ROAD DESIGN MANUAL FOR ROADS

AND BRIDGES

Standard Specifications

April 2016
 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

1000 GENERAL
1001 LOCATION AND EXTENT OF SITE
The location of the Site is described in the Special Specification.
The Site of the Works shall be the area within the various road reserves,
quarries, borrow pits, spoil areas, .access roads and deviations, Contractor's
installations, storage areas, camp sites, Engineer's offices, laboratories and
accommodation, shown on the Drawings or established specifically for the
Contract with the approval of the Engineer.
1002 EXTENT OF CONTRACT
The extent of the Contract is defined in the Special Specification.
1003 DRAWINGS
The Drawings referred to in the Conditions of Contract are those listed in the
Special Specification and such further drawings as shall be supplied under the
Contract.
1004 PROGRAMME
In accordance with Clause 14 of the Conditions of Contract Parts I and II, the
Contractor shall submit a fully detailed and time related programme showing the
order of procedure and method in which he proposes to carry out the Works. The
Contractor shall supply together with his programme an expenditure chart
superimposed on it showing his monthly anticipated expenditure.
If at any time it should appear to the Engineer that the actual progress of the
Works does not conform to the programme referred to above, the Contractor
shall produce, at the request of the Engineer, a revised programme showing the
modifications to the approved programme necessary to ensure completion of the
Works within the time for completion as defined in Clause 43 of the Conditions of
Contract.
1005 ORDER OF WORK
The various operations pertaining to the Works shall be carried out in such a
progressive sequence as will achieve a continuous and consecutive output of
fully completed roadworks inclusive of all bridge works and culverts within the
time limits specified in the Contract. Generally the Contractor shall start at one
end of the road and progress continuously towards the other without leaving any
isolated section or sections of incomplete road, provided always that the land
upon which the Works are to be constructed has been acquired in its entirety and
the encumbrances and services thereon removed.

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1006 SUBMISSIONS TO THE ENGINEER

Wherever the Contractor is required to submit to the Engineer proposals, details,
drawings, calculations, information, literature, materials, test reports and
certificates, the Engineer will consider each submission and, if appropriate, will
reply to the Contractor in accordance with the relevant provisions of the
Conditions of Contract. Unless a defined period of time is stated in this
Specification or the Special Specification, each submission shall be made by
dates to be agreed with the Engineer having regard to the approved programme
and the need to give the Engineer adequate time to consider each submission.
Documents submitted, other than drawings and manufacturers' literature, shall be
A4 in size. All documents shall be in English and any abbreviations shall be
explained. All calculations and technical information shall be in units conforming
to the Systems International Unites (SI).
All drawings shall be Al in size to the ink border. Notes shall be in English. All
dimensions shall be in metres or millimetres and all weights in metric units.
All drawings shall include the title of the Contract at the bottom of the drawing
followed by the title of the drawing concerned. All drawings shall have the
appropriate scales drawn on them and be dated. All amendments to drawings
shall be noted and dated.
The approval of the Engineer of any submission shall not relieve the Contractor
from his responsibilities under the Contract.
1007 CERTIFICATE OF COMPLETION
The minimum length of road for which a Certificate of Completion will be issued
under Clause 48 of the Conditions of Contract shall be specified in the Special
Specification.
In addition to the above, a Certificate of Completion will not be issued for a
section road unless it can conveniently be opened to the public without the
necessity to construct additional detour roads and all works within the section are
complete with the exception of the following which may be completed during the
Period of Maintenance.
(a) Surface dressing to accesses and junctions.
(b) Reinstatement of borrow pits and quarries.
(c) Grouted stone pitching, (except where specified in side drains)
(d) Reinstatement of deviations.
(e) Erection of informatory signs.
(f) Erection of kilometre marker posts.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

1008 METHOD OF CONSTRUCTION

The Contractor shall submit to the Engineer not later than 28 days from the date
of award of the Contract a general description of his proposed arrangements and
methods for the execution of the Works, including inter alia temporary offices,
buildings, access roads, deviations, Constructional Plant and its intended
production output, working shift arrangements, labour strength, skilled and
unskilled and supervision arrangements, power arrangements, supply of
materials, stone crushing, aggregate production and storage, cement handling,
concrete mixing and handling, methods of excavation, dealing with water, testing
methods and facilities.
During the execution of the Works, the Contractor shall also submit to the
Engineer full and detailed particulars of any proposed amendments to the
arrangements and methods submitted in accordance with the foregoing.
The Engineer's normal working hours shall be defined as 7.00 a.m. to 5.00 p.m.
on weekdays with Saturdays and Sundays set aside for rest. If the Contractor
wishes to execute permanent Works outside these hours, he shall obtain the
written permission of the Engineer at least one full working day in advance to
enable the Engineer to make provision for supervision of such work.
1009 NOTICE OF OPERATIONS
No operation shall be carried out without full and complete notice having been
given to the Engineer by the Contractor sufficiently in advance of the time of the
operation to enable the Engineer to make such arrangements as he may deem
necessary for its inspection and checking.
The Contractor shall give the Engineer not less than 1 full working days’ notice in
writing of his intention to set out or give levels for any part of the Works in order
that arrangements may be made for checking.
1010 UNITS OF MEASUREMENT, ABBREVIATIONS AND TERMINOLOGY
(a) Units of measurement
Symbols for units of measurement conform to the SI system as set out in BS
5775 (ISO 31/1.) Examples are given below.
Where reference is made in the documents to imperial units, the equivalent
metric units shall be substituted.

µ micron = m x 10-6
mm millimeter
m metre
km kilometre
n mile nautical mile

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mm2 square millimetre

2
m square metre
km2 square kilometre
ha hectare
3
m cubic metre
L litre
rad radian
°C degrees Celsius
kg kilogram
g gram = kg x 10-3
mg milligram - kg x 10-3
mg/l milligrams per litre
t tonne = kg x 103
kg/m3 kilogram per cubic metre
t/m3 tonnes per cubic metre
N newton
N/m2 newton per square metre

(b) Abbreviations
The following abbreviations are used:

ACV Aggregate Crushing Value

AIV Aggregate Impact Value
ALD Average Least Dimension
BA Bitumen Affinity
CBR California Bearing Ratio
CR Crushing Ratio
FI Flakiness Index
IAA Los Angeles Abrasion Value
LL Liquid Limit
LS Linear Shrinkage
MC Moisture Content
MDD Maximum Dry Density
OMC Optimum Moisture Content

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PI Plasticity Index
PL Plastic Limit
PM Plasticity Modulus (PI x % passing 0.425mm sieve)
SE Sand Equivalent
SG Specific Gravity
SI International Standard Units of Measurements
SSS Sodium Sulphate Soundness Test, loss on 5 cycles
STV Standard Tar Viscosity
TS Tensile Strength
UC Uniformity Coefficient
UCS Unconfined Compressive Strength
VIM Voids in Mix
VMA Voids in Mineral Aggregates
OPC Ordinary Portland Cement
no. Number (units) as in 6 no.
No. Number (order) as in No 6.
w/c Water cement (ratio)
wt Weight
% Percent
dia Diameter
hr Hour
min Minute
sec Second

(c) Terminology
The most important terms related to the cross-section and pavement are shown
in Figure 1-1 and Figure 1-2:
1011 NATIONAL SPECIFICATIONS
Certain specifications issued by national or other widely recognised bodies are
referred to in this Specification and in the Special Specification. Such
specifications shall be defined and referred to as National Specifications as
hereunder and shall be the latest editions of such National Specifications
available twenty eight days prior to the date set for the submission of Tenders.
The Contractor may propose that the materials and workmanship be defined in
accordance with the requirements of other equivalent National Specifications and

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

the Contractor may execute the Works in accordance with such other National
Specifications as may be approved by the Engineer. A copy of the National
Specification, together with its translation into the English language if the
National Specification is in another language, shall be submitted to the Engineer
with any request that it be adopted.

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In referring to National Specifications the following abbreviations are used:-

KS Kenya Bureau of Standards

Materials Materials Branch of the Kenya Ministry of
Branch MOTC Transport and Communications
BS British Standard

BSCP or CP British Standard Code of Practice

American Association of State Highway and
AASHTO
Transportation Officials
ASTM American Society of Testing and Materials

ISO International Organisation for Standardization

The Contractor shall supply and maintain in his office on the Site at least one
complete set of all National Specifications referred to in this Specification and all
other approved Specifications. This set shall be made available for use by the
Engineer.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

FIGURE 1-1

FIGURE 1-2

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

1012 OTHER CONTRACTORS

The Contractor is advised that other contractors employed by the Employer and
employees of the Employer may be working in connection with the Project on
and around the Site.
Pursuant to Clause 31 of the Conditions of Contract the Contractor shall not
interfere in any way with any works, whether the property of the Employer or of a
third party and whether the position of such works is indicated to the Contractor
by the Engineer or not, except where such interference is specifically described
as part of the Works either in the Contract or by the Engineer's instruction. The
Contractor shall respect any works executed by others and articles supplied or
installed by others and will be held responsible for any loss or damage thereto if
caused by him, his employees or his sub-contractors.
1013 TRANSPORT OF WORKMEN
The Contractor shall include in his rates and prices for all transport of staff and
workmen to and from the various parts of and upon or in connection with the
Works and all costs incurred in securing, recruiting and transporting labour to and
from the Site.
1014 TEMPORARY WORKS
After the Contract is placed and before work commences the Contractor shall
submit to the Engineer drawings showing the general arrangement of his
Temporary Works with diagrams and descriptions showing how he proposes to
execute such Temporary Works and how they fit into his programme for the
Permanent Works, all to be subject to adjustment and approval by the Engineer.
The whole of the Temporary Works and the plant and appliances used, will be
the liability of the Contractor in regard to their construction, sufficiency, safety,
maintenance and removal on completion of the Contract and approval by the
Engineer shall in no way relieve the Contractor of his liability.
1015 CONSTRUCTION GENERALLY
The following general requirements shall apply:-
(a) The Contractor shall provide adequate lighting where work is being executed
at night and shall provide and install any additional lighting which the
Engineer may require in order to gain access to, watch and supervise the
Works and carry out any testing and examination of materials.
(b) Materials available on the Site or materials made available or supplied by the
Employer shall be used solely for the execution of the Works.
(c) The Contractor shall minimise the pollution of and disturbance to lands, roads
and other places on and around" the Site. No trees or other vegetation shall
be removed except to the extent necessary for the Works.

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(d) The Contractor shall ensure that access is provided to all properties adjacent
to the Site for the duration of the Contract.
(e) The Contractor shall comply with the current Government regulations with
regard to the transport, storage and use of explosives and radioactive
materials.
(f) The Contractor shall take all reasonable precautions:-
(i) in connection with any rivers, streams, waterways, drains, watercourses,
lakes and the like to prevent silting, flooding, erosion of beds and banks
and pollution of the water so as to affect adversely the quality or
appearance thereof or cause injury or death to human, animal or plant
life;
(ii) in connection with underground water resources (including percolating
water) to prevent any interference with the supply to or abstraction from
such sources and to prevent pollution of water so as to affect adversely
the quality thereof.
(g) The Contractor shall provide, maintain and remove on completion of the
Works, settling lagoons and other facilities to minimize pollution due to the
Contractor's operations including but not limited to quarrying, aggregate
washing, concrete mixing and grouting.
(h) If the Contractor provides a radio communications network around the Site,
he shall allow the Engineer reasonable use of the facilities. Any requirements
for the provision of radio communications for the sole use of the Engineer are
stated in the Special Specification.
(i) The Contractor shall provide, maintain and remove on completion of the
Works, fencing around the Site and appropriate security measures on access
roads, but without prejudice to his obligations including maintenance of free
access for the Employer, the Engineer, other contractors and any other
persons entitled to such access.
(j) In addition to the requirements of Clause 26 of the Conditions of Contract, the
Contractor shall be responsible for acquainting himself with and observing all
current Statute Ordinances, Bye-laws or Regulations including those relating
to training levies and similar taxes.
All buildings erected by the Contractor upon the Site and camp sites, and the
layout of the buildings and the sites, shall comply with Laws of Kenya and all
local Bye- laws in so far as they are applicable.
(k) The Contractor shall be absolutely and solely responsible for the adequacy,
safety and security of Temporary Works including (but not limited to) all
workyards, pilings, staging, dams, cofferdams, trenches, fencing or other
works and for the plant in connection therewith which may be erected or
provided for the carrying out of the Contract and for the execution of the
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Works. This provision shall be applicable to all Temporary Works and

Constructional Plant whenever provided and erected by the Contractor and/or
his sub-contractors for the purpose of or in connection with the Works.
Examination by the Engineer of the Contractor's and/or his sub-contractors'
Temporary Works or of the drawings connected therewith shall not absolve
the Contractor from any liability imposed upon him by the provisions of the
Contract.
1016 PROTECTION FROM WATER
Except as otherwise specified, the Contractor shall be responsible for dealing
with water, whether from existing drainage systems, water courses, underground
springs, precipitation or any other source or cause. In discharging and diverting
water he shall avoid flooding or damaging other works or services, causing
erosion and/or polluting water courses.
The Contractor shall keep the whole of the Works free from water and shall
provide all dams, cofferdams, pumping, piling, shoring, temporary drains, sumps,
etc., necessary for this purpose.
Well in advance of commencing the permanent Works the Contractor shall at his
own expense cut drains and ditches and carry out any other measures necessary
to effectively drain the original ground and/or shall so programme his Works that
the necessity of temporarily draining the original ground is partially or totally
obviated by working in the dry season.
The Contractor shall at his own expense take all necessary precautions to
prevent damage due to erosion and siltation during construction. Precautions will
include temporary drainage berms, scour checks, riprap and the like. Spoil
material or stockpile material shall be dumped so as not to interfere with streams,
watercourses or any of the drainage works detailed by the Engineer.
On cessation of the works each day the surface of each completed layer shall be
trimmed so that ponding and concentration of surface run-off does not occur.
Should any water accumulate on any part of the Works either during construction
or after construction until the end of the Period of Maintenance, giving rise to
soaking or eroding conditions, the Engineer may order the Contractor to remove
and replace at the Contractor's expense any material or Works that has been so
affected.
Any damage to the Works or to adjacent properties resulting from the
Contractors failure to take the necessary precautions shall be made good at the
Contractor's expense.
1017 HEALTH, SAFETY AND ACCIDENTS
The Contractor shall ensure, so far as is reasonably practicable and to the
satisfaction of the Engineer, the health, safety and welfare at work of his

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employees including those of his sub-contractors and of all other persons on the
Site. His responsibilities shall include:-
(a) the provision and maintenance of Constructional Plant and systems of work
that are lighted, safe and without risks to health;
(b) the execution of suitable arrangements for ensuring safety and absence of
risks to health in connection with the use, handling, storage, transport and
disposal of articles and substances;
(c) the provision of protective clothing and equipment, first aid stations with such
personnel and equipment as are necessary and such information, instruction,
training and supervision as are necessary to ensure the health and safety at
work of all persons employed on the Works all in accordance with the Laws of
Kenya;
(d) designation as Safety Officer of one of his senior staff who shall have specific
knowledge of safety regulations, and experience of safety precautions on
similar works and who shall advise on all matters affecting the safety of
workmen and on measures to be taken to promote such safety;
(e) the provision and maintenance of access to all places on the Site in a
condition that is safe and without risk of injury;
(f) the provision of adequate waterborne sanitation, refuse collection and
disposal, complying with the Laws of Kenya and all local Bye-laws and to the
satisfaction of the Engineer, for all houses, offices, workshops, and
laboratories erected on the camp site or sites;
(g) the provision of -an adequate number of suitable latrines and other sanitary
arrangements at sites where work is in progress to the satisfaction of the
Medical Officer in the area and of the Engineer;
(h) the execution of appropriate measures in consultation with the appropriate
Public Health Authority to control within the Site, including the camp sites,
mosquitoes, flies and pests including the application of suitable chemicals to
breeding areas;
(i) Reporting details of any accident to the Engineer and the Kenya Police if
appropriate as soon as possible after its occurrence.
(j) Compliance with The Factories Act (Cap 514) and in particular the Factories
(Building Operations and Works of Engineering Construction) Rules 1984.
1018 PRESERVATION AND MAINTENANCE OF FENCES AND GATES
The Contractor shall be responsible for ensuring the safety of all persons and
property on the Site and for ensuring that livestock cannot stray as a result of his
work. When existing fences and gates have to be removed or altered for the
proper execution of the Works, the Contractor shall erect, temporary fencing and
gates and, if required, provide watchmen to ensure that livestock cannot stray,

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provided always that the fences or gates referred to have not been the subject of
a negotiated agreement for compensation whereby the owner or tenant has been
made responsible for such removal or alteration.
The Contractor shall discipline his employees to ensure that no fence or gate,
except where these are required to be removed or altered for the proper
execution of the Works, is damaged and that no gates are left open which may
allow livestock to stray.
1019 USE OF EXPLOSIVES
The Contractor shall only use explosives for blasting in rock at such times and
places and in such manner as the Engineer may approve. Such approval shall
not relieve the Contractor from his responsibility for damage to the Works and
adjoining or adjacent structures, roads, places and things, injury, loss,
inconvenience and accident to persons, animals and property consequent on the
use of such explosives. The Contractor shall be entirely liable for any accident
which shall occur and shall save the Employer harmless and indemnified from all
claims arising therefrom.
1020 PROTECTION OF EXISTING WORKS AND SERVICES
The Contractor shall acquaint himself with the position of all existing services
such as sewers, surface water drains, cables for electricity and telephone,
telephone and lighting poles, water mains, and the like before commencing any
excavation or other work likely to affect the existing services.
Where work is to be carried out in the vicinity of overhead power lines, the
Contractor shall ensure that all persons working in such areas are aware of the
relatively large distance that high voltage electricity can "short" to earth when
cranes, or other large masses of steel, are in the vicinity of power lines. The
Contractor's attention is drawn to BS 162 which gives safe clearances for the
various voltages.
The Contractor shall be held responsible for injury to existing works or services,
and shall indemnify the Employer against any claims in this respect (including
consequential damages). The Contractor shall be responsible for the
reinstatement of the services so affected.
In all cases where such works or services are exposed, they shall be properly
shored, hung up or otherwise protected. Special care must be exercised in filling
and compacting the ground under mains, cables, etc., and to leave uncovered
exposed water meters, stopcock boxes and similar items.
Installations adjacent to the Works, shall be kept securely in place until the work
is completed and shall then be made as safe and permanent as before.
Notwithstanding the foregoing requirements, and without reducing the
Contractor's responsibility, the Contractor shall inform the Engineer immediately
if any existing works or services are exposed, located or damaged.
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All costs which may be incurred by the Contractor /as a result of programming
and coordinating work to enable any alterations to the services to be carried out
and the cost of any safety precautions which shall be deemed necessary due to
the proximity of the Works to the power lines belonging to the Kenya Power and
Lighting Co. Ltd. shall be at the Contractor's expense.
1021 DIVERSION OF SERVICES
The Contractor shall be responsible for arranging in liaison with the appropriate
Authority as soon as the requirement is known for the moving of or alterations to
services such as power and telephone lines, water mains, sewers and surface
water drains which are affected by the Works. The arrangements for such
moving or alteration shall be subject to the agreement of the Engineer and the
appropriate Authority.
1022 CLOSURE OF ROADS
When a road used by the Contractor for transporting labour or Constructional
Plant or for delivery of any material for the Works is closed under Section 71 of
the Traffic Ordinance 1962, or amendments thereto, the Contractor shall obey
such closure order and shall suspend operations or use alternative roads. The
fact that the Contractor is performing work for the Ministry of Transport and
Communications will give him no special privileges in this respect.
1023 LIAISON WITH GOVERNMENT AND POLICE OFFICIALS
The Contractor shall consult with officials of the Police and Government in the
area regarding their requirements in the control of traffic and other matters and
shall provide all assistance or facilities which may be required by such officials in
the execution of their duties.
1024 PROVISION OF LAND
The Government shall make available free of charge to the Contractor land on
which the Works are to be executed or carried out, as indicated on the Drawings
or as detailed in the Special Specification. Such land shall include the road
reserve, areas required for deviations, quarries, stockpile and spoil areas, and
borrow pits as defined in this Specification and access roads thereto but shall
exclude land for the Resident Engineer's ^laboratories, offices and houses and
land required by the Contractor for his own camps, offices, houses, temporary
works or any other purpose.
The location of land which shall be provided by the Contractor for the Resident
Engineer's laboratories, offices and houses and their layout shall be subject to
approval by the Engineer.
Where it is necessary for the Employer, in fulfilling his obligations," to acquire any
of the above land during the Contract, the Contractor shall determine the
ownership of and shall pay on instruction from the Engineer the cost of the land
or rent, and/or compensation as valued by the Commissioner of Lands. The
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Contractor's obligations are set out in detail in Clause 603 of this Specification.
Although the Contractor may, in the first instance, provide the money for the
purchase of the land, all such land shall be the property of the Employer.
Where the Contractor chooses to use an alternative source of material to that
Specified, the terms of this Clause do not apply and the Contractor shall be
solely responsible for acquisition of the land and its disposal after completion of
the Works.
Should the Contractor request the purchase of land for any purpose and this land
is subsequently not used, the Contractor shall be responsible for all costs
associated with the compensation, purchase and disposal of such land.
1025 WATER SUPPLY
The Contractor shall provide a clean, sufficient and continuous supply of fresh
water, both for construction of the Works and for all houses, offices, laboratories
and workshops. He shall undertake all arrangements including pipelines and
meters for connecting to local water mains and the provision of pumps, storage
tanks or water conveyance where necessary, payment for all fees and water
charges and the satisfactory removal of all such arrangements and provisions on
completion of the Works.
The water shall be clear of suspended solids and free from any matter in
quantities considered by the Engineer to be deleterious to the work. Water
supplied to all the offices, laboratories and houses shall be wholesome and
potable to the satisfaction of the Medical Officer in the Area.
1026 MATERIALS AND MANUFACTURED ARTICLES
The Contractor shall before placing any order for materials and manufactured
articles for incorporation in the Works submit to the Engineer the names of the
firms from whom he proposes to obtain such materials and manufactured articles
giving for each firm a description of the materials and manufactured articles to be
supplied, their origin, the manufacturer's specification, quality, weight, strength
and any other relevant details. The Contractor shall deposit with the Engineer
samples of such materials and manufactured articles when requested and where
appropriate, manufacturer's certificates of recent tests carried out" on similar
materials and manufactured articles.
The Contractor shall provide the Engineer with copies of all orders for the supply
of materials and manufactured articles required in connection with the Works as
the Engineer may require.
1027 INFORMATION FROM EXPLORATORY BORING AND TEST PITS.
The Materials Report, which forms part of the Contract Documents, contains
information on exploratory borings, test pits and other investigations which have
been made by the Engineer on the site of the Works. The Engineer will be
responsible for the suitability of the borrow pits provided by him and shown on
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the Drawings. The Contractor will be solely responsible for any conclusions he
may reach from the Materials Report at all locations other than the borrow pits
provided by the Engineer.
The Engineer reserves the right to adjust foundation levels and other levels for
construction below ground level, in the light of information that becomes available
as general excavation proceeds upon the Site.
The Contractor's attention is drawn to his obligation with regard to the inspection
and examination of the Site as detailed in Clause 11 of the Conditions of
Contract.
1028 STORAGE OF MATERIALS AND MANUFACTURED ARTICLES
All materials and manufactured articles shall be stored on Site in a manner
acceptable to the Engineer and the Contractor shall carefully protect from the
weather and vermin all work, materials and manufactured articles which may be
affected.
1029 TEST CERTIFICATES
When instructed by the Engineer, the Contractor shall submit to him Certificates
of Test from the suppliers of materials and manufactured articles to be used for
the Contract. Such Certificates shall certify that the materials and manufactured
articles concerned have been tested in accordance with the requirements of this
Specification and shall give the results of all the tests carried out. The Contractor
shall provide adequate means of identifying the materials and manufactured
articles delivered to the Site with the corresponding Certificates.
1030 PROGRESS PHOTOGRAPHS
36 number colour negatives showing the progress of the Works shall be taken
every month by the Contractor from positions to be selected by the Engineer.
The Contractor shall supply proof prints from each negative from which the
Engineer shall select negatives from which the Contractor shall produce 2 sets of
progress photographs. Each set shall comprise 10 number, 200 x 150 mm colour
prints, which together with all the negatives shall be handed over to the Engineer.
Each proof and photograph shall be marked with the number of the negative and
a statement shall be submitted giving the location, date when taken and a brief
description or title. The Contractor shall supply one album with each set of
photographs.
1031 SIGNBOARDS
The Contractor shall provide, erect and maintain signboards to the layout,
colours and dimensions shown on the Drawings.
These signboards shall be erected at sites to.be selected by the Engineer.

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The signboards are to be erected within one month of the date of

commencement of the Contract. The Contractor shall remove the signboards at
the end of the Period of Maintenance.
1032 HOUSING ACCOMMODATION FOR THE ENGINEER AND HIS STAFF,
OFFICES AND LABORATORIES FOR THE ENGINEER WITH LABORATORY
AND SURVEY EQUIPMENT AND FURNITURE
The Contractor shall if, required by the Special Specification, provide and
maintain houses, offices, laboratories, survey and laboratory equipment and
furniture for the Engineer and his staff including senior staff, junior staff and
technicians.
A description of the number and type of houses, offices, laboratories, equipment
and furniture required is given in the Special Specification.
1033 TIME FOR ERECTION OF THE ENGINEER'S STAFF HOUSES, OFFICES AND
LABORATORIES
All houses, offices and laboratories to be provided under the Contract shall be
handed over to the Engineer in finished and fully habitable condition not later
than sixty days after the Engineer's order to commence work (Clause 41 of the
Conditions of Contract).
No construction of the Works will be permitted until the Engineer's offices and
laboratory have been accepted by the Engineer as finished and able to function
efficiently.
Should the Contractor fail to hand over the houses, offices and laboratories
within the period specified, the Engineer will make such alternative arrangements
as he considers necessary. These arrangements may include the use of hotels,
rented accommodation and the hire or purchase of caravans, port cabins etc.
The Contractor will be responsible for all costs of such temporary arrangements
made by the Engineer, including that of additional transport.
1034 INSURANCE AND OWNERSHIP OF THE ENGINEER'S STAFF HOUSES,
OFFICES, LABORATORIES, FURNITURE AND EQUIPMENT
All buildings, furniture and equipment provided by the Contractor ^and/or-the
Employer: - for the Engineer's staff houses (senior and junior), offices and
laboratories shall be insured by the Contractor against any loss or damage by
'accident, fire or theft for the duration of the Contract, ^including the Period of
Maintenance.
On completion of the Contract, the ownership of the office furniture and
laboratory and survey equipment shall revert to the Employer. Unless otherwise
stated the ownership of all houses, offices, and laboratories shall revert to the
Contractor.

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1035 MAINTENANCE OF THE ENGINEER'S STAFF HOUSES, OFFICES,

LABORATORIES, FURNITURE AND EQUIPMENT
The Contractor shall keep all buildings, accesses, services and facilities provided
by him, for the use of the Engineer and his staff, in a well maintained, clean and
fully habitable condition, 24 hours per day until the expiry of the Period of
Maintenance.
The Contractor shall also provide constant electricity, water and an adequate
refuse collection service for all houses, offices and laboratories.
The Contractor shall also maintain all furniture and equipment provided by him
and/or the Employer in a reasonable state of repair and useable condition and
shall replace promptly any item which becomes unserviceable or is lost.
1036 REMOVAL OF CAMPS
Unless otherwise instructed, upon completion of the Contract and, after receiving
approval in writing from the Engineer, the Contractor shall take down and remove
all structures forming part of his own camp and that of the Engineer, and shall
arrange for the disconnection of the water supply, remove all drains and culverts,
backfill trenches, fill in all latrine pits, soakways and other sewage disposal
excavations, with the exception of items and services which are required to revert
to the ownership of the Employer and shall restore the Site, as far as practicable,
to its original condition and leave it in a neat and tidy condition.
The Contractor shall carry out similar reinstatement in the event that he relocates
his camp and that of the Engineer.
1037 ATTENDANCE UPON THE ENGINEER AND HIS STAFF
In the Engineer's offices and laboratories the Contractor shall provide a
continuous supply of soap, towels and toilet paper, coffee, tea, sugar and milk,
and cleaning equipment, and shall keep the offices and laboratories in a well
maintained, clean and habitable condition.
The Contractor shall provide all tools, protective clothing, wooden pegs, iron pins
and pickets, water, cement and aggregate for concreting and all assistance as
may be required by the Engineer and his staff for setting out, measuring and
checking the Works.
The Contractor shall provide, pay, including all overtime, and such junior staff as
are listed in the Special Specification.
The Contractor shall provide adequate security by day and by night for the
Engineer's offices, laboratory, vehicles and houses, and for the Engineer's staff.
This shall include the provision of suitable gates and fencing and the full-time
attendance of permanent watchmen.

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1038 PROVISION OF VEHICLES

The Contractor shall, if so required in the Special Specification, supply new
vehicles and maintain them for the exclusive use of the Engineer and his staff, for
any purpose whatsoever authorised by the Engineer.
A description of the number and types of vehicles to be provided is given in the
Special Specification.
Unless otherwise specified, the vehicles shall be owned by the Contractor and be
licensed and comprehensively insured by the Contractor for use within Kenya by
any licensed driver authorised by the Engineer together with authorised
passengers and the carriage of goods and samples. The Contractor shall pay all
tolls, provide fuel, oil, maintenance including replacing defective parts, tyres and
the like whenever required, in conformity with the vehicle manufacturer's
recommendations or as may be necessary. The vehicles shall be fueled, oiled
and maintained as aforementioned until released by the Engineer. The vehicles
on being released shall revert to the Contractor. Each vehicle shall be fitted with
a fire extinguisher, first aid kit, tow hook and rope, tool kit, spare wheel, wheel
wrench, jack and handle and seat belts all of which shall be maintained in
working order or replaced by the Contractor as necessary.
The Contractor shall provide a similar replacement for any vehicle out of service
for more than twenty four hours, and shall replace any vehicle by a similar new
vehicle after it has completed 150,000 km.
The Contractor shall provide, pay including all overtime and night allowances,
and house competent and licensed drivers approved by the Engineer for each of
the vehicles indicated in the Special Specification. Sufficient drivers shall be
available at night and at weekends whenever required by the Engineer.
1039 MISCELLANEOUS ACCOUNTS
The Contractor may be instructed by the Engineer to purchase and supply to the
Engineer, or pay for miscellaneous items including but not limited to stationery,
stores, equipment, office consumables , computer charges and hotel
accommodation. The Contractor shall submit a miscellaneous account including
receipts of all such items purchased or paid for.
1040 PAYMENT OF OVERTIME FOR ENGINEER'S JUNIOR STAFF
The Contractor may be instructed by the Engineer to make" payment for overtime
worked by the Engineer's junior staff. The Contractor shall be reimbursed for
such payments in accordance with the relevant- -items of Clause*- 141 of this
Specification except when any overtime worked by the Engineer's junior staff is
incurred by the need for the Engineer to inspect work which, owing to earlier
default by the Contractor, has resulted in such work being performed outside
normal working hours as defined in Clause 108 of this Specification then the full
cost of such overtime shall be at the Contractors expense.

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1041 MEASUREMENT AND PAYMENT

No separate measurement and payment shall be made for the cost of complying
with the requirements of Clauses 101 to 120 inclusive, Clause 122, Clause 123,
Clause 125 to Clause 129 inclusive and Clause 137 of this Specification and the
Contractor shall be deemed to have allowed elsewhere in his rates and price for
all such costs.
(a) Item : Preliminary Item
Unit: Lump Sum
Measurement and payment of the Preliminary Item shall be made in
accordance with the requirements of Clause 60(1J of the Conditions of
Contract, Part II.
(b) Item : Engineer's senior staff houses
Unit: no. of each type
Engineer's senior staff houses shall be measured by the number instructed to
be built.
The rate for the Engineer's senior staff houses shall include for the cost of
providing each house, furniture, equipment, water, electricity and gas in
accordance with the Special Specification and complying with the
requirements of Clauses 117, 124, 125, 132, 133, 134, 135, 136 and 137 of
this Specification.
Payment for the Engineer's senior staff houses shall be made in instalments
in accordance with the following conditions:-
(i) The Contractor will be paid 50% of the amount due when the buildings
are accepted by the Engineer fully furnished and equipped.
(ii) 30% of the amount due will be paid in equal monthly instalments from the
date the Engineer accepts the buildings over the remainder of the
Contract Period excluding the Period of Maintenance. This payment shall
be deemed to cover maintenance of buildings, furniture, equipment and
services and the Engineer may withhold or reduce any instalments if the
Contractor fails in his maintenance obligations.
(iii) 20% of the amount due will be paid when the buildings have been
removed, if required, and the site cleared at the end of the Period of
Maintenance or earlier if the Engineer has no further requirement for the
houses.
(iv) Each instalment retention money will be subject to the deduction of
retention money

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(c) Item : Engineer's junior staff houses

Unit: no. of each type
Engineer's junior staff houses shall be measured by the type and number
instructed to be built.
The rate for the Engineer's junior staff houses shall include for the cost of
providing each house, furniture, equipment, electricity and water in
accordance with the Special Specification and complying with the
requirements of Clauses 117, 124, 125, 132, 133, 134, 135, 136 and 137'' of
this Specification.
Payment for the Engineer's junior staff houses shall be made in instalments
in accordance with Clause 141(b) of the Specification.
(d) Item: Engineer's office
Unit: no.
Engineer's office shall be measured by the number instructed to be built.
The rate for the Engineer's office shall include for the cost of providing the
office, electricity, water, telephone charges and heating in accordance with
the Special Specification and complying with the requirements of Clauses
117, 124, 125, 132, 133, 134, 135, 136 and 137 of this Specification.
Payments for the Engineer's office shall be made in instalments in
accordance with Clause 141(b) of this Specification.
(e) Item : Engineer's laboratory
Unit: no.
Engineer's laboratory to be built shall be measured by the number instructed
The rate for the Engineer's laboratory shall include for the cost of providing
the laboratory, electricity, water, gas and heating in accordance with the
Special Specification and complying with the requirements of Clauses 117,
124, 125, 132, 133, 134, 135, 136 and 137 of this Specification.
Payment for the Engineer's laboratory shall be made in instalments in
accordance with Clause 141(b) of this Specification.
(f) Item : Furniture and equipment for the Engineer's office and laboratory
Unit: Prime Cost Sum
: Plus \ for Contractor's overheads and profit
Reimbursement for the purchase of furniture and equipment for the
Engineer's office and laboratories shall be on a Prime Cost basis plus a
percentage for overheads and profit. The Prime Cost shall be the cost of the
item ordered, less any discount, in Nairobi. The percentage entered for

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overheads and profit shall be deemed to cover all other costs including
transport from Nairobi to the Engineer's office or laboratory (permanent or
mobile) and maintenance thereof. The Contractor shall be required to
produce quotations and invoices if so required and shall produce receipts of
payments for all goods supplied.
(g) Item : Vehicles for the Engineer
Unit: V. month for each type of vehicle
Provision of vehicles for the Engineer shall be measured by the Vehicle
month (V.month) for each month or part thereof that the vehicle is provided
for the Engineer.
The rate shall include for the cost of complying with the requirements of
Clause 138 of this Specification.
Additional payment will be made under Clause 141(h) of this Specification for
each kilometre travelled.
(h) Item : Kilometre travelled by vehicles for the Engineer
Unit: km for each type of vehicle
Payment will be made for each kilometre travelled by the vehicles for the
Engineer.
The rate for each kilometre travelled shall include for the cost of complying
with the requirements of Clause 138 of this Specification.
(i) Item : Removal and alteration to existing services
Unit: Prime Cost Sum
: Plus % for Contractor's overheads and profit.
Reimbursement for the removal of or alterations "to existing services which
are affected by the Works shall be on a Prime Cost basis plus a percentage
for overheads and profit. This percentage shall be deemed to include for all
costs incurred in liaising with the appropriate bodies and for programming
and coordinating work to enable any removal or alteration to the service to be
carried out and complying with the requirements of Clause 120 and 121 of
this Specification.
(j) Item: Land acquisition
Unit: Prime Cost Sum
: Plus % for Contractor's overheads and profit
Reimbursement for the acquisition of land required for the Works shall be on
a Prime Cost basis plus a percentage for overheads and profits. This
percentage shall be deemed to include for all costs in providing the
information of owner, land registration numbers, local details, maps and

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plans, initially providing the money for the purchase of the land, setting out
and complying with clause 124 of this Specification.
(k) Item: Miscellaneous accounts
Unit: Prime Cost Sum
: Plus % for Contractor's overheads and profit
The Contractor, on provision of receipts, will be reimbursed on a Prime Cost
basis for miscellaneous accounts plus a percentage for overheads and profit.
This percentage shall be deemed to include for all costs in providing the
items in the miscellaneous account including purchase, transport to Site
and complying with the requirements of Clause 139 of this Specification
(l) Item: Payment of overtime for the Engineer's junior staff
Unit: Prime Cost Sum
: Plus % for Contractor's overheads and profit.
Reimbursement for the payment of the Engineer's junior staff overtime shall
be on a Prime Cost basis plus a percentage for overheads and profit. This
percentage shall be deemed to include for all costs of complying with Clause
140 of this Specification.
(m) Item : Progress photographs
Unit: no. of sets
Progress photographs 3hall be measured by the number of sets instructed.
The rate shall include for the cost of complying with Clause 130 of this
Specification.
(n) Item: Signboards.
Unit: no.
Signboards shall be measured by the number instructed.
The rate for signboards shall include for the cost of complying with Clause
131 of this Specification.

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200 MATERIALS AND TESTING OF MATERIALS

201 SCOPE OF SECTION

This Section covers the tests and methods of testing which are required for the
selection and control of the quality of materials and for control of workmanship,
trials and construction control testing.

202 TESTING BY THE CONTRACTOR

The Contractor shall provide, use and maintain on the Site throughout the period
of execution of the Works a suitable laboratory and adequate equipment
operated by competent staff for carrying out tests required for the selection and
control of the quality of materials and for the control of workmanship in
accordance with this Specification. The Contractor shall assume that tests will be
required on all materials used in the Works and on all finished work.
The Contractor shall carry out all necessary tests and shall report to the Engineer
the results of such tests before submitting materials and finished work to the
Engineer for approval. In appropriate circumstances, tests may be carried out at
the place of manufacture.

203 ACCEPTANCE STANDARDS OF MATERIALS

All materials used in or upon the Works shall comply with this Specification and
the Special Specification and shall be acceptable to the Engineer. Where so
specified, the material shall comply with the national specification named or with
an alternative national specification in accordance with Section 1 of this
Specification.
Similarly, where a material has been specified by manufacturer's trade name, the
product of another manufacturer will be acceptable provided it is in all respects of
equivalent or higher quality and provided that the Engineer's approval has been
obtained.
Samples of all materials proposed to be used shall be submitted to the Engineer
and shall, where required, be tested prior to the material being delivered in bulk
upon the Works.

204 SIEVES
ISO sieves shall be used for all tests. The standard sieve series, based on ISO
565, shall be as follows:
75 - 63 - 50 - 37.5 - 28 - 20 - 14 - 10 - 6.3 - 5 – 4
2 - 1 - 0.6 - 0.5 - 0.425 - 0.300 - 0.150 - 0.075 mm
The Engineer may require the use of additional ISO sieves.

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In various standard test procedures quoted in this Section, American or British

sieves shall be replaced by the nearest ISO sieves, e.g.
19.0 mm shall be replaced by 20 mm
9.5 mm shall be replaced by 10 mm
4.75 mm shall be replaced by 5 mm
2.36 mm shall be replaced by 2 mm
1.18 mm shall be replaced by 1 mm

205 SOILS AND GRAVELS

(a) Samples and sampling
Sampling of soils and gravels shall be carried out as specified or as directed
by the Engineer.
Samples shall be prepared for testing as indicated in Clause 1.5 of BS 1377,
except that:
(i) The mass (in g) of a sample required for sieve analysis is about 400 D, D
being the maximum particle size (mm).
(ii) Samples containing particles larger than 20 mm shall be prepared for
compaction and CBR tests as follows:
Sieve an adequate quantity of representative material over the 50 mm
and 20 mm sieve. Weigh the material passing the 50 mm sieve and
retained on the 20 mm sieve and replace it with an equal mass of material
passing the 20 mm sieve and retained on the 5 mm sieve. Take the
material for replacement from the remaining portion of the main sample.
Note: Preparation of gravel samples
The aggregations of particles shall be broken with a wooden or rubber
hammer or pestle.
Care shall be taken that no individual particles are crushed in the
operation.
(b) Standard methods of testing
Tests on soils and gravels shall be performed in accordance with the
standard methods given in Table 2-1.
It is further specified that:
(i) Sieve analysis (BS 1377 - Test 7 (A) - wet sieving) shall be carried out
using ISO sieves, as indicated in Clause 204.

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(ii) Compaction test using a 2.5 kg rammer is denoted AASHTO T99.

Compaction test using a 4.5 kg rammer is denoted AASHTO T180.
Wherever in the text of this Specification and the Special Specification the
term "x% of the MDD (AASHTO T99 or T180)" is used it shall mean that a
standard of compaction shall be achieved such that the dry density of the
compacted material is x% of the maximum dry density determined from
the AASHTO T99 or T180 compaction test.
Samples for the AASHTO T99 or T180 compaction tests shall be taken
before compaction of the layer begins unless in the opinion of the
Engineer the compactive effort proposed or applied by the Contractor is
such that the material characteristics have changed in which case the
samples for the tests shall be taken after all compaction is complete.
(iii) Compaction tests: when the material is susceptible to crushing during
compaction, a separate and new sample shall be used in the
determination of each point on the moisture/density curve.
(iv) In Method A of AASHTO T99 and T180, moulds having a diameter of 102
mm shall normally be used. However, existing moulds to BS 1377
(diameter 105 mm - volume 1 litre) may also be used. The number of
blows shall then be increased from 25 to 27, so as to obtain the same
compactive energy per unit volume.
(v) The dry density of material placed in the Works shall be determined by
the Sand Replacement Method unless the Engineer elects to use a
nuclear method as detailed in Table 2-1 and Clause 226 of this
Specification.

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206 STONE, AGGREGATE, SAND AND FILLER

(a) Sampling and preparation of samples
Sampling shall be carried out and the samples prepared in accordance with
BS 812.
(b) Standard methods of testing
Tests on stone, aggregate, sand and filler shall be performed in accordance
with the standard methods given in Table 2-2.
(i) The Average Least Dimension of an aggregate shall be determined as
follows:
By means of a riffler divide out a representative sample of such a size as
to give at least 200 aggregate particles of each fraction to be tested.
Sieve the sample through a sieve with an aperture size half the nominal
size of the aggregate to be tested and discard the particles passing the
sieve (the nominal size is the smallest sieve through which at least 85%
of the aggregate will pass).
By means of callipers with platens of at least 5 mm diameter (or square)
measure the smallest dimension of each particle retained on that sieve
accurate to 0.1 mm and record the measurement and the number of
particles tested. The average least dimension is then calculated as the
sum of the smallest dimension of the particles divided by the number of
particles measured.

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TABLE 2-1: TEST PROCEDURES APPLICABLE TO DISTURBED SAMPLES OF SOILS AND GRAVELS

Determination of Test Procedure

Moisture Content BS 1377 - Test 1 (A), Oven-drying method
Liquid Limit BS 1377 - Test 2 (A), Cone penetrometer or T Casagrande
Plastic Limit BS 1377 - Test 3
Plasticity Index BS 1377 - Test 4
Linear Shrinkage BS 1377 - Test 5
Specific Gravity of Particles BS 1377 - Test 6
BS 1377 - Test 7 (A), Wet sieving
Particle size Distribution
BS 1377 - Test 7 (D), Hydrometer.
Organic Matter Content BS 1377 - Test 8
Total Sulphate Content BS 1377 - Test 9
pH Value BS 1377 - Test 11(A), Electometric method.
Density-Moisture Content
AASHTO T99 - Method A (Materials with not less than 90% passing a 5 mm sieve)
relationship
(2.5 kg rammer) AASHTO T99 - Method D (Materials with less than 90% passing a 5 mm sieve)
Density-Moisture Content
AASHTO T180 - Method A (Materials with not less than 90% passing a 5 mm sieve)
relationship
(4.5 kg rammer) AASHTO T180 - Method D (Materials with less than 90% passing a 5 mm sieve)
Density-Moisture Content
BS 1377 - Test 14
relationship (Vibrating rammer)
California Bearing Ratio AASHTO T193
Sand Equivalent AASHTO T176 - Mechanical shaker or manual shaker method
BS 1377 - Test 15
Field Dry Density
AASHTO T238 - Method B (Moisture determination in accordance with BS 1377 Test 1(A))

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TABLE 2-2: TEST PROCEDURES APPLICABLE TO STONE, AGGREGATE SANDS AND FILLEERS

Determination of Test Procedure

Particle Sire Distribution BS 812
Clay Silt and dust in aggregate BS 812
Flakiness Index BS 812
Relative density-water absorption BS 812
Bulk density, Voids and Bulking BS 812
Moisture Content BS 812 - Standard method (oven - drying)
Aggregate Crushing Value BS 812
Soluble Chloride Content BS 812
Organic impurities in sands AASHTO T21
Los Angeles Abrasion AASHTO T96 (ASTM C 131) (coarse aggregate)
ASTM C 535 (Large size coarse aggregate)
Sodium Sulphate Soundness AASHTO T104 (ASTM C 88) (5 cycles)
Sand Equivalent AASHTO T176 - Mechanical shaker or manual shaker method

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(ii) Test for presence of organic impurities in aggregates.

This test is designed to indicate the presence of organic impurities in
aggregates used for making concrete.
A 350 cc graduated bottle shall be filled to the 120 cc mark with a sample of
the aggregate to be tested and a 3% solution of sodium hydroxide in water
added until the volume of aggregate and liquid after shaking gives a total
volume of 200 cc. The bottle shall be stoppered, shaken thoroughly and
allowed to stand for 24 hours. If, after 24 hours, the colour of the solution is
no darker than a pale brown, the aggregate under test may be deemed
satisfactory.
(iii) Rapid field test for chlorides in aggregates (Quantab Test).
The purpose of this test is to provide a quick method of testing for chlorides at
the point of delivery so that immediate action can be taken to remove any
contaminated load.
Apparatus required:
Plastic buckets.
Spring balance capable of reading to 5 kg with an accuracy of ±10 g.
Plastic drinking cups or similar containers.
Whatman No. 90 filter papers 125 mm diameter.
Quantab chloride titrators Type 1175 (supplied by Miles Laboratories Ltd.
Stoke Court, Stoke Poges, Slough, Bucks, England)
Method
Weigh out 2 kg of the aggregate under test into a bucket.
Add 2 kg of clean chloride free water.
Stir once every minute for 15 minutes.
Take a container of the solution from the bucket and place into it, point
downwards a filter paper folded into a cone.
Insert into the clear liquid within the filter paper a Quantab titrator strip
and leave until the yellow bar at the top of the strip has turned completely
blue.
Read off from the scale on the strip the level reached at which the strip
has turned white (to first decimal point)
Consult the calibration chart supplied with the test strips and read the
percentage NaCl corresponding to the test strip reading.

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Calculation:
If the % NaCl is X, the amount of CI ion by weight of aggregate is given
by:
CI ion = 0.61X %
Note: It is important to ensure that the control number on the chart
corresponds with the control number on the bottle of test strips in use.

207 CEMENT
Ordinary and Rapid Hardening Portland Cement shall be sampled and tested in
accordance with and shall comply with all the requirements of Kenya Standard
KS 02-21. The main requirements are summarized in Table 2-3.
Portland blast-furnace cement or Portland pozzolan cement may be used if
specified in the Special Specifications, and shall comply with the requirements of
the national specification or AASHTO M240-97 or equivalent standard on
approval of the Engineer.
Other types of cement shall comply with the specification named.

208 LIME
Building limes shall be sampled and tested in accordance with and shall comply
with all requirements of BS 890.
Lime for treatment of road materials shall be Hydrated Calcium Lime or Quicklime
and, unless otherwise specified, shall comply with the following requirements:
Fineness Hydrated lime Quicklime
Residue on 0.2 mm sieve - Maximum 1% 10%
Residue on 0.075 mm sieve - Maximum 10% 50%

Chemical requirement
Free lime content – Minimum 50% 80%
Hydrated lime content – Maximum - 5%

209 CEMENT OR LIME TREATED MATERIALS

(a) Samples and sampling
Sampling of cement or lime treated materials shall be carried out as specified or
as instructed by the Engineer.

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TABLE 2-3
SUMMARY OF THE CHEMICAL AND PHYSICAL REQUIREMENTS OF
KS 02-21 PORTLAND CEMENT (ORDINARY AND RAPID-HARDENING)
CHEMICAL COMPOSITION
1. Lime Saturation Factor:

(CaO) - 0.7 (SO3)

L.F.S =
2.8 (SiO2) + 1.2 (Al2O3) + 0.65 (FeSO3)

The L.S.F. should not be greater than 1.02 and not less than 0.66.
2. Insoluble Residue: The weight of insoluble residue shall not exceed 3%. If a
pozzolana is added then the weight of insoluble residue shall not exceed
(3 + 0.67P)%, where P is the percentage by mass of pozzolana.
3. Magnesium Oxide: The weight of magnesium oxide in the cement shall not
exceed 5%
4. Sulphuric Anhydride: The content of total sulphur in the cement, expressed
as SO3, shall not exceed 3.5%.
5. Loss on Ignition: The total loss on ignition at 900° - 1000°C shall not exceed
5%.
6. Pozzolana: Not more than 15% by mass of pozzolana shall be added.
PHYSICAL REQUIREMENTS ORDINARY RAPID HARDENING
1. SPECIFIC SURFACE
Minimum Specific Surface (m2/kg) 225 325
2. COMPRESSIVE STRENGTH
Minimum average compressive strength of 3 mortar cubes (N/mm2)
at 3 days 17.5 23.0
at 7 days 26.5 31.0
at 28 days 38.0 46.0
3. SETTING TIMES
Minimum initial setting time (min) 45 45
Maximum final setting time (hours) 10 10

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4. SOUNDNESS
Maximum expansion (mm)
Un-aerated cement 10 10
Aerated cement 5 5

Samples shall be prepared for testing as indicated in Clause 1.5.3 of BS 1924,

except that:
Samples containing particles larger than 20 mm shall be prepared for compaction
and CBR tests as indicated in Clause 205 (a) (ii). (The fraction coarser than 20
mm shall be rejected but replaced by an equal weight of 5/20 mm material).

(b) Standard methods of testing

The tests on cement or lime treated materials shall be performed in accordance
with the standard methods given in Table 2 - 1 and Table 2-4.
It is further specified that:
(i) Compaction tests: when cement is used, compaction must start within one
hour and be complete within two hours after the start of mixing operations.
(ii) Determination of the unconfined Compression Strength (UCS): the
specimens shall be statically compacted to a predetermined density.
(iii) Determination of the CBR: the specimens shall be dynamically compacted
with a 4.5 kg rammer, the number of blows being governed by the relative
compaction chosen (Dynamic Compaction - Method 1). If it is required to
soak the specimen, the mould shall be immersed in water to allow free
access of water to top and bottom of the specimen. During soaking, the water
level in the mould and the soaking tank shall be maintained approximately 25
mm above the top of the specimen.
(iv) Curing and soaking temperature: during the curing and soaking periods, the
specimens shall be kept at a temperature of 27°C ± 2°C.

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210 CONCRETE
Sampling and testing on concrete shall be carried out in accordance with BS
1881:
Part 1 Methods of sampling fresh concrete
Part 2 Methods of testing fresh concrete
Part 3 Methods of making and curing test specimens
Part 4 Methods of testing concrete for strength
Part 5 Methods of testing hardened concrete for other than strength.

It is further specified that the test specimens shall be cured at a temperature of

27°C ± 2°C.
Water to be used in concrete shall be tested as specified in BS 3148.

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TABLE 2-4: ADDITIONAL TEST PROCEDURES APPLICABLE TO CEMENT AND LIME TREATED MATERIALS

Determination of Test Procedure

Moisture Content BS 1924 - Test 1 (A), Oven-drying method
Density-Moisture Content AASHTO T99 - Method A (Materials with not less than 90% passing 5 mm
relationship Sieve)
(2.5 kg rammer) AASHTO T99 - Method D (Materials with less than 90% passing 5 mm sieve)
Density-Moisture Content AASHTO T180 - Method A (Materials with not less than 90% passing 5 mm
relationship Sieve)
AASHTO T180 - Method D (Materials with less than 90% passing 5 mm
(4.5 kg rammer)
sieve)
Density-Moisture Content
relationship
(Vibrating Hammer) BS 1924 - Test 5
Unconfined Compressive Strength BS 1924 - Test 10 (Fine and medium grained materials)
BS 1924 - Test 11 (Medium and coarse grained materials)
Effect of immersion on U.C.S. BS 1924 - Test 12
BS 1924 - Test 13 Dynamic compaction - Method 1 soaking as AASHTO
California Bearing Ratio
T193
Cement Content BS 1924 - Test 14
Lime Content BS 1924 - Test 15
Field Dry Density BS 1924 - Test 6 or test 7
AASHTO T238 - Method B (Moisture determination in accordance with BS
1924 Test 1 (A))

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211 BITUMINOUS BINDERS

(a) Samples and sampling
Sampling of straight-run and cut-back bitumens shall be carried out in
accordance with AASHTO Method T40 (ASTM D 140).
Sampling of bitumen emulsion shall be carried out in accordance with BS
434, except that where a delivery is made in drums or barrels, the number of
samples shall be as indicated in AASHTO Sampling Method T40 para 11.1.
(b) Standard methods of testing
(i) Straight-run bitumen
Tests on straight-run bitumen shall be carried out in accordance with the
following test procedures:

Penetration AASHTO T49 (ASTM D 5)

Softening point (Ring and Ball) AASHTO T53 (ASTM D 2398)
Flash and fire points (Cleveland open cup) AASHTO T48 (ASTM D 92)
Loss on heating AASHTO T47 (ASTM D 6)
Ductility. AASHTO T51 (ASTM D 113)
Water AASHTO T55 (ASTM D 95)
Thin film oven test AASHTO T179 (ASTM D 1754)
Solubility in organic solvents AASHTO T44 (ASTM D 2042)
Specific gravity AASHTO T228 (ASTM D 70)

(ii) Cut-back bitumen

Tests on cut-back bitumen shall be carried out in accordance with the following
test procedures:
Kinematic viscosity AASHTO T201 (ASTM D 2170)
Flash point (Tag open cup) (RC-MC) AASHTO T79 (ASTM D 1310)
Flash point (Cleveland open cup) (SC) AASHTO T48 (ASTM D 92)
Distillation AASHTO T78 (ASTM D 402)
Water AASHTO T55 (ASTM D 95)
Specific gravity AASHTO T228 (ASTM D 3142)
Asphalt residue of 100 pen (SC) (ASTM D 243)

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Tests on residue from distillation

Penetration AASHTO T49 (ASTM D 5)
Ductility AASHTO T51 (ASTM D 113)
Solubility AASHTO T44 (ASTM D 2042)
STV viscosity BS 3235

(iii) Bitumen emulsion

Tests on bitumen emulsion shall be carried out in accordance with BS
434 test procedures:
Residue on 0.710 mm sieve
Residue on 0.150 mm sieve
Stability to mixing with coarse aggregate
Stability to mixing with cement
Binder content
Engler viscosity
Redwood 11 viscosity
Storage stability (short period)
Storage stability (long period)
Particle charge
(c) Requirements
(i) General
Before any bituminous binder is delivered to the Site, the Contractor shall
provide the Engineer with a certificate from the manufacturer that the
material to be supplied complies in all respects with the relevant
specification.
Any bituminous binder delivered in leaking or deteriorated containers may
be rejected.
(ii) Straight-run bitumen
Straight-run bitumens shall comply with all the requirements given in
Table 2-5.

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(iii) Cut-back bitumen

Rapid-curing cut-backs shall comply with all the requirements of AASHTO
Standard Specification M81 (ASTM D 2028).
Medium-curing cut-backs shall comply with all the requirements of
AASHTO Standard Specification M 82 (ASTM D 2027), except the cut-
back 800/1400 which shall comply with the following requirements:

STV Viscosity at 40°C (10mm orifice) 80-180 seconds

Distillation (% of total volume).
Distillate to 225°C 0-2%
Distillate to 315°C 3 - 11%
Distillate to 360°C 13% maximum
Penetration on residue from
distillation at 360°C (250°-100g-5s) 80 - 200 10-lmm
Specific gravity at 15°C 0.92 – 1.04

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TABLE 2-5: SPECIFICATION FOR STRAIGHT RUN BITUMEN

Penetration Grade 20/30 40/50 60/70 80/100 180/200

Penetration at 25° (100g-5 s) - 0.1mm 20 - 30 40 - 50 60 - 70 80 - 100 180 - 200

Softening point (Ring and Ball) °C 59 - 69 52 - 60 48 - 56 45 - 52 37 - 43

Flash point (Cleveland open cup)°C (min) 250 250 250 225 200

Ductility at 25°C cm (min) 30 100 100 100 100

Loss on heating (5 h at 163°C)% (max) 0.2 0.2 0.2 0.5 0.5

Penetration of residue from loss on

heating (100g-5s) % of Initial pen (min) 80 80 80 80 80

Specific gravity at 25°C 1.02-1.07 1.01-1.06 1.01-1.06 1.00-1.05 1.00 - 1.05

Solubility In Carbon tetrachloride % (min) 99 99 99 99 99

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Slow curing cut-backs shall comply with all the requirements of AASHTO
Standard Specification M 141 (ASTM D 2026).
(iv) Bitumen emulsion
Bitumen emulsions shall comply with all the requirements of BS 434.

212 BITUMINOUS MIXES

(a) Samples and sampling
Sampling of bituminous mixtures shall be carried out in accordance with
AASHTO Method T168 (ASTM D 979).
(b) Standard methods of testing
Tests on bituminous mixtures shall be carried out in accordance with the following
test procedures:
Moisture and volatile distillates AASHTO T110 (ASTM D 1461)
Quantitative extraction of bitumen AASHTO T164 (ASTM D 2172)
Specific gravity of compacted mixture AASHTO T166 (ASTM D 1188
& D 2726)
Recovery of bitumen from solution AASHTO T170 (ASTM D 1856)
Determining the binder content of hot
bituminous material by the Ignition Method AASHTO T308
Resistance of compacted hot bituminous
material to Moisture-Induced Damage AASHTO T283
Degree of particle coating AASHTO T195 (ASTM D 2489)
Coating and stripping (with adhesion agent) (ASTM D 2727)
Theoretical Maximum specific gravity AASHTO T209 (ASTM D 2041)
Degree of pavement compaction AASHTO T230
Marshall Stability AASHTO T245 (ASTM D 1559)
Hveem mix design procedure ASTM D1560 and ASTM D1561
Hubbard-Field stability (ASTM D 1138)
Preparing and Determining the Density
of the hot bituminous specimens by
means of the Superpave Gyratory
Compactor AASHTO T312

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213 REINFORCING STEEL

Hot-rolled steel bars for the reinforcement of concrete shall comply with BS 4449
Cold-worked steel bars for the reinforcement of concrete shall comply with BS
4461
Steel fabric for the reinforcement of concrete, shall comply with BS 4483

214 PRESTRESSING STEEL

Steel wire for prestressed concrete shall comply with BS 2691. Steel strands for
prestressed concrete shall comply with BS 3617 (seven wire strand) or BS 4757
(nineteen-wire strand)
Hot-rolled and hot-rolled and processed high tensile alloy steel bars for the
prestressing of concrete shall comply with BS 4486.

215 CONCRETE PIPES AND FITTINGS

(a) Concrete pipes shall comply with the requirements of BS 5911 Parts 1 and 3.
(b) Concrete for concrete pipes shall be Class 30/10 as specified in Section 17 of
this Specification.
(c) The pipes shall have flexible joints in accordance with BS 5911 Part 1 or
ogee joints in accordance with BS 5911 Part 3.
(d) Reinforcement may be inserted in the pipes to strengthen them for handling,
but the size, spacing and placing of reinforcement shall be to the approval of
the Engineer.
(e) All concrete shall be compacted either by spinning or vibrating.
(f) All concrete pipes shall be cured by keeping them saturated with water for at
least seven days after casting and protected from the sun and drying winds
for at least fourteen days after casting. No pipe shall be used in the work until
it is twenty-one days old. The date of casting shall be painted on the barrel.
A minimum of 10% (ten per cent) of the pipes shall be tested from initial
batches prepared by the Contractor and thereafter the frequency of testing
shall be decided by the Engineer.
All pipes shall be capable of supporting the works proof loads set out in Table
2 of BS 5911 Part 1 for Class M pipes when tested in accordance with
Paragraph 25.4 of BS 5911 Part 1.
A set of six concrete cubes shall be made for each day's manufacturing of
concrete pipes. Where the crushing strength does not reach the Class 30
requirement, or if pipes appear sub-standard the Engineer may order the
above load tests on a set of three pipes from the suspect batch.

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(g) Concrete pipes for use in subsoil drains shall be one of the following:
(i) Porous concrete pipes to BS 1194;
(ii) Concrete pipes to BS 5911 Parts 1 and 3 with a maximum length of
1.5 m laid with open joints.

216 METAL PIPES AND ARCHES

(a) Corrugated metal pipe culverts shall be in accordance with AASHTO
Specification M 36 - 82.
(b) Structural plate for pipe, pipe-arches and arches shall be in accordance with
AASHTO Specification M 167.

217 PAINTS FOR STRUCTURES

(a) Paint for structural steelwork
(i) Red lead priming paint
Lead based priming paints shall comply with B.S. 2523. The composition
of lead based priming paint shall be one of the following:
Type A: Red lead (Type C) complying with BS 217-78% to 82%.
Remainder as specified in BS 2523.
This type of paint should only be selected when it is intended
to use it within four weeks of manufacture.
Type B: Red lead (Type C) complying with BS 217 - 60% min.
Remainder as specified in BS 2523
Type C: Red lead (Type C) complying with BS 217 - 2 parts;
White lead complying with BS 239 - 2 parts;
Asbestine complying with BS 1795 - 1 part.
These three ingredients shall make 77 - 82%.
The remainder as specified in BS 2523.

Type B and C are suitable for storage for a reasonable period and shall
be selected when the paint is not due to be used within four weeks of
manufacture.
(ii) Bituminous aluminium paint
Bituminous aluminium paint shall be of a type approved by the Engineer.

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(iii) Other paints

All other paints used in the Works shall be subject to approval by the
Engineer.
(b) Paint for road signs
Road signs, posts and fittings shall be prepared, treated and painted in
accordance with the requirements of BS 873, Parts 2, 6 and 7.

218 PAINT FOR ROAD MARKING

(a) General requirements
The paint to be used for road surface marking shall be specifically
manufactured for such purposes. ^It shall be suitable for applying by brush,
low pressure spraying equipment and high pressure spraying equipment. The
paint shall be reflectorized unless otherwise specified.
The paint shall be of a type approved by the Engineer, and If not off the
current approved list, samples shall be submitted to the Engineer at least 6
months prior to its proposed use.
(b) Colour
(i) White
The colour of white markings shall be BS Colour No. 00E55 of BS-4800
The pigment used for white materials shall be titanium dioxide Type A
(Anatase) or Type R (Rutile) complying with BS 1851.
(ii) Yellow
The colour of yellow markings shall be to BS Colour No. 08E51 of BS
4800
(c) Drying time
The drying time allowed shall be as specified by the manufacturer, subject to
the touch dry condition being reached in a maximum of 15 minutes.
(d) Reflectorization
(i) Non-reflectorized
Paint specified to be non-reflectorized shall have minimum reflective
brightness values, as compared to magnesium oxide (MgO) of, for white
80% and for yellow (using a yellow filter of 5800°A) 65%.

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(ii) Internal reflectorization

Internally reflectorized paint shall be specifically manufactured for this
purpose and shall contain ballotini beads to BS 6088. The ballotini shall
be reasonably spherical and free from flaws, and of a size suitable for this
method of reflectorization, subject to a maximum size of 0.5 mm.
(iii) Surface reflectorization
Surface reflectorization of the paint shall be by application of ballotini
beads to BS 6088 to the wet paint film. The ballotini shall be reasonably
spherical and free from flaws and of a size suitable for this method of
reflectorization, subject to a maximum nominal size of 0.8 mm.

219 HOT-APPLIED THERMOPLASTIC MATERIAL FOR ROAD MARKING

(a) General requirements
The material for hot-applied thermoplastic "paint" for road marking shall be in
accordance with BS 3262: Part 1.
The material shall be of & type approved by the Engineer, and if not on the
current approved list, samples shall be submitted to the Engineer at least 6
months prior to the proposed use.
(b) Colour
(i) White
The colour of white markings shall be BS Colour No 00E55 of BS 4800.
(ii) Yellow
The colour of yellow markings shall be to BS Colour No. 08E51 of BS
4800.
(c) Composition
The thermoplastic material shall consist of light coloured aggregate, pigment
and extender bound together with resin plasticized with oil as necessary, in
approximately the following proportions:
Aggregate, including ballotini: 60%
Pigment and extender: 20%
Binder: 20%
The maximum size of the aggregate shall be 2 mm.
The softening point of the binder shall be 45° - 50°C.

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(d) Reflectorization
Reflectorization shall be by ballotini beads to BS 6088, which shall make up
approximately 20% of the total mix, and shall be treated as part of the
aggregate. The ballotini shall be reasonably spherical and free from flaws and
of a size suitable for this method of reflectorization, subject to a maximum
size of 2 mm.

220 REFLECTIVE MATERIALS ON ROAD SIGNS

The reflective material, when applied to the sign plate, shall give the appearance
of a continuous reflecting surface under any angle of observation. It shall consist
of a smooth exterior film with spherical lenses embedded beneath the surface,
and shall have a protected, precoated adhesive backing which shall be tack-free,
heat-activated for mechanical vacuum-heat application. The combination"- of
various elements shall result in a non-exposed lens type optical reflecting
system. The reflective material shall be applied as per the instructions from the
manufacturer of the retro-reflective material used.
The reflective material shall comply with the following specifications:
(a) Reflective brightness
The minimum coefficient of luminous intensity CIL (Coefficient d'Intensite
Lumineuse) of the reflective sign surface, when illuminated by CIE Standard
Illuminant A (colour temperature of 3127°C), shall be as specified in Table 2-
6. The response of the photoelectric receiver shall be corrected to the colour
sensitivity of the average photopic human eye.
The brightness of the reflective material totally wet by rain shall be not less
than 90% of the above values.
(b) Weather resistance
The reflective surface of the sign shall be weather resistant and shall show no
appreciable cracking, blistering, crazing or dimensional changes after 2 years
unprotected outdoor exposure at 45° upwards inclination to the vertical facing
West in Nairobi or Mombasa in accordance with approved testing procedures
conducted by Ministry of Transport and Communications, Materials Branch.
After cleaning, the CIL values of the reflective surface shall then be not less
than 80% of the values given in Table 2-6, and the colours shall still conform
to the specified requirements.

