Volume 3 - Sec 4

Roads and Infrastructure Works for
Shiab Al Ashkar Neighbourhood

General Specifications
SECTION 4
PAVEMENT CONSTRUCTION
4.1 AGGREGATES FOR PAVING LAYERS
4.1.1 All aggregates for use in the construction of the pavement layers shall be
obtained only from sources approved by the Engineer.
4.1.2 The contractor shall have determined the location, suitability and quantity
of material available before tendering as well as the cost and the amount
of work required to extract, crush, screen and clean the material and the
length of haul to the job site.
4.1.3 The contractor shall provide the Engineer, within thirty (30) days prior to
the
schedules beginning of the crushing and screening operations, with a
complete report on the origin and composition of all stone and/or gravel
aggregates to be used in the work (Aggregate Resources Report). All
materials shall comply with the specified requirements for the various
aggregates.
4.1.4 The contractor shall provide petrographic analysis conducted by a

competent independent testing laboratory which shall include reports on
the suitability of the proposed materials for their use in concrete and
asphaltic mixes.
4.1.5 The source and manufacture of the aggregates, which will meet the
requirements of the Specification, is the sole responsibility of the
Contractor. It is also the contractor's sole responsibility to provide such
aggregates at the rates and in the quantities required to complete the
work within the specified Contract Period.
4.1.6 The approval of the Contractor crushing and screening plant equipment
by the Engineer shall in no way relive the contractor of the responsibility
of producing aggregates which met the Specifications and in the
quantities required for the completion of the work within the specified
Contract Period.
4.1.7 Stock piles of materials produced from each source shall be properly
labeled for clear identification of source and size.
4.1.8 Delivery of materials produced from commercial manufacturing process

shall be accompanied by the manufacturer's certification and test reports
showing that materials comply with the specification for which it is
supplied.
4.1.9 No aggregate producing equipment shall be put into operation prior to the
approval of the equipment by the Engineer. If after the equipment is put
into operation it fails to perform as proposed the Contractor shall provide
additional equipment or replace the original equipment with more suitable
equipment, as may be directed by the Engineer.
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4.1.10 The Contractor shall commence crushing and screening of aggregates

immediately after the Contractor receives approval of his aggregate
sources.
4.1.11 Testing to ascertain the properties of all aggregate materials shall be

cared out in accordance with project specification.
4.1.12 All sources of aggregates shall be approved by the Engineer prior to the
processing of material from such sources. An individual source of
aggregate is deemed to be a particular location within a quarry or borrow
pit where material of a constant specific gravity is obtained (with possible
variation due to minor changes in characteristics of rock). During the
execution of the works variation in the specific gravity of any individual
fraction of aggregate used in the asphaltic mixes by more than 0.020 may
be a cause for rejection of mix design in which case the Engineer may
ask the Contractor for a new mix design. Test certificates obtained by the
Contractor or tests performed by the Contractor at his expense are
intended to assist him in his estimate of the location, extent and
quantities which will comply with the specification, when properly
processed, and will in no way obviate the need for future testing by the
Engineer.
4.1.13 Only materials from approved sources shall be processed for

incorporation into the work. Approval of specific sources of materials shall
not be considered as final approval and acceptance of materials from
such sources. The presence of weathered materials discovered in the
quarry areas shall be a cause of rejection of the source of materials.
4.1.14 After having received approval of specific sources of material the

Contractor cannot change these without prior written approval of the
Engineer.
4.1.15 All processed materials shall be tested and approved before being stored
on the site or incorporated in the works and may be inspected and tested
at any time during the progress of their preparation and use.
Questionable materials, pending laboratory testing subsequent approval
shall not be unloaded and incorporated with materials previously
approved and accepted.
4.1.16 If the grading and quality of the material delivered to the site does not
conform to the grading and quality as previously inspected and tested,
or does not comply with the Specifications the Engineer reserves the right
to reject such material at the site of the work.
4.1.17 Samples must meet all test requirements as specified under the project
Specifications. The Contractor shall permit the Engineer to inspect any
and all material used or to be used, at any time during or after its
preparation, or while being used during the process of the work or after
the work has been completed. All such materials not complying with the
required specifications whether in place or not, shall be rejected and shall
be removed promptly from the work. The Contractor shall supply, or
arrange with any producers or manufacturers to supply, all necessary
material, labour, tools and equipment for such inspection.
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4.1.18 The stockpile site shall be prepared by clearing and smoothing and must
be approved by the Engineer. Prior to any stockpiling of aggregates,
cross-sections of the stockpile site shall be taken and control points
established for use in determining the quantity of subsequently stockpiled
material.
4.1.19 The equipment and methods used for stockpiling aggregates and for
removing aggregates from the stockpiles must be approved by the
Engineer and shall be such that no segregation of the aggregates will
result and no foreign material will contaminate the aggregate. The stock
pile shall be kept flat and the formation of high cone shaped piles shall
not be permitted. The height shall not exceed 5m. For asphalt works,
stock piles of aggregate shall be suitably separated by bin walls and shall
be formed on bituminous or concrete floors.
4.1.20 Material shall be stored in a manner that will ensure preservation of their
specified quality and fitness for the work. They shall be placed on hard,
clean surfaces and, when required by the Engineer they shall be placed
under cover. Stored materials shall be located in such a manner to
facilitate prompt inspection and control. Private property shall not be used
for storage purposes without written consent of the owner or lessee and
payment to him, if necessary, at the Contractor's expense.
4.1.21 The centre of the storage area shall be elevated and sloped to the sides
in order to provide proper drainage of excess moisture. The material shall
be stored in such a way to prevent segregation and to allow proper
control of moisture. Aggregate stockpiles shall be built up in layers not
exceeding one (1) meter. The height of each stockpile shall be limited to
a maximum of five (5) meters.
4.1.22 Sufficient material must be stored in stockpiles to allow for testing and
approval of such materials prior to use in the works.
4.1.23 The contractor shall tidy-up the quarry areas on completion and ensure
that side slopes are not steeper than 1 to 2 and in a condition acceptable
to the Employer and to the Engineer.
4.1.24 Following removal of existing asphalt / Interlocking paving blocks, the

under laying materials (sub-base/aggregate road base/wet mix
macadam) shall be retained for their re-use at such places as directed by
the engineer. Any excavated material wasted by the contractor without
written permission of the engineer, shall be replaced by the contractor at
his own expenses.
4.1.25 Excavated material, when required, shall be improved to meet the

requirements of the specification by adding borrow material which shall
be quantified by the engineer. In such cases payment shall be made for
the quantity of the extra material borrowed.
4.2 GRANULAR SUBBASE

4.2.1 Description
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Granular sub-base shall consist of furnishing, spreading, and compacting,

sub-base in accordance with the details shown on drawings and these
specifications: Granular sub-base used under the carriageway/footpath shall
consist of hard, durable natural/screened gravel or crushed stone, having
suitable binding quality and shall be free from dirt, shale, clay balls gypsum
or other deleterious substances. The material shall lie within the grading
envelope stated below when tested in accordance with BS 812 Part 103 and
shall comply with the properties referred under Clause 4.2.5.
If more than one source is used, the Contractor shall provide a method
statement to the Engineer indicating the method of mixing, stockpiling and
delivery of the mixed material to roadbed. Each time the stockpile is made,
the Engineer shall take samples to check binding quality, homogeneity of the
mix as well as Grading, MDD, CBR and SE. Mixing of dune sand shall not be
permitted. Use of salty water for mixing in sub-base under laying bituminous
mixes shall not be permitted.
The Contractor shall carryout a site trial of at least 100m outside the
permanent work to check and confirm the blending quality and homogeneity
of the mix material and also to establish the compacting effort required to
achieve the required degree of compaction.
4.2.2 Materials
a) Sub-base Type I
Granular sub-base material used under footpath shall be well graded and lie
within the grading envelope stated below when tested in accordance with BS
812 Part 103 Clause 7.3 and shall comply with the properties of type I as
referred under Clause 4.2.5.
b) Sub-base Type II
Granular sub-base type II used under the carriageway shall lie within the
grading envelope stated below when tested in accordance with BS 812 Part
103 Clause 7.3 and shall comply with the properties of type II as referred
under Clause 4.2.5.
SIEVE SIZE PERCENTAGE PASSING

Type I Type II
75mm 100 100
37.5mm 85-100 85-100
19mm 62-94 62-82
9.5mm 40-90 40-70
4.75mm 25-70 25-45
0.6mm 8-35 8-22
0.075mm 0-10 0-10
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4.2.3 Equipment
Equipment shall be according to the type and number outlined in the

Contractor's detailed Programme of Work, as approved by the Engineer.
4.2.4 Construction
Road sub-base material shall be delivered to the roadbed as uniform mixture

and shall be spread in layers. Segregation shall be avoided and the sub-base
shall be free from pockets of coarse or fine materials.
Each road sub-base layer shall be spread by grader or other approved

mechanical methods, watered, shaped to a compacted thickness not
exceeding 150 mm and compacted to the required grade and cross section.
The compaction procedure and plant shall be to the satisfaction of the

Engineer. At the time of compaction the moisture content of the laid material
shall not vary by more than + 2% from the optimum moisture content.
The granular sub-base shall be compacted to not less than 98% of the
maximum density determined in accordance with AASHTO T 180 Method - C
with correction for oversized material Particle size analysis of solid for sieve
analysis of fine and coarse aggregate shall be carried out in accordance with
BS 812 part 103 Clause 7.3.
The surface on completion of compaction shall be well closed, free from

movement under compaction plant and free from ridges cracks or loose
material. The finished surfaces of the road sub-base shall not vary at any
point more than 10 mm above or below the grade established by the
Engineer. The road sub-base shall be maintained in a condition satisfactory
to receive any subsequent base or surfacing material. Sub-base, which does
not conform to the above requirements, shall be reshaped or reworked
watered and thoroughly re-compacted to conform to the specified
requirements.
4.2.5 Relevant Test and Standards
The following tests should be carried out on each source and the material shall conform to
the requirements stated below:
STANDARD LIMIT
TEST Type I Type II
Sampling AASHTO T2 - -
Los Angeles Abrasion AASHTO T96 40 % max. 40 % max.
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Soundness (Magnesium ASTM C88 15 % max. 12 % max.

Sulphate Solution) (5 Cycles)
Liquid Limit AASHTO T89 35 % max. 35 % max.
Plasticity Index AASHTO T90 6 % max. 6 % max.
Compaction Test (Modified AASHTO T180 2.0 gram/ cc min. 2.0 gram/ cc
Proctor) with correction for min.
oversized material
C.B.R. at 98% of modified ASTM D- 1883 45 % min. 60% min.
Proctor density (96 hours
soaked)
Field Density AASHTO T191 98% min. MDD 98% of MDD
Linear Shrinkage BS 1377 Part 2 3% max. 3% max.
Method 6.5
Sulphate Content (Acid BS 812 Part 118 0.5% max. 0.5% max.
Soluble)
Chloride Content (Water BS'812 Part 117 1% max. 1% max.
Soluble)
Sand Equivalent AASHTO T- 176 25% min. 35% min.
4.2.6 Minimum Test Requirements
One sample every l,000Cu.m shall be tested for Grading, Plasticity Index,
Maximum Dry Density, CBR and Loss by Abrasion, one in-situ Density test
shall be made every 500Sq.m of granular sub-base laid but a minimum of
two tests have to be made for each section prepared.
4.3 PROTECTION OF SHOULDERS AND SLOPES

4.3.1 Cement Stabilized Aggregate Capping Layer
1) Materials – Materials shall conform to Section 4.2 “Granular Subbase

Materials (Type I)” of the Specifications except that CBR shall not be
required to be determined.
2) The Sulphate Resisting Cement shall conform to Section 6 of the

Specifications.
3) Water to conform to Section 6 of the Specifications.
4) The mix shall have the following properties/proportions:
i) Cement 6% by weight of the aggregates.
ii) Water to conform to the Optimum Moisture Content

corresponding to the Maximum Dry Density determined
according to BS 1377 part 4.
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iii) Capping Layer shall be compacted to 95% of the MDD.
When tested in accordance with the British Department of Transportation

Specification for Highway Works, Part 3, the minimum compressive strength
at 7 days for an individual cube compacted at OMC should be not less than
4.5 N/mm2; and not less than 7.0 N/mm2 for an average of 5 cubes.
4.3.2 Testing
The testing frequencies shall conform to the following:
a) One sample each for grading, P.I., Sand Equivalent and Loss due to
Abrasion per 2000 cu.m of mixed aggregate before the addition of
cement.
b) MDD determination every 2000 cu.m compacted volume of complete

mix including cement.
c) One sample every 2000 cu.m of compacted volume for cement

content determination according to BS 1924 Part 2 Method 5.1.
d) One In situ Density determination for every 500 sq.m of laid capping
layer.
4.3.3 Method
1. The approved material is stockpiled next to blending plant.
2. The required quantity of cement and water shall be added before the
aggregate material passed through the mixer. After mixing, the
material is loaded on trucks ready for site use.
3. The verge and side slopes shall be prepared to the specified levels
and slopes ready to receive the capping layer material, 50cm
rounding to both verge and slope shall be done.
4. The material is dumped by trucks and is spread by grader to cover

the verge and side slope up to the existing ground, the 50cm
rounding is also formed.
5. The material shall be compacted to 95% of M.D.D.
a) First by steel roller, starting from the toe and moving up;
b) then tire roller, starting from the toe and moving up;
c) and a final pass with steel roller.
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6. The levels and compaction of the capping layer shall be checked.
7. Curing for three consecutive days shall be done by spraying sweet

water on the finalized surface to keep it continuously wet.
4.4 IMPROVED ROCK SUBBASE

4.4.1 Description
This work shall consist of the furnishing and placing of courses of approved
graded coarse and fine aggregates in accordance with clause 4.4.2.1 and
conforming to the specifications given below in an approved manner and in
conformity with the lines, grades and thickness as shown on the typical
cross-sections or as established by the Engineer.
4.4.2 Materials
Improved rock sub-base shall be non plastic crushed rock materials free
from dirt, organic matter, clay, shale, cemented particles and other
extraneous or deleterious matter and shall be of such a quality that will bind
readily to form a firm stable mass with a sound, smooth, well knit upper
surface free from loose materials.
At least 80 percent by weight of the materials shall have at least one

fractured face materials will be accepted based on the sampling stock piles.
However, acceptance of the materials does not constitute acceptance of the
course in place.
The materials shall be laid in layers of the types and depths specified in
Table 4.1 and shall be spread, rolled and compacted in such a manner that
the sizes of materials remain distinct. The surface of the Type I or II layer as
appropriate shall be blinded with Type III materials to refusal and the whole
re-rolled. The whole mass shall not be less than the specified thickness and
the finished surface shall be shaped and compacted to the required levels
and tolerances. Each layer shall be inspected for approval before
commencing the next layer.
Table 4.1 - Improved Rock Sub-base layer details
Completed thickness of Layer Type and Thickness

improved rock subbase Bottom Top
(mm)
Type I Type II Type III
300 180 100 Nominal to complete layer
200 180 - Nominal to complete layer
Where instructed by the Engineer a geo-textile membrane shall be provided,

either below or above the rock layer or the whole rock layer shall be wrapped
on the top and bottom by the geo-textile membrane. Depending on the
requirements of the site the engineer will issue the instructions or it will be
indicated on the drawing. A protection layer of Type III materials to a nominal
thickness of 50mm shall be placed on top and/ or below the geo-textile
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membrane prior to placing subsequent layers. Geo-textile fabric shall meet

the requirements as described hereunder:
Grading
Gradation of the three types of layer shall be as shown in Table 4.2.

Samples for checking compliance with grading requirements of Type I and II
materials shall be taken at the Engineer’s instruction from completed layer
after spreading and before compaction.
Type III material may be naturally occurring in sands and gravels excluding
dune sand.
Table 4.2 - Gradation of Improved Rock Sub-base
AASHTO SIEVE Type I (% Passing) Type II Type III

(mm) 300mm 200mm (% Passing) (% Passing)
6" 100 100 - -

4" 25-70 60-90 100 -
2.5" 5-20 25-50 2 5- 60 -
1.5" - - 0-15 -
1" 0-10 10-25 - -
3/4" - - 0-5 -
3/8" - 0-5 - 100
3/16" - - - 85 - 100
No.4 - - - -
No.8 - - - 60-80
No.40 - - 30 -5 0
No. 100 - - 8-20
No.200 - - 0-10
Physical Requirements
Improved Rock Sub-base material shall comply with the following physical
requirements:
Loss of Sodium Sulphate Soundness) Type I & II 20% Max.

(AASHTO T104), (5 Cycles) Type III 15% Max.
Loss of magnesium Sulphate

(AASHTO T104), (5 Cycles) 25% Max
Thin and elongated pieces by weight 5% Max.

(Thickness less than 1/5 of length)
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Friable Particles 0.25% Max.
Dry Density of Particles 250 gm/cc Min.
Soluble Salts (Type III Material) 5% Max.
Plasticity Index (Type III Material) 6% Max.
In the case where qeotextile membrane is provided beneath the improved

rock sub-base layer, a geotextile protection layer to a nominal thickness of
50mm and conforming with the requirements of Type III material shall be
placed on top of the geotextile membrane prior to placing rock sub-base to
prevent the geotextile membrane from being damaged by the sub-base
layer. Geotextile shall meet the requirements of section 4.5.
4.4.3 Construction Requirements
The material shall be laid in two (2) layers of the compacted depths as given
in Table 4.1 or in one layer up to 200mm thick. The material shall be spread /
laid even in such a way that there be no voids and no large lumps of material
are concentrated in small areas but shall be distributed in well packed round
with the finer material and rolled / compacted in such manner that the sizes
of material remain distinct.
The whole mass shall be to specified thickness and the finished surface shall
be shaped compacted to the required levels and tolerances, blinded with
specified blinding material and re-rolled to form a hard smooth and regular
surface.
The improved Rock Subbase shall be compacted by means of approved

compaction equipment progressing gradually from the outside towards the
centre with each succeeding pass uniformly overlapping the previous pass.
Rolling shall continue until the entire thickness of each layer is thoroughly
and uniformly compacted to the Contract requirements. The surface of the
top layer shall be finished with sufficient balding and rolling or similar in a
manner approved by the Engineer to ensure a smooth surface free from ruts
and ridges and having a cross section conforming to the requirements of the
Contract. The whole shall be carefully blinded to refusal with blinding
material and the surface re-rolled to be hard, smooth, free from lean patches
and be suitable for the operation of paving plant for the overlying layer. If the
surface of the rock Subbase becomes loose and dusty following compaction
then the surface layer shall be watered and compacted.
Compaction trials shall be carried out as specified in the Specification for

Aggregate Road base using the materials and equipment proposed for the
Works.
Sampling and testing shall be carried out by excavation at not less than one
pit per kilometer of each carriageway to check the compaction and
penetration of the fines (blinding material). After approval the pits shall be
refilled and compacted by the Contractor at his own cost and to the approval
of the Engineer.
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The compacted thickness shall be such that the finished level does not vary
by more than 20mm from the required elevation. The variation between two
points on testing with a 3m straightedge shall not exceed 20mm.
No further construction shall be laid on the Improved Rock Subbase until the
later has been approved.
4.4.4 STABILISING CRUSHED MATERIAL
4.4.4.1 In the event the foundation on which the embankment or the subgrade
materials will be laid is saturated by water and unstable, the Engineer may
decide to lay crushed granular material to stabilise the foundation. Stabilising
crushed material shall not be laid directly on ground soil but it shall always be
laid on geotextile fabric covering the area to be stabilised as shown on the
drawings or directed by the Engineer.
4.4.4.2 Such stabilising crushed material when tested in accordance with BS

1377:P2 Cl:9.3, 1990 in accordance with Clause 1/12.8 shall have the
following gradation:-
ASTM SIEVE % PASSING

2" 100
1" 80 - 100
1/2" 60 - 85
No.4 40 - 70
No.10 20 - 50
No.20 5 - 25
No.40 0 - 10
No.80 0 - 2
4.4.4.3 The stabilising crushed material shall have the following characteristics:-
Los Angeles Abrasion - Not more than 30% loss

