JKR Flexible Pavement

Standard Specification For Road Works
FOR INTERNAL USE ONLY
SECTION 4
FLEXIBLE PAVEMENT
Cawangan Jalan, Ibu Pejabat JKR, K.L
Page 75
SECTION 4 - FLEXIBLE PAVEMENT

Page
4.1
UNBOUND PAVEMENT COURSES
S4-78
4.1.1
Lower Subbase
4.1.1.1 Description
4.1.1.2 Materials
4.1.1.3 Construction Methods
S4-78
S4-78
S4-78
S4-78
4.1.2
Subbase
4.1.2.1 Description
4.1.2.2 Materials
S4-79
S4-79
S4-79
S4-80
4.1.3
Gravel Surfacing
4.1.3.2 Materials
S4-81
S4-81
S4-82
4.1.4
Crushed Aggregate Roadbase
4.1.4.1 Description
4.1.4.2 Materials
S4-83
S4-83
S4-83
S4-84
4.2
BITUMINOUS PAVEMENT COURSES
S4-85
4.2.1
4.2.1.1
4.2.1.2
4.2.1.3
4.2.1.4
Bitumen Prime Coat

Description
Materials
Equipment
Construction Methods
S4-85
S4-85
S4-85
S4-85
S4-87
4.2.2
4.2.2.1
4.2.2.2
4.2.2.3
4.2.2.4
Bituminous Tack Coat

Description
Materials
Equipment
S4-88
S4-88
S4-88
S4-88
S4-89
4.2.3
4.2.3.1
4.2.3.2
4.2.3.3
4.2.3.4
Bituminous Surface Dressing

Description
Materials
Equipment
S4-90
S4-90
S4-90
S4-91
S4-93
Page 76

Page
4.2.4
4.2.4.1
4.2.4.2
4.2.4.3
4.2.4.4
4.2.4.5
Asphaltic Concrete
Description
Materials
Asphaltic Concrete Mix Design
Equipment
S4-99
S4-99
S4-99
S4-102
S4-105
S4-110
4.2.5
4.2.5.1
4.2.5.2
4.2.5.3
4.2.5.4
Bituminous Macadam
Description
Materials
Equipment
S4-116
S4-116
S4-116
S4-116
S4-116
4.3
SHOULDERS
4.3.1
S4-119
Description
S4-119
4.3.2
Materials
4.3.2.1 Earth Shoulders
4.3.2.2 Gravel Shoulders
S4-119
S4-119
S4-119
4.3.3
S4-119
4.4
HORIZONTAL ALIGNMENT, SURFACE LEVELS AND

SURFACE REGULARITY OF PAVEMENT COURSES
S4-120
4.4.1
Horizontal Alignment
S4-120
4.4.2
Surface Levels of Pavement Courses
S4-120
4.4.3
Surface Regularity
S4-121
Page 77
SECTION 4 FLEXIBLE PAVEMENT

4.1
UNBOUND PAVEMENT
COURSES
4.1.1
Lower Subbase
4.1.1.1 Description
This work shall consist of
furnishing, placing, compacting
and shaping lower subbase
material on a prepared and
accepted subgrade in accordance
with this Specification and the
lines, levels, grades, dimensions
and cross-sections shown on the
Drawings and/or as required by
the S.O.

accordance with the provisions of
Sub-Section 2.2.7.
Notwithstanding any earlier
approval of finished subgrade,
any damage to or deterioration of
the subgrade shall be made good
to the satisfaction of the S.O.
before lower subbase is
constructed.
Lower subbase shall be placed
over the full width of the
formation to the required
thickness as shown on the
Drawings or directed by the S.O.
in one layer or more, each layer
not exceeding 200 mm
compacted thickness. Where two
or more layers are required they
shall be of approximately equal
thickness and none shall be less
than 100 mm compacted
thickness.
4.1.1.2 Materials
Lower subbase material shall be
inorganic soil, sand, gravel,
weathered or fragmented rock, or
a mixture of any of these
materials, essentially free from
vegetative and other organic
matter and expansive clay
minerals. It shall have a
maximum particle size of 75 mm
or less, and shall have a CBR
value not less than that shown on
the Drawings when compacted to
95% of the maximum dry density
determined in the B.S. 1377
Compaction Test (4.5 kg rammer
method) and soaked for 4 days
under a surcharge of 4.5 kg.
Each layer of lower subbase shall

be processed as necessary to
bring its moisture content to a
uniform level throughout the
material suitable for compaction,
and shall then be compacted
using suitable compaction
equipment approved by the S.O.
to not less than 95% of the
maximum dry density determined
in the B.S. 1377 Compaction Test
(4.5 kg rammer method).
Compaction shall be carried out
in a longitudinal direction along
the roadbed, and shall generally
begin at the outer edge and
progress uniformly towards the
crown on each side in such a
manner that each section receives
equal compactive effort, all to the
satisfaction of the S.O.
Prior to placing any lower

subbase material, the underlying
subgrade (particularly the top 300
mm of the subgrade) shall have
been shaped and compacted in
Page 78
The lower subbase shall be

finished in a neat and workman
like manner, and shall have an
average thickness over any 100
metre length not less than the
required thickness. The top
surface of the lower subbase shall
have the required shape,
superelevation, levels and grades,
and shall be everywhere within
the tolerances specified in SubSection 4.4.
4.1.2 Subbase
4.1.2.1 Description
and shaping subbase material on
a prepared and accepted subgrade
or lower subbase in accordance
the S.O.
4.1.2.2 Materials

i) the liquid limit shall be not
more than 25%;
ii) the plasticity index shall be
not more than 6;
iii) the aggregate crushing value
when tested in accordance
with M.S. 30 shall be not
more than 35;
iv) unless otherwise specified on
the Drawings or directed by
the S.O., the material shall
have a CBR value of 30 or
more when compacted to
95% of the maximum dry
density determined in the B.S.
1377 Compaction Test (4.5 kg
rammer method) and soaked
for 4 days under a surcharge
of 4.5 kg;
v) the gradation shall conform
to one of the envelopes
shown in Table 4.1 with the
fraction passing the B.S. 75
um sieve not greater than 2/3
of the fraction passing the
B.S. 425 um sieve.
Subbase material shall be a

natural or prepared aggregate
comprising crushed rock,
weathered or fragmented rock,
gravel or crushed gravel, sand, or
a mixture of any of these
materials. It shall have a small
proportion of plastic or
non-plastic fines and shall be
essentially free from vegetative
and other organic matter,
expansive clay minerals and
lumps of clay. The material
shall conform to the following
physical and mechanical quality
requirements :-
Page 79
TABLE 4.1 - GRADATION LIMITS FOR SUBBASE MATERIAL
B.S.
Sieve
Size
50.0 mm
25.0 mm
9.5 mm
4.75 mm
2.00 mm
425 um
75 um
% Passing By Weight
A
100
30-65
25-55
15-40
8-20
2-8
B
100
79-95
40-75
30-60
20-45
15-30
5-20
C
100
50-85
35-65
25-50
15-30
5-20

Prior to placing any subbase
material, the underlying subgrade
(particularly the top 300 mm of the
subgrade) or lower subbase shall
have been shaped and compacted in
Sub-Section 2.2.7 or Sub-Section
4.1.1.3 as appropriate.
approval of finished subgrade or
lower subbase, any damage to or
deterioration of the subgrade or
lower subbase shall be made good
to the satisfaction of the S.O. before
subbase is constructed.
Subbase shall be placed with
over the full width of the formation
to the required thickness as shown
on the Drawings or directed by the
S.O. in one layer or more, each
layer not exceeding 200 mm
than 100 mm compacted thickness.
Each layer of subbase shall be
processed as necessary to bring
its moisture content to a uniform
level throughout the material
D
100
60-100
50-85
40-70
25-45
5-20
E
100
55-100
40-100
20-50
6-20
F
100
70-100
55-100
30-70
8-25
suitable for compaction, and shall

then be compacted using suitable
compaction equipment approved
by the S.O. to not less than 95%
of the maximum dry density
method). Compaction shall be
carried out in a longitudinal
direction along the carriageway,
and shall generally begin at the
outer edge and progress
uniformly towards the centre on
each side, except on
superelevated curves where
rolling shall begin at the lower
edge and progress uniformly
towards the higher edge. In all
cases compaction shall be carried
out in such a manner that each
section receives equal compactive
effort, all to the satisfaction of the
S.O.
Throughout the placing,
adjustment of moisture content
and compaction of subbase
material, care shall be taken to
maintain a uniform gradation of
the material and prevent its
separation into coarse and fine
parts, all to the satisfaction of the
S.O.
Page 80
The subbase shall be finished in a

neat and workmanlike manner;
its width shall be everywhere at
least that specified or shown on
the Drawings on both sides of the
centre-line; and its average
thickness over any 100 metre
length shall be not less than the
surface of the subbase shall have
the required shape,
and shall be everywhere within
the tolerances specified in SubSection 4.4.
4.1.3
4.1.3.2 Materials
Gravel surfacing material shall be
a natural or prepared soilaggregate mixture comprising
gravel and sand size particles
together with a small proportion
of plastic fines, and shall be
essentially free from vegetative
and other organic matter,
expansive clay minerals and
lumps of clay. The material shall
conform to the following physical
and mechanical quality
requirements :-
Gravel Surfacing
i) the liquid limit shall be not

more than 35%;
4.1.3.1 Description
ii) the plasticity index shall be in
the range 4 to 10;

and shaping gravel surfacing
material on a prepared and
accepted subgrade or lower
subbase in accordance with this
Specification and the lines, levels,
grades, dimensions and
cross-sections shown on the
the S.O.
iii) the aggregate crushing value

more than 35;
iv) the gradation shall conform
to one of the envelopes
shown in Table 4.2 with the
fraction passing the B.S. 75
um sieve not greater than 2/3
of the fraction passing the
B.S. 425 um sieve.
TABLE 4.2 - GRADATION LIMITS FOR GRAVEL SURFACING
% Passing By Weight
B.S. Sieve
Size
37.5 mm
12.5 mm
4.75 mm
2.00 mm
425 um
75 um
100
45 - 75
30 - 60
20 - 45
15 - 30
8 - 20
100
55 - 85
35 - 65
25 - 50
15 - 30
8 - 20
100
60 - 100
50 - 85
40 - 70
25 - 45
8 - 20
D
100
55 - 90
40 - 70
20 - 50
8 - 25
Page 81
Material with a maximum

particle size of 37.5 mm, while
otherwise not conforming to the
gradation specification but
satisfying the other requirements,
shall be acceptable provided that
it shall have a CBR value of 30
or more when compacted to 95%
method) and soaked for 4 days
under a surcharge of 4.5 kg.
Prior to placing any gravel
surfacing material, the underlying
subgrade (particularly the top 300
mm of the subgrade) or lower
subbase shall have been shaped
and compacted in accordance
with the provisions of SubSection 2.2.7 or Sub-Section
4.1.1.3 as appropriate.
approval of finished subgrade or
lower subbase, any damage to or
lower subbase shall be made
good to the satisfaction of the
S.O. before gravel surfacing is
constructed.
Gravel surfacing shall be placed
to the required width and
thickness as shown on the
thickness.
Each layer of gravel surfacing
shall be processed as necessary to
bring its moisture content to a

uniform level throughout the
material suitable for compaction,
and shall then be compacted
using suitable compaction
to not less than 95% of the
maximum dry density determined
in the B.S. 1377 Compaction Test
(4.5 kg rammer method).
the carriageway, and shall
generally begin at the outer edge
and progress uniformly towards
the centre on each side, except on
S.O.
and compaction of gravel
surfacing material, care shall be
taken to maintain a uniform
gradation of the material and
prevent its separation into coarse
and fine parts, all to the
The gravel surfacing shall be
finished in a neat and
workmanlike manner; its width
shall be everywhere at least that
specified or shown on the
Drawings on both sides of the
required thickness and its
minimum thickness at any point
shall be not less than the required
thickness minus 20 mm.
Page 82
The top surface of the gravel

surfacing shall have the required
shape, superelevation, levels and
grades, and shall be everywhere
within 10 mm of the required
plane or such higher,
approximately parallel plane, as
the S.O. shall approve.
4.1.4
iv) not less than 80% of particles

retained on the B.S. 4.75 mm
sieve shall have at least one
fractured face;
v) the weighted average loss of
weight in the sodium sulphate
soundness test (5 cycles)
with AASHTO Test Method
T 104 shall be not more than
12%;
Crushed Aggregate Roadbase
4.1.4.1 Description
and shaping crushed aggregate
roadbase material on a prepared
and accepted subgrade or lower
subbase or subbase in accordance
the S.O.
vi) the material shall have a CBR

value of not less than 80 when
compacted to 95% of the
maximum dry density
Compaction Test (4.5 kg
rammer method) and soaked
for 4 days under a surcharge
of 4.5 kg;
vii)the gradation shall comply
with the envelope shown in
Table 4.3 for the type
specified.
4.1.4.2 Materials
Crushed aggregate roadbase
material shall be crushed rock, or
crushed gravel, or a mixture of
crushed and natural aggregates,
which is hard, durable, clean and
essentially free from clay and
other deleterious materials.
The material shall conform to the
following physical and
mechanical quality requirements:i) the plasticity index shall be not
more than 6;
ii) the aggregate crushing value
when tested in accordance with
M.S. 30 shall be not more than
30;
iii) the flakiness index when tested in
accordance with M.S. 30 shall be
not more than 30;
TABLE 4.3 - GRADATION LIMITS FOR

