Table of Contents

1.0 QUALITY CONTROL OF MATERIALS.......................................................................3

1.1 At Borrow pits - Sampling Of Materials from Borrow Pit (Gen Spec Clause
1041).........................................................................................................................3
1.2 At Work Site......................................................................................................3
2.0 QUALITY CONTROL TESTS....................................................................................4
2.1 Preliminary Tests...............................................................................................4
2.2 On the job tests.................................................................................................4
2.3 Laboratory.........................................................................................................5
3.0 ROAD WORKS QUALITY-CONTROL - SPECIFICS OF PROCEDURAL ACTIVITIES......5
3.1 INTRODUCTION.................................................................................................5
3.2 PRELIMINARIES/EARTHWORKS..........................................................................5
3.2.1 Site Clearing...................................................................................................5
3.2.2 Unsuitable Materials.......................................................................................5
3.2.3 Unsuitable Material Below Formation Level...................................................5
3.2.4 Areas of Cut....................................................................................................6
3.2.5 Sub-grade/Filling.............................................................................................6
3.3 PAVEMENT WORKS............................................................................................6
3.3.1 Sounding (Penetration Test)...........................................................................6
3.3.2 Dynamic Plate Load Bearing Test...................................................................6
3.3.3 In-situ Density Test.........................................................................................7
3.3.4 Sub-Grade/Filling Material (Laterite)...............................................................7
3.3.5 Sand Fill (Gen Spec Clause 6127)...................................................................8
3.3.6 Completion and Shaping Of Sub-Grade........................................................10
3.3.7 Tests for the Classification of Compacted Sub-Grade and Filling.................10
3.3.8 Sub-Base Course..........................................................................................11
3.3.9 Materials for Compacted Sub-Base Course..................................................11
3.3.10 Tests for Sub-Base (Classification and Control Tests)...............................12
3.3.11 Completion of Sub-Base Course................................................................13
3.3.12 Base Course...............................................................................................13
3.3.14 Completion of Base Course.......................................................................14
3.3.15 Surfacing Of Base Course (Prime Coat Mc 1)..........................................14
3.3.16 Preparation of Base Course to Receive Bitumen Prime Coat.....................14
3.3.17 Test for the Selection Of Laterite Sub-Base Course And Base Course
Materials...............................................................................................................14
 3.3.18 Test for Classification and Control of Compacted Lateritic Sub-base Course
and Base Course...................................................................................................15
3.3.19 Crushed Stone To Be Laid And Compacted In Layers................................18
3.3.20 Laying And Compacting Crushed Stone Dry Process.................................18
3.3.21 Crushed Stone Base Course Laid By The Wet Process (Gen Spec Clause
6253) 19
3.3.22 Preparation Of Crushed Stone Base Course To Receive Bituminous
Surfacing (Gen Spec..............................................................................................19
Clause 6258).........................................................................................................19
3.4 CONCRETE WORKS..........................................................................................19
3.4.1 Concrete Materials.......................................................................................19
3.4.2 Concrete Workability....................................................................................20
3.4.3 Concrete Strength........................................................................................20
3.5 BITUMINOUS WORKS.......................................................................................20
3.5.1 Priming.........................................................................................................20
3.5.2 Bituminous Surface Dressing.......................................................................21
3.5.3 Asphaltic Concrete.......................................................................................21
1.0 QUALITY CONTROL OF MATERIALS

This is one of the two most important aspects of good Engineering construction. It is also
where unscrupulous Contractors usually want to cut corners or make fast deals. Little is it
realized that the cheapest cost they pay on a job is when the job is well done. Cutting
corners inevitably lead to loss of revenue to the Contractor, delayed completion and hand
over to the client.
Whatever the Contractors view on this, it is the primary duty of the Supervising Consultants
to see that good quality of materials and workmanship is achieved in every part
of the construction.

1.1 At Borrow pits - Sampling Of Materials from Borrow Pit (Gen Spec Clause
1041)
Trial pits in proposed borrow pit areas shall be dug from original ground level. Trial pits shall
be at least one metre by one metre in size, dug to such a depth that the full extent of the
material intended for incorporation in the works is exposed.

Materials for testing shall not be taken from the spoil of the trial pit but shall be made up
of increments taken from each face of the pit, each increment to be a representative sample
of the entire depth of a horizon. The four increments shall be mixed three times and
quartered or riffled down to the size required for testing. Visual examination will be made to
ensure that sampling more than one horizon in any sample is avoided.
Borrow pits may not be opened unless tests performed on samples from them meet
relevant standards. The usual tests are:
Liquid limit Tests
Plasticity Tests
Classification Tests
Compaction CBR Tests at BS or WAS, AASHO/AASTO
Intended materials are:
Lateritic Fill Materials
Dredged Sand Fill Material

1.2 At Work Site

Trouble areas which may or not be reflected on the drawings are identified visually by
experience. These areas are swamps, unsuitable materials, rock outcrops, fissures etc.
Appropriate advice mostly from Quality Control Laboratory/Material Engineer must be given
to the Contractor on each of these areas. Any instructions given must be carefully
considered as they are likely to have cost consequences.
Experience also may show when fills are well compacted, but not in all cases they must be
cross checked by the tests to determine relative densities. Some of these tests include
but are not limited to:
 Relative Densities in case of sub-grade, sub base, base course, dredged sand and or
stone base
Atterberg Limit
Unconfined Compression Test
Total voids of less than 12% if crushed stone (Note that Relative Density is no longer
acceptable for crushed stone as a method of determining the state of compaction)
Tensile Test in case of reinforcement
Concrete Cube Tests, Cement Tests, Slump Tests

Progress to the next layer must be prevented until approval is given by satisfactory test
results on a previous layer. Even when a layer passes the prescribed tests, attention must be
given to other often over sighted/ignored defects such as flaking, shaking, wheel-tracking,
roughness etc. The most pungent of Contractors excuse against the performance of tests is
the testing time. They usually do not want to be delayed until the results are out, especially
as the determination of moisture content in the laboratory takes about 24hrs. The answer
to this is to employ a speedy moisture tester, crossed checked later by actual moisture
content determination using oven method. On the other hand, a calibration curve may be
produced for the Speedy Moisture Tester. The Contractor may proceed on the basis of the
result of a Speedy Moisture Content Tester, but he owns the risk of removing the new layer
to re-compact the previous layer if the test subsequently fails. The Contractor MUST NEVER
be allowed to bring to the work materials that are below specification. To refuse them, from
experience from both International and Indigenous Contractors subsequently brings rancour
and uncharitable name calling.

2.0 QUALITY CONTROL TESTS

The mandatory, but normal, relevant quality-control tests, of which we all are aware, need to
be carried-out. Some of these tests, as of usual practice, MUST be done on regular basis
as the construction work progresses. Strict compliance with the quality control
guidelines stated below must therefore be ensured.
Such tests and the related stages of construction work, where they are required, are hereby
stated for strict compliance.