(ASTM C-131 or
(ASTM C-535)
BulkSpecific Gravity - Not less than 2.65

(ASTM C-127 and C-128)
Absorbtion - Not more than 2.0%

(ASTM C-127 and C-128)
4.4.4.4 The stabilising crushed material will be laid in layers of 15 cm and

compacted until the foundation is fully stabilised such that the total thickness
of the stabilising layer shall not be less than 30 cm. Only after inspection and
approval by the Engineer the Contractor may be allowed to continue the
construction of the embankment with other layers of embankment material
and/or subgrade material. The Engineer may decide, after having taken the
levels of the existing water table in the area, and keeping in consideration
the finished road levels, to excavate portions of the foundation saturated by
water, disposing of the excavated material, and replacing it with stabilising
crushed material.
4.4.4.5 Before starting any stabilising of the foundation the Engineer will instruct the
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Contractor specifying the areas to be stabilised and the final levels to be

reached with the stabilising crushed material.
4.5 GEOTEXTILE FABRIC
4.5.1 Description
The Contractor shall furnish and install geotextile fabric at locations and to the
lines and grades shown on the Drawings or as directed by the Engineer.
Geotextile fabric shall be supplied, tested or suitably certified, and placed on the
prepared roadway subgrade and at other locations prepared for its use to restrain
soil movement, to provide for drainage, and/or to prevent soil erosion.
4.5.2 Material.
Geotextile fabric shall be supplied, tested or suitably certified, and placed on

the prepared base at the locations shown on the drawings or as directed by the
Engineer.
The geotextile fabric shall be a non-woven type produced from long chain
polymeric filaments or yarns such as polypropylene, polyethylene, polyester,
polyamide, or polyvinyl-chloride and formed into a stable network such that the
filaments or yarns retain their relative position to each other when subjected to the
proposed use within the limits of the physical characteristics required and
specified herein. In addition, the fabric shall be inert to commonly
encountered chemicals and shall conform to the requirements of AASHTO
Designation: M288, Standard Specifications for Geotextiles used for
Subsurface Drainage Purposes, except as amended and supplemented herein.
The physical characteristics of the geotextile fabric shall comply with the
requirements of Table 4.3 when subjected to the tests indicated therein. Prior to
shipping of any geotextile fabric to the Site, the Contractor shall provide the
Engineer with certification by the manufacturer of the date and location of its
manufacture, and a statement that the material has been manufactured and
tested and found to comply with the requirements of these specifications. A
copy of such certification, a listing of test results obtained, and date of such
testings shall be physically attached to each roll by the manufacturer prior to
shipment. In addition each roll of fabric shall show the date that it has been
supplied from the manufacturer's plant. At the discretion of the Engineer,
random samples of fabric from any or all rolls of fabric delivered to the job site
shall be tested prior to use. Such samples of material shall be tested at a
laboratory approved by the Engineer for the purpose of verifying the certification
provided. Any sample of material that fails to pass the specified requirements or
material that does not fully comply with these specifications shall subject the
entire roll of fabric to rejection by the Engineer, and such rolls of fabric shall be
removed from the job site within three (3) calendar days after the date of such
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notification by the Engineer. To insure proper control of fabric delivered to the

job site, each roll shall be marked and identified by date of delivery and an alpha-
numeric designation approved by the Engineer.
The fabric shall be supplied in rolls wound on a suitable disposable paper

tube or other non-abrading resilient tube that has an outside diameter of not
less than 10 cm. The width of fabric supplied on each roll shall be such as to
minimize the development of longitudinal and transverse overlaps. Where
longitudinal overlaps are required the width of fabric used shall be not less
than 4.5 m. A narrower width may be used if the number of longitudinal
overlaps is the same as would be developed using the minimum fabric width of
4.5 m. Where transverse overlaps are required, the minimum length of fabric on
a roll shall be 90m. Shorter lengths of fabric may be employed provided that the
number of overlaps resulting there from is the same as that developed using the
specified 90m minimum length rolls.
Table 4.3 - Physical

Requirements
Test Minimum Physical Characteristics

of Fabrics
Description Method Applicable Protected Unprotected
Units Type 1 Type 2
Fabric Weight ASTM D19IO GM/m2 100 135
Tensile Strength ASTMD1682 N 560 900
Elongation ASTM D 1682 % 20 20
Puncture ASTMD751 N 200 600

Strength
Mullen Burst ASTM D3786 kPa 860 2,200

Strength
Tear Strength ASTM Dl 117 N 80 225
Permeability AASHTO M288* cm/sec 0.01 (Note 1) 0.01 (Note 1)
E.O.S CW-022 15-77 U.S. STD (Note 2) (Note 2)
Sieve
Strength ASTM D 1682 N 560 900

Retention
After AATCC-
30-74
Flow Rate AASHTO M288 l/s/m2 25 25
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Appendix
Note 1: Permeability shall not be less than 10 times the permeability of the
soil being drained where the fabric is used to permit drainage of water from the
soil. A constant head (10 cm) permeability test may be utilized when approved by
the Engineer.
Note 2: The E.O.S. value shall be based upon retention of 95% of the size of
beads used in the test. For soil having less than 50% of its sand fraction
(minus No. 4 sieve) passing a No. 200 sieve, the fabric shall have a maximum
E.O.S. of No. 70. Where soil has more than 50% of its sand fraction passing
a No. 200 sieve, the fabric shall have a maximum E.O.S. of 100.
4.6 POLYETHYLENE SHEETS
Where described in the Contact or directed by the Engineer, a protective

membrane to asphalt pavements shall be alkathene grade min 1500 or
similar approved and shall comply with the following requirements: -
a) Tensile Strength - 16.7 MN/Sq.m

b) Strain at break - 800%
c) Tear Strength - 125gm/0.001 inch
d) Bursting Strength - 0.7 MN/Sq.m
e) Impact Strength - 800gm
The protective membrane layer shall be laid over the ground at a minimum
depth of 150 mm below finished subgrade level with a minimum overlap at
joints of 300 mm. It shall be retained in a manner approved by the Engineer
until covered by suitable material.
Before laying the membrane all necessary measures shall be taken to

ensure all the voids in the ground are filled, the surface of the area is graded
to a smooth profile and cleared of all debris and material liable to penetrate
or damage the membrane. Any damage to the membrane shall be rectified
by overlaying a new layer of protective membrane with a minimum overlap of
600mm beyond the damaged area.
The overlaying subgrade material shall be free of large or sharp stones or

other injurious materials and shall be of size not greater than 25mm
diameter. It shall be deposited by end tipping and spread evenly over the
membrane by tracked plant approved by the Engineer. The tracked plant
shall not run on the surface of the membrane. Compaction of the subgrade
and formation shall be undertaken in accordance with the requirements of
Section 3 unless otherwise directed by the Engineer.
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January 2009
A test area of not less than 300 square metres will be carried out prior to
approval being given by the Engineer. Should approval not be given by the
Engineer the test will be repeated until such time as the Engineer is satisfied
with the Contractor's method of working.
At overlaps of the polythene membrane, the splice shall be effected by
means of an approved adhesive tape of adequate width.
4.7 AGGREGATE ROAD BASE

4.7.1 Description
This work shall consist of furnishing and placing one or more courses of
aggregate including binder soil if required, on a prepared subgrade or sub-
base in accordance with the Specifications, in conformity with the lines,
grades, thickness and typical cross-sections shown on the drawings or
established by the Engineer.
4.7.2 Material
4.7.2.1 Material used for aggregate road base shall be free from dirt, shale, gypsum
or other deleterious matter and shall be of such quality that it will bind readily
to form a stable aggregate road base. If more than one source is used the
contractor shall provide a method statement to the Engineer indicating the
method of mixing, stockpiling and delivery of the mixed material to roadbed.
Each time the stockpile is made, the Engineer shall take samples to check
binding quality, homogeneity of the mix as well as grading, MDD, CBR and
SE. Mixing of the dune sand shall not be permitted to improve the SE. Use of
salty water for mixing in sub-base/aggregate road base underlying
bituminous mixes shall not be permitted. The contractor shall carry out a site
trial of at least 30 m outside the permanent work to check and confirm the
binding quality and homogeneity of the mixed material and also to establish
the compacting effort required to achieve the required degree of compaction.
The tests shall be carried out on each source of materials and shall confirm
to the requirements as stated in clause 4.7.2.2.
4.7.2.2 The following tests shall be carried out on each source of material and shall
comply with the requirement stated against each test:-
Liquid Limit (AASHTO T89)
25% max
Plasticity Index (AASHTO 90) 6% max
Sand Equivalent (AASHTO T176) 40% min
Loss by Abrasion (AASHTO T96) 35% max
Flakiness Index (85812 Part 105.1) (Coarse Aggregate) 35% max
Elongation Index (85812 Part 105.2) (Coarse Aggregate) 35% max.
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Soundness (ASTM C88) (Magnesium Sulphate) (5 Cycles) 12% max.
Organic Impurities (BS 1377 Part 3 Method 3) 0.15%

max.
Acid Soluble Chlorides (BS 812 Part 117) 1% max
(Combined Aggregate)
Dry Density (AASHTO –T180 Method C
(with correction for oversized material) 2.0% gr/cc
min.
CBR on Remolded Samples after 4 days soaking at 98% of 80% minimum

MDD (ASTM D1883)
4.7.2.3 The gradation limits when tested in accordance with BS 812 Part 103 Clause
7.3 shall be as follows:
SIEVE SIZE (BS) PERCENT PASSING

50mm 100
37.5mm 70-100
28mm 55-85
20mm 50-80
100mm 40-70
5mm 30-60
2.36mm 20-50
0.425mm 10-30
0.075mm 5-15
4.7.2.4 Aggregate road base shall consist of uniform mixtures of gravel and/or
crushed gravel with sand, silt and clay, conforming to the specified gradation
limits.
4.7.3 Spreading / Laying
4.7.3.1 Aggregate road base shall only be machine laid with approved paver and laid
on subgrade or subbase, which has been approved by the Engineer.
Aggregate road base, which has been placed on a subgrade or subbase not
approved by the Engineer, shall be removed at the Contractor's expense.
4.7.3.2 Aggregate road base shall be laid on the approved subgrade in layers not
exceeding fifteen (15) centimeters in compacted depth.
4.7.3.3 The material shall be handled in a manner, which avoids segregation.

Segregated materials shall be remixed until uniform. Suitable precautions
shall be taken to prevent rutting of the subgrade or sub-base during the
laying of aggregate road base materials. No hauling or placement of material
will be permitted when, in the judgment of the Engineer, the weather or road
conditions are such that the hauling operations will cause cutting or putting of
the subgrade or cause contamination of aggregate road base material.
4.7.4 Compaction
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4.7.4.1 The moisture content of the aggregate road base material shall be adjusted
prior to compaction, by watering with approved sprinkler trucks or by drying
out as directed by the Engineer, to that required to obtain the specified
density for aggregate road base. Aggregate road base shall be compacted to
ninety eight (98) percent of the maximum dry density determined according
to AASHTO T- 180 Method C with correction for oversized material.
Variation of moisture content shall be between +2% of the OMC. The field
density and actual moisture content shall be determined according to
AASHTO T 191-86.
4.7.4.2 The aggregate road base shall be compacted by means of approved

compaction equipment progressing gradually from the outside of the road
towards the centre with each succeeding pass uniformly overlapping the
previous pass. Rolling shall continue until the entire thickness of each layer
is thoroughly and uniformly compacted to the specified density. Rolling shall
be accompanied by sufficient blading in a manner approved by the Engineer,
to ensure a smooth surface free from ruts ridges and having the proper
section and crown.
4.7.4.3 The surface of the course shall, on completion of compaction, be well

closed, free from movement under the compaction plant and free from
ridges, cracks, or loose material.
4.7.4.4 Any areas inaccessible to normal compaction equipment shall be compacted

by means of mechanical tampers until satisfactory compaction is obtained.
4.7.4.5 The Contractor shall program his operations to avoid the drying out of the
subbase during construction. If any layer of aggregate road base material or
part thereof, is permitted to dry out after compaction or does not conform to
the required density or finish, the contractor shall, at his own expense,
rework, water and recompact the material, as directed by the Engineer, to
the density specified, before the next layer of aggregate road base or
subsequent pavement layers is placed.
4.7.5 Compaction trials
4.7.5.1 If directed by the Engineer, prior to the commencement of the aggregate

road base operations, the Contractor shall construct trial lengths not less
than 100 metres. The materials used in the trials shall be those approved for
use as aggregate road base, and the equipment used shall be that according
to the contractor's approved detailed program of work.
4.7.5.2 Trial lengths may not form part of the permanent works but may be permitted
in the construction of temporary detours of sufficient length.
4.7.5.3 The object of these trials is to determine the adequacy of the Contractor's
equipment, the loose depth measurements necessary to result in the
specified compact layers depths, the field moisture content, and the
relationship between the number of compaction passes and the resulting
density of the material.
4.7.5.4 The Contractor may proceed with the aggregate road base work, only after
the methods and procedures, established in the compaction trials have been
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January 2009
approved by the Engineer.

4.7.6 Finishing
4.7.6.1 Immediately prior to the placing of the first layer of the next pavement course
onto the aggregate road base the final layer of aggregate road bases shall
be at the specified density and to the required grade and section. In order to
maintain these requirements while placing the next course it may be
necessary to water and reshape the surface of the aggregate road base.
This work shall be at the contractor's expense.
4.7.6.2 The surface of the finished aggregate road base will be tested with a three
(3) metre straightedge by the Engineer at selected locations. The variations
of the surface from the testing edge of the straightedge between any two (2)
Contacts with the surface shall at no point exceed nine (9) millimeters when
placed on or parallel to the centerline or nine (9) millimeters when placed
perpendicular to the centerline of the roadway. The aggregate cross-section
as shown on the drawings shall not vary by more than nine (9) millimeters
from the required elevation. All humps and depressions and thickness
deficiencies exceeding the specified tolerance shall be corrected by removing
the defective work or by adding new material as directed by the Engineer.
4.7.7 Minimum Test Requirement
4.7.7.1 One sample every l,000 Cu.m shall be tested for grading, plasticity Index,
Sand Equivalent, Maximum Dry Density, C.B.R and loss by abrasion. One in
situ Density test shall be made every 300Sq.m of aggregate road base laid.
4.8 Wet –Mix Macadam Road Base

4.8.1 Description
This work shall consist of furnishing and placing one or more courses of high
quality crushed aggregate, bound by means of carefully controlled moisture
content, on the approved subgrade or sub-base in conformity to the line,
level and thickness shown on the drawings or as directed by the Engineer.
4.8.2 Material
4.8.3 The coarse aggregate shall consist of crushed rock (each particle shall have
a minimum of one crushed face) and the fine aggregate also shall be
crushed rock. The aggregate shall conform to the following gradation.
BS SIEVE PERCENT
SIZE PASSING
50 mm 100
37.5 mm 95-100
20 mm 60-80
10 mm 40-60
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January 2009
5 mm 25-40
2.36 mm 15-30
0.6 mm 8-22
0.075 mm 2-8
The particle size shall be determined in accordance with the requirements of

BS 1377 Part 2 (Method 9.2 and 9.3).
The gradation shall be adjusted as required or as directed by the Engineer

within the above limits to ensure the mix has adequate binding properties.
Wet-mix road-base material shall have physical properties, which do not

exceed the following values:
Liquid Limit (AASHTO T 89) 25%

Linear Shrinkage (BS 1377 Part 2 Method 6.5) 3%
Plasticity Index (AASHTO T90) 6%
Aggregate Crushing Value (BS 812 Part 110) 25%
Water Absorption (ASTM C 128/C127) 2%
Flakiness Index (BS 812 Part 105.1)
30%
Elongation Index (BS 812 Part 105.2) 30%
Los Angeles Abrasion Loss (AASHTO T 96) 30%
(*) Soundness Loss (ASTM C 88) (5 cycles) (Magnesium) 12%
Organic Impurities (BS 1377 Part 3 Method 3) 0.1%
Chloride Content (Acid Soluble) BS 12 Part 117 1% max
Sulphate Content (Acid Soluble) BS 12 Part 118 0.5% max
Sand equivalent (AASHTO T 176) 45%
(*) Soundness requirements shall apply to both course and fine aggregates.
The moisture content of the wet-mix macadam at the time of laying shall be
the optimum + 1%. Water required to achieve this moisture content shall be
added at the mixing plant only.
The mix shall be produced from mechanical mixing plant.
4.8.3.1 Transport and Spreading
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Transport vehicles carrying the plant mixed material shall have a capacity
suited to the output of the mixing plant and the site conditions and be
capable of discharging cleanly. Material when mixed shall be removed at
once from the mixer and transported directly to the point where it is to be laid
and protected from the weather both during transit from the mixer to the
laying site and whilst awaiting tipping. No. water shall be added on site.
The material shall be placed and spread evenly. The material shall be spread
using a paving machine or spreader box operated with a mechanism while
levels of the material at an even depth and without delay. Except where
otherwise specified, the material shall be laid and compacted in layers of
maximum thickness of 150mm.
4.8.3.2 Compaction Trials
If directed by the Engineer, prior to the commencement of the Wet -mix

Macadam Road base operations, the contractor shall construct trial lengths
not less than 100 metres. The materials used in the trials shall be those
approved for use as Wet mix Macadam Road base and the equipment used
shall be that according to the Contractor's method statement.
Trial lengths may not form part of the permanent works but may be permitted
in the construction of temporary detours of sufficient length.
The objective of these trials is to determine the adequacy of the contractor's

equipment, the loose depth measurements necessary to result in the
specified compacted layer depths, the field moisture content, and the
relationship between the number of compaction passes and the resulting
density of the material.
The contractor may proceed with the Wet-mix Macadam Rod base work only
after the methods and procedures established in the compaction trials have
been approved by the Engineer.
4.8.3.3 Compaction
The Material shall be compacted to a field density equal to or greater than

98% of the maximum dry density value obtained when tested in accordance
with (AASHTO T-180) method C with correction for oversized material and
shall have a minimum CBR of 80% at 98% compaction after 96 hours
soaking (Test 16, BS 1377). Field Density tests shall be carried out in
accordance with Clause 4.4.2.7.
Compaction shall be completed as soon as possible after the material has

been spread.
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January 2009
Special care shall be taken to obtain full compaction in the vicinity of both
longitudinal and transverse joints.
The surface of any layer of material shall on completion of compaction be

well closed, free from movement under compaction plant and free from
compaction planes, ridges, cracks or loose material. All loose, segregated or
otherwise defective areas shall be made good to the full thickness of layer
and re-compacted.
Where directed by the Engineer a sieve analysis shall be carried out on the
material recovered from 5 consecutive field density tests. Where this sieve
analysis shows oversize material content of 10% or greater the area of
construction will be removed and the source of the material rejected until
further tests are carried out to ensure compliance with the specification
requirements. Where considered necessary other areas of work which were
carried on using material from the same source shall be tested in a similar
manner.
4.8.3.4 Finishing
Immediately prior to the placing of the first layer of the next pavement course
on to the Wet-mix Macadam Road base the final layer of Wet-mix Macadam
Road base shall be at the specified density and to the required grade and
section. In order to maintain these requirements while placing the next
course it may be necessary to water and reshape the surface of the Wet-mix
Macadam Road base. This work shall be at the contractor's expense.
The surface of the finished Wet -mix Macadam Road base will be tested with
a three (3) metre straight edge by the Engineer at selected locations. The
variations of the surface from the testing edge between any two (2) contacts
with the surface shall at no point exceed ten (10) millimeters when placed on
or parallel to the centerline, or ten (10) millimeters when placed perpendicular
to the centerline of the roadway. The Wet-mix Macadam Road base shall be
compacted to the thickness and cross sections as shown on the drawings
and shall be compacted to the thickness and cross sections as shown on the
drawings and shall not vary by more than ten (10) millimeters from the
required elevation. All humps and depressions and thickness deficiencies
exceeding the specified tolerance shall be corrected by removing the
defective work or by adding new material as directed by the Engineer.
Before placing the next construction layer or applying prime coat, the wet-mix
road base shall be mechanically swept then cleaned with compressed air to
remove loose material. As soon as possible after cleaning of the surface the
wet-mix road base shall be sealed by the application of a prime coat as
specified. Should the surface of the material be allowed to dry out before the
seal is applied, it shall be lightly watered and re-compacted immediately prior
to spraying with prime-coat.
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January 2009
In the event of a section of Wet-mix Road base failing to comply, either by

level or degree of compaction, and where the full depth of the layer has been
allowed to dry out, it shall be removed and replaced at the contractor's
expense, with fresh material. Watering and re-mixing in place will not be
permitted.
4.8.3.5 Minimum Test Requirements
One sample every l, 000 Cu.m shall be tested for Grading, Plasticity Index,
Sand Equivalent Value, Maximum Dry Density, C.B.R and loss by Abrasion.
For compaction and moisture content; one test per 250 sq.m of each layer of
carriageway and one test per 100 linear metre of shoulder.
Special care shall be taken to obtain full compaction in the vicinity of both
longitudinal and transverse joints.
4.9 BITUMINOUS PAVING COURSES
4.9.1 Description
This work shall consist of the construction of the following hot-mix bituminous
courses which shall be either Asphaltic Concrete or Dense Bitumen Macadam
as shown on the drawings.
Bituminous Base Course.
Bituminous Binder Course
Bituminous Wearing Course
Bituminous paving courses shall consist of coarse aggregates, fine

aggregates, filler material, and bitumen binder. Mixture of two different types of
rocks e.g. igneous and sedimentary having different specific gravities in a
single fraction shall not be permitted.
4.9.2 Coarse Aggregates
4.9.2.1 Coarse aggregates, which is the material retained on a 4.75mm sieve, shall
consist of crushed rock or crushed gravel. It shall be clean, hard, tough,
durable and sound, and shall be of uniform quality and free from decomposed
stone, shale, clay, lumps and other deleterious substances. Organic matter
shall not exceed0.05% (BS 1377 Test 3 Method 3) mixing of two different
types of rocks e.g. igneous and sedimentary having different specific gravities
in a single proctor shall not be permitted.
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January 2009
4.9.2.2 Crushed gravel for use as coarse aggregate shall consist of the product
obtained by crushing material that has first been screened in such a manner
4.9.2.3 that not less than ninety (90) percent of the material to be crushed is retained
on an AASHTO 3/8 inch sieve.
4.9.2.4 The coarse aggregate shall have an affinity for bitumen such that when coated
with bitumen it shall pass a stripping test prepared in accordance with
AASHTO T-182.
Each particle will have a minimum of one crushed face. In addition each
stockpile aggregate shall have all faces crushed as indicated below: -
11/2" - 40% Min.