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(c) Bonding strength

When reflective surfaces are laminated to the base materials, the adhesion
shall be such that the reflective material shall resist peeling, scuffing and
marring during the normal handling or shocking off when jabbed with a
spatula at -20°C. It shall withstand 8 hours of soaking in water at 25°C
without any noticeable edge lifting or curling. The adhesive shall have no
staining effect on the reflective material. The adhesive shall permit the
reflective material to adhere securely 48 hours after application at
temperatures between -20°C and + 93°C.

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TABLE 2-6: CIL FOR REFLECTIVE SIGNS

MINIMUM CIL VALUE

ANGLE OF
Calendas per hex m2
DIVERGENCE INCIDENCE
+ ++ WHITE YELLOW RED GREEN BLUE

5° 70 50 14.5 9 4

0.2° 30° 30 22 6 3.5 1.7

40° 12 10 2.7 1.5 0.7

5° 50 35 10 7 3

0.33° 30° 24 10 4 3 1

40° 9 6 1.8 1.2 0.4

5° 30 25 7.5 4.5 2

0.5° 30° 15 13 3 2.2 0.8

40° 7 5 1.4 1.1 0.3

5° 4 5 1 1 0.5

2° 30° 2 2.5 0.5 0.4 0.1

40° 1.5 1.3 0.3 0.2 0.06

+ Divergence Angle -
The angle between the line formed by a light beam striking the
surface and the line formed by its reflected light.
++ Incidence Angle -
The angle between a light beam striking a surface at a point and
the line perpendicular to the surface at the same point.

(d) Flexibility
When bent around a 20 mm diameter mandrel at a temperature of 20°C, the
reflective material applied to an aluminium panel of 0.5 mm ' thickness shall
show no evidence of cracking around the outside of the bend. After flattening
out, the CIL values shall be not less than those given in Table 2-6.
(e) Impact resistance

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When a 25 mm diameter steel ball is dropped from 2 metres height onto the
reflective face of the sign specimen at an ambient temperature of 20°C, the
reflective material around the impact point shall show no evidence of cracking
or peeling off. The CIL values of the impact area shall be not less than those
given in Table 2-6.
(f) Solvent resistance and cleaning
After immersion of a specimen of reflective sign material for 10 minutes in
methyl alcohol, kerosene or turpentine, or for 1 minute in toluol or xylol, the
reflective material shall show no evidence of dissolving, puckering or
blistering. The reflective material shall be capable of withstanding washing
with a mixture of water and mild detergent, turpentine and methanol. The
reflective surface shall be such as to be readily refurbished by cleaning and
clear overcoating in accordance with the manufacturer's recommendations.

221 COLOURS FOR ROAD SIGNS

Standard colours to be used for signs, posts and fittings shall be as described in
the relevant BS as follows:
Red BS 381C No. 537
Blue BS 4800 No 18 E 53
Yellow BS 381C No. 355
Green for primary route signs BS 4800 No. 14 C 39
Grey for posts, fittings and
backs of signs BS 4800 No. 10 A 11
Cream BS 381C No. 352
White BS 873 Part 1 - Clause 1-3.2
Black BS 873 Part 1 - Clause 1-3.3

222 WATERPROOF PAPER

Waterproof paper to be used under concrete slabs and foundations shall comply
with BS 1521 for Waterproof Building Paper, Class B, and shall have fibrous
reinforcement.

223 GALVANIZED COATINGS

Galvanized coatings on iron and steel shall comply with the following standards
as appropriate:-
Galvanized coatings on corrugated sheets BS 3083
Galvanized coatings on iron and steel BS 729

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Galvanized coatings on steel sheet and strip BS 2989

Galvanized coatings on wire BS 443

224 TRIALS TO CONFIRM COMPLIANCE WITH SPECIFICATIONS

(a) Laboratory trials
Laboratory trials shall be carried out by the Contractor and the Engineer on
earthwork and pavement materials which are to be used in the Works in their
natural state to establish a relationship between their specified end product
requirements and properties which can be readily determined in the field for
construction control purposes.
Laboratory trial mixes and site trials for bituminous mixes shall be carried out
in accordance with the requirements of Section 16 of this Specification.
For mixed materials the composition which meets the specified requirements
and is accepted by the Engineer shall then be used in the site trials carried
out in accordance with Clause 224(b) to establish that all specified
requirements of the completed pavement course can be achieved.
The laboratory trials on mixed materials shall be undertaken, and the
Contractor's proposals based thereon submitted to the Engineer, at least two
weeks before the Contractor proposes to use the mixed material in the site
trials in accordance with Clause 224(b).
(b) Site trials
Full scale laying and compaction site trials shall be carried out by the
Contractor on all earthwork and pavement materials proposed for the Works
using the Constructional plant and methods proposed by the Contractor for
constructing the Works. The trials shall be carried out with the agreement,
and in the presence of the Engineer.
The trials shall be carried out to enable the Contractor to demonstrate the
suitability of his mixing and compaction equipment to provide and compact
the material to the specified density and to confirm that the other specified
requirements of the completed earthwork or pavement layer can be achieved.
Each trial area shall be at least 100 metres long and to the full construction
width and shall be laid to the specified depth for the material. It may form part
of the Works provided it complies with this Specification. Any areas which do
not comply with this Specification shall be removed and a new trial shall be
laid.
The Contractor shall allow in his programme for conducting site trials and for
carrying out the appropriate tests on them. The trial on each pavement layer
shall be undertaken at least 21 days ahead of the Contractor proposing to
commence full scale work on that layer.

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The Contractor shall compact each section of trial over the range of
compactive effort the Contractor is proposing and if appropriate, the following
data shall be recorded for each level of compactive effort at each site trial:
(i) The composition and grading of the material before the site trial.
(ii) The composition and grading of the material including the cement, lime or
bitumen content.
(iii) The moisture content at the time of compaction and the optimum moisture
content for the specified compaction.
(iv) The type, size, tyre pressures, frequency of vibration and the number of
passes of the compaction equipment.
(v) The maximum dry density or target density as appropriate measured on a
sample before and at intervals through the site trials.
(vi) The density achieved.
(vii)The compacted thickness of the layer.
(viii) Any other relevant information as directed by the Engineer.
At least eight sets of tests shall be made by the Contractor and the Engineer
on each 100 metres of trial for each level of compactive effort and provided
all eight sets of results over the range of compactive effort proposed by the
Contractor meet the specified requirements for the material the site trial shall
be deemed successful. The above data recorded in the trial shall become the
agreed basis on which the particular material shall be provided and
processed to achieve the specified requirements.
If, during the execution of the Works, the construction control tests indicate
that the requirements for a material are not being consistently achieved, then
work on that layer shall stop until the cause is investigated by the Contractor.
Such investigation may include further laboratory and site trials on the
material to determine a revised set of data as above which, when Agreed,
shall be the basis on which all subsequent material will be provided and
processed to achieve the specified requirements.
Agreement by the Engineer to a set of data recorded in a site trial shall not
relieve the Contractor of any responsibility to comply with the requirements of
this Specification and the Special Specification.

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225 CONSTRUCTION CONTROL TESTING FOR EARTHWORK LAYERS,

PAVEMENT LAYERS, AND BACKFILL TO DRAINAGE WORKS AND
STRDCTURES
All earthwork and pavement layers and backfill to drainage works and structures
will be subject to construction control testing by the Engineer, and the Contractor
must allow for any disturbance or delays to the sequence of his operations
occasioned by such control testing.
The Contractor shall request, in writing, the Engineer's approval for each layer of
each section of earthworks and pavement construction and backfill to drainage
works and structures. Such requests shall be made only when the Contractor is
fully satisfied that the section of the work concerned is in the condition required
by this Specification. Such requests shall be accompanied by the test results
required by Clause 202 of this Specification.
The Engineer shall thereupon without undue delay inspect the section for any
visible wet spots, laminations, heaving material (visible during compaction or on
proofrolling), segregation, and for the uniformity of the mixing and compaction.
Providing the visual aspects are satisfactory the Engineer shall test the section of
the works submitted and inform the Contractor in writing of the results of the tests
at the same time accepting or rejecting the section or layer concerned.
Work on layers shall in no circumstances commence until the preceding layer
has been approved and accepted by the Engineer in writing. The Contractor is
wholly responsible for protecting and maintaining the condition of the work which
has been submitted for approval.
Should any layer be left unprotected for more than 24 hours subsequent to
approval the Contractor shall request reapproval of the layer and the layer will
again be subject to proofrolling, construction control testing, and tolerance
checks in accordance with this specification.
Notwithstanding the Engineer's approval of a layer, the Contractor shall be
responsible for making good any subsequent damage due to traffic, ingress of
water or any other reason and should any damage occur the layer will again be
subject to proofrolling, construction control testing and tolerance checks in
accordance with this Specification.

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226 FREQUENCY OF TESTING

If a nuclear method is used for determining the wet density, tests will be done at
least at the same frequency required when using the sand replacement method
but at each nuclear densometer test location the average of three readings taken
at positions rotated by 90° will be used. A check/comparison test using the sand
replacement method will be carried out at a 10 test interval.
Initial calibration of the nuclear density testing equipment will be done by carrying
out at least fifty tests in parallel with the sand replacement method for each
different material encountered. The check tests will be used to update the initial
calibration of the nuclear density testing equipment.
(i) Original ground
The AASHTO T99 MDD and OMC shall be determined for each new material
encountered, and at intervals of at least once per 1000 m2 of each layer of
compacted ground but at a maximum interval of 50 m along the alignment.

(ii) Bulk earthworks

The AASHTO T99 MDD and OMC shall be determined for each new material
encountered, and at intervals of at least once per 150 m3 of compacted
material placed. The field dry density shall be determined at least once per
150 m3 of compacted material placed or at least three tests per section,
whichever is the more frequent.

(iii) Upper 300mm of earthworks

The AASHTO T99 MDD and OMC shall be determined for each new material
encountered, and at intervals of at least once per 500 m2 of each layer of
compacted subgrade.
The field dry density shall be determined at least once per 250 m2 of each
layer of compacted subgrade but with a minimum of three tests per section.
The soaked CBR of material in the upper 300 mm of earthworks shall be
determined at least once per 500 m2 of each layer.
(iv) Backfill/fill to culverts and structures (including excavated surface to receive
culvert or structure)
The AASHTO T99 MDD and OMC shall be determined for each new material
encountered.
The field dry density shall be determined at least twice per 10 m3 of material
placed and compacted but with a minimum of two tests per section.

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(v) Gravel wearing course

The AASHTO T180 MDO and OMC shall be determined for each new
material encountered and at intervals of at least once per 400 m2 off each
layer of compacted material.
The field dry density shall be determined at least once per 200 m2 of each
layer of compacted material but with a minimum of three tests per section.
The soaked CBR and Plasticity Index of material used for gravel wearing
course shall be determined on opening up each new source of material and
at least once per 150 m3 of compacted material taken from that source. The
grading of the material shall be determined at least once per 300 m3 of
compacted material.
(vi) Natural materials in subbase and base
The AASHTO T180 MDD and OMC shall be determined for each new source
of subbase or base course material used and at intervals of at least once per
400 m2 of each layer of compacted subbase or base course laid.
The field dry density shall be determined at least once per 200 m2 of each
layer of compacted subbase or base but with a minimum of three tests per
section.
The soaked CBR and Plasticity Index of gravel used for subbase or base
shall be determined on opening up each new source of gravel and at least
once per 75 m3 of compacted gravel taken from that source.
The ACV and LAA of a gravel used for base and subbase shall be
determined on opening up each new source of gravel and whenever the
Engineer considers that its quality may have altered. The grading and
Plasticity Modulus shall be determined at least as often as the CBR.
(vii)Crushed stone subbase and base
The MDD (Vibrating Hammer Method) and the Specific Gravity of the graded
crushed stone shall be determined at least once per 400 m2 of each layer of
compacted subbase or base course laid.
The field dry density shall be determined at least once per 200 m2 of each
layer of compacted subbase or base but with a minimum of three tests per
section.
The LAA, ACV, SSS and CR shall be determined on opening up and crushing
material from each new source for subbase or base and whenever the
Engineer considers that the material has altered.
The grading, PI and FI of crushed material for subbase or base shall be
determined at least once per 500 m3 of material produced.

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(viii) Cement.or lime treated materials in subgrade, subbase and base

The AASHTO T99 MDD and OMC shall be determined for each new treated
material used for subgrade and at intervals of at least once per 400 m2 of
each layer of compacted subgrade.
The AASHTO T180 MDD and OMC shall be determined for each new treated
material used for subbase or base and at intervals of at least once per 400
m2 of each layer of compacted treated subbase or base layer.
The field dry density shall be determined at least once per 200 m2 of each
layer of compacted treated subgrade, subbase or base course, but with a
minimum of three tests per section.
The following properties shall be determined on opening up of each new
source, and when in the opinion of the Engineer the nature of the material
has changed, and once per 300 m3 of subbase or base laid and compacted:
• Grading
• Atterberg Limits
• CBR or UCS as indicated in the Special Specification.
(ix) Bituminous surface treatments and surface dressing
(a) Aggregates, sand, gravel
The properties listed below, as appropriate to the type of surface
treatment specified, shall be determined on opening up of each new
source and when the Engineer considers that the properties may have
altered:-
• FI
• LAA
• ACV
• SSS
• PI
• Sand Equivalent
• ALD
The properties listed below, as appropriate to the type of surface treatment
specified, shall be determined twice daily when surfacing dressing or slurry
seal work is in progress:
• FI
• Grading

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• Angularity
• Cleanliness
• PI
• Deleterious Matter
• Spread Rate (Tray Test)
• Sand Equivalent
(b) Binder
Compliance with Clause 211 of this Specification shall be determined at
least once per 20,000 litres delivered to site.
Binder spray rate shall be determined once per section sprayed. The rate
of application of slurry seal shall be determined once per load of slurry
applied.

(x) Bituminous mixes

(a) Aggregates
The aggregate properties listed below, as appropriate to the type of mix
specified, shall be determined on opening up of each new source of
aggregate, and whenever the Engineer considers that the aggregate
properties may have altered:
• Grading
• LAA
• ACV
• SSS
• FI
• CR
• Sand Equivalent
• Uniformity Coefficient
• Atterberg Limits
• Soluble Salts and Deleterious Matter
• Real and apparent Specific Gravity and Absorption in the mixed
aggregate
• Voids

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The grading of cold feed mixed aggregates shall be determined at least

once per day during mixing.
(b) Mineral filler
The grading and bulk density in toluene shall be determined once per 100
tonnes of filler used, and when the source of filler is changed.
(c) Bituminous mixture (from the mixing plant)
The properties of the bituminous mixture, as appropriate to the type of
mix specified shall be determined every 4 hours or part thereof of mixing
time on samples taken from the mixing plant:
• Bitumen Content
• Grading
• Marshall Stability
• Flow
• Voids
• Absorbed Water
(d) Bituminous mixture (on cores from the compacted layer)
The properties of the bituminous mixture, as appropriate to the type of
mix specified, shall be determined at least once for every 1000 m2 of mix
laid from core samples cut from the compacted layer:
• Bitumen Content
• Grading
• Density
• Voids

227 MEASUREMENT AND PAYMENT

No separate measurement and payment will be made for testing of materials,
trials and construction control testing and the Contractor shall be deemed to have
allowed in his rates and prices for the cost of complying with the requirements of
Section 2 of this Specification.

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3000 SETTING OUT AND TOLERANCES

3001 SETTING OUT
(a) General
The Engineer will provide sufficient basic survey information to enable the
Contractor to set out the Works and the Contractor shall be responsible for
setting out all necessary reference points and for the maintenance thereof.
The Contractor shall satisfy himself as to the accuracy in line, level and
dimension of the basic survey and setting out details provided and should the
Contractor discover any error in the information provided by the Engineer, he
should at once notify the Engineer. If the information is confirmed to be in error
the Engineer will issue amended drawings or instructions regarding the
correction of the error.
Prior to commencing construction, the Contractor shall establish the road reserve
boundary posts in accordance with Clause 2001 of this Specification or if no
boundary posts are instructed then the Contractor shall establish reference
points to define the road reserve at 100 m intervals on both sides.
The Contractor shall establish temporary benchmarks along the road at intervals
not exceeding 200 m and shall provide the Engineer with a schedule of their
levels and locations.
The Contractor shall not remove, damage, alter or destroy in any way plot
beacons or survey beacons of the Survey of Kenya. Should the Contractor
consider that any beacon will be interfered with by the Works he shall notify the
Engineer who, if he considers necessary, will make arrangements for the
removal and replacement of the beacon.
If the Contractor removes or disturbs a beacon without permission of the
Engineer, he shall be liable for the full cost of its replacement and a fine under
the Survey Ordinance, 1951, or any subsequent amendment.
(b) Detailed setting out
In addition to the requirements of Clause 301(a) the Contractor shall set out the
line and level of the Works at intervals of not more than 25 m or such lesser
intervals as are required to construct the Works to the tolerances specified in
Clause 302 of this Specification. Reference pegs and batter rails clearly and
indelibly marked with all the relevant information shall be provided clear of the
road and at right angles to it from which the center line, level and batter slope
can be directly established at any time. These shall be maintained by the
Contractor for as long as they are needed to check the work.
After completion of the setting out and site clearance the Contractor shall take
ground cross sections at intervals of 25 m along the road centerline and along
the centerline of all culverts and structures. These shall be plotted to a natural

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scale off 1:100 on a stable transparent material and a copy of the plot submitted
to the Engineer for agreement. If the Contractor fails to take requisite levels,
levels determined by the Engineer shall be taken as correct.
The Contractor shall programme for a period of 30 days between submitting the
ground cross-sections and being issued with final road, culvert and structure
levels. A minimum 5 km section of road shall be submitted but where the
Contractor submits cross-sections for more than 10 km of road within the same
30 day period the initial 30 day period shall be extended by 30 days for each
additional 10 km or part thereof. Final road, culvert or structure levels will be
determined by the Engineer and may be different from the levels shown on the
Drawings.
On receipt of the final road levels the Contractor shall mark up the details on the
transparencies and the original and one print of the cross-sections shall be
provided free of charge by the Contractor for the Engineer.
On completion of the earthworks but before starting formation or pavement layers
the Contractor shall establish steel pins at a constant offset to the edges of the
carriageway shoulders. The offset nay however vary between sections in cut and
those in fill. The steel pins will be clearly and indelibly marked with all the
relevant information necessary to directly establish the centerline and level at any
point across the carriageway by using either boning rods or a string line.
The interval between pins shall not be more than 12.5 m and the pins shall be
maintained by the Contractor for as long as they are needed by the Engineer to
check the work.
3002 TOLERANCES
(a) Horizontal alignments
Horizontal alignments shall be determined from the centerline of the pavement
surface as shown on or calculated from the Drawings. The centerline of the
pavement surface as constructed, and all other parallel alignments, shall be
correct within a tolerance of ±13 mm therefrom.
(b) Thickness of pavement layers
The average thickness of any pavement layer measured at five points in any
length of 100 m shall not be less than 1.00% nor more than 120% of the
thickness specified or ordered by the Engineer. In addition the thickness of any
pavement layer measured at any point shall not be less than 98% nor more than
125% of the thickness specified or ordered by the Engineer.
(c) Surface levels of pavement layers and formation
The level measured at any point on the surface of a pavement layer or the
formation level shall not deviate from the corresponding level calculated from the
Drawings by more than the tolerances shown in Table 3-1.

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For checking compliance with Table 3-1 measurements of surface levels will be
taken at points to be selected by the Engineer at 12.5m centers longitudinally
and at 2 m centers transversely. At junctions, the grid point spacing shall be
determined by the Engineer.
(d) Surface regularity
The surface regularity of pavement layers and the formation shall be tested at
points decided by the Engineer with a rigid, steel straightedge 3 m long placed
parallel to or at right angles to the centerline of the road. The maximum allowable
deviation of the surface below the straightedge shall be as given in Table 3-1.
In addition the longitudinal slope or transverse cross fall shall not deviate from
that shown on the Drawings by more than the tolerances shown in Table 3-1.
(e) Shoulders
Shoulders shall be constructed to the same surface regularity requirements as
for layers thickness, level and the adjacent pavement
Table 3-1

STRAIGHT SLOPE OR
LAYER LEVEL EDGE CROSSFALL
mm mm %
Bituminous Wearing Course ±10 6 ±0.25
Bituminous Binder Course ±10 6 ±0.25
Base ±10 6 ±0.25
Subbase ±15 10 ±0.5
Gravel Wearing Course ±15 15 ±0.5
Formation +0 20 ±0.5
-50

(f) Cutting and embankment slopes

In the final trimmed slope of cuttings a tolerance of + 0.25 will be permitted, i.e. if
a slope of 1 in 2 is specified, the acceptable slope shall be not steeper than 1 .in
2 or slacker than 1 in 2.25.
In the final trimmed slopes of embankments, a tolerance of +0.25 will be
permitted, i.e. if the specified slope is 1 in 2, the acceptable slope shall be not
steeper than 1 in 2 or slacker than 1 in 2.25.
(g) Width of cuttings and embankments
The tolerance permitted in the width of the bottom of cuttings shall be 200 mm
between the centerline of the road and the toe of the cutting slope.

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The width of embankments measured as the horizontal distance from the

centerline of the road to the top of the embankment shall not be less than that
shown on the Drawings or more than that shown on the Drawings plus 0.25 m.
(h) Depth of side drains
The depth of side drains measured as the vertical height difference from the
centerline of the finished pavement and the invert of the side drain shall not be
less than that shown on the Drawings nor more than that shown on the Drawings
plus 0.15 m.
(i) Construction control testing
Unless otherwise directed values given in this Specification are minimum values
and the workmanship will only be considered as satisfactory if all tests, taken at
the frequency specified in Section 2 of this Specification are at least equal to that
specified in the relevant section.
3003 RECTIFICATION OF EARTHWORKS AND PAVEMENT LAYERS OUTSIDE
PERMITTED TOLERANCES
Where any tolerances in Clause 302 are exceeded, the Contractor shall
determine the full extent of the area which is out of tolerance and shall make
good the surface of the pavement course, earthworks or formation in the manner
described below.
(a) Earthworks
Where a cutting slope is steeper, and an embankment slope is slacker, than the
specified slope then the slope shall be trimmed to the specified slope. Where a
cutting slope in slacker, and an embankment slope is steeper, than the specified
slope then the slope shall be benched and fill material placed and compacted
and the slope shall be trimmed all in accordance with the requirements of Section
5 of this Specification.
Where the width of a cutting is less than, and the width of an embankment more
than, the specified width then the cutting or embankment shall be trimmed to the
specified width. Where the width of a cutting is more than, and the width of an
embankment is less than the specified width then the embankment or cutting
shall be benched and fill material placed and compacted and the slopes shall be
trimmed all in accordance with the requirements of Section 5 of this Specification.
Where the depth of a side drain is less than that specified the side drain shall be
trimmed to the specified depth. Where the depth of a side drain is more than
specified the side drain shall be backfilled with fill material compacted to a dry
density of at least 95% MDD (AASHTO T99) up to the specified depth.
Where the results of the construction control tests are less than that specified the
full depth of the layer shall be reworked to specification. The area treated shall be
the whole section submitted for approval or, following a retest, a length of at least

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50 m both sides of each test and retest failure or such area to be determined by
the Engineer as necessary to obtain compliance with this Specification.
(b) The 300 mm layer below formation level
Where the levels or widths are out of tolerance then the full depth of the layer
shall be reworked to specification. The area treated shall be at least 12.5m long
and 3 m wide or such area to be determined by the Engineer as necessary to
obtain compliance with this Specification.
Where the results of the construction control tests are less than that specified the
full depth of the layer shall be reworked to specification. The area treated shall be
the whole section submitted for approval or following a retest a length of at least
50 m both sides of each test and retest, failure.
(c) Base and subbase
Where these consist of unbound (i.e. natural or graded stone) material the full
depth of the material shall be removed from the pavement and replaced to
specification. The area treated shall be at least 30m long and 3m wide or such
area to the determined by the Engineer as necessary to obtain compliance with
this Specification.
Where the courses consist of cement or lime treated material or lean concrete
the full depth of the layer shall be removed from the pavement and replaced to
specification. The area treated shall be at least 5 m long and the full width of the
paving laid in one operation. If areas are corrected within 7 days of laying, no
construction traffic or compaction plant shall use the surrounding satisfactory
areas.
For bituminous bases the full depth of layer shall be removed and replaced with
fresh material laid and compacted to specification. Any area so treated shall be
at least 5 m long and the full width of the paving laid in one operation.
Where the results of the construction control tests for any of the base or subbase
materials are less than that specified the full depth of the layer shall be removed
and replaced to specification. The area treated shall be the whole section
submitted for approval or, following a retest, a length of at least 50m both sides
of each test and retest failure or such area to be determined by the Engineer as
necessary to obtain compliance with the Specification.
(d) Wearing course
These shall have the full depth of the layer removed and replaced with fresh
material laid and compacted to specification. The area rectified shall be the full
width of the paving laid in one operation and at least 15m long.
Where the results of the construction control tests for the wearing course are less
than that specified the full depth of the layer shall be removed and replaced to
specification. The area treated shall be the whole section submitted for approval

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or, following a retest, a length of at least 50m both sides of each test and retest
failure or such area to be determined by the Engineer as necessary to obtain
compliance with this Specification.
3004 MEASUREMENT AND PAYMENT
The Contractor shall be deemed to have allowed in his general rates and prices
for the cost of complying with the requirements of Clauses 301, 302 and 303 of
this Specification.
Notwithstanding the provisions of Clauses 302 and 303 of this Specification,
measurement and payment for earthworks and pavement works shall be made
on the basis of the net cross-section ordered by the Engineer and no additional
payment shall be made in respect of variation within or without the specified
tolerances.

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400 SITE CLEARANCE AND TOPSOIL STRIPPING

401 SITE CLEARANCE

(a) General
Site clearance is defined as the clearing, grubbing, removal and disposal of
all vegetation, grass, debris, bushes, scrub, dense bush, trees, hedges,
undergrowth, stumps, roots, shrubs plants and the backfilling of holes left by
the removal of stumps and roots.
The width and length over which site clearance is to be carried out shall be as
shown on the Drawings or instructed by the Engineer.
Site clearance over the area of quarries, borrow pits, stockpiles, spoil tips,
road junctions, ditches and drains and other areas shall be carried out where
shown on the Drawings or instructed by the Engineer.
The Engineer may give instructions that specific trees, stumps or objects
shall not be removed during the site clearance operation.
(b) Clearing, except trees
Where the Engineer instructs that site clearance is required, the entire area
shall be cleared and all materials thus cleared shall become the property of
the Employer. Unless otherwise instructed, vegetation and perishable
materials shall be disposed of by burning. Where material or debris cannot be
burnt, it shall be carted to spoil areas, which spoil areas shall be provided in
accordance with requirement of Section 6 of this Specification.
If the Contractor clears the Site in advance of the main Works such that grass
and other vegetation re-grows prior to the main Works commencing at any
particular location then any additional, or repeating of, site clearance required
shall be at the Contractor's expense.
(c) Removal of trees
Trees outside the construction width but within the road reserve having a
trunk girth of more than 450mm at a point 600mm above the ground shall not
be cut down without the prior approval of the Engineer.
Where the Engineer instructs that site clearance is required, trees not
designated to remain shall be uprooted or cut down as near to ground level
as possible, and shall be either burnt, or, where the Engineer instructs that
they shall be saved, the trunk and branches shall be cut into convenient
lengths and stacked neatly off the line of the road and shall become the
property of the Employer and shall be preserved and protected by the
Contractor until removed by the Employer or until the expiry of the period of
Maintenance. The remainder of the trees shall be disposed of by burning.

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Stumps and tree roots shall be grubbed up and burnt. All holes left by
removal of stumps and roots shall be backfilled with approved material
compacted to 95% MDD (AASHTO T99) up to the existing ground level or up
to the formation level if the area is in cut.

402 REMOVAL OF TOPSOIL

Where shown on the Drawings or directed by the Engineer the Contractor shall
remove topsoil. The depth of the topsoil shall be as directed by the Engineer but
shall not exceed 200 mm. At any cross-section the depth instructed may vary
and such variation may occur both along the road and across the cross-section.
Where directed by the Engineer the Contractor shall, prior to removal of topsoil,
excavate trial holes of a depth sufficient to enable the Engineer to measure the
depth of topsoil. Where topsoil is found to depths greater than 200 mm that
portion below 200 mm shall, if required by the Engineer, be treated as fill or spoil
in accordance with the requirements of Section 5 of this Specification.
Topsoil shall be stripped, loaded, transported and deposited in stockpile areas,
which stockpiles areas shall be provided in accordance with the requirements of
Section 6 of this Specification.
Should the Contractor strip to depths greater than those instructed by the
Engineer, then the Contractor shall replace the material with fill material at the
Contractor's expense.

403 REMOVAL OF STRUCTURES, FENCES AND OBSTRUCTIONS

When instructed by the Engineer, the Contractor shall demolish wholly or in part,
remove and dispose of all buildings, foundations, structures, fences and any
other obstructions -which have not been designated to remain.
The Contractor shall carefully take down such buildings, structures, fences etc.
and the components shall be dismantled, cleaned and stacked in separate
heaps. All materials which, in the opinion of the Engineer, are not fit for re-use
shall be removed from the Site to spoil areas provided in accordance with the
requirements of Section 6 of this Specification. All materials which are re-usable
shall remain the property of the Employer and shall be preserved and protected
by the Contractor until removed by the Employer or until the expiry of the Period
of Maintenance.

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404 PROTECTION OF FENCES, TREES, HEDGES ETC.:

All existing paths, fences, walls, hedges, trees, shrubs, lawns and other features
which the Engineer instructs shall not be removed or otherwise dealt with, shall
be protected from damage, and any damage which occurs due to the
Contractor's failure to 'take adequate precautions shall be repaired at the
Contractor's expense.

405 MEASUREMENT AND PAYMENT

(d) Item : Site clearance
Unit: ha
Site clearance shall be measured by the hectare calculated as the plan area
instructed by the Engineer to be cleared.
The rate for site clearance shall include for the cost of complying with the
requirements of Clauses 401 and 404 of this Specification.

(e) Item : Removal of topsoil

Unit: m3
Removal of topsoil shall be measured by the cubic metre calculated as the
product of the plan area measured from cross-sections taken prior to site
clearance and the vertical depth of topsoil instructed to be removed.
The rate for removal of topsoil shall include for the cost of all hauls as
necessary and compliance with the requirements of Clauses 402 and 404 of
this Specification.
(f) Item : Allow for the removal of structures and obstructions
Unit: Provisional Sum
Payment will be made on a day work basis where the Engineer orders the
removal of structures and obstructions.

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500 EARTHWORKS
501 SCOPE OF SECTION
This Section covers all excavation of cuttings, which for the purposes of this
Section includes side drains and benches, the placing and compaction of hard
and soft material for fill in embankments, ground compaction, the formation- of
the subgrade, excavation and rock fill to swamps and top soiling and grassing.

502 GENERAL
All earthworks shall be constructed as shown on the Drawings or as directed by
the Engineer to the specified slopes, levels, depths, widths, tolerances and
heights. Should any earthworks not be constructed to the slope, level, depth,
width, tolerance or height shown on the Drawings or as directed by the Engineer
the Contractor shall make good the area affected at the Contractor's expense.

The Contractor shall excavate cuttings and place fill in embankments in

accordance with the Drawings or as directed by the Engineer. Suitable excavated
materials will be used to form embankments, excess or unsuitable materials
being disposed of to spoil areas. Where the mass haul diagram in accordance
with Clause 509 of this Specification indicates that the quantity of material
required for embankments exceeds that available from cuttings, the Contractor
will be instructed by the Engineer to widen cuttings and/or to open borrow pits.

At all times the Contractor shall ensure that earthworks are not damaged by
weather or traffic. In the event of such damage occurring the Engineer may
withdraw approval from the affected Works until the Contractor has carried out
repairs to restore the Works to their original condition. The expenses of all such
repairs and any additional testing will be borne by the Contractor.

The Contractor shall provide adequate supervision to ensure that only suitable
materials are incorporated in embankments. If any unsuitable material is included
it shall be removed and replaced with suitable material at the Contractor's
expense.

All trimming of cuttings, embankments, side drains, and shoulders to the

specified slopes and shapes shall be carried out concurrently with the earthworks
that are being carried out at that particular site and level.

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503 CLASSIFICATION OF MATERIAL

There shall be two classifications of material, that is "hard material" and "soft
material" which shall be defined as follows:-

(a) Hard material

Hard material shall be material which cannot be ripped to an average depth

of rip greater than 300mm by a track type crawler tractor complying with the
following:

(i) in good order complete with all equipment and accessories as supplied;

(ii) rated 300 BHP flywheel power or over;

(iii) with an operating weight of not less than 37.2 tonnes;

(iv) equipped with a hydraulically operated single tine ripper compatible with
the tractor used; and

(v) operated by a qualified operator in accordance with the manufacturer's

recommendations and to the satisfaction of the Engineer.

Where it is impractical to prove hard material by the above method then the
quantity of hard material, if any, shall be determined by the Engineer.

Where excavation contains individual boulders of hard material greater than

0.3 m3 each in volume then such boulders shall be classified as hard material.

Hard material shall not be placed within 600 mm of the formation level in
embankments and shall be removed to a depth of 300 mm or as otherwise
instructed by the Engineer below formation level in cuttings.

(b) Soft Material

Soft material shall be all materials other than hard material. Soft material shall
include waterlogged and swampy material except within swamps covered by
Clause 506 of this Specification.

504 PREPARATION PRIOR TO FORMING EMBANKMENTS

The Contractor shall excavate benches in natural ground having a side slope
greater than 1 in 5 or as instructed by the Engineer. The existing slopes, after the
removal of topsoil shall be benched in accordance with the Drawings prior to the
construction of embankments. The material which is excavated to form benches
shall either be taken to spoil or if suitable used as fill. The actual bench widths
will be shown on the Drawings or Instructed by the Engineer.

The existing ground under embankments, and bench surfaces where

appropriate, shall be compacted over the full width of construction to 95% MDD
(AASHTO T99) to a depth of 150 mm. The existing ground moisture content shall

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be adjusted prior to compaction by either uniformly mixing in water or drying out

the material such that at the time of compaction the moisture content shall be
within the range 75 - 105% of the Optimum Moisture Content (AASHTO T99).

Whenever the existing ground is unsuitable in quality for receiving fill, the
Contractor shall excavate to the depth instructed by the Engineer, remove the
material to a spoil area and replace it with suitable material.

505 CONSTRUCTION OF EMBANKMENTS

Material obtained from cuttings shall be used to construct embankments. Material
from borrow pits shall be used only where the Contractor has demonstrated and
the Engineer agreed that there is an inadequate quantity of suitable material
obtainable from cuttings.

The Contractor may, to suit his method of working, take suitable fill material
obtained from cuttings to spoil provided he substitutes an equivalent quantity of
suitable fill material from a borrow pit or other source. The Contractor shall be
solely responsible for the acquisition of land for the spoil and borrow areas
required in these circumstances and any additional costs due to the substitution
over and above the cost of taking the material from cuttings or benches to fill
shall be at the Contractor's expense.

Soft material f for in the 300 mm below formation level in both embankments and
cuttings shall not contain particles larger than 25 mm. In addition the material
shall have a CBR of not less than 8% measured after a 4-day soak on a
laboratory mix compacted to a dry density of 100% MDD (AASHTO T99), a swell
of less than 1% and a Plasticity Index of less than 50%. In-situ material in the
300 mm below formation level in cutting that does not meet these requirements
shall either be spoiled or if suitable placed in the embankment and replaced with
material from cuttings or borrow pits that does meet the requirements for soft
material for use in the 300 mm below formation level.

Where materials of differing quality are available for placing in embankments the
Engineer may instruct that certain materials should be excluded from the upper
300mm of fill and he may instruct that certain materials should be set apart, or
obtained from borrow pits, for use in these upper layers. He may also instruct
that part or all of these upper layers be stabilised using either cement or lime in
accordance with Section 14 of this Specification. The extent of stabilisation will
be detailed in the Special Specification or shown on the Drawings.

The Contractor shall ensure that earthworks proceeds towards completion in an

orderly and continuous manner. The Contractor shall submit a written request for
approval of any layer at least 18 working hours before he intends to cover a
completed layer. Fill material for subsequent layers shall be placed immediately
approval of the previous layer has been given to ensure retention of moisture.

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Should any layer be left unprotected for more than 24 hours subsequent to
approval, the Contractor shall request re-approval of such layer.

Soft material as fill shall be deposited in layers not exceeding 150mm compacted
depth unless, as a result of site compaction trials, the Contractor has satisfied the
Engineer that his compaction plant is capable of consistently achieving the
specified densities at a greater depth; in no case shall this depth exceed 250
mm. Each layer shall extend over the full width of the embankment and shall be
compacted in accordance with Clause 508.

Hard material used for fill shall be of maximum dimension 250 mm, and be
deposited in horizontal layers not exceeding 400 mm loose depth and shall
extend over the full width of the embankment except for any specified external
cover to slopes. The material shall be spread and levelled by a crawler tractor
weighing not less than 15 tonnes. Each layer shall consist of reasonably well
graded rock and shall be blinded with smaller rock fragments and gravel so as to
fill as many of the voids as possible before the next layer is placed. The top 600
mm of the subgrade shall be formed using soft material.

In forming embankments, the Contractor shall make due allowance in height and
width for consolidation, settlement and shrinkage. Any consolidation, settlement,
bulking, punching of material into the underlying layer, or shrinkage during the
construction of embankments shall be rectified by the Contractor by providing,
placing and compacting approved fill material to reinstate each layer to the
instructed level and width and shall be at the Contractor's expense.

During the construction of embankments the Contractor shall control and direct
constructional traffic uniformly over the full width. Fill material shall not be
stockpiled on embankments without the express permission of the Engineer

When constructing embankments up to bridges and up- to and over culverts, the
Contractor shall raise the embankment equally on each side of such structures
and shall unless otherwise instructed by the Engineer carryout this work
concurrently with the filling to the structure. The embankment compaction plant
shall be used as close to the structure as is feasible without damaging the
structure. Any damage to the structure will be made good at the Contractor's
expense.

506 SWAMPS
Areas that are to be classified as swamps will be identified and the treatment
thereof specified in the Special Specification. All areas other than those so
specified shall be considered as normal earthworks and the Contractor's rates
shall include for all the requirements of Clause 114 of this Specification.

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507 ROCKFILL TO SWAMPS

Where specified in the Special Specification or instructed by the Engineer the
Contractor shall place rockfill to swamps. The rockfill shall be obtained from a
rock quarry and shall be loaded, transported from a rock quarry, placed in
uniform layers rolled and trafficked until it is fully embedded over the whole area
instructed. The rockfill shall be of maximum dimension 250 mm, reasonably well
graded and with not more than 5% finer than 10 mm. The layer thickness and
number of layers shall be as instructed by the Engineer who may vary the
requirement during the rockfill operation. Each layer shall be blinded with smaller
rock fragments so as to fill as many of the voids as possible before the next layer
is placed. Before additional layers are placed or before normal earthworks
resume the Contractor shall proof roll each layer in accordance with Clause 512
of this Specification.

Where instructed by the Engineer the Contractor shall place a filter fabric
(‘Terram’ or similar approved) under or around the rockfill. When placing the
rockfill onto or in the filter fabric the Contractor shall ensure that the filter fabric is
not punctured or damaged in any way. Where the filter fabric is placed around
the rockfill the final layer of rockfill shall be blinded with gravel so as to present a
smooth surface to receive the filter fabric. The filter fabric shall be installed in
accordance with the manufacturer's instructions.

Where instructed by the Engineer, the Contractor shall first excavate unsuitable
material and then place and embed rockfill on and into the underlying material, or
on a filter fabric if specified by the Engineer.

508 COMPACTION OF EARTHWORKS

The moisture content of fill material, except the 300 mm below formation, shall be
adjusted immediately prior to compaction by either uniformly mixing in water or
drying out the material such that the moisture content during compaction is
between 75% and 105% of the Optimum Moisture Content (AASHTO T99). The
300 mm below formation in both embankments and cuttings shall be adjusted by
either uniformly mixing in water or drying out the material such that the moisture
content during compaction is between 75% and 100% of the Optimum Moisture
Content (AASHTO T99). The moisture content shall be kept within these limits
until compaction is complete except where otherwise instructed by the Engineer.

Each layer of material shall be compacted at a moisture content within the above
limits to a dry density equal to at least the percentage of the Maximum Dry
Density (MDD) specified below:-

(i) All fill material in embankments, except the 300 mm below formation: 95%
MDD (AASHTO T99)

(ii) The 300 mm below formation in embankments: 100% MDD (AASHTO T99)

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(iii) The 300 mm below formation in cuttings under the carriageway and
shoulders: 100% MDD (AASHTO T99).

Compaction under and in embankments, and on the 300 mm below formation in

cuttings, shall be completed to the procedures proposed by the Contractor in
accordance with Clause 224 of this Specification. The 300 mm below formation
in both fill areas and in cuttings shall be completed in two 150 mm compacted
layers.

Each layer of hard material used as fill in embankments shall be systematically

compacted by at least 8 passes of a towed vibrating roller weighing not less than
5 tonnes dead weight or a grid roller weighing not less than 13 tonnes dead
weight or other approved plant. During compaction the surface of the layer shall
be watered as necessary to facilitate the filling of the voids with the blinding
material.

In accordance with Section 2 of this Specification the Contractor shall submit to

the Engineer his proposals for the compaction of each main type of material to be
used in the embankments, including those in relation to the types of plant, the
range of passes and the loose depth of layer. The Contractor shall carry out site
compaction trials, supplemented by any necessary laboratory investigations
using the procedure proposed by the Contractor for earthworks and shall satisfy
the Engineer that all the specified requirements regarding compaction will be
achieved. Site compaction trials with the main types of material likely to be
encountered shall be completed before the permanent Works with corresponding
materials commences.

The Contractor shall provide all water necessary for compaction. The water to be
used shall be clean and fresh, free from all Impurities and shall be obtained from
a source approved by the Engineer. The Contractor shall if required by the
Engineer arrange for the analysis of water to demonstrate compliance with this
Specification.

The Contractor shall provide all plant necessary for conveying and distributing
water. Water shall be evenly sprinkled on the surface of the fill material by
machines of a type approved by the Engineer, and capable of distributing water
at a known, predetermined and constant rate.

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509 MASS HAUL DIAGRAM

The mass haul diagram which is included in the Drawings is a guide only and
must be considered as such by the Contractor. The final measurement and
quantities will be determined from the actual ground cross sections and final road
levels and the mass haul diagram adjusted accordingly.

In the event of any realignment being instructed a revised mass haul diagram will
be prepared for that realignment and agreed between the Contractor and the
Engineer.

In the event that the Contractor elects to spoil suitable fill material from cuttings
and substitute material from borrow pits, the mass haul diagram will not be
amended and the quantities and distances determined from the adjusted mass
haul diagram as referred to in the first paragraph of this clause shall apply.

Where unsuitable material is encountered in cuttings it shall be replaced if

required by suitable material from borrow pits or widened cuttings. The mass
haul diagram will be adjusted to take account of the change.

The mass haul diagram will be drawn 'in fill' on the basis that 1m3 of material
obtained from cuttings will on being compacted into the embankments produce
0.8m3 of fill unless otherwise specified in the Special Specification. No allowance
will be made for variations in materials, wastage, or consolidation etc. as referred
to in Clause 505 of this Specification.

510 SPOIL MATERIAL

Spoil material shall be material which, being obtained from cuttings, is surplus to
that required for fill and/or unsuitable material from cuttings which the Engineer
has instructed to be excluded from use as fill in embankments, and/or unsuitable
material from beneath embankments or below formation level in cuttings which
the Engineer has instructed to be spoiled.

Spoil material shall be deposited in spoil areas located by the Contractor subject
to the approval of the Engineer and the Contractor shall give the Engineer at
least 24 hour notice of his intention to commence spoiling operations at a
particular location.

511 BORROW PITS

Fill material which is required in addition to that provided by the excavation, or
widening of cuttings shall be obtained from borrow pits which shall be located by
the Engineer.

Should the Contractor locate alternative borrow pits then he shall obtain the
Engineer's approval to such borrow pits. In such instances no additional
payments will be made for such borrow pits over and above such payment as
would have been made for borrow pits located by the Engineer.

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The Engineer may direct that materials be selected in borrow pits which may
include double handling, stockpiling and excavation in particular areas of a
borrow pit.

The Contractor shall construct all accesses, clear and remove all ant hills, ants,
nests, vegetation, boulders and unsuitable or oversize material. The Contractor
shall provide adequate supervision in every borrow pit to ensure that suitable
material is not contaminated with unsuitable material. Unsuitable material shall
be spoiled in accordance with Clause 510 of this Specification.

Borrow pits shall be excavated to regular widths and shapes and shall be
cleaned up on completion so that the sides are neatly trimmed and the bottoms
levelled and drained away from the Works all in accordance with the provisions
of Section 6 of this Specification.

512 PROOFROLLING
All subgrade and, embankment layers, cuttings, benches-and original ground
shall be proof rolled with a loaded scraper or truck with a minimum axle load of 8
tonnes. Proof rolling shall be satisfactorily completed before the layer is
submitted to the Engineer for approval and shall be carried out in the presence of
the Engineer. All such proof rolling shall be at the Contractor's expense.

513 TRIMMING OP SLOPES

The slopes of cuttings and embankments shall be trimmed by hand or by
approved mechanical means to uniform batters as shown on the Drawings or as
instructed by the Engineer. Such trimming shall be completed before the
commencement of sub base construction.

Any rock or boulder appearing in the face of a cutting or embankment shall be

trimmed back to within the tolerance specified and in addition any such rock or
boulder which is unstable shall be completely removed and the resulting void
filled with suitable material compacted to the approval of the Engineer.

514 TOPSOILING AND GRASSING

Where specified or instructed by the Engineer, the Contractor shall provide
protection to embankment slopes, cut faces, side drains, shoulders, guiding
dams and spoil or borrow areas by one of the following means:-

(a) Grassing

(b) Topsoiling and grassing

Where grassing is required the Contractor shall plant sprigs of approved

indigenous 'runner' type grass at 150 mm centres. The Contractor shall care for
and water the grass until it is firmly established.

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Where topsoiling is required prior to grassing the minimum compacted thickness

of topsoil shall be 50 mm and the quality of the topsoil shall be to the approval of
the Engineer. Light compaction shall be carried out to the approval of the
Engineer.

The Contractor shall ensure that neither his watering nor rainfall or rainfall runoff
from adjacent areas washes out the topsoil or grass, and any damage before the
grass is firmly established shall be rectified at the Contractor's expense.

515 SIDE DRAINS

Side drains are considered as cuttings in accordance with Clause 501 of this
Section of this Specification and the excavation thereof is classified as
earthworks. The Engineer may during the course of the Works instruct
amendments to the dimensions, slopes and depths of side drains and providing
such amendments are instructed before the completion of earthworks in the
section side drains will continue to be considered as cuttings and the excavation
thereof classified as earthworks. Where the side drain detail is amended after
completion of earthworks in the section, then such additional excavation shall be
classified as excavation of catchwater drains in accordance with Section 8 of this
Specification.

516 TREATED MATERIALS

Lime or cement treatment if required by the Special Specification or Drawings
shall be carried out on subgrade materials that comply with the requirements of
Section 5 and shall be treated in accordance with Section 14 of this Specification.

517 MEASUREMENT AND PAYMENT

Unless specified otherwise, the method of computation of volumes will be that of
average end areas and centerline distances between cross-sections taken at
25m intervals. In irregular ground or tight curvature the Engineer may direct that
ground cross-sections are taken at closer intervals.

Earthwork fill shall be measured by the cubic metre of compacted material

measured in the completed embankment. No separate measurement or payment
shall be made for excavating material to form embankments.

Where the mass haul diagram indicates that fill material is required in addition to
that provided by the excavation, including widening of cuttings, and the Engineer
instructs the opening of a borrow pit, separate measurement and payment shall
be made for:-

(i) Site clearance of the borrow area and access road per hectare in accordance
with Section 4 of this Specification.

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(ii) Removal of topsoil (if instructed by the Engineer to be stockpiled separately)

from the borrow area per cubic metre in accordance with Section 4 of this
Specification.

(iii) The construction of access road, per km, in accordance with Section 9 of this
Specification.

(iv) Removal to topsoil and/or overburden, as "Spoil", from the borrow area per
cubic metre in accordance with Section 5 of this Specification.

Excavation to spoil of unsuitable material (as defined in Clause 510 of this

Specification) shall be measured as the volume of the excavation formed.
Measurement of spoil of surplus material shall be measured by the volume of
“cut” taken from the mass haul diagram prepared in accordance with Clause 509
of this Specification.

Material shall be classified as either hard or soft in accordance with Clause 503
of this Specification.

(a) Item : Fill in soft material

Unit: m3

The rate for fill in soft material shall include for the cost of excavating the
material either from cutting, bench or borrow pit, loading, transporting a free
haul of 1.0 km and depositing the material in an embankment or other area
requiring fill, trimming, shaping and compacting, and complying with the
requirements of Clauses 502, 504, 505, 508, 509, 511, 512 and 513 of this
Specification.

(b) Item: Fill in hard material

Unit: m3

The rate for fill in hard material shall include for the cost of excavating the
material from cutting, loading, transporting a free haul of 1.0 km and
depositing the material in an embankment or other area requiring fill, breaking
down the material, production of rock fragments, trimming, shaping and
compacting, blinding, and complying with the requirements of Clauses 502,
504, 505, 508, 509, 512 and 513.

(c) Item: Spoil in soft material

Unit: m3

The rate for spoil in soft material shall include for the cost of excavating the
material, loading, transporting a free haul of 1.0 km and depositing the
material in a spoil area, providing trimming, shaping and topsoiling spoil

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areas in accordance with Section 6 of this Specification, and complying with

the requirements of Clauses 502, 504, 510, 511 and 513 of this Specification.

(d) Item: Spoil in hard material

Unit: m3

The rate for spoil in hard material shall include for the cost of excavating the
material, loading, transporting a free haul of 1.0 km and depositing material in
spoil areas, providing trimming, shaping and topsoiling spoil areas in
accordance with Section 6 of this Specification, and complying with the
requirements of Clauses 502, 504, 509, 510, 513 of this Specification.

(e) Item: Overhaul

Unit: m3km

Overhaul shall be measured by the unit m3km calculated as the product of

'Overhaul Earthworks' in cubic metres and 'Overhaul Distance' in kilometres
all as shown on Figure 5-1.

The distance between the centres of volume of cut and fill shall be measured
along the centreline of the new road. Should the Contractor elect to haul by a
different route no additional measurement or payment will be made.

FIGURE 5-1

Diagram showing method of computation of

Free haul and overhaul on typical mass haul section

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NOTES:-

1) A & B are centres of volume of Free Haul Earthworks

2) C & D are centres of volume of Overhaul Earthworks.

3) M N is limit of Free Haul.

4) Free Haul Earthworks = V

5) Overhaul Earthworks = VI

6) Overhaul Distance = CD - 1.0

7) Overhaul = VI (CD - 1.0) m3km

Cut and fill volume for ramps, slip roads, junctions, road approaches, and
connections on either side of the road shall be considered as concentrated at the
centreline of the road.

The distance between the centres of volume of borrow pits and fills and for cut to
spoil material shall be measured along the shortest route determined by the
Engineer as feasible and satisfactory. If the Contractor chooses to haul
earthworks material over some other longer route, computations for
measurement shall nevertheless be based on the distance measured along the
shortest route designated by the Engineer. |

The mean "Free Haul Distance" for all materials to which "Overhaul" shall apply
shall be one kilometre.

"Overhaul" shall be calculated on the basis of a Mass Haul Diagram approved by

the Engineer. Any change in the earthworks material utilization shall be subject to
the Engineer's approval.

The rate shall include for the cost of haulage in excess of the free haul and the
maintenance of the haul road

(f) Item : Compaction of existing ground

Unit: m3

The volume of existing ground compacted shall be calculated as the product

of the plan area and the vertical compacted thickness specified.

The rates for compaction of existing ground shall include for scarifying,
supplying and mixing in water or drying the material, levelling and compacting
and complying with the requirements of Clauses 502, 504, 508, and 512 of
this Specification.

(g) Item : Compaction of the 300mm below formation level

in cutting to 100% MDD (AASHTO T99)

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Unit: m3

The rate for compaction of the 300 mm below formation level in cutting shall
include for compacting underlying material as necessary to achieve the
specified compaction in the 300 mm below formation level, compacting that
300 mm of subgrade in two 150 mm layers including the removal of the upper
150 mm to allow the compaction of the lower 150 mm, scarifying, supplying
and mixing in water or drying the material, levelling and compacting and
complying with Clauses 502, 503, 504, 508, 510, 511, 512 and 513 of this
Specification.

(h) Item: Extra over (a) for compaction of top

300mm to 100% MDD (AASHTO T99)
Unit: m3

The rate for extra over Clause shall include 517(a) “Fill in soft material” for
compaction of the 300 mm below embankments to 100% MDD (AASHTO
T99) shall include for compacting underlying material as necessary to
achieve the specified compaction in the 300 mm below formation level,
compacting that 300 mm of subgrade in two 150 mm layers, scarifying,
supplying and mixing In water or drying out the material, levelling and
compacting and complying with Clauses 502, 503, 504, 505, 508, 511, 512
and 513 of this Specification.

(i) Item: Excavation in swamps

Unit: m3

The rate for excavation in swamps shall include for the cost of excavating the
material, loading, transporting and depositing the material on a spoil areas,
trimming shaping and topsoiling of spoilt areas in accordance with section 6
of this specification, all additional excavation required to achieve the
instructed area and depth, excavating underwater, a free haul of 1.0 km and
complying with the requirements of clause 506 and 507 of this specification.
Overhaul will be measured in accordance with Clause 517 (e) of this
specification

(j) Item: Rockfill

Unit: tonne

Rockfill shall be measured by the number of tonnes instructed to be placed.

The rate for rockfill shall include for the cost of providing the material, all
hauls as necessary and complying with the requirements of Clause 507 of
this Specification.

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(k) Item: Filter fabric under, over or around rockfill

Unit: m2 of each weight of fabric specified

The filter fabric placed under, over or around rockfill shall be measured as the
net area of filter fabric instructed.

The rate for filter fabric shall include for the cost of the preparation of the
surface to receive the filter fabric, the provision, transport, storing and laying
the fabric in accordance with the manufacturer's instructions, all laps and/or
stitching and for complying with Clauses 506 and- 507 of this Specification.

(l) Item : Topsolling

Unit: m2 for each situation

Topsoiling shall be measured by the square metre calculated as the net area,
measured on the slope, instructed by the Engineer for each different situation
i.e. side drain, embankment, etc.

The rate for topsoiling shall include for the cost of providing the topsoll, all
hauls as necessary and complying with the requirements of Clause 514 of
this Specification.

(m) Item: Grassing

Unit: m2 for each situation

Grassing shall be measured by the square metre calculated as the net area,
measured on the slope, instructed by the Engineer for each different situation
i.e. side drains, embankments, etc.

The rate for grassing shall include for the cost of providing and establishing
the grass sprigs and complying with the requirements of Clause 514 of this
Specification.

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600 QUARRIES, BORROW PITS, STOCKPILE AND SPOIL AREAS

601 GENERAL
Unless stated otherwise in the Special Specification, it is the responsibility of the
Contractor to select the sources of aggregate for concrete and lean concrete,
stone for bases and subbases, bituminous mix bases, binder courses and
wearing "courses, chippings for surface dressings and rockfill for swamps. Such
sources shall be designated as quarries and are defined in Clause 602 (a). Such
potential quarry sites as may have been identified prior to commencement of the
Contract and were available for inspection at the time- of tender will also be the
responsibility of the Contractor should the elect to use them.
The sources of natural materials such as fill material for the construction of
embankments, and gravel for subbase, base, surfacing and shoulders shall be
designated as borrow pits and are defined in Clause 602 (b). Certain borrow pits
have been identified prior to commencement of the Contract and the Engineer
will instruct the Contractor as to which of these are to be utilised for the extraction
of natural material, to be used in the Works.
Provisions are included in subsequent clauses of this Section of the Specification
for additional borrow pits to be identified and located by the Contractor during the
Contract. Stockpile and spoil areas shall be located by the Contractor subject to
the approval of the Engineer.
602 DEFINITIONS
(a) Quarry
A quarry is an open surface working from which stone is removed by drilling
and blasting for use in the Works.
(b) Borrow pit
A borrow pit is a site from which material, other than stone, is removed for
use in the Works.
A borrow pit may have been selected by the Engineer and be available for
inspection at the time of Tender or alternatively it may be one proposed by
the Contractor and approved by the Engineer during the Contract.
(c) Stockpile area
A stockpile area is an area where material such as topsoil, fill material, gravel
or aggregate is stockpiled prior to use in the Works.
(d) Spoil area
A spoil area is a site upon which surplus or unsuitable materials arising out of
the Works are dumped. Surplus or unsuitable material shall not be dumped
within the road reserve without the approval of Engineer.

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603 PROVISION OF LAND

The Employer shall make available free of charge to the Contractor and be
responsible for acquisition of all land required for quarries, borrow pits, spoil and
stockpile areas and for access thereto in accordance with Section 1 of this
Specification.
The location and size of quarries, borrow pits, spoil and stockpile areas proposed
by the Contractor shall be subject to the approval of the Engineer. The Engineer's
approval may be withheld for any of the following reasons:-
If the quarry, borrow pit, spoil or stockpile area, or access into then, in the opinion
of the Engineer:
(a) is less than 3 km from the next quarry, borrow pit, spoil or stockpile area;
(b) will have a detrimental effect on the environment;
(c) will incur relatively high land acquisition costs or would be very difficult to
acquire;
(d) is in or near an urban centre
(e) will require an access road which is excessively long;
(f) has excessively thick layers of overburden;
(g) covers too large an area;
(h) would constitute a danger to the public;
(i) is an excessive distance from the location the material is to be used 0^
removed from; or
(j) a source of suitable material is closer at hand.
The Contractor shall inform the Engineer in writing not later than 90 days after the
Engineer's order to commence work (Clause 41 of the Conditions of Contract) of
all quarries, borrow pits, spoil and stockpile areas that the Contractor will require
for the whole of the Works and the Contractor shall programme for a period of 90
days from the date of the Contractor's written notice to the date when the
Engineer makes the quarries, borrow pits, spoil and stockpile areas available to
the Contractor. Prior to the submission of written notice the Contractor shall set
out each quarry, borrow pit, spoil and stockpile area with concrete beacons
clearly identifying the areas required for working areas, stockpile areas, blasting
safety tones and access routes. The Contractor's written notice shall include the
following for each quarry, borrow pit, stockpile and spoil area:-

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(1) A plan at 1:500 scale in ink on a stable transparent material giving details of:
(i) plot boundaries;
(ii) owners' names and addresses, and if appropriate ID numbers;
(iii) the District, Location, Registration Section and Number for each plot;
(iv) local details such as buildings, fences, graves, types and areas of
cultivation and services, all agreed with the land owners; and (v) areas to
be used for working areas, stockpile areas, blasting safety zones etc.
(2) Cadastral maps covering the areas to be acquired.
(3) Details of the proposed access road route.
Where Contractor uses a quarry or borrow pit identified or instructed by the
Engineer he shall obtain the Engineer's approval of the areas required for the
quarry or borrow pit and of the siting of the access toads into the quarry or borrow
pit. The Engineer may require the Contractor to modify his requirements for any
of the reasons outlined in (b), (c), (d), (e), or (g).
Where borrow pits, available for inspection at the time of Tender, are instructed
by the Engineer the Contractor shall satisfy himself as to the quality and quantity
of material available before providing the information required in this Clause,
Should such investigations reveal that there is insufficient suitable material for the
use for which the borrow pit was intended, the Contractor shall immediately
inform the Engineer in writing and the Engineer shall either direct that the borrow
pit is extended or that a new borrow pit shall be used.
The Contractor shall be responsible for any delays in the land acquisition which
occur due to any of the above information being incorrect and the 90 day period
for land acquisition shall be extended by the period of any such delay.
When a quarry, borrow pit, spoil or stockpile area has insufficient suitable
material or area for the use for which it was intended the Contractor shall propose
in writing that either an existing quarry, borrow pit, spoil or stockpile area be
extended or that a new quarry, borrow pit*- spoil or stockpile area shall be used.
The approval and acquisition of such new or extended quarries, borrow pits, spoil
or stockpile areas shall be in accordance with all the above provisions of this
Clause 603 for the acquisition of the original quarries, borrow pits, spoil or
stockpile areas.
The Contractor's obligations with regard to quarries etc. as set out above shall
also apply to land required in accordance with Clause 124 of this Specification.

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604 ENTRY UPON LAND

The Contractor shall, before entering upon any land provided by the Employer,
satisfy himself that legal rights of entry have been obtained.
Where it is necessary to agree levels for the calculation of quantities, the
Contractor shall not enter the area until such levels have been agreed and the
Engineer's approval obtained.
605 SAFETY AND POBLIC HEALTH REQUIREMENTS
The Contractor shall comply with the Bye-laws of the Local Authority regarding
public health and safety in respect of the operation of quarries, borrow pits,
stockpile or spoil areas, and in the absence of, or in addition to such Bye-laws,
shall comply with the following conditions;-
(a) All areas being worked shall be drained and kept drained. Where a quarry or
borrow pit has been excavated so that it will not drain naturally, it shall be
kept pumped dry while being used.
(b) The Contractor shall confine his operations solely to the areas provided and
shall demarcate the boundary of the area and erect temporary or permanent
fencing as instructed by the Engineer.
(c) Where the height of any face exceeds 1 metre, the Contractor shall provide,
erect and maintain at his own expense stockproof to prevent unauthorised
access to the top of the working face.
(d) On completion of work all faces shall be neatly trimmed to a slope flatter than
1 in 4. Where this is impracticable or where the working face is to be left
exposed, the edge shall be permanently fenced, as instructed by the
Engineer, and measurement and payment for such fencing shall be in
accordance with the requirements of Section 20 of this Specification.
(e) On completion of work temporary fences and all temporary structures shall be
demolished and removed, all latrine pits filled in and drained and the site
topsolled and left neat and tidy.
606 ACCESS ROADS AND TRAFFIC CONTROL
The Contractor shall comply with the provisions of Section 9 of this Specification
with regard to the construction and maintenance of access roads to quarries,
borrow pits, spoil and stockpile areas and with regard to traffic operations
thereon.

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607 SITE CLEARANCE AND REMOVAL OF TOPSOIL AND OVERBURDEN

Unless otherwise instructed by the Engineer, the Contractor shall clear the sites
of all quarries, borrow pits, stockpile and spoil areas in accordance with Section 4
of this Specification, but measurement and payment will be in accordance with
this Section of this Specification.
All existing fences, trees, hedges and other features which the Engineer instructs
shall not be removed or otherwise dealt with shall be protected in accordance
with the requirements of Section 4 of this Specification.
Unless otherwise directed by the Engineer the Contractor shall remove topsoil
and/or overburden from quarries, borrow pits, spoil and stockpile areas. The
Engineer shall direct whether topsoil shall be stripped and stockpiled separately
or shall be excavated and spoiled together with the overburden. If suitable the
Engineer may direct that overburden be used in the Works.
On completion of work in any quarry, borrow pit, spoil or stockpile area the
overburden and/or topsoil which has not been used in the Works shall be pushed
back, spread and landscaped over the area of the quarry, borrow pit, spoil or
stockpile area. Where topsoil has been stockpiled separately it shall be pushed
back and spread over the quarry, borrow pit, spoil or stockpile area after
landscaping unless the Engineer has instructed that it be used for topsoiling in
accordance with Section 5 of this Specification.
608 MIXING, SELECTING AND STOCKPILING OF MATERIALS
Before a borrow pit is opened, the Engineer will instruct the Contractor as to the
type of material to be excavated and the areas and depths to be worked.
The Contractor may be required to mix the selected materials by bulldozing into
stockpiles and/or by face loading by shovel. The stockpiles shall be formed at
least six weeks before intended use for materials which are to be treated and at
least three weeks before intended use for materials which are not to be treated.
The Contractor shall ensure that oversize material, clay, humus or other inferior
material encountered in the workings is separated from the materials proposed
for use in the Works and such inferior material shall be removed to spoil.
A separate stockpile shall be used for each type and grading of material.
When removing material from stockpiles, none of the underlying material shall be
mixed with it, and generally at least the bottom 100 mm layer shall be left behind.
Should any stockpiles prove surplus to requirements the Contractor shall spread
the material over the area of the quarry or borrow pit unless directed otherwise by
the Engineer.

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609 MATERIAL UTILIZATION

Where the Contractor uses a borrow pit, instructed by the Engineer for use in
earthworks or under 'Method 3' of Section 10, 11 and 12 of this Specification, for
the construction of access roads, deviations, detours, haul roads, camps,
temporary works or for any other works not part of the permanent works then the
cost of site clearance, topsoil and overburden removal and access roads to such
borrow pits shall be borne by the Contractor in the proportion that the volume of
material removed for the Contractor's purposes and not part of the permanent
Works bears to the total volume of material removed from the borrow pit.
Where a borrow pit instructed by the Engineer for use in earthworks or under
‘Method B’ of Sections 10, 11 or 12 of this Specification is used to construct
works for which there are different methods of measurement and payment then
the quantity of site clearance, topsoil and overburden removal and access roads
to such borrow pits shall be divided between each method of measurement in the
proportion that the volume of material removed for each purpose bears to the
total volume of material removed from the borrow pit.
Where a borrow pit instructed by the Engineer under ‘Method A’ of Sections 10,
11, or 12 of this Specification is used to construct several works for which there
are different methods of measurement and payment then the site clearance,
topsoil and overburden removal and access roads shall all be measured and paid
for in accordance with 'Method A1 of Sections 10, 11, or 12 of this Specification.
All materials from borrow pits instructed by the Engineer shall only be used for
permanent Works shown on the Drawings or instructed by the Engineer and any
other use shall be subject to the Engineer's approval.
610 MEASUREMENT AND PAYMENT
Reimbursement for land acquisition shall be made in accordance with the
provision of Section 1 of this Specification.
No separate measurement and payment will be made in respect of this Section 6
of this Specification. The Contractor shall be deemed to have allowed elsewhere
in his rates and prices for the cost of complying with all the requirement of this
Section 6, including all site clearance, overburden and topsoil removal, access
roads to quarries, borrow pits, spoil areas and stockpile areas and reinstatement
including landscaping and spreading topsoil.
Where the Engineer has instructed that overburden or topsoil is used in the
Works measurement and payment will be in accordance with the relevant
Sections of this Specification.