2.1 Preliminary Tests

All intended relevant construction materials ought to have been tested for suitability and
results of such tests approved before such materials are supplied to site. Such materials
include, but they are not limited to, the followings;
i. Laterite for fill, sub-base and base-course
ii. Fine aggregates (sharp sand) for either concrete works or blinding
iii. Coarse aggregates, for good quality concrete can be 05-20mm size in form of
granite chippings and specified grading analysis for stone-base.
iv. Sandrete blocks, tested for strength acceptability and approved before being used
for line-drain construction works and building purposes if applicable.
2.2 On the job tests
These are quality-control tests that should be carried-out during and while the construction
works last. Such tests include, but they are not limited to
i. Slump/cube tests for wet (fresh) concrete
ii. In-situ Density Tests for filling, sub-grade, sub-base and base-course
iii. Bitumen Tray-Test for bitumen rate of spray during priming
iv. Temperature Test for bitumen and asphalt appropriate temperature
v. Coring test for asphalt thickness and adequacy of compaction

2.3 Laboratory
To this end, If any Contractor is not able to provide the service, we have identified
reputable laboratories that can offer the required services. These are;
i. Lagos State Materials Testing Laboratory, Ojodu Berger.
ii. The University of Lagos Civil Engineering Department. and
iii. SPOAK Nigeria Limited; 23 Ibironke Crescent, Maryland, Lagos State.

3.0 ROAD WORKS QUALITY-CONTROL - SPECIFICS OF PROCEDURAL ACTIVITIES

3.1 INTRODUCTION
Simply explained, the topic means ensuring strict compliance with the relevant specifications
relating to the construction works so that an acceptable standard job is delivered at a
desirably minimum cost to the Client. To this end the oficer charged with the assignment of
controlling the quality must be knowledgeable about geotechnics and materials testing
procedure inclusive of related construction technology.

3.2 PRELIMINARIES/EARTHWORKS

3.2.1 Site Clearing

In the process of clearing the site of any vegetation, it must be ascertained that the top-soil
removal is inclusive of stumping and grubbing. This is a preceding essential before the
subsequent earth works is permitted.

3.2.2 Unsuitable Materials

A reconnaissance survey of the road alignment, soon after the site clearing, ought to
be carried-out. This is to identify places or locations made-up of materials strongly
suspected to be un-suitable and or unstable due to high-water table which often undermines
the pavement because non-optimum water is not known to be on friendly terms with a road.
This is a development that usually comes into play after site clearing.

3.2.3 Unsuitable Material Below Formation Level

Where unsuitable ground or other unsuitable material is found below formation level or
below the slope of cutting under areas of fill, this shall be excavated and disposed of as
directed by the Engineers Representative, and the space left void shall be backfilled with
selected fill and compacted to at least 100% of the M.D.D. achieved in the British
Standard compaction test.

Payment shall be made under this clause for any material removed as unsuitable soil only on
the written direction of the Engineers Representative provided such unsuitable material
could not have been discovered during the tendering period.

Measurement for this item shall be on the compacted backfill only and payment for this work
will be at the rates entered in the bill of quantities for earthworks.

3.2.4 Areas of Cut

All identified cut-areas, as of normal practice, are to have their materials thoroughly
examined and possibly made to undergo confirmatory laboratory tests. The essence is to
classify such cut-materials into either cut-to-spoil or cut-to-fill category from the out-come of
the relevant tests so conducted

3.2.5 Sub-grade/Filling
Having addressed areas confirmed to be either unsuitable or need to be cut to spoil, the
subsequent resultant replacement (i.e filling) will have to be carried-out with APPROVED
appropriate good-quality material and accorded adequate compaction. In case of high water
table sections, the use of granular materials (e.g sand) is advised for construction of
sub- grade.

3.3 PAVEMENT WORKS

All materials intended for pavement works, both sub-base and base-course ought to
have their samples examined, tested and approved before being permitted for use.
This all important preliminary exercise supersedes all other related pavement subsequent
works. Furthermore, it has to be noted that, while heavy filling could be laid at a maximum of
200mm compacted t h i c k n e s s , sub-base and or base-course should be at 150mm
compacted thicknesses.

3.3.1 Sounding (Penetration Test)

This is a quality control exercise aimed at determining the suitability of an existing subgrade
most especially in a water logged or swampy area. The test is carried out to determine
the strength of an existing subgrade in serial layers inclusive of the relative C. B. R. value.
In case of a swampy area the test must be carried out at a distance of 10 15 meters
regular interval or as agreed by all parties. The acceptable equipment for this test is 10kg
light penetrometer tester.
3.3.2 Dynamic Plate Load Bearing Test
This is a quality control exercise aimed at determining the deformation modulus. (Bearing
capacity) of a particular layer, it is also used to determine the rate of compaction and C. B.
R. value of each component of the pavement.
This test must be carried out at a distance of 50 meters regular interval on sub base and
base course.
The test also is used as a confirmatory Test on subgrade this time at a minimum of 75
meters and maximum of 100meters interval. The Dynamic Deformation Modulus (Evd).
2
For sub-grade, value must not be less than 25mn/m , while sub base, should not be less

2 2
than 55MN/m and the base course not be less than 60MN/m .

The acceptable equipment for this test is the Light Weight Deflectometer (LWD) machine
(i.e 300mm/10kg).

3.3.3 In-situ Density Test

This is a quality-control exercise aimed at ensuring the adequacy of compaction which
results in a stable pavement. It should be carried out as at when due and the result and
approval is essential before any related subsequent road work activity is permitted.
As of normal practice, in-situ density test is carried out at a distance of 50 100
metres regular interval. This is done in a staggered pattern thus. The first point may be at
the centre of the left half width of the road. The next point will be right at the centre of the
whole road surface while the subsequent one will have to be at the centre of the road
right half width. This thus ensures even coverage over the whole road surface. Relative
Compaction test-result must not be less than 99% - 100% in most cases obtained before
approval to carry out any subsequent bituminous road works is permitted.
However, a short-length road may have its distance, for density-test, reduced to 50
metres interval for an efective quality control.

Table 1: Test Check List for Filling

Conformit Remark
Ite Test Applie Support Approval
Reque Frequen y s
m Descriptio d Tools Documen DN
st cy
No n Officer ts C A NA
C
1 BS RE Confir Lab Every Gen Spec
Proctor/ m Test 2000m 6124
B.B. QC/ME
Heavy
Compacti Tech
on Suppo
2 Plasticity rt Confir Lab Every 6125,
m Test 2000m 6127,
Others 6180
3 Grading Confir Lab Every 6125,
m Test 2000m 6127,
 6180
4 WAS/ Confir Lab Every 6181
AASHTO/ m Test 2000m
Compacti
on
5 CBR Confir Lab Every 6124,
m Test 2000m 6127
6 Field Confir Dynami Every 6127,
Density m Test c Plate/ 50m 6162
DCP/
Speedy
Moistur
e Tester

