacked.

(ii) By the use of proprietary steel open-mesh permanent formwork intended for use in construction joints.
Retarding agents shall not be used unless permitted in contract specific Appendix 17/4.
The joint surface shall be clean and damp but free of standing water immediately before any fresh concrete is
placed against it.
(12/14) Falsework and Formwork
2 (i)
(12/14) Design and construction. The formwork shall be sufficiently rigid and tight to prevent loss of
grout or mortar from the concrete at all stages and for the appropriate method of placing and
compacting. The falsework and formwork shall be so arranged as to be readily dismantled and removed
from the cast concrete without shock, disturbance or damage.
Where necessary, the falsework and formwork shall be so arranged that the soffit form, properly
supported on props only, can be retained in position for such period as may be required by maturing
conditions as described in sub-Clause 1710.4(ii). If the 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. Where it is intended to re-use formwork it shall be thoroughly cleaned and made good.
Internal metal ties which require being withdrawn through hardened concrete shall not be used where
either face is permanently exposed. Where internal ties are left in, they shall be provided with a mortar
cover of at least 50 mm. The jointing faces of the pocket shall be prepared with an exposed aggregate
finish and dampened immediately prior to mortar filling.
(ii) (12/14) Cleaning and treatment of forms. The faces of the forms in contact with the concrete shall be
clean and treated with a suitable release agent, where applicable as described in sub-Clause 1708.3.
Immediately before concreting, all forms shall be thoroughly cleaned out. The source of any compressed
air used for the clearing of foreign matter from formwork shall be free from oil and other contaminant.
(iii) (12/14) Projectingreinforcement and fixing devices. 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 striking forms.
(iv) (03/20) Permanent formwork or special formwork shall comply with contract specific Appendix 17/4.
When reinforced concrete plank permanent formwork (floor plates) is used, it shall comply with
BS EN 15050 and contract specific Appendix 17/7, as described in sub-Clause 1710.8.
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Gaps between permanent formwork units shall be adequately sealed to prevent leakage through the gaps.
For composite steel and concrete structures where permanent formwork is used, a suitable compressible
construction seal shall be placed between the steel member and the permanent formwork where they
overlap, to prevent leakage of grout during subsequent concreting operations. On completion of the
curing of the concrete a suitable proprietary adhesive sealant shall be placed along the external interface
between the steelwork and the permanent formwork to prevent ingress of moisture. The sealant shall be
compatible with the surfaces it will be in contact with and shall have comparable durability to the
corrosion protection to the steelwork. In the case of the use of weather resistant steels no sealant shall be
provided.
Profiled steel sheeting (PSS) permanent formwork systems shall not contain indentations which may
form a shear connection with the in-situ concrete, unless otherwise specified in contract specific
Appendix 17/4. Protective treatment on edges and adjacent surfaces, including the edges of PSS which
have been damaged by cutting, shall be restored to meet the contract specific requirements or an
equivalent level of corrosion protection durability, in accordance with Series 1900.
Only single skin panels, either flat sheet or corrugated, shall be used for glassfibre reinforced concrete
(GRC) permanent formwork. Polystyrene formers shall not be used in the corrugations of GRC
permanent formwork.
When ribbed glass reinforced polymer (GRP) permanent formwork is used, there shall be no filler
materials such as expanded polystyrene placed between the GRP ribs, which would prevent full contact
between the deck concrete and the surface of the ribbed panels.

Permanent formwork panels which have dimensions that do not comply with manufacturers’
dimensional tolerances shall not be used in the works. Damaged panels including those that are cracked,
split or have, in the case of the GRP type, exposed steel in the ribs, shall not be used in the works.
Formwork panels shall be thoroughly cleaned to remove all traces of oil or grease. Any glass fibre
reinforced cement (GRC) panel which cannot be cleaned by following the manufacturers’
recommendations shall be replaced.
(12/14) Transporting, Placing and Compacting
3 (03/20) Concrete shall be transported and placed so that contamination, segregation or loss of the constituent
materials does not occur, in accordance with Clause 14 of BS 8500-2.
Concrete, when deposited, shall have a temperature of not less than 5°C. Where the concrete is made using CEM I
or a CEM II/A cement the concrete temperature shall not be more than 30°C. Where the concrete is made using a
CEM II/B or a CEM III cement, or equivalent combination, the concrete temperature shall not be more than 35°C.
The temperature of fresh concrete shall be measured in accordance with BS 8500-2. Fresh concrete shall not be
placed against in situ concrete that has been in position for more than 30 minutes unless a construction joint is
formed as described in sub-Clause 1 of this Clause.
Where lightweight aggregate concrete is to be pumped, the Contractor shall demonstrate to the satisfaction of the
Overseeing Organisation that pumping will have no significant effect on the strength of the hardened concrete.
No concrete shall be placed in flowing water. Underwater concrete shall be placed in position by tremies or by
pipelines using methods to ensure the requirements of this Specification are met.
When concreting bridge decks of substantial thickness to avoid layering of concrete, the whole thickness shall be
placed in one pass. In deck slabs where void formers are used, adequate means to prevent flotation shall be
employed and care taken to ensure adequate compaction of the concrete placed beneath the void formers; joints
between adjacent units, or units and form faces shall be sealed to prevent loss of grout.
Where the minimum dimension of a concrete section to be placed at a single time is greater than 600mm measures
shall be taken to reduce the adverse affects of high temperatures in the concrete or to reduce the temperature of
concrete to prevent high temperatures having an adverse effect on the finished concrete.
Concreting operations shall not displace reinforcement, tendon ducts, tendon anchorages or formwork, or damage
the faces of formwork.
Concrete shall not be allowed to accumulate in heaps to a total height, nor dropped onto horizontal surfaces from a
height, greater than those described in 17.4.3 of BS 5975, unless the additional loading has been specifically taken
into account in the design and is clearly indicated in the drawings or in contract specific Appendix 17/4.
Storage of materials on falsework, formwork or permanent formwork that produces concentrated or distributed
pressures greater than 1.5 kN/m2 shall not be permitted unless the additional loading has been specifically taken
into account in the design and is clearly indicated in the drawings or in contract specific Appendix 17/4.
Concrete shall be thoroughly compacted by vibration during the operation of placing, and thoroughly worked
around the reinforcement, tendons or duct formers, around embedded fixtures and into corners of the formwork,
including permanent formwork, to form a solid mass free from voids. When vibrators are used to compact the
concrete, vibration shall be applied continuously during the placing of each batch of concrete until the expulsion of
air has practically ceased. A sufficient number of vibrators in serviceable condition shall be on site to ensure that
spare equipment is always available in the event of breakdowns. Vibration shall not be applied by way of the
reinforcement. Where vibrators of the immersion type are used, contact with reinforcement and inserts shall be
avoided as far as is practicable.
The use of self-compacting concrete is not covered by this Specification.
Concrete shall not be subjected to disturbance between 4 hours and 24 hours after compaction except that re-
compaction of the upper layers of deep lifts to prevent or anneal settlement cracking may be carried out. Whenever
vibration has to be applied externally, the design of formwork and disposition and operation of vibrators shall
ensure efficient compaction and the avoidance of surface blemishes.
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There shall be no excess water on the top surface on completion of compaction.

Slipforming shall be performed with appropriate equipment using methods to ensure that the requirements of this
Specification are met.
(12/14) Removal of Formwork and Falsework
4 (i)
(12/14) General. Falsework and formwork shall be removed in a manner that does not damage the
concrete, and at times to suit the requirements for its curing and to prevent restraint that may arise from
elastic shortening, shrinkage or creep.
(ii) (03/20) Timing of removal for cast in situ concrete. Where the concrete compressive strength is confirmed
by tests on concrete cubes stored under conditions that simulate the field conditions, formwork
supporting concrete in bending may be removed when the cylinder/cube strength is 12/15 N/mm2 or the
strength needed by the design, whichever is the greater. For ordinary structural concrete made with
Portland cement (CEM I) or sulfate-resisting Portland cements (CEM I-SR 0 or CEM I-SR 3) of strength
class 42.5 or above, in the absence of control cubes the period before removal shall be in accordance
with the minimum periods given in Table 17/5.
TABLE 17/5: (03/20) Minimum Period Before Removing Falsework and Formwork (CEM I or SRPC
Concrete)
Minimum Period Before Removal
Surface temperature of concrete:
16°C 7°C t°C (any temperature between 0°C

and 25°C)
Vertical formwork to 12 hours 18 hours 300/(t+10) hours

columns, walls and large
beams
Soffit formwork to slabs 4 days 6 days 100/(t+10) days
Props to slabs 10 days 15 days 250/(t+10) days
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Soffit formwork to Beams 9 days 14 days 230/(t+10) days
Props to beams 14 days 21 days 360/(t+10) days
Where surface temperatures of concrete fall outside or are likely to fall outside the above temperature ranges
agreement shall be reached between the Contractor and Overseeing Organisation on appropriate removal times.
(12/14) Curing of Concrete
5 (03/20) General. Curing Class 3 in accordance with Clause 8.5 of BS EN 13670 shall be used unless
(i)
otherwise specified in contract specific Appendix 17/4. Additional special curing requirements may be
given in contract specific Appendix 17/4.
Immediately after compaction and thereafter for the duration of applied curing, except where elevated
temperature curing is used, concrete shall be protected against harmful effects of weather, including rain,
rapid temperature changes, frost, and from drying out. The method of curing shall provide a suitable
environment for the concrete to mature and prevent loss of moisture harmful to the quality of the
concrete.
Where the Contractor proposes to use a curing liquid, compound or membrane on surfaces on which a
waterproofing system is to be laid, it shall be completely removable. The Contractor shall keep records
of all curing liquids, compounds and membranes and the areas of subsequent removal; such records shall
be subsequently supplied to the Overseeing Organisation in accordance with the requirements of
CG 302.

(ii) (12/14) Accelerated curing. Elevated-temperature curing as described below may be used only for
concrete made with Portland cement (CEM I) or sulfate-resisting Portland cements (CEM I-SR 0 or
CEM I-SR 3).
(a) The formwork may be generally heated to no more than 20°C prior to the placing of concrete.
(b) Once placing is complete the concrete shall be left for 4 hours without additional heating. The
concrete temperature can then be raised at a maximum rate of 10°C per ½hour.
(c) The concrete temperature shall at no time exceed 70°C.
(d) The rate of subsequent cooling shall not exceed the rate of heating.
(e) Cubes shall be manufactured and cured under identical conditions to those to which the concrete is
subjected.
The use of accelerated curing methods for concrete containing other types of cement or any admixture
shall not be used.
(12/14) Cold Weather Work
6 (12/14) When concrete is placed at air temperatures below 2°C, the following requirements shall be met:
(i) The aggregates and water used in the mix shall be free from snow, ice and frost.
(ii) The surface temperature of the concrete at the time of placing shall be at least 5°C. Where the concrete
is made using CEM I or a CEM II/A cement, the concrete temperature shall not be more than 30°C.
Where the concrete is made using a CEM II/B or a CEM III cement, or equivalent combination, the
concrete temperature shall not be more than 35°C.
(iii) The surface temperature of the concrete shall be maintained at not less than 5°C until the concrete
reaches a strength of 5 N/mm² as determined by tests on cubes that were cured under identical conditions
to the structural concrete.
(iv) Before placing concrete, the formwork, reinforcement, prestressing steel and any surface with which the
fresh concrete will be in contact shall be free from snow, ice and frost.
(v) Cement shall not be allowed to come into contact with water at a temperature greater than 60°C.
(12/14) Hot Weather Work
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7 (12/14) During hot weather the Contractor shall ensure that the constituent materials of the concrete are
sufficiently cool to prevent the concrete from stiffening in the interval between its discharge from the mixer and
compaction in its final position.
Cement shall not be allowed to come into contact with water at a temperature greater than 60°C.
(12/14) Precast Concrete Construction
8 (i) (12/14) General
Precast concrete elements to be used in the works shall comply with the following Product Standards as
appropriate, which are relevant for highway structures:
(a) Bridge deck elements shall comply with BS EN 15050.
(b) Foundation piles shall comply with BS EN 12794.
(c) Box culverts shall comply with BS EN 14844.
(d) Retaining wall elements shall comply with BS EN 15258.
(e) Masts and poles shall comply with BS EN 12483.

All precast concrete elements to be used in the works that fall within the scope of a Product Standard shall
be supplied in accordance with that Standard. Precast elements that are outside the scope of a Product
Standard shall conform to BS EN 13369 ‘Common rules for precast concrete products’, unless otherwise
Where minor site manufactured precast elements do not conform to any product standard or BS EN 13369,
manufacture and construction operations shall comply with the provisions of BS EN 13670 and with this
Specification.
For precast products, the manufacturing requirements as detailed in their relevant Product Standard or in
BS EN 13369 shall be complied with; the construction operations from the reception at the site or, if site
manufactured, from removal from the forms, shall comply with the provisions of BS EN 13670 and with
this Specification. Where precast products are manufactured in temporary plants on site, the production
shall be protected against adverse weather conditions and production control shall satisfy the requirements
of Clause 6 of BS EN 13369.
(ii) (12/14) Manufacture of precast products
Precast products shall be suitable for their intended use and place of installation in the works. The relevant
Product Standard for each precast product to be used shall be as identified in contract specific Appendix
17/7. Where there is no relevant Product Standard, reference to manufacture in accordance with BS EN
13369 shall be as quoted in contract specific Appendix 17/7.
Where a precast product is to be manufactured in accordance with a Product Standard, evidence of
compliance with the harmonised part of the Product Standard with respect to product performance shall be
demonstrated by CE marking and a Declaration of Performance where the declared performance for the
essential characteristics given in Annex ZA of that Standard is equal to or greater than the performance
level required for the intended use of the precast product.
The minimum set of information to be included with the CE marking and labelling in accordance with
Annex ZA of the Product Standard shall be as required in contract specific Appendix 17/7.
(iii) (12/14) Manufacture of precast concrete elements not conforming to any Product Standard or to BS EN
13369
The Contractor shall give reasonable notice to the Overseeing Organisation in advance of the date of
commencement of manufacture and casting of each type of element. A copy of all 28-day cube test results
relating to the work, as scheduled in contract specific Appendix 1/5, shall be made available by the
Contractor to the Overseeing Organisation in accordance with Clause 105.
For all prestressed elements, the Contractor shall provide to the Overseeing Organisation, not more than 7
days after the transfer of stress, a certificate showing the force and extension in the tendons after they were
anchored, the strength and age of test cubes cast as described in sub-Clauses 1724.3 and 1724.4 and the
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minimum age in hours of the concrete at the time the stress was applied to the element.
For all prestressed pretensioned elements the length, cross-section dimensions and straightness of precast
concrete shall be measured, as far as practicable, at 28 ± 2 days after casting. If earlier measurement is
required, the manufacturer should allow for further shrinkage and creep between the time of measurement
and 28 days, based on recorded experience.
All elements shall be indelibly marked to show the element mark as shown on the drawings, the weight of
the element, the production line on which they were manufactured, the date on which the concrete was cast
and, if they are of symmetrical section, the face that will be uppermost when the element is in its correct
position in the works. The markings shall be so located that they are not exposed to view when the element
is in its permanent position.
(iv) (03/20) Requirements for all precast elements (including precast products)
(a) General. Where tests are to be carried out, no elements to which the tests relate shall be dispatched
to the site until the tests have been satisfactorily completed. In the case where elements are
manufactured in temporary plants on site, they shall not leave the designated production area until
the tests have been satisfactorily completed.

Unless interface shear calculations in accordance with BS EN 1992-2 (Clause 6.2.5 of BS EN 1992-1-1)
show that a non-prepared surface between concrete cast at different times is sufficient for structural
purposes, the vibrated top surface of precast concrete elements which will subsequently receive in situ
concrete shall be further prepared using one of the following methods and therefore considered as
“Rough” in accordance to Clause 6.2.5 of BS EN 1992-1-1:
Class 1 surface preparation. The surface finish shall be in accordance with sub-Clause 1710.1.
lass 2 surface preparation. The hardened surface shall be jetted with air or water to remove laitance and
C
all loose material and no further roughening shall then be carried out (rough as cast).
The surface classification and the method of preparation shall be shown on the drawings.
(b) Handling. Elements shall be lifted or supported at points described in contract specific Appendix 17/7
and shall be handled and placed without impact. Additional constraints on the support, restraint and
dynamic loading during handling or transport are described in contract specific Appendix 17/7. The
Contractor shall incorporate, in the erection specification in accordance with BS EN 13670, the
requirements of the lifting scheme for the precast concrete elements.
(c) Storage. When elements are stored, they shall be firmly supported only at the points described in
contract specific Appendix 17/7. Where elements are stacked several units high, packings shall be
vertically above each other to prevent additional bending stresses in the elements, and the maximum
height of the stack and any provision required to maintain stability shall be as described in contract
specific Appendix 17/7. The accumulation of trapped water and deleterious matter in the units shall be
prevented. Care shall be taken to avoid rust staining and efflorescence. Where disfigurement would be
detrimental, packing pieces shall not discolour or otherwise permanently damage the elements.
(d) Protection. At all stages of construction, precast concrete elements and other concrete associated
therewith shall be properly protected to prevent damage to permanently exposed concrete surfaces,
especially arrises and decorative features.
(e) Placing and adjustment. An erection specification shall be prepared by the Contractor in accordance with
BS EN 13670 and it shall be submitted for acceptance of the Overseeing Organisation at least 4 weeks
prior to the delivery of the elements. The method of assembly and erection shall comply with any
particular requirements in contract specific Appendix 17/7 and form part of the erection specification.
(f) Requirements for placing and adjustment of composite slab bridges. In a composite slab bridge where
precast beams are laid side by side with minimal gaps to form a deck, the difference in soffit level
between adjacent units before the in situ concrete is placed shall nowhere exceed 5 mm for units up to 5
m in length or 10 mm for longer units, and the width of the deck soffit shall be within + 25 mm of that
shown on the drawings; furthermore, the width of the gap between individual beams shall not exceed
twice the nominal gap shown on the drawings. The alignment of transverse holes shall permit the
reinforcement or prestressing tendons to be placed without distortion. In adjacent spans, the continuity
of line of the outside beams shall be maintained.
Prior to placing permanent formwork, the rebates in precast concrete beams intended to receive the
formwork shall be inspected to confirm they have been well formed and that any dressing-off is carried
out before placing the formwork to ensure an even seating.
The in situ concrete in composite slab bridges shall be placed in such a sequence that the advancing edge
of the freshly deposited concrete over the full width of the deck, between longitudinal construction
joints, is approximately parallel to the deck supports. Precast beams shall be prevented from moving
laterally during the placing of the in situ concrete.
(g) Jointing and completion works. The composition and water/cement ratio of the in situ concrete or mortar
used in any connection and in the packing of joints shall be in accordance with the erection specification.
Levelling devices shall only be released or removed, in accordance with the erection specification when
the structural connection is complete and has achieved sufficient strength.
Care shall be taken to ensure that the in situ material is thoroughly compacted.

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When using proprietary jointing materials, the manufacturer’s recommendations and any particular
requirement in contract specific Appendix 17/7 for the application and methods shall be strictly followed
to ensure full compatibility between the joint type and size and the sealing method.
(03/20) Formation of Continuity Joints in Bridge Decks
9 (i) (03/20) General
When concrete bridge decks are being widened, built in stages or reconstructed in stages with continuity
joints, either by construction of a new part of the deck attached directly to the trafficked deck or by
construction of a separate parallel deck followed by an in-fill strip as a second stage, the deck in the
finished state shall be monolithic without any permanent joints or gaps.
(ii) Monitoring requirements
The differential deflection between the existing and the new part of the deck at the interface shall be
monitored by the Contractor in accordance with contract specific requirements in Appendix 17/4 until
the concrete achieves the specified characteristic strength or at least 7 days after placement, whichever is
later, in the following situations:
(a) when decks are widened by attaching a new part of the deck directly to the existing trafficked deck;
(b) when decks are widened using the in-fill strip method and traffic is running less than 1m to the
interface.
The limits on differential deflection between the new and existing parts of deck at the interface shall be
as follows:
(a) 6mm due to the weight of fresh concrete when the concrete for the new part of the deck is poured;
and
(b) 1mm due to traffic actions.
The vibration of the existing trafficked deck during the construction of the new part of the deck shall be
monitored by the Contractor in accordance with the requirements in contract specific Appendix 17/4
until the concrete achieves the specified characteristic strength, or at least 7 days after placement,
whichever is later. The measured peak particle velocity shall not exceed 5mm/s.
If the differential deflection or peak particle velocity measured on site are greater than the specified
limits and no specific analysis is available to evaluate their effects on the structure, mitigation measures
shall be implemented to reduce the differential deflection and peak particle velocity below their limits.
Results of the vibration and differential deflection monitoring shall be supplied to the Overseeing
Organisation in accordance with the requirements of CG 302.
(iii) Existing concrete deck preparation
Existing concrete shall be removed in accordance with Clause 5707. Sufficient reinforcement shall be
exposed in the removal to provide the full lap length in accordance with BS EN 1992-2.
The removal of existing concrete shall not damage the existing reinforcement.
Requirements for and restrictions on phased removal of concrete shall be as specified in contract specific
Appendix 17/4.
The existing concrete substrate shall be prepared to concrete surface profile grade CSP6 or higher in
accordance with the Guideline for Surface Preparation for the Repair of Deteriorated Concrete Resulting
from Reinforcing Steel Corrosion, 310.1R-2008 published by the International Concrete Repair Institute.
The surface of the exposed concrete substrate at the joint shall then be cleaned of all dust and grit using
methods that themselves do not add contaminants to the exposed substrate.
The prepared substrate shall be continuously wetted with potable water for a minimum period of
four hours. Any surface water remaining on the concrete breakout surface or reinforcement shall be
removed prior to placement of the new concrete.
Placement of the new concrete shall commence before the substrate dries out, and not more than
one hour after completion of wetting.

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(iv) Requirements for concrete

The concrete used for the construction of the new parts of the deck shall comply with the requirements
given in contract specific Appendix 17/1, with the slump limited to a maximum of 100mm.
(v) Requirements for reinforcement
Reinforcement shall be continuous across the continuity joint.
When the in-fill strip method is used, the reinforcement of the existing deck shall not extend beyond the
in-fill strip to lap with new reinforcement.
The exposed existing steel reinforcement within the continuity joint shall be cleaned to achieve surface
preparation standard SA2 ½ to BS EN ISO 8501-1. The exposed surface of the steel reinforcement shall
be clean immediately prior to concreting and only light flash rusting on the reinforcement shall be
permitted.
The reinforcement within continuity joints shall be securely tied at all bar intersections in accordance
with Clause 1714.
(vi) Requirements for formwork
When the in-fill strip method is used, formwork for the new part of the deck shall be kept independent
from the existing deck to ensure that traffic vibration is not transmitted at the first stage of parallel strip
construction.
1711 (12/14) Concrete – Grouting and Duct Systems for Post-tensioned Tendons
(12/14) Planning, Trials and Basic Requirements
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1 (12/14) Site operations, including duct installation, stressing and grouting, shall be carried out by organisations
certificated in accordance with the requirements of the CARES product acceptance scheme for the Supply and
Installation of Post-tensioning Systems in Concrete Structures (PT1), or an equivalent scheme. Post-tensioning
systems shall be in accordance with Clause 7.2 of BS EN 13670. The system shall have the intended use category
and shall meet any performance requirement stated in contract specific Appendix 17/6. The performance
characteristics of the post-tensioning system shall be demonstrated by CE marking and a Declaration of
Performance where the declared performance for the product characteristics is equal or greater than the
performance level required for the intended use of the product.
Precast segmental construction using internal grouted tendon system is not permitted.
Grouts for protection of prestressing tendons shall be as required in contract specific Appendix 17/6 and defined in
sub-Clause 1711.2. Grease and wax for post-tensioned unbonded tendons shall be as required in Clause 1725.
Unless otherwise agreed with the Overseeing Organisation, the Contractor shall undertake full-scale trials of the
grouting operations as required in the Contract for duct installation, testing, concreting, grouting and any other
associated requirements in accordance with the details described in contract specific Appendix 17/6. The trials are
required to demonstrate that the grouting methods and procedures proposed by the Contractor shall ensure that
grout fills the ducts and surrounds the prestressing steel.
The Contractor shall submit for acceptance of the Overseeing Organisation, a detailed method statement, at least 4
weeks prior to use in any trials or in the works, covering proposed materials, ducts, anchorage and vent
arrangements, personnel, equipment, grouting procedures and quality control. The method statement shall also
describe arrangements for storage and protection of materials (tendons etc.) on site, in the time between delivery
and grouting.
Where full scale trials are required, these shall be carried out at least 56 days before the planned commencement of
fixing ducts for prestressing for the permanent works unless specified otherwise in contract specific Appendix 17/6.
The trials shall incorporate all relevant details of ducts, vents, duct supports, prestressing anchorages and couplers,
prestressing strands, grout inlets and outlets. The tendons shall be sufficiently tensioned such that the strands within
the duct take up a representative alignment. All systems, methods and materials are to be those proposed for the
permanent works and shall have been submitted to the Overseeing Organisation as part of the detailed method
statement required. After three days the Contractor shall carefully cut or core the trial section to expose cross

sections and longitudinal sections of the duct, anchorages and any other locations where required, or as further
directed by the Overseeing Organisation, to demonstrate that the duct is satisfactorily grouted. A report shall be
prepared by the Contractor giving full details of the trial, testing results and photographs of the exposed sections
and submitted to the Overseeing Organisation.
Grouting of the ducts shall be shown to leave no void which has either a dimension greater than 5% of the duct
diameter measured in the radial direction of the duct or which poses a risk to the protective system. The location of
any voids with respect to grout vents and their adequate grouting and subsequent sealing, and the disposition of the
steel tendons within the body of the grout shall be reported in writing by the Contractor to the Overseeing
Organisation within 24 days. Prestressing for the permanent works shall not be permitted without the prior written
acceptance of the grouting procedures by the Overseeing Organisation and formal acceptance of the results of the
grouting trial.
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Irrespective of whether the Contract requires full-scale grouting trials, the Contractor shall carry out a materials
suitability assessment in accordance with sub-Clause 1711.2. Inspection and conformity of grouting works,
including requirements prior, during and after grouting shall be in accordance with Section 9 of BS EN 446 for
Execution Class 3.
(12/14) Grout Materials, Batching and Mixing
2 (12/14) Grouts shall comply with BS EN 447 and with the requirements in this sub-Clause and sub-Clause
1711.3.
The properties of the grout, made with the materials, and using the plant and personnel proposed for use on site,
shall be assessed for suitability for the intended purpose by the Contractor in accordance with 6.1 of BS EN 446.
This assessment shall be carried out sufficiently in advance of grouting operations to enable adjustments to be made
in use of materials or plant or personnel. The assessment shall consist of the preparation of the grout, made with the
materials, and using the plant and personnel proposed for use on site, and the testing of it in accordance with
sub-Clause 1711.3. The preparation shall be carried out under representative conditions of temperature expected on
site. If grouting operations are likely to cover different seasons, the assessment shall be carried out for the expected
range of temperatures.
No departures from the sources of the materials and procedures approved as a result of satisfactory trials will be
permitted without the written approval of the Overseeing Organisation.
When pre-bagged grouts are used, they shall be obtained from companies holding a valid CARES product
acceptance scheme certificate for the production of pre-bagged grouts complying with the requirements of BS EN
445, BS EN 446 and BS EN 447 (PT10), or an equivalent scheme.
All bagged materials shall be weighed before use, unless clearly weight marked with stated tolerance.
(12/14) Admixtures
(12/14) 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 1711.3. 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.
Admixtures are divided into two types, expanding and non-expanding and they may be used to obtain the required
grout performance. Admixtures used in combination shall be checked for compatibility by the Contractor, and
reported to the Overseeing Organisation for acceptance.
Admixtures shall not contain substances in quantities that will adversely affect the grout or cause the grout to
promote corrosion of the prestressing steel by rusting, pitting, stress corrosion or hydrogen embrittlement.
The admixture shall not segregate, shall be uniform in colour and the composition shall not change. Admixtures
shall comply with BS EN 934-4; evidence of compliance with the harmonised part of BS EN 934-4 with respect to
product performance shall be demonstrated by CE marking and a Declaration of Performance where the declared
performance for the essential characteristics given in Annex ZA of that Standard is equal or greater than the
performance level required for the intended use of the admixture.

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
shall comply with this sub-Clause or as otherwise agreed with the Overseeing Organisation.
(12/14) Batching and Mixing
(12/14) All materials shall be batched by mass except the mixing water and liquid admixtures which may be batched
by mass or by volume. Bagged materials shall be weighed before use, unless clearly weight marked with stated
tolerance. The accuracy of batching shall be or have been (in case of pre-bagged materials):
± 2% for dry materials, cement and admixtures
± 1% for mixing water
of the quantities specified. The total amount of mixing water shall include the water content of liquid admixtures.
Where proprietary pre-bagged grouts are used, they shall be mixed in accordance with the manufacturer’s
instructions.
Depending upon environmental or material influence (e.g. temperature, configuration of the tendon and properties
of the materials used), the water/cement ratio shall be kept as low as possible having regard to the required plastic
properties of the grout (see sub-Clause 1711.3). Actual water/cement ratios shall be recorded.
The material shall be mixed to produce a homogeneous grout and kept in slow continuous agitation until pumped
into the duct. Unless manufacturers specify otherwise, water shall be added to the mixer first, followed by the dry
materials which may be added as a whole or in part in sequence until the total quantities are added. The minimum
mixing time determined from grouting trials shall be adhered to.
The temperature of freshly mixed grout shall be between 5°C and 30°C. The maximum temperature may be
increased provided trials demonstrate that the grout meets the requirements of sub-Clause 1711.3.
(12/14) Properties, Performance and Testing of Grout
3 (12/14) The properties and performance requirements for grout shall be in accordance with Section 6 of BS EN
447. The requirements for suitability testing shall be in accordance with Section 6 of BS EN 446. Test methods are
described in BS EN 445. Test requirements for grout during grouting shall be in accordance with Section 9 of BS
EN 446 for Execution Class 3.
(12/14) Duct Systems
4 (12/14) The system of ducts, duct connectors, grouting connections, vents, vent connections, drains, transitions
to anchorages and caps for anchors shall form a complete encapsulation for the tendons which is resistant to the
ingress of air and water. Ducts shall be of plastic and shall not degrade during the expected life of the structure. The
system shall be fully compatible with the prestressing anchorages, couplers and other details. Where ducts are
non-conductive, metal parts of anchorages shall be electrically bonded to the adjacent reinforcement at each end of
the tendon and electrical continuity of the structure over the length of the tendon shall be confirmed by testing. All
ducts shall be kept free from standing water at all times and be thoroughly clean before grouting.
The following air pressure tests shall be carried out on site unless specified otherwise in contract specific Appendix
17/6.
(12/14) Duct Assembly Verification Tests
Each complete duct system including vents, anchorages, anchorage caps, and where appropriate couplers and their
connections, shall be air-pressure tested before concreting. Testing to a pressure of 0.01 N/mm2 unless otherwise
specified in contract specific Appendix 17/6, shall demonstrate that the system is undamaged and has been correctly
assembled. The testing shall demonstrate that a loss of pressure no greater than 10% occurs after 5 minutes.
The minimum manufactured wall thickness of ducting for internal tendons shall be 2 mm. The duct rigidity and
type and spacing of fixings and supports shall be such as to maintain line, position and cross section shape during
concreting. Local deformation of the duct at supports shall be avoided.
For external tendons the minimum wall thickness shall be 4 mm for durability, or such thicker wall as required to
withstand grouting pressures of the particular duct configuration.
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The Contractor shall provide evidence of testing to demonstrate the following requirements:
(i) Wall thickness of ducts for tendons after tensioning of the tendons shall be not less than 1.5 mm unless
specified otherwise in contract specific Appendix 17/6.
(ii) For internal tendons the duct shall transmit full bond strength from the tendons to the surrounding
concrete over a length no greater than 50-100 duct diameters or other such requirement as given in
(12/14) Vents
Vents providing an air passage of at least 15 mm internal diameter shall be provided at the anchorages and in the
troughs and crests and beyond each intermediate crest in the direction of flow of the grout at the point where the
duct is one half diameter lower than the crest, (but no further than 1 m from the crest), unless otherwise described
in contract specific Appendix 17/6. The maximum spacing of vents shall be 15 m unless specified otherwise in
The vent diameter and spacing may be varied in full-scale trials demonstrating the suitability of alternatives. The
vents shall be rigidly connected to the ducts, and shall be capable of being closed and re-opened. Holes in the ducts
shall be at least the internal diameter of the vents and shall be formed before pressure testing.
For external tendons the arrangement and detailing of the vents at positions within deflectors/diaphragms shall be
proven by detailed testing.
Vents on each duct shall be identified by labelling and shall be protected against damage at all times.
Vents at high points shall extend to a minimum of 500 mm above the highest point on the duct profile unless
described otherwise in contract specific Appendix 17/6.
(12/14) Grouting Equipment
5 (12/14) Grouting equipment shall comply with the requirements of Section 7 of BS EN 446.
The equipment shall be capable of maintaining pressure on completely grouted ducts and shall be fitted with a
valve that can be locked off without loss of pressure in the duct.
During the grouting operation the Contractor shall provide adequate flushing-out plant to facilitate complete
removal of the grout in the event of a breakdown of the grouting equipment or other disruption before the grouting
operation has been completed. Stand-by and emergency equipment shall be provided.
All equipment shall be kept free from build-up of adhering materials.
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(12/14) Grouting Procedures
6 (12/14) Grouting procedures shall comply with the requirements of Section 8 of BS EN 446.
Grouting of the ducts shall be carried out within 14 days of installation of the tendon or as soon as is practicable
thereafter, in which case additional measures shall be taken to avoid corrosion of the prestressing steel. The
Overseeing Organisation’s written agreement to commence grouting operations shall be obtained.
During grouting operations, once the fluidity of the grout flowing from the vents is the same as the grout being
injected (to within the limits specified in BS EN 447, as per 8.4 of BS EN 446), 5 litres of grout at each vent, or
such other requirement of contract specific Appendix 17/6, shall be vented into a clean receptacle and then
discarded. The volume of all grout that is expelled shall be measured. The opening shall be firmly closed. All vents
shall be closed in a similar manner one after another in the direction of the flow except that at intermediate crests
the vents immediately downstream shall be closed before their associated crest vent. The injection tubes shall then
be sealed off under pressure with a pressure of 0.5 N/mm2 being maintained for at least one minute. Grout vents at
high points shall be reopened immediately after 1 minute, while the grout is still fluid. Any escape of air, water or
grout shall be recorded and reported immediately to the Overseeing Organisation. A further 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 with a further 5 litres being released at each vent. In the event of
disagreement over the quality of the vented grout, testing shall be undertaken immediately by the Contractor.
Finally, when all outlets are closed the grout pressure shall be maintained for at least one minute to confirm there is
no unintended loss due to leakage.

The filled ducts shall not be subjected to shock or vibration for at least 24 hours from the time of grouting.
When the grout has set, the grout vents shall be temporarily reopened. If voids are apparent on inspecting vents at
end caps, the Overseeing Organisation may require all or some of the end caps to be removed to demonstrate that
they are satisfactorily filled with grout. End caps which have been removed shall then be replaced and permanently
sealed against ingress of contaminants, such sealing to be proved to the Overseeing Organisation.
If the method of demonstrating filling of the anchorage caps involves their removal, a photographic record shall be
made by the Contractor. The record shall clearly identify the individual anchorages, and shall be included in the
report to the Overseeing Organisation.
If, in the opinion of the Overseeing Organisation, there is doubt that the ducts or any part of the system are not
satisfactorily filled with grout, the Overseeing Organisation may require investigations to be carried out.
The Contractor shall keep full records of grouting for each duct in accordance with the acceptance scheme
requirements for the installation of post-tensioning systems. Copies of these records shall be supplied to the
Overseeing Organisation within 24 hours of completing grouting to each duct.
On completion of grouting, grout vents shall be positively sealed and waterproofed by a means additional to but
separate from the concrete waterproofing.
(12/14) Grouting During Cold or Hot Weather
7 (12/14) Requirements for grouting in cold or hot weather are given in 8.3 of BS EN 446.
When the ambient temperature is expected to fall below 5°C, accurate records shall be kept by the Contractor of the
maximum and minimum air temperatures, and the temperatures of the structural elements adjacent to the ducts to
be grouted.
When heating is considered appropriate, methods of heating shall be to the acceptance of the Overseeing
Organisation. Ducts shall not be warmed with steam.
(12/14) Void Grouting
8 (12/14) Void grouting is the injection of grout into voids left in tendon ducts after the original grout has
hardened and shall not be confused with regrouting, which means the reinjection of grout into ducts while the
original grout is still fluid. Where the use of void grouting is proposed, it shall be subject to the approval of the
Overseeing Organisation through its Departure from Standard processes.
1712 (12/14) Reinforcement – Materials

(12/14) Hot Rolled and Cold Worked Carbon Steel Bars
1 (12/14)All hot rolled and cold worked steel bars shall conform to BS EN 10080 and BS 4449 Grades B500B or
B500C. Reinforcement shall be cut and bent in accordance with BS 8666. The bars shall be obtained from and cut
and bent by organisations holding a valid CARES product acceptance scheme (or equivalent scheme) certificate of
approval for the production and supply of steel for the reinforcement of concrete (see also sub-Clause 1712.8).
2 (12/14) Hot rolled and cold worked carbon steel bars shall conform to BS EN 10080 and BS 4449 except that no
bar shall contain a flash weld.
(12/14) Steel Wire
3 (12/14) Steel wire shall only be used in precast concrete elements and shall be ribbed Grade 500 conforming to
BS EN 10080 and BS 4482 . Steel wire shall have a minimum nominal diameter of 8 mm and shall be obtained
from organisations holding a valid CARES product acceptance scheme (or equivalent scheme) certificate of
approval for the production and supply of steel wire (see also sub-Clause 1712.8).
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(12/14) Steel Fabric

4 (12/14) Steel fabric reinforcement shall be Grades B500A, B500B or B500C conforming to BS EN 10080 and
BS 4483. Steel fabric reinforcement shall be cut and bent in accordance with BS 8666. Steel fabric reinforcement
shall have a minimum nominal bar size of 6 mm (8 mm for Grade B500A) and shall be obtained from organisations
holding a valid CARES product acceptance scheme (or equivalent scheme) certificate of approval for the
production and supply of steel fabric reinforcement (see also sub-Clause 1712.8). Steel fabric reinforcement shall
be delivered to site in flat mats or pre-bent.
(12/14) Stainless Steel Reinforcement
5 (12/14) All stainless steel reinforcement shall conform to BS 6744 and shall be cut and bent in accordance with
BS 8666 and shall be obtained from organisations holding valid CARES product acceptance scheme (or equivalent
scheme) certificates of approval for the production and supply of stainless steel reinforcement (see also sub-Clause
1712.8).
6 (12/14) Stainless steel reinforcement shall be ribbed Grade 500 conforming to BS 6744 and the additional
properties described in contract specific Appendix 17/4.
(12/14) Bond Strength
7 (12/14) For hot rolled and cold worked carbon steel bars, and for steel fabric reinforcement, the bond property
requirements of BS 4449 shall be complied with based on the surface geometry requirements of that standard. For
steel wire, the bond property requirements of BS 4482 shall be complied with based on the surface geometry
requirements of that standard.
(12/14) Traceability and Identification of Reinforcement
8 (12/14) Any product acceptance scheme shall ensure that materials used in reinforcing bars are traceable from
their initial production casts, through rolling and other treatments to delivery on site of straight bar or cut and bent
steel. The marking system on reinforcement shall be secure, clear and unambiguous. Marking must also identify the
grade of a reinforcement bar both in terms of strength and ductility. Materials complying with the requirements
given in sub-Clauses 1712.1 to 6 and supplied in accordance with the CARES product acceptance scheme or
equivalent scheme shall be deemed to meet the requirements for traceability and identification of materials
described above.
1713 (12/14) Carbon Steel Reinforcement and Stainless Steel Reinforcement – Bar Schedule
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Dimensions – Cutting and Bending
1 (12/14) The bar schedules are based on the dimensions of the concrete and the nominal cover to the
reinforcement shown on the drawings. The reinforcement shall be cut and bent within the tolerances given in BS
8666 but this shall not relieve the Contractor of his responsibility for the correct fit of the reinforcement and the
achievement of the required cover as described in Clause 1714. The mandrel diameter for bending bars shall
comply with Clause 8.3 of BS EN 1992-1-1.
Bending of reinforcement at temperatures below 5°C or in excess of 100°C shall not be carried out.
Re-bending of carbon steel bars and fabric reinforcement shall not to be permitted.
Re-bending of stainless steel reinforcement bars shall not be permitted.
Site storage of reinforcement shall ensure that it is clear of the ground and covered with a waterproof sheeting or
fixed cover, in order to reduce contamination and excess corrosion prior to placement.
1714 (12/14) Reinforcement – Fixing

1 (03/20) Reinforcement shall be secured against displacement and tied together in accordance with BS 7973-2.
The positioning of reinforcement shall be within the tolerances given in sub-Clause 1728.3.
Bars in inner layers shall be located as shown on the drawings.

Welding of carbon steel reinforcing bars for fixing purposes shall be in accordance with Clause 1717. Welding of
stainless steel reinforcement bars shall not be permitted.
Cover shall be achieved by using spacers and chairs which meet the performance requirements of BS 7973-1. They
shall be designed so that they will not overturn or be displaced when the concrete is placed. Reinforcement spacers
and chairs shall be fixed in accordance with BS 7973-2.
Spacer blocks shall be factory produced proprietary products. Site produced or other non-proprietary spacers shall
not be used.
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Wire cast in spacer block for the purpose of tying it to the reinforcement shall be as described below. Projecting
ends of ties or clips shall not encroach into the concrete cover.
Tying wires shall be 1.2 mm diameter stainless steel wire for bridge decks and exposed surfaces and any other
locations as described in contract specific Appendix 17/4. In other areas 1.6 mm soft annealed iron wire may be
used. Stainless steel tying wire shall be used when tying stainless steel reinforcement.
The Contractor shall provide access and carry out a cover measurement survey of all reinforced concrete surfaces
within the 24-hour period following the removal of formwork. The cover measurement survey shall be carried out
on a 500 mm grid over the whole structure. A record of the survey shall be kept and subsequently supplied to the
Overseeing Organisation in accordance with the requirements of CG 302.
1715 (12/14) Reinforcement – Surface Condition

1 (12/14) Immediately before concrete is placed around it, reinforcement shall be free from mud, oil, paint,
retarder, release agent, loose rust, loose mill scale, snow, ice, grease or any other substance that can be shown to
have an adverse chemical effect on the steel or concrete, or to reduce the bond between the steel and the concrete.
1716 (12/14) Reinforcement – Laps and Joints

1 (12/14) Laps and joints shall be made only where shown on the drawings, except in the case where additional
laps or splice bars are required and the Overseeing Organisation’s approval has been obtained.
2 (12/14) Where reinforcing bars are required to be coupled the coupling system shall have a current British Board
of Agrément Roads and Bridges Certificate or CARES product acceptance scheme Certificate of Product
Assessment TA1-A for use with Highway Structures or equivalent scheme and shall be sourced, applied and
processed from organisations holding relevant valid CARES product acceptance scheme (or equivalent scheme)
certificate of approval. Couplers shall comply with cover requirements of sub-Clause 1714.1.
1717 (12/14) Reinforcement – Welding

(12/14) General
1 (12/14) Welded reinforcement, other than steel fabric reinforcement, shall not be incorporated in the permanent
works unless permitted in contract specific Appendix 17/4. When required, welding of reinforcing bars shall
comply with the requirements of Clause 3.2.5 of BS EN 1992-1-1, shall be carried out in accordance with BS EN
ISO 17660 and be subject to the demonstration of the satisfactory performance of trial joints. The Contractor shall
demonstrate that at each location the fatigue life, durability and other properties of the member are not adversely
affected by the proposal.
Site welding of stainless steel reinforcement bars shall not be permitted.
(12/14) Strength of Structural Welded Joints
2 (12/14) The strength of all structural welded joints shall be assessed following tests on trial joints to establish
the minimum specified mechanical properties of the joint. Tests shall be carried out by an independent testing body
appropriately accredited as described in Clause 105.

1718 (12/14) Prestressing Tendons – Materials

(12/14) Steel Wires and Strands
1 (12/14) Steel wires and strands shall comply with BS 5896 and shall be obtained from an organisation holding a
valid CARES product acceptance scheme certificate of approval for the production of prestressing steel wires and
strands (PT6-PT8), or equivalent scheme.
(12/14) Cold Worked High Tensile Alloy Bar
2 (12/14) Cold worked high tensile alloy steel bars for prestressed concrete shall comply with BS 4486 and shall
be obtained from an organisation holding a valid CARES product acceptance scheme certificate of approval for the
production of prestressing steel bars (PT7), or equivalent scheme.
3 (12/14) When it is proposed to use other than the lowest strength diameter wire or strand complying with BS
5896, the following shall apply:
(i) A sample shall be taken from each reel of material proposed for use in the works.
(ii) A reel shall only be accepted if both the breaking load and the 0.1% proof load of the sample exceeds the
specified characteristic loads given in BS 5896.
4 (12/14) Where scheduled in contract specific Appendix 1/5, the Contractor shall arrange for samples of the steel
intended for use in the permanent works to be tested at a testing laboratory appropriately accredited as described in
Clause 105.
5 (12/14) Testing of prestressing steel bar, wire and strand shall be performed in accordance with BS EN ISO
15630-3.
1719 (12/14) Prestressing Tendons – Handling and Storage

1 (12/14) Prestressing tendons shall not be mechanically damaged, work hardened or heated during handling. All
prestressing tendons shall be stored clear of the ground and protected from the weather, from splashes from any
other materials, and from splashes from the cutting operation of an oxy-acetylene torch, or arc-welding processes in
the vicinity.
In no circumstances shall prestressing tendons after manufacture be subjected to any welding operation, or heat
treatment or metallic coating such as galvanizing. This does not preclude cutting as described in Clause 1722.
1720 (12/14) Prestressing Tendons – Surface Condition

1 (12/14) Prestressing tendons and internal and external surfaces of sheaths or ducts shall be clean and free from
pitting at the time of incorporation in the works. Slight surface rusting is generally acceptable, unless in
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environmentally severe sites (marine or industrial).
1721 (12/14) Prestressing Tendons – Straightness

(12/14) Wire
1 Low relaxation and normal relaxation wire shall be in coils of sufficiently large diameter to ensure that the
wire pays off straight, except that in cases where straight as-drawn wire is not essential, wire in small-diameter
coils (corresponding to the diameter of the blocks in the drawing machine) may be used.

(12/14) Strand
2 Prestressing strand, however manufactured, shall be in coils of sufficiently large diameter to ensure that the
strand pays off straight.
(12/14) Bars
3 (12/14) Prestressing bars as delivered shall be straight. Any small adjustments for straightness that are necessary
on site shall be made by hand. Bars bent in the threaded portion shall be rejected. Any straightening of bars shall be
carried out cold but at a temperature of not less than 5°C. Any necessary warming shall be by means of steam or
hot water.
1722 (12/14) Prestressing Tendons – Cutting

1 (12/14) All cutting of wire, strand or bar shall be carried out after gradual release of the tension in the tendons to
be cut. Cutting shall be executed using either:
(i) a high-speed abrasive cutting wheel, friction saw or equivalent mechanical method at not less than one
tendon diameter from the anchor; or
(ii) an oxy-acetylene cutting flame, using excess oxygen to ensure a cutting rather than a melting action, not
less than 75 mm from the anchor. The temperature of the tendon adjacent to the anchor shall not be
greater than 200°C. Neither the flame nor splashes from the cutting operations shall come into contact
with the anchorages or uncut tendons.
1723 (12/14) Prestressing Tendons – Positioning of Tendons, Sheaths and Duct Formers
1 (12/14) Tendons, sheaths and duct formers shall be accurately located and maintained in position both vertically
and horizontally as shown on the drawings. The position shall be within the tolerances given in sub-Clause 1728.3.
Where tendons are described in the contract as debonded from the concrete they shall be covered with suitable
sleeves. The ends of the sleeves shall be taped to the tendon to prevent the ingress of grout.
Joints in sheaths shall be securely taped to prevent penetration of the duct by concrete or laitance, and ends of ducts
shall be sealed and protected after the stressing and grouting operations. Joints in adjacent sheaths shall be spaced
at least 300 mm apart.
1724 (12/14) Prestressing Tendons – Tensioning

(12/14) General
1 (12/14) All wires, strands or bars stressed in one operation shall be taken, where possible, from the same parcel.
Each cable shall be tagged with its number from which the coil numbers of the steel used can be identified. Cables
shall not be kinked or twisted. Individual wires and strands for which extensions are to be measured shall be readily
identifiable at each end of the member. No strand that has become unravelled shall be used. Strands of the same
diameter but with different strength grades must not be used in the same beam.
(12/14) Tensioning Apparatus
2 (12/14) The tensioning apparatus shall meet the following general requirements:
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(i) The means of attachment of the tendon to the jack or tensioning device shall be safe and secure.
(ii) Where two or more wires or 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
variation shall be small compared with the expected extension.
(iii) 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.

(iv) The force in the tendons during tensioning shall be measured by direct-reading load cells or obtained
indirectly from gauges fitted in the hydraulic system to determine the pressure in the jacks. Facilities
shall be provided for the measurement of the extension of the tendon and of any movement of the tendon
in the gripping devices. The load measuring device shall be calibrated to an accuracy within ± 2% and
checked at frequent intervals. The valid calibration records shall be available on site before tensioning
starts. Elongation of the tendon shall be measured to an accuracy within 2% or 2 mm, whichever is the
greater.
(v) The tensioning equipment shall be calibrated before the tensioning operation and subsequently at
frequent intervals.
(12/14) Pretensioning
3 (12/14)Where pretensioning methods are used, the tension shall be fully maintained by some positive means
during the period between tensioning and transfer. The transfer of stress shall take place slowly to minimize shock.
(i) Straight tendons. In the long-line method of pretensioning, sufficient locator plates shall be distributed
throughout the length of the bed to ensure that 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
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direction of their length and thus permit transfer of the prestressing force to the concrete along the whole
line. In the individual mould system, the moulds shall be sufficiently rigid to provide the reaction to the
prestressing force without distortion.
(ii) Deflected tendons. Where possible, the mechanisms for holding down or holding up tendons shall ensure
that the part in contact with the tendon 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 force, this force shall be determined
by test and due allowance made. For single tendons the deflector in contact with the tendon shall have a
radius of not less than 5 times the tendon diameter for wire or 10 times the tendon diameter for strand,
and the total angle of deflection shall not exceed 15°. The transfer of the prestressing force to the
concrete shall be effected in conjunction with the release of hold-down and hold-up forces.
Unless otherwise described in contract specific Appendix 17/4, concrete shall not be stressed until it has reached at
least the age at which 2 test results from specimens taken from it (each obtained from the average of two test cubes
made from one concrete sample) attain the specified characteristic compressive strength at the time when the
concrete is subjected to the prestressing force. Testing shall be as described in Annex B.5 of BS 8500-1 and Annex
B of BS EN 206-1. The samples shall be taken as described in BS EN 12350-1 and the test cubes shall be made and
tested as described in BS EN 12390-2 and BS EN 12390-3 respectively. They shall be cured in similar conditions to
the concrete to which they relate. The Contractor shall cast and test sufficient cubes to demonstrate that the required
strength of the concrete at transfer has been reached.
(12/14) Post-tensioning
4 (12/14) In addition to the present Clause, the installation of post-tensioning systems shall comply with the
requirements of Clause 1711.
(i) Arrangement of tendons. Where wires, strands or bars in a tendon are not stressed simultaneously, the
use of spacers shall be in accordance with the recommendations of the system manufacturer.
(ii) Anchorages. Prestressing anchorages for post-tensioning systems shall be in accordance with Clause 7.2
of BS EN 13670 and shall be supplied by organisation certificated with the CARES product acceptance
scheme for the Production and Supply of Prestressing Anchorages for Post-tensioning Systems (PT3), or
an equivalent scheme. Anchorages shall comply with the minimum performance requirements of BS EN
13391. For each anchorage system used in the works, the characteristic value for anchorage efficiency
shall be not less than 95%. Proprietary anchorages shall be handled and used strictly in accordance with
the manufacturer’s instructions and recommendations.
(iii) Deflected tendons. The deflector in contact with the tendon shall have a radius of not less than 50 times
the diameter of the tendon, and the total angle of deflection shall not exceed 15°.