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700 EXCAVATION AND FILLING FOR STRUCTURES

701 SCOPE OF SECTION
This section covers all excavation and filling operations to bridges, box culverts,
retaining walls and other major structures.
702 CLASSIFICATION OF EXCAVATION
(a) Hard material is material which can be excavated only after blasting with
explosives or barring and wedging or the use of a mechanical breaker fitted
with a rock point in good condition and operated correctly. Boulders of more
than 0.20m3 occurring in soft material shall be classified as hard material.
(b) Soft material is all material other than hard material.
703 MATERIALS
(a) General
Material used in the permanent foundation work shall comply with the
requirements specified for the particular material elsewhere in these
Specifications.
(b) Rock (for rock fill)
Boulders, cobbles or gravel shall be unweathered, angular, natural or quarried
material of such quality that they will not disintegrate on exposure to water or
weathering processes. There shall be no Inclusions of clay, silt, sand or organic
material within or adhering to the materials used. Suitable rock sources shall
consist of materials as classified in BS EN ISO 14689-1:2003 with properties
defined for particular uses as detailed in the Special Specifications. Where the
Specifications are silent selected material shall be approved by the Engineer
following testing.
The mass and/or grading requirements for rock fill shall be as provided in the
Special Specifications or on the Drawings or as given elsewhere in these
Standard Specifications.
(c) Crushed rock
Crushed rock used for the construction of rock fill shall originate from sound
unweathered rock approved by the Engineer.
(d) Granular fill
Granular material used for constructing compacted granular fill layers shall be
approved granular material of at least gravel subbase quality as defined in this
Specifications, compacted to achieve a density and strength appropriate for the
design load.
(e) Sand fill

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Sand used for filling caissons shall be clean, well graded medium to coarse
quartz sand free from lumps of clay or organic or other deleterious matter. The
sand type should comply with the requirements for zone 2 or 3 of BS 882.
Alternative sand types may be proposed but will be subject to the approval of the
Engineer
(f) Structural steel
Steel piles shall comply with the requirements of relevant Kenyan Standards and,
where more specific detail is required, reference shall be made to: BS EN 10137-
1:1996, BS EN 10137-2:1996, BS EN 1013, BS 7668:2004, BS EN 10029:1991,
Parts 1 to 3 of BS EN 10113:1993, BS EN 10125:2004, Parts 1 and 5 and BS EN
10210-1:2006. Equivalent Standards may be required in accordance with
alternative grades of steel specified on the Drawings. I and H sections shall
comply with the requirements of BS 4-1:2005 and BS EN 10034:1993. Sheet
piles shall comply with BS EN 1993-5:2007
In the manufacture of precast concrete piles and jointed precast concrete
segmental piles, fabricated steel components shall comply with BS EN 10025-1
and BS EN 10025-2, Grades S275 or S355, cast steel components with BS
3100, grade A (A1, A2 or A3) and ductile iron components with BS EN 1563
material designation symbol EN-GJS-350-22, EN-GJS-400-15, EN-GJS-400-10.
Fabricated sections shall comply with the details shown on the Drawings and the
requirements of this Specification.
(g) Permanent pile casings
Permanent pile casings shall be sufficiently rigid so as not to deform permanently
or damage during handling and construction. The casings and their joints shall
be sufficiently watertight to prevent the fluid components of the concrete from
leaking during the placing of the concrete or from the ingress of groundwater
prior to concreting. Where steel casings contribute to the strength of the pile, the
casings shall have a minimum wall thickness of 4.5 mm and shall comply with the
requirements of ASTM A 252-98:2007 or equivalent. Welded joints shall comply
with the requirements of this Specification.
(h) Driven pile casings
Driven pile casings shall have sufficient strength to withstand driving forces and
provide adequate resistance to distortion from the effects of driving of adjacent
piles. They shall be sufficiently watertight to prevent water leaking through the
casing walls, prior to and during the placing of concrete.
(i) Grouting
(i) Cement grout
Cement grout shall meet the appropriate requirements of Subclause 6503(g).

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(ii) Proprietary brand grout

Proprietary brand grout shall be prepared and used strictly in accordance with
the instructions of the manufacturer and conform with BS EN 934.
(iii) Bentonite
Bentonite suspensions may be used to counterbalance hydrostatic forces where
soil conditions and the groundwater table impose restrictions on pile construction
methods. The bentonite used shall be subject to appropriate testing and the
Contractor’s Quality Control procedures. Bentonite shall be provided in bags and
the source of the material shall be to the approval of the Engineer.
704 GENERAL
(a) Subsurface data
If it is found during the course of excavating, founding-pile or caisson work that
the soil or founding conditions differ greatly from those shown on the Drawings,
the Contractor shall immediately notify the Engineer.
The Engineer shall, as often as he may deem necessary during the course of
excavation, be entitled to call on the Contractor to conduct additional foundation
investigations and/or tests at or below the intended founding levels in order to
establish safe bearing pressures and founding depths.
(b) Channel preservation
The flow of any watercourse and the conservation of marine and freshwater life
at the site shall be maintained at all times. Access to cofferdams, artificial
islands and piling platforms shall be effected without unnecessarily disrupting the
flow of the watercourses at the point of crossing, unless otherwise specified.
Precautions shall be taken by the Contractor to maintain water quality standards.
Water contaminated with silt shall be settled in ponds before being pumped into
streams. Water contaminated with chemicals shall be purified before being
returned to the stream or disposed of in an appropriate manner as directed by
the Engineer.
Precautions shall be taken by the Contractor to ensure that the natural pH,
electrical conductivity and other indicators as prescribed for the water are not
raised or lowered.
On completion of the work surplus excavated materials including materials
excavated from caisson compartments and holes for piles, materials used in
cofferdams and other temporary works, as well as in-situ material, shall be
removed and disposed of by the Contractor. The channel shall be reinstated to
the level of the original bed or such elevation as may be agreed to by the
Engineer or required for stream channelization.

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705 6104 ACCESS AND DRAINAGE

(a) General
This Clause covers the provision of access, including the construction of
cofferdams, and draining the excavations.
After completion of the permanent works, all temporary works shall be completely
removed, the ground levelled and the site left in a neat and tidy condition to the
satisfaction of the Engineer. Where this is impracticable, such portions as have
not been removed, shall be dealt with in accordance with the Engineer's
instructions.
(b) Access
Where temporary banks or artificial islands are constructed to afford access to
the location where structural members, piles or caissons are to be constructed,
the banks or islands shall be adequately compacted with a working platform at
surface sufficient to safely support any constructional plant and provide
temporary storage for materials required for incorporation in the works. The
Contractor shall submit a detailed design and construction method statement
giving details materials to be used, dead and live loads, bearing capacity and
expected settlement, for the approval of the Engineer.
When constructing temporary banks or artificial islands no separate payments
will be made for any obstructions, hard or unsuitable material encountered in the
excavation works or in borrow areas used.
(c) Cofferdams
Design and construction of any cofferdams shall comply with the requirements of
BS 8004:1986. Before commencing construction the Contractor shall submit
drawings to the Engineer showing complete details of the cofferdams and the
method of construction proposed.
(d) Drainage
The Contractor shall adopt suitable, effective drainage methods for preventing
the ingress of water into excavations to allow works to proceed in dry conditions.
The drainage measures, with the exception of pumping, shall be maintained until
backfilling has been completed. Between the various construction stages
pumping may be interrupted if the Engineer is satisfied that the works will not be
adversely affected.

706 EXCAVATIOK OF FOUNDATIONS FOR STRUCTURES

The excavation of foundations for structures and any associated drainage works
shall be kept to the minimum. The sides of the excavation shall be kept vertical

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and shall be properly timbered or sheet piled, shored and strutted as necessary
to prevent subsidence or slipping of the surrounding soil.
All excavated surfaces, in material other than hard material, on which
foundations for structures are to be placed shall be compacted to 95% MDD
(AASHTO T99) immediately before foundations are constructed.
Excavated surfaces in hard material shall be further excavated to achieve a
minimum thickness of 50mm of blinding concrete.
Where a combination of hard and soft materials exist in the excavated surfaces
then, dependent on the proportions of existing materials, the Contractor will
either, remove a minimum of 300 mm of soft material below underside of
foundation and replace it with lean concrete to the top of blinding level or remove
a minimum of 300mm of hard material below the underside of blinding concrete
and replace it with soft material compacted to 95% MDD (AASHTO T99).
The Engineer's approval of any excavation shall be obtained prior to any
construction thereon.
707 EXCAVATIONS TO BE KEPT DRY
All excavations shall be kept dry and the Contractor shall take all necessary
measures to maintain excavations free from water.
Where required by the Engineer, the sumps from which pumps operate shall be
constructed outside the area of the foundation base. Excessive pumping from the
excavation which is liable to cause settlement, disturbance, or washing out of
fines from the adjacent ground will not be permitted.
Where, in the opinion of the Engineer, the foundation has become soft and
additional excavation is required due solely to the Contractor's method of
working, the resulting backfill shall be with approved material or concrete as
instructed by the Engineer. All such backfill shall be at the Contractor's expense.
708 FOUNDATIONS AND ABUTMENTS CAST AGAINST IN-SITU MATERIAL
Where shown on the Drawings or instructed by the Engineer that a foundation
and/or abutment shall be cast against the in-situ material, the excavations shall
be neatly excavated to the shape required. Should any over-excavation occur the
space between the foundation and/or abutment and the in-situ material shall be
backfilled with Class 15/20 concrete or with the same grade of concrete as the
foundation and/or abutment and shall be placed in advance of the concrete for
the foundation and/or abutment. All such backfill shall be at the Contractor's
expense.
709 SURPLUS EXCAVATED AND BACKFILLING MATERIALS.
Surplus excavated material shall be taken to spoil areas or may be used in
adjacent earthworks if suitable.

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The Engineer's approval must be obtained to the Contractor's proposed material

for backfilling and filling behind and around a structure.
710 BACKFILLING OF EXCAVATIONS AND FILLING FOR STRUCTURES
No filling around a structure or backfill in a trench or excavation shall commence,
neither shall a structure be loaded, without the approval of the Engineer.
The sequence of filling and backfilling behind and around a structure and the
maximum difference in height at any time between fill levels shall as directed by
the Engineer.
All filling and backfilling shall be with selected materials approved by the
Engineer, brought up in horizontal layers not exceeding 150 mm compacted
thickness. Each layer shall be thoroughly mixed, watered or dried as necessary,
and compacted to a minimum dry density of 95% MDD (AASHTO T99).
Timbering and sheeting left in for the purpose of supporting the excavation shall
be eased up 150 mm at a time in step with the backfill layer. Where instructed by
the Engineer, timbering or sheeting shall be left in place.
Where instructed, or shown on the Drawings, selected granular fill material
and/or porous filter material approved by the Engineer shall be placed. A sliding
form or other approved means shall be used during backfilling such that the
porous filter, is brought up and compacted at least 150 mm ahead of the selected
granular fill material and that the selected granular fill is brought up and
compacted at least 150 ram ahead of the adjacent earthworks fill. The interface
between selected granular material to this Section of the Specification and the
adjacent earthworks to Section 5 of this Specification shall be as shown on the
Drawings or as instructed by the Engineer. Where selected granular fill material
is not instructed the Contractor shall backfill the excavation behind and around
the structure and up to ground level using the excavated material. Above ground
level the Contractor shall use the same material as that being used for the
adjacent embankment.
711 PROTECTION OF STRUCTURES
The Contractor shall furnish, construct and maintain all necessary cofferdams,
cribs, channels, flumes and other diversion and protection works and shall
furnish, install, maintain and operate all necessary pumping and other equipment
for the exclusion or removal of water from various parts of the Works.
Drawings for cofferdams and other proposed temporary installations shall be
submitted to the Engineer before commencement of the work. The Contractor
shall avoid any measures in the proposed installations which will cause flooding
or endanger the safety of persons or property upstream or downstream of the
site-All such structures shall be removed on completion of the works unless
otherwise instructed by the Engineer.

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712 EXCAVATIONS FOR RIVER TRAINING AND NEW WATERCOURSES

Excavations carried out in the diversion, enlargement, deepening or straightening
of streams and rivers or in the formation of new watercourses shall be performed
as shown on the Drawings or as instructed by the Engineer, and may include site
clearance, trimming of slopes, grading of beds and disposal of the excavated
materials.
Where water courses have to be diverted, the original channels shall be cleared
of all vegetable growth and soft deposits and carefully filled in with approved
materials, deposited and compacted as instructed by the Engineer.
713 STONE PITCHING
Where shown on the Drawings or directed by the Engineer the Contractor shall
excavate for, trim to line and level, provide and lay stone pitching.
Stone pitching shall be formed of hard stone, roughly dressed square. The least
dimension of any stone shall not be less than 200 mm, and the volume not less
than 0.01 m3. No rounded boulders shall be used.
The stones shall be set on edge and securely bedded with the largest
dimensions at right angles to the flow of water, fitted closely together so as to
leave only a minimum of voids between the stones which shall be filled in with
suitably shaped and tightly wedged spalls. The top of the pitching shall be
finished flush with the adjacent material.
Where grout is specified, a 1:4 cement: sand mortar shall be rammed into the
wetted interstices and smoothed off flush with the pitched face.
714 GABIONS
Where shown on the Drawings or directed by the Engineer the Contractor shall
excavate for, trim to line and level, provide and erect gabions including providing
selected rock, crushed if necessary, packed and compacted inside the gabions.
Gabions shall include gabion mattresses and gabion boxes and for the purposes
of construction and method of measurement and payment no distinction shall be
made between them.
Gabions shall be "Maccaferri" boxes and/or "Reno" mattresses both with
diaphragms at 1 metre centres, or similar approved. The maximum mesh size
shall be 100 mm x 120 mm for boxes and 60 mm x 80 mm for mattresses. The
wire used for the construction of gabions shall unless otherwise instructed by the
Engineer comply with the requirements of Table 7-1.

TABLE 7-1

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Diameter Galvanising
(mm) (g/m2)

Mesh Box 3.4 275

Mattress 2.7 260
Binder BOX 2.2 240
Mattress 2.2 240
Selvedge Box 3.9 290
Mattress 3.4 275

All wire shall be to BS 1052 having a tensile strength of not less than 40kg/ma2
Galvanizing shall comply with the requirements of BS 443.
Gabions shall be constructed to the shapes and dimensions as shown on the
Drawings or given in the Special Specification or as directed by the Engineer.
Gabions, as constructed shall be within a tolerance of ±5% on the height or width
instructed and ± 3% on the length instructed.
The alignment of the gabion shall be correct within a tolerance of 100mm of -the
instructed alignment and the level of any course of gabion shall be correct to
within a tolerance of 50mm of the instructed level. In addition adjacent gabions
shall not vary by more than 25mm in line and/or level from each other.
The surface upon which gabions are to be laid shall be compacted to a minimum
dry density of 95% HDD (AASHTO T99) and trimmed to the specified level or
shape.
Joints in gabions shall be stitched together with 600mm minimum lengths of
binder wire, with at least one stitch per 50mm, and each end of the wire shall be
fixed with at least two turns upon itself.
Adjacent gabions shall be stitched together with binder wire along all touching
edges.
Gabion boxes shall be laid with broken bond throughout to avoid continuous
joints both horizontally and vertically. Pre-tensioning of gabions shall be subject
to the approval of the Engineer.
Gabions shall be hand packed with broken rock of 150 mm minimum dimension
and 300mm maximum dimension. The sides shall be packed first in the form of a
wall, using the largest pieces, with the majority placed as headers with broken
joints to present a neat outside face. The interior of the gabion shall be hand
packed with smaller pieces and the top layers shall be finished off with larger
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pieces. The whole interior and top layers shall be packed tight and hammered
into place.
Where instructed by the Engineer the Contractor shall place filter fabric ('Terram'
or similar approved) behind gabion faces in contact with existing or backfilled
ground. The Contractor shall ensure that the filter fabric is not damaged during
the construction or backfilling around the gabion works and any damaged or torn
fabric shall be replaced at the Contractor's expense. The filter fabric shall be
installed in accordance with the manufacturer's instructions and the filter fabric
shall not be left exposed to sunlight for more than 3 weeks.
At the back face and ends of completed gabion work or where shown on the
Drawings or instructed by the Engineer the existing soil shall be backfilled,
thoroughly compacted against the sides of the gabions and finished flush with the
top surface of the gabion.
On completion of gabion construction the exposed joints shall be painted with a
thick bitumen to the approval of the Engineer to discourage vandalism.
715 RIP-RAP
Stone for rip-rap shall consist of well-shaped hard dense durable rock. At least
50 per cent of the pieces shall have a volume greater than 0.03m3 and not more
than 5 per cent shall have a volume of less than 0.01m3. Where instructed by the
Engineer or shown on the Drawings the stones shall be laid with close Joints
from the bottom of the slope of embankment, or existing ground upward, the
larger of the stones being laid at the bottom- The surface shall be hand packed,
carefully bedded and tightly wedged with suitable spalls to form an even surface.
Alternatively the Engineer may direct that the stones are dumped from above and
that the rip-rap is roughly dressed to the dimensions shown on the Drawings or
instructed by the Engineer.
716 FOUNDATION DOWELS
Where required, foundation dowels of specified material, diameter and length
shall be installed at the positions and to the dimensions shown on the Drawings
or as directed by the Engineer. After exposing, clearing and trimming the rock
formation, holes with specified diameters and depths shall be drilled in the rock.
After the holes have been cleared and pre-wetted, they shall be filled with grout.
Within 15 minutes of having been filled with grout, dowel bars shall be carefully
driven into the holes. The cement and water in the grout shall be mixed in the
ratio of 50 kg of cement to 20 litres of water and an approved expanding additive
which complies with the requirements of this Specification shall be added.

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717 FOUNDATION LINING

Where specified or directed by the Engineer, foundation linings shall be installed
as described hereafter. The Engineer shall have the right to order the use of
linings against the sides of excavations and the undersides of bases if deemed
necessary and also under slabs. Linings may be adopted in lieu of formwork and
concrete blinding where appropriate.
All surfaces to be lined shall be covered with an approved sheeting to provide a
clean impervious layer. The material shall be of sufficient strength to provide a
durable working surface and to support the concrete and reinforcement without
tearing. The joints of the material between strips shall have a 150 mm overlap
and the lining shall be held firmly in position by nails, pegs, etc.
Polyethylene sheeting with a thickness of 0.150 mm is generally considered to be
adequate for use below bridge approach slabs and bases if required.

718 FOUNDATION PILING PRELIMINARY ITEMS

(a) General
This Clause covers the construction of bearing piles of concrete, steel, timber or
a combination of these materials. Wherever more specific detail is required the
Engineer shall adopt the requirements of the latest edition of the U. K. ICE
Specification for Piling and Embedded Retaining Walls.
(b) Piling layout
The piling layout, the minimum pile size and/or bearing capacity and type,
together with the steel reinforcement and class of concrete required for concrete
piles, shall be as shown on the Drawings and/or as otherwise detailed in the
Special Specifications.
(c) Alternative designs for piling and piling layouts
(i) Submission
The priced Bill of Quantities submitted for alternative designs shall be compiled
strictly in accordance with the relevant measurement and payment clauses of
these Specifications.
Where pay items defined in these Specifications have been omitted, it shall mean
either that the items do not apply, or that where the Engineer requires work
falling under such items to be done, it shall be done without any cost to the
Employer. The inclusion of 'rate-only" items will not be permitted.
Where pay items not defined in these Specifications are used, the measurement
and payment requirements for such items shall be specified in detail by the
Contractor. In the absence of such definitions, or in the case of any ambiguity,
the ICE Specifications shall apply.

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Except in piling-only Contracts or where otherwise provided in the Special

Specifications, the Contractor shall price the Bill of Quantities for the original
design irrespective of whether or not an alternative design is offered.
(ii) Design
The critical design-load combinations acting upon the underside and the centre
of gravity of the pile-capping slab, the maximum permissible settlement of the
pile-capping slab, and the technical data required for designing alternative piles
and or piling layouts will be indicated on the Drawings. Alternative designs shall
comply with the provisions of relevant codes and the prescriptions set out below.
For alternative designs submitted the Contractor shall submit with his bid a
detailed description of the method of analysis used in the design of the piles and
the pile group layouts. The average length of pile and/or of the piles per group
on which the quantities in the Bill of Quantities for the alternative designs are
based shall be stated in each case. The type of pile offered shall be defined in
terms of size, materials, working and ultimate loads.
The Contractor shall be responsible for and shall bear the cost for redesigning,
drafting and submitting the detail drawings for any structural element affected by
the alternative pile design. Any additional costs related to the construction of
such element as compared to the original design shall be for the account of the
Contractor.
The Contractor shall submit to the Engineer at least eight weeks prior to work
being commenced, drawings detailing the piling-group layout and piles,
incorporating such amendments to his original design as may be required by the
Engineer, and drawings detailing the amendments required to the pile-capping
slab dimensions and reinforcement as a result of the layout of the piles, all as
applicable.
No work of whatsoever nature shall be commenced on the piling until the
Drawings have been submitted and have been approved by the Engineer in
writing. After approval of the Drawings, no departure therefrom shall be made
without the authorisation of the Engineer.
(iii) Basis of payment
Where the quantities in the Bill of Quantities, differ from the number of piles and
the average pile length given in the submission for the alternative pile design, the
Engineer shall accept the sum in the Bill of Quantities, correct the quantities, and
adjust the rates for the applicable pay items accordingly.
(iv) Design responsibility
Approval of alternative designs shall in no way relieve the Contractor from
responsibility for adequate design and construction of the Works nor shall any of

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the provisions of these clauses relive the Contractor of his obligations under the
General Conditions of Contract.
(d) Details to be furnished by the Contractor
In all cases where the choice of the type of pile to be used is left to the
Contractor, full particulars, specifications, calculations and drawings of the piles
proposed for use by the Contractor shall be submitted with the bid. The
Contractor shall submit to the Engineer a fully detailed method statement for
construction of the piles two weeks before any piles are driven or holes are
formed. The method statement shall describe, inter alia:
(i) How the piles and casings will be installed or the holes will be formed;
(ii) How the piles and casings will be installed or the holes will be made
through identified obstructions;
(iii) The expected size of the bulbous base, under ream, rock socket, etc, if
any;
(iv) How concrete is to be placed and compacted in the case of cast in situ
piles;
(v) How reinforcing steel is to be placed and held in place during the placing
and compaction of the concrete in cast in situ piles;
(vi) Details of permanent casing, if any;
For driven piles:
(a) The weight of the piling hammer;
(b) The set during the last ten blows;
(ix) The mix design for the concrete together with an adequate quantity of
cement and aggregate to enable the Engineer to conduct the necessary tests.
The Contractor shall submit any further details as may be required by the Special
Specifications or requested by the Engineer.
(e) Pile-installation plant and equipment
The pile-installation rigs, leaders, frames or other plant and associated
equipment used for driving the piles or forming the holes or for other methods of
sinking the piles shall be in a good working condition and to the prior approval of
the Engineer and shall be licensed, have current certification for lifting and safety
and in all ways comply with relevant legal requirements.
The piling rigs or installation frames shall be so designed as to ensure that piles
can be installed in their proper positions and true to line and slope within the
required tolerances.

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The Contractor shall supply all necessary plant and testing equipment,
kentledge, load frames and instruments required for the prescribed investigations
tests and inspections.
(f) Piling platforms and mats
Piling platforms shall include the prepared in situ material or artificial islands or
any structure (excluding the piling equipment) constructed for gaining access to
the positions where the piles are to be installed and for carrying out the piling
operations.
Structural piling platforms shall be rigid. Floating barges used for piling
operations shall afford sufficient stability to enable piles to be properly installed.
The Contractor shall submit full details of the design of any working platforms or
piling mats demonstrating that an adequate Factor of Safety will be in operation
under the most onerous dead and live loading configuration for the piling rig or
frame selected for the work.
On completion of the piling, the Contractor shall remove all the platforms and
reinstate the site to the satisfaction of the Engineer.
(g) Setting out
The Contractor shall set out the pile positions and shall stake these positions with
a durable marker. Where the level from which the piling is undertaken is above
the underside of the pile capping slab, due allowance shall be made for the offset
of raking piles so that the pile at the underside of the pile-capping slab will be in
the correct position.
(h) Ground surface for foundation piling
Before starting any piling work, the Contractor shall notify the Engineer in good
time to ensure that levels of the ground surface be taken in order that an average
ground surface from which the piling is to be measured can be established and
agreed upon by the Engineer and the Contractor. Where foundation piling at a
site is preceded by excavation or the construction of fill, which may be designed
to act as the piling mat, the surface from which the piling is to be done shall be
formed as near as possible to the underside of the pile-capping slab as directed
by the Engineer.
719 TYPES OF PILES
(a) Bored cast in situ concrete piles
(i) Reinforcement
Reinforcement shall not be placed in the pile holes until immediately before
concreting. Before the reinforcement is placed in position, all mud, water, and
any loose or soft material shall be removed from the hole.

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Steel reinforcing shall be accurately maintained in position without damage being

done to the sides of the hole or the reinforcing itself. Spacers shall be used to
keep the reinforcing steel at the required distance from the inside face of the pile
casing and wall of the pile hole. The details of the reinforcement cages and
spacers shall be such as to ensure satisfactory distribution of concrete without
risk of creation of voids, segregation or honeycombing during placement.
Pile reinforcement will not be shown in the bending schedules. Only the number,
diameter and type of bars and their arrangement will be shown on the Drawings.
The Contractor, with the permission of the Engineer, may replace the bars shown
on the Drawings with bars of different diameters and spacing and of different
types, on a basis of equivalent strength.
The reinforcement shall be assembled in cages, which shall be sufficiently robust
to prevent their permanent deformation during handling. In the case of cast in
situ piles, the inner sides of the cages shall be left unrestricted for the placing of
the concrete.
The longitudinal bars shall project above the cut-off point by the distance shown
on the Drawings, or by 40 times the bar diameter if no dimension has been given.
Splicing of the reinforcing may be necessary or ordered and the Contractor shall
keep available on the site sufficient steel reinforcing so that an additional length
of pile reinforcing cage can be assembled whenever necessary.
The assembly of this additional reinforcing shall be carried out expeditiously and
before any concreting of any specific pile commences. If splices have to be
provided, the longitudinal bars shall overlap for a distance of 40 bar diameters, or
as required by the Engineer.
(ii) Concreting of piles
The concreting of the piles shall not be commenced before the Engineer's
permission has been given.
Except in self-supporting pile holes, a temporary or permanent casing shall be
installed for the full depth of the hole to prevent lumps of material from falling
from the sides of the hole into the concrete. Where concrete is to be placed
under drilling mud the temporary casing may be omitted, except at the top end of
the hole.
The concrete mix design shall be so proportioned as to be of sufficient strength,
but shall be sufficiently workable to enable satisfactory placement, and, where
self-compacting concrete is not used, it shall be thoroughly compacted by
approved means. Extraction of the temporary casing during placement of the
concrete shall be such that no damage is caused to the pile and the advancing
concrete level is at all times kept considerably above the temporary casing's
trailing edge. Concrete shall generally be placed in the dry, but where this is

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impracticable; it shall be placed by tremie. The method of placement shall be

agreed with the Engineer and shall ensure that segregation does not occur.
The requirements of Section 17 together with the following requirements shall
apply when concrete is placed under water or bentonite (drilling mud) by tremie:
(1) The cement content shall be not less than 400 kg/m3 and the slump shall
be such that the concrete of the specified strength and desired density can be
obtained.
(2) The hopper and tremie shall be a closed unit which cannot be penetrated
by water.
(3) The tremie shall be at least 150 mm in diameter for 20 mm aggregate and
of greater diameter for larger aggregates.
(4) The concrete shall be so placed as to prevent the mixing of water and
concrete. The tremie shall at all times penetrate into the concrete.
(5) Placing the concrete in that part of the pile below the water level in the
casing shall be done in one operation, and the same method of placing the
concrete shall be maintained throughout.
(6) All tremies shall be scrupulously cleaned before and after use.
(7) Before placing the concrete in the water, the Contractor shall ensure that
no silt or other materials have collected at the bottom of the hole, and where
drilling mud is used, the Contractor shall ensure that no drilling mud suspension
with a relative density exceeding 1.3 has collected at the bottom of the hole.
Concrete shall be placed in a manner that prevents segregation.
(b) Auger piles
Piles may be constructed using rotary flight augers with concrete placed through
a central stem.
The Contractor shall provide full details of the equipment to be used and
demonstrate to the Engineer that adequate monitoring devices are installed and
functioning to control the pressure and head of concrete and ensure that augers
are not withdrawn in an uncontrolled manner. Continuous logs of pressure,
depth and flow of concrete shall be provided for every pile together with rates of
penetration and extraction of the auger.
(c) Precast concrete piles
(i) General
The piles shall be of reinforced or prestressed concrete and shall be
manufactured, handled, stored and installed in accordance with BS 8004:1986,
unless otherwise specified.
(ii) Manufacture

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The piles may be manufactured in a factory or a casting yard on the site of the
Works. The Contractor shall ensure that the factory or casting yard will at all
reasonable times be accessible for inspection by the Engineer.
The relevant requirements of Section 6400 shall apply to the concrete work.
Reinforcement shall comply with the requirements of BS 8004:1986.
The piles shall be cast on a rigid horizontal platform in approved moulds.
Particular care shall be taken to keep the reinforcement, coupler sockets and pile
shoes accurately in position. Adequate provision shall be made for lifting the
piles.
Each pile shall be clearly marked with the date of casting, a reference number,
and from the tip of the pile at 1.0m intervals, with distance marks.
Piles shall be cured for a period sufficient to develop the strength required to
withstand, without damage to the pile, the stresses caused by handling,
transporting, storing and driving. The piles shall not be driven before the
concrete in the pile has attained the specified 28-day strength.
(iii) Handling, transport and storage
Care shall be taken at all stages of lifting, handling and transporting to ensure
that the piles are not damaged or cracked.
Piles shall be stored on firm ground which will not settle unequally under the
weight of the stack of piles. The piles shall be placed on timber supports which
are cut square and levelled and spaced so as to avoid undue bending in the
piles. The supports in the stack shall be located vertically above one another.
(iv) Lengthening of precast piles
Piles shall be lengthened where required by such means and methods as
approved by the Engineer. Care shall be taken to ensure that the additional
length of pile joined is truly axially in line with the original pile within the tolerance
requirements for straightness set out in this Specification.
Proprietary jointing systems will be approved subject to any tests that may be
required by the Engineer which may include full scale load tests to check the
performance of a jointed pile in bending.
Driving shall not be resumed until the pile extension and any grout or bonding
agent used has attained the required strength.
(c) Steel piles
Steel piles shall be proprietary sheet piles, or of standard circular pipe, I or H-
section construction.

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Hollow steel piles may be filled with cast in situ concrete and designed to act as a
composite member with load being carried proportionately between the steel and
concrete elements
In order to combat corrosive ground or water conditions or to reduce friction
forces, piles may require a bituminous or other proprietary surface coating. Full
details of any such coating shall be provided unless already prescribed in the
Special Specifications or on the Drawings. Alternatively the cross-sectional area
of the steel shall be adapted to the aggressiveness of the subsurface conditions
to compensate for possible reduction in the pile wall thickness caused by
abrasion and corrosion during the service life of the pile. In marine conditions a
cathodic protection system shall be adopted.
(d) Timber piles
(i) General
Timber piles shall be of pressure treated round timber approved by the Engineer
and shall be manufactured, handled and installed in accordance with BS 5268-
2:2002 unless otherwise specified.
Hardwoods shall be used for all permanent piles. Softwoods may be used for
temporary structures subject to the approval of the Engineer.
An Environmental Impact Assessment shall be made prior to approval of the use
of timber piles.
(ii) Manufacture and testing
The piles may be manufactured in a factory or treated on the site of the Works in
accordance with BS 5268-5:1989, unless otherwise specified.
When required, the Engineer will order and the Contractor shall carry out tests on
the timber piles in accordance with BS 5268-5:1989 to satisfy himself that the
timber is fit for the purpose for which it is to be used.
The Contractor shall ensure that the factory or treatment yard will at all
reasonable times be accessible for inspection by the Engineer.
The piles shall be treated and stored in a horizontal position and protected from
the weather.
Each pile shall be clearly marked with the date of manufacture, type of tree, date
of treatment, a reference number, and from the tip of the pile at 1.0 m intervals,
with distance marks.
Piles shall be seasoned for a period sufficient to develop the strength required to
withstand, without damage to the pile, the stresses caused by handling,
transporting, storing and driving. The piles shall not be driven before they have
attained the specified strength.

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(iii) Handling, transport and storage

Care shall be taken at all stages of lifting, handling and transporting to ensure
that the piles are not damaged or cracked.
Piles shall be stored on firm ground which will not settle unequally under the
weight of the stack of piles. The piles shall be placed on timber supports which
are level and spaced so as to avoid undue bending in the piles. The supports in
the stack shall be located vertically above one another.
(iv) Lengthening of timber piles
Piles shall be lengthened where required by such means and methods in
accordance with BS 5268:2002 or as instructed by the Engineer. Care shall be
taken to ensure that the additional length of pile joined is truly axially in line with
the original pile within the tolerance requirements for straightness set out in this
Specification. Driving shall not be resumed until the pile extension and any
bonding agent used has attained the required strength.
720 INSTALLATION OF PILES
(a) Driving
(i) Pile hammers, leaders and frames
Piles and pile casings shall be driven with a gravity hammer, a rapid-action
power hammer or by other approved means. Selection of an appropriate
hammer shall be the Contractor’s responsibility and he shall provide calculations
demonstrating that the type of hammer will be capable of efficiently driving the
piles to the depths specified without damaging the pile in any way.
Pile driving leaders shall be constructed in such a manner as to afford freedom of
movement of the hammer and shall be held in position to ensure adequate
support for the pile or pile casing during installation. Inclined leaders shall be
used for installing raking piles.
The heads of precast concrete piles shall be protected with packing of resilient
material, care being taken to ensure that it is evenly spread and held in place. A
helmet shall be placed over the packing, and a dolly of hardwood or other
material not thicker than the diameter of the pile shall be placed on top.
(ii) Water jetting
The Contractor may employ water jetting to install piles in granular material.
Jetting shall be discontinued before the leading end of the pile reaches a depth of
80% of the anticipated final depth or at a depth agreed with the Engineer. After
jetting, piles or their casings shall be driven to the required depth, level or set.
(iii) Installation sequence
Unless otherwise specified or ordered the sequence for installing the piles shall
be to the Contractor’s programme. However, the sequence for driving the piles

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in a group shall be programmed to minimise the creation of consolidated blocks

of ground into which piles cannot be driven or which cause fictitious penetration
values. Piling shall generally commence at the centre of the group and be
progressively extended to the perimeter unless otherwise instructed by the
Engineer.
The installation of piles shall be undertaken in such a manner that structural
damage, distortion or positioning defects will not be caused to previously
installed piles or casings.
(iv) Heaving of piles
In soils in which the installation of piles may cause previously installed piles to
heave, accurate level marks shall be placed on each pile immediately after
installation and all piles that have heaved shall be re-driven to the required
resistance, unless re-driving tests on neighbouring piles have shown this to be
unnecessary. Piles shall not be concreted neither shall any pile-capping slab be
constructed until the piles within a heave-influence zone have been re-driven as
required.
(v) Bulbous bases
Where required, bulbous (enlarged) bases shall be formed after the driven casing
has reached the required depth. The base shall be formed by progressively
displacing the surrounding subsoil with concrete placed by the repeated action of
a gravity hammer. The size of the base will depend on the compressibility of the
surrounding subsoil but shall in no case have a diameter of less than 1.5 times
the diameter of the pile.
(vi) Piling alignment
Where the inclination of a precast concrete pile deviates from the correct slope
during installation, the pile shall not be forced into the correct position. The slope
of the guiding frame shall be adjusted so as to coincide with the actual inclination
of the pile to prevent bending of the pile. Where the verticality or the inclination
of the installed pile falls outside the specified tolerances, the pile will be classified
as being defective.
(b) Augering and boring
(i) Auger and bore pile holes
The augering and boring of pile holes shall be carried out as expeditiously as
local conditions permit taking due account of services or other restrictions on the
site.
Holes shall be cleaned after augering and boring to obtain a clean and level
surface.

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Where indicated by the Engineer, suitable casing shall be installed in those parts
of the augered holes where the sides are in danger of caving in before the
concreting has been completed.
During extraction of the casing, care shall be taken to avoid lifting the concrete
and damaging the pile.
The use of water for augering and boring holes shall not be permitted unless
approved by the Engineer. Surface water shall not be allowed to enter the hole.
(ii) Under-reaming
Where required, the holes shall be enlarged or belled out to form an under ream.
The earth excavated shall be removed in a manner which will not damage the
walls of the hole.
The shape of the under ream shall be a truncated cone of which the base
diameter depends on the bearing capacity of the founding material, but it shall be
not less than twice the shaft diameter. The base angle of the cone between the
inclined face and horizontal plane shall be not less than 600.
No workmen shall be allowed to enter under reamed bases to pile shafts and,
where this type of pile is approved, the Contractor must provide remote cleaning
tools and cctv or other monitoring devices which can show the cleanliness of the
pile base before concreting commences.
(iii) Inspecting preformed holes
Equipment for inspecting the pile shafts shall be provided and operated in
accordance with BS 8008:1996 Safety Precautions and Procedures for the
Construction and Descent of Machine-Bored Shafts for Piling and Other
Purposes or similar document.
Immediately before the reinforcement is to be installed or the concrete placed,
the Engineer shall be informed thereof with a view to inspecting the pile holes.
When piles are to be under-reamed, the excavation shall be inspected twice by
the Engineer, firstly to ascertain that suitable founding material has been
obtained before under-reaming may start, and, secondly, after the under-reaming
has been completed for approval to be given by the Engineer for casting the pile.
(c) Rock sockets
Rock formations of adequate strength, quality and thickness for carrying the
specified load shall be drilled with appropriate equipment to the required
dimensions.
The socket thus formed shall be cleaned of all loose material and inspected prior
to placement of concrete.
(d) Obstructions

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(i) Definitions
(1) Identified obstructions
Identified obstructions shall mean any obstruction described on the Drawings or
in the Special Specifications and for which provision for payment has been made
in the Bill of Quantities in respect of penetrating or removing the obstructions.
(2) Unidentified obstructions
Where provision has been made in the Bill of Quantities for penetrating identified
obstructions and obstructions not described are encountered, such obstructions
shall be classified as unidentified obstructions. The penetration of such
obstructions shall be paid for separately subject to the condition that the rate of
penetration drops below that achieved for identified obstructions when the same
method and effort are used, or subject to additional methods and effort over and
above those required for identified obstructions being required for penetrating the
obstruction.
or
Where no provision has been made in the Bill of Quantities for penetrating
identified obstructions and obstructions are encountered and, after resorting to
the methods specified, it is found to be impossible to form the holes in the proper
positions and at the proper inclinations and depths, and the Contractor has to
resort to additional methods for forming the pile holes successfully, such
obstructions shall be classified as unidentified obstructions.
(ii) Classification of materials
For piling, only the following classification of materials shall apply to the
identification and description of obstructions.
(1) Matrix
The matrix shall comprise that part of the material which will pass through a sieve
with 50 mm x 50 mm openings.
(2) Cobbles
Coarse material which will pass through a 200 mm x 200 mm opening, but will
not pass through a 50 mm x 50 mm opening. The cobbles shall be obtained from
material with at least Class R2 hardness as defined in Table 720/1.
(3) Boulders
Boulders shall mean any rock mass of hardness of at least Class R2 which will
pass through a square opening with dimensions equal to the maximum size
boulder specified in the Bill of Quantities but will not pass through a 200 mm x
200 mm opening.
(4) Rock formation

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A rock formation shall be any rock mass with hardness of at least Class R2 which
will not pass through a square opening with dimensions equal to the maximum
size boulder specified in the Bill of Quantities.
Where a boulder is cut through and part of it is left imbedded in the wall of the
hole, such boulder obstruction shall be classified as rock formation.
For the identification of rock in terms of this Clause, the classification in Table
720/1 shall apply.
(iii) Driven displacement and prefabricated piles
Where obstructions make it difficult to install driven displacement and
prefabricated piles in the positions and at the inclinations shown and to the
proper lengths by the methods specified, the Contractor shall resort to additional
methods which are suitable for the type of pile. If the successful installation of a
pile proves to be impossible after such methods have been tried, the Engineer
may order an additional pile or piles to be installed.
All such work and additional piles shall be paid for in accordance with the bid
rates where applicable.
(iv) Auger and bore pile holes
Where identified or unidentified obstructions are encountered when shaping
holes for piles, payment for penetrating the obstructions shall be made against
the appropriate pay items.
(e) Determining pile lengths
The design of the piles and pile groups, and the quantities in the Bill of Quantities
are based on the subsurface data shown on the Drawings.
The Engineer will determine the depth of piles as work proceeds.
Where variations in the subsurface water and/or soil conditions occur, the
Engineer shall be informed immediately.
If the Contractor is not satisfied that the piles will be capable of carrying the
specified loads at the depth determined by the Engineer he may, in consultation
with the Engineer, lengthen the piles to reach a suitable founding depth. Where
the Engineer and the Contractor cannot agree on the founding depth, the
Engineer may require the Contractor to:
(i) undertake additional foundation investigations and/or core drilling in
accordance with this Specification, and/or
(ii) install one or more test piles and conduct a load test in accordance with
this Specification. The Engineer will prescribe the positions for each test pile.
Test piles shall comply with the specified requirements for piling.

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(f) Piling data

The Contractor shall provide daily records of work done and materials and labour
utilised. Weekly summaries of production and individual pile records shall also
be submitted. Inter alia, the following data on each pile installed shall be
recorded in a form approved by the Engineer:
(i) The effort used for driving the pile and the resistance to penetration at
founding level.
(ii) A description of subsurface material, the presence of ground water and
the quality of material on which the pile is founded.
(iii) The quality of the materials used in the construction or manufacture of the
pile, as well as of the permanent casing if used. The method of placing and
compacting the concrete in cast in situ piles.
(iv) The method of founding of the piles e.g. bulbous bases, underreams, rock
sockets, etc, and their dimensions.
(v) The design working load of the pile.
(vi) The length of the pile and the accuracy of installation in respect of
position and inclination.
(vii) Nominal dimensions and type of pile.
(viii) Length and details of any temporary and permanent casings used.
(ix) Date of piling, pile reference number and pile location (sketch) relative to
the other piles of the same set.

TABLE 720/1
ROCK CLASSIFICATION
A scale of strength, based on the uniaxial compressive test is shown in the following table
based on BS5930 -1999. The strength of a rock material determined in the uniaxial
compression or point load test is dependent on the moisture content of the specimen,
anisotropy and the test procedure adopted, all of which influence the classification. The use of
simpler index tests in the field is recommended to provide additional data and as a check on the
manually assessed strengths; the Point Load Test and Schmidt Hammer are amongst the more
commonly used. The size and shape of lumps, strength of operator, weight of hammer and
surface on which lumps rest affect the assessment of the strength. It is therefore vital that each
description is calibrated by strength determinations.

Class Term Field definition Unconfined

compressive
strength (MPa)

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R1 Very weak Gravel size lumps can be crushed between finger and thumb. < 1.25

R2 Weak Gravel size lumps can be broken in half by heavy hand pressure. 1.25 – 5.0

R3 Moderately weak Only thin slabs, corners or edges can be broken off with heavy hand pressure. 5 – 12.5

R4 Moderately strong When held in the hand, rock can be broken by hammer blows. 12.5 – 50

R5 Strong When resting on a solid surface, rock can be broken by hammer blows. 50 – 100

R6 Very strong Rock chipped by heavy hammer blows. 100 – 200

R7 Extremely strong Rock rings on hammer blows. Only broken by sledgehammer. > 200

(g) Stripping the pile heads

Precast and timber piles shall be installed to a level of at least 0.6 m above the
cut-off level, and cast in situ piles shall be cast to a level of at least 150 mm
above the cut-off level. The excess concrete shall be so stripped off that only
sound concrete will project into the pile-capping slab.
The method of breaking the pile head shall be approved by the Engineer.
Proprietary methods may be adopted including inserts in cast in-situ piles. For
conventional break out the cut-off plane shall be marked by cutting a 20 mm
deep groove with a grinding-machine around the full circumference of the pile.
Heavy concrete demolishing equipment may not be used for the stripping of pile
heads. All loose aggregate shall be removed from the cut-off plane.
The concrete shall be so stripped off that the pile below the cut-off level will not
be damaged, or, should defective concrete be found in the completed pile, the
damaged or defective concrete shall be cut away by the Contractor at his own
cost and replaced with new concrete well bonded to the old concrete, or the pile
shall be replaced as directed by the Engineer.
The main reinforcement of the piles shall extend at least 40 times the diameter of
the main reinforcing bar beyond the cut-off level into the pile-capping slab or as
otherwise instructed. This reinforcement shall be left straight unless otherwise
directed by the Engineer.
The cut-off level for piles shall be the level shown on the Drawings.
(h) Construction of pile-capping slab
The Contractor shall not construct the pile-capping slab before the Engineer has
confirmed, in writing, that all the relevant load and/or integrity tests have been
completed and the piles have been accepted.
(i) Core drilling

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The Engineer may instruct core drilling to be done with a view to obtaining cores
of the founding formation and/or of the concrete in the completed structural
member. In the case of piling, the core drilling may precede the piling or may be
done through the completed pile, as specified, or as instructed by the Engineer.

The Contractor shall supply the necessary construction plant on the site for
drilling under the above conditions. The plant and techniques used shall be
suitable for ensuring 100% core recovery. The diameters, depths and lengths of
the cores shall be in accordance with the specifications or the instructions of the
Engineer.
The Contractor shall keep accurate records of the drilling, which, together with
the cores, shall be handed over to the Engineer. The cores shall be placed in the
correct sequence in a clearly identified wooden core box with a lid.
721 TESTING OF PILES
(a) Integrity testing
(i) Method of testing
Where integrity testing is called for, the method to be adopted shall be one of the
following, as specified:
(a) impulse method;
(b) Sonic Echo, Frequency Response or Transient
Dynamic steady state vibration method;
(c) sonic logging method.
Other methods may be considered subject to satisfactory evidence of
performance. Particular requirements are detailed in the Special Specifications.
(ii) Age of piles at time of testing
In the case of cast-in-place concrete piles, integrity tests shall not be carried out
until the number of days specified have elapsed since pile casting.
(iii) Preparation of pile heads
Where the method of testing requires the positioning of sensing equipment on
the pile head, the head shall be broken down to expose sound concrete and shall
be clean, free from water, laitence, loose concrete, over-spilled concrete and
blinding concrete and shall be readily accessible for the purpose of testing.
(iv) Specialist Sub-contractor
The testing shall be carried out by specialist personnel or an independent
integrity testing firm, subject to demonstration of satisfactory performance on
other similar contracts before the commencement of testing.

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Where required in the Special Specifications, the Contractor shall submit the
name of the specialist or integrity testing firm, a description of the test
equipment, a test method statement and a programme for executing the
specified tests prior to commencement of the Works.
(v) Interpretation of tests
The interpretation of tests shall be carried out by competent and experienced
persons. The Contractor shall give all available details of the ground conditions,
pile dimensions and construction method to the specialist before the
commencement of integrity testing in order to facilitate interpretation of the tests.
(vi) Report
Preliminary results of the tests shall be made available within 24 hours of
carrying out the tests. The test results and findings shall be recorded and made
available within 10 days of the completion of each phase of testing. The report
shall contain a summary of the method of interpretation including all
assumptions, calibrations, corrections, algorithms and derivations used in the
analyses. If the results are presented in a graphical form, the same scales shall
be used consistently throughout the report. The units on all scales shall be
clearly marked.
(vii) Anomalous results
In the event that any anomaly in the acoustic signal is found in the results
indicating a possible defect in the pile the Contractor shall demonstrate that the
pile is satisfactory for its intended use or shall carry out remedial works to make it
so. Sonic logging tubes shall be grouted up after the Contractor has
demonstrated that the pile is satisfactory.
(b) Static Load tests
(i) General
The Engineer may order certain selected piles to be load tested. The procedure
for loading tests shall comply with the requirements of BS 8004. During the
period of testing, driving of other piles or other activities which may affect the
testing shall cease.
The Engineer may specify Maintained Load (ML) or Constant Rate of Penetration
(CRP) Tests.
No working pile shall be used as an anchor pile. Where anchor piles or earth
anchors are required for providing reaction, they shall be at least three test pile
diameters and no less than 2.0m distant from the perimeter of the test pile and
be so placed as to have a minimal effect on the test results. The minimum
distance of the anchor piles to the test piles shall be confirmed and approved by
the Engineer.

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The Contractor shall provide the complete testing assembly, the necessary
constructional plant, equipment, instruments and labour for carrying out the test
and for determining accurately the settlement of the piles under each increase or
decrease of load. The test assembly, constructional plant, equipment and
instruments used shall be subject to the approval of the Engineer.
(ii) Test data
Within 24 hours of having completed the tests a preliminary copy of the test
records shall be made available which shall show:
For a ML test; for each stage of loading, the period for which the load was held,
the load and the maximum pile movement at the end of the stage.
For a CRP test; the maximum load reached and a graph of load against
penetration.
The complete set of recorded data as detailed in the Special Specifications or
requested by the Engineer shall be provided within 7 days of completion of the
test.
(iii) Loading
For ML tests the maximum test load applied shall be equal to the sum of the
design verification load (DVL) plus 50 % of the specified working load (SWL).
The loading and unloading shall be carried out in stages as shown in Table
721/1.
TABLE 721/1:
Minimum Loading Times for Pile Test

Load* Minimum Time of Holding Load

25% DVL 30 minutes

50% DVL 30 minutes

75% DVL 30 minutes

100% DVL 6 hours

75% DVL 10 minutes

50% DVL 10 minutes

25% DVL 10 minutes

100% DVL 1 hour

100% DVL + 25% SWL 1 hour

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100% DVL + 50% SWL 6 hours

100% DVL + 25% SWL 10 minutes

100% DVL 10 minutes

75% DVL 10 minutes

50% DVL 10 minutes

25% DVL 10 minutes

0 1 hour

*SWL denotes specified working load; DVL denotes design verification load.
The loading regime for CRP tests shall be defined by the Engineer unless
otherwise provided in the Special Specifications. Soil conditions actually
encountered in the test pile bore or established by test drilling at the site will be
considered by the Engineer prior to confirmation of the loading regime. Loading
shall be continued until one of the following results is obtained:
a) the maximum required test load as given in the Special Specifications or by
the Engineer is reached
b) a constant or reducing load has been recorded for an interval of penetration of
10 mm
c) a total movement of the pile base equal to 10% of the base diameter, or any
other greater value of movement specified has been reached.
The load shall then be reduced in five approximately equal stages to zero load,
penetration and load at each stage and at zero load being recorded.
(c) Defective piles
The test pile and the piles represented by the test pile shall be classified as
defective if shown to be unable to achieve either the DVL or permissible
settlement with the required minimum Factor of Safety.
Defective piles shall also include piles damaged beyond repair, piles with
structural defects, or piles which do not comply with the tolerance requirements
of this Specification.
Any piles deemed to be defective may be downgraded and utilised in the works
at the discretion of the Engineer. If required, the defective piles shall be
corrected by the Contractor at his own cost, by applying one of the following
methods approved by the Engineer:
(i) Extracting the pile and replacing it with a new pile.
(ii) Installing a new pile adjacent to the defective pile.

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(iii) Lengthening the pile to the correct length if defective in length only.
(iv) Altering the design to fit in with the new conditions caused by the
defective pile(s).
722 CAISSONS
(a) General
Caissons shall, for the purposes of these Specifications, be hollow concrete
vessels which are wholly or partly constructed at a higher level and lowered by
internal excavation or kentledge to the desired founding level to form structural
bearing members. Caissons may be of circular, rectangular or any other shape
and may contain one or more excavation compartments, all as detailed on the
Drawings.
Unless otherwise specified hereafter, the provisions of BS 8004:1986 shall apply
for the construction of caissons.
The Contractor shall submit a detailed method statement for the Works for the
approval of the Engineer prior to commencement of work. This shall include all
necessary provisions for Health and Safety and a risk assessment. If the
Contractor intends to adopt pneumatic methods (with use of a compressed air
chamber) he must employ specialist personnel experienced in this type of work.
(b) Construction and sinking
A firm base shall be prepared on which the cutting edge of the caisson shall be
laid horizontally. The level of the base shall be determined and shall be agreed
between the Engineer and the Contractor, and shall serve as the ground surface
from which the excavation inside the caisson will be measured.
Successive stages of the caisson shall be of convenient height, or as directed by
the Engineer, and shall be lined up accurately with the preceding stages.
All precast elements shall have properly constructed joints in accordance with the
Drawings to ensure that they fit correctly.
For in-situ phase construction, all construction joints in the walls shall be
reinforced and the joints shall be made as specified in this Specification.
The lowest element of every caisson, which contains the cutting edges, shall be
cured for at least four days or shall have attained at least 50% of the specified 28
day strength before sinking is commenced. Subsequent elements shall be cast
in sufficient time to ensure adequate strength for safely resisting the applied
forces.
During construction and sinking the caissons shall be maintained in a vertical
alignment.

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The position and inclination of each caisson shall be determined accurately by

measurement after every 2m of sinking, or after sinking through the depth of one
element, whichever distance is the smaller.
With a view to eliminating excess friction, the Contractor may use bentonite or a
similar lubricant or a water-jet system.
Excavation inside caisson compartments shall, unless otherwise specified herein,
comply with the provisions of this Specification.
In multi-compartmented caissons, the excavation in any one compartment shall
not be taken deeper than 0.6m below that in any other compartment, except
where necessary for correcting deviations.
Cutting edges shall be frequently inspected or probed to locate obstacles, which
shall be removed immediately.
The Contractor shall supply all grabs, pumps, diving gear and other
constructional plant required for sinking and founding all caissons and shall allow
the Engineer to use the diving suit and equipment for inspection purposes.
The Contractor shall employ a competent diver to carry out work under water and
shall make provision in the rates bid for the respective items for this cost.
Where the caisson strikes a hard inclined layer and work has to be carried out
below the cutting edge, such work shall be measured and paid for under the
relevant items of Clause 6118, and, where no applicable items exist, such work
shall be paid for as extra work.
(c) Founding
The soil or rock strata at the founding level, if sloping and/or irregular, shall in so
far as is possible be cut to as nearly level a surface as possible until the entire
cutting edge is evenly and firmly supported. Subject to the approval of the
Engineer, blasting may be used for this purpose. If blasting techniques are
required, only light charges may be used and the caisson shall be protected
against damage by suitable cushioning.
Should the sloping surface be of hard rock which cannot be cut or broken by any
safe and feasible means, the foundation shall be built up by means of a solid
wedge of concrete which fills the entire space between the bedrock surface and
the horizontal plane through the cutting edge. This concrete shall be of the same
class as that specified on the Drawings or in the Bill of Quantities for the concrete
seal.
The rock or hard material on which the structure is to be founded shall be
completely uncovered. The founding surface shall be cleared of all loose
material before inspection by the Engineer immediately prior to casting the
concrete seal.

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No concrete shall be placed in the wedge or the seal before the Engineer has
inspected and approved the foundation. For this purpose the Contractor shall
adequately dewater the caisson to enable the Engineer to conduct the
inspection.
In the event of a caisson not being vertical or in its correct position when it has
reached the required depth, or in the event of a caisson being cracked during the
sinking process, the Contractor shall at his own cost carry out the necessary
remedial work to the satisfaction of the Engineer.
(d) Data
The Contractor shall provide the Engineer with a complete record of the strata
encountered during excavation with levels related to an agreed datum. In
addition, a daily record shall be kept showing full details of work undertaken,
labour and plant utilised and the rate of sinking achieved.
(e) Filling the caissons
(i) Concrete seal
The seal shall be constructed of mass concrete of the class specified and shall
be placed in accordance with the dimensions and levels shown on the Drawings
or as prescribed by the Engineer.
If this seal cannot be placed in the dry and has to be placed under water, the
method of placing this concrete shall be approved by the Engineer. The
Contractor shall cease placing the concrete under water when sufficient concrete
has been placed to seal the foundation effectively.
After the concrete has been placed, the concrete seal and the head of water over
it shall remain undisturbed for a period of at least seven days after which the
caisson shall be dewatered by pumping for inspection. If water is found to be
leaking into the caisson the process of sealing as specified herein shall be
continued until the water level within the caisson does not rise at a rate
exceeding 10 mm per hour or other rate to be agreed with the Engineer.
The relevant requirements of the Specification shall apply for placing concrete
under water. For concrete placed under water by methods other than by tremie,
the cement content shall be 20% more than the quantity required for ordinary
concrete of the same mix but shall be not less than 450 kg/m3 of concrete. The
mix design may include additives and shall be approved by the Engineer.
(ii) Filling
Subsequent to inspection of the caisson compartments above the concrete seal,
the compartments shall be filled with sand of an approved grading and moisture
content.

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The first 2 m of filling above the concrete seal shall be lowered gently into
position. The sand may then be poured from the top and compacted sufficiently
to prevent settlement while the cover slab concrete is being placed.
The top of the sand fill within the caisson shall be finished off to the level
specified below the underside of the caisson cover slab.
(f) Stripping
Where the walls of the caisson have been overbuilt, the concrete shall be
stripped to the required level without damage being done to the concrete below
the cut-off level. The longitudinal reinforcement of the caisson shall project
above the cut-off level by a distance of at least 40 times the bar diameter.
(g) Concrete blinding below the caisson cover slabs
A concrete blinding of the specified thickness and class of concrete shall be
provided to the level shown on the Drawings over the area covered by the cover
slab, including the area within the caissons on top of the sand filling, except
where the underside of the cover slab is being formed with formwork.
(h) Environmental considerations
Water quality and marine life shall not be adversely affected in any way during
operations.
Where adverse impacts have been indicated in the Environmental Impact
Assessment Report, the Contractor shall carry out such measures as required to
mitigate and minimise negative impacts to the water quality and marine life.
The Engineer shall approve all methods that the Contractor proposes according
to the Environmental Impact Assessment Report.

723 MEASUREMENT AND PAYMENT

(a) Item : Excavate for structures in soft material
Unit: m3
Excavate for structures in soft material shall be measured by the cubic metre,
calculated as the product of the net plan area of the foundation to be
excavated and the average depth of the excavation. No allowance will be
made for working space. The average depth shall be calculated as the
difference between the original ground level as agreed between the Engineer

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and the Contractor or the formation level/ whichever is the lower, and the
required level.
The rate for excavate for structures in soft material shall include for the cost
of excavation to any depth, compaction at the foundation level of the
excavation, backfilling with the excavated material or removing the excavated
material to spoil if it is unsuitable or surplus to requirements, and complying
with the requirements of Clauses 702, 703, 704, 705, 706, 707 and 708 of
this Specification.
(b) Item : River training in soft material
Unit: m3
River training in soft material shall be measured by the cubic metre,
calculated as the product of the average end areas measured at intervals of
not greater than 10m along the centreline of the area to be excavated and the
length of the excavation. The end areas shall be calculated from existing
ground levels or existing river or stream profiles taken prior to
commencement of excavation and the cross-section shown on the Drawings
or instructed by the Engineer.
The rate for river training in soft material shall include for the cost of
excavation to any depth and to any bed width, disposal of the excavated
material to spoil and compliance with the requirements of Clauses 702, 704,
708 and 709 of this Specification.
(c) Item : Backfill to existing channels In soft material
Unit: m3
Backfill in soft material to existing channels shall be measured in accordance
with Clause 713 (b) of this Specification-
The rate for backfill in soft material to existing channels shall include for
excavating the material to be used for backfill, clearing vegetation from the
channel, transporting, depositing and compacting the material in the existing
channel all hauls as necessary and complying with Clause 709 of this
Specification.
(d) Item : Extra over (a) and (b) for excavation in hard material
Unit: m3
Hard material encountered in any excavation covered by Clause 713 (a) and
(b) of this Specification shall be measured by the cubic metre, calculated as
the product of the average end areas measured at intervals agreed with the
Engineer along the centreline of the excavation and the length over which
hard material is encountered. The end areas shall be calculated from levels
taken on top of the hard material prior to excavation and levels taken after

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excavation of the hard material or to the levels instructed whichever is the

higher.
The rate for extra over clause 713 (a) and (b) foe excavation in hard material
shall include for the cost of excavation in excavation to any depth and
compliance with the requirements of Clauses 702, 703, 704, 705, 706, 707,
708 and 709 of this Specification.
(e) Item: Porous filter material
Unit: m3
Porous filter material shall be measured by the cubic metre, calculated as the
plan area instructed to be backfilled with porous filter material and the
average depth of porous filter material instructed to be placed.
The rate for porous filter material shall include for the cost of providing the
material, backfilling at any depth, all hauls as necessary and complying with
the requirements of Clause 707 of this Specification.
(f) Item: Selected granular fill material
Unit: m3
Selected granular fill material shall be measured by the cubic metre,
calculated as the plan area instructed to be backfilled with selected granular
fill material and the selected granular fill material instructed.
The rate for selected granular fill material shall include for the coat of
providing the material, backfilling at any depth, all hauls as necessary and
complying with Clauses 702, 703, 704, 705, 706, 707 and 708 of this
Specification.

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(g) Item: Stone pitching

Unit: m3
Stone pitching shall be measured by the square metre calculated as the net
area, measured on the slope, instructed by the Engineer.
The rate for stone pitching shall include for the cost of excavating, trimming to
line and level, providing and laying the stone and of complying with the
requirements of Clause 710 of this Specification.
(h) Item: Extra over (g) for grout
Unit: m2
Grouting of the stone pitching covered by Clause 713 (g) of this Specification
shall be measured by the square metre of stone pitching instructed by the
Engineer to be grouted.
The extra over rate for grouting of stone pitching shall include for providing
the sand, cement, mortar, wetting of the stone to be grouted, ramming the
grout into the interstices and smoothing off flush with the pitched face and
complying with Clause 710 of this Specification.
(i) Item: Excavate for gabions in soft material
Unit: m3
Excavate for gabions in soft material shall be measured by the cubic metre,
calculated as the product of the net plan area of the gabion to be excavated
and the average depth of the excavation. No allowance will be made for
working space. The average depth shall be calculated as the difference
between the original ground level as agreed between the Engineer and the
Contractor or the formation level or drain profile whichever is the lower, and
the required level.
The rate for excavate for gabions in soft material shall include for the cost of
excavation to any depth, compaction of the surfaces to receive the gabions,
backfilling with the excavated material or removing the excavated material to
spoil if surplus to requirements, and complying with the requirements of
Clauses 702, 703, 704, 706, 707, 708 and 711 of this Specification.
(j) Item: Extra over (1) for excavation in hard material
Unit: m3
Hard material encountered in any excavation covered by Clause 713 (i) 'of
this Specification shall be measured by the cubic metre, calculated as the
product of the average end areas measured at intervals agreed with the
Engineer along the centreline of the excavation and the length over which the
hard material is encountered. The end areas shall be calculated from levels
taken on top of the hard material prior to excavation and levels taken after

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excavation of the hard material or to the levels instructed whichever is the

higher.
The rate for extra over Clause 713 (i) of this Specification for excavation in
hard material shall be extra over that for excavating in soft material and shall
include for the cost of excavation to any depth and compliance with the
requirements of Clauses 702, 703, 704, 706, 707, 708 and 711 of this
Specification.
(k) Item: Gabion mesh
Unit: m2
Gabion mesh shall be measured by the square metre calculated as the net
area of material required to construct the gabions, including diaphragms.
The rate for gabion mesh shall include for the cost of providing and fixing the
mesh and the cost of complying with requirements of Clause 711 of this
Specification.
(l) Item : Rockflll to gabions
Unit: m3
Rockfill to gabions shall be measured by the cubic metre calculated as the
volume of the gabions instructed to be placed.
The rate for rockfill to gabions shall include for the cost of providing, hauling
and placing the rock and the cost of complying with the requirements of
Clause 711 of this Specification.
(m) Item : Filter fabric under and/or behind gabions
Unit : m2 of each weight of fabric specified
The filter fabric placed under and/or behind gabions shall be measured as the
net area of filter fabric instructed.
The rate for filter fabric shall include for the cost of the preparation of the
surface to receive the filter fabric, the provision, transport, storing and laying
the fabric in accordance with the manufacturer's instructions, all laps and/or
stitching and for complying with the requirements of Clause 711 of thia
Specification.

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(n) Item : Dumped rip-rap

Unit: m3
Rip-rap shall be measured by the cubic metre calculated from the dimensions
given on the Drawings or instructed by the Engineer.
The rate for dumped rip-rap shall include for the cost of providing, dumping
and roughly dressing the rip-rap and complying with the requirements of
Clause 712 of this Specification.
(o) Item: Close jointed rip-rap
Unit: m3
Close jointed rip-rap shall be measured as the volume of close jointed rip-rap
instructed to be placed.
The rate for close jointed rip-rap shall include for the cost of providing,
dumping and close jointing the rip-rap and complying with the requirements of
Clause 712 of this Specification.

(p) Item Drilling of holes (diameter and type of drilling indicated)

Unit: m
The bid rate shall include full compensation for establishment on the site,
moving to individual bridge positions and the subsequent removal of all
special plant for drilling the holes and additional plant for carrying out
operations drilling and clearing the holes as specified, equipment moving and
setting up in position, drilling and clearing the holes as specified.