3.3.4 Sub-Grade/Filling Material (Laterite)

Material for filling in the embankment shall be obtained from sources approved by the
Engineers Representative (AEC Quality Control/Material Engineer) and no slurry, and or
soft or otherwise unsuitable materials shall on any account or under any circumstances be
placed in embankments. Large pieces of rock, clay or other materials shall be properly
broken up and beaten down and no accumulation at the foot of side slopes of embankments
of boulders or lumps having no cohesion will under any circumstances be permitted. The
Engineers decision regarding the suitability of any material shall be final, and any material
of which more than 15% passes the No 75m sieve may be rejected depending on the
plasticity characteristics of this material, provided good quality fill materials are available,
otherwise such material may be modified for use.
The material to be used for the forming of embankments shall generally be obtained from
cuttings which may be widened as agreed with the Engineers Representative.
The material shall be spread evenly over the area of embankment and compacted in uniform
layers to the specified density and moisture using B.S. comp active efort, each
compacted layer shall not be greater than 150 mm or as directed by the Engineers
Representative
Soils shall be obtained from areas of cut including ditching or from approved borrow pits. All
grass and vegetation shall be removed from the surface of the areas of cut or borrow pits
before excavation of the fill material is commenced and no such grass or vegetation shall be
included in the fill. In borrow pits, the top soil shall be carefully removed and stockpiled.
During the course of the excavation from an area of cut or borrow pit or other approved
source of fill material, the Contractor shall provide adequate supervision to ensure that only
soil of a type approved by the Engineers Representative is excavated. Care shall be taken
during such excavations to avoid any pockets of heavy clay, vegetation or other unsuitable
material and if any such unsuitable material or soil of an unapproved type is included in the
fill it shall be dug out and made good with approved material where directed by the
Engineers Representative and at the Contractors own expense.
3.3.5 Sand Fill (Gen Spec Clause 6127)
Where sand fill either hydraulic or otherwise, is specified, it shall be obtained from a source
or sources approved by the Engineer. Where such sources occur in waters or areas under the
jurisdiction of the Nigerian Ports Authority or the Inland Waterway department of the Federal
Ministry of Transport or other appropriate authority, then the Contractor shall first obtain
written permission to remove material from the authority concerned and shall comply, in all
respects with all regulations laid down by such an authority.
The quality of the material intended for use as sand fill shall be subject to the approval of
the Engineer. For hydraulic sand fill the grading of the material shall be such that not more
than 15% passes the 75 m sieve and in no-case will isolated pockets or layers of silt, clay
or other organic impurities he accepted. For sand fill placed by any method other than the
hydraulic, the grading shall be such that not more than 15% passes the 75 sieve, and in no
case will isolated pockets or layers of silt, clay or other organic impurities be accepted.

The relative density of hydraulics sand fill placed in embankment shall be as follows:

Top 600mm 90%

Next 600mm 80%
Below the Top 1200mm 70%

Table 2: Relationship between Compaction Plant and Laboratory Test: MDD and
OMC
Soil Types
Compact Gravelly
Heavy Clay Silty Clay Sandy Clay Sand
ion Sandy Clay
MDD OMC MDD OMC MDD OMC MDD OMC MDD OMC
B.S 2.5Kg 1554 26 1666 21 1842 14 1938 11 2067 9
B.S. 1810 17 1922 14 2051 11 2083 9 2211 7
Heavy
4.5Kg
2800KG 1522 21 1762 17 1826 16 2034 10 2147 8
S. W.
Rolle

Note!
B.S British Standard
S. W Roller Steel Wheel Roller

Sand fill placed by any method other than the hydraulic shall be compacted in layers by a
method approved by the Engineers Representative to a density of not less than 100% of
the maximum dry density obtained in the British Standard Compaction Test Vibrative system
of compaction is recommended.
In the case of hydraulic sand fill the Contractor shall construct all drains, ditches, spillways,
marginal bunds necessary for the proper protection of the works. Such drains, marginal
bonds etc., shall be constructed sufficiently in advance of the deposit of the sand fill, so as to
efectively drain and retain the sand fill and to prevent any of the material from flowing into
any harbours, creeks, canals, drains etc or from causing any damage or nuisance to persons
or property. The Contractor shall be responsible for any slip or settlements which may occur
during the construction of the sand fill or the bunds, chains, etc., and shall also be
responsible for same during the maintenance period. The Contractor shall make good such
slips and settlements to the satisfaction of the Engineers Representative.
The Contractor shall be responsible for the full and efficient drainage of water resulting from
the hydraulic sand fill operation and shall construct such open drains as may be necessary
to drain all surface and rainwater, so as to avoid all ponding. The Contractor shall make due
allowance for settlement and drying-out of the sand-fill and for the making good of same.

Before any hydraulic sand fill is commenced, the Contractor shall, in conjunction with the
Engineers Representative, survey the site and mutually agree on the surface levels, and
such agreement shall be recorded in writing by both parties. The levels shall be taken on a
grid with points at not exceeding 15 metres centres and the Contractor shall construct
concrete pilot- pillars to the satisfaction of the Engineers Representative to enable the grid
lines to be located during the filling operations. The Contractor shall construct sufficient
tell-tales, consisting of
50mm x 50mm x 10mm angle of adequate length with a flange of 900mm in diameter
fixed at one end, all in non-corrosive metal, to the satisfaction of the Engineers
Representative, to enable any subsidence of the original ground level to be measured. The
method of measurement of hydraulic sand fill shall be on the basis of the volume of
material placed as determined from the area filled and the depth of fill to the finished level
from the original ground level or the subsided original ground level, as applicable.
Hydraulic sand fill shall be done in layers as directed by the Engineer, but in any case
the thickness of such layers shall not exceed the limits stipulated as follows:

First Layer - not exceeding 450mm in thickness

Second Layer - not exceeding 750mm in thickness
All subsequent Layers - not exceeding 900mm in thickness

The finished level shall be as shown on the drawings or as directed by the Engineer, and
shall be agreed as the result of a joint survey carried out by the Contractor and the
Engineers Representative. A tolerance of 75mm above or below the finished level may be
permitted during pumping operations, but the same shall be made good by subsequent
grading or dozing to the satisfaction of the Engineers Representative and to the tolerances
stipulated for the sub-grade. Without limiting his commitments under the terms of the
contract, the Contractor shall be required to make good any normal expected settlement of
the original ground levels after completion of the sand fill. The Contractor shall be deemed
to have allowed for all the foregoing provisions in his rates and prices for sand filling.
Should the Engineer so desire the Contractor shall place stock piles of material in quantities
and areas as directed.

3.3.6 Completion and Shaping Of Sub-Grade

Immediately before the construction of the sub-base course, the upper surface of the sub-
grade shall be tested for smoothness and accuracy of formation and if any areas are found
to lack the required smoothness or accuracy, such areas shall be scarified, reshaped, re-
compacted as specified, or otherwise treated as the Engineers Representative may require
until the required smoothness and accuracy is obtained.
The finished surface of the sub-grade shall be left as smooth as possible and the accuracy
of finish in the longitudinal direction shall not vary at any point by more than 12mm from a
5-0 metre straight edge, placed in any position on the finished surface parallel to the centre
line. The transverse profile shall conform to the same accuracy using a correctly shaped
template instead of the straight edge. The level of any point on the aforesaid surface shall
not vary by more than 12mm from the finished level of the pavement less the specified
thickness of the pavement construction. Payment for all of the work required by this clause
shall be deemed to be included in the tendered rates and prices.
The requirements of the above shall not be held to apply to the existing bituminous surfacing
scarified, shaped and recompacted on lengths of strengthening of the existing alignment.
Payment for all of the operations required under this clause shall be deemed to be included
in the tendered rates and prices.

3.3.7 Tests for the Classification of Compacted Sub-Grade and Filling

The tests listed below will normally be required to be carried out for each 2 kilometres of
sub- grade or each layer of fill. The numbers and types of tests listed however are given only
as a guide to the Contractor for tender purposes and the actual number and type of tests
which will be carried out during the construction of the works will be determined entirely at
the discretion of the Engineer.