(iv) Tensioning procedure. Before tensioning, the Contractor shall demonstrate that all tendons are free to
move in the ducts unless the geometry of the ducts makes this impracticable. Tensioning shall be carried
out in such a manner that the stress in the tendons increases at a gradual and steady rate. Tensioning shall
not be carried out at a temperature below 0°C.
Unless otherwise described in contract specific Appendix 17/4, concrete shall not be stressed until it has reached at
least the age at which 2 test results from specimens taken from it (each obtained from the average of two test cubes
made from one concrete sample) attain the specified characteristic compressive strength at the time when the
concrete is subjected to the prestressing force. Testing shall be as described in Annex B.5 of BS 8500-1 and Annex
B of BS EN 206-1. The samples shall be taken as described in BS EN 12350-1 and the test cubes shall be made and
tested as described in BS EN 12390-2 and BS EN 12390-3 respectively. They shall be cured in similar conditions to
the concrete to which they relate. The Contractor shall cast and test sufficient cubes to demonstrate that the required
strength of the concrete at transfer has been reached.
The Contractor shall ensure that those carrying out the stressing are provided with particulars of the required tendon
loads, order of stressing and extensions. Allowance shall be made during stressing for the friction in the jack and in
the anchorage, although the former is not necessary when using load cells, and for draw-in of the tendon during
anchoring.
Stressing shall continue until the required extension and tendon load are reached. The extension shall allow for any
draw-in of the tendon occurring at a non-jacking end, but measurement shall not commence until any slack in the
tendon has been taken up.
Immediately after anchoring, the forces in the prestressing tendons shall not exceed 70% of their characteristic
strength. During stressing the value may exceed 70% of their characteristic strength but shall not exceed 80%.
After the tendons have been anchored, the force exerted by the tensioning apparatus shall be decreased gradually
and steadily so as to avoid shock to the tendon or the anchorage. Full records shall be kept of all tensioning
operations, including the measured extensions, pressure-gauge or load-cell readings, and the amount of draw-in at
each anchorage. When requested by the Overseeing Organisation, copies of these records shall be provided within
24 hours of each tensioning operation.
Tendons shall not be cut within 3 days of their being grouted; however, in the case of deviation from the planned
performance during tensioning, cutting of the tendons, grouting and work which can impair the re-tensioning shall
not take place until the causes have been investigated and revised tensioning report has been approved.
1725 (12/14) Prestressing Tendons – Protection and Bond

1 (12/14) The prestressing tendons shall be protected in their permanent positions from both mechanical damage
and corrosion as described in contract specific Appendix 17/4.
Grout and grouting operations for filling ducts and anchorages of post-tensioned bonded tendons (internal or
external) shall be in accordance with Clause 1711.
Grease and wax for the protection of sheaths and anchorages of unbonded tendons shall be in accordance with
Clauses 7.2 and 7.6 of BS EN 13670.
Vents, grout inlets and outlets and anchorages shall be sealed to assure corrosion protection equivalent to that
provided along the tendon. Anchorage zones shall be protected from drainage water.
Unbonded tendons shall be sealed throughout their length against penetration of moisture.
1726 (12/14) Stainless Steel Dowels – Materials

1 (12/14) Dowels shall be made from Steel Designation 1.4429 or 1.4436 and Grade 200 or 500 steel bars
complying with BS 6744.
Amendment – December 2014

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33
1727 (12/14) Inspection and Testing of Structures and Components

(12/14) General
1 (12/14) Inspection and testing of structures and components shall be in accordance with BS EN 13670 for the
designated Execution Class (see Clause 1701) and carried out as described in contract specific Appendix 17/4 and
as scheduled in contract specific Appendices 1/5 and/or 1/6. The documentation of inspection shall be in
accordance with BS EN 13670 and this Specification.
1728 (12/14) Geometrical Tolerances

(12/14) General
1 (12/14) The tolerances given in Clauses 10.4 to 10.6 of BS EN 13670 and in its Annex have been derived
specifically for buildings and shall not be applied to highway works. Instead, the requirements of this Clause apply.
The tolerances given in this Clause are not cumulative. Further project specific tolerances shall be as described in
contract specific Appendix 17/4 and on the drawings.
(12/14) Reference System
2 (12/14) The location of the reference grids or primary lines and levels for the overall positioning of the works
shall be agreed between the Overseeing Organisation and the Contractor before the works are set out.
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34
(12/14) Sections MANUAL OF CONTRACT DOCUMENTS

FOR HIGHWAY WORKS
3 (12/14) The dimensions of cross-section, the cover and position of reinforcement and prestressing tendons shall
not deviate more than the values given in Figure 17/2. With the exception of case (d) in Figure 17/2, these values
MANUAL OF CONTRACT DOCUMENTS
do notNo.
applyType
to precast concrete elements, which shall conform
of deviation to the provisions
Description for Permitted
geometrical
FOR HIGHWAY tolerancesΔ in BS
WORKSdeviation
EN 13369
a and/or to the relevant Product
Cross-sectional dimensions Standard as appropriate (see sub-Clause 1710.8).
li = Length of
No.No. Type Type
of of deviation
deviation Description
Description cross-sectional Permitted
Permitted deviation Δ deviation Δ
a a Cross-sectional dimensions
Cross-sectional dimensions li =dimension
Length of cross-
li = Length of
sectional
cross-sectional
dimension
Applicable totobeams,
Applicable
dimension
beams,
slabs and slabscolumns
and
Applicable to columns
beams, slabs Forand li < 150 mm ± 5 mm
columns l =
For ii < 150 mm 400 mm ±
± 5 mm10 mm
l ≥ 2500
li =i 400 mm mm ±
± 10 mm30 mm
For li < 150 mm
li ≥linear
2500interpolation
mm ± 5 mm ± 30 mm
with
li = 400 mm ± 10 mm
for mm
li ≥ 2500 intermediate values ± 30 mm
with linear
interpolation for
with linear
interpolationintermediate
for
intermediatevalues
values
b Location of ordinary reinforcement
b Location of ordinary reinforcement
b Location
Cross of ordinary reinforcement
Section h ≤ 150 mm, Δ(plus) = + 5 mm
Cross Section h ≤ 150 mm, Δ  = + 5 mm
Cross Section h ≤ 150 mm, (plus) Δ(plus) = + 5 mm
h =
h = 400 mm, 400 mm, Δ  = + 10 mm
h = 400 mm,Δ(plus) = + 10 mmΔ(plus) = + 10 mm
(
  plus)
≥h2500
≥ 2500
h ≥ 2500hmm, mm,
mm, Δ
Δ(plus) = + 20 plus)Δ=
(mm + 20=mm
(plus) + 20 mm
with linear
with linear
with linear
interpolation
interpolation
interpolation
for intermediate
for intermediate
for intermediate
values
values
cmin = required minimum cover values
cmin
cn =min
==required
required
nominal
minimum
cover =minimum
cover
cover
cmin + | Δ(minus) | All values of h Δ(minus) = Δcdev a)
c = nominal
c =c actual
n cover cover = c min + | Δ(minus) |
nominal cover = cmin + | Δ(minus) |
n==actual All values of h Δ(minus) = Δcdev a)
Δ=c permitted cover
deviation from cn All values of h Δ(minus) = Δcdev a)
c
Δ = actual
permitted deviation from cn
cover
h = height of cross-section
∆= permitted deviation from c
Requirement: cn + Δ( plus)> c > cn - | Δn(minus) |
Requirement: cn + Δ( plus)> c > cn - | Δ(minus) |
a) Δcdev can be taken equal to 10 mm, as recommended in the UK National Annex to BS EN
1992-1-1 and cBS
Requirement: n +EN
Δ(plus) > cSee
1992-2. > cNG
n – 1704.4
| Δ(minus)
and| Table NG 17/1 for guidance on cover.
a) Δcdev can be taken equal to 10 mm, as recommended in the UK National Annex to BS EN
a) ∆cdev can and
be taken equal to 10See
mm,NG as recommended in the
NGUK National Annexon
tocover.
BS EN 1992-
NOTE:1992-1-1 BS EN 1992-2.
Permitted plus-deviations for cover 1704.4 andforTable
to reinforcement 17/1
foundations for guidance
1-1 and BS EN 1992-2. See NG 1704.4 and Table NG 17/1 forand concrete
guidance on cover.
members in foundations may be increased by 15 mm. The given minus-deviations apply.
NOTE:
NOTE: Permitted
Permitted plus-deviations
plus-deviations for
for cover
cover to
to reinforcement
reinforcement for
for foundations
foundations and
and concrete
concrete members
members in foundations
in foundations may be increased
may be increased by 15 mm.byThe 15 given
mm. The given minus-deviations
minus-deviations apply. apply.
(03/20) Figure 17/2 – Permitted Sectional Deviations

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35
Specification for Highway Works MANUALOF
MANUAL OFCONTRACT
CONTRACT Structural Concrete
DOCUMENTS
DOCUMENTS
FOR HIGHWAY WORKS
FORHIGHWAY
FOR HIGHWAYWORKS
WORKS
c Lap-joints
cc Lap-joints
Lap-joints
l = Lap length l
- 0,06- 0,06
c Lap-joints ll==lLap
= Lap
Lap length
length
length 0,06ll
--0,06 l
d Location of prestressing duct

dd Locationof
Location ofprestressing
prestressingduct
duct
d Location of prestressing duct y = Intended distance to ± 5 mm
Longitudinal section y = Intended distance ± 5mm
Longitudinalsection
Longitudinal
Longitudinal section
section yycentreline
==Intended
Intendedofdistance
duct in plan
distance ±±5mm
5mm
to centreline
or of duct in
elevation
tocentreline
to centrelineofofduct
ductin
in
plan or elevation
planor
plan orelevation
elevation
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Figure 17/1 – Permitted Sectional Deviations

Figure17/1
Figure 17/1––Permitted
PermittedSectional
SectionalDeviations
Deviations
(03/20) Figure 17/2 – Permitted Sectional Deviations (Continued)
(??/??) Permitted Deviations at Support Bearings
Permitted
(??/??) Permitted
(12/14)(??/??)
Deviations
Deviations atSupport
at SupportBearings
Bearings
4Permitted Deviations
(??/??) The positionat
ofSupport
bearings Bearings
at supports shall not deviate more than the values given in
4 4 The position of bearings at supports shallnot
(??/??) The position of bearings at supports shall
(??/??) notdeviate
deviatemore
morethan
thanthe
thevalues
valuesgiven
givenin
in
FigureThe
4 (12/14) 17/2.
position of bearings at supports shall not deviate more than the values given in Figure 17/3.
Figure17/2.
Figure 17/2.
No. No. Type of deviation
No. Type
Typeof
ofdeviation
deviation
Description
Description
Description
Permitted
PermittedPermitted
No. Description Permitted
deviation Δ
deviationΔΔ Δ
deviation
deviation
a Position of bearing axis of support when structural
a aa Positionof
Position ofbearing
bearingaxis
axisof
ofsupport
supportwhen
whenstructural
structural l = Intended The larger value,
bearings are used l = Intended The larger value,
bearingsare
bearings areused
used ll==distance
Intended
Intended Thelarger
from The larger value,
value,
taken with the
distance from taken with the
distance
distance from
all edges
from takennegative
taken withthe
with the sign,
all edges negative sign,
alledges
all edges negativebetween
negative sign,
sign,
between
between
between
l/50 -and
- l/50- and 5mm – 5 mm
l/50and
--l/50 and--5mm
5mm
and not greater than
and not greater
- 15 mm
andnot
and notgreater
greater
than
but than columns not
than
- 15for mm
--1515 mm than the
mm
greater
larger
but for value, taken
columns
butfor
but for
with columns
columns
the negative
not greater than
notgreater
not greater
sign, than
than
between
the larger value,
thelarger
the largervalue,
value,
takenwith
15 mm theand –
takenwith
taken with the
the
negative sign,h/600
negativesign,
negative sign,
between
between
between
where h = free
- 15height
mm and of column
-
--15
15mm mmand and--
h/600
h/600
h/600
where h = free
(03/20) Figure 17/3 – Permitted Deviations at Support Bearings wherehh==free
where free
height of column
heightof
height ofcolumn
column
Figure 17/2 – Permitted deviations at support bearings

Figure17/2
Figure 17/2––Permitted
Permitteddeviations
deviationsat
atsupport
supportbearings
bearings

AUGUST 2014
AUGUST2014
AUGUST 2014
36
FOR HIGHWAY WORKS
Specification for Highway Works Structural
FOR HIGHWAY WORKS
Concrete
(??/??) Permitted Deviations for Columns and Walls
5 (??/??) The dimensions of columns and walls shall not deviate more than the values given in
(??/??)
(12/14)
Figure Permitted
Permitted Deviations
17/3. Deviations for Columns
for Columns andand Walls
Walls
5 (??/??) The dimensions of columns and walls shall not deviate more than the values given in
5 (12/14) The dimensions of columns and walls shall not deviate more than the values given in Figure 17/4.
Figure
No. Type17/3. of deviation Description Permitted
No. Type of deviation Description deviation Δ
Permitted
aNo. Type of deviation
Inclination of a column or wall Description Permitted
deviation Δ
deviation Δ
a a Inclination
Inclination of
of aa column
column or
or wall
wall h = free height The larger of
h/600
or
The larger of
15 mm
h = free height h/600
The larger
or of
h = free height h/600
15mm
or
15mm
b Curvature of a column or wall
b Curvature of a column or wall

b Curvature of a column or wall h = free height The larger of
h/600
The larger of
or
h/60015 mm
h = free height The larger
or of
h/600
15mm
h = free height or
15mm
(03/20) Figure 17/4 – Permitted Deviations for Columns and Walls

Figure 17/3 – Permitted deviations for columns and walls
1729 (03/20) Post-Installed Anchors

Figure and Reinforcing
17/3 – Permitted deviationsBar Connections
for columns and walls
(03/20) General
1 (03/20) Post-installed anchors and systems for post-installed reinforcement bar connections shall have a
European Technical Assessment (ETA) issued under regulation (EU) No. 305/2011 suitable for their intended use
and application, and shall comply with the requirement in contract specific Appendix 17/8.
2 (03/20) The Contractor shall design the post installed anchors and/or reinforcing bars connections stated in
3 (03/20) Post-installed anchors and reinforcing bars connections shall be designed in accordance with the
design method in the relevant ETA, the requirements in CD 372 and requirements listed in contract specific
Appendices 1/10 and 17/8.
(03/20) Installation
4 (03/20) Post installed anchors and systems for post-installed reinforcement bar connections shall be installed in
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accordance with their ETA and the manufacturers’ recommended methods.
AUGUST 2014

AUGUST 2014 37
5 (03/20) The position of post-installed anchors and reinforcing bar connections in the permanent works shall be
as stated in contract specific Appendix 17/8.
6 (03/20) The installation shall comply with the following:
(i) The installation work shall not cause damage to the concrete base material or any waterproofing around
the drill holes.
(ii) Reinforcement within the concrete base material shall not be struck, damaged or cut unless permitted in
(iii) Before and after drilling holes, the Contractor shall carry out a survey of the surrounding existing
concrete, to include all concrete within 300mm of the drilling location. Defects such as fractures, cracks
and voids shall be brought to the attention of the Overseeing Organisation.
(iv) For bonded anchors and reinforcing bar connections, the Contractor shall ensure that the cementitious
grout or resin fills the hole entirely without air voids following insertion of the anchor or reinforcing bar
and that the anchor or reinforcing bar is fully surrounded by the grout or resin. Excess grout or resin
shall be removed immediately.
(v) The anchors or reinforcing bars shall be free of rust and contamination that may affect the anchorage
bond.
(vi) Dissimilar metals shall be isolated.
(03/20) Reinforcing Bars for Reinforcing Bar Connections
7 (03/20) The material of the reinforcing bars shall be carbon steel conforming to BS 4449 or stainless steel
conforming to BS 6744.
8 (03/20) The stainless steel grade shall be as stated in contract specific Appendix 17/8.
(03/20) Testing
9 (03/20) Axial load proof tests shall be carried out on the fixings in accordance with the procedures of the
Construction Fixings Association (CFA) guidance note ‘Procedure for site testing construction fixings’.
10 (03/20) The testing shall be carried out by a person holding suitable, current qualifications. The qualifications
shall include assessment by a third party and shall include testing of the type of anchor(s) or post-installed
reinforcing bar connection(s) to be used in the works. Evidence of the qualifications shall be submitted to the
Overseeing Organisation prior to testing being undertaken. An example of suitable qualifications would be those
assessed by CFA.
11 (03/20) The magnitude of the proof load tests shall be determined in accordance with the requirements in
contract specific Appendix 17/8. Testing shall be undertaken in accordance with the details stated in contract
specific Appendices 1/5 and 17/8. The number of fixings to be tested shall be a minimum of 3 for each different
installation team.
12 (03/20) The total movement of the anchor/reinforcing bar, less the calculated elongation of the anchor/
reinforcing bar during the test, based on the length of the anchor/reinforcing bar between the concrete surface and
the point of load application, shall not exceed 5% of the nominal diameter of the anchor/reinforcing bar.
13 (03/20) Any evidence of slip during loading up to the test load, as demonstrated by a significant change in the
slope of the load/extension curve, shall constitute a failure.
14 (03/20) If the failure load of any of the tested post-installed anchor or reinforcing bar connection is less than the
required test load, the testing frequency shall be increased by a factor of 2 and remedial actions shall be proposed
for agreement by the Overseeing Organisation.
15 (03/20) A test report, prepared in accordance with CFA guidance note ‘Procedure for site testing construction
fixings’, shall be supplied to the Overseeing Organisation in accordance with the requirements of CG 302 within
14 days of the testing.
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(03/20) Reuse of Anchors

16 (03/20) Permanent anchors shall not be removed and reused elsewhere.
(03/20) Records
17 (03/20) Records from the design of permanent anchors or reinforcing bar connections, as set out in CD 372,
shall be submitted to the Overseeing Organisation upon completion of the works in accordance with the
requirements of CG 302.
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39F
SERIES 1800
STRUCTURAL STEELWORK
Contents
Clause Title Page
1800 (08/14) General 2
1801 (08/14) Scope 4
1802 (08/14) Normative References 4
1803 (08/14) Terms and Definitions 5
1804 (08/14) Specifications and Documentation 5
1805 (08/14) Constituent Products 7
1806 (08/14) Preparation and Assembly 10
1807 (08/14) Welding 13
1808 (08/14) Mechanical Fastening18
1809 (08/14) Erection 21

1810 (08/14) Surface Treatment 22
1811 (08/14) Geometrical Tolerances 24
1812 (08/14) Inspection, Testing and Correction 25
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1
Specification for Highway Works Structural Steelwork
STRUCTURAL STEELWORK
1800 (08/14) General
1800.1 (08/14) Introduction and basis of execution
with all other Series relevant to the specification for the particular Works to be undertaken.
2 (04/21) The Contractor shall supply and install all structural steelwork in accordance with this Series. Any
requirement to be fulfilled by the constructor in this Series and contract specific Appendix 18/1 is a requirement on
the Contractor.
3 (04/21) The terms ‘execution’ and ‘constructor’ have been used throughout this Series to be compatible with the
terms used and defined in BS EN 1090-2:2018.
4 (04/21) The basis for the execution of structural steelwork in this Series shall be BS EN 1090-2:2018, with
options and requirements described in this Series; see 1800.3.
1800.2 (04/21) Clause numbering and cross referencing
1 (04/21) The Clause and sub-Clause numbering and headings in Clauses 1801 to 1812 in this Series adopt those
in BS EN 1090-2:2018, Clauses 1 to 12 respectively, except that the Clause and sub-Clause numbers are pre-fixed
by ‘180’ for Clauses 1 to 9 and ‘18’ for Clauses 10, 11 and 12.
2 (04/21) The numbering of paragraphs in this Series bears no specific relationship to the order of paragraphs
presented in BS EN 1090-2:2018.
3 (04/21) Cross reference to a specific paragraph within this Series is by sub-Clause number followed by the
paragraph number in brackets.
1800.3 (04/21) Options and additional requirements
1 (04/21) Where the requirements specified in BS EN 1090-2:2018 are to apply to this Series without amendment,
the heading of the related sub-Clause in this Series is followed by the abbreviation (AEN) (i.e. as in BS EN 1090-
2:2018).
2 (04/21) Where there is a choice between two or more different requirements in a sub‑clause in BS EN 1090-
2:2018 the selected requirement(s) shall be as described in this Series. All other requirements in that sub-clause in
BS EN 1090-2:2018 shall apply to this Series unless otherwise described in this Series.
3 (04/21) Where requirements are described in this Series, the requirements in the related sub-clause in BS EN
1090-2:2018 shall also apply to this Series unless otherwise described in this Series.
4 (04/21) Contract specific Appendix 18/1 shall be referred to for any contract specific requirements where the
heading of the sub-Clause in this Series is followed by the abbreviation (18/1). Other contract specific Appendices
shall be referred to for any contract specific requirements where the heading of the sub-Clause in this Series is
followed by (XX/Y), where XX/Y refers to the contract specific Appendix in question. For example, for contract
specific Appendix 19/1 relating to Series 1900, the abbreviation (19/1) is used.
5 (04/21) Where a requirement in BS EN 1090-2:2018 is qualified in that standard by the words ‘unless otherwise
specified’, the requirement shall not be amended unless it is described otherwise in this Series or in contract specific
Appendix 18/1.
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2
1800.4 (04/21) Qualification of constructors (18/1)

1 (04/21) In order to satisfy the general assumptions stated in BS EN 1990:2002+A1:2005, 1.3 (2) relating to the
execution of structures designed to the Eurocodes, all structural steelwork executed in accordance with this Series
shall be undertaken by a constructor which has the necessary technical capability and competence for the general
type and value of work to be undertaken. These requirements will be satisfied by registration and audit through
a registration scheme such as the Register of Qualified Steelwork Contractors Scheme for Bridgeworks (RQSC,
see www.steelconstruction.org) to the levels appropriate for the value and technical complexity of the structural
steelwork.
2 (04/21) The constructor shall undertake a review to confirm that their technical capability and competence is
sufficient for the execution of the particular works described in contract specific Appendix 18/1. The review shall
be documented, and shall be submitted to and approved by the Overseeing Organisation in advance of execution.
The documented review shall be treated as an execution record and shall form part of the execution documentation;
see 1804.2.2 and 1804.2.4. The review shall include supporting evidence that shall cover the following as a
minimum:
a) details demonstrating compliance with 1800.4 (1), 1800.5.1 (1) and 1807.1 (2);
b) type and size of construction works;
c) product forms and thicknesses;
d) material grades and qualities;
e) types of process equipment;
f) execution quality requirements;
g) qualification of personnel; see 1806.5.3.1 (11), 1807.3 (2), 1807.4.2, 1807.4.3 and 1812.4.1; and
h) QSC requirements; see 1803 (1)
1800.5 (08/14) Quality management schemes
1800.5.1 (08/14) Execution of steelwork
1 (04/21) In order to satisfy the requirements stated in BS EN 1990:2002+A1:2005, 2.5 relating to quality
management measures in the execution of structures designed to the Eurocodes, the constructor shall have an
independently certified quality management system complying with BS EN ISO 9001 in place for all structural
steelwork executed in accordance with this Series. This requirement will be satisfied by the constructor being
registered to National Highway Sector Scheme 20 ‘The Execution of Steelwork in Transportation Infrastructure
Assets’, as stated in Appendix A.
1800.5.2 (08/14) Supply of mechanical fasteners
1 (04/21) The requirements stated in 1812.2.1 (2) for the verification of mechanical fasteners, as covered by BS
EN 1090-2:2018, 5.6, will be satisfied through mechanical fasteners being supplied by an Organisation registered
to National Highway Sector Scheme 3 ‘Stocking and Distribution Activities for Mechanical Fasteners’, as stated in
Appendix A.
1800.5.3 (04/21) Supply of structural steel products
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1 (04/21) The requirements stated in 1812.2.1 (4) for the verification of structural steel products, as covered by
BS EN 1090-2:2018, 5.3, will be satisfied through structural steel products being supplied by an Organisation
registered to National Highway Sector Scheme 3B ‘Stocking and Distribution Activities for Structural Steel
Products’, as stated in Appendix A.
Amendment – April 2021 3

1800.6 (04/21) CE/UK Marking

1800.6.1 (08/14) General
1 (04/21) Conformity assessment of structural steel components shall be undertaken in accordance with BS EN
1090-1:2009+A1:2011. A declaration of performance under a CE/UK marking in accordance with the Construction
Products Regulations shall be provided for all structural steel components. The declaration of performance shall
include a declaration of Structural Characteristics in accordance with 1800.6.2 (1).
1800.6.2 (08/14) Declaration of structural characteristics
1 (04/21) In the property declaration for ‘Structural Characteristics’ of a structural steel component, the entry for
‘Manufacturing’ shall read as follows:
‘According to component specification “X”, which specifies the relevant BS EN 1090-2 requirements and
execution class(es).’
where:
“X” is the component specification reference defined in 1800.6.3 (1).
1800.6.3 (08/14) Component specification reference (18/1)
1 (04/21) The component specification reference to be adopted for the conformity assessment of a structural steel
component shall be as stated in contract specific Appendix 18/1.
1800.6.4 (08/14) Component specification
1 (04/21) The component specification for a structural steel component shall comprise the following:
a) this Series; and
b) contract specific Appendix 18/1.
1801 (08/14) Scope

1 (04/21) This Series shall apply to the execution of all permanent structural steelwork, and to all temporary
structural steelwork including that required for the execution of permanent structural steelwork.
1802 (08/14) Normative References

1 (04/21) For normative references not given in BS EN 1090-2:2018 see Appendix F.
2 (04/21) For normative references of parts of standards not given in BS EN 1090-2:2018, see PD 6705-2:2020,
Annex D.
1802.1 (04/21) Constituent products
1802.1.1 (04/21) Steels (AEN)
1802.1.2 (04/21) Steel castings (AEN)
1802.1.3 (04/21) Welding consumables (AEN)
1802.1.4 (04/21) Mechanical fasteners
1802.1.5 (04/21) High strength cables (AEN)
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1802.1.6 (04/21) Structural bearings


1802.2 (04/21) Preparation (AEN)
1802.3 (04/21) Welding

1802.4 (04/21) Testing
1802.5 (04/21) Erection (AEN)
1802.6 (04/21) Corrosion protection (AEN)
1802.7 (04/21) Miscellaneous (AEN)
1803 (08/14) Terms and Definitions

1 (04/21) Quantified service category (Abbreviated to QSC in this Series): Category that characterises a detail,
component or structure (or part thereof) in terms of the circumstances of its use within specified limits of static and
cyclic stressing. QSC is designated by one of the symbols F36, F56, F71, F90, F112 or F140. See also 1804.1.1 (2)
and 1804.1.1 (3).
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2 (04/21) National Accreditation Body: As defined in Series 100, Clause 104 (11).
3 (04/21) Exceptional Welding Process (Abbreviated to EWP in this Series): A welding process which is not
covered by BS EN 1090-2:2018, Table 12 or Table 13. See also 1807.3.
4 (04/21) Factory production control (Abbreviated to FPC in this Series): The documented, permanent and
internal control of production in a factory, in accordance with BS EN 1090-1:2009+A1:2011, 6.3.
5 (04/21) Inspection lot (for mechanical fasteners): As defined in BS EN ISO 3269.
1804 (08/14) Specifications and Documentation

1804.1 (08/14) Execution specification
1804.1.1 (08/14) General (18/1)
1 (04/21) The execution specification for structural steelwork shall comprise the following:
a) this Series; and
b) contract specific Appendix 18/1.
2 (04/21) Certain requirements in this Series are differentiated on the basis of QSC. These are given in the
following sub-Clauses:
1805.3.1 (3) Repair of the body of hollow sections
1805.3.3 (1)(2)(3) Surface repair of steel products
1805.3.4 (1) Internal discontinuity quality class in welded cross plates
1806.2 (2)(3)(4) Identification marking methods
1806.4.4 (2) Free edge hardness limits for machine plasma cut edges
1806.6.3 (1)(2) Holing methods
1806.7 (1) Minimum radii for cut outs

1806.9 (1) Execution of connections for temporary components

1807.2.2 (1) Conditions for welding cold formed zones
1807.4.1.2 (2) Imperfection limits used in qualification of welding procedures
1807.5.6 (1) Restrictions on location and methods of removal of temporary welded attachments
1807.5.9.2 (1) Execution of the continuity weld in permanent steel backing
1807.5.16 (1) NDT checks of stray arc sites
1807.5.16 (3) Direction of grinding of weld surfaces
1807.6.1 (2) Weld acceptance criteria used for FPC during the work
1812.2.1 (5) Testing requirements and acceptance levels for steel castings
1812.4.2.4 (1)(2)(5) Scope of project specific supplementary weld NDT
1812.4.2.5 (1) Final visual acceptance criteria for welds
1812.4.2.6 (1) Final MT, PT, UT and RT acceptance criteria for welds
1812.4.4 (2) Specific production tests on weld run-off coupon plates
3 (04/21) Where requirements are differentiated on the basis of QSC, the QSC for a detail, component or structure
(or part thereof) is identified in contract specific Appendix 18/1.
1804.1.2 (08/14) Execution classes
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1 (04/21) Certain technical requirements in BS EN 1090-2:2018 are differentiated on the basis of execution class.
For these requirements the execution class given in each relevant sub-Clause in this Series shall apply. Where
this Series, including contract specific Appendix 18/1, specifies a requirement which is common to more than one
execution class all relevant execution classes are indicated. For example, if the specified requirement is the same
for EXC2, EXC3 and EXC4 this is designated EXC2/3/4.
1804.1.3 (04/21) Requirements for surface preparation for corrosion protection
1 (04/21) All surfaces shall meet the preparation grades stated in 1810.2.
1804.1.4 (08/14) Geometrical tolerances (AEN)
1804.2 (08/14) Constructor’s documentation
1804.2.1 (04/21) Quality documentation (18/1)
1 (08/14) Quality documentation shall conform to the requirements for EXC2/3/4.
1804.2.2 (08/14) Quality plan
1 (04/21) A quality plan for the execution of the works is required and shall include the items recommended in BS
EN 1090-2:2018, Annex C and 1809.4.1 (1).
2 (08/14) The execution records shall include the constructor’s drawings (including electronic files) for the
execution of all components.
3 (04/21) The constructor’s drawings (including electronic files) shall include the QSC and unique component
mark information.
4 (04/21) Constructor’s drawings in this Series shall be treated as working and fabrication drawings in accordance
with Series 100.
5 (08/14) Execution records described in this Series shall be treated as quality records in accordance with Series
100.
1804.2.3 (04/21) Safety of the erection works (AEN)

1804.2.4 (04/21) Execution documentation

1 (04/21) The execution documentation shall be treated as quality records in accordance with Series 100.
1805 (08/14) Constituent Products

1805.1 (08/14) General (AEN) (18/1)
1805.2 (08/14) Identification, inspection documents and traceability

1 (04/21) Stages of traceability shall conform to the requirements for EXC3/4.
2 (04/21) Specialist proprietary and/or bespoke products, including products for which the product manufacturer
has declared a derogation under the Construction Products Regulation, incorporating non-standardised features,
components or methods of manufacture, e.g. castings, forgings, cables and their terminations, energy absorbing
devices, mechanical components such as movement joints and major bearings etc, shall be individually traceable.
3 (04/21) Small identical bespoke products such as special fasteners shall be traceable to their individual
manufacturing lot.
4 (04/21) The identification of different grades and/or qualities of each individual constituent product shall
conform to the requirements for EXC2/3/4.
1805.3 (08/14) Structural steel products
1805.3.1 (08/14) General (18/1)
1 (04/21) The following options for impact property verification shall apply:
a) Option 3 in BS EN 10025-1:2004, 7.3.2.2; the lowest test temperature shall be adopted; and
b) Option 3 in BS EN 10025-5:2004, 7.3.2.2 and 8.4.2; the impact properties of steel grade S355WP shall
be verified.
2 (04/21) The following options for steel that is to be hot dip galvanized shall apply:
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a) Option 5 in BS EN 10025-1:2004, 7.4.3; the product shall be suitable for hot-dip zinc-coating;
b) Option 1.4 in BS EN 10210-1:2006, 6.7.2; the product shall be suitable for hot dip galvanizing; and
c) Option 1.4 in BS EN 10219-1:2006, 6.8.2; the product shall be suitable for hot dip galvanizing.
3 (04/21) The following options for weld repair of hollow sections in zones of QSC F112 and F140 shall apply:
a) Option 1.5 in BS EN 10210-1:2006, 6.8.4; repair of the body by welding shall not be permitted; and
b) Option 1.5 in BS EN 10219-1:2006, 6.9.4; repair of the body by welding shall not be permitted.
1805.3.2 (08/14) Thickness tolerances
1 (08/14) Thickness tolerance Class A shall be used.
1805.3.3 (08/14) Surface conditions (18/1)
1 (04/21) For plates and wide flats, the limits on surface discontinuities and ground areas shall conform to BS EN
10163-2 Class A or Class B unless otherwise stated in contract specific Appendix 18/1. Repair by welding shall not
be carried out (subclass 3) on steels conforming to BS EN 10025-6 or where QSC F112 or F140 applies. Where
repairs by welding are required, they shall conform to subclass 2 with the following additional requirements:
a) reports on weld repairs shall be submitted;
b) UT and MT shall be used for inspection of weld repairs; and
c) weld repairs on components with a QSC of F71 or F90 shall be rechecked on delivery.

2 (04/21) For sections, excluding hollow sections covered by 1805.3.3 (3), the limits on surface discontinuities
and ground areas shall conform to BS EN 10163-3 Class C or Class D unless otherwise stated in contract specific
Appendix 18/1. Repair by welding shall not be carried out (subclass 3) for steels conforming to BS EN 10025-6 or
where QSC F112 or F140 applies. Imperfections such as cracks, shells and seams shall be repaired if a permissible
repair method is available; otherwise the affected product shall be treated as nonconforming. Where repairs by
welding are required, they shall conform to subclass 2 with the following additional requirements:
3 (04/21) For hot finished and cold formed welded hollow sections, surface defects in the body of the section
shall be repaired in accordance with BS EN 10210-1 and BS EN 10219-1 respectively, subject to the restrictions in
1805.3.1 (3). Where repairs by welding are required, the following additional requirements shall apply:
4 (04/21) Steel with pitted surfaces, i.e. rust grades C and D according to BS EN ISO 8501-1 shall not be used.
1805.3.4 (04/21) Additional properties (18/1)
1 (04/21) The following requirements shall apply to cross plates in welded cruciform and welded tee joints
transmitting primary stresses through the plate thickness on a band of width four times the thickness of the plate
each side of the proposed attachment.
a) for QSC F56, BS EN 10160 internal discontinuity quality class S1 shall apply.
b) for QSC F71 and above, BS EN 10160 internal discontinuity quality class S2 shall apply.
2 (04/21) Flange or web plates close to bearing diaphragms and /or single sided bearing stiffeners, where attached
by welding, shall conform to BS EN 10160 internal discontinuity quality class S1 in the areas defined in BS EN
1090-2:2018, 5.3.4.
3 (04/21) The precautions necessary to avoid lamellar tearing in tee, cruciform and corner joints shall be decided
by the constructor, whether or not improved deformation properties to BS EN 10164 have been specified for the
through plates. The guidance on suitable precautions given in BS EN 1011-2 and PD 6695-1-10 shall be followed.
1805.4 (04/21) Steel castings (18/1)
1 (04/21) The properties of delivered castings shall be evaluated by destructive and non-destructive testing as
stated in 1812.2.1 (5).
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1805.5 (08/14) Welding consumables

1 (04/21) For welding steels supplied to BS EN 10025-5 one of the following options for welding consumables
shall be used.
a) one of the options 1, 2 or 3 of BS EN 1090-2:2018, Table 6; or
b) C-Mn consumables, but only for:
i) single run fillet welds not exceeding 8mm leg length using processes 135 and 121;
ii) butt welds using one run only per side; or
iii) the body of multi-pass fillet or butt welds except for the outer 3mm thick surface zones of the cap,
root and ends (excluding any overfill). The surface zones shall be deposited using consumables
conforming to options 1, 2 or 3 of BS EN 1090-2:2018, Table 6. See also BS EN 1090-2:2018,
7.5.10.

1805.6 (08/14) Mechanical fasteners

1805.6.1 (08/14) General (AEN)
1805.6.2 (08/14) Terminology
1 (04/21) The ‘part-turn’ method of tightening of preloaded fasteners is similar to the ‘combined method’ in
BS EN 1090-2:2018. However, it shall be restricted to Grade 8.8 assemblies of all class (K2, K1 and K0). It has
reduced torque values in the first step and higher nut rotations in the second step; see 1808.5.1(5).
1805.6.3 (04/21) Structural bolting assemblies for non-preloaded applications (18/1)
1 (04/21) The surface finishes for structural bolting assemblies shall be as given in Series 1900, Table 19/2B.
1805.6.4 (08/14) Structural bolting assemblies for preloading (18/1)
1 (04/21) The following products shall be used for preloaded bolt assemblies using all tightening methods, except
the HRC method:
a) bolt assemblies conforming to BS EN 14399-3 (HR type); and
b) nuts fully lubricated by the manufacturer after the nuts have been tapped (and, if relevant, after any
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coating passivation process has been completed). Lubricant coatings which are permanently liquid and
could risk contamination of faying surfaces shall not be used.
2 (04/21) The surface finishes for structural bolting assemblies shall be as given in Series 1900, Table 19/2B.
3 (04/21) Electroplated property class 10.9 bolting assemblies shall not be used.
4 (04/21) Cleaning of property class 10.9 bolting assemblies prior to hot dip galvanising shall be by a mechanical
process such as blast cleaning and not by pickling.
5 (04/21) Nuts of property class 10 shall be used with bolts of property class 8.8.
6 (04/21) Bolts of property class 10.9 shall not be used for assemblies tightened by the part turn method; see
1808.5.1 (4) and (5).
1805.6.5 (08/14) Direct tension indicators (AEN)
1805.6.6 (08/14) Weather resistant assemblies
1 (04/21) The chemical composition of weather resistant assemblies shall comply with the requirements for Type
3 Grade A fasteners to ASTM standard F3125/F3125M, or equivalent.
1805.6.7 (08/14) Foundation bolts (18/1)
1 (04/21) Reinforcing steels shall not be used for foundation bolts subject to applied tension forces.
1805.6.8 (08/14) Locking devices (AEN) (18/1)
1805.6.9 (08/14) Washers (AEN)
1805.6.9.1 (08/14) Plain washers (AEN)
1805.6.9.2 (04/21) Taper washers (AEN) (18/1)
1805.6.9.3 (04/21) Plate washers (AEN)
1805.6.10 (04/21) Solid rivets for hot riveting
1 (04/21) Solid rivets for hot riveting shall conform to BS 4620.
1805.6.11 (04/21) Special fasteners (AEN) (18/1)
1805.6.12 (04/21) Delivery and identification
1 (08/14) See 1800.5.2 (1).

1805.7 (08/14) Studs and shear connectors

1 (04/21) Headed stud connectors shall be Type SD1 in accordance with BS EN ISO 13918.
1805.8 (04/21) Reinforcing steel welded to structural steel (AEN)
1805.9 (04/21) Grouting materials (18/1)

1 (08/14) Bedding mortars shall conform to the requirements of Series 2600, Clause 2601.
1805.10 (04/21) Expansion joints for bridges (23/1)
1 (04/21) Expansion joints shall conform to the requirements of Series 2300, Clause 2301 and contract specific
Appendix 23/1.
1805.11 (04/21) High strength cables, rods and terminations (AEN) (18/1)
1805.12 (04/21) Structural bearings (18/1) (21/1)

1 (04/21) Bridge bearings shall conform to the requirements of Series 2100 and contract specific Appendix 21/1.
2 (04/21) Structural bearings other than bridge bearings shall conform to the requirements stated in contract
3 (04/21) The guidance given in PD 6703 on the execution of bearings shall be followed, where relevant.
1806 (08/14) Preparation and Assembly

1806.1 (08/14) General (AEN)
1806.2 (08/14) Identification (18/1)

1 (04/21) A suitable identification system shall identify each finished component to the documentation supplied
for its constituent product(s).
NOTE: Examples of types of documentation are given in BS EN 1090-2:2018, 12.2.1, Note 1.
2 (04/21) Hard stamps, punched or drilled marks shall only be used for zones with a QSC of F56 and below.
3 (04/21) Soft or low stress stamps shall only be used for zones with a QSC of F90 and below.
4 (04/21) No type of marking process involving deformation of or removal of metal from the surface shall be used
for zones with a QSC of F112 and above.
5 (04/21) Markings shall be visible when steelwork is assembled and erected; see 1806.10 (3) d) and 1809.6.2.
1806.3 (08/14) Handling and storage (AEN)
1806.4 (08/14) Cutting

1806.4.1 (08/14) General (AEN)
1806.4.2 (04/21) Shearing and nibbling
1 (04/21) All sheared edges shall be ground or filed normal to the thickness direction of the plate to remove all
visible signs of drag lines and glass-like surfaces.
1806.4.3 (08/14) Thermal cutting
1 (04/21) The quality of cut surfaces shall conform to the requirements for EXC3/4.
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2 (04/21) Isolated faults such as gouges, melting beads and oxide remainders, as described in BS EN ISO
9013:2017, 7.2.1, shall be smoothly dressed out by grinding, linishing or machining.
1806.4.4 (08/14) Hardness of free edge surfaces (18/1)
1 (04/21) Free edge surfaces with hardnesses exceeding 380 (HV10) values shall be ground, linished or machined
until sufficient material has been removed such that the 380 (HV10) limit is not exceeded, subject to the exceptions
in 1806.4.4 (2).
2 (04/21) Unless prohibited in contract specific Appendix 18/1, the hardness limit stated in 1806.4.4 (1) need not
apply to straight machine plasma cut plain edge surfaces away from stress raising zones (SRZs), see 1806.4.4 (3),
where all the following conditions are met:
a) the steel grade does not exceed S420;
b) the plain edge surfaces are not subject to a QSC above F71 (subject to 1806.4.4(3));
c) the plain edge surfaces are not subject to subsequent cold forming (unless fully fused over the full length
and width by subsequent welding); and
d) procedure tests have been carried out to verify that the proposed method of surface preparation of the
plasma cut edge can readily achieve the cleanliness and profile stated in Series 1900, where corrosion
protection of the edges is required.
3 (04/21) The requirements in 1806.4.4 (1) shall apply to machine plasma cut edge surfaces in SRZs, which
include all cut surfaces within 25mm of stress raising features such as re-entrant corners, openings or weld
terminations on the edge, subject to a QSC of F56 and above, except in cases where it can be demonstrated that the
QSC does not exceed F36.
1806.5 (04/21) Shaping
1806.5.1 (08/14) General (AEN)
1806.5.2 (08/14) Hot forming (AEN)
1806.5.3 (08/14) Flame straightening
1806.5.3.1 (04/21) General
1 (04/21) Documented procedures for correction of distortion using flame straightening shall be developed for all
steel grades and for the following typical modes of distortion:
a) an out-of-plane bow of a flat element;
b) an in-plane bow of a flat element or a bow about the minor axis of an open section; and
c) a bow about either axis of a hollow section or about the major axis of an open section.
2 (04/21) The method of heating shall be by oxy-acetylene fuel gas using equipment with purpose made heating
nozzles. The fuel gas mixture, nozzle size and arrangement, flame distance, heat zones and sequence of heating
shall be specified.
3 (04/21) The surface temperature of the heated zones shall be measured and controlled using a contact pyrometer
or temperature sensitive crayons.
4 (04/21) Maximum surface temperatures, according to the material groups and delivery conditions, shall not be
greater than:
a) 625 °C for steels conforming to BS EN 10025-2, BS EN 10025-3, BS EN 10025-5 and BS EN 10210,
but excluding those supplied in the “+M” delivery condition; or
b) 550 °C for steels conforming to BS EN 10025-4, BS EN 10025-6 and BS EN 10219, including any other
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steels supplied in the “+M” delivery condition.

NOTE: For stainless steel grades see 1806.5.3.2.

5 (04/21) The temperatures in 1806.5.3.1 (4) a) and b) are irrespective of the temperatures reached during any
flame straightening procedure trials.
6 (04/21) The cooling phase down to 350 °C shall be unassisted. Below this temperature cooling by an air blast
is permitted. Quenching by water shall not be used except where permitted for stainless steels, see BS EN 1090-
2:2018, 6.5.3.2 c).
7 (04/21) The use of passive restraints during the heating cycle is permitted. Active application of force during the
heating cycle, for example by jacking, shall not be used.
8 (04/21) For steel grades greater than S355, procedures shall be qualified by applying the method to a test piece
of appropriate form and known rolling direction, thickness and material grade.
9 (04/21) Following completion of the qualification test and cooling to ambient temperature, a set of longitudinal
tensile, impact and hardness tests shall be taken from 2 mm below the material surface of the heated zone where the
maximum specified temperature had been sustained for the longest period. The results, as tested in accordance with
BS EN 10025-1, shall demonstrate that the specified mechanical properties of the product have been maintained.
10 (04/21) A conforming procedure qualification test shall qualify procedures within the following limits:
a) all material grades and subgrades up to and including those tested;
b) all element thicknesses up to and including that tested; and
c) the number of full thermal cycles per heat zone up to and including the number applied in the test.
11 (04/21) Flame straightening personnel shall be assessed and approved by the welding coordinator to ensure
satisfactory understanding and capability of implementing the documented instruction for correction.
1806.5.3.2 (04/21) Additional requirements for stainless steels
1 (04/21) Flame straightening of stainless steels shall not be undertaken on duplex, low nickel austenitic and
martensitic grades. Flame straightening of other stainless steels grades shall not be undertaken without the prior
approval of the Overseeing Organisation.
1806.5.4 (08/14) Cold forming (AEN) (18/1)
1806.6 (08/14) Holing
1806.6.1 (08/14) Dimensions of holes (AEN) (18/1)
1806.6.2 (08/14) Tolerances on hole diameter for bolts and pins (AEN)
1806.6.3 (08/14) Execution of holing
1 (04/21) Round holes for fasteners or pins shall be drilled, or be punched at least 2mm undersize in diameter and
reamed after punching, where any of the following conditions apply:
a) the material thickness is greater than 3mm;
b) the QSC is F71 or higher; or
c) the joint is made using preloaded bolting assemblies.
2 (04/21) The restrictions on forming slotted holes shall be as for round holes as stated in 1806.6.3 (1), except
that:
a) machining (e.g. reaming, milling) shall be used to complete slotted holes formed by drilling or
punching;
b) hand thermal cutting of slotted holes shall not be permitted in any material thickness; and
c) slotted holes shall not be permitted in zones with a QSC above F112.
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3 (04/21) For holes formed by thermal cutting, isolated faults such as gouges, melting beads and oxide
remainders, as described in BS EN ISO 9013:2017, 7.2.1, shall be smoothly dressed out by grinding, linishing or
machining. See 1806.6.3 (1) and 1806.6.3 (2) b) for restrictions on the use of thermal cutting to form holes.
1806.7 (08/14) Cut outs (18/1)
1 (04/21) The minimum radius for re-entrant corners and notches shall be 5mm for QSC F56 and 10mm for QSC
F71 and above, subject to a smaller radius not being required by contract specific Appendix 18/1.
2 (04/21) Punched cut outs shall not be permitted.
1806.8 (08/14) Full contact bearing surfaces (AEN) (18/1)
1806.9 (08/14) Assembly (18/1)

1 (04/21) All connections for temporary components shall be executed in accordance with the requirements of
this Series including those described in contract specific Appendix 18/1, according to the QSC appropriate at each
connection location. See also 1807.5.6.
2 (04/21) Connections for temporary components shall not result in the removal or addition of permanent material
or introduction of permanent stress concentrating details, unless permitted by contract specific Appendix 18/1.
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Any filling of permitted temporary holes by welding shall be subject to qualification of the procedure(s) and the
welder(s) using the preparation(s) and material thickness(es) to be used in production, and to specific testing.
3 (04/21) A record of the details of any connections for temporary components shall be provided and shall form
part of the execution documentation; see 1804.2.2 and 1804.2.4.
1806.10 (08/14) Assembly check (18/1)
1 (04/21) Trial assembly shall be undertaken where required by contract specific Appendix 18/1.
2 (04/21) Where a full or staged trial assembly is undertaken, the correction of hole alignment by reaming of
bolted splices, selection of pack thicknesses, correction of weld preparation fit-up and correct positioning of
temporary alignment cleats shall be carried out during the trial assembly.
3 (04/21) The following requirements shall be taken into account, where applicable:
a) support of the assembly parts shall minimise self-weight stresses, where the unstressed camber profile is
being checked;
b) correct alignment of assembly parts shall be re-established in staged trial assembly including correct
relative levels of bearings;
c) differential temperature distributions throughout the steelwork shall be controlled or allowed for if
exposed to direct sunlight when surveys are made;
d) unique marking for identification and orientation of individual members shall be used;
e) all shop welding and bolting shall be complete;
f) every bolt hole shall be proved with a bolt of identical size to those to be used at the site;
g) lack of fit between components shall not be corrected by bolt tensioning; and
h) the position and level of all bearings and primary control points shall be surveyed at the trial erection.
1807 (08/14) Welding

1807.1 (08/14) General (18/1)
1 (04/21) The BS EN ISO 3834 quality requirements shall conform to the requirements for EXC3/4, unless EXC2
is required by contract specific Appendix 18/1.

2 (04/21) The constructor shall have a valid BS EN ISO 3834 certificate issued by a certification body accredited
for the standard by a National Accreditation Body. The certified Welding Quality Management system shall be in
accordance with the relevant part of BS EN ISO 3834 identified in 1807.1 (1).
3 (04/21) Permanent welds that are not described in contract specific Appendix 18/1 shall not be permitted.
1807.2 (08/14) Welding plan
1807.2.1 (08/14) Requirements for a welding plan (AEN)
1807.2.2 (04/21) Content of a welding plan
1 (04/21) When applying the conditions for welding cold formed zones according to BS EN 1993-1-8:2005, 4.14,
Table 4.2, the ‘predominantly static loading’ condition shall be deemed to apply to a QSC of F56 and the ‘fatigue
predominates’ condition to QSCs of F71 and above.
1807.3 (04/21) Welding processes
1 (04/21) A welding process which is not covered by BS EN 1090-2:2018, Table 12 or Table 13 shall be classified
as an Exceptional Welding Process (EWP).
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2 (04/21) An EWP shall conform to the relevant requirements of 1807 with the following additional provisions:
a) The welding procedure specifications (WPSs) shall include all essential and non-essential variables
necessary for control of the EWP over the range of joint types, materials and thicknesses for which it is
to be used. It shall also include fit up tolerances and details of jigging, other fixtures and measurement
devices.
b) The WPSs shall also include details of any thermal processes to be used in conjunction with the EWP.
These shall include tack welding, pre- and post-heating, other welding processes (including repair
welds) and thermal cutting.
c) Each preliminary welding procedure specifications (pWPSs) in 1807.3 (2) a) and b) shall be qualified by
pre-production tests in accordance with BS EN ISO 15613 followed by non-destructive and destructive
testing in accordance with the requirements for the relevant weld type in BS EN 15614-1.
d) The range of qualification of the pWPS shall be in accordance with BS EN 15614-1 for the type of weld
tested.
e) The welding personnel shall be qualified by performing the tests necessary for qualification of the
pWPSs in 1807.3 (2) c) and d).
f) Evidence shall be provided to show that the welding coordination personnel have in-depth knowledge
and experience of the EWP.
g) The proportion of production EWP welds subject to supplementary NDT shall be 2 levels higher than
required by Table 18/4, Table 18/5 and Table 18/6; see 1812.4.2.4 (4).
h) The NDT procedures for welds made by an EWP shall be approved by an operator qualified to Level 3
of BS EN ISO 9712 for the technique(s) used.
i) Production EWP welds shall be tested in accordance with Table 18/11 except that the frequency of
tensile and Charpy testing of in-line transverse butt welds in tension shall be 1 in 5 for all material
grades.
j) The documentation for items 1807.3 (2) a) to f) shall be submitted to and approved by the Overseeing
Organisation in advance of implementation of the EWP.
1807.4 (08/14) Qualification of welding procedures and welding personnel
1807.4.1 (08/14) Qualification of welding procedures

1807.4.1.1 (04/21) General (18/1)

1 (04/21) For tack welds, the welding procedure specification (WPS) shall include the special deposition
conditions and the tests stated in 1807.4.1.1 (4).
2 (04/21) The tolerances on cross section and length of the tack weld and any subsequent profiling requirements,
such as feathering of ends, shall be specified in the WPS.
3 (04/21) To qualify the procedure for a tack weld where it is to be incorporated in the joint, the maximum
permitted cross section of tack weld shall be used in the qualification test. The positions of the ends of the tack
weld shall be marked on the test piece.
4 (04/21) Macroscopic examination and hardness testing shall be carried out within the tack weld length. This test
is not required if the original test for qualifying the complete weld includes the tack weld tested as described in this
paragraph.
1807.4.1.2 (08/14) Qualification of welding procedures for processes 111, 114, 12, 13 and 14
1 (04/21) Methods of qualification shall be in accordance with those permitted for EXC3/4 in BS EN 1090-
2:2018, Table 12. Qualification by means of a standard welding procedure shall not be permitted.
NOTE: For method of qualification of tack welds see 1807.4.1.1.
2 (04/21) The welding coordinator shall take account of the fact that some of the imperfection acceptance limits
in BS EN 15614-1 are less restrictive than are required for FPC purposes in BS EN 1090-2:2018, 7.6, particularly
for the higher EXCs. Where the limits given in BS EN 15614-1 are less restrictive than are required for Fitness
for Purpose (FFP) purposes in 1812.4.2.5 and 1812.4.2.6, the relevant WPS and associated welding procedure
qualification record (WPQR) (where available) shall be reviewed to establish whether any additional controls need
to be added to the WPS to ensure that the FFP limits will have an adequate probability of being met in production;
for example, restrictions on tolerances for joint preparation/fit-up and welding parameters, and limitations
on welding position. In cases of doubt that the FFP limits might not be met, a pre-production test of the joint
concerned shall be carried out, followed by a non-destructive and/or destructive examination, as appropriate, to
provide the necessary assurance.
3 (04/21) Alternatives to the cruciform tensile test to BS EN ISO 9018 for fillet welds on steel grades S460 and
above shall not be permitted.
4 (04/21) Joints with restricted access for welding (e.g. slot and plug welds, shallow angle branch connections),
shall be subject to procedure testing in accordance with BS EN ISO 15613.
1807.4.1.3 (04/21) Qualification of welding procedures for other welding processes
1 (04/21) Welding procedure qualification for welding process numbers 783, 784 and 786 shall be carried out by
a welding procedure test in accordance with BS EN ISO 14555:2017, 10.2. For process 783, the examination and
testing of test pieces shall be carried out in accordance with BS EN ISO 14555:2017, Table 1 for comprehensive
quality requirements according to BS EN ISO 3834-2.
2 (04/21) Fillet, partial penetration and full penetration tee joint welds shall be qualified by a supplementary in-
line butt weld procedure qualification record to demonstrate mechanical properties in accordance with BS EN ISO
15614-1:2017+A1:2019, Table 2 Footnote f.
3 (04/21) Qualification testing for welded joints involving reinforcing steel shall be carried out in accordance with
BS EN ISO 17660-1, irrespective of whether a joint is nominally classified as ‘load’ or ‘non-load’ bearing.
4 (04/21) For preparation and qualification of procedures for welds made by an EWP, see 1807.3 (2) a) to d).
1807.4.1.4 (08/14) Validity of a welding procedure qualification
1 (08/14) Welding production tests shall be carried out in accordance with the qualification standard for the
process concerned.
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1807.4.2 (08/14) Welders and welding operators

1807.4.2.1 (04/21) General
1 (04/21) Welders shall be qualified by specific test for welding of joints with restricted access; see 1807.4.1.2 (4).
2 (04/21) Welders of joints involving reinforcing steel shall be qualified in accordance with BS EN ISO 17660-1.
3 (04/21) For qualification of welders and welding operators for welds made by an EWP, see 1807.3 (2) e).
1807.4.2.2 (04/21) Branch connections (AEN)
1807.4.3 (08/14) Welding coordination
1 (08/14) Welding coordination shall conform to the requirements for EXC2/3/4.
2 (04/21) For welding coordination of EWPs, see 1807.3 (2) f).
1807.5 (08/14) Preparation and execution of welding
1807.5.1 (08/14) Joint preparation
1807.5.1.1 (08/14) General
1 (04/21) Where prefabrication primers are to be left on fusion faces or heat affected zones, the weld procedures
shall be tested in accordance with the requirements for EXC2/3/4.
1807.5.1.2 (04/21) Hollow sections
1 (04/21) The guidance on joint preparation for joints between hollow sections given in BS EN 1090-2:2018,
Annex E shall be applied.
1807.5.2 (08/14) Storage and handling of welding consumables (AEN)
1807.5.3 (08/14) Weather protection (AEN)
1807.5.4 (08/14) Assembly for welding
1 (04/21) The guidance on the assembly of hollow section components given in BS EN 1090-2:2018, Annex E
shall be applied.
2 (04/21) For the assembly of hollow section components where access to the joint for welding is restricted, a pre-
production welding test conforming to BS EN ISO 15613 shall be conducted using the tolerances on preparation
and fit-up that give the most restricted access, to demonstrate that the required penetration can be achieved.
1807.5.5 (08/14) Preheating (AEN)
1807.5.6 (08/14) Temporary attachments (18/1)
1 (04/21) In accordance with EXC3/4, restrictions on the use of temporary welded attachments shall be as stated
in contract specific Appendix 18/1, and as follows.
a) Temporary welded attachments shall not be permitted in zones of QSC F112 and above.
b) Temporary welded attachments shall not be permitted within 25mm of an edge.
c) Except where excluded in 1807.5.6 (1) d), removal of temporary welded attachments by thermal
cutting, gouging or chipping is permitted provided that the finished cut surface of the remainder of the
attachment is at least 3mm from the permanent member surface prior to grinding smooth. Remnants of
temporary material proud of the permanent member surface shall be removed by grinding parallel to
the member axis. The final ground surface shall be checked for freedom from cracking using magnetic
particle testing.
d) Gouging and chipping shall not be used for the removal of temporary welded attachments on steel
grades S460 and above, or where a QSC of F71 or above applies.
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1807.5.7 (08/14) Tack welds

1 (04/21) Tack welds shall conform to the requirements for EXC2/3/4; see 1807.4.1.1.
1807.5.8 (04/21) Fillet welds
1807.5.8.1 (04/21) General
1 (04/21) In the case of fillet welded joints with root gaps, compensation shall be made for loss of throat and
effective leg length by increasing the deposit size accordingly; see Table 18/7, Note G).
1807.5.8.2 (04/21) Fillet welds on member connections (AEN)
1807.5.9 (08/14) Butt welds
1807.5.9.1 (08/14) General (18/1)
1 (04/21) Run-on and run-off pieces shall be used on all butt welds and shall conform to the requirements for
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EXC2/3/4, where access allows.

