GENERAL SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

SERIES 4000 - BITUMINOUS LAYERS AND SEALS

SERIES 4000
BITUMINOUS LAYERS AND SEALS
SECTION 4100 PRIME AND CURING MEMBRANES 40002 4200 BITUMINOUS BASE COURSE AND ASPHALT CONCRETE SURFACING 40009 4300 GENERAL REQUIREMENTS FOR SEALS 4000-24 4400 SINGLE SURFACE DRESSINGS 4000-34 4500 DOUBLE SURFACE DRESSINGS 4000-38 4600 SAND SEALS AND SLURRY 4000-42 4700 SURFACING OF BRIDGE DECKS 400045 4800 TREATMENT OF SURFACE DEFECTS, PATCHING, REPAIRING EDGE BREAKS AND CRACK SEALING 4000-46 PAGE

CONTENTS OF THE GENERAL SPECIFICATIONS:

SERIES 1000 GENERAL SERIES 2000 DRAINAGE SERIES 3000 EARTHWORKS AND PAVEMENT LAYERS OF GRAVEL OR CRUSHED STONE SERIES 4000 BITUMINOUS LAYERS AND SEALS SERIES 5000 ANCILLARY ROADWORKS SERIES 6000 STRUCTURES SERIES 7000 TOLERANCES, TESTING AND QUALITY CONTROL APPENDICES

THE REPUBLIC OF UGANDA, MINISTRY OF WORKS, HOUSING AND COMMUNICATIONS

PAGE 4000 - 1

SERIES 4000: BITUMINOUS LAYERS AND SEALS

4103 EQUIPMENT
(a) General The following equipment shall be available and in good working order: Binder distributor. See SUBCLAUSES 4103(b), (c) and (d). Water sprinkler. The water sprinkler shall have efficient spray equipment, capable of spraying a uniform film of water over the whole area to be primed. Rotary broom. The rotary broom shall be selfpropelled or supplied together with a suitable pneumatic tyred towing vehicle. Other equipment such as compressors, hand brooms, reinforced paper for joints, string, nails and all other ancillary equipment as required to carry out the operation efficiently and neatly. (b) Equipment for heating bituminous materials The equipment for heating bituminous materials shall be of adequate capacity to heat the material properly by circulating steam or hot oil through the coils and/or the jacket of a tank or by circulating the bituminous material around a system of heated coils or pipes or other approved means. The heating device shall be so constructed that it will prevent the direct flame from a burner from striking the surface of the coils, pipes, or jacket through which the bituminous material is circulated. The heating device shall be operated in a manner that will not injure the bituminous material. The use of any equipment for the agitation of bituminous material to aid in heating will be prohibited if it injures or in any way changes the characteristics of the bituminous material or introduces free steam or moisture into the tank containing the bituminous material. Tank car or truck connections for transferring bituminous material from tank cars to distributors, supply tanks, or storage tanks shall be so constructed that they cannot be used for any other purpose. The use of a tank car or truck connection or any other equipment by means of which free steam can be introduced directly into the bituminous material as a means of agitation or auxiliary heating shall not be permitted. (c) Bitumen distributors (i) General The distributor vehicle shall be a self-propelled vehicle mounted distributor of nominal tank capacity not less than 2,000 nor more than 20,000 litres, equipped with a spray bar with a width of not less than 3.5 metres, nor more than 6.0 metres. The spray rate of the bitumen must be controlled by one of the following methods: Type A: Controlling the pressure constant in the spray bar and precisely controlling the speed of the vehicle. Type B: Using a metering bitumen pump, precisely controlling the speed of the pump to give constant output, and precisely controlling the speed of the vehicle. Type C: Using a metering bitumen pump driven at a speed proportional to the road speed of the vehicle, the vehicle being controlled to within 5% of a predetermined speed. The exhausts of all motors on the vehicle shall be directed so that fumes do not reach driver or operator and there is no danger of sparks from the exhausts coming into contact with fumes or materials coming

SECTION 4100: PRIME AND CURING MEMBRANES

CONTENTS:
CLAUSE 4101SCOPE 4000-2 4102MATERIALS 4000-2 4103EQUIPMENT 4000-2 4104WEATHER AND OTHER LIMITATIONS 4000-6 4105 PREPARATION OF THE LAYER TO BE
PRIMED OR TO RECEIVE A CURING MEMBRANE 4000-7 4106APPLICATION OF THE PRIME COAT OR CURING MEMBRANE 4000-7 4107MAINTENANCE AND OPENING TO TRAFFIC

PAGE

4000-7 4108TOLERANCES 4109TESTING 4110MEASUREMENT AND PAYMENT

4000-8 4000-8 4000-8

4101 SCOPE
This Section covers the application of a bituminous prime to a prepared pavement layer. This Section also covers the application of a bituminous curing membrane to a prepared pavement layer made of a cemented material.

4102 MATERIALS
(a) Material for priming The priming material shall be one of the following as specified or directed by the Engineer, complying with the given relevant material specification or equivalent standards approved by the Engineer: MC-30 cutback bitumen complying with BS EN 12591:2000 MC-70 cutback bitumen complying with BS EN 12591:2000 Invert bitumen emulsion complying with SANS 1260 / SABS 1260:1979.

(b) Aggregate for blinding The aggregate used for blinding the primed surface shall consist of crushed rock or river sand, with 100% passing the 6.3 mm sieve and should not have more than 10% passing the 2.36 mm sieve. The aggregate shall be clean and shall contain no clay, loam or other deleterious matter and shall have no excessive contents of fines in the opinion of the Engineer. (c) Material for curing membranes Curing membranes for cemented pavement layers shall be made of bitumen emulsion or as specified or directed by the Engineer. Bitumen emulsion shall comply with the relevant requirement: AASHTO designations M140-88 or M20896 or equivalent standards approved by the Engineer. Cutback bitumen, MC30 or MC70 complying with BS EN 12591: 2000 or equivalent standard approved by the Engineer, may be employed on approval of the Engineer provided there is no detrimental effect to the cemented layer.

from the overflow pipe or any other inflammable material. Self propelled distributors shall have sufficient engine torque to maintain the steady speeds required for any application rate between 0.4 and 2.7 litres per square metre on an ascending grade of 10% when fully laden. Self-propelled distributors shall be equipped with a guide arm with suitable pointer and chain, to assist the sprayer driver in following the correct line. The guide arm shall be mounted on drivers side of the vehicle, forward of, and in full view of the driver, and shall be marked and numbered relative to the spray bar nozzles. (ii) Distributor Tanks (1) Construction The tank shall be structurally sound, securely attached to and positively located on the distributor vehicle. No part of the tank or its fittings shall leak when filled with hot bitumen. (2) Insulation The tank shall be covered with suitable noncombustible insulation of adequate thickness. The insulating material shall be firmly secured so that it does not move in use and protected by a strong waterproof sheathing. The temperature of a full load of bitumen, at an initial temperature (measured 30 minutes after loading) of 150C, in an ambient temperature of 15-20C, shall not fall by more than the rates listed below for self propelled distributors: Load at Rest: 10C/4 hours

the operator to be directly behind the heating tubes when operating the burners. A legible red warning sign shall be attached near the burners bearing the wording: This burner equipment must not be operated while the vehicle is loading or unloading or is in transit or when the level of bitumen in the tank is below the warning mark on the dipstick. Alternative methods of heating the bituminous material, with or without heating tubes, may be applied on approval of the Engineer, provided the above levels of performance are achieved. (iv) Thermometers The tank shall be fitted with a thermometer located so as to accurately indicate the temperature of the material as it is sprayed. A second thermometer shall be fitted as close as possible to the heating line, near the other end of the tank. The thermometers shall be of dial type, located so that they can be read conveniently without parallax error. The thermometer dials shall read in increments of not more than 5C and shall include a range of at least 70C to 200C over a scale distance based on 0-200C of at least 150 mm. The thermometer assemblies shall be readily removable for checking and shall be accurate to within +5C. (v) Speed Control Distributors shall be fitted with a dial type road speed indicator. The speed indicator shall be positioned near the drivers line of sight to the guide arm. The dial indicator shall be mounted so that it can be read without parallax error by the driver of the distributor. The speed indicator shall comply with the requirements for an Industrial class 1.5 tachometer to BS 3403:1972. The indicator scale shall be calibrated in suitable metric units, marked in increments corresponding to a change in speed of not more than 5%, with not less than 3 mm spacing between such markings. The road speed indicator shall be operated from a separate retractable wheel attached to the distributor. The tyre of the wheel shall be at least 300 mm diameter and constructed of either solid rubber or permanently inflated rubber. For Type C distributors a revolution counter or speedometer operated by the transmission may be substituted, provided that the mounting and accuracy of the instrument comply with this clause. (vi) Pumping system (1) General Requirements The pumping system, comprising the pump and its associated valves and pipe network, shall be capable of the following operations: Loading and unloading bituminous materials: It shall be possible to empty the tank by either the distributors own pump or by gravity flow. Mixing bituminous materials in the tank by circulation:

(3) Circulatory System A system capable of circulating and thoroughly mixing the contents over the full length of the sprayer tank shall be provided. (4) Dipstick The tank shall be provided with a dipstick of rigid construction. It must be mounted in the centre of the tank, must hang from a T piece so that wear can be detected and must not touch the bottom of the tank. A guide shall be provided to hold the dipstick in a vertical position as it is withdrawn and surging of bituminous material as the dipstick is lowered. The dipstick shall be graduated in litres, in increments not more than 50 litres. Where the spacing between any two markings is less than 10 mm, an alternative method of indicating the load quantity shall be provided. The dipstick shall be marked at the level below which heating equipment shall not be used; this level shall be at least 150 mm above the highest part of the heating tubes or elements. (iii) Heating Equipment The distributor shall be provided with heating tubes and burners capable of maintaining the material in the tank at a steady temperature of up to 190C, and also of raising it from 135C to 175C in not more than 4 hours when the ambient temperature is 15C to 20C and the tank is fully loaded. The heating tubes shall have a slight upward slope away from the burners. No part of the tubes or their flues shall pass through the vapour space above the bituminous material. Flue outlets shall be fitted with spark arresters. The burners and their controls shall be so arranged as to avoid the necessity for

The circulation pipe inside the tank shall have suitably designed orifices so that the flow of bituminous material into each baffled compartment is proportional to the volume of the compartment divided by the total volume of the tank. The pump shall have sufficient capacity when operating on the tank circulate mode to show turbulent mixing in each baffled compartment.

The mixing efficiency shall initially be assessed by observation through the manhole when the tank is at least 30% full. The following test may be used to determine mixing efficiency when the distributor does not comply with the inspections above. Mixing efficiency shall be such that if 25 parts by volume of lighting kerosene and 100 parts of 80/100 bitumen are added separately to the tank and circulation is undertaken for 20 minutes, with the pump operating at not more than 80% of its output when spraying with the full width of the spray bar, the amount of lighting kerosene in any sample taken from the output of the pump as the tank is pumped out shall be within the limits of 22 and 28 parts per hundred parts of bitumen. Positively emptying the complete pumping and spraying systems of bituminous materials without requiring the tank to be emptied. These systems shall also be capable of draining by gravity. Flushing the pumping and spraying systems with light oil without the oil entering the tank.

moved and then reset and the level of binder in the tank is varied between each measurement. (3) Pump Drive The binder pump drive shall be capable of driving the pump without appreciable pulsation or vibration. Where a separate engine drives the pump, the engine shall be fitted with an efficient governor capable of maintaining the engine at a steady speed without hunting, and shall be capable of controlling the spray pump shaft revolutions within +2.5% of the predetermined spraying speed within the full operating range. In the case of type (C) sprayers (single engine for propulsion and spraying), the transmission between the engine and the pump shall be capable of being adjusted to different ratios. At any selected coupling ratio, the pump output shall vary with the road speed in such a manner that for an increase of 20% above a selected road speed, the pump output will be between 16% and 24% greater than the output at the selected speed. In like manner, for a decrease of 20% in road speed, the pump output shall be between 16% and 24% less than the output at the selected speed. (4) Strainers A strainer must be provided in the pump suction line and/or the pump output line. It must be easily removable for cleaning and designed so that all the bitumen flow will pass through it. The maximum mesh orifice size shall be not greater than 3 mm and the total area of the orifices shall not be less than seven times the cross sectional area of the pipe in which the strainer is fitted. (5) By-pass and relief valves Where a by-pass valve is used for controlling the pressure and the discharge from the sprayer, it shall be capable of smoothly and uniformly varying the quantity of material by-passed in order to maintain the required pressure in the spray bar. It shall be capable of by-passing not less than 25% of the maximum output of the pump. Means shall be provided to prevent excessively high pressures, due to blockages or other causes, from damaging the pumping system. Where relief valves are used, they shall be set to a pressure not less than 80% more than the recommended spraying pressure. Provision shall be made for checking the operating pressure of these valves. (vii) Spraying equipment (1) Pump Revolution Counter A revolution per minute counter of an approved type shall be fitted to show the speed of the pump shaft. The instrument shall be calibrated in revolutions per minute and marked at intervals of not more than 5% of the full operating range which shall occupy a scale distance of not less than 150 mm. The instrument shall comply with the requirements for an Industrial Class 1.5 tachometer to BS 3403:1972. A digital tachometer of similar accuracy may be used where the instrument exhibits suitable damping characteristics and the displayed increments are not more than 5% of the full operating range.

In none of the above operations shall significant amounts of bituminous materials be permitted to fall through the vapour space of the tank. No part of the pumping or spraying system shall leak bituminous material under any circumstances. (2) Pump output The pump outlet shall have a steady nonpulsating discharge. Where flat fan type spray nozzles are used, the design and operating procedures of the distributor shall be such that, when the spray bar is used to apply any application rate on spray width within the limits specified the total spray output shall meet the following requirements, without recourse to pump system adjustments while spraying. Type (A) and Type (B) distributors shall be operated so that the mean spray output per nozzle for any width of spray shall not differ by more than 5 percent from the optimal value recommended by the distributor manufacturer. Type (C) distributors (i.e. pump speed proportional to vehicle speed) shall be operated in accordance with a spraying table that defines the vehicle speeds for all application rates and the pump speeds for all bar widths which correspond to the optimal output per spray nozzle recommended by the manufacturer. For type (B) and type (C) distributors, the total pump outputs shall be delivered through the spray nozzles, for all spray widths. The mean output of sprayed binder per revolution of the metering binder pump, for any pump output rate in the operating range, shall not differ by more than 5 percent from the mean output per revolution when spraying with the full width of the spray bar. For all distributors, spraying any particular spray width in the operating range, the pump output measured over any 60 second period shall not vary by more than +2.5% from the mean output over three such 60 second periods spraying the same width, where the controls are

Where an accumulating pump revolution counter is fitted, it shall be calibrated in pump revolutions and shall be accurate to +2.5% over the full range of pump speeds. It must have a reset and start control that may be interlocked with the spray controls so that the number of pump shaft revolutions can be recorded for any spray run. (2) Pressure Gauge A pressure gauge complying with BS EN 837:1998 Bourdon Tube Pressure and Vacuum Gauges Part 2 Metric Units shall be fitted. Type (A) distributors (constant pressure type) shall be fitted with an Industrial Class I gauge of not less than 100 mm nominal size. All other types of distributors shall be fitted with an Industrial Class I or II gauge of not less than 100 mm nominal size. The gauge shall be fitted so as to measure the pressure in the spray bar and shall be mounted so that it is protected from heat and vibration in accordance with BS 837-1:1998. The working fluid in the bourdon tube shall be isolated from the bituminous material by a suitable pressure transmitting device mounted so that all material in the device is maintained at a minimum temperature of not more than 40C below that of the main material flow. The gauge shall be protected from both pressure pulsations and steady pressures exceeding 120% of its range. The maximum scale value of the gauge shall be approximately twice the normal bar spraying pressure. (3) Spray bar Length: The length of the spray bar, defined as the distance between centres of the two extreme end nozzles, shall comply with the requirements of SUBCLAUSE 4103(c) (l). Circulation and Check Valves: The bar shall be of the fully circulating type, in which the bituminous material is pumped from the tank through the full length of the spray bar in use, and returned to the tank while the valves controlling the individual spray nozzles are closed. The spray nozzles in the bar shall be controlled by a linkage or other means which shall open or close the check valves of all nozzles equally, simultaneously, and fully, and which shall be capable of being operated by an operator positioned at the rear of the vehicle with a clear view of all parts of the spray bar. A check valve shall be provided for each nozzle for at least the 10 nozzles nearest one end of the spray bar. For the remainder of the bar, two spray nozzles may be controlled by a single check valve if desired. Each check valve shall be readily disconnected from the master control and operated independently. Extensions and Transverse Slew: Spray bars fitted to self propelled distributors shall be fitted with readily removable or foldable extension sections to enable the bar to be reduced to less than 2.5 m and shall be capable of spraying when shortened. These bars shall also be capable of being moved at least 400 mm transversely while spraying, such movement being readily controlled by an

operator at the rear of the vehicle. Operation of the transverse movement control shall not cause any associated rotating movements of the bar. Any associated vertical movements shall be less than +5 mm. The spray bar shall be mounted on the sprayer in such a manner that the nozzle tips are maintained within plus and minus 10% of the optimum height recommended by the distributor manufacturer irrespective of the loading of the sprayer. The maximum height of the bar shall in no case exceed 325 mm. Hinged extensions and bar height adjustments shall incorporate positive stops and locks, non positive adjustment means such as chains, cables or pneumatic or hydraulic rams shall not be deemed sufficient. (4) Spray Nozzles General Spray nozzles shall be of the flat fan (slot) type and apart from any approved special end nozzles shall be of similar construction and interchangeable. Nozzles shall be mounted with their flow axes vertical and so that all nozzle tips are within 3 mm of a straight line parallel with the rear axle of the vehicle. The nozzles shall be spaced at intervals of not more than 110 mm and no spacing shall vary more than +1.5 mm from the mean spacing. All nozzles except end nozzles must be mounted with the slots in the nozzles at the same horizontal angle. At least 1 spare nozzle shall be carried for every 5 mounted on the spray bar. The construction and mounting of the sprayer shall be such that all nozzles are positively and rigidly set and maintained. Plain screwed connections must not be used unless supplemented by some positive locking device, mark or approved adjustment tool or gauge to ensure that the correct alignment is maintained. End Nozzles: An end nozzle or other approved means shall be provided to reduce the cut off spray taper at the road shoulder edge of the spray bar to comply with SUBCLAUSE 4103(b) (viii). Where used, three such end nozzles (1 spare, 2 on the spray bar) shall be carried on the distributor.

(5) Hand spray equipment Approved hand spray equipment shall be provided. This equipment shall be suitable for operation at a pressure of 6.0 bar but must be capable of withstanding a minimum test pressure of 20 bar and a temperature of 205C. (viii) Performance requirements (1) Definitions SIGNIFICANT WIDTH: The significant width of spray shall be the whole sprayed width. EFFECTIVE WIDTH: The effective width of spray shall be the significant width less the permitted spray taper widths specified below. SPRAY TAPER WIDTH: The spray taper width shall be the portion of spray fan width, at either edge of the

significant width, that is overlapped by a lower number of spray fans than an equivalent sprayed width within the effective width. END NOZZLE TAPER: The spray taper width shall be deemed to be 150 mm when an end nozzle or an approved equivalent is used. END TAPER WITHOUT AN END NOZZLE: The spray taper width shall be deeded to be 200 mm when an end nozzle or an approved equivalent is not used.

The amount of binder sprayed onto any length of 50 mm within the effective length shall not differ by more than 10% from the average binder application over the effective length. The effective length shall be the full sprayed length less 500 mm from each end. The full intensity of spray application shall be reached or cut-off within a length of travel of the sprayer not exceeding 500 mm.

(2) Rate of Application Distributors shall be capable of applying bituminous material evenly and uniformly to the road surface at any required temperature not exceeding 190C and at any rate of application required in the range 0.4 to 2.7 litres per square metre. The distributor shall be capable of achieving these spray rates at vehicle speeds not exceeding 25 km/hr. (3) Transverse distribution Within the range of application rates stated above, transverse uniformity requirements, specified in terms of the amounts of bituminous binder applied to successive 50 mm widths, are as follows: The amount of bituminous material sprayed on to any width of 50 mm within the effective width shall not differ by more than 20% from the average application over the effective width. The mean amount of bituminous material sprayed on to any four adjacent widths of 50mm shall not differ by more than 12% from the average application over the effective width. The effective width shall be divided into three approximately equal sections. The mean amount of bituminous material per 50 mm width sprayed on any one section shall not vary by more than five percent from that on any other section. End Nozzle TAPER: The amount of bituminous binder sprayed onto any 50 mm width within the end nozzle taper shall be less than 120% of the average application over the effective width. In addition the mean amount of bituminous material sprayed onto the 3 adjacent 50 mm widths immediately outside the effective width shall be greater than 50% of the average application over the effective width. END TAPER WITHOUT AN END NOZZLE: The mean amount of bituminous material sprayed onto the four adjacent 50 mm widths within this taper shall be between 40% and 60% of the average application over the effective width. In addition the amount of bituminous material on each 50 mm width, within the taper, shall be less than the amount on the adjacent 50 mm width that is closer to the effective width.

(5) Widths of spray In the case of self propelled distributors, the application rates and uniformity requirements specified above shall be met when any set of six or more adjacent nozzles are operated up to and including the full bar width. (6) Calibration and check of distributors All distributors shall be calibrated and checked to demonstrate compliance with this specification before being used on the Work. The calibration testing of the distributor will be done by the Contractor in the presence of the Engineer by the method prescribed by the manufacturer and/or as directed by the Engineer. When the test results confirm compliance of the Equipment with this Specification the Contractor shall submit a written record of the calibration testing to the Engineer for approval. A certificate of approval will be given to the distributor operator by the Engineer, showing the record of the calibration and check. This certificate shall be kept in the distributor at all times and shall be available to the Engineer or Inspector in charge on each location on which the distributor is used. This certificate may be revoked at any time due to unsatisfactory performance of the distributor and will be returned only when satisfactory repairs or adjustments have been made. Failure to present the certificate will necessitate a re-check and if deemed necessary, a re-calibration of the distributor before it can be used on the Works. The Contractor shall furnish at his/her own expense all necessary equipment, materials and assistance necessary for the calibration. The operation of the distributor will be checked by the Engineer the first time it is used and as often as he/she deems it necessary thereafter, and when the operation is found to be satisfactory, a new certificate will be issued by the Engineer. (d) Equipment for preparation of bituminous material Tanks for the storage of bituminous material shall be equipped to heat and hold the material at the required temperatures. The heating shall be accomplished by steam coils, electricity, hot oil coils or other approved means so that the flame shall not be in contact with the tank. The circulating system for the bituminous material shall be designed to ensure proper and continuous circulation during the operating period. Provision shall be made for measuring and sampling storage tanks. Storage tanks shall have sufficient capacity to provide for continuous operation. All heating or storage tanks shall be fitted with working thermometers. The storage tanks shall be calibrated and equipped with a device whereby the Engineer may determine the amount of bituminous material on hand at any time.

(4) Longitudinal Distribution Within the range of application rates stated above, longitudinal uniformity requirements specified in terms of the amounts of bituminous binder applied to 50 mm lengths are as follows:

4104 WEATHER AND OTHER LIMITATIONS

(i) General The Engineer's decision on whether or not to apply the curing membrane or prime coat under specific conditions shall be final. (ii) Prime coat No prime coat shall be applied under the following adverse conditions; during foggy or wet conditions; when rain is imminent; when wind is blowing sufficiently hard to cause uneven spraying; when the surface of the layer is visibly wet, i.e. more than damp; before sunrise; after sunset; when at any position the moisture content of the base layer is more than 50% of the optimum moisture content as determined by the Engineer when the layer is soft, i.e. sponging under load; (iii) Curing membranes for cemented layers No curing membrane shall be applied under the adverse conditions as decided by the Engineer. Curing membranes shall be applied within the time limits given in the Special Specifications for the respective layer and type of cemented material.

The rate of application for tendering purposes shall be considered to be 1.0 l/m2. The final rate of application shall be decided and agreed on by the Engineer after the Contractor has completed and documented trial sections. TABLE 4106/1 TEMPERATURES FOR STORING AND SPRAYING PRIME OR
CURING MEMBRANES

Type of prime or curing membrane

Maximum storage temperature (C ) Up to Over 24 hrs 24 hrs 65 80 ambient 40 50 ambient

Spraying temperature range (C)

Cut-back bitumen: MC-30 MC-70 Bitumen emulsions (all types)

45-60 60-80 ambient above 10C

The total width of the sprayed surface shall be as shown on the Drawings or as prescribed by the Engineer, and the edges of the sprayed surface shall be parallel to the centreline of the road. The bituminous material shall be applied in one or more lanes evenly over the full width of the road and allowed to cure until traffic can pass over the surface without the wheels picking up the bituminous material. All traffic shall be kept off the surface until this condition is obtained. Where no convenient detour is available for traffic, operation shall be confined to one half the roadway width at a time. The Contractor shall provide proper traffic control so that vehicles may proceed without damage to the primed area. Where it is not feasible for traffic to use deviations, the bituminous material shall be applied and allowed to cure for as long as is practicable in the opinion of the Engineer before a blinding layer of aggregate is applied at a rate of 0.0035 m3/m2 or as directed by the Engineer. Care shall be exercised in this operation to avoid the aggregate being applied too soon after spraying the bituminous material. Where practicable two to four hours shall elapse as directed by the Engineer. Any "caking" of aggregate which may take place and cause problems during the surfacing process and all loose aggregate shall be removed before the final surfacing is commenced. If the bituminous material is applied in more than one strip, allowance shall be made for overlapping of strips by 100 mm. No additional payment will be made for the overlapping strips. Care shall be taken to protect all kerbing and guttering, guard rails and channelling from the bituminous material by covering them with a suitable protective material when spraying. The Contractor shall, at his/her own cost, replace all soiled items, which cannot be properly cleaned. Painting the soiled surfaces will not be accepted as a suitable remedial measure.