1. CLASSIFICATION TESTS
2 NO. LIQUID LIMIT TESTS
2 NO. PLASTIC LIMIT TESTS
2 NO. SIEVE ANALYSES TESTS
4 NO. BRITISH STANDARD COMPACTION TESTS
2 NO. LABORATORY C.B.R.TESTS AT THE SPECIFIED DENSITY AND MOISTURE CONTENT.
2. CONTROL TESTS
20 No In-situ Dry Density Tests.
Except where otherwise stated to the contrary, these tests shall be carried out as described,
or where no such description is given in accordance with the appropriate British Standard,
AASHTO and ASTM Standards.
The sieve analysis shall be carried out in accordance with the standards laid down in the
latest amended report of the Lagos Materials Testing Conference a copy of which shall be
made available to the Contractor on request, or as per the latest B.S 1377.
Normally, the minimum strength of such grade course materials shall not be less than
80% CBR value being determined at maximum dry density and optimum moisture content
un- soaked with either West African or Modified AASHTO compaction. However, where the
Engineers Representative considers it necessary on account of perched water-table or any
other reasons, he may specify that a C.B.R. value of 80% be obtained after at least 24 hours
soaking.

The tests listed below will normally be required to be carried out for each 2 kilometres of
Sub- grade course. The actual number and type of tests which will be carried out during the
construction of the works will be entirely at the discretion of the Engineers Representative

3.3.8 Sub-Base Course

This is a structural layer above sub-grade course and the material shall consist of pit-run
laterite, sand, or screening, and soil of other similar binding or filler material and shall be
obtained from approved sources. The maximum dimensions of any particle shall not
be greater than two-thirds of the compacted thickness of the layer in which it is to be
placed. Oversize material shall be removed by screens, grizzles or by hand picking. The
gradation and soil constants shall comply to the requirements specified herein. The
material shall be free from vegetable matter, and excessive amount of lumps of clay, and
other objectionable or foreign substances.

3.3.9 Materials for Compacted Sub-Base Course

All material for the Sub-Base course, and hard shoulders shall be selected by the Contractor.
Where a preliminary survey has been carried out by the Engineer, a copy of the report on
the soil survey shall be made available to the Contractor. Where no such soil survey has
been carried out the Contractor shall make his own arrangements for the location of
borrow pits and sources of materials and the cost of any surveys shall be deemed to be
included in the tendered rates and prices. The soil survey reports of the Engineer, when
available shall be used for guidance only, and shall not relieve the Contractor of his
responsibility for executing the works in accordance with the conditions of contract and this
specification. All selected material shall be free of roots, vegetable matter and other
deleterious materials and shall be approved by the Engineers Representative before its
incorporation in the works.
Normally, the minimum strength of such base course materials shall not be less than 80%
CBR value being determined at maximum dry density and optimum moisture content
unsoaked with either West African or modified AASHTO compaction. However, where the
Engineers Representative considers it necessary on account of perched water-table or any
other reasons, he may specify that a C.B.R. value of 80% to be obtained after at least 24
hours soaking.
The minimum strength of material for sub-base course shall not be less than 30% C.B.R.
After at least 24 hours soaking, the C.B.R value being assessed in the same manner as for
Sub-base, at that optimum moisture content and maximum dry density of the West African
Standard Compaction (WASC) Test.
At the Engineers Representatives discretion material with a liquid limit greater than 30, and
a plascticity index greater than 12 may be disqualified for use as sub-base course or base
course.

Table 3: Gradation of Sub-base Materials

Sieve Percent Passing By Weight
75 mm 100
600m 25-60
425m 10-40
75m 5-20

The Percent by weight passing the No 75 m sieve shall be less than but not greater than
35%. The material passing the 425 m sieve shall have a liquid limit of not more than 35%
and a plasticity index of not more than 12, as determined by American Society for Testing
Materials methods, serial designation D 432-39 and 424-39 respectively or as determined by
test No 2 or 2A and test Nos. 3 of B.S 1377 (1975). Prior to approval of the sub-base
material, a test section shall be constructed to the thickness shown on the typical pavement
section and compacted to 100 percent of maximum density. When the test section is
compacted to 100 percent maximum density at optimum moisture content, the sub-base
material shall be of such quality that it shall have the minimum CBR of 30% after at least 24
hours soaking. Once established that the sub-base meets the CBR quality requirement at
100 percent maximum density it shall be placed and compacted in the field to that density.

3.3.10 Tests for Sub-Base (Classification and Control Tests)

Table 4: Classification and Control Tests

Modifie
Type of Liquid Plastic Insitu C.B.R Grading Remark
WASC d
Tests Limit Limit Density [%] s s
AASHTO
Classificati 4 4 2 2 - 4 2 Carry out
on either of
 item 1 or
2
Laborator
y results
to be
Control - 4 - - 20 4 -
used as
control
values

3.3.11 Completion of Sub-Base Course

Compaction of the sub-base course and the base course shall be carried out separately, and
shall begin immediately the soil has been brought to the required moisture content and
shall be carried out rapidly until completion. The compaction of the sub-base course and
base course shall be carried out to a dry density not less than 100% of that achieved in the
West African Standard Compaction Test at optimum moisture content, but the compaction of
the base course may be carried out to a dry density of not less than 100% of that achieved
in the Modify A.A.S.H.T.O. Compaction Test at optimum moisture content, if so directed by
the Engineer.
Immediately before the construction of the base-course, the Sub-base course shall be
tested for thickness, surface finish and accuracy, and If any areas are found to lack the
required thickness, surface finish, or accuracy or specified density, such areas shall be
scarified, re- compacted to the specified density or otherwise treated as the Engineers
Representative may require until the required thickness smoothness, accuracy or density is
obtained.
The finished surface of the Sub-base course shall be left as smooth as possible and
the accuracy of finish in the longitudinal direction shall not vary at any point by more than
12mm for a 5 metre straight edge, placed in any position on the finished surface parallel to
the centre line. The transverse profile shall conform to the same accuracy using a correctly
shaped template instead of straight edge. The level of any point the aforesaid surface shall
not vary by more than 12mm from the finished level of the pavement less the specified
thickness of the base construction.
The thickness of the Sub-base course at any point shall not be less than the specified
thickness by more than 12 mm. The Contractor shall include in his rates the digging of
trial holes, and making good same, to the satisfaction of the Engineers Representative.

3.3.12 Base Course

The tests listed below will normally be required to be carried out for each 2 kilometres of
Base course. The actual number and type of tests which will be carried out during the
construction of the works will be entirely at the discretion of the Engineers Representative

3.3.13 Tests for Base-Corse (Classification And Control Tests)

Table V: Classification and Control Tests
Modifie
Type of Liquid Plastic Insitu C.B.R Grading Remark
WASC d
Tests Limit Limit Density [%] s s
AASHTO
Carry out
Classificati either of
4 4 2 2 - 4 2
on item 1 or
2
Laborator
y results
to be
Control - 4 - - 20 4 -
used as
control
values

3.3.14 Completion of Base Course

Immediately before the application of the surfacing, the base course shall be tested
for
thickness, smoothness and accuracy as specified below and if any areas are found to lack
the required thickness, smoothness and accuracy or the specified density, such areas shall
be scarified, reshaped and re-compacted with additional approved material added where
necessary or otherwise treated as the Engineers Representative may require until
the required thickness, smoothness, accuracy or density is obtained.
The finished surface of the base shall be left as smooth as possible and the accuracy of finish
in the longitudinal direction shall not vary at any point by more than 5 mm from a 3.0
meter straight edge, placed in any position on the profile and shall conform to the same
accuracy using a correctly shaped template instead of the straight edge. The level of any
point on the aforesaid surface shall not vary by more than 5 mm from the finished level of
the pavement. The thickness of the base course at any point shall not be less than the
specified thickness by more than 12 mm and the average thickness over a length of 0.4
kilometres shall be equal to, or in excess of the specified thickness. The contractor shall
include in his rate for digging necessary trial holes, and making good same, to the
satisfaction of the Engineers Representative
In the process of completing the base course it may be necessary to place material to a
greater thickness than that specified and to grade it to the specified finish. In so doing
excess material will be wasted. Payment for this and for other operations required to
obtain the specified finish shall be deemed to be included in the tendered rate and prices.