2 (08/14) Where a weld surface is required to be ground or machined flush, this shall be executed prior to non-
destructive testing.
1807.5.9.2 (08/14) Single sided welds (18/1)
1 (04/21) Permanent steel backing shall only be used if described in contract specific Appendix 18/1. The
continuity of permanent steel backing shall conform to the requirements for EXC3/4. The execution of the
continuity weld shall depend upon the QSC related to stresses parallel to the axis of the backing component, as
follows:
a) F36: no additional requirements;
b) F56 to F90: make continuous by full penetration butt weld at any stage, followed by surface crack
detection; and
c) F112 to F140: make continuous by full penetration butt weld, followed by flush grinding and surface
crack detection before assembly.
1807.5.9.3 (08/14) Back gouging (AEN)
1807.5.10 (08/14) Welds on steels with improved atmospheric corrosion resistance
1 (08/14) The requirements for the consumables to be used for welds on steels with improved atmospheric
corrosion resistance are given in 1805.5.
1807.5.11 (04/21) Branch connections
1 (04/21) The guidance on the execution of branch connections in hollow sections given in BS EN 1090-2:2018,
Annex E shall be applied.
1807.5.12 (08/14) Stud welding
1 (04/21) With reference to BS EN ISO 14555, the comprehensive quality requirements in accordance with BS
EN ISO 3834-2 shall be adopted.
1807.5.13 (08/14) Slot and plug welds (18/1)
1 (08/14) The depth-to-minimum width ratio of the slot or plug hole shall not exceed that used for the weld
procedure qualification test.
1807.5.14 (04/21) Other weld types (AEN) (18/1)
1807.5.15 (04/21) Post-weld heat treatment (AEN)
1807.5.16 (04/21) Execution of welding (18/1)
1 (04/21) Stray arc sites shall be checked for cracking by PT or MT on all steel grades for QSC F90 and above.

2 (04/21) Deposits of weld spatter shall be removed from all surfaces where it is not permitted in accordance with
Table 18/7, Note J) and Table 18/8, Note I).
3 (04/21) The direction of grinding of the surfaces of completed welds shall be parallel to the stress direction for
welds with a QSC of F90 and above.
1807.5.17 (04/21) Welding of orthotropic bridge decks (AEN)
1807.6 (08/14) Acceptance criteria
1807.6.1 (04/21) Routine requirements
1 (04/21) The selection of EXC in BS EN 1090-2:2018, 7.6.1 for routine FPC acceptance criteria shall be
determined by the manufacturer, according to the nature of their work in normal production.
2 (04/21) Acceptance criteria used for FPC during the work shall not be to a lower standard than that required
for specific inspection of the work, taking into account the method of testing and QSCs required for the work; see
1812.4.2.5 and 1812.4.2.6 for acceptance levels for specific inspection and testing.
1807.6.2 (04/21) Fatigue requirements
1 (04/21) The method of specification and the acceptance criteria given in BS EN 1090-2:2018, 7.6.2 shall not be
used in place of those given in Tables 18/7 to 18/10 for specific inspection of production welds. See 1812.4.2.5 and
1812.4.2.6.
1807.6.3 (04/21) Orthotropic bridge decks
1 (04/21) The requirements in BS EN 1090-2:2018, 7.6.3 shall not take precedence over the requirements for
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specific inspection and testing of welds in orthotropic bridge decks; see 1812.4.2.5 and 1812.4.2.6.
1807.7 (04/21) Welding of stainless steels (AEN) (18/1)
1808 (08/14) Mechanical Fastening

1808.1 (08/14) General (AEN)
1808.2 (08/14) Use of bolting assemblies

1808.2.1 (08/14) General (18/1)
1 (04/21) Welding of nuts, bolts or washers shall not be used on bolting assemblies above property class 4.6.
2 (04/21) Welding of property class 4.6 nuts, bolts and washers shall only be undertaken where stated in contract
specific Appendix 18/1 and shall be subject to the requirements in 1807, 1812.4 and BS EN 1090-2:2018, 7. Weld
procedure qualification shall be carried out in accordance with BS EN ISO 15613.
3 (04/21) Restrictions on the orientation of bolting assemblies shall be as stated in contract specific Appendix
18/1.
1808.2.2 (08/14) Bolts (AEN) (18/1)
1808.2.3 (08/14) Nuts (AEN)
1808.2.4 (08/14) Washers (18/1)
1 (08/14) Washers shall be placed under the nut or head of the bolt in non-preloaded assemblies whichever is
rotated.

1808.3 (04/21) Tightening of non-preloaded bolting assemblies (AEN) (18/1)
1808.4 (08/14) Preparation of contact surfaces in slip resistant connections (18/1)

1 (04/21) All surfaces which overlap each other in the final assembled connection excluding any painted edge strip
around the perimeter of the connection shall be deemed to be ‘contact surfaces’.
2 (08/14) The specified surface treatment applied to the friction surfaces shall be maintained until the surfaces are
brought together and the connection assembled.
1808.5 (04/21) Tightening of preloaded bolting assemblies
1808.5.1 (08/14) General (18/1)
1 (04/21) At the snug tight stage, the exposed surfaces of the components being connected shall be aligned within
1mm where they emerge from beneath the cover plate(s) at the joint plane. If this tolerance is exceeded, the cover
plate(s) shall be removed and corrective steel packing plates installed. The tolerance on thickness difference
between the two components (including any packing plates) in BS EN 1090-2:2018, 8.1 shall also be met.
2 (04/21) In the case of preloaded lap joints subject to axial load acting in the plane of the friction surfaces,
measures to limit the out-of-plane bending stiffness of cover plates shall be as stated in contract specific Appendix
18/1. Any additional contact surfaces shall be treated as contact surfaces in slip resistant connections.
3 (04/21) Where a connection is designed to transfer applied tensile forces through a flanged and bolted end
plate, as a minimum, the area of the mating surfaces in direct line with the tension member cross section shall be
in contact when all bolts are snug tight. Any remaining gaps in this zone shall be filled by steel shims prior to the
application of the remaining preload. The following shall apply:
a) If necessary, bolts can be partially slackened to enable shims to be inserted.
b) The shims shall not be loose in the final snug tight stage.
c) In the event of a tapering gap, use of a purpose machined tapered steel shim is permitted.
d) As an alternative to 1808.5.1 (3) c), flat (parallel) steel shims of not less than 0.1mm and of not more
than 0.2mm thick shall be inserted to refusal, in steps until the gap in the contact zone is filled, followed
by retightening to the snug tight stage.
e) If sealing of the joint is required, the remaining gaps shall be filled with a corrosion protection medium
compatible with the corrosion protection to be applied to the joint after final tightening of the bolting
assemblies.
4 (04/21) Use of the part turn method is permitted for tightening preloaded bolts if all the following conditions
apply:
a) the bolts are property class 8.8 and assemblies conform to 1805.6.4;
b) the required nominal minimum preloading force is not in excess of the values specified in BS EN 1090-
2:2018, Table 18; and
c) the joint fit-up conforms to 1808.5.1 (1) or 1808.5.1 (3), whichever is applicable.
5 (04/21) The part turn method shall be carried out as for the combined method in BS EN 1090-2:2018, 8.5.4,
except that:
a) the k-class of the bolting assemblies shall comply with 1805.6.2 (1);
b) in the first tightening step the nut shall be tightened to the specified torque, as given in Table 18/1; and
c) in the second tightening step the nut shall be tightened to the specified turn as given in Table 18/2.

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(04/21) Table 18/1 Torque values for the part turn method – step one
Bolt diameter 12 14 16 18 20 22 24 27 30 36
d, mm
Torque value 40 60 80 110 160 210 270 340 460 810
M, Nm
(04/21) Table 18/2 Rotation values for the part turn method – step two
Bolt diameters, mm Grip lengthA), mm Rotation, °

t < 115 180 (½ turn)
12 to 22
115 < t < 275 270 (¾ turn)
t < 160 180 (½ turn)
24 to 36
160 < t < 350 270 (¾ turn)
A) Equal to nominal thickness, t, in BS EN 1090-2:2018, Table 21
6 (04/21) The torque method shall not be used for the tightening of preloaded bolts unless stated in contract
7 (04/21) When direct tension indicators or HRC bolts are used, surfaces shall be brought into contact using
temporary service bolts with the same grade and diameter as the permanent bolts.
8 (04/21) Any coating passivation process to be undertaken by the constructor shall only be undertaken after the
inspection after tightening of the affected preloaded bolts has been completed.
1808.5.2 (08/14) Torque reference values (AEN)
1808.5.3 (08/14) Torque method
1 (04/21) Where the torque method is to be used, see 1808.5.1 (6), the k value shall be checked daily with torque
wrenches in accordance with BS EN 1090-2:2018, Annex H and the torque for both tightening steps adjusted
accordingly. Any assembly lots that fail to conform to this test shall be discarded.
1808.5.4 (08/14) Combined method
1 (04/21) For property classes 8.8 and 10.9 bolting assemblies to BS EN 14399-3, see 1805.6.4, the further
rotation values in BS EN 1090-2:2018, Table 21 shall be amended as follows for the same thickness ranges:
a) replace 60° by 90° (¼ turn);
b) replace 90° by 120° (⅓ turn); and
c) replace 120° by 180° (½ turn).
2 (04/21) The k value shall be checked daily with the torque wrenches in accordance with BS EN 1090-2:2018,
Annex H and the torque for the first tightening step adjusted accordingly. Any assembly lots that fail to conform to
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this test shall be discarded.

3 (04/21) The simplified value of 0.75Mr,1 = 0. 094dFp,C shall not be used.
1808.5.5 (08/14) HRC method
1 (04/21) The preload shall be checked on sample assemblies for each assembly lot within seven days prior to
use in accordance with BS EN 1090-2:2018, Annex H. Any assembly lots showing values of preload below the
minimum specified value shall be discarded.
2 (04/21) The pre-tightening step shall be repeated until the shear wrench outer socket has stopped turning on all
assemblies in a connection.

1808.5.6 (08/14) Direct tension indicator method (AEN)

1808.6 (08/14) Fit bolts (AEN)
1808.7 (08/14) Hot riveting

1808.7.1 (08/14) Rivets (AEN)
1808.7.2 (08/14) Installation of rivets (AEN) (18/1)
1808.7.3 (08/14) Acceptance criteria (AEN) (18/1)
1808.8 (04/21) Use of special fasteners and fastening methods (AEN) (18/1)
1808.9 (04/21) Galling and seizure of stainless steels (AEN)
1809 (08/14) Erection

1809.1 (08/14) General (AEN)
1809.2 (08/14) Site conditions (AEN)
1809.3 (08/14) Erection method

1809.3.1 (04/21) Design basis for the erection method (AEN) (18/1)
1809.3.2 (04/21) Constructor’s erection method
1 (04/21) The method of securing and sealing permanent formwork shall be as given in Series 1700.
1809.4 (08/14) Survey
1809.4.1 (08/14) Reference system (18/1)
1 (04/21) The reference temperature shall be 15°C, unless otherwise stated in contract specific Appendix 18/1. The
reference temperature shall be recorded in the quality plan.
1809.4.2 (08/14) Position points (AEN)
1809.5 (08/14) Supports, anchors and bearings
1809.5.1 (08/14) Inspection of supports (AEN)
1809.5.2 (08/14) Setting out and suitability of supports (AEN)
1809.5.3 (08/14) Maintaining suitability of supports (AEN) (18/1)
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1809.5.4 (08/14) Temporary supports (18/1)

1 (08/14) Levelling nuts or other devices providing temporary support shall be slackened off before final
tensioning of foundation bolts where a post-tensioning force is specified, to allow the post-tensioning force to be
transferred to the foundations.
2 (08/14) In the case of exposed steelwork and irrespective of bedding material, the minimum finished cover to
steel packings or other steel temporary support devices left in position shall be 50mm.
1809.5.5 (08/14) Grouting and sealing (18/1)
1 (04/21) Unless otherwise stated in contract specific Appendix 18/1, the surfaces of steelwork and bearings that
are to be in contact with grout or bedding mortar shall be treated in accordance with 1810.7.
1809.5.6 (08/14) Anchoring (AEN)

1809.6 (08/14) Erection and work at site

1809.6.1 (08/14) Erection drawings (AEN)
1809.6.2 (08/14) Marking (AEN)
1809.6.3 (08/14) Handling and storage on site
1 (04/21) Procedures for restoration of damage shall be documented in accordance with the requirements for
EXC2/3/4, and shall be submitted to and approved by the Overseeing Organisation in advance of implementation.
2 (08/14) The processes used for the restoration of damaged steelwork shall be in accordance with the
requirements of this Series.
1809.6.4 (08/14) Trial erection (AEN)
1809.6.5 (04/21) Erection works
1809.6.5.1 (08/14) General (AEN)
1809.6.5.2 (08/14) Temporary works (AEN)
1809.6.5.3 (08/14) Fit-up and alignment
1 (08/14) The use of shims shall be avoided where possible by suitable controls on preparation, assembly and
weld distortion and, if necessary, by machining.
2 (04/21) If welding is required for securing shims, it shall be carried out in accordance with BS EN 1090-2:2018,
7. The requirements of 1807 and 1812.4 shall also apply.
3 (04/21) Where steel shims are needed to correct the fit between members, particularly in preloaded tension
joints, see 1808.5.1, and where gaps are variable across the interface, use of flat (parallel) steel shims is permitted
as an alternative to a purpose machined tapered steel shim. The gap shall be filled by insertion of shims of not less
than 0.1mm and not more than 0.2mm thick from the widest gap position until refusal. The excess material shall be
cut off on completion.
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1810 (08/14) Surface Treatment
1810.1 (04/21) General (18/1) (19/1) (19/5)
1 (08/14) Treatment of surfaces to receive corrosion protection shall be in accordance with Series 1900.
2 (04/21) The requirements for the execution of corrosion protection in BS EN 1090-2:2018, Appendix F shall be
supplemented by those in Series 1900.
3 (04/21) The performance specification required by BS EN 1090-2:2018, F.1.2 shall be as given in contract
4 (04/21) The prescriptive requirements for corrosion protection required by BS EN 1090-2:2018, F.1.3 shall be as
given in Series 1900.
5 (04/21) With reference to BS EN 1090-2:2018, F.4, the requirements for friction surfaces and class of treatment
or tests required for surfaces in slip resistant connections shall be as stated in contract specific Appendix 18/1.
6 (04/21) With reference to BS EN 1090-2:2018, F.4, where corrosion protection is specified, the requirements for
corrosion protection and extent of surfaces to be painted at preloaded connections shall be as given in Series 1900,
Clause 1906 and contract specific Appendix 19/5.
7 (04/21) With reference to BS EN 1090-2:2018, F.4, the extent of surfaces affected by preloaded bolts in
connections that are not required to be slip resistant shall be as given in contract specific Appendix 18/1.
8 (04/21) The requirements for the protection of the lower embedded part of foundation bolts shall be as stated in
BS EN 1090-2:2018, F.5, unless otherwise stated in contract specific Appendix 18/1.

9 (04/21) With reference to BS EN 1090-2:2018, F6.3, for cold formed components that are to be galvanized
after manufacture, the requirements for procedure qualification of the dipping process shall be as given in contract
10 (04/21) With reference to BS EN 1090-2:2018, F6.3, the requirements for the inspection, checking and
qualification of the preparation to be carried out before subsequent overcoating of galvanized components shall be
as given in contract specific Appendix 18/1.
11 (04/21) With reference to BS EN 1090-2:2018, F.7.3, reference areas shall be as required by Series 1900, Clause
1915.
12 (04/21) With reference to BS EN 1090-2:2018, F.7.4, all hot dip galvanized components shall be subjected to
post-galvanizing inspection.
13 (04/21) With reference to BS EN 1090-2:2018, F.7.4, components or specific locations that shall be subjected to
additional NDT, and the scope and method of NDT shall be as given in contract specific Appendix 18/1.
1810.2 (08/14) Preparation of steel substrates for paints and related products (18/1)
1 (04/21) All surfaces shall meet the requirements of BS EN ISO 8501-3 preparation grade P2, except for edges
which shall be rounded to a constant radius of not less than 2mm, the radius being tangential to the original
surfaces; see BS EN ISO 8501-3:2007, Table 1 imperfection type 2.1, 2.2 and 2.3, and BS EN ISO 12944-3:2017,
Fig. D.5 c).
1810.3 (04/21) Weather resistant steels (18/1)
1 (08/14) Exposed surfaces of uncoated weather resistant steel shall be blast cleaned to grade Sa2 to BS EN ISO
8501-1 to achieve a uniform surface. Any surfaces that are subsequently marked or contaminated shall be cleaned
to a similar standard.
2 (08/14) Uncoated weather resistant steel shall be kept free of contamination such as oil, grease, paint, concrete
and asphalt.
3 (04/21) Wax or grease markers shall not be used to mark surfaces of weather resistant steels.
1810.4 (08/14) Galvanic coupling (AEN)
1810.5 (04/21) Hot dip galvanizing (18/1)

1 (04/21) The preparation of surfaces prior to hot dip galvanizing shall be as given in Series 1900.
1810.6 (04/21) Sealing of spaces (18/1) (19/1)
1 (04/21) The internal treatment system to be provided to enclosed spaces that are to be sealed by welding or
provided with internal protective treatment shall be as stated in contract specific Appendix 19/1.
2 (04/21) All internal spaces which have been identified as being hermetically sealed in contract specific Appendix
18/1 shall have all joints, whether welded, mechanically fastened or bonded, leak tested prior to application of the
external protective coating; see BS EN 1779. The bubble emission technique in accordance with BS EN 1593 shall
be used.
3 (04/21) Where spaces are to be fully enclosed by sealing welds to prevent the ingress of moisture, weld
imperfections involving surface breaking voids otherwise permitted under the welding specification shall be sealed
using an appropriate weld repair.
1810.7 (08/14) Surfaces in contact with concrete (18/1)
1 (08/14) When formwork is in contact with the outer surfaces of the steelwork the embedded length shall be
measured from the junction between the concrete, the formwork and the steelwork.
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23
1810.8 (08/14) Inaccessible surfaces

1 (08/14) Faying surfaces and surfaces beneath washers in connections other than slip resistant connections that
are to be painted shall be treated in accordance with Series 1900.
2 (08/14) In uncoated weather resisting steels, faying surfaces and surfaces beneath washers in connections
other than slip resistant connections shall be cleaned to grade St2 to BS EN ISO 8501-1 immediately prior to the
connection being made.
1810.9 (08/14) Repairs after cutting or welding (18/1)
1 (04/21) Protective treatment on edges and adjacent surfaces which have been damaged by cutting or after
welding shall be restored in accordance with the original specification.
2 (04/21) Coatings on precoated constituent products that have been damaged by welding shall be restored in
accordance with contract specific Appendix 18/1
1810.10 (04/21) Cleaning of stainless steel components (AEN) (18/1)
1811 (08/14) Geometrical Tolerances

1811.1 (08/14) Tolerance types (18/1)
1 (04/21) Where full contact end bearing is specified, see BS EN 1090-2:2018, Table B.19, special tolerances
are required. The maximum gap between the two surfaces shall be limited to 0.5mm. In the case of fitted web
stiffeners, the gap shall also be limited to a maximum of 0.25mm over 60% of the fitted area.
1811.2 (08/14) Essential tolerances
1811.2.1 (08/14) General (AEN)
1811.2.2 (08/14) Manufacturing tolerances
1811.2.2.1 (08/14) Rolled sections (AEN)
1811.2.2.2 (08/14) Welded sections(AEN)
1811.2.2.3 (08/14) Cold formed sections (AEN)
1811.2.2.4 (08/14) Stiffened plating (AEN)
1811.2.2.5 (04/21) Shells (18/1)
1 (04/21) The scope of dimensional checking for dimple measurements shall be as given in contract specific
Appendix 18/1. See BS EN 1090-2:2018, Table B.11.
1811.2.3 (08/14) Erection tolerances
1811.2.3.1 (08/14) Reference system (AEN)
1811.2.3.2 (04/21) Foundation bolts and other supports (AEN) (18/1)
1811.2.3.3 (08/14) Column bases (AEN)
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1811.2.3.4 (08/14) Columns (AEN)

1811.2.3.5 (08/14) Full contact bearing (AEN)
1811.3 (08/14) Functional tolerances
1811.3.1 (08/14) General (AEN)

1811.3.2 (08/14) Tabulated values

1 (04/21) Functional tolerance class 1 shall be adopted, except in the following cases from BS EN 1090-2:2018
where class 2 shall be adopted:
a) Table B.1, No 1 to No 6 at bearing and bearing stiffener locations; and
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b) Table B.6, No 3 and No 4.
1811.3.3 (08/14) Alternative criteria (AEN) (18/1)
1812 (08/14) Inspection, Testing and Correction

1812.1 (08/14) General (AEN)
1812.2 (08/14) Constituent products and components

1812.2.1 (08/14) Constituent products (18/1)
1 (04/21) Proprietary products not covered by the European or International standards references in BS EN 1090-
2:2018 shall be subject to specific testing as stated in contract specific Appendix 18/1.
2 (04/21) Mechanical fasteners, see BS EN 1090-2:2018, 5.6, shall be verified by the constructor to show that
they conform to the requirements of the product standard to which they have been manufactured; see 1800.5.2 (1).
Reports of the verification undertaken shall be prepared. The reports shall be treated as execution records and shall
form part of the execution documentation; see 1804.2.2 and 1804.2.4. The verification shall include the following
requirements:
a) evidence of certification of the quality of the mechanical fasteners such as the manufacturer’s
declaration of performance under a CE/UK marking, manufacturer’s certificates, and test reports from
manufacturers or suppliers shall be obtained;
b) mechanical fastener documentation shall be reviewed to confirm authenticity, relevance, accuracy and
completeness; and
c) inspection and sample testing of the mechanical fasteners in accordance with BS EN ISO 3269 shall
be undertaken, to confirm that the dimensional characteristics and mechanical, physical and functional
properties comply with the product standard to which the mechanical fasteners have been manufactured.
3 (04/21) Mechanical fasteners supplied for use in the works shall be suitability tested by the constructor in
accordance with the relevant standard for the fasteners selected. This testing is in addition to the requirements of
1800.5.2 (1) or 1812.2.1 (2) as appropriate. For each inspection lot of mechanical fasteners, three fasteners shall
be selected at random and tested in accordance with the suitability test related to the product standard to which the
mechanical fasteners have been manufactured. The mechanical fasteners that are subjected to the suitability testing
shall be discarded following testing. In the event of a mechanical fastener not meeting the requirements of the
suitability test, all mechanical fasteners in the associated inspection lot shall be discarded. The suitability testing
shall be reported in accordance with the relevant standard for the fasteners selected. The reports shall be treated as
execution records and shall form part of the execution documentation; see 1804.2.2 and 1804.2.4.
4 (04/21) Structural steel products, see BS EN 1090-2:2018, 5.3, shall be verified by the constructor to show that
they conform to the requirements of the product standard to which they have been manufactured; see 1800.5.3 (1).
Reports of the verification undertaken shall be prepared. The reports shall be treated as execution records and shall
form part of the execution documentation; see 1804.2.2 and 1804.2.4. The verification shall include the following
requirements:
a) evidence of certification of the quality of the structural steel product such as the manufacturer’s
declaration of performance under a CE/UK marking, manufacturer’s certificates, and test reports from
manufacturers or suppliers shall be obtained;

b) structural steel product documentation shall be reviewed to confirm authenticity, relevance, accuracy and
completeness; and
c) inspection and sample testing of a structural steel product shall be undertaken where manufacturer’s or
supplier’s test reports confirming compliance with product standard requirements are not reviewed or are
reviewed but are not found to be authentic, relevant, accurate or complete. The inspection and sample
testing shall be to confirm that the dimensions, chemical composition and mechanical properties comply
with the product standard to which the structural steel product has been manufactured.
5 (04/21) Steel castings shall be verified by the constructor in accordance with the specific testing requirements
and acceptance levels given in Table 18/3.
(04/21) Table 18/3 Specific testing requirements and acceptance levels for steel castings
BS EN 1090-2:2018, Testing Requirement QSC

5.4 Item F56 F71 F90 F112 F140
a) Visual inspection % of lot 100
b) Destructive tests Test piece type Product Sample
c) Non-destructive 6) MT % of lot 20 100 100 100 100
tests 7) UT % of lot 20 50 100 100 100
7) RT % of lot 20 20 50 100 100
Acceptance Criteria MT 2 2 1 NPA) NPA)
severity level SM
MT 3 2 1 NPA) NPA)
severity level LM/AM
UT 2 1 1 NPA) NPA)
severity level
RT 3 2 1 NPA) NPA)
severity levelB)
A) NP = no indications permitted
B) In accordance with BS EN 12681
1812.2.2 (08/14) Components (AEN)

1812.2.3 (08/14) Non-conforming products
1 (04/21) Records of testing undertaken to prove product conformity shall be treated as execution records and
shall form part of the execution documentation; see 1804.2.2 and 1804.2.4.
1812.3 (08/14) Manufacturing: geometrical dimensions of manufactured components
1 (04/21) The inspection plan shall identify all dimensions which could be at risk of non-conformity. Checks
shall be made during execution and action taken to correct any non-conformity at the earliest opportunity. All such
dimensions shall be checked before the steelwork is dispatched to site. Components in the neighbourhood of site
connections shall be re-checked once the connections are complete.
2 (04/21) If the correction of a nonconformity is not practicable, proposed modifications to the steel structure to
compensate for the nonconformity shall be submitted to and approved by the Overseeing Organisation in advance
of implementation.
3 (04/21) Repair of local dents in the surface of hollow sections by means of welded cover plates shall only be
undertaken if approved by the Overseeing Organisation in advance of implementation.
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1812.4 (08/14) Welding

1812.4.1 (04/21) General (AEN)
1812.4.2 (04/21) Inspection after welding
1812.4.2.1 (08/14) Timing (AEN)
1812.4.2.2 (04/21) Type testing (AEN)
1812.4.2.3 (04/21) Routine inspection and testing
1 (04/21) The selection of EXC in BS EN 1090-2:2018, Table 24 for the extent of their routine FPC inspection
shall be determined by the manufacturer according to the nature of their work in normal production. It shall be not
less than that required for EXC3 or for the project specific inspections required in 1812.4.2.4 (2) to (6), whichever
is the greater.
2 (04/21) Any FPC inspections undertaken on a specific structure which conform to Table 18/4, providing that the
acceptance criteria in 1812.4.2.5 and 1812.4.2.6 are fully met, are permitted to be included and documented as part
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of the specific inspection required in 1812.4.2.4 (2) to (6).

1812.4.2.4 (04/21) Project specific inspection and testing
1 (04/21) All welded joints shall be subject to specific inspection, as permitted for EXC1/2/3.
2 (04/21) The scope of specific inspection for each joint shall be 100% visual and in accordance with the extent
and methods of supplementary non-destructive testing (NDT) given in Table 18/4, Table 18/5 and Table 18/6,
according to the required QSC.
3 (04/21) Table 18/4 specifies the minimum proportions of welded joints subjected to specific supplementary
NDT for shop welds in steel grades up to and including S355 and QSC F56, which represent the most common
conditions. The percentages in Table 18/4 shall be applied to the number of joints tested up to weld lengths of
one metre in any joint. For joints with weld lengths exceeding one metre, the percentage shall be applied to the
proportion of weld in every joint.
4 (04/21) Where other conditions than those assumed in Table 18/4 apply, the minimum proportions of welded
joints to be subjected to specific supplementary NDT shall be increased (or decreased) by one or more levels
in accordance with Table 18/5. This shall be done by applying the next highest (or lowest) proportion using the
following sequence of seven increasing levels of proportion: 0%, 2%, 5%, 10%, 20%, 50%, 100%. See Table 18/5,
footnote B).
5 (04/21) If adjustments are made according to more than one condition in Table 18/5, the net number of levels
shall be used, after adding and/or subtracting the number of levels given for each condition. See Table 18/5,
footnote C).
6 (04/21) For QSC F71 and above for shop welds in steel grades up to and including S355, the minimum
proportions of welded joints which shall be subjected to supplementary NDT are specified in Table 18/6. For other
conditions, the proportion tested in Table 18/6 shall be adjusted in accordance with Table 18/5 as described in
1812.4.2.4 (4) and (5) for Table 18/4.
7 (04/21) For the proportion of inspection and testing of welds made by an EWP, see 1807.3 (2) g).
8 (04/21) For approval of NDT procedures for welds made by an EWP, see 1807.3 (2) h).
1812.4.2.5 (04/21) Visual inspection of welds
1 (04/21) The criteria for final acceptance without the need for remedial action shall be in accordance with Table
18/7 and Table 18/8, according to the required QSC. These criteria shall apply irrespective of those used for FPC.
1812.4.2.6 (04/21) Supplementary NDT methods
1 (04/21) The criteria for final acceptance without the need for remedial action shall be in accordance with Table
18/9 for magnetic particle and penetrant testing and Table 18/10 for ultrasonic and radiographic testing, according
to the required QSC. These criteria shall apply irrespective of those used for FPC.

1812.4.2.7 (04/21) Correction of welds

1 (04/21) Repairs by welding shall be carried out as required for EXC2/3/4.
1812.4.3 (08/14) Inspection and testing of welded shear studs for composite steel and concrete structures
1 (04/21) Production tests shall be carried out in accordance with BS EN ISO 14555 before the beginning of
welding operations and repeated after every 5000 welds for each combination of stud diameter, parent material and
type of equipment that is used.
2 (04/21) Simplified production tests shall be carried out as required by BS EN ISO 14555, and at a minimum rate
of one test (comprising three studs) after every 100 welds on each piece of steelwork, with a minimum of one test
(comprising three studs) per piece. The direction of the bend test shall be such that the bent stud shall not interfere
with other elements of the works.
3 (04/21) Production surveillance in accordance with BS EN ISO 14555 shall include the testing of every stud on
a production piece of steelwork by striking the side of the head of the stud with a 2kg hammer. The weld shall be
deemed to be acceptable if there is a clear ring tone due to the striking. Any stud deemed to be unacceptable as a
result of this test shall be tested as part of the testing described in 1812.4.3 (2).
4 (04/21) All stud shear connectors shall be aligned to within 4° from the normal to the plate to which the studs
are welded. The length of each stud after welding (LAW) shall be within +1.5mm and -2mm of the manufacturer's
specified nominal LAW.
5 (04/21) The production surveillance records in accordance with BS EN ISO 14555 shall be treated as execution
records and shall form part of the execution documentation; see 1804.2.2 and 1804.2.4.
1812.4.4 (08/14) Production tests on welding
1 (04/21) Production tests conforming to the requirements for EXC3/4 shall be carried out.
2 (04/21) Specific production tests shall be conducted on run-off coupon plates in accordance with Table 18/11,
according to the required QSC, and shall apply to all parts of the structure. Where the use of run-off coupon plates
is not practicable, e.g. in the case of circumferential butt welds in tubular members, the production tests shall be
conducted at the same time on separate coupon plates. The coupon material shall be from the same batch with
the same weld preparation and orientation relative to the rolling direction(s) as in the production joint. The same
welding equipment and welder/welding operator shall be used.
3 (04/21) For the production testing of welds made by an EWP, see 1807.3 (2) i).
1812.4.5 (04/21) Inspection and testing of welding of reinforcing steel
1 (04/21) Inspection and testing of welded joints involving reinforcing steel shall be carried out in accordance
with BS EN ISO 17660-1, irrespective of whether a joint is nominally classified as ‘load’ or ‘non-load’ bearing.
2 (04/21) Project specific inspection and testing of welded joints involving reinforcing steel shall be carried out in
accordance with 1812.4.2.4.
1812.5 (08/14) Mechanical fastening
1812.5.1 (08/14) Inspection of non-preloaded bolted connections (AEN) (18/1)
1812.5.2 (08/14) Inspection and testing of preloaded bolted connections
1812.5.2.1 (04/21) General (AEN) (18/1)
1812.5.2.2 (04/21) Inspection of friction surfaces (AEN)
1812.5.2.3 (04/21) Inspection before tightening
1 (08/14) The tightening procedure shall be checked as required for EXC2/3/4.
1812.5.2.4 (04/21) Inspection during and after tightening
1 (08/14) Inspection during and after tightening shall be as required for EXC2/3/4.
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2 (04/21) In BS EN 1090-2:2018, 12.5.2.4 c), the number of bolt assemblies inspected overall in a structure shall
conform to the requirements for EXC3/4.
3 (04/21) The part turn method shall conform to the requirements of BS EN 1090-2:2018, 12.5.2.4 c) 2) i).
4 (04/21) In BS EN 1090-2:2018, 12.5.2.4 d) the sampling plan shall conform to the requirements for EXC2/3.
5 (04/21) Bolting assemblies shall be checked for overtightening.
6 (04/21) For the part turn method, the inspection and testing requirements of BS EN 1090-2:2018, 12.5.2.6 shall
apply except as follows:
a) the first step shall be checked as required for EXC3/4 but using the same torque conditions as given in
Table 18/1; and
b) for inspection after the second step, rotation angle values given for the combined method shall be
replaced with:
i) 0° (in lieu of 15°); and
ii) 60° (in lieu of 30°).
1812.5.2.5 (04/21) Torque method
1 (04/21) Inspection of tightening by the torque method shall conform to the requirements for EXC3/4 in BS EN
1090-2:2018, Table 25.
1812.5.2.6 (04/21) Combined method
1 (08/14) For the combined method, checking of the first step shall conform to the requirements for EXC3/4.
1812.5.2.7 (04/21) HRC method
1 (04/21) For the HRC method, checking of the first tightening step shall conform to the requirements for
EXC2/3/4.
1812.5.2.8 (04/21) Direction tension indicator method (AEN)
1812.5.3 (04/21) Inspection and repairs of solid rivets for hot riveting
1812.5.3.1 (08/14) Inspection
1 (04/21) The sequential sampling plan shall conform to the requirements for EXC2/3.
1812.5.3.2 (08/14) Repairs (AEN)
1812.5.4 (04/21) Special fasteners and fastening methods
1812.5.4.1 (04/21) General (AEN) (18/1)
1812.5.4.2 (04/21) Other mechanical fasteners (AEN)
1812.6 (08/14) Surface treatment and corrosion protection (AEN)
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1812.7 (08/14) Erection

1812.7.1 (08/14) Inspection of trial erection (18/1)
1 (04/21) In addition to the checks that are stated in contract specific Appendix 18/1, the following checks shall be
carried out during trial erection, where applicable.
a) dimensions critical to assembly to other parts of the structure;
b) overall horizontal and vertical alignment and twist;
c) evidence of correct re-establishment of alignment of units in staged trial erection;
d) temperature differentials in box girders;

e) fit-up of bolted joints and site welding preparations;

f) alignment of bolt holes; and
g) identification marks of members and their orientation, including packer plates.
1812.7.2 (08/14) Inspection of the erected structure (AEN)
1812.7.3 (08/14) Survey of geometrical position of connection nodes
1812.7.3.1 (04/21) Survey methods and accuracy (18/1)
1 (04/21) The survey of the completed structure shall conform to the requirements for EXC3/4. This shall
include recording of dimensional checks at acceptance of the structure. Records of the survey including records of
dimensional checks shall be treated as execution records and shall form part of the execution documentation; see
1804.2.2 and 1804.2.4.
2 (04/21) For components comprising weather resistant steels, residual material thickness monitoring locations
shall be established, and initial measurements of residual material thickness shall be taken on completion of the
construction works, as stated in contract specific Appendix 18/1. Details of the monitoring locations and the
material thickness measurements shall be recorded. The records shall be treated as execution records and shall form
part of the execution documentation; see 1804.2.2 and 1804.2.4.
1812.7.3.2 (08/14) System of measurement (AEN)
1812.7.3.3 (08/14) Reference points and levels (AEN)
1812.7.3.4 (08/14) Location and frequency (18/1)
1 (08/14) Account shall be taken of the deflection effects due to temporary equipment supported by or supporting
the erected structure, and any non-steelwork dead weight which is in place at the time of measurement of the
positional accuracy of the steelwork.
1812.7.3.5 (08/14) Acceptance criteria (AEN)
1812.7.3.6 (08/14) Definition of nonconformity (AEN) (18/1)
1812.7.3.7 (08/14) Action on nonconformity (AEN)
1812.7.4 (08/14) Other acceptance tests (AEN) (18/1)
Amendment – April 2021 --`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---

30
(04/21) Table 18/4 Minimum extent of supplementary NDT of shop welds in steel grades up to and including
S355 and QSC F56
Weld type Orientation A) Thickness (t) or throat Proportion of joints tested %

(a) B) mm Magnetic particle (MT) Ultrasonic testing (UT)
or penetrant testing C)
(PT)
Butt Transverse t<8 100 Not applicable
8 < t < 20 20 50 D)
t > 20 50 100
Longitudinal t<8 50 Not applicable
8 < t < 20 5 0
t > 20 10 10
Fillet Transverse t < 20 5 No requirement
t > 20, a < 10 10 0F)
t > 20, 10 < a < 15 20 5F)
t > 20, a > 15 20 10F)
Longitudinal As per transverse fillet but reduced by 2 levels E)
A) Transverse applies to all welds orientated within 60° of the longitudinal axis of members, except for connection zones where all
orientations are deemed to be transverse. Connection zones are all locations within 200 mm of a main structural connection, loading point
or support position.
B) t = the nominal maximum parent metal thickness in the joint; and
a = the nominal fillet weld throat dimension (including any specified penetration).
C) Testing conditions to BS EN ISO 17640 shall be as follows: Level B, evaluation level DAC –14 dB.
D) 100% for single sided butt where there is no access to root side.
E) See 1812.4.2.4(4) and (5) for definition of change in level.
F) The main purpose of these inspections is to provide assurance that there are no systematic embedded imperfections which are either not
permitted, such as solidification or HAZ cracking, lamellar tearing etc, or which would also contribute to a resulting loss of required cross
section in the weld throat or leg (fusion boundary) zones, such as LORP, LOSWF, laminations, etc
(04/21) Table 18/5 Adjustments in proportions of supplementary NDT for conditions other than those covered
by Table 18/4 and Table 18/6
Condition Change in level A) B) C)

Site welded joints +1
Automatic and robotic welded joints D) −1
Standard proprietary products manufactured on a mass production basis D) −1
Steel grades above S355 and below S500 +1
Steel grades S500 and above +2
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QSC F36 (relative to F56) −1

After a non-conformance with acceptance criteria in Table 18/9 or Table +2 (minimum, depending on
18/10, applicable to all joints of similar type tested in the same production degree of severity of non-
batch; to be maintained until the cause has been identified and rectified and conformance)
defects eliminated.
A) See 1812.4.2.4(4) and (5) for definition of change in level.
B)If the proportion in Table 18/4 is say 20%, an increase of one level according to this table would change the proportion to 50% and a
decrease of one level to 10%.
C) Where more than one condition exists, if the proportion in Table 18/4 is say 100% and the adjustments according to this table are -1, -1
and +1 level respectively, the net adjustment would be -1 level, which would result in a final proportion of 50%.
D) Not applicable to transverse butt welds of F90 and above.

(04/21) Table 18/6 Minimum extent of supplementary NDT of shop welds in steel grades up to and including S355 and QSCs F71 to F140

Volume 1
Weld Orientation A) Thickness (t) Proportion of joints tested according to QSC
type or throat (a) B) %
mm Magnetic particle (MT) or Ultrasonic testing (UT) C) Radiographic testing
penetrant testing (PT) (RT) D)
F71 F90 F112 F71 F90 F112 and F140 F90 F112 F140
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and
F140
Butt Transverse t <8 100 100 100 Not applicable 20F) 100F) 20 100 100E)
8 < t < 20 50 100 100 100 100 100F) 0 20 100E)
t > 20 100 100 100 100 100 100F) 0 50 100E)
Longitudinal t<8 100 100 100 Not applicable 20F) 100F) 10 50 100
8 < t < 20 20 50 100 10 20 100F) 0 10 100
t > 20 20 50 100 10 20 100F) 0 10 100
Fillet Transverse t < 20 20 100 100 No requirement No requirement No requirement
t > 20, a < 10 50 100 100 10 20 20

t > 20, 10 < a < 15 100 100 100 20 50 50 No requirement
t > 20, a > 15 100 100 100 50 100 100
Longitudinal As per longitudinal butt weld
A) and B) As per Table 18/4, footnotes A) and B).
C) Testing conditions to BS EN ISO 17640 shall be as follows:
• QSCs F71 and F90: testing level B, evaluation level DAC −14dB;
• QSC F112: testing level C, evaluation level DAC −17dB;
• QSC F140: testing level C, evaluation level DAC −20dB; and
• transverse indication scans required for longitudinal welds.
Where phased array technique is to be used, the principles of BS EN ISO 13588 shall be applied. Testing level D shall apply where the test
Structural Steelwork
procedures, the equipment and the operator’s competency shall be subject to independent validation for suitability for assessment of Table 18/10
requirements.
D) Applies to in-line butt welds only. BS EN 17636 test class B shall be used. RT not required if phased array technique used for UT.
Series 1800
E) Not relevant for designs based on Table 8.3 in BS EN 1993-1-9:2005.
F) Phased array required if RT not used.

32
(04/21) Table 18/7 Weld acceptance criteria for visual inspection (all dimensions in mm)

Volume 1
Main Imperfection type A) Dimensional Joint type Weld type Acceptance limits B), C) according to Remedial action
criterion parameter B) QSC in event of non-
[ ] applies to longitudinal welds only D) conformance E)
Description BS EN ISO Symbol BS EN ISO F56 F71 to F140

6520-1 ref 5817 ref no. (For F36, see F))
no.
Overall Weld location — Dr — All Fillet Dr + 10 [+10] As per F56 Refer to welding co-
joint error ordinator for remedial
geometry action
Incorrect weld — Dr — All All NP [NP] As per F56 Refer to welding co-
type ordinator for remedial
action
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Inadequate — Dr — All All Dr −0 [−5] As per F56 Add extra weld length
weld length
Linear 5071, 5072 h 3.1 In line butt Butt h < 0.2t [0.3t] See Table 18/8 Remove existing weld,
misalignment h<4 [5] realign joint, remake
507 h — Cruciform All h < 0.4t [0.4t] See Table 18/8 preparations and check
h<6 [6] with MT or PT, reweld to
AWPS, check with UT

Angular 508 β — In line butt Butt β < 2° [3°] See Table 18/8 Correct using approved
misalignment procedure, check with
MT or PT
Root gap G) 617 h 3.2 Lap, tee, Fillet h<2 [3] See Table 18/8 Refer to welding co-
cruciform ordinator for remedial
action
Excess weld 502, 503, h 1.9, 1.10, All All NLB) [NL]B) As per F56 Correct by grinding if
dimensions 504, 512, 1.11, 1.16, any functional limits are
5214 1.21 required B)
Crack 100 to 106 — 1.1, 1.2 All All NP [NP] As per F56 Remove imperfections
Lack of 401, 506 — 1.5, 1.13 All All NP [NP] As per F56 by grinding to
fusion approved excavation
Surface Lack of 402 h 1.6 All Single NP [h < 0.1t] As per F56 shape, check with
notches penetration sided butt [h < 1] [NP] PT, reweld to AWPS,
Series 1800
(unspecified) refer to welding co-
ordinator to determine
Large 2015, 2016, — 2.6 All Butt NP [NP] As per F56
cause
cavities 202, 510 2.7, 1.15
33

Volume 1
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no.
Surfaces Undercut, 501, 509, h 1.7, 1.8, All All h < 0.5 [1] See Table 18/8 Remove by grinding,
notches - under fill etc. 511, 1.14, 1.17, repair to AWPS
continued 515, 517 1.19
Pore 2017 d 1.3 All All d<2 [2] See Table 18/8 Remove to depth of 3
mm, repair to AWPS
Toe angle 5051 α 1.12 All All α > 90° [90°] See Table 18/8 Correct with high
speed rotary burr or
reweld to AWPS
Damage 601, 603 to — 1.22 All All NP [NP] As per F56 Grind out to smooth
606 profile, repair by
AWPS if h > 1
Loss of Insufficient 5213 h 1.20 Tee, lap, Fillet NP G) [h < 0.1a] G) As per F56 Increase size using
cross- weld throat, cruciform [h < 1] G) same AWPS
section a H)
Insufficient 521 h — Tee, lap, Fillet NP G) [h < 0.1z] G) As per F56
leg length, cruciform [h < 2] G)
z H)
Multiple 201, 202, h, l, d, 4.2, 4.1 All All See I) [See I)] As per F56 Increase cross
con-forming 501, 509, lp sectional area using
surface 511, 515, methods above,
imperfections 5213 depending on
imperfection type
Surface Deposits 602, 613, — 1.23 All All Not permitted for See Table 18/8 Remove by grinding or
condition 614, 615 various surface blast cleaning
conditions J)
Series 1800
34
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Volume 1

no.
A) The three digit BS EN ISO 6520-1 designation is deemed to include all four digit sub-categories.
B) ymbols are as defined by BS EN ISO 5817 or BS EN ISO 6520-1.
S
Dr = the dimension (or weld type) specified on the drawings. NP = not permitted. NL = no limits specified for FFP; functional limits shall apply where specified for a particular
application.
C) Where more than one limit is given for an imperfection for a given QSC and weld orientation, all limits shall apply.
D) Longitudinal welds are those not deemed to be “transverse”; see Table 18/4 footnote A).
E) AWPS = approved welding procedure specification for repair, qualified in accordance with 1807.4.1
F) For joints in any orientation to F36, the imperfection limits given for longitudinal welds [ ] for F56 are applicable.
G) Where a root gap h has been observed in a tee, cruciform or corner joint, the nominal required fillet weld dimensions, as measured with a weld gauge, shall be increased as follows,
unless compensating penetration beyond the root has been proven: minimum required throat size a + 0.7h; minimum required leg length z + h (on affected leg only). See also H).
H) Both a and z measurements shall be checked, irrespective of which has been specified on the drawings. They are related as follows:
Angle between fusion faces 120° 110° 100° 90° 80° 70° 60° See also G)
z/a 2.0 1.74 1.56 1.41 1.31 1.22 1.15
I) All permitted imperfections resulting in loss of cross-section shall be summed and assessed as follows:
∑hl+ ∑0.5dt < 4.5t or [< 9t]. ∑hl shall include subsurface imperfections assuming h = 3; see Table 18/10, footnote K). Measurement length lp = 100 mm. For fillet welds “a” shall be
substituted for “t”.
J) Not permitted if surface is to receive corrosion protection except as allowed by 1810.2, or on uncoated steels conforming to BS EN 10025-5 and BS EN 10088-1. See 1807.5.16.
Series 1800
35
(04/21) Table 18/8 Weld acceptance criteria for visual inspection for QSCs F71 to F140 where limits differ from those for F56 in Table 18/7 (all

Volume 1
dimensions in mm)
Imperfection type A) Acceptance limits according to QSC B), C) Remedial action

[ ] applies to longitudinal welds only D) in event of non-
conformance
F71 F90 F112 F140
Linear In-line h < 0.15t [0.2t] h < 0.1t [0.2t] h < 0.05t [0.2t] h < 0.05t [0.2 t] As per Table 18/7
misalignment butt h<4 [5] h<3 [4] h<3 [4] h<3 [4]
Cruc- h < 0.3t [0.4t] h < 0.2t [0.4t] h < 0.1t [0.3t] h < 0.1t [0.2t]
iform h<5 [6] h<4 [6] h<3 [5] h<3 [3]
Angular misalignment β < 2° [3°] β < 1.5° [2°] β < 1° [2°] β < 0.5° [2°] As per Table 18/7
Root gap E) h<2 [2] h<2 [2] h<1 [1] h < 0.5 [0.5] As per Table 18/7
Undercut, underfill h < 0.3 [h < 1] NP [h < 1] NP [h < 0.5] NP [h < 0.5] As per Table 18/7
Porosity d < 1.5 [1.5] d<1 [1] NP [NP] NP [NP] As per Table 18/7
Toe angle α > 110° [90°] α > 150° [90°] α > 165° [110°] α > 175° [110°] As per Table 18/7
Deposits Not permitted for various NP [NP] NP [NP] NP [NP] See F)
surface conditions I)
Variation in root or cap ∆h < 3 G) [∆h < 3] ∆h < 2 G) [∆h < 2] ∆h < 1 G) [∆h < 1] ∆h < 0.5 G) [∆h < 0.5] See H)
longitudinal profile B)
A) Imperfection types as designated in Table 18/7, footnote A).
B) ymbols are as defined by BS EN ISO 5817 or BS EN ISO 6520-1.
S
NP = not permitted. ∆h = the maximum variation in cap or root profile measured along weld axis over any length of 3 mm.
C) Where more than one limit is given for an imperfection for a given QSC and weld orientation, all limits shall apply.
D) Longitudinal welds are those not deemed to be “transverse”; see Table 18/4, footnote A).
E) Correct fillet weld sizes as per Table 18/7, footnote G).
F) For F112 and above, remove with high speed rotary burr.
G) Transverse welds outside connection zones are exempt from this restriction; see Table 18/4, footnote A).
H) Correct by tapering slope to shallower angle or repair to AWPS.
I) Not permitted if surface is to receive corrosion protection except as allowed by 1810.2, or on uncoated steels conforming to BS EN 10025-5 and BS EN 10088-1. See 1807.5.16.
Series 1800
36
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(04/21) Table 18/9 Weld acceptance criteria for magnetic particle and penetrant testing

Volume 1
Imperfection Acceptance Indication Acceptance limits according to QSC A) Remedial actions in event of
type standards pattern [ ] applies to longitudinal welds with longitudinal linear non-conformance C)
indications only B)
F56 F71 F90 to F140

(For F36, see D))
Surface notches BS EN ISO 23278 Isolated Level 2 [Level 3] Level 1 [Level 2] NP [NP] Remove by high speed burr
identified in and Grouped E) NP [NP] NP [NP] NP [NP] machining with machining marks
Table 18/7 and BS EN ISO 23277 in longitudinal direction. Repair to
Table 18/8 AWPS if non-conformance with
Table 18/7 and Table 18/8 depth
requirements (h).
A) NP = not permitted.
B) Longitudinal welds are those not deemed to be “transverse”; see Table 18/4, footnote A).
C) AWPS = Approved welding procedure specification for repair, qualified in accordance with 1807.4.1.
D) For joints in any orientation to F36, the imperfection limits given for longitudinal welds [ ] for F56 are applicable.
E) “Grouped” shall be deemed to apply to any indications separated by less than 2.5 mm.
Series 1800
37
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(04/21) Table 18/10 Weld acceptance criteria for ultrasonic testing with limited optional radiographic testing (all dimensions in mm)

Volume 1
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Imperfection type A) Dimensional Location in Acceptance limits according to QSC B), C) Remedial
parameter B) cross- [ ] applies to longitudinal welds only D) action in
section or event of non-
Description BS EN Symbol BS EN F56 F71 F90 F112 F140
throat conformance
ISO ISO 5817 (For F36, see F)) E)
6520-1, ref no.
ref no.
Cracks 100 to — 2.1, 2.2 Full depth NP H) [NP] H) NP H) [NP] H) NP H) [NP] H) NP I) [NP] I) NP J) [NP] J) Refer to
106 welding
co-ordinator
Pores G), 2011, h, l 2.3, 2.5, Within 6 h<3 [3] h<3 [3] NP H) [h < 3] NP I) [NP] I) NP J) [NP] J)
to determine
inclusions G), 2014, 2.6 to 2.13 mm of any l < 10 [20] l<5 [10] NP H) [l < 5] NP I) [NP] I) NP J) [NP] J)
cause.
cavities G), lack 2015, surface
Remove by
of fusion, lack of 2016,
grinding to
penetration 202,
Deeper than h<3 [3] h<3 [3] h<3 [3] NP H) [h < 3] NP I) [NP] I) approved
203
6 mm from l < 1.5t [3t] l < 10 [1.5t] l<5 [20] NP H) [l < 5] NP I) [NP] I) excavation
301 to
any surface shape. Check
304,
with MT or
401,
PT. Reweld to
402
h, l, lp, 4.2 Full depth ∑l < 1.5t K) [3t] J) ∑l < 1.5tK) [3t] K) ∑l < 1.5t K) [3t] K) NP [∑l < 1.5t] K) NP [NP] AWPS.
H, L lp = 100 [100] lp = 100 [100] lp = 100 [100] NP [lp = 100] NP [NP]
H>6 [6] H>6 [6] H>6 [6] NP [H > 6] NP [NP]
L > 10 [10] L > 10 [10] L > 10 [10] NP [L > 10] NP [NP]
Uniformly 2012, — 2.3, 2.4, Full depth Not permitted if obstructs detection or evaluation of imperfections above NPL) [NP] L)
distributed 2013
or clustered
porosity
A) Imperfection types as designated in Table 18/7, footnote A).
B) ymbols are as defined by BS EN ISO 5817.
S
NP = not permitted. H = the clear gap between adjacent imperfections measured in through thickness direction. L = the gap between ends of adjacent imperfections measured along weld axis.
C) Where more than one limit is given for an imperfection for a given QSC and weld orientation, all limits shall apply. If surface breaking imperfections are detected by UT, the criteria given in Table 18/7,
Table 18/8 and Table 18/9 apply.