CRUSHED AGGREGATE ROADBASE
B.S. Sieve
Size
50.0 mm
37.5 mm
28.0 mm
20.0 mm
10.0 mm
5.0 mm
2.36 mm
2.00 mm
600 um
425 um
75 um
% Passing By Weight
Type I
Type II
100
95 - 100
60 - 80
40 - 60
25 - 40
15 - 30
8 22
08
100
85 - 100
70 - 100
60 - 90
40 - 65
30 - 55
20 - 40
10 - 25
2 - 10
Page 83

Prior to placing any crushed
aggregate roadbase material, the
underlying subgrade or lower
subbase or subbase shall have
the appropriate Section of this
Specification. Notwithstanding
any earlier approval of finished
subgrade or lower subbase or
subbase, any damage to or
lower subbase or subbase shall be
made good to the satisfaction of
the S.O. before crushed aggregate
roadbase is constructed.
Crushed aggregate roadbase shall
be placed to the required width
and thickness as shown on the
thickness. Spreading shall be
done by a mechanical spreader
approved by the S.O. or, if
approved by the S.O., by motor
grader.
Prior to spreading, crushed
aggregate roadbase shall be
processed as necessary to bring
its moisture content to a uniform
level throughout the material
suitable for compaction. Spread
material shall be maintained at
the correct moisture content for
proper compaction by sprinkling
with water or drying as may be
necessary, and shall be
compacted using suitable
compaction equipment approved
by the S.O. to not less than 95%

method).
the carriageway, and shall
generally begin at the outer edge
and progress uniformly towards
the centre on each side, except on
S.O.
and compaction of crushed
aggregate roadbase material, care
shall be taken to maintain a uni
form gradation of the material
and prevent its separation into
coarse and fine parts, all to the
The crushed aggregate roadbase
shall be finished in a neat and
workmanlike manner; its width
specified or shown on the
surface of the crushed aggregate
roadbase shall have the required
within the tolerances specified in
Sub-Section 4.4.2.
Page 84
4.2
BITUMINOUS PAVEMENT
COURSES
4.2.1
Bitumen Prime Coat
4.2.1.1 Description
This work shall consist of the
careful and thorough cleaning of
the surface of a prepared and
accepted crushed aggregate
roadbase, and the furnishing and
application to the cleaned
roadbase surface of a bituminous
priming material, all in
accordance with this
Specification and the lines,
dimensions and cross-sections
shown on the Drawings and/or as
required by the S.O.
4.2.1.2 Materials
The bituminous priming material
shall be either cut-back bitumen
or bitumen emulsion as stated in
the Bill of Quantities.
Cut-back bitumen shall be grade
RC-70 or MC-70 conforming to
the requirements of M.S. 159.
Bitumen emulsion shall be slow
setting, grade SS-1 or SS-1K,
conforming to the requirements
of M.S. 161, as appropriate to the
type of roadbase material to be
primed and approved by the S.O.
4.2.1.3 Equipment
The equipment used by the
Contractor shall include a power
broom, a compressed air blower,
a self-propelled pressure
distributor for bituminous
material, and as necessary,
equipment for storing and heating
bituminous material.

(a) Power Broom
The power broom shall be a
rotary type specifically
designed for sweeping road
surfaces, and shall be
approved by the S.O.
(b) Compressed Air Blower
The compressed air blower
shall comprise a portable air
compressor of 3 cu.m/min. in
capacity at 0.7 N/sq.mm
delivery pressure with a
suitable hose and nozzle for
blowing clean a road surface
after power brooming, and
shall be approved by the S.O.
(c) Pressure Distributor for
Bituminous Material
The distributor shall be a
purpose built model of
recognised manufacture and
shall be approved by the S.O.
It shall conform to the
requirements described
hereunder.
The distributor shall have a
suitable capacity and shall be
equipped with a gas or oil
fired heating system capable
of heating a full charge of
bituminous material to
l80C. The heating system
shall be such that overheating
of the bituminous material
will not occur and shall be of
a type in which flames from
the burner do not come into
direct contact with the casing
of the tank containing the
bituminous material. The
tank shall be insulated in such
a manner that when filled
with bituminous material at
l80C and not heated,
Page 85
the drop in temperature shall be

less than 3C per hour. A
thermometer shall be provided to
measure continuously the
temperature of the bituminous
material in the tank and shall be
so arranged that the highest
temperature in the tank is
measured. The tank shall be
fitted with an accurately
calibrated dipstick or contents
gauge, and the pipe for filling the
tank shall be fitted with an easily
replaceable filter.
The distributor shall run on
pneumatic tyred wheels of such
width and number that the load
produced on the road surface
when the vehicle is fully charged
shall not exceed l2 kg/mm of tyre
width. The vehicle shall be
equipped with a `fifth wheel'
tacheometer system to accurately
measure its forward speed during
spraying operations.
The distributor shall be equipped
with a full circulation type spray
bar with nozzles from which the
bituminous material is sprayed on
to the road surface uniformly
over the full spraying width. The
spraying width shall be variable
in increments of not more than
100 mm up to a maximum of 5.0
metres. The spraying pump shall
be driven by a separate power
unit and shall be equipped with
an accurate pressure gauge and
an accurate flow rate gauge or
meter. On the suction side the
pump shall be fitted with an
easily replaceable filter. The
spray bar and pump shall be so
designed that bituminous material
at even temperature and uniform
pressure may be sprayed uni
formly over the spraying width at
controlled rates in the range

0.25 to 8.0 litres/sq.m at normal
distributor operating speeds, such
that deviation from the prescribed
rate of application shall not
exceed 10%.
The distributor shall be equipped
with a hand spraying system.
The meters for the `fifth wheel'
tachometer system and the
bituminous material pumping
flow rate, pumping pressure and
temperature shall be located in
such a manner that the vehicle
driver can easily read them while
operating the distributor. The
spray bar shall be controlled by a
second operator riding at the rear
of the vehicle in such a position
that all the discharge sprays are in
his good view.
All measuring equipment on the
distributor shall have been
recently calibrated, and accurate
and satisfactory records of the
calibrations shall be submitted to
the S.O. If in the course of the
work the rates of application of
bituminous material are found to
be inaccurate, the distributor shall
be withdrawn from the Works
and recalibrated to the
satisfaction of the S.O. before
being returned to service.
The S.O. may require such
performance tests as he considers
necessary to check that the
distributor is operating
satisfactorily. As directed by the
S.O., the Contractor shall make
the distributor and its equipment
available for such tests and shall
supply all necessary assistance,
materials, tools, testing apparatus,
etc., all at the Contractor's own
expense.
Page 86
(d) Storage and Heating Facilities

for Bituminous Material
Tanks for storage of
bituminous material shall
have a capacity suited to the
proposed rate of utilisation of
the material and the method
and frequency of its delivery
to the Works, all to the satis
faction of the S.O. The tanks
and, where necessary, barrel
decanters shall be equipped
with heating systems which
provide for effective and
positive control of the
temperature of the bituminous
material at all times up to the
temperature required for
utilisation. The method of
heating shall be such that
neither flames nor the
products of combustion shall
come into direct contact with
the bituminous material or the
casing of its immediate
container, and such that no
portion of the bituminous
material shall be subject to
overheating.
(a) General Conditions
Bitumen prime coat work
shall only be carried out in
dry, warm weather when the
surface to be treated is
essentially dry.
(b) Surface Preparation and
Cleaning
Prior to applying the prime
coat, the crushed aggregate
roadbase shall have been
shaped and compacted in
accordance with the
provisions of Sub-Section
4.1.4.3.

approval of finished crushed
aggregate roadbase, any
damage to or deterioration of
the roadbase shall be made
good to the satisfaction of the
S.O. before prime coat is
applied.
Immediately prior to applying
the bituminous material, the
full width of the surface to be
treated shall be swept using a
power broom followed by a
compressed air blower and, if
necessary, scraped using hand
tools to remove all dirt, dust
and other objectionable
material, all to the satisfaction
of the S.O.
(c) Application of Bituminous
Material
The bituminous priming
material shall be sprayed on
to the cleaned roadbase
surface by means of a
pressure distributor. Any
areas inaccessible to the
distributor spray bar shall be
treated using the distributor's
hand spraying system. The
rate or rates of application
shall be as directed by the
S.O. based on the results of
test applications, but shall
usually be in the range 0.5 to
1.0 litre/sq.m. The
temperature of cut-back
bitumen shall be maintained
in the range 50C to 70C
during spraying operations.
For bitumen emulsions, the
spraying temperature shall be
in the range 25C to 45C.
Page 87
If necessary, in order to
prevent the bituminous
material from flowing on the
sprayed surface, the pre
scribed prime coat shall be
applied in two separate
spraying operations. Where
the condition of the treated
surface indicates that it is
necessary, bituminous
material additional to that
prescribed shall be applied as
the S.O. shall direct.
Prime coat shall be distributed
uniformly over the surface to
be treated without streaking;
the quantities applied shall not
deviate by more than 10%
from those prescribed. Areas
with insufficient bituminous
material shall be resprayed as
necessary to make up the
deficiency, all to the
The surfaces of structures,
road furniture and trees
adjacent to the areas being
sprayed shall be protected in
such a manner as to prevent
their being spattered or
marred by bituminous
material. Bituminous material
shall not be discharged into
road drains, gutters, etc.
(d) Curing and Opening to Traffic
Prime coat shall normally be
left undisturbed for at least 24
hours after application and
shall not be opened to traffic
until, in the opinion of the
S.O., it has penetrated the
roadbase and cured
sufficiently so that it will not
be picked up by the wheels of
vehicles.
The Contractor shall maintain

the prime coat, all to the
satisfaction of the S.O., until
the overlying pavement
course is constructed, which
shall not be within 24 hours
after the application of the
bituminous priming material
nor within such longer period
as is required, in the opinion
of the S.O., for the prime coat
to achieve maximum
penetration of the roadbase
and become fully cured.
4.2.2
Bituminous Tack Coat
4.2.2.1 Description
accepted bituminous or bitumen
primed pavement course, and the
furnishing and application to the
cleaned surface of a bituminous
tack coat prior to the construction
of an overlying bituminous
pavement course, all in
accordance with this
required by the S.O.
4.2.2.2 Materials
Bituminous tack coat material
shall be rapid setting bitumen
emulsion of grade RS-1 or RS1K conforming to the
requirements of M.S. 161.
4.2.2.3 Equipment
The equipment shall be as
specified in Sub-Section 4.2.1.3.
Page 88