4105 PREPARATION OF THE LAYER TO BE PRIMED OR TO RECEIVE A CURING MEMBRANE

Prior to prime coat application, the Contractor shall carry out the necessary field trials to allow the Engineer to check the methods of surface preparation and the performance of the pressure distributor and to establish the exact rate of application and the application temperatures of the bituminous material. No longer than 24 hours before spraying, the layer to be sprayed with prime coat shall be cleaned by heavy mechanical brooming. The brooming shall clean the surface of dust and foreign matters and leave the coarse aggregate standing proud of the surface. The brooming shall be carried out in such a manner so that the surface is not damaged. A light spray of water, sufficient to dampen the surface, shall be uniformly applied to the layer immediately before the application of the prime. If the water is over applied the layer shall be allowed to dry until a uniform damp surface is obtained. Before any material is applied, the layer to be sprayed shall be checked by the Engineer for compliance with the surface and other requirements specified. Any sections not complying with the specified requirements shall be corrected as specified in CLAUSE 1218.

4106 APPLICATION OF THE PRIME COAT OR CURING MEMBRANE

A minimum of 1.0 m of reinforced paper or other suitable approved material shall be used at all joints at the beginning and end of all sprays in order to obtain a neat start and cut-off. The temperatures for storage and spraying shall be in accordance with TABLE 4106/1. All cutback bitumen stored in a heated condition shall be stored in a container with a properly functioning circulation system and having a securely fitting lid.

4107 MAINTENANCE AND OPENING TO TRAFFIC

The Contractor shall maintain the prime coat until the next course is applied. Care shall be taken that the application of bituminous material is not in excess of the specified amounts; any excess shall be blotted. All areas inaccessible to the distributor shall be sprayed manually using the device for hand spraying from the distributor.

Where a blinding layer has been applied to the sprayed surface, the Contractor shall maintain the blinding layer and the sprayed surface during the period when the surface is opened to traffic, and shall repair all damage caused to the blinding layer or the sprayed surface by such traffic, as directed by the Engineer, at no additional payment to the Contractor. If it is desired to pass traffic for a period in order to show up any weak spots in the foundation, the rate of application of prime coat may be increased as ordered by the Engineer and the treated areas shall be blinded with rock crusher dust or coarse sand at the approximate rate of 0.004 m/m. The prime coat shall be left undisturbed until it has penetrated and cured sufficiently so that the wheels of passing vehicles will not pick it up. Where no convenient detour is available for traffic, operation shall be confined to one half the roadway width at a time. The primed surface is to be so designed that it will not be damaged by weather or traffic prior to the application of the next layer. Major patching of the primed surface will not be acceptable, and damaged sections of the prime and base gravel will have to be reworked and reprimed at the Contractor's expense. The Contractor shall provide proper traffic control in order that vehicles may proceed without damage to the primed area. The primed surface shall be inspected and repaired if necessary prior to the next layer being placed if the surface has been opened to traffic.

The unit of measurement shall be the litre of bituminous material measured at spraying temperature and sprayed as specified. The area of bituminous prime coat application shall be measured by station length along the centreline of the roadway for the length multiplied by the width as shown on the plans or directed by the Engineer. The bid rates shall include full compensation for supplying the bituminous material, cleaning and watering the layer to be sprayed as required, applying the bituminous material and maintaining the sprayed surface as specified. The rate of application for the prime coat shall be checked by weighing test trays before and after application. ITEM 41.03
BLINDING:

UNIT AGGREGATE FOR CUBIC METRE (m3)

The unit of measurement shall be the cubic metre of aggregate used for blinding the prime coat on the instruction of the Engineer. The bid rate shall include full compensation for procuring, furnishing and applying the aggregate for blinding where directed by the Engineer, and for maintenance of the blinding layer, as specified.

4108 TOLERANCES
The actual spray rates measured at spraying temperature shall not deviate from the required spray rate as specified or ordered by the Engineer by more than 0.03 l/m2. The average spray rate shall not be less than the required spray rate as specified or ordered by the Engineer calculated over any area of the work determined by the Engineer. The sprayed surface shall nowhere be narrower than the specified edge line.

4109 TESTING
The Contractor shall give the Engineer at least 24 hours notice of his/her intention to apply prime or curing membranes so that the actual spray rates can be verified and approved by the Engineer. Unless otherwise agreed in advance the Contractor shall only spray when the Engineer or his/her representative is present and approval of the Engineer has been obtained.

4110 MEASUREMENT AND PAYMENT

ITEM 41.01 PRIME COAT:
LITRE LITRE LITRE LITRE

UNIT (l) (l) (l) (l)

(a) MC-30 CUT-BACK BITUMEN (b) MC-70 CUT-BACK BITUMEN (c) INVERT BITUMEN EMULSION (STATE TYPE AND BITUMEN CONTENT) 41.02 BITUMINOUS CURING

MEMBRANE:

(a) MC-30 CUT-BACK BITUMEN (b) MC-70 CUT-BACK BITUMEN (c) BITUMEN EMULSION (STATE TYPE AND BITUMEN CONTENT)

LITRE LITRE LITRE

(l) (l) (l)

SERIES 4000: BITUMINOUS LAYERS AND SEALS

SECTION 4200: BITUMINOUS BASE COURSE AND ASPHALT CONCRETE SURFACING

CONTENTS:
CLAUSE 4201SCOPE 4000-9 4202MATERIALS 4000-9 4203MIX DESIGN AND PROPERTIES OF MIXED MATERIALS 4000-14 4204COMPOSITION OF MIXTURES FOR BITUMINOUS BASE COURSE AND SURFACING 4000-15 4205CONSTRUCTION EQUIPMENT 4000-15 4206GENERAL LIMITATIONS AND REQUIREMENTS AND THE STOCKPILING OF MIXED MATERIAL 4000-17 4207PRODUCING AND TRANSPORTING THE MIXTURE 4000-18 4208SPREADING THE MIXTURE 4000-19 4209JOINTS 4000-20 4210COMPACTION 4000-20 4211LAYING TRIAL SECTIONS 4000-21 4212PROTECTION AND AFTERCARE 4000-21 4213CONSTRUCTION TOLERANCES AND FINISH REQUIREMENTS 4000-22 4214SAMPLING AND TESTING 4000-23 4215MEASUREMENT AND PAYMENT 4000-23 PAGE

The coarse and fine aggregate shall be produced by crushing of rock obtained by blasting of hard solid rock formation. The crushing shall be by multi-stage equipment in order to produce aggregates of angular shape. All materials shall be handled and stockpiled in a manner that will prevent contamination, segregation or damage. Stocks of cement and lime shall be rotated in a manner whereby it is used in the order in which it has been received. The Contractor shall, as often as necessary, test and control the materials produced by himself/herself or the materials received by him/her from suppliers to ensure that the materials always comply with the specified requirements. The Contractor will not be expected to construct layers of which the compacted layer thickness is less than one and a half times the maximum aggregate size. (b) Bituminous binders (i) General The various bituminous binders specified shall comply with the relevant specifications as stated in TABLE 4202/1 or equivalent standards according to the Special Specifications and on the approval of the Engineer: TABLE 4202/1 SPECIFICATIONS FOR BITUMINOUS BINDERS Type of binder Penetration grade bitumen Performance Grade Asphalt Cutback bitumen Specification BS EN 12591: 2000 SP-1*) BS EN 12591: 2000

4201 SCOPE
This Section covers all the work in connection with the construction of bituminous base courses and asphalt concrete surfacing for new roads, pavement rehabilitation or maintenance. It includes the procuring and furnishing of aggregate and bituminous binder, mixing at a central mixing equipment, alternatively on the road, spreading and compaction of the mixture, all as specified for the construction of: Continuously graded asphalt concrete surfacing (AC20, AC14, AC10, 19.0, 12.5, 9.5 Nominal mixes). Hot mixed bituminous base course (DBM40, DBM30, 37.5, 25.0 Nominal mixes). Cold mixed bituminous base course ( FBMIX, BEMIX). This Section also covers the widening of bituminous layers. This Section also covers the recycling of bituminous materials by reprocessing recovered materials, adding fresh aggregate, bituminous binders and other agents for obtaining a bituminous mix, which will comply with the specified requirements, and placing the recycled material. The provisions of SECTION 4200 shall apply throughout to recycled bituminous materials, except where explicitly specified otherwise.

Bitumen emulsions, BS 434: 1984 anionic Bitumen emulsions, BS 434: 1984 cationic *) Appendix A, Performance Graded Asphalt Binder Specification and Testing, Superpave Series No.1 (SP-1) [Asphalt Institute] The Type and grade of bituminous binders to be employed for the specific project shall be described in the Special Specifications. Representative test certificates showing all relevant properties of the adhesion agent and bitumen shall be submitted for approval of the Engineer. Such certificates shall be submitted minimum 28 days prior to proposed use or as required by the Engineer to conduct further testing of the materials. Samples of the materials shall be submitted together with the test results if required by the Engineer. New test certificates and samples shall be provided for approval in the event of changes in type or source of adhesion agent, bitumen grade, crude oil source, refinery equipment or refinery method, or as deemed necessary by the Engineer. (ii) Additional requirements for foamed bitumen In addition to the general requirements stated in this SUBCLAUSE foamed bitumen shall meet the following requirements when tested using a 10 litre cylindrical bucket: The ratio between the volume of the bitumen in a foamed state and in an un-foamed state shall be minimum 15.

4202 MATERIALS
(a) General Coarse and fine aggregate shall be clean and free from decomposed materials, vegetable matter and other deleterious substances and shall meet all relevant requirements in the Specifications.

At least one of the following requirements shall be met: The time from the foam is ejected into atmospheric pressure until the volume has decreased to half its maximum volume shall be minimum 15 seconds. The ratio between volume of bitumen in a foamed state and in an un-foamed state shall be minimum 7.5 after 15 seconds have elapsed since the foam was ejected into atmospheric pressure.

The flakiness index when tested in accordance with BS 812-105: 1989 shall be less than 25%. (iv) Aggregate strength The TFV of the coarse aggregate used in asphalt concrete surfacing, when determined in accordance with BS 812-111: 1990 or equivalent shall not be less than 110 kN. The wet/dry strength ratio shall not be less than 75%. (v) Absorption The water absorption of the coarse aggregate shall not exceed 2% by mass, when tested in accordance with BS 812-2: 1995 or equivalent, (vi) Soundness The sodium soundness when tested in accordance AASHTO T104 shall be less than 12%. (vii) Coating and Stripping Test The coating of the aggregates when tested in accordance AASHTO T182 shall be greater than 95%. (d) Aggregates Gradings for Asphaltic Wearing Courses The grading of the combined aggregate including any filler added in an approved working mix shall be within the limits stated in TABLES 4202/2 - 4202/5 for the respective mixes. The approved grading shall be designated as the target grading. The mean grading of each lot of the working mix (minimum of 6 tests per lot) determined from samples obtained in a stratified random sampling procedure, shall conform to the approved target grading within the tolerances specified in CLAUSE 4213. TABLE 4202/2 GRADING LIMITS FOR COMBINED AGGREGATE AND NOMINAL MIX PROPORTIONS FOR ASPHALT CONCRETE SURFACING EMPLOYING MARSHALL MIX DESIGN. Sieve size (mm) 28 20 14 10 5.0 2.36 1.18 0.600 0.300 0.150 0.075 Aggregate Bitumen content *) ASTM 2172-88 Asphalt Concrete, continuously graded AC20 AC14 AC10 100 80-100 100 60-80 85-100 100 50-70 72-94 85-100 36-56 52-72 55-72 28-44 37-55 38-57 20-34 26-41 27-42 15-27 16-28 18-32 10-20 12-20 13-23 5-13 8-15 9-16 2-6 4-10 4-10 95% 94.5% 94% 5% 5.5% 6%

(iii) Pre-construction binder investigations The Contractor shall immediately after signing of contract prepare pre-construction binder investigations, including: 1. Identification of a capable and independent bitumen testing laboratory for comparative testing of binders 2. Collection of samples of potential bitumen 3. Documentation of sample origin, including: The refinery (name of owner(s) and full address) Date, and time of sampling. Point of sampling, (tank number, flow line valve, truck, drum, etc.) Person responsible for sampling. Production data: i. Production date ii. iii. iv. v. vi. vii. Manufacturing method (direct vacuum distillation, propane precipitation, etc.) Feed stock data Batch ID No. Composition of product (raw materials, additives, etc.) Product characteristics softening point, etc.) Storage temperature (penetration,

The sample should be accompanied with a signed certificate from the manufacturer with the abovementioned information and a declaration that the sample to be tested is representative of their production and that a corresponding product will be available to the project during the construction period. 4. Prepare a bitumen testing programme according to the present Specifications. 5. The Contractor shall test the bitumen samples in accordance with this Specification and send the results to the Engineer for his/her approval. (c) Aggregates The aggregates employed for all the asphaltic pavement layers when tested shall conform to the following requirements unless otherwise stated in the individual clauses: (i) Cleanliness The Sand Equivalent of the fine aggregate shall be minimum 45 when tested in accordance with AASTHO T176. The plasticity index when tested in accordance with BS 1377-2: 1990 shall be less than 4%. (ii) Particle Shape

*) The nominal bitumen content is for bidding purposes. Exact percentage to use shall be determined after the Engineers approval of mix design and result of field trials. The type of bitumen shall be 60/70 or 40/50 penetration grade, or according to the Special Specifications, or as directed by the Engineer.

(e) Aggregates Grading for Asphaltic Base Courses The grading of the combined aggregate including any filler added in an approved working mix shall be within the limits stated in TABLES 4202/6 - 4202/8 for the respective mixes. The approved grading shall be designated as the target grading. The mean grading of each lot of the working mix (minimum of 6 tests per lot) determined from

samples obtained in a stratified random sampling procedure, shall conform to the approved target grading within the tolerances specified in CLAUSE 4213. TABLE 4202/3 GRADING LIMITS FOR COMBINED AGGREGATE FOR A 19 Mm NOMINAL SIZED ASPHALT CONCRETE SURFACING EMPLOYING SUPERPAVETM MIX DESIGN. Sieve 19 mm Nominal Size Size Control Points Restricted Zone*) (mm) Min Max Min Max 25 100 19 90 100 12.5 90 9.5 4.75 2.36 23 49 34.6 34.6 1.18 22.3 28.3 0.600 16.7 20.7 0.300 13.7 13.7 0.075 2 8 *) The Restricted Zone forms a band trough which the gradation may not pass.

GRADING LIMITS AND NOMINAL MIX PROPORTIONS FOR DENSE BITUMEN MACADAM BASE COURSE EMPLOYING MARSHALL MIX DESIGN. Sieve size (mm) 50 37.5 28 20 14 10 5.0 2.0 1.18 0.425 0.300 0.075 Bitumen content*), ASTM 2172-88 Bitumen type, BS EN 12591: 2000 DBM40 (% passing) 100 95-100 70-95 56-76 53-70 39-56 24-40 19-35 9-25 7-21 2-9 4.0% DBM30 (% passing) 100 90-100 70-95 58-82 52-73 40-56 24-40 19-35 9-25 7-21 2-9 4.5%

TABLE 4202/4 GRADING LIMITS FOR COMBINED AGGREGATE FOR A 12.5 mm NOMINAL SIZED ASPHALT CONCRETE SURFACING EMPLOYING SUPERPAVETM MIX DESIGN. Sieve 12.5 mm Nominal Size Size Control Points Restricted Zone*) (mm) Min Max Min Max 25 19 100 12.5 90 100 9.5 90 4.75 2.36 28 58 39.1 39.1 1.18 25.6 31.6 0.600 19.1 23.1 0.300 15.5 15.5 0.075 2 10 *) The Restricted Zone forms a band trough which the gradation may not pass.

Maximum compacted layer thickness (mm) *) The nominal bitumen content is for bidding purposes. Exact percentage to use shall be determined after the Engineers approval of mix design and result of field trials.

60/70 or 40/50 penetration grade or according to the Special Specifications, or as directed by the Engineer. 80-200 60-150

TABLE 4202/7 GRADING LIMITS FOR A 37.5 mm NOMINAL SIZED ASPHALTIC ROAD BASE EMPLOYING SUPERPAVETM MIX DESIGN. Sieve 37.5 mm Nominal Size Size Control Points Restricted Zone*) (mm) Min Max Min Max 50 100 37.5 90 100 25 90 19 12.5 9.5 4.75 34.7 34.7 2.36 15 41 23.3 27.3 1.18 15.5 21.5 0.600 11.7 15.7 0.300 10 10 0.075 0 6 *) The Restricted Zone forms a band trough which the gradation may not pass. (f) Requirements for hot mixed bituminous base course (DBM40, DBM30)

TABLE 4202/5 GRADING LIMITS FOR COMBINED AGGREGATE FOR A 9.5 mm NOMINAL SIZED ASPHALT CONCRETE SURFACING EMPLOYING SUPERPAVETM MIX DESIGN. Sieve 9.5 mm Nominal Size Size Control Points Restricted Zone*) (mm) Min Max Min Max 25 19 12.5 100 9.5 90 100 4.75 90 2.36 32 67 47.2 47.2 1.18 31.6 37.6 0.600 23.5 27.5 0.300 18.7 18.7 0.075 2 10 *) The Restricted Zone forms a band trough which the gradation may not pass. For recycled asphalt the nominal mix ratios of recovered asphalt, new aggregate, new bituminous binders, and active mineral filler to be used for bidding purposes, shall be as specified in the Special Specifications. TABLE 4202/6

(i) Grading and mix properties, DBM40 and DBM30 The grading of the combined aggregate including any filler added in an approved working mix shall be within the limits stated in TABLE 4202/9 for the various mixes. The approved grading shall be designated as the target grading. The mean grading of each lot of the working mix (minimum of 6 tests per lot) determined from samples obtained in a stratified random sampling procedure, shall conform to the approved target grading within the tolerances specified in CLAUSE 4213.

TABLE 4202/8 GRADING LIMITS FOR A 25 mm NOMINAL SIZED ASPHALTIC BINDER COURSE EMPLOYING SUPERPAVETM MIX DESIGN. Sieve 25 mm Nominal Size Size Control Points Restricted Zone*) (mm) Min Max Min Max 50 37.5 100 25 90 100 19 90 12.5 9.5 4.75 39.5 39.5 2.36 19 45 26.8 30.8 1.18 18.1 24.1 0.600 13.6 17.6 0.300 11.4 11.4 0.075 1 7 *) The Restricted Zone forms a band trough which the gradation may not pass.

BEMIX: Bituminous base course material made in accordance with this SPECIFICATION with approved bitumen emulsion by mixing in an appropriate equipment or as specified in a cold process. BITUMEN CONTENT: Percentage of residual bitumen by weight of total mix excluding water. MOISTURE CONTENT: Percentage of water by weight of dry aggregate including bitumen when bitumen is present. MARSHALL DENSITY: Density of Marshall specimens excluding water. Standard Marshall compaction with 75/75 blows is assumed unless alternative compaction methods giving similar densities are used on approval of the Engineer.

(ii) General The aggregate shall be natural gravel, crushed material or approved material milled off existing pavement layers. Unless otherwise approved by the Engineer the material shall be placed in stockpile prior to mixing with bitumen. All operations to produce, stockpile and lay bituminous base course and shall be carried out in a manner which ensures a homogeneous mixture with even distribution of additives, bitumen and water without segregation or contamination or excessive variations in moisture contents within the material. All aggregate shall be free from lumps, soft or unsound particles, clay or other deleterious material. The aggregates shall be free of organic matter and the flakiness index shall not exceed 35%. Unless otherwise approved by the Engineer the aggregate shall be screened into a minimum of two fractions before use. Minimum one fraction shall be free of fines within a tolerance of maximum 5% passing the 2.0 mm sieve. The fractions shall be combined to achieve the required grading uniformly throughout the production of bituminous base. The mix design shall be based on laboratory tests of parallel sets of representative samples with a minimum of 5 different bitumen contents respectively. The mix design shall adequately show test results that can be expected on material produced within the tolerances given. The mix design shall give one moisture content and one bitumen content for the proposed mix recipe. (iii) Aggregate strength The TFV of the coarse aggregate used in cold mixed bituminous base course, when determined dry in accordance with BS 812-111: 1990 or equivalent, shall not be less than: 110 kN for Traffic Load greater than 1 x 106 esa's 80 kN for Traffic Load less than 1 x 106 esa's The appropriate Traffic Load Class shall be as given in the drawings or Special Specifications. Where such information is not given, the decision of the Engineer shall apply. The wet strength shall not be less than 75% of the dry strength. (iv) CBR soaked 4 days When tested in accordance with BS 1377-4: 1990 or equivalent, the CBR value shall not be less than 30% before admixture of bitumen. (v) Plasticity index When tested in accordance with BS 1377-2: 1990 or equivalent, the plasticity index before admixture of bitumen shall not be more than: FBMIX material: 14% BEMIX material: 8%

TABLE 4202/9 GRADING LIMITS AND NOMINAL MIX PROPORTIONS FOR DENSE BITUMEN MACADAM BASE COURSE. LABORATORY TEST METHOD Sieve size (mm) 50 37.5 28 20 14 10 5.0 2.0 1.18 0.425 0.300 0.075 Bitumen content, *) ASTM 2172-88 Bitumen type, BS EN 12591: 2000 DBM40 (% passing) 100 95-100 70-95 56-76 53-70 39-56 24-40 19-35 9-25 7-21 2-9 4.0% DBM30 (% passing) 100 90-100 70-95 58-82 52-73 40-56 24-40 19-35 9-25 7-21 2-9 4.5%

Maximum compacted layer thickness (mm) *) The nominal bitumen content is for bidding purposes. Exact percentage to use shall be determined after the Engineers approval of mix design and result of field trials. (g) Aggregates and mix design requirements for cold mixed bituminous base course (FBMIX, BEMIX) (i) Definitions The following definitions apply for cold mixed bituminous base course materials: FOAMED BITUMEN: Bituminous binder temporarily expanded as specified in this SPECIFICATION by the aid of appropriate techniques for introducing water into hot bitumen. FBMIX: Bituminous base course material made in accordance with this SPECIFICATION with approved foamed bitumen by mixing in an appropriate equipment or as specified in a cold process

60/70 or 40/50 penetration grade or according to the Special Specifications, or as directed by the Engineer. 80-200 60-150

(vi) Properties of mixed material The grading of the combined aggregate including any filler added in an approved working mix shall be within the limits stated in TABLE 4202/10 for the respective mixes. The approved grading shall be designated as the target grading. The mean grading of each lot of the working mix (minimum of 6 tests per lot) determined from samples obtained in a stratified random sampling procedure, shall conform to the approved target grading within the tolerances specified in SUBCLAUSE 4213(b). TABLE 4202/10 GRADING LIMITS FOR COMBINED AGGREGATE FOR COLD MIXED BITUMINOUS BASE COURSE Sieve size (mm) FBMIX (% passing) 100 80-100 60-95 42-78 30-65 20-50 10-30 5-15 Foamed 90 BEMIX (% passing) 100 80-100 60-95 35-70 25-50 18-35 10-25 5-8 Emulsion 90

(i) Asphalt reinforcing Asphalt reinforcing shall be of the type specified in the Special Specifications and shall be obtained from an approved manufacturer. Where the use of reinforcing for asphalt has been specified, the Contractor shall, at least three months before the material is to be used, submit samples of the type he/she intends to use, together with complete specifications of the material, as well as the manufacturer's instructions for use, to the Engineer for approval. Where the material does not carry the mark of an acknowledged standards authority, the Engineer may instruct the Contractor to have the material tested by an approved laboratory and to submit the results. (k) Recycling (i) Recovered asphalt The Engineer will test the existing asphalt in any part of the road and determine its suitability for recycling before removal. He/she may instruct the Contractor to drill additional cores at specified points. Recovered asphalt intended for recycling shall be stored separately from other asphalt, and the Engineer may also direct different types of asphalt to be stored separately. The recovered asphalt shall be free from any underlying base material and other foreign matter. Asphalt milled out shall be of a maximum size of 28 mm, unless another maximum size has been approved by the Engineer. Asphalt not milled out shall be broken down in an approved manner so that it can be properly remixed in a equipment to the satisfaction of the Engineer. Mixes of recycled asphalt containing fragments of recovered asphalt exceeding 28 mm in size, will not be accepted. Payment for recovered asphalt will distinguish between milled out and non-milled out material. Samples shall be taken from the recovered asphalt intended for recycled mixes in the stockpile and shall be tested for grading and quality of the aggregate, binder content and properties of the binder. (ii) Bituminous binders The provisions of CLAUSE 4202 shall apply. The grade of new binder used in the recycled asphalt mix shall be such that the mix of new and residual binder will comply with the requirements of the Special Specifications. Recycling agents such as blended oils and other additives may not be used without prior approval by the Engineer. (iii) New aggregate New aggregate required for use in recycled asphalt mixtures shall comply with the requirements of CLAUSE 4202. (iv) Combined aggregate The aggregate mix obtained from new aggregate and the aggregate in the recovered asphalt including any mineral filler, an approved quantity of which may be added in accordance with CLAUSE 4202, shall comply with the requirements specified in the Special Specifications for the relevant recycled asphalt layer. (l) Hot in-situ surface recycling With regard to new binder, recycling additives, new asphalt, new aggregate or combinations of these

37.5 28 20 10 5.0 2.0 0.425 0.075 Bitumen type *) *) Nominal consumption of bitumen (litres per m3 of compacted material) *) The nominal consumption of bitumen is for bidding purposes. Exact percentage bitumen content shall be determined after the Engineers approval of mix design and result of field trials. The type of bitumen shall be according to the Special Specifications or as specified by the Engineer. (h) Fillers If the grading of the combined aggregates for asphalt surfacing mixes shows a deficiency in fines an approved filler may be used to improve the grading. Filler may consist of active filler as defined hereinafter or of inert material such as rock dust having the required grading necessary to improve the grading of the combined aggregates. In no instance shall more than 2% by mass of active filler be used in asphalt mixes. Inert filler such as rock dust used to improve grading shall not be subject to this limitation. The Engineer may order the use of any active filler to improve the adhesion properties of the aggregate. Active filler shall consist of milled blast furnace slag, hydrated lime, Portland cement (CEM I), Portland blast furnace cement fly-ash, or a mixture of any of the above materials. Individual materials shall comply with the requirements of the relevant specifications for such material. Active filler shall have at least 70% by mass passing the 0.075 mm sieve, all passing the 0.600 mm sieve and a bulk density in toluene falling between 0.5 and 0.9 g/ml. The voids in dry compacted filler shall be between 0.3% and 0.5%, when tested in accordance with BS 812103.2:1999. Active fillers for use in bituminous base courses shall be introduced to the mix prior to wetting with the binder. Only active filler added on the instructions of the Engineer, for the purpose of improving adhesion, will be paid for. No payment will be made for filler added to improve the grading.

materials, hot in-situ surface recycling shall comply with the requirements in the Special Specifications. (m) Cold in-situ recycling Cold in-situ pavement recycling shall comply with the requirements in the Special Specifications.