1" - 50% Min.
3/4" - 55% Min.
3/8" - 65% Min.
Water absorption of the coarse aggregate as determined by BS 812 shall not

exceed 2% by weight.
4.9.2.5 Coarse aggregate shall have properties, which comply with the following
values:
Los Angeles Abrasion Loss (AASHTO T96)
Base Course and Binder Course 30% max
Wearing Course 25% max;
Aggregate Crushing Valve (BS 812 part 110)
Base Course and Binder Course 25%max
Wearing Course 20% max
Soundness Loss (ASTM C88) (5 cycles)
Magnesium Sulphate 10% max
Flakiness Index (BS 812 part 105.1)
Wearing course 25% max
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January 2009
Elongation Index (BS 812 part 105.2)
Wearing course 25% max
4.10 FINE AGGREGATE
4.10.1 Fine Aggregate shall consist of the material passing a 4.75mm sieve.
4.10.2 Fine aggregate including filler shall be obtained from 100% crushed gravel or
crushed rock pre-screened to exclude natural uncrushed fine material or
weathered unsound fines. The use of dune sand shall not be permitted.
4.10.3 Fine aggregates shall have properties, which comply with the following
values:
Soundness Loss (ASTM C88) (5 cycles)
Magnesium Sulphate 10 % max
Plasticity Index (AASHTO T 90) Non Plastic
Acid Soluble Chlorides
(BS 812 Part 117) 0.1% max
Acid Soluble Sulphate 0.5% max
Water Absorption (BS 812) 2% max.
4.11 MINERAL FILLER
4.11.1 When the combined grading of the coarse and fine aggregates is deficient in
material passing the AASHTO No. 200 sieve, mineral filler shall be added as
approved by the Engineer at the Contractor's expense.
4.11.2 Mineral filler shall consist of finely ground particles of limestone or cement in
accordance with AASHTO M 17. It shall be thoroughly dry and free from
organic substances and clay and meet the following grading requirements:
MINERAL FILLER
ASTM PRECENTAGE BY
BS SIEVE
SIEVE SIZE MASS PASSING
600 micron No. 30 100
300 Micron No. 50 95-100
150 Micron No. 100 90-100
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January 2009
70 Micron No. 200 70-100
4.12 COMBINED AGGREGATE
4.12.1 The combined mineral aggregate shall meet the following physical
requirements:
Sand Equivalent (AASHTO T 176)

Determined after all processing
Except for addition of asphalt binder 65% Minimum
Plasticity Index (AASHTO T 90) Non Plastic
4.12.2 When tested according to AASHTO T 11 and AASHTO T 27, the combined
mineral aggregate shall conform to Table 4.4 for Asphaltic Concrete.
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January 2009
TABLE 4.4 – AGGRERATE GRADING FOR ASPHALTIC CONCRETE
SIEVE SIZE (SQUARE OPENINGS) PERCENT PASSING (BY WEIGHT)
Base Binder Wearing

ASTM Course Course Course
37.5mm 100 _ _
25mm 80-100 100 100
19mm 62-92 80-100 86-100
12.5mm - 63-85 69-87
45-75 57-77 58-78

9.5mm
4.75mm 30-55 40-60 40-60
2.36mm 20-40 25-45 25-45
0.85mm 15-30 15-30 15-30
0.425mm 10-22 10-22 10-22
0.18mm 6-15 6-15 6-15
0.075mm 2-8 2-8 2-8
4.12.2.1 The coarse aggregate shall show no detrimental amount of stripping when
tested in accordance with AASHTO T 182. The minimum value of non stripped
area shall be 95%. If stripping occurs, the aggregate shall be rejected and an
approved method of treatment specified to change the material from a
hydrophilic to a hydrophobic state as directed by the Engineer, or an approved
additive shall be used with the bituminous binder
4.12.2.2 When necessary to improve the coating of aggregate by bitumen, additives of

approved type will be added to the bituminous material in such percentage as
required to obtain satisfactory results in the affinity, with bitumen test
performed in accordance with ASTM D 1664. The approved additive will be
used in accordance with Technical Specifications issued by the manufacturer
and approved by the Engineer after appropriate testing,
4.12.2.3 No extra payment will be made for required anti stripping additives.
4.13 BITUMEN BINDER
4.13.1 Bitumen Binder for the “Bituminous paving Courses shall be Bitumen Binder
penetration grade 60-70 unless otherwise specified as 40-50. Generally,
penetration grade 40-50 will be used for Type "H" mixes.
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January 2009
4.13.2 The bitumen shall be prepared by refining crude petroleum by suitable

methods and shall be homogeneous, free from water and shall not foam
when heated to175 degrees C (347 F).
4.13.3 Bitumen penetration grade 60-70 and 40-50 shall conform to the requirements
of Table 4.5.
TABLE 4.5
METHOD 60-70 PEN 40-50 PEN

TEST
AASHT
ASTM MIN. MAX. MIN. MAX.
O
T49 D5 60 70 40 50
Penetration at 25 ° C 100g, 5sec.
Flash Point, Cleveland Open T48 D92 232 - 232 -

Cu.p,°C
Ductility at 25° C, cm T51 D 113 100 100
T44 D 2042 99 - 99 -
Solubility tricolor ethylene, %
Thin film oven test 3.2mm, 163 ° T179 D 2872 - 0.80 - 0.80
C, 5 hour loss on heating, %
Penetration of residue % of original - 54 - 58 -
T49
Ductility of residue at 25 °C, T51 - 50 - - -

5cm/min. cm
Kinematics Viscosity T201 - 240 - 280
-
(centistokes) at 135 ° C
Softening Point Ring & Ball 735 D36 48 52 51 55
apparatus
4.13.4 A sample of the bitumen that the contractor proposes to use in the work
together with a statement as to its source and properties shall be submitted to
and approved by the Engineer at least 45 days before the asphalt work begins.
4.13.5 No bitumen other than that represented by the approved sample shall be used
by the Contractor except with the written consent of the Engineer. Blending of
bitumen from different refineries will not be permitted.
4.13.6 For asphaltic concrete the percentage range of bitumen by weight of total mix
to be added to the aggregate shall be as prescribed in Table 4.6.
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January 2009
TABLE 4.6 - BITUMEN CONTENT FOR ASPHALTIC CONCRETE
PAVEMENT BITUMEN PERCENTAGE BY WEIGHT OF MIX

COURSE INCLUSIVE OF TOLERANCES
Base 3.2 to 4.4
Binder 3.4 to 4.4
Wearing 3.4 to 4.4
4.13.7 Each consignment of bituminous material delivered to asphalt plant site shall
be accompanied by a delivery note and test certificates indicating name of the
refinery, country of origin and results in support of the material's compliance
with the specification. Samples for compliance test shall be taken by the
Engineer as and when deemed necessary.
4.14 JOB MIX
4.14.1 The mix approved for use in the works shall be designed by Marshall method
as per MS-2 and field trials with the following recommendations taken into
account.
a) For base course the aggregates for Marshall specimen shall be

modified by substituting all aggregate size over 25 mm with an equal
weight of aggregate sizes in the next lower grading size.
b) The combined aggregate gradation should be adjusted within the

allowable limits to achieve maximum stability whilst not going below the
minimum requirement for void content.
c) The minimum bitumen binder content according to the results of the

Marshall Method of Mix Design as recommended by MS-2 should be
used provided that it will still satisfy the durability, the stability and the
void content requirements.
d) Prior to final approval, the proposed job mix, but with a bituminous
content at the upper percentage limits shall be compacted to refusal,
(400, 500 and 600 blows) and the resulting voids in the mix shall not be
less than 2% for asphaltic concrete.
e) The final job mix must display the marshal characteristics specified in
Table 4.8 for Asphaltic Concrete.
f) Height of the Marshall specimens outside the limit specified in AASHTO

T-245 shall be discarded but a minimum of 3 specimens shall be
averaged.
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January 2009
4.14.2 The mix formula must take into consideration the absorption of bitumen in to
the aggregates. Thus, for calculations for air voids in the mix (VIM) the
maximum theoretical specific gravity as prescribed by ASTM D 2041 (Rice
Method) shall be used. For calculation of voids in the mineral aggregate (VMA)
the equations as mentioned in Asphalt Institute Manual MS-2 shall be used.
VFB shall be calculated using the following equation:-
VFB = {VMA – VIM} X 100

VMA
4.14.3 The Contractor shall be responsible for the design and performance of all
bituminous mixes. The Contractor shall submit, for the Engineer's approval, a
proposed "Laboratory Design Mixture" together with all applicable design data
atleast 30 days prior to commencement of the relevant asphalt works. The
Engineer will take samples of materials proposed for use in the mix in order to
check their quality and to cross check the proposed mix design for which the
Contractor shall repeat the laboratory design exercise in the site laboratory
under the supervision of Engineer to confirm the Marshall properties submitted
by the Contractor.
After receiving the approval of aggregate and bitumen from the Engineer, the
Contractor shall make a written request for the approval of the job mix formula
prepared by the Contractor under the supervision of the Engineer in the
laboratory.
The approved Laboratory Design Mixture shall be used for agreeing the
approved Job Standard Mixture.
4.14.4 The laboratory job mix formula shall fix a single definite percentage of
aggregate
passing each required sieve size, a single definite percentage of bitumen
binder to be added to the aggregate, a single definite temperature at which the
mix is to be emptied from the mixer, and a single definite temperature at which
the mix is to be delivered to the works site.
4.14.5 The laboratory job mix formula shall be used for the basis of approval of the
Job standard mixture.
4.14.6 Trial areas having lengths of at least 100m and to the specified layer thickness
shall be laid outside the area of the permanent work by the Contractor. At least
two samples of non compacted material from the trial area shall be taken in
accordance with AASHTO T 168, and shall be analyzed in the presence of the
Engineer to determine the aggregate grading, binder content, stability, flow,
Marshall density and voids. The results shall be submitted to the Engineer and
shall be approved by him before further mixing or laying is carried out.
4.14.7 Trial areas may from part of a temporary traffic detour subject to the approval
of the Engineer. The compaction trials should be performed on the trial mixes.
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January 2009
If the trial areas form a part of the temporary traffic detour they shall not be
paid for under the relevant bill item.
4.14.8 Should the laboratory job mix formula after passing the mixing plant and laid
and compacted with approved plant fail to produce a satisfactory trial area, the
mix proportions may be modified by agreement with the Engineer, as
necessary and within the requirements of Tables 4.7 and 4.8 as applicable to
produce a mix of satisfactory workability and acceptable surface finish. After
approval of the trial area by the Engineer this mix shall be designated the job
standard Mix and shall there after be the approved mix. A copy of the
approved job Standard Mixture signed by the Contractor and Consultant have
to be submitted to the road section, Al Ain Municipality.
4.14.9 All mixes produced shall conform to the job Standard Mix approved by the
Engineer, within the ranges of tolerance specified in Table 4.7, (within) the
limits of Tables 4.4, 4.6 and 4.8 for asphaltic concrete. Each day the Engineer
shall take as many samples of the materials and mix as he considers
necessary and minimum of one sample for every 200 tons laid or part thereof
for checking their required characteristics. When unsatisfactory results or
changed conditions make it necessary, the Engineer shall instruct the
Contractor to establish a new job standard.
4.14.10 Should a change in a material be encountered or should a change in a source

of material be made a new job-Standard Mix shall be submitted by the
Contractor and approved by the Engineer before the mix containing the new
material is delivered. Job materials will be rejected if they are found not to
have the characteristics required by the approved job Standard Mix.
TABLE 4.7 - JOB MIX TOLERANCE

Aggregate retained on 4.75mm sieve or large ± 5%
Aggregate passing 4.75mm sieve and retained on
± 4%
0.85mm sieve
Aggregate passing 0.85mm sieve and retained on
± 2%
0.075mm sieve
Aggregate passing 0.075mm sieve ± 1%
Bitumen Binder ± 0.2%
Temperature of mixing and placing ± 10 ° C
TABLE 4.8 - PROPERTIES OF MIX FOR ASPHALTIC CONCRETE
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PROPERTIES BITUMINOUS BITUMIOUS BITUMINOUS

BASE BINDER WEARING
COURSE COURSE COURSE
Number of Compaction 75 75 75
blow at each end of
specimen
Stability ( Marshall ) 1200 1400 1500

Minimum Kg. F
Flow (Marshal) mm 2-4 2-4 2-4
Stiffness minimum Kg. 500 500 550

F/mm
Percent air voids (VIM) 4-8 4-8 4-8
Percent voids in 13 14 15
Mineral Aggregate (VMA)
Percent voids filled 50-65 50-70 50-75

with Bitumen (VFB)
Loss of Marshall stability Max. 25% Max. 25% Max. 25%

by submerging specimens
in water at 60deg. C for
twenty four (24) hours
compared to stability
measured after
submersion in water at 60
deg. C for thirty (30)
minutes
Filler / Bitumen Ratio 0.6-1.5 0.6-1.5 0.6-1
4.14.11 Samples of the mixed materials shall be taken from the first two hundred tones
and from every two hundred tones thereafter to determine aggregate grading
and binder content. Samples of loose asphaltic concrete mix shall be taken
behind the paver before compaction and shall be obtained in accordance with,
ASTM D 979.Samples of compacted asphaltic concrete shall be obtained by
coring in accordance with Method B of AASHTO T-230.
Determination of bitumen content and extraction gradation may be performed

on either loose or compacted samples in accordance with AASHTO T-164 and
AASHTO T-30 except that the mass of mineral matter in the total volume of
the extract shall be determined by using a bitumen meter or other equipment
and procedures which give equally satisfactory results. The specific gravity of
compacted asphalt course shall be measured in accordance with AASHTO T -
230. Gmm as per ASTM D2041shall be checked on daily bases and used for
calculating air voids.
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If any of these tests show results which are not in accordance with approved
job standard mix within permissible variations the material shall be rejected
and suitable adjustments shall immediately be made to ensure compliance
therewith. Samples of the mixed material shall be taken at least twice a day or
as determined by the Engineer for making Marshall specimens to determine
stability, flow and unit weight. For the taking of daily Marshall specimens the
mixing pug mill temperature shall be set to the mixing temperature as specified
in AASHTO T-245 and the compaction temperature of the moulds shall also
be in accordance with AASHTO T-245. Should for practical reasons the pug
mill temperature be different from that used in AASHTO T-245 then the
Engineer shall set the compaction temperatures for the moulds to so
compensate. All approved sampling and testing required under the sub-clause
of this clause shall be undertaken by the Engineer. Sampling and testing by
the Engineer in no way relives the Contractor of his responsibility for regular
quality control testing in order to ensure compliance with the Specifications.
4.14.12 The density of the compacted mixes shall be related to the daily Marshall
Density, which shall be determined by making four standard Marshall
specimens from samples of the mix taken from the mixing plant or paver. The
density of each sample shall be determined and compared with the mean
value. Any individual result which varies from the mean by more than 0.015
gm /cc shall be rejected. Marshall tests shall be repeated on a daily basis to
establish the daily Marshal Density for that particular day's production. The
daily Marshall Density shall not vary from the job mix Design Density by more
than + 0.75%. If it does, the Job Standard Density shall be applied to satisfy
the requirements of in-situ compaction.
4.14.13 The “Job Standard Mixture Reference Density” shall be obtained by making six
standard Marshall Specimens from samples of the approved “Job Standard
Mixture” determining the relative density or each and comparing them with the
mean values of the six. Any individual result which differs from the mean by
more than 0.015 gm/cc shall be rejected and provided not more than two
results are so rejected the mean of the remaining results shall be designated
the “Job Standard Mixture Reference Density”.
4.14.14 The assistance of the Engineer in the preparation of the job standard mix in no
way relieves the Contractor of the responsibility of producing a bituminous mix
meeting the requirements of the Specifications.
4.15 EQUIPMENT FOR BITUMENS PAVING OPERATIONS
The Method statement and equipment list shall be according to the type and number
outlined in the Contractor's detailed programme of work, as approved by the
Engineer.
In addition to the above requirements, trucks used for hauling bituminous mix
shall have tight, clean, smooth metal beds which have been thinly coated with
a minimal amount of paraffin oil, lime solution, or other approved material to
prevent the mix from adhering to the beds. When required by the Engineer,
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each vehicle shall be equipped with a canvas cover or other suitable material
of such size as to protect the mix from the weather.
Rolling equipment shall be self-propelled. The wheels on the rollers shall be

equipped with adjustable scrapers and the rollers shall have water tanks and
sprinkling apparatus, which shall be used to keep the wheel wet and prevent
the surface material from sticking.
4.16 PREPARATION OF BITUMEN BINDER
The heating of the bitumen binder for mixing and compacting shall be in
accordance with AASHTO T-245.
4.17 PREPARATION OF MINERAL AGGREGATE FOR BITUMINOUS MIX
4.17.1 Coarse and fine aggregate shall be stored at the asphalt plant in such a
manner that the separate stockpiles will not become intermixed. The
stockpiles shall be of sufficient size to provide a minimum quantity of one week
continuous production of asphalt mix. Aggregates brought to the asphalt plant
to supplement stocks should be tested and approved prior to placing in the
existing approved stockpiles.
The cold bins shall be calibrated with the materials to be used and the settings
shall be such as to produce a combined gradation in accordance with the job
mix. The proportioning shall be such that surpluses and shortages in the hot
bins will not cause breaks in the continuous operation. All the above shall be
as approved by the Engineer.
The materials shall be thoroughly dried and heated so that their temperature
is within 8 deg. C of the temperature needed to satisfy the viscosity
requirements of the asphalt cement. The moisture content of the heated and
dried materials shall not exceed 0.5 per cent. The quantity of materials fed
through the drier shall in all cases be held to an amount, which can be
thoroughly dried and heated within the limits specified.
4.17.2 Immediately after heating, the aggregate or aggregates shall be screened into
at least five (5) sizes and conveyed in to separate bins ready for batching and
mixing with bituminous material. When the aggregates supplied are of such
size and grading that separating into five (5) bins is impractical, the number of
required separations may be reduced to four (4) or to three (3) with the
approval of the Engineer. The efficiency of the screening operations shall be
sufficient to produce, at plant operating capacity, gradations in each of the
sizes of heated and dried aggregates which are reasonably uniform and result
in the production of a mix complying with the limits specified for the aggregate
gradation.
4.18 REPARATION OF BITUMINOUS MIX
4.18.1 Dried aggregate as specified and prepared as prescribed above shall be

combined in the plant conforming to ASTM D 995 in the approved
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proportions. The bitumen binder shall be introduced into the mix in the
proportion specified by the job-mix formula.
4.18.2 The initial mixing time will be designated by the Engineer. Mixing time may be
increased by the Engineer if additional time is necessary to obtain a
homogeneous mix and satisfactory coating.
4.18.3 The batch plants timing shall begin at the start of the introduction of the
bitumen
into the pug mill.
4.18.4 The length of mixing time for continuous plants will be determined by the
following formula or other approved methods: -
Mixing time in seconds = Pug mill dead load capacity in kg

Pug mill output in kg / second
4.18.5 The temperature of the aggregate immediately prior to mixing shall be within +
10 deg. C of the temperature of the asphalt cement and the temperature of the
aggregate and asphalt prior to mixing shall be approximately that of the
completed mix as defined in the job mix formula approved by the Engineer.
The mix temperature shall be within the limits set out in the job mix formula
when emptied from the mixer.
4.19 SURFACE PREPARATION
4.19.1 When the Bituminous mix is placed on a prepared road base and whether or
not a prime coat is designated on the Drawings, the Granular Road base shall
be even and firm and within the construction tolerances specified for the road
base to the satisfaction of the Engineer.
4.19.2 When the paving layer is constructed on an existing bituminous surface, the
surface shall be cleaned of all foreign material and broomed free of dust, In
addition any loose, broken or shattered bituminous material along the edge of
the existing surface shall be removed, and the exposed subgrade and
sufficient width of the shoulder adjacent to the edge of the existing surface to
receive the new bituminous mix shall be shaped, bladed, compacted and
broomed and primed to provide a uniform firm sub grade of the new surface
course.
4.19.3 The existing bituminous surface, base, or sub grade shall be removed if
broken, shattered, or unstable. The areas shall be excavated to a depth as
directed by the Engineer, and refilled with the bituminous mix according to the
specifications.
4.19.4 Prior to the placing of the mix, when designated on the Drawings or as directed
by the Engineer, a prime coat or tack coat shall be applied to the road base or
surface in accordance with the specification for prime coat or Tack coat.
4.20 PLACING OF THE MIX
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4.20.1 All bituminous mixes shall be introduced to the paver at a temperature not less
than 135 deg. C and not more than 163 deg. C. Mixes outside this temperature
range shall be discarded. Temperature along the edge of the longitudinal joint,
prior to rolling, shall not fall below 120 deg. C.
4.20.2 The bituminous mix shall be spread and finished to crown and grade by
automatically controlled bituminous paver. Bituminous mix may be spread and
finished by hand methods only where machine methods are impractical as
determined by the Engineer.
4.20.3 The automatically controlled paver shall lay the bituminous mix without tearing
the surface and shall strike a finish that is smooth, true to cross-section,
uniform in density and texture, free from hollows, transverse corrugations and
other irregularities.
All paving machines, prior to using on site shall be checked to ensure proper
functioning and expected surface finish. Texture of the paved asphalt behind
the paver shall be smooth, uniform close textured, free from segregation drag
or other unacceptable surface finish. Extension of the paver with extra screeds
shall be subject to extension of the auger as well as proper functioning of the
inbuilt tamping mechanism of the screeds and the paved surface being similar
to the remaining section without any sign of drag or any other surface defects.
Defective pavers shall not be used on site unless they are rectified to the
satisfaction of the Engineer.
4.20.4 The paver shall be operated at a speed which will give the best results for the
type of paver being used and which co-ordinates satisfactorily with the rate of
delivery of the mix to the paver, to provide a uniform rate of placement without
intermittent operations of the paver.
4.20.5 The mix shall be delivered to the paver in time to permit completion of
spreading, finishing and compaction of the mix during daylight hours.
4.20.6 The longitudinal joints in successive layers shall be offset not less than fifteen
(15) centimeter. The width of surface or top course placements shall conform
to trafficlane edges as shown on the Drawings.
4.20.7 The leading half of half road way paving shall not get ahead of the trailing half
of the pavement by more than one (1) average full-day of paving and, in no
case, shall the leading half be more than one half (1/2) kilometers ahead of the
trailing half without the written permission of the Engineer. If the Contractor
fails to comply with this requirement, the Engineer may suspend paving on the
leading half until such time, as the Contractor shall pave the trailing half to a
point approximately even with the leading half.
4.20.8 Unless otherwise directed by the Engineer, where successive layers are to be
placed, the surface of the existing layer shall be swept clean with a power
broom, or by other means as approved by the Engineer, and tack coat applied.
Tack coat may not be required where the delay between courses laying is less
than 48 hours and when the surface is fresh and clean and at the discretion of
the Engineers
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4.20.9 After the approval of the "job standard mixture" (JSM) the trial area as
specified in Clause 4.14.6 of the specifications shall be used to establish the
rolling/compaction method required to produce the specified relative density.
Three pairs of course shall be taken from the compacted trial area and the
mean density of each pair shall be not less than 98% of the "Job Standard
Mixture density (JSMD). If the required field density is not obtained the rolling
procedure shall be adjusted and further trial areas shall be laid and tested until
satisfactory results are obtained. These procedures shall be reported to the
Engineer and the rolling method agreed before mixing or laying of the
pavement works is commenced. Agreed procedures shall not subsequently be
varied without the Engineer's written approval.
4.21 RELIMINARY SURVEY AND REFERENCE STRING LINE
4.21.1 The contractor shall make the necessary survey required for the reference
grade. When the survey is approved by the Engineer the Contractor shall erect
and maintain an approved reference string line and operate the paver to
conform to the reference string line for the initial layer and /or any other layers
as directed. Elevation control point stakes for the first layer of bituminous
paving course shall be set at a maximum spacing of twenty (20) metres. For
subsequent layers, control points shall be set at ten (10) metres maximum
spacing. The contractor shall furnish and maintain an approved mobile string
line for all layers not laid with the erected string line. The string line shall be
erected parallel to the reference grade, and the bituminous mix shall be spread
at a constant elevation above, below or at the string line elevations as directed.
4.21.2 The use of the automatically controlled bituminous paver, to provide both
longitudinal and traverse control, shall include the furnishing and maintaining of
a string line, fixed or mobile, by the Contractor. The longitudinal and traverse
controls shall operate independently of each other to the extent that the
surface of the bituminous mix will conform to the string line and will be uniform
in cross -section and crown.
4.21.3 The Contractor shall establish the centre -line points and shall maintain the
location of the points until the completion of the surfacing or as directed. When
directed by the Engineer, the contractor shall erect a string line, to be used as
a guide for the furnishing machine, in order to maintain a uniform edge
alignment. If any other method is proposed by the Contractor it shall first be
4.22 BITUMINOUS LEVELING AND WIDENING OF EXISTING PAVEMENT
4.22.1 A levelling course, consisting of a layer of bituminous material of variable