Material

Bituminous tack coat shall
only be applied to a clean,
dry, bituminous or bitumen
primed surface.
Bituminous tack coat shall
only be applied as far in
advance of the construction of
the overlying bituminous
pavement course as is
necessary to achieve a satis
factory degree of tackiness
before the overlying material
is placed, all to the
Cleaning
Prior to applying bituminous
tack coat, the surface to be
treated shall have been
prepared in accordance with
the appropriate Sections of
this Specification.
approval of this surface, any
damage to it or deterioration
of it shall be made good
before tack coat is applied.
Immediately prior to applying
bituminous tack coat, the full
width of the surface to be
treated shall be swept using a
compressed air blower, and if
necessary, scraped using hand
tools, to remove all dirt, dust
and other objectionable
material, all to the satisfaction
of the S.O.
The bituminous tack coat

shall be sprayed on to the
cleaned bituminous or
bitumen primed surface by
means of a pressure
distributor. Any areas
inaccessible to the distributor
spray bar shall be treated
using the distributor's hand
spraying system. The rate or
rates of application shall be as
directed by the S.O. based on
the results of test applications,
but shall usually be in the
range 0.25 to 0.55 litres/sq.m.
The temperature of the
bituminous material shall be
maintained in the range 25C
to 45C during spraying
operations.
Tack coat shall be distributed
uniformly over the surface to
be treated without streaking;
the quantities applied shall not
deviate by more than 10%
from those prescribed. Areas
with bituminous material in
excess of these limits shall
have the excess removed at
the Contractor's expense, and
areas with insufficient
bituminous material shall be
resprayed as necessary to
make up the deficiency, all to
the satisfaction of the S.O.
sprayed shall be protected in
such a manner as to prevent
Page 89
Traffic shall be kept off the

tack coat at all times, and the
Contractor shall maintain the
tack coat, all to the
satisfaction of the S.O., until
the overlying pavement
course is constructed.
4.2.3
Bituminous Surface Dressing
4.2.3.1 Description
primed pavement course, and the
furnishing and placing on the
cleaned surface of one or two
applications of bituminous
material and cover aggregate, all
in accordance with this
required by the S.O. When one
application of bituminous
material and cover aggregate is
placed the term `single
bituminous surface dressing'
(SBSD) shall apply, and when
two applications of bituminous
material and cover aggregate are
placed, the term `double
bituminous surface dressing'
(DBSD) shall apply.
4.2.3.2 Materials

Penetration graded bitumen
shall be 80-100 grade con
forming to M.S. 124.
Cut-back bitumen shall be
grade RC-70 or MC-70
conforming to M.S. 159.
Bitumen emulsion shall be
rapid setting of grade RS1, RS-1K, RS-2, RS-2K or
RS-3K conforming to M.S.
161. The grade of emulsion
selected shall be anionic or
cationic as appropriate to the
type of rock from which the
cover aggregate is derived,
and shall be approved by the
S.O.
(b) Additives for Bituminous
Material
An adhesion and antistripping agent shall be added
to the bituminous material if
the S.O. shall so direct or
approve. The additive shall be
of a type approved by the
S.O. and the required quantity
of additive shall be
thoroughly mixed with the
bituminous material in
accordance with the
manufacturer's instructions or
as directed by the S.O. for
such time as is necessary to
produce a homogenous
mixture.
(a) Bituminous Material

Bituminous binder for
bituminous surface dressing
shall be penetration graded
bitumen, or cut-back bitumen,
or bitumen emulsion as
shown on the Drawings or
otherwise specified.
(c) Aggregates for Bituminous

Surface Dressing
For single bituminous surface
dressing the cover aggregate
shall be nominal 20 mm, 14
mm, 10 mm or 6 mm size
chippings as shown on the
Drawings and/or directed by
the S.O.
Page 90
For double bituminous

surface dressing the cover
aggregate for the first
material and cover aggregate
shall be nominal 20 mm size
chippings, and the cover
aggregate for the second
shall be nominal 10 mm size
chippings.
iii) the weighted average loss

of weight in the sodium
sulphate soundness test (5
cycles) when tested in
accordance with AASHTO
Test Method T 104 shall
be not more than 12%;
Cover aggregates shall be

screened, crushed stone and
shall comprise clean, dry,
hard, tough, sound, angular
and cubical chippings free
from vegetative and other
organic matter, clay and other
deleterious substances, and
containing few, if any, flaky
or elongated particles. Dusty
chippings shall be washed
clean, all to the satisfaction of
the S.O. Cover agregates
physical and mechanical
requirements :-
v) the polished stone value

less than 40;
i) using the type of

bituminous material to be
used in the Works, treated
with additive if so
required, the coated area in
the coating and stripping
test for bitumen aggregate
mixtures, AASHTO Test
Method T 182, shall not
be less than 95%;
ii) the aggregate crushing
value when tested in
accordance with M.S. 30
shall be not more than 30;
iv) the flakiness index when

tested in accordance with
M.S. 30 shall be not more
than 25;
vi) the gradation shall con

form to the appropriate
envelope shown in Table
4.4.
4.2.3.3 Equipment
The Contractor shall provide all
the plant and equipment
necessary for executing the work
Specification, and shall furnish
the S.O. with such details of
particular items of equipment,
e.g. manufacturer, model type,
capacity, weight, etc., as the S.O.
shall require.
The equipment shall include a
power broom, a compressed air
blower, a self-propelled pressure
distributor for bituminous
material, all necessary equipment
for storing and heating
bituminous material, aggregate
spreading equipment, a suitable
number of tip-trucks and a selfpropelled pneumatic tyred roller.
Page 91
TABLE 4.4 - GRADATION LIMITS FOR BITUMINOUS SURFACE DRESSING
% Passing By Weight
B.S.
Sieve
Size
25.0 mm
20.0 mm
14.0 mm
10.0 mm
6.3 mm
4.75 mm
2.36 mm
Nominal
20 mm
Chippings
Nominal
14 mm
Chippings
Nominal
10 mm
Chippings
Nominal
6 mm
Chippings
100
85 - 100
0 - 20
0-5
0-2
100
85 - 100
0 - 20
0-5
0-2
100
85 - 100
0 - 20
0 - 10
0-2
100
85 - 100
0 - 25
0 - 10
(a) Power Broom

The power broom shall be
as specified in Sub-Section
4.2.1.3(a).
(b) Compressed Air Blower
The compressed air
blower shall be as
specified in Sub-Section
4.2.1.3 (b).
(c) Pressure Distributor for
Bituminous Material
The distributor shall be as
4.2.1.3(c).
(d) Storage and Heating
Facilities for Bituminous
Material
Storage and heating
facilities for bituminous
material shall be as
4.2.1.3 (d).
(e) Aggregate Spreading

Equipment
Aggregates shall be placed
using mechanical
spreaders of a type
approved by the S.O. The
spreaders shall be capable
of applying aggregate
uniformly over the full
width of the area being
treated and shall have
controls to regulate the
rate of spread as required
by this Specification, all to
(f) Tip-Trucks
The Contractor shall
provide a suitable number
of tip-trucks of a type
approved by the S.O.,
capable of spreading
aggregate in accordance
with this Specification.
Page 92
(g) Pneumatic Tyred Roller

The pneumatic tyred roller
shall be of recognised
manufcature and shall be
approved by the S.O. It
shall conform to the
requirements described
hereunder.
shall be self-propelled and
capable of being reversed
without backlash; it shall
be equipped with power
steering and dual controls
allowing operation from
either the left or right side.
The roller shall have nine
wheels equipped with
smooth treaded tyres all of
the same size and
construction, and capable
of operating at inflation
pressures of up to 0.9
N/sq.mm. Five wheels
shall be on the driven axle
and four on the steering
axle, all equally spaced on
both axles and arranged so
that the tyres on the
steering axle track midway
between those on the
driven axle with a small
overlap. The roller shall be
equipped with water tanks,
sprinkler systems and pads
of coconut matting to keep
all tyres evenly wetted
during operation.
The roller shall be
equipped with means of
adjusting its total weight
by ballasting so that the
load per wheel can be
varied in the range 1.0 to
2.0 tonnes.

In operation, the ballasted
weight and the tyre
inflation pressure shall be
adjusted to meet the
requirements of each
particular operation. Each
tyre shall be kept inflated
at the specified pressure
such that the pressure
difference between any
two tyres shall not exceed
0.04 N/sq.mm. Means
shall be provided for
checking and adjusting
tyre pressures at all times
at the place of the works.
The Contractor shall
provide the S.O. with a
calibration chart for the
roller showing the
relationship between the
quantity or depth of ballast
and total weight, and also
a chart showing the
relationship between
wheel load, tyre inflation
pressure and contact
pressure.
Bituminous surface dressing
shall only be carried out in
dry, warm weather when the
surface to be treated is dry.
Work shall be discontinued
when rain appears imminent
and during periods of strong
wind.
The S.O. may order the
discontinuation of work on
account of adverse weather,
unsatisfactory condition of
materials, equipment or
Page 93
surface to be treated, or such

other conditions as he shall
consider detrimental to the
work.

Material
The bituminous material for a
single bituminous surface
dressing or for each
of a double bituminous
surface dressing, shall be
sprayed on to the cleaned
surface to be treated by means
of a pressure distributor. Any
areas inaccessible to the
distributor spray bar shall be
treated using the distributor's
hand spraying system.

Cleaning
Prior to constructing a
bituminous surface dressing,
the surface to be treated shall
have been prepared in
accordance with the
appropriate Sections of this
Specification.Notwithstanding
any earlier approval of this
surface, any damage to or
deterioration of it shall be
made good before surface
dressing is commenced.
Immediately prior to
commencing surface dressing,
the full width of the surface to
be treated, together with an
additional 300 mm width on
each side, shall be swept
using a power broom
followed by a compressed air
blower and, if necessary,
scraped using hand tools to
remove all loose particles,
dirt, dust and other
objectionable material, all to
In double bituminous surface
dressing construction, the
surface of the first application
of bituminous material and
cover aggregate shall be
similarly made good and
cleaned, immediately prior to
commencing the second
application.
The rate or rates of

application shall be as
the results of laboratory tests
and/or test applications but for
penetration graded bitumen
shall usually be in the
appropriate range given in
Table 4.5.
TABLE 4.5 RATES OF APPLICATION

OF PENETRATION GRADED BITUMEN
Nominal Size
of Aggregate
Rate of Application of
Penetration Graded
Bitumen
20 mm
2.0 - 3.0 litre/sq.m
14 mm
10 mm
6 mm
Page 94
The rates of application

for cut-back bitumens and
bitumen emulsions shall
be commensurately higher
depending on their residual
bitumen contents.
The temperature of the
be maintained during
spraying operations within
the appropriate range
given in Table 4.6.
The bituminous material
shall be distributed
uniformly over the surface
to be treated without
streaking; the quantities
applied shall not deviate
by more than 10% from
those prescribed. The rate
of application shall be
checked for each spraying
run by measuring the
volume of bituminous
material in the distributor
before and after spraying
and the area treated.
Adjustments shall be made
as necessary to ensure that
the prescribed rate of
application is maintained
in subsequent runs.
Spraying shall be
discontinued immediately
if any defect develops in
the distributor, and it shall
not be resumed until the
fault has been rectified to