3.3.15 Surfacing Of Base Course (Prime Coat Mc 1)

The base course of the carriageway shall where applicable be provided with prime coat and
other surfacing as specified in the relevant clauses of the specification. The surfacing shall
be laid as soon as possible after the construction of the base course.
3.3.16 Preparation of Base Course to Receive Bitumen Prime Coat
Immediately before spraying of the prime coat, the surface of the base course shall be swept
clean, and all loose dust, dirt and the like removed. The Engineers Representative may
also direct that any very smooth surface to which the surfacing is unlikely to adhere, be
roughened with wire brushes or other approved means.
If any weak areas are found they shall be cut out and refilled with base course material and
rolled to correct cross section and gradient. The surface shall be slightly damped before the
application of the prime coat surface.

3.3.17 Test for the Selection Of Laterite Sub-Base Course And Base Course
Materials
The following tests shall be carried out on all material proposed for use as sub-base
course and base course:
1. Plasticity Test.
2. Grading Test.
3. Density/Moisture Content Compaction Test.
4. Laboratory C.B.R. Test.
These tests shall be carried out as described in Section 1 of this specification.

3.3.18 Test for Classification and Control of Compacted Lateritic Sub-base

Course and Base Course.
I. Classification

2 NO. Liquid Limit Tests

2 No. Plastic Limit Tests
2 No sieve Analysis Tests
4 No West African Standard Compaction Tests or
4 No Mod. A.A.S.H.O Compaction Tests

The tests listed above will normally be required to be carried out for each 2 kilometres of
sub- base course and base course. The numbers and types of tests listed are, however,
given only as a guide to the Contractor for tender purposes and the actual number and
type of tests which will be carried out during the construction of the works will be entirely at
the discretion of the Engineers Representative:

II. Crushed Stone Base Course

Base course aggregate shall consist of crushed Stone.
III. Physical Properties Of Aggregate
Materials for use as Stone base shall be classified under two categories i.e. coarse aggregate
and Fine aggregate.
IV. Coarse Aggregates
Coarse aggregate shall be granite crushed stone sourced from approved Quarry by the
Engineers Representative and shall have sizes ranging from 50mm and retained on
5mm sieve. The aggregate shall be free from clay or silty materials, and when subjected to
10% fine test or aggregate crushing value the value of the results shall range from 7.5%
to 12.5% for fine and not more than 35% for aggregate crushing value.

V. Fine Aggregates
Fine aggregate known as binder material shall be materials passing sieve 5mm and
retained on 75m sieve. It may be sourced from river bed at location approved by the
Engineers Representative or the fines from crushed stone. It shall be free from vegetation or
other objectionable matter. Fine aggregate shall be clean without any clay content,
strong and

sharp. It shall be of such grading characteristic that when combined with coarse
aggregate, the composite material shall conform to the gradation and other requirements
specified in clause 2004 (1-3). Liquid limit and Plasticity Index requirements stated
herein shall apply to any aggregate component that is blended to meet the required
gradation and also to the aggregate in the compacted base course. The portion of fine
aggregate passing the 75 m sieve shall be either non-plastic or shall have liquid limit not
greater than 30% and Plasticity Index not greater than
6. This index test will only be applicable to materials for wet laying.

VI. Combination Procedure

It is easier to handle gradation size by use of two categories of materials: - Firstly grade
the coarse aggregate and plot on the stone base design envelope, next, grade the fine
sand and plot in the design envelope. By simple physical examination of the two graphs,
guided by experience, two to three controls produce the required satisfactory grading that
will fall into the envelope, otherwise simple calculation may be used to achieve the required
combination. NOTE: Once an acceptable combination is produced frequent grading
checks on both specimens must be carried out to ensure that deviation from gradation
is not allowed to occur. The results of such grading test will enable adjustment to be made
on the combination proportion.

VII. Combination of diferent sizes of aggregates

Coarse aggregate of different sizes and the fine aggregate shall be placed in different
Bins. Each aggregate sizes and the fines shall be sieved and plotted on appropriate log
chart. Simple arithmetic calculation may be used to determine the combined proportion.
Alternatively, careful study of the graphs coupled with experience will enable user to guess
the proportion by trial and error. Once a suitable mix proportion is established, the grading
of each size of aggregate shall be checked from time to time, to ensure that there is no
deviation or variation.
VIII. Establishing Mix Control Criteria
When a mix proportion has been established representative sample of each materials shall
be combined and quartered to make six number of CBR mould specimens, moisturized to 5%
of dry weight of sample and kept in air tight container for 18 hours. Before the samples are
compacted the moisture shall be checked using calibrated SPEEDY TESTER. If the moisture is
lower than 5% more water to attain this moisture shall be added. When the material is
mixed thoroughly it shall be compacted using AASHO compactive effort or using a
vibrating kango hammer. Whichever compactive efort is used, (not B.S.) it shall be in five
layers and the thickness of compacted specimen shall not be less than 125mm or more that
130mm, otherwise it shall be discarded. The loose material on the specimen after
compaction shall be removed carefully. and with a straight edge placed across the top in a
minimum of two directions, the depth of the compacted specimen surface from the top shall
be determined in three i.e. along each direction of the straight edge. The mean of six
readings shall be used to check the depth of the specimen and thereafter its volume.
Unless directed to the contrary the six specimens will be tested for Dry Density only.
Alternatively 3 specimens may be soaked for 24 hours (complete immersion in water
with
25mm water head above the specimen) tested for CBR after the specimen is allowed to
drain for 15 Minutes. The remaining average of two close results shall be tested for CBR
(strength) unsoaked average of two close results shall be the CBR or Dry Density of the
specimen. If CBR of over 100% is obtained the dry density established with corresponding
moisture content shall be the design criteria and control for the works.

IX. The grading of crushed stone for use in crushed stone base course shall be
as follows:

Dry Process
75 mm to 12 mm or 50 mm -12 mm herein after referred to as coarse stone.
12 mm to dust hereinafter referred to as screening

Wet Process
The composite mixture of coarse aggregate and binder material proceed as hereinafter
specified shall conform to one of the applicable gradations shown in Table and shall not vary
from the low limit on one sieve to the high limit on adjacent sieve or vice versa, but shall be
uniformly graded from coarse to fine.
Gradation requirement specified herein shall apply to the completed base course after
undergoing the mixing placing compacting and other operations. The portion of the
aggregate passing No 75m sieve shall not be greater than one-third of the portion passing
the No. 425
m sieve. The aggregates shall continuously be well graded within the limits of Gradation A,
B. C, D or E as specified below. The methods of test used will be ASTM Standards C117.
C127, C128, C136 and D422. Sieves shall conform to ASTM Standard E.11 or BS sieve.