*) The appropriate Traffic Load Class, and whether requirements for severely loaded areas apply to any location, shall be as given in the drawings or Special Specifications. Where such information is not given, the decision of the Engineer shall apply. In general, the Marshall Mix Design method shall be employed unless the SuperpaveTM method is particularly specified. When the SuperpaveTM Mix Design has been specified then the compacted effects shown in Table 4203/1 shall be employed for the different traffic classes. (a) Properties of mixed materials The Contractor shall, by conducting the necessary tests, prove to the satisfaction of the Engineer that he/she will be able to produce a mixture meeting the design requirements in TABLES 4203/2 - 4203/5 for the respective mixes, using the aggregate he/she proposes to supply, within the grading limits specified. TABLE 4203/3 DESIGN REQUIREMENTS FOR SuperpaveTM Mix Design Property of mixture and laboratory test method Asphalt, continuously graded, (37.5, 25, 19, 12.5, 9.5 Nominal Size) 91 90 89 89 96 98 11.0 12.0 13.0 14.0 15.0 70 - 80 65 - 78 65 - 75 65 - 75

4203 MIX DESIGN AND PROPERTIES OF MIXED MATERIALS

The Asphaltic mix design shall be carried out in accordance with the current edition (28 days prior to tendering) of one of the following standards: Marshall Mix Design SuperpaveTM Mix Design - Asphalt Institute Manual Series, MS-2; - Asphalt Institute Manual Series, SP-2.

TABLE 4203/1 SUPERPAVETM MIX DESIGN, GYRATORY COMPACTION EFFORTS Design Traffic (esa x 106) < 0.3 0.3 - < 3 3 - < 30 30 Nintial 6 7 8 9 Ndesign 50 75 100 125 Nmaximum 75 115 160 205

Voids in mineral Maximum Relative Density Aggregate (%) (% Gmm)

Nmax Agg. Size

Property of mixture and laboratory test method

Marshall stability (Newton)

Traffic Loads

Marshall flow (mm) Marshall stability (Newton), all severely loaded areas*) > 10 x 106 esa's 1 - 10 x 10 esa's < 1 x 106 esa's
6

Asphalt Concrete, continuously graded, (AC20, AC14, AC10) 24 Minimum 9000 8000 18000 7000 15000 6000 10000

Ndes

TABLE 4203/2 DESIGN REQUIREMENTS FOR ASPHALT CONCRETE SURFACING

< 0.3 x 106 esa's 0.3 - < 3 x 106 esa's esa 3 - < 30 x 106 esa's 30 x 106 esa's All traffic loads All traffic loads 37.5 mm 25.0 mm 19.0 mm 12.5 mm 9.5 mm < 0.3 x 106 esa's 0.3 - < 3 x 106 esa's 3 - < 30 x 106 esa's 30 x 106 esa's

Air voids (%) Voids Filled with Voids in mineral Bitumen (%) Aggregate (%) Asphalt Mix AC 20 AC 14 AC 10

35 min. 14 min. 15 min. 16

Filler to binder ratio Indirect Dry tensile strength (kPa) AASHTO T 283 Indirect wet tensile strength (kPa) AASHTO T 283

Voids Filled with Bitumen (%)

Nintial

0.6 -1.2 Minimum 800 tested at 25C 80 % of dry strength

Traffic Loads

> 10 x 106 esa's 1 - 10 x 106 esa's < 1 x 106 esa's

65 - 75 65 - 78 70 -80

Requirement after refusal laboratory compaction BS 594 - Part 598 (severely loaded areas only) *) Indirect tensile strength (kPa) AASHTO T 283 Indirect wet tensile strength (kPa) AASHTO T 283

Air voids shall be minimum 3% Minimum 800 Tested at 25 oC 80 % of dry strength

TABLE 4203/4 DESIGN REQUIREMENTS FOR DENSE BITUMEN MACADAM BASE COURSES Property of mixture and laboratory test method Marshall flow (mm) Marshall stability (Newton), all severely loaded areas > 10 x 106 esa's Compaction levels Marshall stability (Newton) Traffic Loads 1.5 - 10 x 106 esa's < 1.5 x 106 esa's DBM40 & DBM30 24 Minimum 9000 Minimum 7000 Minimum 6000 Minimum 3500

in payment for binder or active filler variations as described in CLAUSE 4215. Before production or delivery of the bituminous material the Contractor shall submit samples of the materials he/she proposes to use in the mix, together with his/her proposed mix design as determined by an approved laboratory, to the Engineer in accordance with TABLE 7109/1, so that the Engineer may test the materials and confirm the use of the proposed mix if he/she is satisfied that it meets the specified requirements. A mix design shall be submitted for the approval of the Engineer for each new material source the Contractor proposes to use or when significant changes in the material properties are encountered within a material source or as deemed necessary by the Engineer. Any proposed change of mix design for use in Permanent Works shall be notified to the Engineer for his/her approval minimum 7 days in advance of proposed use. As soon as the materials become available the Contractor shall produce a working mix with the approved equipment in accordance with the design mix. The working mix shall again be tested by him/her for compliance with the design requirements. Samples of the working mix shall also be made available to the Engineer, who will authorise the use of the working mix proportions finally approved for use. The composition of the approved working mix shall be maintained within the tolerances given in TABLEs 4213/3 and 4213/4. The design of the bituminous mixes shall be in accordance with the relevant design guidelines and the mix properties and requirements shall be as specified in the Special Specifications.

Traffic Loads

Severely loaded areas* > 10 x 106 esa's 1.5 - 10 x 106 esa's < 1.5 x 10 esa's
6

To refusal *) To refusal *) 2 x 75 2 x 50

* Severely loaded areas will only be identified during the detailed design, when information such as alignment, soil conditions and traffic volumes are determined, and therefore these areas should be identified in the Special Specifications. *) Requirement after refusal laboratory compaction to BS 594: 2003.

TABLE 4203/5 DESIGN REQUIREMENTS FOR COMBINED AGGREGATE AND MIX PROPERTIES FOR COLD MIXED BITUMINOUS BASE COURSE Property of mixture and laboratory test method Marshall stability tested at 400C, (N) BS EN 12591: 2000 Marshall flow tested at 400C, (mm) ASTM D 1559-89 Minimum E-modulus tested at 290C by indirect tensile strength method or alternative approved methods, (MPa) ASTM D 3967 Minimum moisture content at the time of laying, (%) Maximum moisture content at the time of laying, (%) Minimum compacted field density, (% of Marshall dry density). FBMIX BEMIX (% passing) (% passing) 6000 4500 2-4 1600 2-4 1200

4205 CONSTRUCTION EQUIPMENT

(a) General The Contractor shall submit to the Engineer full details of the Construction Equipment he/she proposes to use and the procedures he/she proposes to adopt for carrying out the Permanent Works. The Engineer shall have access at all times to construction equipment for the purpose of inspection. All equipment shall so be designed and operated to produce a mixtures complying with the requirements of this specification. The construction equipment used in the mixing, transportation, laying, and compaction of bituminous materials shall be of adequate rated capacity, in good working order and subject to approval by the Engineer. Obsolete and worn-out equipment will not be allowed onsite. Prior to the start of the work the Contractor shall supply the Engineer with copies of the manufacturer's handbooks and copies of check lists where applicable pertaining to the mixing, remixing and paving equipments, containing details of the correct settings and adjustments of the equipment. Any alteration which has been or is being effected to any construction equipment, and which does not comply with the specifications of the manufacturer, shall be brought to the notice of the Engineer. (b) Mixing equipment (i) General Mixing of the bituminous mixture shall be carried out in appropriate equipment acceptable to the Engineer.

Mix design moisture less 1.5% points Mix design moisture plus 0.5% points 96%

4204 COMPOSITION OF MIXTURES FOR BITUMINOUS BASE COURSE AND SURFACING

The rates of application and mix proportions of bituminous binder, aggregates and fillers which are given in this SPECIFICATION are nominal rates and proportions and shall only be used for tendering purposes. The rates and proportions actually used shall be determined to suit the materials used and conditions prevailing during construction and any approved variation on a nominal mix in the bitumen content or active filler content shall be the subject of an adjustment

(ii) Stationery or portable mixing equipment Bituminous mixture shall be mixed by means of an approved type mixer of proven suitability for producing a mixture complying with all the requirements of the Specifications. The mixing equipment may be either automatically or manually controlled. Two control operators shall be provided. The heating system of the tanks storing the binder shall be so designed that the binder will not be degraded during heating. A circulating system for the binder shall be provided which shall be of adequate size to ensure the proper and continuous circulation between storage tanks and mixer during the entire operating period. Binder storage tanks shall be fitted with thermometers designed to provide a continuous record of the temperature of the binder in the tank. Copies of these records shall be supplied to the Engineer on a daily basis. Satisfactory means shall be provided to obtain the proper amount of binder in the mix within the tolerances specified, either by weighing or volumetric measurements. Suitable means shall be provided for maintaining the specified temperatures of the binder in the pipelines, weigh buckets, spray bars and other containers or flowlines. In the case of a drum type mixer, the system shall control the cold feeding of each aggregate fraction and of the filler by mass, by means of a load cell or another device regulating the feed automatically, and by immediately correcting any variation in mass which results from moisture or from any other cause. The cold feed shall be regulated automatically in regard to the binder feed so as to maintain the required mix proportion. Suitable dust collecting equipment shall be fitted to prevent pollution of the atmosphere in accordance with the provisions of any local Act governing pollution. The fuel chosen and control of the burner shall be such as to ensure the complete combustion of the fuel in order to prevent pollution of the atmosphere and the aggregate. (iii) Recycling In addition to the requirements set out in CLAUSE 4205 the mixing equipment shall be specially adapted to deal with recycling and any such adjustments shall be in accordance with the instructions of the manufacturer of the mixing equipment on the approval of the Engineer. The recovered asphalt portion of the mix shall not be exposed directly to the heating source whilst the feeding rate and proportioning shall be accurately controlled. Before work is commenced, the Contractor shall submit full details of his/her mixing equipment to the Engineer for his/her approval. (c) Spreading equipment, pavers The bituminous base course shall be laid by an appropriate type of self-propelled mechanical spreader of a type approved by the Engineer and shall be kept in a good running condition and adjusted correctly according to the manufacturers specifications. The pavers shall be equipped with a powerful tamper and vibrating screed. The pavers shall be capable of laying the material to widths, lines, grades cross-fall and thickness within the specified tolerances without causing separation, dragging or other surface defects.

All pavers used for laying Permanent Works shall be fitted with automatic electronic screed controls to maintain the required levels, cambers and cross-falls. Where skids are used they shall be at least 9m long or as specified by the Engineer. The paver shall be constructed in such a manner that the asphalt can be tipped from the trucks into the hopper without any spillage. Where levelling beams on multiple skids or sliding beams are used they shall be at least 9 m long. (d) Rollers, general requirements Compaction shall be done by means of approved flat steel wheeled, vibratory or pneumatic-tyred rollers, sufficient in size and numbers to achieve the specified density through the entire depth of the layer. Minimum one roller shall be pneumatic tyred with a weight of minimum 2.5 tonnes per wheel and not less than 18 tons total un-ballasted weight. The frequency as well as the amplitude of vibratory rollers shall be adjustable. Vibratory rollers shall be used only where there is no danger of damage being done to the layer, structures of bridge decks, or other layers. It will be indicated in the Special Specifications whether vibratory compaction equipment may be used on bridge decks and what the constraining parameters will be. The rollers shall be self-propelled and in good working condition, free from backlash, faulty steering mechanism and worn parts. Rollers shall be equipped with adjustable scrapers to keep the drums clean and with efficient means of keeping the wheels wet to prevent mixes from sticking to the rollers. No leakage of any nature may occur in the rollers. Rollers shall not be left stationary on fresh mat, compacted or not. (e) Binder distributors Where bituminous binders are to be sprayed onto areas before laying the asphalt is done, the binder distributors shall comply with CLAUSE 4103. (f) Vehicles All vehicles used for transporting asphalt shall be insulated. Delivery trucks should be fitted with rear spill trays to facilitate transfer of material to paver without spillage. All vehicles used for transporting asphalt shall be fitted with canvas for transport in excess of 10 km or when weather conditions demand such cover in the opinion of the Engineer. Such covers shall be securely fixed over the asphalt from time of departure at the storage or mixing equipment until immediately prior to discharge of the asphalt into the paver. (g) Construction equipment for recycled asphalt Construction equipment for producing, hauling and placing the recycled asphalt shall comply with the provisions of Subclauses 4204(a) to 4204(f), as applicable, and subject to the following additional requirements: The mixing equipment shall be capable of producing asphalt mixes with or without recovered material. Where necessary, the mixing equipment shall be specially adapted to deal with recycling, and any such adjustments shall be made in accordance with the instructions of the manufacturer. The equipment, with any necessary adjustments, shall be so designed, equipped and used that the measuring, heating and mixing of the material will give a uniform asphalt mix which complies with all the specified requirements in regard to temperatures within the limits necessary for properly placing and compacting

the asphalt in accordance with the specified requirements. Before work is commenced, the Contractor shall submit full particulars of his/her mixing equipment to the Engineer.

4206 GENERAL LIMITATIONS AND REQUIREMENTS AND THE STOCKPILING OF MIXED MATERIAL
(a) Weather conditions (i) General Bituminous material may be mixed and placed only under favourable weather conditions, and shall not be mixed or placed when rain is imminent or during wet conditions. (ii) Hot mixes (AC [Marshall & SuperpaveTM Mixes], DBM) The following wind and temperature conditions are regarded as being suitable for paving work with hot mixed material: While the air temperature is rising, work may be performed at temperatures of: 6C with an allowable wind velocity of less than 25 km/h 10C with an allowable wind velocity of less than 55 km/h, or for asphalt with a compacted thickness of less than 30 mm with an allowable wind velocity of less than 25 km/h. With falling air temperatures, work must be stopped when the temperature reaches 6C regardless of the wind velocity and may not be restarted before the temperature is definitely rising. (iii) Cold mixes (FBMIX, BEMIX) The Contractors attention is drawn to the fact that cold mixed material is likely to be pervious until sealed. Damage to unsurfaced layers may occur in wet weather. Due allowance should be provided in the programme of works during rainy seasons, such that exposure of un-sealed layers are kept to a minimum. Time limits for the laying operation are given in SUBCLAUSE 4212(b). The time limits are applicable only in dry weather working conditions. Allowance to weather conditions in the programme of works may include reduction of these maximum time limits and/or complete stoppage of the laying operations in wet weather. (b) Moisture content The mixing and placing of asphalt will not be allowed if the moisture content of the aggregate affects the uniformity of temperature or if free water is present on the working surface, or when the moisture content of the underlying layer, in the opinion of the Engineer, is too high. No surfacing shall be placed unless the moisture content of the upper 50 mm of the base course is less than 50% of the optimum moisture content as determined by the Engineer. No overlay shall be placed immediately after a rainy spell on an existing partly cracked and/or highly permeable surfacing resulting in the trapping of moisture in the pavement structure. A minimum delay of 24 hours or such extended period as ordered by the Engineer shall apply. (c) Surface requirements (i) General Any defects of the surface shall be made good and no bituminous material shall be laid until the surface has been approved by the Engineer.

(ii) Correction of base courses, or subbase in the case of bituminous base course. The base course (after the prime coat has been applied) or the subbase, as the case may be, shall be checked for smoothness and accuracy of grade, elevation and cross section. Any portion of the base or subbase, as the case may be, not complying with the specified requirements, shall be corrected with asphalt at the Contractor's own expense, until the specified requirements are met. The Engineer may, however, in his/her sole discretion, allow minor surface irregularities to remain, provided they can be taken up in the following asphalt layer without adversely affecting that layer. The bituminous material used for the correction of the base or subbase, shall be the same mixture as specified for the surfacing or as directed by the Engineer, and the maximum size of aggregate used shall be dictated by the required thickness of the correction in each case. Notwithstanding these provisions for the correction of the base or subbase, the Engineer reserves the right to order the removal and reconstruction of the layer or of portions of the base and subbase layers not complying with the specified requirements, instead of allowing the correction of substandard work with asphalt material. (iii) Cleaning of the surface Immediately before applying the tack coat, or where there is no tack coat, before the application of the asphalt, the surface shall be cleaned of all loose or deleterious material by means of a rotary broom, and hand brooms, compressed air or as required to the satisfaction of the Engineer. Where the prime coat (if any) has been damaged, it shall be repaired by hand brushing or spraying priming material over the damaged portions. The prime coat shall be sufficiently dry before the tack coat and/or the asphalt may be applied. The Contractor's programme shall allow for delays that are a function of the type of prime, rate of application, base porosity and moisture content, and climatic conditions. (iv) Tack coat A tack coat shall be applied to the surface to be paved in accordance with the specifications,and drawings or as instructed by the Engineer, The tack coat shall consist of a stable-grade bituminous emulsion diluted to have a 30% bitumen content and shall be applied at a rate of 0.55 l/m 2 or as directed by the Engineer. The use of hand operated equipment for the application of tack coats shall be at the sole discretion of the Engineer. Portions of kerbing and guttering, bridge kerb and railing which will be exposed, shall be protected in terms of SECTION 2300 when the tack coat is applied. The tack coat shall not be applied more than 24 hours before the paving is done. (v) Preparation for placing overlays The provisions of SECTION 4800 shall apply to any surface to be covered with overlays. The type of treatment to be applied, if any, will be specified in the Special Specifications or instructed in writing by the Engineer.

(vi) Preparation where asphalt layers are to be widened or where surfacing over a section of the road width requires replacement. The existing asphalt shall be removed as described in SECTION 3800, where applicable, or as instructed by the Engineer. Where a road has to be widened, the overlay shall be cut back not less than 100 mm from the existing edge. Unless otherwise indicated on the Drawings or instructed by the Engineer. Asphalt joints may not fall within a wheel track. (d) Storage (i) Hot mixes (AC, [Marshall & Superpave TM Mixes] DBM) Mixing shall not be allowed to take place more than four hours before paving begins unless provision has been made for storage. Storage of mixed material will only be permitted in approved hoppers, which are capable of maintaining the temperature of the mix uniform throughout. in any case storage will not be permitted for a period longer than 12 hours after mixing, unless otherwise approved by the Engineer. (ii) Cold mixes (FBMIX, BEMIX) The material for use in Permanent Works shall not be laid on the same day as it is mixed unless otherwise approved by the Engineer. The length of time for mixed material to remain in stockpile before laying in Permanent Works shall not be more than 7 days after mixing. Should the Contractor propose to use material which has been stockpiled for longer than 7 days, then the Engineer may allow a trial section to be constructed if the proposal is to his/her satisfaction. The Engineer may subsequently allow the material to be used in Permanent Works if the outcome of the Trial Section is to his/her satisfaction. All equipment used for stockpiling and transportation of the mixture shall have buckets that are cleaned of all foreign material, fuel, lubricants or other contamination before use.

(1) Heating the aggregate The aggregate shall be dried and heated so that, when delivered to the mixer, its temperature shall be between 0C and 20C lower than the maximum temperature indicated in TABLE 4207/1 for the mixture. The moisture content of the mix shall not exceed 0.5%. (2) Batching Each fraction of the aggregate and binder shall be measured separately and accurately in the proportions by mass in which they are to be mixed. If filler is used, it shall be measured separately on a scale of suitable capacity and sensitivity. The error in the weighing apparatus used shall not exceed 2% for each batch. (3) Mixing The aggregate, filler and binder shall be mixed until a homogeneous mixture is obtained in which all particles are uniformly coated. Care shall be taken to avoid excessively long mixing times which can cause hardening of the binder. (ii) Hot mixes using drum-type mixer equipments The aggregate and filler shall be accurately proportioned and conveyed into the drum-mixing unit. The calibrated amount of binder shall be sprayed onto the aggregates at the correct position so that no hardening of the binder shall take place. A homogeneous mixture and uniform coating of binder must be achieved and the moisture content of the asphalt mixture shall not exceed 0.5%. Once the final mix temperature has been agreed upon it may not be altered without the prior consent of the Engineer. (iii) Cold mixes using stationary, portable or in-situ mixing equipment Mixing of bituminous base for use in Permanent Works shall only be carried out in mixing equipment approved by the Engineer and on the basis of an approved mix design. Any proposed change of mix design for use in Permanent Works shall be notified to the Engineer for his/her approval minimum 7 days in advance of proposed use. The length of time for storage of additives from the moment of mixing with hot bitumen until mixed with aggregates shall be limited to maximum 2 hours, unless otherwise approved by the Engineer. Such approval shall be subject to proof that adhesion properties are adequate at the time of mixing bitumen with aggregate. (c) Transporting the mixture The mixture shall be transported from the mixing equipment to the Works in trucks complying with the requirements of CLAUSE 4205. Deliveries shall be made so that spreading and rolling of all the mixtures prepared for a days run can be completed during daylight, unless artificial lighting, as approved by the Engineer, is provided. Any asphalt which has become unusable in the opinion of the Engineer due to rain or any other cause will be rejected. Hauling over freshly laid material is not permitted. The mix at delivery to the paver shall be not more than 10C below discharge temperature at the mixing equipment. The minimum temperature for the commencement of breakdown rolling shall be determined on trial sections. Mix loads of temperature less than the minimum temperature shall be disposed of. If there is consistent failure to meet the temperature requirement the paving operations shall be suspended until suitable measures are taken by the Contractor to ensure that the temperature requirements are met.

4207 PRODUCING AND TRANSPORTING THE MIXTURE

(a) Mixing and storage temperatures of binder Bituminous binders shall be stored at temperatures not exceeding those given in TABLE 4207/1 or the Special Specifications, and the aggregate and bituminous binders shall be heated at the mixing equipment to such temperatures that the mixed product shall have a temperature within the range given in TABLE 4207/1. TABLE 4207/1 TEMPERATURE RANGES FOR BITUMINOUS BINDERS Bitumen type, pen. grade Max. storage temperature of binder (C ) Over Under 24 hrs 24 hrs 145 175 135 175 Temperature range of mix (C ) Continuously graded mixes 140-165 135-160

40/50 pen 60/70 pen

(b) Production of the mixture (i) Hot mixes using batch equipments

Hauling equipment for bituminous mixes shall have isolated, tight, clean and smooth beds, which are periodically coated with a lime solution or other approved material to prevent adherence of the mix. All hauling units shall be equipped with a canvas or other approved type of cover which shall be used to cover the material upon loading at the mixing equipment and shall not be removed until the mix is discharged into the paver. The Engineer may instruct that hauling equipment shall have an engine exhaust system blowing the gas vertical not to cause inconvenience to the paving crew. (d) Recycled asphalt The provisions of SUBCLAUSES 4207(a) to 4207(c) shall apply with changes as required. At least four weeks before paving with recycled material will commence, the Contractor shall submit to the Engineer full particulars regarding the recycling methods he/she intends to use. Where recovered asphalt material is taken from a stockpile, it shall be done by excavating from the pile over its full depth. Where segregated material is fed into the mixing equipment, the Engineer will have the right to order the work to cease and to instruct the Contractor to remix the stockpile, retest the mixed material and redesign the asphalt mixture all at his/her own cost.