thickness may be used to eliminate irregularities in existing surfaces or bases
and to vary existing cross -section elements of roadways.
4.22.2 In areas where levelling courses are required as shown in the drawings
determined by the Engineer, the Contractor shall make a survey of the existing
surface or base. When the survey is approved, the Engineer will determine
and inform the Contractor of the precise locations and thickness of leveling
course to obtain the smoothest possible riding surface. Upon receipt of the
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location and thickness from the Engineer, the Contractor shall proceed with
the placement of the levelling course.
4.22.3 Where the existing carriageway is to be widened, the sides shall be trimmed in
accordance with the drawings or as required by the Engineer. The bituminous
courses shall be cut back to a clean vertical face which shall be completely
coated with a grade of hot bitumen suitable for the purpose immediately
before laying new bituminous material adjacent to it.
4.22.4 The material for regulating shall be as shown on the drawings and shall be
made and laid in accordance with the appropriate clauses of the Specification.
4.22.5 Unless stated to the contrary, any thickness of material described means the
finished or fully compacted thickness.
4.22.6 Where the existing carriageway requires regulating to accommodate the new
pavement overlay the following methods may be adopted.
a) Cold Planning
Cold planning is the recommended method for removing large quantities of

bituminous material. Trial sections are to be carried out, under the supervision
and direction of the Engineer to establish the degree of cold planning required
along each individual section as indicated on the drawings or instructed by the
Engineer.
b) Heating and Planning
Heating and planning may only be used as an alternative to cold planning with
the Engineer's permission. Should this method be adopted there shall be a
minimum period two weeks before the pavement overlay is applied. Trial
sections shall be carried out under the Engineer's supervision and direction to
determine the degree of planning required along each individual section as
indicated on the drawings. A tack coat shall be applied to the planed surface in
accordance with Section 4.36 at the discretion of the Engineer.
4.22.7 The material removed from the existing carriageway shall be disposed off as
instructed by the Engineer.
4.22.8 Scarifying of the existing pavement shall be used to prepare the surface of the
existing pavement to provide a key for the subsequent layers of asphalt. The
scarification shall comprise forming a grooved surface to the existing asphalt
with an average depth of groove being 5mm from the existing surface with an
average spacing between grooves of 50mm or as otherwise approved by the
Engineer.
4.23 THICKNESS CORES
4.23.1 The depth of each bituminous paving course shall be measured by cores
samples.
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The Contractor shall furnish and operate an approved core drill for cutting
samples from the compacted mix on the road. The equipment shall be capable
of cutting the mix without shattering the edges of the specimen or otherwise
disturbing the density of the specimen. Cored samples shall be ten (10)
centimeters in diameter for binder course and wearing course and fifteen (15)
centimeters in diameter for base course and road base.
Cores extracted for thickness measurement may be used for density

determination and density samples may be used for thickness measurements.
4.24 COMPACTION OF BITUMINOUS LAYERS
4.24.1 After spreading and strike off, and as soon as the mix conditions permit the
rolling to be performed without excessive shoving or tearing, the mixture shall
be thoroughly and uniformly compacted. Rolling will not be prolonged to an
extent that cracks appear.
4.24.2 Rollers shall be of the steel-wheel and pneumatic tyre type and shall be in
good condition, capable of reversing without backlash, and shall be operated at
speeds slow enough to avoid displacement of the bituminous mix. The number
and weight of rollers shall be sufficient to compact the mix to the required
density while it is still in a workable condition. The use of equipment which
results in excessive crushing of the aggregate will not be permitted. A
minimum of three (3) rollers, one (1) steel-wheel and two (2) pneumatic -tyre
type, shall be used with each spreading operation for each lane.
4.24.3 The Contractor shall provide adequate back-up equipment for use in the event
of mechanical failure, all to the satisfaction of the Engineer.
4.24.4 Initial or breakdown rolling shall be done by means of either a tandem power
steel roller or three-wheel roller followed by a pneumatic-tyre roller or as
agreed by the Engineer. Rolling shall be longitudinal, beginning at the low side
of the spread of material and proceeding toward the high side, overlapping on
successive passes by at least one half (1/2) the width of the near wheels,
alternate passes of the roller shall be of slightly different lengths.
4.24.5 The motion of the roller shall at all times be slow enough to avoid displacement
of the mix. To prevent adhesion of the mix to the rollers, the wheels of the
rollers shall be kept properly moistened with water, but an excess of water will
not be permitted. Under no circumstances shall the use of diesel fuel or any
other asphalt-stripping agent be used for preventing adhesion of the asphalt to
the roller wheels.
4.24.6 Final compaction and finish rolling shall be done by means of a tandem power
steel roller, unless otherwise directed. When the specified density is not
obtained, changes in the size and / or number of rollers shall be made as
corrective measures, to satisfy the density requirements.
4.24.7 Rollers shall be operated by competent and experienced roller men and shall
be kept in operation continuously if necessary, so that all parts of the
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pavement will receive substantially equal compaction. Due care shall be taken
to ensure required compaction along longitudinal as well as transverse joints.
4.24.8 The road density requirements shall be equal to or greater than ninety eight
(98) percent of the average Marshall density of each day's production for
wearing course and ninety eight (98) percent of the average Marshall density
of each day's production for base course and binder course. However,
densities in excess of 101.8% shall not be permitted. The specific gravity of
compacted asphalt cores shall be measured in accordance with ASTM D
2726/AASHTO T-230.
4.24.9 Any mix that becomes loose, broken, mixed, with foreign material, or which is
in any way defective in finish or density, or which does not comply in other
respects with the requirements of the specification shall be removed, replaced
with new materials, and finished in accordance with the specifications.
4.25 RE -ROLLING OF BITUMINOUS COURSE
Should any bituminous course fail to achieve the specified density, at the
discretion of the Engineer re-rolling may be allowed subject to the following
conditions: -
a) The identification to be achieved shall be 1% or less.
b) Only PTR's to be used weighting no greater than 18 Tonnes.
c) Re-rolling to take place at the time of the day when the asphalt has
attained its maximum natural temperature but within 72 hours of its
initial rolling.
d) Re- rolling to be applied for a maximum of two hours.
e) Re-rolling to be carried out in the presence of the

Engineer'sRepresentative and representative from Al Ain Municipality
Roads Section.
f) The Section of the works in question shall be cored for

density determination immediately after completion of re- rolling.
g) If after re-testing, the density achieved is 0.5% below the specified

density, the asphaltic material will be accepted in the works subject to a
20% reduction to the billed rates. If, on the other hand the density is
greater than 0.5% bellow the specified density, the asphaltic material
shall be removed and new material to the specification laid at the
contractor's cost.
4.26 CONTACT SURFACES
Contact surface between the bituminous courses and kerbs, gutters,

manholes, and other appurtenances shall be painted with a thin uniform
coating of tack coat as approved by the Engineer.
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4.27 JOINTS IN BITUMINOUS PAVING
4.27.1 Joints between old and new pavement or between successive day's work shall
be made, to ensure thorough and continuous bonding between the two. All
construction joints in previously laid material shall be constructed by cutting the
material back vertically for its full depth to expose a fresh surface.
While widening each layer of existing asphaltic payment shall be cut back
vertically by 200mm or as indicated in the drawings and as additionally directed
by the Engineer. If the saw cut is used, the depth of cutting must not extend to
the underlying asphaltic layer.
4.27.2 Before placing the fresh mix against a cut joint or against old pavement the
contact surface shall be sprayed or painted with a thin uniform coat of tack
coat. Where a finishing machine is used the longitudinal joint shall be made by
over lapping the screed on the previously laid material for a width of at least
ten (10) centimeters and depositing a sufficient amount of mix so that the joint
formed will be smooth and tight.
4.27.3 The number of joints shall be minimized wherever possible.
Where joints between laying widths or transverse joints have to be made in

bituminous courses, the material shall be fully compacted and the joint well
sealed and made flush using one of the following methods which has to be
agreed with the Engineer.
4.27.3.1 By heating the joint with an approved joint heater at the time when the
additional width is being laid but without cutting back or coating with binder.
The heater shall raise the temperature of the full depth of the course to a figure
within the rolling temperature range specified for the material and for a width
not less than 150 mm on each side of the joint.
4.27.3.2 Unless otherwise agreed by the Engineer asphalt shall be paved using two or
more mechanical pavers in echelon not more than 20m apart, to avoid loss of
temperature of the mix along the longitudinal joint. Temperature at the joints
prior to rolling shall not drop below 120 0 C.
4.27.3.3 By using two or more pavers operating in echelon where this is practicable and
in sufficient proximity for adjacent widths to be fully compacted by continuous
rolling or by using a multiple-lane-width paver: wherever practical this method
shall be used for wearing and finishing courses.
4.27.3.4 By cutting back the exposed joints with approved mechanical cutters to a
vertical face or regular horizontal alignment and not less than the specified
thickness, discarding all loosened material and coating the vertical face
completely with a grade of hot bitumen suitable for the purpose before the next
width is laid. The cutting back of the joint shall be such as to ensure that all
material, which in the opinion of the Engineer is out of specification, is
removed. The minimum cut back dimension shall be 150mm. The use of
pneumatic hammers will not be permitted.
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Width of the paving machine shall be so adjusted that the longitudinal and
transverse joints in successive course are offset from the underlying courses
by not less than 20 cm. Every attempt shall be made to ensure that the
longitudinal joint in the surface course shall coincide with the lane line marking.
Transverse joints in succeeding layers shall be offset at least 2 meters.
4.28 PROTECTION OF COMPACTED LAYER

The Contractor shall protect all sections of newly compacted pavement from
traffic until they have hardened sufficiently to the approval of the Engineer. On
heavily trafficked roads during the summer months a minimum period of 7 days
must elapse before the newly compacted pavement is trafficked.
4.28.1 Compaction Trials for Bituminous Courses
4.28.2 Prior to the commencement of the bituminous paving operations, the

Contractor shall construct trial lengths, of at least 30 metres. The materials
used in the trials shall be those approved for use in the bituminous paving
courses and the equipment used shall be that according to the contractor's
approved detailed Method Statement and equipment list and the programme of
work.
4.28.3 The object of these trials is to determine the adequacy of Contractor's

equipment, the loose depth measurements necessary to result in the specified
compacted layer depths, the field moisture content, (for earth works, subbase
aggregate base course) and the relationship between the number of
compaction passes and the resulting density of the material.
4.28.4 The Contractor may proceed with the bituminous paving operations only after
the method and procedures established by the compaction trials have been
4.29 SURFACE TOLERANCE FOR BITUMINOUS COURSES
4.29.1 At final compaction, the finished surfaces of the individual layers shall fall
within the following maximum tolerances, measured with a 3m straightedge
laid in any direction.
Base Course - 6mm
• Binder Course - 6mm
• Wearing Course - 3mm
4.29.2 The longitudinal regularity of the surfaces of surface course, binder courses
and base course in pavements without binder course shall be such that the
number of surface irregularities is within the relevant limits stated in Table 4.9.
An irregularity is a variation between 4mm and 7mm and between 7mm -

10mm in the profile of the road surface as measured by the rolling straightedge
or the type designed by Transport and Road Research Laboratory or
equivalent, along any line or lines parallel to the centre line of the carriageway,
on sections of 300m selected by the Engineer, whether or not it is constructed
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in shorter lengths. Where the total length is less than 300m the measurements
shall be taken on 75m lengths. No irregularity exceeding 10mm shall be
allowed.
Table 4.9
Wearing and Binder Course Base course

Irregularity 4mm-7mm 7mm-10mm 4mm-7mm 7mm-10mm
Length (m) 300 75 300 75 300 75 300 75
No. permitted 20 9 2 1 40 18 4 2
4.29.3 Prior to checking any final road surface, binder course or top surface of base in
pavements without binder course for level, regularity or texture depth, it shall
be cleaned of loose or extraneous materials. These operations shall be carried
out without damaging the surfaces of the pavement, as soon as possible and
within 3 days of construction of the pavement.
4.29.4 Compliance with surface regularity shall be checked by the rolling straight edge
along any line or lines parallel to the edge of pavement on sections of 300m at
regular intervals, whether or not it is constructed in shorter lengths. Sections
shorter than 300m forming part of a longer pavement shall be assessed using
the number of irregularities for a 300m length pro-rata to the nearest whole
number.
4.29.5 Pavements shall be measured transversely for irregularities at regular

intervals, by a 3m long straight-edge 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 3mm. In addition the finished wearing
course shall meet the following requirements when tested for readability.
i) The rideability of the finished wearing course when tested with a laser
Road Surface testing Machine shall have IRI (international Roughness
Index) hot exceeding the following valves.
Average value over a 400 m section < 0.90

Peak value over 25 m section < 1.50
(more than 2 values per 400 m section)
ii) The amplitude of the longitudinal profile of the road, filtered between
(a) 1 meter and (b) 3.3m and 13m shall not exceed, the following
values.
1m 3.3m < 1.80
3.3m 13m < 3.50
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Cost of test for rideability using laser road surface testing machine shall be
included in the rate quoted for wearing course.
4.29.6 Rectification
Where any pavement area does not comply with the Specification for
regularity, surface tolerance, thickness, texture depth, material properties or
compaction, the Engineer shall determine the full extend of the area which
does not comply with the Specification and Contractor shall make good and the
surface of the pavement course in the manner described below:
(i) Aggregate Road base or Wet mix Macadam Road

base
The top of 75mm shall be scarified, reshaped, with material added or removed
as necessary, and re-compacted all to the Specification requirements. The
area treated shall not be less than 30m long and 2m wide or such area as
determined by the Engineer to be necessary to obtain compliance with the
Specification.
(ii) Wearing Courses, Binder courses and Base courses.
These shall have the full depth of the course removed and replaced with fresh
material laid and compacted in accordance with the Specification
requirements. The removal of pavement layers shall be by cold planning to
give a surface grooves not more than 5mm in depth.
Irrespective of the dimension of the defective area, the areas to be removed

and rectified shall be a minimum of 20m in length for wearing course and 15m
for binder and base course. The width shall be full width of the paver. When
more than one layer is involved, each layer shall be vertically cut back by
20cm.
Where the number of surface irregularities exceeds the limits in the Table 4.9,
the area to be rectified shall be 300m or 75m long as appropriate and 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.
Testing of the wearing course for compliance with

specification clause 4.29 shall be carried out as soon as possible after
completion of the surfacing and remedial works completed before the road is
opened to traffic.
4.29.7 All humps and depressions exceeding the specified tolerance shall be
corrected by removing the defective work and replacing it with new material as
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directed by the Engineer at the Contractors cost.
4.30 TOLERANCE IN BITUMINOUS PAVING THICKNESS
4.30.1 The thickness of the bituminous paving courses shall be determined in

accordance with ASTM D 3549.
4.30.2 For the purpose of establishing an adjusted unit rate for bituminous paving
courses, units to be considered separately are defined as three hundred (300)
linear meters in each traffic lane. The last unit in each lane shall be three
hundred (300) meters plus the fractional part of three hundred (300) metres
remaining. At least three (3) cores shall be taken at random from each unit
being sampled.
4.30.3 Other areas such as intersections, entrances, crossovers, ramps, etc., will be
considered as one unit and the thickness of each unit shall be determined
separately. Small irregular unit areas may be included as part of another unit.
At such point as the Engineer may select in each unit, one core shall be taken
for each seven hundred fifty (750) square metres of bituminous paving course.
4.30.4 If the core so taken is not deficient by more than three (3) millimeters from the
specified thickness, full payment will be made. If the core is deficient in
thickness by more than three (3) millimeters, from the specified thickness, two
(2) additional cores shall be taken from the area represented and if the
average of the three (3) cores is not deficient by more than three (3)
millimeters from the specified thickness, full payment will be made. If the
average thickness of three (3) cores is deficient by more than three (3)
millimeters, but not more than ten (10) millimeters, or fifteen (15) percent
(whichever is less) from the specified thickness, an adjusted unit price as
provided in the bill of quantities will be paid for the area represented by these
cores.
4.30.5 In calculating the average thickness of each bituminous paving course,

measurements, which are in excess of the specified thickness by more than
three (3) millimeters will be considered as the specified thickness plus three (3)
millimeters, the measurements which are less than specified thickness by more
than ten (10) millimeters or fifteen (15) percent (whichever is less), will not be
included in the average.
4.30.6 When the measurement of any core is less than specified thickness by more
than ten (10) millimeters, or fifteen percent (whichever is less), the actual
thickness of the bituminous paving course in this area will be determined by
taking additional cores at not less than three (3) metre intervals parallel to the
centre-line in each direction from the affected location until, in each direction, a
core is found which is not deficient by more than ten (10) millimeters, or fifteen
(15) percent (whichever is less). Asphalt areas which are deficient by more
than ten (10) mm or 15% (whichever is less) shall be removed and replaced at
the Contractor's expense. Exploratory cores for deficient thickness may be
used average for adjusted unit price.
4.31 COMPACTION, SAMPLING AND TESTING OF BITUMINOUS COURSES
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4.31.1 Density of the mix as placed and compacted on the road shall be determined
from cores cut from the compacted courses on the road at locations specified
by the Engineer. Samples shall be obtained in accordance with ASTM D 979 in
sets of two (2) from the same location on the road. The frequency of testing
shall be one (1) set of samples per traffic lane per one hundred fifty (150)
linear metres per layer or a minimum of one (1) set per day for shorter runs,
and such additional tests to determine limits of area deficient in density, or for
recheck. The density of these samples will be referred to as "Road Density".
Twins cores (within 60 cm of one another) shall be taken between 24 and 48
hours after paving.
4.31.2 The Contractor shall cut the samples with an approved core drill in the
presence of the Engineer. The equipment shall be capable of cutting the
material without shattering the edges of the specimen. Samples shall be ten
(10) centimetres in diameter for binder course and wearing course and fifteen
(15) centimetres in diameter for base course and road base.
4.31.3 All test holes shall be filled and made good with approved material by the
contractor at his expense.
4.32 WEATHER LIMITATIONS FOR PAVING OPERATIONS
4.32.1 Hot bituminous mix shall be placed when the air temperature is eight (8)
degrees C or above, and when the weather in not dusty, foggy or rainy and
when the existing surface is free from moisture. Bituminous mix shall not be
placed during sandstorms.
4.32.2 No paving operations shall be started if rain is imminent.
4.33 MINIMUM TEST REQUIREMENTS
4.33.1 Each delivery of Asphaltic concrete shall be accompanied by compliance test

certificate. Generally one sample shall be tested for every 40 tons bitumen
used on site to check compliance with table 4.5. However the engineer, at his
discretion, may ask for sampling from any tanker to confirm compliance with
specs. Requirements for “penetration” and “ softening points” to be checked at
the site laboratory for which the site labs shall be equipped.
4.33.2 Aggregate: One sample for each stockpile every l,000 Cu.m shall be taken
and all the required tests shall be performed. Specific gravity of hot bins
aggregates shall be checked every 7000 tones of asphaltic mixes laid on site.
4.33.3 Bituminous Mix: One sample of mix shall be obtained from at least every 200
tones or part thereof and tested or bitumen content (AASHTO T-164) grading
(AASHTO T-30), density (AASHTO T-166), stability (ASTM D 1559) and
voids.
4.33.4 Loss of Marshall Stability shall be tested for at least every 7,000 tones.
4.33.5 At least three (3) cores shall be taken at random from each unit of 300 linear
metres in each traffic lane.
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4.34 MAJOR EQUIPMENT & PLANT
4.34.1 General
Equipment shall mean, where mentioned in these

Specifications, all machines, tools, equipment and all necessary parts for its
operation and maintenance. Also, the laboratory tools and instruments and /or
equipment necessary for the proper construction of the road and the proper
completion of all the works.
The Contractor shall submit, as stipulated in the