The spraying of bituminous
material over any portion of
the surface to be treated shall
not be carried out more than
two minutes in advance of
placing the cover aggregate
on that portion at the specified
rate; an the progress of
spraying the bituminous
material shall be restricted as
necessary to comply with
this requirement.
TABLE 4.6 - SPRAYING TEMPERATURE
FOR BITUMINOUS
Bituminous Material Spraying Temperature
80-100 penetration
grade bitumen
150 oC to 165 oC
Cut-back bitumen
grade
RC-70 or MC-70
50 oC to 65 oC
25oC to 45 oC
Bitumen emulsions
Bituminous materials
Bituminous materials shall
not be heated to spraying
temperatures too soon in
advance of requirements.
Any bituminous material
which has been heated to
spraying temperature for
more than ten hours or
which has been overheated
shall be rejected.
Page 95
In cases where the

bituminous material is
applied in lanes there shall
be a small overlap of
bituminous material at the
joints between lanes equal
in width to the edge strip
of the sprayed area which
does not receive the full
rate of application of
bituminous material. For
double bituminous surface
dressing, joints in the
second application of
be offset from those in the
first application by 150 300 mm for longitudinal
joints and by at least 1.0
metre, where possible, for
transverse joints.
Each spraying run shall
commence and terminate
on lengths of building
paper placed across the
full spraying width
immediately before and
after the section to be
sprayed. Sufficient building
paper shall be
placed so that the distributor
may be started and stopped
with the spray bar over paper,
and so that the correct
distributor road speed and rate
of spraying can be maintained
over the entire length of the
section to be sprayed, all to
Immediately after use and
before application of cover
aggregate, the building
paper shall be removed
and disposed of in a manner

Provision shall be made
for a volume of
bituminous material of at
least 10% of the capacity
of the distributor, or such
other quantity as the S.O.
shall direct, to remain in
the distributor tank at the
completion of each spraying
run, in order to avoid air
entrapment within the
bitumen spraying system.
sprayed shall be protected
in such a manner as to prevent
(d) Application of Cover
Aggregate
Before each spraying run
of bituminous material
commences, sufficient
aggregate to provide full
cover at the prescribed rate
of application over the
entire area to be sprayed
shall have been loaded in
trucks at the Site of the
Works in readiness for
spreading.
Immediately following
the application of the
bituminous material, the
clean, dry cover aggregate
shall be uniformly spread over
the bituminous material using
mechanical spreaders
Page 96
The aggregate shall be placed

as quickly as practicable after
the application of bituminous
material on all parts of the
area to be covered, and for no
portion of the surface to be
treated shall there be a delay
of more than two minutes
between the application of the
bituminous material
and the spreading of
the aggregate.
The trucks feeding the
aggregate to the mechanical
spreaders shall operate
backward during aggregate
spreading in order that the
wheels of the spreaders and
trucks shall not run on
uncovered bituminous
material.
The rate of application of
cover aggregate shall be as
the results of laboratory tests
and/or tests applications, but
shall usually be in the
appropriate range given in
Table 4.7
TABLE 4.7 - RATES OF APPLICATION OF
COVER AGGREGATE
Nominal
Size
Rate of Application
of Aggregate
20 mm
17 27 kg/sq.m
14 mm
12 18 kg/sq.m
10 mm
8 12 kg/sq.m
6 mm
5 8 kg/sq.m
The rate of application shall

be checked for each spraying
run from measurements of the
quantities of aggregate in the
trucks and the area treated, or
by sampling and measuring
the aggregate spread on the
road. Any bare or
insufficiently covered areas
shall be made good by hand
spreading as quickly as
possible. Aggregate in excess
of the rate prescribed shall be
evenly distributed over the
surface or removed as quickly
as possible, all to the
In cases where the surface
dressing is constructed in
lanes, the edge of the
aggregate spread adjacent to
an untreated lane shall
coincide with the edge of the
sprayed area which receives
the full rate of application of
the bituminous material. This
will leave a narrow strip of
bituminous material of partial
thickness which shall be
overlapped by the bituminous
material spray and aggregate
spread of the adjacent lane.
Immediately following the
spreading of the aggregate to
the satisfaction of the S.O.,
the aggregate shall be rolled
with a pneumatic tyred roller
approved by the S.O. to
embed the aggregate in the
bituminous material. Rolling
shall commence as quickly as
practicable after the
application of the bituminous
material and aggregate on all
parts of the area to be
covered, and for no portion
of the surface to be treated
shall there be a delay of more
Page 97
than 3 minutes between the

application of the bituminous
material and the
commencement of rolling.
shall be ballasted to an
operating weight of 9 - 10
tonnes and its tyre inflation
pressure shall be 0.53
N/sq.mm for surface dressing
work. Rolling shall be
continued for as long as is
necessary to thoroughly
embed the aggregate in the
bituminous material, all to the
Rolling shall generally begin
at the outer edge of surface
dressing and progress
uniformly towards the centre
on each side, except on super
elevated curves where rolling
shall begin at the lower edge
and progress uniformly
towards the higher edge.
Consecutive roller passes
shall generally overlap by
about one half of the roller's
width.
When, in the opinion of the
S.O., the bituminous material
has hardened sufficiently to
prevent the dislodgement of
embedded aggregate by the
action of the power broom, all
loose aggregate shall be swept
from the treated surface using
the power broom and
compressed air blower and
disposed of to the satisfaction
of the S.O. Where the
dressing so prepared is the
first application of a double
bituminous surface dressing,
construction of the second

shall then proceed as soon as
is practicable.
(e) Opening to Traffic
Bituminous surface dressing
shall normally not be opened
to traffic until such time as,
in the opinion of the S.O., the
surfacing shall have
developed sufficient strength
to withstand normal traffic
forces without dislodgement
of the aggregate. This will
usually be not less than 24
hours after the completion of
rolling. Where it is necessary
to allow earlier use of the
finished surface to facilitate
the movement of traffic,
vehicles may be allowed to
run on the work after rolling
has been completed, provided
that speeds are restricted to 30
km per hour or less and sharp
turning movements are
prohibited. The finished
surface shall subsequently
have to be closed
temporarily to enable the
loose aggregate to be swept
off and disposed of as
described in Sub-Section
4.2.3.4 (d).
Ideally, the first application of
bituminous material and cover
aggregate of a double
bituminous surface dressing
should not be opened to
traffic before construction of
the second application.
However, where it is
necessary to facilitate the
movement of traffic, the first
application may be opened to
traffic prior to construction of
the second application.
Nevertheless, traffic
movement on the completed
Page 98
first application shall be kept

to a practicable minimum and
the second application shall
be constructed as soon as is
practicable after the
completion of the first.
4.2.4 Asphaltic Concrete

4.2.4.1
organic matter, and other

deleterious substances. They
physical and mechanical quality
requirements :i) the aggregate crushing value
more than 30;
Description
furnishing, placing, shaping and
compacting asphaltic concrete
binder course and/or wearing
course on a prepared and
primed pavement course, and
shall include the careful and
thorough cleaning of surfaces
which are to be covered without
receiving a bituminous tack coat.
The work shall be carried out all
levels, grades, dimensions and
cross-sections shown on the
the S.O.
4.2.4.2
Materials
(a) Aggregates
Aggregate for asphaltic
concrete shall be a mixture of
coarse and fine aggregates
and, if necessary, mineral
filler. The individual aggregates
shall be of sizes suitable for
blending to produce the required
gradation of the combined
aggregate, all to the satisfaction
of the S.O.
Coarse aggregates shall be
screened crushed hard rock,
angular in shape and free from
dust, clay, vegetative and other
ii) the weighted average loss of

with AASHTO Test Method T
104 shall be not more than
12%;
iii) the flakiness index when
than 30;
iv) the water absorption when
than 2%;
v) the polished stone value when
M.S. 30 shall be not less than
40 (only applicable to
aggregates for wearing
course).
Fine aggregates shall be clean
natural sands, screened quarry
fines, or mining sand. Mining
sand shall be thoroughly washed
before use. Other types of fine
aggregate may be used subject to
the approval of the S.O.
Fine aggregates shall be nonplastic and free from clay, loam,
aggregations of material,
vegetative and other organic
matter, and other deleterious
substances.
Page 99
They shall conform to the

following physical and
mechanical quality requirements:i) the weighted average loss of
with AASHTO Test Method T
104 shall be not more than
12%;
ii) the water absorption when
than 2%.
Notwithstanding compliance with

the requirements of this
Specification, limestone
aggregates shall not be permitted
for use in wearing course.
The gradation of the combined
coarse and fine aggregates,
together with ordinary Portland
cement added as an adhesion and
anti-stripping agent and, if
necessary, any other mineral
filler, shall conform to the
appropriate envelope shown in
Table 4.8
TABLE 4.8 - GRADATION LIMITS FOR ASPHALTIC CONCRETE
Mix Type
Wearing Course
Binder Course
Mix
Designation
ACW 20
ACB 28
B.S. Sieve
% Passing by weight
37.5 mm
100
28.0 mm
100
80 - 100
20.0 mm
76 - 100
72 - 93
14.0 mm
64 - 89
58 - 82
10.0 mm
56 - 81
50 - 75
5.0 mm
46 - 71
36 - 58
3.35 mm
32 - 58
30 - 52
1.18 mm
20 - 42
18 - 38
425 um
12 - 28
11 - 25
150 um
6 - 16
5 - 14
75 um
4-8
3-8
Page 100
The gradation envelopes in the

above Table are purposely wider
than the tolerances for good
works control of asphaltic
concrete mixes. For each type of
mix required in the Works, the
Contractor shall establish a job
mix formula gradation which
shall consist of a single definite
percentage passing for each sieve
size in the above Table and shall
produce a smooth curve within
and essentially parallel to the
appropriate gradation envelope.
This job mix formula gradation,
with the allowable tolerances for
a single test as specified in SubSection 4.2.4.3 (c), then becomes
the job control envelope and this
job control envelope must be
totally within the limits of the
appropriate gradation envelope in
the above Table.
(b) Mineral Filler
Mineral filler shall be finely
divided mineral matter such as
rock dust, limestone dust, hydrated
lime, hydraulic cement, or such other
suitable material as the S.O. shall
approve. At the time of mixing with
bitumen it shall be sufficiently dry to
flow freely and shall be essentially
free from agglomerations. Not less
than 70% by weight shall pass the
B.S. 75 um sieve.
(c) Bituminous Material
Bituminous binder for asphaltic
concrete shall be penetration graded
bitumen of 80-100 grade conforming
to M.S. 124.
(d) Anti-Stripping Agent
Ordinary Portland cement shall be
added to the combined aggregate for
asphaltic concrete to serve as an

adhesion and anti-stripping agent. The
amount of cement added for this
purpose shall be 2% by weight of the
combined aggregate. (Additional
cement may also be added, if necessary,
to serve as filler.)
Ordinary Portland cement for this
purpose shall conform to the
requirements of M.S. 522 and shall be
dry, free flowing and free from
agglomerations at the time of use.
Notwithstanding the use of ordinary
Portland cement as an anti-stripping
agent as specified above, the Contractor
shall be responsible for ensuring that the
bitumen binder adheres satisfactorily to
the aggregate and does not strip from it
during the service life of the asphaltic
concrete.
Accordingly, the Contractor shall
carry out bitumen stripping tests with
the proposed aggregates to demonstrate
to the complete satisfaction of the S.O.
that the aggregates will perform
satisfactorily in service with the
specified bitumen binder. Such tests
shall be carried out in accordance with
AASHTO Test Method T 182, or such
other test methods as the S.O. shall
direct or approve. When AASHTO Test
Method T 182 is used, the coated area at
the end of the mixture's period of
immersion in water shall be not less
than 95%.
Where, in the opinion of the S.O.,
ordinary Portland cement does not per
form satisfactorily as an anti-stripping
agent, the Contractor may propose to
use another adhesion and anti-stripping
agent in addition to, or wholly or
partially instead of, the ordinary
Portland cement specified above. Such
agent shall be of a type approved
by the S.O. and shall be thoroughly
mixed with the bituminous binder,
Page 101
all in accordance with the

manufacturer's instructions. In such a
case, the agent shall be added to the
bitumen binder used in the bitumen
stripping tests in the appropriate amount
and manner.
Aggregate which does not perform
satisfactorily in the bitumen stripping
tests, using the approved adhesion and
anti-stripping agent when appropriate,
shall not be used in asphaltic concrete.
4.2.4.3 Asphaltic Concrete Mix Design
(a) Job Mix Formulae
After obtaining supplies or
production (as applicable) of all
aggregates consistent as to gradation
and other qualities, the Contractor
shall propose a job mix formula for
each class of mix required in the
Works. In order to attain optimum
quality of the mixtures, the job mix
formula for each class shall be
prepared on the basis of testing
several trial gradations within the
limits set in Table 4.8 at an
appropriate range of bitumen
contents. As a guide to the testing
range of bitumen contents, the design
bitumen content will usually be in
the appropriate range given in Table
4.9.
A sample of each trial mix (i.e. each

combination of trial gradation and
bitumen content) shall be subject to a
comprehensive Marshall method test
and analysis as follows :i) preparation of specimens for the
standard stability and flow test in
accordance with AASHTO Test
Method T 245 using the 75
blows/face compaction standard;
ii) determination of the bulk
specific gravity of the specimens
in accordance with AASHTO
Test Method T 166;
iii) determination of the stability and
flow values in accordance with
AASHTO Test Method T 245;
iv) analysis of the density and
voids parameters to determine
the percentage of voids in the
compacted aggregate, the
percentage of voids in the
compacted aggregate filled with
bitumen, and hence the
percentage of air voids in the
compacted mix.
For each trial mix conforming to a
proposed job mix formula, the
parameters of the above tests and
analyses shall conform to the
requirements of the appropriate type
of mix as given in Table 4.10.
TABLE 4.9 - DESIGN BITUMEN