Table VI: Grading Envelope for Stone Base Course Wet Method (Gen Spec Clause 6252)
Sieve Percentage by weight passing square mesh sieve
Designation Grading A Grading B Grading C Grading D Opening
Grading E
75 mm 100 100 100 100 50 mm 100

50 mm 85-100 85-100 90-100 90-100 37.5 mm 95-100

25 mm 60-95 65-95 75-100 80-100 20 mm 60-80
10 mm 30-65 40-75 50-85 60-100 10 mm 40-60
5 mm 25-55 30-60 35-65 50-85 5 mm 25-40
2 mm 15-40 20-45 25-50 40-70 2.36 mm 15-30
425 m 8-20 13-30 15-30 25-45 600 m 8-22
75 m 2-8 5-10 5-10 5-15 75 m 6-12

Note: - The table is based on aggregate of uniform specific gravity, and the
percentages passing the various sieves may require appropriate correction by the
Engineer when aggregates of varying specific gravities are used.

3.3.19 Crushed Stone To Be Laid And Compacted In Layers

Crushed stone base course laid by either the wet dry method shall be laid in layer of not less
than 150 mm compacted thickness to the satisfaction of the Engineers Representative.

3.3.20 Laying And Compacting Crushed Stone Dry Process

When crushed stone base-course is to be laid by the dry process method of laying and
compacting shall be as follows:
The coarse stone 75mm to 12mm or 50mm to 12mm shall be spread in a manner
approved by the Engineers Representative to even depth which, after compaction will
produce the specified thickness of layer.

The coarse stone shall then be regulated and compacted by not less than three passes of an
approved roller.
Successive uniform layers of screening 12mm to dust shall then be applied over the
surface and shall be vibrated into the interstices of the coarse stone by means of an
approved

vibrating plate compactor or other approved means. Screening may be spread by hand
shovel using a sweeping motion or by approved tailboard spreader attached to lorries. In
no case shall screenings be dumped on the surface in piles and spread there from. Great
care shall be taken to ensure that the screening are not applied either so quickly or so
thickly as to CAKE or bridge on the surface in a manner which prevents the filling of the
interstices or causes the vibrating or compacting equipment bearing directly on the coarse
stone. The addition of screenings and vibrating into the interstices of the coarse stone
shall continue until all the voids are filled in.
The surface of the crushed stone shall then be checked transversely and longitudinally
for level and camber and any indicated variations adjusted. The surface shall then be
sprinkled with water from a water browser and rolled with a smooth wheel roller having a
weight of roll of not less than 58 kilograms per centimetre. Voids in the Base-course which
occur during this process shall be filled by sweeping screenings into them.
The sprinkling, sweeping and rolling shall continue until all voids are filled with grout to the
satisfaction of the Engineers Representative.
The final surface shall be smooth and even, free from irregularities or loose material and
true to line and level having regard to the tolerances for base course finish specified
elsewhere herein.

3.3.21 Crushed Stone Base Course Laid By The Wet Process (Gen Spec Clause
6253)
When crushed stone Base course is to be laid by the dry or wet process the method of laying
and compacting shall be as follows:
The approved crushed stone, graded as specified shall be mixed with between 3% and 5% of
water as directed in a mixer of a type approved by the Engineers Representative.

The mixed material shall be protected from the rays of the sun during transit from the
mixer to the site in order to prevent loss of moisture due to evaporation and shall be laid by
a self- propelled asphalt finisher or other approved plant in layers of not less than 75mm
or more than 150mm thickness after compaction. During this operation care shall be
taken to avoid segregation.

Water can only be added to any wet laid stone base if it was discovered that evaporation
had taken place during rolling. The finished rolled stone base shall not have moisture less
than 3% or more than 5% by weight of dry aggregate.

Should any patchiness appear during compaction, areas deficient in fines shall be blinded
with screenings, watered, and rolled and areas showing an excess of fines shall be
removed and reconstructed with graded material to the satisfaction of the Engineers
Representative
The final surface shall be smooth and even free from irregularities or loose material and
true to line and level having regards to tolerances for Base-courses specified elsewhere
herein.
3.3.22 Preparation Of Crushed Stone Base Course To Receive Bituminous
Surfacing (Gen Spec
Clause 6258)
Crushed stone Base course laid by either the dry or wet shall be prepared for the addition
of bituminous surfacing as specified under the relevant parts of this section of the
specification. COMPACTION. Compaction of crushed stone Base Course shall be to the
satisfaction of the Engineers Representative

3.4 CONCRETE WORKS

3.4.1 Concrete Materials

All prospective related materials intended for use ought to have their samples examined,
tested and approved before being permitted for construction consumption on site. This is to
simply forestall the use of sub-standard materials to which poor quality jobs are often
traceable.

3.4.2 Concrete Workability

The ultimate strength of any concrete, of a given mix-proportion, is often negatively
afected by the poor workability. This translates into either too little or too much water in a
concrete mix with grave consequences. Too little water frustrates the desirable degree of
compaction which often results into voids. An aggregated voids of up to 5% is known
to reduce the related concrete strength by as much as 30%. Equally too much water results
into segregation with no good concrete strength result either. To this end, a slump test
ought to be carried out, as regularly as possible, on wet concrete being produced on the site
to assist in maintaining eficient consistent concrete production.

3.4.3 Concrete Strength

It has to be noted that a good concrete strength is the chief of all the ultimate desirables
of any concrete structure. A good concrete strength normally increases with age.
Interestingly such standard concrete develops 80% of its 12 month strength in 28 days while
it develops not less than 55% in the seventh day. We Engineers do not feel comfortable,
therefore, if and when a grade 20 universal concrete for example falls below the 55% cut-of
at age seven. This is why six concrete cubes are often cast on site and three each are
tested at ages seven and twenty-eight days to confirm the above stated desirable strength
development pattern. Consequently for every maximum of hundred cubic metres of concrete
works, six (6) numbers of cubes must be tested at 7 and 28days accordingly.

3.5 BITUMINOUS WORKS

All bituminous road works, ranging from priming, surface dressing and asphaltic concreting,
as of practice, must be made to undergo quality control tests as stated below.
3.5.1 Priming
This starts with a bitumen tray test in order to ascertain the correct rate of spray. Too
much bitumen on the road, resulting in bleeding, might be caused by a slow speed at which
the sprayer vehicle was moving. Equally, too little bitumen might be as a result of over
speeding. An appropriate predetermined rate of bitumen spray is to be ensured. The
sprayed bitumen must be given enough time, say 6 24 hours, to achieve a 6 9mm
desired percolation (penetration).

Thereafter, sharp sand or an equivalent crushed rock quarry fines is to be used to blind the
surface. A 2.5 tons roller is to be brought in to press down the grains of the fine aggregates.
Thereafter, this surface must either be brushed-clean or washed before applying tack-coat in
case of surface-dressing. Priming performs three major functions. It water-proofs the
surface, makes it dust-proof and provides a bonding surface.

3.5.2 Bituminous Surface Dressing

The rate of spray of S.1.5 bitumen, to be employed as tack-coat, also needs to be
ascertained and ensured that is correct. An incorrect specified rate of spray kick-starts a
poor quality job.

Usually the tray-test exposes any related short-coming. The single-sized coarse
aggregate, that will have to come on board, must have undergone both sieve analysis and
aggregate crushing value (ACV) plus ten percent fines suitability tests and approved before
use.
The services of a chipping spreader, if engaged, will offer a good quality surface. Thereafter,
a
6 ton roller will have to press the grains of aggregates into the bitumen. The surface
is allowed to mature and not to be opened to trafic earlier than 24 hours.