"Instructions to Tenderer a detailed list of plant equipment which he shall
undertake to bring to the site to carry out the work. The list shall include for
each piece of equipment, the type, size, quantity, manufacturer, model,
identification number and year of manufacture. The Contractor shall supply all
plant and equipment necessary for the construction of each phase of the work
and it must be on the site, inspected and approved by the Engineer prior to the
commencement of the particular phase of work. Any plant or equipment of
portion thereof, which becomes worn or defective shall be immediately
repaired or replaced to the satisfaction of the Engineer.
In addition to the above requirements, trucks used for hauling bituminous mix
shall have tight, clean, smooth metal beds which have been thinly coated with
a minimal amount of paraffin oil, lime solution, or other approved material to
prevent the mix from adhering to the beds. When required by the Engineer,
each vehicle shall be equipped with a canvas cover or other suitable material
of such size as to protect the mix from the weather.
4.34.2 Compacting Equipment
The compaction equipment of earthwork may be towed or self-propelled and

shall include a suitable combination of tamping rollers, grid roller, segmented
pad rollers, vibrating rollers, pneumatic rollers and other compaction
equipment that can satisfactory and uniformly obtain the required compaction.
i) Tamping or Sheep foot Rollers
Tamping or sheep foot rollers shall consist of metal rollers, dumps, or shells
surmounted by metal studs with tamping feet projecting not less than sixteen
and one-half (16.5) centimeters from the surface for the roller, drum or shell.
Tamping feet shall be spaced not less than fifteen (15) centimeters or more
than thirty (30) centimeters measured diagonally perpendicularly to the axis of
the stud, shall be not less than eight tenth (25.8) square centimeters. The
weight of tamping rollers shall be such that when fully loaded, the load on each
taper foot will be determined by dividing the total weight of the roller (loaded)
by the number of tamper feet in one (1) row parallel to the axis of the roller.
Pull -type steel rollers shall have not les than one and two-tenths (1.2) metre
effective width of roller and shall be designed and constructed so that the
weight per linear centimeter of roller can be varied from thirty five and seven-
tenths (35.7) kilograms to at least fifty-three and six (53.6) kilograms.
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ii) Self Propelled Steel Rollers
The power mechanism shall be capable of propelling the roller smoothly and
without jerking when starting, stopping, or reversing directions free from
backlash, loose link motion, faulty steering mechanism and worn king bolts,
the steering mechanism shall have no lost motion, shall operate readily and
permit the roller to be directed on the alignment desire. The faces of all rollers
shall be smooth and free from defects which mark the finished road surface.
Rollers shall be equipped with water tanks and sprinkling devices which shall
be used for wetting the roller to prevent adherence of the placed material.
Two-axle tandem steel rollers shall weigh not less than

eight (8) tones or more than twelve (12) tones and shall have a weight per
centimeter width of roll between 35kg and 70kg.
Three axle tandem steel rollers shall weigh not less than
eleven (11) tones. Three axle tandem roller shall be so constructed that the
roller, when locked in position for all treads to be in one plane, are held with a
rigidity which will satisfy the following test under full load: with the weight of the
roller supported on the central roller, the tread of the central roller, the tread of
the central roller shall not be more than three (3) millimeters above the plane
tangent to the tread of the end roller. With the weight of the roller supported to
the end rollers, the tread of the central roller shall not be more than six (6)
millimeters below the plane tangent to the treads of the end roller.
iii) Trench Rollers
The trench roller shall be of an approved type and shall

weigh not less than fifty-three and six tenths (53.6) kilograms per centimeter of
width and shall be equipped with water and sprinkling device that shall be used
for wetting the roller to prevent adherence of the placed material.
iv) Pneumatic - Tyred Rollers
The tyres on the front and rear axles shall have wide
smooth treads and shall be staggered to provide complete coverage of the
entire area which the roller travels. The tyres shall be inflated to a pressure
that has been approved by the Engineer and the pressure shall be reasonably
uniform in all tyres. The Contractor shall provide a suitable gauge for
determining air pressure in the tyre. Light self-propelled pneumatic tyred rollers
shall be so constructed so that they may be loaded to provide a gross weight
of at least forty (40) kilograms per centimeter of width of tyre tread.
Heavy self-propelled pneumatic-tyred rollers shall be constructed so that they

can be loaded to provide a gross weight of not less than twenty five (25) tones
and they shall have tyre pressures of 6-6.3 Kg/Cm2.
v) Vibration Compactors
Equipment using principle of vibration as a tamping force shall be in good

mechanical condition and shall be capable of transmitting forceful vibrations or
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impacts to the various materials placed in construction. The equipment may be

the roller or pad type or a combination of roller and pad type. Vibrating
compactors shall be of the type and force approved by the Engineer.
4.34.3 Hauling and Weighting Equipment
I) Hauling Equipment
Hauling equipment for aggregate shall consist of vehicles having dump bodies
suitable for dumping materials in a windrow or in spreader boxes. The bodies
shall be so constructed that their volume measurement can be accurately
determined. They shall be so constructed and maintained to prevent loss of
materials during hauling operations.
The equipment shall be provided with dump controls that can be operated from
the driver's seat. The bodies of hauling equipment using public roads shall be
fitted with tarpaulins to prevent the nuisance of spillage.
II) Weighing Equipment
Weighting equipment for truck-hauled material shall consist of accurate and

reliable platform scales and they shall be accurate to one percent throughout
the range of use. The scale shall have a platform of adequate length to weigh
the longest truck or truck-trailer combination which is in use on the Project.
Scales shall be inspected and sealed or certified by an approved scale
company, as often as the Engineer deems necessary to ensure their accuracy.
The seal or certification shall show the date of the inspection. Where no
approved scale company exists or at the option of the Engineer, the Contractor
shall check and adjust the scale in the presence of the Engineer in the method
recommended by the manufacturer and / or approved by the Engineer. It is the
Contractor's responsibility to have sufficient standard test weights for each
scale on the site.
The Engineer, as often as he deems it necessary, shall direct the Contractor to

check and adjust any scale on site to ensure its accuracy.
The Contractor, shall when directed by the Engineer, make weight

comparisons with other permanently located scales that meet with the
approval of the Engineer. These weight comparisons shall be for the purpose
of providing information on the performance of the contractor's scale and will
not be used as a basis for adjusting the scale.
III) Controlled Water Distribution Equipment
Equipment for distribution of water shall consist of distribution or tanks

equipped with spray bars and, when required, pumps to operate under
pressure, the pumps shall be of sufficient capacity to provide uniform and
adequate distribution. They shall be mounted on pneumatic-tyred trailers
pulled by pneumatic-tyred equipment. The minimum capacity of any tank
shall be four (4) cubic metres where applicable.
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The distributor equipment shall be constructed to permit accurate and

uniform distribution of the desired quantities of water per unit of surface area.
The control valves shall be constructed to permit full closing and to prevent
leakage. The water control valves shall be constructed to operate from the
driver's seat or provisions made for an additional operator to operate the
control valves while the equipment is traveling at the proper speed for
distribution.
4.34.4 Main Plant for Bituminous Paving Works
I) Equipment for Heating Bituminous Materials
Equipment for heating bituminous materials shall be of adequate capacity to

heat the materials properly by circulating the bituminous material around the
system of heated coils or pipes, or by circulating the bituminous material
through a system of coils or pipes enclosed in a heated jacket or other
approved means.
The heating device shall be constructed so that it will prevent the direct flame
from a burner from striking the surface of the coils, pipes or jackets through
which the bituminous material is circulated. The heating device shall not be
operated in a manner that will damage the bituminous material.
Tankers or trucks received on the work which have defective coils, or from
which the coils have been removed, will be rejected by the Engineer unless
some satisfactory auxiliary means can be provided by the Contractor for the
heating of the bituminous material without the introduction or moisture. The
use of any equipment for the agitation of bituminous material to aid in heating
will be prohibited if it injures or in any way changes the characteristics of the
bituminous material or introduces free steam or moisture into the tank
containing the bituminous material.
Tanker or truck connections for transferring bituminous material from tankers

to distributors, supply tanks, or storage tanks shall be constructed so that
they cannot be used for any other purpose. The use of a tanker or truck
connections or any other equipment by means of which free steam can be
introduced directly into the bituminous material as a means of agitation or
auxiliary heating will be prohibited.
II) Bitumen Distributor Equipment
Equipment for the distribution of bituminous materials shall be equipped with

the following appliances or devices:
Tachometers.
Pressure Gauge.
Adjustable Length Spray Bars.
Separate Power Unit & Pump on distributing System.
Heating Coils and Burner.
Thermometer well and Accurate Thermometer
Measuring Sticks.
Quick Opening Gate in dome.
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All distributors and supply tanks shall be mounted on

dependable motor trucks or trailers equipped with pneumatic tyres. The units
shall be so designed to ensure that no rutting or other injury to the road
surface will result. The distributor shall have pneumatic tyres of such width and
number that the load produced on the road surface shall not exceed one
hundred and ten (110) kilograms per linear centimeter of eh width. They will be
sufficiently powered to maintain the desired speed of the equipment during
operation.
The manometer designating the speed of the truck shall be a separate

operating unit attached to the truck equipped with a larger gauge
approximately fourteen (14) centimeters in diameter within limits of
approximately three (3) metres per minute or equivalent thereto. The gauge
shall be so located that it can be easily read at all times by the driver of the
distributor.
The distributor shall be equipped with either a tachometer, calibrated to

indicate revolutions per minute, attached to the pump shaft or a pressure
gauge, calibrated to indicate kilograms per square centimeter placed in the
distributing system, by which the flow of bitumen may be regulated.
The spray bars shall be constructed to permit adjustment for length in

increments of thirty (30) centimeters for any length up to seven (7) metres, to
permit vertical adjustment of all nozzles to the desired height above the road
surface conforming to the roadway crown, and to permit lateral shifting of the
entire spray bar during operation. The spray bars and nozzles shall be
constructed to prevent clogging of the nozzle during the intermittent operation
and to provide positive and immediate cut-off when distribution of oil ceases,
thus preventing dripping of oil from the bar.
The power unit and pump distribution systems shall have

a capacity of not less than nine hundred fifty (950) litres per minute, shall be
equipped with a by-pass into the supply tank and shall be capable of
distributing a uniform and constant flow of bituminous material through all
nozzles at a pressure between one and one quarter (1.25) and three and one
half (3.5) kilograms per square centimeter.
The entire distributors assembly shall be so constructed

and operated to ensure accurate distribution of bituminous material at rates of
from two-tenths (0.2) to seven and five tenths (7.5) liters per square metre with
uniform pressure, and with an allowable variation from any specified rate not to
exceed one tenth (0.1) liters per square metre. Minimum capacity of the
distributor shall be four thousand (4,000) liters.
III) Calibration and Check of Distributors
All distributors shall be calibrated and checked before being used on the work.
The calibration of the tank will be doe by the Contractor in the presence of the
Engineer by the method prescribed by the manufacturer and / or as directed by
the Engineer.
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The operation of the distributor will be checked by the Engineer the first time it
is used and as often as he deems it necessary thereafter, and when the
operation is found to be satisfactory, a new certificate will be issued.
IV ) Plant Yard Requirements
Ideally each type of plant should have a clearly defined

area and each one independent of the other. However the following
requirement shall be met if different plants are located within the same yard.
a) Space of each unit shall be adequate to accommodate in proper shape &

order all the relevant materials (raw & processed) involved in the
processing and operation.
b) Use of a single stock pile for a fraction (say crusher plant & asphalt plant)
for two different units shall not be acceptable.
c) Manufacturer certification for compliance / Engineer's approval shall be

required prior to adding any freshly processed material with the
previously approved stock pile at the asphalt plant yard.
d) Stock piles of only approved materials shall be allowed to be stored close

to the plant where it is meant to be used.
e) Handling & stockpiling of aggregates, shall at all times, be so maintained

as to eliminate segregation, intermixing or contamination of different
sizes. Due care shall be taken by the contractor for the space between
two sock piles & their height so that mechanical shovel, when required,
can be used for sampling / opening the stock pile.
f) If materials of different sources are used to produce different asphaltic

mixes from a single asphalt plant, handling and stockpiling shall be so
arranged as to make all the fractions accessible and as close as possible
to the cold feeder of the asphalt plant for timely and proportionate
feeding to achieve continuous production of uniform mixture.
g) The contractor shall provide the engineer with necessary information in

respect of the location of his plants and the position of the stock piles at
the plant yard prior to production of mixes.
h) Mixing Plant Requirements
The asphalt plant shall be located within 35km of the projects work site.
Contractor shall take adequate measure, to the satisfaction of the Engineer, to
avoid loss of temperature of the mix in the truck as well as its oxidation due to
exposure to air for a longer period.
The mixing plant used for producing bituminous mixes shall be so designed
and operated to produce job mixtures complying with the specified job mix
tolerances.
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The mixing plant shall be maintained in good order and controlled by an

experienced plant operator and a senior laboratory technician.
Before the start of production, all measuring scales shall be calibrated in the
presence of the Engineer. The calibration shall be repeated as and when
deemed necessary by the Engineer.
All plant used for preparation of bituminous mixtures shall consist of the
following basic components:
a) A cold feed system, either a single reciprocating feeder or a multiple
feeder. The feeding shall be belt feeding system.
b) A conveyor or elevator to move the cold aggregate into the drier.
c) A rotary drier.
d) A dust collection system powerful enough to keep filler content in the
sand bin below 2% with a means for returning dust in part or in whole to
the hot mix, if so required or discharging to waste in an approved
manner.
e) A hot stone elevator.
f) A set of screens to make full separation of the aggregate to the sizes as
required by the specifications.
g) A set of hot stone bins for the storage of the various components of the
aggregate prior to proportioning.
h) Thermometric equipment.
i) An approved proportioning system, either by volume or by weight.
j) Adequate and approved scales or volumetric devices for the control of
the proportioning.
k) Two shaft mixer pug mill, rotary drum of other approved type.
l) An insulated discharge hopper for loading trucks.
m) Adequate and approved asphalt and fuel storage tanks. Separate
storage tanks shall be provided for each grade of asphalt polymer
modified binder, prime coat and tack coat.
n) An effective filter system to prevent the escape of dust, smoke and any
other pollutant to the atmosphere.
o) The plant shall be capable of producing not less then 200 Tons of mixed
material per hour.
p) Plant shall be equipped with the facilities to provide computer print out
indicating the batch time, discharge temperature of the mix, quantity of
each ingredient – all against the target as per approved mix design.
V) Requirements of All Plants
a) Uniformity
The plants shall be so designed, coordinated and operated to produce a

uniform mixture.
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b) Scale
Scales for any weight box or hopper may be of either the

beam or spring less dial type and shall be of a standard make and design,
accurate to one (1) percent of the maximum load that may be required.
When scales are of the beam type, there shall be a

separate beam for each size of aggregate. There shall be provided a "Tell-tale
Dial" that will start to function when the load being applied is within fifty (50)
kilograms of to permit the tell-tale dial to function properly. Each beam shall
have a locking device so designed and located that the beam can easily be
suspended or thrown into action.
Dial scales shall be spring less, of a standard make, and

of such size that the numeral on the dial can be read at a distance of at least
(8) metres. The dial shall be of the compounding type having full complement
of index. Pointers so placed as to give excessive parallax errors shall not be
used. The scrabbles shall be substantially constructed, and those that easily
gent out of adjustment shall be replaced with other makes when so ordered. All
dials shall be so located as to be plainly visible to the operator at all times
Scales shall be inspected and sealed or certified as often

as the Engineer may deem necessary to ensure their continued accuracy. The
initial inspection shall be done by an approved scale company, or by the
Contractor.
c) Equipment for Preparation of Bituminous Material
Tanks for the storage of bituminous material stall be

equipped to heat and hold the materials at the required, temperature. The
heating shall be accomplished by steam coils, electricity, hot coils, or other
approved means so that the flame shall be in contact with the tank
The circulating system for the bituminous material shall

be designed to ensure proper and continuous circulation during the operating
period. Provision shall be made for measuring and sampling storage tanks.
Storage tanks shall have sufficient capacity to provide for continuous
operation. The storage tanks shall be calibrated and equipped with a device
whereby the Engineer may determine the amount of asphalt on hand at any
time.
d)Feeder for Drier
The plant shall be provided with accurate mechanical means for uniformly
feeding the aggregate into the drier so that uniform production and uniform
temperature will be obtained. A separate mechanical feeder equipped with an
adjustable gate opening shall be provided for each individual aggregate being
combined to produce the total aggregate. The feeders and gate shall be so
constructed and equipped that a continuous and uniform flow of each material
will be ensured. They shall also be installed in such a manner as to be readily
accessible for calibrating at all times.
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e) Drier
The plant shall include a drier or driers which continuously agitate the
aggregate during the heating and drying process. The drier shall be capable or
drying and heating the mineral aggregate to specification requirements. The
burners shall be of such capacity, and they shall be so constructed and
operated that complete combustion of the fuel is obtained.
f) Screens
Plant screens, capable of screening all aggregates to the specified sizes and
proportions and having normal capacities in excess of the full capacity of the
mixer, shall be provided.
g) Bins
T
he plant shall include storage bins (cold &. hot) of sufficient capacity to supply
the mixer when it is operating at full capacity. The plant shall have the provision
of "Filler Silo" and facilities available to accurately measure and feed filler into
the mixes. Bins shall be arranged to ensure separate and adequate storage of
appropriate fractions of the mineral aggregates. Separate dry storage shall be
provided for Portland cement, hydrated lime, or other similar materials when
used and the plant shall be equipped to feed such material into the mixer.
Each bin shall be provided with overflow pipes, of such size and at such
location as to prevent backing up of material into other compartment shall be
provided with its individual outlet gate, constructed so that when closed there
shall be no leakage. The gates shall cut off quickly and completely. Bins shall
be so constructed that samples can be readily obtained. Bins shall be
equipped with adequate tell-tale devices to indicate the position of the
aggregates in the bins at the lower quarter point.
The minimum number of bins shall include at least one bin for each different
stockpile of material being used. Intermixing of material from different
stockpiles in one bin or on the ground shall not be permitted.
h) Bituminous Control Unit
Satisfactory means, either by weighing or metering shall be provided to

obtain the proper amount of bituminous material in the mix within the tolerance
specified. Means shall be provided for checking the quality or rate of flow of
bituminous material into the mixer. Suitable means shall be provided for
maintaining the specified temperature of the bituminous material in the
pipelines, meters, weight buckets, and spray bars.
i) Thermometric Equipment
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An armored thermometer of adequate range in temperature reading shall be

fixed in the bituminous feed line at a suitable location near the charging valve
at the mixer unit.
The plant shall also be equipped with either an approved dial-scale mercury-
actuated thermometer, an electric pyrometer, or other approved thermometric
instrument so placed at the discharge chute of the drier as to register
automatically or indicate the temperature of the heated aggregates.
All plants whether continuous or batch type shall be equipped with two
recording thermometers. These instruments shall be provided with dustproof
cases, long leads, and automatic recording mechanism capable of recording
the desired temperature for a period of twenty-four (24) hours on a chart not
less than twenty (20) centimeters in diameter, or on a continuous sheet. The
chart for either type shall be graduated in hours, minuets, and degrees of
temperature. The maximum temperature graduation shall be five (5) degrees
centigrade. Hours on the chart shall be designated as am or pm.
The temperature recording thermometers shall be installed on a points or a

framework, separated from the plant, to eliminate plant vibration.
They shall be located in a manner to provide easy access to the case and
charts. The bulb of one instrument shall be installed in the hot asphalt line as
close as is practicable to the spray bar discharge, the bulb of the second
recording thermometer shall be installed in the hot aggregate bin, which
contains the fine aggregate. The bulb shall be located where the hot materials
will flow over it during the proportioning operation and shall not be located near
the corners of the bin or at locations where the material will collect or pack
around it.
The Engineer reserves the right to pass judgment upon the efficiency of
thermometric instruments.
j) Control of Mixing Time
The plant shall be equipped with positive means to govern the time of mixing
and to maintain a constant time unless changed by order of the Engineer.
k) Dust collectors
The plant shall be equipped with a dust collector constructed to waste or return
uniformly to the hot elevator or all any part of the material collected as desired.
l) Safely Requirements
Adequate & safe stairway to he mixer platform and sampling points shall be
provided and guarded ladders to other points shall be placed at all points
where accessibility to plant operation is required. Accessibility to the top of
truck bodies shall be provided by a platform or other suitable device to enable
the Engineer to obtain sampling & mixture temperature data. A hoist or pulley
system shall be provided to raise scale calibration equipment, sampling
equipment and other similar equipment from the ground to the mixture
platform.
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All gears, pulley, chains, sprockets, and other dangerous moving parts shall be
thoroughly guarded and protected. Ample and unobstructed space shall be
provided on the mixing platform. A clear and unobstructed passage shall be
maintained at all times in and around the truck loading area. The area shall be
kept free from dropping from the mixing platform.
m) Specification Requirements for Batching Plants Weigh Box or Hopper
The equipment shall include a means for accurately weighing each size of
aggregate in a weigh box or hopper suspended on scales and of ample size to
hold a full patch without hand raking or running over. The gate shall close
tightly so that no material is allowed to leak into the mixer while batch is being
weighed. Asphalt plants shall meet requirements in accordance with ASTM
D995 & ASTM D290.
a) Bituminous Control
The equipment used to measure the bituminous material shall be

accurate to plus minus five-tenths (0.5) percent. The bituminous material
bucket shall be non-tilting type with a loose sheet metal cover. The length of
the discharge opening or spray bar shall be not less than (3/4) the length of the
mixer and it shall discharge directly into the mixer. The bituminous material
bucket, its discharge valve or valves and spray bar shall be adequately heated.
Steam jackets, if used, shall be efficiently drained and all connections shall be
so constructed that they will not interfere with the efficient operation of the
bituminous scales. The capacity of the bituminous material bucket shall be at
least 15 percent in excess of the weight of bituminous material required in any
batch. The plant shall have an adequately heated quick-acting, non drip,
charging valve located directly over the bituminous material bucket.
The indicator dial shall have a capacity of at least 15 percent in excess of

the quantity of bituminous material used in batch.
The dial shall be in full view of the mixer operator. The flow of bituminous
material shall be automatically controlled so that it will begin when the dry
mixing period is over and all of the bituminous material required for one batch
will be discharged in not more than 15 seconds after the flow has started. The
section of the bituminous line between the charging valve and spray bar shall
be provided with a valve and outlet for checking the meeting device.
b) Mixer
The batch mixer shall be an approved type capable of producing uniform
mixture.
If not enclosed, the mixer box shall be equipped with a dust hood to prevent
loss of dust.
The clearance of blades from all fixed and moving parts shall not exceed 2.5
centimeters unless the maximum diameter of the aggregate in the mix exceeds
3 centimeters, in which case the clearance shall not exceed 3.8 centimeters.
c) Control of Mixing Time
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The mixer shall be equipped with an accurate time lock to control the
operations of a complete mixing cycle. It shall lock the weigh box gate after the
charging of the mixer until the closing of the mixer at the completion of the
cycle. It shall lock the bituminous material bucket throughout the dry mixing
periods. The dry mixing period is defined as the interval of the time between
the opening of the weigh box gate and the start of introduction of bituminous
material. The wet mixing period is the interval of time between the start of
introduction of bituminous material and the opening of the mixer gate.
The control of the timing shall be flexible and capable of being set at intervals
as necessary for mixing time throughout the total mixing cycle. A mechanical
batch counter shall be installed as a part of the timing device and shall be so
designed as to register only completely mixed batches.
VI) Special Requirements of Continuous Mixing Plants Aggregate Proportioning
Continuous Mixing Plants are not recommended.
a) Weight Calibration of Aggregate Feed
The plant shall include a means for calibration of gate opening by weighing test
samples. Provisions shall be made so that the materials fed out of individual
orifices may be bypassed to individual test boxes. The plant shall be equipped
to conveniently handle individual test samples weighing not less than 100 Kg.
Accurate scales shall be provided by the Contractor to weigh test samples.
b) Weight calibration of Bituminous Material
The bituminous discharge line shall be equipped with suitable valves and a
bypass so that the asphalt pump of meter may be readily calibrated. For each
change of stockpiles, the plant shall be recalibrated.
c) Synchronization of Aggregate Feed and bituminous Material