D) Longitudinal welds are those not deemed to be “transverse”; see Table 18/4, footnote A).
E) AWPS = Approved welding procedure specification for repair, qualified in accordance with 1807.4.1.
F) For joints in any orientation to F36, the imperfection limits given for longitudinal welds [ ] for F56 are applicable.
G) Use of radiographic testing is permitted to assist in interpretation of these imperfections.
H) Rejection level DAC −14dB.
I) Rejection level DAC −17dB.
J) Rejection level DAC −20dB.
K) If permitted surface imperfections resulting in loss of cross-section also exist, the criteria in Table 18/7, footnote I) also apply.
L) Also, not permitted when checked by radiographic testing.
Series 1800
38
(04/21) Table 18/11 Specific production tests on run-off coupon plates
Weld type QSC Material grades Test type Testing rate
In-line transverse butt S355 to S460 ML, NL Charpys 1 in 10

weld in tension F56 and above S460 to S690 Q Tensile 1 in 5
S420 to S690 QL, QL1 Tensile and Charpys 1 in 5
F90 and above All UT+3 macros A) 1 in 5
Longitudinal butt or F90 All UT + 3 macrosB) 1 in 20
fillet F112 and above All UT + 3 macrosB) 1 in 5
A) These tests are additional to those described in the rows above.
B) A tack weld shall be included in the coupon plate if used in production and at least one macro shall be taken at each end of the tack weld
Amendment – April 2021 --`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---

39F
SERIES 1900
PROTECTION OF STEELWORK
AGAINST CORROSION
Contents
1901 (05/01) Introduction 2 #1920 (05/01) Additional Requirements for 34
the Protection of Steel in Bridge Bearings
1902 Surface Preparation – General 2
Requirements 1921 (11/03) Additional Requirements for 35F
the Protection of CCTV Masts,
1903 Surface Preparation – Materials and 3
Cantilever Masts, Steel Lighting
Methods
Columns and Bracket Arms
1904 (05/01) Workmanship Standards for the 5
Surface Preparation of Steel by Blast
Cleaning, Abrading, Grinding and
Cleaning
1905 (05/01) Workmanship Standards for the 5
Surface Preparation of Coated Steelwork
by Blast Cleaning, Abrading, Grinding SCOTLAND, WALES AND NORTHERN
and Cleaning IRELAND
1906 (05/01) Procedures for Treatment 6
at Joints
Clause Title Page
1907 (05/01) Procedures for Treatment at 9
Scotland
Areas of Mechanical Damage or
Other Surface Defects 1911SE (05/01) Paint and Similar Protective S1
Coatings
1908 (05/01) Procedures for Treatment of 10
Local Failure in Protective Coatings 1912SE (05/01) Testing of Paints S1
1909 (05/01) Metal Coatings 10
1920SE (05/01) Additional Requirements for S2F
1910 (08/14) Testing of Thermally 11
the Protection of Steel in Bridge
Sprayed Aluminium Metal Coatings
Bearings
#1911 (05/01) Paint and Similar Protective 12
Coatings
#1912 (05/01) Testing of Paints 29 # denotes a Clause which has a substitute National Clause for one
or more of the Overseeing Organisations of Scotland, Wales or
1913 Storage Requirements and Keeping 30 Northern Ireland.
Periods for Paints
1914 Application of Paint 30
1915 Procedure Trials 33
1916 Storage and Transport of Steel and 33
Fabricated Steelwork
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1917 (05/01) Surfaces in Contact with Concrete 34

1918 (05/01) Form HA/P1 (New Works) 34
Paint System Sheet (Appendix 19/1)
Form HA/P2 Paint Data Sheet
(Appendix 19/3)
1919 Access and Lighting 34
Amendment – August 2014 1

Specification for Highway Works Protection of Steelwork Against Corrosion
PROTECTION OF STEELWORK AGAINST CORROSION

2 (08/14) Surface preparation and protection against corrosion of steelwork shall be carried out in compliance
with Clauses 1901 to 1921 and where applicable Series 1800, 1810, using systems appropriate to the information
given in Appendix 19/1, Form HA/P1 (New Works) Paint System Sheet (parts 3, 4 and 5) and Appendix 19/2 if
applicable, as appropriate to the design and method of execution of the components.
3 (08/14) The Manual of Paints for Structural Steelwork, which is included in BD 35 (DMRB 2.4.1), provides
data on paints and similar materials for use in the Overseeing Organisation’s contracts. The Manual contains item
numbers and a summary is also given in Table 19/1.
4 (08/14) Subject and without prejudice to the Conditions of Contract, the Contractor shall comply with any
measures to contain people, plant, materials, dust and debris described in Appendix 19/5.
5 (08/14) Compliance with sub-Clause 4 of this Clause does not confer immunity from relevant legal
requirements.
6 (08/14) Corrosion protection of steelwork shall be undertaken by a Contractor registered to National Highways
Sector Scheme 19A ‘For corrosion protection of ferrous metals by industrial coatings’, as described in Appendix A.
7 (08/14) Numbered appendices (identified by digits, e.g. 19/5) contain contract specific information and
requirements.
1902 Surface Preparation – General Requirements

(05/05) Workshop and Site Work
1 (08/14) Before blast cleaning or abrading steel surfaces or before overcoating painted or hot dip galvanized
surfaces, any contamination including by oil or grease shall be removed. Unless otherwise described in Appendix
19/5, solvents shall not be used.
2 (08/14) Clean water which does not leave harmful residues on the surface shall be used for wet cleaning and
rinsing.
3 (08/14) Cleaning agents which are not harmful to the surface being cleaned and which do not leave harmful
residues on the surface after final rinsing may be used for cleaning.
4 (08/14) Surface preparation shall be continued until the required standard has been achieved.
5 (08/14) Weld spatter shall be removed, in accordance with Series 1800, 1807.5.17 if applicable.
6 After dry surface preparation of internal surfaces and before any wet cleaning, all dust and debris shall be
removed from accessible areas by sweeping and vacuum cleaning.
7 (08/14) Immediately before application of each coat of paint, the Contractor shall ensure that the surfaces to be
painted:
(i) meet the required standard of preparation;
(ii) are free from harmful residues and detrimental contamination, including water, moisture, condensation,
oil, grease, mortar, concrete, dust, grit, paint degradation products, chlorides and sulphides. (See sub-
clause 1904.7)
8 (05/01) Joints, plies and fasteners shall be sealed in compliance with sub-Clauses 1906.27 and 28.
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9 Coats of paint shall be free from embedded metallic or other foreign particles including metallic dust. Deposits
of adherent matter on metallic coatings or painted surfaces shall be cleaned off immediately they occur. Coatings
damaged in the process shall be restored.
10 (05/05) Unless otherwise described in Appendix 19/5, the final workshop coats on external surfaces shall be wet
cleaned on site.
1903 Surface Preparation – Materials and Methods

(05/05) Dry Blast Cleaning in the Workshop
1 (08/14) Unless otherwise described in Appendix 19/5, metallic blast cleaning abrasives complying with BS EN
ISO 11124 or non-metallic blast cleaning abrasives complying with BS EN ISO 11126 shall be used.
Grades for metallic abrasives shall comply with the following:
Profile (see sub-Clause Grade
1904.1)
Fine G050 or S060
Medium G070 or S100
Coarse G100 or S120
2 The particle size of metallic abrasive in plant or equipment shall not exceed the maximum for the relevant
grade as specified above.
3 (05/01) Before the start of blast cleaning and during blast cleaning the Contractor shall ensure that the abrasive
is free from matter which could leave detrimental contamination, as defined in sub-Clause 1904.7, on the surfaces
to be coated.
(05/08) Abrading in the Workshop or on Site
4 Any encrusted foreign matter or paint which may be difficult to remove by abrading alone shall be dislodged
by scraping, aided by hand or power wire-brushing. This work shall be completed before abrading the areas so
affected.
5 (08/14) Abrading shall be carried out using abrasive paper or other material or a flexible abrasive disc mounted
on a power driven flexible pad, or a power driven arbor or spindle-mounted flexible abrasive flap wheel. Abrading
tools may be used to remove weld spatter. Wet abrading may be employed for the preparation of finishes over
sound undercoats, over unsound systems over hot dip galvanizing, or hot dip galvanizing. Wet abrading shall not be
allowed to come into contact with exposed thermally sprayed aluminium metal coatings.
6 (05/05) All equipment including tools, abrasive sheets, abrasive discs and abrasive wheels shall be of a type,
capacity and in a condition appropriate for the work. The use of hard grinding wheels for abrading shall not be
permitted.
7 (05/03) A polished appearance caused by polishing in of paint, rust or dirt shall not be acceptable.
8 (05/03) Areas of previously corroded steel or unsound metal coatings, except hot dip galvanizing, which have
been prepared by abrading down to bright steel or bright metal coating, and blast cleaned where appropriate, shall
be protected by the primer and next coat of paint before any cleaning down or preparation of adjacent surfaces.
(05/05) Wet Cleaning in the Workshop or on Site
9 (05/03) Wet cleaning shall be carried out by scrubbing with a stiff-bristled brush using water and a cleaning
agent or a pressure washer. Immediately after cleaning, the surfaces shall be thoroughly rinsed.
(05/05) Dry Cleaning in the Workshop or on Site
10 Surfaces shall be cleaned by scrubbing with a dry stiff-bristled brush.

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(05/03) Dry Blast Cleaning on Site Using Dry Air/Abrasive System

11 (08/14) Metallic abrasives shall comply with sub-Clauses 1, 2 and 3 of this Clause. Metallic grit or aluminium
oxide abrasive shall be used for dry blast cleaning of relatively small areas on site which are to receive a thermally
sprayed aluminium metal coating, such as at site welds, at areas prepared to clean steel or areas where a thermally
sprayed aluminium metal coating is to be restored, as indicated in sub-Clause 1905.3(i). The Contractor shall
ensure that the grade and particle shape of non-metallic abrasives are adequate for the purpose intended. Non-
metallic abrasives shall not be recycled.
(05/03) Wet Blast Cleaning Using Low Pressure Air/Water/Abrasive System on Site
12 (05/05) Unless otherwise specified in Appendix 19/5 a low-pressure air/water/abrasive system shall be used. The
air/water pressure at the nozzle shall not exceed 7.0 kgf/cm² and shall be fully adjustable below this level. The
system shall incorporate a mechanical metering device remote controlled by the operator from the nozzle to enable
him to regulate from zero to maximum the quantity of non-metallic abrasive being fed into the air/water mixture.
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During abrasive cleaning, the air, water and abrasive shall be thoroughly mixed and this mixture shall be projected
on to the surface to be cleaned through a single bore nozzle or tube. The use of an inhibitor during wet blast
cleaning or washing shall not be permitted.
(05/03) Wet Blast Cleaning using High Pressure Water/Abrasive System or Ultra High Pressure Water System
on Site
13 (05/03) Unless otherwise specified in Appendix 19/5, the water pressure shall not exceed 562 kgf/cm2 for high
pressure or between 1750 and 2860 kgf/cm2 for ultra high pressure. The system shall incorporate a mechanical
metering device controlled by the operator at the nozzle, to regulate from zero to maximum the quantity of non-
metallic abrasive being fed into the water.
14 (08/14) Within 60 minutes of wet blast cleaning, the whole of the cleaned surface shall be thoroughly washed
using the blast cleaning equipment with air and water. Any further deposits of abrasive on already rinsed surfaces
shall be removed in a similar manner also within 60 minutes of being deposited. All accumulated deposits of
abrasive and debris on other parts of the structure shall be removed by the same method before the end of the
working day. After washing, the surfaces shall be free from all detrimental contamination. Tests for freedom from
detrimental contamination shall be made after the washing.
Combined Wet/Dry Blast Cleaning on Site
15 (05/05) Wet blast cleaning using the low pressure air/water/abrasive system (in compliance with sub-Clauses
12 and 14 of this Clause) shall be followed, after a minimal interval, by dry blast cleaning in compliance with
sub-Clause 11 of this Clause, of all the previously wet blast cleaned areas.
16 (05/03) The specified standard of surface preparation shall have been achieved in full, initially by wet blast
cleaning and washing, before any later dry blast cleaning of the same areas to remove flash rusting or to restore the
required standard of surface preparation.
Other Requirements
17 (05/03) When surface preparation is to be carried out by dry blast cleaning and, on adjacent surfaces, by wet
cleaning and or abrading, then unless otherwise necessary, the wet cleaning and any abrading shall be carried out
first.
When combined wet/dry blast cleaning has been specified instead of dry blast cleaning only, the above sequence
may be reversed. On completion of the wet blast cleaning part of the process, the areas to be abraded shall be
cleaned in compliance with sub-Clause 9 of this Clause except that for rinsing, the wet blast cleaning equipment
may be used. The dry blast cleaning part of the process, and dry abrading shall be carried out after any wet abrading
required and final rinsing. Any prepared dry metal surface shall be protected from the effects of any further wet
method of surface preparation by the application of a minimum 75 microns dry film thickness of paint.
(05/05) Grinding After Surface Preparation in the Workshop or on Site
18 (05/05) Grinding wheels and discs shall be of the size, shape and grade of coarseness appropriate to the
particular operation. The speed of revolution shall be appropriate for the work.

19 (05/05) Grinding shall be carried out after surface preparation by other methods, including cleaning down, has
been completed, except where it is necessary to achieve a blast profile and this would necessitate blast cleaning
after grinding.
20 (05/03) Surfaces prepared by grinding to bright steel shall be protected by the application of the primer and the
next coat of paint, including any stripe coats, before cleaning down or other preparation of adjacent surfaces
specified in Appendix 19/5 is undertaken.
1904 (05/01) Workmanship Standards for the Surface Preparation of Steel by Blast Cleaning,
Abrading, Grinding and Cleaning
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1 (08/14) The surface profile to be achieved by blast cleaning, either ‘Fine’ ‘Medium’ or ‘Coarse’ as appropriate,
shall be within the limits set by the Surface Profile Comparator for the Assessment of Abrasive Blast Cleaned
Surfaces, conforming to ‘BS EN ISO 8503-1’.
2 Blast cleaned surfaces shall be virtually free from sharp spikes of parent metal defined as ‘rogue peaks’ formed
by the impact of abrasive particles and which project above the blast cleaning profile. Any ‘rogue peaks’ which
would be detrimental to the protective system shall be removed.
3 (08/14) ‘Hackles’ and inclusions caused by the rolling process, visible after blast cleaning, which would be
detrimental to the protective system, shall be removed. Affected surfaces shall be prepared by grinding or abrading
to bright steel in compliance with sub-Clause 1907.1. Sharp edges shall be rounded to a radius of not less than
2mm, in accordance with Series 1800, 1810.2 if applicable. If thermally sprayed aluminium metal coating is to be
applied the surfaces shall then be blast cleaned.
4 Steel surfaces to be prepared by any of the methods described in the Contract shall be such that after surface
preparation the surfaces are free from detrimental contamination.
5 Surface preparation by blast cleaning shall be to one or more of the following standards of visual cleanliness:
(i) (08/14) Sa3 to ‘BS EN ISO 8501-1’
(ii) (08/14) Sa2½ to ‘BS EN ISO 8501-1’
6 (05/05) Additionally, after surface preparation by blast cleaning to Sa3 or Sa2½ quality the surface profile shall
be virtually free from embedded abrasive particles when viewed through a 10X illuminated magnifying glass.
Surfaces assessed as unsatisfactory in this respect shall be blast cleaned again with fresh abrasive. Another abrasive
complying with the Specification may be used if necessary.
7 ‘Harmful residues’ or ‘detrimental contamination’:
(08/14)Surfaces shall be deemed to be free from ‘harmful residues’ or ‘detrimental contamination’ after surface
preparation when any such remaining matter will not be detrimental to the application, adhesion, curing or reduce
the required durability of the specified protective system.
8 ‘Bright steel’:
Surfaces free from defects or prepared to this standard by grinding or abrading shall have an overall bright
appearance.
1905 (05/01) Workmanship Standards for the Surface Preparation of Coated Steelwork by Blast
Cleaning, Abrading, Grinding and Cleaning
1 Before overcoating, surfaces shall be free from:
(i) (05/05) any visible gloss;
(ii) any unsound paint down to sound paint;
(iii) any unsound paint down to Sa3 or Sa2½ quality steel;
(iv) any unsound paint down to bright steel;
(v) any unsound paint down to sound metal coating;

(vi) any unsound paint down to bright metal coating;

(vii) any unsound metal coating down to sound metal coating;
(viii) any unsound metal coating down to bright metal coating;
(ix) any unsound metal coating down to Sa3 or Sa2½ quality steel;
(x) any unsound metal coating down to bright steel;
(xi) detrimental contamination.
2 Definitions of terms used in describing the above standards of workmanship are as follows:
(i) Sa3 or Sa2½ quality, as in sub-Clause 1904.5;
(ii) ‘bright steel’, as in sub-Clause 1904.8;
(iii) ‘free from detrimental contamination’, as in sub-Clause 1904.7;
(iv) ‘bright metal coating’ resulting from abrading, a metal coating whose surfaces are free from all corrosion
products and of bright appearance overall;
(v) ‘unsound metal coating’, a metal coating showing signs of disruption, inadequate adhesion or
penetration by rust or other corrosion products;
(vi) ‘sound metal coating’, a metal coating which complies with sub-Clause 1909.2 including such a metal
coating which has been blast cleaned but which has a reduced thickness in accordance with sub-Clause
1908.1;
(vii) ‘unsound paint’, paint showing signs of disruption, rusting through, having inadequate adhesion or
covering rust scale, loose rust, loose mill scale or other detrimental products;
(viii) ‘sound paint’, paint which is sound down to a metal substrate.
3 Definitions of terms used in Clauses 1906, 1907 and 1908 are as follows:
(i) (08/14) ‘restored’ coatings. Unless otherwise described in Appendix 19/5, when paint or similar coatings
or thermally sprayed aluminium metal coatings are to be restored, the standard of surface preparation
and coating material shall comply with the original standard. Damaged or failed paint systems over
thermally sprayed aluminium metal coating shall be restored using dry blast cleaning. The thickness of
any underlying thermally sprayed aluminium metal coating or paint coating which may have been
reduced in thickness during surface preparation shall be brought up to specification;
(ii) (08/14) ‘restored’ surface preparation. Unless otherwise described in Appendix 19/5, the original standard
shall be obtained. When further thermally sprayed aluminium metal coating is to be applied, the surface
of the existing thermally sprayed aluminium metal coating shall be restored by dry blast cleaning with
metallic grit abrasive or aluminium oxide to metal coating;
(iii) ‘local failure’. An isolated breakdown of a protective coating or system due to extraneous causes
excluding mechanical damage.
4 Permitted residual thermally sprayed aluminium.
(08/14) When clean steel is exposed through a metal coating during remedial surface preparation, remnants of sound
thermally sprayed aluminium metal coating, which cannot be removed with a tungsten scraper blade, may be
retained within the blast clean profile.
1906 (05/01) Procedures for Treatment at Joints

Fasteners, Joint Material and Parent Material in Joints, Before Assembly or Welding, in the Workshop
(05/05)
or on Site
Fasteners, Including Bolts, Nuts and Washers

1 Surfaces of uncoated fasteners shall be free from all but traces of oil or grease before assembly.

6
2 (08/14) Unless otherwise described in Appendix 19/5, threaded fasteners at joints in hot dip galvanized
steelwork or in hot dip galvanized steelwork which is to be painted, shall be hot dip galvanized. Hot dip galvanized
fasteners which are to be painted shall be treated with an adhesion promoter as described in Table 19/2B.
3 Metal coatings on surfaces of fasteners which are to be painted shall be:
(i) (05/08) free from all traces of oil or grease and then treated with an adhesion promoter where specified; or
(ii) treated at the same time as the parent material where fasteners are already assembled in compliance with
(08/14) Fasteners excluding those in (ii) above shall be pressure-rinsed with water and allowed to dry before
assembly or packing for delivery at least one hour and not more than four hours after satisfactory application of
adhesion promoter Item 155.
4 Fasteners which have become difficult to tighten because of corrosion shall be replaced.
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Joint Material and Parent Material in Joints
5 (08/14) The standard of blast cleaning of joint material and parent material in joints shall be at least equal to that
for the parent material. The standard of preparation and treatment of the friction surfaces of joint material and
parent material in slip resistant connections shall be as described in Series 1800, 1810.1(5). Before a slip resistant
connection is made, friction surfaces shall meet the standard of preparation and treatment described in Series 1800,
1810.1(5).
(08/14) At Preloaded Connections
6 In steelwork painted only overall:
(08/14) Unless otherwise described in Appendix 19/5, the blast primer applied to the parent material shall be taken
10 mm to 15 mm inside the perimeter of the joints. The outer surfaces and edges of site joint material may, at the
option of the Contractor, also be given a coat of the blast primer.
7 (08/14) In steelwork with thermally sprayed aluminium metal coating at joints only, and painted overall:
(08/14) Unless otherwise described in Appendix 19/5, the thermally sprayed aluminium metal coating shall be
applied to the contact surfaces of the joints and to the outer surfaces and edges of joint material. The thermally
sprayed aluminium metal coating on the contact surfaces of the parent material shall be taken 10 mm to 15 mm
outside the perimeter of the joints. The blast primer applied to the parent material shall be taken 10 mm to 15 mm
inside the perimeter of the joints. The thermally sprayed aluminium metal coating on the outer surfaces and edges
of site joint material shall be given a coat of aluminium epoxy sealer (Item 159).
8 (08/14) In steelwork with thermally sprayed aluminium metal coating overall and sealed only or painted overall:
(08/14) Unless otherwise described in Appendix 19/5, the thermally sprayed aluminium metal coating shall be
applied to the contact surfaces of the joints and to the outer surfaces and edges of joint material. The sealer applied
to the parent material shall be taken 10 mm to 15 mm inside the perimeter of the joints. The thermally sprayed
aluminium metal coating on outer surfaces and edges of site joint material shall also be given a coat of aluminium
epoxy sealer (Item 159).
9 In steelwork hot dip galvanized only or hot dip galvanized and painted overall:
All material at joints shall be hot dip galvanized. When an adhesion promoter and a first undercoat are applied
before a joint is made they shall be taken 10 mm to 15 mm inside the perimeter of the joint; these coats shall also
be applied to edges and outer surfaces of the joint material.
10 (08/14) The thickness of a protective paint coat applied to the outer surfaces of joint material prior to assembly
of any preloaded connection shall not exceed 50 microns dry film thickness.
(08/14) At Non Preloaded Connections
11 (08/14) At workshop joints in all steelwork other than in hot dip galvanized steelwork the blast primer alone or
thermally sprayed aluminium metal coating plus sealer shall be applied initially to parent and joint material.
Immediately before assembly of a joint which is to be painted the first undercoat shall be applied to the contact
surfaces and the joint made while the paint is wet.

12 (05/05) At site joints in all steelwork other than in hot dip galvanized steelwork unless otherwise described in
Appendix 19/2, all surfaces except those of fasteners, shall receive in the workshop the workshop protective system
which is applied to the parent material.
13 (05/05) At all joints in hot dip galvanized steelwork, an adhesion promoter and workshop coats may be applied
to the joint material before or after workshop joints are made. When hot dip galvanized steelwork is painted on site
an adhesion promoter and paint shall be applied to joint material after the joint has been made.
At Welded Joints
14 (05/05) At workshop and site joints in all steelwork, surfaces to be welded shall be restored to Sa2½ quality or
to bright steel and shall be free of any protective or other coating immediately prior to welding.
(05/05) Parent Material, Workshop Treatment Adjacent to Joints Which Are to be Assembled or Welded Later
on Site
(08/14) At Preloaded Connections

15 The paint coats, with the exception of the primer or first coat of paint, shall be stepped back at 30 mm intervals
commencing 10 mm from the perimeter of the joints.
(08/14) At Non Preloaded Connections
16 (05/05) Unless otherwise described in Appendix 19/5, workshop paint coats are not required to be stepped back.
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At Welded Joints
17 (08/14) Thermally sprayed aluminium metal coating shall be kept clear of the weld by a distance of at least 15
times the thickness of the steel in the area to be welded, with a minimum of 150mm and maximum of 300 mm from
the joint. The restricted area shall be masked during metal spraying. Hot dip galvanizing shall be removed a
minimum of 5 mm back from the edges of weld areas. Paint coats shall be stepped back at 30 mm intervals
commencing at least 150 mm from the joint, or from the edge of the thermally sprayed aluminium metal coating,
starting with the 2nd coat of paint.
At Completed Joints
18 Within 14 days of a joint being completed, exposed surfaces of parent and joint material shall be prepared in
compliance with sub-Clauses 19 to 23 of this Clause and fasteners in compliance with sub-Clauses 24 to 26 of this
Clause.
At Bolted Joints
19 (05/05) In steelwork painted only overall, blast cleaned only or primed surfaces shall be prepared by dry blast
cleaning to restore or provide the required standard of surface preparation, for workshop or site work as
appropriate.
20 (08/14) In steelwork with thermally sprayed aluminium metal coating at joints only, and painted overall, primed
or sealed thermally sprayed aluminium metal coatings shall be prepared by dry blast cleaning to restore the surfaces
to the required standard.
21 (08/14) In steelwork with thermally sprayed aluminium metal coating overall, and sealed only or painted
overall, thermally sprayed aluminium metal coatings shall be prepared as described in sub-Clause 20 of this Clause.
22 (08/14) In steelwork hot dip galvanized only or hot dip galvanized and painted overall the surfaces shall be free
from detrimental contamination by wet cleaning.
At Welded Joints
23 (08/14) In all steelwork, welds shall be prepared by the methods and to the standards described in sub-Clause
1911.6 (ii), 1911.7, 1911.9 or Appendix 19/2 for workshop or site work as appropriate. Surfaces of areas adjacent to
the weld shall be similarly prepared. For site welds in hot dip galvanized steelwork, surfaces shall be treated in

Surfaces of Fasteners
24 (08/14) Uncoated and temporarily coated fasteners shall be free from all traces of oil and grease and be blast
cleaned to Sa2½ quality, medium profile, before painting.
25 (08/14) Fasteners, including those which have been treated with an adhesion promoter shall be dry cleaned after
final surface preparation of the joint and then painted.
26 (08/14) Fasteners which are to receive thermally sprayed aluminium metal coating after assembly shall be blast
cleaned to Sa3 quality, medium profile, with chilled iron grit, cast steel grit or aluminium oxide.
Sealing at Joints or Plies
27 Bolted joints or built-up sections shall be free from any water which has penetrated the plies.
When drying out has been completed or when surfaces are dry after surface preparation, fine gaps around the
perimeter of joints or along plies shall be sealed by successive application of undercoat paint. All wider gaps shall
be sealed with a proprietary sealant compatible with the paint system.
Sealing of Gaps at Nibs of Load Indicating Fasteners or Washers
28 Gaps shall be sealed by brush application of primer and successive undercoats, of the types used on adjacent
areas.
1907 (05/01) Procedures for Treatment at Areas of Mechanical Damage or Other Surface
Defects
1 (08/14) Score marks, other surface defects and indentations in the surface of a steel substrate or of a metal
coating shall be treated by abrading or grinding to bright steel or bright metal coating, to produce a surface without
sharp edges or abrupt change in contour. Damage to unprepared surfaces shall be treated before blast cleaning. A
blast cleaning profile shall be restored on areas to be thermally aluminium metal sprayed but not necessarily areas
to be painted only. Other surface defects in the steel substrate, including fissures caused by the removal of ‘hackles’
or inclusions described in sub-Clause 1904.3, shall be similarly treated.
2 In the case of damage to paint coatings only, surface preparation shall be by blast cleaning or abrading. The
paint coatings shall then be restored.
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3 (08/14) When a two-pack Epoxy paint system is restored over a steel substrate prepared by abrading, the
adhesion of the first paint coat to the substrate shall be checked in accordance with ‘ASTM D4541 (type III)’,
before overcoating with the next coat in the system. The first paint coat over abraded surfaces shall be an
aluminium epoxy (two-pack) primer (Item 115).
4 (08/14) When an area of a thermally sprayed aluminium metal coating is to be restored after surface preparation
by abrading or grinding, any affected thermally sprayed aluminium metal coating or exposed steel substrate shall be
dry blast cleaned immediately before further application of thermally sprayed aluminium metal coating.
5 (08/14) In the workshop, a damaged thermally sprayed aluminium metal coating, together with any damaged
sealer or paint coats, shall be restored.
6 (08/14) On site, with the exception of the small areas, relative to the size of the component, permitted under
sub-Clause 7 of this Clause, a damaged thermally sprayed aluminium metal coating, together with any damaged
sealer or paint coats shall be restored but with a minimum thickness of 150 microns of thermally sprayed
aluminium metal coating.
7 (08/14) On site, small areas of isolated damage in a thermally sprayed aluminium metal coating plus paint
system, need not be restored; after surface preparation in compliance with sub-Clause 1 of this Clause, the
thermally sprayed aluminium metal coating shall be replaced by 100 microns of the first undercoats, omitting the
sealer. Adjacent paint coats, excluding the sealer shall then be restored over the repaired area.

8 (08/14) In the workshop, in the case of hot dip galvanizing only, small isolated areas of up to 40 mm2, and not
exceeding 0.5% of the total surface area of the component, whichever is the lesser, may after surface preparation,
be repaired with low melting point zinc alloy, providing that the total area of any damage on a component does not
exceed 0.5% of the total surface area of the component. Components with damaged areas greater than the above
limits shall be regalvanized.
Isolated areas of damage larger than 40 mm² in hot dip galvanizing which is to be painted later or which has already
been painted may be repaired with low melting point zinc alloy after surface preparation. Alternatively the whole of
the affected area including exposed steel substrate shall, after surface preparation, be overcoated with two coats of
Zinc Rich Epoxy Blast Primer (Item 109), minimum dry film thickness of 50 microns each.
9 (08/14) On site, surfaces of hot dip galvanized components found to have minor damage shall be prepared in
accordance with sub-Clause 8 of this Clause and coated with two coats of Zinc Rich Epoxy Blast Primer (Item
109), minimum dry film thickness of 50 microns each. Alternatively, the components shall be regalvanized.
10 In all cases where paint coats only are to be restored, or thermally sprayed aluminium metal coatings replaced
or restored, or hot dip galvanizing is to be replaced by paint, the edges of paint coatings or metal coating adjacent
to the affected area shall be bevelled back into sound paint or metal coating. This work shall be carried out before
any final blast cleaning described in sub-Clause 4 of this Clause.
11 (08/14) In the workshop exposure and overcoating times shall not exceed those specified in Clause 1914. On
site overcoating shall be started immediately after surface preparation of the affected area and before any
deterioration in the standard of the prepared surface occurs, and continued as soon as each coat is dry enough for
overcoating.
1908 (05/01) Procedures for Treatment of Local Failure in Protective Coatings

1 (08/14) In the workshop, failed paint coatings and failed thermally sprayed aluminium metal coating shall be
restored. Abrading down to sound paint only is permissible. If a thermally sprayed aluminium metal coating is
damaged or reduced to less than 80% of the specified minimum thickness during abrading, it shall be restored.
2 (08/14) On site, failed paint coatings and thermally sprayed aluminium metal coatings shall be restored except
that:
(i) abrading down to sound paint or to bright steel; or
(ii) blast cleaning to Sa2½ quality
are permissible methods of surface preparation when restoring paint systems over a steel substrate.
3 (05/05) In the workshop and on site, hot dip galvanized components showing signs of failure, eg blisters and
rust, of the coating shall be regalvanized.
4 (05/05) In the workshop and on site, failed paint coatings over hot dip galvanizing shall be restored. Surface
preparation of affected areas shall be by abrading. Areas of sound hot dip galvanizing exposed through a paint
system shall be abraded only as necessary to ensure satisfactory application of an adhesion promoter and paint. If
the hot dip galvanizing is damaged or reduced to less than 80% of the specified minimum thickness during
abrading, the component shall be regalvanized.
5 (08/14) Sub-Clauses 1907.3, 4, 10 and 11shall be complied with.
1909 (05/01) Metal Coatings

Hot Dip Galvanized Coatings
1 (08/14) Hot dip galvanized coatings shall, unless otherwise described in Appendix 19/5, comply with BS EN
ISO 1461 and with the following:
(i) Inhibited hydrochloric acid with a strength not exceeding 18% and within a temperature range of 15ºC
to 25ºC or inhibited sulphuric acid with a strength not exceeding 18% and within a temperature range of
60ºC to 80ºC shall be used for pickling.
Amendment – August 2014

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(ii) Components shall not be immersed in the pickling acid longer than is necessary for cleaning the surfaces
prior to hot dip galvanizing. Components shall receive a fresh water rinse between pickling and the
galvanising bath.
(iii) The surfaces of components to be hot dip galvanized shall be dried before immersion in the molten zinc.
(iv) When an aqueous flux is to be used, all traces of acid shall be washed off immediately after pickling.
(v) Hot dip galvanized coatings shall be relatively smooth, continuous and free from flux staining.
(vi) Detrimental contamination of hot dip galvanized coatings which are to be painted shall be removed by
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wet cleaning in compliance with sub-Clause 1903.9. Surfaces to be painted shall not receive chromate
passivation treatment.
(vii) Vent holes drilled in hollow sections prior to hot dip galvanizing shall be plugged after hot dip
galvanizing and before any painting, in accordance with Series 1800, 1810.5 if applicable.
(viii) The contractor shall take measures to minimise the potential for liquid metal assisted cracking occurring
during the galvanizing process and to identify any cracks that may have occurred in galvanized
steelwork.
(08/14) Thermally Sprayed Aluminium Metal Coating
2 (08/14) Thermally sprayed aluminium metal coatings shall, unless otherwise described in Appendix 19/5,
comply with BS EN ISO 2063 and with the following:
(i) Aluminium coating material shall have a composition complying with BS EN ISO 14919 – 3.1.
(ii) The thickness of the coating shall be not less than 100 microns.
(iii) The strength of adhesion of thermally sprayed aluminium metal coatings shall not be less than the
following:
Aluminium 50 kgf/cm²
(iv) Thermally sprayed aluminium metal coatings shall be applied continuously over each 0.5 m² per gun or
the area of the component whichever is the lesser until the specified thickness has been achieved.
(v) The application of thermally sprayed aluminium metal in separate layers shall not be permitted.
(vi) All surfaces to be thermally metal sprayed, including that of the reference panel having equivalent
hardness to that of the parent material, shall be blast cleaned with chilled iron grit or high carbon cast-
steel grit with a hardness value greater than 650 HV, or aluminium oxide with a hardness value greater
than 9 Mohs, and the standard shall be Sa3 quality, medium profile.
(vii) Thermally sprayed aluminium metal coatings shall be de-nibbed.
Other Requirements
3 (08/14) When a metal coating is required on only part of a component it shall be applied before the rest of the
component receives paint.
1910 (08/14) Testing of Thermally Sprayed Aluminium Metal Coatings

1 (08/14) At the start of the works, and subsequently at intervals scheduled in Appendix 1/5 (with the exception of
coatings on steel in bearings, curved surfaces, repairs to mechanical damage, local failure of thermally sprayed
aluminium metal coating at site joints or areas restored on site), the Contractor shall demonstrate by means of a pull
off adhesion test in accordance with ‘ASTM D4541-Type III’, that the minimum adhesion requirement is being
attained as detailed in sub-Clause 1909.2 (iii). In the excepted areas, the Contractor shall demonstrate that the
adhesion is satisfactory by means of grid tests in accordance with BS EN ISO 2063. Areas affected by the tests
shall be restored in accordance with Clause 1907.

2 (08/14) The tensile tests shall be carried out initially on flat panels 150 mm x 150 mm x 6 mm which are of the
same grade of steel as the parent material and which before blast cleaning had the same surface condition. The
panels shall be blast cleaned and thermally aluminium metal sprayed together with the parent material to the same
standard and using the same technique.
3 The Contractor shall ensure that adhesion tests have been carried out satisfactorily before any further work
continues.
4 (08/14) If the adhesion requirement on any test panel is not met, the Contractor shall carry out a further test on
the parent material adjacent to the panel position. In the case of adhesion failure on the steelwork itself by either
method of test, unsound thermally sprayed aluminium metal coating shall be restored and the tests repeated.
5 (08/14) If more than two local areas of faulty adhesion occur on any one component, the whole of the thermally
sprayed aluminium metal coating on the component shall be considered as having failed, and it shall be restored.
Sub-Clause 1905.4 is not applicable in the case of adhesion failure.
#1911 (05/01) Paint and Similar Protective Coatings

General
1 (08/14) The term paint shall be deemed to refer to protective coatings in general.
2 (08/14) The paints permitted for use by the Overseeing Organisation in the works are listed in the Manual of
Paints for Structural Steelwork which is included in BD 35 (DMRB 2.4.1) and which also contains details of the
quality assurance scheme for paints and similar protective coatings. All paints shall have a current BBA HAPAS
Roads and Bridges Certificate or equivalent appropriate to the use of the paint in the proposed paint system.
3 (08/14) All paints shall be supplied in sealed containers of a capacity suitable for the volume and method of
application. For sitework, all paints shall be supplied in sealed containers of not more than 25 litre capacity. The
capacity of the containers to be used shall be confirmed as being suitable as part of the Procedure Trials described
in Clause 1915. All containers shall be used in order of date of manufacture and batch number, the oldest being
used first. Each container shall have a completely removable lid and be clearly marked on the side to show the
name of the manufacturer, registered description of the material (including purpose, e.g. whether primer, undercoat
or finish), colour, Item No, paint manufacturer’s reference number, batch number and date of manufacture. Where
date of manufacture is coded, the Contractor shall provide the code key. In addition paints may be supplied in
sealed containers of 5 litre capacity for testing purposes in accordance with Clause 1912, for ‘A’ samples.
4 (08/14) The Contractor shall ensure that the properties of the paints he has selected are suitable for the
conditions in the workshop and on site, including temperature and humidity, and that he is able to apply the paints
satisfactorily to all parts of the structure in these conditions.
5 (05/05) Unless otherwise described in Appendix 19/5, all paints forming any one protective system or
overlapping systems shall be obtained from the same manufacturer, as named by the Contractor in Appendix 19/1
Form HA/P1 (New Works) Paint System Sheet.
(05/05) Surface Preparation and Protective Systems for Steelwork Except Bearings, CCTV Masts, Cantilever
Masts and Steel Lighting Columns and Bracket Arms
6 (08/14) Protective systems
Note: mdft = minimum dry film thickness
B = apply by brush
AS = apply by airless spray
HB = High Build (dft: above 75 µm per coat)
NB = Normal Build (dft: between 50 and 75 µm per coat)
LB = Low Build (dft: below 50 µm per coat)

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(i) (05/05) Item numbers in the Protective Systems are listed in the Manual of Paints for Structural Steelwork
at Annex A of BD 35 (DMRB 2.4.1) and a summary is shown in Table 19/1.
(ii) (05/05) Details of Surface Preparation and Protective Systems for Steelwork Except Bearings, CCTV
Masts, Cantilever Masts and Steel Lighting Columns and Bracket Arms are given in Tables 19/2A and
19/2B.
Surface Preparation and Protective Systems for Steel in Bridge Bearings (and Metal Coated Fasteners)
7 (05/05) Details of surface preparation are given in Table 19/3A and the protective system Type V is given in
Table 19/3B.

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TABLE 19/1: (08/14) BD 35 Quality Assurance Scheme for Paints and Similar Protective Coatings
Annex A Manual of Paints for Structural Steelwork
Current Paint Item Numbers
Item Description Coat Type Build Applied by

109 Zinc Rich Epoxy Blast Primer Blast Primer LB or NB B or AS
(two pack) (B to small areas only)
110 Zinc Phosphate Epoxy (two- Blast Primer/Sealer LB B or AS
pack) (B to small areas only)
111 Zinc Phosphate High Build Blast Primer HB AS
Quick Drying Epoxy (two- (B to small areas only)
pack)
112 MIO High Build Quick Drying Undercoat/Finish HB AS
Epoxy (two-pack)
113 Water based epoxy primer for Primer HB B or AS
blast cleaned internal surfaces
(two-pack)
114 Water based epoxy undercoat/ Undercoat/Sheen Finish HB B or AS
sheen finish for internal use
(two-pack)
115 High Build Aluminium Surface tolerant HB B or AS
Epoxy(two-pack) maintenance (e.g. for
abraded surfaces)
116 High Build Epoxy (2-pack) Surface tolerant HB B or AS
maintenance undercoat
121 Extended Cure Epoxy MIO Primer, Undercoat and/or HB AS
(two-pack) Finish for hot dipped (B to small areas only)
galvanized steel
123 High Build Glass Flake Epoxy Undercoat for blast cleaned HB AS
(two-pack) steel new construction (stripe coats and small
repairs only by brush)
155 ‘T’ Wash Adhesion promoter for hot LB B
dip galvanized steel
157 Adhesion promoting (single- To promote substrate LB B or AS
component) adhesion properties of
coating systems for hot dip
galvanized steel,
aluminium and stainless
steel surfaces
159 Aluminium Epoxy (two-pack) Sealer/Primer LB B or AS
160 Red Oxide Moisture Cured Primer/Blast Primer for LB B or AS
Polyurethane (single- maintenance or new works
component)
162 MIO Moisture Cured Undercoat/Finish NB or HB B or AS
Polyurethane
164 Moisture Cured Polyurethane Semi-gloss Finish LB B
(single-component)
NB AS
167 Epoxy Acrylic Finish (two- Gloss or Semi-gloss Finish NB B (small areas by brush)
pack)
AS

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TABLE 19/1: (08/14) BD 35 Quality Assurance Scheme for Paints and Similar Protective Coatings
Annex A Manual of Paints for Structural Steelwork (continued)
Item Description Coat Type Build Applied by
168 Polyurethane (two-pack) Gloss Finish LB B
NB AS
169 Polyurethane (two-pack) Semi-gloss Finish NB B (small areas by brush)
HB AS
185 Organic Modified Gloss Finish for new NB B
Polysiloxane (two-pack) works or maintenance
HB AS
200 Grease Paint Primer B (AS for difficult access
areas)
201 Grease Paint Undercoat/Finish HB B or AS

(05/05) Notes:
1 Colour reference shall be as per the manufacturer’s declared colour given with reference to BS 4800 and/or BS
381C where appropriate.
2 (08/14) Dry Film Thickness (dft) range shall be as per the manufacturer’s data sheet. The minimum dry film
thickness of the paint coats and paint system shall be as per the protective systems detailed in Tables 19/2 to 19/4
where given.
3 (08/14) All materials to be handled and applied in accordance with the manufacturers Product and Health &
Safety Data Sheets.

15
TABLE 19/2A: (08/14) Requirements For Bridges, Parapets and Other Highway Structures
Except Bearings, CCTV Masts, Cantilever Masts and Steel Lighting Columns and Bracket
Arms
Surface Preparation and Protective Systems
Surface preparation Protective systems (given

in Table 19/2B)
(i) Bridge steelwork, fabrication stage
Area Description Method Surface Standard Type
Area A
Exterior main surfaces, Blast clean Sa3, Medium profile I for Inland Ready Access
including shop welds
II for Inland Difficult
Access, Marine Ready or
Difficult Access
Area B
Interior of box girder Blast clean Sa2½, Medium profile III
surfaces, except area C, but
including shop welds
Area C
Friction surfaces of parent As described in Series As described in Series As described in Series
material at slip resistant 1800, 1810.1(5) 1800, 1810.1(5) 1800, 1810.1(5)
connections
Area D
Friction and outer surfaces of Friction surfaces: As Friction surfaces: As Friction surfaces: As
joint material at slip resistant described in Series described in Series 1800, described in Series 1800,
connections. 1800, 1810.1(5) 1810.1(5) 1810.1(5)
Outer surfaces: Blast Outer surfaces: Sa3, Outer surfaces: I for Inland
clean Medium profile Ready Access
Difficult Access
(ii) Bridge steelwork, erection stage
Area E
Exterior surfaces of site welds Remove slag, wire Sa3, Medium profile I for Inland Ready Access
and weld affected areas brush, wet clean and
blast clean as Area A
Difficult Access
Area F
Interior surfaces of site welds Remove slag, wire Sa2½, Medium profile III with additional coat of
and weld affected areas brush, wet clean and primer
blast clean as Area B
(iii) Parapets.
Area G
All surfaces, subject to Pickling for hot dip In accordance with Clause IV
accessibility galvanizing 1909

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TABLE 19/2B: (08/14) Requirements for Bridges, Parapets and Other Highway Structures
Arms
Protective Systems
Type Metal 1st Coat 2nd Coat 3rd Coat 4th Coat Minimum total
Coating dry film thickness
of the paint
system (microns)
I Item No 109 112 167, 168, 275 (325 if Item
169 or 185 185 finish is
Min dry film thickness 50 125 50 or 100* specified)
per coat(µm)
Item No 111 112 167, 168, 300 (350 if Item
per coat(µm)
II Item No 109 112 112 167, 168, 400 (450 if Item
169 or 185 finish is
185 specified)
Min dry film thickness 50 125 125 50 or
per coat(µm) 100*
Item No 110 123 167, 168, 525 (575 if Item
per coat(µm)
Item No 111 112 112 167, 168, 425 (475 if Item
169 or 185 finish is
185 specified)
Min dry film thickness 75 125 125 50 or
per coat(µm) 100*
III Item No 109 112 200
Min dry film thickness 50 125
per coat(µm)
Item No 111 112 225
per coat(µm)
Item No 113 114 225
per coat(µm)
IV Item No Hot dip 155 or 110, 112 112 or 121 167, 168, 2nd Coat Item 110:
galvanize sweep or 121 169 or 225 (275 if Item
blast 185 185 finish is
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specified)
Min dry film thickness 25 (Item 125 50 or 2nd Coat Items 112
per coat(µm) 110) or 100* or 121: 350 (400 if
125 Item 185 finish is
(Items specified)
112 or
121)

TABLE 19/2B: (08/14) Requirements for Bridges, Parapets and Other Highway Structures
Arms Continued
(08/14) Notes
(08/14) Finish Coats
(i) *Items 167, 168 or 169 finish coats min. dft 50µm. Item 185 finish coat min. dft 100 µm.
(ii) Type I, Type II and Type IV: A finish coat may need to be applied in the workshop to comply with the
maximum overcoating times for the preceding epoxy MIO undercoat (Item 112 or Item 121). In such
circumstances an additional finish coat shall be applied on site to meet the requirements of sub-Clause
1914.9. Prior to applying the additional finish coat on site any damage to the paint system shall be
restored in accordance with the requirements of Clause 1907 and the surface of the workshop applied
finish coat shall be prepared by light abrading and wet cleaning.
(08/14) Area D, Type II
(i) A Type II system incorporating a metal coating of thermally sprayed aluminium metal, 1st coat Item
159 (12-20 m2/litre), 2nd coat Item 111 (mdft 75 µm), 3rd coat Item 112 (mdft 112 µm), 4th coat Item
167, 168, 169 (mdft 50 µm) or 185 (mdft 100 µm), with a total minimum dft of the paint system of
350 µm (Items 167, 168, or 169) or 400 µm (Item 185) may be used for Area D outer surfaces only,
where aluminium metal spray is identified as the required treatment of Area D friction surfaces in
Series 1800, 1810.1(5).
(08/14) Parapets
(i) Type IV: For parapets to be erected in a Marine environment, 1st, 2nd and 3rd coats shall be applied
in the workshop; the 4th coat may be applied in the workshop or, if within the intermediate coat
overcoating time, on site. For parapets in an Inland environment, all coats of paint may be applied in
the workshop or on site.
(ii) Where sweep blast is the chosen method of adhesion promotion, it shall be undertaken in accordance
with BS EN ISO 12944-4 to surface roughness ‘fine’ in accordance with BS EN ISO 8503-2.
(08/14) Fasteners
(i) Unless otherwise specified in Appendix 19/2, fasteners in steelwork shall be supplied with an anti-
corrosive protective coating comprising hot dip galvanizing in accordance with BS EN ISO 10684, or
a similar alternative surface protection treatment which has a current BBA HAPAS Roads and
Bridges Certificate or equivalent, as an anti-corrosion protective coating for use on steel fixings
intended for use on steel highway structures. For such similar alternative surface protection
treatments, prior to commencement of the works, the Contractor shall provide to the Overseeing
Organisation a copy of the BBA HAPAS Roads and Bridges Certificate or equivalent, and the
fasteners shall be installed and prepared prior to application of paint in accordance with the
requirements of the Certificate.
(ii) Hot dip galvanized fasteners in steelwork that is to be painted shall have surfaces that are to be
painted treated with an adhesion promoter (Item 155) before installation, or alternatively after
installation, shall be cleaned with a solvent wipe to remove all traces of oil and grease and be abraded
with (coarse grade) abrasive paper to sufficiently roughen the exposed galvanized surface in order to
provide a suitable ‘adhesion key’ and be painted with a coat of either Item 110, Item 157 or Item 160
as an adhesion promoter.
(iii) After the joints are made and fasteners have been treated with an adhesion promoter, fasteners shall
be protected as specified for the joint material.

18
TABLE 19/3A: (08/14) Requirements for Steel in Bridge Bearings (and Metal Coated Fasteners)
Surface Preparation
Area Description Method: Standard:

Area A
Exterior surfaces, excepting wearing surfaces but Blast clean Sa3, Medium profile
including a 25mm minimum return on areas of top
bearing plates or base plates in contact with grout
or mortar
Area B
Central area of top bearing plates in contact with Blast clean Sa2½, Medium profile
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grout or mortar
Area C
Areas of top bearing plates or base plates in Blast clean Sa3, Medium profile
contact with structural steel components
Area D
Exposed shop fasteners in components to be Blast clean Sa3, Medium profile
coated after assembly
Area E
Concealed shop fasteners No requirement No requirement
Area F
Site fasteners for fixing bearings to piers or Restore metal coating as Restore metal coating as
abutments and for fixing bridge components to necessary to specified necessary to specified
bearings standard of cleanliness standard of cleanliness

TABLE 19/3B: (08/14) Requirements for Steel in Bridge Bearings (and Metal Coated Fasteners)
Protective System Type V
Applied Metal Coating 1st Coat 2nd Coat 3rd Coat 4th Coat Minimum total
dry film
over
thickness of the
paint system
(microns)
Area A Item No Aluminium 110 or 111 112 167, 168, 275 (325 if Item
and D metal spray 159 169 or 185 185 finish is
Min dry film 150 12-20 m2/ 75 125 50 or 100* specified)
thickness per litre
coat (µm)
Area B Item No 112 150
Min dry film 150
thickness per
coat (µm)
Area C Item No Aluminium 159
metal spray
Min dry film 150 12-20 m2/
thickness per litre
coat (µm)
Area F Item No Hot dip Adhesion 110 112 or 167, 168, 275 (325 if Item
galvanize promoter 121 169 or 185 185 finish is
(see specified)
Notes)
Min dry film 25 125 50 or 100*
thickness per
coat (µm)
(08/14) Notes
(08/14) Finish Coats

(i) *Items 167, 168 or 169 finish coats min. dft 50µm. Item 185 finish coat min. dft 100 µm
(08/14) Area A and D
(i) 4th coat for bearings for steel bridge beams, brush applied on site; colour to match finish on main
steelwork.
(ii) Aluminium metal spray plus Items 110 or 159 are required on interfaces of machined surfaces of
spreader plates and of bearing.
(08/14) Areas A, B, C and D
(i) Aluminium metal spray, Items 110 or 159, 111 and 112 shall be applied at the bearing manufacturer’s
works. Item 167, 168, 169 or 185 shall be applied on site.
(ii) Items 110 or 159 shall not be over-applied and shall not be included in the overall thickness of the
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protective paint system.