CONTENTS
ACW14 - Wearing Course
5.0 7.0 %
ACW14 - Binder Course
4.5 - 6.5 %
ACB 28 - Binder Course
4.0 - 6.0%
Page 102
TABLE 4.10 - TEST AND ANALYSIS PARAMETERS

FOR ASPHALTIC CONCRETE
Parameter
Wearing Course
Binder Course
Stability S
> 500 kg
> 450kg
Flow F
> 2.0 mm
> 2.0mm
Stiffness S/F
> 250 kg/mm
> 225 kg/mm
Air voids in mix
3.0% - 5.0%
3.0% - 7.0%
Voids in aggregate
filled with bitumen
75% - 85%
65% - 80%
Air voids shall be defined as the

small pockets of air between the
coated aggregate particles in a
compacted asphaltic concrete mix.
The portion of the bitumen absorbed
into the aggregate particles must
therefore be allowed for when
calculating the air voids. For
combined aggregate with a water
absorption of not more than 2.0%,
the absorbed bitumen may be
estimated on the basis that the
absorption of bitumen will be
approximately 20% of the water
absorption.
Voids in the aggregate of a mix shall
be calculated on the basis of the
weighted average bulk specific
gravity on an oven dried basis of the
coarse and fine aggregate fractions
(separated by the ASTM # 10 sieve
or B.S. 2.0 mm sieve) as determined
in accordance with AASHTO Test
Method T 84 and T 85 as applicable.
The Marshall density of an asphaltic

concrete mix is defined as the
average density of a set of three (3)
test specimens moulded for the
Method T 245 using the 75 blows
per face compaction standard.
The Contractor shall submit to the
S.O. full details of his proposed job
mix formula for each class of mix
required in the Works including :i) the gradation analysis of each
aggregate to be used in the mix;
ii) the proportions for cold batching
the aggregates;
iii) the mixing plant screen sizes, the
smallest of which shall generally
be not more than 3.2 mm;
iv) the gradation analysis of the
aggregate in each of the mixing
plants' hot bins and of the mineral
filler (including any ordinary
Portland cement added as
anti-stripping agent);
Page 103
v) the job mix formula gradation of

the combined aggregate and
filler;
vi) the proportions for combining the
hot bin aggregates and filler;
vii)the bitumen content (by weight of
total mix);
viii)the dry and wet mixing times if a
batch plant is to be used, or the
mixing time if a continuous mix
plant is to be used;
ix) the full results of the
comprehensive Marshall method
tests and analyses as described
above for each trial mix used in
determining the job mix formula.
The S.O. may require changes of any
of the factors in each proposed job
mix formula and further tests and
analyses in order to attain optimum
quality of the asphaltic concrete
mixes.
(b) Plant Trials
After having received the S.O.'s
preliminary approval of his proposed
job mix formulae, the Contractor
shall arrange to mix, lay and compact
asphaltic concrete conforming to the
proposed formula for each class of mix
required in the Works. A minimum of
10 tonnes of each mix shall be placed
in trial areas to demonstrate to the
satisfaction of the S.O. that the mixing,
laying and compacting equipment
conforms to the requirements of this
Specification, and that the proposed
mixes are satisfactory. The trial areas
shall not be part of the Contract Works
but shall be provided by the Contractor
at his own expense. They shall be

As directed by the S.O., comprehensive
sampling and testing of each class of
mix shall be carried out to check for
satisfactory compliance with its job mix
formula, and for a satisfactory degree of
compaction.
As a result of the plant trials, the S.O.
may require amendments to the job mix
formulae, further tests and analyses,
and possibly additional plant trials
before finally approving the mixes for
full scale production and use in the
Works.
(c) Compliance with the Job Mix Formulae
The S.O.'s final approval of the job mix
formulae shall bind the Contractor to
furnish asphaltic concrete mixes
meeting the precise gradations and
bitumen contents specified in these
formulae within the tolerances set
forth in Table 4.11.
Modifications to a job mix formula may
only be made with the approval of the
S.O. Should the S.O. at any time have
reason to believe that the materials and
methods of mixing and laying are
different from those approved, he shall
so advise the Contractor, and may order
that asphaltic concrete works be
discontinued pending further trials and
testing.
Page 104
TABLE 4.11 - TOLERANCES FOR ASPHALTIC CONCRETE MIXES
ParameterPermissible Variation
% By Weight of Total
Mix
Bitumen.
+ 0.2%
Fractions of combined
aggregate passing 5.0 mm
and larger sieves.
+ 5.0%
aggregate passing 3.35 mm
and 1.18 mm sieves.
+ 4.0%
aggregate passing 425 um
and 150 um sieves.
+ 3.0%
Fraction of combined
aggregate passing 75 um
sieve.
+ 2.0%
4.2.4.4 Equipment
The Contractor shall provide all the
plant and equipment necessary for
executing the work in accordance
with this Specification and shall
furnish the S.O. with such details of
particular items of equipment, e.g.
manufacturer, model type, capacity,
weight, operating features, etc., as
the S.O. shall require.
(a) Road Cleaning Equipment
Road cleaning equipment will be
required where asphaltic concrete is
to be laid on a surface which is not
to receive a tack coat. The
equipment shall be the same as that
required for preparing a surface for
a tack coat, and shall include a
power broom and compressed air
blower as specified in Sub-Sections

4.2.1.3 (a) and 4.2.1.3 (b) respectively.
(b) Asphalt Mixing Plant
The asphalt plant shall be either a
batch plant or a drum mix plant or a
continuous mix plant of recognized
manufacture and shall be approved by
the S.O. It shall conform to the
requirements described hereunder.
The mixing plant shall have a capacity
suited to the Works and sufficient to
enable the paver to operate more or less
continuously when paving at normal
speeds at the required thicknesses. The
plant shall be so designed as to enable
consistent production of asphaltic
Page 105
concrete mixes within the tolerances

prescribed in this Specification, all to
Scales for all weigh boxes or hoppers
shall be of the springless dial type,
accurate to within 0.5% of the
maximum load that may be required.
Scale dials and pointers shall be easily
read from their operator's normal
position without significant parallax
errors. Scales shall be substantially
constructed so that they shall maintain
their accuracy after initial adjustment.
The Contractor shall furnish not less
than ten 25 kg test weights at the plant
for checking, adjusting and calibrating
scales.
Tanks for storage of bitumen shall have
a capacity suited to the proposed rate of
utilization of the material and the
method and frequency of its delivery to
the Works, all to the satisfaction of the
S.O. The tanks shall be provided with
means of measuring the volume of their
contents at all times and of drawing off
samples of the contents. The bitumen
feeding system shall provide for
continuous circulation of hot binder
through the system and back into the
feed tank. The end of the return line
discharging into the feed tank shall
always be kept submerged in the
bitumen in the tank in order to prevent
oxidation of the returning hot binder.
The storage tanks, and where necessary
barrel decanters, and all elements of the
bitumen feeding system shall be
equipped with heating systems or
insulating jackets as necessary to
provide for effective and positive control
of the temperature of the bitumen at all
times up to the temperature required for
utilisation. . The method of heating
shall be such that neither flames nor the
products of combustion shall come into
direct contact contact with the bitumen
or the casing of its immediate container,
and such that no portion of the bitumen
shall be subject to overheating.

The plant shall be provided with
accurate mechanical means for
uniformly feeding the aggregates into
the dryer so that uniform production and
temperature of the heated aggregates
will be obtained. A separate feed bin
with an adjustable gate opening shall be
provided for each aggregate to be
included in the combined aggregate for
the mix; normally four bins will be
required. The feed bins and gates shall
be so constructed and equipped that they
shall be readily accessible for calibrating
at all times, and shall provide for a
continuous and uniform flow of each
aggregate required in the mix.
The plant shall have a rotary drum dryer
of satisfactory design for drying and
heating the combined aggregate so that
its temperature will be at the required
level at the time it is mixed with the
bitumen. The burner shall be so
designed that complete combustion of
the fuel will be obtained, and the
aggregate will remain clean and not
become coated with soot or oil.
The plant shall be equipped with four
(or more) screens, the smallest of which
shall generally be not more than 3.2
mm. The screens shall have a normal
capacity slightly in excess of the
maximum output of the mixing plant.
The screens shall be readily accessible
for inspection.
The plant shall include four (or more)
storage bins for screened aggregates,
each with a capacity of not less than
twice the pugmill dead load capacity.
The bins shall be arranged so as to
provide separate dry storage for each
screened fraction of the aggregate. Each
bin shall be provided with an overflow
pipe of such size and location as to
prevent any backing up of material into
other bins. Each bin shall be so
constructed that representative aggregate
samples can be readily obtained, and
Page 106
shall have means for observing the

aggregate level. Separate dry storage
shall be provided for mineral filler, and
the plant shall be satisfactorily equipped
to feed filler into the mixer.
Satisfactory means by either weighing
or metering shall be provided to obtain
the prescribed amount of bitumen in the
mix within the specified tolerance.
Means shall be provided for checking
the quantity or flow rate of binder
entering the mixer. Suitable means shall
be provided for maintaining the
prescribed temperature of the bitumen in
the pipelines, weigh bucket or flow
meter, and spray bars.
An armoured thermometer with a
range of 30 oC to 200 oC shall be fitted
in the bitumen feed line at a suitable
location near the discharge valve at the
mixer unit. Suitable dial-scale mercury
actuated thermometers, electric
pyrometers or other thermometric
instruments shall be fitted at the
discharge chute of the dryer and in each
hot aggregate storage bin to indicate the
temperatures of the heated aggregates.
The plant shall be equipped with a dust
collector so constructed as to waste the
material collected or feed it uniformly to
the heated aggregate.
The plant shall be equipped with
adequate and safe stairways to the
mixing platform and sampling locations,
and guarded ladders and cat-walks shall
provide access to all other positions as
necessary for proper operation,
inspection and maintenance of the plant,
all to the satisfaction of the S.O. All
gears, pulleys, chains, sprockets and
other dangerous moving parts shall be
properly guarded and protected. Ample
and unobstructed space shall be
provided on the mixing platform, and
clear and unobstructed passage shall be
maintained at all times in and around