(q) Item Grouting (type of grout and for which purpose it is required
indicated)
Unit: kg
The unit of measurement for grouting shall be the kilogram of cement or
proprietary brand of grout mix as may be applicable used in the grouting
operation.
The bid rate shall include full compensation for providing the equipment and
all the material, and mixing and pumping the grout into the prepared holes in
accordance with the instructions of the Engineer, and also for the water-
pressure tests

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8000 CULVERT AND DRAINAGE WORKS

8001 SCOPE OF SECTION
This section covers the following:-
(a) The provision and installation of circular concrete pipe culverts, nestable and
multiplate corrugated metal pipe culverts and arches and half round
channels.
(b) The construction of minor structures including culvert inlet and outlet
structures, scour checks, catchpits, cascades and the like.
(c) The construction of drainage protection works including rip-rap, stone pitching
and gabions.
(d) The excavation and/or fill and all work associated with the construction of:-
• trenches to receive culverts
• inlets drains
• outfall drains
• mitre drains
• cut-off drains
• subsoil drains
• catchwater drains
• minor structures
• scour checks
• erosion protection works
• guiding dams.
Side drains are covered in Section 5 of this Specification.
Concrete box culverts are covered in Sections 7 and 17 of this Specification.
8002 ORDER OF WORKS
(a) The Drawings give a guide only to the location and size of each culvert.
Precise details of length, skew and invert levels will be issued to the
Contractor from time to time as construction proceeds. The Contractor should
allow in his prograiraae a period of 30 days between submission of cross-
sections in accordance with Section 3 of this Specification and the issue of
precise culvert details.
(b) All culverts and drainage works shall be carefully programmed and the
Contractor shall normally allow in his programme (submitted under Clause 14
of the Conditions of Contract) for the completion of all pipe culverts and
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drainage works prior to the construction of embankment* over or beside

them.
(c) Where the Contractor considers that drainage conditions are such that it is
not necessary to construct a pipe culvert ahead of the embankment/ the
Engineer may consent to its installation after construction of the embankment
on the following conditions:
(i) that the Contractor will be responsible for any damage or delays to the
culvert or to the embankment earthworks; and
(ii) that the construction of the culvert shall follow Immediately upon the
substantial completion of the embankment earthworks.
(d) Where culverts are to be constructed under a road formation in cutting,
excavation and backfill shall be carried out after the bulk earthworks are
complete but before the processing of the 300mm layer below formation level
in cuttings. The Engineer may consent to the excavation for these culverts
being carried out before the earthworks are completed but payment for the
excavation of the trench will only be made for the volume excavated below
formation level.
8003 CLASSIFICATION OF EXCAVATION
All excavation for culverts and drainage works shall be classified as follows:-
(a) Hard material is material which can be excavated only after blasting with
explosives or barring and wedging or the use of a mechanical breaker fitted
with a rock point in good condition and operated correctly. Boulders of more
than 0.20 m3 occurring in soft material shall be classified as hard material.
(b) Soft material is all material other than hard material.
8004 EXCAVATION FOR CULVERTS AND DRAINAGE WORKS
The Contractor shall carry out all excavations for culverts and drainage works to
the lines, levels, inclinations, and dimensions shown on the Drawings or
instructed by the Engineer.
Should excavations be effected to a greater depth or width than is necessary,
then the Contractor shall at his own expense backfill the excess excavation with
approved materials, compacted to the density of the adjacent ground, to the
correct levels and dimensions all to the approval of the Engineer.
The Contractor shall carefully set aside the various suitable materials
encountered so that they may be reused for backfilling. If excavated materials
are unsuitable the Contractor may spoil the material only after approval by the
Engineer.
All excavations shall be kept clean and free from water, and the Contractor shall
dig diversion channels, erect cofferdams or otherwise de-water the excavation.

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Where, in the opinion of the Engineer, the surface of the excavation has become
soft or unsuitable due to the Contractor's method of working, the Contractor shall
at his own expense remove and replace the unsuitable material with non-
structural concrete as specified in Section 17 of this Specification or other
approved material as instructed by the Engineer.
The final excavated surface in soft material on which culverts or structures are to
be constructed shall be compacted to a dry density of at least95% MDD
(AASHTO T99) to a depth of 150 mm. All particles larger than 20 mm shall be
removed prior to compaction.
For culverts which are to be constructed approximately on the existing ground
after the removal of topsoll, the Contractor Bhall level the existing ground by
excavating and/or filling in layers. He shall then compact the ground for 150 mm
below invert or underside of bedding material to a dry density of 95% HDD
(AASHTO T99) such that the foundation for the culvert or bedding is true to
grade and of uniform density over the whole length of the culvert.
The Engineer's approval to the final excavated surface shall be obtained prior to
the installation of culverts or the construction of structures.
The sides of pits, trenches and other excavations shall, where required, be
adequately timbered and supported, and all such excavations shall be of
sufficient size to enable the pipes and concrete to be laid accurately, and proper
refilling and compaction to be carried out.
Where instructed by the Engineer, shoring and supporting timber shall be left in
trenches or other excavations.
Where ground conditions are such that a satisfactory foundation cannot be
achieved the Contractor shall, if instructed by the Engineer, remove the
unsuitable material either until a suitable material is encountered or to the depth
and width instructed by the Engineer. The Contractor shall backfill the resultant
excavation with approved material to a dry density of 95% HDD (AASHTO T99).
Approved material may include rockftll as specified in Clause 507 of this
Specification and/or selected backfill material in accordance Clause 812 of this
Specification.
8005 EXCAVATION IN HARD MATERIAL
(a) For concrete pipe culverts
Where hard material is encountered in trenches for concrete pipe culverts, it
shall be excavated so that no hard material protrudes within 50 mm of the
underside of the pipe barrel. A regulating layer of non-structural concrete of
minimum thickness 50 mm shall be placed and compacted on, the excavated
hard material surface, the top of which shall be at the level of the underside of
the pipe barrel. The maximum thickness of regulating layer shall be 150 mm.
Where both soft and hard material are encountered in the trench either the

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soft material shall be removed to a depth of 300 am or to such depth as

instructed by the Engineer, or If directed by the Engineer the hard material
shall be removed to a depth of 300 mm or (to such depth as instructed by
Engineer and backfilled to -95V HDD (AASHTO T99) with similar material to
that in the remainder of the trench invert.
(b) For metal pipe culverts
Where hard material is encountered in trenches for corrugated metal pipe
culverts. It shall be excavated to a depth of 150 ram below the invert level of
the culvert and replaced with 150 ram of sand or other approved material to
provide a firm but flexible bed for the culvert. Where both soft and hard
material are encountered in the trench the hard material shall be removed to
a depth of 300mm or to such depth as instructed by the Engineer and
backfilled to 95% MDD (AASHTO T99) with similar material to that in the
remainder of the trench invert.
(c) For minor structures
In accordance with the relevant sections of Clause 703 of this Specification.
8006 WATER IN EXCAVATION
The Contractor shall at his own expense make good any damage caused by
prolonged and/or excessive pumping and shall take all precautions necessary for
the safety of adjoining structures and buildings by shoring or otherwise, during
the time that excavations are open.
8007 CONCRETE PIPES
Concrete pipes shall be manufactured and tested in accordance with Section 2 of
this Specification.
8008 CORRUGATED METAL PIPES AND ARCHES
Corrugated metal pipes and arches shall comply with Section 2 of this
Specification.
8009 BEDDING AND LAYING OF PIPE CULVERTS
Pipe culverts shall normally be bedded directly on in-situ soft material. Where the
in-situ material is unsuitable the Invert shall be excavated and backfilled as
specified in Clause 804 and Clause 805 of this Specification.
(a) Bedding and laying of concrete pipe culverts on in-situ or imported soft
material or imported granular material.
The bottom of the excavation shall be compacted to 95% MDD
(AASHTO.T99) and shaped to the lower part of the pipe such that the barrel
of the culvert rests on it over a width of at least one third of its diameter/ and
throughout the length of barrel.

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Voids shall be formed under the joints and sockets so that adequate space is
provided under the pipe to form the joint. When the joint has been formed the
void shall be packed hard with bedding material. The underside of the barrel
shall be packed hard with selected fill material with a maximum particle size
of 20 mm, at a suitable moisture content, and rammed solid.
(b) Bedding and laying of concrete pipes on a concrete bed
Where pipes are laid on a concrete bed the pipes shall be bedded on 1:3
cement: sand mortar at least 50 mm thick, 150 mm wide and extending the
full length of the barrel.
After the joints have been formed, concrete Class 15/20 shall be packed hard
under the barrel and sockets of the culvert and extending upwards on each
side of the pipe to the height shown on the Drawings.
(c) Bedding and laying of metal culverts
All pipes shall be laid, bedded and jointed in accordance with the
manufacturer's recommendations where shown on the Drawings the
excavation shall be trimmed to the contour of the base of the culvert and a
bed of fine granular material not less than 75 mm thick shall be placed,
compacted and shaped to enable the culvert to be bedded.
Unless otherwise directed, all pipes shall be painted prior to assembly both
inside and out with one coat of purpose made bituminous paint, approved by
the Engineer. During assembly both areas of pipe sections in contact shall be
painted with a second coat of purpose made bituminous paint immediately
prior to fixing.
After assembly all pipes shall be painted over the exposed area outside with
a further coat of purpose made bituminous paint, and all pipes of 1.2 m
diameter and over shall also be painted internally.
Pipe laying shall be started at the inlet end with the separate sections firmly
jointed together and with outside laps of circumferential joints pointing
upstream. With the permission of the Engineer pipes may be assembled out
of the trench and lowered in, in which case particular care shall be taken to
ensure-the barrels are properly bedded along the whole length. Outside laps
of longitudinal joints shall point downwards.
Multiple installations shall be laid with centrelines parallel. Unless otherwise
instructed or shown on the Drawings, the clear distance between barrels of
adjacent pipes shall be at least equal to one half the diameter of the pipes.
Where instructed by the Engineer the gradeline shall be cambered to allow
for future settlement-
8010 JOINTING CONCRETE PIPES
(a) Rigid joints
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When laying rigid jointed concrete pipes with integral sockets, before entering
a pipe spigot into its socket, both spigot and socket shall be clean and free
from mud, oil, grease or other deleterious matter. A gasket of tarred hemp
yarn, cut to length so that it forms a butt joint at the crown of the pipe, shall be
wrapped round the spigot which shall then be fully entered into the socket
and the gasket caulked up hard into the joint. The joint shall then be filled
completely with a plastic mortar composed of one part of cement to two parts
of sand and finished off with a fillet at an angle of 45°.
Rigid jointed sleeves used to join two spigots shall be jointed in the same
manner as integral sockets*
If the Drawings require ogee jointed pipes to be laid with a mortar joint, the
joint shall be made at the time of laying.
Mortar as described above shall be applied to the lower semi-circumference
of the socket and to the upper semi-circumference of the spigot and the pipe
shall be drawn hard into the socket. The outside of the joint shall be pointed
up with a fillet of 1:2 cement: and mortar, 75 mm wide and 25 mm thick, all
the way round and central over the joint.
All pipes shall be saturated with water before jointing and shall be scraped,
cleaned inside and the joint flushed up with 1:2 cement: sand mortar.
All joints shall be protected from the wind, sun and rain by covering approved
by the Engineer, and shall be kept constantly damp for a period of at least
three days.
The pipes shall not be disturbed in any way for at least 48 hours after jointing.
(b) Flexible joints
Flexible joints between concrete pipes having integral sockets may be formed
by a shaped rubber gasket fitted within the socket or by a rubber ring of
circular cross section (O-ring) placed on the pipe spigot. The type of flexible
joint to be used shall be subject to the approval of the Engineer.
Before any joint is made all parts of the joint shall be clean and free from
mud, oil, grease or other deleterious matter.
Fixed gaskets shall be lubricated strictly in accordance with the
manufacturer's recommendations. O-ring gaskets shall not be lubricated.
Components of flexible joints from different manufacturers shall not be used
together.
The spigot of the pipe to be laid shall be entered into the socket of the
previous pipe with the two pipes in line, and a firm steady pressure exerted
on the end of the pipe being laid. If necessary a jack anchored round the
collar of the previous pipe shall be used to pull in pipes. The spigot shall be

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pulled hard into the socket and then eased back the distance recommended
by the manufacturer to provide flexibility in the joint.
After jointing, the position of O-rings shall be tested with a feeler to ensure
that they are correctly positioned. If any ring shows a significant departure
from a line following a pipe circumference, the joint shall be broken and
remade using a new ring.
Where plain ended pipes are connected by a sleeve incorporating flexible
joints, the joints shall be made as described for pipes with integral sockets.
The joint between the first pipe and the sleeve shall be completed before the
second pipe is inserted into the sleeve.
The annular space inside the socket of each pipe or sleeve but outside the
gasket shall be filled with puddled clay, uncaulked yarn or other suitable
material approved by the Engineer to prevent the entry of stones.
(c) Pipe ends
mbooniwwwUnless otherwise specified pipe ends shall be left square.
8011 CONCRETE BEDS, SURROUNDS AND HAUNCHES
The floor of the trench shall be thoroughly cleaned trimmed and compacted
before any bed, surround or haunch is placed and shall be subject to approval by
the Engineer before concreting is commenced.
All concrete for beds, surrounds and haunches shall be Class 15/20 complying
with Section 17 of this Specification formed to the dimensions shown on the
Drawings or instructed by the Engineer.
Unless otherwise instructed by the Engineer, 150 mm of concrete surround shall
be provided to concrete pipes - in the following circumstances:
(a) Concrete pipes up to and including 600 mm diameter with less than 0.60
m cover or more than 3.0 B of cover;
(b) concrete pipes over 600 mm diameter and not exceeding 900 mm
diameter with less than 1.0 m of cover or more than 3.0 m of cover; and
(c) concrete pipes over 900 mm diameter, at any depth.
8012 BACKFILL
Backfill for concrete and metal pipes and minor drainage structures shall be
obtained from the material excavated in forming the excavation and in the event
of there being insufficient excavated material or the culvert is laid close to or
above existing ground then selected backfill shall be obtained from borrow pits.
All backfill whether from excavated material or borrow pits shall have a
CBR of at least 5 measured after 4 day soak on laboratory mix compacted to
95% MDD (AASHTO T99), a Plasticity Index of less than

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35%, a maximum particle size of 20 mm and shall be compacted to a dry density

of 95% MDD (AASHTO T99).
For pipe culverts which have been placed and where no concrete haunch for
surround is called for, selected fill material, consisting of the finest available from
the excavation shall be placed in layers not exceeding 150 mm loose thickness
and water shall be uniformly mixed in or the material dried out, such that the
moisture content at the .time of compaction shall be between 75% and 105% of
the Optimum Moisture Content (AASHTO T99) and thoroughly compacted along
the remainder of the underside of the barrel of the pipe and in the joint holes.
Similar selected material shall then be laid in layers, not exceeding 150 mm
loose thickness, mixed, dried or watered as necessary and compacted, and
brought up uniformly on both sides of the pipe up to a height of not less than 300
mm over the crown.
The remainder of the trench shall then be backfilled with the best selected
material available, placed in layers not exceeding 150 mm loose thickness,
mixed, watered or dried as necessary, and compacted.
All backfilling material shall be compacted to a minimum dry density of 95% Of
MDD (AASHTO T99).
Timbering and sheeting left in for the purposes of supporting the excavation shall
be eased up 150 mm at a time in step with the backfill layer and compaction of
the backfill shall be achieved under and behind such timber and sheeting.
For pipe culverts which have been constructed close to, above or where the
Culvert protrudes above the existing ground the backfilling under the flanks and
alongside and over the culverts shall be placed and compacted in layers not
exceeding 150 mm after compaction to a density of at least the density required
for the material in adjoining layers of fill. The width of backfilling - along the flanks
of the culvert shall be at least (2+1.5h) metres from each side of the culvert
(Where 'h’ Is the height from the underside of the layer being compacted to the
crown of the pipe in metres). All existing ground under this backfill shall be
compacted to 95% MDD (AASHTO T99) to a depth of 150 mm.
The material used for filling alongside the culvert above existing ground shall be
the same material as will be used for the adjacent fill and no additional payment
will be made other than that provided for the fill In Section 5 of this Specification.
Backfilling shall be carried out simultaneously and equally on both sides of the
culvert to avoid unequal lateral forces.
In all cases there shall be cover of at least 600 mm over the crown of the culvert
before construction equipment is driven over it unless other protective measures
approved by the Engineer have been provided.
Where instructed by the Engineer that the acidity of the material used for
backfilling shall be neutralised, the Contractor shall add 5% of lime by weight, or

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such other quantity as the Engineer may instruct, to the fill material throughout
the width and depth instructed by the Engineer. The lime shall be evenly spread
over the surface of each layer of fill material and shall be mixed in with rakes and
the moisture content adjusted as necessary before it is compacted.
8013 HALF ROUND CONCRETE CHANNELS
600 mm diameter half round concrete channels shall comply with Section 2 of
this Specification except that they will not be subject to a load test. Where a
channel is cast in pipe moulds, every care shall be taken to see that the battens
separating the two halves are rigidly secured to the mould, the edges of the
channel are parallel to the axis of the barrel, and each channel is of identical
shape.
The excavation to receive the half round concrete channels shall be compacted
to 95% MDD (AASHTO T99) to a depth of 150 mm and shaped as shown on the
Drawings before the channel is laid. The invert of the trench shall be accurately
excavated to line and level and shaped so that the barrel of the channel rests on
a width of one third of its diameter and throughout the length of the barrel.
After the channel is laid selected fill material shall be placed, watered if
necessary, and compacted against the sides of the channel for the remainder of
the height so that the channel is rigidly held in position before the next length is
laid. Joints shall be made by placing a thick covering of 1:3 cement mortar on the
joint face of the section already installed before driving the ne*t channel section
hard up against it. The excess mortar squeezed out of the joint shall be neatly
trowelled off to a smooth invert.
All channel ends shall be soaked with water for one hour before jointing and all
joints shall be protected from the wind, sun and rain by a covering acceptable to
the Engineer and shall be kept constantly damp for a period of at least 3 days
after forming.
8014 SUBSOIL DRAINS
A subsoil drain includes any type of drain designed to collect groundwater
whether this is rising from below or percolating from the surface and may or may
not include a pipe* It may also include impermeable membranes above or below
the pipe or permeable filter membranes all as detailed on the Drawings, or
instructed by the Engineer during the course of the Works. Instructions for
subsoil drains in cuttings will not generally be given until the bulk earthworks are
complete within that particular cutting and subsoil drains that are instructed shall
be completed before the work on the adjacent 300 mm layer below formation
commences.
Trenches for subsoil drains shall be not less than 0-5 m wide or the outside
diameter of the pipe plus 0.3m whichever is the greater. Concrete pipes shall

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comply with Section 2 of this Specification and shall be laid with joints open by 10
mm.
The filling in subsoil drains shall be clean hard crushed rock or gravel, and, in
soils where fines are not liable to migrate, the grading shall be in accordance with
BS 882 for 37.5 mm maximum size graded aggregate or as otherwise instructed
by the Engineer,
Where more than one size of stone is required in a trench, the different sizes
shall be kept separate by temporary metal or plywood baffles which shall be
removed when the filling is complete, or by other suitable means acceptable to
the Engineer.
Where permeable filter membranes are instructed they shall be ‘Terram' or
similar approved material. Transverse joints shall be lapped by at least 0.5m with
the upstream material laid on top.
Longitudinal joints shall be stitched together. 'Terram' or similar approved
material shall not be left exposed to sunlight for more than 3 weeks, and shall be
installed in accordance with the manufacturer's instructions.
8015 PROTECTION WORK
Where shown on the Drawings or instructed by the Engineer the Contractor shall
provide and place protection works.
Protection work in connection with drainage channels, culvert inlets and outlets
and river training will consist generally of stone pitching, gabions or rip-rap in
accordance with Section 7 of this Specification.
8016 MINOR DRAINAGE STRUCTURES
Minor drainage structures shall include culvert inlet and outlet structures,
catchpits, cascades, spillways and the like. Typical details are shown on the
Drawings but working details will be issued by the Engineer from time to time
during the Contract-Concrete for minor drainage structures shall be Class 20/20
in accordance with Section 17 of this Specification unless otherwise shown on
the Drawings. The surface finish shall be DTI for unformed surfaces and Class PI
for formed surfaces.
Unless otherwise specified or shown on the Drawings concrete shall be
reinforced in the back and front faces of all walls and the top and bottom of all
slabs with 10 ram diameter high yield deformed bars placed at 200 mm centres
both horizontally and vertically to form a mesh. The reinforcement shall be fixed
in accordance with, and shall comply with, the requirements of Section 17 of this
Specification.

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8017 MITRE DRAINS, CUT-OFT DRAINS, CATCHWATER DRAINS, SIDE DRAINS,

CULVERT OUTFALL DRAINS ASP EARTH DAMS
Mitre drains, cut-off drains, catchwater drains, culvert outfall drains and earth
dams shall be formed at the locations and to the lines and levels shown on the
Drawings or as instructed by the Engineer.
Where shown on the Drawings or instructed by the Engineer the Contractor shall
construct earth dams in side drains, cut-off drains, catchwater drains, mitre and
outfall drains to prevent the flow overshooting the drainage works or to direct
flows into culvert inlets. Similar earth structures may also be used as erosion
checks.
Earth dams shall be formed in selected fill material compacted to a minimum dry
density of 95% MDD (AASHTO T99). Where stone pitching and/or gabions are
Instructed they shall be in accordance with Section 7 of this Specification. Where
topsoiling and grassing is instructed it shall be in accordance with Section 5 of
this Specification.
8018 SCOUR CHECKS
The Contractor shall excavate in the invert of aide drains, cut-off drains,
catchwater drains, outfall drains and mitre drains for scour checks to be located
as shown on the Drawings or directed by the Engineer. The width and depth of
the scour check will be determined by the drain and scour check dimensions and
shall be as directed by the Engineer.
Concrete for scour checks shall be Class 20/20 which shall comply with the
requirements of Section 17 of this Specification or if shown on the Drawings or
directed by the Engineer scour checks shall be gabions in accordance with
Section 7 of this Specification. Formwork shall be provided and placed for all
concrete required above the existing drain profile and shall comply with the
requirements of Section 17 of this Specification. Unless otherwise specified or
shown on the Drawings concrete for scour checks shall be reinforced in the back
and front faces with 10 mm diameter high yield deformed bars placed at 200 mm
centres both horizontally and vertically to form a mesh. The reinforcement shall
be fixed in accordance with, and shall comply with, the requirements of Section
17 of this Specification.
Where the overflow section of a scour check is above the invert level of the drain
the void upstream of the scour check shall be backfilled to the level of the
overflow section. The upper 50 mm of the backfill shall be topsoil and shall be
planted with grass and such topsoiling and grassing shall comply with the
requirements of Section 5 of this Specification*
8019 CLEANING AND MAINTENANCE
The Contractor shall be responsible for maintaining the existing and new
drainage system during construction of culverts and all other drainage works

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such that water is passed along and across the Works without damage to the
Works and all cofferdams, diversions, pumping, temporary drainage works or
other, works necessary shall be provided and maintained at the Contractor's
expense. Any damage to the Works caused by the Contractor's failure to make
adequate provision for drainage of the Works shall be repaired at the
Contractor.'s expense.
Before any drainage channel, culvert or other drainage structure is brought into
use, the Contractor shall ensure that such channel or structure is free from all silt
and extraneous material and the removal and disposal of all such material shall
be at the Contractor's expense.
Notwithstanding Clause 48 of the Conditions of Contract, the Contractor shall be
responsible for maintaining all drainage structures, culverts, channels and drains
free of silt and extraneous material at his own expense until the issue of the
Maintenance Certificate in accordance with Clause 62 of the Conditions of
Contract and any damage to the Works caused by his failure to maintain the
drainage system shall be repaired at the Contractor's expense.
8020 MEASUREMENT AND PAYMENT
(a) Item : Excavate for culverts and subsoiI drains in soft material
Unit: m3
Excavation for culverts and subsoil drains shall be measured by the cubic metre,
calculated as the product of the width of the excavation and the sectional area of
the excavation measured along its length and these shall be determined from (1)
and (2) below:-
1. Width of excavations
(i) The width of excavation, W, to install a culvert shall be determined from the
following formula:
W - nD + (n-l)C + A
Where:
n - the number of culverts
D = the external diameter of the pipe in metres which, in the case of corrugated
metal pipes, shall be measured to the outside edge of the corrugations.
C = 0.15 m for concrete pipes surrounded in concrete
C = 0.30 m for concrete pipes not surrounded in concrete
C = 0.5 D for corrugated metal pipes
A = 0.3 m for concrete pipes surrounded in concrete
A = 0.6 m for concrete pipes of 600 mm nominal diameter or less not surrounded
in concrete
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A = 0.9 m for concrete pipes of 750 mm nominal diameter or greater not

surrounded in concrete.
A = 0.9 m for corrugated metal pipes.
(ii) The width of trenches for subsoil drains shall be as shown on the Drawings or
as instructed or measured by the Engineer, whichever is the lesser.
2. Sectional area of excavations
The sectional area of the excavation, measured in square metres, shall be
calculated as the product of the average depth of the excavation and the length
of subsoil drain or culvert which is to be constructed. The average depth shall be
measured from the Instructed final profile and the average depth as calculated
from the following:-
(i) Where a trench excavation Is carried out in and "" through a previously
constructed road embankment, the depth of the trench shall be measured
from the underside of the pipe or the concrete surround, haunch or bed, to
formation level, or to a point one metre above the top of the pipe culvert, -
whichever is the lesser.
(ii) Where a trench excavation is carried out ahead of road embankment
construction, the depth of the trench shall be measured from ground level
existing at the time of excavation to the underside of the pipe or the concrete
surround, haunch or bed.
(iii) Where a trench excavation is required under a road cutting, its depth shall be
measured from formation level to the underside of the pipe or concrete
surround, haunch or bed.
(iv) The depths of excavation measured in (2) (i) to (2) (iii) above, refer to
excavation in soft material; where the excavation is in hard material the
underside of the excavation shall be in accordance with Clause 805 of this
Specification.
Where a satisfactory invert cannot be achieved the depth and width of the
excavation shall be in accordance with Clause 804 of this Specification.
The rate for excavation of culverts and subsoil drains in soft material shall include
for the cost of excavation to any depth, compaction of the invert of the
excavation, backfilling with the excavated material or removing the excavated
material to spoil if it is unsuitable or surplus to requirements, and complying with
the requirements of Clauses 802, 803, 804, 806, 809, 812, 814 and 819 of this
Specification.
(b) Item : Excavate for minor drainage structures
Unit : m3

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The rate for excavation for minor drainage structures in soft material shall include
for the cost of excavation to any depth, compaction of the invert of the
excavation, backfilling with the excavated material or removing the excavated
material to spoil if it is unsuitable or surplus to requirements, and complying with
the requirements of Clauses 802, 803, 804, 806, 812, 816 and 819 of this
Specification.
(c) Item : Excavate for inlet, outfall, mitre and catchwater drains in soft material
Unit : m3
Excavation for inlet, outfall, mitre and catchwater drains shall be measured by the
cubic metre, calculated as the product of the average end areas measured at
intervals of not greater than 10 m along the centreline of the drain and the length
of the drain. The end areas shall be calculated from existing ground levels or
existing drain profiles taken prior to commencement of excavation and the cross-
section and longitudinal profile of the drain as shown on the Drawings or
instructed by the Engineer.
The rate for excavation for inlet, outfall, mitre and catchwater drains shall include
for the cost of excavation to any depth, excavation for bed widths not greater
than 2.5 m wide, disposal of the excavated material to spoil and compliance with
the requirements of Clauses 802, 803, 804, 806, 817 and 819 of this
Specification. Where the instructed bed width for an inlet, outfall, nitre or
catchwater drain is greater than 2.5 m then the excavation shall be measured
and paid for under Clause 820 (d) : Channel excavation in soft material.
(d) Item : Channel excavation in soft material
Unit : m3
When the instructed bed width for an inlet, outfall, mitre or catchwater drain is
greater than 2.5 m it shall be classified as channel excavation which shall be
measured by the cubic metre calculated as for Clause 820 (c) of this
Specification.
The rate for channel excavation in soft material shall include for the cost of
excavation to any depth, disposal of the excavated material to spoil and
compliance with the requirements of Clauses 802, 803, 804, 806, 817 and 819 of
this Specification.
(e) Item : Excavate for cut-off drains in soft material
Unit: m3
Excavation for cut-off drains shall be measured by the cubic metre, calculated as
the product of the average end areas measured at intervals of not greater than
10 m along the centreline of the drain and the length of the drain. The end areas
shall be calculated from existing ground levels or existing drain profiles taken

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prior to commencement of excavation and the cross-section and longitudinal

profile of the drain as shown on the Drawings or instructed by the Engineer.
The rate for excavation for cut-off drains in soft material shall include for the cost
of excavation to any depth, forming and compacting the berm on the lower side
of the drain and for compliance with the requirements of Clauses 802, 803, 804,
806, 817 and 819 of this Specification*
(f) Item: Extra over (a) to (e) for excavation in hard material.
Unit: m3
Hard material encountered in any excavation covered by Clause 820 (a) to (e)
shall be measured by the cubic metre, calculated as the product of the average
end areas measured at intervals agreed with the Engineer along the centreline of
the excavation and the length over which hard material is encountered. The end
areas shall be calculated from levels taken on top of the hard material prior to
excavation and levels taken after excavation of the hard material.
(g) Item : Selected backfill material
Unit: m3
Selected backfill material shall be measured by the cubic metre, calculated as
the product of the average end area (excluding any pipe or concrete surround)
and the length of selected backfill material instructed to be placed.
The rate for selected backfill material shall include for the cost of providing the
material, backfilling at any depth, all hauls as necessary and complying with the
requirements of Clauses 809, 812 and 814 of this Specification.
(h) Item : Crushed rock backfill in subsoil drains
Unit: m3
Crushed -rock backfill in subsoil drains shall be measured by the cubic metre,
calculated as the product of the average end area and the length of the subsoil
drain. The end area shall be calculated as the product of the depth of crushed
rock backfill instructed and the width of the excavation calculated in accordance
with Clause 820 (a) of this Specification less the end area of the pipes.
The rate for crushed rock backfill shall include for the cost of providing the
material, backfilling at any depth, all hauls as necessary and complying with the
requirements of Clause 814 of this Specification.
(i) Item : Rockfill below culverts
Unit: m3
Rockfill below culverts shall be measured by the cubic metre calculated as the
plan area and average depth of rockfill instructed.

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The rate for rockfill below culverts shall include for the cost of providing and
placing the material, all hauls as necessary and complying with the requirements
of Clauses 507 and 804 of this Specification. The filter fabric will be measured
and paid for separately.
(j) Item : Provide, lay and joint pipes
Unit: m of each type, diameter and gauge
Provide, lay and joint pipes shall be measured by the metre calculated as the
instructed length measured along the centreline of the culvert or subsoil drain.
The rate for provide, lay and joint pipes shall include for the cost of providing the
pipes and complying with the requirements of Clause 807, 808, 809, 810, 814
and 819 of this Specification.
(k) Item : Concrete Class 15/20 to beds, surrounds and haunches
Unit: m3
Concrete Class 15/20 to beds, surrounds and haunches shall be measured by
the cubic metre calculated as the product of the end area and the instructed
length of bed, surround or haunch. The end area shall be as shown on the
Drawings or directed by the Engineer and shall exclude the area of the pipe.
The rate for concrete Class 15/20 to beds, surrounds and haunch.es shall
Include for the cost of providing and placing the concrete and complying with the
requirements of Clauses, 805, 809, 811, and 819 of this Specification.
(l) Item : Concrete Class 20/20 to minor drainage structures
Unit: m3
Concrete Class 20/20 to minor drainage structures shall be measured by the
cubic metre calculated from the dimensions given on the Drawings or Instructed
by the Engineer.
The rate for concrete Class 20/20 to minor drainage structures shall Include for
the cost of providing and placing the concrete, reinforcement and shuttering and
complying with the requirements of Clauses 816 and 819 of this Specification,
(m) Item: Earth dams
Unit: m3
Earth dams shall be measured by the cubic metre calculated from the
dimensions shown on the Drawings or directed by the Engineer.
The rate for earth dams shall include for the cost of providing the fill material,
placing and compacting, all hauls as necessary and complying with the
requirements of Clause 817 of this Specification.
(n) Item: Concrete scour checks

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Unit: m3
Scour checks shall be measured by the cubic metre calculated from the
dimensions of the scour check shown on the Drawings or directed by the
Engineer.
The rate for scour checks shall include for the cost of providing and placing the
concrete, reinforcement and shuttering and complying with the requirements of
Clause 818 of this Specification.
Measurement and payment for gabion scour checks will be made in accordance
with Section 7 of this Specification.
(o) Item: filler fabric to rockfill and subsoil drains
Unit: m2 each weight of fabric specified
The rate for filter fabric shall include for the preparation of the *- surface to
receive the filter fabric, the provision, transport, storing and laying the fabric in
accordance with the manufacturer's instructions, all laps and/or stitching and
complying with the requirements of Clauses 804 and 814 of this Specification.
(p) Item: Lime to backfill PROVISIONAL
Unit: tonne
Lime to backfill shall be measured by the tonne calculated as the product of the
rate of addition instructed and the volume instructed to be treated with lime.
The rate for lime to backfill shall include for the cost of providing, transporting,
spreading and mixing the lime at the rate of spread instructed by the Engineer
and for complying with the requirements of Clause 812 of this Specification.
(q) Item : Half round concrete channels
Unit: m
Provide and lay half round concrete channels shall be measured by the metre
calculated as the instructed length measured along the centreline of the channel.
The rate for half round concrete channels shall include for the cost of excavation
in any material, preparation of the bed, providing and laying the half round
concrete channel, backfilling with selected material and complying with the
requirements of Clauses 802, 804, 806 812, 813 and 819 of this Specification.

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9000 PASSAGE OF TRAFFIC

9001 SCOPE OF THE SECTION
(a) Where public traffic using an existing road is affected by construction of the
new road and, where shown on the Drawings or instructed by the Engineer to
do so, the Contractor shall carry out one or more of the follow1ng:-
(i) Effect improvements to and maintain existing roads.
(ii) Construct and maintain deviations.
(iii) Pass traffic through or over the Works.
(b) The Contractor shall provide and maintain temporary signs, barriers, lights
etc. along deviations and existing roads adjacent to the Works in order to
ensure the safe passage of traffic during the Contract.
(c) The Contractor shall provide adequate notice of the Implementation of
deviations etc. and shall ensure efficient and safe passage of traffic at all
times.
(d) The Contractor shall be required to provide and maintain all access and haul
roads to ensure access to all parts of the Site for his plant, labour and
materials.
(e) The Contractor shall be required to protect the Works and adjacent public
roads from the effects of his own construction traffic.
9002 IMPROVEMENTS TO EXISTING ROADS
Where shown on the Drawings or instructed by the Engineer the Contractor shall
carry out improvements to any existing road adjacent to or affected by the Works
including:-
(a) Site clearance and removal of topsoil from the shoulders and verges.
(b) Scarifying, re-shaping, widening and watering and compacting the top
150mm of the existing road to 95% MDD (AASHTO T99) compaction.
(c) Laying, gravel wearing course.
(d) Cutting, re-shaping and deepening where necessary, side drains and mitre
drains, including clearing and maintaining existing protection works.
(e) Clearing and maintaining culverts and cutting or deepening outfall drains.
(f) Clearing and maintaining existing watercourses and protection works
(g) Repair of potholes in bitumen roads.
(h) Re-sealing of bitumen roads.
(i) Providing erecting and maintaining temporary traffic signs, barriers lights etc.

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The extent of improvements required will be detailed in the Special Specification.

9003 MAINTENANCE OF EXISTING ROADS
The Contractor shall maintain the existing roads scheduled in the Special
Specification from the commencement of the Contract until the adjacent section
of new road or deviation where applicable is opened to public traffic.
The road shall be maintained to the same standard as existed at the
commencement of the Contract or to the standard following improvement under
Clause 902 of this Specification. Maintenance shall include watering, full width
grading and dragging as necessary, keeping clear watercourses and culverts,
cutting grass, minor repairs to culverts and bridges and assistance to traffic. In
the case of bitumen roads, potholes and edge failures shall be repaired with cold
asphalt mixed and laid in accordance with Part D of Section 16 of this
Specification.
Major repairs to culverts and bridges, flood damage, resealing and re-gravelling
may be instructed in which case separate payment will be made.
9004 CONSTRUCTION OF DEVIATIONS
(a) General
Where shown on the Drawings or instructed by the Engineer the Contractor
shall construct and maintain deviations.
The length of a deviation shall be the shortest practicable route having regard
to gradient and obstructions and the detailed alignment shall be agreed
between the Engineer and the Contractor.
The Contractor shall give at least one months’ notice in writing of his intention
to commence construction of any deviation along any section of the Works
and such notice shall include details of locations of any deviation, cross-
overs, one-way traffic operations, restricted widths, culverts, drainage, drifts,
bridges, gradients in excess of 7.0%, earthworks, signs, barriers, lights, traffic
lights, and methods of operation of the entire system. Upon approval of such
notice in writing from the Engineer the Contractor shall become responsible
for the passage of traffic including maintenance of the deviation and the
project road in that section.
Should the Contractor propose/ and the Engineer approve, that a deviation
be located other than as shown on the Drawings then the Contractor shall be
responsible for all land acquisition, payment for land acquisition, negotiation
with landowners and appropriate Authorities, diversion of services including
telephone lines, power lines, water pipes etc., all at the Contractor's expense,
and the construction, operation and maintenance of the deviation in
Specification.

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Where telephone poles, power poles or other services are outside but close
to the edge of a deviation the Contractor will be responsible for protection of
such poles or services and for negotiation with the relevant Authority or
owner with respect to the type of protection and the method of removing or
replacing stay wires, propping of poles etc.
Where services cross the deviation the Contractor shall protect such services
and shall negotiate with the relevant Authority or owner as to the method of
protection and shall comply with all the requirements of such Authorities or
owners. Where services are required to be moved, diversion of such services
shall be in accordance with Clause 121 of this Specification.
Land required for deviations shall be acquired in accordance with Clause 124
of this Specification except where the Contractor has proposed an£
alternative route for the deviation.
(b) Geometry
Deviation shall be constructed to the cross-section shown on the Drawings.
Single-lane traffic operation shall not be permitted unless in the opinion of the
Engineer, it is impracticable 'to provide a two-lane deviation. A single-lane
carriageway shall not be less than 4.0m wide with traffic control and passing
bays provided at approximately 250 metre intervals.
The gradient of any deviation shall not exceed 7%, except with the approval
of the Engineer, and any change of gradient shall be formed to a smooth
vertical curve with a length of not less than 60 m. Where gradients In excess
of 7.0% are encountered on any deviation the Contractor shall ensure the
safe and convenient passage of traffic and if necessary shall seal the
deviation with a double seal surface dressing or other approved seal and
shall maintain such seal whilst the deviation is in use.
(c) Construction
Site Clearance and earthworks shall be carried out in accordance with
Sections 4 and 5 of this Specification except in respect of measurement and
payment which shall be in accordance with Clause 912 of this Specification.
Gravel wearing course shall be constructed in accordance with Section 10 of
this Specification. The thickness of gravel wearing course shall be as shown
on the Drawings or instructed by the Engineer.
(d) Drainage and drifts
Temporary ditches, culverts, drifts and bridges of adequate size and strength
shall be constructed for the deviation where necessary.
The length of a drift shall be such that there is less than 150mm of water over
it, except in flood.

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The edge of a drift shall be defined with posts or other markers acceptable to
the Engineer and a gauge installed to indicate the maximum depth of water
over the road. The minimum width of drift shall be 3.5m.
Existing bridges shall be checked by the Contractor and if found inadequate
to pass the traffic, and at other locations where a drift would not be
practicable, the Contractor shall construct temporary bridges of adequate size
and strength to pass the traffic.
(e) Reinstatement of deviation
Prior to the commencement of construction of any deviation or the use of land
provided for the deviations the Contractor shall supply one 125 mm by 175
mm colour print of each of a series of photographs taken at a maximum of
500 m intervals- along the line of the deviation and the Contractor shall not
commence construction of any deviation until the prints have been agreed
with the Engineer as being a true record of the condition of the land prior to
construction including land usage, fences, existing roads and tracks, drainage
and any other features.
The Contractor shall reinstate the deviation to a condition similar to the
condition prevailing prior to the commencement of construction of the
deviation. The colour prints provided by the Contractor may be used by the
Engineer to confirm that the reinstatement is satisfactory. Where the
deviation is on private land the Contractor may obtain a written statement,
signed by the landowners, requesting that the deviation be left unreinstated in
lieu of reinstating the deviation. Where the deviation is within the road reserve
or on other land owned by the Government of Kenya the Contractor shall
reinstate the deviation to a condition similar to the condition prevailing prior to
the commencement of construction of the deviation.
9005 MAINTENANCE OF DEVIATIONS
The Contractor shall maintain the deviations constructed under Clause 904 of
this Specification to the standard existing at the time of opening to traffic, from
the date of opening until the adjacent section of new road is opened to public
traffic.
Maintenance shall include watering, full width grading and dragging as
necessary, keeping clear watercourses and culverts, cutting grass, minor repairs
to culverts drifts and bridges, and rendering assistance to public traffic.
9006 PASSAGE OF TRAFFIC THROUGH THE WORKS
Where shown on the Drawings or instructed by the Engineer that traffic is to be
passed through or across the works the Contractor shall so order his work in half
widths or in short lengths, so as to pass traffic over or across his work.

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The frequency and duration of delays to traffic while being passed through or
across the Works, shall be kept to a minimum and shall not exceed 30 minutes
without the prior agreement of the Engineer and should normally be less than 5
minutes. Any method of working, which requires a road closure in excess of 30
minutes shall require 48 hours prior notice to, and the agreement of, the
Engineer, who may refuse to allow such closure in default of due notice or may
require rescheduling of the closure.
The Contractor shall ensure, when passing traffic through the works that all
excavations and other hazards are properly protected with barriers and are
illuminated at night.
9007 SIGNS, BARRIERS AND LIGHTS
The Contractor shall provide, erect and maintain temporary signs, barriers, lights,
traffic lights etc. along existing roads scheduled in the Special Specification and
along deviations constructed in accordance with Clause 904 of this Specification.
The number, type and siting of these signs etc. shall be in accordance with the
Drawings and this Specification, or as directed by the Engineer.
The construction of all warning signs, prohibitory signs, mandatory signs and
priority signs used for temporary signing shall comply with the requirements of
the latest edition of the "Manual for Traffic Signs in Kenya", Part II.
Direction signs, advance direction signs and confirmatory signs may be
manufactured as fixed short life signs.
Sign plates for fixed short life signs shall be manufactured from hardboard
""plywood or chipboard or other material that is approved by the Engineer. The
sign shall be constructed so as not to deteriorate during the estimated time the
sign will be in use, and shall be to the satisfaction of the Engineer. The face of
the sign shall be sealed with a wood filler, or otherwise treated to provide a
satisfactory appearance. The sign shall be supported on one or more posts made
of wood. The support shall be strong enough to withstand the loading that is
estimated will be placed on the sign. The fixing of fixed short life signs may be
achieved by nailing, screwing or glueing the sign plate to its supports, to the
satisfaction of the Engineer.
Where one-way traffic operation is necessary the Contractor shall provide,
maintain and operate traffic lights. The use of "Stop" and "Go* boards provided,
maintained and operated by the Contractor shall be permitted between 0630
hours and 1830 hours in lieu of traffic lights. Traffic lights shall be used at all
other hours. The use of flags in lieu of either "Stop" and "Go" boards or traffic
lights will not be permitted.
Where the distance between the edge of a road or deviation and the permanent
Works is less than 10 m, continuous fences and barriers shall be erected. Such
fences and barriers shall be painted red and white in alternate sections. Where

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pedestrians must use the line of the road or deviation for access, similar fences
and barriers shall be provided to separate pedestrians and traffic.
Barriers, other hazards and entrances to detours and deviations and one-way
operations shall be illuminated throughout the night by red lamps or amber
flashing lights provided by the Contractor and supported at a height of between
0.7m and 1.35m above the road, and maintained burning bright.
In addition to the signs detailed on the Drawings the Contractor shall provide,
erect and maintain on deviations and existing roads the temporary traffic signs
detailed in Table 9-1 whose reference numbers refer to the "Manual for Traffic
Signs in Kenya" Part II.
9008 DIVERSION OF ACCESS ON TO NEW CONSTRUCTION
Where as a result of the Works, an existing public or private road is to be
permanently closed, or diverted, or temporarily diverted or re-opened to traffic,
the Contractor shall give the Engineer at least one month's notice of his
requirements or intentions. Depending on the length of road and amount of work
involved, the Engineer may negotiate with the appropriate Authority or owner
regarding the method, order and times of carrying out the work and issue
instructions to the Contractor accordingly. Where the amount of work involved is
small, the Engineer may instruct the Contractor to make his own arrangements.
In all cases, the Contractor shall obtain the Engineer's Instructions and no road
shall be interfered .with in any way until the appropriate Authority's or owner's
consent to the work has been obtained.

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TABLE 9-1 TEMPORARY TRAFFIC SIGNS

Reference Description Location

100 m each side of all bends having a radius of less than 160
W1/W2 Sharp bend ahead
m.

100m each side of all series of bends having radii of less than
W3/W4 Sharp bends ahead
160 m-

W5/W6 Steep hill ahead 100 x each side of all gradients exceeding 7.0%.

100 m each side of locations where the deviation reduces from

W7 Road narrows ahead
normal width to restricted width.

W13A Severe dip ahead 100 m each side of hazard.

W138B River-bed crossing 100 m each side of all drifts.

W22 Roadworks ahead 100 m each side of roadworks.

W23 Traffic lights ahead 200 m each side of lights.

W25 Two-way traffic ahead 100 x before and at 250 m intervals within the two-way section.

W26 Hazard ahead 100 m each side of hazard.

100 m before all junctions where traffic is required to yield or

W27 Road junction ahead
stop.

Dangerous change in
W36 At dangerous locations.
direction of road

W38 Hazard demarcation At hazards.

R1/R2 Stop/Give Way At junctions where traffic is required to yield or stop.

M3 Turn at next junction As required.

A6 "Deviation Ahead" As required.

A6 "Heavy Plant Turning" As required.

A4 200 m As required.

A4 100 m As required.

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9009 ASSISTANCE TO PUBLIC

The Contractor shall render such assistance to the public aa shall be necessary
to allow safe and convenient passage of traffic at all times.
9010 ACCESS ROADS
(a) Access to the Site
The Contractor shall be responsible for providing and maintaining at his own
expense access to all parts of the Site for his plant, labour and materials and
local public traffic where no alternative access is available. Where there is no
deviation or existing road providing access to or along the new alignment, the
Contractor must construct and maintain his own access and haul roads as
required, all at his own expense. All such accesses shall be available for the
use of the Employer.
(b) Public highways
Where the Contractor proposes to use an existing public highway as an
access to a borrow area, or as a haulage road for the construction of any
work under the Contract, such as is likely to cause a subsequent claim for
"extraordinary traffic", the Contractor shall give the Engineer at least one
month's notice of his intention to use such a road. The Engineer may call for
a joint inspection of the road by the appropriate Highway Authority, the
Contractor and the Engineer, to agree upon a statement of the actual
condition of the road prior to use by the Contractor and to determine the
extent of any remedial work required.
Where, in the opinion of the Engineer, the existing highway is inadequate to
withstand the volume and weight of the Contractor's traffic, the Engineer may
instruct the Contractor:
(i) to improve the road;
(ii) to construct a temporary road in lieu; or
(iii) to use an alternative route.
(c) Private roads
Where the Contractor proposes to use a private road as an access road to
the Works, a quarry or a borrow pit it shall be entirely his responsibility to
comply with any conditions laid down by the owner, and the Employer will be
in no way responsible for any claim arising from such arrangements.
(d) New roads
Access roads to stockpile and spoil areas, quarries and borrow pits shall be
constructed on the line agreed or instructed by the Engineer. The access
road shall follow the shortest practicable route between the stockpiles or spoil
area, quarry or borrow pit and the nearest point to it on the new alignment.

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The access road shall be drained with ditches and culverts of adequate size
and strength and existing watercourses shall be maintained in proper working
order.
The siting of the junction of an access road with the existing road shall be to
the satisfaction of the Engineer and the Contractor shall comply with the
Engineer's instructions, particularly regarding clearance of obstructions to
provide adequate sight lines, temporary drainage or culverts and the
provision of signs and traffic control.
(e) Reinstatement
The Contractor shall be required to reinstate all access roads in accordance
with Clause 904 (e) of this Specification.
(f) Administration
The Contractor shall be wholly responsible for all administrative and financial
arrangements for the construction of access roads and for all costs arising
out of them, such as negotiations with the owner and occupier for the use of
the land, and paying rent and/or compensation.

9011 CONTRACTOR’S CONSTRUCTION TRAFFIC

(a) Use of new road or road under construction
The Contractor will not be permitted to use completed sections of the road or
deviation or any completed pavement or surfacing layer for hauling
earthworks, pavement or other materials with earthwork plant or vehicles
having axle loads exceeding the legal limit. Furthermore, the use of
completed sections of the road or completed pavement layers will be
restricted if, in the opinion of the Engineer, damage to structures, subgrade,
the formation, and pavement or surfacing could ensue.
Any damage to the completed formation or to a completed pavement layer
caused by any of the Contractor's vehicles, whether with legal axle loading or
otherwise, shall be repaired as instructed by the Engineer and at the
Contractor's expense.
In addition the Contractor will not be permitted to operate vehicles having
axle loads exceeding the legal limit on any public road in Kenya.
The Contractor shall allow the Engineer to carry out check axle weighing on
his vehicles and shall observe any instructions given by the Engineer with
regard to reduced loadings should this prove necessary.
(b) Use of deviations and existing road
If, in the opinion of the Engineer, additional work is required on deviations
and existing roads, solely as a result of the requirements or effects of the

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Contractors construction traffic, the cost of all such additional work shall be
borne by the Contractor.
9012 MEASUREMENT AND PAYMENT
(a) Item: Improve existing road
Unit: Km
Improve existing road shall be measured by the kilometre to the nearest 0.1
km along the centreline of the existing road.
Measurement and payment will only be made for lengths of road over which
improvements have been carried out in accordance with the Engineer's
instructions.
The rate for improve existing road shall include for the cost of complying with
all, the requirements of Clause 902 of this Specification with the exception of
gravel wearing course which shall be measured and paid for separately.
(b) Item : Construct deviation
Unit: km
Construct deviation shall be measured to the nearest 0.1 km along the
centreline of the deviation. Measurement and payment will only be made for
lengths of deviation instructed by the Engineer and constructed to his
approval.
The rate for construct deviation shall include for the cost of complying with all
the requirements of Clause 904 of this Specification with the exception of
gravel wearing course which shall be measured and paid for separately.
(c) Item : Provide signs and barriers
Unit: Km
Provide signs and barriers shall be measured to the nearest 0.1 km along the
centreline of the project road as defined in the Special Specification.
Measurement and payment will only be made when the Contractor has
submitted, and the Engineer approved, the proposals for the passage of
traffic In accordance with Clause 904 ' of this specification and when the
Contractor has Installed the necessary signs and barriers etc. along
deviations and existing roads, all to the Engineer's satisfaction.
The rate for provide signs and cost of complying with the Specification
barriers shall include for the requirements of Clause 907 of this
(d) Item : Maintain the passage of traffic
Unit: Lump Sum

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Maintenance of deviations and existing roads, maintenance of signs, barriers,

lights, traffic lights, stop-go boards, etc., the passing of traffic through or
across the Works and compliance with all the provisions of Section 9 of this
Specification for which no separate payment is expressly stated shall be paid
for by the Lump sum stated in the Special Specification.
Payment of the Lump Sum will be by equal monthly instalments over the
period of the Contract excluding the Period of Maintenance.
The conditions attached to the payment of the instalments are:-
(i) That the total sum of instalments paid shall not exceed the Lump Sum.
(ii) If, in any month, the Engineer is not satisfied that the Contractor has fully
complied with all the provisions of Section 9 of this Specification, he shall
withhold the whole of the instalment due and if the Contractor fails to
comply with the Engineer' s instructions within 14 days of the instalment
becoming due the Contractor shall forfeit such instalment.
The Engineer, having given 14 days’ notice to the Contractor and in the
event of the Contractor's subsequent default, may deduct from any
payments due to the Contractor, in addition to withholding any
instalments due, all reasonable expenses incurred by the Employer,
including the costs of employing another Contractor to carry out the works
instructed, necessitated by the failure of the Contractor to comply properly
with the provisions Included in Section 9 of this Specification.
(iii) That the instalment will be subject to the deduction of retention money.
The Contractor shall be deemed to have allowed elsewhere in his rates
and prices for any difference between the Lump Sum stated and the
actual cost of maintaining the passage of traffic.
(e) Item: Gravel wearing course
Unit: m3
Where the Engineer instructs gravel wearing course to be laid on existing
roads or deviations, measurement and payment shall be in accordance with
Clause 1011(a) of Section 10 of this Specification.
(f) Item : Overhaul of gravel wearing course
Unit: m3 km
Overhaul of gravel wearing course shall be measured and paid for in
accordance with Clause 1011(b) of Section 10 of this Specification.
(g) Item: Access roads
Unit: km

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Access roads shall be measured by the kilometre to the nearest 0.1 Km, from
the boundary of the borrow pit along the centerline of the access road to the
edge of the new road reserve.
(h) Item: Reinstatement of deviations
Unit: Lump Sun
Reinstatement of deviations shall be paid for by the Lump Sum stated in the
Special Specification.
Payment of the Lump Sum shall be made when all the deviations along the
entire project road have been reinstated in accordance with the requirements
of Clause 904 of this Specification.
The Contractor shall be deemed to have allowed elsewhere in his rates and
prices for any difference between the Lump Sun stated and the actual cost of
reinstating deviations.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

1000 GRAVEL WEARING COURSE

1001 GENERAL
(a) Definitions
The term "gravel" used throughout this Section means any material used as a
wearing course, and shall - include lateritic gravel, quartzitlc gravel,
calcareous gravel, decomposed rock, soft stone, coral rag, clayey sands and
crushed rock.
A "gravel wearing course" means a top surfacing course constructed from
one or a combination of these materials and may be a course placed on the
formation of a new road where no pavement and final bituminous surface is
included in the Contract, or placed on the formation of a service road,
deviation or access road.
(b) Sources of material
Material for gravel wearing course may be obtained from any of the following
sources:-
(i) Borrow pits
(ii) Spoil areas
(iii) Excavation in cuttings, widened if necessary.
In all cases the Engineer will instruct the Contractor as to the source of
material to be used and the location in which it is to be placed.
(c) Inspection of site
Where a source of material is available for inspection during the Tender
Period the Contractor shall satisfy himself as to the nature and amount of
work involved particularly in respect of the volume of overburden, the quality
and hardness of material, the degree of selection necessary, the method of
extraction, and access to the source.
(d) Borrow pits and spoil areas
The Contractor shall comply with all the requirements of Section 6 of this
Specification in respect of borrow pits and spoil areas.

1002 CLASSIFICATION OF MATERIAL

Gravel wearing course material shall be material which can be extracted from a
borrow area or a road cutting by ripping to a depth of 300 mm with a single tine
hydraulic ripper acceptable to the Engineer drawn by a track type crawler tractor
in good order complete with all equipment and accessories as supplied and rated
at 300 BHP flywheel power or over with an operating weight of not less than 37.2

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

tonne and being operated in accordance with the manufacturer

recommendations.
The material may require the use of either a grid or sheepsfoot roller with-more
than 8000 kg mass per metre width of roll to break it down and/or screening to
achieve the specified grading.

1003 MATERIAL REQUIREMENTS

The grading of the gravel after placing and compaction shall be a smooth curve
within and approximately parallel to the following envelope:-

Sieve % by weight passing

(mm) Class 1 Class 2
37.5 - 100
28 100 85 - 100
20 95 - 100 85 - 100
14 80 - 100 65 - 100
10 65 - 100 55 - 100
5 45 - 85 35 - 92
2 30 - 68 23 - 77
1 25 - S6 18 - 62
0.425 18 - 44 14 - 50
0.075 12 - 32 10 - 40

The material shall have a minimum CBR of 20 at 95% MDD (AASHTO T180) and
4 days soak.
The plasticity requirements and the class of material shall be specified in the
Special Specification.

1004 ORDER OF WORK

Unless otherwise instructed by the Engineer, the Contractor shall commence
laying wearing course starting 4s close as possible to the source and shall work
away from it so that the maximum amount of compaction is given to the wearing
course by the Contractor's vehicles. The Contractor shall route his vehicles to
give even wear and compaction over the whole width of the wearing course.
Where black cotton, or other high-swelling material, is used in the upper
subgrade layers, the Contractor shall place wearing course material upon this
section immediately after compaction of formation level.

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1005 PREPARATION OF FORMATION

The formation shall be cleaned of all foreign matter, and any potholes, loose
material, ruts, corrugations, depressions and other defects which" have appeared
due to improper drainage, traffic or any other cause shall be corrected, and, if
considered necessary by the Engineer, the Contractor shall ' scarify, water, grade
and recompact the subgrade to line and level all at his own expense. The
Engineer may require the formation to be proofrolled by a loaded truck, scraper
or other approved means prior to dumping of the wearing course material. The
cost of all such proofrolling shall be at the Contractor's expense.

1006 SETTING OUT

The gravel wearing course shall be set out in accordance with Section 3 of this
Specification.

1007 LAYING AND COMPACTING GRAVEL WEARING COURSE

The gravel wearing course material shall be deposited in such quantity and
spread in a uniform layer across the full width required, so that the final
compacted thickness is nowhere less than shown upon the Drawings or
instructed by the Engineer. Every reasonable effort shall be made to prevent
segregation during the loading, hauling, dumping, spreading, mixing, trimming
and compacting operations.
The compacted thickness of any layer laid, processed and compacted at one
time shall not exceed 225 mm and where a greater compacted thickness is
required, the material shall be laid and processed in two or more layers. The
minimum layer thickness shall be 100 mm.
The material shall be broken down in the pavement to the grading specified in
Clause 1003 of this Specification. Any oversize material which cannot be broken
down to the required size shall be removed and disposed of by the Contractor.
The material shall be scarified and the moisture content adjusted by either
uniformly mixing in water or drying out the material such that the moisture
content during compaction is between 80% and 105% of the Optimum Moisture
Content (AASHTO TI80). It shall be graded and trimmed to final line and level.
Light compaction may be applied before the final trim is carried out but once 2S%
of the compactive effort has been applied no further trimming or correction of
surface irregularities will be allowed.
The final trim shall be in cut and the Contractor shall ensure that material from
the trim is neither deposited in low areas nor spread across the section but
graded clear of the works.
Following the final trim the material shall be compacted to a dry density of at
least 9S% MDD (AASHTO T180). During the grading, trimming and compaction
of the material the Contractor shall ensure that the surface and/or the material

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

does not dry out by applying fog sprays of water or other approved means
sufficient to maintain the surface and/or material within the specified limits of
moisture content.

1008 PROOFROLLING
The Contractor shall proofroll the completed layers in accordance with Clause
1205 of this Specification.

1009 TOLERANCES
The gravel wearing course shall be constructed to the tolerances specified in
Section 3 of this Specification.

1010 MAINTENANCE
The wearing surface shall be maintained by the Contractor in its finished
condition and shall be watered, graded, dragged, reshaped, or recompacted as
necessary, until the Certificate of Completion is issued, or until the Engineer
instructs that the road shall be opened to public traffic, whichever is the sooner.

1011 MEASUREMENT AND PAYMENT

(a) Item: Gravel wearing course
Unit: m3 of each type in each method of measurement.
Gravel wearing course shall be measured by the cubic metre placed and
compacted upon the road calculated as the product of the compacted
sectional area specified to be laid and the length instructed.
Separate items are included in the Bills of Quantities to cover the following
circumstances:-
(i) The source of material is available for inspection by the Contractor at the
time of tendering - Method A.
(ii) The source of material is not available for inspection by the Contractor at
the time of tendering - Method B.
The rates for gravel wearing course provided in accordance with Method A
shall include for the cost of the following:-
(i) Opening up the borrow area, site clearance, removal of topsoil and
overburden, fencing, drainage, and landscaping and topsoiling on
completion and leaving neat and tidy.
(ii) Constructing and maintaining access roads, complying with •conditions of
access, traffic control, safety and public health requirements, fencing,
drainage and making good on completion and leaving neat and tidy.

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(iii) Excavation and selection of material, removing and spoiling of oversize

material, screening, stockpiling, providing and mixing water, or drying out
the material, mixing, processing, spreading, and compaction.
(iv) Spreading, providing and admixing of fines if necessary, rolling,
brooming, making good defective areas and maintenance of the surface.
(v) Loading, hauling a free haul of 1.5km measured from the centre of
volume of the source of material and dumping the material.
(vi) Complying with the requirements this Specification of Section 2, 6 and 10
of this specification
The rates for gravel wearing course provided in accordance with Method B
shall include for the cost of complying with all the provisions for Method A
described above except the following which shall be measured and paid for
separately:-
(i) Site clearance of the borrow area per hectare in accordance with Section
4 of this Specification.
(ii) Removal of topsoil (if instructed by the Engineer stockpiled separately!
from the borrow area per accordance with Section 4 of this Specification.
(iii) Length of access road, per km, in accordance with Section 9 of this
Specification.
(iv) Removal of top soil and/or overburden, as "Spoil", from the borrow area
per cubic metre in accordance with Section 5 of this Specification.
(b) Item: Overhaul
Unit: m3 km
The unit of overhaul will be the m3 km. The overhaul quantity shall be
measured as the product of the overhaul length and the quantity of material
overhauled measured in accordance with Clause 1011(a) of this
Specification.
The rates for providing and laying gravel wearing course shall include for the
cost of a free haul of 1.5km measured from the centre of volume of the
source of the material.
The overhaul length shall be the length from a point 1.5km from the centre of
volume of the source of material to the centre of volume of the total
overhauled material. It shall be measured to the nearest 0.1 km along the
shortest practicable route from the source of the material to the nearest point
on the new alignment and then along the new alignment to the centre of
volume of the overhauled material.
The rate shall include for the cost of haulage in excess of the free haul and
the maintenance of all haul roads.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

1100 SHOULDERS TO PAVEMENT

1101 DEFINITIONS
The term "shoulder" means that part of the road construction above formation
level, between the edge of the pavement and the side ditch or embankment
slopes. It is illustrated in Fig 1-2 in Section 1 of this Specification and is divided
into "upper shoulder" and "lower shoulder".

1102 MATERIAL FOR CONSTRUCTION OF SHOULDERS

Material for construction of shoulders shall be as shown on the Drawings or
instructed by the Engineer. It may consist of:-
(a) Gravel wearing course or natural material in accordance with Sections 10 and
12 of this Specification.
(b) Graded crushed stone in accordance with Section 13 of this Specification.
(c) Cement or lime treated material or lean concrete in accordance with Section
14 and 14A of this Specification.
(d) A bituminous mix in accordance with Section 16 of this Specification*
(e) A combination of (a) to <d) above.

1103 CONSTRUCTION OF SHOULDERS

Shoulders shall be construed concurrently with, or subsequent to, construction of
the adjacent pavement layers. Shoulders shall not be constructed ahead of
adjacent pavement layers and the Contractor shall ensure that the method of
construction is such that at no time is water prevented from draining off any of
the pavement layers. The method of laying and compacting shoulder material
and the compaction requirements will be in accordance with the relevant sections
of Clauses 1204 and JJQS of this Specification.

1104 SETTING OUT AND TOLERANCES

Shoulders shall be set out and constructed to the tolerances given in Section 3 of
this Specification.

1105 SURFACE TREATMENT OF SHOULDERS

Surface treatment of shoulders shall be as shown on the Drawings or instructed
by the Engineer.
Bituminous surface treatments shall be in accordance with Section 15 of this
Specification.

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Where topsoil and grassing is shown on the Drawings or instructed by the

Engineer, 50 ram of humus or topsoil shall be spread on the completed shoulder
and lightly rolled. Sprigs of approved indigenous 'runner' type grass as directed
shall be planted and kept watered until growth is established. Topsoiling and
grassing shall be in accordance with the requirements of Clause 514 of this
Specification.

1106 MEASUREMENT AND PAYMENT

Where shoulders are constructed in the same material as the adjacent pavement
layers no separate items will be included in the Bill of Quantities for shoulder
construction and the measurement and payment will be in accordance with the
relevant Clauses in Sections 10, 12, 13, 14 and 16 of this Specification.
Where shoulder construction differs from that of adjacent pavement layers the
method of measurement and payment will be in accordance with the relevant
clauses relating to the type of material shown on the Drawings or instructed by
the Engineer for shoulder construction but itemised in this Section 11 of this
Specification. The rate for shoulder construction shall include for the costs of
complying with Clauses 1101, 1102, 1103 and 1104 of this Specification.

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1200 NATURAL MATERIAL SUB BASE AND BASE

1201 GENERAL
(a) Definitions
The term "natural material- includes .lateritic gravel, quartzitic gravel,
calcareous gravel, soft stone, coral rag, conglomerate, sand or clayey sand
or a combination of any of these materials. A natural material is also referred
to as “gravel".
(b) Sources of materials
Natural material for subbase and base may be obtained from any of the
following sources:-
(i) Borrow pits
(ii) Spoil areas
(iii) Excavation in cuttings, widened if necessary.
In all cases the Engineer will instruct the Contractor as to the source of
material to be used and the location in which it is to be placed.
(c) Inspection of site
Where a source of material is available for inspection during the Tender
Period the Contractor shall satisfy himself as to the nature and amount of
work involved particularly in respect of the volume of overburden, the quality
and hardness of material, the degree of selection necessary, the method of
extraction, and access to the source.
(d) Borrow pits
The Contractor shall comply with all the requirements of Section 6 of this
Specification in respect of borrow pits.
1202 CLASSIFICATION OF MATERIAL
Natural material shall be material which can be extracted from a borrow area or a
road cutting by ripping to a depth of 300 mm with a single tine hydraulic ripper
acceptable to the Engineer drawn by a track type crawler tractor in good order
complete with all equipment and accessories as supplied and rated at 300 BHP
flywheel power and over with an operating weight of not less than 37.2 tonne and
being operated in accordance with the manufacturer's recommendations.
The material may require the use of either a grid or sheepsfoot roller with more
than 8000 kg mass per metre width of roll to break it down and/or screening to
achieve the specified grading.