TABLE 19/3B: (08/14) Requirements for Steel in Bridge Bearings (and Metal Coated Fasteners)
Continued
(08/14) Area F
(i) Adhesion promoter: Item 155 shall be applied on site, either before or after erection, to surfaces to be
painted. Item 155 coming into contact with adjacent paint coats shall be removed immediately.
Alternatively after installation, surfaces to be painted shall be cleaned with a solvent wipe to remove
all traces of oil and grease and be abraded with (coarse grade) abrasive paper to sufficiently roughen
the exposed surface in order to provide a suitable ‘adhesion key’ and be painted with a coat of either
Item 110, Item 157 or Item 160 as an adhesion promoter. The remaining site coats shall be applied to
exposed surfaces after erection.
(08/14) Stripe coats for bearings only
(i) Area F: Stripe coats are not required for bearing site fasteners.
(ii) Area A and D: A single stripe coat in Item 112 paint shall be applied over Item 111 at the bearing
manufacturer’s works. A second stripe coat in Item 112 shall be applied on site. Item 112 coats shall be
in contrasting shades, eg medium grey, natural grey.
(08/14) Site Coats
(i) Site coats shall be applied by the Contractor.
(08/14) Paint suppliers
(i) The requirements of Clause 1920 shall be noted.
(08/14) Appendix 19/1
(i) When completing Appendix 19/1, the appropriate finish paints shall be selected from the protective
system. The letter references, A, B, C etc shall be varied as appropriate, and the application
instructions arranged to suit.
(05/05) Surface Preparation and Protective Systems for CCTV Masts, Cantilever Masts, Steel
Lighting Columns and Bracket Arms
8 (08/14) General
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(i) Details of protective systems A1, G1, A2a and G2a, A2b and G2b are given in Tables 19/4A, B & C.
(ii) In the case of protective systems A2a and G2a, A2b and G2b the Contractor may opt to apply the
finishes in the workshop or, if within the intermediate coat overcoating time, at site, unless otherwise
specified.
(iii) When a white or pale tint finish is specified, an additional finish coat may be required to ensure full
opacity is achieved, completely obliterating the Item 112 undercoat.
(iv) Type A1, A2a and A2b protective systems are based on aluminium metal spray.
(v) Type G1, G2a and G2b protective systems are based on hot dip galvanizing.
(vi) Unless otherwise stated in Appendix 19/5 the nominal ground level adjacent to a mast or column shall
be assumed to be at a distance of 600 mm below the door opening. The ‘ground section’ of planted masts
and columns shall extend from the bottom of the mast or column to 250mm above the nominal ground
level. The ‘ground section’ of flange mounted masts and columns applies where the flange is below
ground level or is built over and shall extend from the bottom of the mast or column to 250mm above
the nominal ground level. The ‘upper section’ of a mast or column with a ground section is the
remainder of the mast or column above the ground section.
9 (05/05) Protective system

TABLE 19/4A: (11/03) Requirements for CCTV Masts, Cantilever Masts, Steel Lighting Columns
and Bracket Arms Systems
System Environment Access
A1 Inland Ready
A2a and A2b Inland Difficult
Marine Ready or Difficult
G1 Inland Ready
G2a and G2b Inland Difficult
Marine Ready or Difficult
TABLE 19/4B: (08/14) Requirements for CCTV Masts, Cantilever Masts, Steel Lighting Columns
and Bracket Arms Surface Preparation
System A1, A2a and A2b
Location Method Surface Standard
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External surface:
Flange mounted and planted masts Blast clean Sa3, Medium profile
and columns, overall surface
preparation.
Internal surfaces:
Flange mounted and planted masts Blast clean where access allows Sa2½, Medium profile
and columns, surface preparation
or or
from the bottom to 300mm above
the door opening. Hand tool preparation Bright steel
System G1, G2a and G2b
External and internal surfaces:
Flange mounted and planted masts In accordance with sub-clause In accordance with sub-clause
and columns, overall surface 1909.1 1909.1
preparation.

TABLE 19/4C: (08/14) Requirements for CCTV Masts, Cantilever Masts, Steel Lighting Columns
and Bracket Arms
Protective Systems
Type Metal 1st Coat 2nd Coat Minimum total

Coating dry film
thickness of the
paint system
(microns)
A1 (i) External surfaces
Flange mounted and Item No Thermally 159 112 * 125
planted masts and sprayed
columns, overall aluminium
protection plus 2nd metal
coat for ground
section (See 1911.8
(vi)).
Application rate/Min 12-20 125
dry film thickness m2/litre
per coat (µm)
(ii) Internal surfaces
Flange mounted and Item No 110 112 * 175
planted masts and
columns, protection
applied from the
bottom to 300mm
above the door
opening.
Min dry film 25 125
thickness per coat
(µm)
(08/14) Notes
(i) * Item 112 finish coat colour to be black (BS 4800 shade 00 E 53)
(ii) Blast cleaning, thermally sprayed aluminium metal and all workshop paint coats on external
surfaces shall be returned on to edges at ends, at door and other openings and under the base flange.
(iii) All paint coats shall be applied in the workshop.
(iv) Item 159 shall be overcoated within 96 hours.

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and Bracket Arms
Protective Systems (continued)
Type Metal Coating 1st Coat 2nd Coat 3rd Coat Minimum
total dry
film
thickness of
the paint
system
(microns)
A2a (i) External surfaces
Flange mounted Item No Thermally 110 or 112 167, 168, 200 (250 if
and upper section sprayed 159 169 or Item 185
(See 1911.8 (vi)) aluminium metal 185 finish is
of masts and Application 12-20 m2/ 125 50 or specified)
columns, overall rate/Min dry litre 100*
protection. film thickness
per coat(µm)
Overall Item No Thermally 110 or 112 112** 275
protection for sprayed 159
ground section aluminium metal
(See 1911.8 (vi)). Application 12-20 125 125
rate/Min dry m2/litre
film thickness
per coat(µm)
Flange mounted Item No 110 112** 175
and planted Min dry film 25 125
masts and thickness per
columns, coat(µm)
protection
applied from the
bottom to
300mm above
the door opening.
(08/14) Notes
(i) * Items 167, 168 or 169 finish coats min. dft 50µm. Item 185 finish coat min. dft 100 µm
(ii) ** Item 112 finish coat colour to be black (BS 4800 shade 00 E 53)
(iii) Blast cleaning, thermally sprayed aluminium metal and all workshop paint coats on external
surfaces, and site paint coats where access permits shall be returned on to edges at ends, at door and
other openings and under the base flange.
(iv) All paint coats except finish coats shall be applied in the workshop. Finish coats may be applied in
the workshop or, if within the intermediate coat overcoating time, on site.
(v) Item 110 or 159 applied over thermally sprayed aluminium metal shall be overcoated within 96
hours.
(vi) For external surfaces, the upper section finish coat shall overlap the ground section finish coat by
25mm.

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and Bracket Arms
Type Metal Coating 1st Coat 2nd Coat 3rd Coat Minimum
total dry
film
thickness of
the paint
system
(microns)
A2b (i) External surfaces
Flange mounted Item No Thermally 110 or 111 112 225
and planted masts sprayed 159
and columns, aluminium
overall protection. metal
Application 12-20 75 125
rate/Min dry
film thickness
per coat(µm)

Flange mounted Item No 111 112 225
and planted masts Min dry film 75 125
and columns, thickness per
protection applied coat(µm)
from the bottom to
300mm above the
door opening.
(08/14) Notes
(i) Blast cleaning, thermally sprayed aluminium metal, and all workshop paint coats on external
surfaces, and site paint coats where access permits, shall be returned on to edges and 25mm inside
at ends, at door and other openings and under the base flange.
(ii) Item 110 or 159 shall be overcoated within 96 hours.
(iii) The ground section (See 1911.8 (vi)) of masts and columns shall have an additional sacrificial steel
section thickness of a minimum 1.0mm, above that needed in the design. The additional thickness
shall be recorded in which ever is appropriate of the following: Part A of Appendix 13/2 – Typical
Lighting Column and Bracket Data Sheet; Part A of Appendix 13/5 – Typical CCTV Mast Data
Sheet; Part A of Appendix 13/8 – Typical Cantilever Mast Data Sheet.
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and Bracket Arms
Type Metal 1st Coat 2nd Coat 3rd Coat Minimum

Coating total dry
film
thickness of
the paint
system
(microns)
G1 (i) External surfaces
Flange mounted and Item No Hot dip 155, or 112 or 112 or 275 (at
planted masts and galvanize sweep 121 121** ground
columns, overall blast section)
protection plus Min dry film 125 125
adhesion promotion thickness per
and 2nd and 3rd coats coat(µm)
for ground section (See
1911.8 (vi)).
Flange mounted and Item No Hot dip
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planted masts and galvanize
columns, overall Min dry film
protection thickness per
coat(µm)
(08/14) Notes
(i) ** Items 112 or 121 finish coat colour to be black (BS 4800 shade 00 E 53)
(ii) The requirements of sub-Clause 1914.21 relating to the application of the first coat of paint need
not apply for CCTV masts, cantilever masts and steel lighting columns and bracket arms which
remain in a workshop environment after hot dip galvanizing.
(iii) All workshop paint coats on external surfaces shall be returned on to edges and 25mm inside at
ends, at door and other openings and under the base flange.
(iv) All paint coats shall be applied in the workshop.
(v)
Where sweep blast is the chosen method of adhesion promotion, it shall be undertaken in
accordance with BS EN ISO 12944-4 to surface roughness ‘fine’ in accordance with BS EN ISO
8503-2.


and Bracket Arms
Type Metal 1st Coat 2nd Coat 3rd Coat 4th Coat Minimum
Coating total dry
film
thickness of
the paint
system
(microns)
G2a (i) External surfaces
Flange mounted Item No Hot dip 155 or 112 or 112 or 167, 168, 275 (325 if
and upper galvanize sweep 121 121 169 or Item 185
section (See blast 185 finish is
1911.8 (vi)) of Min dry film 100 100 50 or specified)
masts and thickness per 100*
columns, overall coat(µm)
protection.
Overall Item No Hot dip 155 or 112 or 112 or 112 or 350
protection for galvanize sweep 121 121 121**
ground section blast
(See 1911.8 Min dry film 100 100 100
(vi)). thickness per
coat(µm)
Overall Item No Hot dip
protection. galvanize
Min dry film
thickness per
coat(µm)
(08/14) Notes
(i) *Items 167, 168 or 169 finish coats min. dft 50µm. Item 185 finish coat min. dft 100 µm
(ii) ** Items 112 or 121 finish coat colour to be black (BS 4800 shade 00 E 53)
(iii) The requirement of sub-Clause 1914.21 relating to the application of the first coat of paint need not
apply for CCTV masts, cantilever masts and steel lighting columns and bracket arms which remain
in a workshop environment after hot dip galvanizing.
(iv) All workshop paint coats on external surfaces, and site paint coats where access permits shall be
returned on to edges and 25mm inside at ends, at door and other openings and under the base flange.
(v) All paint coats except finish coats shall be applied in the workshop. Finish coats may be applied in
the workshop or, if within the intermediate coat overcoating time, on site.
(vi) Where sweep blast is the chosen method of adhesion promotion, it shall be undertaken in accordance
with BS EN ISO 12944-4 to surface roughness ‘fine’ in accordance with BS EN ISO 8503-2.
(vii) For external surfaces, the upper section finish coat shall overlap the ground section finish coat by
25mm.


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and Bracket Arms
Type Metal 1st Coat 2nd Coat 3rd Coat 4th Coat Minimum
Coating total dry
film
thickness
of the
paint
system
(microns)
G2b (i) External surfaces
Flange mounted Item No Hot dip 155 or 110 112 or 167, 168, 200 (250 if
and upper section galvanize sweep 121 169 or Item 185
(See 1911.8 (vi)) blast 185 finish is
of masts and Min dry film 25 100 50 or specified)
columns, overall thickness per 100*
protection. coat(µm)
Overall Item No Hot dip 155 or 110 112 or 112 or 250
protection for galvanize sweep 121 121**
ground section blast
(See 1911.8 (vi)). Min dry film 25 100 100
thickness per
coat(µm)
Overall Item No Hot dip
protection. galvanize
Min dry film
thickness per
coat(µm)
(08/14) Notes
(i) *Items 167, 168 or 169 finish coats min. dft 50 µm. Item 185 finish coat min. dft 100 µm
(ii) ** Items 112 or 121 finish coat colour to be black (BS 4800 shade 00 E 53)
(iii) The requirements of sub-Clause 1914.21 relating to the application of the first coat of paint need not
apply for CCTV masts, cantilever masts and steel lighting columns and bracket arms which remain
in a workshop environment after hot dip galvanizing.
(iv) All workshop paint coats on external surfaces, and site paint coats where access permits shall be
returned on to edges and 25mm inside at ends, at door and other openings and under the base flange.
(v) Where sweep blast is the chosen method of adhesion promotion, it shall be undertaken in
accordance with BS EN ISO 12944-4 to surface roughness ‘fine’ in accordance with BS EN ISO
8503-2.
(vi) For external surfaces, the upper section finish coat shall overlap the ground section finish coat by
25mm.
(vii) The ground section (See 1911.8 (vi)) of masts and columns shall have an additional sacrificial steel
section thickness of a minimum 1.0mm, above that needed in the design, from the bottom of the
column to at least 250mm above ground level. The additional thickness shall be recorded in which
ever is appropriate of the following: Part A of Appendix 13/2 – Typical Lighting Column and
Bracket Data Sheet; Part A of Appendix 13/5 – Typical CCTV Mast Data Sheet; Part A of Appendix
13/8 – Typical Cantilever Mast Data Sheet.

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#1912 (05/01) Testing of Paints

Provision of Samples
1 (08/14) Unless otherwise described in Appendix 19/5, the Contractor shall provide unopened samples, known as
‘A’ samples, for quality assurance purposes, for each type of paint to be used for the works in accordance with this
Clause. In addition the Contractor shall supply at least 500 ml samples, known as ‘B’ samples, for application
control purposes.
2 (08/14) ‘A’ and ‘B’ samples are tested for paint composition and/or properties against the values obtained during
the approval testing of the original formulation and issued by the paint manufacturer to the certifying body.
‘A’ Samples
3 (08/14) ‘A’ samples are required in all cases where more than 500 litres of any one type of paint is to be used in
the works. ‘A’ samples are not required for paints to be applied to bearings, CCTV masts, cantilever masts, steel
lighting columns and bracket arms. For two-pack systems separate samples of the base and activator shall be
despatched by the Contractor to the testing authority.
4 (05/05) The first ‘A’ samples shall be taken from the first representative batch of each type of paint delivered to
the fabricator’s workshop or to site.
5 (08/14) Additional ‘A’ samples of the paints subject to testing under sub-Clause 3 of this Clause shall be
provided by the Contractor at a rate of one set of samples for each 500 litres (or part there of) of each type of paint
used in the works.
The Contractor shall also provide an ‘A’ sample:
(i) of any replacement batch of paint subject to testing under sub-Clause 3 of this Clause;
(ii) returned paint described in sub-Clause 1913.4;
(iii) when the paint is showing unsatisfactory application characteristics under Clause 1914.
6 (08/14) The ‘A’ samples shall be selected at random to be fully representative of each 500 litres (or part thereof)
of paint to be used in the Works.
7 (05/05) Immediately after selection, the ‘A’ samples shall be despatched by the Contractor to the testing
authority, together with Appendix 19/4 Form HA/P3.
8 (05/05) Paint shall be supplied in sufficient time to allow for sampling and testing before the start of application.
9 (08/14) Except for procedure trials, paint shall not be applied until the ‘A’ sample from the paint to be applied
has been tested and confirmed as being satisfactory for use.
‘B’ Samples
10 (08/14) ‘B’ samples are required in all cases including for paints to be applied to bearings, CCTV masts,
cantilever masts, steel lighting columns and bracket arms. ‘B’ samples shall be taken as spot checks, with a
minimum of every batch of paint being sampled. The Contractor shall take ‘B’ samples for two-pack materials as
separate unmixed samples of the base and activator (cure) components. The ‘B’ samples shall be taken following
homogenization of the individual components and immediately prior to mixing the two components for use in the
Works. The samples shall be decanted directly into clean, new and clearly labelled 500ml tins which shall be filled
and immediately sealed prior to despatch to the testing authority.
11 (05/05) Immediately after selection, the ‘B’ samples shall be despatched by the Contractor to the testing
authority, together with Appendix 19/4 Form HA/P3.
Provision of 500 ml Tins, Packing and Transport of ‘A’ and ‘B’ Samples
12 (05/05) The Contractor shall provide 500 ml tins with lids and lid clips, for ‘B’ samples at the start of painting or
before any procedure trials required by Clause 1915. The quantity supplied shall be sufficient to avoid any delay in
taking ‘B’ samples throughout the work.

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13 (05/05) The Contractor shall ensure that the lids of all tins of sample paint are securely clipped down when they
are despatched for testing.
14 (05/05) The Contractor shall be responsible for handling, packing as necessary, prompt despatch and transit of
‘A’ and ‘B’ samples, including collection of samples from the testing authority for use or disposal as appropriate,
following satisfactory testing and reporting.
15 (08/14) Overseeing Organisation shall report back to the Supervising Firm, as stated on Appendix 19/4 Form
HA/P3, all results of the testing, who shall then notify the Contractor of the results.
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1913 Storage Requirements and Keeping Periods for Paints
1 (08/14) On delivery to the workshop or site, paint shall be unloaded directly into one or more secure paint stores
which shall be located within 100 metres of the painting area. Insulation and means of heating and ventilating shall
be provided as necessary to maintain the temperature of paint stores between 10ºC and 27ºC.
(08/14) If at any time or place paint in tins, painters’ kettles or airless spray containers is allowed to reach
temperatures outside the 10ºC and 27ºC limits or the paint manufacturer’s recommended storage temperature, the
paint shall be discarded and not used in the works. Two pack products which produce an exothermic reaction when
mixed, may be allowed to exceed the specified higher temperature limit.
(08/14) The Contractor shall also implement any additional storage requirements recommended by the paint
manufacturer.
2 (05/05) Unless excepted in accordance with sub-Clause 4 of this Clause, paint which has not been used within
the shelf life recommended by the manufacturer or within 18 months of the date of manufacture, whichever is the
lesser, shall be discarded or returned to the manufacturer and not used in the works.
3 Chemically or moisture cured paints shall not be used after the expiry of the pot life stipulated by the paint
manufacturer. They shall be discarded on expiry of the pot life or at the end of each working day/night whichever is
the less. All other paints in opened tins or open containers including painters’ kettles shall be returned to store and
kept in sealed containers with not more than 10% ullage.
4 (08/14) Exceptionally, components of two-pack epoxy paints may have their shelf life extended to 24 months
provided that the Contractor returns the paints to the paint manufacturer and ascertains that the manufacturer
examines the contents of each tin and reconstitutes the paints as necessary so that such paints are equal in all
respects to the paints described in the Contract. The Contractor shall provide a Certificate of Conformity
confirming that such paints have been inspected and where necessary reconstituted and conform in all respects to
the Contract.
5 (08/14) Each tin of reconstituted paint returned to the workshop or site by the manufacturer shall have an
additional label affixed stating ‘Extended Shelf Life to (date)’. The previous date marking shall remain and not be
obscured. A set of ‘A’ samples shall be taken and be submitted for testing in accordance with Clause #1912 from all
batches of paint that have their shelf life extended.
1914 Application of Paint

1 (08/14) Paint shall be supplied from the Contractor’s paint store to the painters ready for application, the only
adjustment of formulation permitted being as described in sub-Clause 1915.4. In exceptional circumstances any
addition of solvent necessary to improve application shall be in accordance with the paint manufacturers
instructions and be carried out by the paint manufacturer, preferably in the paint process plant with adequate
equipment and controlled measurements.
2 (08/14) Paint shall be applied only to surfaces that have been prepared and cleaned to the specified standard as
described in this Series.

3 (08/14) Unless otherwise described in Appendix 19/2 a coat of paint in a system shall be applied by one of the
following methods:
(i) brush (B);
(ii) airless spray (AS);
(iii) air assisted spray.
Application of paint by roller is not permitted.
4 (08/14) Paint shall not be applied when the following conditions will apply during paint application and/or
curing:
(i) when the temperature of the surfaces to be coated is less than 3ºC above the Dew Point, and/or when the
ambient air temperature is at or below 5ºC or the relative humidity is above 75% in an enclosed
workshop or 80% on site; or, outside the temperatures and humidities recommended in the paint
manufacturer’s data sheet;
(ii) during rain, snow, fog, mist or in a dust laden atmosphere;
(iii) when moisture is likely to be deposited on the surface by condensation or rain;
(iv) when wind-borne dust may adhere to and contaminate the paint.
5 (08/14) All workshop painting of steelwork shall be carried out in a fully enclosed weatherproof workshop.
6 Before starting the procedure trials described in Clause 1915, the Contractor shall make available details of the
overall wet film thickness for each coat he proposes to apply. He shall also make available information as to the
total amount of paint that he expects to use for each coat of each system for which procedure trials are required.
The calculation of the amount of paint to be used shall be based on the volume solids plus an allowance for waste.
7 (05/01) The following requirements on paint film thicknesses shall apply:
(i) Wet film thickness gauges shall be used where practicable to check that the wet film thickness is not less
than:
minimum dry film thickness (mdft) x 100
volume solids %
(ii) During the application of a paint system the Contractor shall ensure that the progressive total
(05/05)
thickness of the applied coats shall allow the specified minimum total dft of the system to be attained
without exceeding, overall, the proposed wet film thicknesses referred to in sub-Clause 6 of this Clause
by more than 20%.
(iii) (05/05)In no case shall the total dry film thickness of a paint system or the mdft of the last undercoat and
finish be less than that specified in Appendix 19/1 Form HA/P1 (New Works) Paint System Sheet.
(iv) The local dry film thickness for any primer shall not exceed the specified mdft by more than 30% and
for other paints by more than 75%.
8 (08/14) Each coat of paint of a specified system shall have satisfactory adhesion which shall be determined by
testing to ASTM D4541 – Type III. A minimum value of 52 kgf/cm2 (750psi) shall be achieved before any paint
film detachment occurs. The satisfactory adhesion of the coating system shall be confirmed by representative
testing. Damage resulting from the adhesion testing shall be restored in accordance with Clause 1907.
9 (08/14) Each applied specified paint coat shall be free from defects, including bloom, cratering, pin-holing,
blistering, rivelling, sagging, bittiness, dry spray and cissing etc. The presence of these defects shall be determined
by unaided visual assessment supplemented by other appropriate test methods. The presence of pin-holing or
porosity in the completed paint system, except at corners, bolted joints or welds, shall be determined by using low
or high-voltage detectors in accordance with ASTM G62-07. The finished system shall have an even and uniform
appearance with no defects and the finishing paint in visually sensitive areas shall be from the same batch.
Amendment – August 2014 --`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`--- 31

10 (05/05) The gloss level of the finishing coat shall be established before the procedure trials. A painted tin plate
reference panel, 150 mm x 100 mm, shall be provided by the Contractor for this purpose.
11 (08/14) All successive coats in a system including the stripe coats shall be contrasting colours to aid
identification.
12 (08/14) Before starting the procedure trials described in Clause 1915, the Contractor shall provide a reference
panel, coated with the stepped-back paint system to indicate the contrast between each coat of paint.
Stripe Coats
13 (08/14) Stripe coats shall be applied to all welds and all fasteners including washers and to all external corners
except those of RHS. The first stripe coat, using second undercoat paint, shall be applied over the primer, sealer or
adhesion promoter. When a second stripe coat is specified in Appendix 19/5, it shall be separated from the first
stripe coat by an undercoat. All stripe coats shall be applied by brush.
A solvent shall be used to remove all traces of oil and grease from fasteners before treatment with an adhesion
promoter.
The Contractor shall enter the details of the stripe coats he has selected in Appendix 19/1 Form HA/P1 (New
Works) Paint System Sheet giving the Item No., colour and method of application.
14 Square solid infill bars shall, after the second undercoat has been applied, be given an extra coat of first
undercoat in lieu of stripe coats.
Exposure Times for Prepared Steel Surfaces and for Metal Coatings.
(05/01) Exposure Times and Treatment of Item 155 and Overcoating Times for Paints
15 Clean steel prepared by dry blast cleaning or bright steel prepared by abrading or by grinding shall be primed
within 4 hours.
16 Clean steel prepared by wet blast cleaning only, shall be primed within 4 hours of being dry enough for
painting.
17 Clean steel prepared by combined wet/dry blast cleaning shall be primed within 4 hours of dry blast cleaning.
18 (08/14) Steel or steelwork blast cleaned and primed at the mills or in the workshop shall be overcoated within 8
weeks. The primed surfaces shall only be exposed outside for a maximum of 2 weeks of the 8 week period.
Prepared surfaces affected by detrimental contamination or corrosion shall be restored before overcoating.
19 (05/05) Workshop steelwork which has been thermally metal sprayed shall be primed and sealed within 4 hours.
The next coat shall be applied within 72 hours.
20 (08/14) Workshop prepared steel surfaces, unsealed thermally sprayed aluminium metal coating and undercoats,
except final workshop undercoat, shall not be exposed outside.
21 (05/01) All surfaces treated with Item 155, except those of fasteners which have been treated in compliance with
sub-Clause 1906.3, shall, after initial drying, be wet cleaned in compliance with sub-Clause 1903.9, taking care not
to remove adhering Item 155, and allowed to dry before overcoating. The first coat of paint shall be applied within
48 hours of the surfaces treated with Item 155 being first dry enough for painting over.
22 (08/14) When hot dip galvanized steel is to be protected by a paint system, the adhesion promoter shall be
applied not later than 14 days after delivery to site.
23 (08/14) When hot dip galvanized steelwork is to be erected in a Marine environment and is to be protected by a
paint system, the adhesion promoter and the workshop coats shall be applied within 7 days after hot dip
galvanizing.
24 (05/05) A first workshop undercoat shall be overcoated within 72 hours. Further shop coats shall be applied
within 72 hour intervals per coat.

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25 (05/01) The application of sealant in gaps, in compliance with sub-Clause 1906.27, may be carried out either
before or after application, as appropriate, of the first coat of paint to be applied to the completed joints or
assembled plies.
26 (08/14) Prepared steel surfaces and thermally sprayed aluminium metal coatings which have been restored, also
paint coats and hot dip galvanizing which have been prepared after surface damage or deterioration shall be
overcoated with the sealer primer or first undercoat as appropriate before the surfaces have been affected by
moisture and in any case within 4 hours.
27 (08/14) On site, steel surfaces and thermally sprayed aluminium metal coating shall be primed or sealed within 4
hours and shall have the following coat applied within 72 hours. The next coat shall be applied within a further 72
hours. Finish coats shall be applied within 7 days of application of the preceding undercoat.
1915 Procedure Trials

1 (08/14) Unless otherwise described in Appendix 19/5, the Contractor shall carry out workshop and site
procedure trials of the protective system when more than 50 litres of any coat of paint are to be applied to ‘Difficult
Access’ road-bridge, footbridge and gantry steelwork.
Procedure trials are not required for systems applied to joints or for hot dip galvanizing only. The procedure trials
shall be completed at least ten days before the start of application of the systems on the main steelwork. The trials
shall be carried out with the labour, methods and equipment to be used for the work.
2 (08/14) The Contractor shall provide for the workshop trials, samples of steel from 2 m² to 10 m² representing
the main steelwork, hot dip galvanized when necessary. The Contractor shall demonstrate his ability to carry out
surface preparation by blast cleaning and by using power assisted tools, to apply thermally sprayed aluminium
metal coating where specified, and the paints he has selected. The Contractor shall provide sufficient paint for the
trials in containers of the size to be used for the works.
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3 (08/14) Thermally sprayed aluminium metal coating application and painting of the main steelwork shall not be
started in the workshop or on site until procedure trials have been completed satisfactorily.
4 Any adjustment to the registered paint formulations shown to be required by the trials, other than an
adjustment to the solvent shall be agreed with the Overseeing Organisation and made at the paint manufacturer’s
works.
5 The Contractor shall carry out further procedure trials whenever he employs replacement skilled labour or
proposes to use equipment of a different type.
1916 Storage and Transport of Steel and Fabricated Steelwork

1 (05/05) Steel awaiting fabrication for the works and uncoated steelwork shall be adequately protected from
contaminants liable to cause heavy rusting and possibly pitting of the surfaces.
2 Steelwork shall not be loaded for transport until the paint system is sufficiently hard for handling.
3 During storage, steelwork shall be kept clear of the ground and shall be laid out or stacked so as to prevent
water or dirt accumulating on or against any of the surfaces. Suitable packings shall be placed between layers of
stacked steelwork. When cover is provided it shall be ventilated sufficiently to keep condensation to a minimum.
4 Components weighing less than one tonne shall be kept in a storage area away from their erection point in
order to minimise damage to protective coatings.
5 (11/03) Lengths of parapet and individual steel lighting columns and masts shall be supported on timber, and
precautions taken to prevent damage to their protective coatings and ingress of water. They shall only be positioned
adjacent to their erection point immediately before erection. If the planned erection time is delayed by more than 72
hours the components shall be returned to the storage area.

6 (05/05) Hot dip galvanized components shall be transported and stored under dry and well ventilated conditions,
to avoid wet storage staining. If stored outdoors, close contact of surfaces of components shall be avoided, and
suitable packing shall be placed between components, and to keep the components clear of the ground. Components
shall be stored wherever possible at a slight angle to allow water run off. When cover is provided it shall be
ventilated sufficiently to keep condensation to a minimum.
7 If damage to coatings is excessive, or may be difficult to deal with satisfactorily after erection, the Contractor
shall restore the coatings before erection.
1917 (05/01) Surfaces in Contact with Concrete

1 (08/14) Unless otherwise described in Appendix 19/5 or in Series 1800,1810.7 if applicable, thermally sprayed
aluminium metal coating and all workshop paint coats shall be returned 50 mm into the concrete/steelwork contact
area.
2 Where aluminium metal spray, which has been sealed only, is returned into the contact area, it shall be given a
coat of Item 110 of 30 microns mdft, not later than 48 hours before concreting. Application of the paint outside the
contact area shall be prevented, by masking if necessary.
3 (08/14) Hot dip galvanized coatings shall be applied overall. Unless otherwise described in Appendix 19/5 or in
Series 1800,1810.7 if applicable, concrete may come into direct contact with the hot dip galvanized surfaces.
1918 (05/01) Form HA/P1 (New Works) Paint System Sheet (Appendix 19/1)
Form HA/P2 Paint Data Sheet (Appendix 19/3)
1 (05/05) As soon as the Contract has been awarded the Contractor shall prepare and make available a copy of
Form HA/P1 (New Works) Paint System Sheet (Appendix 19/1), of which he shall have completed Parts 6 to 10
together with relevant copies of Form HA/P2 Paint Data Sheet (Appendix 19/3).
2 (08/14) Following any relevant approvals in accordance with the Contract and recorded in Part 11 of Form HA/
P1 (New Works) Paint System Sheet (Appendix 19/1), Forms HA/P1 (New Works) Paint System Sheet (Appendix
19/1) shall be adopted for the works.
1919 Access and Lighting

1 Without prejudice to the Conditions of Contract, access for inspection shall be provided and erected by the
Contractor. The access shall be adequate in all respects for inspection purposes.
2 Manual surface preparation and coating application work shall not be carried out when light intensity at the
workface is less than 500 lux. When the natural light intensity falls below this level the Contractor shall install and
maintain temporary lighting which shall provide a minimum light intensity of 500 lux over at least 1.0 m² at the
workface during the work and also for inspection when required.
#1920 (05/01) Additional Requirements for the Protection of Steel in Bridge Bearings
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Applicable Clauses
1 (08/14) Unless otherwise described in Appendix 19/5, the work described in this Clause shall be carried out in
compliance with Appendix 19/1 and with Clauses 1901 to 1919, and the following:
Supply of Coatings
2 (05/05) Information, including the name of the paint manufacturer, required for completing Form HA/P1 (New
Works) Paint System Sheet (Appendix 19/1), for the bearings, shall be obtained by the Contractor from the bearing
manufacturer.

3 (08/14) Item 155 and Epoxy MIO paints when required for application on site shall be obtained from the
manufacturer of the workshop applied coats. Paint applied to the bearings on site to match the bridge steelwork
paint system shall be obtained from the manufacturer of that system.
1921 (11/03) Additional Requirements for the Protection of CCTV Masts, Cantilever Masts,
Steel Lighting Columns and Bracket Arms
Applicable Clauses
1 Unless otherwise described in Appendix 19/5, the work described in this Clause shall be carried out in
compliance with Appendix 19/1 and with Clauses 1901 to 1919 and the following:
Surface Preparation
2 (05/05) In the workshop, any CCTV mast, steel lighting column or component material, the surfaces of which
show rust pitting when viewed by normal vision after surface preparation, shall be discarded and not used for the
works.
3 (11/03) On site, any CCTV mast, cantilever masts, steel lighting column and bracket arms or component
material, the internal surfaces of which show rust pitting when viewed by normal vision after surface preparation,
shall be discarded and not used for the works.
Stripe Coats
4 (08/14) For CCTV Masts, cantilever masts and steel lighting columns and bracket arms, only one stripe coat in
undercoat paint is required. For protective system Types A2 and G2, the stripe coat shall be applied before the last
undercoat of the total protective system, in the workshop or on site as appropriate. All stripe coats shall be applied
by brush.
Adhesion Strength of Aluminium Metal Spray
5 (08/14) For aluminium metal sprayed CCTV masts, cantilever masts and steel lighting columns and bracket
arms, the strength of adhesion of thermally sprayed aluminium metal coating to the steel shall not be less than 35
kgf/cm² when tested by means of a tensile test in accordance with BS EN ISO 2063.
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Amendment – August 2014 35F


1911SE (05/01) Paint and Similar Protective Coatings

1 The term paint shall be deemed to refer also to similar protective coatings including specialist coatings such as
grease paints.
2 (05/05) The paints permitted for use by the Overseeing Organisation in the works are listed in the Manual of
Paints for Structural Steelwork, which is included in BD 35 (DMRB 2.4.1) and which also contains details of the
quality assurance scheme for paints and similar protective coatings. All paints shall have a current BBA HAPAS
Roads and Bridges Certificate or equivalent.
3 All paints shall be supplied in sealed containers of not more than 5 litre capacity and these shall be used in
order of delivery. Each container shall be of the completely removable lid type and be clearly marked on the side to
show the name of the manufacturer, registered description of the material (including purpose, eg whether primer,
undercoat or finish), colour, Item No, paint manufacturer’s reference number, batch number and date of
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manufacture. Where date of manufacture is coded, the Contractor shall provide the code key.
4 (05/05) The Contractor shall ensure that the properties of the paints he has selected are suitable for the
conditions in the workshop and on site, including temperature and humidity, and that he is able to apply the paints
satisfactorily to all parts of the structure in these conditions.
5 (05/05) Unless otherwise described in Appendix 19/5, all paints forming any one protective system, or
overlapping systems, shall be obtained from the same manufacturer, as named by the Contractor in Form HA/P1
(New Works) Paint System Sheet (Appendix 19/1).
6 (05/05) The requirements of sub-Clauses #1911.5, 6 and 7 and their respective Tables shall apply in Scotland.
1912SE (05/01) Testing of Paints

1 (05/05) Unless otherwise described in the Contract, the Contractor shall provide unopened 5 litre samples,
known as ‘A’ samples, of each type of paint to be used in the works for testing for quality assurance purposes. ‘A’
samples shall be taken from the first batch of each type of paint delivered to the fabricator’s workshop or site. In
addition, during the painting work, the Contractor shall supply 500ml samples, known as ‘B’ samples taken from
painters’ kettles or from nozzles of airless spray guns directly into clean new tins. For two-pack systems separate
unmixed samples of the base and activator shall be dispatched by the Contractor to the testing authority, approved
2 Depending upon the importance of the proposed painting application, the Overseeing Organisation may elect
to have ‘A’ samples sent for limited testing by a local paint testing firm or other agency approved by the Overseeing
Organisation. Appropriate forms for use in connection with limited testing shall be derived from the standard paint
forms and shall be agreed with the Overseeing Organisation.
3 (05/05) The Contractor shall supply paint in sufficient time to allow for sampling and testing of ‘A’ samples at
least 3 weeks prior to the start of application. The Contractor shall be responsible for handling, provision of clean
tins for samples, packing as necessary, and prompt despatch and transit of all samples for testing.
4 (05/05) ‘A’ and ‘B’ samples are tested for paint composition and/or properties against the original formulation
issued by the paint manufacturer to the certifying body.
5 (08/14) The requirements of sub-Clauses #1912.12, 13 and 14 shall apply in Scotland.
6 Except for procedure trials painting shall not start until the first of the ‘A’ samples are confirmed as
satisfactory.
Amendment – August 2014 S1

1920SE (05/01) Additional Requirements for the Protection of Steel in Bridge Bearings
Applicable Clauses
1 Unless otherwise described in the Contract, the work described in this Clause shall be carried out in
compliance with Appendix 19/1 and with Clauses 1901 to 1919 inclusive.
Supply of Coatings
2 (05/05) Information, including the name of the paint manufacturer, required for completing Form HA/P1 (New
Works) Paint System Sheet (Appendix 19/1), for the bearings, shall be obtained by the Contractor from the bearing
manufacturer.
3 (05/05) Item 155 and MIO Epoxy paints when required for application on site shall be obtained from the
manufacturer of the workshop applied coats. Paint applied to the bearings on site to match the bridge steelwork
paint system shall be obtained from the manufacturer of that system.
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Amendment – August 2014 S2F

SERIES 2000
WATERPROOFING FOR CONCRETE
STRUCTURES
Contents
Clause Title Page
2001 (05/01) General 2

2002 Protection of Bridge Deck
Waterproofing During
Construction 2
2003 (05/01) Materials for
Waterproofing Concrete Bridge
Decks 2
2004 Materials for Waterproofing
Below Ground Concrete
Surfaces 2
2005 (05/01) Workmanship for
Waterproofing Concrete Bridge
Decks 3
2006 Workmanship for Waterproofing
Below Ground Concrete Surfaces 3
2007 (05/01) Integrity Testing of
Concrete Bridge Deck
Waterproofing 4
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2008 (05/01) Repair and Replacement
of Bridge Deck Waterproofing 4

Specification for Highway Works Waterproofing for Concrete Structures
WATERPROOFING FOR CONCRETE STRUCTURES
2001 (05/01) General 2003 (05/01) Materials for Waterproofing

Concrete Bridge Decks
1 The surface finish for new bridge decks between
parapet upstands and to top of buried structures to be
Permitted Waterproofing Systems
waterproofed shall be Class U4 finish in accordance
with sub-Clause 1708.4. 1 Permitted waterproofing systems incorporated in
2 Existing waterproofing systems to bridge decks the Permanent Works shall have a current BBA (British
between parapet upstands are to be repaired or replaced Board of Agrément) Roads and Bridges Agrément
in accordance with Clause 2008. Certificate which shall be registered with the
Prior to commencement of the Works the Contractor
2002 Protection of Bridge Deck shall provide to the Overseeing Organisation a copy of
Waterproofing During Construction the BBA Roads and Bridges Agrément Certificate
1 (05/01) On any structure, providing no damage appropriate to the work to be undertaken. The
results, plant and equipment all fitted only with rubber procedure shall be repeated for each subsequent
tyres may stand or travel on permitted waterproofing operation either for a different system or a different
systems solely for the purposes of laying an additional location.
protective layer or surfacing course on that structure.
Additional Bituminous Protection
Rollers shall not be permitted to stand or travel directly
on the waterproofing system. 2 (11/04) Bituminous protection where required as an
additional protective layer, shall comply with
Where it is necessary for plant, equipment or traffic to BS 594-1 recipe type F surface course mixture
stand or travel on a bridge deck that has been designation 0/2 except that 5% ± 0.5% of the total mix
waterproofed with a permitted system before the laying shall be inorganic red oxide and regarded as part of the
of an additional protective layer, suitable temporary filler content, where the additional protective layer is
protection shall be provided. All such plant and required to be tinted.
equipment shall have its tyre treads regularly inspected
and any embedded hard objects removed.
2 Temporary protection shall be provided where 2004 Materials for Waterproofing Below
damage to the waterproofing, protective layer or Ground Concrete Surfaces
additional protective layer could result from particular
site traffic. Primer for Tar and Bitumen
3 (05/01) The protective layer of a permitted two layer 1 Primer for sealing concrete surfaces prior to
waterproofing system, or any protective layer additional waterproofing shall be compatible with the selected tar
to that included as part of a permitted waterproofing or bitumen waterproofing material. The viscosity of the
system, shall be laid immediately after the primer shall be such that it penetrates the concrete
waterproofing layer’s bonding agent has set or cured. without forming a skin.
Where a waterproofing membrane also serves as an
Tar
adhesive for the protective layer, any additional
protective layer shall not be laid until the liquid 2 Tar shall comply with BS 76 of viscosity grade
waterproofing membrane/adhesive has set or cured. within the range 30-38°C equi-viscous temperature.
Cut Back Bitumen

3 Cut back bitumen shall comply with
BS 3690 : Part 1 of viscosity grade 50 seconds.
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Proprietary Materials Bond Between Additional Protective Layer or

Surfacing and the Waterproofing System
4 (05/01) Subject to any restrictions specified in
Appendix 20/1, proprietary materials may be used. 5 The additional protective layer or surfacing laid on
the waterproofing system shall be fully bonded to the
system for the life of the system. The bond shall be
2005 (05/01) Workmanship for Waterproofing achieved by either:
Concrete Bridge Decks
(i) the binder within the directly applied
additional protective layer or surfacing; or
Permitted Waterproofing Systems
(ii) a separate tack coat which has been assessed
1 Permitted waterproofing systems shall be supplied by the BBA as part of the registration
and installed in accordance with the BBA Roads and procedure and details of which are given on
Bridges Agrément Certificate. the BBA Roads and Bridges Agrément
The formation of defects affecting the integrity of the Certificate.
membrane including pin/blow holes (continuous or Where the tack coat is of the type activated by the heat
non-continuous) and blisters in the waterproofing shall: of the succeeding bituminous layer the rolling
(i) be made good by repair in accordance with temperature of this layer shall be sufficient to ensure
the BBA Roads and Bridges Agrément adhesion.
Certificate before any subsequent layers are
applied; or
2006 Workmanship for Waterproofing Below
(ii) require the system to be replaced. Ground Concrete Surfaces
For sheet membranes bonded with oxidized bitumen the
heating and temperature of the bitumen shall comply Priming for Tar and Bitumen
with the manufacturer’s requirements within the limits
1 (05/01) Unless otherwise described in
stated in BS 8000 : Part 4.
Appendix 20/1 and prior to the application of the
A means of checking the bitumen temperature shall be selected tar or bitumen waterproofing, concrete surfaces
provided. shall be thoroughly sealed with an evenly applied
Sheet membranes shall wherever possible be laid in the primer. The primer shall be well brushed in and not
direction that the additional protective layer or allowed to pond in any depressions.
surfacing will be laid and compacted by roller.
Tar
2 Unless otherwise specified in the BBA Roads and
Bridges Agrément Certificate, joints between sheets 2 For tar waterproofing two coats of tar shall be hot
shall be lapped with end laps of at least 150 mm and applied at a rate of spread per coat of 1 litre/m². The
side laps of at least 100 mm. The joints shall be first coat shall be allowed to dry before the second coat
arranged so that: is applied.
(i) at no point are there more than three Cut Back Bitumen
thicknesses of sheeting and,
3 For bitumen waterproofing two coats of cut back
(ii) water will drain away from the exposed bitumen shall be hot applied at a rate of spread per coat
edge.
of 0.6 litre/m². The first coat shall be allowed to dry
3 Permitted waterproofing systems shall be laid to before the second coat is applied.
follow the contours of the concrete surface. Laps,
ridges and ripples in waterproofing sheeting, and peaks Proprietary Materials
and steps at butt joints in waterproofing boards, shall
not be greater than 10 mm in height. 4 (05/01) For proprietary materials the method of
application, rate of spread, number of coats and other
Additional Bituminous Protection requirements for each system shall be as described in
the product literature supplied by the manufacturer.
4 Bituminous protection complying with
sub-Clause 2003.2 shall be laid on the clean and dry
substrate, and compacted in accordance with Clause
901 to the areas and thickness shown on the Drawings.

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2007 (05/01) Integrity Testing of Concrete

Bridge Deck Waterproofing
1 Waterproofing systems to concrete bridge decks
shall be tested where required in Appendix 20/1 in
accordance with the requirements therein to verify the
integrity of the waterproofing.
2008 (05/01) Repair and Replacement of Bridge

Deck Waterproofing
1 The repair and replacement of existing bridge deck
waterproofing systems shall comply with the
requirements of Clauses 2002, 2003, 2005 and 2007
and any additional requirements described in
Appendix 20/1.
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SERIES 2100
BRIDGE BEARINGS
Contents
Clause Title Page
2101 (02/16) General 2F
(02/16) Surface Preparation and
2102
Protection Against Corrosion 2F
2103 (02/16) Bedding Mortars 2F
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Specification for Highway Works Bridge Bearings
BRIDGE BEARINGS
2101 (02/16) General
2 (02/16) Bridge bearings shall be in accordance with this Series and contract specific Appendix 21/1. They
shall conform to BS EN 1337 and the Contractor shall submit a Declaration of Performance for each bearing to
the Overseeing Organisation a minimum of four weeks prior to the installation of the bearing. The Declaration of
Performance shall demonstrate that the bearing meets the requirements of the relevant part of BS EN 1337 and the
performance requirements stated in contract specific Appendix 21/1.
3 (02/16) The system of ‘attestation of conformity’ or ‘assessment and verification of consistency of performance
(AVCP)’ as detailed in Annex ZA of the relevant part of BS EN 1337 shall be that which has intended use
requirements on individual bearings which are critical.
4 (02/16) The Contractor shall undertake the design of bearings detailed in contract specific Appendix 1/10. The
design shall be in accordance with requirements stated in contract specific Appendix 21/1.
5 (02/16) The Contractor shall undertake the contract compliance testing detailed in contract specific Appendix
1/5 in accordance with requirements given in contract specific Appendix 21/1.
6 (02/16) The Contractor shall provide reports on the transport, storage and installation of the bearings
installed and information on the required maintenance, in accordance with the relevant parts of BS EN 1337 and
requirements given in contract specific Appendix 21/1. This shall include identifying any requirements for the
bearings to be replaced in the future. The reports shall be submitted to the Overseeing Organisation within the
timescale stated in contract specific Appendix 21/1. The reports shall include the following as appropriate:
(i) details of clamping required during transport, storage and lifting;
(ii) details for protection measures for improved durability, including skirts, concertinas or housing
assemblies, this shall include details of how to remove, maintain or replace these for inspection and/or
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maintenance of the bearing;
(iii) installation and removal methods, including sequences and timings;
(iv) as installed information, including confirmation of removal of any temporary measures for example,
transit bolts or props;
(v) specific maintenance requirements, including cleaning, grease, measurements, and the required intervals.
2102 (02/16) Surface Preparation and Protection Against Corrosion

1 (02/16) Unless otherwise stated in contract specific Appendix 21/1, the surface preparation and corrosion
protection of bearings shall comply with Series 1900
2103 (02/16) Bedding Mortars

1 (02/16) Bedding mortars shall be in accordance with Clause 2601.