On restricted areas, inaccessible to the paving equipment used, the mixture may be placed by hand or other means to obtain the specified results. Paving shall be carried out in a manner which will avoid segregation and which will allow control of levels. Paving shall be carried out with good workmanship for such operations. This requirement includes, but is not restricted to, particular attention to the following: paving shall commence at the bottom of the grades and the lower edges of superelevated curves paving shall be done upgrade on grades steeper than 5% the paver shall be operated in a manner that provides the maximum possible degree of compaction exerted by the screed, evenly distributed across and along the layer. spreading shall be so arranged that longitudinal joints do not coincide with joints in lower layers of asphalt base or surfacing. The mixture shall be delivered continuously to the paver to avoid stop-go paving operations. The temperature of the mixture shall be controlled by measuring in a random pattern in the truck immediately before emptying, and shall not be less than the minimum temperature defined during the trial section. The adjustment of the screed, tamping bars, feed screws, hopper feed, etc. shall be checked frequently to ensure uniform pre-compaction and spreading of the mixtures. If segregation occurs, the spreading operations shall immediately be suspended until the cause is determined and corrected. The pavers shall be equipped with 60 sloped sideplates on the screed to confine and to form a stable and neat permanent outer shoulder edge. Spreading shall be so arranged that longitudinal joints do not coincide with joints in the lower layers. (iii) Base course thickness paved in one operation Base course with a compacted thickness greater than 100 mm may only be placed to its full thickness in one layer if site trials show that satisfactory finish, evenness and compaction of the full thickness can be achieved and the result is to the satisfaction of the Engineer. (iv) Base course thickness, first layer No bituminous base course material shall be placed as the first layer of the base course in a compacted thickness less than 60 mm or less than three times the aggregates maximum particle size, whichever is smaller. (v) Base course thickness, following layers Following layers to be placed on freshly laid bituminous base course layers may be placed in a compacted thickness less than the above subject to satisfactory results of site trials and on approval of the Engineer, but not less than twice the maximum aggregate size for materials. (vi) Weather Paving shall stop when rain is imminent and compaction of all laid material shall be completed immediately. (vii) Hot mixes, special requirements The temperature of hot mixtures shall be controlled by measuring in a random pattern in the truck immediately before emptying, and shall not be more

4208 SPREADING THE MIXTURE

(a) General (i) The paver, general The paver shall be kept in good working order, and adjustment of the screed tamping bars, feed screws, hopper feed, etc, shall be checked frequently to ensure uniform spreading of the mix. If segregation or other imperfections occur, the spreading operations shall immediately be suspended until the cause is determined and corrected. The mixer capacity and the operating speed of the paver are to be so co-ordinated as to ensure continuous laying and to avoid intermittent stopping of the paver. Unless otherwise stated in the Special Specifications the paver shall be equipped to provide automatic control of levels and cross section. In the case of asphalt base construction, automatic control shall be run off guide wires and in the case of surfacing and overlays skids or guide wires shall be used. (ii) Workmanship The bituminous layer shall be laid and compacted in one or more layers giving a total thickness as specified. The addition and removal of material behind the paver shall normally not be allowed and the paver shall be capable of spreading the mixture to the correct amounts that will provide the required compacted thickness and surface evenness without resorting to spotting, picking-up or otherwise shifting or disturbing the mixture. Repairs to joint and isolated surface irregularities may be carried out by hand or other suitable methods at a thickness other than the above, subject to approval of the Engineer.

than 10C below the minimum specified for mixing in TABLE 4207/1.

temperature

(viii) Cold mixes: special requirements No cold mixed bituminous base course material shall be laid unless the moisture content is within the specified limits. Should the moisture content of stockpiled materials fall outside these limits, the Contractor may propose methods to bring the moisture content back to comply with the requirements. The Engineer may then allow a Trial Section as described in CLAUSE 4211 to be constructed if the proposal is to his/her satisfaction. The Engineer may subsequently allow the material to be used in Permanent Works if the outcome of the Trial Section is to his/her satisfaction. (b) Overlays In the case of overlays, guide wires will be required during the placing of the mix if so specified in the Special Specifications. In all cases, including levelling courses, the paver shall be provided with skid beams with electronically controlled equipment which can ensure a constant crossfall and can even out local irregularities. (c) Restricted areas Bituminous material shall be placed in restricted areas with the aid of smaller specially equipped pavers, hand tools, or other approved equipment. The space concerned shall be properly filled with asphalt, without leaving any gaps between the fresh asphalt and existing pavement layers. All the relevant provisions in regard to temperature, mix composition, uniformity, etc, shall remain applicable, but layer thickness and control shall be such that the requirements for compaction and surface tolerances can still be attained where bituminous material is laid in restricted area. (d) Recycled asphalt The provisions of SUBCLAUSES 4208(a) to 4208(c) shall apply unless otherwise stated below. Where the average thickness of a completed asphalt layer exceeds the specified thickness, and/or recovered asphalt has been wasted indiscriminately, and, if in the opinion of the Engineer it has resulted in a deficiency of recovered material, the Contractor shall supplement such deficiency at his/her own cost with a quantity of similar or better material equal to the quantity wasted, as determined by the Engineer.

Joints shall be neat and shall have the same texture and density as the remainder of the asphalt course. All joints shall be marked out with chalk lines prior to cutting. The outside edges of the completed asphalt course shall be trimmed along the shoulder, and parallel to the centre line, to give a finished width, as shown on the Drawings, within the tolerances specified. Any fresh mixture spread accidentally onto existing work at a joint shall be carefully removed by brooming it back with stiff brooms onto the uncompacted work, so as to avoid the formation of irregularities at the joint. Whenever the paving operation is stopped due to lack of mixture, the Contractor shall form a proper joint as specified above, if so directed by the Engineer. The paved pre-compacted "over height" after the screed shall be carefully determined on the trial sections (with e.g. 10, 20 and 30 mm over height) and properly implemented for satisfactory joint construction. Joints shall have the same texture and density as the remainder of the asphalt course.

4210 COMPACTION
The mix shall be rolled immediately after it has been laid by vibratory, steel wheel and pneumatic-tyred rollers in a sequence predetermined and approved during the laying of trial sections. Such rolling shall commence and be continued only for so long as it is effective and does not have any detrimental effect. The use of pneumatic-tyred rollers for continuously-graded non-homogeneous modified binders shall be assessed in the trial section. As many rollers shall be used as are necessary to provide the specified pavement density and the required surface texture. During rolling of surfacing only, the roller wheels shall be kept moist with only sufficient water to avoid picking up the material. After longitudinal joints and edges have been compacted, rolling shall start longitudinally at the sides and gradually progress towards the centre of the pavement, except on super-elevated curves, or where the area to be paved has a straight cross-fall, when rolling shall begin on the low side and progress to the higher side, uniformly lapping each preceding track, covering the entire surface. During breakdown rolling, the rollers shall move at a slow but uniform speed (not to exceed 5 km/h) with the drive roller nearest the paver, unless otherwise specified on account of steep gradients. No movement of the asphalt layer shall occur under steel wheel rollers once the asphalt temperature has dropped to below 100C. Three-wheeled steel rollers, with large diameter rear wheels are preferable to tandem rollers and may be used in conjunction with pneumatic tyred rollers, provided pick-up of the asphalt on the wheels does not occur. The sequence of rollers used in compaction is at the discretion of the Contractor provided the completed pavement shall have a density as measured on recovered cores equal to or greater than the nominal density specified in Table 7114/2 and assessed by the statistical method defined in SECTION 7200. The Contractor shall utilise a calibrated nuclear gauge for process control during compaction operations. Notwithstanding this requirement, the acceptance control carried out for compaction by the Engineer, shall still be based on cores taken from the compacted layer. The nuclear device shall: be operated by a suitably trained technician. comply with all the safety regulations of the relevant regulatory Authority.

4209 JOINTS
All joints between adjacent sections of the work shall be made by cutting back the layer against which the material is to be placed unless otherwise approved by the Engineer. All loose and incompletely compacted material shall be removed. A cutting wheel shall be used for cutting longitudinal joints. Joints shall be either at right angles or parallel to the centre line, and joints in the final layer of the surfacing shall, where possible, correspond with the lane markings. Joints in lower layers shall be offset not less than 150 mm on either side of the edges of the traffic lanes. Before a new layer is placed next to an existing layer, the cut edge of the existing layer shall be painted with a coat of bituminous emulsion of the same type and application rate as used for the tack coat.

be certified to be suitably calibrated.

The portion of trial section having the desired surface texture shall be designated as a reference for what is required in the permanent work. The following requirements shall apply to rolling and compacting generally: The material shall not be excessively displaced in a longitudinal or transverse direction especially when changing gears, stopping or starting rollers. No cracks or hair cracks shall be formed and the bond with the underlying layer shall not be broken. The density shall be uniform over the whole area of the layer and extend over the full depth of the layer. Rollers shall not be left standing on the asphalt layer before it has been fully compacted. In restricted areas where the specified rollers cannot be used, compaction shall be carried out with hand-operated mechanical compaction equipment or approved smaller vibratory rollers. The prescribed density requirements remain applicable throughout, over the full layer thickness, irrespective of the method of compaction. An adequate number of roller passes shall be used to provide the specified pavement density. The density shall be uniform over the whole area of the layer, as well as at the joints after approximately 10 cm backcutting of tentative free edges. The tyre pressure of pneumatic-tyred rollers shall be adjusted to the maximum that the mixture can carry without excessive displacement of the asphalt layer. The Contractor shall, when necessary only employ approved slippage agents for the rollers. Diesel will under no circumstances be accepted. The provisions of CLAUSE 4210 shall apply with changes as required, and with the approval of the Engineer, to recycled asphalt.

trial sections be laid before allowing the Contractor to continue with the permanent work. Any work that does not comply with the Specifications shall be removed or made good to comply with the Specifications to the satisfaction of the Engineer. The trial sections shall be laid where indicated by the Engineer. The Contractor shall prepare the surface on which to lay the trial section and shall also, if required by the Engineer, remove the trial section after completion and restore the surfaces on which it was constructed, at his/her own cost. The Contractor shall for each trial section prepare a plan for execution of the trial. It shall at least include the following subjects: date and time, location, sketch of location, type of asphalt preparation of surface, spray rate of tack coat or prime coat and curing time mixing and paving temperature, cooling rate, infrared camera photos and locations for temperature control paving speed, tamper settings and type/angle of screed side plates illustrate intended rolling pattern for at least 3 levels of compaction efforts (medium, high and extra high) and describe methods to record and control number of passes and the rolling pattern actually used joint construction method, over height of the second paving lane, control of the over height core drilling and test programme for testing of the mix and the finished pavement. The programme shall include recovered binder and mix properties, wheel track rutting test programme for instruction of every person involved in the trial section. The activity plan for the trials shall be forwarded to the Engineer for approval not less than 7 working days before the planned trials. The Contractor shall assess back-cuttings and separately document that finished joints satisfy the compaction requirements by taking asphalt cores at a distance of 50 mm from joints and tentative free edges. The trial sections shall include continuous measurements of asphalt temperatures to determine the rate of cooling and the time available for compaction. No payment shall be made for trial sections and the Contractor must allow for all costs in his/her rates.

4211 LAYING TRIAL SECTIONS

A trial section of minimum 50 m length shall be constructed prior to the use of any new mix design, when there are changes in the type or numbers of construction equipment, or as required by the Engineer. The Trial Section shall demonstrate that the materials, equipment and procedures proposed are adequate to achieve a bituminous layer in accordance with the Specifications and to the satisfaction of the Engineer. Any bituminous material laid in a trial area that forms part of the Permanent Works and subsequently found unacceptable, shall be removed or made good to comply with the Specifications. The Engineer may require a number of different binder contents, and a number of different moisture contents in the case of cold mixed material, to be incorporated in one such trial section to verify the laboratory design recipe. Cores extracted from the completed trial section and in locations determined in a stratified randomly sampled manner. Only when such a trial section has been satisfactorily laid and finished, and complies with the specified requirements will the Contractor be allowed to commence with construction of the permanent work. If the Contractor should make any alterations in the methods, processes, equipment or materials used, or if he/she is unable to comply consistently with the Specifications, the Engineer may require that further

4212 PROTECTION AND AFTERCARE

(a) General The Contractor shall protect the bituminous base course and asphalt surfacing from all damage until the work is finally accepted by the Employer and he/she shall maintain the surfacing work until the issue of the taking over certificate. Any damage occurring to the completed base or surfacing, excepting fair wear and tear on surfacing during the defect liability period, or any defects which may develop due to faulty workmanship, shall be made good by the Contractor at his/her own expense and to the satisfaction of the Engineer. Traffic can under normal conditions be allowed on to the fresh layer immediately after compaction is completed unless otherwise directed by the Engineer. (b) Special requirements for cold mixed base course material Traffic can under normal dry conditions be allowed on the fresh layer immediately after the compaction is completed unless otherwise directed by the Engineer.

Where the base course is placed in more than one layer, no more than 7 days shall elapse between completion of consecutive layers. No more than 14 days shall elapse from completion of the base course until the surface dressing is constructed. The time limits in the above paragraph are applicable only in dry weather working conditions. The Contractors attention is drawn to the fact that the material is likely to be pervious until sealed. Damage to unsurfaced layers may occur in wet weather. Due allowance should be provided in the programme of works during rainy seasons, such that exposure of un-sealed layers are kept to a minimum. This may include reduction of the above maximum time limits and/or complete stoppage of the laying operations in wet weather. If the times specified above are not adhered to the Contractor shall place tack coat or priming in accordance with this Specification on approval of the Engineer without additional costs to the Employer. Approved crusher dust or clean sand shall at no additional costs to the Employer be evenly spread at a rate of 0.005 m3/m2 immediately following the spraying of tack coat. Notwithstanding the above, construction of consecutive layers or surface dressing shall not be unduly delayed. In no case shall more than 90 days elapse since completion of the previous layer.

TABLE 4213/2 AGGREGATE AND FILLER GRADING FOR BITUMINOUS BASE

COURSE MATERIALS

Size of aggregate: Material passing through the following sieves (mm) Sieve 5 mm and larger Sieve smaller than 5 mm and larger than 0.075 mm Sieve 0.075 mm

Permissible deviation from the approved target grading Individual sample Average of three consecutive samples 10 5

15 10

(c) Binder content (i) Hot mixed material The binder content shall be controlled to comply with the limits given in CLAUSE 7205. Cold mixed material The maximum accepted deviation in bitumen content of cold mixed bituminous base course material compared to that of the approved Mix Design is given in TABLE 4212/3 or according to the Special Specifications.

(ii)

4213 CONSTRUCTION TOLERANCES AND FINISH REQUIREMENTS

(a) Construction tolerances Construction tolerances and finish shall meet all relevant requirements in SECTION 7300. The riding quality of the final layer shall be to the satisfaction of the Engineer. (b) Grading The combined aggregate and filler grading shall not deviate from the approved target grading for the working mix by more than that given in TABLES 4213/1 and 4213/2 respectively for Asphalt Concrete surfacing and bituminous base course materials. TABLE 4213/1 AGGREGATE AND FILLER CONCRETE SURFACING Size of aggregate: Material passing through the following sieves (mm) 37.5 28 20 14 10 6.3 5 2.00 1.18 0.600 0.300 0.150 0.075

TABLE 4213/3 ACCEPTANCE LIMITS FOR BITUMEN CONTENT FOR COLD MIXED BITUMINOUS BASE COURSE MATERIALS Size of sample, number of tests (no) Max. deviation of sample average from the specified bitumen content (in % bitumen) 0.30 0.28 0.26 0.24 0.22 0.20 Max. deviation of any single value from the specified bitumen content (in % bitumen) 0.70 0.68 0.66 0.64 0.62 0.60

GRADING

FOR

ASPHALT

5 or less 6 7 8 9 10 or more

Permissible deviation from the approved target grading 4.0 4.0 5.0 5.0 5.0 5.0 4.0 4.0 4.0 4.0 3.0 1.5

4214 SAMPLING AND TESTING

(a) General All sampling and testing shall be carried out in accordance with sampling and testing standards laid down in the standards of the Central Materials Laboratory or equivalent approved by the Engineer, and shall be carried out to adequately show compliance with the Specifications. (b) Coring of asphalt layers The Contractor shall provide suitable coring machines capable of cutting 100 mm diameter cores from the completed asphalt layers. The cost of extracting cores for process control in accordance with the Specifications shall be included in the Contractor's prices for the construction of asphalt pavement layers and will not be paid for separately.

Cores in the carriageway lanes shall be taken at the outer permanent edge, at the centre of the paved lane and at the longitudinal joint. Cores at the outer edges and at the joints shall be taken 50 mm from the edge after back-cutting as directed. Cores in the shoulders shall be taken 300 mm from the outer shoulder edge and 50 mm from the longitudinal joints to the carriageway pavement. All core holes shall be neatly repaired with asphalt and compacted to the specified density. The cores shall be filled with the same mix as used for the layer tested. (c) Laboratory testing Testing shall be carried out by the Contractor at the site laboratory or an external laboratory approved by the Engineer. All operations of the testing shall be available for inspection by the Engineer at all times and the Contractor shall give notice well in advance of all testing as required by the Engineer. All test results shall at all times be available to the Engineer. All test results representative for Permanent Works shall meet the relevant requirements in the Specifications within the tolerances specified and shall be approved by the Engineer. In case the tests disclose non-conditional properties of the test specimens, additional tests shall be carried out by the Contractor as required by the Engineer. Test results (laboratory readings and measurements) as well as calculated results in digital form shall be submitted daily to the Engineer in continuously updated summary sheets.

specified and accepted by the Engineer. The quantity calculated from the recipe of the mix design, at asphalt density, shall be used in the calculation of the binder quantity. A new mix design and recipe shall be prepared if, in the opinion of the Engineer, this is warranted due to significant variations in mix density or other material properties The bid rate for bituminous mixes shall include for procuring, preparing the surface to the satisfaction of the Engineer, providing, heating, drying or adding water as required, mixing, transporting, laying and compacting the mix in accordance with the Specifications and to the satisfaction of the Engineer. The rate shall also include for trials sections, process control testing, protecting and maintaining the work as specified. No payment will be made for material wasted. ITEM 42.03 TACK COAT OF 30% STABLE
GRADE BITUMEN EMULSION

UNIT
LITRE

(l)

The unit of measurement shall be the litre of 30% stablegrade bitumen emulsion applied as specified. The bid rate shall include for the cleaning the surface to the satisfaction of the Engineer, procuring, furnishing and application of the material as specified. ITEM 42.04 ADDITIVES (STATE TYPE) UNIT
KILOGRAMME

(kg)

4215 MEASUREMENT AND PAYMENT

ITEM 42.01 BITUMINOUS BASE COURSE:
CUBIC METRE

UNIT

Additives except binder, aggregate, filler or water shall be paid for separately where these are specified or instructed by the Engineer. The quantity shall be calculated as the kilogram used in accordance with the recipe of the mix design, on approval of the Engineer.

(a) HOT MIX (STATE TYPE, MAXIMUM COMPACTED THICKNESS, TYPE OF

BITUMEN AND MAXIMUM SIZE OF AGGREGATE)

(m3)

(b) COLD MIX (STATE TYPE, MAXIMUM COMPACTED THICKNESS, TYPE OF

BITUMEN AND MAXIMUM SIZE OF AGGREGATE)

CUBIC METRE

(m3)

(c) BITUMEN FOR BITUMINOUS BASE COURSE MIXES (STATE TYPE OF BITUMEN)

TONNES

(t)

ITEM 42.02 ASPHALT CONCRETE SURFACING: (a) ASPHALT CONCRETE SURFACING (STATE TYPE OF BINDER AND MAXIMUM SIZE OF AGGREGATE) (b) BITUMEN FOR ASPHALT CONCRETE SURFACING (STATE TYPE OF BITUMEN)

UNIT

CUBIC METRE

(m3)
TONNES

(t)

The unit of measurement for bituminous mixes shall be the cubic metre constructed to the thickness specified, compacted on the road as specified, 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 binder for asphalt concrete surfacing is paid for separately for material produced and placed as

SERIES 4000: BITUMINOUS LAYERS AND SEALS

SECTION 4300: GENERAL REQUIREMENTS FOR SEALS

CONTENTS:
CLAUSE 4301SCOPE 4000-24 4302MATERIALS 4000-24 4303CONSTRUCTION EQUIPMENT 4000-27 4304GENERAL LIMITATIONS AND REQUIREMENTS 4000-28 4305HEATING AND STORAGE OF BITUMINOUS BINDERS 4000-29 4306STOCKPILING OF AGGREGATE 4000-30 4307CONSTRUCTION OF SEALS 4000-31 4308RATES OF APPLICATION 4000-32 4309DUST CONTROL 4000-32 4310OPENING TO TRAFFIC 4000-32 4311DEFECTS 4000-32 4312MAINTENANCE 4000-32 4313TOLERANCES AND FINISH REQUIREMENTS 4000-32 4314MEASUREMENT AND PAYMENT 4000-33 PAGE

(1) Base bitumen The bituminous binder used in the production of the bitumen-rubber shall be a 60/70, 80/100 or 150/200 penetration-grade bitumen respectively that complies with the requirements of AASHTO M20-70 or equivalent, or a blend of any two or all three grades to provide a product with the required viscosity properties. (2) Rubber The rubber shall be obtained by processing and recycling pneumatic tyres. It shall be pulverised, free from fabric, steel cord and other contaminants. A maximum of 4% by mass of fine particle size calcium carbonate, or talc, may be added to the rubber crumbs to prevent the rubber particles from sticking together. At the time of use the crumbs shall be free flowing and dry and comply with the requirements of TABLE 4302/1. TABLE 4302/1 RUBBER CRUMBS Sieve analysis: Sieve size Percentage (mm) passing by mass 1.18 100 0.60 40-70 0.075 0-5 Other requirements: Natural rubber hydro-carbon 30% (minimum) content Fibre length 6 mm (maximum) Relative 1100-1250 density (kg/m3) *) Refer to SUBCLAUSE 7205 (h) Test Method

BR6T (Sabita) *)

4301 SCOPE
This Section covers the materials, construction equipment, construction and requirements common to the construction of all seals detailed in these Specifications.

BS 903 Parts B11 and B12 BR9T (Sabita) *)

4302 MATERIALS
(a) Bituminous binders (i) Conventional bituminous binders Bituminous binders shall comply with the following specifications or suitable equivalent: Type of binder Penetration grade bitumen: Cutback bitumen: Bitumen emulsions, anionic: Bitumen emulsions, cationic: Invert bitumen emulsion: Specification AASHTO designation M20-70 AASHTO designation M82-75 AASHTO designation M140-88 AASHTO designation M208-96 SANS 1260 / SABS 1260: 1979 (3) Extender oils The extender oil shall be petroleum derived material of high aromaticity and shall comply with the requirements of TABLE 4302/2. TABLE 4302/2 EXTENDER OILS Property Flash point % by mass of saturated hydrocarbons % by mass of aromatic, unsaturated hydrocarbons Requirements 180C 25% (max) 50% (min)

(4) Dilutent The dilutent shall be a distillate of hydrocarbon. (5) Bitumen-rubber blend The bitumen-rubber blend, including extender oil and/or dilutent, it necessary, shall comply with the requirements of TABLE 4302/3. TABLE 4302/3 BITUMEN-RUBBER BLEND Property % rubber by mass of total blend % extender oil by mass of total blend % of dilutent by mass of total blend Blending/Reaction temperature Reaction time Requirements 20% - 24% 6% (max) 7% (max) 170C 210C 0.5 - 2 hours

The type and grade of bituminous binder to be used shall be as specified under the appropriate SECTION of these Specifications for each type of bituminous seal, or in the Special Specifications. (ii) Non-homogeneous (heterogeneous) modified binders If non-homogeneous modified binders are required, they shall comply with the requirements in the Special Specifications. Where applicable the following details will be indicated in the Special Specifications: The bitumen-rubber binder shall comply with the following requirements:

Prior to commencement of the work, the supplier shall state in writing the percentage of rubber and the blending/reaction temperature he/she intends to use for his/her specific product. The actual percentage of rubber shall not deviate by more than 1.0% from the stated value and the actual reaction temperature shall not deviate by more than 10% from the stated value. A continuous record of both percentage rubber added and reaction temperatures shall be kept on site by the Contractor. The bitumen-rubber binder shall comply with the requirements of TABLE 4302/4. TABLE 4302/4 BITUMEN-RUBBER BINDER Property Requirements Test Method (or equivalent method on approval of the Engineer) BR3T (Sabita)

Where applicable the following details will be indicated in the Special Specifications: (1) Type elastomer polymer SBR or SBS. Unless otherwise specified SBR shall be used for bidding purposes. (2) Grade base bitumen 80/100 penetration grade or 150/200 penetration grade. Unless otherwise specified 80/100 penetration grade road grade shall be used for bidding purposes. (3) Modified binder content 65% or 70% unless otherwise specified 65% shall be used for bidding purposes. The aforementioned components together with polymer content will dictate the attributes attainable. Unless otherwise specified, the properties of cationic modified bitumen emulsion containing SBR or SBS solids shall comply with the requirements in TABLE 4302/5 (following page). A volatile solvent flux content of up to 3% mass by mass of the bitumen may be added to enhance emulsion performance with regard to prevailing climatic conditions. Any expected change to specified values shall first be discussed with the Engineer prior to the addition of any such enhancer. The properties of the recovered modified bitumen using a rotary vacuum evaporation method or simple evaporation method as described in CLAUSE 7108 shall be required to comply with the requirements of TABLE 4302/6 (next page). If there is any discrepancy in the test results on recovered modified binder, then the results on recovered binder obtained from the rotary vacuum evaporation method shall be binding. (iv) Homogeneous hot-applied modified binders (summer grades) The requirements for any polymer other than the generic types listed in TABLE 4302/7 (next page) used for the manufacture of homogeneous hot-applied modified binders will be indicated in the Special Specifications. Where applicable the following details will be indicated in the Special Specifications: (1) Generic type (plastomer or elastomer) and type polymer. (2) Grade base bitumen (80/100 or 150/200) required. The aforementioned components together with polymer content will dictate the attributes attainable. (v) Homogeneous hot-applied modified binders (winter grade) Where applicable the requirements for homogeneous modified binders (winter grade) will be specified in the Special Specifications. (b) Aggregates The aggregate shall consist of approved crushed stone or natural material complying with the relevant requirements set out for each type of seal and the grading, flakiness index and hardness and soundness shall be as specified for each nominal size of stone. All aggregates shall be clean and free from dust and other deleterious materials.