3.5.3 Asphaltic Concrete

I. General
The asphaltic concrete must have its temperature checked when it arrives on site before
being layed. This is to ensure that asphalt of appropriate temperature is laid. Equally,
the laying thickness is checked as regularly as possible. This is inclusive of the adequacy of
the desirable compaction.
Furthermore, samples of asphalt delivered to site must be obtained and analyzed regularly
to
ensure that the design-mix agrees with or compares favourably with the mix-design.
A pneumatic tyred roller, with a wetting device, is to be engaged for the compaction of
the laid asphalt. The checking accorded the thickness will alert the paver-operator to
carry-out necessary thickness related adjustment on the paver.
This item consists of hot mixed, hot laid asphaltic concrete composed of mineral
aggregate and asphalt cement thoroughly mixed in an approved plant until all aggregate
particles are uniformly coated with asphalt. The asphaltic concrete shall be laid in two
courses surface and binder courses, with or without wedge or levelling courses or any
combination of these as shown on the drawings. Unless specified in Volume III or on the
drawings, the compacted thickness of each course shall not be less than 60mm for the
binder and 40mm for the surface course. The compacted thickness of any single constructed
course shall exceed 75mm for binder or levelling course or 60mm for surface course.
Priming of untreated base and application of tack coat to existing paved surfaces shall be
done as follows:
For Priming Base: MC-0 or MC-1 shall be used at the rate of 1.0 2.0 Litres/sq.m
For Applying Bitumen emulsion,
Tack Coat: quick breaking type applied at the rate of 0.25 0.70 Litres/sq.m. Tack coat
shall be applied in all areas to take the binder course if warranted by surface
conditions and directed by the Engineers Representative.
All materials and method of preparation and construction shall conform with
the requirements of these specifications. The finished pavement shall conform in all respects
with the lines, grades, dimensions and cross sections shown on the drawings or as
may be otherwise specified or directed by the Engineer.

II. Material
The materials used shall be those prescribed for the several parts which constitute
the finished work and shall conform with all the required for such materials as set out herein.
Aggregate

Coarse aggregate shall be the portion of the aggregate retained on the No. 5mm
opening sieve and shall be hard, clean and durable crushed igneous rock from a source to
be approved by the Engineer. The crushed stone shall be free from dirt or other
objectionable matter.

The coarse aggregate when tested by the methods described in B. S.812 shall have
properties not exceeding the following values.

Table VII: Aggregate Specification for Dense Bitumen Macadam, Asphaltic Base & Wearing
Courses
 Pavement Course Aggregate Flakiness Absorptio
Crushing Index n
Dense Bitumen Macadam Base Value
30 35 Factor
1.5
Dense Bitumen Macadam Wearing30 35 0.5
Asphaltic Concrete Base course 30 35 0.5
course
Asphaltic Concrete Wearing Course 30 35 0.5

Fine aggregate shall be the portion of the aggregate passing the No. 5mm opening sieve and
shall be quarry fines produced from the crushing of igneous rock. They shall be composed of
clean, tough, rough surfaced and angular particles, free from lump or ball of clay, loam and
other deleterious substances.

Mineral filler shall consist of finely ground particles of hydrated lime, Portland cement or
other non mineral matter approved by the Engineer. It shall be free from foreign or other
objectionable material, and shall meet the following grading requirements:

Table VIII: Specifications for Mineral Filler

SIEVE % BY WEIGHT PASSING
300 m 100
200 m 95-100
75 m 85-100
Bituminous Material

Table IX: Quality of Asphaltic Cement

ASPHALTIC CEMENT
PROPERTY 80-100 60-70
PEN PEN
Specific Gravity @ 25C 1.00-1.05 1.01-1.06
Softening Point R and B (C) 45-52 48-56
Penetration @ 25C 0.1 mm 80-100 60-70
Ductility @ 25C CM 100 100
Minimum
Loss on Heating for 5 99 99
Hours at 163C % Weight
Max Solubility in CS % WT..
MIN
Drop in Penetration after 20 20
Heating % Original . MAX
Flash Point (Open Cup) C 225 250
MIN.
Ash. % by WT. MAX. 0.5 0.5

Bitumen emulsion for tack coat shall be emulsion quick breaking type containing 30-
50% bitumen.

Cutback bitumen for priming shall be MC-O or MC-1.

III. Approval of Material

Representative samples of all materials proposed for use under these specifications shall be
submitted to the Engineer by the Contractor at the Contractors expense for test and for the
preparation of trial mixes to determine the job mix formula. The Engineer shall make tests
of the proposed materials and inform the Contractor if the tests indicate compliance with
the specifications.

Suitable sizes of aggregate shall be stored in bins at each point where bituminous
materials are mixed. The bins shall be in such numbers and of such capacities as to ensure
that an uninterrupted supply of all the necessary sizes of aggregates are available at the
mixer.
If aggregates are stockpiled prior to their transference to the bins, the stockpiles shall be
formed on concrete floors laid to falls suficient to permit drainage at the base of
the stockpiles. Aggregates shall be handled to and from the stockpiles in a manner such that
they are not contaminated by the ground or by extraneous matter and also in a manner such
that segregation is prevented. In as much as possible the bins shall be covered to
prevent dampness of aggregate by rain.

Coarse and fine aggregates and aggregates from different sources shall be
stockpiled separately and if aggregates of different grading or from different sources are
stockpiled in close proximity the stockpiles shall be separated by partitioning.

All aggregates produced or handled by hydraulic methods and all washed aggregates shall
be stockpiled under cover for draining for at least 24 hours before use.

Material used as filler shall be stored in dry conditions to the satisfaction of the
Engineers Representative.

No material shall be used until it has been approved by the Engineer. Permission to use
material shall not be construed as an approval of its source nor any acceptance as continued
acceptance.

IV. Sampling
The Contractor shall provide equipment, labour and such trained staf as may be required by
the Engineer for carrying out the following tests on materials to be used in the manufacture
of hot asphaltic concrete in accordance with the following standards:

Grading tests on aggregates in accordance with the latest B. S. 812 - Sampling and testing
of mineral aggregate and fillers.

Determination of binder content of mixed materials in accordance with either:

Hot extraction method BT 1 described in B.S. 598 (1974) - Sampling and examination of
bituminous road mixtures. The Contractor is to comply with the requirements of B.S. 598:
and to the need of providing results in duplicate.
Or
By reflux extractor method.

Aggregates shall be sampled and tested on delivery to the mixing plant and after each
extraction test and the result of each test shall be submitted to the Engineer or his
Representative within 24 hours of the sample being taken.
The number of such tests shall be adequate for proper control of the materials and shall
not be limited to those made on specified instructions of the Engineer or his Representative.
Samples of mixed materials shall be taken and tested during the first days mixing and
throughout the work to confirm that the grading and binder contents are as specified. Such
samples shall be taken either at the place and time of mixing or at the place of laying as
directed by the Engineer or his Representative. Samples for testing shall also be cut from the
surfacing as laid when directed by the Engineer or his Representative.

The frequency of sampling mixed materials shall be at least once per day or once for each
90 tonne of material mixed whichever is the more frequent. The result of each test on mixed
materials shall be submitted to the Engineer or his representative within 24 hours of the
sampling and any adjustment shown to be necessary shall be made immediately. Until such
adjustment have been made and until a certificate to the effect has been forwarded to
the Engineer or his representative no further batches or mixed material shall be made.

Independent sampling and testing may be carried out by the Engineer throughout the
contract period and for this purpose the contractor shall grant free access to the mixing
plant and storage depots, supply materials and provide every facility for the Engineer or his
representative to take sample whenever required.