SERIES 2200
NOT USED (05/04)
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SERIES 2300
BRIDGE EXPANSION JOINTS AND
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SEALING OF GAPS
Contents
Clause Title Page
2301 General 2
2302 Installation of Bridge Deck
Expansion Joints 2
2303 Sealing of Gaps 2
2304 Protective Treatment 3
March 1998 1
Specification for Highway Works Bridge Expansion Joints and Sealing of Gaps
BRIDGE EXPANSION JOINTS AND SEALING OF

GAPS
2301 General parallel, as described in Appendix 23/1. Seals which are

not held in metal runners shall remain in compression
1 Bridge deck expansion joints, and sealing of gaps for the full range of joint movement.
in bridges and structures shall be as described in
Appendices 23/1 and 23/2 respectively and shall 6 Expansion joints shall be of uniform width and
comply with the requirements of this Series. straight alignment and shall be accurately set and
finished and aligned with the finished surface.
2 (05/01) Only bridge deck expansion joints which
have been registered with the Overseeing Organisation 7 During the placing and hardening of the bedding
in accordance with the requirements of BD 33 shall be and bonding materials, movement between the joint and
incorporated into the Works. the substrate shall be prevented.
3 Storage and installation of joints, jointing 8 Where required in Appendix 23/1, subsurface and
materials, sealants and other associated items shall be in below-joint drainage systems shall be designed,
accordance with the manufacturer’s recommendations. provided and installed in accordance with the
requirements therein, and the joint manufacturer’s
4 The same joint system, seal or sealant shall recommendations. The complete drainage system shall
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continue across the full width of the deck including be accessible for cleaning and, on completion of the
footway, verge, hard strip, hard shoulder and central joint, the drainage system shall be checked and cleared
reserve. Different joint systems shall not be combined of any obstructions.
at one end of a deck unless otherwise specified in
Appendix 23/1. 9 Before vehicles traffic the joints, temporary covers
capable of withstanding vehicular loading shall be
provided over expansion joints during and after their
2302 Installation of Bridge Deck Expansion installation as appropriate for protection.
Joints
1 The positioning of holding down bolts and 2303 Sealing of Gaps
anchorage systems shall be checked for accuracy before
the casting of concrete commences. Templates or 1 Sealant materials and water stops shall be as
shuttering shall be fixed to box out the concrete for the described in Appendix 23/2. Joint filler board in any
joint and to locate holding down bolts or anchorage gaps shall comply with Clause 1015.
pockets. Threaded parts shall be protected, kept clean 2 Joint filler board and sealant materials shall be
and free from rust. compatible.
2 Where the surfacing and bridge deck waterproofing 3 Gunned or poured sealants shall be placed when
are to be removed to accommodate the bridge joint the temperature of the structure is such that any
these shall be cut to a clean straight line for the full movements which may take place will not cause the
depth of the surfacing without damage to the concrete strain in the sealant to exceed the maximum value
substrate. recommended by the manufacturer.
3 Before installation of the joint, the concrete 4 Immediately before sealing, the Contractor shall
surfaces shall be free from laitance, sound, clean and ensure that the sides of the joint gap are clean, dry and
comply with the manufacturer’s requirements. free from loose material. Any concrete projections into
4 The expansion joint and the bridge deck the gap shall be removed.
waterproofing shall be formed so that a watertight seal 5 Where a bond breaker in the form of a
is provided. Where prefabricated units are used, the seal compressible strip is placed between the filler board
between each unit shall be made watertight and in and the sealant it shall be compatible with both
addition a secondary waterproofing system in the form materials.
of a continuous membrane shall be installed.
6 All seals shall, where practicable, be poured or
5 The gap width shall be set, in relation to the fixed in one continuous length. Where required, a joint
prevailing deck temperature, with the joint gap sides

Specification for Highway Works Bridge Expansion Joints and Sealing of Gaps
in a seal shall be located and formed in accordance with

the manufacturer’s instructions.
7 Where gunned or poured sealants are visible, the
concrete shall be masked on either side of the joint with
suitable tape prior to the placement of the sealant to
prevent its adherence to the exposed concrete surface.
The tape shall not stain the concrete surface.
2304 Protective Treatment

1 Surface preparation and protection of metal
components of expansion joints shall be in accordance
with the joint manufacturer’s recommendations unless
otherwise specified in Appendix 23/1.
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SERIES 2400
BRICKWORK, BLOCKWORK AND
STONEWORK
Contents
Clause Title Page
2401 Cement 2
2402 Aggregates 2
2403 Water 2
2404 Mortar 2
2405 Lime Mortar 2
2406 (05/05) Masonry Units (Bricks) 2
2407 Blocks 3
2408 Reconstructed Stone 3
2409 Natural Stone 3
2410 Reinforcement 3
2411 Anchorages, Dowels, Fixings
and Ties 3
2412 Brickwork and Blockwork 3
2413 Stonework 3
2414 Cold Weather Working 4
2415 Protection of New Work 4
2416 Brick, Block and Stone, Facework
Fixed to Concrete 4
(05/05) Brick and Other Works for Unreinforced
Masonry Arch Bridges
2417 (05/05) Unreinforced Masonry
Arch Bridges 4
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Specification for Highway Works Brickwork, Blockwork and Stonework
BRICKWORK, BLOCKWORK AND STONEWORK
2401 Cement mortar from one of the mixes for the designation given
in Table 24/1. If the work is to be carried out in frosty
1 Cement shall be one of the following: weather and the bricks are wet when laid, then a cement
(i) (05/05) Portland cement conforming to sand mortar with an air entraining plasticiser shall be
BS EN 197-1; used. Admixtures shall conform to BS EN 934-3 and
any additional performance requirements stated in
(ii) (05/05) Masonry cement conforming to Appendix 24/1 and shall not contain calcium chloride.
BS EN 413-1;
(iii) (05/05) Sulfate-resisting Portland cement TABLE 24/1: Mortar Proportions by Volume
conforming to BS 4027 where described in
Mortar Cement: Masonry Cement:
Appendix 24/1. designation lime: sand cement: sand sand with
plasticiser
2402 Aggregates (i) 1:0 to 1/4:3 - -

(ii) 1:½:4 to 4½ 1:2½ to 3½ 1:3 to 4
1 (05/05) Fine aggregate shall conform to (iii) 1:1:5 to 6 1:4½ 1:5 to 6
BS EN 13139.
4 (05/05) The inclusion of lime in mortar designation

2403 Water (i) is optional. The proportions of lime given in
Table 24/1 are for lime putty conforming to
1 (11/03) If water for the Works is not available from a BS EN 459-1. If the lime is measured as the dry
water company’s supply, the Contractor shall ensure hydrate, the amount may be increased up to 1.5
that the water complies with the guidance given in volumes for each volume of lime putty. Where a range
BS EN 1008. The sulfate content of the water shall be of sand contents is given in Table 24/1, the higher shall
tested in accordance with Test No. 1 in TRL Report be used for sand that is well graded and the lower for
447. The water shall not be used if the sulfate content coarse or uniformly fine sand.
exceeds 1.4 g of sulfate (as SO4) per litre. Water from
the sea or tidal rivers shall not be used. 5 Mortar shall be mixed thoroughly either by hand or
mechanically until its colour and consistency are
uniform. The constituent materials shall be accurately
2404 Mortar gauged, allowance being made for bulking of sand.
Mortar shall be made in small quantities only as and
(05/05) Mortar Work
Other Than Unreinforced when required. Mortar which has begun to set or which
Masonry Arch Bridges has been mixed for a period of more than one hour in
the case of a mortar designation (i) or more than two
1 Cement mortar for brickwork, blockwork and hours in the case of other designations shall be
stonework shall be mixed in the proportions given in discarded.
Table 24/1 according to the mortar designation
described in Appendix 24/1. 6 (05/06) A set of mortar prisms shall be made for
each type of mortar designated to be used and shall be
2 (11/03) The chloride ion content of the mortar tested in accordance with sub-Clause 2417.9.
determined in accordance with BS EN 1744-1 shall not
exceed 0.3% of the mass of cement for mortar made
with Portland cement and 0.2% for mortar made with 2405 Lime Mortar
sulfate-resisting Portland cement. Calcium chloride or
admixtures containing calcium chloride shall not be 1 (05/05) Lime mortar shall consist of one part by
used. volume of hydrated lime conforming to BS EN 459-1 to
2.5 parts by volume of sand.
3 (05/05) For work in which cement mortars of
designation (ii) or (iii) as defined in BS 5628-3 are
required, the Contractor shall select the appropriate
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2406 (05/05) Masonry Units (Bricks) 2408 Reconstructed Stone

Brick Work Other than Unreinforced
(05/08) 1 (05/08) Reconstructed stone shall be used only in
Masonry Arch Bridges blockwork and shall comply with BS EN 771-5 and any
particular requirements described in Appendix 24/1.
1 (05/05) Clay masonry units (bricks) shall conform to
the particular requirements of BS EN 771-1 as
described in Appendix 24/1. The determination of 2409 Natural Stone
sulfate content for the soluble salt content test shall be
in accordance with Test No. 2 in TRL Report 447. 1 Building stone shall be of the type and quality
2 (05/08) Calcium silicate bricks (sand lime and flint
lime) shall comply with BS EN 771-2.
3 (05/08) Bricks beneath frames for chambers and 2410 Reinforcement
gullies, and for the construction of brick chambers, 1 (11/03) Wire or fabric, laid between brickwork or
shall, unless otherwise described in Appendix 24/1, be blockwork shall be stainless steel to BS EN 10088-1,
HD type Class B clay engineering bricks conforming to designation 1.4301, 1.4401 or 1.4436, softened
BS EN 771-1 and the performance characteristics given condition, excluding free machining specifications.
in Table 24/2:
2 (05/05) Steel bars laid between brickwork or
TABLE 24/2: (05/05) Performance Characteristic blockwork shall be stainless steel to BS 6744,
Requirements designation 1,4301 or 1,4436, softened condition,
excluding free machining specifications.
Performance Reference Clay engineering
characteristic bricks
Class B 2411 Anchorages, Dowels, Fixings and Ties
Compressive strength (N/ BS EN 772-1 ≥ 75
1 (05/05) Anchorages, dowels, fixings and ties shall be
mm2)
stainless steel designation 1.4301, 1.4401 or 1.4436,
Water absorption (% by BS EN 772-7 ≤ 7,0 (and softened condition, excluding free machining
mass) and also when used DPC2) specifications, complying with the requirements given
as DPC units in the British Standards listed in Table 24/3.
and and and
Net dry density (kg/m3) BS EN 772-13 ≥ 2100 TABLE 24/3: (05/06) Austenitic Stainless Steel
Freeze/thaw resistance BS EN 772-1 F2 Form Standard to be complied with
category
Strip BS EN 10029, BS EN 10048, BS EN 10051,
Active soluble salts BS EN 772-5 S2
BS EN 10258, BS EN 10259
content category
Rod BS EN 10088-1
Bar BS 6744
or concrete bricks or blocks conforming to
BS EN 771-3 and BS EN 772-2 having an average Tube BS EN 10296-2
crushing strength value of not less than 20 N/mm² when Wire BS EN 10088-3
used for surface water drainage, or special purpose
concrete bricks having a minimum cement content of
350 kg/m3 when used for foul drainage. 2412 Brickwork and Blockwork
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1 Brickwork and blockwork shall be laid on a full

2407 Blocks bed of mortar and bonded as described in
Appendix 24/1. Single frogged bricks shall be laid with
1 (05/08) Concrete blocks shall comply with the the frog uppermost. Perpends between bricks and
particular requirements of BS EN 771-3 and blocks shall be filled with mortar before the next mortar
BS EN 772-2 as described in Appendix 24/1. bed is laid. Whole bricks and blocks shall be used
except where it is necessary to cut closers.
2 Brickwork and blockwork shall be built uniformly.
Corners and other advanced work shall be stepped back
and not raised above the general level more than

900 mm. Courses shall be kept horizontal and matching 900 mm into the wall or for the full thickness of the
perpends shall be in vertical alignment. wall if the latter is less than 900 mm. Unless described
in Appendix 24/1 as tooled or worked, the exposed face
3 Unless stated in Appendix 24/1, overhand work
of all stone shall be blocked and left rough. Arrises shall
shall not be permitted.
be dressed square at all beds and joints.
4 Bed-joint reinforcement shall have a 15 mm
minimum of mortar cover to each masonry face. It shall Squared Random Rubble Coursed and Uncoursed
not be laid dry on a bed face, but shall be embedded
8 All stones shall be truly squared and dressed on the
within the mortar bed thickness.
beds and joints for a distance of at least 125 mm from
5 Where pointing is required in Appendix 24/1 the the exposed face. Bond stones shall be provided at the
joint shall be raked out to a depth of 12 mm and after rate of not less than one to every square metre of
the completion of the entire facework, pointed in mortar exposed face, and shall measure not less than 150 mm x
as described in Appendix 24/1. 150 mm on the face, and not less than 450 mm or the
full thickness of the wall if the latter is less than 450
6 Where jointing is required in Appendix 24/1 it shall
mm. Sneck stones shall be not less than 75 mm in any
be done as the work proceeds to the finish described in
dimension. Vertical joints shall not include more than
Appendix 24/1.
three consecutive stones, and the horizontal lapping of
the stones shall be not less than 100 mm.
2413 Stonework Random Rubble Coursed and Uncoursed
General 9 All stones shall be carefully set with a bond stone
provided at the rate of not less than one to every square
1 Except where otherwise described in
metre of exposed face. Bond stones shall measure not
Appendix 24/1, the length of any stone shall not exceed
less than 150 mm x 150 mm on the exposed face, and
three times its height. The breadth on the bed shall be
not less than 450 mm in length or the full thickness of
not less than 150 mm, nor greater than three-quarters of
the wall if the latter is less than 450 mm unless
the thickness of the wall.
otherwise described in Appendix 24/1. For coursed
2 All stratified stone possessing bedding planes shall work the joints shall be levelled as described in
be laid with its natural bed as nearly as possible at right Appendix 24/1 and the backing flushed up in mortar.
angles to the direction of load. In the case of arch rings,
the natural bed shall be radial. Dry Rubble
3 Facework quoins shall be built to a height not 10 Dry rubble stonework shall be constructed
exceeding 900 mm in advance of the main body of the generally to the requirements of uncoursed random
work and adjacent walling stepped down on either side. rubble stonework, as specified in sub-Clause 9 of this
Clause but without mortar. All stones shall be carefully
4 Stone facework between the quoins shall then be
shaped to obtain a close fit at all beds and joints, any
built to a height not exceeding 450 mm above the
interstices between the stones being filled with selected
backing which shall then be brought up level with the
stone chippings or spalls. The exposed tops or copings
completed facework. At no time shall the backing be
of dry rubble walls shall be formed as shown on the
built up higher than the facework.
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Drawings.
5 Except for dry rubble walling, all joints shall be
sufficiently thick to prevent stone-to-stone contact and Special Stonework Including Quoins, Copings,
shall be completely filled with mortar. Plinths, Voussoirs etc
Ashlar 11 Special stonework shall consist of selected stones

dressed to the shapes and dimensions, and where
6 All stones shall be dressed to accurate planes on the required their faces worked, all as shown on the
beds and joints, and they shall be fair and neatly or fine Drawings.
tooled on the face as described in Appendix 24/1.
Block-in-course 2414 Cold Weather Working
7 Beds and joints shall be squared and dressed for a 1 (05/05) No bricks, blocks or stones shall be laid
distance of at least 225 mm from the exposed face. when the air temperature in the shade is below 3°C
Bond stones shall form not less than one sixth of the unless precautions are taken either in accordance with
area of the exposed face and shall extend at least

BS 5628-3 or to ensure that all materials when used are 4 (05/05) The variation in depth, front to back of
free from snow, ice and frost. stones for natural stone facework shall not exceed that
described in Appendix 24/1 and the space between the
facework and the backing shall be completely filled as
2415 Protection of New Work the work proceeds with concrete strength class C12/15
and a maximum aggregate size of 10 mm conforming to
1 Immediately after laying and for 3 days thereafter,
Series 1700.
brickwork, blockwork and stonework shall be protected
against the harmful effects of weather. The upper
surface of newly laid brickwork, blockwork and (05/05) Brick and Other Works for
stonework shall be protected against rain as the work Unreinforced Masonry Arch Bridges
proceeds until such time as the work is completed and
the upper damp-course, coping or other finishing
feature is laid.
2417 (05/05) Unreinforced Masonry Arch
2 (11/03) All visible brickwork, blockwork and Bridges
stonework and any surface below such work which is
visible at the completion of the Works, shall be clean General
and free from damage and spillage. All purpose-made
open joints shall be free from debris of any description. 1 The masonry and associated work requirements for
unreinforced masonry arch bridges shall conform to this
Series.
2416 Brick, Block and Stone Facework Fixed Brick Work
to Concrete
2 (05/08) Unless otherwise described in
1 Any loose material shall be removed from the Appendix 24/1, masonry units (bricks) shall be HD type
concrete, and its surface washed with clean water before Class A or Class B clay engineering bricks conforming
any bricks, blocks or masonry is laid. to the particular requirements of BS EN 771-1 and the
2 The portion of the stainless steel fixing projecting performance characteristics given in Table 24/4. The
from the concrete shall be completely embedded in the determination of sulfate content for the soluble salt
mortar of the facework and shall be kept back a content test shall be in accordance with Test No. 2 in
minimum of 30 mm from the face of the brickwork and TRL Report 447.
blockwork or 40 mm from the face of the masonry.
3 The cavity between brick and block facework and
the concrete shall be completely filled as the work
proceeds with mortar of the same mix as that specified
for the facework.
TABLE 24/4: (05/06) Performance Characteristic Requirements
Performance characteristic Reference Clay engineering bricks

Class A Class B
Compressive strength (N/mm2) BS EN 772-1 ≥ 125 ≥ 75
Water absorption (% by mass) and also when BS EN 772-7 ≤ 4,5 (and DPC1) ≤ 7,0 (and DPC2)
used as DPC units
and and and and
Net dry density (kg/m3) BS EN 772-13 ≥ 2200 ≥ 2100
Freeze/thaw resistance category BS EN 772-1 F2 F2
Active soluble salts content category BS EN 772-5 S2 S2

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3 (05/08) Concrete bricks and blocks shall conform to TABLE 24/6: (05/06) Mortar Compressive Strengths
BS EN 771-3 and BS EN 772-2 having an average
crushing strength value of not less than 30 N/mm² and a
Mortar 28-day mean compressive strength in N/mm2
minimum cement content of 350 kg/m3.
designation Minimum Maximum
4 Natural stone shall conform to BS 5628-3 and shall (i) 9.9 11.5
be selected on the basis of proven durability and
(ii) 4.1 4.7
weather resistance as described in Appendix 24/1.
(iii) 2.3 2.6
5 (05/08) Reconstructed stone shall conform to
BS EN 771-5 and the requirements stated in
Appendix 24/1. 10 In cases, such as where an existing arch with lime
mortar is being widened or where additional tolerance
6 Calcium silicate units shall not be permitted for use of movement is considered desirable, lime mortar may
in unreinforced masonry arch bridge construction. be used. In such cases the mortar shall comply with the
Mortar Work recommendations of ‘Best Practice Guide for Hydraulic
Lime Mortar for Stone, Brick and Block Masonry’.
7 Mortar shall be in accordance with Clause 2404
and the following. WORKMANSHIP FOR BRICKWORK,
BLOCKWORK AND STONEWORK
8 (05/06) Mortar designation shall be in accordance
with Table 24/5. Materials and mix proportions shall be 11 Workmanship shall be in accordance with
in accordance with sub-Clauses 2404.1 to 2404.6, and Clauses 2412, 2413, 2414 and 2415 and Annex A of
2417.10, as appropriate. BS 5628-3.
TABLE 24/5: (05/06) Mortar Designation 12 Forms of bonding in which the rings of masonry
are jointed by mortar alone, as with concentric rings in
stretcher bond, shall not be used unless stated in
Location/Element Mortar Appendix 24/1.
Designation 13 Clay bricks shall not be used within 14 days of
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Below a level of 150mm above finished (i) or (ii) firing.
ground level
14 Masonry in an arch ring shall be flush jointed.
Above a level of 150mm above finished (ii) or (iii) (iii)
ground level 15 Exposed surfaces of masonry shall be regular, clean
and have an acceptable appearance.
- Abutments, spandrel/wing walls,
piers & parapets 16 Finished surfaces of buried masonry to be
waterproofed shall have no abrupt irregularities greater
- Arch rings
than 3 mm.
17 Masonry shall not be subjected to loading,
9 (05/06) A set of mortar prisms shall be made for including its own weight, within 28 days of construction
each type of mortar designation used on each arch which will induce a stress exceeding 1/3 of its strength
structure. The mortar used shall be representative of the at the time of loading.
mortar used in the structure. The prisms shall be made
18 Removal of centring to the arch ring shall only take
and tested for compressive strength in accordance with
place after the material has gained sufficient strength.
BS EN 1015-11. Each set comprises three prisms each
The centring shall not be removed until at least 7 days
divided in two to give six individual tests. The mean of
after completion of the arch ring.
the six tests shall be within the limits shown in
Table 24/6: Waterproofing
19 Unless otherwise described in Appendix 24/1, the
waterproofing system shall be a permitted system
conforming to Clauses 2003 and 2005.
Protection of Waterproofing
20 Waterproofing systems shall be protected with a
single leaf of masonry or in-situ concrete when
unbound materials are used as a permeable backing.

21 Waterproofing systems with a permeable backing

of porous no fines concrete or precast hollow concrete
blocks in accordance with sub-Clauses 513.1(ii) and
(iii) shall require no further protection.
Permeable Backing to Structures

22 Permeable backing to spandrel/wing walls and
abutments shall comply with Clause 513. Where
foamed concrete fill to Clause 1043 is used,
sub-Clause 513.2 shall apply.
23 Where Class 6N or 6P fill is used, permeable
backing to the arch ring shall be a granular material or
porous no-fines concrete in accordance with
Clause 513.1.
24 Where Class 7A, 7B or foamed concrete fill is
used, permeable backing to the arch ring shall conform
to sub-Clause 513.2.
Fill
25 Fill shall be Class 6N, 6P, 7A or 7B conforming to
Clause 610 or foamed concrete conforming to
Clause 1043.
26 Fill shall be placed and compacted in accordance
with Clause 610.
27 Plant for compaction of material within 1 metre, or
within one fifth of the span if greater, of the arch ring
shall conform to sub-Clause 623.10.
28 For bridges carrying public highways, a minimum
depth of fill of 300 mm shall be provided between the
crown of the arch and the underside of the pavement as
29 Unless otherwise described in Appendix 24/1, fill
shall be drained by a 150 mm minimum diameter pipe
with rodding facilities provided at springing. Drainage
pipes and rodding facilities shall conform to Series 500.

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SERIES 2500
SPECIAL STRUCTURES
Contents
Clause Title Page
2501 Corrugated Steel Buried

Structures 2
2502 Reinforced Soil and Anchored
Earth Structures 3
2503 Reinforced Clay Brickwork
Retaining Walls of Pocket-type
and Grouted-Cavity
Construction 4
2504 Environmental Barriers 6
2505 (05/01) Drainage Structures 8
2506 (05/01) Buried Rigid Pipes for
Drainage Structures 9
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Specification for Highway Works Special Structures
SPECIAL STRUCTURES
2501 Corrugated Steel Buried Structures beyond each end crest. Cut edges shall be free from
notches, gouges, rust or burrs.
General 8 When all the plates of a bolted segmental structure
1 Corrugated steel buried structures of clear span or have been assembled, the nuts shall be tightened by
internal diameter exceeding 900 mm shall comply with applying a torque within the range stated on the Type
this Clause. Approval Certificate. The tightening shall be repeated if
necessary to achieve the required torque.
2 (11/03) The Contractor shall design the corrugated
steel buried structures listed in Appendix 1/10 in Bolts, nuts and washers (if provided) shall be of such a
accordance with Standard BD 12 (DMRB 2.2.6) and the design that no damage is caused to metal coatings when
design requirements given in Appendix 25/1. the nuts are tightened as described above.
Earthworks Hot Dip Galvanizing of Steel Components
3 Earthworks shall comply with Series 600. 9 (05/01) All surfaces of steel components shall be hot
dip galvanized in compliance with the standards listed
Steel Components in the appropriate Type Approval Certificate and British
Board of Agrément Roads and Bridges Certificate.
4 All helically wound systems and all bolted Plates for bolted segmental structures shall be
segmental systems to be incorporated in the Works shall galvanized after forming the corrugations and
have a current Type Approval Certificate. All the completing all necessary cutting, punching and drilling.
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individual components and materials making up the Units in which the galvanized coating has been burned
system shall comply with the properties listed in the by welding or otherwise damaged in fabrication,
current Type Approval Certificate. transport, cutting or handling at site shall be made good
5 Helically wound systems shall additionally have a in compliance with Clauses 1907 and 1908.
current British Board of Agrément Roads and Bridges 10 Bolts and nuts shall be hot dip galvanized in
Certificate. compliance with the standards listed in the appropriate
6 The lockseams of helically wound systems shall be Type Approval Certificate and British Board of
able to withstand tensile forces across the seam, Agrément Roads and Bridges Certificate.
according to steel sheet thickness, as tabulated below:
Concrete Foundations of Arch Profile Structures
Nominal Sheet Minimum Tensile Force 11 Concrete foundations shall be constructed as
Thickness across Seam described in Appendix 25/1 with concrete complying
(mm) (kN/m) with Series 1700.
1.00 36
1.30 51
Concrete Invert Pavings
1.60 65
12 (11/03) Where described in Appendix 25/1, concrete
2.00 88
2.80 136 invert pavings shall be constructed in compliance with
3.50 182 that Appendix using strength class C25/30 concrete and
4.20 234 a maximum aggregate size of 20mm complying with
Series 1700.
For intermediate sheet thicknesses, the minimum tensile 13 Concrete invert pavings shall be reinforced with a
force required may be determined by linear steel fabric complying with Series 1700 having mesh
interpolation. dimensions not greater than 150 mm x 300 mm and a
7 After forming, the depth of the corrugations shall nominal wire size not less than 5 mm. All laps in the
be within a tolerance of ± 6% and the pitch of the mesh shall be at least 150 mm. The steel fabric shall be
corrugations within a tolerance of ± 4% of the nominal securely fixed to the structure by means of fixings at the
dimensions. Plates shall have a minimum lip of 45 mm bolt positions. It shall extend to within a distance not
greater than 100 mm, nor less than 40 mm inside the
edges of the concrete on each side. A nominal cover of 2502 Reinforced Soil and Anchored Earth
45 mm shall be provided to all other faces, including Structures
that to the crest of the corrugations in the structural
steel. General
14 Concrete invert pavings shall be cast in lengths not 1 (11/03) Reinforced soil or anchored earth structures
exceeding 10 metres with the provision of a water bar shall comply with this Clause.
between adjacent panels and the joints sealed with a
joint sealant to Clause 2303. The Contractor shall design the reinforced soil or
anchored earth structures listed in Appendix 1/10 in
15 At each end of the structure the concrete invert accordance with Standard BD 70 (DMRB 2.1.5) and the
paving shall be either:
design requirements and procedures described in
(i) (11/03) terminated with a toe that returns at Appendix 25/2.
least 200 mm under the structural steel
forming the structure. The steel fabric shall Earthworks
be folded under the lips of the structure to
suit. The toe shall be detailed with a 2 Earthworks for reinforced soil and anchored earth
thickness of not less than that required for structures shall comply with Series 600.
the paving, in Standard BD 12
Reinforcing Elements for Reinforced Soil and
(DMRB 2.2.6); or
Anchor Elements for Anchored Earth
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(ii) detailed to suit any headwall arrangement eg

paving reinforcement lapped with headwall 3 (11/05) Carbon steel strip to be hot dip galvanized
reinforcement. shall comply with BS EN 10025-1 and BS EN 10025-2
either grade S235 JR or S355 JR or BS 1449 : Part 1.1,
16 All foreign matter, (but not any secondary either quality KHR 34/20P or quality KHR 50/35P, each
proprietary protective coating unless indicated having a silicon content of not less than 0.25% and not
otherwise in the Type Approval Certificate or British more than 0.40%. The fabricated element shall be hot
Board of Agrément Roads and Bridges Certificate dip galvanized in compliance with Clause 1909 except
referred to in sub-Clauses 4 and 5 of this Clause) and that the average zinc coating weight for any individual
free standing water shall be removed from the steel test area shall be not less than 1000 g/m².
surfaces to be paved, before commencing work.
4 Stainless steel strip shall comply with:
Proprietary Invert Pavings (i) (11/03) BS EN 10029, BS EN 10048,
17 Any proposed proprietary invert paving system BS EN 10051, BS EN 10258, BS EN 10259
shall have a current British Board of Agrément Roads designation 1.4401 or 1.4436 except that the
and Bridges Certificate. material shall be cold rolled to provide a
0.2% proof stress of not less than 400 N/
Proprietary Secondary Protective Coatings Applied mm² and the tensile strength shall be not less
Above Hot Dip Galvanized Coating than 540 N/mm²; or
(ii) (11/03) BS EN 10029, BS EN 10048,
18 Any proposed proprietary protective coating BS EN 10051, BS EN 10258, BS EN 10259
system shall have a current British Board of Agrément designation 1.4401 CR temper rolled to a
Roads and Bridges Certificate. minimum 0.2% proof stress of 310 N/mm².
Additional Protective Coatings 5 Proprietary reinforcing elements and systems using
such elements shall have a current British Board of
19 Where described in Appendix 25/1, exposed Agrément Roads and Bridges Certificate.
galvanized steel surfaces shall be prepared and
protected after erection in compliance with that 6 (11/06) Anchor elements for anchored earth shall be
Appendix. The additional protective coating may be made of cold worked steel reinforcing bar conforming
factory or site applied and shall have a service life of at to BS EN 10080 and BS 4449 (Grade B500B) except
least six years in aggressive conditions. that no bar shall contain a flash weld. Welding of steel
reinforcement bars to form anchors shall comply with
Clause 1717. The fabricated elements shall be hot dip
galvanized in compliance with Clause 1909 except that
the average zinc coating weight for any individual test
area shall be not less than 1000 g/m².

7 Reinforcing and anchor elements shall be (i) (11/06) Steel bar conforming to BS EN 10080
prefabricated and delivered to Site ready for installation and BS 4449 (Grade B500B), hot dip
into the Works. The elements shall be: galvanized in compliance with Clause 1909.
(i) Loaded, unloaded and handled in such a (ii) Steel of grade S 355 JR complying with
manner that: BS EN 10 025 hot dip galvanized in
(a) no permanent set or other structural
damage is caused; (iii) (11/03) Stainless steel to BS EN 10088-1,
designation 1.4401 or 1.4436 except that the
(b) the1 protective coating is not damaged.
0.2% proof stress shall be not less than 450
(ii) Stored flat and clearly marked to identify N/mm² and the tensile strength shall be not
items having different lengths and cross- less than 700 N/mm².
sectional dimensions.
Prefabricated and Precast Facing and Capping
Fasteners Units
8 (05/06) Bolts, screws and nuts complying with 12 (11/03) Carbon steel strip or sheet to be hot dip
BS EN ISO 898-1, property classes A and B, shall galvanized shall comply with BS 1449 : Part 1.1, either
comply with BS EN ISO 4014, BS EN ISO 4017 and quality KHR 34/20P or quality KHR 50/35P each
BS EN ISO 4032, and shall be made from one of the having a silicon content of not less than 0.25% and not
following: more than 0.40%. Following fabrication, the units shall
(i) (05/06) Steel
property class 8.8, complying be hot dip galvanized in compliance with Clause 1909
with BS EN ISO 898-1 and hot dip except that the average zinc coating weight for any
galvanized in compliance with Series 1900. individual test area shall be not less than 1000 g/m².
(ii) (11/03) Stainlesssteel to BS EN 10088-1, 13 (11/03) Stainless steel strip or sheet shall comply
designation 1.4401 or 1.4436 except that the with BS EN 10029, BS EN 10048, BS EN 10051,
0.2% proof stress of the bolt shall be not less BS EN 10258 and BS EN 10259 designation 1.4401 or
than 450 N/mm² and the tensile strength 1.4436.
shall be not less than 700 N/mm². 14 Reinforced concrete shall comply with Series 1700.
9 (05/01) Bolts, screws and nuts shall comply with one 15 Proprietary facing units and systems using such
of the following: units shall have a current British Board of Agrément
(i) (05/06) BS EN ISO 898-1 and
Roads and Bridges Certificate.
BS EN ISO 4016, BS EN ISO 4018 and
Metal Components - Material Compatibility
BS EN ISO 4034, hot dip galvanized in
compliance with Clause 1909. The property 16 All metallic components buried in the soil, ie
class of the bolts and screws shall be not less reinforcing elements, connections, facing lugs and
than 4.6, while the property class of the nuts facing units, shall be of electrolytically compatible
shall not be less than 4.0. material. Where this is not possible, effective insulation
(ii) (11/03) Stainless steel to BS EN ISO 3506-1 shall be provided between different materials.
and BS EN ISO 3506-2 grade A4-70.
10 (05/01) Plain washers shall be of either Form A or 2503 Reinforced Clay Brickwork Retaining
Form E complying with BS 4320 and shall be made Walls of Pocket-type and Grouted-Cavity
from one of the following: Construction
(i) (11/03) Coldrolled carbon steel strip CS4
complying with BS 1449 : Part 1.1 hot dip Materials
galvanized in compliance with Clause 1909.
1 Cement, aggregates, water and mortars for
(ii) (11/03) Stainless
steel strip designation 1.4401 reinforced brickwork retaining wall structures shall
or 1.4436 complying with BS EN 10029, comply with the relevant Clauses of Series 2400, except
BS EN 10048, BS EN 10051, BS EN 10258 where different requirements are given in this Clause.
and BS EN 10259.
11 (05/01) Dowels and rods shall be made from one of Masonry cement or high alumina cement shall not be
the following: used.

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2 (05/05) Unless otherwise described in Joints shall be tooled as the work progresses to either a
Appendix 25/3, masonry units (bricks) shall be HD type flush or bucket handle profile. Bricks shall not be used
Class B clay engineering bricks conforming to the within 14 days of firing.
particular requirements of BS EN 771-1 and the
12 The maximum height of brickwork to be built in a
performance characteristics given in Table 25/3. The
day shall be limited to 1.0 m and 12 hours shall elapse
equivalent strength grades of BS EN 771-1 as compared
before recommencing bricklaying.
to BS 3921, see BD 91 (DMRB 2.2.14), shall be given
in Appendix 25/3. The determination of sulfate content 13 Cutting of bricks shall be kept to a minimum.
for the soluble salt content test shall be in accordance When cutting is necessary, cutting discs shall be used.
with Test No. 2 in TRL Report 447. 14 Where sleeves, chases or holes are required, they
Selection of bricks shall follow the recommendations shall be provided during the erection of brickwork.
contained in BS 5628-3 in respect of durability and
other considerations. Second hand masonry units shall Mixing of Mortar
not be used.
15 Mortar shall be mixed mechanically until its colour
3 (11/03) Unless otherwise described in Appendix 25/3, and consistency are uniform. The constituent material
concrete shall be a designed concrete and shall be either shall be accurately measured.
ordinary structural concrete or special structural
16 (11/05) Where ready mixed mortars are specified,
concrete. It shall comply with the requirements of
their use shall be in accordance with the manufacturer’s
Series 1700.
instructions and BS EN 998-1 and BS EN 998-2.
4 (11/03) Reinforcement types shall comply with
17 Mortar shall be made in small quantities only as
Series 1700 and 2400 Clauses, except that all stainless
and when required. Mortar which has begun to set or
steel shall be designation 1.4401. Bed-joint
which has been mixed for a period of more than one
reinforcement shall not exceed 6 mm diameter.
hour shall be discarded.
No bi-metallic contact is permitted.
18 When additives or admixtures are specified in
5 Wall ties shall be as described in Appendix 25/3. Appendix 25/3, their use shall strictly follow the
Dove-tail wall ties shall not be used. manufacturer’s instructions and shall be demonstrated
6 Damp proof courses shall be as described in in the trial panel.
Appendix 25/3. 19 (05/06) Mortars shall be tested in accordance with
Annex A of BS 5628-1.
Storage of Materials
Concrete - General
7 (05/05) The handling, storage and mixture of
materials shall follow the recommendations of 20 Batching and mixing of concrete shall comply with
BS 5628-3. Clause 1706.
8 Bricks shall be unloaded with due care to minimize 21 (11/03) Concrete compliance shall be in accordance
damage, placed on site in different stacks according to with Clauses 1701 to 1705 and 1707.
strength and type and be marked clearly. They shall be
22 Transporting, placing, compacting and finishing of
stacked on prepared level areas avoiding ground
concrete shall be in accordance with Clauses 1708 and
contamination and be protected from rain or snow.
1710. The rate of placing of concrete with respect to the
9 Cement, lime and lime/sand mix shall be stored off rate of brickwork construction shall be as required by
the ground in dry areas and used in the sequence of Appendix 25/3. The placing and compaction of
delivery. Different types of cements shall be stored concrete shall not disrupt either the masonry or the
separately and clearly identified. Lime and lime/sand reinforcement.
mix shall be protected from drying out.
Cold Weather Working
10 Reinforcement shall be stored on site in a safe
manner and be free from loose rust, scale, dirt, paint, 23 (05/01) Cold weather working shall be in accordance
oil, grease or any other harmful material, prior to fixing. with Clauses 1710 and 2414.
Laying of Bricks Hot Weather Working
11 Brickwork shall be laid in accordance with 24 During hot weather, the Contractor shall ensure
Clause 2412. Jointing is preferable to pointing and shall that the constituent materials of mortar and concrete are
be used unless there is a specific need for pointing. sufficiently cool to prevent stiffening before placement in

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their final position. Cement shall not be allowed to come gradient of not greater than 1 in 50 along the line of the
into contact with water at a temperature greater than 60°C. barrier, the top of the barrier shall follow a flowing
vertical alignment. Where the earthwork environmental
Protection of New Work bund or original ground has a slope exceeding 1 in 50,
25 Protection of newly laid brickwork shall be in the top of the barrier may be stepped, where permitted
accordance with Clause 2415. in Appendix 25/4. The minimum height of the barrier
and the maximum step increments where steps are
26 In addition, during freezing conditions, brickwork permitted, shall be as specified in Appendix 25/4.
shall be covered with an insulating layer followed by a Where necessary the ground shall be excavated or filled
waterproofing material. Covers shall be held clear of and compacted in compliance with the appropriate
the brickwork and be well secured. Clauses in Series 600. Any excavation required shall
27 Side protection shall be provided in exposed site not affect the minimum height of the barrier as shown
conditions. in Appendix 25/4. The gravel board or bottom edge of
the barrier shall be buried to a depth of at least 50 mm.
Weatherproofing, Backfill and Drainage 3 (05/04) Where the environmental barrier is
28 The retaining face of the wall shall be flush-jointed combined with a safety barrier, the safety barrier shall
and tooled and shall be subsequently painted with a comply with the current standards issued by the
waterproofing material in accordance with Overseeing Organisation.
Clauses 2001, 2004 and 2006. 4 (05/01) Where the environmental barrier is to be
29 Backfilling shall be in accordance with Clause 610. erected on an earthwork environmental bund, the bund
Before commencing backfilling, a period of 14 days or shall comply with Clause 619.
longer if required by Appendix 25/3 shall elapse after
the completion of the wall. Tolerances
30 Permeable backing to the retaining wall shall be in 5 Tolerances shall be as follows:
accordance with Clause 513. (i) An environmental barrier shall be erected
31 When used, weep-holes shall not be allowed to along a line or smooth curve as indicated on
drain freely across footways or carriageways. the contract drawings within a tolerance of
± 75 mm normal to the plane of the barrier;
Trial Panel in addition, the horizontal deviation from the
32 The Contractor shall construct a trial panel of required positions at adjacent panels or posts
pocket type or grouted-cavity reinforced brickwork shall not vary by more than ± 15 mm.
retaining wall of dimensions specified in Appendix 25/3 (ii) The top edge of the barrier shall be at the
prior to commencement of permanent work. The trial specified height above the road surface,
panel shall be used to demonstrate the colour of mortar, existing ground or finished ground level of
workability of mortar, formation of pockets and the earthwork environmental bund within a
infilling of concrete. Where required in Appendix 25/3, tolerance of ± 50 mm and the deviation from
the panel shall be dismantled in such a manner that the the required levels at adjacent panels or
effectiveness of each element can be examined. posts shall not vary by more than ± 15 mm.
33 Where required in Appendix 25/3, the Contractor (iii) Barriers shall be vertical unless otherwise
shall construct additional panels to comply with the stated in Appendix 25/4.
appearance requirements of BS 3921.
Timber
2504 Environmental Barriers 6 Timber shall comply with Clause 304. Non-
structural timber shall be acceptable if it complies with
General
HCD Drawing Number H37 and H38. For checking
1 (05/01) Environmental barriers shall be constructed compliance, the rejection numbers shall be 3, 4, 6, 8, 11
from the quality of materials and be erected to and 15 respectively instead of 4, 6, 8, 11, 15 and 22.
standards described in the following sub-Clauses,
7 Timber surfaces shall be sawn unless otherwise
unless otherwise specified in Appendix 25/4.
stated in Appendix 25/4.
2 Where an environmental barrier is erected on
8 Timber within panels shall not be butt jointed. The
ground or any other surface which follows the
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thickness of panel boards shall be sufficient to ensure

longitudinal profile of the adjacent road or on existing
the specified acoustic requirements and their width
ground or earthwork environmental bund which has a

shall not be more than 150 mm measured at 28% Design

moisture content. Exposed ends of vertical boards shall
be protected against weathering by a top or capping rail. 15 Where required, the Contractor shall design the
environmental barriers listed in Appendix 1/10 in
Fittings accordance with the design specification and
procedures in Appendix 25/4. In addition, if required in
9 (11/03) Fittings shall comply with Clause 305 unless
Appendix 25/4 he shall design foundations, posts and/or
otherwise stated in Appendix 25/4. Nails in timber
other supports. The Contractor shall submit his design
preserved with copper/chromium/arsenic (CCA)
to the Overseeing Organisation for aesthetic approval.
treatment shall be austenitic stainless steel designation
The Contractor shall also take account of the following:
1.4301 to BS EN 10088.
(i) (05/04) The Contractor shall, when required in
Concrete Appendix 25/4, erect 2 sample panels of
10 (05/01) Reinforced concrete components shall barrier not less than 6 weeks before starting
comply with the requirements of Annex A of construction. One section shall show the
BS 1722 : Part 2. horizontal elevation, the other a sloping
elevation. Spacing of barrier posts shall be as
Combination of Timber and Concrete described in Appendix 25/4. When Appendix
11 (05/01) Timber cladding used to screen concrete 25/4 requires a safety barrier to be attached
panel barriers shall comply with BS 1722 : Part 5 and to the environmental barrier, the safety
Clause 304. barrier shall be supplied and fixed to the
sample panels of the environmental barrier.
Steel The sample panels shall be used as the
12 (05/01) Steel posts and environmental barrier standard which must be maintained
members shall comply with the requirements in throughout the Contract.
Series 1800 and shall: (ii) The Contractor shall provide working
(i) be hot dip galvanized to comply with drawings of the design and details of
Clause 1909, and either be: fabrication.
(a) (05/04) painted with the following paint (iii) The Contractor shall supply the Overseeing
system to comply with Series 1900 Organisation with the following:
(Table 19/2B, system IV), (a) Design calculations.
1 coat of Item 155 (b) Details of materials and components
1 coat of Item 110 or Item 121 used in the barrier.
1 coat of Item 112 or Item 121 (c) Details of gates and methods of fixing
where applicable.
1 coat of Item 168 or Item 169
(d) Details of fixing to adjoining structures
to achieve a minimum total dry film and parapets where applicable.
thickness of the paint system of
175 microns; or (iv) Fixings shall be fitted so that bolts either do
not protrude on the traffic side, or only do so
(b) plastic coated to comply with with a coach bolt head, a cup square head, or
Clause 2604; with a dome headed nut.
(ii) have improved atmospheric corrosion (v) Fixings and fastenings used shall be
resistance complying with Clauses 1801 and designed to prevent wilful damage. The
1803. design and materials used shall also enable
damaged components to be replaced.
Brickwork
(vi) Stepping of panels shall only be permitted as
13 Brickwork shall comply with Series 2400.
specified in Appendix 25/4 to be compatible
Other Materials with aesthetic requirements.
14 Other materials, or combination of materials, shall (vii) The design shall be such that movement due
comply with Appendix 25/4. to change in moisture content, thermal
effects or weathering will not reduce the
acoustic attenuation of the barrier.

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(viii) All joints shall be sufficiently masked by Absorption Requirements

cover strips or rebated to ensure acoustic
integrity. 18 The performance characteristic DLα determined in
accordance with BS EN 1793 Part 1 shall meet the
(ix) The design shall ensure that all members of requirements stated in Appendix 25/4.
the barrier can drain freely and do not allow
water to stand on their surfaces or within Post Foundation Test
joints.
19 (i) Where stated in Appendix 25/4 the
(x) Where access gates are required in Contractor shall provide test equipment and
Appendix 25/4, their design shall be such carry out loading tests on post foundations as
that they blend unobtrusively into the barrier. described in Appendix 25/4. The results shall
They shall open away from the nearest be available at least one week prior to
carriageway and leave no gap when closed. installation of the relevant length of fence,
The gates shall be self-closing by the unless otherwise stated in Appendix 25/4.
provision of a heavy duty spring and be
secured as described in Appendix 25/4. In (ii) The Contractor shall install foundations for
barriers up to and including 2.00 m high the testing after completion of the finished
top edge of the gate shall be at the specified ground.
height of the barrier. Gates in barriers over (iii) On completion of loading tests the
2.00 m high shall be 2.00 m high and Contractor shall remove the test posts and
provided with a header panel to align with foundations and make good the finished
the top of the barrier. Where a gate is not to ground, unless the posts and foundations
be provided, but a gap is to be left for access have not exhibited failure and can be
as described in Appendix 25/4, a length of incorporated into the Permanent Works.
barrier shall be erected behind the gap or an
overlap provided sufficient to maintain the (iv) The Contractor shall establish and maintain
acoustic properties of the barrier. appropriate traffic safety and management
measures complying with Clause 117 during
(xi) When timber is used in the barrier the installation, loading and removal of the test
following shall apply: posts and foundations.
(a) One or two gravel boards not less than
150 mm deep shall be provided having a
total thickness of not less than 50 mm. 2505 (05/01) Drainage Structures
Concrete gravel boards or edging will be
acceptable. General
(b) Fixings shall be such as to allow timber 1 All drains, piped and box culverts, sewers and
movement due to change in moisture drainage structures, other than bridges, that have a
content to be accommodated without diameter or clear span exceeding 900 mm shall comply
inducing splitting. with this Clause and any additional requirements
described in Appendices 25/1 and 25/5. Where the term
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Testing of Acoustic Performance drain is used in this Series it shall be deemed to include
the terms sewer and piped culvert.
16 (11/03) Where required in Appendix 25/4 the
complete form of construction proposed for an 2 The Contractor shall design the piped and box
environment barrier shall have been tested, by an culverts and other drainage structures listed in
appropriate organisation accredited in accordance with Appendix 1/10 in accordance with the requirements of
sub-Clauses 105.3 and 105.4, for acoustic testing in Clause 106. Unless otherwise described in
accordance with BS EN 1793. Appendices 25/1 and 25/5 only one type of pipe shall
be used within any individual drain between
Insulation Requirements consecutive chambers.
17 The overall performance characteristic DLR 3 Pipes for drains shall be selected from the
determined in accordance with BS EN 1793 Part 2 shall alternatives in Table 25/1 and shall comply with the
meet the requirements stated in Appendix 25/4. standards and particular requirements therein. The
Contractor shall show that the pipes which have been
selected have an hydraulic flow capacity equal to that
adopted in the hydraulic design of the system as

described in Appendices 25/1 and 25/5. On completion 3 Unless otherwise described in Appendix 25/5, all
of the whole of the drainage works the Contractor shall pipes in or under new embankments shall be laid only
provide the Overseeing Organisation with a schedule when the embankment has been formed and compacted
showing details of all pipe types used, including quality, to formation level under paved areas, to finished
joints and name of manufacturer. earthworks level in other areas, or to a level which will
give a minimum cover of 1.2 m to the pipes, whichever
TABLE 25/1: (05/05) Pipes for Drains and Culverts
is the lowest.
having Diameter or Clear Span Exceeding 900 mm
Bedding, Laying and Surrounding of Pipes
Material Usage Standard Particular
requirements 4 Immediately following the excavation of the
Vitrified clay Surface & foul BS EN 295 Shall comply with
trench, the pipes shall be laid and jointed on the pipe
water drains Clause 2506 bed in accordance with sub-Clause 503.1. Where
described in Appendix 25/5, limestone aggregates shall
Concrete (With Surface & foul BS 5911-1 Pipes having a not be used as bedding.
cement types water drains and BS EN concrete mix meeting
CEM I or SRPC, 1916 or the following 5 Drainage pipe and bedding combinations shall be
as defined in BS 5911-5 requirement. (Testing selected from the alternatives described in
Table A.17 of in accordance with the
BS 8500-1, when relevant BS and Appendix 25/5. Pipe bedding, haunching and
required in sampling in surrounding material shall be as shown on HCD
Appendix 25/5. accordance with Drawing Numbers F1 and F2, and shall comply with
Supersulfated sub-Clause 28 of sub-Clause 503.3(i), (ii), (iii), (iv) and (vi).
cement shall not Clause 2506):
be used) 6 Completion of the bedding, haunching and
A total chloride
surrounding of the pipes shall be carried out
content not exceeding
the values in immediately after jointing in accordance with sub-
Table 17/1 Clause 503.4.
Shall comply with 7 Precautions shall be taken to minimise water flows
Clause 2506 through the granular beddings surrounding rigid pipes
as required in Appendix 25/5.
Iron Surface & foul BS EN 598
water drains (Ductile
iron) Jointing of Pipes
Corrugated steel Surface water BD 12 Type approval 8 Rigid joints shall mean joints made solid by
drains (DMRB certificate and BBA caulking the sockets, or bolting together flanges integral
2.2.6) Roads and Bridges with the pipes. Flexible joints shall mean joints made
Certificate
with deformable rings or gaskets held between pipe
Shall comply with spigots and sockets, sleeves or collars.
Clause 2501
9 Joints in surface water drains and foul sewers shall
be watertight and comply with the appropriate British
2506 (05/01) Buried Rigid Pipes for Drainage Standards and the manufacturer’s instructions. Rigid
Structures joints shall be used only where permitted in
Appendix 25/5. Spigots and sockets of rigid joints may
Scope be caulked with tarred rope yarn or equivalent and the
socket completely filled with mortar designation (i)
1 For the purposes of this Clause, rigid pipes include complying with Clause 2404, but excluding lime; a
vitrified clay pipes and plain, reinforced and prestressed fillet of mortar shall be worked around the socket
concrete pipes as set out in Table 25/1. The maximum extending for a length of not less than 50 mm from the
length of pipe between flexible joints shall comply with face of the socket.
the requirements of Appendix 25/1. 10 Where a concrete bed, cradle, arch or surround is
used with rigid pipes having flexible joints, joint filler
Excavation for Pipes and Chambers
board complying with Clause 1015 shall be placed in
2 Excavation shall comply with Clause 602, and with contact with the end of the socket at all pipe joints and
sub-Clause 502.1. Trenches shall not exceed the shall extend through the full thickness of the concrete
maximum widths scheduled in Appendix 25/5. bed, haunch and surround in contact with the pipe.
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Backfilling of Trenches 18 Brickwork shall comply with Series 2400 and be

built with mortar designation (i) in English bond. The
11 Backfilling shall be undertaken immediately after joints of brickwork where exposed shall be finished as
the required operations preceding it have been specified for unpointed joints in Clause 2412. The ends
completed. of all pipes shall be neatly built into the brickwork and
12 Except where otherwise described in finished flush with mortar designation (i) complying
Appendix 25/5, trenches shall be backfilled above the with Clause 2404.
pipe surround material described in Clause 503, with 19 (11/04) Precast concrete chambers shall comply with
Class 1, 2 or 3 general fill material complying with BS 5911-3 and BS EN 1917. Cast in situ concrete
Series 600. chambers shall be constructed of ST4 concrete
13 Backfilling shall be deposited and compacted in complying with Clause 2602 unless otherwise described
compliance with Clause 612. The material used for in Appendix 25/5.
backfilling shall be deposited in even layers and shall 20 (11/04) Manhole steps complying with
not be heaped in the trench before being spread. BS EN 13101 shall be built in accordance with relevant
Spreading and compaction shall be carried out evenly Series F HCD Drawings. Steelwork used for ladders,
without dislodging, distorting or damaging the pipe. handholds and other fittings shall comply with
Power rammers shall not be used within 300 mm of any BS 970 : Part 1 and be galvanized in compliance with
part of the pipe or joint. Clause 1909 after fabrication. Threaded components
14 Except in carriageways and other paved areas and shall be galvanized in compliance with Clause 1909.
locations described in Appendix 25/5, backfill of 21 (11/03) Excavation around chambers shall be
trenches shall be brought up to ground level. Where backfilled with Class 2A wet cohesive fill material
topsoil is at the surface on the line of the trench, the (Table 6/1) with the plasticity and grading requirements
upper section of the backfill shall be topsoil of the set out in Appendix 25/5; this material shall be
thickness described in Appendix 6/8, or of the same compacted in accordance with Clause 612. Where
thickness and quality of topsoil as on the surrounding mechanical compaction is impracticable, the excavation
ground where no thickness is specified. For trenches in shall be backfilled with ST2 concrete complying with
carriageways or other paved areas the backfill shall be Clause 2602. Where there are precast concrete access
brought up to formation level, or sub-formation level shafts to precast concrete chambers, the shafts shall be
where capping is required, unless a lower level is surrounded by a minimum thickness of 150 mm of ST4
described in Appendix 25/5. Sheeting and other concrete complying with Clause 2602, and the
excavation supports shall be removed as the filling remaining excavation backfilled with general fill
proceeds unless otherwise described in Appendix 6/3. material as described in Table 6/1 compacted in
Connecting to Existing Drains, Chambers and
Channels 22 Chambers for foul drains shall be tested for
watertightness as scheduled in Appendix 25/5.
15 Connections to existing drains, chambers and
channels shall be carried out in accordance with 23 Chamber covers, gratings and frames shall be as
Clause 506 with the exception that where Appendix 5/1 described in Appendix 25/5. and shall comply with
is mentioned in sub-Clauses 506.1 and 506.3 it shall be BS EN 124 and sub-Clauses 10, 11, 12, 13 and 15 of
altered to read Appendix 25/5. Clause 507; they shall be set in cement mortar or quick
setting mortar complying with sub-Clause 507.16.
Chambers 24 For rigid pipelines the nearest joint to any chamber
shall be not more than 500 mm from the inner face of
16 Chambers, other than those used in motorway
the wall and shall not be restricted by any concrete
communications installations, shall include manholes,
surround. Between this and the next joint, the length of
catchpits, inspection chambers, draw pits and walled
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the articulated pipe (rocker pipe) shall be not less than

soakaways. Chambers shall be one of the types
1250 mm.
specified in Appendix 25/5.
25 Where the adjustment or replacement of existing
17 (11/03) Foundations to chambers shall be of ST4
frames and covers or gratings is required, the units shall
concrete complying with Clause 2602. Channels for
be taken up and refixed or replaced with new units in
chambers shall be formed and finished smooth in the
accordance with sub-Clause 23 of this Clause, or such
foundation concrete or constructed of preformed half
other specification as agreed with the Overseeing
circle channels, with sides benched in the same mix of
Organisation. The finished thickness of the mortar bed
concrete, or mortar designation (i) complying with
shall be between 10 mm and 25 mm. Unless otherwise
Clause 2404, but excluding lime.
described in Appendix 25/5, adjusted or replaced (i) For the hydraulic or hydrostatic test and for
chamber frames and covers or gratings shall be set flush the works proof load test, samples shall be
with the new surface. Any additional adjustments shall taken at random from each batch of
be by modifying the brickwork in compliance with consecutively manufactured pipes of each
sub-Clause 18 of this Clause or by using a frame of a diameter, joint type and strength class as
suitable depth. described in Table 25/2.
(ii) For the maximum load test, one pipe shall be
Pipe Junctions
taken at random from those which have been
26 Junction pipes shall be manufactured of the same selected for, and have passed, the proof load
type and class of material as the remainder of the pipes test. If this pipe fails, a further two pipes
in the run. Junction pipes, which are laid but not taken from those which have been selected
immediately connected, shall be fitted with temporary for, and have passed, the proof load test shall
stoppers or seals and the position of all such junctions be tested and if either pipe then fails, the
shall be clearly defined by means of stakes or tracing whole batch shall be rejected.
wires properly marked or labelled.
Testing and Cleaning
27 (11/03) Saddles may be used to form junctions only
where permitted in Appendix 25/5. No internal 29 Drainage structures shall be visually examined
projections greater than 5 mm shall be permitted. before backfilling is commenced and after backfilling is
Saddles for rigid pipes shall be jointed with mortar completed. Where such installations are subsequently
designation (i) complying with Clause 2404, but subjected to heavy construction plant loads they shall
excluding lime. Saddles and pipes shall be surrounded be inspected again when the construction work has
with ST2 concrete complying with Clause 2602. finished and before handover of the completed works.
30 Drainage structures shall at all times be left clean
Pipe Quality
and free from silt and obstruction.
28 For rigid pipes the Contractor shall obtain test
certificates provided by the manufacturer, based on the
following sampling rates:
TABLE 25/2: Sampling Rates
Number of pipes Sample size If all pass If 2 or more fail If 1 fails take a If 1 or more of the
in batch further sample of further sample fails
40 or less 2 REJECT or test 2 REJECT or test ALL

ALL remaining pipes remaining pipes in
41-60 3 in batch, failing pipes 3 batch, failing pipes to
to be rejected be rejected
61-80 4 ACCEPT 4
81-100 5 5
More than 100 5 per batch of 100 5

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Amendment - November 2003 11F

SERIES 2600
MISCELLANEOUS
Contents
Clause Title Page
2601 Bedding Mortar 2

2602 Concrete for Ancillary Purposes 5
2603 Porous No Fines Concrete 6
2604 Plastic Coating to Fencing Posts,
Gates and Ancillaries 6
2605 Plastic Coated High Tensile Wire 6
2606 Cored Thermoplastic Node Markers 7
2607 Granolithic Concrete Rendering
and Screed 7
2608 (03/20) Foamed Concrete for Structures 8F
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MISCELLANEOUS
2601 Bedding Mortar (iii) The material shall not be removed from the
store for use in the Works until immediately
General prior to mixing.
1 Bedding mortar shall satisfy the following (iv) Material shall not be used more than six
performance requirements: months after the date of manufacture or any
lesser period specified by the manufacturer
(i) Unless otherwise described in or supplier.
Appendix 26/2, bedding mortar shall have a
compressive strength not less than 50 N/mm² (v) The Contractor shall supply with each batch
when tested in accordance with sub-Clause or part of a batch of the material delivered to
4(iv) or 4(v) of this Clause. the Site, certificates furnished by the supplier
or manufacturer stating the following:
(ii) The flow characteristics shall be such that
the volume of the bed or plinth as shown on (a) Manufacturer’s name and address.
the Drawings is completely filled with (b) Manufacturer’s agent’s name and
homogeneous material when placed within address where applicable.
the range of ambient temperature between
5°C and 25°C, or as otherwise described in (c) Description of material and brand
Appendix 26/2. name.
(iii) The physical and chemical properties shall (d) Batch reference number, size of batch,
be compatible with those of all adjoining and number of containers in the
surfaces. delivery order.
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The stress in the mortar shall not exceed that defined in (e) Date of manufacture.
Appendix 21/1 for bridge bearings and Appendix 26/2 (f) The chloride ion content, expressed as
for other applications. Where the mortar is required to a percentage by mass of cement.
resist stress before attaining its 28-day strength the
compressive strength shall be confirmed by tests on (vi) Calcium chloride or admixtures containing
mortar cubes stored under conditions that simulate the chloride salts shall not be used and the total
field conditions. chloride ion content shall not exceed 0.1% of
the mass of cement.
Materials (vii) (11/03) Portland cement CEM I shall comply
2 (i) (11/03) The
maximum aggregate size in with BS EN 197-1.
bedding mortar shall be 2.8 mm. (viii) (11/03) The total acid-soluble sulfate content
(ii) Proprietary materials shall be stored as of the mortar mix, as SO4 shall not exceed
follows: 5% of the mass of cement in the mix. The
acid-soluble sulfate (AS) shall be determined
(a) The materials shall be stored in a dry in accordance with Test No. 2 in TRL Report
environment at a temperature of 447. The sulfate content shall be calculated
between 10°C and 27°C. as the total from the various constituents of
(b) The containers shall be damp-proof, the mix.
leak-proof and readily emptied of their (ix) (11/03)If water for the Works is not available
contents. from a water company’s supply, the
(c) Containers shall be marked with the Contractor shall ensure that the water complies
batch reference number, component with the guidance given in BS EN 1008.
identification, manufacturer’s name, Water from a water company supply may be
net weight and such warnings or used without testing. Where testing is
precautions concerning the contents as required, the sulfate content of the water
are required. shall be tested in accordance with Test No. 1
in TRL Report 447. The water shall not be

used if the sulfate content exceeds 1.4 g of final position within 25 minutes of
sulfate (as SO4) per litre. Water from the sea commencement of mixing. Immediately after
or tidal rivers shall not be used. casting, the mortar shall be protected to
prevent evaporation for at least three days.
(x) Resinous bedding mortars shall be based on
thermosetting organic polymers consisting of (iii) For resinous bedding mortars the substrate
stable fluid and/or solid components which on shall be dry, free from loose dirt and dust and
mixing react chemically to form a hardened shall meet the conditions specified by the
solid mass. Products shall be formulated manufacturer. The underside of the base
from epoxide, polyester, polyurethane or plate shall be clean and free from loose rust
acrylic resin systems. Fillers or aggregates to and loose mill scale at the time of bedding.
be incorporated in accordance with the The mortar shall be placed in its final
manufacturer’s recommendations, to extend position within one hour, or lesser period
or modify the properties of the resinous specified by the manufacturer, of
composition, shall be pre-bagged, dry and commencement of mixing.
factory proportioned. The addition of other
(iv) The mortar shall be poured in one corner of
fillers or aggregates shall not be permitted.
the plinth. The addition of mortar to the sides
Site Mixing, Placing and Curing of the plinth shall only be permitted after the
mortar has flowed completely under the
3 (i) Mixing, placing and curing of proprietary plinth.
bedding mortar shall be carried out in
(v) No internal metal shims shall be allowed to
accordance with the manufacturer’s written
remain in the hardened bedding mortar
instructions together with the following:
except where described in Appendix 26/2.
(a) The material shall not be mixed or
placed in the Works at ambient Laboratory Approval Tests
temperatures of less than 5°C. If for 24
4 (i) General
hours before, during or after placing,
the ambient temperature falls below Every batch of mortar to be used in the Works
5°C the Contractor shall maintain the shall be tested by the Contractor. Where more
temperature of the substrate and other than one batch of mortar is to be used in the
adjoining surfaces at not less than 5°C Works the Elastic Stability Test may be
for the duration of the curing period omitted from the testing regime subsequent to
recommended by the manufacturer. the initial laboratory approval tests.
(b) For cementitious bedding mortars the The Contractor shall state the water content
water/cement ratio shall not exceed to be used, expressed as a percentage by
0.4. The water content shall be weight of the material. Mixing shall be
confirmed during the approval tests, carried out in accordance with the
and maintained within a tolerance of manufacturer’s written instructions.
± 1 per cent in mortars placed in the (ii) Flow Cone Test, Calibration of Flow
Works. (a) (11/03) Theflow characteristics of the
(c) Only full packs of mortar as supplied mortar shall be determined by the
shall be mixed. On-site proportioning Flow Cone Test method described in
shall not be permitted. ASTM Standard C939-02.
(d) The temperature of the mortar on (b) Tests shall be conducted at ambient
completion of mixing shall be between temperatures of 5°C and 20°C within 15
5°C and 25°C. minutes of commencement of mixing.
(ii) For cementitious bedding mortars, the (c) For the test at 5°C the temperature of
substrate shall be flushed clean with water the flow cone and the mixer shall be
two hours before placing and maintained wet 5°C, the temperature of the dry
until placing commences. Any free water on material 10°C, and the temperature of
the surface of the substrate shall be removed the water where required, 20°C.
before placing the mortar. The underside of (d) For the test at 20°C the temperature of
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the base plate shall be clean and free from the flow cone, the mixer, the dry
loose rust and loose mill scale at the time of material and the water where required
bedding. The mortar shall be placed in its shall be 20°C.
(e) For each temperature at least two tests strengths obtained is lower than
having times of efflux within ± 5% 50 N/mm² and the difference between
shall be made and the average time of the highest and lowest values is not
efflux to the nearest 0.2 second shall more than 20% of the average. All
be reported. results shall be reported.
(iii) Flow Between Glass Plates (v) Compressive Strength (Resinous)
(a) The flow characteristics of the mortar (a) The compressive strength for resinous
between glass plates shall be bedding mortars shall be carried out
determined using the apparatus shown on six 40 mm cubes at an age of 24
in HCD Drawing Number K2. hours.
(b) Tests shall be conducted at ambient (b) The 40 mm cube moulds shall comply
temperatures of 5°C and 20°C. with BS 6319 : Part 1 and shall be
carefully filled using a funnel to
(c) The temperature of the apparatus, dry
ensure void-free cubes. There shall be
material and water for each test shall
no compaction.
comply with sub-Clause 4(ii)(c) and
(d) of this Clause. (c) Testing shall comply with
BS 6319 : Part 2.
(d) The mortar shall be poured in one
corner of the apparatus commencing (d) The strength requirement shall be
between 18 minutes and 20 minutes satisfied if none of the compressive
after commencement of mixing. strengths obtained is lower than
50 N/mm² and the difference between
(e) A satisfactory flow shall be achieved
the highest and lowest values is not
when the mortar flows under the glass
more than 20% of the average. All
plate and rises at least 10 mm above the
results shall be reported.
underside of the top plate at all
positions, without signs of segregation, (vi) Expansion Test
bleeding, effervescence or air inclusions.
(a) (11/03)Short term expansion shall be
(iv) Compressive Strength (Cementitious) determined by the method described in
ASTM Standard C827-01a. Results
(a) The compressive strength of
shall be determined from the mean of
cementitious bedding mortars shall be
two tests.
carried out on six 70 mm cubes at an
age of 28 days. (b) The expansion of cementitious
bedding mortars at 24 hours shall be
(b) The temperature of the mixer, the dry
less than 2.5% and greater than 0.25%.
material, the water and the moulds
shall be 20°C. (c) The volume change of resinous
bedding mortars at 24 hours shall be
(c) (11/03) The 70 mm cube moulds shall
between -0.6% and +1.0%.
comply with BS EN 12390-1. Test
specimens shall be made by filling the (vii) Water Absorption Test
moulds carefully through a funnel to
(a) (11/03) Absorption of water by resinous
produce a void-free mortar. The
bedding mortars shall be determined
moulds shall be covered by a steel
by the method described in ASTM
plate to prevent expansion of the
Standard C413-01. The absorption
mortar.
shall be not more than 0.4%.
(d) (11/03) There shall be no compaction.
(viii) Elastic stability tests for cementitious
Specimens shall be damp-cured for the
bedding mortars shall be carried out on one
first 24 hours, removed from the
set of three cubes made at 20°C as described
moulds and then water cured. Curing
in sub-Clause 4(iv) of this Clause.
shall comply with BS EN 12390-2.
(a) Curing shall comply with
(11/03)
(e) (11/03) Testing
shall comply with
BS EN 12390-2. After a minimum of
BS EN 12390-3.
28 days, the cubes shall be placed in
(f) The strength requirement shall be water at 20°C heated at a uniform rate
satisfied if none of the compressive to 45°C in 24 hours.