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1203 MATERIAL REQUIREMENTS

(a) Subbase
The grading and material requirements after placing and compaction shall
conform to the following requirements:-
Gravels:
- Maximum size max 63mm
- Plasticity Index max 15%
Sands, silty and clayey sands:
- % passing 2mm sieve max 95%
- % passing 0.075 mm sieve min 10 - max 30%
- Plasticity Index min 5 – max 12%
All materials
- Uniformity Coefficient min 5%
- Plasticity Modulus max 250%
- CBR at 95% MDD (AASHTO T180)
and 4 day soak min 30%
(b) Base
The grading of the material after placing and compaction shall be a smooth
curve within and approximately parallel to the following envelope:-

Sieve Size Percentage by

(mm) weight passing
50 100
37.5 95 - 100
28 80 - 100
20 60 - 100
10 35 - 90
5 20 - 75
2 12 - 50
1 10 - 40
0.425 7 - 33
0.075 4 - 20
The material requirements after placing and compaction shall comply-with the
following limits:-

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- Los Angeles Abrasion max 50%

- Aggregate Crushing Value max 35%
- Plasticity Index max 15%
- Plasticity Modulus max 250%
- CBR at 95% MDD (AASHTO T180)
and 4 day soak min 80%
(c) Natural material for cement or lime Improved subbase
The material to be treated shall conform to the following requirement:-
Gravels:
- Maximum size 10 - 50mm
- % passing 0.075mm sieve max 40%
Sands, silty and clayey sands:
- Maximum size 0.5 - 10mm
- % passing 0.075mm sieve max 50%
All materials:
- Plasticity Index max 30%
- Plasticity Modulus max 2500
- Organic matter max 2%
Additional requirements for lime treated materials:
- % passing 0.425mm sieve min 15%
- Plasticity Index min 10%
After treatment the material shall have a CBR of "at least 60% measured
after 7 day cure and 7 day soak on the site mix compacted to at least 95%
MDD (AASHTO T180) and the treated material shall have a Plasticity Index
between 5 and 12% and a Plasticity Modulus less than 250.

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(d) Natural material for cement or lime improved base

The materials to be treated shall conform to the following requirements:-
Gravels:
- maximum size 10 - 50mm
- % passing 0.075mm sieve 5 - 35%
Sands, silty and clayey sands:
- maximum size 1 – 10mm
- % passing 0.075mm sieve max 40
- Uniformity Coefficient min 5
All materials:
- Plasticity Index max 20%
- Plasticity Modulus max 2000
- Organic matter max 1%
- CBR at 95% MDD (AASHTO T180)
and 4 day soak min 20%
Additional requirements for lime treated materials:
- % passing 0.425mm sieve min 15%
- Plasticity Index min 10%
After treatment the material shall have a CBR of at least 160% measured
after 7 day cure and 7 day soak on the site mix compacted to at least 95%
MDD (AASHTO T180) and the treated material shall have a Plasticity Index
less than 6% and a Plasticity Modulus less than 250.
(e) Natural materials for cement stabilized base
The material to be treated shall conform to the following requirements.
Gravels and coarse clayey sands:
- maximum size 2 – 40mm
- % passing 0.075mm sieve max 35%
- Uniformity Coefficient min 10
- Plasticity Index max 25%

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- Plasticity Modulus
Mix-in-place method max 1500
Stationary plant method 700
- CBR at 95% MDD (AASHTO T180)
and 4 day soak min 30%
After treatment the material shall have a UCS of at least 1800 kN/m^
measured after 7 day cure and 7 day soak on the site mix compacted at 95%
MDD (AASHTO T180J and the treated material shall have a Plasticity Index
of less than 6% and a Plasticity Modulus of less than 250.
1204 LAYING AND COMPACTING
The material shall be deposited in such quantity and spread in a uniform layer
across the full width required, so that the final compacted thickness is nowhere
less than shown on the Drawings or instructed by the Engineer. Every
reasonable effort shall be made to prevent segregation after mixing and during
the dumping spreading, trimming and compacting operations.
The compacted thickness of any layer laid, processed and compacted at one
time shall not exceed 225 mm and where "a greater compacted thickness is
required, the material shall be laid and processed in two or more layers. The
minimum layer thickness shall be 100 mm.
The material shall be broken down to the grading specified in Clause 1203. Any
oversize material which cannot be broken down to the required size shall be
removed and disposed of.
The material shall be scarified and the moisture content adjusted by either
uniformly mixing in water or drying out the material such that the moisture
content during compaction is between 80% and 105% of the Optimum Moisture
Content (AASHTO T180). It shall be graded and trimmed to final line and
level. Light compaction may be applied before the final trim is carried out but
once 25% of the compactive effort has been applied no further trimming or
correction of surface irregularities will be allowed.
The final trim shall be in cut and the Contractor shall ensure that material from
the trim is neither deposited in low areas nor spread across the section but
graded clear of the works. Following the final trim the material shall be
compacted to a dry density of at least 95% MDD (AASHTO T180). During the
grading, trimming and compaction of the material the Contractor shall ensure that
the surface and/or the material does not dry out by applying fog sprays of water
or other approved means sufficient to maintain the surface and/or material within
the specified limits of moisture content.

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On completion of compaction, the surface shall be well closed, free from

movement under compaction plant and free from compaction planes, ridges,
cracks, loose or segregated material. If the surface fails to meet the requirements
of this Specification the Contractor shall take the action set out in the appropriate
part of Section 3 of this Specification or such other action as the Engineer may
instruct or agree.
1205 PROOFROLLING
Unless otherwise directed by the Engineer, the Contractor shall proofroll the
completed layer with a steel three wheeled roller applying a load of not less than
5 tonnes per metre width of roll and the layer shall be free from visible movement
under the proofroller. Approval of the layer will only be given after the satisfactory
completion of the proofrolling and any remedial measures will be at the
Contractor's expense.
1206 SETTING OUT AND TOLERANCES
The layer shall be set out and constructed to the appropriate tolerances
specified in Section 3 of this Specification.
1207 DRAINAGE OF SUBGRADE, SUBBASE AND BASE LAYERS
The subgrade, subbase and base shall be kept continuously drained and any
damage caused by water accumulating on or running off the surface shall be
made good at the Contractor's expense. In particular, the drainage requirements
of Section I and Section 11 of this Specification shall apply.
Should water accumulate on any part of the subgrade, subbase or base, the
Contractor shall remove and dispose of any material which becomes saturated,
or cannot then be compacted to the required density, and shall replace it to
specification, all at his own expense.
1208 TREATED MATERIALS
Lime or cement treatment, if required by the Special Specification or Drawings,
shall be carried out in accordance with Section 14 of this Specification.
1209 MEASUREMENT AND PAYMENT
(a) Item : Natural material for subbase or base
Unit: m3 of each type in each method of measurement
Natural material for subbase or base shall be measured by the cubic metre
placed and compacted upon the road calculated as the product of the
compacted sectional area specified to be laid and the length instructed.

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Separate items are included in the Bills of Cjuantities to cover the following
circumstances:-
(i) The source of material is available for inspection by the Contractor at the
time of tendering - Method A.
(ii) The source of material is not available for inspection by the Contractor at
the time of tendering - Method B.
The rates for natural material for subbase or base provided in accordance
with Method A shall include for the cost of the followlng:-
(i) Opening up the borrow area, site clearance, removal of topsoil and
overburden, fencing, drainage, landscaping and topsoiling on completion
and leaving neat and tidy.
(ii) Constructing and maintaining access roads, complying with conditions of
access, traffic control, safety and public health requirements, fencing,
drainage and making good on completion and leaving neat and tidy
(iii) Excavation and selection of material, removing and spoiling of oversize
material, screening, stockpiling, providing and mixing water or drying out
the material, mixing, processing, spreading, and compacting.
(iv) Spreading, providing and admixing of fines if necessary, rolling^, making
good defective areas and maintenance of the surface.
(v) Loading, hauling a free haul of 1.5km measured from the centre of
volume of the source of material and dumping the material.
(vi) Complying with the requirements of Section 2, 6 and 12 of this
Specification.
The rates for natural material for subbase and base provided in accordance
with Method B shall include for the cost of complying with all the provisions
for Method A described above except the following which shall be measured
and paid for separately:-
(i) Site clearance of the borrow area per hectare in accordance with Section
4 of this Specification.
(ii) Removal of topsoll (if instructed by the Engineer to be stockpiled
separately) from the borrow area per are in accordance with Section 4 of
this Specification.
(iii) Length of access road, per km, in accordance with Section 9 of this
Specification.
(iv) Removal of topsoil and/or overburden, as "Spoil", from the borrow area
per cubic metre in accordance with Section 5 of this Specification.
(b) Item: Overhaul

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Unit: m3 km
The unit of overhaul will be the m3km. The overhaul quantity shall be
measured as the product of the overhaul length and the quantity of material
overhauled measured in accordance with Clause 1209(a) of this
Specification.
The overhaul length shall be the length from a point 1.5km from the centre of
volume of the source of material to the centre of volume of the total
overhauled material. It shall be measured to the nearest 0.1 km along the
shortest practicable route from the source of the material to the nearest point
on the new alignment and then along the new alignment to the centre of
volume of the overhauled material.
The rate shall include for the cost of haulage in free haul and the
maintenance of all haul roads.

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1300 GRADED CRUSHED STONE SUBBASE AND BASE

1301 DEFINITIONS
"Graded crushed stone" shall mean crushed stone with a smooth grading curve
which is within a specified envelope. The stone class shall be specified in the
Special Specification.
The nominal size of graded crushed stone shall be referred to by the
denomination O/D as defined by the grading in Clause 1303 (c) below.
The class and nominal size of the graded crushed stone to be provided will be
specified in the Special Specification.
1302 SOURCES OF MATERIAL
The Contractor shall be responsible for locating and developing suitable sources
of material for graded crushed stone. Such sources shall be termed quarries and
the opening up of quarries and the construction and maintenance of access
roads shall be carried out in accordance with Section 6 of this Specification.
1303 MATERIAL REQUIREMENTS
The material shall comply with the following requirements:-
(a) It shall consist of crushed stone, free from clay, organic or other deleterious
matter.
(b) It shall comply with the following physical requirements:-
(i) Stone Classes A, B and C.

Base Subbase

Stone Class A B C A B C

LAA Max. 30 40 45 40 45 50

ACV Max. 25 30 32 30 32 35

SSS Max. 12 12 12 20 20 20

FI Max. 25 30 30 35 35 35

CR Min. 100 80 60 30 30 -

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(ii) Stone Class D

Base
CBR at 95% MDD (AASHTO T180) and 4 days soak min 80%
Los Angeles Abrasion max 50%
Aggregate Crushing Value max 35%
Plasticity Index max 15%
Subbase
The plasticity of the material will be specified in the Special Specification.
CBR at 95% MDD (AASHTO T180) and 4 days soak min 30%
(c) It shall comply with the following grading:
(i) Stone Classes A, B and C.
The grading of the material, after processing, placing and compaction in
the pavement shall be a smooth curve within, and approximately parallel
to, one of the following envelopes. The class and nominal size shall be
specified in the Special Specification:

Sieve Percentage by weight

Size Base Subbase
(mm) 0/30 0/40 0/40 0/60
75 - - - 100
63 - - - 95 - 100
50 - 100 100 85 - 100
37.5 100 90 - 100 90 - 100 75 - 95
28 90 - 100 75 - 95 75 - 95 60 - 87
20 65 - 95 60 - 90 60 - 90 50.- 80
10 40 - 70 40 - 75 35 - 75 30 - 67
6.3 30 - SS 30 - 63 25 - 63 23 - 58
2 20 - 40 20 - 45 15 - 4S 13 - 40
1 15 - 32 8 - 3S 7 - 32
0.425 10 - 24 15 - 31 4 - 23 4 - 20
0.075 4 - 10 5 - 15 0-12 0-10

Cleanliness and plasticity: Material passing the 0.425 mm sieve shall be non-
plastic

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(ii) Stone Class D

Base

Sieve Size % by weight

(mm) passing
50 100
37.5 90 - 100
28 80 - 100
20 60 - 100
10 35 - 90
5 20 - 75
2 12 - 50
1 10 - 40
0.425 7 - 33
0.075 4 - 20

Subbase
Maximum particle size to be 2/3 layer thickness or 80 mm whichever is
the lesser
Uniformity Coefficient : min 5
(d) The grading and physical requirements of the material for use in treated
material in accordance with Section 14 of this Specification shall be specified
in the Special Specification.
1304 CRUSHING, SCREENING AND MIXING
Unless otherwise instructed, crushing shall be carried out in at least two stages.
The crushing, screening and proportioning of materials, and their subsequent
mixing shall be carried out using such methods and machines as shall be
acceptable to the Engineer.
To avoid segregation, graded crushed stone shall be moistened when being
handled and shall not be stockpiled in heaps higher than 5 m.
Should the Contractor wish to add material from another source in order to
achieve the specified grading, the following conditions shall apply:-
(i) The Contractor shall be responsible for all costs associated with the provision
and mixing in of the material, including land acquisition.
(ii) The material shall be non-plastic and consist of 90-100% quartz or other
approved hard, sharp durable particles and shall be free from organic
materials, clays and other, deleterious substances.

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(iii) Only material passing the 6.3mm sieve may be added. The percentage to be
added shall be agreed with the Engineer and in any case shall not exceed
15% by weight of the mixture.
(iv) The minimum crushing ratios specified in Clause 1303 of this Specification
shall be maintained.
1305 TRANSPORTING GRADED CRUSHED STONE
Graded crushed stone shall be transported damp and in such a way that no
segregation occurs.
1306 LAYING AND COMPACTING GRADED CRUSHED SUBBASE AND BASE
The Contractor shall take appropriate measures to prevent segregation during
dumping and spreading operations.
The graded crushed stone shall be laid by plant capable of distributing the
graded crushed stone in a layer of uniform thickness and without segregation.
The compacted thickness of any layer laid, processed and compacted at one
time shall not exceed 200 mm/ and where a greater thickness is required, the
graded crushed stone shall be laid in two or more layers.
The compacted thickness of any base layer shall not be less than 3 times the
maximum size of the graded crushed stone and the compacted thickness of any
subbase layer shall not be less than 2 times the maximum size of the graded
crushed stone.
As soon as possible after laying, compaction shall be carried out. The moisture
content shall be adjusted as necessary and, during compaction, care shall be
taken to maintain the moisture content evenly at the required value. Unless
otherwise instructed by the Engineer, the moisture content at the time of
compaction shall be between 80 and 100% of the Optimum Moisture Content as
determined by the vibrating hammer method in BS 1377 - Test 14. The
appropriate sections of Clause 1204 of this Specification shall apply.
All rolling shall be longitudinal and shall commence at the outer edges of the
pavement and progress towards the center, except that on super elevated
curves, rolling shall progress from the lower to the higher edge. Where laying is
carried out in lanes care must be taken to prevent water entrapment.
The dry densities to be achieved as a percentage of the Maximum Dry Density
(MDD) determined by the vibrating hammer method in BS 1377 Test 14 shall be:
Base:
Average dry density not less than 98% MDD with no result less than 96%
MDD with no results less than 96% MDD

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1400 CEMENT AND LIME TREATED MATERIALS

1401 SCOPE OP SECTION

This section deals with the addition and mixing in of cement or lime,
hereinafter described as the "stabilizer", to the upper layers of
earthworks as described in Section 5, natural materials as described
in Section 12, and crushed materials as described in Section 13, of
this Specification.
Following the addition and mixing in of the stabilizer the material is
referred to as "treated material". Treated material may either be lime
on cement improved material, or cement stabilized material.
This section also deals with the compaction and curing of the treated
material.
Treated materials may be used in the upper earthworks layers,
shoulder layers, subbase layer or base layer.

1402 SOURCES OF MATERIALS

In accordance with Sections 5, 12 and 13 of this Specification.

1403 MATERIAL REQUIREMENTS

(a) Natural materials
In accordance with Sections 5, 12 and 13 of this
Specification.
(b) Cement and lime
(i) Cement
Unless otherwise specified cement shall be ordinary
Portland cement complying with the requirements of
Section 2 of this Specification.
(ii) Lime
Lime shall be hydrated calcium lime or quicklime and shall
comply with the requirements of Section 2 of this
Specification.
(iii) Storage and handling
The requirements of Section 17 of this Specification shall
apply to cement.
All lime shall be kept under cover and protected from
moisture. Consignments shall be used in the same
sequence as they are delivered. Stocks which become
damaged or which are stored on the Site for more than 3
months shall not be used, and shall be replaced at the

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Contractor's expense. Operators and labour shall be

provided with protective clothing, masks and goggles.

1404 AMOUNT OF STABILIZER TO BE ADDED

The amount of cement or lime to be added shall be determined by
the Engineer following laboratory trials, and site trials carried out
by the Contractor in accordance with Section 2 of this
Specification.

1405 MIX-IN-PLACE METHOD OF CONSTRUCTION

The mix-in-place method may be used for the addition and mixing
in of stabilizer.
(a) Mixing equipment
The equipment for pulverizing the material and mixing in the
stabilizer shall be purpose - built equipment, capable of pulverizing
the materials and mixing in the stabilizer to the full depth of the
loose layer necessary to give the specified thickness of compacted
material mixed and compacted in accordance with this section of
this Specification.
The equipment may be either single or multipass machines and
shall only be acceptable if, during the site trials carried out in
accordance with Section 2 of this Specification, it can produce
material to the specified requirements.
If single-pass equipment is used for plastic soils, the degree of
pulverization as determined In accordance with Test 17 of BS
1924 shall be not less than 80 percent.
The mixers shall be equipped with a device for controlling the
depth of processing and mixing blades shall be maintained or
reset periodically so that the correct depth of mixing is obtained at
all times.
Mixing by grader will not be permitted.
(b) Preparation of the layer
Before the stabilizer is applied, the material to be treated shall be
spread and broken down and oversize material removed so that
the maximum size of the particles is not more than specified. If
multi-pass processing is employed, the material shall first be
pulverised to the required tilth by successive passes. The material
shall then be shaped true to line, grade and cross-section and, if
required, lightly compacted. The loose thickness shall be such as
to give the specified thickness after full compaction has been
carried out.

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The moisture content of the layer before the addition of the

stabilizer shall be adjusted to within the range of 70% to 85% of
the" Optimum Moisture Content (AASHTO TI80).
(c) Spreading the stabilizer
After the layer to be treated has been* prepared to the satisfaction
ot the Engineer, the stabilizer shall be uniformly spread over the
width to be worked at the specified rate. If a spreader is used to
spread the stabilizer ahead of the mixer, it shall be fitted with a
device to ensure a uniform and controllable rate of spread both
transversely and longitudinally.
Only sufficient stabilizer for immediate use shall be spread ahead
of the mixing operation and any which, in the opinion of the
Engineer, becomes defective, shall be replaced at the Contractor's
expense.
Only equipment actually used in the spreading or mixing operation
shall be allowed to pass over the stabilizer, when so spread,
before it has been mixed into the material to be treated.
(d) Mixing and watering
Immediately after the stabilizer has been spread, it shall be
thoroughly and intimately mixed into the material for the full depth,
of the layer. Mixing shall continue until the resulting mixture forms
a fine and homogeneous tilth. The mixing machine shall be set so
that it cuts at least 100 mm into the edge of any adjoining lane
processed previously so as to ensure that all the material forming
the layer has been properly processed.
Care shall be taken both during this and during subsequent
watering operations that the underlying layer is not disturbed and
that no material from the underlying layer or shoulders is mixed
with that being processed.
If watering is necessary to bring the mixture to the required
moisture content, then this shall be done after spreading and
mixing in the stabilizer. Water shall be added in a uniform and
controllable manner and, where necessary, in successive
increments. Each increment shall be mixed in as a separate
mixing operation. Care shall be taken to avoid a concentration of
water at any point or a flow of water over the surface.
Any part of the mixture which becomes too wet after the stabilizer
has been added and before the mixture is compacted will be
rejected and any such part shall be allowed to dry out until its
moisture content is satisfactory and shall be retreated with fresh
stabilizer and finished off in accordance with this Clause.

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Throughout the process of mixing in the stabilizer and water, a

uniform thickness of the mixture shall be maintained and, if
necessary, the mixture shall be graded to maintain the correct
uncompacted thickness and shape. Any part of the mixture that
becomes segregated shall be removed and replaced.

1406 STATIONARY PLANT METHOD OF CONSTRUCTION

(a) Mixing Equipment
Stationary mixing plant shall be of the power driven paddle or pan
type and may be of the batch or continuous type.
If batch mixers are used, the appropriate measured amounts of
material and stabilizer shall first be placed in the mixer, water
being then added as necessary to bring the moisture content of
the resulting mixture within the range determined in the laboratory
and site trials. Special care shall be taken with batch type paddle
mixers to ensure that the stabilizer is spread uniformly in the
loading skip so that it is fed evenly along the mixing trough and
that with both paddle and pan mixers the stabilizer is proportioned
accurately by a separate weighing or proportioning device from
that used for the material being stabilised. Mixing shall be
continued until the mixture has the required uniformity and for not
less than 1 minute unless a shorter minimum period is permitted
by the Engineer after satisfactory trials.
If continuous mixing is used, the paddles, baffles and rate of feed
of materials shall be adjusted to give uniformly mixed material.
If a spray is used for distributing water into the mixer, it shall be
adjusted to give uniformity in moisture content throughout the mix.
(b) Transporting
Mixed material shall be transported to the road in suitable vehicles.
Material that becomes segregated or is affected by weather shall
be removed and replaced at the Contractor's expense.
(c) Laying
The mixed material shall be spread by means of a mechanical
paver to the required width and such thickness that the tolerance
requirements as specified in Section 3 of this Specification are
obtained after final compaction. Segregation shall be avoided and
the layer shall be free from pockets of coarse or fine material.

1407 COMPACTION AND FINISHING

For cement treated materials final compaction and finishing shall be
completed within 2 hours after the cement comes into contact with the
material to be treated.

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For lime treated materials, final compaction and finishing shall be

completed within 4 hours after the lime comes into contact with the
material to be treated.
(a) Thickness limitations
The compacted thickness of any treated layer laid, processed
and compacted at one time shall not exceed 180 mm where a
greater thickness is required, the material shall be laid in two
or more layers.
The compacted thickness of any base layer shall not be less than
3 times the maximum particle size of the material and the
compacted thickness of any subbase layer shall not be less than
twice the maximum particle size of the material.
(b) Compaction requirements
The minimum density for all lime and cement treated materials
shall be 95% MDD (AASHTO T180). The moisture content at the
time of compaction shall be between 95% and 105% of Optimum
Moisture Content (AASHTO T180).
(c) Finishing
The surface finish after compaction of any treated layer shall be
free from ridges, compaction planes, laminations, loose and
segregated material and other surface irregularities and shall be to
line and level and within the tolerances specified in Section 3 of
this Specification. If the surface fails to meet the requirements of
this Specification the Contractor shall take the action set out in the
appropriate part of Section 3 of this Specification or such other
action as the Engineer may instruct, or agree.

1408 JOINTS BETWEEN NEW AND EXISTING WORK

The forming of construction joints and the protection of previously
treated or other work shall be carried out so as to produce a uniformly
compacted and homogeneous layer free from ridges or other
irregularities.
Full width working, without longitudinal joints, will generally be
required. Half-width working may be instructed by the Engineer to
pass traffic. When forming longitudinal joints, with the mix-in-place,
method at least 100 mm of the first Laid half-width layer shall be
retreated and mixed in with the 3econd half-width layer.
When forming transverse joints, with the mix-in-place method, at least
1.0m length of the previously laid treated work shall be incorporated
into the new treated layer and the Engineer may instruct that the
percentage of stabilizer be increased at these places.

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When forming longitudinal or transverse joints with the stationary plant

method of construction, previous work shall be cut back to expose
fully treated and compacted material.

1409 PROTECTION AND CURING

Treated layers shall be kept continuously damp by lightly spraying with
water, from completion of compaction until one of the curing systems
specified below is placed.
Treated layers shall be protected, within 4 hours of completion of
compaction in the case of cement treated material and 8 hours in the
case of lime treated material, by one of the following methods:-
(i) Completely covering the layer with clear or light coloured approved
polythene sheeting of minimum thickness 0.1mm. The sheeting
shall be laid to cover the whole of the surface of the layer. At joints
the sheeting shall be lapped by at least 500mm and any damaged
sheeting shall be replaced at the Contractor's expense.
The sheeting shall be securely held in contact with the layer by an
approved method.
(ii) Completely covering the treated material with a layer of damp
uncompacted gravel or soil material of minimum thickness 100mm.
This material, which may be that forming the next layer, shall be
kept continuously damp.
(iii) Spraying the layer with A3 anionic emulsion at a rate of 1.5 1/m2 to
be applied in accordance with Parts A and B of Section 15 of this
Specification. This method shall not be permitted where the
following layer is to be a bituminous mix in accordance with
Section 16 of this Specification.
(iv) Unless otherwise instructed by the Engineer, no prime will be
required where method (iii) is adopted and the contractor shall
comply with the requirements of Parts A and B of Section 15 of
this Specification.
Plant used for dumping and spreading material, and the application of
water or emulsion shall be approved by the Engineer and shall have
individual axle loads not exceeding 6 tonnes.
Immediately prior to placing protection methods (i) or (iii) the surface
of the treated layer shall be made thoroughly damp by lightly spraying
with water.
The curing system shall be kept in place and intact for a minimum of 7
days after completion of compaction although small areas may be
temporarily removed for the purposes of carrying out control testing
but only for the minimum amount of time required for the testing.

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1410 TRAFFIC
Traffic or equipment, other than that actually engaged in the various
treatment or protection processes, shall not run over the layer being
processed or compacted.
On completion of curing no traffic or equipment shall be allowed on
the treated layer with the exception of that required for proofrolling,
priming or construction of the subsequent layer.

1411 TOLERANCES
(a) Geometric tolerances
The treated upper earthworks, subbase and base shall be
constructed within the tolerances specified in Section 3 of this
Specification.
(b) Amount of stabilizer
(i) Mix-in-place method of construction.
The average amount of stabilizer, measured before mixing,
over a length of 100 m, shall not be less than the amount
ordered.
The average amount of stabilizer in the treated material,
measured at five points over a length of 100 m, shall not be
less than the amount ordered.
The amount of stabilizer, measured after mixing, shall at no
point be less than 70% or more than 130% of the amount
ordered.
(ii) Stationary plant method of construction
The average amount of stabilizer in the treated material
measured at five points over a length of 100 m, shall not be
less than the amount ordered.
The amount of stabilizer measured after mixing shall at no
point be less than 90% or more than 110% of the amount
ordered.
(iii) Determination of stabilizer content
The cement content in mixed materials shall be determined
according to Test 14 of BS 1924 or to AASHTO T211-65
(1982).
The lime content in mixed materials shall be determined
according to Test 15 of BS 1924.

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1412 MEASUREMENT AND PAYMENT

For the purpose of measurement and payment no distinction shall be
made between the mix-in-place and stationary plant methods of
construction.
The work of providing, placing, spreading mixing, watering shaping
and hauling the materials to be stabilised will be measured and paid
for in Sections 5, 11, 12 and 13, as appropriate, of this Specification.
For the additional work of providing and mixing-in the stabilizer and
curing the treated materials the Contractor will be paid as follows:-
a) Item: Stabilizer
Unit: Tonne of each type of stabilizer
The provision of the stabilizer shall be measured by the tonne
calculated as the specified weight of stabilizer added to the
material.
The rate for stabilizer shall include for the cost of provision,
storage, handling, transport and spreading of the stabilizer at any
point on the Works and complying with the requirements of
Clauses 1401, 1403, 1404, 1405, 1406, 1408 and 1411 of this
Specification.
b) Item: Mix – in – stabilizer
Unit: m3
Mixing stabilizer into the material shall be measures by the cubic
metre of treated material calculated as the product of the
compacted sectional area specified to be treated and the length
instructed.
The rate of mixing shall include for the cost of complying with the
requirements of section 14 of this specification.
c) Item: Curing treated material
Unit: m2
Curing treated material shall be measured by the square metre of
the layer cured calculated as the product of the specified width of
treated layer and the length cured.
The rate for curing shall include for the cost of watering, provision
placing and maintenance of the curing system, and for complying
with the requirements of Clause 1409 and Parts A and B of
Section 15 of this Specification.

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14A/01 LEAN CONCRETE

14A/02 SCOPE OF SECTION
This section deals with the addition and mixing in of cement to graded
aggregate, and the transporting, laying and compaction of the mix,
hereinafter referred to as "lean concrete" for base or subbase.
14A/03 SOURCE OF MATERIALS
The Contractor shall be responsible for locating and developing
suitable sources of material for lean concrete. Such sources shall be
termed quarries and the opening up of quarries and the construction
and maintenance of access roads shall be carried out in accordance
with Section 6 of this Specification.
14A/04 MATERIALS REQUIREMENTS
(i) Aggregates
(a) Grading

Sieve Size % passing

(mm) (by weight)
37.5 100
28 90 - 100
20 65 - 95
10 40 - 70
5 30 - 55
2 18 - 40
1 13 - 32
0.425 10 - 24
0.075 0-6

(b) Combined aggregate

Sodium Sulphate Soundness : Max 12%
Fines (passing 0.425mm) : Shall be non-plastic
Sand-equivalent : Min 30%
Organic matter : Max 0.3% (by weight)

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(c) Aggregate retained on a 2mm sieve

CR : Min 80%
FI : Max 25%
LAA : Max 35%
ACV : Max 28%
(ii) Cement
(a) Cement
Unless otherwise specified cement shall be ordinary Portland
cement complying with Section 2 of this Specification.
(b) Storage and handling
The requirements of Section 17 of this Specification shall apply
to the storage and handling of cement.
(c) Water shall comply with Section 17 of this
Specification.
14A/05 MIX REQUIREMENTS
(i) Proportions
The ratio of cement to aggregate by weight (including any
absorbed moisture but excluding free water in the aggregate) shall
be such as to produce average crushing strengths to the
requirements of this Section.
The amount of cement to be added shall be determined by the
Engineer following laboratory trials, and site trials carried out by
the Contractor in accordance with Section 2 of this Specification.
The water content of the mixed concrete shall be such as to
ensure that the specified degree of compaction can be achieved
under all normal working conditions.
(ii) Crushing strength
The essential strength requirement for the material is that the
average 28-day strengths of groups of three cubes shal-1 be such
that not more than one such average strength in any consecutive
five such averages is less than 10 N/mm2. If, however, the overall
average of any consecutive five groups of three cubes (i.e. fifteen
cube strengths) falls below 12 N/mm2 at 28 days, or if the average
range of five consecutive groups exceeds 20N/nm2 the Engineer
may require the use of different materials, mix proportions, plant or
methods notwithstanding any approval which may have been
previously given to such materials, mix proportions, plant or
methods.

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The initial rate of testing shall comply with the requirements of

Section 17 of this specification until the engineer is satisfied that
the specified material is being consistently produced.
Further, in order to ensure a high probability that at an early stage
the above requirements will be met, the average 7-day strengths
of groups of three cubes shall be not less than 7 N/mm2 and if
more than one of the one of the 7-day strengths of groups of three
cubes in any consecutive five such averages falls below 9N/mm2
the cement content shall be increased to such a value as may be
approved by the engineer and the making of the cubes shall be
continued at the same rate as at the start of the work until the
results show that a satisfactory material is being consistently
produced.
14A/06 METHOD OF CONSTRUCTION
(i) Site trials
The Contractor shall carry out site trials in accordance with Section
2 of this Specification at least one month before he intends
commencing full scale construction of any lean concrete layer.
Should the trial show that the specified strength and compaction
requirements cannot be achieved the Contractor shall amend the
mix proportions or the laying and compaction techniques in order
to achieve the required result.
(ii) Mixing, transporting and laying
Lean concrete shall be mixed, transported and laid in accordance
with Section 14 of this Specification (stationary plant method of
construction).
(iii) Compaction
Immediately after laying, the mix shall be compacted by vibratory
and smooth wheel rollers to 96% of the target dry density.
Compaction shall be completed within 2 hours of the cement being
added to the aggregates at the batching plant.
The target dry density shall be determined daily as follows:-
From three separate batches of the mix, two 150mm test cubes
shall be prepared in accordance with BS 1881 except that the
cubes shall be compacted to refusal in three layers using a
vibrating hammer a described in BS 1377, Test 14, but with a
square flat plate head with an area of between 10,000 and
15,000nm2. As soon as the cubes can be handled without
damage, their density and moisture content shall be determined in
accordance with BS 1881. The average dry density of the six
cubes shall be the target dry density.

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The density of the compacted base shall be determined for each

500m2 laid. The Contractor shall provide a portable coring rig
capable of cutting acceptable cores of minimum diameter 150mm
and to a depth of at least 250mm. The density and moisture
content of each core shall be measured in accordance with BS
1881.
Following the determination of the density each core shall be
crushed and the minimum equivalent cube strength shall be 7
N/mm2 at 7 days calculated in accordance with BS 1881.
The compacted thickness shall not exceed 250mm.
(iv) Finishing
The surface finish after compaction shall be free from ridges,
compaction planes, laminations, loose and segregated material
and other surface irregularities and shall be to line and level and
within the tolerances specified in Section 3 of this Specification. If
the surface fails to meet the requirements of this Specification the
Contractor shall take the action set out in the appropriate part of
Section 3 of this Specification or such other action as the Engineer
may instruct, or agree.
(v) Joints
At the end of each day's work the lean concrete shall be
compacted against a securely fixed vertical temporary stop-end
and if compaction is being done with a vibratory roller this shall be
used transversely close to the stop-end. In addition, the material in
the corners adjacent to the stop-end shall be compacted by means
of a small power-operated compactor. When the stop-end is
removed any poorly compacted material adjacent to it shall be
removed and a 1: 1 cement: sand grout shall be applied to the
exposed face to a thickness of 5 - 10mm before proceeding with
the laying of further adjoining lean concrete. Such fresh lean
concrete shall be thoroughly compacted against the joint and
where a vibratory roller is employed this shall be used transversely
close to the joint again using the small power-operated compactor
in the corners of the new work. None of the compacting equipment
shall be allowed to bear directly on the hardened or partially
hardened lean concrete previously laid.
Where the full width of the layer cannot be placed by one pass of
the paver, work shall be arranged so that at longitudinal joints a
free edge of spread material is not exposed for more than one
hour after mixing before placing the adjacent layer. Where a free
edge is exposed for more than one hour after mixing, it shall be cut
back to expose fully compacted material before laying the adjacent
layer.
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(vi) Curing
Curing and the period of curing shall be in accordance with the
special Specification.
14A/07 TRAFFIC
Traffic or equipment, other than that actually engaged in the various
treatment processes, shall not run over the layer being processed or
compacted.
No traffic or equipment will be allowed on a treated layer earlier than
that period specified in the Special Specification after completion of
compaction, and subsequently only that traffic necessary for
construction of the next layer will be permitted on the treated layer.
14A/08 SETTING OUT AND TOLERANCES
Lean concrete base and subbase shall be set out and constructed to
the tolerances given in Section 3 of this Specification.
14A/09 MEASUREMENT AND PAYMENT
(a) Item : Lean concrete for base or subbase
Unit: m3
Lean concrete shall be paid by the cubic metre calculated as the
compacted sectional area instructed to be laid and the length
instructed.
The rate for lean concrete for base or subbase shall include for the
cost of providing mixing hauling spreading and compacting the
material and complying with the requirements of Section 14A of
this Specification.
No overhaul will be paid.
(b) Item : Curing lean concrete
Unit: as specified in the Special Specification
The unit and method of measure shall be as specified in the
Special Specification.
The rate shall include for complying with Section 14A of this
Specification and with the Special Specification.

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1500 BITUMINOUS SURFACE TREATMENTS AND SURFACE

DRESSINGS
1501 SCOPE OF SECTION
This Section covers the application of different bituminous
binders and aggregates to any kind of road surface and is
divided into the following parts:

PART A General
PART B Prime Coat and Tack Coat
PART C Surface Dressing
PART D Sand Seal
PART E Gravel Seal
PART F Emulsion Slurry Seal

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PART A - GENERAL
1501A SCOPE OF PART A
Part A comprises all the general requirements for bituminous
binder and aggregate common to Parts B to F Inclusive.
1502A BITUMINOUS BINDER SPECIFICATIONS
All bituminous binders shall comply with the relevant
requirements set out in section 2 of this Specification.
1503A BITUMINOUS BINDER STORAGE AND HANDLING
When carried in bulk containers, records of binder
temperature and time in a manner acceptable to the Engineer
shall be kept. Any bituminous binder not conforming to the
requirements of Clause 1504A may be rejected by the
Engineer as unsuitable for use in the Works.
The bitumen storage area and heating station shall be kept
neat and tidy. The storage area shall be cleared of vegetation
and the drums stacked on their sides and only in small
quantities with gaps between each stack to reduce fire risk.
Bitumen distributors and boilers shall be kept clean, at all
times. When changing the grade of bitumen and at the end of
each day's work, all boilers and distributors shall be
thoroughly cleaned out with a solvent. The flushings from
boilers and distributors shall not be poured over the area
indiscriminately, but shall be led by drainage channels to
disposal pits, care being taken that flushings do not find their
way into stormwater ditches or streams.
All boilers, pre-heating pits, tools, and plant shall be kept
scrupulously clean.
When filling the bitumen distributor from the boilers or bulk
containers, the bitumen shall be passed through a filter of fine
wire gauze.
On completion of the Works, the disposal pits and drainage
channels shall be filled in, topsoiled and the site left clean and
tidy.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

1504A HEATING OF BITUMINOUS BINDER

During storage the temperature of the bituminous binder shall
be kept as low as possible, consistent with reasonable
pumpabllity.
The bituminous binder shall be heated in boilers or bulk
storage containers, equipped with adequate pumps and
accurate thermometers. No bitumen shall be heated in a
boiler when the thermometer is broken or inaccurate.
The minimum pumping temperatures, the range of spraying
temperatures and the maximum heating temperatures of cut-backs,
penetration grade bitumens and emulsions are given in the following
table:-

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

Temperature (°C)

Minimum Spraying Maximum

Binder
Atomising
Pumping Slot-jets Heating
jets

Cut-back RC 30 10 35 - 45 - 50

Cut-back RC 70 25 55 - 65 - 70

Cut-back RC 250 45 80 - 90 - 90

Cut-back RC 800 60 100 - 115 - 120

Cut-back RC 3000 80 125 - 135 - 135

Cut-back MC 30 10 35 - 45 50 - 60 65

Cut-back MC 70 25 55 - 65 70 - 85 85

Cut-back MC 250 45 80 - 90 90 - 110 110

Cut-back MC 800 60 100 - 115 120 - 135 135

Cut-back MC 3000 80 125 - 135 153 - 150 150

Cut-back 800/1400
90 135 - 145 145 - 160 160
(France)

Bitumen 400/500 95 140 - 150 160 - 170 170

Bitumen 280/320 100 150 - 160 160 - 170 170

Bitumen 180/200 105 155 - 165 160 - 170 170

Bitumen 80/100 115 160 - 170 160 - 170 170

Emulsion K1-70 15 75 - 85 75 - 85 95

Emulsion **K1-60 - - - 95

* These spraying temperatures are for guidance only since the optimum
spraying temperature depends on the temperature/viscosity
relationship of the bitumen.
** The minimum pumping and spraying temperatures for K1-60 shall be
in accordance with the manufacturer's recommendation.
For slot-Jets the viscosity for spraying shall be 70 to 100 centistokes
and for atomizing jets 35 to 60 centistokes.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

No penetration grade bitumen, cut-back bitumen, or emulsion shall be

heated above the maximum temperature given above and any that is
overheated shall be removed from the Site and disposed of by the
Contractor.
The rates of application of binder specified or instructed by the
Engineer refer to volumes of binder corrected to 15.6°C using the
Standard Petroleum Measurement Table (ASTM D 1250).
1505A ADHESION AGENT
Where required the adhesion agent shall be of an approved type and
shall be used in accordance with the manufacturer's instructions and
as instructed by the Engineer.
1506A CONSTRUCTION LIMITATIONS
No bituminous construction work will be permitted in adverse weather
conditions (rain, wind etc…) or whenever so instructed by the
Engineer.
Bituminous material, except for bitumen emulsions and certain types
of prime coat if instructed by the Engineer, shall not be applied on a
damp surface.
1507A SAFETY PRECAUTIONS
The Contractor shall take every precaution to avoid fire or health
hazards. He shall always ensure that:
(a) bitumen is heated only to the temperature required for the
particular application;
(b) hot bitumen never comes in contact with water;
(c) suitable protective clothing and gloves are used when handling hot
bitumen; and
(d) dust is reduced to a minimum.
Great care is required when using rapid-curing cut-back, because
of the highly flammable nature of the solvent.
1508A MEASUREMENT AND PAYMENT
No separate measurement and payment shall be made for
complying with the requirements of Clauses 1501A to 1507A
inclusive of this Specification and the Contractor shall be
deemed to have allowed in his rates in Parts B to F inclusive
of Section 15 of this Specification for the costs of complying
with the requirements of Part A of Section 15 of this
Specification.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

PART B - PRIME COAT AND TACK COAT

1501B DEFINITIONS
A prime coat means an application of low viscosity bituminous
binder to an absorbent non-bituminous surface. If the prime
coat is to be trafficked, it shall be covered with blinding
material.
A tack coat shall mean a light application of bituminous binder
to a bituminous or concrete surface.
1502B MATERIALS FOR PRIME COAT AND TACK COAT
For prime coat, the binder shall be a medium-curing cut-back
MC30 or MC70 unless otherwise instructed by the Engineer.
For tack coat, the binder shall be a penetration grade bitumen
applied hot immediately prior to laying the bituminous mixture
layer or alternatively a rapid curing cut-back or medium curing
cut-back applied at sufficient time before laying the
bituminous mixture to allow the evaporation of the cutter
(solvent); or a quick-breaking emulsion or slow-setting
emulsion diluted with water, applied a sufficient time before
laying the bituminous mixture to allow the emulsion to break
and the water to evaporate and run off.
Blinding material if required shall consist of fine aggregate, or
sand, or crusher dust and shall contain not more than 15 per
cent retained on a 6.3 mm sieve. The blinding material if
required by the Engineer will be specified in the Special
Specification.
1503B PREPARATION OF SURFACE
The surface to be sprayed shall be thoroughly cleaned by
sweeping with mechanical brooms and/or washing or other
approved means. All laitance of soil or binder material, loose
and foreign material shall be removed.
All loose material shall be swept clear of the layer to expose
the full width of the layer.
The surface to be sprayed shall be checked for line, camber
and level, and the surface corrected, made good as
necessary and approved by the Engineer before any
bituminous spray is applied.
The Engineer's approval, or otherwise, of the surface will be
given immediately prior to the Contractor's intention to start
spraying.
Unless otherwise directed by the Engineer, immediately prior
to the application of prime coat, the surface of the layer shall

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

be lightly sprayed with water to give complete coverage of the

layer, but in no case saturated.
In order to bring the surface to be primed to the condition
required, water shall-be applied in small Increments by a
distributor. Any water on the surface after spraying shall be
allowed to drain away before the prime coat is applied.
1504B PRAYING OF PRIME COAT AND TACK COAT
As soon as possible after the surface to be sprayed has been
prepared as specified in Clause 1503B and approved by the
Engineer, the prime or tack coat shall be sprayed on to it at
the specified rate. Spraying shall be carried out not later than
12 hours after the surface has been prepared.
The quantity of binder used shall give complete coverage of
the surface with a slight trace of run-off in places. Should the
specified rate of spray appear to be incorrect, the Contractor
shall immediately stop spraying, inform the Engineer and
amend the spray rate as instructed by the latter.
The edge of the area shall be marked out with a line of string
or wire pegged down at intervals not exceeding 15 m on
straights or 7.5 m on curves.
Bitumen shall be sprayed from a pressure distributor and no
hand spraying shall be permitted except in small areas, or to
make good a defective area caused by a blocked nozzle.
The nozzles shall be arranged to give a uniform spray and
shall be tested prior to spraying by discharging on to suitable
material (such as building paper, metal sheets, etc…) or into
purpose made troughs. Testing shall not take place on the
road, and any bitumen spilt on the ground shall be cleaned
off.
If during spraying, a nozzle becomes blocked or develops a
defect, the spraying shall be immediately stopped, any area
incompletely sprayed shall be made good with a hand spray,
and the machine repaired before further spraying is
commenced.

When commencing and stopping spraying, sheets of building

paper or metal at least 2 m wide shall be spread across the
full width to be sprayed to give a clean sharp edge.
The metal sheets used for stopping and starting work shall be
cleaned after each run and the troughs used for testing shall
be cleaned at the end of each day's work.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

During spraying all kerbs, road furniture, culvert headwalls,

tree boles and the like which are liable to be disfigured by
splashing of bitumen shall be protected, and any such feature
which is accidentally marred by bitumen shall be cleaned off
with a suitable solvent or made good.
1505B CURING AND BLINDING OF PRIME COAT
If, after the application of the prime coat, the bituminous
material fails to penetrate within the time specified or if the
road must be used by traffic, blinding material shall be spread
in the amount required to absorb any excess bituminous
material and to protect the primed surface.
Blinding material shall be spread from trucks in such a
manner that no wheel will travel on uncovered bituminous
material.
Unless the Engineer permits otherwise, all loose material on
the sprayed surface, including any blinding material, shall be
removed before any further layer of the pavement is laid.
1506B TOLERANCES
The rate of application of bituminous binder across the width
of each spray run shall not vary by more than +/- 10% of the
rate ordered and the average rate of binder for each single
run of the spray truck shall be at least equal to the rate
ordered. Tray tests should be taken at least once a day
during priming operation to check calculations based on
dipping of spray trucks.
1507B MEASUREMENT AND PAYMENT
(a) Item : Prime coat or tack coat
Unit: 1 (litre) of each type of bituminous binder
Prime coat or tack coat shall be measured by the litre of
each type of bituminous binder calculated as the product
of the area in square metres instructed to be sprayed and
the instructed rate of application in litres/square metre,
corrected to 15.6°C.
The rate for prime coat or tack coat shall include for the
cost of providing, hauling and spraying the prime or tack
coat at the instructed application rate, blinding and
complying with the requirements of Clauses 1502B,
1503B, 1504B, 1505B and 1506B of this Specification.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

PART C - SURFACE DRESSING

1501C DEFINITIONS
A single surface dressing means an application of bituminous
binder to any kind of road surface followed immediately by a
single layer of uniform sized chippings.
A multiple surface dressing means two or more surface
dressings placed one on the other.
1502C MATERIALS FOR SURFACE DRESSING
(a) Binder
The binder will generally be a suitable cationic quick-
breaking emulsion such as K1-60 or K1-70, a medium-
curing cut-back MC 3000 or a penetration/cutback mixture
blended to the approval of the Engineer. The type of
binder will be specified in the Special Specification.
(b) Chippings
(i) Hardness, soundness, shape and cleanliness
The chippings shall consist of crushed stone, cubical in
shape and free from visible stone dust and harmful
material such as clay, salt, organic matter or other
deleterious substances. The percentage passing the
0.075 sieve shall not exceed 0.5% by weight.
The chippings shall comply with the following
requirements, for the appropriate class as specified in
the Special Specification.

Chipping
1 2 3 4
Class
LAA Max. 20 25 30 35

ACV Max. 16 20 23 26

SSS Max. 12 12 12 12

FI Max. 20 20 25 25

(ii) Angularity
The minimum size of the stone to be crushed to
produce the chippings shall be at least 4 times the
maximum size of the chippings.

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(iii) Grading

Sieve Percentage by weight passing

Size Nominal sizes

(mm) 14/20 10/14 6/10 3/6

28 100 - - -

20 80 - 100 100 - -
14 0 - 30 85 - 100 100 -
10 0-7 0 - 30 85 - 100 100
6.3 - 0 - 10 0 - 30 85 - 100
5 - - 0 - 10 -
3 - - - 0 - 30
2 0-2 0-2 0-2 0 - 10
0.5 - - - 0 -2

1503C RATE OF APPLICATION OF BINDER AND CHIPPINGS

The rate of spray of binder and the size and rate of spread of
chippings shall be as specified in the Special Specification or
as instructed by the Engineer.
Tray tests shall be carried out at least once per day during
surface dressing operations to check spray and spread rates
calculated from spray truck dippings and chip-spreader
coverage, and more frequently when a number of short
lengths are being surface dressed. Spray truck dippings shall
be taken for each length sprayed and chip-spreader coverage
shall be checked each day chipping operations are in
progress.
1504C CRUSHING, SCREENING, WASHING AND STOCKPILING
CHIPPINGS
The construction plant provided and the methods of operating
it shall be such as will produce chippings which meet the
specified requirements of Clause 1502C(b). This may require
washing the chippings to meet the cleanliness requirements.
The Contractor shall comply with Section 6 of this
Specification when stockpiling chippings. If required the
stockpile area shall be surfaced with 100 mm thickness of
gravel or other material, acceptable to the Engineer. Any
contaminated chippings shall not be used in the Works. After

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

use the stockpile area shall be cleared, topsoiled and left neat
and tidy.
1505C PRECOATED CLIPPINGS
The bituminous binder used for precoated chippings shall be
a medium curing cut-back MC30 or a semi-stable or stable
emulsion such as anionic A2 or A3 or cationlc K2 or K3
unless otherwise instructed by the Engineer. The amount of
bituminous binder used to precoat chippings shall be
specified in the Special Specification or shall be as instructed
by the Engineer.
Precoating shall be carried out in a mixing machine
acceptable to the Engineer.
The precoated chippings shall not be tacky and liable to
agglomerate. The chippings precoated with cut-back or
emulsion shall be stockpiled for the lapse of time required by
the solvents or water to evaporate.
The precoated chippings shall be kept free of contamination
by dust or other deleterious matter.
1506C CONSTRUCTION PLANT FOR SURFACE DRESSING
(a) Bitumen distributors
Bitumen distributors shall be truck mounted and shall have
sufficient power to maintain uniform speeds for the proper
application of the binder. The truck shall be equipped with
an accurate tachometer showing the driver the speed in
metres per minute. The truck shall be fitted with a gauge
bar and chain or any other acceptable device clearly
visible to the driver to enable him to follow the required
edge. The distributor tank shall have a capacity of at least
4,000 litres and shall be fitted with a device for Indicating
the quantity in the tank at any time. It shall be equipped
with heaters capable of maintaining temperatures up to
200°C and be fitted with an accurate thermometer.
The circulation system shall permit pumping around the
tank and around the spray bar without actually spraying.
Spray bars shall be available for spraying in widths varying
from 0.5m to 4m and shall be adjustable transversely so
that the operator can follow the required edge
independently. The spray nozzles shall be arranged to
give a uniform spray and the shut-off shall be quick-acting
with an antidrip device. The pressure in the spray bar shall
be sufficient to give a good distribution and spraying of the
binder.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

Distributors shall be capable of applying bituminous binder

within the limits of +/- 10% of the specified rate of
application over any portion of the surface.
Distributors shall be checked and calibrated before
starting any work or when required by the Engineer. This
shall include the calibration of all the metering devices and
checking the uniformity of the transverse distribution of
spray.
All distributors shall be furnished with a "rate of
spray/machine speed" chart.
(b) Chip-spreaders
Mechanical chip-spreaders shall be capable of spreading
the chippings uniformly over variable widths, from 0.5 to
3.5m, at the rates specified.
The number and output of chip-spreaders shall be
sufficient to ensure that chippings are spread immediately
after the bituminous binder has been applied.
Chip-spreaders shall be checked and calibrated before
starting any work or when required by the Engineer.
(c) Rollers
The main rolling shall be carried out with self-propelled
pneumatic tyred rollers, having a wheel-load of more than
2 tonnes. The tyres shall be smooth and their pressure
shall be more than 0.4 N/mm2. .
Steel-wheeled rollers shall not be used until all excess
chippings have been removed and insufficiently chipped
areas have been chipped over and then only in tandem
with pneumatic tyred rollers or where approved by the
Engineer. Only steel-wheeled rollers weighing less than 8
tonnes (total weight) will be accepted.
The number and output of rollers shall be sufficient to
ensure that rolling does not lag behind spreading. Two
pneumatic tyred rollers shall be used for each chip-
spreader.
(d) Miscellaneous equipment
Sufficient trucks and loading machinery shall be employed
to ensure an adequate, prompt and continuous supply of
chippings. Rubber tyred mechanical rotary brooms towed
by or mounted on rubber tyred vehicles shall be provided.
All labour working with or on bitumen shall be provided
with protective clothing and footwear.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

1507C PREPARATION OF SURFACE

Immediately before spraying, all loose material and foreign
matter shall be removed by thorough brushing with
mechanical brooms and/or washing or other acceptable
methods. All hardened mud or other foreign matter shall be
loosened by scraping before sweeping. The debris shall be
deposited well clear of the surface to be sprayed.
Any defect of the surface shall be made good as instructed by
the Engineer and no binder shall be sprayed until the surface
has been approved by the Engineer. The Engineer's approval
or otherwise of the surface will be given immediately prior to
the Contractor's intention to start spraying.
1508C APPLICATION OF SURFACE DRESSING
As soon as possible after the surface has been prepared and
approved, the binder shall be uniformly sprayed at the
specified rate. Spraying shall not be carried out later than 12
hours after the surface has been prepared.
The spraying width shall normally be one lane width so that
construction traffic may run over the other lane
Immediately after the binder has been sprayed, clean dry
chippings shall be uniformly applied at the specified rate by
the use of as many mechanical chip-spreaders as necessary
to match the rate of spraying. The elapsed time between the
spraying of binder and the spreading of chippings shall in no
case exceed one minute.
Should it become apparent that the supply of chippings is
about to fail, the binder spraying shall be immediately
stopped and shall not resume until an adequate supply of
chippings is assured.
The correct rate of spread is generally assessed visually, as
providing complete coverage, with the film of binder still
visible between the chippings. Should the coverage appear to
be incorrect, the Contractor shall immediately inform the
Engineer, who will amend the rate of spread accordingly. Any
excess of chippings shall be removed by hand and any
insufficiently chipped area shall be chipped over by hand, so
that adequate coverage is obtained. Brooming of the material
to effect redistribution of chippings will not be permitted.
Rolling shall begin immediately after the chippings have been
spread and, in no case, later than two minutes after the
application of binder.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

Rolling shall continue until all chippings are firmly embedded

into the binder and until all excess chippings have been
removed or insufficiently chipped areas have been chipped
over. The number of passes shall be agreed with the
Engineer. Usually, each point shall receive at least 6 passes
of the pneumatic tyred roller.
Excessive rolling, resulting in the crushing of chippings, shall
be avoided.
The roller speed shall not exceed 8 km/h, unless otherwise
directed by the Engineer.
Additional rolling on a previously completed section shall be
given later in the heat of the day by pneumatic tyred rollers in
tandem with steel three wheeled rollers unless otherwise
instructed by the Engineer.
1509C AFTERCARE AND CONTROL OF TRAFFIC
The road shall not be opened to traffic until the binder has
attained sufficient viscosity to prevent the stones being
whipped off.
The Contractor shall erect temporary restriction signs,
barriers and removable bumps or any other device, as
instructed by the Engineer, to prevent vehicles travelling too
fast over the newly laid surface dressing. Vehicle speed shall
be restricted to a maximum of 30 km/h, until there is sufficient
adhesion to ensure that the chippings will not be dislodged by
faster vehicles.
After traffic has been permitted to run on the surface dressing
for a period of at least two weeks and when instructed by the
Engineer, all loose chippings shall be swept and taken away.
Windrows of loose chippings shall not be allowed to
accumulate at the sides of the road.
1510C TOLERANCES
The final average overall width of the surface dressing
measured at six equidistant points over a length of 100 m
shall be at least equal to the width specified or instructed. At
no point shall the distance between the centreline of the road
and the edge of the surface dressing be narrower than that
instructed by more than 13 mm.
The rate of application of binder across the lane width shall
not vary by more than +/-10% of the rate ordered and for
each length of lane sprayed in a single pass the average rate
of binder application shall be not less than the rate ordered.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

The average rate of application of chippings along and across

the lane width for each single pass of the chip-spreader shall
not vary by more than +/-10% of the rate ordered.
1511C MEASUREMENT AND PAYMENT
(a) Item: Seal coat
Unit: 1 (litre) for each type of bituminous binder for
each seal coat.
Seal coats shall be measured by the litre, for each type of
bituminous binder for each seal coat, calculated as the
product of the area in square metres instructed to be
sprayed and the instructed rate of application in
litres/square metre, corrected to 15.6°C.
The rate for the seal coat shall include for the cost of
preparation of the surface to receive the binders,
providing, hauling and spraying the bituminous binder at
the instructed application rate and complying with the
requirements of Parts A and C of Section 15 of this
Specification.
(b) Item : Chippings
Unit: m3 of each nominal size for each class
Chippings shall be measured by the cubic metre of each
nominal size for each class calculated as the product of
the area in square metres instructed to be covered and the
reciprocal of the instructed rate of application in square
metres/cubic metre or the actual rate of application in
square metres/cubic metre whichever calculation gives the
lower volume.
The rate for chippings shall include for the cost of
providing, hauling spreading and rolling the chippings at
any instructed application rate, all hauls as necessary and
complying with Parts A and C of Section 15 of this
Specification.

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(c) Item : Precoated chippings

Unit: as specified in the Special Specification
The method of measurement for precoated chippings shall
be as specified in the Special Specification.
The rate for precoated chippings shall include for the cost
of complying with Parts A and C of Section 15 of this
Specification and with the relevant sections of the Special
Specification.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

PART D - SAND SEAL

1501D DEFINITION
A sand seal means an application of bituminous binder
covered with aggregate as specified below.
1502D MATERIAL FOR SAND SEAL
(a) Binder
The binder shall be a medium-curing cut-back MC800 or
MC3000 or K1-60 cationic emulsion unless otherwise
instructed by the Engineer.
(b) Aggregate
The aggregate shall consist of sand, or fine screenings,
free from organic matter, clay and other deleterious
material. The fines (passing a 0.425 mm sieve) shall be
non-plastic. The Sand Equivalent shall exceed 40.
The grading shall be as follows:

Sieve (mm) % by weight passing

6.3 100
5 95 - 100
4 90 - 100
2 50 - 95
1 20 - 80
0.6 10 - 50
0.425 3 - 25
0.3 0-15
0.15 0-8
0.075 0-5

1503D RATE OF APPLICATION OF BINDER AND FINE AGGREGATE

The rate of spray of binder and the rate of spread of the fine
aggregate shall be as specified in the Special Specification or
as instructed by the Engineer.
During the sand sealing operation tray tests to determine
spray and spread rate shall be carried out at least once per
day.

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1504D CONSTRUCTION
The surface to be covered shall be prepared in accordance
with Clause 1507C
The binder shall be uniformly sprayed at the specified rate.
The fine aggregate shall be uniformly spread and rolled, all in
accordance with Clause 1508C, except that the fine
aggregate shall be spread in excess of that required to cover
the binder.
1505D AFTERCARE AND CONTROL OF TRAFFIC
The road shall be opened to traffic when instructed by the
Engineer.
Traffic speed shall be restricted as per Clause 1509C for as
long as the Engineer may require.
Any whipped-off aggregate shall be broomed back onto the
road, as many times as are necessary for it to adhere fully to
the binder.
1506D TOLERANCES
Sand seal shall be constructed within the same width
tolerance as given in Clause 1510C for surface dressing.
The rate of application of binder and aggregate across the
lane width shall not vary by more than +/-10% of the rate
ordered. The average rate of application of binder for a single
pass of the spray truck shall be not less than the rate
ordered. The average rate of application of sand for a single
pass of the spreader shall not vary by more than +/-10% of
the rate ordered.
1507D MEASUREMENT AND PAYMENT
(a) Item: Seal coat
Unit: 1 (litre) for each type of bituminous binder
Seal coats shall be measured by the litre for each type of
bituminous binder calculated as the product of the area in
square metres instructed to be sprayed and the instructed
rate of application in litres/square metre corrected to
15.6°C.
The rate for the seal coat shall include for the cost of
preparation of the surface to receive the binder, providing,
hauling and spraying the bituminous binder at the
instructed application rate and complying with the
requirements of Parts A and D of Section 15 of this
Specification.

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(b) Item: Aggregate

Unit : m3
Aggregate shall be measured by the cubic metre
calculated as the product of the area in square metres
instructed to be covered and the reciprocal of the
instructed rate of application in square metres/cubic metre
or the actual rate of application in square metres/cubic
metre whichever calculation gives the lower volume.
The rate for aggregate shall include for the cost of
providing, hauling spreading and rolling the aggregate at
any instructed application rate, brooming back whipped-off
aggregate, and complying with Parts A and D of Section
15 of this Specification.

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PART E - GRAVEL SEAL

1501E DEFINITION
A gravel seal means an application of bituminous binder
covered with graded granular material.
1502E MATERIAL FOR GRAVEL SEAL
(a) Binder
The binder shall be a medium curing cut-back MC800 or
MC3000 unless otherwise instructed by the Engineer.
(b) Aggregate
(i) Source of material
The Contractor shall be responsible for locating
suitable sources of material for the gravel seal.
Notwithstanding Clause 602 of this Specification such
sources whether or not requiring drilling and blasting
for the extraction of the material shall be termed as
quarries and shall be provided in accordance with
Section 6 of this Specification.
(ii) Material
The cover aggregate shall consist of graded gravel or
graded crushed stone or a mixture of these and shall
be free from organic matter, clay and other deleterious
material. Its hardness shall be as follows:
Los Angeles Abrasion : 40% maximum
Aggregate Crushing Value : 30% maximum
The cover aggregate shall have a grading within and
approximately parallel to the following envelope:

Sieve (mm) % by weight passing

20 100
14 65 - 95
10 45 - 95
6.3 25 - 80
4 15 - 65
2 10 - 50
1 5 - 40
0.425 3 - 30
0.075 0-10

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(c) Adhesion agent

The adhesion agent specified in the Special Specification
or as instructed by the Engineer shall be added to the
bituminous binder.
1503E RATE OF APPLICATION OF BINDER AND AGGREGATE
The rate of spray of binder and the rate of spread of
aggregate shall be as specified in the Special Specification or
as instructed by the Engineer.
1504E CONSTRUCTION
The surface to be covered shall be prepared in accordance
with Clause 1507C.
The binder shall be uniformly sprayed and the aggregate
shall be uniformly spread and rolled in accordance with
Clause 1508C.
1505E AFTERCARE AND TRAFFIC CONTROL
The road shall be opened to traffic when so instructed by the
Engineer. The traffic speed shall be restricted as per Clause
1509C for as long as the Engineer may require.
1506E TOLERANCES
Gravel seal shall be constructed within the width tolerance
given In Clause 1510C.
The rate of application of binder and aggregate across the
lane width shall not vary by more than +/-10% of the rate
ordered. The average rate of application of binder for a single
pass of the spray truck shall be not less than the rate
ordered. The average rate of application of aggregate for a
single pass of the spreader shall not vary by more than +/-
10% of the rate ordered.
During gravel sealing operations tray tests to determine spray
and spread rates shall be carried out at least once per day.
1507E MEASUREMENT AND PAYMENT
(a) Item : Seal coat
Unit: 1 (litre) for each type of bituminous binder
The seal coat shall be measured by the litre for each type
of bituminous binder calculated as the product of the area
in square metres instructed to be sprayed and the
instructed rate of application in litres/square metre
corrected to 15.6°C.

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The rate for the seal coat shall include for the cost of
preparation of the surface to receive the binder, providing,
hauling and spraying the bituminous binder at any
instructed application rate and complying with the
requirements of Parts A and E of Section 15 of this
Specification.
(b) Item : Aggregate
Unit : m3
Aggregate shall be measured by the cubic metre
calculated as the product of the area in square metres
instructed to be covered and the reciprocal of the
instructed rate of application in square metres/cubic metre
or the actual rate of application in square metres/cubic
metre whichever calculation gives the lower volume. The
rate for aggregate shall include for the cost of providing,
hauling, spreading and rolling the aggregate at any
Instructed application rate, and complying with Parts A
and E of Section 15 of this Specification.

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PART F – EMULSION SLURRY SEAL

1501F DEFINITION
An emulsion slurry seal means a mixture of bitumen emulsion, fine
aggregate, cement or lime and water prepared in a mixer and then
spread on the road surface.
1502F MATERIALS FOR SLURRY SEAL
(a) Emulsion
The emulsion shall be either an anionic emulsion A4 (slow setting
or rapid-setting) or a slow acting cationic emulsion K3 unless
otherwise instructed by the Engineer
(b) Aggregate
The aggregates shall be free from organic matter, clay, silt or other
deleterious matter. It shall have a sand equivalent of at least 40.
The grading curve shall be within one of the following envelopes,
as specified in the special specification.

Sieve
Percentage by weight passing
size
(mm) Type I Type II Type III
(Fine) (Normal) (Coarse)
10 - - 100
6.3 - 100 80 - 95
5 - 90 - 100 70 - 90
2 100 60 - 87 40 - 65
1 60 - 85 40 - 67 25 - 45
0.425 30 - 48 22 - 38 15 - 28
0.3 25 - 42 18 - 30 12 - 25
0.15 15 - 30 10 - 20 7 - 18
0.075 10 - 20 5 - 15 5 - 15

(c) Cement/Lime
Cement and lime shall comply with the requirements of section 2
of this special specification

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1503F PREPARATION OF THE SLURRY MIXTURE

The proportion by weight of dry aggregate of bitumen emulsion and
cement or lime shall be specified in the special specification. These
shall be termed the nominal proportions of bitumen emulsion and
cement or lime.
Water shall be added in significant quantity to obtain the correct slurry
consistency as directed by the engineer.
The slurry mixture shall be prepared in a slurry mixer acceptable to
the Engineer. The mixer shall be charged with materials in the
proportions specified.
The mixing cycle shall be sufficient to produce a uniform coating of the
aggregate and a uniform consistency of the slurry. It shall continue
until the slurry mixture is discharged into the spreader box or onto the
road surface. The entire batch shall be discarded if there is evidence
that the emulsion has broken. The slurry, ready for application, shall
be a smooth, free flowing mixture throughout.
1504F RATE OF APPLICATION OF SLURRY MIXTURES
The rate of application of the slurry mixture shall be as specified in the
special specification or as instructed by the Engineer
Tray tests shall be carried out at least once per day during slurry seal
operations.
1505F CONSTRUCTION
Where a slurry seal is to be applied to a surface dressing the surface
dressing shall be trafficked for a period of at least two weeks prior to
application of the slurry.
The surface to be covered shall be prepared in accordance with
clause 1507C.
The slurry mixture shall be evenly spread at the specified rate by a
slurry machine, except in restricted areas where hand spreading may
be permitted.
The surface immediately ahead of the spreader shall be slightly
dampened, unless otherwise instructed by the Engineer. Unless
otherwise directed by the Engineer, slurry seal shall be rolled with
smooth tyred pneumatic rollers acceptable to the engineer. Rolling
shall commence as soon as the slurry has set sufficiently to ensure
that no rutting or pick-up will occur. The number of passes shall be as
agreed with the engineer but usually each spot shall receive at least
six passes of the pneumatic tyred roller

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The finished slurry shall be of uniform surface texture and colour

throughout the work. The finished surface shall be free from blow-
holes and irregularities.
1506F CURING AND CONTROL OF TRAFFIC
All traffic shall be kept off the slurry seal until it has cured to a firm
condition that will prevent pick-up of the mixture. Where two
applications of slurry are required, the initial treatment shall be cured
thoroughly prior to placing the succeeding application.
1507F TOLERANCES
Slurry seal shall be constructed within the same width tolerances
given in clause 1510C.
The rate of application of slurry seal across the width of a lane sealed
in a single pass shall not vary by more than +/-10% of the rate
ordered, and the average rate of application along the length of a
single pass shall not be less than the rate ordered.