Minimum compression recovery: after 5 minutes after 1 hour after 4 hours Ring-and-ball softening point Resilience Dynamic viscosity (Haake at 1900C) Flow (mm)

70% 70% 48-55% Minimum 550C 13%-35% 20 35 cPas

BS EN 12591: 2000 BR2T (Sabita) BR5T (Sabita)

20 75

BR4T (Sabita)

The Contractor shall provide the Engineer with time-temperature ratios in regard to the above properties of his/her specific product before work may start in order to determine the final process and the acceptance limits. The methods of testing bitumen-rubber material have been published in Manual 3 of the Southern African Bitumen and Tar Association (SABITA). If a supplier uses a dilutent, an ageing test may be required in which the binder is placed in an oven for 5 hours at 150C, after which time it shall comply with the above Specifications. The Contractor shall provide the performance record for three recent projects of the materials he/she intends to use in order to assess the successful use of the materials. The information shall include mean values obtained for the prescribed tests as well as any relevant comments. This information shall be submitted at bidding stage. (iii) Homogeneous cold applied modified binders If any polymer other than the elastomer polymers styrene-butadiene rubber (SBR) or styrenbutadiene-styrene (SBS) is required for the manufacture of cationic modified bitumen emulsions it shall comply with the requirements in the Special Specifications.

5. The polished stone value (PSV) when tested in accordance with BS EN 1097-8: 2000 or equivalent shall be at least 50 where this requirement is included in the Special Specifications, unless otherwise specified or approved by the Engineer. The aggregates shall be tested for stripping employing the following method (the rolling bottle method): 8. 1. 2. 3. 4. Heat the bitumen to 163C. Preheat the aggregate for 1 hour at 163C to remove all moisture before blending with bitumen. Mix 150 g aggregate and 4.65 g bitumen manually with a spatula (to make a sample having 3% binder content). Re-heat the mixture for 15 minutes at 163C in a pulvis bottle (250 ml). 6. 7.

Roll the bottle manually 2 minutes and put the coated aggregate in a 500 ml bottle containing 300 g of distilled water. After cooling, remove the water from the bottle and store the cooled sample at room temperature for 24 hours. Fill the bottle with distilled water and roll the bottle containing the sample in the rolling bottle machine for 96 hours. After one week curing in the bottle, wash the sample with fresh water and evaluate the coating degree.

The degree of coating when measured in accordance with the test method described above shall be a minimum 60%. The aggregates shall be washed when it is considered necessary by the Engineer or his/her appointed representative.

TABLE 4302/5 CATIONIC MODIFIED BITUMEN EMULSION Polymer modifier Required properties, grade of base bitumen 80/100 150/200 80/100 150/200 Minimum modified binder content (%) 70 65 70 65 ASTM D244 Minimum viscosity at 50C Saybolt Furol (sec.) 80 70 80 50 ASTM D244 Maximum Particle residue on charge sieving (g/100ml) 0.25 Positive 0.25 Positive 0.25 Positive 0.25 Positive BS EN 1097-8: 2000 Sedimentation after 60 rotations Nil Nil Nil Nil

SBR SBS Test Method

TABLE 4302/6 RECOVERED MODIFIED BITUMEN Polymer modifier Required properties Grade of Mini-mum base Softening bitumen point (C) Elastic recovery (%) at 5C (%)

Minimum dynamic viscosity at 135C (Pa.s)

Mini-mum ductility at 10C (mm)

at 50C (%)

SBR

100 100 SBS 80/100 60 1.2 500 55 100 150/200 47 1.0 500 60 100 Test Method ASTM D36 ASTM DIN 52013 DIN 52013 TMH D4402 method B11 Note: Modified binder is bitumen plus polymer. The dust content criteria shall be according to TABLE 4302/8 grade 2 stone for the adhesion test.

90 90 90 90 DIN 52013

TABLE 4302/7 HOT-APPLIED MODIFIED BINDERS, REQUIRED PROPERTIES Genetic type of modified binder Required properties Minimum Minimum ductility elastic at 10C recovery (mm) 10C (%) 300 1000 500 1000 500 DIN 52013 45 55 60 55 60 DIN 52013

Grade of base bitumen 150/200 80/100 80/100 150/200 150/200 -

Minimum Softening point (C) 48 47 49 45 47 ASTM D36

Plastomerpolymer (EVA) ElastoSBR merpol- SBS ymer SBR SBS Test Method

Minimum dynamic viscosity at 135C (Pa.s) 0.5 1.0 1.0 0.5 0.5 ASTM D4402

Maximum stability difference (C) 2 2 2 2 2 DIN 52013

Minimum adhesion at 5C at 50C (%) (%) 90 90 100 90 90 90 100 TMH 1 Method B11

(c) Slurry (i) Filler for slurry Common cements shall comply with the requirements of US 310-1:2001/EAS 18-1, BS EN 197-1:2000 or equivalent standard on approval of the Engineer. Road lime shall comply with the requirements of US 288:2001, AASHTO M216-92, or equivalent (Lime for Soil Stabilisation). Only one of the above materials shall be used throughout in order to prevent undesirable colour differences in the surface. (ii) Immersion index The immersion index of briquettes made with slurry aggregate and penetration-grade bitumen at the specified net bitumen content for the slurry shall be not less than 75. (d) Hydrophilic aggregates Where hydrophilic or other aggregates which may cause problems are encountered, the Engineer may order that the stone chips be precoated, as described below, or that a fog spray be applied, as specified in SUBCLAUSE 4403(d). (e) Precoating (i) Precoating of aggregate for stockpiling or for immediate use. The method to be employed for the precoating of chippings shall be described in the Special Specifications and be approved by the Engineer. The wetting agent approved by the Engineer shall be added to the precoating fluid at a rate of 0.5% of the volume of precoating fluid. The mixture of aggregate and precoating fluid shall then be dumped on a site prepared as specified in CLAUSE 4306. This process shall be repeated until a stockpile of approximately 15 m 3 to 20 m3 has been built up. This stockpile shall then be turned over with the front-end loader until the aggregate is uniformly coated with the precoating fluid. Three complete turnings of the stockpile may be required. The time between the precoating and the placing of the aggregate shall not exceed the time given in the Special Specifications or agreed on by the Engineer and the Contractor. Before the aggregate is used the precoating fluids shall have set or dried sufficiently in the opinion of the Engineer. All aggregates used with hot-applied homogeneous and non-homogeneous modified binders, shall be precoated. Precoating stockpiles shall be covered to protection the chippings against rain and contamination. (ii) Precoating constraints No precoating shall be applied where emulsion binders are used unless specifically specified or ordered by the Engineer.

All construction equipment that will be operated on the road during construction of the seal shall be free from any binder, fuel or oil leaks and no refuelling or servicing of any equipment will be allowed to take place while such equipment is on the road. (b) Binder distributors (i) General The binder distributor shall comply with all the provisions of CLAUSE 4103. (ii) Non-homogeneous modified binder The binder distributor used for non-homogeneous modified binder shall be adapted to spray the rubber modified binder satisfactorily. The Contractor shall provide proof by way of a test on the site that the binder distributor has sufficient reserve power to maintain the required constant speed up the steepest incline to which spray has to be applied, and to obtain a uniform distribution of the mix. The optimal spray-bar level shall be determined during testing, and the spray-bar level shall be adjusted accordingly before each spray. The uneven application of binder will be unacceptable. In addition to the requirements of CLAUSE 4103 the equipment shall be capable of heating the binder to 210C. (c) Chip spreaders The chip spreaders shall be capable of spreading stone of the specified size uniformly over widths varying between 2.4 m and 4 m and shall be capable of adjustment to permit variation of the rate of application within the specified tolerances, and uniform spreading in both the transverse and longitudinal directions. At least two chip spreaders shall be provided, one of which shall be self-propelled. Spreaders which are not self-propelled, shall be of a type that can be attached quickly to the rear of trucks, and operated while backed over the stone chippings being spread. (d) Rollers Sufficient operational rollers of each of the following types shall be available on the Works to maintain the required tempo of work: (i) Pneumatic-tyred rollers Pneumatic-tyred rollers shall be of a self-propelled type equipped with smooth flat profile pneumatic tyres of uniform size and diameter. The mass of the roller shall not be less than 15 tonnes (unloaded). The rollers shall be equipped with suitable devices for keeping the wheels wet and clean during operation. The wheels of the roller shall be so spaced that one pass of the roller will provide one complete coverage equal to the rolling width of the machine. The total operating mass and tyre pressure may be varied by the Engineer at his/her discretion. Individual tyre pressures shall not differ by more than 35 kPa from one another. (ii) Rubber-soled steel-wheeled rollers Rubber-soled steel-wheeled rollers shall be selfpropelled, and have a mass of between 6 and 8 tonnes. It shall be equipped with suitable devices for cleaning and moistening the wheels. The wheels of the roller shall be so arranged as to give one complete coverage, by one passage of the

4303 CONSTRUCTION EQUIPMENT

(a) General All construction equipment used on the Works shall be of an adequate rated capacity and in a good working condition.

roller, over a width equal to the rolling width of the roller. (iii) Steel-wheeled rollers Steel-wheeled rollers shall be self-propelled threewheel or tandem rollers of between 6 and 8 tonnes mass and shall be equipped with suitable devices for cleaning and moistening the wheels. The mass of the roller required shall be determined by the Engineer. No steel-wheeled rollers shall be used without the consent of the Engineer. (iv) Additional requirements The type and number of rollers shall be subject to the approval of the Engineer for each type of seal and the proposed programme. No seal work shall continue if the required rollers are not on site or in an operational condition. (e) Brooms (i) Drag broom The drag broom shall be of a size, type and mass which will enable the chips to be distributed evenly over the surface without dislodging any chips from the binder. (ii) Rotary broom An approved rotary broom, complete with towing vehicle fitted with smooth pneumatic tyres, shall be available at all times on the Works. (f) Mixer for slurry A mobile mixer of a type approved by the Engineer shall be provided. It may be either a batch mixer or a continuous type mixer. The paddles of the mixer shall be so designed as to ensure a complete blending of the constituents of the slurry. For the rapid setting slurry types, the mixing and application of the slurry shall be done by a mixer designed to provide a rapid mixing time, and sufficient agitation within the spreading system to prevent segregation or premature hardening. The mixer shall be capable of continuous mixing and application. The purpose designed mixer for continuous type mixing of either conventional or rapid setting slurries, shall be equipped with precise metering systems to enable the various constituents to be combined continuously to the prescribed formulation. No central mixing equipment will be allowed. Details of the type of mixer shall be submitted in advance of actual construction, for approval by the Engineer. (g) Loader for slurry A loader, or equivalent capacity labour force where so required in the Special Specifications, compatible with the needs and capacity of the mixer unit shall be available at the stockpiling site. (h) Spreader box for slurry The type of spreader box used for spreading the slurry shall be submitted to the Engineer, in advance, for approval. The spreader box for rapid setting slurry shall be of a proven and approved type, fitted with a proven and approved device to ensure sufficient agitation within the spreader system. The spreader box shall be so constructed as to distribute the weight onto metal skids in such a way that no damage shall be done to the surface when the box is in operation. Soft rubber belting shall be attached to the framework in such a manner as to prevent slurry from being spilt

past the sides of the spreader box when the box is in operation. The spreader box shall be capable of spreading a uniform application of the slurry in adjustable widths from 1.5 m to 4 m, at specified rates, and it shall have efficient mechanical means of adjusting the rates and widths of application specified. (i) Precoating equipment The precoating of chips may be done in any suitable equipment capable of uniformly coating the chips. (j) Mass-measuring device Where payment per tonne is specified, the Contractor shall keep available on the site as directed by the Engineer, a suitable gauged mass-measuring device. The device shall be provided with a printer for printing the mass, the time and date. The printed data shall be submitted to the Engineer on a daily basis. (k) Miscellaneous equipment Sufficient equipment for handling and hauling aggregate, binder and slurry, and blending units for non-homogeneous modified binders, shall be provided to ensure prompt and continuous placing and application of bituminous materials as specified. The Contractor shall have available all the necessary ancillary equipment and hand tools to carry out the work efficiently. Suitable fire-fighting equipment for dealing with bitumen fires shall be available on site, together with suitable first aid equipment for dealing with bitumen burns. (Refer to Sabita Manual 8: Bitumen Safety Handbook.) The Engineer shall be entitled to request reserve equipment, should there be any doubt as to the efficiency or capability of the equipment provided.

4304 GENERAL LIMITATIONS AND REQUIREMENTS

(a) Weather limitations The minimum road-surface temperatures at which the spraying of the different types and grades of binder may be done are: (i) Conventional binders Penetration grade bitumen: 150/200 penetration-grade bitumen: 20C 80/100 penetration-grade bitumen: 25C Cutback grade bitumen MC800 / MC3000: 10C Bitumen emulsions: 10C (ii) Non-homogeneous modified binders: Bitumen-rubber (spray application) 20C (iii) Other non-homogeneous modified binders: As set out in the Special Specifications. (iv) Homogeneous cold applied modified binders SBR modified cationic emulsion: 10C SBS modified cationic emulsion: 10C (v) Homogeneous hot-applied modified binders Modified binder 150/200 penetration grade base bitumen: 20C Modified binder 80/100 penetration grade base bitumen: 25C (vi) Other homogeneous hot-applied modified binders As set out in the Special Specifications. (vii) General

Whenever the temperature of the road surface falls below the aforesaid temperature for the binder in question, or, in the opinion of the Engineer, will probably fall below the required temperature before spraying the binder, no binder shall be sprayed. No bituminous work shall be done during foggy or rainy weather, and, when a cold wind is blowing, the above temperatures shall be increased by 3C to 6C as directed by the Engineer. Conventional slurry shall not be applied at an air temperature of less than 7C when temperatures are rising, or less than 13C when temperatures are dropping. Rapid setting slurry shall be sufficiently versatile to be laid in air temperatures of 4C to 40C, as well as capable of being laid under damp conditions. During hot weather slurry operations shall be suspended when aggregate is being displaced by the spreader box or squeegees. When the breaking process accelerates to such an extent that it renders the product unworkable to attain the required end result, for instance when the surface temperature is in excess of 60C, or as otherwise prescribed by the Engineer, no sealing shall be done. When strong winds are blowing which are likely to interfere with the proper execution of the work, no sealing, especially spraying of binder, shall be done. (b) Moisture content No seal shall be placed unless the moisture content of the upper 50 mm of the base is less than 50% of the optimum moisture content as determined by the Engineer. No reseal shall be placed immediately after a rainy spell on an existing partly cracked and/or highly permeable surfacing resulting in the trapping of moisture in the pavement structure. A minimum delay of 24 hours or such extended period as ordered by the Engineer shall apply. (c) Other constraints (i) The following curing periods shall apply to the various treatments listed, prior to applying a seal/reseal unless otherwise given in the Special Specifications: Texturing using fine slurries: 6 weeks Rapid setting slurry (rut filling, etc): 12 weeks Crack sealing: 2 weeks Repair of distressed patches: 6 weeks (ii) Unless otherwise agreed by the Engineer, and subject to the outcome of a trial section, the Contractor shall programme all spraying to cease each working day at 15:00 hours. (d) Preparation of areas to be sealed (i) General The areas to be sealed shall be cleaned of all dust, dirt, dung, oil or any other foreign matter that may be deleterious to the seal. (ii) Newly constructed seals Where newly constructed base or shoulder areas are to be sealed, the surfaces shall be checked for compliance with the surface tolerances and all other requirements specified. Any portions that do not meet these requirements shall first be either corrected or removed and reconstructed before they are sealed. (iii) Existing surfaces to be resealed

Existing roads that require resealing shall, if so specified or ordered by the Engineer, be given a pre-treatment in accordance with one or more of the methods described in SECTION 4800. Any failures shall be repaired as set out in the Special Specifications. (e) Demarcation of working area (i) New work The Contractor shall demarcate the area of the primed base to be sealed by means of setting out wire lines down each edge of the specified seal width. (ii) Reseal work Immediately before the tack coat or bituminous binder is sprayed, the centre line of the road shall be marked by a 3 mm thick sisal or hemp twine, secured by nails driven, at 15 m intervals on straights and 5 m intervals on curves, into the existing surface. This twine shall be left in position during all subsequent operations.

4305 HEATING AND STORAGE OF BITUMINOUS BINDERS

(a) Conventional binders The temperature ranges between which bituminous binders are to be heated shall be as given in TABLES 4305/1 and 4305/2. Binders stored in a heated condition shall be kept in a container with a securely fitting lid, the circulatory system of which is functioning properly. The container shall be provided with a built-in thermometer. Binders which have been heated above the maximum temperatures indicated in this table shall not be used and shall be removed from the site. Every effort shall be made to maintain the binder temperature for spraying to within 5C of the recommended temperature. For single seals the temperature limits for 150/200 penetration-grade bitumen, cut back with the indicated amounts of kerosene in parts per 100 parts of bitumen by volume as described in SECTION 4400, shall be as set out in TABLE 4305/3. TABLE 4305/1 MAXIMUM STORAGE TEMPERATURES, CONVENTIONAL BINDERS Materials Maximum storage temperature (C) Over 24 Up to 24 hours hours 115 125 75 100 Air temperature (all types) 165 175 125 155 60 (all types)

Pen. grade bitumens: - 150/200 pen grade - 80/100 pen grade Cut-back bitumen: MC-800 MC-3000 Bituminous emulsions: 60%, 65% or 70%

(b) Cutting back bitumen on site Kerosene shall be used as the cutter where correction of viscosity is required or cutback bitumen is to be made on site from penetration grade bitumen. Allowance shall be made for quantities between 0 45% by volume of the total quantity hot sprayed bitumen, as directed by the Engineer. The Contractors attention is drawn to the potential hazards involved in the cutting back operation and he/she shall take all necessary precautions to prevent fire. The temperature of the bitumen, when the kerosene is introduced, shall not be higher than 140C. TABLE 4305/2 HEATING AND SPRAYING TEMPERATURES, CONVENTIONAL BINDERS Materials Heating and spraying temperatures (C) Min Max Recommended 150 175 110 135 Air temp. (all types) 175 190 135 155 60 (all types) 165 180 - 185 125 145 60 (all types)

Binder that has failed to meet the requirements for storage and handling shall not be used and shall be removed from the site. (d) Other Non-homogeneous modified binders The Contractor shall comply with the requirements given in the Special Specifications with regard to the storage, heating and spraying temperatures, and with regard to the information to be provided in the bidding stage, unless otherwise approved by the Engineer. (e) Homogeneous cold applied modified binders Modified bitumen emulsions may be stored at ambient temperature for long periods, provided that some circulation/mixing takes place from time to time. The spraying temperatures of these emulsions are the same as for conventional bitumen emulsions. Excessive temperature over extended periods will degrade all modified bitumen and negatively affect the properties of these binders. The temperature limits for the storage and spraying of modified hot-applied binders shall be as set out in TABLE 4305/4 unless otherwise approved by the Engineer. TABLE 4305/4 TEMPERATURE LIMITS FOR STORAGE AND SPRAYING, MODIFIED BINDERS Bitumen grade used 80/100 150/200 80/100 150/200 80/100 150/200 Polymer type EVA EVA SBR SBR SBS SBS Max storage temp.(C) Up to 24 to 24h. 48h. 175 150 175 150 175 175 175 175 150 150 150 150 Spraying temp. (C) Max. Min. 180 180 210 200 180 180 170 170 190 180 165 165

Pen. grade bitumens: 150/200 80/100 Cutback bitumens: MC-800 MC-3000 Bituminous emulsions: 60%, 65% or 70%

The kerosene shall be sucked in measured quantities through the bitumen pump to the bottom of the tank and circulated with the bitumen for a minimum of 45 minutes. During this process all burners shall be shut off and no open flames allowed near the distributor. The power paraffin shall not be introduced into the distributor through the manhole, which shall be kept closed. Each distributor shall at all times have two fire extinguishers in good working order available. TABLE 4305/3 TEMPERATURE LIMITS FOR CUTBACK BITUMEN Proportion of kerosene (% of total volume of mixed binder) 5% 10% 15% 20% Spraying temperature Lower limit Upper limit C C 140 155 125 145 105 125 90 110

Modified binders stored in a heated condition shall be kept in a container having a properly functioning circulation system and a securely fitting lid. Many long chain polymers have low shear stability and can be degraded by the action of a high shear rate pump such as a close tolerance gear pump. Any material damaged by handling shall not be used on the road and shall be removed from site. The Contractor shall comply with the requirements of the Special Specifications with regard to the storage, heating and spraying temperatures, and with regard to the information to be provided in the bidding stage, unless otherwise approved by the Engineer.

(c) Non-homogeneous (heterogeneous) modified binders modified with rubber After completion of the bitumen-rubber reaction, the binder shall be cooled to below 160C. The binder mixture may not be kept for more than 2 days. The mix may only be stored in tanks with circulation systems. The spray and storing temperatures of the bitumenrubber binder shall comply with the following requirements: Spray temperature (C): Provided by supplier Max storing time at spray temperature: 4 hours Max storing temperature (up to 2 days): 35C below spray temperature, but not more than 160C

4306 STOCKPILING OF AGGREGATE

(a) General Sites for the stockpiling of aggregates shall be prepared in such a manner that no grass, mud, dirt or other deleterious material will be included when the aggregates are loaded for use. Access roads to stockpile sites shall be prepared and maintained in such a way that no dirt is conveyed by vehicle wheels onto the areas to be sealed or resealed whilst aggregate is being transported to or from the stockpiles.

Stockpiles shall be so sited that they will not be exposed to excessive contamination with dust arising from traffic on the road or access roads. Aggregates contaminated to the extent that it contains more than the allowable percentage of material passing through the 0.425 mm sieve and 0.075 mm sieve shall not be used for sealing. (b) Precoating Areas used for stockpiling precoated aggregate shall be so sited that dust deposited on the chips is prevented. Where necessary, temporary diversions and access roads in the immediate proximity shall at the Contractors own cost be watered, sprayed with a suitable chemical dust suppressant, or sealed. During the wet season when there is danger of the precoating fluid being washed off the aggregate, the stockpiles shall be covered with tarpaulins or similar protective coverings. During cooler periods the Engineer may order that stockpiles be covered with tarpaulins to ensure that the aggregate temperature remains compatible with the limiting temperature applicable to the specified binder type.