the truck loading area, which shall be
kept free from drippings from the mixer.
Special Requirements for Batch Plants
Each storage bin for screened aggregate
shall be provided with a bottom outlet
gate so constructed as to prevent leakage
when closed. These gates shall have a
quick and complete closing action.
The plant shall be equipped with a
weigh box or hopper for accurately
weighing out aggregate from each of the
screened aggregate storage bins. The
weigh box or hopper shall be
suspended from its scale's lever
mechanism and shall be sufficiently
large to hold a full batch equal to the
pugmill capacity without hand raking or
spilling of the aggregate. The discharge
gate shall be so constructed as to allow
rapid and complete emptying of the
weigh box or hopper into the mixer, and
prevent leakage when closed.
The plant shall be equipped with a
binder weigh bucket which shall be
charged through a fast acting non-drip
valve in the binder feed pipe located
directly over the bucket. The bucket
shall be suspended from its scale's lever
mechanism and shall have a capacity
sufficient to weigh out binder up to 20%
of the weight of the pugmill dead load
capacity. The bucket shall have a
discharge mechanism which shall
provide for rapid and complete
emptying of the bucket in a thin uniform
sheet or multiple sprays over the full
length and width of the mixer. The
dicharge mechanism shall not leak or
drip when closed.
The batch mixer shall be a suitable
twinshaft pugmill, with a capacity of at
least 500 kg of asphaltic concrete,
capable of producing a thoroughly
homogeneous mixture. The clearance of
the paddle blades from all fixed and
Page 107
moving parts of the mixer shall be not

more than 20 mm. If the pugmill is not
enclosed it shall be equipped with a dust
hood to prevent loss of fines from the
mixture. The discharge gate shall be so
constructed as to allow rapid and
complete emptying of the mixer, and
prevent leakage of any mix constituent
when closed.
The mixer shall be equipped with an
accurate time lock system for
controlling the operations of a complete
mixing cycle. It shall lock the aggregate
weigh box or hopper gate after charging
the mixer with aggregate, until the
closing of the mixer gate at the
completion of the mixing cycle; it shall
lock the binder weigh bucket discharge
mechanism during the dry mixing and
wet mixing periods. (The dry mixing
period is defined as the interval of time
between the opening of the aggregate
weigh box or hopper gate and the start
of discharging the binder weigh bucket.
The wet mixing period is defined as the
interval of time between the start of
discharging the binder weigh bucket and
the opening of the mixer gate.) The dry
and wet mixing periods shall both be
adjustable in increments of not more
than 5 seconds from zero to not less than
120 seconds total for dry and wet
mixing.
Special Requirements for Drum Mix
Plants
The cold material feeder unit shall
consist of not less than 5 compartments
with suitable heaped capacity
appropriate for the plant. Each bin shall
be provided with a control gate and
measuring feeder suitable for accurate
blending of the aggregates on to the cold
feed collecting conveyor. The cold feed
system shall incorporate a device for
moisture compensation capable of

producing an accurate and continuous
blend of the individual aggregate sizes
from the cold feed compartment.
The drum mixer shall be of an inclined,
oil-fired and parallel flow type in which
the aggregates and exhaust gases flow in
the same direction. The drum mixer
length to diameter ratio shall be such as
to ensure efficient drying and intimate
mixing of aggregate, filler and binder
over the full range of rated operating
efficiencies. A bypass chute shall be
incorporated for sampling of cold
aggregate.
Freshly mixed material shall be
delivered and stored in a surge silo
through a proper conveyor system.
Special Requirements for Continuous
Mix Plants
Each storage bin for screened aggregate
shall be provided with an accurately
controlled variable orifice gate
discharging on to an aggregate feed
mechanism. The discharge orifice shall
be rectangular with one dimension
variable by means of an adjustable and
lockable gate, which shall have an
indicator showing the distance it is open.
These gates shall be used for accurately
proportioning the screened aggregates
for the mix.
The plant shall have means of
calibrating the aggregate bin discharge
gate openings by weighing test samples
obtained by diverting the aggregate fed
out of each bin into a suitable test box.
Test boxes shall have a capacity of not
less than 100 kg each.
The plant shall have satisfactory means
of effecting positive interlocking control
between the flow of screened aggregates
from the storage bins and the flow of
binder from the meter or other
proportioning device. This control shall
Page 108
be accomplished by interlocking
mechanical means or another positive
method satisfactory to the S.O.
The continuous mixer shall be a suitable
twin-shaft pugmill with an adjustable
dam and paddles with reversible blade
pitch for adjusting the volume of
mixture held in the pugmill. The
clearance of the paddle blades from all
fixed parts of the mixer shall be not
more than 20 mm. The binder shall be
fed into the mixer through a spray bar
directed on to the aggregate across the
full width of the pugmill at the feed end.
The discharging mixture shall pass over
the dam into a hopper with a discharge
gate so constructed as to allow rapid and
complete emptying of the hopper, and
prevent leakage of the mix when closed.
The mixer shall be equipped with a
permanent gauge for measuring the
depth of mixture in the pugmill and a
manufacturer's calibration plate showing
the volume of mixture in the pugmill at
each increment of depth.
The mixing time shall be determined
using the formula :Mixing time (seconds) =
Dead weight of mix in pugmill (kg)
Pugmill output (kg per second)
and for a given output it may be varied
slightly by adjusting the depth (and
hence weight) of the mixture held in the
pugmill by varying the dam height, the
configuration of the paddle blades, or
both. However for substantial
adjustments of the mixing time, in order
to maintain the depth at a level
compatible with efficient mixing, i.e. so
that the paddle tips just break out of the
mixture at the height of their action, the
rate of feed of materials to the mixer
(and hence output) should be changed.

(c) Tip-Trucks
The Contractor shall provide a suitable
number of tip-trucks of a type approved
by the S.O. for transporting asphaltic
concrete from the mixing plant to the
paving works. The trucks shall have
trays with smooth, flat beds and sides,
and shall have load capacities of not less
than 5 tonnes. Prior to loading, the
inside of each truck tray shall be lightly
and evenly coated with a soap or
detergent solution, or such other liquid
as the S.O. shall approve, to prevent
adhesion of the asphaltic concrete. The
trucks shall be equipped with covers of
canvas or other suitable material to
protect the asphaltic concrete.
(d) Asphalt Paver
The asphalt paver shall be of recognized
manufacture and shall be approved by
the S.O. It shall conform to the
requirements described hereunder.
The paver shall be self-propelled and
capable of reverse as well as forward
travel. It shall be equipped with a
hopper at the front designed to receive
the paving mixture from tip-trucks, and
shall have a mechanical distribution
system for spreading the mixture evenly
and without segregation over the surface
to be paved in front of a screeding and
compacting unit which shall be
equipped with a suitable heating device.
The screeding and compacting
mechanism shall be capable of
confining the edges of the material
being laid without the use of stationary
side forms, shall be adjustable to strike
off the mixture to the thickness and
cross-section shape required, and shall
be controlled by an automatic levelling
device to produce an even carpet of
bituminous mixture with a uniform sur
face texture free from indentations,
ridges, tear marks or other irregularities.
Page 109
The paver shall be capable of laying the

bituminous mixture in paving widths in
the range 2.5 to 3.75 m and of finishing
the pavement layer true to the required
lines, grades, levels, dimensions and
cross-sections, subject to compaction by
rolling, all to the satisfaction of the S.O.
(e) Rollers
A pneumatic tyred roller and two steel
wheeled tandem rollers shall be
provided. However, a three wheeled
steel roller may be substituted for one of
the tandem rollers if the S.O. shall so
approve. All rollers shall be of
recognized manufacture and shall be
The pneumatic tyred roller shall be as
specified in Sub-Section 4.2.3.3 (g).
Steel wheeled rollers shall conform to
the requirements described hereunder.
Steel wheeled rollers shall be selfpropelled and capable of being reversed
without backlash; they shall be equipped
with power steering and dual controls
allowing operation from either the left or
right side. They shall be equipped with
water tanks, sprinkler systems and
scraper blades to keep all wheels evenly
wetted and clean during operation.
Each steel wheeled roller shall be
ballasted so that its total operating
weight is in the range 8 to 10 tonnes and
its driven roll (or rolls) shall exert a
rolling force of not less than 3.5
tonnes/metre of roll width. The
Contractor shall provide the S.O. with a
calibration chart for each roller showing
the relationships between the quantity or
depth of ballast and total weight and
rolling force.

Asphaltic concrete paving work
shall only be carried out in dry
weather when the surface to be
covered is dry, or if so specified,
has received a bituminous tack
coat which shall have achieved a
satisfactory degree of tackiness,
all to the satisfaction of the S.O.
All laying, rolling and finishing
work shall be carried out during
daylight hours, unless the Contractor
shall have provided suitable floodlighting for the job site, to the
The S.O. may order the
discontinuation of work on account
of adverse weather, unsatisfactory
condition of materials, equipment or
surface to be paved, or such other
conditions as he shall consider detri
mental to the work.
(b) Surface Preparation and Cleaning
Prior to constructing an asphaltic
concrete pavement layer, the surface
to be covered shall have been
prepared in accordance with the
appropriate Sections of this
Specification. Notwithstanding any
earlier approval of this surface, any
damage to or deterioration of it shall
be made good before asphaltic
concrete paving work is commenced.
If the surface to be covered is not to
be provided with a bituminous tack
coat, then immediately prior to
commencing asphaltic concrete
paving, it shall be swept using a
compressed air blower and, if
necessary, scraped using hand tools
to remove all loose particles, dirt,
dust and other objectionable
Page 110
material, all to the satisfaction of the

S.O.
If the surface to be covered is to be

provided with a bituminous tack coat,
then this shall be applied all in
accordance with the provisions of SubSection 4.2.2.
Ordinary Portland cement and/or

other mineral filler to be used in the
mix shall be stored separately and
kept completely dry. Its rate of feed
into the plant shall be accurately
controlled by weight or volumetric
measurement, all to the satisfaction
of the S.O.
(c) Aggregate Handling and Heating
(d) Heating of Bitumen
Each aggregate to be used in the

asphaltic concrete mixes shall be stored
in a separate stockpile near the mixing
plant. Stockpiles of sand and other fine
aggregates shall be kept dry using
waterproof covers and other means as
necessary. In placing the aggregates in
the stockpiles and loading them into the
mixing plant's cold aggregate feed bins,
care shall be taken to prevent
segregation or uncontrolled combination
of materials of different gradation.
Segregated or contaminated materials
shall be rescreened or rejected for use in
the Works and removed from the mixing
plant site.
The binder shall be heated so that

when delivered to the mixer it shall
be at a temperature in the range
140C to 160C.
The aggregates shall be fed into the

dryer at a uniform rate proportioned in
accordance with the appropriate job mix
formula. The rate of feed for each
aggregate shall be maintained within
10% of the rate prescribed, and the
total rate of feed shall be such that
the plant's screens shall never be
overloaded.
For each batch the screened hot

aggregates shall be weighed out into
the aggregate weigh hopper in
accordance with the proportions
prescribed in the appropriate job mix
formula; the sequence of weighing
out shall commence with the largest
sized aggregate and progress down
to the fines, unless the S.O. shall
otherwise approve. Mineral filler
shall be weighed out into the filler
weigh hopper, where this is
provided, or added last to the
aggregate weigh hopper, in
accordance with the job mix formula
proportions.
The aggregates shall be dried and heated

so that when delivered to the mixer they
shall be at a temperature in the range
150C to 170C.
Immediately after heating, the
aggregates shall be screened into four
(or more) fractions which shall be
separately stored in the hot aggregate
storage bins in readiness for mixing.
(e) Mixing Asphaltic Concrete