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1508F MEASUREMENT AND PAYMENT

(a) Item : Slurry seal
Unit: m3 of dry aggregates for each different mixture
specified in the special specification
Slurry seal shall be measured by the cubic metre of dry aggregate
for each different mixture calculated as the product of the area in
square metres instructed to be covered and the reciprocal of the
instructed rate of application in square metres/cubic metre of dry
aggregate or the actual rate of application in square metre/cubic
metre of dry aggregate whichever calculation gives the lower
volume.
The rate for slurry seal shall include for the cost of preparation of
the surface, providing bitumen emulsion and cement or lime at the
nominal proportions specified, providing water as required, all
haulage, mixing, laying and rolling and complying with the
requirements of part A and F of section 15 of this specification and
with the relevant clauses of the special specification.
(b) Item : Variation in emulsion content
Unit: 1 (litre) of each different emulsion
Measurement of the variation in emulsion content shall be per litre
of emulsion more than or less than the nominal proportion
specified and the amount calculated by extending the quantity and
the rate shall be added to or deducted from the total value of work
certified.
(c) Item : Variation in cement or lime content
Unit : tonne of each type
Measurement of the variation in cement or lime content shall be
per tonne of cement or lime more or less than the nominal
proportion specified and the amount calculated by extending the
quantity and the rate shall be added to or deducted from the total
value of work certified.

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SECTION 16
BITUMINOUS MIX BASES, BINDER COURSES AND WEARING
COURSES
1601 SCOPE OF SECTION
This section covers different types of bituminous mixes for Base and
Surfacing (Wearing and Binder Courses) and is divided into the
following Parts:
PART A General
PART B Asphalt Concrete for Surfacing
PART C Dense Bitumen Macadam for Base
PART D Cold Asphalt for Surfacing, Base, Levelling courses
and Patching

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PART A - GENERAL
1601A SCOPE OF PART A
Part A comprises all the general requirements for bituminous mixes
which apply to Parts B to D inclusive.
1602A REQUIREMENTS FROM OTHER SECTIONS
The following Sections of this Specification apply to Parts B to D of
this Section and shall be read in conjunction therewith:
Section 2 Materials and Testing of Materials
Section 3 Setting Out and Tolerances
Section 6 Quarries, Borrow Pits, Stockpile and Spoil Areas
Section 15 Bituminous Surface Treatments and Surface
Dressing
1603A CONSTRUCTION PLANT
(a) General
The Contractor shall submit to the Engineer in accordance with
Section 1 of this specification, full details of the construction plant he
proposes to use and the procedures he proposes to adopt for carrying
out the permanent Works.
The Engineer shall have access at all times to construction plant for
the purposes of inspection. The Contractor shall carry out regular
calibration checks in the presence of the Engineer and shall correct
forthwith any faults which are found.
All construction plant used in the mixing, laying and compacting of
bituminous mixes shall be of adequate rated capacity, in good working
condition, and shall be acceptable to the Engineer. Obsolete or worn-
out plant will not be allowed on the work.
(b) Mixing plant
Bituminous materials shall be mixed in a plant complying with ASTM
Designation D995 and shall be located on the Site unless otherwise
agreed by the Engineer. It shall be equipped with at least three bins
for the storage of heated aggregates and a separate bin for filler. All
bins shall be covered to prevent the ingress of moisture.
The plant may be either the batch-mix type or the continuous-mix type
and shall be capable of regulating the composition of the mixture to
within the tolerances specified in Clause 1614A of this Specification.
The bitumen tank shall be capable of maintaining its contents at the
specified temperature within a tolerance of plus or minus 5°C and
shall be equipped with a thermostat to prevent the temperature rising

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above 180°C and a fixed thermometer easily read from outside the
tank. Any bitumen which has been heated above 180°C or has
suffered carbonisation from prolonged heating shall be removed from
the plant and disposed off.
(c) Laying plant
Bituminous materials shall be laid by a self propelled spreader finisher
equipped with a hopper, delivery augers and a heated adjustable
vibrating screed. It shall be capable of laying bituminous materials with
no segregation, dragging, burning or other defects and within the
specified level and surface regularity tolerances. Delivery augers shall
terminate not more than 200mm from the edge plates.
(d) Compaction plant
The Contractor shall provide sufficient rollers of adequate size and
weight to achieve the specified compaction. Prior to commencing the
laying of bituminous mixes in the permanent Works the Contractor
shall carry out site trials in accordance with Section 2 of this
Specification to demonstrate the adequacy of his plant and to
determine the optimum method of use and sequence of operation of
the rollers.
1604A PREPARATION OF SURFACE
Immediately before placing the bituminous mix in the pavement, the
existing surface shall be cleaned of all loose material and foreign
matter with mechanical brooms or by other approved methods. The
debris shall be deposited well clear of the surface to be covered.
Any defect of the surface shall be made good and no bituminous mix
shall be laid until the surface has been approved by the Engineer.
If instructed by the Engineer a tack coat shall be applied in
accordance with Section 15 of this Specification. If the Engineer
considers a tack coat is required prior to laying the bituminous mix or
between layers of the bituminous mix, due solely to the Contractors
method of working, then such tack coat shall be at the Contractor's
expense.
1605A DESIGN AND WORKING MIXES
At least two months prior to commencing work using a bituminous mix,
the Contractor shall, having demonstrated that he can produce
aggregates meeting the grading requirements of the Specification,
submit samples of each constituent of the mix to the Engineer.
The Engineer will then carry out laboratory tests in order to decide
upon the proportions of each constituent of the initial design mix or
mixes to be used for site trials to be carried out in accordance with
Clause 1606A of this Specification.

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Should the Engineer conclude from the site trials that the mix
proportions or aggregate gradings are to be changed, the Contractor
shall submit further samples of the constituents and carry out further
site trials all as directed by the Engineer.
The Engineer may instruct the alteration of the composition of the
minus 75 micron fraction of the aggregates by the addition or
substitution of mineral filler. The Engineer may also instruct the
alteration of all or part of the minus 6.3mm fraction of the aggregates
by the addition or substitution of a natural sand.
The Contractor shall make the necessary adjustments to his plant to
enable the revised mix to be produced.
Following laboratory and site trials the Engineer will determine the
proportions of the working mix and the Contractor shall maintain this
composition within the tolerances given in Clause 1614A.
Should any changes occur in the nature or source of the constituent
materials, the Contractor shall advise the Engineer accordingly. The
procedure set out above shall be followed in establishing the new mix
design.
1606A SITE TRIALS
Full scale laying and compaction site trials shall be carried out by the
Contractor on all asphalt pavement materials proposed for the Works
using the construction plant and methods proposed by the Contractor
for constructing the Works. The trials shall be carried out with the
agreement, and in the presence of the Engineer, at a location
approved by the Engineer.
The trials shall be carried out to enable the Contractor to demonstrate
the suitability of his mixing and compaction equipment to provide and
compact the material to the specified voids content and to confirm that
the other specified requirements of the completed asphalt pavement
layer can be achieved.
Each trial area shall be at least 100 metres long and to the full
construction width and depth for the material. It may form part of the
Works provided it complies with this Specification. Any areas which do
not comply with this Specification shall be removed.
The Contractor shall allow in his programme for conducting site trials
and for carrying out the appropriate tests on them. The trial on any
pavement layer shall be undertaken at least 21 days ahead of the
Contractor proposing to commence full scale work on that layer.
The Contractor shall compact each section of trial over the range of
compactive effort the Contractor is proposing and the following data
shall be recorded for each level of compactive effort at each site trial:

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(i) The composition and grading of the material including the

bitumen content and type and grade of bitumen used.
(ii) The moisture content of aggregate in the asphalt plant hot
bins.
(iii) The temperature of the bitumen and aggregate immediately
prior to entering the mixer, the temperature of the mix on
discharge from the mixer and the temperature of the mix on
commencement of laying, on commencement of
compaction and on completion of compaction. The
temperature of the mixture is to be measured in
accordance with BS 598, Part 3, Appendix A.
(iv) The type, size, mass, width of roll, number of wheels, wheel
load, tyre pressures, frequency of vibration and the number
of passes of the compaction equipment, as appropriate for
the type of roller.
(v) The target voids and other target properties of the mix
together with the results of the laboratory tests on the mix.
(vi) The density and voids achieved.
(vii)The compacted thickness of the layer
(viii) Any other relevant information as directed by the
Engineer.
At least eight sets of tests shall be made by the Contractor and the
Engineer on each 100 metres of trial for each level of compactive
effort and provided all eight sets of results over the range of
compactive effort proposed by the Contractor meet the specified
requirements for the material then the site trial shall be deemed
successful. The above data recorded in the trial shall become the
agreed basis on which the particular material shall be provided and
processed to achieve the specified requirements.
If during the execution of the Works, the construction control tests
indicate that the requirements for a material are not being consistently
achieved, then work on that layer shall stop until the cause is
investigated by the Contractor. Such investigation may include further
laboratory and/or site trials on the material to determine a revised set
of data as above which, when agreed, shall be the basis on which all
subsequent material will be provided and processed to achieve the
specified requirements.
Agreement by the Engineer to a set of data recorded in a, site trial
shall not relieve the Contractor of any responsibility to comply with the
requirements of this Specification and the Special Specification.

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1607A MIXING OF AGGREGATES AND BITUMEN

Bitumen binders shall be stored at temperatures not exceeding those
given in Table 16A-1 or as specified in the special specifications and
the aggregate and bituminous binders shall be heated at the mixing
plant to such temperatures that that the mixed product shall have a
temperature within the range given in Table 16A-1.
TABLE 16A-1: Storage and mixing temperatures

Max. storage Temperature range of

temperature of binder mix (°C)
Binder
Continuously and gap
Over 24hrs Under 24hrs
graded mixes
T 40/50 145 175 150-180
h 60/70 135 175 140-170
e 80/100 125 175 130-165

Dried aggregates shall be combined in the mixer in the amount of

each fraction instructed by the Engineer and the bitumen shall then be
introduced into the mixer in the amount specified. The materials shall
then be mixed until a complete and uniform coating of the aggregate is
obtained.
The mixing time shall be the shortest required to obtain a uniform mix
and thorough coating. The wet mixing time shall be determined by the
Contractor and agreed by the Engineer for each plant and for each
type of aggregate used. It shall normally not exceed 60 seconds.
1608A TRANSPORTING THE MIXTURE
The bituminous mix shall be kept free of contamination and
segregation during transportation. Each load shall be covered with
canvas or similar covering to protect it from the weather and dust.
1609A LAYING THE MIXTURE
Immediately after the surface has been prepared and approved, the
mixture shall be spread to line and level by the laying plant without
segregation and dragging.
The mixture shall be placed in widths of one traffic lane at a time,
unless otherwise agreed by the Engineer. The compacted thickness of
any layer shall be at least 2.5 times the maximum size of the
aggregate for wearing course and at least 2 times for binder course.
The minimum thickness shall be 25mm.
Only on areas where irregularities or unavoidable obstacles make the
use of mechanical laying impracticable, may the mixture be spread
and compacted by hand.

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1610A COMPACTION
Immediately after the bituminous mixture has been spread, it shall be
thoroughly and uniformly compacted by rolling.
The layer shall be rolled when the mixture is in such a that rolling does
not cause undue displacement or shoving condition

The number weight and type of rollers furnished shall be sufficient to

obtain the required compaction while the mixture is in a workable
condition. The sequence of rolling operations shall be as agreed with
the Engineer and proved during site trials.
Initial rolling with a steel tandem or three-wheeled roller shall follow
the laying plant as closely as possible. The rollers shall be operated
with the drive roll nearest the laying plant, at a slow and uniform speed
(not exceeding 5km/h).
Rolling shall normally commence from the outer edge and proceed
longitudinally parallel to the centreline, each trip overlapping one half
of the roller width. On superelevated curves, rolling shall begin at the
low side and progress to the high side. Where laying is carried out in
lanes care must be taken to prevent water entrapment.
Intermediate rolling with a pneumatic tyred or vibratory roller shall
follow immediately. Final rolling with a steel wheeled roller shall be
used to eliminate marks from previous rolling.
To prevent adhesion of the mixture to the rollers, the wheels shall be
kept lightly moistened with water.
In areas too small for the roller, a vibrating plate compactor or a hand
tamper shall be used to achieve the specified compaction.
1611A FINISHING, JOINTS AND EDGES
Any mixture that becomes loose and broken, mixed with dirt or foreign
matter or is in any way defective, shall be removed and replaced with
fresh hot mixture, which shall be compacted to conform with the
surrounding area.
Spreading of the mixture shall be as continuous as possible.
Transverse joints shall be formed by cutting neatly in a straight line
across the previous run to expose the full depth of the course. The
vertical face so formed shall be painted lightly with hot 80/100, 60/70
or 40/50 penetration grade bitumen just before the additional mixture
is placed against it.
Longitudinal joints shall be rolled directly behind the paving operation.
The first lane shall be placed true to line and level and have an
approximately vertical face. The mixture placed in the abutting lane
shall then be tightly crowded against the face of the previously placed

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lane. The paver shall be positioned to spread material overlapping the

joint face by 20 - 30 mm. Before rolling, the excess mixture shall be
raked off and discarded.

When the abutting lane is not placed in the same day, or the joint is
destroyed by traffic, the edge of the lane shall be cut back as
necessary, trimmed to line and painted lightly with hot 80/100, 60/70
or 40/50 penetration grade bitumen just before the abutting lane is
placed.
Any fresh mixture spread accidentally on the existing work at a joint
shall be carefully removed by brooming it back on to uncompacted
work, so as to avoid formation of irregularities at the joint. The finish at
joints shall comply with the surface requirements and shall present the
same uniformity of finish, texture and density as other sections of the
work.
The edges of the course shall be rolled concurrently with or
immediately after the longitudinal joint. In rolling the edges, roller
wheels shall extend 50 to 100mm beyond the edge.
1612A SAMPLING AND TESTING OF BITUMINOUS MIXTURES
The sampling of bituminous mixtures shall be carried out in
accordance with AASHTO T168 (ASTM Designation D979).
1613A QUALITY CONTROL TESTING
During mixing and laying of bituminous mixtures, control tests on the
constituents and on the mixed material shall be carried out in
accordance with Clause 1612A and Section 2 of this Specification.
If the results of any tests show that any of the constituent materials fail
to comply with this Specification, the Contractor shall carry out
whatever changes may be necessary to the materials or the source of
supply to ensure compliance.
If the results of more than one test in ten on the mixed material show
that the material fails to comply with this Specification, laying shall
forthwith cease until the reason for the failure has been found and
corrected. The Contractor shall remove any faulty material laid and
replace it with material complying with this Specification all at his own
expense.
1614A TOLERANCES
Surfacing courses and base shall be constructed within the geometric
tolerances specified in Section 3 of this Specification.
The Contractor shall maintain the composition of the mixture as
determined from the laboratory and site trials within the tolerances
given in Table 16A-1, per single test:

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TABLE 16A-1: TOLERANCES

Bitumen Content ± 0.3% (by total weight of total

mix)
Passing 10mm sieve and ± 6% (by total weight of dry
larger sieve s aggregate including mineral filler)
Passing sieves between ± 4% (by total weight of dry
10mm and 1.0 mm sieves aggregate including mineral filler)
Passing sieves between 1.0 ± 3% (by total weight of dry
mm and 0.075 mm sieves aggregate including mineral filler)
Passing 0.075 mm sieve ± 2% (by total weight of dry
aggregate including mineral filler)

The average amount of bitumen in any length of any layer, calculated

as the product of the bitumen contents obtained from single tests and
the weight of mixture represented by each test, shall not be less than
the amount ordered.
The average amount of bitumen for each day's production calculated
from the checked weights of mixes shall not be less than the amount
ordered.
The final average overall width of the upper surface of a bituminous
mix layer measured at six equidistant points over a length of 100m
shall be at least equal to the width specified. At no point shall the
distance between the centreline of the road and the edge of the upper
surface of a bituminous mix layer be narrower than that specified by
more than 13mm.
1615A MEASUREMENT AND PAYMENT
No separate measurement and payment shall be made for complying
with the requirements of Clauses 1601A to 1614A inclusive and the
Contractor shall be deemed to have allowed in his rates in Parts B, C
and D of Section 16 of this Specification for the costs of complying
with the requirements of Part A of Section 16 of this Specification.

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PART B - ASPHALT CONCRETE FOR SURFACING

1601B DEFINITION
Asphalt concrete means a thoroughly controlled, hot-mixed, hot-laid,
plant mixture of well graded dried aggregate and penetration grade
bitumen, which, when compacted, forms a dense material.
A distinction is drawn between asphalt concrete Type I (High Stability)
and asphalt concrete Type II (Flexible). The asphalt concrete type will
be specified in the Special Specification.
1602B MATERIALS FOR ASPHALT CONCRETE
(a) Penetration grade bitumen
The type of bitumen shall be 80/100, 60/70 or 40/50 penetration grade
as specified in the Special Specifications.
(b) Aggregate
Coarse aggregate (retained on a 6.3mm sieve) shall consist of
crushed stone free from clay, silt, organic matter and other deleterious
substances- The aggregate class will be specified in the Special
Specification and it shall comply with the requirements in Table 16B-1
and Table 16B-2.
Table 16B-1: COARSE AGGREGATE SOURCE PROPERTIES
REQUIREMENTS

Coarse Aggregate (retained on a 6.3 mm sieve)

Aggregate Class a b c

LAA Max 30 35 40

ACV Max 25 23 30

SSS Max 12 12 12

For asphalt concrete Type I, the coarse aggregate shall be entirely

crushed. For asphalt concrete Type II, the Crushing Ratio of the
coarse aggregate shall be as specified in the Special Specification or
as instructed by the Engineer, but shall in no case be less than 60%.
Fine aggregate (passing a 6.3 mm sieve) shall be free from clay, silt,
organic and other deleterious matter and shall be non-plastic. Unless
otherwise specified in the Special Specification it shall consist of
entirely crushed rock produced from stone having a Los Angeles

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Abrasion of not more than 40. The Sand Equivalent of the fine
aggregate shall be not less than 40, and the SSS not more than 12.

Table 16B-2: COARSE AND FINE AGGREGATE CONSENSUS

REQUIREMENTS

Uncompacted Void
Coarse Aggregate
Design Content of Fine
Angularity (%), Sand Flat and
(ESAL)1 x 106 minimum2 Aggregate (%), Equivalent Elongated3
minimum (%), (%),
Position in ≤ 100mm >100mm ≤100mm >100mm minimum maximum
Pavement4
<0.3 55/- -/- - - 40 -
0.3 to <3 75/- 50/- 40 40 40 10
3 to <10 85/80 60/- 45 40 45 10
10 to <30 95/90 80/75 45 40 45 10
>30 100/100 100/100 45 45 50 10
Note:
1. Design ESAL is the expected volume of traffic on the design
lane over 20 years
2. 85/80 denotes that 85% of the coarse aggregate has one
fractured face and 80% has two or more fractured face
3. Criterion based upon 5:1 maximum-to-minimum ratio
4. If less than 25% of a layer is within 100mm of the surface, the
layer may be considered to be below 100mm for the purpose
of the mix design
(c) Mineral filler
Mineral filler shall consist of finely ground particles of limestone,
hydrated lime, Ordinary Portland cement or other non-plastic mineral
matter as specified in the Special Specification. It shall be thoroughly
dry and free from lumps. At least 75% (by weight) shall pass a
0.075mm sieve and 100% shall pass a 0.425mm sieve. It shall have a
bulk density in toluene measured in accordance with BS 812 of
between 0.5 and 0.9 g/ml.
1603B GRADING REQUIREMENTS
The grading of the mixture of coarse and fine aggregate shall be
within and approximately parallel to one of the grading envelopes
given in Table 16B-3 and/or should pass through the Control Points
presented in Table 16B-4, as specified in the Special Specification.

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TABLE 16B-3
GRADING REQUIREMENTS FOR ASPHALT CONCRETE

Percentage by weight passing

Sieve Type I Type II
Size
(mm) Wearing Course Binder Course Wearing Course
0/14 0/10 0/6 0/20 0/14 0/10 0/14 0/10
28 - - - 100 - - - -
20 100 - - 90-100 100 - 100 -
14 90-100 100 - 75-95 90-100 100 90-100 100
10 70-90 90-100 100 60-82 70-90 90-100 70-95 90-100
6.3 55-75 60-82 90-100 47-68 52-75 60-82 55-85 62-90
4 45-63 47-67 75-95 37-57 40-60 45-65 46-75 50-80
2 33-48 33-50 50-70 25-43 30-45 30-47 35-60 35-65
1 23-38 23-38 33-50 18-32 20-35 20-35 25-45 25-50
0.425 14-25 14-25 20-33 11-22 12-24 12-24 14-32 14-33
0.300 12-22 12-22 16-28 9-17 10-20 10-20 11-27 11-27
0.150 8-16 8-16 10-20. 5-12 6-14 6-14 6-17 6-17
0.075 5-10 5-10 6-12 3-7 4-8 4-8 3-8 3-8

TABLE 16B-4
GRADING REQUIREMENTS FOR ASPHALT CONCRETE –
SUPERPAVE

Sieve Percent passing sieve size

Size Nominal size (mm)
mm 19 12.5 9.5
Control Control Control
Point Point Point
Min Max Min Max Min Max
25 100 - - - - -
19 90 100 100 - - -
12.5 - 90 90 100 100 -
9.5 - - - 90 90 100
4.75 - - - - - 90
2.36 23 49 28 58 32 67
1.18 - - - - - -
0.600 - - - - - -
0.300 - - - - - -
0.075 2 8 2 10 2 10

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1604B REQUIREMENTS FOR ASPHALT CONCRETE

The mixture shall comply with the requirements as specified in the
Special Specification given in Table 16B-5 for Marshall and/or
Table16B-6a and Table16B-6b for Superpave.
The proportion, by weight of total mixture, of bitumen shall be stated in
the Special Specification. This shall be termed the nominal binder
content. The binder content of the working mix will be instructed by the
Engineer following laboratory and site trials.
TABLE 16B-5
REQUIREMENTS FOR ASPHALT CONCRETE

Type I Type II
Type I
Asphalt Concrete (Wearing (Wearing
(Binder Course)
Course) Course)

Marshall Stability Min 9000 Min 7000 4000 - 9000

50 blows (N)

Flow Value (mm)

2-4 2-4 3-5

Voids in total mix (%) 3-5 3-7 3-5

TABLE 16B-6a
GYRATORY COMPACTIVE EFFORT - SUPERPAVE

Design Compaction Parameters

Traffic esa Ninitial Ndesign N maximum
x 106
<0.3 6 50 75

0.3 to <3 7 75 115

3 to <30 8 100 160

>30 9 125 205

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TABLE 16B-6b
VOLUMETRIC DESIGN REQUIREMENTS FOR ASPHALT
CONCRETE - SUPERPAVE

Design Relative density Minimum VMA, % VFB, Filler to

Traffic Nominal Maximum aggregate range, binder
Esa*106 Size, mm % ratio
Ninitial Ndesign Nmaximum 19.0 12.5 9.5

<0.3 ≤91.5 70-80

0.3-<3 ≤90.5 65-78
0.3-<10 0.6-1.2
10-<30 ≤89.0 96.0 ≤98.0 13.0 14.0 15.0 65-75
>30
Notes:
1. Design traffic is the predicted traffic for a 20 year period, regardless of the
actual design life of the road.
2. Relative density = % of theoretical max specific gravity
3. VMA = Voids in Mineral Aggregate
4. VB = Voids filled with bitumen
5. For 37.5mm nominal maximum aggregate size, the lower limit of the VFB
shall be 64%, for all traffic levels
6. For 25.0mm nominal maximum aggregate size, the lower limit of the VFB
shall be 67%, for <0.3M esa
7. For 9.5mm nominal maximum aggregate size, the specified range in VFB
shall be 73 to 76%, for ≥3M esa

1605B MIXING AND LAYING ASPHALT CONCRETE

Typical mixing temperatures are summarised in Table 16B-7 for
guidance. Where possible the viscosity of the bitumen should be
measured over a range of temperatures and plotted on the Bitumen
Test Data Chart (FIGURE 16B-7) so that the ideal mixing temperature,
at which the viscosity of the bitumen is between approximately 0.2 and
0.5 Pa.s, can then be read from the chart.

TABLE 16B-7
TEMPERATURE RANGES FOR BITUMINOUS BINDERS

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Temperature range of mix (°C)

Bitumen type, penetration
grade
Continuously graded mixes

40/50 pen 150-180

60/70 pen 140-170
80/100 pen 130-165

The minimum thickness of the compacted layer shall be 25mm when

0/10 and smaller aggregate is used and 50mm when 0/20 aggregate
is used.

1606B COMPACTION
Rolling shall be continued until the voids measured in the completed
layer are within the appropriate ranges tabulated in Table 16B-5
and/or 16B-6b above. During compaction the optimal viscosity should
be between 2 - 20 Pa.s. The BTDC (Figure 16B-1) is useful in
ensuring that the appropriate operating temperatures are selected to
achieve the appropriate viscosity for the bitumen being used.

FIGURE 16B-1
BITUMEN TEST DATA CHART

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1607B MEASUREMENT- AND PAYMENT

(a) Item : Asphalt concrete
Unit: m3 of each type, binder and nominal size for each layer
Asphalt concrete shall be measured by the cubic metre compacted on
the road calculated as the product of the length instructed to be laid
and the compacted cross-sectional area shown on the Drawings or
instructed by the Engineer.
The rate for asphalt concrete shall include for the cost of providing,
transporting, laying and compacting the mix with the nominal binder
content and complying with the requirements of Parts A and B of
Section 16 of this Specification.
(b) Item : Variation in binder content
Unit: 1(litre)
Measurement of variation of binder content shall be by the litre
calculated as the product of the difference, corrected to 15.6°C,
between the nominal binder content and the binder content instructed
by the Engineer, and the weight of compacted mix to which the
variation applies, calculated from the volume determined in
accordance with Clause 1607B (a) of this Specification.

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Adjustment of compensation to the Contractor shall be as follows:

as a payment to the Contractor where the binder content is increased
above the nominal rate specified, but only where such increase has
been instructed in writing by the Engineer.
as a refund to the Employer where the binder content is reduced
below the nominal rate specified. The binder content may only be
reduced if the Engineer so instructs.
(c) Item : Mineral filler
Unit: tonne of each type
The rate per cubic metre for asphalt concrete shall include for
providing any mineral filler necessary to achieve the specified
gradings.
The Engineer may require the addition or substitution of mineral filler
to modify a grading curve which already meets the specified
requirements and in this case measurement and payment shall be
made for the mineral filler so added or substituted.
Measurement shall be by the tonne of mineral filler added or
substituted at the Engineer's Instruction.
The rate for additional or substituted mineral filler shall include for the
cost of the following:-
Provision, haulage and storage of mineral filler.
Batching and mixing of mineral filler.
Removal from the graded aggregates of part or all of the minus 75
micron fraction if required by the Engineer.
(d) Item : Sand
Unit: tonne from each source
The rate per cubic metre for asphalt concrete shall include for
providing aggregates to the specified gradings.
The Engineer may instruct the alteration of all or part of the minus
6.3mm fraction by the addition or substitution of natural sand in which
case measurement and payment shall be made for sand so added or
substituted.
Measurement shall be by the tonne of sand added or substituted at
the Engineer's instructions.
The rate for sand shall include for the cost of the following:
(i) Provision, haulage and storage of sand
(ii) Batching and mixing of sand

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(iii) Removal from the graded aggregates of part or all of the

minus 6.3mm fraction if required by the Engineer.

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PART C - DENSE BITUMEN MACADAM FOR BASE

1601C DEFINITION
Dense bitumen macadam means a hot-mixed, hot-laid plant mixture of
well graded aggregate and penetration grade bitumen.
1602C MATERIAL REQUIREMENTS
(a) Penetration grade bitumen
The type of bitumen shall be 80/100, 60/70 or 40/50 penetration grade
as specified in the Special Specifications.
(b) Aggregate
Coarse aggregate (retained on a 6.3 mm sieve) shall consist of
crushed stone produced from rock or boulders, the minimum size of
which are at least 4 times the maximum size of the final crushed
stone. The coarse aggregate shall be free from clay, silt, organic
matter and other deleterious substances and shall comply with the
requirements in Table 6C-1 and Table 6C-2.
Table 16C-1: COARSE AGGREGATE SOURCE PROPERTIES
REQUIREMENTS

Coarse Aggregate (retained on a 6.3 mm sieve)

LAA Max 35

ACV Max 28

SSS Max 12

The Crushing Ratio shall not be less than 100%.

Fine aggregate (passing a 6.3 mm sieve) shall be free from clay, silt,
organic and other deleterious matter. Unless otherwise specified in the
Special Specification it shall consist of entirely crushed rock produced
from stone having a Los Angeles Abrasion of not more than 40. The
Sand Equivalent of the fine aggregate shall be not less than 40 and
the SSS not more than 12.

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Table 16C-2: COARSE AND FINE AGGREGATE CONSENSUS

REQUIREMENTS

Uncompacted Void
Coarse Aggregate
Design Content of Fine
Angularity (%), Sand Flat and
(ESAL)1 x 106 minimum2 Aggregate (%), Equivalent Elongated3
minimum (%), (%),
Position in ≤ 100mm >100mm ≤100mm >100mm minimum maximum
Pavement4
<0.3 55/- -/- - - 40 -
0.3 to <3 75/- 50/- 40 40 40 10
3 to <10 85/80 60/- 45 40 45 10
10 to <30 95/90 80/75 45 40 45 10
>30 100/100 100/100 45 45 50 10
Note:
1. Design ESAL is the expected volume of traffic on the design lane over 20 years
2.85/80 denotes that 85% of the coarse aggregate has one fractured face and 80%
has two or more fractured face
3. Criterion based upon 5:1 maximum-to-minimum ratio
4. If less than 25% of a layer is within 100mm of the surface, the layer may be
considered to be below 100mm for the purpose of the mix design
(c) Mineral filler
Mineral filler shall consist of finely ground particles of limestone,
hydrated lime, ordinary Portland cement or other non-plastic mineral
matter as specified in the Special Specification. It shall be thoroughly
dry and free from lumps. At least 75% (by weight) shall pass a
0.075mm sieve and 100% shall pass a 0.425mm sieve. It shall have a
bulk density in toluene measured in accordance with BS 812 between
0.5 and 0.9 g/ml.
1603C GRADING REQUIREMENTS FOR DENSE BITUMEN MACADAM
The grading of the mixture of coarse and fine aggregate shall be
within and approximately parallel to one of the grading envelopes
given in Table 16C-3 and/or should pass through the Control Points
presented in Table 16C-4, as specified in the Special Specification.

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TABLE 16C-3
GRADING REQUIREMENTS FOR DENSE BITUMEN MACADAM

Sieve Size % by weight passing

(mm) 0/40 0/30
50 100 -
37.5 95-100 100
28 70-94 90-100
20 - 71-95
14 56-76 58-82
6.3 44-60 44-60
2 25-40 26-40
1 20-33 20-33
0.3 7-21 7-21
0.15 4-15 -
0.075 2-8 2-8

TABLE 16C-4
GRADING REQUIREMENTS FOR DENSE BITUMEN MACADAM -
SUPERPAVE

Sieve Percent passing sieve size

Size Nominal size (mm)
mm 37.5 25
Control Control
Point Point
Min Max Min Max
50 100 - - -
37.5 90 100 100 -
25 - 90 90 100
19 - - - 90
4.75 - - - -
2.36 15 41 19 45
1.18 - - - -
0.600 - - - -
0.300 - - - -
0.075 0 6 6 7

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1604C REQUIREMENTS FOR DENSE BITUMEN MACADAM

The mixture shall comply with the requirements as specified in the
Special Specification given in Table 16C-3 for Marshall and/or
Table16C-4a and Table16C-4b for Superpave.

The proportion, by weight of total mix, of bitumen shall be stated in the

Special Specification. This shall be termed the nominal binder content.
The binder content of the working mix will be instructed by the
Engineer following laboratory and site trials.
TABLE 16C-3: REQUIREMENTS FOR DENSE BITUMEN MACADAM

DENSE BITUMEN MACADAM 0/40 0/30

Marshall Stability (50blows) N min 5000 min 5000
Flow Value (mm) 2-5 2-4
Voids in total mix (%) 4-10 4-10
Loss of Stability after soaking (ASTM
max 35% max 35%
1075) as % of unsoaked value

TABLE 16C-4a: GYRATORY COMPACTIVE EFFORT - SUPERPAVE

Design Compaction Parameters

Traffic esa Ninitial Ndesign N maximum
x 106
<0.3 6 50 75

0.3 to <3 7 75 115

3 to <30 8 100 160

>30 9 125 205

TABLE 16C-4b: VOLUMETRIC DESIGN REQUIREMENTS FOR

ASPHALT CONCRETE - SUPERPAVE

Minimum VMA, %
Design Relative density Nominal Maximum aggregate VFB, Filler to
Traffic Size, mm range, binder
esa x106 % ratio
Ninitial Ndesign Nmaximum 37.5 25.0
<0.3 ≤91.5 70-80
0.3-<3 ≤90.5 65-78

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0.3-<10 96.0 ≤98.0 11.0

10-<30 12.0 0.6-1.2
≤89.0 65-75
>30
Notes:
1. Design traffic is the predicted traffic for a 20 year period, regardless of the
actual design life of the road.
2. Relative density = % of theoretical max specific gravity
3. VMA = Voids in Mineral Aggregate
4. VB = Voids filled with bitumen
5. For 37.5mm nominal maximum aggregate size, the lower limit of the VFB
shall be 64%, for all traffic levels
6. For 25.0mm nominal maximum aggregate size, the lower limit of the VFB
shall be 67%, for <0.3M esa
7. For 9.5mm nominal maximum aggregate size, the specified range in VFB
shall be 73 to 76%, for ≥3M esa

1605C MIXING AND LAYING DENSE BITUMEN MACADAM

Typical mixing temperatures are summarised in Table 16C-5 for
guidance. Where possible the viscosity of the bitumen should be
measured over a range of temperatures and plotted on the Bitumen
Test Data Chart (Figure 16C-1) so that the ideal mixing temperature,
at which the viscosity of the bitumen is between approximately 0.2 and
0.5 Pa.s, can then be read from the chart.

TABLE 16C-5
TEMPERATURE RANGES FOR BITUMINOUS BINDERS

Temperature range of mix (°C)

Bitumen type, penetration
grade
Continuously graded mixes

40/50 pen 150-180

60/70 pen 140-170
80/100 pen 130-165

The temperature of the freshly mixed dense bitumen macadam shall

be between 130°C and 180°C depending on the type binder selected.
The minimum temperature at laying and commencement of
compaction shall be 120°C and at completion of compaction shall be
not less than 90°c.
The requirements regarding laying specified in Clause 1609A shall be
modified as follows:
Laying plant capable of spreading the mixture over the full
carriageway width shall be used as much as possible, otherwise the

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longitudinal joint shall be compacted before the temperature of the

existing lane has dropped to 70°C where 80/100 bitumen is used, to
80°C where 60/70 bitumen is used and 90°C where 40/50 is used.
This temperature limitation requires the use of at least two mechanical
pavers working in echelon.
The minimum thickness of the compacted layer shall be 60mm when
0/30 aggregate is used and 75mm when 0/40mm is used. No
compacted layer shall exceed 100mm thickness when 0/30mm
aggregate is used and 125mm when 0/40mm is used.
1606C COMPACTION
Rolling shall be continued until the voids measured in the completed
layer are within the appropriate ranges tabulated in Table 16C-3
and/or 16C-4b above. During compaction the optimal viscosity should
be between 2 - 20 Pa.s. The BTDC (Figure 16C-1) is useful in
ensuring that the appropriate operating temperatures are selected to
achieve the appropriate viscosity for the bitumen being used.

FIGURE 16C-1
BITUMEN TEST DATA CHART

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1607C SEALING OF DENSE BITUMEN MACADAM BASE

Bitumen macadam base course shall be sealed by applying the
wearing course or surface dressing specified within two weeks of
completing any section of base course or as specified by the
Engineer. If the Contractor is unable to comply with this clause he
shall apply a temporary single seal surface dressing at his own
expense within the two weeks.
1608C MEASUREMENT AND PAYMENT
(a) Item : Dense bitumen macadam
Unit: m3 of each type, binder and nominal size for each layer
Dense bitumen macadam shall be measured by the cubic metre
compacted on the road calculated as the product of the length
instructed to be laid and the compacted cross-sectional area
shown on the Drawings or instructed by the Engineer.
The rate for dense bitumen macadam shall include for the cost of
providing, transporting, laying and compacting the mix with the
nominal binder content and complying with the requirements of
Parts A and C of Section 16 of this Specification.
(b) Item : Variation in binder content
Unit: 1(litre)
Measurement of variation of binder content shall be by the litre
calculated as the product of the difference, corrected to 15.6°C,
between the nominal binder content and the binder content
instructed by the Engineer, and the weight of compacted mix to
which the variation applies, calculated from the volume determined
in accordance with Clause 1608C(a) of this Specification.
Adjustment of compensation to the Contractor shall be as follows:-
As a payment to the Contractor where the binder content is
increased above nominal rate specified, but only where such
increase has been instructed in writing by the Engineer.
As a refund to the Employer where the binder content is reduced
below the nominal rate specified. The binder content may only be
reduced if the Engineer so instructs.
(c) Item : Mineral filler
Unit: tonne of each type
The rate per cubic metre for dense bitumen macadam shall
include for providing any mineral filler necessary to achieve the
specified gradings.

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The Engineer may require the addition or substitution of mineral

filler to modify a grading curve which already meets the specified
requirements and payment shall be made for the mineral filler so
added or substituted
Measurement shall be by the tonne of mineral filler added or
substituted at the Engineer's instruction.
The rate for additional or substituted mineral filler shall include for
the cost of the following:
(i) Provision, haulage and storage of mineral filler.
(ii) Batching and mixing of mineral filler.
(iii) Removal from the graded aggregates of part or all of the minus
75 micron fraction if required by the Engineer.
(d) Item: Sand
Unit: tonne from each source
The rate per cubic metre for dense bitumen macadam shall
include for providing aggregates to the specified gradings.
The Engineer may instruct the alteration of all or part of the minus
6.3mm fraction by the addition or substitution of natural sand in
which case measurement and payment shall be made for sand so
added or substituted.
Measurement shall be by the tonne of sand added or substituted
at the Engineer's instruction.
The rate for sand shall include for the cost of the following:-
(i) Provision, haulage and storage of sand.
(ii) Batching and mixing of sand.
(iii) Removal from the graded aggregates of part or all of the minus
6.3mm fraction if required by the Engineer.

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PART D - COLD ASPHALT FOR SURFACING, BASE, LEVELLING

AND PATCHING
1601D DEFINITION
Cold asphalt means a hot or cold-mixed, cold-laid plant mixture of
graded aggregate and bituminous binder.
1602D MATERIALS FOR COLD ASPHALT
(a) Bituminous binder
For cold-asphalt to be used immediately, tbe bituminous binder
shall be a medium-curing cut-back MC 250, MC 800 or MC 3000
or an anionic emulsion A2 or A3, or a cationic emulsion K2 or K3,
as specified in the Special Specification or as instructed by the
Engineer.
For cold-asphalt to be stockpiled, the bituminous binder shall be a
medium-curing cut-back MC 250 or MC 800 or a slow-curing cut-
back SC 250 or SC 800 or a slow-setting emulsion A3 or K3, as
specified in the Special Specification or as instructed by the
Engineer.
(b) Aggregates
Coarse aggregate (retained on a 6.3 mm sieve) shall consist of
crushed stone produced from rock or boulders the minimum size
of which are at least 4 times the maximum size of the final crushed
stone. The coarse aggregate shall be free from clay, silt, organic
matter and other deleterious substances. The aggregate class will
be specified in the Special Specification and shall comply with the
following requirements as appropriate:

Coarse Aggregate (greater than 6.3 mm)

Aggregate Class a b c
LAA Max 30 35 40
ACV Max 25 28 30
SSS Max 12 12 12
FI Max 20 25 25

The fine aggregate (passing a 6.3mm sieve) shall be free from clay,
silt, organic and other deleterious matter. Unless otherwise specified
in the Special Specification it shall consist of entirely crushed rock
produced from stone having a Los Angeles Abrasion of not more than
40.
The Sand Equivalent of the fine aggregate shall be not less than 40
and the SSS not more than 12.

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(c) Mineral filler

The mineral filler shall consist of finely ground particles of limestone,
hydrated lime, ordinary Portland cement or other non-plastic mineral
matter as specified in the Special Specification. It shall be thoroughly
dry and free from lumps. At least 75% (by weight) shall pass a
0.075mm sieve and 100% shall pass a 0.425mm sieve. It shall have a
bulk density in toluene measured in accordance with BS 812 between
0.5 and 0.9 g/ml.
1603D GRADING REQUIREMENTS FOR COLD ASPHALT
The mixture of aggregates shall be within and approximately parallel
to the grading envelope specified in the Special Specification or as
instructed by the Engineer.
1604D REQUIREMENTS FOR COLD ASPHALT
The density and stability of the cold asphalt shall be as specified in the
Special Specification or as instructed by the Engineer.
The proportion, by weight of total mix, of bitumen shall be stated in the
Special Specification. This shall be termed the nominal binder content.
The binder content of the working mix will be instructed by the
Engineer following laboratory and site trials.
1605D MIXING AND LAYING COLD ASPHALT
When bitumen emulsion is used as the binder, heating and drying of
aggregates are not required. Heating of the binder shall be in
accordance with the manufacturer's recommendations. The moisture
content of the mixture shall be adjusted in the mixing plant to permit
optimum compaction. The aggregate shall have a moisture content in
the range 3% - 5% at the time the emulsion is added.
When cut-back bitumen is used as the binder the requirements of
Clause 1607A shall apply but with the following temperature
limitations:-
Cut back Mixing Heating (Max)
MC and SC 250 55-80°C 100°C
MC and SC 800 70-100°C 125°C
MC 3000 90-120°C 140°C

The aggregates shall be dried and heated so that they are mixed at
the following temperatures
60 - 90°C when MC or SC 250 is used
75 - 115°C when MC or SC 800 is used
90 - 130°C when MC 3000 is used.

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Cold asphalt may be placed at ambient temperature and may be laid

by grader, provided the Contractor can demonstrate in the site trials
that he can achieve the geometric tolerances for the base with this
method.
1606D COMPACTION
The average density of the 100mm cores cut from the cold asphalt
should not be less than 98% of the average density obtained from
Marshall specimens (50 blows) made during laboratory trials on the
mixture used for site trials. No individual density shall be below 95% of
the average of the laboratory specimens.
1607D MEASUREMENT AND PAYMENT
(a) Item : Cold Asphalt
Unit: m3 of each type, binder and nominal size for each layer
Cold asphalt shall be measured by the cubic metre compacted on
the road calculated as the product of the length instructed to be
laid and the compacted cross-sectional area shown on the
Drawings or instructed by the Engineer.
The rate for cold asphalt shall include for the cost of providing,
transporting, laying and compacting the mix with the nominal
binder content and complying with the requirements of Parts A and
D of Section 16 of this Specification.
(b) Item : Variation in binder content
Unit: 1(litre)
Measurement of the variation of binder content shall be by the litre
calculated as the product of the difference, corrected to 15.6°C,
between the nominal binder content and the binder content
instructed by the Engineer, and the weight of compacted mix to
which the variation applies, calculated from the volume determined
in accordance with
Clause 1607D (a) of this Specification.
Adjustment of compensation to the Contractor shall be as follows:-
As a payment to the Contractor where the binder content is
increased above the nominal rate specified, but only where such
increase has been instructed in writing by the Engineer.
As a refund to the Employer where the binder content is reduced
below the nominal rate specified. The binder content may only be
reduced if the Engineer so instruct.

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(c) Item : Mineral filler

Unit: tonne of each type
The rate per cubic metre for cold asphalt includes for providing any
mineral filler necessary to achieve the specified grading.
The Engineer may require the addition or substitution of mineral
filler to modify a grading curve which already meets the specified
requirements and in this case measurement and payment shall be
made for the mineral filler so added or substituted.
Measurement shall be by the tonne of mineral filler added or
substituted at the Engineer's instructions.
The rate for additional or substituted mineral filler shall include for
the cost of the following:-
(i) Provision, haulage and storage of mineral filler.
(ii) Batching and mixing of mineral filler.
(iii) Removal from the graded aggregates of part or all of the minus
75 micron fraction if required by the Engineer.
(d) Item : Sand
Unit: tonne from each source
The rate per cubic metre for cold asphalt shall include for providing
aggregates to the specified gradlngs.
The Engineer may instruct the alteration of all or part of the minus
6.3mm fraction by the addition or substitution of natural sand in
which case the measurement and payment shall be made
for sand so added or substituted.
Measurement shall be by the tonne of sand added or substituted
at the Engineer's instruction.
The rate for sand shall include for the cost of the the following:
(i) Provision, haulage and storage of sand.
(ii) Batching and mixing of sand.
(iii) Removal from the graded aggregates of part or all of the minus
6.3mm fraction if required by the Engineer.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

17000 CONCRETE WORKS

17001 SCOPE OF SECTION
This section covers the materials, design of mixes, mixing, transport, placing,
compaction and curing of concrete and mortar required in the Works. It also
covers formwork and reinforcement for concrete.
17002 DEFINITIONS
Structural concrete is any class of concrete which is used in reinforced,
prestressed or unreinforced concrete construction, which is subject to stress.
Non-structural concrete is composed of materials complying with the
Specification but for which no strength requirements are specified and which is
used only for filling voids, blinding foundations and similar purposes where it is
not subjected to significant stress.
A formed surface is a face which has been cast against formwork.
An unformed surface is a horizontal or nearly horizontal surface produced by
screeding or trowelling to the level and finish required.
A pour refers to the operation of placing concrete into any mould, bay or
fonnvork, etc, and also to the volume which has to be filled, Pours in vertical
succession are referred to as lifts.
17003 MATERIALS FOR CONCRETE
(a) General
The Contractor shall submit to the Engineer full details of all materials which
he proposes to use for making concrete. No concrete shall be placed in the
works until the Engineer has approved the materials of which it is composed.
Approved materials shall not thereafter be altered or substituted by other
materials without the consent of the Engineer.
(b) Cement
Cement shall comply with the following Kenya Standards:-
KS02-21 for ordinary Portland cement
KS02-21 for rapid hardening Portland cement plus all special
conditions to its use stipulated by the manufacturer
Cement shall be free flowing and free of lumps. It shall be supplied in the
manufacturer's sealed unbroken bags or in bulk. Bagged cement shall be
transported in vehicles provided with effective means of ensuring that it is
protected from the weather.
Bulk Cement shall be transported in vehicles or and in containers built
equipped for the purpose.

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Cement in bags shall be stored in a suitable weatherproof structure of which

the Interior shall be dry and well ventilated at all times. The floor shall be
raised above the surrounding ground level and shall be so constructed that
no moisture rises through it
Each delivery of cement in bags shall be stacked together in one place. The
bags shall be closely stacked so as to reduce air circulation but shall not be
stacked against an outside wall. If pallets are used, they shall be constructed
so that bags are not damaged during handling and stacking. No stack of
cement bags shall exceed 3 m in height. Different types of cement in bags
shall be clearly distinguished by visible markings and shall be stored in
separate stacks.
Cement from broken bags shall not be used in the Works.
Cement in bags shall be used in the order in which it is delivered.
Bulk cement shall be stored in weatherproof silos which shall bear a clear
indication of the type of cement contained in them. Different types of cement
shall not be mixed in the same silo.
The Contractor shall provide sufficient storage capacity on Site to ensure that
his anticipated programme or work is not interrupted due to lack of cement.
Cement which has become hardened or lumpy or fails to comply with the
Specification in any way shall be removed from the Site.
All cement for any one structure shall be from the same source.
All cement used in the Works shall be tested the Contractor in a laboratory
acceptable to the Engineer. The tests to be performed shall be those set out
in Section 2 of this Specification and the Contractor shall supply two copies of
each certificate to the Engineer.
Cement which does not comply with the Specification shall not be used in
Works and it shall be disposed of by the Contractor.
The Contractor shall keep full records of all data relevant to the manufacture,
delivery, testing and use of all cement used in the Works and shall provide
the Engineer with two copies thereof.
(c) Fine aggregate
Fine aggregate shall be clean hard and durable and shall be natural sand,
crushed gravel sand or crushed rock sand complying with BS 882. All the
material shall pass through a 5 mm BS sieve and the grading shall be in
accordance with Zones 1, 2 or 3 of BS 882. In order to achieve an acceptable
grading, it may be necessary to blend materials from more than one source.
Fine aggregate for mortar only shall comply with BS 1200.

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The fine aggregate shall not contain iron pyrites or iron oxides. It shall not
contain mica, shale, coal or other laminar, soft or porous materials or organic
matter unless the Contractor can show by comparative tests, on finished
concrete as set out in BS 1881, that the presence of such materials does not
adversely affect the properties of the concrete.
Other properties shall be as set out below:
Content passing a 75 micron BS sieve shall not exceed 3 per cent for natural
or crushed gravel sand or 15 per cent for crushed rock sand.
Chlorides soluble in a 10 per cent solution by weight of nitric acid shall not
exceed 0.05 per cent by weight expressed as chloride ion when tested as set
out in BS 812, subject also to the further restriction given in the note on total
chloride content In Sub-Clause 1703 (d).
Sulphates soluble in a 10 per cent solution by weight of hydrochloric acid
shall not exceed 0.4 per cent by weight expressed as SO3, when tested as
set out in BS 1377, subject also to the further restriction given in the note on
total sulphate content in Sub-Clause 1703 (d).
Soundness: After five cycles of the test in AASHTO T104 the aggregate shall
not show a weight loss of more than 10 per cent.
Organic impurities: If the test described in Section 2 of this Standard
Specification shows that more than a trace of organic impurities is present,
the fine aggregate shall not be used in the Works unless the Contractor can
show by tests on finished concrete as set out In BS 1881 that the presence of
organic Impurities does not adversely affect the properties of the concrete
(d) Coarse aggregate
Coarse aggregate shall be clean hard and durable crushed rock, crushed
gravel or natural gravel complying with the requirements of BS 882 - The
material shall not contain any iron pyrites, iron oxides, flaky or laminated
material, hollow shells, coal or other soft or porous material, or organic matter
unless the Contractor can show by comparative tests on finished concrete as
set out in BS 1881 that the presence of such materials does not adversely
affect the properties of the concrete. The pieces shall be angular rounded or
irregular as defined in BS 812 Part 1.
Coarse aggregate shall be supplied in the nominal sizes called for in the
Contract and shall be graded in accordance with BS 882 for each nominal
size.
Other properties shall be as set out below:-
The proportion of clay, silt and other impurities passing 75 micron BS sieve
shall be not more than one per cent by weight.

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The content of hollow and frat shells shall not be such as will adversely affect
the concrete quality when tested as set out in BS 1881. The total shell
content of aggregate shall not be more than the following:
40 mm nominal size and above 2% of dry weight
20 mm nominal size 5% of dry weight
10 mm nominal size 15% of dry weight
Chlorides soluble in a 10 per cent solution by weight of nitric acid shall not
exceed 0.03 per cent by weight, expressed as chloride ion when tested as set
out in BS 812 but subject also restriction under the note on total chloride
Sulphates soluble in a 10 per cent solution by weight of hydrochloric acid
shall not exceed 0.4 per cent by weight expressed as SO3 when tested as
set out in BS 1377 subject also to the further restriction given in the note on
total sulphate content hereunder.
Soundness: After 5 cycles of the test in AASHTO T104, the aggregate shall
not show a weight loss of more than 12 per cent.
When tested in accordance with test C289 of the American Society for
Testing and Materials, the aggregate shall be non-reactive.
Flakiness Index when tested in accordance with BS 812 shall be as set out
hereunder:-
For 40 mm stone and above, not more than 40
For 20 mm stone and below, not more than 35
If the Flakiness Index of the coarse aggregate varies by more than five units
from the average value of the aggregate used in the approved trial mix, then
a new set of trial mixes shall be carried out if the workability of the mixes has
been adversely affected by such variation.
Impact value: Not more than 45 per cent when tested in accordance with BS
812.
Ten per cent fines value: Not less than 50kN when tested in accordance with
BS 812.
Shrinkage: When mixed with other ingredients in the approved proportions for
concrete and tested as set out in BS 1881, the shrinkage factor shall not
exceed 0.05 per cent.
Organic impurities: If the test described in Section 2 of this Specification
shows that more than a trace of organic impurities is present, the aggregate
shall not be used in the Works unless the Contractor can show by tests on
finished concrete as set out in BS 1881 that the presence of organic
impurities does not adversely affect the properties of the concrete.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

Water absorption: The aggregate shall not have a

water absorption of more than 2.5
per cent when tested as set out in
BS 812.
Aggregate Crushing Value (ACV): Not more than 35%.
Los Angeles Abrasion (LAA): Not more than 50%.
NOTE: Total chloride and sulphate content:-
The total chloride content, expressed as chloride ion, arising from all
ingredients in a mix including cement, water and admixtures shall not exceed
the following limits, expressed as a percentage of the weight of cement in the
mix:-
For prestressed concrete, steam cured concrete or concrete containing
sulphate resisting or super-sulphated cement: 0.05 per cent.
For any other reinforced concrete: 0.3 per cent in 95 per cent of all test
results provided no result is more than 0.5 per cent.
The total sulphate content expressed as SO3 of all the Ingredients in a mix
including cement, water and admixtures shall not exceed 0.4 per cent by
weight of the aggregate or 4.0 per cent of the weight of cement in the mix,
whichever is the lesser.
(e) Testing aggregates
(i) Acceptance testing
The Contractor shall deliver to the Engineer samples containing not less
than 50 kg of any aggregate which he proposes to use in the Works and
shall supply such further samples as the Engineer may require. Each
sample shall be clearly labelled to show its origin and shall be
accompanied by all the information called for in BS 882.
Tests to determine compliance of the aggregates with the requirements of
Sub-Clause 1703 7c) and (d) shall be carried out by the Contractor in a
laboratory acceptable to the Engineer. If the tested materials fail to
comply with the Specification, further tests shall be made in the
presence of the Contractor and the Engineer and acceptance of the
material shall be based on such tests.
A material shall be accepted if not less than three consecutive sets of test
results show compliance with the Specification.
(ii) Compliance testing
Routine testing of fication during the d for the Works. The on aggregates
from one set of tests for ed to Site provided more than 250 tonnes of
coarse aggregates are of from any source is shall be increased as

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

The Contractor shall carry out aggregates for compliance with the Spec
period that concrete is being produce tests set out below shall be
performed each separate source on the basis of each day on which
aggregates are deliver that no set of tests shall represent of fine
aggregate nor more than 50 aggregate, and provided also that the
uniform quality. If the aggregate variable, the frequency of testing
instructed by the Engineer.
Grading BS 812
Silt and clay contents BS 812
Moisture content BS 812
Check on organic impurities Section 2 of this Specification
In addition to the above routine tests, the Contractor shall carry out the
following tests at the frequencies Stated:
Moisture content; as frequently as nay be required in order to control the
water content of the concrete as required by the Specification.
Chloride content: as frequently as may be required to ensure that the
proportion of chlorides in the aggregates does not exceed the limit stated
in the Specification.
The Contractor shall take account of the-fact that when the chloride
content is variable it may be necessary to test every load in order to
prevent excessive amounts of chloride contaminating the concrete. For
this purpose the Contractor shall use the rapid field test described in
Section 2 of this Specification (the Quantab test). In the event of
disagreement regarding the results of the field test, the chloride content of
the aggregate shall be determined in the laboratory as described in BS
812 (the Volhard test).
(f) Delivery and storage of aggregates
Aggregates shall be delivered to site in clean and suitable vehicles. Different
types or sizes of aggregate shall not be delivered in one vehicle.
Each type or size of aggregate shall be stored in a separate bin or
compartment having a base such that contamination of the aggregate is
prevented. Dividing walls between bins shall be substantial and continuous
so that no mixing of types or sizes occurs.
The storage of aggregates shall be arranged so that as far as possible rapid
drying out in hot weather is prevented in order to avoid sudden fluctuations in
water content. Storage of fine aggregates shall be arranged so that they can
drain sufficiently before use in order to prevent fluctuations in water content of
the concrete.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

(g) Water for concrete and mortar

Seawater or brackish water containing more than 1000 ppm chloride ion or
2000 ppm sulphate ion shall not be used for mixing or curing concrete.
Water shall be clean and free from harmful matter and shall comply with the
requirements of BS 3148.
The Contractor shall carry out tests in accordance with BS 3148 to establish
compliance with the Specification.
(h) Admixtures
(i) General
The use of the admixtures in concrete may be required under the
Contract to promote special properties in the finished concrete or may be
proposed by the Contractor to assist htm in compliance with the
Specification.
In all cases the Contractor shall submit to the Engineer full details of the
admixture he proposes to use and the manner in which he proposes to
add it to the mix. The information provided shall include:-
(a) The typical dosage, the method of dosing and the detrimental effects
of an excess or deficiency in the dosage.
(b) The chemical names of the main active ingredients in the admixture.
(c) {c) Whether or not the admixture contains chlorides, and if so the
chloride ion content expressed as a percentage by weight of
admixture.
(d) Whether the admixture leads to the entrainment of air when used at
the manufacturer's recommended dosage, and if so, the extent to
which it does so.
(e) Details of previous uses of the admixture in Kenya.
The chloride ion content of any admixture shall not exceed 2 per cent
by weight of the admixture nor 0.03 per cent by weight of the cement
in the mix.
Admixtures shall not be mixed together without the consent of the
Engineer.
Calcium chloride or admixtures containing calcium chloride shall not
be used in prestressed concrete.
(ii) Workability agents
Workability agents shall comply with BS 5075 and shall not have any
adverse effect on the properties of the concrete.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

17004 THE DESIGN OF CONCRETE MIXES

(i) Classes of concrete
The classes of structural concrete to be used in the Works shall be those
shown on the Drawings and designated in Table 17—1, in which the class
designation includes two figures. The first figure is the nominal strength at 28
days expressed in N/mra2 and the second figure is the maximum nominal
size of aggregate in the mix expressed in millimetres.

TABLE 17-1 Concrete classes and strengths

Maximum Trial Early works test

Maximum water/cement mixes cubes Clause1704
Nominal ratio Target (d)
Nominal mean
Class of size Average
Strength strength
concrete of Any one of any
N/mm2 (Clause
aggregate A B cube group of
(mm) 1704(c)
N/mm2 4 cubes
(N/mm2) N/mm2
10/75 10 75 0.6 0.55 13.5 8.5 13.3
15/75 15 75 0.6 0.5 21.5 12.8 20
15/40 15 40 0.6 0.5 21.5 12.8 20
15/20 15 20 0.57 0.5 21.5 12.8 20
20/40 20 40 0.55 0.48 31.5 17 27.5
20/20 20 20 0.53 0.48 31.5 17 27.5
20/10 20 10 0.5 0.48 31.5 17 27.5
25/40 25 40 0.52 0.46 36.5 21.3 32.5
25/20 25 20 0.5 0.46 36.5 21.3 32.5
25/10 25 10 0.48 0.46 36.5 21.3 32.5
30/40 30 40 0.5 0.45 41.5 25.5 37.5
30/20 30 20 0.48 0.45 41.5 25.5 37.5
30/10 30 10 0.47 0.45 41.5 25.5 37.5
40/20 40 20 0.46 0.43 51.5 34 47.5
40/10 40 10 0.45 0.43 51.5 34 47.5
Note: Under water/cement ratio, column A applies to moderate and intermediate exposure, and
column B applies to severe exposure. See Note after table 17.2

(ii) Design of proposed mixes

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

The contractor shall design all the concrete mixes called for on the Drawings,
making use of the ingredients which have been approved; by the Engineer for
use in the Works and in compliance with the following requirements :-
(i) The aggregate portion shall be well graded from the nominal maximum
size of stone down to the 150 micron size.
(ii) The cement content shall be such as to achieve the strengths called for
in Table 17-1but in any case not less than the minimum necessary for
impermeability and durability shown in Table 17-2.
(iii) The workability shall be consistent with ease of placing and proper
compaction having regard to the presence of reinforcement and other
obstructions.
(iv) The water/cement ratio shall be the minimum consistent with adequate
workability but in any case not greater than that shown in Table 17-1
taking due account of any water contained in the aggregates. The
Contractor shall take into account that this requirement may in certain
cases require the inclusion of a workability agent in the mix.
(v) The drying shrinkage determined in accordance with BS 1881 shall not be
greater than 0.05 per cent.
Table 17-2 Minimum Cement Content

Minimum Cement Content – kg/m3

of compacted concrete
Class of concrete
Moderate Intermediate Severe
Exposure Exposure Exposure
10/75, 15/75 200 220 270
15/40, 20/40, 25/40, 30/40 240 270 290
15/20, 20/20, 25/20, 30/20 260 300 330
40/20, 300 320 330
20/10, 25/10, 30/10 300 340 390
40/10, 310 340 390

Note: The minimum cement content shown in the above table are required in
order to achieve impermeability and durability. In order to meet stress
requirements in the specification higher contents may be required
The categories applicable to the Works are based on the factors-listed
hereunder:

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

Moderate exposure Surface sheltered from severe rain buried

concrete, concrete continuously under water
Intermediate exposure Surface exposed to driving rain; alternate
wetting and dryingi traffic; corrosive fumes;
heavy condensation
Severe exposure Surface exposed to sea water, moorland
water having a pH of 4.5 or less,
groundwater containing sulphates.
(iii) Trial mixes
At least six weeks before commencing placement of concrete in the
Permanent Works trial mixes shall be prepared for each class of concrete
specified.
For each mix of concrete for which the Contractor has proposed a design, he
shall prepare three separate batches of concrete using the materials which
have been approved for use in the Works and the mixing plant which he
proposes to use for the Works. The volume of each batch shall be the
capacity of the concrete mixer proposed for full production.
Samples shall be taken from each batch and the following action taken, all in
accordance with BS 1881:-
(i) The slump of the concrete shall be determined.
(ii) Six test cubes shall be cast from each batch. In the case of concrete
having a maximum aggregate sire of 40 mm or less, 150 mm cubes shall
be used. In the case of concrete containing 75 mm or larger aggregate,
200 mm cubes shall be used and in addition any pieces of aggregate
retained on a 53 mm BS sieve shall be removed from the mixed concrete
before casting the cubes.
(iii) Three cubes from each batch shall be tested for compressive strength at
seven days and the remaining three at 28 days.
(iv) The density of all the cubes shall be determined before strength tests are
carried out-
The subject to the agreement of the Engineer, the compacting factor
apparatus may be used In place of a slump cone. Zn this case the
correlation between slump and compacting factor shall be established
during preparation of the trail mixes.
The average strength of the nine cubes tested -at 28 days shall be not
less than the target mean strength shown in Table 17-1
The Contractor shall also carry out tests to determine the drying
shrinkage of the concrete unless otherwise directed by the Engineer.