Feed
Synchronization means shall be provided to afford positive interlocking control

between the flow of aggregate from the bins and the flow of bituminous
material from the meter or other proportioning device. This control shall be
accomplished by interlocking mechanical means or by any other positive
method satisfactory to the Engineer.
d) Mixer
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The plant shall include a continuous mixer of an approved type, adequately

heated and capable of producing a uniform mixture. It shall be equipped with a
discharge hopper with dump gates, which will permit rapid and complete
discharge of the mixture. The paddles shall be adjustable for angular position
on the shaft and reversible to retard the flow of the mix. The mixer shall have a
manufacturer's plate giving the net volumetric gauge. Charts shall be provided
showing the rate of feed of the aggregate per minute for the aggregate being
used.
e) Bituminous Paver
Bituminous pavers shall be self-contained, power propelled units, provided

with automatically controlled activated screed or strike-off assembly, heated if
necessary, and capable of spreading and finishing courses of bituminous plant
mix material in lane and trenches widths applicable to the specified typical
section and thickness shown on the plants. Pavers used for shoulders and
similar construction shall be capable of spreading and finishing courses of
bituminous plant mix material in widths on the plans. Pavers shall be capable
of laying 100 ton per hour.
The machines shall employ mechanical devices such as equalizing runners,

straight-edge runners, evener arms, or other compensating devices to adjust
the grade and confine the edges of the mixer to true lines without the use of
stationary side forms.
The paver shall be equipped with a distribution system to place the mixer
uniformly in front of the screed.
The screed of strike-off assembly shall effectively produce a finished surface

of a required evenness and texture without tearing, shoving or gouging the
mixture.
The paver shall be capable of being operated, when laying mixture, at forward
speed consistent with satisfactory laying of the mixture.
The automatic controls for the paver shall be automatic linkage arrangement
so that through the process of automatically adjusting the screed, the
thickness of asphaltic mixture can be placed and finished to predetermined
grade and a uniform crown or cross-section.
Manually controlled bituminous pavers may be used only with the written
consent of the Engineer. A manually controlled bituminous paver shall be of
the self-propelled type with spread and strike-off facilities designed to spread
the mixture in such a manner that no supplemental shaping will be required.
It shall be capable of spreading the mixture evenly, with uniform density,

without segregation and shall strike off true to the cross section. Screeds must
be constructed so as not to follow minor irregularities in the base and must be
readily adjustable to control accurately the depth spread. No manually
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operated bituminous paver shall be delivered to the site prior to its approval by
the Engineer.
4.35 BITUMINOUS PRIME COAT
4.35.1 Description
Bituminous prime coat shall consist of supplying and

applying liquid asphalt to a previously prepared and approved subgrade,
subbase, aggregate base course or wet mix road -base in accordance with this
specification.
4.35.2 Material
Material for prime coat shall be:-
Liquid asphalt for prime coat shall be medium curing cut

back asphalt MC-70 to the requirements of AASHTO M82 / ASTM D-2027 as
modified by Table 4.10 or as directed by the Engineer.
TABLE 4.10 - MEDIUM CURING LIQUID ASPHALT MC 70
TEST MIN. MAX.

Saybolt Furol Viscosity at 50 deg. C. sec 60 120
Flash point, Tag open cup, deg. C
Distillation:
* Distillate (% of total distillation to 360 ° C)
To 225 deg. C 2 -
To 260 deg. C 0 60
To 315 deg. C 20 90
Residue from distillation to 360 deg. C, percent by 55 volume difference

Tests on residue from distillation:
* Penetration 25 deg. C, l00g 5 sec. 120 250

* Ductility 25 deg. C, cm 100 -
* Solubility in Trichloro ethylene % 99 -
*Water percent - 0.2
4.35.3 Application / Spray
4.35.3.1 Prime coat shall be applied at a rate of not less than 0.7 liters per square metre
and not more than 1.2 liters per square metre.
4.35.3.2 The exact rate of application, which may be varied to suit field conditions, will
be determined by the Engineer following trials to be carried out by the
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Contractor.
4.35.3.3 The surface to be prime coated shall be uniformly smooth and firm and true to
the grades and cross-section shown on the drawings within specified
tolerances, and so maintained throughout prime coating. Prime coat shall not
be placed on a soft, uneven base. Any holes, depressions or irregularities shall
be repaired by the removal of loose and unsuitable material and its
replacement with suitable material compacted to produce a dense, even
surface of uniform texture. When required, the surface to be primed shall be
lightly bladed and compacted and the Engineer may instruct a light application
of water to facilitate penetration. Priming will not be permitted when the surface
is wet.
4.35.3.4 Prime coat shall not be applied when the ambient temperature is less than 13
deg. C or during rain, fog, dust storms or other unsuitable weather. The
application temperature for MC-70 liquid asphalt shall be between 50deg. C
and 80 deg. C as approved by the Engineer. It shall be applied to one lane of
the carriageway width at a time. When applied in two or more lanes there shall
be a slight overlap along adjoining edges. Overlapping will not be permitted at
transverse joints and thick paper shall be used to protect the previous
application.
4.35.3.5 Traffic shall be kept off the prime coat until it has penetrated the subgrade or
road base and fully cured. It should be left undisturbed for a period of 48 hours
or as otherwise directed by the Engineer.
4.35.3.6 The Contractor shall furnish and spread at his cost sufficient clean fine sand, of
an approved quality, to blot up areas, which show an excess of prime coat.
4.35.3.7 The primed surface shall be maintained in a good, clean condition at all times
until the next course is placed. Any surface irregularities or holes in the primed
surface, however caused, shall be repaired and corrected to the Engineer's
satisfaction.
4.36 BITUMINOUS TACK COAT

4.36.1 Description
Bituminous tack coat shall consist of supplying and applying emulsified

asphalt, diluted with an equal quality of water (1:1) to a previously prepared
bituminous base course or binder course or to an existing bituminous surface,
in accordance with this specification.
4.36.2 Material
The material for bituminous tack coat shall be slow setting emulsified asphalt,
grade SS1h (anionic) or CSS1h (cationic) conforming to the requirements of
AASHTO M 140 and AASHTO M 208 respectively.
4.36.3 Application / Spray

4.36.2 The tack coat (diluted emulsion) shall be applied in quantities of not less than
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0.2 litres per square metre and not more than 0.4 litres per square metre.
4.36.3 Immediately before applying the tack coat, all loose material, dirt, clay or other
objectionable material, shall be removed from the surface with a power broom
or blower supplemented with hand brooms, as directed by the Engineer. After
the cleaning operation, and prior to the application of the tack coat, an
inspection of the area to be coated will be made by the Engineer.
4.36.4 The application temperature for the tack shall be between 10 deg. C and 60
deg. C as directed by the Engineer. The material should not be applied when
the ambient temperature is less than 13 deg. C or during rain, for, dust storms
or other unsuitable weather.
4.36.5 After application the surface shall be allowed to dry to the proper condition of
tackiness to receive the following pavement Coat shall be applied only so far in
advance to pavement courses to obtain the proper condition of tackiness and
the Contractor shall protect the tack coat from damage during this period.
4.36.6 If the completed tack coat is damaged by rain or dust, it shall be allowed to dry
cleaned by poser broom or blower and, if required by the Engineer, an
additional light application of tack coat shall be applied. NO additional payment
shall be made in the event of any additional spray for this work.
4.36.7 Where, in the opinion of the Engineer, a tack coat is not necessary, the
contractor shall clear, at his expense the existing surface free of dust and other
deleterious material as per paragraph 4.36.3.2 above.
4.37 APPLICATION AND HEATING EQUIPMENT FOR LIQUID ASPHALT

4.37.1 A self -powered pressure distributor should be used for applying asphalt
mixture. The distributor shall have pneumatic tyres of such width and number
that the load produced on the based surface shall not exceed 110kg per
centimeter of tyre width, and shall be so designed and equipped as to
distribute the bituminous material uniformly at even heat on variable width of
surface at readily determined and controlled rates from 0.2 to 7.5 liters per sq.
m with a pressure range of 1.25 kg to 5.2 kg per sq. m and with an allowable
variation from any specified rate not exceeding 5 percent. Distributors and
booster tanks shall be so maintained at all times that no dripping of bituminous
material will occur from any part of the equipment.
4.37.2 Distribution equipment shall include an independently operated bitumen pump,

technometer pressure gauges, volume measuring devices, a thermometer for
reading the temperature of tank contents, and a hose attachment for applying
bituminous material to spots unavoidably missed by the distributor. The
distributor shall be equipped for circulation and agitation of the bituminous
material during the heating process.
4.37.3 The equipment for heating shall consist of steam coils and equipment for
producing steam, so designed that steam will not be introduced into the
material in the event of storage tanks being used, an armored thermometer
with a range from 10 deg. C to 150 deg. C shall be fixed to the tank so that the
temperature of the bituminous material may be determined at all times.
4.37.4 Other heating facilities may be used subject to the approval of the Engineer.
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4.38 DOUBLE BITUMINOUS SURFACE TREATMENT
4.38.1 Description
This work shall consider of a wearing surface composed of a bituminous

prime followed by two (2) applications of bituminous seal coats with each seal
coat receiving an application of cove material in accordance with the
specifications and in conformity with the lines shown on the drawings or
established by the Engineer.
4.38.2 Materials
4.38.2.1 Prime coat
The prime coat shall be medium curing cut-back asphalt grade MC-70. The
rate of application shall be between 1.00 to 1.75 liters per square metre as
specified by the Engineer.
4.38.2.2 The seal coat shall be 80/100 penetration grade bitumen. The bitumen may
be cut back with up to 2 percent by weight of kerosene to improve adhesion to
the stone. The characteristics of the bitumen are shown below:
80/100 PENETRATION GRADE BITUMEN

TEST METHOD MIN. MAX.
Penetration at 25 deg. C,
100g, 5 sec. T49 85 100
Flash Point, Cleveland

open cup, deg. C T48 232 -
Ductility at 25 deg. C,
cu.m T51 100 -
Solubility in trichloro
Ethylene, % T44 99 -
Thin film oven test

3.2 mm, 163 deg. C 5 hour
loss on heating, percent T179 - 1.0
Penetration of residue
percent of original T49 50 -
Ductility of residue at T51 73 -
25 deg. C min cm
4.38.2.3 Cover Material
Aggregate for cover material shall be screenings of crushed stone, which are
clean, tough, durable and free from dirt and other objectionable matter. The
percentages of wear shall not be more than thirty (30) as determined by
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MSHTO T-96. When subjected to five (5) cycles of magnesium sulphate

soundness testing, as determined by MSHTO T-104, it shall have a weight
loss not greater than ten (10) percent and a flakiness index of 30% (BS 812
part 105.1) and ACV of 20% (BS 812 part 3 test 6). No less than sixty (60)
percent by weight of crushed stone shall consist of crushed pieces having two
or more faces produced by fracture when tested by DM standard test method
DM 301. Aggregate shall conform to the following gradations and shall be
DOUBLE BITUMINOUS SURFACE
TREATMENT
Sieve Size First Course Second Course

25 mm (1 inch) 100
19.0 mm (3/4 inch) 55-85 100
12.5 mm (1/2 inch) 0-15 90-100
9.5 mm (3/8 inch) - -
4.75mm (No.4) 0-2 10-30
2.36mm (No.8) 0-3 0-10
2.00mm (No.10) 0-3 -
0.300mm (No.50) - 0-5
4.39 EQUIPMENT FOR DOUBLE BITUMINOUS SURFACE TREATMENT
4.39.1 The equipment used by the Contractor shall include a power broom or a power
blower, or both, a self-propelled pneumatic - tyred roller or steel-wheeled
tandem roller (4 to 6 tones) or both; self-propelled aggregate spreading
equipment that can be adjusted to spread accurately the specified amount per
square metre; a bitumen distributor and equipment for heating the asphaltic
materials.
4.39.2 Other equipment may be used in addition to the specified equipment when
approved or requested by the Engineer.
4.40 PREPARATION OF MATERIAL
4.40.1 Heating of Bituminous Materials shall be with equipment as specified. The use
of any method or agitation or heating that introduces free steam or moisture
into the bituminous material is prohibited. Materials heated to temperatures
above twenty eight (28) degrees C higher than the maximum application
temperature specified shall be considered as overheated and shall be rejected
until the material can be resampled and retested. The reacceptance or final
rejection will be made by the Engineer on the same requirements under which
the material was originally tested.
4.40.2 If aggregates are deemed by the Engineer to be dusty or dirty they shall be
washed after which their use shall not be permitted until all free water has
evaporated or been drained.
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4.41 APPLICATION
4.41.1 After the prime coat has been applied and has thoroughly penetrated the
surface and cured as specified, the Contractor shall apply 80/100 penetration
bitumen and shall apply the cover material and roll and manipulate the
surface, all in accordance with the requirements specified hereinafter. The
material shall be uniformly applied at the rate designated to the surface being
sealed.
4.41.2 Bituminous material shall be applied by means of a pressure distributor in a

uniform, continuous speed over the section to be treated and when the
within temperature range specified the quantity of bituminous material to be
used per square metre shall be within the limits hereinafter specified and as
directed by the Engineer.
4.41.3 A strip of building paper, at least one (1) metre in width and with a length equal
to that of the spray bar of the distributor plus thirty (30) centimeters, shall be
used at the beginning of each spread. The paper shall be removed and
disposed of in an approved manner. The distributor shall be moving forward at
proper application speed at the time the spray bar is opened. Any skipped
areas or deficiencies shall be corrected in an approved manner. Junctions of
spreads shall be carefully made to ensure a smooth riding surface.
4.41.4 The length of spread of bituminous materials shall not be in excess of that
whichtrucks loaded with cover coat material can immediately cover.
4.41.5 The spread of bituminous material shall not be more than fifteen (15)
centimeterswider than the width covered by the cover coat material from the
spreading device.Under no circumstances shall operations proceed in such a
manner that bituminousmaterial will be allowed to chill, set up, dry or otherwise
impair retention of thecover coat.
4.41.6 The distributor, when not spreading, shall be so designed that the spray bar or
mechanism will not drip bituminous material on the surface of the traveled
way.
4.41.7 Distribution of the bituminous material shall be so regulated and sufficient

bituminous material must remain in the distributor at the end of each
application so that there will be a uniform distribution of bituminous material. In
no case shall the distributor be allowed to expel air with the bituminous
material thereby causing uneven coverage.
4.41.8 The angle of the spray nozzles and the height of the spray bar shall be so
adjusted and frequently checked so that uniform distribution is ensured. If the
raise of the spray bar as the load is removed is excessive and contributes to
dripping and streaking of the seal course the frame of the distributor shall be
blocked or snubbed to the axle of the truck to maintain a constant height of the
spray bar above the road surface. The distribution shall cease immediately
upon any clogging or interference of any nozzle and corrective measures shall
be taken before distribution is resumed.
4.41.9 Immediately following the application of the bituminous material, cover material
shall be spread with an approved aggregate spreader in quantities as
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specified by the Engineer and within the limits specified herein. Spreading
shall be accomplished in such a manner that the tyres of the trucks or
aggregate spreader at no time contact the uncovered and newly applied
bituminous material.
4.41.10 The operation of distributing bituminous material shall not be in excess of one
hundred (100) linear metres ahead of the spreading of the aggregate.
4.41.11 Procedures of starting, stopping or turning of any piece of equipment which

results in displacement of the cover material or damage to the seal course
shall be prohibited.
4.41.12 The spreading equipment shall be of such width and arrangement, that as the
aggregate is placed, complete coverage will be obtained. No booming, or
egging or blading of the cover material shall be permitted prior to initial rolling.
Any rearrangement of the cover material shall be done by hand methods.
Overlapping the applications of cover material shall be avoided and all spillage
shall be removed from the surface. Before rolling, the bituminous material shall
be uniformly covered.
4.41.13 The rates of application for bituminous material and aggregate for “Bituminous
Surface Treatment" shall be within the following limits:
RATES OF APPLICATION OF ASPHALT AND AGGREGATE FOR DOUBLE

BITUMINOUS SURFACE TREATMENT
80/100 PENETRATION AGGREG/ Kg/Sq.m
Per Kg/Sq.m
MIN. MAX. MIN. MAX.
First application
1.1 1.8 20 28
(Course)
Second
1.6 2.1 12 16
application
4.41.14 Immediately after the application of bituminous material and aggregate to the
road surface and after the aggregate has been rearranged as may be
necessary to provide uniform and complete coverage, the surface shall be
sufficiently rolled with an approved pneumatic-tyred roller to embed the
aggregate thoroughly into the bituminous material. Sufficient rollers shall be
provided such that the initial rolling consisting of a single pass of a 10-12
tonne tandem steel wheel roller followed by at least two (2) complete
coverage's with the pneumatic tyred roller shall be completed within thirty (30)
minutes after the cover material is applied. The rollers shall be operated on
each coverage so that each succeeding trip of the roller will overlap at least
fifty (50) percent of the width of the precious trip. No blading or
dragging of the aggregate will be permitted for the first seal coat. Any
rearrangement of the cover material before or during the initial rolling shall be
done by approved hand methods.
Rolling shall be continued after the rolling specified above is completed until a
maximum mount of the aggregate is satisfactorily embedded in the bituminous
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material. Pneumatic tyred rollers shall be operated at a maximum speed of

eight (8) kilometers per hour.
4.41.15 Unless otherwise designated on the drawings, or directed by the Engineer, the
second seal coat shall not be applied for 48 hours after the application of the
first seal coat.
4.41.16 Immediately prior to the second application of bituminous material for sealing,
the surface shall be cleaned in an approved manner of all dust and excess
cover material which is not embedded in the first application of bituminous
material for sealing. Care shall be exercised not to dislodge any cover
material, which is embedded in the bituminous material. The second seal coat
shall be applied as previously specified. Brooms or drag brooms shall not be
used to shift the cover material until the initial rolling with the pneumatic-tyred
roller is completed and until the bituminous material has cooled and set up
sufficiently to hold the cover material, preferably not earlier than the day
following the application off the second seal coat. Any rearrangement of the
cover material during the initial rolling shall be done by approved hand
methods.
4.41.17 The rolling shall be longitudinal and shall commence at the outer edge of the
shoulder and then progress towards the inner edge. Rolling shall continue until
the entire surface has been completely covered at least three (3) times with a
pneumatic tyred roller. Maximum speed of rollers shall be as previously
specified.
4.41.18 The contractor shall manipulate the surface for a period of five (5) days after
the second seal coat has been applied. The manipulation shall consist of the
application of additional aggregate or additional dragging and rolling or all of
these operations to portions of the surface that, as determined by the
Engineer, require such additional treatment. The manipulation shall also
include the dragging and one (1) complete rolling over the entire surface each
th
day from the time the surface is completed until and including the fifth (5 ) day
after. A light blade equipped with a broom drag shall be operated immediately
ahead of the roller throughout all rolling during the manipulation period. The
daily dragging and rolling under manipulation may be omitted, if in the opinion
of the Engineer, the weather and roadbed conditions are such that the
dragging and rolling would not be beneficial to the surface.
4.41.19 Aggregate and additional manipulation ordered by the Engineer, in this work,
will not be paid for separately but will be considered subsidiary to the item of
"Double Bituminous Surface Treatment" included in the "Bill of Quantities".
4.41.20 Except for times when it is necessary for hauling equipment and / or pilot
trucks to travel on the newly applied seal coat, traffic of all types shall be kept
off the seal coat until it has had time to set properly. The minimum traffic free
period shall be 24 hours.
4.41.21 Surface treatment operations shall be carried on only when the surface is dry,
when the atmospheric temperature is above fifteen (15) degrees C, and when
the weather is not dusty, foggy or rainy. The above requirements may be
waived, but only when so directed and in writing by the Engineer.
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4.42 ROTECTION OF ADJACENT STRUCTURES FROM BITUMEN SPLASHING
When bituminous materials are being applied, the

surface of all structures e.g. guard rail, kerbs and gutters, and other roadway
appurtenances shall be
protected in an approved manner to prevent them from being splattered with
bituminous material or marred by equipment operation. In the event that any
appurtenances become splattered or marred, the Contractor shall at his own
expense, remove all traces of bituminous materials, and repair all damages,
and
leave the appurtenances in an approved condition.
4.43 PAVEMENT REPAIR
4.43.1 General
The repair works to the existing pavement will generally