The aggregate shall be applied uniformly by means of self-propelled chip spreaders, unless otherwise specified. In the case of single seals, the use of a self-propelled chip spreader shall be obligatory. The immediate application of the chips is of prime importance. The chip spreader shall be so operated that the tack coat shall be covered with aggregate before the wheels of the chip spreader or truck pass over the uncovered tack coat. The quantity of bitumen sprayed in any single spray operation shall be governed by the quantity of aggregate, and the number of trucks available shall be sufficient to ensure the continuous application of stone behind the distributor. In addition the available roller capacity at normal operating speed shall also govern the extent of the tack coat and aggregate that may be applied. (ii) Initial rolling of aggregate Immediately after the aggregate has been applied, rolling shall be commenced. A self-propelled 15tonne pneumatic-tyred roller only shall be used in the case of single seals, and a steel-wheeled roller may also be used in the case of double seals on condition that excessive crushing of the aggregate shall not take place. Rollers shall operate parallel to the centre line of the road, from the shoulders inwards towards the crown of the road, until the entire surface has been covered at least three times with the wheels of the roller. (iii) Broom drag and final rolling of aggregate After the bituminous binder has set-up sufficient to prevent any aggregate from being dislodged, the surface shall be slowly dragged with a broom drag to ensure even distribution of the aggregate. If there are areas which are deficient in stone chips, additional material shall be added by hand so as to leave a single layer of chips lying shoulder to shoulder. If there are areas with an excess of stone chips, such excess shall be removed by hand so as to leave a single layer of chips lying shoulder to shoulder. The importance of applying only a single layer of chips is stressed. Every care shall be taken to avoid an over-application of stone. After completing the spreading of the aggregate, the surface shall be rolled with a 15-tonne pneumatic-tyred roller for three to four coverages. Except in the case of single seals final rolling shall then be done with a steel-wheeled roller with a mass of 6 to 8 tonnes working parallel to the centre line of the road from the shoulders towards the crown of the road, until every portion of the surface concerned has been covered by at least two to four passes of the roller, provided that only a limited degree of crushing of the aggregate will take place, but if, in the opinion of the Engineer, general crushing occurs under the rollers, such rolling shall be stopped regardless of the number of passes completed by the roller. The surface shall be well knit and have a uniform appearance free of roller-tyre marks; all aggregate contaminated by fuel, oil or grease shall be removed and replaced with clean aggregate. (iv) Joints between binder sprays In order to prevent overlapping at junctions of separate binder applications the previous work along the joint shall be covered with twin-reinforced building paper for a sufficient distance back from the joint to ensure that the sprayer is operating at

4307 CONSTRUCTION OF SEALS

(a) General Adequate advance notice shall be given to the Engineer before the Contractor proceeds with any seal work. (b) Single and double aggregate seals (i) Application of binder coat and aggregate A bituminous coat consisting of the type and grade of binder specified in these Specifications under each of the appropriate Sections for each type of bituminous seal, or in the Special Specifications, shall be sprayed on the properly cleaned and prepared base or existing surface over the full specified width of the seal. Where the tank of the binder distributor could become empty during spraying against inclines, the spraying shall be done while the binder distributor is moving uphill. Should the Engineer be of the opinion that the Contractor is unable to place the sealant over the specified width in one movement, the Contractor shall execute the spraying and the distribution of the chips in strips. The spraying of adjacent strips shall overlap by 100 mm. Chips may not be placed on the 100 mm overlap before the adjacent strip has been sprayed. The adjacent strip may not be sprayed before the preceding strip, excluding the 100 mm overlap, has been covered satisfactorily with chips in compliance with the Specifications. In so far as is practicable, the Contractor shall so place the strips that the joint between two adjacent chip applications shall fall on the centre line of the road. Immediately after the binder has been sprayed, it shall be covered with clean, dry aggregate of the size given in these Specifications under each of the appropriate Sections for each type of seal. The actual rates of application of binder and aggregate to be used in the construction will be determined by the Engineer, after he/she has tested the aggregates the Contractor proposes to use for the seal and prior to any sealing being carried out.

the required rate before the untreated surface is reached, and also to prevent additional binder application onto the previously treated section. The same method shall be used to ensure a neat joint at the end of the run. (v) Protection of kerbs, channels, etc Kerbs, channels, guttering, manholes, guard rails, bridge railings and any other structures which may be soiled by bituminous binders during spraying operations shall be protected in terms of SECTION 2300 during spraying operations. The Contractor shall replace at his/her own cost any items that have been soiled and cannot be cleaned entirely. The painting of soiled surfaces will not be accepted as a suitable remedy. (c) Slurry seals Slurry seals shall be applied as specified in SECTION 4600.

The Engineer shall be responsible for determining when any sealing layer is to be opened to public traffic. The road shall not be opened to traffic until the binder has set sufficiently to retain the aggregate, or in the case of slurry seals, the slurry has set sufficiently so as not to be picked up by the wheels of passing traffic. The Contractor shall not allow any construction equipment, which is likely to cause damage, over the completed seal. The Contractor shall display speed restriction signs in accordance with SECTION 1500 and the instructions of the Engineer.

4311 DEFECTS
Where, in the opinion of the Engineer, any unacceptable loss of stone from, or bleeding of the road surface that occurs during the course of the Contract or during the maintenance period, and that can be attributed to the Contractor not observing any of the requirements of the Specifications, not using the correct rates of application, or to any other omission or fault on the part of the Contractor, the work shall be rejected, and any corrective work ordered by the Engineer shall be at the Contractor's cost, including the supply, precoating, stockpiling at selected sites and later removal if not used, of any aggregate reserved for corrective work during the period of maintenance or thereafter. The Contractor shall carry out an investigation to determine the reasons for the defect works and send a proposal of how the works should be repaired. No repair works shall be implemented prior to the Engineers approval of the investigation of the cause of the defect and the Contractor proposal to repair them.

4308 RATES OF APPLICATION

Whenever the terms or quantity of bitumen, spray rate or application rate are used in these Specifications to specify the rate of application of the binder for conventional or homogeneous modified binder, they shall mean at spraying temperature. All rates of application for seal works shall be properly designed by the Contractor and approved by the Engineer prior to any trial sections of the works. All rates of application for seal works shall be documented daily and recorded on a spray record sheet. All binders, aggregates, and slurry used in the various types of seals shall be applied at the rates of application as determined by the Engineer after tests on the materials proposed for use. No payment will be made for bituminous binder applied in excess of the rate ordered unless, in the opinion of the Engineer, such overspray or any shortages can be satisfactorily corrected in the case of a first application by the adjustment of the application rate of a subsequent spray. Unless otherwise specified, the nominal rates of application of bituminous binders given in further sections, and also the variations in application rate, shall be measured at spraying temperature. The nominal rates of application are for bidding purposes only and will not necessarily be used in construction. The actual rates of application to be used on the site shall in all cases be as instructed by the Engineer.

4312 MAINTENANCE
The Contractor shall maintain the bituminous surface until the work is finally accepted by the Employer. Any damage done to the surface or any defects which may develop before the issue of the taking over certificate, fair wear and tear excepted, shall be corrected by the Contractor at his/her own cost and to the requirements of the Engineer.

4313 TOLERANCES AND FINISH REQUIREMENTS

(a) Binder spray rates The following terms are used for measure of binder spray rates: CONVENTIONAL BINDERS: Conventional binders shall be measured at spraying temperature in litres per square metre. MODIFIED BINDERS: Whenever the terms net bitumen or net quantity of bitumen are used in these Specifications to specify the rate of application of the binder for conventional or homogeneous modified binder (hot or cold), they shall mean viscosity grade (penetration-grade) bitumen net cold. Non-homogeneous modified binders, however, shall be specified at spraying temperature.

4309 DUST CONTROL

Any temporary diversions and construction roads shall be kept watered and damp, or sprayed with a suitable chemical dust suppressant, during all sealing operations and all dust shall be removed from surfaces before any binder, aggregate or slurry is applied. The supply and application of water or chemical dust suppressants on temporary diversions will be paid for separately as specified in SECTION 1500, but payment for dust control on the haul and construction roads shall be included in the unit rates bid for the various types of seals used.

4310 OPENING TO TRAFFIC

(b) Surface tolerances, rate of application, conditional acceptance The completed seal shall be free from corrugations or any other wave effect where depressions are preceded and followed by humps or ridges no matter how small the distance between the top of the hump to the bottom of the preceding or following depression.

The completed bituminous work shall comply with the requirements set out in SECTION 7300 regarding surface tolerances and finish. The provisions of SECTION 7200 shall apply to conditional acceptance. (c) Surface appearance The completed seal shall be of uniform texture without gaps or patches and shall be free from any loose aggregate or bitumen spillage. Corrective work shall be carried out in such a manner as to blend in colour, texture and finish with adjacent work. The completed seal should be an even mosaic of aggregates firmly held by the bitumen so that there is no stripping of the aggregates or bleeding and providing a good even skid resistant surface. In double seal applications the aggregates should be matched to give the maximum mechanical interlock.

4314 MEASUREMENT AND PAYMENT

Measurement and payment will be made under the various sections where the different seals are described.

SERIES 4000: BITUMINOUS LAYERS AND SEALS

4402 MATERIALS
(a) Bituminous binders The bituminous binder shall consist of one of the following binders, whichever is specified in the Special Specifications or the Bill of Quantities or ordered by the Engineer: 80/100 penetration-grade bitumen; 150/200 penetration-grade bitumen, 60%, 65% or 70% spray-grade emulsion; MC-3000 cut-back bitumen; Modified binder as specified. (i) Bitumen coats The specified bituminous binders shall comply with the conditions of SECTION 4300. (ii) Fog spray Fog spray, when specified, shall be 30% or 60% spray grade emulsion of anionic or cationic type, as specified or ordered by the Engineer. (iii) Pre coating fluid Pre coating fluid, when pre coating of aggregate is specified, shall be bitumen emulsion, or alternative approved types, as specified or ordered by the Engineer. (b) Aggregate Aggregate for surface dressing shall consist of clean, tough, durable fragments of crushed stone free from any deleterious matter and shall comply with the requirements given in TABLES 4402/1 and 4402/2.

SECTION 4400: SINGLE SURFACE DRESSINGS

CONTENTS:
CLAUSE 4401SCOPE 4402MATERIALS 4403CONSTRUCTION 4404MEASUREMENT AND PAYMENT 4000-34 4000-34 4000-35 4000-36 PAGE

4401 SCOPE
This Section covers the supply and furnishing of all materials for the repair of existing surfaces and for the construction of reseals or new single seals. The requirements of all relevant clauses of SECTION 4300 shall apply to this Section.

TABLE 4402/1 GRADING LIMITS AND REQUIREMENTS FOR CHIPPINGS Chipping, nominal size of aggregates, (% passing) 14 mm 10 mm

20 mm Sieves (mm): 25 20 14 10 6.3 5 2.36 Fines: 0.425 Dust: 0.075 100 85-100 0-30 0-5 < 0.5 < 0.3

7 mm

100 85-100 0-30 0-5 < 1.0 < 0.5

100 85-100 0-30 0-5 < 1.0 < 0.3

100 85-100 0-30 0-5 < 1.5 < 1.0

TABLE 4402/2 REQUIREMENTS FOR CHIPPINGS Aggregate properties Maximum Flakiness index BS 812 : 105.1 Minimum strength, TFV dry. BS 812 : 111 Chipping, nominal size of aggregates, (% passing) 20 mm 20 14 mm 25 *) For AADT > 1000: 160 kN *) For AADT < 1000: 120 kN 10 mm 7 mm 30

Ratio dry to soaked TFVsoaked shall be minimum 75% of the corresponding TFVdry value value of TFV. BS 812 : 111 *) The appropriate traffic volume that applies to any location, shall be as given in the Drawings or Special Specifications. Where such information is not given, the decision of the Engineer shall apply.

(c) Average Least Dimension (ALD) The ALD of the chippings shall be tested by the following method: 1. A sieve analysis is first carried out on a sample of the chippings and the results plotted on a large scale grading curve. The median size of chipping is then determined as that theoretical sieve size through which 50 percent of the material will pass. The flakiness index is determined. Then using Figure 4402/1 the median size is marked on scale A and flakiness index on scale C. A straight line is drawn between the two marks and the ALD read off on scale B.

shall be covered with suitable plastic sheeting during spraying operations. The sheeting shall be kept firmly in position by soil, stones or adhesive tape in such a manner that it will not lift or be blown away during windy conditions but will keep the areas to be protected fully covered. The use of paper bags, sand or other materials will not be permitted in lieu of plastic sheeting and the Contractor shall replace at his/her own expense any items that have been soiled and cannot be cleaned entirely. The painting of soiled surfaces will not be acceptable as a suitable remedy. (b) Application of binder and aggregate (i) General The bitumen coat and aggregate, of the types and sizes specified in the Special Specifications, or ordered by the Engineer, shall be applied as specified in SUBCLAUSE 4307(b). The Contractor shall demonstrate the suitability of the application rates together with construction equipment and methods by carrying out trial sections for the approval by the Engineer. The Trial sections shall be carried out on surfaces identical to those used in the permanent works and shall include at least 3 different binder and aggregate application rates covering the range of application rates determined according to both publications mentioned above. Each combination of application rates shall be spread on a trial length of minimum 25 m. Chip spreaders shall be checked and calibrated before starting any trial or permanent work and further when required by the Engineer. (ii) Nominal rates of application The nominal rates given are for information only. The application rates for which payment is calculated, are given in the Bill of Quantities. If, however, no application rates are given in the Bill of Quantities, then the rates in TABLE 4403/1 shall be used for bidding purposes. TABLE 4403/1 NOMINAL RATES OF BINDER AND AGGREGATE APPLICATION, SINGLE SURFACE DRESSING Nominal size of aggregate (mm) 20 14 10 7 Nominal rates of application Binder hot Aggregate spray rate spread rate ( l/m2 ) ( kg/m2 ) 1.80 19 1.50 14 1.10 11 0.80 7

2. 3.

The ALD of the chippings when tested as described above shall meet the requirements of Table 4402/3. FIGURE 4402/1 FIGURE FOR THE DETERMINATION OF THE AVERAGE LEAST DIMENSION

TABLE 4402/3 ALD REQUIREMENTS FOR CHIPPINGS Nominal size of aggregate (mm) 20 14 10 7 ALD Requirement (mm) 11 - 15 8 -10 5 - 6.5 2-4

4403 CONSTRUCTION
(a) Preparation of the surface Surface treatment shall not commence until the existing surface has been repaired of any defects and cleaned to the satisfaction of the Engineer by the use of brooms, water, compressed air or any other method required to give a satisfactory result. Kerbs, channels, guttering, manholes, guard rails, bridge railings, and any other structures that may be soiled by bituminous binders during spraying operations

(iii) Actual rates of application The actual rates of application for use on site on any part of the Works, shall be as determined on site, on approval of the Engineer. The difference in actual rates of application compared to the rates for bidding purposes are paid for separately in variation rates measured in tonnes and litres (hot sprayed) for aggregate and binder respectively, as specified in CLAUSE 4404. Brooming of chippings after spreading to effect redistribution will not be permitted. Any excess of chippings shall be removed by hand and any

insufficiently chipped area shall be chipped by hand to obtain adequate coverage. (c) Initial rolling Initial rolling shall be carried out as specified in SUBCLAUSE 4307(b). 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 the tyre pressure shall be minimum 0.4 N/mm2. The number and capacity of rollers shall be sufficiently to ensure that rolling does not lag behind spreading. As a minimum 2 pneumatic rollers shall be used for each chip spreader. Rolling shall begin immediately after the chippings have been spread and, in no case, later than 2 minutes after the application of the binder. Rolling shall continue until all chippings are firmly embedded into the binder. The number of passes shall be as agreed with the Engineer, but as a rule all chippings shall receive at least six passes of the pneumatic tyred roller. Excessive rolling resulting in crushing of chippings shall be avoided. The roller speed shall not exceed 8 km/hr, unless otherwise agreed with the Engineer. The road shall not be opened to traffic until the binder has attained sufficient viscosity to prevent the chippings being whipped off. (d) Final rolling Any areas deficient in aggregate shall have additional material added so as to leave the carpet with a single layer of chippings lying shoulder to shoulder. It is essential to ensure that only one layer of chippings is applied and every care shall be taken to avoid overapplication of chippings. The final rolling shall be done with a pneumatic-tyred or a rubber-soled steel-wheeled roller only, applying a minimum of four coverages. The finished surface shall be well-knit and have a uniform appearance free of roller-tyre marks. All aggregate contaminated by oil, fuel or grease shall be removed and dumped in an approved waste site and replaced by clean aggregate. All loose aggregate shall be broomed off the surface with a rotary broom or hard brooms as directed by the Engineer. (e) Fog spray If stated in the Special Specifications, or if so directed by the Engineer, a fog spray of 60% or 30% anionic or cationic emulsion shall be applied to the surface of the aggregate by means of a pressure distributor at the required rate. (f) Blinding If stated in the Special Specifications, or if so directed by the Engineer, a light blinding layer of natural or crusher sand shall be applied by the Contractor to prevent chippings from being picked up by traffic. The blinding layer shall be spread evenly over the full indicated surface. Should it be required by the Engineer, the layer shall be spread evenly by means of hand brooms. (g) Precoating of aggregate If stated in the Special Specifications, the aggregate shall be precoated with a precoating fluid as specified in SUBCLAUSE 4302(e).

(h) Protection of the new surface Vehicle speed shall be restricted to a maximum of 30 km/hr until there is sufficient adhesion to ensure that chippings will not be dislodged by fast moving vehicles.

4404 MEASUREMENT AND PAYMENT

ITEM 44.01 SINGLE SEALS (INDICATE
TYPE OF BINDER AND HOT SPRAYED APPLICATION RATE IN LITRES PER SQUARE METRE):

UNIT

(a) USING 7 mm AGGREGATE (b) USING 10 mm AGGREGATE (c) USING 14 mm AGGREGATE (d) USING 20 mm AGGREGATE

SQUARE METRE

(m2)
SQUARE METRE

(m2)
SQUARE METRE

(m2)
SQUARE METRE

(m2) The unit of measurement shall be the square metre of completed and accepted seal. The bid rates shall include full compensation for furnishing all materials, marking the centre or reference lines, spraying of binder, spreading of aggregate, rolling and all other incidentals necessary for completing the work as specified. ITEM 44.02 SINGLE SEALS. BITUMINOUS BINDER VARIATIONS:
BITUMEN

UNIT LITRES (l) LITRES (l) LITRES (l) LITRES (l) LITRES (l) LITRES (l) LITRES (l)

(a) 150/200 PENETRATION GRADE (b) 80/100 PENETRATION GRADE BITUMEN (c) MC3000 CUTBACK BITUMEN (e) BITUMEN EMULSION (STATE TYPE AND COMPOSITION) (h) PRECOATING FLUID (STATE TYPE) (g) OTHER TYPES OF BITUMEN (STATE TYPE AND COMPOSITION)

The unit of measurement of bituminous binder in respect of an increase or a decrease in the specified rates of application shall be the litres measured at spraying temperature. Payment for variations shall be made as specified in CLAUSE 1212. ITEM 44.03 SINGLE SEALS. AGGREGATE VARIATIONS: (a) USING 7 mm AGGREGATE (b) USING 10 mm AGGREGATE (c) USING 14 mm AGGREGATE (d) USING 20 mm AGGREGATE TONNE TONNE TONNE TONNE UNIT

The unit of measurement shall be the tonne of increased or decreased aggregate applied, as compared to the amounts required at the specified nominal rate of application. Payment for variations shall be made as specified in CLAUSE 1212. ITEM 44.04 APPLICATION OF FOG SPRAY:
LITRE LITRE

UNIT (l) (l)

(a) USING 60% SPRAY-GRADE EMULSION (b) USING 30% SPRAY-GRADE

EMULSION The unit of measurement shall be the litre of emulsion sprayed as specified and measured at spraying temperature. The bid rate shall include full compensation for furnishing the material and applying the fog spray as specified. ITEM 44.05 PRECOATING THE AGGREGATE (INDICATE TYPE OF PRECOATING
FLUID AND RATE OF APPLICATION IN LITRES PER TONNE OF AGGREGATE)

UNIT TONNE

The unit of measurement for the precoating of aggregate shall be the tonne of aggregate so treated and used on the surfacing in quantities according to drawings or as instructed by the Engineer. The bid rate shall include full compensation for furnishing the equipment and precoating fluid and precoating the aggregate as specified, including the handling, stockpiling and protecting of the stockpiles against inclement weather. ITEM 44.06 ADDITION OF APPROVED
WETTING AGENT TO THE BINDER (STATE TYPE AND NOMINAL APPLICATION RATE PERCENT OF BINDER):

UNIT
KILOGRAMS

(kg)

The bid rate shall include full compensation for providing, handling the material, storing and introducing it into the mix, including any equipment required, for the work. ITEM 44.07 AGGREGATE FOR BLINDING: (a) NATURAL SAND (b) CRUSHER SAND TONNE TONNE UNIT

The unit of measurement shall be the tonne of sand according to drawings or as instructed by the Engineer. The bid rate shall include full compensation for providing the material and applying the blinding coat complete as specified, and, should it be required, stockpiling the sand at an approved locality.

SERIES 4000: BITUMINOUS LAYERS AND SEALS

4502 MATERIALS
(a) Bituminous binders The bituminous binder shall consist of one of the following binders, whichever is specified in the Special Specifications or the Bill of Quantities or ordered by the Engineer: 80/100 penetration-grade bitumen; 150/200 penetration-grade bitumen, 60%, 65% or 70% spray-grade emulsion; MC-3000 cut-back bitumen; Modified binder as specified. (i) Bitumen coats The specified bituminous binders shall comply with the conditions of SECTION 4300. (ii) Fog spray Fog spray, when specified, shall be 30% or 60% spray grade emulsion of anionic or cationic type, as specified or ordered by the Engineer. (iii) Pre coating fluid Pre coating fluid, when pre coating of aggregate is specified, shall be bitumen emulsion, or alternative approved types, as specified or ordered by the Engineer. (b) Aggregate Aggregate for surface dressing shall consist of clean, tough, durable fragments of crushed stone free from any deleterious matter and shall comply with the requirements given in TABLES 4502/1 and 4502/2.

SECTION 4500: DOUBLE SURFACE DRESSINGS

CONTENTS
CLAUSE 4501SCOPE 4502MATERIALS 4503CONSTRUCTION 4504MEASUREMENT AND PAYMENT 4000-38 4000-38 4000-39 4000-41 PAGE

4501 SCOPE
This section covers the supply and furnishing of all materials for the construction of a bituminous double seal for resealing or new construction. The seal shall be constructed using either 20 mm plus 10 mm aggregate or 14 mm plus 7 mm aggregate, whichever is shown in the Bill of Quantities. The requirements of all relevant clauses of SECTION 4300 shall apply to this SECTION.

TABLE 4502/1 GRADING LIMITS AND REQUIREMENTS FOR CHIPPINGS Chipping, nominal size of aggregates, (% passing) 14 mm 10 mm

20 mm Sieves (mm): 25 20 14 10 6.3 5 2.36 Fines: 0.425 Dust: 0.075 100 85-100 0-30 0-5 < 0.5 < 0.3

7 mm

100 85-100 0-30 0-5 < 1.0 < 0.5

100 85-100 0-30 0-5 < 1.0 < 0.3

100 85-100 0-30 0-5 < 1.5 < 1.0

TABLE 4502/2 REQUIREMENTS FOR CHIPPINGS Aggregate properties 20 mm Maximum Flakiness index BS 812 : 105.1 Minimum strength, TFV dry. BS 812: 1051: 1989 20 Chipping, nominal size of aggregates, (% passing) 14 mm 25 *) For AADT > 1000: 160 kN *) For AADT < 1000: 120 kN 10 mm 7 mm 30

Ratio dry to soaked TFVsoaked shall be minimum 75% of the corresponding TFVdry value value of TFV. BS 812: 105-1: 1989 *) The appropriate traffic volume that applies to any location, shall be as given in the Drawings or Special Specifications. Where such information is not given, the decision of the Engineer shall apply.

(i) Average Least Dimension (ALD)

The ALD of the chippings shall be tested by the following method: 1. A sieve analysis is first carried out on a sample of the chippings and the results plotted on a large scale grading curve. The median size of chipping is then determined as that theoretical sieve size through which 50 percent of the material will pass. 2. The flakiness index is determined. 3. Then using Figure 4502/1 the median size is marked on scale A and flakiness index on scale C. A straight line is drawn between the two marks and the Average Least Dimension read off on scale B. The ALD of the chippings when tested as described above shall meet the requirements of Table 4502/3. FIGURE 4502/1 FIGURE FOR THE DETERMINATION OF THE AVERAGE LEAST DIMENSION

The sheeting shall be kept firmly in position by soil, stones or adhesive tape in such a manner that it will not lift or be blown away during windy conditions but will keep the areas to be protected fully covered. The use of paper bags, sand or other materials will not be permitted in lieu of plastic sheeting and the Contractor shall replace at his/her own expense any items that have been soiled and cannot be cleaned entirely. The painting of soiled surfaces will not be acceptable as a suitable remedy. (b) Nominal rates of application of binder and aggregate The bitumen coat and aggregate, of the types and sizes given in the Special Specifications, or ordered by the Engineer, shall be applied as specified in SUBCLAUSE 4307(b). The Contractor shall demonstrate the suitability of the application rates together with construction equipment and methods by carrying out trial sections for the approval by the Engineer. The Trial sections shall be carried out on surfaces identical to those used in the permanent works and shall include at least 3 different binder and aggregate application rates covering the range of application rates determined according to both publications mentioned above. Each combination of application rates shall be spread on a trial length of minimum 25 m. Chip spreaders shall be checked and calibrated before starting any trial or permanent work and further when required by the Engineer. Nominal rates of application of binder and aggregate are given in TABLES 4503/1 and 4503/2. The given nominal rates of application of binder and aggregate are for information only. The application rates for which payment shall be calculated, are given in the Bill of Quantities. If, however, no application rates are given in the Bill of Quantities, then the rates in TABLES 4503/1 and 4503/2 shall be used for bidding purposes. (c) Actual rates of application of binder and aggregate The actual rates of application for use on site on any part of the Works, shall be as determined on site, on approval of the Engineer. The difference in actual rates of application compared to the rates for bidding purposes are paid for separately in variation rates measured in tonnes and litres (hot sprayed) for aggregate and binder respectively, as specified in CLAUSE 4504. Brooming of chippings after spreading redistribution will not be permitted. Any chippings shall be removed by hand insufficiently chipped area shall be chipped obtain adequate coverage. to effect excess of and any by hand to

TABLE 4502/3 ALD REQUIREMENTS FOR CHIPPINGS Nominal size of aggregate (mm) 20 14 10 7 ALD Requirement (mm) 11 - 15 8 -10 5 - 6.5 2-4

4503 CONSTRUCTION
(a) Preparation of the surface Surface treatment shall not commence until the existing surface has been repaired of any defects and cleaned to the satisfaction of the Engineer by the use of brooms, water, compressed air or any other method required to give a satisfactory result. Kerbs, channels, guttering, manholes, guard rails, bridge railings, and any other structures that may be soiled by bituminous binders during spraying operations shall be covered with suitable plastic sheeting during spraying operations.