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Based on the results of the tests on the trial mixes, the Contractor shall
submit full details of his proposals for mix design to the Engineer,
including the type and source of each ingredient, the proposed
proportions of each mix and the results of the tests on the trial mixes.
If the Engineer does not agree to a proposed concrete mix for any
reason, the Contractor shall amend his proposals and carry out further
trial mixes. No mix shall be used in the Works without the written consent
of the Engineer.
(iv) Quality control of concrete production
(i) Sampling
For each class of concrete in production at each plant for use in the
Works, samples of concrete shall be taken at the point of mixing or of
deposition as instructed by the Engineer, all in accordance with the
sampling procedures described in BS 1881 and with the further
requirements set out below*
Six 150 mm or 200 from each sample and accordance with BS four at 28
days mm cubes as appropriate shall be mad shall be cured and tested all
in
1881, two at seven days and the other
Each sample shall be taken from one batch selected at random and at
intervals such that each sample represents not more than 20m3 of
concrete unless the Engineer agrees to sampling at less frequent
intervals.
Until compliance with the Specification has been established the
frequency of sampling shall be three times that stated above or such
lower frequency as may be instructed by the Engineer.
(ii) Testing
(a) The slump or compacting factor of the concrete shall be determined
for each batch from which samples are taken and in addition for other
batches at the frequency instructed by the Engineer
The slump of the concrete in any batch shall not differ from the value
established by the trial sixes by more than 25 mm or one third of the
value, whichever is the greater.
The variation in value used in place of a following limits: of the
compacting factor. If slump value, shall be within the following limits.
For value of 0.9 or more ± 0.03
For value of between 0.8 and 0.9 ±0.04
For values of 0.8 or less ±0.05

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(b) The water/cement ratio as estimated from the results of (a) above,
determined by samples from any batch shall not vary by more than
five per cent value from the established during the trial mixes.
(c) The air content of air entrained concrete in any batch shall be within
1.5 units of the required value and the average value of four
consecutive measurements shall be within 1.0 unit of the required
value, expressed as a percentage of the volume of freshly mixed
concrete.
(d) Until such time as sufficient test results are available to apply the
method of control described in (e) below, the compressive strength of
the concrete at 28 days shall be such that no single result is less than
the value shown in Table 17-1 under the heading early works test
cubes' and also that the average value of any four consecutive results
is not less than the value shown in Table 17-1 under the same
heading
The 7-day cube result may be used as an early strength indicator, at
the discretion of the Engineer.
(e) When test cube results are available for at least 20 consecutive
batches of any class of concrete mixed in any one plant, the average
of any four consecutive results at 28 days shall exceed the nominal
strength by not less than half the current margin (see below) and each
individual result shall not be less than 85 per cent of the nominal
strength.
The current margin shall be defined as 1.64 times the standard
deviation of cube tests on at least 20 separate consecutive batches
produced from one plant over a period exceeding five days but not
exceeding six months or on at least 50 separate consecutive batches
produced from one plant over a period not exceeding 12 months. If
both figures are available, the smaller shall be taken.
The current margin shall in any case not be less than the figure given
below:-

Minimum Current Margin for

10N/mm2 15N/mm2 20N/mm2 and above
After 20 batches 3.3 5 7.5
After 50 batches 1.7 2.5 3.8

(f) Failure to comply with requirements

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If any one test cube result in a group of four consecutive results is

less than 85 per cent of the nominal strength but the average of the
group of which it is part satisfies the strength requirement, then only
the batch from which the failed cube was taken shall be deemed not
to comply with the Specification.
If more than one cube result in a group of four consecutive results is
less than 85 per cent of the nominal strength or If the average
strength of the group fails to satisfy the strength requirement then all
the batches between those represented by the first and last cubes in
the group shall be deemed not to comply with the Specification, and
the Contractor shall immediately adjust the mix design subject to the
agreement of the Engineer to restore compliance with the
Specification. After adjustment of the mix design the Contractor will
again be required to comply with sub-Clauses 1704 (b) and 1704 (c)
of this Section of this Specification.
The Contractor shall take necessary action to remedy concrete which
does not comply with this Specification. Such action may include but
is not necessarily confined to the following:-
(i) Increasing the frequency of sampling until control is again
established.
(ii) Cutting test cores from the concrete and testing in accordance
with BS 1861.
(iii) Carrying out strengthening or other remedial work to the concrete
where possible or appropriate.
(iv) Carrying out non-destructive testing such as load tests on beams.
(v) Removing the concrete.
17005 MIXING CONCRETE
Before any plant for batching, mixing, transporting, placing, compacting and
finishing concrete is ordered or delivered to Site, the Contractor shall submit to
the Engineer full details including drawings of all the plant which he proposes to
use and the arrangements he proposes to make.
Concrete for the Works shall be batched and mixed in one or more central plants
unless the Engineer agrees to some other arrangement. If the Contractor
proposes to use ready mixed concrete he shall submit to the Engineer for his
approval full details and test results of the concrete mixes. The Engineer may
approve the use of ready mixed concrete provided that:
(a) the proposed mixes, the material to be used and the method of storage and
mixing comply with the requirements of the Specification; and
(b) adequate control is exercised during mixing.
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Approval to the use of ready mixed concrete may be withdrawn if the Engineer is
not satisfied with the control of the materials being used and control during
mixing.
Batching and mixing plants shall be modern efficient equipment complying with
the requirements of BS 1305 and capable of producing a uniform distribution of
the ingredients throughout the mass. Truck mixes shall comply with the
requirements of BS 4251 and shall only be used with the prior agreement of the
Engineer. If the plant proposed by the Contractor does not fall within the scope of
BS 1305, it shall have been tested in accordance with BS 3963 and shall have a
mixing performance within the limits of Table 6 of BS 1305.
All mixing operations shall be under the control of an experienced supervisor.
The aggregate storage bins shall be provided with drainage facilities arranged so
that drainage water is not discharged to the weigh hoppers. Each bin shall be
drawn down at least once per week and any accumulations of mud or silt
removed.
Cement and aggregates shall be batched by weight. Water may be measured by
weight or volume-
The weighing and water dispensing mechanisms shall be maintained in good
order^. Their accuracy shall be maintained within the tolerances described in BS
1305 and checked against accurate weights and volumes when required by the
Engineer.
The weights of cement and of each size of aggregate as indicated by the
mechanisms employed shall be within a tolerance of plus or minus two per cent
of the respective weights per batch agreed by the Engineer.
The Contractor shall provide standard test weights at least equivalent to the
maximum working load used on the most heavily loaded scale and other auxiliary
equipment required for checking the satisfactory operation of each scale or other
measuring device. Tests shall be made by the Contractor at least once a week or
at intervals to be determined by the Engineer and shall be carried out in his
presence. For the purpose of carrying out these tests, there shall be easy access
for personnel to the weigh hoppers. The Contractor shall furnish the Engineer
with copies of the complete results of all check tests and shall make Any
adjustments, repairs or replacements necessary to ensure satisfactory
performance.
The nominal drum or pan capacity of the mixer shall not be exceeded. The
turning speed and the mixing time shall be as recommended by the
manufacturer, but in addition, when water is the last ingredient to be added,
mixing shall continue for at least one minute after all the water has been added to
the drum or pan.

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The blades of pan mixers shall be maintained within the tolerances specified by
the manufacturer of the mixer and the blades shall be replaced when it is no
longer possible to maintain the tolerances by adjustment.
Mixers shall be fitted with an automatic recorder registering the number of
batches discharged.
The water to be added to the mix shall be reduced by the amount of free water
contained in the coarse and fine aggregates. This amount shall be determined by
the Contractor by a method agreed by the Engineer immediately before mixing
begins each day and thereafter at least once per hour during concreting and for
each delivery of aggregates during concreting. When the correct quantity of
water, determined as set out in the Specification, has been added to the mix, no
further water shall be added, either during mixing or subsequently.
After mixing for the required time, each batch shall be discharged any materials
for the succeeding completely from the mixer before batch are introduced.
Mixers which have been out of use for more than 30 minutes shall be thoroughly
cleaned before any fresh concrete is mixed and thereafter the first batch of
concrete through the mixers shall contain only half the normal quantity of coarse
aggregate. This batch shall be mixed forgone minute longer than the time
applicable to a normal batch.
Mixers shall be cleaned out before changing to another type of cement.
17006 HAND MIXED CONCRETE
Concrete for structural purposes shall not be mixed by hand. Where non-
structural concrete is required, hand nixing may be carried out subject to the
agreement of the Engineer.
The mixing shall be done on a hard impermeable surface. The materials shall be
turned over not less than three times dry, water shall then be sprayed on and the
materials again turned over not less than three tiroes in a wet condition and
worked together until a mixture of uniform consistency is obtained.
For hand mixed concrete the specified quantities of cement shall be increased by
10% and not more than 0.5 cubic metre shall be mixed at one time. During windy
weather efficient precautions shall be taken to prevent cement from being blown
away during the process of gauging and mixing.
17007 TRANSPORT OF CONCRETE
The concrete shall be discharged from the mixer and transported to the Works by
means which shall prevent adulteration, segregation or loss of ingredients, and
which shall ensure that the concrete is of the required workability at the point and
time of placing. The loss of slump between discharge from the mixer and placing
shall not exceed 25 mm.

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The time elapsing between mixing and placing a batch of concrete shall be as
short as practicable and in any case not longer than will permit completion of
placing and compaction before the onset of initial set. If the placing of any batch
of concrete is delayed beyond this period, the concrete shall not be placed in the
Works.
17008 PLACING OF CONCRETE
(a) Consent for placing
Concrete shall not be placed in any part of the Works until the Engineer's
consent has been given in writing, and the Contractor shall give the Engineer
at least 1 full working days’ notice of his intention to place concrete.
If concrete placing is not commenced within 24 hours of the Engineer's
consent the Contractor shall again request consent as specified above.
(b) Preparation of surface to receive concrete
Excavated surfaces on which concrete is to be deposited shall be prepared
as set out in Section 7 of this Specification.
Existing concrete surfaces shall be prepared as set out in Clause 1717.
Before deposition of further concrete they shall be clean, hard and sound and
shall be wet but without any freestanding water.
Any flow of water into an excavation shall be diverted through proper side
drains to a sump, or be removed by other suitable methods which will prevent
washing away the freshly deposited concrete or any of its constituents. Any
underdrains constructed for this purpose shall be completely grouted up
when they are no longer required by a method agreed by the Engineer.
Unless otherwise instructed by the Engineer surfaces against which concrete
is to be placed shall receive a prior coating or mortar mixed in the proportions
similar to those of the fines portion in the concrete to be placed. The mortar
shall be kept ahead of the concrete. The mortar shall be well worked into all
parts of the excavated surface and shall be not less than 5 mm thick.
If any fissures have been cleaned out as described in Section 7 of this
Specification they shall be filled with mortar or with concrete as instructed by
the Engineer.
The amount of mortar placed at any one time shall be limited so that it does
not dry out or set before being covered with concrete.
(c) Placing procedures
The concrete shall be deposited as nearly as possible in its final position. It
shall be placed so as to avoid segregation of the concrete and displacement
of the reinforcement, other embedded items, or formwork. It shall be brought
up in layers approximately parallel to the construction joint planes and not

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exceeding 500 mm in compacted thickness unless otherwise permitted or

directed by the Engineer, but the layers shall not be thinner than four times
the maximum nominal size of aggregate.
Layers shall not be placed so that they form feather edges nor shall they be
placed on a previous layer which has taken it» initial set. In order to comply
with this requirement, a layer
All the concrete in a single bay or pour shall be placed as a continuous
operation. It shall be carefully worked round all obstructions, irregularities in
the foundations and the like so that all parts are completely full of compacted
concrete with no segregation or honeycombing- It shall also be carefully
worked round and between water stops, reinforcement, embedded steelwork
and similar items which, protrude above the surface of the completed pour.
All work shall be completed on each batch of concrete before its initial set
commences and thereafter the concrete shall not be disturbed before it has
set hard. No concrete that has partially hardened during transit shall be used
in the Works and the transport of concrete from the mixer to the point of
placing shall be such that this requirement can be complied with.
Concrete shall not be placed during rain which is sufficiently heavy or
prolonged to wash mortar from coarse aggregate on the exposed faces of
fresh concrete. Means shall be provided to remove any water accumulating
on the surface of the placed concrete. Concrete shall not be deposited into
such accumulations of water.
In drying weather, covers shall be provided for all fresh concrete surfaces
which are not being worked on. Water shall not be added to concrete for any
reason.
When concrete is discharged above its place of final deposition, segregation
shall be prevented by the use of chutes, downpipes, trunking, baffles or other
appropriate devices.
Forms for walls, columns and other thin sections of significant height shall be
provided with openings or other devices that will permit the concrete to be
placed in a manner that will prevent segregation and accumulation6 of
hardened concrete on the formwork or reinforcement above the level of the
placed concrete.
When it is necessary to place concrete under water the Contractor shall
submit to the Engineer his proposals for the method and equipment to be
employed. The concrete shall be deposited either by bottom-discharging
watertight containers or through funnel-shaped tremie which are kept
continuously full with concrete up to a level above the water and which shall
have the discharging bottom fitted with a trapdoor and immersed in the

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concrete in order to reduce to a minimum the contact of the concrete with the
water. Special care shall be taken to avoid segregation.
If the level of concrete in a tremie pipe is allowed to fall to such an extent that
water enters the pipe, the latter shall be removed from the pour and filled with
concrete before being again lowered into the placing position. During and
after concreting under water, pumping or de-watering in the immediate
vicinity shall be suspended if there is any danger that such work will disturb
the freshly placed concrete.
(d) Interruptions to placing
If concrete placing is interrupted for any reason and the duration of the
interruption cannot be forecast or is likely to be prolonged, the Contractor
shall immediately take the necessary action to form a construction joint so as
to eliminate as far as possible feather edges and sloping top surfaces and
shall thoroughly compact the concrete already placed in accordance with
Clause 1709. All work on the concrete shall be completed while it is still
plastic and it shall not thereafter be disturbed until it is hard enough to resist
damage. Plant and materials to comply with this requirement shall be readily
available at all times during concrete placing.
Before concreting is resumed after such an interruption the Contractor shall
cut out and remove all damaged or uncompacted concrete, feather edges or
any other undesirable features and shall leave a clean sound surface against
which the fresh concrete may be placed.
If it becomes possible to resume concrete placing without contravening the
Specification and the Engineer consents to a resumption, the new concrete
shall be thoroughly worked in and compacted against the existing concrete so
as to eliminate any cold joints.
(e) Dimensions of pours
Unless otherwise agreed by the Engineer, pours shall not be more than two
metres high and shall as far as possible have a uniform thickness over the
plan area of the pour. Concrete shall be placed to the full planned height of all
pours except in the circumstances described in Sub-clause 1708 (d).
The Contractor shall plan the dimensions and sequence of pours in such a
way that cracking of the concrete does not take place due to thermal or
shrinkage stresses.
(f) Placing sequence
The Contractor shall arrange that aa far as possible the intervals between
placing successive lifts of concrete in one section of the Works are of equal
duration. This duration shall normally be not less than three or more than

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seven daya under temperate weather conditions unless otherwise agreed by

the Engineer.
Where required by the Engineer to limit the* opening of construction joints
due to shrinkage, concrete shall not be placed against adjacent concrete
which is less than 21 days old.
When the Drawings call for contraction gaps In concrete, these anal V-be of
the widths and in the locations shown on the Drawings and they shall not be
filled until the full time interval shown on the Drawings has elapsed,
17009 COMPACTION OF CONCRETE
The concrete shall be fully compacted throughout the full extent of the placed
layer. It shall be thoroughly worked against the formwork and around any
reinforcement and other embedded items, without displacing them. Particular
care shall be taken at arises and other confined spaces. Successive layers of the
same pour shall be thoroughly worked together.
Concrete shall be compacted with the assistance of mechanical immersion
vibrators, unless the Engineer agrees another method.
Immersion vibrators shall operate at a frequency of between 7000 and 10 000
cycles per minute. The Contractor shall ensure that vibrators are operated at
pressures and voltages not less than those recommended by the manufacturer in
order that the compactive effort is not reduced.
A sufficient number of vibrators shall be operated to enable the entire quantity of
concrete being placed to be vibrated for the necessary period and, in addition,
stand-by vibrators shall be available for instant use at each place where concrete
is being placed.
Where the concrete contains aggregate with a nominal size of 75 mm or more,
vibrators with a diameter of 100 mm or more shall be used.
Vibration shall be continued at each point until the concrete ceases to contract, a
thin layer of mortar has appeared on the surface and air bubbles have ceased to
appear. Vibrators shall not be used to move concrete laterally and shall be
withdrawn slowly to prevent the formation of voids.
Vibration shall not be applied by way of reinforcement nor shall vibrators be
allowed to touch reinforcement or other embedded items-The vibrators shall be
inserted vertically into the concrete to penetrate the layer underneath at regular
spacing which shall not exceed the distance from the vibrator over which
vibration is visibly effective.
17010 CURING OF CONCRETE
(a) General

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Concrete shall be protected during the first stage of hardening from loss of
moisture and from the development of temperature differentials within the
concrete sufficient to cause cracking. The methods used for curing shall not
cause damage of any kind to the concrete.
Curing shall be continued for as long as may be necessary to achieve the
above objectives but in any case for at least seven days or until the concrete
is covered by later construction whichever is the shorter period.
The above objectives are dealt with in sub-clauses 1710 (b) and (c) but
nothing shall prevent both objectives being achieved by a single method
where circumstances permit.
The curing process shall commence as soon as the concrete is hard enough
to resist damage from the process, and in the case of large areas or
continuous pours, shall commence on the completed section of the pour
before the rest of the pour is finished.
Details of the Contractor's proposals for curing concrete shall be submitted to
the Engineer before the placing of concrete commences in the Works.
(b) Loss of moisture
Exposed concrete surfaces shall be closely covered with impermeable
sheeting, properly secured to prevent its removal by wind and the
development of air spaces beneath it. Joints in the sheeting shall be lapped
by at least 300 mm.
If for some reason it is not possible to use impermeable sheeting, the
Contractor shall keep the exposed surfaces continuously wet by means of a
water spray or by covering with a water absorbent material which is kept wet,
unless this method conflicts with sub-clause 1710 (c).
Water used for curing shall be of the same quality as that used for mixing as
stated in sub-clause 1703 (g).
Formed surfaces may be cured by retaining the formwork In place for the
required curing period.
If the use of the foregoing methods is inappropriate, surfaces which will not
have further concrete bonded to them and which are not to receive an
application of a finish may be cured by the application of a curing compound
having an efficiency index of at least 90 per cent. Curing compounds shall
contain ft fugitive dye to enable the extent of the spread to be seen easily.
Curing compound used on surfaces exposed to the sky shall contain
sufficient finely divided flake aluminium in suspension to produce a complete
coverage of the surface with a metallic finish when applied at the rate
recommended by the manufacturer.

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Curing compounds shall become stable and Impervious to the evaporation of

water from the concrete surface within 60 minutes of application. The material
shall not react chemically with the concrete and shall not crack, peel or
disintegrate within three weeks after application.
If instructed by the Engineer, the Contractor shall. In addition to the curing
provisions set out above provide a suitable for* of shading to prevent the
direct rays of the sun reaching the concrete surfaces for at least the first four
days of the curing period.
(c) Limitation of temperature differentials
The Contractor shall Unit the development of temperature differentials in
concrete after placing by any means appropriate to the circumstances
including the following:
(i) limiting concrete temperatures at placing as set out in sub-clause 1712
(b);
(ii) use of low heat cement, subject to the agreement of the Engineer!
(iii) insulation of exposed concrete surfaces by insulating blankets. Such
blankets shall have an insulation value at least equivalent to 50 mm of dry
mineral wool;
(iv) leaving formwork in place during the curing period. Steel forms shall be
suitably insulated on the outside;
(v) preventing rapid dissipation of heat from surfaces by shielding from wind;
(vi) avoiding the use of water sprays when such use would cause rapid
cooling of the surface.
17011 PROTECTION OF FRESH CONCRETE
Freshly placed concrete shall be protected from rainfall and from water
running over the surface until it is sufficiently hard to resist damage from
these causes.
No traffic shall be allowed on any concrete surface until such time as it is
hard enough to resist damage by such traffic.
Concrete placed in the Works shall not be subjected to any loading until it has
attained at least its nominal strength as defined in Clause 1704.
If the Contractor desires to impose loads on newly-placed concrete, he shall
make^at least three test cubes and cure them in the same conditions as the
concrete they represent- These cubes shall be tested singly at suitable
intervals in order to estimate the time at which the nominal strength is
reached.

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17012 CONCRETING IN HOT WEATHER

(a) General
The Contractor shall prevent damage to concrete arising from exposure to
extreme temperatures, and shall maintain in good working order all plant and
equipment required for this purpose-
In the event that conditions become such that even with the use of the
equipment the requirements cannot be met, concrete placing shall
immediately cease until such time as the requirements can again be met.
(b) Concrete placing in hot weather
During hot weather the Contractor shall take all measures necessary to
ensure that the temperature of concrete at the time of placing in the Works
does not exceed 30*C and that the concrete does not lose any moisture
during transporting and placing.
Such measures may include but are not necessarily limited to the following:-
(i) Shielding aggregates from direct sunshine.
(ii) Use of a mist water spray on aggregates.
(iii) Sun shields on mixing plants and transporting equipment.
(iv) Cooling, the mixing water. If ice is used for this purpose it should
preferably be in flake form lump ice shall not be allowed to enter the tank
supplying the mixer drum.
(v) Covering skips closely with polythene sheet »o that the latter is in contact
with the concrete.
Areas in which concrete is to be placed shall be shielded from direct sunshine
and rock or concrete surfaces shall be thoroughly wetted to reduce absorption of
water from the concrete placed on or against them.
After concrete in any part of an area has been placed, the selected curing
process shall be commenced as soon as possible. If any interval occurs between
completion of placing and start of curing, the concrete shall be closely covered
during the interval with polythene sheet to prevent loss of moisture.
17013 FINISHES ON UNFORMED SURFACES
Horizontal or nearly horizontal surfaces which are not cast against formwork shall
be finished to the class shown on the Drawings and defined hereunder*
UF 1 finish
All surfaces on which no higher class of finish is called for on the Drawings or
instructed by the Engineer shall be given a OF 1 finish

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The concrete shall be levelled and screened to produce a uniform plain or ridged
surface, surplus concrete being struck off by a straight edge immediately after
compaction.
UF 2 finish
This is a floated finish for roof or floor slabs and other surfaces where a hard
trowelled surface is not required.
The surface shall first be treated as a Class UF 1 finish and after the concrete
has hardened sufficiently, it shall be floated by hand or machine sufficient only to
produce a uniform surface free from screed marks.
UF 3 finish
This is a hard trowelled surface for use where weather resistance or appearance
Is important, or which is subject to high velocity water flow.
The surface shall be floated as for a UF 2 finish but to the tolerance stated below.
When the moisture film has disappeared and the concrete has hardened
sufficiently to prevent laitance from being worked to the surface, it shall be steel-
trowelled under firm pressure to produce a dense, smooth uniform surface free
from trowel marks.

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Table 17-3 Surface Tolerances

Class of Tolerance in mm. see notes

Finish A B C
UF1 Not applicable 10 +20 or - 10
UF2 Nil 10 +20 or - 10
UF3 Nil 5 +12.5 or -7.5

Notes:
1. Col A is the maximum level in the surface.
2. Col B is the maximum allowable value of any gradual irregularity of the
surface, as indicated by the gap between the surface and a three metre long
straight edge or correctly shaped template placed on the surface.
3. Col C is the maximum allowable value of the difference in level or position
between a three metre long straight edge or correctly shaped template placed
on the surface and the specified level or position of that surface.
Where dimensional tolerances are given on the Drawings or in this Special
Specification they shall take precedence over those given in Table 17-3.
17014 MORTAR
This clause covers mortar for use ahead of concrete placing, and other uses not
covered elsewhere in the Specification.
Mortar shall be composed of fine aggregate complying with sub-Clause 1703 (c)
and ordinary Portland cement complying with KS02-21. The mix proportions shall
be as stated on the Drawings or elsewhere in this Specification or if not stated
shall be one part of cement to two parts of fine aggregate by weight.
Small quantities of mortar may be hand mixed but for amounts over 0.5 m3 a
mechanical mixer shall be used.
The water content of the mortar shall be as low as possible consistent with the
use for which it is required but in any case the water/cement ratio shall not be
more than 0.5
Mortar which is specified as 'dry pack* shall b« mixed with sufficient- water for
the mix to become cohesive but not plastic when squeezed in the hand. Dry pack
mortar shall be rammed into the cavity it is required to fill, using a hand rammer
with sufficient force to ensure full compaction.
17015 CONCRETE FOR SECONDARY PURPOSES
(a) Non-structural concrete (NS concrete) shall be used only for non-structural
purposes where shown on the Drawings.

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NS concrete shall be composed of ordinary Portland cement complying with

XS02-21 and aggregates complying with BS 882 including all-in aggregate
within the grading limits of Table 3 of BS 882.
The weight of cement mixed with 0.3 m3 metres of combined or all-in
aggregate shall not be less than 50 kg. The mix shall be proportioned by
weight or by volume. The maximum aggregate size shall be 40 mm nominal.
The concrete shall be mixed by machine or by hand to a uniform colour and
consistency before placing. The quantity of water used shall not exceed that
required to produce a concrete with sufficient workability to be placed and
compacted where required.
The concrete shall be compacted by hand or by mechanical vibration.
(b) No Fines concrete (NF concrete) is intended for use where a porous concrete
is required and shall only be used where shown on the Drawings or instructed
by the Engineer.
The mix shall consist of ordinary Portland cement complying with KS02-21
and aggregate complying with BS 882. The aggregate size shall be 40.0 mm
to 10.0 mm only. The weight of cement mixed with 0.3 m3 metre of aggregate
shall not be less than 50 kg. The quantity of water shall not exceed that
required to produce a smooth cement paste which will coat evenly the whole
of the aggregate.
17016 RECORDS OF CONCRETE PLACING
Records, in a form agreed by the Engineer, shall be kept by the Contractor of
the details of every pour of concrete placed in the Works. These records shall
include class of concrete, location of pour, date of pour, ambient temperature
and concrete temperature at time of placing, moisture contents of
aggregates, details of mixes, batch numbers, cement batch number, results
of all tests undertaken, location of test cube sample points and details of any
cores taken.
The Contractor shall supply to the Engineer four copies of these records each
week covering work carried out the preceding week. In addition he shall
supply to the Engineer monthly histograms of all 28
day cube strengths together with accummulative and monthly standard
deviations-- and any other information which the Engineer may require
concerning the concrete placed in the Works.
17017 CONSTRUCTION JOINTS
Whenever concrete is to be bonded to other concrete which has hardened,
the surface of contact between the sections shall be deemed a construction
joint.

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Where construction joints are shown on the Drawings, the Contractor shall
form such joints in those positions. The location of joints which the Contractor
requires to make for the purpose of construction shall be subject to the
agreement of the Engineer. Construction joints shall be in vertical or
horizontal planes except in sloping slabs where they shall be normal to the
exposed surface or elsewhere where the Drawings require a different
arrangement.
Construction joints shall be so arranged as to reduce to a minimum the
effects of shrinkage in the concrete after placing, and shall be placed in the
most advantageous positions with regard to stresses in the structures and the
desirability of staggering joints.
Feather edges of concrete at joints shall be avoided and any feather edges
which may have formed where reinforcing bars project through a joint shall be
cut back until sound concrete has been reached.
The intersections of horizontal or near horizontal joints and exposed faces of
concrete shall appear as straight lines produced by use of a guide strip fixed
to the formwork at the top of the concrete lift, or by other means acceptable to
the Engineer.
Construction joints formed as free surfaces shall not exceed a slope of 20 per
cent from the horizontal.
The surface of the fresh concrete in horizontal or near horizontal joints shall
be thoroughly cleaned and roughened by means of high pressure water and
air jets when the concrete is hard enough to withstand the treatment without
the leaching of cement. The surface of vertical or near vertical joints shall be
similarly treated if circumstances permit the removal of formwork at a suitable
time.
Where concrete has become too hard for the above treatment to be
successful, the surface whether formed or free is to be thoroughly scabbled
by mechanical means or wet sand blasted and then washed with clean water.
The indentations produced by scabbling shall be not less than 10 mm deep
and shall not extend closer than 40 mm to a finished face.
If instructed by the Engineer the surface of the concrete shall be thoroughly
brushed with a thin layer of mortar composed of one part of cement to two
parts of sand by weight and complying with Clause 1714 all as set out in Sub-
Clause 1708 (b) immediately prior to the deposition of fresh concrete. The
mortar shall be kept just ahead of the fresh" concrete being placed and the
fresh layer of concrete shall be thoroughly and systematically vibrated to full
depth to ensure complete bond with the adjacent layer.
No mortar or concrete nay be placed in position on or against a construction
joint until the joint has been inspected and passed by the Engineer.

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17018 EXPANSION AND CONTRACTION JOINTS

Expansion and contraction joints are discontinuities in concrete designed to
allow for thermal or other movements in the concrete.
Expansion joints are formed with a gap between the concrete faces to permit
subsequent expansion of the concrete. Contraction joints are formed to
permit initial contraction of the concrete and may include provision for
subsequent filling.
Expansion and contraction joints shall be formed in the positions and in
accordance with the details shown on the Drawings or elsewhere in the
Specifications.
17019 WATERSTOPS
All references to waterstops include groutstops.
Waterstops shall be of the material and form shown on the Drawings. No
waterstop material shall be brought onto site until the Contractor has
submitted full details of the materials he proposes to usef including samples,
and these have been approved by the Engineer. All samples shall be of
adequate length for testing.
Waterstops shall be made of material which are resistant to chlorides,
sulphates, or other deleterious substances which may be present in the
environment of the Works.
Rubber waterstops may be of natural of synthetic rubber and shall have an
elongation at breaking stress of at least 500 per cent at 25*C and shall allow
a joint movement of at least 50 an.
Polyvinyl chloride (PVC) waterstops shall be extruded from an unfilled
plasticised PVC polymer or copolymer which does not contain any reclaimed
or scrap PVC. PVC waterstops shall have an elongation at breaking stress of
at least 225 per cent at 25*C and shall allow a joint movement of at least 10
mm.
Low modulus waterstops shall be of rubber or PVC as described above but
shall have an elongation of at least 200 per cent at 25°c under a tensile
stress of 6 N/mm* and shall allow a joint movement of at least 50 mm.
Waterstops shall be supplied in lengths as long as possible consistent with
ease of handling and construction requirements.
In rubber or plastic materials joints other than butt joint* shall be supplied
ready made by the manufacturer. Butt joints shall be made on site in
accordance with the manufacturer's instructions and with equipment supplied
for the purpose by the manufacturer

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Waterstop material shall be stored carefully on Site to avoid damage and

contamination with oil, grease, or other pollutants Rubber and plastic
waterstops shall be stored in cool well ventilated places away from direct
sunlight
Rubber and plastic waterstops which are embedded in one side of a joint
more than one month before the scheduled date of placing concrete on the
other side, shall be protected from the sun
Waterstops shall be firmly fixed in the formwork so that they cannot be
displaced during concrete placing and shall be completely free of all dirt,
grease, oil, etc before placing concrete. Where eyelets are provided these
shall be fully wired to the reinforcement and be the only means whereby the
waterstop is fixed. In no circumstances shall a waterstop be punctured with
nails etc as a means of fixing.
Concrete shall be placed carefully round waterstops so as to avoid distortion
or displacement and shall be fully compacted. Where waterstops lie in a
horizontal or nearly horizontal plane the Contractor shall ensure that no voids
are left on the underside of the waterstop
Formwork round waterstops shall be carefully removed to avoid damage. If
waterstops suffer any damage which cannot be properly repaired in situ the
Engineer may require a section of concrete to be removed and the waterstop
replaced.
17020 GROUTING OF POCKETS AND HOLES AND UNDERPINNING OF
BASEPLATES
Pockets and holding-down bolt holes shall be thoroughly cleaned out using
compressed air and water jet. Holes drilled by a diamond bit shall be
roughened* The pockets and holes shall be filled with grout consisting of
cement and clean fresh water mixed in proportion of two parts by weight of
cement to one part by weight of water. The pouring of liquid grout shall cease
as soon as each hole is filled and any excess grout on the surface of the
concrete foundation shall be completely removed and the surface dried off
before the next operation proceeds*
The space between the top surface of foundation concrete and the underside
of baseplates shall be filled with a special mortar made up in the following
proportions:-
Portland cement 50 kg
Fine aggregate 50 kg
An additive acceptable to the Engineer to counteract shrinkage in proportions
recommended by the manufacturer.

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The special mortar shall be mixed with the lowest water-cement ratio which
will, result in a consistency of mix of sufficient workability to enable maximum
compaction to be achieved.
The special mortar shall then be well rammed in horizontally below the
baseplate and from one edge only until it is -extruded from the other three
sides. The mortar which has extruded shall then be rammed back to ensure
complete support without voids.
17021 FORMWORK FOR CONCRETE
Definitions
Formwork means the surface against which concrete is placed to form a face,
together with all the immediate supports to retain it in position while concrete is
placed.
False work means the structural elements supporting both the formwork and the
concrete until the concrete becomes self-supporting.
A formed face is one which has been cast against formwork*
An exposed face is one which will remain visible when construction has been
completed.
17022 CONSTRUCTION OF FORMWORK AND FALSEWORK
Before construction begins, the Contractor shall submit to the Engineer drawings
showing details of the proposed formwork and falsework.
Formwork and falsework shall be so constructed that they will support the loads
imposed on them by the fresh concrete together with additional stresses imposed
by vibrating equipment and by construction traffic, so that after the concrete has
hardened the formed faces shall be in the positions shown on the Drawings
within the tolerances set out in Clause 1726.
Ground supports shall be properly founded on footings designed to prevent
settlement.
Joints in formwork for exposed faces shall, unless otherwise specified, be evenly
spaced and horizontal or vertical and shall be continuous or form a regular
pattern.
All joints in formwork including formwork for construction joints shall be tight
against the escape of cement and fines. Where reinforcement projects through
formwork, the form shall fit closely round the bars.
Formwork shall be so designed that it may be easily removed from the work
without damage to the faces of the concrete. It shall also incorporate provisions
for making minor adjustments in position. If required, to ensure the correct
location of concrete faces. Due allowance*" shall be made in the position of all
formwork for movement and settlement under the weight of fresh concrete.

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Where overhangs in formwork occur, means shall be provided to permit the

escape of air and to ensure that the space is filled completely with fully
compacted concrete.'
Formwork shall be provided for concrete surfaces at slopes of 30* to the
horizontal or steeper. Surfaces at slopes less than 20* may be formed by
screeding. Surfaces at slopes between 20* and 30* shall generally be formed
unless the Contractor can demonstrate to the satisfaction of the Engineer that
such elopes can be screeded with the use of special screed boards to hold the
concrete in place during vibration.
Horizontal or inclined formwork to the upper surface of concrete shall be
adequately secured against uplift due to the pressure of fresh concrete.
Formwork to voids within the body of the concrete shall also be tied down or
otherwise secured against floating.
The internal and external angles on concrete surfaces shall be formed with fillets
and chamfers of the sizes shown on the Drawings unless otherwise instructed by
the Engineer.
Supports for formwork may be bolted to previously placed concrete provided the
type of bolt used is acceptable to the Engineer. If metal ties through the concrete
are wsed in conjunction with bolts, the metal left in shall not be closer than 50
mm to the face of the concrete.
Formwork shall not be re-used after it has suffered damage which is sufficient to
impair the finished surfaces of the concrete.
Where circumstances prevent easy access within the form for cleaning and
inspection, temporary openings for this purpose shall be provided through the
formwork.
Shear keys shall be provided in all construction joints of the size and shape
indicated on the Drawings.
Where precast concrete elements are specified for use as permanent formwork,
or proposed by the Contractor and agreed by the Engineer, they shall comply
with the requirements of the Specification. Such elements shall be set true to line
and level within the tolerances prescribed for the appropriate class of finish in
Clause 1726 and fixed so that they cannot move when concrete is placed against
them.
17023 PREPARATION OF FORMWORK
Before any reinforcement is placed into position within formwork, the latter shall
be thoroughly cleaned and then dressed with a release agent. The agent shall be
either a suitable oil incorporating a wetting agent, an emulsion of water
suspended In oil or a low viscosity oil containing chemical agents. The Contractor
shall not use an emulsion of oil suspended in water nor any release agent which

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causes staining or discolouration of the concrete, air holes on the concrete

surface, or retards the set of the concrete.
In order to avoid colour differences on adjacent concrete surfaces, only one type
of release agent shall be used in any one section of the Works.
In cases where it is necessary to fix reinforcement before placing formwork, all
surface preparation of formwork shall be carried out before it is placed into
position. The Contractor shall not allow reinforcement or prestressing tendons to
be contaminated with formwork release agent.
Before placing concrete all dirt, construction debris and other foreign matter shall
be removed completely from within the placing area.
Before concrete placing commences, all wedges and other adjusting devices
shall be secured against movement during concrete placing and the Contractor
shall maintain a watch on the formwork during placing to ensure that no
movement occurs.
17024 REMOVAL OF FORMWORK
Formwork shall be carefully removed without shock or disturbance to the
concrete. No formwork shall be removed until the concrete has gained sufficient
strength to withstand safely any stresses to which it may thereby be subjected.
The minimum periods which shall elapse between completion of placing concrete
and removal of forms are given in Table 17-4 and apply to ambient temperatures
higher than lO'c. At lower temperatures or if cement other than ordinary Portland
are involved, the Engineer may instruct longer periods.
Alternatively, formwork may be removed when the concrete has attained the
strength set out in Table 17-4, provided that the attained strength is determined
by making test cubes and curing them under the same conditions as the concrete
to which they refer.
Compliance with these requirements shall not relieve the Contractor of his
obligation to delay removal of formwork until the removal can be completed
without damage to the concrete.
Table 17-4 Minimum Periods for Formwork Removal

Minimum Strength
period for to
Position of Formwork
Temps be
over 10°C attained
Vertical or near vertical faces of mass concrete 24 hours 0.2 C
Vertical or near vertical faces of reinforced walls,
48 hours 0.3 C
beams and columns
Underside to underside of arches, beams and slabs 4 days 0.5 C

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

Supports to underside of arches, beams and slabs 14 days C

Arched lining in tunnels and underground works 24 hours 4 N/mm2
NOTE: C is the nominal strength for the class of concrete used.
If the Contractor wishes to strip formwork from the underside of arches beams
and slabs before the expiry of the period for supports set out above, it shall be
designed so that it can be removed without disturbing the supports. The
Contractor shall not remove supports temporarily for the purpose of stripping
formwork and subsequently replace them.
As soon as the formwork has been removed, bolt holes in concrete faces other
than construction joints which are not required for subsequent operations shall be
completely filled with mortar sufficiently dry to prevent any slumping at the face.
The mortar shall be mixed in the same proportions as the fine aggregate and
cement in the surrounding concrete and with the same materials and shall be
finished flush with the face of the concrete.
17025 SUPFACE FINISHES
Classes of finish
The surface finish to be achieved on formed concrete surfaces shall be as shown
on the Drawings and defined hereunder:-
(a) Class Fl finish
This finish is for surfaces against which backfill or further concrete will be
placed. Formwork may be sawn boards, sheet metal or any other suitable
material which will prevent the loss of fine material from the concrete being
placed.
(b) Class F2 finish
This finish is for surfaces which are permanently exposed to view but where
the highest standard of finish is not required. Forms to provide a Class F2
finish shall be faced with wrought thicknessed tongued and grooved boards
with square edges arranged in a uniform pattern and close jointed or with
suitable sheet material. The thickness of boards or sheets shall be such that
there shall be no visible deflection under the pressure exerted by the
concrete placed against them. Joints between boards or panels shall be
horizontal and vertical unless otherwise directed. This finish shall be such as
general filling of surface pitting, but discolouration and other minor defects
shall methods agreed by the Engineer.
(c) Class F3 finish
This finish is for surfaces which will be in contact with water flowing at high
velocity, and for surfaces prominently exposed to view where good
appearance Is of special importance. To achieve this finish, which shall be

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

free of board marks, the formwork shall be faced with plywood complying with
BS 1088 or equivalent material in large sheets. The sheets shall be arranged
in an approved uniform pattern. Wherever possible, joints between sheets
shall be arranged to coincide with architectural features or changes in
direction of the surface.
All joints between panels shall be vertical and horizontal unless otherwise
directed. Suitable joints shall be provided between sheets to maintain
accurate alignment in the plane of the sheets. Unfaced wrought boarding or
standard steel panels will not be permitted for Class F3 finish. The Contractor
shall ensure that the surface is protected from rust marks, spillages and
stains of all kinds.
(d) Curved surfaces
For curved surfaces where F2 or F3 finishes are called for, the formwork face
shall be built up of splines cut to make a tight surface which shall then be
dressed to produce the required finish.
Alternatively single curvature surfaces may be faced with plastic or plywood
linings attached to the backing with adhesive or with escutcheon pins driven
flueh. Linings shall not bulge, wrinkle or otherwise deform when subjected to
temperature and moisture changes.
17026 TOLERANCES
All parts of formed concrete surfaces shall be in the positions shown on the
Drawings within the tolerances set out in Table 17-5.
In cases where the Drawings call for tolerances other than those given in Table
17-5 the Drawings shall rule.
Where precast units have been set to a specified tolerance, further adjustments
shall be made as necessary to produce a satisfactory straight or curved line.
When the Engineer has approved the alignment, the Contractor shall fix the units
so that there la no possibility of further movement
Table 17-5 Tolerances

Class of Tolerance in mm (See Note)

finish A B C
F1 10 10 +25 to - 10
F2 5 10 + or - 15
F3 2 5 + or - 10

Note: The tolerances A, B and C given in the table are defined as follows:

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A is an abrupt irregularity in the surface due to misaligned formwork or

defects in the face of the formwork.
B is a gradual deviation from a plane surface as indicated by a straight
edge 3 m long. In the case of curved surfaces the straight edge shall be
replaced by a correctly shaped template.
C is the amount by which the whole or part of a concrete face Is displaced
from the correct position shown on the Drawings.
17027 REMEDIAL WORK TO DEFECTIVE SURFACES
If on stripping any formwork the concrete surface is found to be defective in any
way, the Contractor shall make no attempt to remedy such defects prior to the
Engineer's inspection and the receipt of any instructions which the Engineer may
give.
Defective surfaces shall not be made good by plastering.
Areas of honeycombing which the Engineer agrees may be repaired shall be cut
back to sound concrete or to 75 ma whichever is the greater distance. In the
case of reinforced concrete the area shall be cut back to at least 25 mm clear
distance behind the reinforcement or to 75 mm, whichever is the greater
distance. The cavity shall have sides at right angles to the face of the concrete.
After cleaning out with water and compressed air, a thin layer of cement grout
shall be brushed on to the concrete surfaces in the cavity and it shall then be
filled immediately with concrete of the same class as the main body but with
aggregate larger than 20 mm nominal size removed. A form shall be used
against the cavity, provided with a lip to enable concrete to be placed. The form
shall be filled to a point above the top edge of the cavity.
After seven days the lip of concrete shall be broken off and the surface ground
smooth.
Surface irregularities which are outside the limits of tolerance set out in Clause
1726 shall be ground down in the manner and to the extent instructed by the
Engineer.
Defects other than those mentioned above shall be dealt with as instructed by
the Engineer.
17028 REINFORCEMENT FOR CONCRETE
Reinforcement which shall comply with the following British Standards, covers
plain and deformed bar reinforcement and steel fabric to be cast into concrete in
any part of the Works but does not include prestressing tendons or any other
embedded steel.
BS 4449 for hot rolled plain bar and high yield deformed bar
BS 4482 for hard drawn mild steel wire

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BS 4461 for cold worked steel bar

BS 4483 for steel mesh fabric
All reinforcement shall be from an approved manufacturer and, if required by the
Engineer, the Contractor shall submit a test certificate from the manufacturer.
All reinforcement for use In the Works shall be tested for compliance with the
appropriate British Standard In a laboratory acceptable to the Engineer and two
copies of each test certificate shall supplied to the Engineer. The frequency of
testing shall be as set out In the British Standard.
In addition to the testing requirements described above, the Contractor shall
carry out additional teats at instructed by the Engineer*
Any reinforcement which does not comply with the Specification shall be
removed from Site.
17029 STORAGE OF REINFORCEMENT
All reinforcement shall be delivered to Site either in straight lengths or cut and
bent. No reinforcement shall be accepted in long lengths which have been
transported bent over double.
Any reinforcement which is likely to remain in storage for a long period shall be
protected from the weather so as to avoid corrosion and pitting. All reinforcement
which has become corroded or pitted to an extent which, in the opinion of the
Engineer, will affect its properties shall either be removed from Site or may be
tested for compliance with the appropriate British Standard in accordance with
Clause 1726 of this Specification at the Contactor's expense.
17030 BENDING REINFORCEMENT
Unless otherwise shown on the drawings, bending and cutting shall comply with
BS 4466.
The Contractor shall satisfy himself as to the accuracy of any bar bending
schedules supplied and shall be responsible for cutting, bending, and fixing the
reinforcement in accordance with the Drawings.
Bars shall be bent cold by the application of slow steady pressure. At
temperatures below 5*C the rate of bending shall be reduced if necessary to
prevent fracture of the steel-
After bending, bars shall be securely tied in bundles or together groups and
legibly labelled as set out in BS 4466.
Reinforcement shall be thoroughly cleaned and all dirt, scale, loose rust, oil and
other contaminants removed before it is placed in the Works.

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17031 FIXING REINFORCEMENT

Reinforcement shall be securely fixed in position within a dimensional tolerance
of 20 mm in any direction parallel to a concrete face and within a tolerance of 5
mm at right angles to a face, provided that the cover is not thereby decreased
below the minimum shown on the Drawings, or if not shown shall be not less
than 25mm or the diameter of the bar, whichever is the greater. Cover on
distribution steel shall not be less than 15mm or the diameter of the bar
whichever is the greater
Unless otherwise agreed by the Engineer, all intersecting bars shall either be fled
together with 1.6 son diameter soft annealed iron wire and the ends of the wire
turned into the body of the concrete, or shall be secured with a wire clip of a type
agreed by the Engineer.
Spacer blocks shall be used for ensuring that the 'correct cover is maintained on
the reinforcement. Blocks shall be as small as practicable and of a shape agreed
by the Engineer. They shall be made of mortar mixed in the proportions of one
part of cement to two parts of sand. Wires cast into the block for tying in to the
reinforcement shall be 1.6 mm diameter soft annealed iron.
Alternatively another type of spacer block may be used subject to the Engineer's
agreement.
Reinforcement shall be rigidly fixed so that no movement can occur during
concrete placing. Any fixings made to the formwork shall not be within the space
to be occupied by the concrete being currently placed.
No splices shall be made in the reinforcement except where shown on the
Drawings or agreed by the Engineer. Splice lengths shall be as shown on the
Drawings.
Reinforcement shall not be welded except where required by the Contract or
agreed by the Engineer. If welding is employed, the procedures shall be as set
out in BS 2640 for gas welding or BS 5135 for metal arc welding. Full strength
butt welds shall only be used for steel complying with BS 4449, and if used on
high yield deformed bars complying with BS 4449 the permissible stresses in the
vicinity of the weld shall be reduced to those applicable to plain bars complying
with that specification.
Mechanical splices shall not be used unless the Engineer agrees otherwise.
The Contractor shall ensure that reinforcement left exposed in the Works shall
not suffer distortion, displacement or other damage. When it is necessary to bend
protruding reinforcement aside temporarily, the radius of the bend shall not be
less than four times the bar diameter for mild steel bars or six times the bar
diameter for high yield bars. Such bends shall be carefully straightened before
concrete placing continues, without leaving residual kinks or damaging the

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concrete round them. In no circumstances will heating and bending of high yield
bars be permitted.
Bars complying with BS 4461 or other high tensile bars shall not be bent after
placing in the Works
Before concrete is placed in any section of the Works which includes
reinforcement, the reinforcement shall be completely clean and free from all
contamination including concrete which may have been deposited on it from
previous operations.
17032 PRECAST CONCRETE
Precast concrete covers all precast units for use In the Works, whether instructed
under the Contract or proposed by the Contractor, and includes prestressed units
where applicable. Additional requirements for prestressed units are set out in
Section 18 of this Specification.
17033 FORMWORK FOR PRECAST UNITS
Moulds for precast units shall comply with the general requirements of Clauses
1721 to 1729.
Moulds shall be so constructed that they do not suffer distortion or dimensional
changes during use and are tight against loss of cement grout or fines from the
concrete-Moulds shall be set up on firm foundations so that no settlement occurs
under the weight of the fresh concrete.
Moulds shall be constructed so that units may be removed from them without
sustaining any damage.
Release agents used for demoulding shall not stain the concrete or affect its
properties in any
17034 REINFORCEMENT FOR PRECAST UNITS
Reinforcement in precast units shall comply with the requirement of Clauses
1728 to 1731. When preformed cages are used the cages shall be made up on
jigs to ensure dimensional accuracy and shall be carefully supported within the
mould in such a way that they cannot move when concrete is placed.
Reinforcement complying with BS 4449 may be tack welded where bars cross to
provide rigidity in the cage but reinforcement complying with BS 4461 shall not
be welded.
Cover to main reinforcement shall be as shown on the Drawings, or if not shown
shall be not less than 25 mm or the diameter of the bar, whichever is the greater.
Cover on distribution steel shall not be less than 15 mm or the diameter of the
bar whichever is the greater.

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Bars shall be spaced so that the minimum clear distance between them is the
maximum nominal aggregate size plus five millimeters but in any case not less
than the diarater of the bars.
Bars may be placed in pairs provided that there are no laps in the paired lengths.
17035 CASTING OF UNITS
Concrete for precast units shall comply with Clauses, 1703 to 1709 using the
class of concrete specified on the Drawings.
If lightweight aggregates are specified, they shall comply with BS 3797.
The area in which units are cast shall be adequately protected from the weather
so that the process is not affected by rain, sun or drying winds.
17036 CURING PRECAST UNITS
Requirements for curing shall be generally as set out in Clause 1710.
The Contractor shall ensure that units do not suffer any loss of moisture or
sudden changes of temperature for at least four days after casting. If a water
spray is used for curing, the water shall be at a temperature within 5aC of the
temperature of the unit being cured.
If the Contractor proposes curing at elevated temperatures, the method shall be
subject to the agreement of the Engineer and shall include means whereby units
are heated and subsequently cooled evenly without sudden changes of
temperature.
17037 DIMENSIONAL TOLERANCES OF PRECAST UNITS
Units shall be accurately formed to the dimensions shown on the Drawings and
within the tolerances set out in BSCP 110 unless closer tolerances are called for
in the Special Specification or on the Drawings
17038 SURFACE FINISH OF PRECAST UNITS
The formed faces of precast units shall be finished to Class F3 as set out in
Clause 1725 unless another class of finish is specified on the Drawings.
Free faces shall be finished to Class UF2 unless another class of finish is
specified on the Drawings.
In cases where a special finish is required a trial panel shall be constructed by
the Contractor which after approval by the Engineer shall be kept available for
inspection at the place of casting and production units shall thereafter match the
approved pattern.
Those parts of the unit which are to be joined to other units or to in situ concrete
shall be brushed with a stiff brush before the concrete has fully hardened.
Alternatively, if the concrete has been allowed to harden, the surfaces shall be
roughened by sand blasting or the use of a needle gun.

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17039 HANDLING AND STORAGE OF PRECAST UNITS

Precast units shall be handled in a manner which will not cause damage of any
kind and shall be stored on a hard impermeable base.
Prestressed units and large precast normally reinforced units shall be handled
and stored so that no stresses shall be induced in excess of those which they will
incur in their final positions in this Works unless they have been designed to
resist such stresses.
Units shall be provided with adequate lifting holes or loops, placed in the
locations shown on the Drawings or agreed by the Engineer and they shall be
lifted only by such holes or loops. Where it is not possible to provide holes or
loops, suitable sling positions shall be indicated in paint on the units.
Units shall be marked indelibly with the reference number and date of casting
and shall be stacked on suitable packers which will not damage the concrete or
stain the surfaces. Not more than two packers shall be placed under each unit
and these shall be located either at the positions of the permanent support points
or in positions such that the induced stresses in the unit will be a minimum.
17040 TESTING PRECAST UNITS
Precast units shall be capable of safely sustaining the loads which they have
been designed to carry. The Contractor shall subject units selected by the
Engineer to load tests simulating the working conditions. Details of such tests
shall be agreed between the Engineer and the Contractor.
In the case of units subject to bending loads the test piece shall be supported at
full span and a loading equivalent to 1.25 times the sum of the live and dead
loads which were assumed in the design shall be maintained for one hour without
the appearance of any signs of distress. The recovery one hour after the removal
of load shall be not less than 75 per cent of the full load deflection.
If the unit fails to meet the above requirements, further tests shall be carried out
on two more units. If either of these fall the whole batch of units will be rejected.
If the Engineer so requires, a test to destruction shall also be carried out which
on unite subject to bending shall be as follows:-
The units shall be supported at full span and a load applied In increments
instructed by the Engineer up to 95 per cent of the designed ultimate load. This
load shall be held for 15 minutes without failure of the unit. The deflection at the
end of this period shall be not more than l/40th of the span. The load shall then
be further increased until failure occurs.
If the unit falls to sustain the required load for the prescribed period or if the
deflection exceeds the specified amount, the Engineer may order two further
tests, and if either of these fail, the batch of units which they represent may be
rejected.

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17041 MEASUREMENT AND PAYMENT

(a) Item: Concrete
Unit: m3 of each class
Concrete shall be measured by the cubic Metre of each class calculated from
the dimensions given on the Drawings or instructed by the Engineer. No
deduction shall be made in the measurement for
(i) bolt holes, pockets, box outs and cast in components provided that the
volume of each is less than 0.15 cubic metres
(ii) mortar beds, fillets, drips, rebates, recesses, grooves, chamfers and the
like of 100 mm total width or less;
(iii) reinforcement:
The rate for concrete shall include for the cost of:
(i) Provlson and transport of cement aggregates and water.
(ii) admixtures and workability agents Including submission of details unless
specified.
(iii) batching, mixing, transporting, placing, compacting and curing.
(iv) class DFI finish.
(v) Laying to sloping surfaces not exceeding 15° from the horizontal and to
falls.
(vi) formwork to blinding concrete-
(vii)Placing and compacting against excavated surfaces where required
including any additional concrete to fill overbreak or working space.
(viii) Complying with the requirements of Clauses 1701 to 1718
inclusive and Clause 1727 of this Specification.
(b) Item : Blinding concrete
Unit: m3
Blinding concrete shall be measured by the cubic metre calculated as the
product of the plan area of the foundation as shown on the Drawings and the
instructed thickness. No deduction shall be made for openings provided that
the area of each is less than 0.5 square metres. Blinding concrete over

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Inclined formwork shall be measured In accordance with the following

classification:
(i) Horizontal: 85 to 90° inclination from vertical
(ii) Sloping; 10 to 85° inclination from vertical
(iii) Battered; 0 to 10° inclination from vertical
(iv) Vertical; 0°
(v) Sloping upper surfaces inclined at more than 15° from the horizontal.
Formwork required for blinding concrete, to form construction joints and shear
keys for future concrete and other construction surfaces shall not be
measured and the costs shall be included in the rates for other work.
Formwork to contraction and expansion Joints shall be measured by the
square metre on one face only the rates shall include for the costs stated
below and for forming recesses for sealant and channels for grout.
The rates for formwork shall include for the cost of submission of details,
providing and transporting all materials formwork and false work, erection
including provision of supports, fillets and chamfers 75 mm and less in width,
bolts,
ties, fixings, cutting to waste, drilling or notching the formwork for
reinforcement where required, working around pipes, ducts, conduits and
waterstops, temporary openings, cleaning, dressing, stripping, filling bolt
holes and any remdial work and for complying with Clauses 1708, 1710,
1717,1718, 1719 and 1721 to 1727 inclusive of this Specificaiton.
(c) Item: Formwork to edges of slabs
Unit: m of each class of finish
Formwork less than 300 mm high to edges of slabs shall be measured by the
linear metre.
The rate shall include for the costs stated in Clause 1741 (c) of this
Specification.
(d) Item: Waterstops
Unit: m of each type
Waterstops shall be measured by the metre run of each type.
The rate for waterstops shall include for the provision installation, jointing, any
sealants required at the face of the concrete and for placing and compacting
concrete around the watercetop.
(e) Item: Mortar
Unit: m2

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Mortar used for bedding baseplates and the like shall be measured by the
square metre as the area of the base plate at the specified nominal thickness
of bedding.
Mortar used in filling bolts pockets and the like shall not be measured
separately and the costs shall be included in the rates for the bolts.
The rates for mortar shall include for the cost of providing and placing the
mortar and of complying with the requirements of Clauses 1714 and 1720 of
this Specification.
(f) Item : Admixtures, workability and hardening agents
Unit: as specified in the Special Specification
Where required by the Special specification admixtures, workability and
hardening agents will be measured and paid for In accordance with the
Special Specification.
(g) Item : Reinforcement
Unit: tonne of each type for each range of diameters.
Reinforcement shall be measured separately for each of the following ranges.
(i) of diameter equal to or less than 16 mm.
(ii) of diameter greater than 16 mm.
Steel fabric reinforcement shall be measured in accordance with Clause 1741
(k) of this Specification.
Steel plain and deformed bar reinforcement shall be measured by the tonne
and shall be the calculated weight of the steel required including splice
lengths shown on the Drawings. No allowance shall be made in the
measurement for rolling margin or cutting waste. The densisty of steel shall
be taken as 7850 kilogrammes per cubic metre.
The rates for reinforcement shall include for the cost of providing, cutting to
length, splice lengths additional to those shown on the Drawings, laps,
bending, hooking, waste incurred by cutting, cleaning, spacer blocks,
provision and fixing of chairs or other types of supports, welding, fixing the
reinforcement in position including the provision of wire or other material for
supporting and tying the reinforcement in place, bending reinforcement aside
temporarily and straightening, placing and compacting concrete around
reinforcement and for complying with the requirements of Clause 1728 to
1731 inclusive of this Specification.
(h) Item: Fabric reinforcement
Unit: m2 of each type

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Steel fabric reinforcement shall be measured by the square metre and shall
be the calculated area excluding any allowance for laps.
The rate for steel fabric reinforcement shall include the costs stated in Clause
1741 (j) of this Specification.
(i) Item: Precast Units
Unit: no. of each type
Precast units shall be measured by the number of each type instructed
unless otherwise specified in the Special Specification.
The rate for precast unite shall include for the cost of all the materials,
forming, and placing units, complying with the requirements of Clauses
1732 to 1740 inclusive and with the relevant Clauses of the Special
Specification.
No separate measurement or payment will be made for formwork
reinforcement or prestressing tendons to precast units.

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18000 PRESTRESSED CONCRETE WORKS

18001 SCOPE OF SECTION
This section covers the materials, equipment and methods required for carrying
out prestressing operations on in-situ and precast concrete. The production of in-
situ concrete and precast concrete units is covered by Section 17 of this
Specification.
18002 DEFINITIONS
The following definitions shall apply to these Specifications:
(a) Anchorage
Anchorage is the device comprising all the components and materials required
for retaining the force in a tensioned tendon and to transmit this force to the
concrete of the structure.
(b) Anchorage reinforcement
Anchorage reinforcement is the spiral and other reinforcement which forms part
of the anchorage and is required for strengthening the anchorage and/or
assisting in transmitting the tendon force to the concrete.
(c) Bursting reinforcement
Bursting reinforcement is the reinforcing steel required in and adjacent to the
anchorage zones to resist the tensile stresses induced in the concrete by the
anchorage(s).
(d) Cable
Cable is the tendon, together with the anchorage, sheathing and all fittings.
(e) Characteristic strength
Characteristic strength of prestressing steel is the manufacturer's guaranteed
tensile strength below which no more than 5% of the test results in a statistical
population shall fall.
(f) Duct
Duct is the void formed to house the tendon(s) and may be formed by coring, or
by using sheaths or by way of extractable cores.
(g) Prestress
Prestress is the stress induced in concrete by tensioned tendons.
(h) Prestressed concrete
Prestressed concrete is structural concrete in which effective internal stresses
are induced by means of tensioned tendons.

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(i) Pre-tensioned concrete

Pre-tensioned concrete is prestressed concrete where the tendon is tensioned
before the concrete has been cast.
(j) Post-tensioned concrete
Post-tensioned concrete is prestressed concrete where the tendon is tensioned
after the concrete has hardened.
(k) Pull-in
Pull-in is the elastic shortening of the tendon caused by relative movement
between the anchorage or coupler components on account of seating and
gripping action during or immediately after transfer.
(I) Release
Release is the specified elastic shortening of the tendon at the anchorage
achieved before or during transfer.
(m) Duct
Duct or sheath is the tube or casing enclosing the tendon and which temporarily
or permanently allows a relative movement between the tendon and the
surrounding concrete.
(n) Tendon
Tendon is the prestressing steel consisting of the bar, wire or strand individually
placed, or of bars, wires or strands placed in a duct, all of which are tensioned to
impart prestress to a concrete member.
(o) Tensioning
Tensioning is the action of inducing and regulating the force in a tendon by
means of tensioning and measuring equipment.
(p) Transfer
Transfer in the case of post-tensioned concrete is the action of transferring the
tensioning force from the tensioning equipment (jack) to the anchorage.
Transfer in the case of pre-tensioned concrete is the action of transferring the
force in the tensioned tendon(s) to the concrete.
(q) Bond breaker
Bond breaker is the coating or sheath placed on a tendon to prevent it from
bonding to the surrounding concrete.
(r) Coupler
Coupler is the device comprising all components required to join two tendons.
(s) Deflector

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Deflector is the device used to deflect a tendon alignment within a structural

element.
(t) Transmission length
Transmission length is the tendon length required to transmit via bond stresses
the full force in the tendon to the concrete.
(u) Precamber
Precamber is the allowance made into formwork to accommodate the slightly
convex shape of a horizontal prestressed member.
18003 GENERAL
Prestressed concrete work shall be carried out In accordance with the
recommendations of BSCP 110, 'The Structural Use of Concrete, Part I, Design,
Materials and Workmanship, except that where the requirements of the Code
differ from this Specification, this Specification shall take precedence.
The Contractor shall submit to the Engineer full details of the plant he proposes
to use for the installation of prestressing tendons, the materials he proposes to
use and the arrangements he proposes to make- He shall also submit evidence
of his competence to undertake the installation.
18004 DUCTING
All ducting shall be sufficiently strong to withstand without damage the stresses
to which it may be subjected during handling and after being fixed in position.
The ducting shall completely protect the wires or cables from contact with
concrete and the Contractor shall ensure that the wires or cables are completely
free in the duct before tensioning. Any ducting which has been damaged during
transportation to the Site or which in the opinion of the Engineer is Inadequate for
its purpose shall not be used in the Works. Ducting shall be free from loose
material, oil coatings, or other contaminants which may affect the bond with the
concrete.
The stools, saddles or supports for the ducts shall be of rigid construction and of
such form that they remain securely in position and maintain the correct profile of
the cables until the concrete placed round them has hardened-Vents shall be
Incorporated into each duct at high and low points, at each end and at
Intermediate points not more than five metres apart. Blocking of vent3 during
concreting operations shall be prevented.
18005 ANCHORAGES
Anchorages shall be the correct type for the prestressing system used and shall
be rigidly fixed true to alignment in the formwork so that they cannot move during
concreting operations. The anchorages shall be provided with means for injecting
grout into the ducts.

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If the anchorage is fixed after the main body of the concrete has been placed, it
shall be carefully bedded so that it is bearing evenly and is in intimate contact
with the concrete.
Anchorages and couplers to be used in prestressed concrete shall comply with
the requirements of BS EN 13391:2004 and shall be of a proved and approved
type, constructed from durable material completely free from imperfections and
shall not damage, distort or kink the prestressing steel in a manner that will result
in ultimate tensile strength reduction. They shall resist, without failure and/or
excessive deformation or relaxation of the force in the tendons, the full ultimate
tensile strength of the tendons. The characteristic value for anchorages and
couplers, determined in accordance with BS EN 13391:2004, shall not be less
than 90%

18006 PRESTRESSINC TENDONS

Tendons used in prestressed concrete shall comply with the British Standards
indicated on the Drawings. The Standards include the following:
BS 5896 for high tensile steel wire
BS 4486 for high tensile alloy steel bars
BS 5896 for 7 wire steel strand
BS 4757 for 19 wire steel strand
Tendons shall be stored on site under cover and protected from the weather. The
storage area shall have a hard impermeable floor. Tendons shall be stored either
straight or in the coils in which they left the factory.
Tendons shall not be allowed to become affected by excessive rusting or by
pitting of the surface by corrosion. If pitting is present the Contractor shall replace
the affected tendons by new ones.
18007 INSTALLATION OF PRESTRESSING TENDONS
Prestressing steel shall be cut by rotating disc or blade cutters or by such method
as is recommended by the manufacturer.
Before being installed, prestressing tendons shall be thoroughly cleaned of mill
scale, mortar, oil, paint, dust, grease, or any other deleterious matter whatsoever.
The prestressing steel (or where the tendons are accommodated in ducts, the
sheaths, ducting or formers) shall be accurately placed in the positions shown on
the Drawings and shall be firmly secured in position. Wooden supports shall not
be used nor shall the sheaths, ducting or formers be placed on previous layers of
fresh concrete or be adjusted during the placing of concrete.

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The prestressing steel, sheaths, ducting or formers shall be so placed and

secured that twisting, kinking or excessive deformation during and subsequent to
concreting is eliminated and the prestressing tendons when finally stressed shall
conform accurately to the profiles shown on the Drawings. Ducts and formers
shall not be placed with small radius bends which would induce excessive
frictional restraint on the wires or strands.
Where many individual wires or strands are placed in a duct, adequate provision
shall be made to keep the wires separated by means of suitable spacers of
approved design, construction and spacing.
18008 JACKS FOR PRESTRSSSISG
Jacks for tensioning tendons shall be hydraulically operated and capable of
providing a slow uniform increase of load. Each jack shall be equipped with an
appropriate pressure gauge capable of Indicating the hydraulic fluid pressure at
all- times during the stressing operation. A certified calibration chart showing the
relationship between gauge readings and force on the ram for both ascending
and descending ram movements shall be made available on the Site by the
Contractor.
The Contractor 8h4.ll maintain tensioning jacks in good working order and shall
ensure true and accurate readings by regular testing, calibration and servicing.
18009 TENSIONING OPERATIONS
Prestressing force, whether partial or full, shall not be transferred to the concrete
until cube crushing tests have indicated that the concrete has attained the
strength specified on the Drawings.
Stressing of the tendons shall be carried out with due care by experienced
workmen under competent supervision and adequate steps shall be taken to
safeguard against injury.
Pull and accurate records shall be kept of all stressing operations and two copies
of the records, which shall include wedging-device slip measurements during
anchoring, loads and extensions, shall be submitted to the Engineer on the day
following each stressing operation. The accuracy of the measurement of cable
extensions, shall be plus or minus two per cent. The Engineer may order the
Contractor to cease any or all stressing operations where proper records are not
being kept or where the operations are not being properly or safely carried out
and the Contractor shall take Immediate steps to ensure that the work is carried
out to the satisfaction of the Engineer.
Where the required tensions or extensions are not obtained the tendons shall be
re-tensioned as directed by the Engineer. If on re-stressing, the extensions are
not achieved, the Engineer may at his discretion reject the tendons involved.

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18010 POST-TENSIONTNG
When a post-tensionlng system is employed, all cable ducts, excluding
extractable formers shall be thoroughly flushed with water immediately after
concreting and before the concrete has hardened.
Ducts produced by extractable formers shall be flushed out as soon as the
concrete has hardened.
Where anchorage of the prestressing tendons is by friction grips or wedges and
where no other slipping limitations is specified, the slip of each individual
prestressing steel element, both during tensioning and after anchoring shall not
exceed seven millimetres. Tendons failing to satisfy this limitation shall be re-
stressed,
The sequence of stressing shall be as shown on the Drawings and shall be such
that lateral eccentricity of stress on any member is reduced to a minimum.
After stressing and anchoring, no tendon shall be cut, bent or in any way
deformed until the bonding grout or concrete is at least seven days old.
Where tendons are cut back, the exposed ends of the tendons and anchorages
shall be heavily coated with an approved bituminous compound or epoxy resin to
prevent corrosion of the pre3tressing steel.
18011 PRE-TENSIONING
Pre-tensioning tendons shall be either crimped or indented wire, ribbed or
deformed alloy bar or strand complying with the requirements of Clause 1805 of
this Specification.
The tendons shall be anchored in such a manner that during concreting they will
not suffer any loss of tension whatsoever due to anchorage yield or deficiency or
due to yielding of the prestressing beds. No variation in the tension of the
tendons shall be made subsequent to the commencement of concreting until
transfer of prestressing force to the concrete is authorised.
At the appropriate time the prestressing force shall be transferred to the concrete
uniformly by means of slow de-tensioning. The tendons shall not be de-tensioned
individually and the de-tensioning operation shall be applied to all the tendons
simultaneously. Where a set of tendons passes through several units, the units
shall be free to move longitudinally during de-tensioning.
The prestressing steel shall be cut off flush with the end of the member and the
exposed ends of the prestressing steel and anchorages shall be heavily coated
with an approved bituminous compound or with an epoxy resin to prevent
corrosion of the prestressing steel.