4
(b) Upon attaining 45°C the cubes shall (ii) Compressive Strength. Three cubes from
be sealed in a plastic bag and then each load of mortar mixed for placing in the
loaded at a compressive stress of Works shall be tested for compressive
30 N/mm² maintained for six hours at strength as described in sub-Clause 4(iv) or
45°C and the strain measured. 4(v) of this Clause as appropriate.
(c) The total compressive strain shall not Tolerances
exceed 1% on each cube.
6 The following tolerances shall apply to all
(ix) Elastic stability tests for resinous bedding
temperatures referred to in this Clause:
mortars shall be carried out on one set of two
40 mm cubes complying with 5°C (- 0°C + 2°C)
BS 6319 : Part 1. 10°C (- 0°C + 2°C)
(a) On removing the cubes from the 20°C (- 0°C + 2°C)
moulds after 24 hours they shall be
heated at a uniform rate to 45°C in a 45°C (- 2°C + 2°C)
further 24 hours. 110°C (- 5°C + 5°C)
(b) Upon attaining 45°C the cubes shall The tolerances applying to all linear dimensions, unless
be loaded at a compressive stress of otherwise shown on the Drawings shall be ± 1%.
30 N/mm² maintained for six hours at
45°C and the strain measured.
(c) The total compressive strain shall not 2602 Concrete for Ancillary Purposes
exceed 1% on each cube.
General
Site Control Tests
1 Concrete mixes referred to in the Contract as ST
5 (i) If the efflux times at 5°C and 20°C followed by a number shall mean concrete for ancillary
determined as described in sub-Clause 4(ii) purposes which shall comply with this Clause and any
of this Clause are within 10% or two seconds additional requirements in Appendix 26/1.
of each other, whichever is the greater, then 2 (11/03) Concrete for ancillary purposes shall be a
site control tests for flow shall be carried out standardised prescribed concrete complying with
as described in (a) below. In other cases, BS EN 206-1 and BS 8500 and with the additional
when the air temperature is less than 10°C requirements of this Clause.
site control tests for flow shall be carried out
as described in (b) below and when the air Cement
temperature is greater than 10°C site control
tests for flow shall be carried out as 3 (11/04) Cement types as defined in BS 8500, see
described in (a) below. Table A.17 of BS 8500-1 or Table 1 of BS 8500-2, shall
comprise one of the following:
(a) Each load of mortar mixed for placing
in the Works shall be tested at ambient CEM I, CEM II/A-V, CEM II/B-V, BIIIA
temperature by the flow cone test or, where required in Appendix 26/1, SRPC
method as described in sub-Clause (sulfate-resisting Portland cement).
4(ii) of this Clause. The results shall
agree within ± 10% or ± two seconds Aggregates
whichever is the greater, of the values
4 (11/03) Aggregates shall comply with BS EN 12620
obtained in the approval tests at 20°C.
and unless otherwise described in Appendix 26/1 the
(b) Each load of mortar mixed for placing maximum size shall be 20 mm. The total acid-soluble
in the Works shall be tested at ambient sulfate content of the concrete mix, as SO4, shall not
temperature by the flow cone test exceed 5% of the mass of cement in the mix. The
method as described in sub-Clause acid-soluble sulfate (AS) shall be determined in
4(ii) of this Clause. The results shall accordance with Test No. 2 in TRL Report 447.
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agree within ± 10% or ± two seconds

whichever is the greater, of the values
obtained in the approval tests at 5°C.

(11/03) Consistence 9 Surface finishes shall comply with Clause 1708

and, unless otherwise described in Appendix 26/1, the
5 (11/03) The consistence of the concrete shall be following:
defined by its consistence class (slump) and be within
either consistence class S2 or consistence class S3 of Buried surfaces:
BS EN 206-1 BS 8500 as appropriate to the purpose. Unformed surfaces shall be Class U1
Formed surfaces shall be Class F1
(11/03) Standardised Prescribed Concrete
Exposed surfaces:
6 (11/03) The standardised prescribed concrete used
for each purpose shall be as described in Table 26/1 Unformed surfaces shall be Class U2 except
unless otherwise described in Appendix 26/1. benching to chambers, which shall be Class
U3
TABLE 26/1: (05/04) Concrete for Ancillary Purposes Formed surfaces shall be Class F2
10 Formwork shall be struck without damage to the
Purpose Standardised concrete not less than two days after placing the
prescribed concrete and exposed surfaces shall be cured as
concrete* described in Clause 1027 or by covering them with an
1 Footings for fence posts and augered ST2
opaque impermeable membrane or with hessian or sand
foundations for traffic sign posts
which shall be kept damp. Such covering shall not be
removed for two days after placing.
2 Foundations for environmental barrier posts ST5
and planted lighting columns 11 (11/03) This Clause shall be complied with where
standardised prescribed concrete to BS EN 206-1 and
3 Blinding concrete, backfill for structural ST1 BS EN 8500-2, are shown on the Drawings for purposes
foundations, overdig of post holes and other than those in Table 26/1.
preparation of formation to Clause 616
4 Bedding and backing to precast concrete ST1
kerbs, channels, edgings and quadrants 2603 Porous No Fines Concrete
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5 Bed to drains Type A#. Foundations, ST4 1 (11/03) No fines concrete shall consist of Portland
channels and benching to chambers cement CEM I to BS EN 197-1 and 40 mm single size
6 Bed, haunch and surround to drains other ST2
aggregate complying with BS EN 12620.
than Type A#. Surround to chambers and 2 The ratio of aggregate to cement shall be 8:1 by
gullies volume or 10:1 by mass.
* Unless otherwise described in Appendix 26/1 3 The concrete shall be mixed by machine or by hand
# Refer to HCD drawing number F1 and F2 to a uniform colour and consistency before placing. The
quantity of water used shall not exceed that required to
Transporting, Placing and Compacting Concrete coat all of the aggregate particles without forming
excess grout.
7 (05/05) Concrete shall be transported and placed so
that contamination, segregation and loss of materials 4 The concrete shall be compacted by hand only.
does not occur. The maximum temperature of the
concrete at any time between mixing and placing shall
be no greater than 30°C. Concrete shall be placed and 2604 Plastic Coating to Fencing Posts, Gates
compacted within two hours of mixing. After and Ancillaries
compaction it shall not be disturbed within 12 hours.
1 (11/03) Plastic coating to steel or galvanized steel
8 (11/03) Concrete shall be compacted by tamping or fence posts, gates and ancillaries shall comply with
vibrating until it is thoroughly worked around any BS 1722: Part 16. Preparation of steel and galvanizing
embedded metal and into corners of formwork or shall comply with Series 1900.
excavations, until a solid mass substantially free from
voids is obtained without segregation and with no free
water on the surface. The Contractor shall select the 2605 Plastic Coated High Tensile Wire
consistence as described in sub-Clause 5 of this Clause
to achieve this. 1 (11/03) Wire shall be 4.40 mm diameter high tensile
drawn carbon steel wire with a minimum tensile
strength of 1050 N/mm², zinc coated to class A to
comply with BS EN 10244-2 and plastic coated to

comply with the following sub-Clauses and shall be joining the centres of the markers shall be
grade designated Grade A. perpendicular to the centre line of the lane in
which the markers are installed.
2 Plastic coatings shall be applied to wire by
extrusion using a compound complying with BS 2571 (ii) (05/05) The base of the pockets shall be
Type E1A and with the following additional cleaned and dried ensuring that all loose
requirements (i) to (iii): material is removed.
(i) The vinyl chloride homopolymer shall be (iii) (11/03) Thermoplastic road marking material
mixed with appropriate primary plasticizers, or paint shall be in accordance with BS EN
heat and light stabilizers, lubricants and 1871, shall then be poured into the pockets
pigments. No extender or filler other than until the material projects slightly above the
stabilizers or pigments shall be used. No level of the road surface, but the material
other material shall be added to the must not be allowed to spread onto the
compound. surrounding carriageway surface.
(ii) Not more than 5% of clean, once re-worked 3 The completed markers shall be free from
material, which shall be of the same raggedness at their edges and free from streaks, and be
composition, shall be added to the virgin flush (ie not more than 2 mm above) with the surface of
material from which the compound is to be the adjacent carriageway.
manufactured.
(iii) The softness number of the compound shall 2607 Granolithic Concrete Rendering and
be not less than five nor greater than 15, when
Screed
tested as described in BS 2782 : Part 3 :
Method 365A. 1 (11/06) Granolithic concrete shall be designed
3 The surface of extruded plastic coatings shall be concrete to Clause 1701 and shall be strength class
smooth, continuous and free from discolouration. The C32/40 with maximum aggregate size 4/10 mm to
colour of the coating shall be as required by Clause 1704. It shall conform to Clauses 1702, 1705,
Appendix 3/1 either green or black in accordance with 1706, 1707 and 1710.
BS 4800. 2 (11/06) Aggregate shall be crushed granite
4 The overall nominal diameter of the plastic coated complying with BS EN 12620 for heavy duty concrete
wire shall be 4.00 mm. When two diameter floor finishes. The aggregate shall comply with either
measurements are made at right angles to each other at the grading requirements in Table 6 for 0/10 GA90 or
a cross-section, the average of the two measurements 0/6.3 GA90 maximum size, all-in aggregate, or the
shall not differ from the specified nominal diameter by coarse aggregate grading in Table 2 for 4/10 GC85/20
more than + 0.05 mm. single sized aggregate and the sand within the limits of
0/4 (CP) or 0/2 (MP) of BS EN 12620.
3 (11/06) Granolithic concrete to this Clause shall be
2606 Cored Thermoplastic Node Markers laid on base concrete which has been prepared in the
following manner. The laitance on the base concrete
General shall be removed by wire brushing and by hosing with
1 Cored thermoplastic node markers shall be white water. This shall be done after the initial set of the base
and installed in pairs or sets of three at the locations concrete but before hardening and without disturbing
described in Appendix 26/3. the aggregate. Granolithic concrete to this clause shall
be laid not later than three days after placing the base
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Node Markers concrete.

2 The node markers shall be constructed as follows: 4 (11/06) After compaction the surface of the render or
screed shall be trowelled to a smooth finish to the
(i) 100 mm diameter pockets 10 mm ± 5 mm required levels, profiles and contours and shall present a
deep shall be cored in the finished road surface finish Class U3 to Clause 1708.
surface at 175 mm ± 5 mm centres within a
longitudinal tolerance of ± 0.25 m. The
pockets shall be cored using a drill consisting
of central pilot bit surrounded by a 100 mm
annular bit. The material within the annulus
shall be carefully broken out leaving a rough
surface to the base of the pocket. The line

2608 (03/20) Foamed Concrete for Structures

1 (03/20) Foamed concrete for use in structures and
other related applications (except for highway
reinstatements) shall comply with this Clause and any
additional contract specific requirements in
Appendix 26/8.
2 (03/20) Foamed concrete shall have the following
compressive strengths:
(i) a minimum cube compressive strength of
4 N/mm2 at an age of 7 days; and
(ii) a maximum cube compressive strength of
10 N/mm2 at an age of 7 days.
3 (03/20) The compressive strength shall be
determined by testing foamed concrete cubes which
have been made in accordance with BS EN 12390-1
except that the foamed concrete shall be placed in the
mould without any tamping or vibration other than
gently rocking the mould on a firm base. The test cubes
shall be cured in accordance with BS EN 12390-2 and
tested for compressive strength in accordance with
BS EN 12390-3.
4 (03/20) All aggregate used in foamed concrete shall
pass a 6.3 mm sieve and shall comply with the MP and
FP grading limits given in BS EN 12620. Larger size
aggregate may be used provided it can be shown to be
practicable.
5 (03/20) The foamed concrete permissible
constituents shall exclude potash and incinerator bottom
ash aggregate.
6 (03/20) Admixtures shall comply with the
requirements of BS EN 934-2. The stability of foamed
concrete shall be tested in accordance with Annex D of
BS 8443.
7 (03/20) Fibres shall not be used for foamed concrete
for structures.
8 (03/20) The maximum depth of a single pour shall
not exceed 1.0m within a 16 to 24 hour period.
9 (03/20) Where the foamed concrete surface is
exposed the poured foamed concrete must remain
visible until it has set.

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8F
SERIES 3000 (05/01)

LANDSCAPE AND ECOLOGY
Contents
Clause Title Page
3001 General 2
3002 Weed Control 3
3003 Control of Rabbits and Deer 4
3004 Ground Preparation 5
3005 Grass Seeding, Wildflower
Seeding and Turfing 6
3006 Planting 7
3007 Grass, Bulbs and Wildflower
Maintenance 14
3008 Watering 17
3009 Establishment Maintenance
for Planting 18
3010 Maintenance of Established
Trees and Shrubs 20
3011 Management of Waterbodies 26
3012 Special Ecological Measures 27
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Specification for Highway Works Landscape and Ecology
LANDSCAPE AND ECOLOGY
3001 General Working Group on Peat Extraction and

Related Matters, published by DETR. The
(05/06) Quality Management Schemes Contractor shall provide such proof to the
Overseeing Organisation of Wales in the
1 (05/06) Organizations providing landscape and manner stated in Appendix 30/1.
ecology works for highway schemes shall comply with
this Series and the associated quality management Pesticide Application
schemes detailed in Appendix A.
4 (05/06) A ‘pesticide’ shall be any agent exerting
Notice and Liaison biological control over living organisms and as such,
shall include herbicides, pesticides, lumbricides,
2 (05/06) If required in Appendix 30/1, the Contractor fungicides, algaecides, moss killers and all such similar
shall give at least 48 hours’ notice to the Overseeing products or materials.
Organisation of the intention to commence any of the
following operations, or other operations stated in 5 (05/06) All pesticides, methods of application,
Appendix 30/1: materials and tank mixes, methods of working,
transportation, storage and records shall be strictly in
(i) Subsoil treatment. accordance with current legislation and codes of
(ii) Topsoil cultivations. practice. The Contractor shall make available to the
Overseeing Organisation evidence of competency in the
(iii) Grass or wildflower seeding or turfing. use of pesticides.
(iv) Planting. 6 (05/06) The pesticides shall be fit for the purpose for
(v) Mulching. which they are intended. Only pesticides intended for
horticultural applications (not agricultural applications)
(vi) Tree felling. shall be used. All pesticides shall be used in strict
(vii) Arboricultural works. accordance with the manufacturer’s instructions.
(viii) Application of pesticides. 7 (05/06) The method of application and the
undertaking of the work shall not lead to the pollution
(ix) Works outside the road boundary. of any watercourse or water supply. The Contractor
(x) Any works within, adjacent to, or which may shall comply with current advice pertaining to the
affect any site of nature conservation or Overseeing Organisations of England, Scotland, Wales
archaeological interest stated in or Northern Ireland, as appropriate, for pesticides
Appendix 30/1. application near watercourses. Such advice is given as
follows:
This notice shall be repeated subsequent to periods
when the operations have been temporarily suspended. In England and Wales, the Contractor shall comply with
If required in Appendix 30/1, the Contractor shall liaise current Department for Environment, Food and Rural
directly with other landowners to give notice and Affairs (DEFRA) and Environment Agency guidelines
arrange precise access dates for works outside the road for pesticides application near watercourses. Before
boundary. each pesticide application near a watercourse, the
Contractor shall notify the Environment Agency and
Peat obtain any necessary consent forms. The Contractor
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shall be responsible for the return of completed consent

3 (05/06) Peat or peat-based products shall not be forms to the Environment Agency.
used, except:
In Scotland, the Contractor shall comply with current
(i) where peat is excavated on Site; or Environment and Rural Affairs Department, Scottish
(ii) where peat is required in Appendix 30/1; or Executive and Scottish Environment Protection Agency
guidelines for pesticides application near watercourses.
(iii) in Wales, where reduced peat products are
Before each pesticide application near a watercourse,
acceptable provided proof that the peat is
the Contractor shall notify the Scottish Environment
extracted from areas of little conservation
Protection Agency and obtain any necessary consent
value, as defined in the Report of the
forms. The Contractor shall be responsible for the Inspection Reports

return of completed consent forms to the Scottish
Environment Protection Agency. 15 (05/06) If required in Appendix 30/1, the Contractor
shall provide Inspection Reports for the activities
In Northern Ireland, the Contractor shall comply with carried out under Clauses 3007, 3009 and 3010. The
current Department of Agriculture and Rural reports shall identify the level of work activities
Development, and Environment and Heritage Service undertaken for each operation on a form as detailed in
guidelines for pesticides application near watercourses. Appendix 30/1.
Before each pesticide application near a watercourse,
the Contractor shall notify the Environment and
Heritage Service and obtain any necessary consent 3002 Weed Control
forms. The Contractor shall be responsible for the
return of completed consent forms to the Environment General
and Heritage Service.
1 Weed control shall be required in the locations and
8 (05/06) All pesticides shall be securely and safely at the frequencies given in Appendix 30/2, for
stored and transported. All used or partly used infestations of injurious weeds as follows:
containers shall be removed from Site immediately after
use. Application equipment and containers shall not be (i) Broad leafed dock.
rinsed out on Site under any circumstances. (ii) Curled dock.
9 (05/06) The Contractor shall ensure that all (iii) Common ragwort.
machinery and equipment used in the application of all
pesticides is properly cleaned, maintained, serviced and (iv) Creeping thistle.
repaired in accordance with the manufacturer’s (v) Spear thistle.
instructions to ensure correct application and to prevent
malfunction and leakage at all times. (vi) Himalayan Balsam.
10 (05/06) Water used for dilution of pesticides shall be (vii) Giant hogweed.
from a clean supply. (viii) Japanese knotweed.
11 (05/06) The pesticide is to be applied during the Other species which may be a nuisance locally that
season and weather conditions favourable to the require control in accordance with this sub-Clause shall
effective control of the targeted species. The method of be stated in Appendix 30/2.
application shall minimise spray drift. No pesticide
shall be applied when wind speeds are high enough to 2 Weed killing shall achieve total die-back of weeds
cause spray drift. The Contractor shall postpone, cancel and in the case of total weed control shall not allow any
or suspend the application of pesticides at any time significant re-growth (less than 5%) within 6 months of
when it is considered that conditions have become application. In the case of selective weed control there
unsuitable. shall be not more than 5% re-growth during the season.
12 (05/06) Prior to commencement the Contractor shall Total Weed Control

publicise, in accordance with current regulations, that
pesticides applications are to be undertaken. 3 On hardstandings, gravelled or paved areas and
around street furniture, contact, translocated and
13 (05/06) A record of all pesticide use shall be
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residual herbicides approved for total weed control

maintained by the Contractor on a form as detailed in shall be applied in accordance with the manufacturer’s
Appendix 30/1. It shall contain such information as the instructions, at the locations and frequency stated in
pesticide, name of operative, location of Site and Appendix 30/2.
weather conditions. A copy of the record form shall be
submitted to the Overseeing Organisation at intervals to 4 For site preparation, on topsoil heaps and in
be stated in Appendix 30/1. planted beds, a translocated, non-residual herbicide
approved for total weed control shall be applied in
Bird Nesting Season accordance with the manufacturer’s instructions, at the
locations and frequency stated in Appendix 30/2.
14 (05/06) For the purposes of this Specification, the
bird nesting season shall be the period stated in 5 In open ditches, lagoons, watercourses and filter
Appendix 30/1. drains a contact or translocated herbicide approved for
use in or near water shall be applied in accordance with
the manufacturer’s instructions, at the locations and
frequency stated in Appendix 30/2.

Selective Weed Control in Grass 2 The Contractor shall comply with current
legislation in relation to pest control and make available
6 At the locations and frequency stated in to the Overseeing Organisation evidence of suitable
Appendix 30/2, weeds in verges, central reserves, formal training of operatives as competent for the
planted areas and other grassed areas shall be controlled procedures and pesticides to be employed.
using a selective translocated herbicide. The herbicide
shall be applied during a period of active growth in 3 A register shall be maintained by the Contractor
accordance with the manufacturer’s instructions. detailing persons employed, pesticides used, weather,
site observations made (e.g. badger setts, vehicle
Weed Control by Spot Application of Herbicide damage or vandalism), together with confirmation that
the areas are satisfactorily controlled.
7 Where described in Appendix 30/2, weed control
shall be carried out to control the target species listed, Control Operations
using spot treatment with a translocated herbicide, ie
4 Badger setts and fox earths shall be clearly
applied with a device that ensures that the herbicide
identified and marked in an inconspicuous manner,
touches weed species only. The herbicide shall be
using a method to be agreed with the Overseeing
applied in accordance with Clause 3001, at the season
Organisation. The location shall be recorded and
and frequency stated in Appendix 30/2.
reported to the Overseeing Organisation. Sett and earth
Weed Control by Pulling/Handweeding markers shall be removed immediately after rabbit
control operations have been completed. As required
8 Handweeding shall be carried out at the locations under the Wildlife and Countryside Act (1981) and the
and frequency stated in Appendix 30/2. Handweeding Protection of Badgers Act (1992)/in Northern Ireland
shall consist of the removal of the entire weed, the Wildlife (Northern Ireland) Order 1985, the
including roots, by digging, forking, hoeing or pulling. Contractor shall not divulge the location of badger setts
Weeds shall be removed prior to flowering and the to any other party or parties.
arisings removed in accordance with sub-Clause 10 of 5 After treatment, the ground shall be left clear, with
this Clause. rabbit holes filled in. Where stated in Appendix 30/3,
any bramble and herbage that will interfere with the
Weed Control by Cutting
control of rabbits shall be cut and the arisings dealt with
9 Weeds shall be cut at the locations and frequency in accordance with sub-Clauses 3010.3 and 3010.4.
stated in Appendix 30/2. The weeds shall be cut prior to
Rabbit Control within the Road Boundary
flowering to a height of between 50 and 75 mm or as
otherwise stated in Appendix 30/2. 6 Initial clearance and thereafter effective control of
rabbit infestations shall be undertaken within the road
Arisings from Weed Control Operations boundary.
10 Where described in Appendix 30/2, all arisings 7 Effective control is defined as:
from weed control operations shall be removed from
(i) No damage to verges, embankments/cuttings,
Site. Injurious weed arisings shall be destroyed.
site furniture or drains.
(ii) No fresh signs of bark stripping on woody
3003 Control of Rabbits and Deer plants.
(iii) Few fresh droppings seen.
General
(iv) No new appreciable grazing seen.
1 In the locations and for the period of time stated in (v) No complaints from adjoining landowners.
Appendix 30/3, or when instructed by the Overseeing
8 The area where control is required shall be visited
Organisation, the Contractor shall carry out rabbit
a sufficient number of times during the first month, to
control. Prior to instructing rabbit control, the
keep the rabbits controlled, and substantially
Overseeing Organisation will have contacted adjacent
eliminated. Thereafter the Contractor shall ensure
landowners regarding their obligation to control
effective control for the period stated in Appendix 30/3
infestations on their own land. Thereafter the
or instructed by the Overseeing Organisation.
Contractor shall liaise as necessary with adjacent
landowners for access, to control co-ordination and 9 If required in Appendix 30/3, the Overseeing
report any further complaints to the Overseeing Organisation will inspect the Site together with a
Organisation. representative of the Contractor at monthly intervals to
agree whether effective control has been achieved.
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Clearance of Rabbits and Deer in Fenced Areas to Subsoil Treatment

be Planted
5 Where stated in Appendix 30/4 planting areas shall
10 Any rabbit burrows located within fenced be ripped, using a ripping tine or subsoil plough. The
enclosures for planting shall be cleared of all rabbits minimum depth of treatment shall be 450 mm unless
and all exit/entry holes effectively blocked immediately otherwise stated in Appendix 30/4.
after completing the fencing of each enclosure, in
6 The spacing between the tine furrows shall be as
accordance with the requirements described in
stated in Appendix 30/4. If no dimension is stated, the
Series 300.
spacing shall be close enough to cause the uplifting and
11 Unless otherwise instructed by the Overseeing fracturing of the soil throughout the profile to the
Organisation, the Contractor shall not plant any area minimum treated depth and shall be determined by the
until all rabbits and deer have been cleared from the soil type and conditions and the type of subsoiler used.
fenced enclosure. Approximate spacings shall be as follows:
12 The Contractor shall maintain the enclosure free of (i) conventional subsoiler alone - 600 mm;
rabbits, rabbit burrows including exit/entry holes and
(ii) winged subsoiler alone - 750 mm;
deer for the period stated in Appendix 30/3 or instructed
by the Overseeing Organisation. (iii) winged subsoiler with leading tines - 1.0 m.
Replacement of Plants Damaged by Animals Final Preparation of Soils
13 The Contractor shall replace any plant material 7 Where stated in Appendix 30/4, the requirements
damaged by rabbits or deer due to the failure of the of sub-Clauses 3004.8 to 3004.11 shall apply to subsoil
Contractor to effectively block entry points, burrows to be seeded or topsoil spread under the Contract.
and nests or failure of the Contractor to maintain the 8 Any consolidated material is to be broken up to
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fences, shelters or guards as described in the Contract. 300 mm depth and the top 50 mm of all soil reduced to
14 The Contractor shall replace the damaged plants in a tilth suitable for final shaping with a grading blade
accordance with Clause 3006 and maintain them in (particle size 10 mm and below). All undesirable
accordance with Clause 3008 and Clause 3009 for the material brought to the surface including stones larger
period stated in Appendix 30/3 or instructed by the than 50 mm in any dimension, roots, tufts of grass and
Overseeing Organisation. foreign matter is to be removed off Site, unless
otherwise stated in Appendix 30/4.
9 When material is reasonably dry and workable it
3004 Ground Preparation
shall be graded in accordance with the Drawings.
Vegetation Clearance 10 Finished levels of material after settlement shall
be:
1 Where stated in Appendix 30/4, all grass and other
herbaceous vegetation shall be cut in accordance with (i) as shown on the Drawings adjoining
sub-Clause 3002.9 to a height of between 50 mm and pavings, kerbs or grass areas;
75 mm and the arisings removed off Site. (ii) not less than 150 mm below damp proof
2 Where stated in Appendix 30/4, the Contractor course of adjoining buildings;
shall apply a non-residual translocated herbicide in (iii) at the same level as adjoining soil areas.
accordance with sub-Clause 3002.4 to all areas to be
11 Once material has been spread and/or graded, the
planted between 21 and 25 days prior to planting.
area shall not be traversed by machinery or used for
3 Where the area to be treated with herbicide has storage purposes.
been cut in accordance with sub-Clause 3004.1 the
Contractor shall await active vegetative re-growth Soil Contaminated During the Contract
sufficient for the herbicide to be at its most effective
before applying the herbicide. 12 Where the Contractor has contaminated the ground
with cement slurry, oil, tar or any material harmful to
4 The treatment for total herbicide control shall kill plant life, soil shall be excavated to a depth of 1.0 m
all treated growth including their root systems. The and removed off Site. Uncontaminated subsoil and
Contractor shall not commence any excavation or topsoil shall be used for backfilling, to the finished
cultivation of the areas where herbicide has been profiles required under the Contract.
applied until the vegetation has been effectively
controlled.
3005 Grass Seeding, Wildflower Seeding and mixture shall be kept constantly stirred during
Turfing application to maintain a homogenous slurry.
Season Grass Seed Germination
1 Grass seed shall be sown during the period 11 The seeding shall be repeated as necessary until an
1 March to 31 May or 1 September to 31 October, evenly distributed dense sward is established over the
unless otherwise stated in Appendix 30/5. Wildflower seeded area. The Contractor shall allow for
seed shall be sown during the period stated in maintenance of all grass areas in accordance with
Appendix 30/5. Clause 3007 until this has been achieved. Establishment
shall be regarded as achieved when at least 80% of
Final Cultivations quadrant sub-divisions are recorded as ‘filled’ when
tested in accordance with Annex A3 of BS 3969.
2 Where stated in Appendix 30/5, immediately prior
to sowing or hydraulic seeding or laying turf the upper Turf
50 mm of soil shall be reduced to a fine tilth by use of a
chain harrow or other suitable plant. 12 Turfing shall be carried out in accordance with
BS 3969 and BS 4428.
3 If required in Appendix 30/5, fertiliser or other soil
ameliorants shall be evenly incorporated into the upper 13 When it is stated in Appendix 30/5 that turf arising
50 mm of soil during final cultivations at the rate stated on Site shall be used, such turf shall be stripped as
in Appendix 30/5. follows or as otherwise described in Appendix 30/5:
(i) Grass shall be mown before lifting to no
Seed more than 35 mm high.
4 Seed shall comprise the mixture(s) stated in (ii) Turves shall be cut using plant or tools
Appendix 30/5. designed for the purpose.
5 Grass seed shall comply with BS 4428. (iii) Turves shall not be cut from soil that is
6 Grass seed shall be a tested mixture and certificates frozen, waterlogged, as defined in
Clause 618, or excessively dry.
of germination and purity obtained from an Official
Seed Testing Station not more than six months prior to (iv) Turves shall be of uniform thickness, in
sowing shall be provided to the Overseeing accordance with BS 3969.
Organisation before sowing, together with the names of
(v) Turves shall be rectangular, with the shorter
the varieties used in the mixture. The information on
sides not less than 300 mm.
seed certificates and seed bag labels shall correspond.
14 Where stated in Appendix 30/5, imported turf shall
7 The Contractor shall provide written evidence that
be used. All imported turf shall comply with BS 3969
seeds comply with any provenance requirements
and BS 4428. Imported turf shall contain the grass and/
or herb mixture stated in Appendix 30/5.
Conventional Sowing 15 The source of turf shall be notified in writing to the
Overseeing Organisation and a sample of not less than
8 Unless otherwise stated in Appendix 30/5, sowing 6 no. 300 mm x 300 mm turves provided for approval in
shall be carried out by evenly distributing the seed at a accordance with Clause 106, not less than one week
rate of not less than 20 g/m2 for side slopes of prior to commencing turfing.
embankments and cuttings and not less than 15 g/m2
elsewhere. 16 Imported turf shall be delivered to the Site within
24 hours of lifting. Care shall be taken in transport to
9 Sowing shall be immediately followed by lightly avoid deterioration due to inadequate covering or
raking the surface of the soil to cover the seeds, by use overheating.
of a chain harrow or other suitable plant.
17 Turf shall be laid within 18 hours of delivery
Hydraulic Seeding between 1 April and 30 September and within 24 hours
of delivery between 1 October and 31 March. If this is
10 Hydraulic seeding shall be applied in the locations not possible, turf shall be temporarily laid flat on
stated in Appendix 30/5. The hydraulic seeding mixture, topsoil and kept moist.
any special process requirements and the rate of
application shall be as described in Appendix 30/5. The 18 Turves shall not be stored in stacks over 1.4 m in
height.
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6
19 Turf shall be laid on soil that is moist but not frozen 30 Unless permitted otherwise in Appendix 30/5, all
or waterlogged, as defined in Clause 618. Turf shall not areas shall be left clear of grass cuttings following each
be laid during periods of drought or onto soil that is mowing by raking or other suitable method, and
excessively dry, or during heavy rainfall. arisings disposed of off Site.
20 Turf shall be placed working from planks laid on
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previously laid turves. 3006 Planting
21 Turf shall be laid to a bond with broken joints,
butted up with joints no wider than 10 mm. When laid 1 All Planting Works shall be carried out in
on slopes, the bond shall be laid diagonally across the accordance with BS 4043, BS 4428 and BS 5837.
slope. 2 On completion of planting operations, all disturbed
22 Levels shall be adjusted by raking out or infilling accesses to, and ground around the planted areas shall
with fine soil under the turves. When laid, turf shall be be completely reinstated to their former condition as at
lightly tamped in place with clean wooden beaters. The the commencement of planting.
use of rollers shall not be permitted. Plants
23 After laying turf the surface shall be dressed with
3 All plants to be supplied shall be as scheduled in
finely sifted topsoil/sand which shall be brushed in to
Appendix 30/6 and shall comply with BS 3936 : Parts 1
completely fill all joints.
to 10 as relevant, BS 4043, the National Plant
24 Whole turves shall be used at edges and trimmed to Specification, published by the Horticultural Trades
a clean line. Turf shall be neatly cut away to a diameter Association, and/or as otherwise required in
of 800 mm around individual trees. Appendix 30/6. If plants grown in cells are required, the
25 If required in Appendix 30/5, turf shall be secured cells shall be designed for tree or shrub use and the
in position using either: plants shall be grown in open conditions for one
growing season.
(i) Softwood pegs, 200 mm long x 25 mm
square; or 4 No grafted stock shall be supplied unless it is stated
in Appendix 30/6 that grafted plants are permitted.
(ii) Galvanised wire pins, 200 mm long x 4 mm
diameter, bent or hairpin pattern. 5 If required in Appendix 30/6, plants shall be
supplied in a planting medium containing specified
26 Where stated in Appendix 30/5, immediately after mycorrhiza.
laying, turfed areas shall be watered at a rate of 15 l/m2.
6 Where the seed origin of native plant species is
27 Newly sown or turfed grass shall be watered as required to be of specific provenance, the provenance
necessary to ensure establishment. When grassed areas shall be determined and described in accordance with
require irrigation, water shall be applied at the rate of Forestry Commission Practice Note 8: Using Local
15 l/m2 using low pressure hose sprinkler or spray Stock for Planting Native Trees and Shrubs. Written
evenly over the entire area. evidence of its provenance shall be provided to the
Overseeing Organisation prior to planting, using the
Establishment Cuts
Provenance Certificate pro-forma in Appendix 30/6.
28 Any opening of joints or uneven levels in turf areas Plant material shall comply with any other special
caused by shrinkage of turves or settlement shall be provenance requirements stated in Appendix 30/6.
made good by top-dressing with 50% sieved 7 The Contractor shall provide the Overseeing
topsoil/50% fine sand mix. Organisation with written evidence that the supply of
29 For the number of cuts stated in Appendix 30/5, bulbs and wildflower plants is from a cultivated source.
newly-established grass, whether newly-sown or turfed, The Contractor shall inform the Overseeing
shall be mown to leave a nominal 50 mm height. The Organisation in writing of the proposed source of
first mowing shall be carried out once the grass has supply of all plant materials at least 14 days prior to
reached a height of 100 mm, the second and any delivery so as to enable the plants to be inspected at the
subsequent establishment cuts when it has re-grown to nursery before delivery to Site. If required in
100 mm. The plant used for mowing shall comply with Appendix 30/6, the Contractor shall make arrangements
any requirements of Appendix 30/5. Any turves for the Overseeing Organisation to select individual
disturbed by mowing shall be re-firmed into their trees of Standard size and larger, at the nursery.
original position and watered to their full depth.

8 (05/08) Plants shall be lifted, packed and handled in added to completely cover the root systems
accordance with BS 3936, BS 4043 and the and fill the containers. Any containers which
Horticultural Trades Association publication, the have lost more than 10% compost shall be
National Plant Specification, Section 10.2, Handling replaced. All containerised plants shall be
and Establishing Landscape Plants. thoroughly soaked prior to planting and all
containers removed.
9 During the period subsequent to the receipt of the
plants and prior to planting, the Contractor shall comply (viii) Any plants damaged by frost, desiccation, or
with the treatment of nursery stock specified below: in any other way prior to planting, shall be
removed from site and replaced with new
(i) Bare-root plants. Prior to despatch or on
plants.
arrival at Site plants may be stored up to
3 days in bundles with a covering of freely- 10 Unless otherwise stated in Appendix 30/6, all
draining moisture-retentive material such as labels, canes and ties shall be retained on the plant for
wet sacking or straw which is moistened 12 months unless they prove restrictive to growth.
periodically. For a storage period of more
11 All other arisings from the planting including
than three days, bundles shall be opened and
containers, wrappings, paddings, fastenings and bags
the plants spread out and heeled into trenches
shall be collected immediately by the Contractor and
in topsoil, minimum depth 300 mm, with the
removed off Site.
roots fully in contact with the soil.
(ii) Bare-root plants transported in plastic bags. Topsoil, Compost, Fertiliser and Anti-dessicants
Plants in bags shall be stored no more than 12 Unless otherwise stated in Appendix 30/6, topsoil
one layer deep and be protected from direct for tree pits shall be General Purpose Grade conforming
sunlight at all times. Where delay of more to BS 3882.
than one day occurs, the bags shall be stored
upright, not stacked, in a cool shady position 13 Where stated in Appendix 30/6, compost or
or shed, or placed in a cold store. If cold fertiliser shall be deposited over planting areas, for
store facilities are not available, plants shall incorporation into the soil during ground cultivation, or
be removed from bags and heeled into soil incorporated into soil during pit preparation and
with all roots covered. backfilling.
(iii) Container or cell grown plants. Containers 14 Compost shall be peat-free organic composted
shall be maintained upright, watered as material graded less than 25 mm particle size and free
required, sheltered and protected from frost, from any non biodegradable material, weed material or
and shall not be packaged or stored more plant pathogens. It shall have an organic matter content
than one layer deep. Degradable pots, cells greater than 35% on a dry matter basis and readily
or root-trainers that may disintegrate in available trace elements. The pH, conductivity and
transit shall be enclosed in polythene film nutrient composition shall be as required in
(250 gauge) and firmly secured. Appendix 30/6. The compost shall be supplied with a
volume tolerance of less than 5%.
(iv) Rootballed plants. Permeable wrappings
shall be kept moist by watering and plants in 15 Where specified in Appendix 30/6, slow-release
polythene wrappings protected from direct fertiliser shall be used. The fertiliser shall be thoroughly
sunlight. For longer periods of storage, and evenly mixed with the pit backfill or into the top
root-balls with permeable wrappings shall be 75 mm of planting bed soil, or scattered over an area
placed on a well drained surface and covered 600 mm in diameter around the planting position, at the
with a deep layer of sand, pulverised bark, rates specified in Appendix 30/6.
wood shavings or other suitable material. 16 Where stated in Appendix 30/6, anti-transpiration
(v) Protection from frost. When necessary, sprays, root dips, anti-desiccant soil additives or other
additional measures shall be undertaken to forms of anti-desiccant shall be used. Where such
protect plants from frost. anti-desiccant measures are specified these shall be
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applied in strict accordance with the manufacturer’s

(vi) The location for temporary storage shall be instructions.
sheltered from winds and well drained.
(vii) All containers shall remain completely filled Time of Planting
with compost. If up to 10% compost has 17 Planting of bare-rooted, rootballed or cell-grown
been lost from containers at any stage, then trees, shrubs, non-aquatic perennials and wildflowers
further suitable moistened compost shall be

shall take place during favourable weather and soil dimensions given in Table 30/1. The subsoil in the pit
conditions, during the season stated in Appendix 30/6. base shall be broken up to a further depth as given in
Bare rooted or root balled conifers or evergreens shall Table 30/1. If required in Appendix 30/6, pits shall be
be planted during November or March. excavated for whips, transplants and shrubs and
trenches excavated for hedges, to the dimensions given
18 Container-grown plants of the types listed above
in Table 30/1. The subsoil in the pit base shall be broken
may be planted at any time during favourable weather
up to a further depth as given in Table 30/1. Arisings
and soil conditions.
from planting pits and trenches shall be disposed of as
19 Bulbs shall be planted between 15 September and directed in Appendix 30/6.
30 November, unless otherwise stated in
TABLE 30/1: (05/08) Planting Pits, Beds and Trenches
Appendix 30/6.
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20 The planting season for reeds and other marginal/ Type Dimension of Depth of
aquatic plants shall be March to April. excavation cultivation at the
W x W x D mm base of pits or
21 No planting or preparatory operations shall take trenches mm
place when the ground is frost bound, covered by snow,
excessively wet or waterlogged as defined in Semi-mature trees Measurement of 200
Clause 618, or in excessively dry or windy conditions. rootball plus 400 in

each direction
Planting Depth Extra heavy standard and 1800 x 1800 x 750 200
22 Cell-grown plants shall be planted with the top of Heavy standard trees
the root plug covered by 10-20 mm of planting medium. Selected standard trees
Planting depth for all other plants shall be to the Tall standard trees 1000 x 1000 x 600 200
original nursery soil mark on the plant, unless otherwise Standard trees
stated in Appendix 30/6. Light standard trees
Notch Planting of Trees, Shrubs and Hedges Half standard trees 700 x 700 x 600 200
Feathered trees
23 Where pits, beds or trenches are not used, plants Whips) where pit-
shall be notch-planted upright by one of the following Transplants) planting is 300 x 300 x 300 150
methods, as directed in Appendix 30/6: Shrubs) specified
(i) into a T-shaped opening of sufficient size for Hedging (where * x 600 x 300 150
the roots of bare-root plants to be fully specified)
spread out or to accommodate a cell-grown
Cell-grown plants 150 mm greater than
plant without breaking the root-plug; or
W and D of root-plug
(ii) into a T-shaped opening (size as directed in
(i) above) through upturned turf, which has * length of hedging
been dug from the planting location. For 25 On sloping ground, pits shall be dug with vertical
individual plants, turfs shall be cut 300 mm sides and horizontal base and shall maintain the
square and 200 mm deep, for single row specified minimum depth throughout. When backfilled,
hedges, a strip of turf shall be cut 300 mm planting pits shall be finished to existing contours.
wide and for double-row hedges, a strip of
turf shall be cut 600 mm wide. All existing 26 For pits for Standard trees and larger trees, any
vegetation on turf to be inverted shall be cut excavated topsoil shall be set aside to be used as
to a height of not more than 50 mm, before backfill. The Contractor shall import topsoil in
the turf is cut; or accordance with sub-Clause 3006.12, to make up for
any deficiencies caused by the removal of subsoil or fill
(iii) cell-grown plants may be planted using a material.
proprietary tool for the purpose; or
27 (05/08) Unless otherwise stated in Appendix 30/6, or
(iv) as directed in Appendix 30/6. where the soil is naturally free draining, prior to
Surrounding soil shall be firmed back after planting. backfilling 1800 mm x 1800 mm x 750 mm pits, a
200 mm thick layer of river-washed gravel or crushed
Planting Pits, Beds and Trenches stone, 0-25 mm, shall be laid in the base to facilitate
drainage.
24 Planting pits for Feathered trees, Light standard
trees and all larger trees shall be excavated to the

Planting in Cultivated Beds and Hedges Stakes and Ties

28 Where required in Appendix 30/6, hedge-trenches 36 Unless otherwise stated in Appendix 30/6, stakes
excavated in accordance with Table 30/1 shall be shall be round timber, peeled of bark, straight in length
backfilled with topsoil or with a pre-mixed 80% topsoil and free of snags, pests and diseases. Stakes shall have
/ 20% compost mixture or other mixture, as stated in a top diameter of 50-75 mm.
Appendix 30/6.
37 Unless otherwise stated in Appendix 30/6,
29 Where required in Appendix 30/6, the ground shall adjustable tree ties, strapping or spacers shall be made
be cultivated to a minimum depth of 300 mm removing of black PVC or reinforced rubber. The width of the belt
all live injurious weed roots and growth to a tip off Site. shall be 25 mm.
Any stones or other rubbish over 75 mm in any
direction shall be removed from the surface and Planting of Trees
disposed of in accordance with sub-Clause 3004.8. Root 38 Where required in Appendix 30/6, root barriers
disturbance of adjacent plants shall be avoided and the shall be provided at the time of planting, in order to
surface left with a medium tilth. Any ameliorants constrain the growth of tree roots. Root barriers shall be
specified in Appendix 30/6 shall be incorporated in a supplied and installed in accordance with
second pass following initial cultivation. Appendix 30/6 and the manufacturer’s instructions.
30 If required in Appendix 30/6, a 600 mm wide strip 39 All wrappings, insulation and padding shall be
along hedgelines shall be cultivated in accordance with removed from rootballs immediately before backfilling.
sub-Clause 3006.29. No wire or plastic mesh containers may be left in
31 In planting beds, the extent of the area to be planted position. Any damaged or torn roots shall be cut back
shall first be defined by plants spaced around the cleanly to sound wood prior to planting.
perimeter. The remaining plants shall then be used to 40 Stakes for all standards and feathered trees shall be
fill in the centre of the area in an informal manner, firmly driven and positioned into the tree planting pit
avoiding straight lines and regular geometric patterns. before planting to a minimum depth of 300 mm below
32 At each planting position sufficient soil shall be the bottom of the pit. The stake shall be positioned off
excavated from the bed to allow 75 mm clearance centre on the prevailing windward side of the tree as
between either the rootball, or the root-ends when fully near to the tree as possible but shall not interfere with
spread, and the sides and bottom of the planting hole. the free movement of the branches and shall cause no
The plant shall be set in the centre of the plant position, rubbing.
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showing its best side to the front. 41 Unless otherwise stated in Appendix 30/6, the
33 Finely broken back-fill material shall be packed Contractor shall use the shortest possible stake to
around the roots. The plants shall be gently shaken to support the tree; when the stake has been driven into the
allow fine soil to surround the roots. As soil is returned ground there shall be not more than one third of the
it shall be lightly consolidated and firmly heeled around height of the clear stem of the tree above ground.
the root-collar. Immediately after planting the soil 42 Unless otherwise stated in Appendix 30/6, for all
surface shall be evenly graded. Where required in standards and feathered trees, one tie shall be used for
Appendix 30/6, the soil shall then be watered at the rate each tree, fixed within 50 mm of the top of the stake
stated in Appendix 30/6. and secured to the stake with a 25 mm galvanised clout
Planting of Whips, Transplants and Shrubs into Pits nail. Ties shall be of a size appropriate to the size of the
or Trenches tree and stake and equipped with spacers of a size that
will ensure that the tree and stake remain vertical.
34 Each plant shall be placed upright in the centre of
43 For extra heavy standards and heavy standards the
the pit or, where required in Appendix 30/6, the hedge
staking shall be undertaken after the tree has been
trench, with the roots spread evenly outwards and
positioned. Unless otherwise stated in Appendix 30/6,
downwards without restriction. Where necessary, any
three stakes, each of 3 m length shall be driven down
badly damaged roots shall be carefully pruned before
the side of the rootball and into the pit to a depth of
being planted.
500 mm below the bottom of the pit. The stakes shall be
35 The pit or trench shall be backfilled with a pre- angled outwards to between 5° and 10° at the top and
mixed 80% topsoil / 20% compost mixture or other pulled in moderately by tensioning all the supporting
mixture stated in Appendix 30/6 and the backfill lightly bands equally. The stakes shall be equally spaced and
firmed. shall not pass through the rootball.