The mixing plant shall be so
coordinated and operated as to
consistently produce asphaltic
concrete mixes within the tolerances
prescribed in this Specification, all
Mixing in Batch Plants
The hot binder shall be weighed out

into the binder weigh bucket in
ccordance with the proportions
prescribed in the job mix formula.
Page 111
The hot aggregates and filler shall be

discharged into the pugmill and
mixed dry for the dry mixing time
prescribed in the job mix formula,
which shall usually be in the range 5
to 10 seconds. The hot binder shall
then be added and wet mixing per
formed for the wet mixing time
prescribed in the job mix formula;
this shall be sufficient so that all
particles of aggregate are uniformly
coated with bitumen, and shall
usually be 45 seconds or more for
dense graded mixtures.
The volume of each batch shall be
such that the tips of the pugmill
paddle blades just break out of the
mixture at the height of their action.
After the completion of wet mixing,
each batch of asphaltic concrete shall
be discharged from the pugmill
either into a storage hopper or
directly into a truck for hauling to
the paving site. Care shall be taken
that no segregation of the mix
occurs.
Mixing in Continuous Mix Plants
The screened hot aggregates and
filler shall be fed continuously from
their storage bins in accordance with
the proportions prescribed in the
appropriate job mix formula,
combined in the plant, and fed
continuously into the mixer. The hot
binder shall be sprayed on to the
combined aggregate as it enters the
pugmill at the rate required to
achieve the bitumen content pre
scribed in the job mix formula. The
materials shall then be carried
through the pugmill and in the
process be thoroughly mixed by
the action of the paddles and dis
charged over the dam into the stor
age hopper. The mixing time (as
defined in Sub-Section 4.2.4.4 (b)

shall be as prescribed in the job mix
formula; this shall be sufficient so
that all particles of aggregate are
uniformly coated with bitumen, and
shall usually be 45 seconds or more
for dense graded mixtures.
The plant shall be so adjusted as to
maintain the level of mixture in the
pugmill such that the tips of the
paddle blades just break out of the
mixture at the height of their action.
(f) Transportation of Asphaltic
Concrete
Asphaltic concrete shall be
transported from the mixing plant to
the site of the paving works in loads
of not less than 5 tonnes using
tip-trucks as specified in
Sub-Section 4.2.4.4 (c). Except
where asphaltic concrete is to be
hand laid, it shall be discharged
directly into the paver hopper, as
required, from the tip-trucks. Care
shall be taken in the truck loading,
hauling and unloading operations to
prevent segregation of the mix.
During transportation, the asphaltic
concrete shall be protected from
contamination by water, dust, dirt
and other deleterious materials.
The temperature of asphaltic
concrete immediately before
unloading from the truck either into
the paver hopper or on to the road
for hand spreading shall be not less
than 125C. Any load which has
cooled below the specified
temperature in the truck shall be
rejected for use in the Works and
removed from the Site of the Works.
(g) Laying Asphaltic Concrete
The sequence of laying operations
shall be planned in advance by the
Contractor and approved by the S.O.
Page 112
Generally each paving layer shall

have a compacted thickness of not
less than twice the nominal
maximum aggregate size of the
mixture, and not more than 100 mm.
Where applicable, e.g. on
superelevated sections and on
carriageways with cross-slope in one
direction only, laying shall
commence along the lower side of
the carriageway and progress to the
higher side. Laying shall not be
carried out in a downhill direction
along any section of road.
As far as is practicable, laying shall
be carried out using a paver
approved by the S.O. Hand-casting
of bituminous mix on to the machine
finished surface shall be kept to the
practicable minimum necessary for
correcting blemishes and
irregularities. In any areas
inaccessible to the paver, laying shall
be carried out by hand methods
using rakes, lutes and other hand
tools, all to the satisfaction of the
S.O. All laying of bituminous mix
shall be such that after compaction
by rolling the specified course or
layer thickness and surface profile
shall be achieved. Care shall be
taken to achieve a uniform surface
texture free from indentations,
ridges, tear marks or other
irregularities, and to prevent
segregation of the mix.

and before laying restarts after each
interruption of the paving operation.
As far as is practicable, the paver
shall be operated continuously and
the supply of bituminous mix shall
be regulated so as to enable
continuous paving. Transverse joints
in a paving lane shall be kept to a
practicable minimum, and
intermittent stopping and restarting
of the paver shall be avoided as far
as is practicable.
Care shall be taken that no
bituminous mix is placed on
expansion joints at bridges,
inspection covers for utilities ducts,
drainage and sewerage manholes and
the like, and that catchpits, drainage
openings through kerbs, etc., remain
properly open and serviceable.
During laying operations, such areas
and openings shall be protected by
suitably shaped and secured boards
or other materials approved by the
S.O., and compaction of mix in the
immediately surrounding or adjacent
areas shall be completed by hand
methods, all to the satisfaction of
the S.O. Alternatively, bituminous
mix shall be laid and compacted by
hand methods as necessary around
surfacing discontinuities of these
types, all to the satisfaction of the
S.O.
(h) Construction Joints
At the commencement of initial

rolling the temperature of asphaltic
concrete shall be not less than
110C. Material which has cooled
below the specified temperature
before laying shall not be used and
shall be removed from the Site of the
Works. The Contractor shall provide
accurate thermometers at the paving
site at all times, and shall check the
temperature of asphaltic concrete in
the paver hopper at regular intervals
Existing bituminous surfacing which

new bituminous mix is to adjoin
shall be cut back to present a
straight, vertical edge not less than
25 mm deep and a smooth transition
section not less than 0.5 metre long
against which to lay the new
material. The specified thickness of
the new surfacing shall be built up
gradually from the vertical joint to
avoid any bumps or ridges across the
carriageway.
Page 113
Where longitudinal or transverse

joints are required in a layer of
bituminous mix under construction,
the material first laid and compacted
shall be cut back to a vertical face for
the full thickness of the layer on a
line satisfactory to the S.O. before
the adjacent area is paved.
At all construction joints, a thin
uniform coating of bitumen emulsion
of grade RS-1 or RS-1K shall be
brushed on to the vertically cut joint
faces some 10 to 15 minutes before
laying the next section of bituminous
mix commences to ensure good
bonding. Also, all contact surfaces
of kerbs, gutters, manholes,
catchpits, etc., shall be similarly
treated with a coating of bitumen
emulsion before bituminous mix is
placed against them.
Construction joints in a layer of
bituminous mix shall be offset from
those in any immediately underlying
bituminous layer by at least 100 mm
for longitudinal joints and at least 0.5
metre, where possible, for transverse
joints.
(i) Compaction of Asphaltic
Concrete
For each layer of asphaltic concrete,
compaction by rolling shall
commence as soon after laying as the
material will support the rollers
without undue displacement;
nevertheless the temperature of
asphaltic concrete at the
commencement of rolling shall be
not less than 110C.
In any areas inaccessible to the
rollers, proper compaction shall be
carried out using vibrating plate
compactors, hand tampers or other
suitable means, all to the satisfaction
of the S.O.

Initial (or breakdown) rolling shall
be carried out with an approved steel
wheeled tandem roller or three
wheeled steel roller. The principal
heavy rolling shall be carried out
with an approved pneumatic tyred
roller immediately following the
initial rolling; the pneumatic tyred
roller shall be ballasted to an
operating weight of not less than 15
tonnes and its tyre inflation pressure
shall be not less than 0.7 N/sq.mm.
The final rolling shall be carried out
with an approved steel wheeled
tandem roller and shall serve to
eliminate minor surface irregularities
left by the pneumatic tyred roller.
All rollers shall operate in a
longitudinal direction along the
carriageway with their driven wheels
towards the paver. Rolling shall
generally commence at the lower
edge of the paved width and progress
uniformly to the higher edge, except
that where there is a longitudinal
construction joint at the higher edge,
this shall be rolled first ahead of the
normal pattern of rolling. Generally,
successive roller passes shall overlap
by half the width of the roller, and
the points at which the roller is
reversed shall be staggered.
However, when operating on
gradients in excess of 4%, the
breakdown roller shall not pass over
any previously unrolled mix when
operating in the downhill direction.
In all cases, compaction shall be
carried out in such a manner that
each section receives equal
compactive effort, all to the
The steel wheeled rollers shall
operate at speeds of not more than 5
km/hr and the pneumatic tyred
rollers shall operate at speeds of
not more than 8 km/hr. No roller or
Page 114
heavy vehicle shall be allowed to

stand on newly laid bituminous mix
before compaction has been
completed and the material has
thoroughly cooled and set. Rolling
shall continue as long as is necessary
to achieve the appropriate
requirement as follows :-
the average thickness over any 100

metre length shall be not less than
the required thickness, and the
minimum thickness at any point
shall be not less than the required
thickness minus 5 mm.
Wearing course
98 - 100% Marshall
density
The top surface of a wearing or

binder course shall have the required
Sub-Section 4.4.
Binder course
95 - 100% Marshall
density
(k) Opening to Traffic
Type of Pavement
Layer
Required Compacted
Density
Care shall be taken to prevent overcompaction of asphaltic concrete.

Within 24 hours of laying and
compacting the bituminous mix, the
Contractor shall cut core samples of
not less than 100 mm nominal
diameter at locations selected by the
S.O. The rate of sampling shall be 1
sample per 500 sq.m of mix laid, but
not less than 2 samples for the work
completed in each paving session.
These core samples shall be used by
the S.O. to determine the thickness
of the compacted layer of mix and
the compacted density of the
material in accordance with either
ASTM Test Method D 1188 or
ASTM Test Method D 2726,
whichever is applicable.
Asphaltic concrete shall not be

opened to traffic until compaction
has been completed and the material
has thoroughly cooled and set in the
opinion of the S.O. This will usually
be not less than 4 hours after the
commencement of rolling. Where it
is necessary to allow earlier use of
the finished surface to facilitate the
movement of traffic, vehicles may
be allowed to run on the work after
rolling has been completed,
provided that speeds are restricted
to 30 km/hr or less and sharp turning
movements are prohibited.
(j) Finished Asphaltic Concrete

Asphaltic concrete binder and
wearing courses shall be finished in a
neat and workmanlike manner; their
widths shall be everywhere at least
those specified or shown on the
centre-line; ;
Page 115
4.2.5 Bituminous Macadam

4.2.5.1 Description
This work shall consist of furnishing,
placing, shaping and compacting
bituminous macadam roadbase
and/or levelling course and/or binder
course and/or wearing course on a
prepared and accepted bituminous or
bitumen primed pavement course,
and shall include the careful and
thorough cleaning of surfaces which
are to be covered without receiving a
bituminous tack coat. The work shall
be carried out all in accordance with
this Specification and the lines,
levels, grades, dimensions and crosssections shown on the Drawings
and/or as required by the S.O.

4.2.5.3 Equipment
The equipment shall be all as
specified in Sub-Section 4.2.4.4.
All the provisions of Sub-Section
4.2.4.5 for the construction of
asphaltic concrete pavement courses
shall apply as appropriate to the
construction of bituminous macadam
pavement courses with the
following variations and additions.
(a) Aggregate Heating
The aggregates shall be dried and
heated so that when delivered to the
mixer they shall be at a temperature
in the range 140 oC to 160 oC.
4.2.5.2 Materials
(b) Rolling Temperature
The materials for bituminous
macadam (aggregates, mineral filler,
bituminous binder and anti-stripping
agent) shall comply with all the
requirements of Sub-Section 4.2.4.2,
except for the combined gradation
requirements.
For each bituminous macadam mix,
the gradation of the combined coarse
and fine aggregates, together with
ordinary Portland cement added as
an adhesion and anti-stripping agent
and, if necessary, any other mineral
filler, shall conform to the
appropriate envelope given in Table
4.12. The binder content shall also be
in accordance with Table 4.12.
Where the characteristics of the
aggregates require a binder content
other than that given in the above
Table, the revised target binder
content shall be agreed between the
Contractor and the S.O. and the same
tolerances shall apply.
The temperature of bituminous

macadam at the commencement of
rolling shall be not less than 100 oC.
(c) Compacted Density
The compacted density of
bituminous macadam shall be as
follows :Type of Pavement
Layer
Required Compacted
Density
Bound roadbase
90 - 100% Marshall
density
Levelling course
90 - 100% Marshall
density
Binder course
95 - 100% Marshall
density
Wearing course
98 - 100% Marshall
density
Page 116
The Marshall density of a

bituminous macadam mix is defined
as the average density of a set of
three test specimens moulded in the
same way as asphaltic concrete
specimens are prepared for the
Method T 245 using the 75 blows
per face compaction standard. The
bulk specific gravity of the
specimens shall be determined in
Method T 166.
Bituminous macadam levelling

course shall be finished in a neat and
workmanlike manner; its dimensions
shall be as specified or shown on the
Drawings or as directed by the S.O.,
all to the satisfaction of the S.O. The
top surface of bituminous macadam
levelling course shall have the
The Marshall density of each mix

shall be determined using a sample
(or samples) taken from the mixing
plant soon after the commencement
of preparing each mix for the Works.
(Note : Stability and flow tests are
not normally required for bituminous
macadam mixes.)
Bituminous macadam binder and

wearing courses shall be finished in a
neat and workmanlike manner; their
widths shall be everywhere at least
those specified or shown on the
centre-line; the average thickness
over any 100 metre length shall be
not less than the required thickness,
and the minimum thickness at any
point shall be not less than the
required thickness minus 5 mm. The
top surface of a wearing or binder
course shall have the required shape,
and shall be everywhere within the
tolerances specified in Sub-Section
4.4.
(d) Finished Bituminous Macadam