involve, but not limited to the following:
1) Full pavement reconstruction
2) Milling of existing asphaltic pavement.
3) Overlay with approved asphaltic mixes.
4) Patch works:- Shallow depth, partial depth or full depth.
5) Crack sealing
6) Surface treatment
However the actual work to be executed on site shall be

based on the site investigations carried out and report made on each individual
case and accordingly a work order issued by the Engineer. The Contractor
shall be required to submit his method statement, for successful execution of
the work, to the Engineer for his approval. Whenever required by the Engineer,
the Contractor shall demonstrate, through site trial, that the plants /equipment
and the method statement proposed by him are adequate to satisfactorily meet
the requirements of the specification particularly where the patch works are
involved. The Contractor shall be required to get prior approval of the Engineer
for the materials and machinery proposed for use in the works.
General requirements of the Specification shall apply for

the approval of the materials used in the remedial works covered by the work
order involving sub-grade, sub-base/ aggregate road base, asphaltic courses
including those of the patch works up to a minimum of 10m in length and 2m in
width. However for lesser dimension patch works, the engineer, in agreement
with the client, may relax these requirements depending on the merits of the
cases concerned.
4.43.2 Scope of Works
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All repairs works shall be carried out only on Engineer's

written instruction. Details of the type and extent of repair will be provided by
the Engineer along with the Work Order.
The scope of work shall involve the investigation of the

existing pavement by carrying out destructive & non-destructive tests as
required by the engineer in order for the engineer to evaluate the current
condition of the pavement and to subsequently instruct the contractor for
appropriate remedial works.
The contractor shall be responsible for arranging the

equipment and testing facilities required for carrying out "on site" & "laboratory"
tests well in advance so that the relevant data (of asphalt and as well as under
laying layers) are made available to the engineer on time for his evaluation of
the pavement prior to issuing instruction for appropriate remedial measures to
be undertaken. Sampling & testing shall be carried out in accordance with
relevant clauses mentioned elsewhere in the general specification.
Non-destructive test (NDT), when needed, shall be

carried out by a specialist using the falling weight deflectometer or as directed
by the Engineer.
Destructive tests shall include, but not limited to the

following:
a. Cut-out samples of aggregate road base, sub-base, sub-grade to check
CBR, Plasticity index etc.
b. Cores & cut-out samples on asphaltic layers to check bitumen content,
Gmm, insitu air aoids, stability, etc. for each layer of asphalt.
c. Full details of bituminous layers identifying

i) Thickness of each layer of asphalt for each
lane/shoulder.
ii) Location of all full depth cracked asphalt indicating length &
offset
(longitudinal & transverse

cracks),
iii) Rut depth where

applicable
iv) Any localized spot of distress.
4.43.3 Special Equipment
Conventional plants & equipment shall be used wherever

possible. However, the Contractor shall bear in mind that the conventional
plants and equipments may be not enough to successfully execute some of the
works involved in pavement repairs particularly the patch works having limited
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width and may have to be equipped with suitable tools & machineries
including, but not limited to, the following:
a) Mechanical paving machine provided with self mechanical vibrator and

capable of uniformly spreading material for a width of min. 1.5m
extendable to 3m.
b) Vibrating steel roller weighing not less than 3 ton & having drum width
less than 1.5 m. with power mechanism capable of propelling the rollers
smoothly without jerking while reversing.
c) Forward and reverse plate compactor weighing min. 0.5 ton capable of
transmitting forceful vibration or impact. Vibratory compactor shall be of
the type and force approved by the engineer.
d) Special equipment for preparing & pouring crack sealant as

recommended by the manufactures. This shall include, but not limited
to, Mechanical Router, Hot air compressor, Sealant pre-heater unit,
Melter pourer …etc.
Note:-
The milling machine proposed for use shall be checked for minimum working
width, its working condition in respect of uniformity in the depth & spacing of
the grooving teeth & shall be subject to Engineers approval.
4.43.4 Typical Repair Works
General requirements/procedures are outlined

hereunder. However any special requirement included in the work order or
instruction issued by the Engineer shall be applicable where appropriate.
4.43.4.1 Repair of Potholes
The Contractor Shall:

a. Cut the failed pavement down to compacted in-situ material with
pneumatic cutting tools. The cut section shall be square or rectangular in
shape with faces straight and vertical. One pair of faces shall be at right
angles to the direction of traffic.
If more than one layer is to be removed, the engineer may instruct the
underlying layers to be stepped back by 200mm steps on the sides
involved.
b. Remove all the cut and loose unsuitable material from the hole and cart
away and dispose of such unsuitable material in compliance with the
requirements of general spec. and as directed by the Engineer.
c. If damage entails subbase it shall be reinstated using approved

asphaltic mixes in maximum 7 cm compacted layers Use suitable
compactor for proper compaction.
d. Clean the surface with air compressor prior to laying each layer.
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e. Use Prime coat or tack coat as necessary. Vertical cut faces of existing
asphalt shall be tack coated prior to laying asphaltic courses.
f. Check level of the patch with a straight edge and make corrections as
required.
4.43.4.2 Repair of Patches
Patches for repair may be of shallow depth, partial depth or full depth
depending on the site condition.
Shallow depth patch work will generally involve removing the deteriorated
surface course & replacing with a new approved wearing course mix.
Partial depth patch work will involve removal of more than one layer of
deteriorated /defective asphalt and replacing with new approved asphaltic
mixes.
Full depth patch work will involve removal & replacement of all deteriorated
/defective asphalt layers including removal /rectification of under lying sub-
base /sub-grade where required.
Depths and dimensions of the patch work will be indicated in the work orders
issued by the Engineer. Where the repair works involve more than one layer,
each layer shall be stepped back into the existing material on all sides by
200mm for the purpose of achieving the required compaction of the joints.
Depending on the site condition, conventional plants /equipment including

milling machine as well as special equipment as referred to clause 4.43.3 shall
be used for removing the existing defective pavement materials and their
reinstatement.
Regular sampling and testing procedure shall apply to the materials involved in
all the patch works including those having a minimum of 10 m and width 2m
and shall meet the requirements as specified elsewhere in the relevant
specification clauses.
All utility patches having concrete on the surface course shall be removed to
the full depth of concrete and replaced with asphaltic mixes.
Utility patches with defective asphalt shall be made good by replacing all
defective materials, including those underlying the asphalt, where applicable
with approved materials. Where there is no karbstone on either side and
wherever practically possible, the materials of underlying layers (expect for the
top layer) shall be laid and compacted in transverse direction. The top wearing
course layer shall be laid and compacted in longitudinal direction.
For reinstatement of the patches, where the working space is limited, ideally
premixed (to OMC) sub-grade /sub-base material should be delivered to the
site and immediately spread and compacted. Compacted sub-base shall be
duly primed, cured and cleaned prior to laying asphaltic course. The saw cut
vertical faces of adjacent existing asphalt shall be wire brushed and tack
coated prior to laying each layer of asphalt which shall have been stepped
back by 200 mm.
4.43.4.3 Repair of Cracks of any depth.
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The following types for cracks sealant shall be used for

repairing cracks. Following site investigation and depending on the type & nature of
the cracks, as well as the type of the road under consideration, the engineer will
issue the work order indicating the type of crack sealant to be used on specific sites.
The contractor shall submit to the engineer for his approval

full details of the proposed crack sealant along with manufacture's brochure, a
method statement and a track record of performance of the product in U.A.E. or
under similar climatic condition. Acceptance of the sealants shall be subject to
satisfactory site trails.
a) Crack Sealant Type I with asphalt emulsion.
The sealant shall be made up of asphalt emulsion complying with AASHTO –M140
and the filler from the asphalt plant complying with general specification clause 4.11.
A suitable workable mix shall be prepared in the site laboratory followed by trail on
site to confirm the depth of penetration by taking core. Mix proportions shall be based
on satisfactory site trial. The contractor shall then submit his proposal along with a
method statement for application on site to the engineer for his approval.
Generally the work site shall be prepared by wire brooming the surface, blowing out
all the dirt from the crack by compressed air, filling the cracks with the approved
sealant by pressing downwards as much as possible by a thin spatula.
b) Crack sealant Type II
This sealant shall be hot pourable, polymer modified bituminous binder with the
characteristics of good adhesion, high ductility with high elastic recovery and shall
meet the following requirements:
Test Specification Test method designation

Penetration @ 25 °C 60-90 ASTM D - 5
Softening point, °C, min 70 ASTM D - 36
Ductility @ 5 °C, min 30 ASTM D - 113
Ductility @ 15 °C, min 70 ASTM D - 113
Elastic recovery, % min. 90 DIN 52013
Viscosity @ 180 °C, mPa/s 600 ASTM D - 2994
Bond strength Good ASTM D - 3407
Flow @ 60 °C < 3 mm ASTM D - 3407
c) Crack sealant Type III (overseal banding)
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This sealant is made up of a blend of bitumen, polymer and mineral filler producing a
tough compound with improved elastomeric performance. It will provide a tack free
band with good adhesion to the road surface without the use of a primer.
The material shall meet the following properties:
Colour. Black
Pouring temperature 190 to 220 °C.
Safe heating temperature : 220 °C.
Flash point : 230 °C.
Density : 1.20 + 0.05.
Minimum application temperature : 5 °C.
Maximum safe heating period : 6 hours.
Service temperature limits (air) : 0 °C to + 50 °C.
Good resistance to dilute acids and dilute alkalis. Not resistant to petroleum solvents,
mineral oils, vegetable oils and greases
Test Requirement
Softening point Greater than 95 °C

(Ring & ball method: BS 2000 Pt 58)
Flow Resistance 5%
max.
(BS2499 Cup, 65 °C)
Cone Penetration 10 - 30
(25 °C, 150g, 5s)
Extension Test 3 cycles of extension
to
(blocks prepared to ASTM D1191 and 50% at a rate of 3.2mm/h at 25°C
tested to limits BS 2499.1973)
Crack sealant Type IV (overseal banding)
This is a single component polymer modified crack sealer with excellent adhesion to
asphalt that ensures total penetration of the crack without voids. This sealant can be
used for sealing cracks of the existing pavement which are to be overlaid by fresh
asphalt by adopting 'rout and seal' method. When used in overband situation, a
3mm step over the existing pavement is provided for smooth ride over the repaired
crack.
The material shall meet the following properties:-
Specific gravity : 1.4

Softening point : 100 °C
Compression resistance : 250N
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Movement accommodation
Factor (MAF) : 15%
Flow cup @ 75 °C BS2499 : 3% max
Flow plate @ 50 °C BS2499 : 5mm max
Extension @ 25 °C ASTM D1191 : 200N (50%)
Note:
Manufacturer's recommendation shall be followed for cleaning of the cracks as well

as preparation & application of sealant types II, III, IV. However a general
requirement is underlined hereunder.
Cracks shall be thoroughly cleaned by hot air compressor.
The sealant shall be heated in a pre-heater unit provided with agitation

paddles to the recommended temperature.
The heated material shall be transferred to a bucket & hand drawn screed
box or a specialized applicator having a direct connecting pressure hose
type extruding device with nozzles shaped for insertion into the pre-warmed
crack. Manufacturer's recommended temperature for application shall be
maintained.
Where instructed by the Engineer the crack shall be chased out using a
mechanical router and the hole shall be cleaned free of all dust, dirt,
dampness by the use of hot compressed air lances prior to the application of
the heated sealant.
Every attempt shall be made to avoid application of excess sealant.

However, if any, the surface shall be scrapped to avoid formation of ridges &
the sealant being picked up by the traffic.
4.43.4.4 Asphalt Crack Reinforcing Grid
This clause covers the specification and requirements for the supply of a
flexible manufacturer’s installation instructions.
The reinforcing grid shall be made of high modulus geo-synthetic yarns with
low creep properties and minimal stress-relaxation. The grid shall be firmly
connected to an ultra-light polypropylene non woven. The composite shall have
a bituminous finish.
The composite shall be installed parallel to the road axis. Overlaps of 25cm in
the length and 15cm in the cross direction shall be calculated.
The grid properties shall be:
Machine direction
Tensile strength ISO 10319 50 KN/m

Elongation ISO 10319 12%
Cross Direction
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Tensile strength ISO 10319 50 KN/m

Elongation ISO 10319 14%
Strength @ 3% elongation MD/CD ISO 10319 15/14 N/m
Strength @ 5% elongation MD/CD ISO 10319 35/33 N/m
Creep strain (after 20,000 hrs) at 50% of tensile strength

max. 2%
Grid mesh size 30 x 30 mm (or 40 x 40mm).
Heat resistance up to 190oC
Shrinkage properties at 190oC after 15 minutes ASTM D5261 1%
Melting Point (ASTM D276) 260 °C
The grid shall be resistant to solvents and de-icing materials.
Each roll shall have at least one identification label with roll number and
product type.
The Contractor shall submit to the Engineer for his approval, full details of the
proposed geo-gird along with manufacturer's brochure including recommended
installation guide, a method statement, copies of complying test results and a
guarantee by the manufacturer for the performance of the product for at least
(5) years period.
NOTE:
Repair works involving heavy traffic roads (as identified by the engineer/client)
will require the use of different design criteria of asphalt mixes using different
materials. Such requirements specified against "type-H" shall apply, only where
instructed by the Engineer.
4.44 ASPHALT SPECIAL MIXES
SPECIFICATION FOR TYPE H AND M ASPHALT MIX DESIGN
4.44.1 Asphaltic concrete mixes for Type "H" shall be used when instructed and shall
conform to the requirements of these Clauses for which 40-50 penetration
grade of bitumen shall be used.
Generally asphaltic mixes complying with the requirements of Section 4.9 shall
be used unless otherwise specifically instructed by the engineer to use type H
or type M as described under this clause.
4.44.2 Coarse Aggregate for Bituminous Work
The properties for aggregate specified under this clause shall be for
aggregates from individual sources where an aggregate is produced by
blending, each individual fraction shall comply with the specified requirements.
Coarse aggregate is that portion of he mineral aggregates retained on U.S.

Sieve No. 4. Coarse aggregate shall consist of crushed stone and / or crushed
gravel. Crushed particles shall be cubic and angular in shape and shall not be
thin, flaky or elongated. The gradation shall be such that when combined with
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other aggregate fractions in proper proportions, the resultant mixture will meet
the required gradation. The source of crushed aggregate is considered to be
the crushing site from which it is produced.
Coarse aggregate shall be clean with negligible amounts of organic matter,

and free from clay, cemented particles and other extraneous or detrimental
materials. The content of acid soluble salts shall not exceed 0.1% for chloride
and 0.5% for sulphate as determined by BS 812 Part 117 and 118
respectively. The degree of crushing shall be such that 100% has at least one
fractured face and at least the following percentages (by weight) of the
material shall have all faces crushed.
Sieve Size 37.5mm 25mm 20mm 10mm sand
Mix Type H 60% 60% 65% 75% 100%
Mix Type M 50% 50% 55% 65% 100%
For each individual stockpile the Flakiness shall not exceed 30%, the
Aggregate Crushing Value shall not exceed 25% and the Elongation Index
shall not exceed 30% when tested in accordance with BS 812. water
absorption of the coarse aggregate as determined by BS 812 shall not exceed
2% by weight.
Coarse aggregate shall have a maximum Sodium Sulphate Soundness Loss of

10%. Soundness when tested by the Magnesium Sulphate Method shall not
exceed a loss of 14%. For surface or wearing courses, these figures shall be
6% and 10% respectively.
The Los Angels Abrasion loss for coarse aggregate used in asphalt mixtures
shall not exceed 25% except that a maximum abrasion loss of 30% will be
allowed for asphaltic road base and base courses when the surface of these
courses is not to be subjected to traffic.
4.44.3 FINE AGGREGATE FOR BITUMINOUS WORKS

The properties for aggregates specified under this Clause are for aggregates
from individual sources. Where an aggregate is produced by blending, each
individual fraction shall comply with the specified requirements.
Fine aggregate is that portion of the mineral aggregate
passing U.S. Sieve No. 8 fine aggregate shall consist of crushed sand or
crushed stone or gravel or a combination therefore. The source of crushed fine
aggregate will be considered to be the crusher site at which it is produced.
Crushed fine aggregate shall be produced by crushing clean coarse aggregate
and shall not be thin, flaky or elongated.
Fine aggregate shall be clean with negligible amounts of
organic matter and free form clay, cemented particles and other extraneous or
detrimental materials which may be liable to break down during drying or
mixing or subsequently when exposed to the weather. The plasticity index as
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determined by BS 1377 part 2: Test 5 shall be non-plastic. The content of acid

soluble salts shall not exceed 0.1% for chloride and 0.5% for sulphate as
determined by BS 812Part 117 and 118 respectively.
Fine aggregates shall have a maximum Sodium
Sulphate Soundness of 10%. Soundness when tested by the Magnesium
Sulphate Method shall not exceed a loss of 14%. Water adsorption of the fine
material as determined by NS 812 shall not exceed 2% by weight.
The Sand Equivalent for fine aggregate shall be a
minimum of 45% and that of the combined aggregates shall be a minimum of
65%.
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4.44.4 Asphaltic Concrete Mixes
4.44.5 Asphaltic Concrete Road base (identical to regular asphalt concrete base
course)
Materials and Grading

The materials, design mix requirements and construction requirements shall
comply with the provision of this section subject to the modifications given
below.
Asphaltic concrete road base shall conform to the composition shown below:
Composition of Asphaltic Concrete Road Base Mix
B.S. Sieve Size U.S. Sieve Size Percentage by Weight Passing

50mm 2.0 in 100
37.5mm 1.5in 90-100
25mm 1 in 75-90
12.5mm O.5in 55-75
5mm No. 4 36-56
2.36mm No. 8 28-44
1.18mm No. 16 20-34
GOOum No. 30 12-23
300um No. 50 6-15
150um No. 100 2-8
75um No. 200 0-5
Note:
Gradation shown includes mineral filler for all mixes.
Adjustment of Specific Gravity
The procedures for mix design in MS-2 require the removal of the aggregate
portion >25mm size and replacement with an equivalent amount of material
from the next size down from 25mm size.
Where a mix contains more than 10% of the >25mm size, the adjusted
Specific Gravity shall be calculated as follows:-
Adjusted Specific 100 x Empirical Factor

Gravity {A/C + B/D}
Where
A=Dry >25mm material expressed as percentage of total batch weight of
aggregate
B= Percentage of total batch remaining after removal of dry > 25mm material
C= Bulk Specific Gravity of >25mm aggregate
D= Measured Specific Gravity of Marshall specimens with >25mm material

removed
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Empirical Factor = 0.995
Marshall specimens without the >25mm aggregate portion shall be prepared

and tested according to the procedures established in MS-2 with the exception
of he calculation of voids (VIM).
Voids (VIM) shall be calculated using the Adjusted Specific Gravity and
checked against the design criteria in table below.
Stability and flow values obtained from the Marshal Specimens shall comply
with the values given in Table 4.11.
During production, the procedures detailed above shall be used for the
assessment of daily Marshall cylinder testing.
Design Criteria
The criteria given in below shall be used in designing the mix.
Table 4.11 - Design Criteria for Asphaltic Concrete Road Base Mix
Description Minimum Maximum
Marshall specimen's number of compaction 75 75

blows each end of specimen
Min. stability (KN) 12 -
Flow (mm) 2 4
Marshall Quotient (KN/mm) 5 -
Voids in mix (Air voids %) (VIM) 5 9
Voids in mineral aggregate (%) (VMA) 13 -
Voids filled with bitumen 50 65
Filler / Bitumen Ratio - 1.4
Immersion Compression Specimen AASHTO T 25

165 Loss of Marshall Stability on immersion in -
water @ 60°C for 24 hours (%)
Bituminous content 3.0 4.3
At the laboratory design stage:

Marshall cylinders should be compacted to refusal density at 600 blows with
bitumen content at the top of the tolerance range in the Job Mix Formula.
The minimum voids at refusal are to be 3%, when the maximum theoretical
S.G. is determined in accordance with AASHTO T 209.
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A trial area shall be laid outside the permanent works in accordance with
Clause 4.45.
If tests on material placed in the permanent works yield air voids below 5%
VIM in more than 3 in 20 cores as determined according to AASHTO T 209,
then the mix shall be investigated to discover the cause of such low air voids.
If a tendency to progressive densification is observed in the mix it shall be
redesigned.
4.44.6 Asphalt concrete base course and wearing course
(identical to regular asphalt binder course and wearing course)
Asphaltic concrete mixes shall be as specified on the Drawings and shall

conform to the compositions shown below:
Aggregate Gradation for Asphaltic Concrete
Sieve sizes Percent by Weight Passing
Base Course Wearing

37.5mm 100 Course
-
25mm 80-100 100
19mm 62-92 86-100
12.5mm - 69-87
9.5mm 45-75 58-78
4.75mm 30-55 40-60
2.36mm 20-40 25-45
0.85mm 15-30 15-30
0.425mm 10-22 10-22
0.18mm 6-15 6-15
0.075mm 2-8 2-8
4.44.7 Design Criteria General
T
he Marshall method of Mix Design as detailed in the Asphalt Institute
publication "Mix Design Methods for Asphalt Concrete" - Manual Series No. 2
MS-2 (5th Edition) shall be used in designing the asphaltic concrete and dense
bitumen macadam mixes. Test procedures shall be as detailed in AASHTO
T245.
I
n addition to the above, the modified Marshal method shall be followed before
specimens are compacted. The modified procedure is as follows.
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F
or each batch, the selected binder and aggregate shall be heated in an oven
and mixed at the specified temperature. The loose mix shall then be
transferred to an oven held at 150oC for 1.5 hours before compacting the
Marshall specimens as per MS-2.
All of the criteria given below, not stability along, shall be considered in
designing and evaluating each type of mix. The optimum bitumen content
determined by the Marshall Method shall be used in preparing specimens for
the immersion compression (AASHTO T 165) test or the loss in Marshall
stability on immersion in water at 60oC for 24 hours (3 no. test cylinders and 3
no. controls).
Design Criteria for Asphaltic Concrete Mixes
Description Wearing Course Road Base & Base

Course
Min. Max. Min. Max.
Marshall Specimens No. of 75 75 75 75
compaction blows each end of
specimen
Min. Stability (KN) 16 - 16 -
Flow (mm) 2 4 2 4
Marshall quotient (KN/mm)