(d) First layer of double surface dressings (i) Nominal rates of binder and aggregate The nominal rates of binder and aggregate shall be as given in TABLE 4503/1 for the first layer of double surface dressings.

TABLE 4503/1

FIRST LAYER OF DOUBLE SURFACE DRESSINGS. NOMINAL RATES OF BINDER AND AGGREGATE APPLICATION Nominal size of aggregate (mm) Nominal rates of application Binder, hot bitumen (l/ m2) AADT <200 20 14 1.8 1.4 2001000 1.5 1.1 >1000 1.2 1.0 19 14 Aggregate (kg/m2)

(h) Initial rolling of second layer Initial rolling of the second layer of aggregate shall be carried out as specified in SUBCLAUSE 4307(b). The final rolling shall be done with a pneumatic-tyred or a rubbersoled steel-wheeled roller only, applying a minimum of four coverages. The finished surface shall be well-knit and have a uniform appearance free of roller-tyre marks. All aggregate contaminated by oil, fuel or grease shall be removed and dumped in an approved waste site and replaced by clean aggregate. All loose aggregate shall be broomed off the surface with a rotary broom or hard brooms as directed by the Engineer. 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 the tyre pressure shall be minimum 0.4 N/mm2. The number and capacity of rollers shall be sufficiently to ensure that rolling does not lag behind spreading. As a minimum 2 pneumatic rollers shall be used for each chip spreader. Rolling shall begin immediately after the chippings have been spread and, in no case, later than 2 minutes after the application of the binder. Rolling shall continue until all chippings are firmly embedded into the binder. The number of passes shall be as agreed with the Engineer, but as a rule all chippings shall receive at least six passes of the pneumatic tyred roller. Excessive rolling resulting in crushing of chippings shall be avoided. The roller speed shall not exceed 8 km/hr, unless otherwise agreed with the Engineer. The road shall not be opened to traffic until the binder has attained sufficient viscosity to prevent the chippings being whipped off. (i) Broom drag and final rolling of second layer Dragging and final rolling of the second layer of aggregate shall be carried out as specified in SUBCLAUSE 4307(b). (j) Fog spray applied to Second Layer When required by the Special Specifications or if so directed by the Engineer in writing, a fog spray of 30% or 60% bitumen emulsion shall be applied to the surface of the second layer of aggregate by means of a pressure sprayer at the rate of application specified by the Engineer. (k) Precoating of aggregate If stated in the Special Specifications the aggregate shall be precoated with a precoating fluid as specified in Subclause 4302(e). (l) Protection of the new surface Vehicle speed shall be restricted to a maximum of 30 km/hr until there is sufficient adhesion to ensure that chippings will not be dislodged by fast moving vehicles.

(ii) Rolling Initial rolling shall be carried out as specified SUBCLAUSE 4308(b). Any areas deficient aggregate shall have additional material added as to leave the carpet with a single layer chippings lying shoulder to shoulder.

in in so of

It is essential to ensure that only one layer of chippings is applied and every care shall be taken to avoid over-application of chippings. (e) Second layer of double surface dressings (i) Nominal rates of binder and aggregate The bituminous binder specified by the Engineer shall be applied and followed by the second layer of aggregate of the size specified in the Special Specifications or as ordered by the Engineer. The nominal rates of binder and aggregate shall be as given in TABLE 4503/2 for the second layer of double surface dressings. The second application of binder shall preferably take place within 48 hours of the application of the first coat when penetration grade bitumen is used for the first coat and not less than ten days of the application of the fist coat when cutback bitumen is used in the first coat. TABLE 4503/2 SECOND LAYER OF DOUBLE SURFACE DRESSINGS. NOMINAL RATES OF BINDER AND AGGREGATE APPLICATION Nominal size of aggregate (mm) 10 7 Nominal rates of application Binder, hot bitumen (l/ m2) AADT <200 1.2 0.9 2001000 1.0 0.8 >1000 0.9 0.7 Aggregate (kg/m2) 11 7

(f) Fog spray applied to First Layer If specified in the Special Specifications, or if so directed by the Engineer, a fog spray of 60% or 30% anionic or cationic emulsion shall be applied to the surface of the first layer of aggregate by means of a pressure distributor at the required rate. (g) Blinding If specified in the Special Specifications, or if so directed by the Engineer, a light blinding layer of natural or crusher sand shall be applied by the Contractor to prevent chippings from being picked up by traffic. The blinding layer shall be spread evenly over the full indicated surface. Should it be required by the Engineer, the layer shall be spread evenly by means of hand brooms.

4504 MEASUREMENT AND PAYMENT

ITEM 45.01 DOUBLE SURFACE DRESSING USING: SQUARE METRE (m2) UNIT

TABLES 4503/1 and 4503/2 and already paid for in ITEM 45.01. Payment for variations shall be made as specified in CLAUSE 1213. ITEM 45.04 APPLICATION OF FOG SPRAY CONSISTING OF BITUMEN EMULSION (STATE TYPE AND PERCENTAGE BITUMEN CONTENT IN THE EMULSION) UNIT
LITRES

(a) 20 mm AND 10 mm AGGREGATE IN 1ST AND 2ND LAYER RESPECTIVELY (STATE

TYPE OF BINDER AND HOT BINDER APPLICATION RATE FOR EACH LAYER IN LITRES PER SQUARE METRE)

(l)

(b) 14 mm AND 7 mm AGGREGATE IN 1ST AND 2ND LAYER RESPECTIVELY (STATE TYPE OF
BINDER AND HOT BINDER APPLICATION RATE FOR EACH LAYER IN LITRES PER SQUARE METRE)

SQUARE METRE (m2)

The unit of measurement shall be the litre of emulsion sprayed as specified and measured at the application temperature. The bid rate per litre of emulsion shall include full compensation for procuring and furnishing the binder and applying the fog spray as specified. ITEM 45.05 PRECOATING SECOND
APPLICATION OF AGGREGATE (STATE TYPE OF PRECOATING FLUID AND APPLICATION RATE IN LITRES PER TONNE)

The unit of measurement shall be the square metre of completed and accepted surface treatment. The bid rate shall include full compensation for furnishing all materials, marking the centre line or reference lines, spraying of binder, spreading of aggregate, rolling, removing of dust or deleterious material, supplying of water and spraying of haul roads and construction roads, trimming the edges of the completed surface, and all other incidentals necessary for completing the work as specified, except the application of a fog spray and precoating of aggregate, which shall be paid for separately. ITEM 45.02 BITUMINOUS BINDER VARIATION:
LITRES LITRES LITRES LITRES LITRES LITRES

UNIT TONNE

The unit of measurement aggregate shall be the tonne and used on the surfacing at rates according to drawings Engineer.

for the precoating of of aggregate so treated the specified application or as directed by the

UNIT (l) (l) (l) (l) (l) (l)

(a) 150/200 PENETRATION GRADE

BITUMEN

The bid rate shall include full compensation for furnishing the equipment and materials and precoating the aggregate as specified, including the handling. Stockpiling and protecting of the stockpiles against inclement weather. ITEM 45.06 ADDITION OF APPROVED
WETTING AGENT TO THE BINDER (STATE TYPE AND NOMINAL APPLICATION RATE PERCENT OF BINDER):

(b) 80/100 PENETRATION GRADE BITUMEN (c) MC3000 CUTBACK BITUMEN (d) BITUMEN EMULSION (STATE TYPE AND COMPOSITION) (e) PRECOATING FLUID (STATE TYPE) (f) OTHER TYPES OF BITUMEN (STATE TYPE AND COMPOSITION)

UNIT
KILOGRAMS

(kg)

The unit of measurement of bituminous binder in respect of variations in the specified rates of application shall be a litre, measured at spraying temperature. Payment for variations shall be made as specified in CLAUSE 1213. ITEM 45.03 AGGREGATE VARIATION: TONNE TONNE TONNE TONNE
AGGREGATE

The bid rate shall include full compensation for providing, handling the material, storing and introducing it into the mix, including any equipment required, for the work. ITEM 45.07 AGGREGATE FOR BLINDING: (a) NATURAL SAND (b) CRUSHER SAND TONNE TONNE UNIT

UNIT

(a) 20 mm NOMINAL SIZE (b) 14 mm NOMINAL SIZE

AGGREGATE

The unit of measurement shall be the tonne of sand according to drawings or as instructed by the Engineer. The bid rate shall include full compensation for providing the material and applying the blinding coat complete as specified, and, should it be required, stockpiling the sand at an approved locality.

(c) 10 mm NOMINAL SIZE

AGGREGATE

(d) 7 mm NOMINAL SIZE

AGGREGATE

The unit of measurement with respect to variations in application of aggregate shall be the tonne of aggregate specified on site by the Engineer minus the tonne of aggregate calculated from application rates given in

SERIES 4000: BITUMINOUS LAYERS AND SEALS

durable, angular in shape, and shall comply with the grading requirements given in TABLES 4603/2. TABLE 4603/2 GRADING LIMITS FOR SLURRY SEALS Sieve size (mm) 10 5 2 1.18 0.425 0.150 0.075 Percentage passing sieve ( % by mass) Fine type Coarse type 100 100 85-100 90-100 50-90 60-90 32-70 32-60 20-44 10-27 7-20 4-12 2-8

SECTION 4600: SAND SEALS AND SLURRY

CONTENTS:
CLAUSE 4601 4602 4603 4604 4605 4606 SCOPE 4000-42 BINDER 4000-42 AGGREGATE 4000-42 SAND SEAL CONSTRUCTION AND AFTER CARE 4000-42 SLURRY CONSTRUCTION AND AFTER CARE 4000-43 MEASUREMENT AND PAYMENT 400044 PAGE

4604 SAND SEAL CONSTRUCTION AND AFTER CARE

(a) Equipment The following equipment shall be readily available on the site: pneumatic-tyred rollers a rotary broom a drag broom mechanical aggregate spreaders if spreading by hand is not used (b) Preparation of surface before application of seal The road shall be cleaned of all loose or deleterious material to the satisfaction of the Engineer before the sand seal is applied. The surface of the base shall be watered, rolled and swept until a smooth fine texture has been achieved. The base course shall then be primed in accordance with the provisions of SECTION 4100, or as instructed by the Engineer. (c) Binder application rate for sand seal The nominal rate of application of binder for bidding purposes shall be 1.2 litres per square metre of MC 3000 cutback bitumen measured at spraying temperature. The exact spray rate shall be determined on site on approval of the Engineer. (d) Application of sand seal (i) General Granular base courses of non-calcareous materials do not normally require a prime, unless otherwise directed by the Engineer. Base courses of calcrete or coral material shall always be primed. (ii) Application of surfacing The binders, of the type and grade required, and the aggregates, of the size specified in the Bill of Quantities or ordered by the Engineer, shall be applied in accordance with the provisions of SECTION 4300. (iii) Initial rolling Initial rolling shall be carried out as specified in SUBCLAUSE 4307(b). 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 the tyre pressure shall be minimum 0.4 N/mm2. The number and capacity of rollers shall be sufficiently to ensure that rolling does not lag behind

4601 SCOPE
This SECTION covers the supply and application of all materials used for constructing sand seals and slurry seals. The requirements of all relevant clauses of SECTION 4300 shall apply to this Section.

4602 BINDER
The following grades of binder shall be used as set out in the Special Specifications or the Bill of Quantities or as ordered by the Engineer: MC-800 cut-back bitumen MC-3000 cut-back bitumen Spray-grade cationic emulsion (65% or 70% of net bitumen) Spray-grade anionic emulsion (65% or 70% of net bitumen)

4603 AGGREGATE
(a) Sand seal The aggregate for sand seal shall be crusher dust clean river sand free from lumps of clay or any other deleterious matter. The grading shall conform with TABLE 4603/1. TABLE 4603/1 GRADING LIMITS FOR SAND SEAL Sieve size (mm) Percentage passing sieve (% by mass) Natural river Crusher dust sand 100 100 85 100 85 100 20 60 20 80 0 30 0 15 05 0 - 30

10 5 1.18 0.425 0.300 0.150

The sand shall be screened or washed as required to ensure compliance with the Specifications. (b) Slurry The aggregate for slurry seals shall be approved crusher sand obtained from a parent rock having a TFV value of not less than 110 kN or a mixture of such crusher sand and an approved clean natural sand, where the mixture does not contain more than 25% of natural sand. The aggregate shall be clean, tough,

spreading. A minimum of two pneumatic tyred rollers shall be used for the rolling operations. Rolling shall begin immediately after the aggregate has been spread and in no case later than 2 minutes after the application of the binder. Rolling shall continue until all aggregate is firmly embedded into the binder. The number of passes shall be as agreed with the Engineer, but as a rule all aggregate shall receive at least six passes of the pneumatic tyred roller. The roller speed shall not exceed 8 km/hr, unless otherwise agreed with the Engineer. (iv) Subsequent trafficking The road should be opened to traffic immediately after the sealing operations are completed, but a maximum speed limit of 50 km/h should be enforced during the initial period after construction and channelling of the traffic may be required for certain periods. Aggregate that has been dislodged by traffic during the immediate post construction period shall be broomed back into the exposed areas, as directed by the Engineer. (v) Aftercare After 2 - 3 weeks of trafficking the excess aggregate shall be swept off the road surface. If natural gravel is used with a fairly high content of fines, the period may be extended to 6 weeks or as directed by the Engineer.

Material which, in the opinion of the Engineer, is not properly mixed or in which the emulsion shows signs of having broken during mixing shall not be applied to the road and shall be removed from site. (ii) Batch mixer The slurry shall be mixed in an approved type of mixer as specified in SUBCLAUSE 4303(f). All the constituents of the slurry shall be accurately proportioned and due care and attention shall be given to the sequence in which the ingredients are introduced into the mixer and to the period of mixing. Mixing shall be continued until the materials in each batch are thoroughly blended. (iii) Continuous mixer Aggregate and filler contained in separate bins shall be fed through metering devices at controlled rates to the mixer. Water and bitumen emulsion contained in separate tanks shall similarly be pumped to the mixer at controlled rates through metering devices. The mixing of the slurry shall be at a suitable rate adjusted to ensure complete blending of the ingredients and uniformity of mix. (d) Application of slurry Before slurry is applied, the road surface shall be thoroughly cleaned and lightly sprinkled with water but no free water shall be present on the surface when the slurry is applied. The nominal rate of application of slurry shall be in accordance with drawings or as directed by the Engineer. The slurry shall be applied in two layers in the case application rates of 0.008 m 3/m2 or larger, or as directed by the Engineer. The nominal rates of application given in the Bill of Quantities are intended for bidding purposes only and the actual rates of application on the site shall be as directed by the Engineer. When the slurry is applied in two layers, the first layer of slurry shall be struck off level with the tops of the stones in the aggregate layer so that, after application, the tops of the stones will be just visible. The second layer of slurry shall not be applied until the first layer has dried. If required by the Engineer, the Contractor shall open the road to traffic before the second layer of slurry is applied. The surface shall be well rolled with a pneumatic-tyred roller. The second layer shall be applied only after sufficient time has been allowed for the first layer to cure. The Engineer will decide on the time necessary for proper curing, which will in any case be not less than 24 hours. The surface shall be thoroughly cleaned of all dust, dirt or foreign materials before the second layer of slurry is applied. For seals using 14 mm nominal sized chipping the slurry shall be applied in one layer only. The slurry shall also be struck off so that the tops of the stone chipping will be just visible after the emulsion has set and cured. Where slurry is spread by hand. the squeegee squad shall be allowed to complete the spreading of each batch discharged onto the road, using squeegees, before the next is discharged. Where spreading is carried out by means of the spreader box, the slurry shall be discharged into the spreader box by means of a chute, which shall be so directed that an even supply of slurry is maintained against the full width of the strike-off blade of the spreader box. Areas where an excess of slurry has been applied by the spreader box shall be corrected by squeegees being used immediately after the passage of the spreader box.

4605 SLURRY CONSTRUCTION AND AFTER CARE

(a) Condition of surface The surface shall be cleaned to remove all dust, mud, leaves, etc, and shall have a uniform closely knit appearance, with edges trimmed correctly to the specified width. (b) Composition of slurry The slurry shall consist of a mix of the grade of slurry aggregate ordered by the Engineer and specified in SUBCLAUSE 4302(b) together with a 60% stable-grade emulsion, filler and water in the proportions as directed by the Engineer. The following proportions shall apply for bidding purposes only: Slurry aggregate (saturated volume) 1 m3 Stable-grade emulsion 260 litres Cement 0.01 m3 Water (as directed by the Engineer) approximately 235 litres If specified in the Special Specifications, the composition of the slurry shall be based on the following mass proportions for bidding purposes: Slurry aggregate (dry 100 Stable-grade emulsion 20 Cement 1-15 Water +15 The saturated volume of slurry shall be determined by applying a correction for bulking of moist aggregate. (c) Mixing of slurry (i) General A mixer of a type approved by the Engineer shall be provided in a good working order capable of producing uniform slurry of the constituent materials. It may either be a batch mixer or a continuous type mixer. Hand mixing may be used if the result is satisfactory to the Engineer.

Should breaking of the emulsion, segregation of the mix or formation of lumps occur during the application of the slurry, the slurry operations shall be discontinued at once and any defective material removed from the road. Successive strips of slurry shall overlap transversely by not less than 25 mm nor more than 150 mm. Any overlapping on the longitudinal joints and any omitted areas shall be rectified with squeegees. The Contractor shall ensure that either edge of the road surface is finished to the specified widths and lines. All stones dislodged in the process of applying the slurry shall be removed on the same day on which the slurry seal has been applied. All spillage of slurry or excess slurry shall be neatly removed from the road and buried in an approved waste site. If the slurry is spread with a spreader box, a moist burlap drag shall be drawn behind the spreader box to ensure an overall even texture. If applied by hand, the slurry shall be worked from side to side and criss-cross with the aid of squeegees so as to fill as many spaces as possible. In this case the final layer of slurry shall be struck off flush with the tops of the stone chipping so as to leave the chippings to be visible after the emulsion has stiffened and hardened. The work must be so programmed, that the two half road widths of slurry shall be applied on two successive days to complete a full road width section in two days. Any damage to the slurry seal by rain or traffic before the slurry has cured shall be rectified by the Contractor at his/her own expense.

The bid rate shall include full compensation, inter alia, for furnishing all materials, marking the centre line or reference lines, spraying of binder, spreading of aggregate, rolling, removing of dust or deleterious material, supplying of water and spraying of haul roads and construction roads, trimming the edges of the completed surface, and all other incidentals necessary for completing the work as specified. The bid rates shall include full compensation for procuring and furnishing the material including all preparatory work to the surface prior to application of the seal. ITEM 46.03 VARIATION IN THE RATE OF APPLICATION OF THE SLURRY: UNIT
CUBIC METRE

(m3)

The unit of measurement for slurry variations shall be the cubic metre of saturated fine aggregate. Payment for variations shall be made as specified in CLAUSE 1212.

4606 MEASUREMENT AND PAYMENT

ITEM 46.01
SEAL:

UNIT APPLICATION
OF SAND LITRE

(a) BINDER (STATE TYPE) (b) SAND

(l)

CUBIC METRE

(m3) The unit of measurement of binder shall be the litre, measured at spraying temperature. The unit of measurement for the sand shall be the cubic metre of sand applied to the road as specified. The bid rate for binder shall include full compensation for procuring and furnishing the material and applying the binder, including all preparatory work to the surface prior to application of the binder. The bid rate for sand shall include full compensation for supplying the sand, washing, screening and preparing the sand, applying the sand as specified, as well as brooming the sand back onto the surface as often as is required. ITEM 46.02 APPLICATION OF SLURRY (STATE NOMINAL APPLICATION
RATE IN CUBIC METRE PER SQUARE METRE):

UNIT
SQUARE METRE (m2)

The unit of measurement shall be the square metre of completed and accepted slurry seal according to drawings or where directed by the Engineer.

SERIES 4000: BITUMINOUS LAYERS AND SEALS

4707 MEASUREMENT AND PAYMENT

ITEM 47.01 SURFACING ON BRIDGE DECK (STATE TYPE AND THICKNESS) UNIT CUBIC
METRE

SECTION 4700: SURFACING OF BRIDGE DECKS

CONTENTS:
CLAUSE 4701 4702 4703 4704 4705 4706 4707 SCOPE 4000-45 MATERIALS 4000-45 PREPARATION OF SURFACE 4000-45 TYPE AND THICKNESS OF SURFACING 4000-45 CONSTRUCTION 4000-45 SURFACE TOLERANCES 4000-45 MEASUREMENT AND PAYMENT 400045 PAGE

(m3)

The unit of measurement shall be the cubic metre of surfacing completed in accordance with the Specifications to the nominal thickness indicated on the Drawings or to the instruction of the Engineer. The bid rate shall include full compensation for procuring and furnishing all materials, heating the binder and aggregate, mixing, transporting, placing and compaction of the material, and the provision and application of the surfacing. The rate shall also include full compensation for variations in thickness within the specified tolerance for bridge deck levels and for cleaning of the surface to the satisfaction of the Engineer and the application of a tack coat.

4701 SCOPE
This Section covers the construction of a bituminous surfacing on bridge decks where shown on the Drawings or ordered by the Engineer.

4702 MATERIALS
Bituminous binders and aggregate shall comply with the requirements of SECTIONS 4200 and 4300 for asphalt surfacing and seals respectively.

4703 PREPARATION ON SURFACE

Before the surfacing is constructed, the concrete deck shall be thoroughly cleaned by washing and brushing to remove all loose material. After drying, a tack coat consisting of 30% bituminous cationic emulsion shall be applied to the surface at a rate of 0.4 l/m 2. The tack coat shall then be allowed to dry.

4704 TYPE AND THICKNESS OF SURFACING

The type and nominal) thickness of the surfacing shall be as Indicated on the Drawings and specified in the Bill of Quantities. Before commencing with the construction of the surfacing, the actual levels of the bridge deck shall be determined by means of accurate levelling. The levels and grades to which the surfacing is to be constructed shall be as shown on the Drawings or as indicated by the Engineer. If the levels of the concrete deck as constructed by the Contractor deviate by more than the specified tolerances from the specified levels, he/she shall construct a levelling layer at his/her own cost. The nominal size of the aggregate in the levelling layer shall be 10 mm.

4705 CONSTRUCTION
Irrespective of the type of seal applications on the road on both sides of the bridge, asphalt surfacing shall be constructed in accordance with SECTION 4200, and seals in accordance with SECTION 4300.

4706 SURFACE TOLERANCES

The completed surfacing shall comply with the requirements for base of CLAUSE 7115 in respect of surface tolerances for grade, smoothness, cross section and width.

SERIES 4000: BITUMINOUS LAYERS AND SEALS

Specifications or the Bill of Quantities or as ordered by the Engineer. (a) Binder for fog spray (Treatment Type 1) 30% or 60% cationic or anionic spray-grade bituminous emulsion. (b) Tack-coat binder (Treatment Type 2) 60% bituminous emulsion (Treatment Type 2) 30% bituminous emulsion (Treatment Types 3 and 4). (c) Slurry binder (Treatment Type 3) 60% stable grade bituminous emulsion. PAGE

SECTION 4800: TREATMENT OF SURFACE DEFECTS, PATCHING, REPAIRING EDGE-BREAKS AND CRACK SEALING
CONTENTS:
CLAUSE 4801 4802 4803 4804 4805 4806 4807 4808 4809 4810 SCOPE 4000-46 MATERIALS 4000-46 CONSTRUCTION EQUIPMENT 4000-46 TREATMENT OF SURFACE DEFECTS 4000-47 PATCHING 4000-48 REPAIRING EDGE BREAKS 4000-48 CRACK SEALING 4000-49 OPENING TO TRAFFIC 4000-49 JOINTS AND THE PROTECTION OF KERBS 4000-49 MEASUREMENT AND PAYMENT 400049

(d) Binder for asphalt skim coat (Treatment Type 4) 80/100 penetration grade bitumen. (e) Screed (Treatment Type 5) 30% bitumen emulsion shall be used for the tack coat, and the binder for the asphalt shall be approved grade of penetration grade bitumen unless otherwise specified. (f) Binder for asphalt used in reconstructing pavement edges 60% stable grade bituminous emulsion for tack coat and 80/100 penetration-grade bitumen in asphalt (g) Rubber pellets Rubber pellets for crack sealing shall be obtained by processing rubber tyres. The rubber shall be granulated and free from fibres, steel wire and other impurities. The rubber crumbs shall pass through a 2.00 mm sieve. (h) Herbicide Herbicide shall be a non-selective environmentally compatible herbicide approved by the Engineer.