44 Unless otherwise stated in Appendix 30/6, for extra shall be of sufficient length to coil completely around
heavy standards and heavy standards with above ground the root system or rootball and shall be provided with
staking the tree shall be secured centrally between the two ‘T’-piece connections with aeration caps, which
stakes with two sets of supporting bands of fire hose or shall be located opposite each other.
equivalent webbing of minimum width 70 mm. The
51 Where trees are to be situated within mown grass
upper set shall be positioned as near to the tops of the
areas two additional posts of a diameter similar to that
stakes as possible and the lower set shall be positioned
of the stake shall be driven firmly into the ground to
500 mm above ground level. Each band shall take the
leave a finished height of approximately 400 mm above
form of a loop around the tree stem nailed to the stake
soil level. These posts shall be sited clear of the tree
and shall be equally tensioned so as to hold the tree
roots in a triangular relationship to the stake, such that
centrally between the stakes.
the combined effect with the weed-free circle will
45 Where stated in Appendix 30/6, semi-mature trees prevent accidental damage by mowing machinery.
shall be planted as shown on HCD Drawing Number
K5. Three proprietary anchors per pit shall be provided Tubes, Guards and Ties
at angles of 120° around the pit ensuring that they are 52 In the locations stated in Appendix 30/6, individual
securely locked in position with their cable eyes 50 mm plant protectors as described in Appendix 30/6 shall be
above the layer of coarse gravel and 150 mm from the provided. Plant protectors shall be green, brown or
side of the rootball position. The rootball surface shall black and if formed of solid sheet material this shall be
be protected with a triangular timber frame formed from translucent. The top edge of plant protectors shall be
three pieces of 700 mm x 100 mm x 50 mm timber formed to prevent abrasion damage to the enclosed
securely fastened by nails at each corner. Galvanised plants. Plant protectors shall be fixed with releasable
cable shall be threaded using a ratchet tensioner. Wires ratchet ties to softwood or hardwood stakes, 25 mm x
shall not cut across the rootball. 25 mm in cross section. The length of the stakes and the
46 Unless otherwise stated in Appendix 30/6, backfill number of stakes and releasable ratchet ties to be used
to tree pits shall comprise any excavated topsoil and shall be as stated in Appendix 30/6. Where two stakes
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imported topsoil as necessary with compost in are used they shall be placed opposite each other within
accordance with sub-Clause 3006.14, in a 80% the plant protector.
topsoil/20% compost mixture thoroughly mixed.
Mulches: Ground Preparation
47 For bare root trees, each tree shall be planted
upright in the centre of the hole and the root system 53 Before application of any mulch the planting areas
fully spread outwards and downwards in the pit, at the and/or tree positions which are to be mulched shall be
correct level so that the stake passes through the root free of grass and weed growth. Where required in
system as closely to the trunk as possible, with minimal Appendix 30/6, the planting areas and/or tree positions
disturbance to the roots themselves. Once the tree has shall be watered at the rate stated in Appendix 30/6.
been correctly positioned the pit shall be backfilled with
Organic Mulches
the pre-mixed soil/compost mixture.
48 During backfilling, the tree shall be gently shaken 54 Where it is stated in Appendix 30/6 that compost
at regular intervals to settle the mixture closely around shall be applied as a surface mulch it shall comply with
the roots. The backfill mixture shall be firmed in layers sub-Clause 3006.14 or other composition as specified in
not exceeding 150 mm to a finished level equivalent to Appendix 30/6.
the nursery soil mark on the tree. 55 (05/08) Where it is stated in Appendix 30/6 that
49 Where required in Appendix 30/6, each tree shall timber mulch is to be used, it should be a product
be watered in on the same day as planting, at the rate certified under the Forest Stewardship Council (FSC),
stated in Appendix 30/6. The water shall be delivered as an appropriate grade for the site. Two types may be
by means of a low pressure hose to avoid any washing used:
out of the soil, into a depression made in the planting (i) Chipped conifer bark, size range 25-75 mm,
medium around the base of the stem to ensure that the maximum 15% fines, composted for a
water goes to the root system. The planting medium minimum of six weeks prior to delivery; or
shall then be returned to its previous level.
(ii) An organic mulch comprising composted
50 Where stated in Appendix 30/6, a 75 mm or 80 mm wood chips or bark, free of fungi and
diameter perforated flexible plastic irrigation pipe shall diseases, methyl bromide contamination or
be inserted around the rootball during planting, at a foreign material. It shall be matured for a
depth of 150 mm below the ground surface. The pipe minimum of 16 weeks, naturally heated by
the process of decomposition to temperatures

exceeding 50°C for a minimum period of 14 62 As directed in Appendix 30/6, where sheet mulch is
days, followed by a period of stabilisation. used for hedges it shall be laid either in:
56 Where organic mulch is to be used as a mulch, it (i) 3 strips of sheet mulch shall be laid along
shall be spread evenly over the planting bed, or over a 2-row hedges, one between each planted row
1 m diameter circle around trees, to a depth of 75 mm and one on each side, to cover an area
after settlement. extending 300 mm beyond both sides of the
line(s) of hedge plants; or
57 Organic mulch shall be hollowed out where
necessary to ensure low branches and foliage are not (ii) one strip of sheet mulch shall be laid, to
covered. The mulch surface shall be left even, tidy, and extend at least 300 mm beyond both sides of
sloping down at bed edges. the line(s) of hedge plants and an ‘L’ shaped
slit measuring 150 mm x 150 mm shall be
Individual Mulch Mats made to accommodate the planting of
58 Where it is stated in Appendix 30/6, that mulch hedging plants.
mats are to be used they may be square or round. Unless 63 Sheet mulch strips shall be overlapped at joins.
otherwise specified in Appendix 30/6, mulch mats shall Strips used for hedges or over planting beds shall be
be not less than 800 mm x 800 mm (or 800 mm secured by one of the following methods, as directed in
diameter) or greater than 1000 mm x 1000 mm (or Appendix 30/6:
1000 mm diameter). Mulch mats shall be manufactured
(i) 200 mm x 3 mm diameter wire pegs or
from the material specified in Appendix 30/6.
proprietary plastic pegs manufactured for
59 The mulch mat shall be placed over or split and this purpose, driven through the mat to their
placed around the plant stem and shall be spread out full depth at 300 mm intervals along all
over the ground, ensuring that the plant is in the centre edges and overlapping joins. Pegs shall not
of the mat. be used to secure polythene or bituminous
60 Edges of mulch mats shall be secured as directed in felt mulches; or
Appendix 30/6 by either: (ii) burying a strip 100 mm wide along the edges
(i) 200 mm x 3 mm diameter wire pegs or of the mat vertically into the ground. All cut
proprietary plastic pegs manufactured for edges of woven polypropylene sheet mulch
this purpose, driven through the mat to their shall be so buried to prevent fraying; or
full depth at the corners of square mats or at (iii) placing pieces of turf minimum 150 mm x
six equally spaced points around circular 150 mm in size, laid at 500 mm intervals
mats, plus a peg to secure the overlapped slit. along the outer edges and laid at 500 mm
Pegs shall not be used to secure polythene or intervals along overlapping joins.
bituminous felt mats; or
Sheet Mulch Collars
(ii) burying a strip 100 mm wide around the
edges of the mat vertically into the ground. 64 If required in Appendix 30/6, where mulch mats or
All cut edges of woven polypropylene mulch sheet mulch is used, collars shall be fitted around the
mats shall be so buried to prevent fraying; or stem or trunk of each plant to secure the planting slit
and shall be securely stapled in place.
(iii) placing pieces of turf at least 150 x 150 mm
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in size or other materials of equal weight on Planting of Bulbs

at least eight positions around the mat; or
65 Bulbs shall comply with BS 3936 : Part 9. All bulbs
(iv) as specified in Appendix 30/6.
must be commercially grown, not collected from the
Sheet Mulch wild.
66 The number of bulbs per unit area shall be as
61 Where it is stated in Appendix 30/6 that sheet
described in Appendix 30/6. Bulbs shall be thrown onto
mulch shall be used it shall be black, olive green or
the ground to ensure natural spacing and planted where
brown in colour. Unless otherwise specified in
they fall.
Appendix 30/6, sheet mulch shall be manufactured from
at least 500 gauge tear resistant polythene, or from 67 Bulbs shall be planted with the base of the bulb at
woven or spun-bonded polypropylene weighing 100 to the depth stated in Appendix 30/6. Bulbs shall have
110 g/m2 and shall contain an ultra-violet inhibitor. their base in contact with the soil at the base of the hole.
Where bulbs are to be planted in formal grass areas a

plug of turf shall be neatly removed to form the Planting of Reeds, Rushes, Marginal, Emergent and
planting hole and replaced after planting. Aquatic Plants
Wildflower Plant Preparation and Planting 73 Where it is stated in Appendix 30/6, Reeds,
Rushes, Marginal, Emergent or Aquatic Plants shall be
68 Where it is stated in Appendix 30/6 that areas are planted in or adjacent to ponds, rivers, ditches, lakes,
to be planted with wildflowers the Contractor shall and other areas of impeded drainage.
prepare the ground by one of the following methods, or
74 Reeds and rushes shall be clumps of minimum size
otherwise, as stated in Appendix 30/6:
300 x 300 x 300 mm, excluding top growth, excavated
(i) create an area free of all live plant growth from an approved source of established material, and
not less than 300 mm and not more than free of pests, diseases, weed species or pollutant
450 mm in diameter at each plant station chemicals or metals.
using a translocated herbicide to
75 Emergent, marginal, and aquatic plants shall be
sub-Clause 3002.4. Where spacing is very
container-grown in pots of minimum 1 litre size, and
close, plant stations shall be merged; or
shall have been rooted and grown within the pot for at
(ii) cultivate an area at each plant station to the least six months. Aquatic plants may be supplied in
following dimensions: plastic or wire basket pots.
diameter = width of plant rootball x 1.5 76 All plant material shall be kept fully watered up
depth = depth of plant rootball x 1.5. until time of planting, and the soil or rooting zone
prevented from drying out.
69 Wildflower plants shall be distributed in natural,
informal groups or as shown on the Drawings. Where 77 Planting positions above the water level shall be
required in Appendix 30/6, the planting positions or formed by excavating and setting aside sufficient
areas shall be marked out prior to planting for approval material to allow 75 mm between the root/rhizome ends
by the Overseeing Organisation. The density of plants/ and the sides of the pit when the roots are fully spread
m2 shall be as stated in Appendix 30/6. for backfilling. The sides and bottom of the excavated
position shall be cultivated to a depth of 100 mm.
70 A hole shall be formed in the cultivated plant Excavated material from plant clump positions shall be
station of a sufficient depth and width to allow roots to disposed of in locations stated in Appendix 30/6.
be spread without cutting or bending. Friable topsoil
shall be replaced over the roots to bring the surface 78 When the clump has been set in the centre of the
level with that of adjacent areas. Plants shall only be position, fine material selected from the excavated
removed from their protective covering or packing material shall be packed and shaken around the roots
immediately before planting and the roots shall not be and thoroughly firmed. Excavated material shall be
allowed to dry. backfilled in layers not exceeding 150 mm. Following
planting, the area of backfilling around each clump
71 Where stated in Appendix 30/6, wildflowers shall shall be left tidy.
be planted through mulch mats. No more than five
plants per m2 of mat shall be planted. The Contractor 79 For planting positions below the water level,
shall lay the mat above the planting station after the clumps of plant material shall be pushed into the
cultivation is complete and cut the mat so that the hole ground to sufficient depth to cover roots/rhizomes.
created will be no greater than 1.25 times the surface Plants shall be firmed by treading. Aquatic plants shall
area of the plug. The sides of the mat must be buried be securely pegged or wired down into the bed.
sufficiently and securely to prevent rodents or other
Marker Posts for Planted Areas
such vermin entering beneath the mat. The planting
station shall be sufficiently concave to encourage 80 Where stated in Appendix 30/6, the Contractor
positive run-in of rainwater. shall insert marker posts to mark out the boundary of
72 Each plant shall be watered in its container not less each planting or wildflower seeding area which is not
than 2 hours or more than 24 hours before planting. 0.5 otherwise protected by fencing or other structures.
litres of water shall be applied to each plant 81 Marker posts shall be of timber complying with
immediately after planting unless heavy rain is falling Clause 304 and shall be at least 1000 mm long and have
at the time. a diameter of 50-75 mm. The top 300 mm of each
marker post shall be painted with a white waterproof
paint. Where unpeeled stakes are used the top 300 mm
shall be peeled before painting.
Amendment - May 2001 --`,,,`,`,,,`,,,,```,`,`,`,,,,`-`-`,,`,,`,`,,`---

13
82 Marker posts shall be driven at least 500 mm into specification. Where required in Appendix 30/6, plants
the ground leaving 500 mm above ground. shall be watered at the rate stated in Appendix 30/6.
Watering shall be carried out prior to any mulch
83 Posts shall be spaced at not more than 20 m apart
reinstatement.
around the perimeter of the planted area and shall be
located at all corners of over 15°.
Post-planting Maintenance
84 Where a cable or underground service is adjacent
to or within a planted area, then any posts shall not be 92 For the duration of the period stated in
closer than 1.5 m to the cable and painted red. Appendix 30/6, which shall run concurrently with the
period stated under sub-Clause 3006.87, the Contractor
85 The pegs shall be maintained in good condition. shall carry out maintenance of new planting in
accordance with Clauses 3007 and 3009 as appropriate.
Replacement of Failed or Defective Plants
86 The Contractor shall maintain all planting
3007 Grass, Bulbs and Wildflower
undertaken under the Contract in accordance with
Clauses 3007, 3008 and 3009 until all planting works
Maintenance
are certified as completed.
General Grass Maintenance
87 For the duration of the period stated in
Appendix 30/6, the Contractor shall replace all plants 1 The grass and wildflower areas to be maintained
which are missing, have died, or which in the opinion are scheduled in Appendix 30/7. Prior to any cutting
of the Overseeing Organisation are failing to make operation all stones or other harmful material from
satisfactory extension growth. whatever source which may damage grass cutting plant
or create a possible hazard to persons or property shall
88 In early September of each year following be removed off Site. All litter from grass cutting areas
completion of the initial planting of woody plants, the shall be removed off Site prior to grass cutting. Any
Contractor shall arrange an inspection of each area of movable obstructions such as seats and litterbins shall
new planting works with a representative of the be removed to facilitate cutting and replaced prior to
Overseeing Organisation. Where bulbs, perennials, leaving the Site.
wildflowers or aquatic plants have been planted, the
Contractor shall also arrange an inspection of each area 2 Tractors mounted with grass cutting equipment
of new planting works with a representative of the shall comply with manufacturer’s recommendations
Overseeing Organisation in the April following regarding the fitting and operation of attachments.
completion of the initial planting. Grass cutting equipment fitted to tractors shall comply
with manufacturer’s recommendations regarding the
89 All plants which are missing, are damaged, have fitting and operation of such attachments. All dedicated
died, or, in the opinion of the Overseeing Organisation, grass-cutting machines shall have an effective silencer
are failing to make satisfactory extension growth, shall of the type originally fitted on manufacture. All grass
be replaced in the next planting season as stated in sub- cutting equipment, whether self-propelled or attached to
Clauses 3006.17 to 3006.20 immediately following the a tractor, shall comply with the following:
inspection. Replacement plants shall, in all aspects, be
the same as the original stock at the time of planting, (i) All cutters and blades shall be sharpened and
except that it shall be an additional year older for each set according to the manufacturer’s
year that has elapsed since the original stock was first recommendations to ensure a consistent
planted, unless otherwise stated in Appendix 30/6. All cleanly mown sward and the height of cut
replacement planting work shall be carried out in determined as the height above ground level
accordance with Clause 3006. The Contractor shall bear to the cutting blade measured with the
the cost of all plant replacements, unless otherwise machine standing on a hard level surface.
stated in Appendix 30/6. (ii) All guards shall be in place and in good
90 When replacement planting is undertaken, ground condition and all safety devices shall be
and pit preparation and planting shall be undertaken in operational and of a type originally fitted on
accordance with this Clause. All plants removed shall manufacture.
be taken to a tip off Site. Diseased plants shall be (iii) For grass and vegetation cutting on slopes,
disposed of in accordance with sub-Clause 3010.3. the grass-cutting equipment manufacturer’s
91 Following replacement planting, any stakes, ties, recommendations relating to safe gradients
tubes or guards shall be refixed/replaced and any mulch for cutting shall be observed.
or mulch mats shall be reinstated to the original
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14
3 Grass shall be cut cleanly and evenly, at the lines as determined by the original shape of the grass
frequencies and to the heights specified in this Clause, area, or the adjacent structure or hard surface shall be
without damage to the existing surface. Soft vegetative produced. Herbicide treatment in lieu of edging will not
growth such as clover and other broad-leaved be permitted.
vegetation shall be deemed to be part of the cutting
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11 The edges of planted areas adjoining kerbs, hard
operation where it falls within areas of grass.
surfaces and structures shall be re-formed at least twice
4 Mowing shall take place over the whole grass area per year to produce clean straight or curved lines as
up to its boundaries which may be fencing, paving or determined by the original shape and dimension of the
similar, leaving no areas uncut and producing an even grass area. Where edges abut planted areas, re-forming
sward height across the whole area. shall include drawing back the soil from the edges so
that edging shears can be used.
5 The grass cutting operation shall include cutting
around all obstacles such as trees, posts and signs. 12 Where edges abut hard surfaces, re-forming shall
Strimmers may be used where appropriate. Areas include the removal of any soil or vegetation growing
around obstacles shall be cut to the same height as on or through the hard surface.
specified for the surrounding grassed areas, but no
cutting shall be carried out within the distance from Grass Cutting: Medium frequency
individual plants given in Appendix 30/7.
13 In the locations stated in Appendix 30/7, cutting
6 Mowing operations shall avoid spillage of debris requirements for parkway and other grass areas shall be
such as stones onto carriageways or footways. Grass as follows, or as otherwise stated in Appendix 30/7:
clippings and arisings lying on roads, footpaths, car
parks, drains and other hard surfaces shall be (i) First Cut after Winter/Spring. The areas shall
immediately swept up and removed off Site. Grass be cut when the grass reaches a height of
clippings and arisings on all other areas shall be 75 - 150 mm to a height between 50 - 70 mm
dispersed evenly over the sward, unless specified and the cuttings removed off Site.
otherwise in this Clause or in Appendix 30/7. (ii) Subsequent Cuts. The areas shall be cut to a
7 During periods when ground conditions are so wet height between 50 - 60 mm at least 6 times
as to prevent grass cutting without causing damage to per year during the growing season and the
the surface or producing divots, operations shall cease cuttings evenly dispersed.
and shall recommence only when ground and weather 14 The edges to ornamental planting areas adjoining
conditions are suitable. kerbs, hard surfaces and structures shall be trimmed
8 Bulb foliage in areas where grass is cut shall not be with edging shears or mechanical equivalent at least
cut down as a separate operation. The first cut of grass twice per year during the growing season. Clean
areas containing bulbs shall, as far as is possible, be straight or curved lines shall be produced as determined
timed to coincide with the commencement of bulb by the original shape of the grass area. Herbicide
foliage die-back, not earlier than six weeks after treatment in lieu of edging will not be permitted.
flowering and normally early June for Narcissus spp. 15 The edges of ornamental planting areas adjoining
kerbs, hard surfaces and structures shall be re-formed
Grass Cutting: High frequency with a half moon edging iron or a mechanical
equivalent once per year to produce clean straight or
9 In the locations stated in Appendix 30/7, cutting
curved lines as determined by the original shape of the
requirements for close mown grass shall be as follows,
grass area.
or as otherwise stated in Appendix 30/7:
16 Where edges abut hard surfaces, re-forming shall
(i) First cut after Winter/Spring. The areas shall
include the removal of any soil or vegetation growing
be cut when the grass reaches a height of
on or through the hard surface.
50 - 75 mm to a height between 25 - 40 mm
and the cuttings removed off Site. Grass Cutting: Low frequency
(ii) Subsequent cuts. The areas shall be cut to a
height between 25 - 30 mm, at least 12 times 17 In the locations stated in Appendix 30/7, cutting
per year during the growing season. requirements for amenity and other grass areas shall be
as follows, or as otherwise stated in Appendix 30/7:
10 The edges of planted areas adjoining kerbs, hard
(i) First Cut after Winter/Spring. The areas shall
surfaces and structures shall be cut with edging shears
be cut when the grass reaches a height of
or a mechanical equivalent, at least 4 times per year
100 - 150 mm to a height between
during the growing season. Clean straight or curved
50 - 70 mm and the cuttings removed off Site.
(ii) Subsequent Cuts. The areas shall be cut to a tree and shrub seedlings with stems of less than 20 mm
height between 80 - 100 mm at least 3 times diameter, but exclude trees and shrubs of less than
per year during the growing season and the 200 mm diameter which form part of the plantation.
cuttings evenly dispersed.
24 Unless otherwise stated in Appendix 30/7, arisings
shall be raked off and removed off Site, by such means
Grass Cutting: Minimal frequency
that avoids pulling, tearing or causing other damage to
18 In the locations stated in Appendix 30/7, a single the soil surface and retained vegetation.
cut shall be undertaken once per year on swathe cuts, 25 Where it is stated in Appendix 30/7 that grass and
visibility areas and other areas as required in herbaceous plants shall be cut in planted areas/
Appendix 30/7. The cut shall be to a height not exceeding plantations, the Contractor shall cut between the woody
100 mm and the cuttings evenly dispersed to leave a plants over the whole area up to the boundaries of the
neat and uniform appearance. The timing of the cutting planted area/plantation, whilst avoiding damage to the
shall be as stated in Appendix 30/7. Where the areas trees and shrubs, leaving no areas uncut and producing
contain injurious weeds as listed in sub-Clause 3002.1, an even sward height across the whole area.
the first cut shall be undertaken prior to the weeds
flowering. Additional selective cuts shall be undertaken Wildflower Areas and Areas of Nature Conservation
within these areas as required in Appendix 30/7 or Value
instructed by the Overseeing Organisation.
26 Where cutting of wildflower areas or areas of
19 A single cut of 1 m width from the edge of the
nature conservation value is required, one or more of
carriageway shall be undertaken once per year.
the following operations, or any other operations, shall
Additional selective full width cuts shall be undertaken
be carried out, as directed in Appendix 30/7:
within sight lines at hazardous bends, junctions,
roundabouts, some central reservations, major accesses, (i) Annual Spring/Summer Cut
bus stops and laybys and any other areas as required in
Areas shall be cut to a height of between 50
Appendix 30/7 or instructed by the Overseeing
and 60 mm after the seeding of desirable
Organisation.
species, in late spring/early summer or as
20 A single cut shall be undertaken once per year in directed in Appendix 30/7. Arisings shall be
the visibility splay in front of road signs. The cut shall raked off and removed off Site, avoiding any
extend from the edge of the carriageway, at a point 50 m pulling, tearing or causing other damage to
from the sign and be splayed to meet the full width of the soil surface and retained vegetation.
the sign. Additional selective cuts shall be undertaken
(ii) Annual Summer/Autumn Cut
within these areas as required in Appendix 30/7 or
instructed by the Overseeing Organisation. Areas shall be cut to a height of between 50
21 All vehicles involved in verge and visibility area and 60 mm after the seeding of desirable
species, in late summer/early autumn or as
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cutting shall comply with the requirements of
Clause 117. directed in Appendix 30/7. Arisings shall be
raked off and removed off Site, by such
Grass Cutting: Banks and Ditches means that avoids pulling, tearing or causing
other damage to the soil surface and retained
22 In the locations stated in Appendix 30/7, banks and vegetation.
ditches shall be cut to a height of between 60 and
(iii) Topping Cut
80 mm, at a frequency of once per year or as otherwise
stated in Appendix 30/7. The arisings shall either be Areas shall be cut to a height of between 90
dispersed evenly over the sward avoiding blockage of and 100 mm after the seeding of desirable
drains and ditches, or removed off Site, as required in species, in late autumn or as directed in
Appendix 30/7. Appendix 30/7, with the cuttings being
finely chopped and evenly dispersed over the
Grass Cutting: Areas of Planting area.
23 In the locations stated in Appendix 30/7, grass and (iv) Biennial Cut
herbaceous groundcover in uncultivated planted areas/ Areas shall be cut to a height of between 50
plantations shall be cut to a height of between 60 and and 60 mm, after the seeding of desirable
75 mm after the seeding of desirable wildflower species, species, every alternate year. Arisings shall
every alternate year or at a frequency stated in be raked off and removed off Site.
Appendix 30/7. Unless otherwise stated in
Appendix 30/7, the cutting shall include bramble and
27 Within the wildflower areas or areas of nature efficient execution of watering on any particular Site
conservation value stated in Appendix 30/7, the cutting including stand pipes, pressure reducing valves, hoses,
shall include areas of bramble, tree and shrub saplings bowsers, pumps, sprinklers and ascertaining the
of less than 20 mm diameter. Cutting shall be timed to availability of second class water from sewage works or
allow for prior seeding of desirable species listed in other approved sources in the event of a Hose Pipe Ban.
Appendix 30/7.
2 Watering of grass, shrubs, hedges and trees shall be
28 Where directed in Appendix 30/7, to improve the temporarily suspended in areas where ponding occurs
potential for wildflower colonisation in wildflower or where there is a risk of surface run-off. Once any
areas or areas of conservation value identified by the surface water has soaked away, repeated applications
Overseeing Organisation, the ground shall be scarified shall be applied until the watering operation has been
by mechanical means to a depth of 25 mm so that the completed.
thatch is broken up, creating a proportion of exposed
3 Water to individual trees shall be applied either by
soil of 15-20%. Arisings shall be removed off Site. The
low pressure hose or through irrigation hoses to the
method employed shall avoid the uprooting of desirable
base of the plants ensuring thorough soaking of the
vegetation such as fine grasses. A sample area treatment
ground occupied by the root system of the plant. Where
shall be carried out to the Overseeing Organisation’s
necessary a depression shall be formed around the stem
approval prior to the remainder being scarified.
base of the plant to ensure that water reaches the root
29 Where directed in Appendix 30/7, weed control in zone and does not run off at the surface onto the
wildflower areas shall be carried out using spot surrounding ground.
treatment with a translocated herbicide applied in
4 Any damage caused as a result of watering
accordance with sub-Clause 3002.7, at the frequency
operations shall be reinstated including the replacement
stated in Appendix 30/7. Herbicide shall be applied to
of any soil lost from pits or beds due to washing off.
undesirable broadleaved species such as the thistles
Following watering, bed and pit surfaces shall be left
listed in Clause 3002, nettle and bramble unless they are
even and all plants firm and root systems not exposed.
stated in Appendix 30/7 to be of nature conservation
Particular care shall be taken not to damage plants when
value.
handling hoses in planted areas.
30 Where directed in Appendix 30/7, any weed growth
that cannot effectively be controlled by chemical means Establishment Watering
without risk of damage to wildflowers shall be hand- 5 The Contractor shall water all planting undertaken
weeded in accordance with sub-Clause 3002.8, at the under the Contract, in accordance with this Clause, at
frequency stated in Appendix 30/7. the frequency necessary to ensure establishment and
Molehills survival, until all planting works are completed.
6 For the establishment period stated in
31 If required in Appendix 30/7, molehills in grass
Appendix 30/8, the Contractor shall water all planting
areas shall be removed before grass-cutting and the soil
undertaken under the Contract, in accordance with this
distributed widely over surrounding grass or on nearby
Clause, at the frequency necessary to ensure
cultivated areas.
establishment and survival.
Bulbs and Perennials
Additional Watering
32 Where required in Appendix 30/7, bulb foliage
7 Where required in Appendix 30/8, additional
within ornamental planting areas shall be cut down
watering shall be instructed by the Overseeing
when leaves have died back naturally: not earlier than
Organisation in the locations stated in Appendix 30/8,
six weeks after flowering and normally early June for
during periods of abnormally dry weather. When
Narcissus spp. Bluebell stands shall not be cut. Arisings
instructed, water shall be applied at the following rates
shall be raked up and removed off Site.
or as stated in Appendix 30/8:
(i) Grassed areas: water shall be applied at the
3008 Watering rate of 15 l/m2 using low pressure hose
sprinkler or spray evenly over the entire area.
General
(ii) Shrubs, hedges and ornamental beds: water
1 The Contractor shall ensure that there is no delay in shall be applied at the rate of 25 l/m2 to
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the execution of watering by obtaining all necessary shrub beds and 25 litres per linear metre to
licences and permissions from water companies for the

hedgerows by low pressure hose sprinkler or 7 At the edges of planted areas, branches and stems
spray evenly over the entire area. Careful shall be cut back to a minimum of 300 mm behind the
forking of sealed or compacted surfaces shall kerbline, fence, wall or other edge demarcation.
be carried out to facilitate percolation.
Organic Mulch
(iii) Trees: the minimum quantity of water
specified in Appendix 30/8 shall be applied 8 Any mulch which has fallen onto adjoining hard
by low pressure hose to each tree. Before the surfaces and grassed areas shall be swept up and if not
first application of water and after any break contaminated by weeds or rubbish returned to the
of more than five weeks, the ground surface planted area and spread to original depth. Any mulch
around the tree for a radius of 500 mm shall which has been contaminated by weeds or rubbish shall
be loosened with a fork to aid penetration be removed off Site.
into the soil. The water shall be applied at a
steady rate to avoid run-off to and erosion of Weed Control: Young Trees and Shrubs in Grass
the surrounding area. Plots
9 Plant circles shall be defined as the area within a
500 mm radius of an individual tree or shrub, within
3009 Establishment Maintenance for Planting which weed control operations are carried out.
1 Plants and planting areas shall be maintained in 10 At the locations and frequency stated in
accordance with this Clause in the locations and over Appendix 30/9, where mulch mats are not used,
the time periods stated in Appendix 30/9. translocated herbicides shall be applied to the plant
circles around individual trees and shrubs in accordance
Firming
with Clause 3001 and sub-Clause 3002.2, using a shield
2 Plants shall be inspected during each visit to to protect the plants from the herbicide. The operation
undertake maintenance operations and any which have shall include the clearance of vegetation by hand from
been subject to frost heave or wind rock shall be within shelters and guards.
straightened to an upright position and the ground 11 At the locations and frequency stated in
re-firmed. Appendix 30/9, where mulch mats are not used, a
Stakes, Tubes, Guards and their Ties residual herbicide shall be applied to the plant circles
around individual trees and shrubs in accordance with
3 Stakes, tubes, guards and their ties shall be Clause 3001 and sub-Clause 3002.2, whilst protecting
inspected twice per year in October and March, and the trees and shrubs from the herbicide. Prior to
adjusted to allow for the growth of each plant. Any application, the ground surface shall either be free of
damaged items shall be removed off Site and replaced grass or weeds, or any grass present shall be no more
with new items in accordance with Clause 3006. than 50 mm height.
4 Stakes, tubes, guards and ties shall be removed 12 Where directed in Appendix 30/9, the depth of
from plants where they are no longer required and mulch in individual plant circles and overall plant areas
either disposed of off Site or returned to the Overseeing shall be inspected once per year in March and if less
Organisation for re-use, as required in Appendix 30/9. than an even depth of 75 mm, new mulch to
sub-Clause 3006.55 shall be laid to restore the depth to
Pruning 75 mm.
5 (05/08) All pruning shall be undertaken in 13 Where directed in Appendix 30/9, mulch mats shall
accordance with the requirements of Clause 3010, using be inspected three times per year. Any mats and pegs
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secateurs and handsaws. Stems shall only be removed which are not secure shall be re-fixed. Damaged items
so as to retain the natural appearance of the individual shall be replaced with mulch mats to match the
plant species in accordance with the guidance in originals, in accordance with sub-Clauses 3006.59, 60
BS 7370 Part 4. Arisings from pruning shall be disposed and 61.
of in accordance with Clause 3010.
14 Five years after planting, any non-biodegradable
6 (05/08) All broken and badly damaged branches mulch mats and any pegs shall be removed off Site and
from the plants shall be pruned by cutting back to the soil surface made good.
within 10 mm of the parent branch or trunk or to a
suitable bud/node. The cut shall be angled correctly in
accordance with BS 7370 Part 4.

Weed Control: Young Trees and Shrubs in single specimens rather than as part of a planted group.
Cultivated Beds Street trees in pavements, tree grilles and those planted
as specimens within a plot are defined as individual
15 Ornamental planted areas shall be cleared of all trees, as well as any other existing young or semi-
litter and debris prior to weed control operations and mature trees identified in Appendix 30/9 or by the
the arisings removed off Site. Overseeing Organisation.
16 Where required in Appendix 30/9, planting areas 25 The individual trees in the locations stated in
shall be visited monthly to carry out specified weed Appendix 30/9 shall be inspected annually during the
control operations. Any grass and weed growth within growing season and maintained as follows:
the planted beds shall be removed by hand or chemical
means as stated in Appendix 30/9. Herbicides shall be (i) Irrigation systems shall be maintained in
used in accordance with Clause 3001. The roots and working order. Any irrigation pipes shall be
foliage of weeds and grass shall be removed off Site checked and repaired if necessary.
once die back is complete. (ii) All weeds around the base of the tree shall
17 The use of herbicide will not be permitted in be removed, to a radius of 500 mm in grass
planting beds containing perennial plants even when the or to a whole tree station if in the pavement
leaves of these plants have died down and they are or a tree grille. Removal shall be by hand
dormant. and/or chemical means as directed in
Appendix 30/9. When using herbicide the
18 Where organic mulch has been applied, the depth requirements of Clause 3001 and
shall be maintained at an even depth of 75 mm by the sub-Clause 3002.2 shall apply.
addition of fresh mulch in accordance with
sub-Clause 3006.55 at least once a year. (iii) Where organic mulch has been applied to a
weed-free circle it shall be topped up to a
19 Where required in Appendix 30/9, in ornamental depth of 75 mm with bark mulch to
planted beds in urban areas where the bed is not sub-Clause 3006.55.
mulched, the soil surface shall be cultivated in May and
July or at the frequency stated in Appendix 30/9, using (iv) Tree supports, stakes, ties and anchoring
a hoe or light rake to create a fine-to-medium tilth, systems shall be inspected and adjusted.
evenly graded, without damage to plants or roots. (v) Rabbit guards, tree guards and grilles shall
be inspected and adjusted.
Weed Control: Hedges
(vi) The levels of aggregate, mulch and soil
20 Where required in Appendix 30/9, the hedge base beneath grilles shall be made up to the same
and an area of 300 mm width on either side of the level as the surrounding surface.
hedge plants shall be kept free of weeds by herbicide
(vii) When trees can stand unsupported, stakes
treatment or handweeding. Herbicides shall be applied
and/or ties shall be removed, back-filling
in accordance with Clause 3001.
stake holes with topsoil and compacting
21 Where organic mulch was applied after planting, topsoil.
the Contractor shall inspect the depth of mulch once per
(viii) Formative pruning shall be carried out in
year in March. If the mulch is less than an even depth of
accordance with Clause 3010, including
75 mm, new mulch to sub-Clause 3006.55 shall be laid
removal of epicormic shoots and the removal
to restore the depth to 75 mm.
of deadwood. Competing secondary leader
22 Where sheet mulch has been laid, it shall be shoots, and closely spaced, duplicated
inspected three times per year. Any sheet mulch or pegs branches with potentially weak or tight forks
which are not secure shall be re-fixed. Damaged items shall be removed.
shall be replaced with materials to match the original, in
(ix) The Contractor shall report to the
Overseeing Organisation any defects
23 Five years after planting, any non-biodegradable requiring further action.
sheet mulch and any pegs shall be removed off Site and
the soil surface made good.
Individual Trees in Urban Streets

24 Individual trees shall be defined as feathered,
standard and extra heavy standard trees planted as
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19
3010 Maintenance of Established Trees and (iv) Where chippings are to be retained on the
Shrubs Site, the chipper shall produce chippings in
the size range 0-75 mm.
1 Plants shall be maintained in accordance with this
Clause in the locations and over the time periods stated (v) Where chippings are to be spread back onto
in Appendix 30/10. the Site within areas of existing vegetation,
without intending to suppress or kill the
Weed Control: Trees and Shrubs in Cultivated Beds existing ground vegetation, the chippings
shall be returned to within the boundary of
2 Cultivated beds shall receive weed control the areas stated in Appendix 30/10 and
treatment four times per year during the growing season spread to an even consolidated depth of
or at the frequency stated in Appendix 30/10. Any grass 25 mm maximum.
and weed growth within the bed shall be removed by
(vi) Where chippings are intended to act as a
hand or chemical means, as required in Appendix 30/10.
Herbicides shall be used in accordance with weed-suppressant mulch, they shall be
Clause 3001 and Clause 3002. The roots and foliage of spread over the pruned or coppiced
weeds and grass shall be removed off Site when die plantations stated in Appendix 30/10 to a
depth of 75 mm.
back is complete.
(vii) Chippings which are excess to the
Arisings from Pruning, Cutting or Felling of Woody requirements specified in Appendix 30/10
Plants shall be removed off Site.
3 (11/04) Any infected (diseased or pest) prunings or (viii) Arisings of greater than 150 mm diameter
timber arisings shall be removed off Site immediately shall be securely placed on Site in the
after cutting and burned or buried at a depth of no less locations stated in Appendix 30/10 for nature
than 2.0 m in a location to be approved in writing by the conservation purposes.
Overseeing Organisation, except diseased arisings (ix) Where directed in Appendix 30/10, the
affected by diseases described in Arboriculture arisings from thinning and coppicing shall be
Research Notes or Arboriculture Research and windrowed on the centre of embankments or
Information Notes issued by the Arboricultural cuttings within the boundary of the area in
Advisory and Information Service, which shall be dealt which the work has taken place. Material
with in accordance with the advice published in these shall not be dragged from one area to
Notes. another. With cross-cutting and cut branches
In the event of a plant disease epidemic, diseased only the timber shall be windrowed. All side
arising shall be disposed of in accordance with the branches from the cut timber shall be
current recommendations of the Department for removed and the timber reduced to 1 m
Environment, Food and Rural Affairs (DEFRA), or the lengths. Windrows shall be formed in one of
Forestry Commission, or, in Scotland, the Environment the following patterns, as required in
and Rural Affairs Department, Scottish Executive or Appendix 30/10, keeping the arisings at least
Forestry Commission, or in Wales, the Welsh Assembly 500 mm away from the retained trees and
Government or Forestry Commission, or in Northern shrubs:
Ireland, the Department of Agriculture and Rural (a) For younger plantations windrows shall
Development - Forest Service. be 7 m apart and a minimum of 3 m
4 Healthy arisings shall be dealt with in one or more from the edges of the plantation. The
of the following ways, as required in Appendix 30/10: windrows shall be secure, with the
material tightly packed and stacked to a
(i) Removed off Site without chipping first. height and width of between 0.5 and
(ii) Chipping. All arisings shall be processed 1 m.
immediately using a woodchipper. All (b) For older plantations, windrows shall be
remaining arisings from thinning/coppicing 7 m apart and a minimum of 10 m from
that cannot be chipped shall be removed off the edges of the plantation. The
Site. windrows shall be secure, with the
(iii) All arisings from chipping shall be removed material tightly packed and stacked to a
off Site. height and width of between 1 and
1.5 m.

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Shrub Pruning wood in March. For hybrid teas, all growth

shall be pruned back to an outward facing
5 (05/08) All pruning cuts shall be made in accordance bud, 3-5 buds from the base of the previous
with BS 7370 Part 4. season wood in March. For Rugosa cultivars,
6 Pruning shall be undertaken using secateurs and all growth shall be pruned back to an
handsaws. Mechanical hedgecutters may only be used outward facing bud, 3-5 buds from the base
on compact small-leafed species which have dense every five years, in March.
foliage. Pruning shall be undertaken to promote (vi) Shrubs which Require Trimming
flowering and fruiting in accordance with the species
and age of the plant. Stems shall only be removed so as Pruning shall be undertaken back to the
to retain the natural appearance of the individual plant flowering heads, but not into the old wood,
species. immediately after flowering.
7 All broken and badly damaged branches shall be (vii) Overgrown shrubs
pruned from the plants. Where stated in Appendix 30/10, shrubs
8 Species shall be pruned in accordance with the shall be coppiced back to within 300 mm of
following categories: the base in late winter. The final wound
surface shall be smooth and angled to allow
(i) Shrubs grown for coloured stems water run-off.
All stems shall be cut down to 50 mm above 9 All growth which extends over the footway or
ground level, or to 50 mm above the coppice carriageway which is dead, dying or hazardous shall be
stool if cut down previously, at a frequency removed. All shrubs that are encroaching upon, or
to maintain a succession of coloured stems, obscuring visibility of adjacent signs, structures,
as stated in Appendix 30/10. This shall be electrical equipment, gates or visibility splays shall be
carried out during the dormant season but pruned. All suckers shall be removed from rootstocks.
outside the bird nesting season.
Climbing Plants
(ii) Shrubs which flower on Current Season
Wood 10 Climber growth which extends over the footway or
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All wood which has borne flowers shall be carriageway which is dead, diseased, dying or
removed immediately after flowering and all hazardous shall be removed. Species which are
young wood retained to bear flowers in the encroaching onto adjacent trees and shrubs shall be
following year. pruned. The climbers shall be inspected at regular
intervals during the growing season and any branches
(iii) Shrubs which flower on Previous Season which are not secure shall be re-attached to the
Wood supporting netting or wires. Any repairs or replacements
All the previous season wood shall be cut to the supporting structures for the climbers shall be
back to within two or three buds of the old undertaken as necessary.
wood.
Hedge Maintenance
(iv) Shrubs which flower on Old Wood
11 The Contractor shall liaise with adjacent
One or two of the oldest stems from each landowners regarding the access arrangements and
plant shall be removed completely, crowded working hours described in Appendices 1/7 and 1/9 in
and weak growth shall be thinned out and the order to carry out hedge maintenance. All arisings shall
young shoots shall be cut back to fresh be disposed of by the Contractor.
growth on the main stems.
12 No trimming, laying, or clipping shall take place
(v) Roses during the bird nesting season. The frequency and
For modern varieties of groundcover and timing of cutting shall be as given in Appendix 30/10.
bush roses, all growth shall be pruned back 13 All cutters and blades shall be sharpened and set
to the point of the previous cut. Hedge according to the manufacturer’s recommendations.
trimmers may be used on these modern
varieties. For other varieties of groundcover 14 Where growth to be cut is up to two years old,
and floribunda roses, all growth shall be highway hedgerow planting may be maintained with
pruned back to an outward facing bud, tractor mounted side arm flails, provided that they cut
5 buds from the base of the previous season cleanly without leaving ragged ends. For ornamental

hedges and hedges where hard growth over two years (i) Midland Hedge - All the pleachers shall be
old is to be cut, only reciprocating blade cutting cut from one side of the hedge and laid
machinery shall be used. Large leafed evergreen hedges diagonally across the line of the hedge so
shall be pruned with secateurs to avoid half cut leaves. that all the brash protrudes on the opposite
side. The hedge shall be supported by
15 Growth shall be reduced to the point of the
greenwood stakes and binders.
previous cut and on completion, both sides of the hedge
shall be perpendicular and the top shall be level and at (ii) Straight Hedge - All the pleachers shall be
right angles to the sides. Exceptions to this shall be as cut and laid along the line of the hedge and
described in Appendix 30/10. inter-woven between hardwood, cleft stakes
spaced at 1 m intervals.
16 All clippings lodged in the top or sides of the hedge
shall be removed off Site. During the cutting operation (iii) Any other regional variation described in
all litter and debris within the structure of the hedge Appendix 30/10.
shall be removed off Site.
21 All cutting tools used on the hedge laying works
17 All hedge laying works shall be carried out in a shall be maintained in a sharp condition to ensure that
manner to ensure that the newly laid hedge possesses a cut surfaces are smooth and made cleanly without
neat, uniform appearance of even density. The work tearing the wood grain. The cuts which facilitate the
shall be carried out ensuring that the cut hedge plants laying of a pleacher shall be made with an axe or
are able to re-grow vigorously. billhook only. Chainsaws shall only be used in the
preparation of the hedge and the trimming of hedge
18 All hedge laying work shall only be carried out
stovings.
during the dormant season, but not during periods of
extreme frost. 22 When a mixed species hedge is to be laid, the
individual species shall be treated in one of the
19 The terms for the component parts of a cut and laid
following ways, as required in Appendix 30/10:
hedge are as follows:
(i) Cutting and laying; or
(i) Stakes - pointed greenwood stems or
hardwood cleft driven vertically into the (ii) Coppicing - hedge plants shall be felled at a
ground to provide support to the laid hedge height not exceeding 100 mm above ground
plants. level leaving their stumps with an angled
surface to shed water and in a form to
(ii) Binders - flexible greenwood stems woven
promote vigorous regrowth; or
together along the top of the hedge to hold it
down and provide support to the stakes (iii) Removal - unwanted hedge plants shall be
(applicable to Midland Hedge only - see felled to ground level and their stumps either
sub-Clause 3010.20). physically grubbed out or chemically treated
to prevent regrowth; or
(iii) Cut-Side - the side of the hedge from which
the hedge plants are cut (applicable to (iv) Retention - certain young hedge plants which
Midland Hedge only - see sub-Clause are either self set seedlings or growing from
3010.20). a healthy coppice stump may be selected to
be retained to grow on as hedgerow trees.
(iv) Brash Side - the side facing the adjoining
field or forestry plantation through which the 23 Unless otherwise stated in Appendix 30/10, the
hedge brash protrudes (applicable to Midland following materials shall be used for staking and/or
Hedge only - see sub-Clause 3010.20). binding:
(v) Stoving - the exposed stump of a laid hedge (i) Midland Hedge
plant.
(a) Stakes shall be obtained from
(vi) Coppice Stool - the cut stump of a hedge broadleaved species such as Castanea
plant. sativa, Quercus robur, Fraxinus
excelsior or Acer pseudoplatanus.
(vii) Pleacher - a live hedge plant which has been
Stakes from any Salix or Populus
cut and laid to form the body of the hedge.
species shall not be used. The stakes
20 If required in Appendix 30/10 that hedges are to be shall be pointed and cut from live
laid, the work shall be carried out in one of the greenwood stems not more than twelve
following styles, as described in Appendix 30/10: weeks prior to being used. They shall
be at least 1.5 m in length and of
30 mm to 60 mm diameter throughout.
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(b) Binders shall be cut from live driven in to a minimum depth of 300 mm at
greenwood stems of Corylus avellana, 1.0 m intervals along a straight line.
Fraxinus excelsior or Salix viminalis not
28 Only greenwood binders shall be used along the
more than six weeks prior to being used
top of the hedge. These shall be tightly twisted around
and shall be at least 2.5 m in length and
themselves and each stake in order to hold the laid
10 mm to 30 mm diameter throughout.
hedge down and offer support to the line of stakes. A
Binders shall not be trimmed until
minimum of four binders shall be included at any one
immediately prior to use.
point and additional binders introduced at each stake in
(ii) Straight Hedges order to maintain the required number.
(a) Stakes shall be cleft and of a hardwood 29 When the hedge laying works at any location are
species stated in Appendix 30/10, complete, any loose branch or twig ends shall be
pointed at one end, 1.8 m in length and trimmed from the cut side and top of Midland Hedges
75 mm to 100 mm in width throughout. and also from the brash side if necessary and from both
sides and the top of Straight Hedges, to leave a neat and
24 All side branches from any hedge plants which
compact appearance.
may impede or obstruct the laying operation or detract
from the style and appearance of the completed hedge 30 All cut material and other arisings shall be removed
shall be removed. off Site by the end of each working day, unless
otherwise required in Appendix 30/10.
25 Any branches which are tangled or interwoven
with other hedge plants shall be removed to ensure that 31 Where any significant gap exists in the hedge after
the hedge plant to be laid is free to be guided into it has been laid, it shall be planted up with new hedge
position. Any dead, damaged or diseased wood, along plants in accordance with Clause 3006. The size of the
with any other foreign objects and debris, shall also be plants, species and planting density/pattern shall be as
removed before the plant is laid. specified in Appendix 30/10.
26 All plants shall be laid in the same direction unless
Individual Established Trees in Urban Streets
a gap is likely to occur. All laid hedge plants shall, as
far as possible, be interwoven into each other and the 32 Individual trees shall be defined as feathered,
supporting hedge stakes to ensure maximum stability. standard and extra heavy standard trees planted as
On sloping ground, all hedge plants shall be laid in an single specimens rather than as part of a planted group.
uphill direction except when back laying is required to Street trees in footways, tree grilles and those planted as
fill a gap. On level ground the direction of laying shall specimens within a group shall be defined as
be in the direction of traffic flow on that side of the ‘individual trees’ as well as any other young or semi-
carriageway except when back laying is required to fill mature trees identified in Appendix 30/10.
a gap.
33 The individual trees shall be inspected annually
27 Stakes shall be driven centrally down the line of during the growing season, and maintained as follows:
the hedge to offer support to the newly laid hedge
plants in accordance with the following staking (i) All weeds around the base of the tree shall
requirements, specific to the two different styles of be removed, to a radius of 500 mm in grass
hedge described in sub-Clause 3010.20, or as required or to a whole tree station if in the footway or
in Appendix 30/10: a tree grille. Removal shall be by hand and/
or chemical means as appropriate. When
(i) Midland Hedges - greenwood stakes of using herbicide the requirements of
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sufficient length to ensure that at least Clause 3001 and sub-Clause 3002.2 shall
150 mm protrudes above the top of the laid apply.
hedge shall be driven in to a minimum depth
of 300 mm at 0.5 m intervals along an even, (ii) Tree supports, stakes, ties and anchoring
straight line. When the binders have been systems shall be inspected and adjusted.
fitted along the top of the hedge, the stakes (iii) When trees can stand unsupported, stakes
shall be cut off 75 mm above the binders and/or ties shall be removed Stake holes
with a sloping cut, which shall face the cut shall be backfilled with topsoil which shall
side of the hedge. be lightly firmed.
(ii) Straight Hedges - Cleft stakes of sufficient (iv) Tree guards and grilles shall be inspected
length to ensure that 100 mm protrudes and adjusted.
above the top of the laid hedge shall be

(v) The levels of aggregate, mulch and soil 40 All mature trees shall be checked for bat roosts in
beneath grilles shall be made up to the same any cavities, before arboricultural works are carried out.
level as the surrounding surface. Any bat roosts shall be reported to the Overseeing
Organisation and no works shall be carried out on any
(vi) Pruning shall be carried out in accordance
tree in which bat roosts are located without further
with sub-Clauses 3010.5, 6 and 7, including
written instructions from the Overseeing Organisation.
removal of epicormic shoots and the removal
The inspection for bat roosts and any subsequent action
of deadwood. Competing secondary leader
thereon must be carried out by appropriately licensed
shoots, and closely spaced, duplicated
personnel.
branches with potentially weak or tight forks
shall be removed. 41 All tools shall be surface sterilised with methylated
spirits after use on trees which are known or suspected
(vii) The Contractor shall report to the
to be diseased.
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Overseeing Organisation any defects

requiring further action. 42 When using tower wagons or cranes the Contractor
shall ensure that manufacturer’s safety limits are not
Arboriculture: General exceeded. Demountable towers shall have all fastening
brackets secured and shall only be used on the
34 All work specified in this Clause shall be appropriate vehicle.
undertaken in accordance with BS 3998, except that
cuts and wounds shall not be treated with a fungicidal 43 Climbing irons shall not be used in the pruning of
sealant, bitumen or latex paint, unless otherwise stated live trees and shall only be used during felling or
in Appendix 30/10. dismantling operations when this is necessary during
emergency works.
35 Where permission has been obtained to carry out
any work under this Contract on trees covered by a Tree 44 No trees are to be used as winch anchors without
Preservation Order or in a Conservation Area this shall the prior consent of the Overseeing Organisation and
be noted in Appendix 30/10. these shall be protected. Alternative types of winch
anchor may be used provided they are appropriate for
36 The Contractor shall comply with the current the conditions prevailing at the Site and the task to be
Forestry and Arboriculture Safety & Training Council undertaken and are of a recognised arboricultural type.
(FASTCO) recommendations in relation to all aspects
of the arboricultural works.

MCHW

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MANUAL OF CONTRACT DOCUMENTS FOR HIGHWAY WORKS

VOLUME 1 SPECIFICATION FOR

SPECIFICATION FOR HIGHWAY

AMENDMENT OCTOBER 2022

This document contains replacement pages for

INSTRUCTIONS FOR USE

Note: A quarterly index with a full set of Volume

Amendment – October 2022

MANUAL OF CONTRACT DOCUMENTS FOR HIGHWAY WORKS

Volume 1 Specification for Highway Works (MCHW 1)

Appendix F Consequential amendment is made to Sections 10.

Amendment – October 2022

AMENDMENTS TO VOLUME 1 – OCTOBER 2022

Series 000 Replace pages 4 to 5 with new pages 4 to 5

Appendix F Replace pages 1 to 60F with new pages 1 to 60F

Amendment – October 2022

1998 June, July and August

2002 May and November

2003 February, May, August and November

2004 May and November

2005 May and November

2007 May and November

2008 May, August and November

2009 May and November

2014 May, August and December

2017 February and May

2020 January, February and March

2021 February, April, July and November

2022 April and October

Series 000 Introduction

Series 100 Preliminaries

Series 200 Site Clearance

Series 300 Fencing

Series 400 Road Restraint Systems (Vehicle and Pedestrian)

Series 500 Drainage and Service Ducts

Series 600 Earthworks

Series 700 Road Pavements – General

Amendment – October 2022

Series 900 Road Pavements – Bituminous Bound Materials

Series 1000 Road Pavements – Concrete Materials

Series 1100 Kerbs, Footways, Cycleways and Paved Areas

Series 1200 Traffic Signs

Series 1500 Highway Communications

Series 1600 Piling and Embedded Retaining Walls

Series 1700 Structural Concrete

Series 1800 Structural Steelwork

Series 1900 Protection of Steelwork against Corrosion

Series 2000 Waterproofing for Concrete Structures

Series 2100 Bridge Bearings

Series 2200 Not Used

Series 2300 Bridge Expansion Joints and Sealing of Gaps

Series 2400 Brickwork, Blockwork and Stonework

Series 2500 Special Structures

Series 2600 Miscellaneous

Series 3000 Landscape and Ecology

Series 5000 Maintenance Painting of Steelwork

Series 5700 Concrete Repairs

Appendix A Quality Management Schemes

Appendix B Product Certification Schemes

Appendix C Product Acceptance Schemes

Appendix D Statutory Type Approval

Appendix E Type Approval/Registration/Listing

Appendix F Publications Referred to in the Specification

Appendix G Not used