Asphaltic concrete Type H 8.0 - 8.0 -
Type M
6.5 - 6.5 -
Voids in mix 5 9 5 9
Type H (Air voids ) (%)
Type M 4 8 4 8
Voids in mineral aggregate (%) 15 - 14
Voids filled with bitumen 50 70 50 70
Filler Bitumen ratio - 1.4 - 1.4
Loss of Marshall stability on - 20 - 20

immersion in water @ 60° for 24
hours (%)
Voids in Marshall specimen 3 - 3 -

Type H At Refusal
blows (%) 2 - 2 -
Type M
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Bitumen content (% by weight of

total mix)
3.3 4.3 3.0 4.3
Type H
3.5 4.5 3.3 4.3

Type M
4.45 RIAL AREAS
A trial area of the "Laboratory Design Mixture" having a length of at least 100
metres and a minimum width of 3.65 metres shall be laid by the Contractor
outside the area of the permanent works for the Engineer's approval. The
underlying surface of the trial areas shall be in accordance with requirements
of the appropriate Specifications. At least two samples of non compacted
material from the trial area shall be taken in accordance with AASHTO T 168
and shall be analysed for aggregate grading, bitumen content and for the
manufacture of Marshall specimens to determine unit values for stability flow
and voids. Specimens for the determination of the "Job Standard Mixture
Reference Density" as described in Clause 4.46 shall be prepared from these
samples.
Cores shall be cut from the trial area for testing as detailed hereunder. The
core density shall be not less than 99 percent of the "Job Standard Mixture
Density". If the required density is not obtained, further trials shall be
conducted and new cores shall be taken and tested. This procedure shall be
repeated until satisfactory density results have been obtained and the finished
courses and materials are equally satisfactory in all other respects and the
final trial areas have been approved by the Engineer.
At three locations, selected by the Engineer two nominal 150mm dia. cores
shall be taken by the Contractor using an approved coring machine. At least
two of the locations shall be from the wheel track zones of the completed trial
area. For the purpose of this Clause the wheel track zone shall be taken to be
between 0.5m and 1.1m and between 2.55m and 3.15m from the edge of the
trail area.
For each location average refusal density shall be determination of the air void
content of the mixture after compaction to Refusal Density in accordance with
BS 598 Part 104.
During the laying of the trial area three samples of loose mixture shall be taken
at evenly spaced locations along the trial length. The theoretical maximum
specific gravity of each sample of the mixture shall be determined in
accordance with ASTM D2041. The average value of the theoretical maximum
specific gravity shall be used for the calculation of the refusal air void content.
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The trial shall also include the determination of the air void content of the
mixture produced at the upper percentage limit of the optimum binder after
compaction to Refusal Density in accordance with BS 598 part 104.
The refusal air void content shall be determined in accordance with ASTM D
3203. The theoretical maximum specific gravity of the mixture shall be
determined in accordance with ASTM D2041 (based on the average of the
three results). The refusal density for each location (average of two core
results) shall be determined in accordance with BS 598 : Part 104: Clause 4 as
the bulk density required by ASTM D3203.
The material in the trial area shall be deemed acceptable if it meets the
following requirements:
a) Grading, binder content and Marshall properties achieve Specification

requirements.
b) Compaction is to Specification requirements.
c) Surface finish is acceptable to the Engineer.
e) Average air void content of the mixture at Refusal Density is not less
than 3percent.
If the proposed "Laboratory Design Mixture" fails to meet the requirements for
a satisfactory trail area, the grading proportions and or binder content shall be
modified by the Contractor in agreement with the Engineer, as necessary and
within the requirements of Clause 4.44.4 to produce a mixture of satisfactory
workability and acceptable surface finish as determined by further trial areas.
The approved trails shall confirm the "Job Standard of Mixture" and the
Contractor shall report to the Engineer in writing the proposed "Job Standard
of Mixture" before general mixing and laying proceeds, giving the combined
aggregate grading (showing a single defined percentage passing each sieve),
the mixture proportions and the values for stability, flow, unit weight and voids
(on the basis of the mean value of not less than four or more than six
specimen).
The mixing temperature and "Job Standard of Mixture Density" "Laboratory

Design Mixture" modified when necessary as described above and shall be
within the limits for grading, binder content, stability, flow and voids
requirements given in Tables of Clause 4.44.4.
If for any reason the quality, grading, or supply source of aggregate is

changed or if at any time the cause of variations outside the permissible limits
specified in Clause 4.47 cannot be corrected for reasons beyond the control of
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the contractor the Engineer may request a new " "Laboratory Design Mixture"
or Job standard of Mixture" depending on the extent of change or variation.
After approval of the "Job Standard Mixture" (JSM) the trial area as specified
hereunder shall be used to establish the rolling/compaction method required to
produce the specified relative density. Three pairs of cores shall be taken from
the compacted trial area and the mean density of each pair shall be not less
than 99 per cent of the "Job standard mixture Density" (JSMD). If the required
field density is not obtained the rolling procedure shall be adjusted and further
trial areas shall be laid and tested until satisfactory results are obtained. These
procedures shall be reported to the Engineer and the rolling method agreed
before mixing or laying of the permanent works is commenced. Agreed
procedures shall not subsequently be varied without the Engineer's written
approval.
4.46 JOB STANDARD MIXTURE REFERENCE DENSITY
The relative density of cores from the compacted courses throughout the work
shall be checked against the "Job Standard Mixture Density" for aggregate
passing 25mm or to the Adjusted Specific Gravity when the aggregate is larger
than 25mm.
During production, the daily Marshall specimen densities shall not deviate
more than 1.0% from the "Job Standard Mixture Reference Density".
The "Job Standard Mixture Reference Density" shall be obtained by making

six standard Marshall Specimens from samples of the approved "Job Standard
Mixture" determining the relative density or each and comparing them with the
mean values of the six. Any individual result which differs from the mean by
more than 0.015 gm/cc. shall be rejected and provided not more than two
results are so rejected the mean of the remaining results shall be designated
the "Job Standard Mixture Reference Density".
Approval by the Engineer of the Contractor's "Job Standard Mixture" shall in

no way relieve the Contractor of his responsibilities and obligations stipulated
in the Contract and the Contractor shall be responsible for the soundness of
the bituminous paving mixes and the satisfactory execution and performance
of the bituminous paving courses.
4.47 ALLOWABLE TOLERANCES
Mixtures which are produced by the mixing plant during normal routine
production shall be designated the "Plant Mixtures" and the limits of
permissible variations between the "Plant Mixtures" and the "Job Standard
Mixture" approved in accordance with Clause 4.45 shall at all times meet the
requirements of Table 4.12.
Table 4.12 - Job Standard Mixture Tolerances
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Grading Road base & Wearing Course

Base Course
Retained on 5mm Sieve +6% +5%
Passing 5mm sieve and +4% +4%
retained on 600um sieve
Passing 600um sieve and +3% +3%
retained on 75um sieve
Passing 75 um sieve ± 1% ± 1%
NOTE:
Asphalt cement + 0.20% ±0.20%
Temperature of mix when ± 10% ± 10%
"
emptied from mixer
J
Marshall Quotient - 10% - 10%
o
Voids
b in total mixture JSM ± 1 percent but not less than as specified
Voids
S filled with binder JSM ± 5 percent
t
Stability Not less than as specified
a
Flow
n Not more than 4.00mm
d
a
rd Mix" proposed for use and agreed after the trials shall have the grading
within the limits contained in the Specification. The application of the above
job-mix tolerances shall not results in a job control grading band outside the
master grading band, the tolerances shall only be applied up to the limits of the
master grading band for the normal productions of asphalt, asphalt cement
percentage shall not be lower than the specification limit.
During preparation of daily Marshall specimens for stability measurements,

variations in stability due to variations in cylinder volume shall be corrected by
applying the correction factors given in Table 4.13. If the volume of any
specimen is less than 502 cc or more than 528 cc it shall be rejected and shall
be replaced with a new specimen during design and routine production control.
Table 4.13 - Stability Correction Factors
Height of Specimen Volume of Specimen Stability Correction factor

(mm) (cc)
62.0 502-503 1.04
504-506 1.03
507-509 1.02
510-512 1.01
63.5 513-517 1.00
65.0 518-520 0.96
RD4672/D-004 Rev.1 Page 84 of 91

January 2009
521-523 0.99
524-526 0.98
527-528 0.97
Any minor adjustment made to the approved Job Standard Mixture at the mixing
plant shall ensure all mixtures produced are within approved limits for production
control.
Gradation which approach maximum limits on some sieves and minimum limits
on other sieves will not be permitted. The grading of the mineral aggregate
fraction shall be continuous and shall fall within the envelope formed by the
upper and lower limits specified in the relevant Tables.
Throughout the Contract any variations outside the limits shall be investigated
and corrected. If for any reason, whether for quality, grading or supply, the
source of aggregates is changed, or if at any time the cause of variations outside
the permissible limits cannot be corrected for reasons beyond the control of the
Contractor, the engineer may direct the Contractor to produce a new "Laboratory
Density depending on the extent of change or variations. The Contractor shall
comply with the Engineer's directive.
4.48 SAMPLING AND TESTING
Throughout the work whenever mixing is in progress the Contractor shall carry
out tests in his asphalt laboratory as required by this clause.
Particular care shall be taken to ensure that the laying location on site from
which test samples are taken or specimens made can be accurately recorded by
signage and offset in the finished pavement layer.
Samples of the mixed materials shall be taken from the first two hundred tones
and from every two hundred tones thereafter to determine aggregate grading
and binder content. Samples of loose material shall be taken behind the paver
before compaction and shall be obtained in accordance with AASHTO T 164.
Samples of compacted material shall be obtained by coring in accordance with
method B of AASHTO T 230. Determination of bitumen content and extraction
gradation may be performed on rather loose or compacted samples in
accordance with AASHTO T 164 and AASHTO T30. The specific gravity of
compacted asphalt cores shall be measured in accordance with AASHTO T 230.
Samples shall be ten centimeter in diameter for wearing course and fifteen
centimeter for base-course and road base.
Samples of the mixed material shall be taken at least twice a day from the mixing
plant or as determined by the Engineer for making two Marshall specimens to
determine stability. flow and unit weight. The results shall be compared with the
RD4672/D-004 Rev.1 Page 85 of 91
January 2009
"Job Standard Mixture" values and the allowance tolerances. The values
reported shall be the mean of the twin specimens. For the taking of daily
Marshall specimens the mixing pugmill temperature shall be set to the mixing
temperature as specified in AASHTO T 245 and the compaction temperature of
he moulds shall also be in accordance with AASHTO T245. Should for practical
reasons the pugmill temperature be different from that used in AASHTO T 245
then the Engineer shall set the compaction temperatures for the moulds to so
compensate. All required sampling and testing by the Engineer in no way
relieves the Contractor of his responsibility for regular quality control testing in
order to ensure compliance with the Specifications.
If any of these test result show that mixtures laid are not in accordance with
approved "Job Standard Mixture” allowing for tolerances, the Engineer will
investigate the significance of the non-compliance and may order the re-
execution of the work. The contractor shall immediately identify the cause of
non-compliance and make adjustments accordingly.
If during the permanent asphalt works the material has the specified compaction
but contains air voids below 6% for wearing course and 7% base course and
road base for more than three out of twenty samples, the Engineer will consider
this as evidence of a fault in the Contractor's mix design and the mix shall be
adjusted or re-designed.
4.49 POLYMER MODIFIED BITUMINOUS (PMB) MIX
Should the engineer require an improved performance and service life of the
pavement, he may instruct the contractor or indicate in the drawing, to use a
binder modified to give increased resistance to rutting , cracking (thermal and
load associated) , stripping etc.
The polymer modified bituminous mix shall be generally used only in the surface
course. The conventional bitumen shall be modified with polymer modifier to
achieve Superpave Performance Grade PG 76-10 and shall comply with the
requirements of AASHTO M-320 as modified in Table 4.14.
Unless otherwise agreed by the Engineer, the conventional bitumen shall be

60/70 pen. Grade and the specific polymer modifier shall be a SBS with a proven
record of satisfactory performance for at least 5 years under similar climatic
condition of UAE.
However the contractor shall submit full details of the following for Engineer’s
approval.
(a) Type & Penetration grade of the proposed original binder.
(b) Type of proposed polymer modifier including the intended enhanced

performance.
(c) Full details of the polymer modifier provided by the manufacturer

together with laboratory test results confirming that the combination of
RD4672/D-004 Rev.1 Page 86 of 91

January 2009
the bitumen and the polymer additive will meet the requirements as
indicated in Table 4.14.
(d) A method statement for the preparation of PMB blending. The Contractor
shall demonstrate through testing that the modified asphalt
meets all the specification requirements. The polymer modifier shall be
blended and mixed to the bitumen with specialist equipment in strict
accordance with the instructions and recommendations of the polymer
modifier's manufacturer. Full details of the equipment to blend and mix
the proposed polymer modifier and bitumen, together with any other
specialist equipment required to produce and lay polymer modified
bituminous mixtures shall be provided by the contractor.
(e)The contractor shall submit for the Engineer's approval a comprehensive

QA/QC program to ensure that the polymer modified asphalt is delivered,
stored in suitable conditions, incorporated in the bituminous mix and laid
in accordance with the manufacturer's instructions. The minimum
requirements for this program shall include bu t shall not be limited to
the following.
Compatibility with original bitumen:- The modified bitumen shall be tested for
compatibility with the polymer modifier to ASTM D5&92 for both Softening
Point and DSR. The difference in °C between the softening points of the
respective top and bottom portions of the tube sample shall not exceed 4°C.
The separation ratio based on G* shall have an average G* value (median of top
& bottom value) within 0.8 to 1.2 of the initial G* value. Alternative compatibility
test according to ASTM D5841 can be carried out in lieu of ASTM D5 892, only
in case the Contractor/Supplier can prove that the ASTM D5892 cannot be
adopted for the type of polymer proposed.
Mixing and compaction temperatures:- The mixing and compaction

temperatures shall be established in the laboratory by determining the
Brookfield viscosity of the approved Polymer Modified Bitumen at three
different temperatures I35° C, 165° C and 195° C. The established mixing and
compaction temperatures shall then be evaluated and finalized based upon
successful site trials.
Proportion of modifier in the mix: - The ratio of modifier to bitumen in the

completed mix is to be between 4 and 8 parts of modifier for 100 parts of
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January 2009
bitumen according to the manufacturer's recommendations, to be confirmed by

the specified test results.
(f) The Contractor shall obtain from the manufacturer and provide to the
Engineer periodical certificates stating that the modifier is being
incorporated in the bituminous mix in accordance with the approved
QA/QC program.
(g) The modifier shall be pre-blended into the conventional bitumen before
mixing with the aggregate in the hot mix plant.
If the Styrene-Butadiene-Styrene (SBS) polymer is used, it shall have the

following properties:
Butadiene-Styrene Ratio = 70/30

Block Styrene = 30%
Hardness Shore A = 80
Density ASTM D792 - 0.93 - 0.95 g/cm3
The modified bitumen properties shall comply with the requirements of the
latest revision of AASHTTO M320 specifications as modified in Table 4.14.
Table 4.14 - Modified Bitumen Properties
Property Test Standard Requirements Frequency of

Testing
1. Penetration, 25° C5 100g, ASTM D5 to be agreed with at each batch

5s, dmm the Manufacturer
2. Softening Point, °C ASTM 036, Min. 70 at each batch

AASHTOT53
3. Viscosity (Brookfield) at AASHTO T316 3000 CP at each batch

135° C, max °C
4. Flash Poi it Temp, min °C AASHTO T48 230 °C every 500

tons
5. Dynamic Shear before AASHTO T 315 76 °C every 500

RTFOT, G* /sin a, Min. tons
1.00 kPa, test temperature
@ 10 rad/s,°C
6. RTFO Mass Loss, max, % AASHTO T240 1% each batch
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January 2009
7. Elastic Recovery *, ASTMD6084, 75 each batch

25°C 10cm elongation, % AASHTOT301
after RTFOR
4. Dynamic Shear after AASHTO T 315 76 °C every 500

RTFOT, G* /sin a, Min. 2.2 tons
kPa, test temperature @ 10
rad/s,°C
9. Compatibility Test ASTM D5892 every 500

tons
Pressure Aging Vessel Residue

PAV Aging Tempera ture3 °C. AASHTO R28 110 °C
Dynamic Shear, G*sin d, AASHTOT315 37 °C

10
Minimum 5000 kPa, Test
temperature @ 1 0 rad/s, °C.
Physical Hardening Report

Creep Stiffness, S, Maximum AASHTO T3 13 0°C
11
300 MPa m- value, minimum
0.300 Test temperature @ 60
s, °C.
Direct tension, Failure strain AASHTO T3 14 0°c

12
minimum 1.0% Test
temperature @ 1 .0 mm/min,
°C.
It will be the responsibility of the PMB supplier / manufacturer to inspect and

approve the contractor's facilities at the asphalt plant particularly if the polymer
blending plant is away from the asphalt plant. Contactor's holding tanks,
suitability of storage without separation, circulation ability, heating capability to
maintain the minimum required temperature all the time as recommended by
the manufacturer, possibility of cross contamination with normal pen. Grade
bitumen.
General requirements of the specification Clause 4.1 shall apply for the
aggregates used in the mix, composition and design criteria of the mixture and
all relevant tests on the materials produced from plant & laid on site unless
otherwise stated in this clause for PMB with the exception that:-
i) The mix further tested for stability / flow ratio shall not fall below 2.70
kn/mm when Marshall specimens are subjected to 80 degrees C after
oven heating for a period of 2 hours.
RD4672/D-004 Rev.1 Page 89 of 91
January 2009
ii) The adhesion of bitumen to aggregate shall be proven by comparing the

stability of specimens cured in water and air for eight days at 18 degrees
C. The ratio of stability in the two shall not be less than 0.65.
ii) Mixes with a bitumen content corresponding to the maximum allowable

for the selected job mix shall be compacted to refusal, or to 600 blows
whichever shall be reached first, and the resulting voids-in-mix values
shall not be less than 3%.
Full laboratory and field trials shall be undertaken by the Contractor in advance
of the main surfacing works to demonstrate that the requirements of the
specification are met in every respect.
The contractor shall employ a recognized specialist, approved by the Engineer,

in the field of mix design and construction using PMB. The specialist shall be
present on site during the mix design, trial mix preparation and testing, and all
subsequent PMB blending (if on site), batching and placement.
END OF SECTION
RD4672/D-004 Rev.1 Page 90 of 91

January 2009

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Roads and Infrastructure Works for

Shiab Al Ashkar Neighbourhood

4.1 AGGREGATES FOR PAVING LAYERS

4.1.4 The contractor shall provide petrographic analysis conducted by a

4.1.8 Delivery of materials produced from commercial manufacturing process

RD4672/D-004 Rev.1 Page 1 of 91

4.1.10 The Contractor shall commence crushing and screening of aggregates

4.1.11 Testing to ascertain the properties of all aggregate materials shall be

4.1.13 Only materials from approved sources shall be processed for

4.1.14 After having received approval of specific sources of material the

RD4672/D-004 Rev.1 Page 2 of 91

4.1.24 Following removal of existing asphalt / Interlocking paving blocks, the

4.1.25 Excavated material, when required, shall be improved to meet the

4.2 GRANULAR SUBBASE

RD4672/D-004 Rev.1 Page 3 of 91

Granular sub-base shall consist of furnishing, spreading, and compacting,

SIEVE SIZE PERCENTAGE PASSING

RD4672/D-004 Rev.1 Page 4 of 91

Equipment shall be according to the type and number outlined in the

Road sub-base material shall be delivered to the roadbed as uniform mixture

Each road sub-base layer shall be spread by grader or other approved

The compaction procedure and plant shall be to the satisfaction of the

The surface on completion of compaction shall be well closed, free from

4.2.5 Relevant Test and Standards

RD4672/D-004 Rev.1 Page 5 of 91

Soundness (Magnesium ASTM C88 15 % max. 12 % max.

4.2.6 Minimum Test Requirements

4.3 PROTECTION OF SHOULDERS AND SLOPES

1) Materials – Materials shall conform to Section 4.2 “Granular Subbase

2) The Sulphate Resisting Cement shall conform to Section 6 of the

3) Water to conform to Section 6 of the Specifications.

4) The mix shall have the following properties/proportions:

i) Cement 6% by weight of the aggregates.

ii) Water to conform to the Optimum Moisture Content

RD4672/D-004 Rev.1 Page 6 of 91

iii) Capping Layer shall be compacted to 95% of the MDD.

When tested in accordance with the British Department of Transportation

The testing frequencies shall conform to the following:

b) MDD determination every 2000 cu.m compacted volume of complete

c) One sample every 2000 cu.m of compacted volume for cement

1. The approved material is stockpiled next to blending plant.

4. The material is dumped by trucks and is spread by grader to cover

5. The material shall be compacted to 95% of M.D.D.

c) and a final pass with steel roller.

RD4672/D-004 Rev.1 Page 7 of 91

6. The levels and compaction of the capping layer shall be checked.

7. Curing for three consecutive days shall be done by spraying sweet

4.4 IMPROVED ROCK SUBBASE

At least 80 percent by weight of the materials shall have at least one

Table 4.1 - Improved Rock Sub-base layer details

Completed thickness of Layer Type and Thickness

Where instructed by the Engineer a geo-textile membrane shall be provided,

RD4672/D-004 Rev.1 Page 8 of 91

membrane prior to placing subsequent layers. Geo-textile fabric shall meet

Gradation of the three types of layer shall be as shown in Table 4.2.

Table 4.2 - Gradation of Improved Rock Sub-base

AASHTO SIEVE Type I (% Passing) Type II Type III

6" 100 100 - -

Loss of Sodium Sulphate Soundness) Type I & II 20% Max.

Loss of magnesium Sulphate

Thin and elongated pieces by weight 5% Max.

RD4672/D-004 Rev.1 Page 9 of 91

Friable Particles 0.25% Max.