4801 SCOPE
This Section covers the work in connection with the treatment of existing road surfaces prior to the application of a seal or asphalt surfacing, patching, repairing edge breaks and crack sealing. Provision is made for treating existing seals exhibiting any of the following defects: the existing surface is deficient in binder. marked differences in texture occur over the surface. the existing surface is open-textured. the surface is uneven on account of bumps, slacks, etc. edges require trimming and/or repairs. Patching shall be any work to existing pavement layers (and in exceptional cases to fills and the roadbed) with the purpose of repairing local failures, and which is carried out in an area having a width of less than 1.0 m, or a length of less than 25 m or an area of less than 100 m. This does not include the repair of edge breaks, pre-treatment of the road surface, or the rehabilitation of concrete pavements. Patching involves excavating the existing failed sections and reconstructing the excavated fills and pavement layers with the specified pavement material. Backfilling with asphalt will be measured and paid for under SECTION 4200. Compensation for work in restricted areas shall not be applicable to patching and repairing edge breaks. Note: SECTION 4300: Seals: Materials and general requirements shall apply to this SECTION.

4803 CONSTRUCTION EQUIPMENT

All equipment shall be suitable for the specified use and working areas and shall be capable of obtaining the specified results. (a) Planing machine The machine shall be of a design which will be suitable for planing the existing surfacing in order to remove and irregularities and to leave an even surface without tearing the underlying material. An approved milling machine may be used. Before planing may start, the Contractor shall demonstrate to the Engineer that the machine is capable of executing the work in accordance with the Special Specifications. (b) Patching and repairing edge breaks Only approved cutting or sawing equipment may be used for cutting or sawing asphalt layers. The equipment shall be capable of cutting asphalt layers to depths of 200 mm in one operation without fragmenting the material, and in straight lines within the required tolerances. The following items of construction equipment shall also be available and in good working order: (i) A vibratory roller having a mass approximately equal to that of a Bomag 765 or similar vibratory roller, with an adjustable amplitude and frequency of vibration. A mobile compressor capable of producing at least 3 m3/minute compressed air at 750 kPa. Appropriate paving breakers.

4802 MATERIALS
The material shall comply with the requirements specified for the various types of material in the appropriate sections of the Specifications and the Special Specifications. The following grades of binder may be used. The actual type or grade used shall be as specified in the Special (ii) (iii)

(iv) (v)

Manually operated pneumatic compactors as required. Appropriate concrete mixers. A distinction shall be made in respect of the payment for the following two methods of construction: Where the slurry can only be applied by hand methods or where the Engineer so directs or where it is specified that the slurry shall be applied by hand methods. Where the slurry can be applied mechanically with a spreader box.

(c) Crack sealing Over and above the equipment normally used for surface treatments, the following additional equipment shall be available for crack sealing: (i) (ii) Special spraying equipment with 2 mm nozzle openings and provided with spare nozzles. Special heating equipment where appropriate for cleaning cracks, and custom-built applicators for applying sealants to cracks.

4804 TREATMENT OF SURFACE DEFECTS

Before any treatment is carried out, the area to be treated shall be cleaned and prepared and any major failures shall be repaired as specified in the Special Specifications. (a) Treatment Type 1 This treatment shall be applied where the existing surface is deficient in binder. The treatment shall consist of the application of a fog spray of the specified grade of emulsion to the existing surface by means of a pressure distributor at the rates of application as directed by the Engineer, in widths that may vary from 0.5 m to 4.0 m. (b) Treatment Type 2 This Treatment, or a sand seal as specified in SECTION 4600, is intended for application where marked differences in texture occur in the existing surfacing, in order to obtain a uniform texture before resealing. A tack coat of the specified type and grade of emulsion shall be applied to the surface as specified in SUBCLAUSE 4307(b) followed by an application of double-washed crusher sand. The crusher sand shall be the medium grade specified for slurry in CLAUSE 4302, but shall be on the coarse side of the grading envelope. The nominal rates of application shall be: Emulsion 0.7 litres net bitumen per m2 Aggregate 0.004 m3/m2

The slurry shall be prepared, mixed and applied as specified in SUBCLAUSES 4605 (b), (c), and (d), with the following exceptions: Slurry to be applied by hand may be mixed in a suitable concrete mixer. When applied by hand with brooms or rubber squeegees, the slurry shall be worked into cracks and other open areas until a sound, uniform surface is obtained.

The slurry shall, in the case of application by spreader box, be applied in a single layer at a nominal rate, for bidding purposes, of 0.004 m3/m2. (d) Treatment Type 4 This treatment is intended for use where the road surface is uneven or contains slacks, bumps or minor rutting caused by deformation of the pavement layers, but not by failure of these layers. The surface to be treated shall, after having been cleaned and prepared, be given a tack coat of 30% bitumen emulsion at rates directed in the field by the Engineer. Asphalt shall consist of a medium or fine-grade asphalt surfacing mix manufactured as specified with 6% of 80/100 penetration-grade bitumen and 1.0% active filler. The actual composition of the mix shall be as dictated by the required thickness of the asphalt layer, or as directed by the Engineer. The asphalt shall be applied as specified in SECTION 4200 in thicknesses varying between 6 mm and 25 mm depending on the nature of the irregularities that occur so that the final surface will conform to the surface tolerances for cross section and smoothness as specified in CLAUSE 4213. Where the thickness of asphalt required exceeds 25 mm, it shall be laid in separate layers each not exceeding 25 mm thickness. If the final surfacing shows signs of ravelling, disintegration, or an uneven surface, the surface shall be given a Type 3 Treatment or removed and replaced, all at the Contractor's cost. (e) Treatment Type 5 This treatment is used where the road surface is uneven and where depressions, humps or small grooves occur, which, in the opinion of the Engineer, are the result of the deformation of the pavement layers, but not of structural failure of the pavement. Where both planing and screeding are specified, the screed shall be placed after the planing has been completed. Where milling is required, it shall be done in accordance with the requirements of CLAUSE 4803. The existing surface shall be swept clean or cleaned by other approved methods to be free from dust, soil, gravel, loose stones or any other undesirable material.

The actual rates of application shall be as instructed by the Engineer. It can be anticipated that spraying and spreading will have to be carried out in narrow bands varying in width from 0.5 m to 4.0 m. The emulsion shall be allowed to break before the aggregate is applied. As soon as the aggregate has been applied, the distribution thereof shall be corrected by light hand brooming or by means of a light broom drag. Rolling shall be carried out as specified in SUBCLAUSE 4307(b). Any excess aggregate remaining on the road after it has been opened for two days or more shall be removed. (c) Treatment Type 3 This treatment shall be used when an existing surface treatment, which is open-textured or exhibits cracking, requires treatment with bituminous slurry. Prior to Treatment with a slurry, the surface shall be sprayed with a tack coat of 30% bitumen emulsion at the rate prescribed by the Engineer.

A tack coat of 30% anionic stable-grade emulsion shall then be applied at a rate prescribed by the Engineer. The bituminous material used for the screed shall be asphalt or coarse slurry as specified in the Special Specifications.

(1) The base material shall be placed in a concrete mixer, and water shall be added to moisten the material. (2) A suitably diluted 60% stable grade anionic bitumen emulsion shall be added at the specified rate. (3) Portland cement shall be added at a rate of 1.0% by mass to the dry aggregate before adding water, unless otherwise specified. (4) During mixing the fluid content (water plus emulsion) shall not exceed the optimum fluid content (optimum moisture content + percentage residual bitumen) of the base. Mixing shall continue until a uniform mix of the base material and the emulsion is obtained. (5) The Contractor shall place and spread the stabilised material by hand in layers of appropriate thickness. Each layer shall be compacted with a hand-operated self-propelled vibratory roller to the specified density. The process of placing, spreading and compacting shall be repeated until the required total thickness of base is obtained. The stabilised materials shall be placed at a fluid content not exceeding the optimum fluid content for the base course. The finished surface of patching shall be a minimum of 2 mm and a maximum of 5 mm above the adjacent existing pavement. (e) Restrictions Unless otherwise instructed in writing by the Engineer, the excavation, backfilling and all patching work, complete as specified, for any patch shall be carried out and completed on the same day. Special attention shall be given during patching to controlling and protecting traffic, as specified.

4805 PATCHING
(a) Demarcation The Engineer will demarcate any failed areas to be repaired, and shall instruct the Contractor in regard to the repair work to be done. The Contractor shall give adequate notice to the Engineer of his/her intention to commence with repair work on any specific section of the road so that the Engineer will have sufficient time to demarcate the areas to be patched and repaired. In addition to his/her specified responsibilities for the accommodation of traffic, the Contractor shall also be responsible for traffic accommodation during the demarcation work. (b) Excavating pavement material In addition to the provisions of this SECTION the various provisions of SECTIONS 3200, 3400, 3500, 3600, 3800, 4100 and 4200 amongst others shall apply with changes as required. (c) Excavating pavement material Unless otherwise instructed by the Engineer, the patching shall have a neat rectangular shape. The existing material shall be excavated and removed to the full specified depth. Asphalt layers and surfacing shall be cut with approved sawing equipment. Excavation for patching shall be cut with side slopes of approximately 60 to the horizontal. Where required, excavation shall be done with approved milling equipment in accordance with SECTION 3800. Excavated material from each pavement layer shall be placed in separate stockpiles adjacent to the patch. The stockpiled material shall be re-used or spoiled in an approved manner in accordance with the Engineer's instructions. Stockpiled material shall not be spoiled next to the road. After completion of the excavation to the specified depth, the Engineer shall be afforded the opportunity to examine it. Where required, the floor of the excavation shall be compacted to the specified density for the layer concerned. (d) Backfilling excavations (i) Excavations shall be backfilled with pavement material as specified in the Special Specifications or as ordered by the Engineer, and the backfilling shall be compacted and finished to the required levels. The requirements for material quality, density and finish specified in other appropriate SECTIONS shall remain applicable. Untested material from the sides of the road shall not be used. Stabilised materials shall be mixed in concrete mixers or by other approved equipment. (ii) Unless otherwise specified in the Special Specifications, the base shall be backfilled in accordance with the following requirements.

4806 REPAIRING EDGE BREAKS

This treatment is intended for use where trimming and/or repair of the edges of the surfaced area is required, including restoring the road edges to the true edge lines of the original road or to such other edge line as may be required. Where the existing edge of the surfacing is sound but exceeds the required width by more than 150 mm, the excess surfacing shall be cut back to the required width keeping it parallel to the centre line of the road. Where the edges of the surfacing have broken away or where the surfacing is narrower than the required new width, the existing broken edges shall be cut back until a sound edge can be obtained. Where the edge of the surfacing, as cut back, requires building up to bring it to the required width, all material between the edge of the surfacing and the line to which the surfacing has to be built up, shall be removed to a depth of 60 mm below the final road surface or until firm material is found, and the surface so enclosed shall be cleaned, watered and primed at a rate of 0.6 l/m2 with a 60% stable grade emulsion diluted with three parts of water to one part of emulsion. The enclosed surface may also be compacted with suitably sized vibratory rollers to ensure a sound surface. The edges shall then be built up with the asphalt specified for Treatment Type 4 and shall be well compacted by means of a suitable vibratory roller or

compactor. The built-up edges shall be finished neatly to the required line and levels.

4807 CRACK SEALING

(a) General The types of cracks treated will be specified in the Special Specifications. The Engineer will instruct the Contractor regarding the type of treatment to be used in the various cases. (b) Preparation The cracks shall be blown clean with compressed air, and all foreign and loose material shall be removed from the cracks. (c) Cracks narrower than 3 mm Cracks narrower than 3 mm shall be treated with an emulsion or by means of resealing the surface. (d) Cracks 3 mm and wider After the primer has been applied, anionic stable grade emulsion shall be mixed with synthetic modifiers, as set out in the Special Specifications, and applied by means of pneumatic spraying equipment or other approved equipment at the rate given in the Special Specifications. Where the cracks are to be rolled, the Contractor, in accordance with the Special Specifications or the prescriptions of the Engineer, shall treat the cracks as described below. Where Volcano cracks occur and these require to be flattened, in accordance with the Special Specifications or the prescriptions of the Engineer, the Contractor shall treat the cracks as follows: The cracks shall initially be treated for cleaning out and priming the crack as described above. The surface on either side of the crack shall be sprayed with an approved rejuvenator for a width of 300 mm on either side of the crack and allowed to soften the existing surface. The crack shall then be filled with cold rubber slurry which shall be worked in with rubber squeegees. Any excess slurry shall be removed from the sides of the crack. Once the emulsion has broken, the crack can be rolled with a pedestrian vibratory roller until a smooth finish is obtained.

Water may be added to improve workability. The mixture shall be neatly worked into the cracks by rubber squeegees. Excess slurry shall be removed from the surface as soon as the emulsion has broken. (ii) Bitumen rubber Bitumen rubber may be used only where the Contractor is able to convince the Engineer that he/she is able to mix, heat and apply the material satisfactorily. The bitumen rubber shall be mixed on the site or at another approved locality on condition that the Contractor is able to propose efficacious methods for controlling both the mixing process and the end product. Approved heating equipment and mechanical equipment for mixing and applying the mixture shall be used. The rubber content of the mix shall be at least 25% by mass of the total bitumen-rubber mix. (iii) Other sealants Other approved sealants shall comply with and be applied in accordance with the requirements of the Special Specifications. (e) Restrictions Cracks may be sealed only where the temperature of the road surface exceeds 100C. Crack sealing may not be done within three days after rain has fallen on the site, unless otherwise instructed by the Engineer. The Contractor shall note that a single application of crack sealant is usually insufficient and that the application will have to be repeated.

4808 OPENING TO TRAFFIC

The road shall be left open to traffic for such period as the Engineer may direct before further surface treatment work is carried out.

4809 JOINTS AND THE PROTECTION OF KERBS

The requirements of SUBCLAUSE 4307(b) regarding joints between sprays and the protection of kerbs, channels, etc, shall be observed.

For other cracks, the instructions of the Engineer shall be implemented. Cracks shall be treated with cold rubber slurry, hot bitumen rubber, or any other approved sealant. Where, in the opinion of the Engineer, the above treatments are not suitable for the existing cracks, the Contractor shall treat the cracks in accordance with the instructions of the Engineer. (i) Rubber slurry The rubber slurry mixture shall be proportioned as follows (by volume): 10.0 parts of rubber crumbs 4.5 parts of 60% anionic stable grade bitumen emulsion 0.2 parts of Portland cement parts of SBR (net rubber) (anionic emulsified rubber)

4810 MEASUREMENT AND PAYMENT

ITEM 48.01 TREATMENT TYPE 1 (FOG SPRAY):
LITRE LITRE

UNIT

(a) 30% BITUMEN EMULSION (b) 60% BITUMEN EMULSION

(l) (l)

The unit of measurement for Treatment Type 1 (fog spray) shall be the litre of bituminous emulsion sprayed at application rates as instructed by the Engineer, measured at spraying temperature. The bid rates shall include full compensation for cleaning and preparing the existing surface, for furnishing the material and applying the fog spray and for all other incidentals necessary for completing the work as specified.

ITEM 48.02 TREATMENT TYPE 2: (APPLICATION OF SAND SEAL): (a) BINDER (STATE TYPE) (b) SAND

UNIT

LITRE

(l)

The bid rate for tack coat shall include full compensation for procuring, furnishing and applying the tack coat and demarcating the areas to be sprayed, and for all incidentals necessary for completing the work as specified. The bid rate for asphalt shall include full compensation for procuring, furnishing and mixing all the materials required for applying the asphalt, and for all transport and other incidentals necessary to complete the work as specified. ITEM 48.06 TREATMENT TYPE 5: (SCREED): (a) TACK COAT USING 30% BITUMEN
EMULSION LITRE

CUBIC METRE

(m3) The unit of measurement of binder shall be the litre, measured at spraying temperature. The unit of measurement for the sand shall be the cubic metre of sand applied to the road as specified. The bid rates shall include full compensation for procuring and furnishing the material and applying the binder, including all preparatory work to the surface prior to application of the binder. The bid rate shall include full compensation for supplying the sand, washing, screening and preparing the sand, applying the sand as specified, as well as brooming the sand back onto the surface as often as is required. ITEM 48.03 TREATMENT TYPE 3: (SLURRY) (STATE NOMINAL
APPLICATION RATE IN CUBIC METRE PER SQUARE METRE):

UNIT

(l) (t)

(b) CONTINUOUSLY-GRADED ASPHALT (SPECIFY GRADE) (c) COARSE GRADE SLURRY

TONNE

CUBIC METRE

(m3) The unit of measurement for the tack coat shall be the litre of emulsion applied, measured at spraying temperature. The unit of measurement for asphalt shall be the tonne of asphalt laid according to the Specifications. The unit of measurement for coarse grade slurry shall be the cubic metre of aggregate mix used in the slurry. The bid rate for tack coat shall include full compensation for procuring, furnishing and applying the tack coat and demarcating the areas to be sprayed, and for all incidentals necessary for completing the work as specified. The bid rate for asphalt shall include full compensation for procuring, furnishing and mixing all the materials required for applying the asphalt, and for all transport and other incidentals necessary to complete the work as specified. The bid rate for slurry shall include full compensation for all materials, equipment and labour for producing and applying the slurry, irrespective of the number of applications required to attain the required thickness.

UNIT
SQUARE METRE (m2)

The unit of measurement shall be the square metre of completed and accepted slurry seal according to drawings or where directed by the Engineer. The bid rate shall include full compensation, inter alia, for furnishing all materials, marking the centre line or reference lines, spraying of binder, spreading of aggregate, rolling, removing of dust or deleterious material, supplying of water and spraying of haul roads and construction roads, trimming the edges of the completed surface, and all other incidentals necessary for completing the work as specified. The bid rates shall include full compensation for procuring and furnishing the material including all preparatory work to the surface prior to application of the seal. ITEM 48.04 VARIATION IN THE RATE OF APPLICATION OF THE SLURRY: UNIT
CUBIC METRE

ITEM 48.07 SAWING ASPHALT OR

CEMENTED PAVEMENT LAYERS FOR PATCHING:

UNIT

(m3)

The unit of measurement for slurry variations shall be the cubic metre of saturated fine aggregate. Payment for variations shall be made as specified in CLAUSE 1212. ITEM 48.05 TREATMENT TYPE 4: (ASPHALT SKIM COAT):
LITRE

(a) CONTINUOUSLY-GRADED ASPHALT: (i) NOT EXCEEDING 50 mm (ii) EXCEEDING 50 mm BUT NOT EXCEEDING 100 mm (iii) EXCEEDING 100 mm
SQUARE METRE (m2) SQUARE METRE (m2) SQUARE METRE (m2)

UNIT

(b) CEMENTED PAVEMENT LAYERS TO AN AVERAGE DEPTH: (i) NOT EXCEEDING 50 mm (l) (t) (ii) EXCEEDING 50 mm BUT NOT EXCEEDING 100 mm (iii) EXCEEDING 100 mm
SQUARE METRE (m2) SQUARE METRE (m2) SQUARE METRE (m2)

(a) TACK COAT USING 30% BITUMEN

EMULSION

(b) CONTINUOUSLY-GRADED ASPHALT

TONNE

The unit of measurement for the tack coat shall be the litre of emulsion applied, measured at spraying temperature. The unit of measurement for asphalt shall be the tonne of asphalt laid according to the Specifications.

The unit of measurement shall be the square metre of sawcut area calculated in accordance with the authorised length of sawcut and the average saw depth measured after excavation of the material.

The bid rate shall include full compensation for all equipment, labour supervision, materials, transport and for all incidentals for sawing the asphalt and the cemented pavement layers, complete as specified and prescribed by the Engineer.

The bid rate shall also include full compensation for chemical or bituminous stabilisation, including amongst others the provision and application of the stabilising agents. ITEM UNIT COMPACTING THE FLOOR OF
SQUARE METRE (m2)

ITEM 48.08 EXCAVATION IN EXISTING PAVEMENTS FOR PATCHING IN:

UNIT

48.10

EXCAVATIONS FOR PATCHING

(a) ASPHALT LAYERS (b) CEMENTED LAYERS (c) OTHER LAYERS (SPECIFY TYPE)

CUBIC METRE

(m3)
CUBIC METRE

(m3)
SQUARE METRE (m2)

The unit of measurement shall be the square metre of excavation floor compacted on the instruction of the Engineer, and the quantity shall be computed in accordance with the authorised dimensions of the excavation floor. The bid rate shall include full compensation for compacting the floor of excavations complete as specified. Payment will not distinguish between the various methods of compaction or various density requirements. ITEM 48.11 EDGE BREAKS:
METRE

The unit of measurement shall be the cubic metre of material excavated from the existing pavement. The quantity shall be computed in accordance with the authorised dimensions of the excavation. The bid rate shall include full compensation for demarcating the excavation, excavating the material, placing the excavated material in temporary stockpiles, spoiling of material in the stockpiles where ordered by the Engineer, including haul over a free-haul distance of 1.0 km, complete as specified. Payment will not distinguish between the different types of pavement material excavated. ITEM 48.09 BACKFILLING OF EXCAVATIONS FOR PATCHING WITH: UNIT

UNIT

(a) TRIMMING EDGES OF EXISTING

SURFACING

(m)
TONNE

(b) RECONSTRUCTING EDGES FROM CONTINUOUSLY-GRADED ASPHALT

(t)

(a) CHEMICALLY STABILISED PAVEMENT MATERIAL (SPECIFY THE PAVEMENT

MATERIAL AND THE STABILISING AGENT) FOR A PATCH WITH A SURFACE AREA:

The unit of measurement for trimming edges shall be the metre of pavement edge cut back and trimmed as specified. The unit of measurement for reconstructing pavement edges shall be the tonne of continuouslygraded asphalt furnished and compacted as specified. The bid rate for trimming the edges shall include full compensation for cutting back the edges as directed, and removing and dumping of all excavated and loose material in an approved waste site.

(i) NOT EXCEEDING 5 m2 (ii) EXCEEDING 5 m2 BUT NOT EXCEEDING 100 m2 (iii) EXCEEDING 100 m
2

CUBIC METRE CUBIC METRE CUBIC METRE

(m3) (m3) (m3)

(b) BASE COURSE MATERIAL STABILISED

WITH BITUMINOUS EMULSION (SPECIFY THE EMULSION) FOR A PATCH WITH A SURFACE AREA:

The bid rate for reconstructing pavement edges shall include full compensation for compacting the surface on which the new edge is to be constructed and procuring, furnishing and mixing all materials and compacting and trimming the asphalt to the required lines and levels. It shall also include full compensation for applying a tack coat of emulsion to the surface to be treated. The bid rates shall include full compensation for all transport, handling, labour, material and all incidentals necessary to complete all the work specified in the treatment of edge breaks. ITEM UNIT
KILOMETRE

(i) NOT EXCEEDING 5 m

2

(ii) EXCEEDING 5 m BUT NOT EXCEEDING 100m2 (iii) EXCEEDING 100 m

2

CUBIC METRE CUBIC METRE CUBIC METRE

(m3) (m3) (m3)

48.12

The unit of measurement shall be the cubic metre of the specified chemically or bitumen stabilised pavement material placed in accordance with the specified requirements. The quantity will be computed in accordance with the authorised dimensions of the layer. The bid rates shall include full compensation for providing all the material, irrespective of its origin, including gravel (notwithstanding the provisions of SECTION 1600), for all mixing, placing, compacting and finishing as specified in this Section and other appropriate Sections of the Specifications, for all transport, work in restricted areas, and also for all machinery, equipment, labour, supervision and other incidentals for executing the work as specified.

CLEANING THE CRACKS WITH COMPRESSED AIR:

(km)

The unit of measurement for cleaning the cracks with compressed air shall be the kilometre of road along which all the cracks have been blown clean. The bid rate shall include full compensation for providing all equipment, labour, supervision and incidentals for blowing clean the cracks over the full width of the road to the satisfaction of the Engineer. ITEM 48.13 APPLYING BITUMINOUS BINDERS, AND SEALANTS FOR SEALING CRACKS:
LITRE

UNIT

(a) MSP/1 OR SIMILAR PRIMER

(l)

(b) ANIONIC STABLE-GRADE EMULSION MIXED

WITH SYNTHETIC MODIFIERS

LITRE LITRE LITRE

(l) (l) (l)

(c) HOT BITUMEN RUBBER (d) OTHER SPECIFIED AGENTS (TYPE INDICATED)

The unit of measurement shall be the litre of material applied as specified or as instructed by the Engineer. The bid rates shall include full compensation for providing, mixing, heating (where required) and applying all the materials specified, and for all equipment, labour, supervision and incidentals for completing the work. No additional payment shall be made for multiple applications of material, and payment will not distinguish between the various types, widths or lengths of cracks. ITEM 48.14 COLD RUBBER-SLURRY
FOR SEALING CRACKS

UNIT
CUBIC METRE

(m3)

The unit of measurement for crack treatment with rubber slurry shall be the cubic metre of fine rubber crumbs used for preparing the mix. The bid rate shall include full compensation for procuring and providing all the material, including emulsion synthetic modifiers, cement and water, and for mixing and applying the mixture, and for all equipment, labour, supervision, and incidentals for executing the work in accordance with the specifications. Payment will not be made for redundant rubber pellets or redundant mixture or for mixture, which in the opinion of the Engineer has been wasted. ITEM 48.15 ROLLING THE CRACKS UNIT
METRE

(m)

The unit of measurement shall be the metre of crack rolled to the satisfaction of the Engineer.