Bituminous macadam roadbase shall
be finished in a neat and
workmanlike manner; its width shall
be everywhere at least that specified
or shown on the Drawings on both
sides of the centre-line; and its
average thickness over any 100
metre length shall be not less than
the required thickness. The top
surface of bituminous macadam
roadbase shall have the required
Sub-Section 4.4.2.
required shape,, superelevation,

levels and grades, and shall be every
where within the tolerances for
binder course specified in SubSection 4.4.
Page 117
TABLE 4.12 - GRADATION LIMITS AND BINDER CONTENTS

FOR BITUMINOUS MACADAM
Mix Type
Bound
Bound
Roadbas Roadbase
e
Mix
Designatio
n
BMR40
BMR28
Levelling
Course
Binder
Course
Binder
Course
Wearing
Course
Wearing
Coursex
BML10
BMB28
BMB20
BMW14
BMW20
%
Passing
by Weight
B.S. Test
Sieve
50.0 mm
37.5 mm
28.0 mm
20.0 mm
14.0 mm
10.0 mm
6.3 mm
3.35 mm
1.18 mm
300 mm
75 mm
100
95 - 100
70 - 94
56 - 76
44 - 60
32 - 46
7 - 21
2-9
100
90 - 100
71 - 95
56 - 80
44 - 60
31 - 45
7 - 21
2-8
100
85 - 100
30 - 60
15 - 25
2-6
100
90 - 100
71 - 95
58 - 82
44 - 60
32 - 46
7 - 21
2-8
100
95 - 100
65 - 85
52 - 72
39 - 55
32 - 46
7 - 21
2-8
100
95 - 100
70 - 90
45 - 65
30 - 45
15 - 30
3-7
100
95 - 100
65 - 85
52 - 72
39 - 55
32 - 46
7 - 21
2-8
Binder
Content
3.5 "
4.0 "
5.1 "
4.7 "
4.7 "
5.0 "
4.9 "
0.5%
0.5%
0.5%
0.6%
0.6%
0.5%
0.5%
Page 118
4.3
SHOULDERS
4.3.1
Description
This work shall consist of furnishing,
compacting and shaping earth or
gravel shoulder material on a
prepared and accepted subbase or
lower subbase or subgrade, all in
accordance with this Specification
and the lines, levels, grades,
dimensions and cross-sections shown
on the Drawings and/or as required
by the S.O.
For paved shoulders, the bituminous
surfacing and underlying pavement
courses shall be constructed as
described in the appropriate Sections
of this Specification.
4.3.2
Materials
4.3.2.1 Earth Shoulders

Earth shoulder material shall
be suitable material as
described in Sub-Section 2.2.1.
4.3.2.2 Gravel Shoulders
Gravel shoulder material shall
conform to the requirements for
gravel surfacing material set forth
in Sub-Section 4.1.3.2.
4.3.3
Shoulders shall be constructed in
stages or in one operation as directed
or approved by the S.O., but in no
instance shall a shoulder be built up
to a level higher than that part of the
abutting carriageway structure which
has been completed and accepted.
Prior to placing any shoulder
material, the underlying subbase or
lower subbase or subgrade shall have

Sub-Section 4.1.2.3, and the abutting
carriageway structure course or
courses shall likewise have been
shaped and compacted in accordance
with the provisions of the
appropriate Sub-Section or SubSections of this Specification.
Notwithstanding any earlier approval
of the underlying and abutting
pavement courses, any damage to or
deterioration of these underlying
and abutting pavement courses shall
be made good to the satisfaction of
the S.O. before shoulder construction
proceeds.
Shoulders shall be placed to the
required width and thickness as
shown on the Drawings or directed
by the S.O. in one layer or more,
each layer not exceeding 200 mm
compacted thickness at the point of
maximum thickness. Where two or
more layers are required they shall
be of approximately equal shape and
thickness, and none shall be less than
100 mm compacted thickness at the
point of maximum thickness.
Each layer of shoulder material shall
be processed as necessary to bring its
moisture content to a uniform level
throughout the material suitable for
compaction, and shall then be
compacted using suitable
compaction equipment approved by
the S.O. to not less than 95% of the
maximum dry density determined in
the B.S. 1377 Compaction Test (4.5
kg rammer method). Compaction
shall be carried out in a longitudinal
direction along the shoulder and
shall generally begin at the outer
edge and progress uniformly towards
the carriageway, except on
superelevated curves where rolling
shall begin at lower edge and
progress uniformly towards the
higher edge.
Page 119
In all cases, compaction shall be

carried out in such a manner that
each section receives compactive
effort appropriate to its thickness, all
Throughout the placing, adjustment
of moisture content and compaction
of shoulder material, care shall be
taken to maintain a uniform
gradation of the material and prevent
its seperation into coarse and
seperate parts, all to the satisfaction
of the S.O.
Where shown on the Drawings or
directed by the S.O., earth shoulders
shall be turfed in accordance with
Sub-Section 2.2.8.2.
Shoulders shall be finished in a neat
and workmanlike manner. The total
width of carriageway and shoulder
specified or shown on the Drawings
on both sides of the centre-line. The
top surface of each shoulder shall
have the required shape,
shall be everywhere within 10 mm
of the required plane, and shall
provide a flush joint with the
carriageway surface and shall be
uniformly free draining away from
the carriageway, all to the
4.4
HORIZONTAL ALIGNMENT,
SURFACE LEVELS AND
SURFACE REGULARITY OF
PAVEMENT COURSES
4.4.1
Horizontal Alignment
The horizontal alignment shall be
determined from the centre-line of
the pavement surface shown on the
Drawings. The edges of the
pavement as constructed and all
other parallel construction lines shall
be correct within a tolerance of + 50

mm and minus 0 mm from the
centre-line, except for kerbs, channel
blocks and edge lines which shall be
laid with a smooth alignment within
a tolerance of + 25 mm and minus
0 mm from the centre-line.
4.4.2
Surface Levels of Pavement Courses

The design levels of pavement
courses shall be calculated from the
vertical profile, crossfall and
pavement course thicknesses shown
on the Drawings. The level of any
point on the constructed surface of a
pavement course shall be the design
level subject to the appropriate
tolerances given in Table 4.13.
TABLE 4.13 - TOLERANCES IN SURFACE

LEVELS OF PAVEMENT COURSES
Pavement Course
Tolerance
Wearing Course
+ 5 mm
Binder Course
+ 5 mm
Roadbase
+ 0 mm
- 20 mm
Subbase and Lower

Subbase
+ 10 mm
- 20 mm
The combination of permitted

tolerances in the levels of different
pavement courses shall not result in a
pavement thickness less than that
shown on the Drawings. Each
pavement course shall have an
average thickness not less than that
shown on the Drawings.
Page 120
4.4.3
Surface Regularity
The traverse length of 300 m and its

associated maximum permissible
number of irregularities shall apply
wherever the continuous length of
the completed carriageway is 300 m
or more, whether or not it is
constructed in shorter lengths.
The regularity of surfaces shall be

within the relevant limits given in
Table 4.14.
A longitudinal irregularity is a
variation in profile of the road
surface as measured by the rolling
straight-edge or wedge and
straight-edge device. The
permissible number of such
longitudinal irregularities is indicated
in Table 4.14.
Where the total length of pavement

is less than 300 m the measurements
shall be taken on 75 m lengths.
The transverse regularity of a newly
laid surface shall be measured with a
3 m straight-edge and shall have no
greater depression under the
straight-edge than that shown in
Table 4.14
TABLE 4.14 - TOLERANCES FOR SURFACE IRREGULARITIES
Class of
Surface
Regularity
Longitudinal Direction
Transverse
Direction
Maximum Permissible Number

of Surface Irregularities
Maximum
Permissible
Depth of
Transverse
Irregularities
Depth Exceeding 4
mm
over
over
traverse
traverse
length
length
of 300 m
of 75 m
Depth Exceeding 7 mm
over
traverse
length
of 30 m
over
traverse
length
of 75 m
Class SR1
20
mm
Class SR2
40
18
mm
Class SR3
60
12 mm
27
No longitudinal irregularity exceeding 10 mm shall be permitted for Class SR1

Surface Regularity and no longitudinal irregularity exceeding 15 mm shall be
permitted for Class SR2 and Class SR3 Surface Regularities.
The class of Surface Regularity for each portion of the Works shall be as stated on
the Drawings or in the Bills of Quantities.
Page 121

JKR Flexible Pavement

Uploaded by

Copyright:

Available Formats

JKR Flexible Pavement

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

JKR Flexible Pavement

Uploaded by

Copyright:

Available Formats

Standard Specification For Road Works

FOR INTERNAL USE ONLY

Cawangan Jalan, Ibu Pejabat JKR, K.L

FOR INTERNAL USE ONLY

Standard Specification For Road Works

SECTION 4 - FLEXIBLE PAVEMENT

UNBOUND PAVEMENT COURSES

BITUMINOUS PAVEMENT COURSES

Bitumen Prime Coat

Bituminous Tack Coat

Bituminous Surface Dressing

Cawangan Jalan, Ibu Pejabat JKR, K.L

FOR INTERNAL USE ONLY

Standard Specification For Road Works

HORIZONTAL ALIGNMENT, SURFACE LEVELS AND

Surface Levels of Pavement Courses

Cawangan Jalan, Ibu Pejabat JKR, K.L

FOR INTERNAL USE ONLY

SECTION 4 FLEXIBLE PAVEMENT

Standard Specification For Road Works

Each layer of lower subbase shall

Prior to placing any lower

FOR INTERNAL USE ONLY

The lower subbase shall be

Standard Specification For Road Works

Subbase material shall be a

Cawangan Jalan, Ibu Pejabat JKR, K.L

Standard Specification For Road Works

FOR INTERNAL USE ONLY

TABLE 4.1 - GRADATION LIMITS FOR SUBBASE MATERIAL

4.1.2.3 Construction Methods

Cawangan Jalan, Ibu Pejabat JKR, K.L

suitable for compaction, and shall

Standard Specification For Road Works

FOR INTERNAL USE ONLY

The subbase shall be finished in a

i) the liquid limit shall be not

This work shall consist of

iii) the aggregate crushing value

TABLE 4.2 - GRADATION LIMITS FOR GRAVEL SURFACING

Cawangan Jalan, Ibu Pejabat JKR, K.L

FOR INTERNAL USE ONLY

Material with a maximum

Standard Specification For Road Works

FOR INTERNAL USE ONLY

Standard Specification For Road Works

The top surface of the gravel

iv) not less than 80% of particles

Crushed Aggregate Roadbase

vi) the material shall have a CBR

TABLE 4.3 - GRADATION LIMITS FOR

FOR INTERNAL USE ONLY

4.1.4.3 Construction Methods

Standard Specification For Road Works

FOR INTERNAL USE ONLY

Bitumen Prime Coat

Cawangan Jalan, Ibu Pejabat JKR, K.L

Standard Specification For Road Works

FOR INTERNAL USE ONLY