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18012 BONDING AND GROUTING

Poat-tenaioned tendona shall after stressing and anchoring be intimately bonded
to the adjacent concrete by means of concrete or, in the case of internal cables,
by colloidal cement grout.
The properties of grout, shall be as following the equipment and the grouting
procedure
(a) The grout shall be a colloidal mix of water and ordinary Portland cement in
the ratio of between 0.40 to 1.00 and 0.45 to 1.00 by weight. Only common
cements which comply with the requirements of KS-EAS 18-2001, BS EN
197-1:2000 or equivalent shall be used. The temperature of the cement shall
be less than 40°C, and the cement shall be stored in accordance with the
requirements of This Specification
(b) Admixtures of an approved type may be authorised by the Engineer for
incorporation in the grout if tests have shown that their use improves the
properties of the grout, for example by increasing the workability, by reducing
bleeding, by entraining air or by expanding grout.
Admixtures shall not contain chlorides or nitrates. When an expanding agent
is used the total unrestrained expansion shall not exceed 10 per cent.
(c) The mixing equipment shall be of a type capable of producing grout of
uniform consistency with fully dispersed cement particles and shall
incorporate suitable sieves for retaining lumps or other solid ingredients. After
water has been added to the mixer, the cement shall be added. Admixtures if
used, shall be added during the latter half of the mixing time. High speed
mixing shall be carried out continuously for between two and four minutes in
a close clearance high speed centrifugal mixer.
Subsequent to mixing and prior to injection the grout shall be continuously
agitated by slow machine mixing. Any grout that has been left standing for
more than 30 minutes shall be discarded and the container thoroughly
washed before further mixing is carried out.
(d) A positive displacement pump shall be used for injecting the grout, capable of
developing a pressure of at least one N/mm2. The pump shall be fitted with a
pressure gauge and an effective control against build-up of excessive
pressure. The pump suction intake shall be kept below the surface level of
the grout at all times during grouting operations.
(e) All tendons shall be grouted in their ducts as soon - as practicable after the
stressing operation. Each duct shall be cleaned by blowing through
compressed air, flushing with clean water and surplus water shall be removed
by compressed air or other approved means. Openings at the anchorages
other than grout injection nozzle openings shall be plugged with mortar or
other suitable material. Subsequent to the hardening of the plugging material

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the nozzle of the injection pipe shall be firmly connected to the duct in such a
way that air cannot be sucked in. Injection shall be commenced from one end
only and its progress monitored by the appearance of grout at successive
vent holes. When the consistency of the grout emerging from a vent is equal
to that of the grout being injected, that vent shall be plugged.
Injection shall continue until grout of a consistency equal to that being
injected appears at the far end of the duct- The injection nozzle shall then be
withdrawn and all holes and vents plugged to prevent loss of grout.
As far as possible all ducts in any one member shall be grouted in immediate
succession commencing with the lowest duct-Grouting shall not be carried
out when the air temperature is 2BC or lower.
The temperature of newly grouted cable ducts shall be prevented from falling
below 2°C for a minimum period of seven days.
18013 CAMBER OP PRESTRESSED PRECAST BEAMS
Where the predicted camber due to stressing precast beams is indicated on the
Drawings, the actual camber shall not exceed the stated figure by more than 50
per cent.
Where a number of similar units are to be placed side by side, the variation in
camber between adjacent units shall not be more than 6.0 mm for units up to 4.5
metres in length, or more than 9.0 mm for longer units.
18014 REJECTION OF PRESTRESSED WORK
Any structural element in which the prestreasing tendons, the anchorages, or any
part whatsoever of the pre stressed element has been damaged, or in which
excessive loss of prestress has occurred or in which the grouting has not been
satisfactorily carried out, or which is deficient in any other manner, will be
rejected and the Contractor shall rectify the deficiency to the satisfaction of the
Engineer, failing which the element shall be replaced by the Contractor.
18015 TRANSPORT AND STORAGE OF PRESTRESSED UNITS
Unless otherwise agreed, prestressed concrete units shall be transported in the
same attitudes and under the same support conditions as they will have in the
final structure.
All handling, transporting and storing of prestressed units shall be to the
satisfaction of the Engineer, and the Contractor shall ensure that all methods of
handling, transporting and storing prestressed units shall be such as to prevent
over-stressing or any other damage.
18016 JOINTING PRECAST UNITS
Where a load bearing structure is to be formed by tensioning together a string of
precast units, the joints between the units shall be formed as shown on the

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Drawings by one of the methods set out below so as to achieve a uniform

transfer of stress across the joint.
(a) Joints shall be set between 20 and 30 nm wide and shall be packed solid with
mortar mixed in the proportion of one part of cement to 1.5 parts of sand with
water sufficient only to allow the mix to cohere when squeezed in the hand.
The mortar shall be rammed thoroughly into the joint, using formwork to
retain it where necessary.
(b) Where joints are shown on the Drawings as 75 mm or wider, they shall be
filled with concrete of a class similar to that used in the units or as shown on
the Drawings. The concrete shall be compacted by vibration and retained by
formwork.
(c) Procedure when using resin adhesives for jointing will depend on the
configuration of the joint and the type of adhesive to be used and will be
subject to the Engineer's agreement.
Irrespective of the method of joint filling employed, the joint shall be completely
filled with material having a uniform consistency. The joint faces shall be flat
without any high spots which might cause local stress concentrations.
Ducts for tendons shall be truly aligned between units and the duct joints in the
gap between units shall be carefully formed and impervious to the entry of grout
from the joint filling operation.
18017 TESTING PRESTRESSED WORK
If instructed by the Engineer, load testing of structures containing prestressed
units shall be carried out generally as set out in BSCP 110.
Precast units shall be tested in accordance with Section 17 of this Specification
and in addition, where a test of the prestressing is required, the unit shall be
subjected for a period of five minutes to a load which is calculated to result in a
bending tensile stress in the bottom surface equal to one tenth of the nominal
strength of the concrete. The prestressing shall be deemed to be effective if no
cracking is observed during the test.
Details of all testing procedures shall be agreed between the Engineer and the
Contractor before testing is commenced.
18018 MEASUFEMENT AND PAYMENT
Prestressed concrete shall be measured in accordance with Clause 1741 of this
Specification and tendons for prestressing shall be measured under this Section.
(a) Item : Prestresslng tendons
Unit: no. of each type for each length

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Prestressing tendons in in-situ concrete shall be measured by the number

required of each type for each length. No separate measurement or payment
will be made for prestressing tendons in precast concrete.
The rates for tendons shall include for the cost of complying with the
requirements of Section 18 of this Specification.
(b) Item : Load test
Unit: no. for each type of unit
Load tests on prestressed units shall be by the number instructed to be
carried out.
The rates for load tests on prestressed units shall include for the cost of
provision of the unit, testing and complying with the requirements of Clause
1816 of this Specification. If any units fails to meet the requirements of the
Specification the unit and the load test shall not be measured or paid for.

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19000 STRUCTURAL STEELWORK

19001 GENERAL
The fabrication and erection of all structural steelwork shall be under the constant
supervision of competent and experienced personnel. All workmanship shall be
in accordance with the best modern workshop practice and only skilled workers
trained and experienced in steel fabrication and erection shall be employed.
19002 APPLICABLE STANDARDS
The supply, fabrication and erection of structural steelwork shall be in
accordance with the provisions of the relevant clauses of the following British
Standards:-

BS 4 Structural steel sections.

BS 4848 Hot rolled structural steel sections.
BS 153 Steel girder bridges. Part 1 - Materials and workmanship and
Part 2 - Weighing, shipping and erection.

BS 4360 Weldable structural steels.

BS 4395 High strength friction grip bolts and associated Parts 162 nuts
Part 1 & 2 and washers for structural engineering (metric series).
The use of high strength friction grip bolts in structural
BS 4604 steelwork.
Unified black square and hexagon bolts, screws and nuts (UNC
BS 2708 and UNF threads).
BS 4190 I.S.O. metric black hexagon bolts screws and nuts.
BS 3692 I.S.O. metric precision hexagon bolt screws and nuts.
BS 4320 Metal washers for general engineering purposes.
BS 5135 Metal arc welding of carbon and manganese steels.

BS 638 Arc welding plant, equipment and accessories.

BS 639 Covered electrodes for the manual metal-arc welding of mild

steel and medium tensile steel

Approval testing of welding procedures. Part 1 Fusion welding

BS 4870 of steel.
BS 4871 Approval testing of welders working to approved welding
procedures, Part 1-Pusion welding of steel.
BS 5493 Protective coating of iron and steel structures against corrosion.

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19003 MATERIALS
All structural steel shall be to the Grade as defined on the Drawings and shall
comply with the requirements of BS 4360 in every respect.
Mill certificates shall be supplied to the Engineer in duplicate to confirm the
mechanical and chemical properties.
Steel for headed stud shear connectors shall have a minimum yield stress of 385
N/mm2 and a minimum tensile strength of 495 N/mm2.
(a) Structural steel
Structural steel shall comply with the following requirements:
- Mild steel: BS EN 10137-1:1996, BS EN 10137-2:1996, BSEN 1013/BS
7668:2004/BS EN 10029:1991/BS EN 10113:1993/BS EN 10115:1993/BS
EN 10210-1:2006 or equivalents.
- High-yield stress steel: BS 7613:1994/BS 7668:1994/BS EN 10029:1991/BS
EN 10113:1993/BS EN 10115:1993/BS EN 10210-1:2006 or equivalents.
The dimensions and properties of rolled steel sections shall comply with the
prescriptions given in the structural steel tables issued by the British Standards
Institution or equivalent.
(b) Steel tubes
Steel tubes shall comply with the requirements of BS EN 39:2001 or equivalent.
(c) Bolts, nuts and washers
Ordinary bolts and nuts shall be bolts and nuts used for transferring forces by
tensile stress, compressive stress and shear stress without any friction-grip
action being considered. Ordinary bolts and nuts shall comply with BS 3692:2001
or BS 325:1947 or equivalent. Washers for ordinary bolts and nuts shall comply
with the requirements of BS EN 2138:2000 or equivalent.
High-strength friction-grip bolts, nuts and washers shall comply with the
requirements of BS EN 14399-1:2005, BS EN 14399-2:2005, BS EN 1439 or
equivalent.
Other approved friction-grip fasteners equal to the above may be used.
(d) Rivets
Mild-steel rivets shall comply with the requirements of BS 1109:1943 or
equivalent. High-tensile rivets shall be so manufactured that they can be driven
and their heads formed satisfactorily without the physical properties of the steel
being impaired.
(e) Welding consumables

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Welding electrodes shall comply with the requirements of SANS 455:2009 or

equivalent.
The quality, handling and storage of all consumables shall be so as to achieve
the desirable properties of the weld metal.
The welding consumables used shall be appropriate to produce weld metal which
will yield all the weld-metal test specimens as specified in BS EN 1043-1, BS EN
1043-2:1997 BS EN 1320:1 having both minimum yield and minimum tensile
strengths not less than those of the parent metal.
(f) Test certificates
The Contractor shall submit test certificates, as required by the Engineer, of the
structural steel and anchor bolts that will be used.
19004 CODES OF PRACTICE
The design, where undertaken by the Contractor, of all work shall comply with
the requirements of BS 5950:2000 Parts 1 to 9, BS 5400:2000 Parts 3 and 5, and
BS EN 1993-1 to 5:2006 where this Standard supersedes. Equivalent standards
may be used with the approval of the Engineer.
19005 SHOP DETAILS
Where shop details have not been furnished on the Drawings, the Contractor
shall prepare his/her own shop details in accordance with the provisions of this
Specification. Shop details shall be approved and signed by the Engineer prior to
the fabrication of any items.
19006 STORAGE OF MATERIALS
Structural steelwork whether plain or fabricated shall be stored above ground on
platforms, skids or other supports and in such a way as to prevent pools of water
forming on the ground. It shall be kept free from dirt, grease and other
deleterious material and shall be protected as far as is practicable from
corrosion. The time limits for outside storage of unpainted or primed steelwork
shall be as detailed in the Special Specification.
19007 FABRICATION
Fabrication shall generally be in accordance with the requirements of BS 153
Part 1, Workmanship. Rolled material, before being processed, must be straight
or flat. Straightening or flattening, where required and where permitted by the
Engineer, shall be accomplished by a process not harmful to the material.
The Contractor shall submit to the Engineer for his approval two sets of shop
drawings with calculations as appropriate and the Contractor shall not commence
fabrication until written approval has been given by the Engineer. The Engineer
will give comment or approval within 28 days after receipt of the shop drawings

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and calculations. Such approval shall not relieve the Contractor of any of his
responsibilities under the Contract.
Following approval of the shop drawings the Contractor shall supply to the
Engineer a further four copies of each drawing for the use of the Engineer and
the Employer.
The components of various members of the structure shall be placed in jigs of
approved design and all welding shall be carried out in accordance with Clause
1907. Every precaution shall be taken to prevent distortion.
19008 PREPARATION OF EDGES AND ENDS OF PLATES
Edges and ends shall be either
(a) left as rolled, sawn, machine cut, machine flame cut; -
(b) hand flame cut and ground to a smooth profile; or
(c) for stiffeners and gussets not exceeding 12 mm thick, sheared and
subsequently ground to a smooth profile.
Where ends of stiffeners are required to be fitted, they shall be ground to be .in
contact with the flanges over 80% of the area of stiffener.
After shearing or flame cutting of plates, one of the following requirements shall
be satisfied:
(a) the hardness of the cut edge shall not exceed 350 HV 30 of BS 427,
(b) the cut edge is incorporated in a weld;
(c) the material from the edge is removed by machining or grinding to
demonstrate that the hardness of the edge is less than 350 HV 30 of BS 427;
(d) the edge is softened by an approved heat treatment and is shown to be free
from cracks by crack detection procedures; or
(e) the material is Grade 43 steel and is not greater than 40 mm thick and the
edge preparation is by machine flame cutting.
19009 WELDING
Welding will be permitted only where shown on the Drawings, and the agreed
shop drawings.
All welding operations shall comply with the requirements of BS 5135 and BS EN
1011:1998.
The details of all welds shall be arranged to achieve the most satisfactory
welding procedure. The details of the welding procedure shall be submitted to the
Engineer for his approval and no welding may commence without the prior
approval of the Engineer. No departure from an approved procedure may be

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made without the prior approval of the Engineer. Welding procedure details to be
submitted to the Engineer shall include the following:-
• Welding position.
• Fusion face preparation.
• Pre-heating.
• Electrode make, type and size and mechanical properties.
• Number and arrangement of runs.
• Welding current.
• Arc energy
• Method of back gouging and sealing.
• Proposed methods of quality control and testing of welds.

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19010 BOLTING
(a) Black Bolts
All mild steel bolts, washers and nuts shall be of the grade as specified on the
Drawings and shall comply with the requirements of BS 4190, BS 2708 or BS
3692 as appropriate.
All holes shall be drilled or drilled small and reamed and shall be clean cut
without torn or ragged edges. The holes shall be perpendicular to the
member and not more than 2mm larger than the nominal diameter of the bolt.
In all cases where the full bearing area of the bolt is to be developed the bolt
shall be provided with a steel washer under the nut to avoid any threaded
portion of the bolt being within the parts bolted together. Tapered washers of
the correct angle of taper shall be provided under all bolt heads and nuts
bearing on beveled surfaces.
(b) High Strength Friction Grip (HSPG) Bolts
HSFG bolts shall comply with the requirements of BS 4395 Parts 1 and 2 and
shall be used in accordance with the provisions of BS 4604 Parts 1 and 2.
HSFG bolts, nuts and washers shall be supplied cadmium plated to BS 3382
to a thickness of 5 microns and shall be stamped or otherwise marked with a
suitable and permanent mark and the Contractor shall obtain the written
approval of the Engineer to the proposed marks before commencement of
the work.
Each HSFG bolt shall be supplied complete with its nut screwed on. Washers
may be supplied on the bolt or separately and bolts and washers shall be
packed in the manufacturer’s works and delivered to site in waterproof
containers and stored under cover in these containers until required for use.
The method of tightening HSFG bolts shall be either the part turn method, the
torque control method or with the use of load indicating washers In
accordance with the following:-

HSFG bolts complying with Permissible methods of tightening.

standard

BS 4604 Part 1 and 2 1) Part turn for bolts M16 and above.
2) Torque control.
3) Load indicating washers.

BS 4604 Part 2 1) Torque control.

Higher Grade (parallel Shank) 2) Load indicating washers

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Whatever method of tightening is adopted, the Contractor shall supply to the

Engineer full details of the procedures to be adopted which shall be in
accordance with the requirements of BS 4604, together with details of the tools
and equipment he will be using at Site and the tests to be carried out to
determine the load/torque/shank tension characteristics of the tools, bolts and the
load indicating washers. No bolting shall commence until the Contractor has
carried out sufficient site tests to confirm the load/torque/shank tension
characteristics of the tools and bolts.
In the case of torque control tightening methods, calibration of the equipment
shall be carried out daily before commencing bolting operations in accordance
with the requirements of BS 4604.
Where load indicating washers are used they shall be of a type approved by the
Engineer and used in accordance with the manufacturer's instructions. The
general requirements of BS 4604 shall apply to the assembly and use of HSFG
bolts with load indicating washers including check testing to confirm the minimum
shank tension is being achieved.
HSFG bolts that have been slackened off after final tightening by any method
shall be removed, discarded and replaced.
19011 TRANSPORTATION HANDLING AND ERECTION
Erection shall be in accordance with BS 153 Part 2, Weighing, Shipping and
Erection. Structural steel shall be handled with due care at all times and in such a
manner as not to cause damage to the steelwork or its protective coatings.
The Contractor shall submit to the Engineer for his approval two sets of drawings
and calculations and details showing his proposed methods for transport,
handling and erection of structural steelwork including all plant, temporary
supports and bracings required to ensure stability and safety during erection. The
Contractor shall erect the steelwork, remove the temporary supports and do all
the work required to complete the Works in accordance with the Drawings and
this Specification. The work shall be carried out in such a manner as will not
injure, overstress or disfigure any part of the structure or the foundations and any
part injured, overstressed or disfigured shall be removed and replaced or rectified
to comply with the requirements of this Specification.
The steelwork shall be temporarily erected at the fabrication works and be
subject to inspection by the Engineer before being dispatched to Site.
Drift pins will be allowed only for bringing together the several parts of the
structure, and shall not be used in such a way as to distort the work or enlarge
the bolt holes.

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Bolts in site connections shall not be finally tightened until sufficient of the
structure is properly plumbed, aligned and levelled and no subsequent straining
into position will be allowed. Finally all bolts and connections shall be
systematically checked and tightened.
19012 SURFACE PREPARATION OF STEELWORK
Surface preparation of steelwork shall be by blast cleaning in accordance with
the requirements of BS 4232, Second Quality. The maximum amplitude of the
blast cleaned surface shall not exceed 0.1mm.
Manual cleaning of structural steelwork including mechanical wire brushing,
chipping hammers, vibratory needle gun3 and the like shall not be permitted
except for small parts and then only with the prior written permission of the
Engineer.
Surfaces shall be painted with the specified primer paint within four hours of
having been blast cleaned.
As soon as the first undercoat has dried, a further stripe coat of paint shall be
applied by brush to all edges, corners, crevices, exposed parts of bolts, rivet
heads and welds. The stripe coat should have the same specification as the
undercoat but be a contrasting shade.
Painted surfaces shall be cleaned of dust immediately prior to the application of
further paint- All loose paint, dirt and grit shall be removed and areas
contaminated with oil and grease shall be cleaned with emulsion cleaners
followed by washing and rinsing with clean fresh water and allowed to dry
thoroughly before paint is applied.
In the case of painted steelwork where the interfaces of HSFG bolts are bare
steel, the primer coat shall be taken between 10mm and 20mra inside the
perimeter of the joint area*
Where paints are to be applied to parent surfaces before making of a joint they
shall be stepped back at 30mra intervals commencing at 80mm from welded
joints and 10mm from the perimeter of all other joints-All bolted joints shall be
sealed against the ingress of water. Gaps at joints shall be plugged with an
approved filler and the perimeter of all joints shall be sealed with subsequent
coats of paint.
All joints, welds and surfaces affected by welding shall receive the same
protective system as applied to the parent surfaces.
Within 14 days of a joint being made and accepted by the Engineer, the parent
material, exposed parts of bolts, nuts and washers, weld and affected areas shall
be prepared and painted.

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19013 PAINTING
All paint used in the Works shall be subject to the approval of the Engineer-All
paint shall be supplied from the store to the painters ready for application. Any
addition of thinners must be made in the store under the supervision of the
Engineer and only as permitted by the manufacturer's data sheet. All the
requirements of the manufacturer's data sheet shall be strictly complied with.
Paint shall be applied only to surfaces which have been prepared and cleaned in
accordance with the requirements of Clause 1910.
The use of rollers shall not be permitted for the application of paint.
Paint shall not be applied under any of the following conditions:-
(a) When the ambient temperature is less than 4°C.
(b) When the relative humidity is greater than 90%.
(c) During fog, rain or mist.
(d) When any moisture is present or likely to condense on the steel
Each coat of paint shall be free from surface defects.
Successive coats of paint shall have different shades for identification.
The Contractor shall ensure that the proposed application rates shall enable the
specified minimum dry film thickness to be achieved. If the total dry film thickness
is less than the specified minimum, an extra finishing coat or coats shall be
applied until the specified dry film thickness is obtained.
19014 PAINT SYSTEMS
The paint system to be used on structural steel work shall be as specified in the
Special Specification.
19015 DAMAGED SURFACES
Any areas of paint which have been damaged following application shall be
cleaned down to bare metal and the full specified painting system shall be re-
applied. The new paint shall overlap the existing paint by at least 50mm all-round
the affected area.
Galvanised surfaces damaged shall be repaired either by the use of low melting
point zinc alloy repair rods or powders made specifically for this purpose or by
the use of at least two coats of a good quality zinc rich paint to BS 4652.
19016 TESTING
(a) Testing by the Engineer
The Engineer may nominate a testing authority to inspect the Works and to
conduct such tests as he/she may deem to be necessary to test compliance with

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the specifications. Where required, test samples of welds shall be prepared by

the Contractor, free of charge.
Payment for these tests shall be made under Item 71.01.
(b) Quality control
Welds shall be regularly inspected and tested by the Contractor in terms of his
obligations in regard to process control, as described in this Specification. This
shall include visual inspection of welds to ensure that no undercutting, uneven
lengths, porosity, or evidence of cracking occurs and that full fusion of the metals
has been achieved. In doubtful areas, cores containing weld metal and adjacent
parent material shall, if so required by the Engineer, be cut out, polished and
examined and the hole repaired.
At least 30% of the welds shall be examined by ultrasonic or radiographic means.
If more than 5% of the examined welds show unsatisfactory results, additional
examinations covering all welds shall be performed. Certificates of the
examination confirming that the steel plates and welds comply with the
requirements of SABS 044 Part III or equivalent shall be submitted to the
Engineer.

19017 MEASUREMENT AND PAYMENT

(a) Item : Structural Steelwork
Unit: tonne
Structural steelwork shall be measured by the tonne and shall be the
weight calculated from the approved shop drawings excluding bolts,
welds, washers and all other fixings required. No deduction shall be made
in the measurement for splay cuts, notches and holes providing that the
area of each is less than 0-1 square metres. No allowances shall be
made in the measurement for rolling margin or cutting to waste. The
density of steel shall be taken as 7850 kilogrammes per cubic metre.
The rate for structural steelwork shall include for the cost of the following:-
(i) Design, submission of orders, fabrication drawings, details,
calculations and certificates
(ii) Provision of all structural steelwork, materials, bolts, nuts, washers,
welding rods, and all other fixings; fabrication, including drilling,
machining and welding; testing of welds and welders.
(iii) Temporary erection at the fabrication works for inspection by the
Engineer.
(iv) Surface preparation, painting with specified paint system.

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(v) Inspection, and submission of test reports and certificates.

(vi) Marking, handling, packing, transporting and storage.
(vii)Erection, bolting, welding, including temporary bracings, guys, and
craneage.
(viii) Complying with all the requirements of Section 19 of this
Specification.

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20000 ROAD FURNITURE

20001 ROAD RESERVE BOUNDARY POSTS
Where road reserve boundary posts are instructed by the Engineer, they shall be
erected as early as possible after the commencement of the Contract* on the
boundary of the Road Reserve at intervals of 250m or as otherwise instructed by
the Engineer or shown on the Drawings, but not closer than 5 m to any reference
point or peg-Where required by the Special Specification, the Contractor shall
immediately establish a reference point on top of each post coordinated to an
accuracy of +5mm. A schedule of the road reserve boundary posts together with
their chainage, offset and co-ordinates shall lie submitted to the Engineer before
construction on adjacent sections of the Works, begins-
Road reserve boundary posts shall be constructed of concrete Class 20/20
reinforced with 10 mm diameter high yield deformed bars as shown on the
Drawings. The top 0.7 m of the posts shall be painted with two coats of white
lead paint and the location and offset of the post shall be painted onto the front
face in black.
The Contractor shall excavate for the posts in any material, embed the posts in
concrete Class 15/20 all round and under the butt and backfill the remaining
excavation, all as shown on the Drawings.
The posts shall be maintained in position and kept in a clean and legible state
until the issue of the Certificate of Completion.
20002 FENCING AND GATES
Where shown on the Drawings or directed by the Engineer the Contractor shall
provide and erect fences and gates including excavation and backfilling and
complying with the details shown on the Drawings.
All timber for fencing and gates shall be well seasoned hardwood to the approval
of the Engineer. After all cutting and drilling is complete the timber shall be
impregnated by the vacuum/pressure process with an approved preservative
such as 'Tanalith' in accordance with BS 4072 or as specified in the Special
Specification to achieve an anticipated average dry salt retention of 12kg/n3.
Prior to delivery of materials to Site samples are to be submitted by the
Contractor to the Engineer for testing to ensure that the correct treatment has
been applied.
20003 EDGE MARKER POSTS
Edge marker posts shall be constructed and erected in accordance with the
Drawings. They shall be set out at the outer edge of the shoulder with their tops
at a constant height above the edge of the carriage way at such locations as the
Engineer instructs The Contractor shall excavate in any material, provide and
place edge marker posts, backfill and remove surplus material to spoil.

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Markers shall be erected and painted with two coats of an approved white paint
before the road is opened to traffic and shall be kept clean until*the issue of the
Certificate of Completion.
20004 PERMANENT ROAD SIGNS
All permanent road signs shall comply with the requirements of the "Manual for
Traffic Signs in Kenya", Part II.
Road signs shall be obtained from a manufacturer approved by the Engineer and
before placing any order for the manufacture of the road signs, the Contractor
shall submit to the Engineer two copies of the following Information:—
(a) Name of the firm from which he proposes to obtain the signs together with
place of manufacture or fabrication.
(b) A description of the items to be supplied specification together with a
description weight and strength fifth manufacturers of quality, grade,
(c) Manufacturer's type' test certificates, or recent test results carried out on
similar items.
(d) A sample sign, post and fittings which sample shall be stored on site for the
Engineer.
All colours on the permanent road signs, with the exception of black and grey,
shall be reflectorized, unless otherwise specified or instructed by the Engineer.
The reflective sheeting shall comply with the requirements given in Section 2 of
this Specification, and shall be applied by mechanical vacuum-heat application
method to the approval of the Engineer. The sign plate shall be covered by clear
lacquer of a make recommended by the manufacturer of the reflective material.
Permanent road signs shall comply with the requirements of BS 873 Parts 2, 6
and 7 in respect of quality including the pre-treatment, preparation and protective
coatings for the frame, posts and fittings. Unless directed otherwise posts,
frames, fittings and the backs of signs shall be painted with a finish coat of grey.
Bolts and nuts shall be spot welded after erection to prevent theft, and a grey
epoxy paint shall be applied to all areas so treated.
Finished sign plates (with sign face attached) shall be clearly and durably marked
on the back, with the following information:-
(a) The number of the British Standard to which they have been manufactured
(b) The name, trade mark or other means of identification of the manufacturer or
vendor.
(c) The classification of any retro-reflective material used in the manufacture of
the sign face.
(d) The month and year of assembly.

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These markings shall be in characters legible at a normal reading distance such

that the total area of the marking does not exceed 30 cm2 and shall be
sufficiently durable to last the expected life of the sign plate to which it is applied.
The manufacturer or vendor shall make available the following information t-
(a) Instructions on the assembly and erection of the sign.
(b) Details of any limitations in location or usage.
(c) Instructions on the operation and maintenance of the sign.
The Contractor shall excavate in any material for the foundation of the road
signs, provide and place concrete Class 15/20, embedded all round and under
the posts and backfill the remaining excavation all as shown on the Drawings or
directed by the Engineer. Foundations for signs of as over 5m2 shall not be
covered up until they have been approved by tie Engineer.
The Contractor shall cut back trees and vegetation to permit visibility and shall
not permit material to be dumped so as to obscure the signs.
All signs shall be maintained in a clear and legible condition and shall be washed
down when necessary,
20005 ROAD MARKING
(a) General
Road marking shall comply with the requirements of the "Manual for Traffic
Signs in Kenya", Part I. Markings shall be white or yellow as instructed by the
Engineer.
Paint and hot applied thermoplastic material shall comply with Section 2 of
this Specification.
Ballotini beads shall be mixed with the paint before application or applied to
the painted areas immediately after painting, as instructed by the Engineer.
Lines and letters shall be painted on the road as shown on the Drawings or
as instructed by the Engineer. The setting out of lines shall be made by the
Contractor. Words and symbols shall be set out by the Contractor, by means
of stencils and shall be In accordance with drawings provided.
(b) Application
Prior to application of paints, the road surface to be marked shall be
thoroughly cleaned of all loose material and shall be completely dry. Where
instructed by the Engineer a tack coat shall be used to increase adhesion.
The application of paint shall preferably be done by a purpose-made
machine, but the Engineer may accept brushing. All application instructions
issued by the paint manufacturer shall be strictly adhered to. The application

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

of hot-applied thermoplastic material shall be carried out by a purpose-made

machine.
The spraying rate for cold paint will vary with the roughness of the surface,
but shall be such as to give continuous coverage and a minimum dry film
thickness of 0.125 mm. If specified in the Special Specification, reflectorized
paint as detailed in Section 2 of this Specification shall be used.
Hot-applied thermoplastic materials shall have a minimum thickness of 3 mm
and a maximum of 6 mm. Application shall be in accordance with the
manufacturer's instructions.
(c) Traffic control
Warning signs shall be erected when painting is in progress and traffic shall
not be allowed to pass over wet paint. Any painting disfigured by traffic, or
any painting not complying with the Specification shall be effaced and
repainted.
20006 GUARDRAILS
Dimensions and erection details for guardrails Drawings are shown on the
(a) Materials
(i) Beams
Beams for guardrails shall be Class A with a Type 1 finish in accordance
with AASHTO H180 and shall be obtained from a manufacturer approved
by the Engineer.
(ii) Posts
Posts shall be constructed of concrete Class 20/15 reinforced with 16 mm
diameter mild steel bars all as shown on the Drawings.
(iii) Blocks
Blocks shall be made from well-seasoned red cedar free from loose knots
and shakes other than surface splits not exceeding 3 mm depth.
(b) Erection
Guardrail shall be erected in accordance with the manufacturer's published
instructions and the Drawings. Where there is any conflict the Drawings shall
take precedence.
Approximate locations for guardrail are shown on the Drawings but precise
details will be issued to the Contractor by the Engineer as construction
proceeds but generally not before the completion of the earthworks in the
particular section

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The Contractor shall excavate for the posts in any material and provide the
guardrail with all posts, blocks, nuts, washers and shall repair galvanising,
backfill around the posts and remove surplus material to spoil.
When erection is complete and the section has been approved by the
Engineer the nuts shall be spot welded to the guardrail or to the bolt to stop
their removal.
Galvanised coating damaged by spot welding or cutting shall be renovated
either by the use of low melting point zinc alloy repair rods or powders made
specifically for this purpose, or by the use of at least two coats of good quality
zinc-rich paint to BS 4652.
(c) Tolerances
Guardrail shall be erected at the instructed or detailed offsets and levels from
the pavement centreline and shall be correct within a tolerance of + 20 mm in
line and level. In addition adjacent plates shall not vary in line or grade by
more than 5 mm measured from a line extended from one plate to the end of
the adjacent plate; where the guardrail is on a horizontal or vertical curve the
calculated deflection shall be added to this tolerance.
(d) Additional guardrail
Where specified or instructed by Engineer the Contractor shall arrange for an
additional length of guardrail including all posts, blocks, nuts, washers and
bolts, to be stored at the Contractor's camp. This material shall become the
property of the Employer who shall remove it from before the end of the
Period of Maintenance.
20007 KERBS
Where shown on the Drawings or directed by the Engineer the Contractor shall
excavate in any material, provide and place concrete for the haunch, backfill,
remove surplus material to spoil, provide, lay and joint precast concrete kerbs,
edgings and quadrants.
Precast concrete kerbs, edgings and quadrants shall comply with the
requirements of BS 340, and shall be laid in accordance with the Drawings.
The concrete for the haunch shall be concrete Class 15/40 which shall comply
with the requirements of Section 17 of this Specification.
For radii of 12 m or less, kerbs of appropriate radius shall be used.
Any 1.0 m length of kerb, edging or quadrant deviating more than 3 mm from line
and level at either end shall be made good at the Contractor's expense by lifting
and re-laying.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

20008 KILOMETRE MARKER POSTS

Where shown on the Drawings or directed by the Engineer the Contractor shall
excavate in any material, provide and place concrete embedded all round and
under the posts, backfill, remove surplus material to spoil, provide and place
kilometre marker posts.
The sign on kilometre marker posts shall be painted black with white lettering and
the posts shall be painted white and be constructed in accordance with the
Drawings.
Concrete for backfill to kilometre marker posts shall be Class 15/20 complying
with the requirements of Section 17 of this Specification.
20009 RUMBLE STRIPS
Where shown on the Drawings or directed by the Engineer the Contractor shall
provide, place, trim, shape and compact to line and level rumble strips to the
inside of bends of radius less than 1000 m and at junctions or where directed by
the Engineer.
Rumble strips shall be constructed in asphaltic concrete or Concrete Class 20/10
to the dimensions shown on the Drawings or directed by the Engineer.
20010 TREES
Where shown on the Drawings or directed by the Engineer the Contractor shall
excavate for, backfill with topsoil, provide, plant, water and protect trees within
the Road Reserve, around borrow pits and quarries and elsewhere as directed
by the Engineer.
The excavation for each tree shall be 0.3 m deep and backfilled with topsoil
provided by the Contractor.
0-3 m diameter
The tree seedlings shall be obtained by the Contractor from the District Forest
Officer of the Forest Department of the Ministry of Environment and Natural
Resources closest to the Works or, if not available, from an alternative source
approved by the Engineer.
The tree seedlings shall be of indigenous varieties recommended by the District
Forest Officer and the method of transportation, handling, planting and oaring for
each tree seedling shall be as directed by the District Forest Officer.
The Contractor shall water daily each tree seedling for the first four weeks after
planting. For a further 12 weeks the Contractor shall water each tree seedling as
necessary to ensure that each becomes firmly established.
Should any tree be damaged, uprooted or die during the first 16 weeks after
planting the Contractor shall immediately replace the tree with a new tree
seedling and shall water and care for it as prescribed in this Clause 2010. Should

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the replacement tree be damaged, uprooted or die within the first 16 weeks after
planting the same conditions shall apply and the Contractor shall continue to
replace trees and water and care for them until the end of the Period of
Maintenance.
Any protection works that the Contractor deems necessary to protect trees from
damage, uprooting or death shall be provided at the Contractor's expense.
All trees instructed by the Engineer shall be planted by the Contractor prior to the
issuing of a Completion Certificate for the whole Works or any part thereof.
20011 MEASUREMENT AND PAYMENT
Posts
The rates for road reserve boundary posts, fence posts, gates, edge marker
posts and kilometre marker posts shall include for the costs of providing all
materials and fittings, fabrication, transportation, excavation In any material,
concrete foundations where specified, provision of transport, and compaction of
selected backfill, disposal of surplus material, and complying with the
requirements of Clauses 2001, 2002, 2003 and 2008 of this Specification as
appropriate.
(a) Item : Road reserve boundary posts
Unit: no.
Road reserve boundary posts shall be measured by the number instructed.
(b) Item: Fencing
Unit: m
Fences shall be measured by the metre calculated as the length instructed to
be erected.
(c) Item : Gates
Unit: no.
Gates shall be measured by the number instructed.
(d) Item t Edge marker posts
Unit: no.
Edge marker posts shall be measured by the number instructed.
(e) Item : Kilometre marker posts
Unit: no.
Kilometre marker posts shall be measured by the number instructed.
Permanent Road Signs

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The rates for permanent road signs «hall include for the costs of providing all
materials including posts and fittings, fabrication, transportation, excavation in
any material, installation, concrete foundations, selected backfill and disposal of
surplus material and for complying with Clause 2004 of this Specification.
(f) Item: Warning signs
Unit: no. of each size
Warning signs shall be measured by the number of each size instructed.
(g) Item t Priority, prohibitory and mandatory signs
Unit: no. of each size
Priority, prohibitory and mandatory signs shall be measured by the number of
each size instructed.
(h) Item: Standard informatory signs
Unit: no. of each size
Standard informatory signs shall be measured by the number of instructed.
(i) Item : Non-3tandard informatory signs
Unit T no. of each range of sizes.
Non-standard informatory signs shall be measured by the number of each
size in each of the following ranges:-
(i) Less than In2.
(ii) Equal or more than lm2 but less than 2m2.
(iii) Equal or more than 2ra2 but less than 5m2.
(iv) Equal or more than 5m2.
(j) Item : Road marking in yellow or white paint
Unit: m2
Road markings in yellow or white paint shall be measured in square metres
calculated as the plan area instructed to be painted.
The rate for road marking in yellow or white paint shall include for the cost of
setting out, providing paint and painting to any symbol or line of any width
and of complying with the requirements of Clause 2005 of this Specification.
(k) Item : Guardrail
Unit: m
Guardrail shall be measured by the metre as the length of guardrail
instructed.

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The rate for guardrail shall include for the cost of provision and transport of all
materials, excavation, concrete posts, erection, backfilling and complying with
the requirements of Clause 2006 of this Specification.
(l) Item : Provide additional guardrail
Unit: m
Provide additional guardrail shall be measured by the metre as the length of
guardrail instructed to be provided and stored by the Engineer for the use of
the Employer.
The rate for provide additional guardrail shall include for the cost of provision
transport and storage of all materials and complying with the requirements of
Clause 2006 of this Specification.
(m) Item : Kerbs to radii equal to or more than 1.0 m
Unit: m of each range of radius
Kerbs shall be measured separately for each of the following ranges of radii:-
(i) Straight.
(ii) Radius 12m - 6m.
(iii) Radius 5m - lm.
The rate for kerbs shall include for the cost of provision of all materials,
excavation in any material, laying and jointing kerbs, concrete bedding and
haunching, backfill, removal of surplus material and complying with the
requirements of Clause 2007 of this Specification.
(n) Item : Quadrants of radius less than 1.0 m
Unit: no.
Quadrants of less than 1.0 m radius shall be measured by the number
instructed.
The rate for quadrants shall include for the cost of provision of all materials,
excavation in any material, laying and jointing quadrants, concrete bedding
and haunching, backfill, removal of surplus material and complying with the
requirements of Clause 2007 of this Specification.
(o) Rumble strips
Unit: m
Rumble strips shall be measured by the metre of rumble strip instructed.
The rate for rumble strips shall include for the cost of provision and transport
of all materials and complying with the requirements of Clause 2009 of this
Specification.

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(p) Item : Trees

Unit: no.
Trees shall be measured by the number instructed.
The rate for trees shall include for the cost of the provision and transport of
seedling, excavation, provision and backfill with topsoil, watering and
replacement of seedlings as necessary, and complying with the requirements
of Clause 2010 of this Specification.

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 STANDARD SPECIFICATION FOR ROAD AND BRIDGE CONSTRUCTION

21000 MISCELLANEOUS BRIDGE WORKS

21001 WATERPROOFING TO STRUCTURES
Waterproofing shall be applied to all structural concrete surfaces in contact with
fill material or cut soil surfaces and wherever detailed on the Drawings or
instructed by the Engineer.
Prior to application the surface shall be clean and completely free from damp,
moisture, dust, membrane curing compounds, projecting tying wire, nails and the
like.
Waterproofing materials shall consist of either bitumen emulsion or cut-back
bitumen or bitumen/rubber latex emulsion.
Bitumen emulsion shall comply with the requirements of BS 434, Type A160.
Two coats shall be applied, the first coat at a minimum rate of 0.55 litres per
square metre. The first coat shall be allowed to dry before the second coat is
applied.
Cut-back bitumen shall be type MC30 as described in Section 2 of this
Specification. Two coats shall be applied, the application rates being as
described for bitumen emulsion. The first coat shall be allowed to dry before the
second is applied.
Bitumen/rubber latex emulsion shall contain a minimum of 10* rubber. Two coats
shall be applied, the application rates being as described for bitumen emulsion.
The second coat shall be applied when the first coat is touch dry. Bitumen/rubber
latex emulsion shall not be applied during wet weather and should rain occur and
cause damage before the rubber has dried the membrane shall be repaired or
replaced as approved by the Engineer at the Contractor's expense.
Where concrete is cast against existing ground the waterproofing membrane
shall be single layer polythene sheet 0.75mm thick laid with minimum laps
between sheets of 150 mm.
21002 BRIDGE BEARINGS
Bearings shall be manufactured and installed in accordance with the details
shown on the Drawings or as described in the Special Specification.
The levels shown on the Drawings are the soffit levels of the beams or deck at
the bearing locations. Bearings shall be accurately set in their correct positions
and shall be maintained in position during beam installation and deck
construction. Bearing surfaces of bearings shall be kept free from contamination
and after the deck has been completed, each bearing and the area around it
shall be left clean.

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All bearings shall be indelibly marked with the appropriate Type Numbers and
shall be supplied complete with dowels and ^dowel caps, nuts, bolts, adhesives,
mortars and the like as required.
Should the contractor wish to use an alternative system to that shown on the
drawings, he should provide the engineer with full details and technical
specifications of the alternative system and shall satisfy the engineer with the
suitability of the alternative system.
Bearings shall not be dispatched to the site until the tests described in the special
specification have been satisfactorily completed and the certified results of the
tests approved by the engineers.
(a) Materials
(i) General
When requested by the Engineer, the Contractor shall submit test certificates
from an approved, independent testing authority to show that the respective
materials comply with the specified requirements, or a certificate from the patent
holder or designer certifying that the manufactured item complies in all respects
with relevant product specifications.
Unless otherwise specified, all the materials used for manufacturing the bearings
shall comply with the requirements of BS EN 1337-2:2004, BS EN 1337-3:2005,
BS EN 1337-5.
(ii) Roofing felt
Roofing felt shall be 3-ply and comply with the requirements of BS 8217:1994 or
equivalent for Type 1 roofing felt.
(iii) Elastomer
The elastomer used in the manufacture of bearings shall be natural rubber or
synthetic rubber.
Natural rubber shall comply with the requirements of BS 1154:2003 for specified
IRHD hardness.
Synthetic rubber shall comply with the requirements of BS 2752:2003 for
specified IRHD hardness.
(iv) Stainless steel plate
The texture of the sliding surface of stainless steel plate used in conjunction with
PTFE to form low-friction sliding surfaces shall be equal to or better than 0.2 μm
Ra in accordance with the requirements of BS 1134:1988 Parts 1 and 2.
(v) Stainless steel dowels and bolts
Stainless steel used for the manufacture of dowels and anchor bolts shall comply
with the requirements of BS EN 10088 for Steel 316S16.

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(vi) Mortar
Mortar beddings for seating the bearings shall be composed of an approved sand
and either cement or epoxy resin, or may consist of an approved proprietary
mortar. The mortar shall comply with the following strength requirements:
(1) Sand-cement mortar
The 7-day compressive strength of 150 mm cubes made from the mortar and
cured in a moist atmosphere for the first 24 hours and afterwards in water at
20°C shall be not less than 1.5 times the average contact stress under the
bearing or 15 MPa, whichever is the greater.
(2) Sand-epoxy resin mortar.
The cured compressive cube strength of the mortar shall be not less than two
times the average contact stress under the bearing, or 20 MPa, whichever is the
greater.
(3) Proprietary mortar
The strength requirements for proprietary mortars shall be in accordance with
either with the requirement of this Specification.
(b) Concrete hinges
Concrete hinges shall be constructed in accordance with the details shown on
the Drawings.
Construction joints shall not be formed in the throat area. Where a joint is
necessary, it shall be formed as a recess below the throat, level with the top
reinforcement mat. The width of the recess shall be slightly greater than that of
the throat.
Care shall be taken to eliminate the formation of shrinkage cracks within the
throat.
During construction, adequate bracing and support shall be provided to the
satisfaction of the Engineer to prevent rotation in the throat from the time of
casting to completion of the structure incorporating the hinge. During the course
of construction the hinge shall not be subjected to conditions which will induce
tensile stresses in the throat area. Upon completion of the structural members
incorporating the hinge, the space around the throat shall be filled and sealed
with an approved compressible material.
(c) Roofing felt
Roofing felt used as bearing strips shall consist of at least three layers.
Where lubricated linings are specified, the roofing felt shall be saturated with
motor oil and then liberally dusted with graphite powder before it is laid on the
bearing surface.

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(d) Elastomeric bearings

(i) Technical data
The following technical data for the elastomeric bearings will be supplied on the
Drawings, and shall also be supplied on drawings prepared by the Contractor for
submission to the Engineer:
(1) Design loads and deformations
The critical design-load combinations and co-existing rotations and horizontal
displacements for each bearing or each group of identical bearings.
(2) Size and construction of bearing
The size and construction of the bearing shall be designated by:
L x B x n(t)
where:
L = length of bearing in the transverse direction, in mm
B = width of bearing in the span direction, in mm
n = number of elastomer layers.
t = thickness of individual elastomer layers, in mm
The steel plates shall be encased in a 3 mm thick elastomer layer.
(3) Hardness and type of elastomer
The IRHD hardness and type of elastomer, i.e. natural or synthetic rubber, from
which the specified bearings are to be manufactured.
(4) Identification
Each bearing shall be identified by a number.
(ii) Alternative bearings
Where alternative bearings are offered by the Contractor, they shall be designed
in accordance with the requirements of BS EN 1337-2:2004, BS EN 1337-
3:2005, BS EN 1337-4 for the loadings and deformations shown on the
Drawings.
Where a bearing consisting of a type of rubber is offered which differs from that
which is specified, the bearing shall be redesigned to make provision for the
variation in hardness and/or type of rubber.
(iii) Inspection and testing
On completion of the manufacture of the bearings, the Contractor shall submit
bearings selected by the Engineer, or specially manufactured bearings to serve

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as samples as authorised by the Engineer, to an independent testing authority for

testing.
The testing facilities of the manufacturer or supplier may be used if so approved
and on condition that the tests are conducted in the presence of the Engineer.
The Engineer shall determine which tests are to be conducted, and the tests
shall comply with the appropriate requirements of this Specification.
Copies of test results and certificates for the above mentioned tests shall be
submitted by the Contractor to the Engineer in good time to enable the Engineer
to assess the information before the bearings are installed.
The dimensional tolerances for the bearings shall comply with the requirements
of this Specification.
Before the bearings are dispatched to the site of the Works, each bearing, with
the exception of large bearings as provided for in the Special Specifications shall
be subjected simultaneously to a vertical load equal to 150% of the maximum
design load, and to a shear distortion equal to 150% of the maximum design
value. The bearings shall be visually inspected for defects by the Engineer or
his/her nominee and shall not at any stage under this test show any cracks
visible to the naked eye or any other defects.
The Engineer may instruct that one bearing of each consignment shall be cut
open, at the Contractor's expense, with a view to a visual assessment of the
bonding and the thickness of layers.
(e) Proprietary bearings
(i) General
This Clause covers custom-built bearings and bearings manufactured under
licence, except elastomeric bearings. Combined bearings, consisting of an
assembly of an elastomeric bearing in conjunction with a low-friction sliding or
mechanical component shall fall under this Clause.
The bidder may base his/her bid on any bearing which complies with the
specified requirements, provided that the efficacy of the bearing has been
verified by tests and successful previous use. Evidence hereof as well as
information on the durability and suitability of the bearings for the specified use
shall be submitted to the Engineer for consideration.
Details of the product guarantee shall be submitted with the bid.
(ii) Drawings and approval
Prior to manufacturing the bearings, the Contractor or his/her nominee shall
submit the following information to the Engineer for consideration:
(1) The manufacturer's specification containing detailed information on the
design standards, materials, manufacture and technical data.

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(2) Drawings complying with the provision in this Specification showing the
bearing construction and installation details.
(3) Friction properties based on actual tests conducted on the relevant
materials.
(iii) Technical requirements
The following technical requirements will be supplied on the Drawings, and shall
also be supplied on the Drawings prepared by the Contractor for submission to
the Engineer:
(1) Design loads and movement
The maximum and minimum vertical loads and co-existing horizontal loads as
well as the maximum horizontal load and co-existing vertical load. The maximum
values in each direction of the reversible and irreversible movements and the
rotation about each axis.
(2) Identification
Identification of each bearing by a number, data on the degree of freedom of
movement (fixed, multi-directional or unidirectional bearings) and the type of
bearing (spherical, elastomer-pot, etc) shall appear on each bearing.
(iv) Design
The bearings shall be designed in accordance with the requirements and
recommendations of BS 5400:1983 Part 9.1. The following shall also be
complied with:
(1) The average pressure on the area of the elastomer shall not exceed 25
MPa under the serviceability Limit State, unless otherwise prescribed by the
Engineer.
(2) The maximum average contact stress and maximum edge stress on the
concrete or mortar bedding shall not exceed 0.5 and 0.6 times the 28-day cube
characteristic compressive strength under the serviceability Limit State
respectively, unless otherwise prescribed by the Engineer.
(3) The bearing pad shall be of dimensions as will fit into the space allowed
for its installation. Major alterations to the contiguous members will not be
permitted.
(v) Construction
Unless otherwise specified, the following shall be complied with:
(1) The thickness of the elastomer disc shall be not less than 0.066 times its
diameter.
(2) Approved lubricants only shall be used on the PTFE sliding surfaces.

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(3) The bearing shall be provided with tight-fitting seals to prevent the ingress
of dust or deleterious matter onto the moving parts. The seals shall be of an
approved type and sufficiently durable to last in excess of 50 years.
(4) The assembled bearing shall be supplied with welded or bolted lugs or
straps, temporarily securing the moving parts firmly in position to ensure that no
undesirable relative movement occurs before or during construction.
(5) The bearing shall be recessed into adaptor plates or be of such
construction as to facilitate removal of the bearing from the installed position
without damage to any part of the bearing or the surrounding material after the
relevant structural member has been raised by 15 mm or the distance specified.
(6) Anchors and holding-down bolts shall be of the specified material.
(7) Corrosion protection of all exposed steel surfaces, with the exception of
the stainless-steel sliding plate, shall involve the following treatment:
Preparing the surfaces by abrasive blasting to a finish equal to the Sa3 finish of
BS EN ISO 8501-1:2007, BS EN ISO 5801-1, Swedish Standard SIS 05 59 00 or
equivalent.
Spraying the surfaces with zinc to comply with the requirements of AASHTO
M32-97 or equivalent on approval of the Engineer for Type Zn 150 surfacing.
Coating the zinc-sprayed surfaces within four hours with a sealer compatible with
the zinc and the subsequent coats of paint.
Applying a coat of chlorinated rubber paint with a minimum of 75 μm of dry-film
thickness and of a colour which differs from that of the final coat of paint.
Applying a final coat of chlorinated rubber paint with a minimum of 75 μm of dry-
film thickness and of dark grey colour.
Surfaces in contact with concrete shall be sprayed with zinc so that it complies
with the requirements of AASHTO M32-97 or equivalent on approval of the
Engineer for Type Zn 150 surfacing.
(vi) Inspection and testing
The Engineer may require tests to be conducted to verify compliance of the
bearing with the specifications and/or its satisfactory performance under the
design loads.
Test certificates of all the tests conducted shall be submitted to the Engineer.
The Contractor shall give the Engineer at least seven days notice prior to final
assembly of the bearings to enable the Engineer to inspect the bearings at the
factory.
Under no circumstances shall bearings be taken apart and reassembled on the
site, except where it is an unavoidable feature of the installation procedure, in

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which case the dismantling, installation and reassembly shall be under the
supervision of qualified personnel.
Rehabilitation, modification and repair work to bearings shall be carried out only
in the factory or in an approved engineering Works.
(f) Dowels and guides
Where dowels and guides are used in conjunction with bearings they shall not
complicate or prevent the removal of the bearings.
(g) Storage and handling
The bearings shall at all times be stored under cover and clear of the ground,
away from sunlight, heat, oils and chemicals deleterious to the bearings. The
bearings shall not be stacked in a manner or on a surface which will cause
distortion of the bearings.
The bearings shall be handled with care to ensure that they are not subjected to
impact loads or any other conditions which may be harmful.
(h) Installation
The concrete surfaces of elements required to receive bearings shall comply with
the requirements of this Specification. Plastering of the surface will not under any
circumstances be permitted.
Before the mortar bedding is constructed, the concrete surface shall be chipped
back to expose the aggregate and leave a sound irregular surface. Bonding of
the mortar bedding to the concrete surface shall be in accordance with the
manufacturer's recommendations and the Engineer's instructions.
Unless otherwise shown on the Drawings, the bearings shall be installed on a
horizontal plane and shall be in full contact with the concrete and bedding
surfaces.
To accommodate soffit irregularities and camber in the case of precast members,
the member shall be lowered onto a mortar skim on top of the bearing. The
member shall then be propped until the mortar skim has hardened into a wedge.
The bearings shall be accurately installed to the specified level, alignment and
orientation, all within the construction tolerances set out in this Specification and
the details shown on the Drawings.
Where the bearing has long sliding plates, the latter shall be rigidly supported to
prevent their being distorted under the weight of the wet concrete and the
construction loads. Before the bearing is incorporated into the structure, it shall
be cleaned to remove all deleterious substances and adhering matter, after
which it shall be wrapped in polyethylene sheeting and so sealed as to prevent
the ingress of mortar and/or slush onto the bearing during the course of
construction.

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After installation, the polyethylene wrapping shall be removed, the bearing and
the space around the bearing thoroughly cleaned and the lugs removed as
prescribed by the Engineer.
On completion of installation of proprietary bearings, the Contractor shall submit
to the Engineer a certificate from the manufacturer or supplier of the bearings
certifying acceptance of the installation, only if the manufacturer installed the
bearings. The issuing of such a certificate shall not relieve the Contractor of
his/her responsibility under this Contract. No separate payment will be made for
the inspection of the bearings by the manufacturer or supplier and the issuing of
the
21003 MOVEMENT JOINTS AND SEALANTS
(a) General
The term “movement Joint” includes all types of permanent joint or hinge
throat which allow expansion, contraction, shrinkage or angular rotation to
take place.
Movement joints shall be constructed in accordance with drawings and
manufacturer’s instructions.
The size of the gap shall be compatible with the mean structure temperature
at the time of installation. This temperature shall be determined in
accordance arrangements agreed with the engineer after which the engineer
will instruct the size of the gap.
The position of all bolts cast into concrete and holes drilled in place shall be
accurately determined from templates
(b) Epoxy mortar nosing
Epoxy mortar nosing shall be formed under the direction of a competent
supervisor experienced in the use of the material. The work shall be carried
out preferably in m warm dry weather. The air temperature around the joints
shall be not less than 10°c which shall be achieved artificially if necessary.
Concrete surfaces to which the nosings are applied shall be dry, sound and
free from laitance. Before application of the priming coat, loose material and
dust shall be removed by an air jet tested to ensure that no oil is carried over
from the compressor.
Unless otherwise described in the Contract, surfacing shall be carried across
the joint and then cut back to accommodate the nosing. The cutting shall be
done with a diamond saw to give a clean edge throughout the depth of the
material to be removed. Masking material provided to prevent surfacing
materials adhering to the deck where nosings are to be formed shall be
adequately located to prevent displacement by the paving machine.

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A priming coat of unfilled epoxy resin composition shall be well worked in by

brush to all surfaces with which the nosings will be permanent in contact at a
uniform rate of not less than 300 g/m.2. The mortar shall then be applied as
quickly as possible while the priming coat Is still tacky.
The epoxy mortar shall be acceptable to the Materials Branch of the Ministry
of Transport and Communications. Aggregate shall be either silica sand,
calcined bauxite or other approved synthetic or natural aggregate of suitable
grading. The particle size distribution shall be that which produces a mortar
with adequate workability and minimum void volume. Aggregate shall be
clean and completely dry.
Whichever type of aggregate is used, the epoxy mortar components shall be
thoroughly mixed in a suitable mechanical mixer. The sequence, duration and
temperature of mixing shall be in accordance with the manufacturer's
instructions.
The mortar shall be placed in position within the time recommended by the
manufacturer it shall be well worked against the primed surfaces and
trowelled flush with the adjacent road surface to form a dense mortar to the
profiles described in the Drawings.
Epoxy mortar shall generally be compacted in courses of thickness not
exceeding 50 mm. Where an underlying course is more than 1 hour old it
shall, unless otherwise agreed by the Engineer, be primed with an unfilled
epoxy resin priming coat before placing the next course.
Traffic shall not be permitted to run on the mortar until the Engineer's
agreement has been obtained.
(c) Sealing
The sealant shall be as specified in the Special Specification or shown on the
Drawings.
A poured sealant shall only be placed when the mean bridge temperature is
between 10°C and 16°C, unless otherwise agreed in writing by the Engineer.
Joints shall be clean and dry before sealing.
Thermoplastic hot-poured sealants shall comply with the requirements of US
Federal Specification SS-S-1401 B, BS 2499:1993 or AASHTO Specification
M-173. The sealants shall be of the rubberised bituminous type containing a
minimum of 20% natural or synthetic rubber.

Thermoplastic cold-applied sealants shall comply with the requirements of BS

5212-1:1990 or US Federal Specification SS-S-156. The sealant shall be of
the rubberised bituminous type containing a minimum of 20% natural or
synthetic rubber.
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Thermosetting chemically curing sealants shall comply with the requirements

of ASTM C-920 or BS EN ISO 11600:2003.
The final IRHD (International Rubber Hardness Degree) hardness of the
sealant shall be 20+5.
Silicone sealants shall comply with the requirements of the Special
Specifications.
Other sealants may be used if approved by the Engineer after he has been
furnished with full information and specifications by the Contractor.
(d) Waterstops
Waterstops shall be of natural rubber or flexible PVC and of the type
specified or shown on the Drawings.
Natural-rubber waterstops shall comply with the requirements of BS
6213:2000.
Flexible PVC rubber waterstops shall comply with the requirements of BS
2571:1990.
(e) Accessory material
(1) Primers
Where a primer is to be used in conjunction with the sealant, it shall be of the
prescribed proprietary material.
(2) Bond breakers
Polyethylene tape coated paper, metal foil or similar material may be used
where bond breakers are required.
(3) Backup material
Backup material shall consist of a compressible material of correct width and
shape to ensure that, after installation, it will be in approximately 50%
compression and the sealant can be formed to the specified depth.
Backup materials shall be compatible with the sealant used. Material
containing bitumen or solvents shall not be used with thermosetting
chemically curing sealants.
(f) Cover plates
(1) Steel cover plates shall be of
Grade 43A steel which complies with the requirements of BS EN 10113:1993,
BS EN 10025-1and 5:2004, or
Grade 300W steel which complies with the requirements of BS EN
10113:1993, BS EN 10155:1993 or equivalent.

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(2) Galvanising shall comply with the requirements of BS EN ISO 1461:2009

and BS EN 10240:1998 or equivalent.
(3) Anchor bolts shall be of stainless steel Grade 302 S.21, which complies
with the requirements of BS EN 10083 (various dates)/BS EN 10088:1995 or
equivalent.
21004 PIPE HANDRAIL TO BRIDGES
Pipe handrails shall be 50 mm galvanised steel piping supported on
galvanised steel posts all made from material complying with and fabricated
to, the requirements of Section 19 of this Specification and the Drawings.
The Contractor shall drill or form all holes, provide and fix bolts. galvanise
posts and pipe rails, cut and bend railing at bridge ends, grout in bolts and
pack under base plates with 25 mm cement/sand mortar and finish off, all in
accordance with the Drawings.
21005 GUARDRAILS TO BRIDGES
Guardrails shall be Class A with a Type 1 finish in accordance with AASHTO
H180 and shall be obtained from a manufacturer approved by the Engineer, and
shall be attached to the same post as the handrail in accordance with the
Drawings and the Contractor shall drill all holes and provide and fix bolts.
Guardrails shall be erected in accordance with the Drawings.
21006 SURFACING TO BRIDGES
Surfacing to bridges shall be in accordance with the Special Specification.
Weep holes
Where shown on the Drawings or directed by the Engineer the Contractor shall
cast weepholes into concrete walls. The Contractor shall provide and place
plastic pipe of the diameter shown on the Drawings to form weepholes which
shall be firmly held in position during the placing of the concrete and shall be cut
flush with the face of the concrete. A 500mm x 500mm square of 'Terram’ (of
weight 280 g/m2) or similar approved fabric shall be placed, central on the
weephole between the concrete wall and the backfill material.
21007 MEASUREMENT AMD PAYMENT
(a) Item: Waterproofing to structures
Unit: m2
Waterproofing to structures shall be measured by the square metre computed
as the area of the structural surface covered by one or more layers of
waterproofing and no deduction shall be made in the measurement for the
area occupied by gratings, or other openings, provided that the area of each
is less than 1 square metre in extent*

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The rate for waterproofing to structures shall include for the cost of providing
and placing waterproofing materials and complying with the requirements of
Clause 2101 of this Specification.
(b) Item : Bridge bearings
Unit: no. of each type
The rate for bridge bearings shall include for the cost of providing and
installing the bridge bearing and complying with the requirements of Clause
2102 of this Specification.
(c) Item : Movement joints and sealants
Unit: as specified in the Special Specification
The rate for movement joints shall include for the cost of providing and
installing the joints and sealant and all costs of complying with the
requirements of the Special Specification.
(d) Item : Pipe handrail and guardrail to bridges
Unit: m
Handrail and guardrail to bridges shall be measured by the metre as the
instructed length of handrail and guardrail to be erected.
The rate for handrail and guardrail to bridges shall Include for the cost of
providing and erecting handrail and guardrail, posts and fittings and
complying with the requirements of Clause 2104 and Clause 2105 of this
Specification
(e) Item: Surfacing to bridges
Unit: as specified in the Special Specification
The rate for surfacing to bridges shall include for the costs of complying with
the requirements of the Special Specification.
(f) Item: Weepholes
Unit: no. of each diameter
Weepholes shall be measured by the number instructed by the Engineer to
be placed.
The rate for weepholes shall include for the cost of providing and casting the
plastic pipe into the concrete, providing and placing the 'Terrain* filter fabric
and complying with the requirements of Clause 2107 of this Specification.

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21000 DAYWORKS
21001 GENERAL
In accordance with Clause 52(4) of the Conditions of Contract the Engineer may
instruct that additional or substituted work be executed on a daywork basis.
Provisional items are included in the daywork section of the Bills of Quantities to
cover the payment of plant, labour and materials for work executed in
accordance with the Engineer's instructions on a daywork basis by the Contractor
or by his sub-contractors.
21002 MEASUREMENT AND PAYMENT
(a) Plant
Payment shall only be made for the time each item of plant is actually
working on Daywork instructed by the Engineer. Idle time, where due solely
to the nature of the Daywork or authorised method of procedure, shall be paid
for at one half of the tendered rate. Idle time due to breakdowns, inefficiency
or incompleteness of the plant shall not be paid.
The rates for plant shall include for the costs of the following:-
(i) Supervision and transport of supervisory staff.
(ii) Transporting or travelling of each item of plant to and from the place of
Daywork.
(iii) Operators, drivers and turn boys including overtime.
(iv) Electric power, water, fuel, oil, grease and other consumables and
equipment.
(v) Power cables, delivery or suction pipes and fittings, steam or air hoses
and tackle, and all other appurtenances of whatever nature required for
the safe and efficient operation of the plant.
(vi) Maintenance, spare parts, drill bits and chisel points and all costs of
repairs.
(vii)Depreciation, insurance, overheads, profits, and any other costs or
allowances.
(b) Labour
Payment shall only be made for the time each class of labour is actually working
on Daywork Instructed by the Engineer.
The rates for labour shall include for the cost of the following:-
(i) Supervision and transport of supervisory staff.

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(ii) Any special allowance to such labour in respect of subsistence, overtime,

bonuses, feeding, housing, holidays, transport to and from the place of
Daywork, overhead charges in respect of recruitment, camp
administration and welfare and insurances.
(iii) Supply, transport about the Site, use, maintenance and renewal of small
tools used on Daywork, such as picks, shovels, barrows, trowels, hand
saws, buckets, trestles, hammers, chisels and all items of a like nature
and not specifically referred to in the items for Constructional Plant, and
protective clothing.
(iv) All other costs which the Contractor may incur in the employment of
labour including overheads, profit and any other costs or allowances.
(c) Materials
Payment shall only be made for materials instructed by the Engineer for use
on Dayworks. The net weights, volumes and areas as appropriate verified by
the Engineer in accordance with his instructions shall be measured.
The rates for materials shall include for the cost of purchase or provision of
the material, transport to Site and place of Daywork, storage, insurance,
handling, placing, supervision, overheads, profit and any other costs or
allowances.

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