In particular, throughout the contract, the Engineer will carry out control test on the plant
mix material using the marshal test apparatus.

A certificate is to be obtained from the supplier with each consignment of bitumen delivered;
stating the grade of material being supplied, and these certificates are to be handed to
the Engineers Representative.

If the Engineer so requires, the Contractor shall arrange for the testing in an approved
manner of all materials used throughout the contract to ensure that they are up to the
standard specified, i.e. aggregates, bitumen and such other materials as specified or decided
by the Engineer. The Contractor shall arrange for the testing of materials incorporated in
the works to ensure that they have been manufactured as specified, or as ordered by the
Engineer.

Whenever the Contractor intends to carry out any of the above tests, he shall give the
Engineers Representative sufficient notice to enable him, should he so wish, to be present
during the test.
Whenever the Contractor takes samples for testing, and where so directed he is to take
duplicate samples and hand them to the Engineers Representative. Such samples are to be
properly packed and labelled as directed.

The Engineers Representative shall be given the results in writing of all tests, as soon as
they are available, and in any case not later than 24 hours after samples have been taken.

The Engineer shall be supplied with all necessary equipment, material and labour to perform
any additional tests he may wish to carry out himself.

The cost of these tests including the provision of samples will be deemed to have been
included in the bill of quantities under the appropriate item.

V. Composition of Mixes
Asphaltic concrete prepared under these specifications shall be composed of
graded aggregate and asphalt cement within the limits set forth below. When plotted
graphically the aggregate grading shall lie on a smooth curve within the envelope.

Table X: Grading Envelope for Binder and Wearing Courses

Sieve Size % by Weight Passing
40mm - 65mm Binder 40mm-50mm
Wearing Course
31.8mm 100 100
25mm 90-10 100
19.0mm 70-90 100
12.5mm 55-80 85-100
9.5mm 47-70 75- 92
6.4mm 40-60 65- 82
2.8n 27-45 50- 65
1.25mm 20-34 36- 51
600m 14-27 26- 40
330m 8-20 18- 30
150m 5-15 13- 24
Bitumen Content % by weight of 4.5-6.5 5-8.0
aggregate
Asphaltic concrete mixes designed by the Contractor prior, to the selection of Job-Mixes (see
below) shall have combined aggregate grading approximating as closely as possible to the
plotted averages of the respective limits of grading specified above and shall comply with
the following requirements.

Table XI: Properties of Compacted Asphaltic Concrete

Properly Base-Course Wearing Course

Optimum Bitumen4.5% - 6.5% 5.0% - 8.0%
Stability, not less than 3.5KN 3.5KN
Content
Flow 2mm - 6mm 2mm - 4mm
Voids in total mixture 3% - 8% 3% - 5%
Voids filled with bitumen 65%-72% 75% - 82%

The exact job-mix formula will depend on the nature and grading of the aggregate and
the grade of bitumen and will be determined by the Engineer using the marshall method of
mix design. For this purpose the Contractor shall supply to the Engineer without charge
adequate samples (in separate containers) of coarse and fine aggregates and bitumen
which he intends to use. The Engineer will, after testing, furnish the Contractor with the
exact job-mix formula, which will be within the specified limits.

Before any a concrete is laid, the Contractor shall produce sufficient dry mixes in the plant
and carry out sieve analysis to ensure that the correct grading is being obtained. In addition,
he shall produce a number of trial mixes to which the specified quality of bitumen has
been added. He will then carry out extraction tests on this material and further sieve analysis
on the aggregate in accordance with clause 6373 of the specification. The results of these
tests on both the dry and wet mixes shall be approved by the Engineer before any
surfacing is laid in the permanent works.

VI. Job Mix Formula Defined

The job-mix formula is the single definite percentage of aggregate passing each required
sieve size, a single definite bitumen content to be added to the aggregate, a single definite
temperature at which the mixture is to be emptied from the mixer and a single definite
temperature at which the mixture is to be delivered on the road
Unless specifically changed in writing by the Engineer, the maximum variation from the
job- mix formula shall be as follows:

Table XII: Permissible Variation Percent by Weight of Total Mix

Sieves Permissible Variation % By Weight of
Total Mix
Passing Sieve 9.5 mm and layer 5% Passing Sieve 9.5 mm
600 m 4% Passing Sieve 600 m
150 m 3% Passing Sieve 150 m
75 m 0.1% Bitumen Content
0.3%
Note
Temperature of Mixture when emptied from mixer 145C 5C
Temperature of Mixture on delivery on the road 130C 5C

The job mix formula is liable to alternation by the Engineer Throughout the progress of
the work but at all times it will be within the specified limits.

VII. Preparation of Aggregates

The coarse and fine aggregate shall be separately fed by feeder to the cold elevator
or elevators in their proper proportions and at a rate to permit correct and uniform
temperature control of the heating and drying operation.
The aggregate shall be heated before entering the mixer to a temperature range of 120C
-
149C. All aggregates in the bins of a temperature that will produce a mix outside the limits
stated above or that contain moisture or expanding gases to cause Foaming in the
mixture, shall be removed and replaced in their respective stock piles. All aggregates that
have been overheated shall be cooled before being deposited in the feeder. All unsuitable
aggregates that may be in the weigh box or that become combined in the process of
Pulling the bins shall be discarded.
The screening efficiency shall be maintained within the limits set forth in Clause 6383. When
these limits are exceeded, the material shall be discarded and the cause for such
condition skill be corrected.

VIII. Preparation of Asphalt Cement

The asphalt cement shall be delivered to the asphalt bucket at a temperature between
135C and 163C. All asphalt cement heated beyond 177C at the plant before mixing or
heated beyond 163C during the mixing shall be rejected. No asphalt shall be used while
foaming.

IX. Preparation of Mixtures

The exact proportions within the limits specified for each mix shall be regulated so as to
produce a satisfactory mixture with all particles uniformly coated with bitumen.
When batch mixing is used, the aggregate at the temperature specified, shall be mixed dry
for a minimum of 15 seconds; the asphalt cement shall be added in an evenly spread sheet
Over the full length of the mixer. The mixing shall be continued for a minimum of 30 to 45
seconds for all mixtures.
The initial time of mixing shall be the interval of time between the opening of the weigh
box and the opening of the mixer gate. The number of batches produced in one hour
from the mixer shall not exceed 60.
When continuous mixing is used the dry aggregates shall be thoroughly mixed before the
addition of the asphalt cement. The asphalt cement shall then be added in an evenly spread
sheet over the full width of the mixer by means of spray bars. The mixing shall be
continued for a period of not less than 30 seconds. The total time for mixing shall be the
ratio of the
dead load in the mixer to the kilograms per minute delivered. The kilograms per minute
delivered shall be determined by timing and weighing a load of mixed material. The dead
load shall be determined by weighing the Mixer-full of material. The dry mixing shall be
the product of the ratio of dry mixer length to the total mixer length and total mixing time.
The Engineer may vary the length of the dry and wet mixing periods, but under no
circumstances shall the total mixing time be less than 45 seconds:
The mixture shall be loaded into trucks in such a manner that segregation will not occur.
The temperature of the mixture on arrival at the project site shall be as determined by
the Engineer in keeping with the temperature range set for the mix design and heat losses
in transit.

X. Transporting Mixed Materials

The mixed materials shall be transported from mixing plant to site in clean metal
lined vehicles. Every precaution is to be taken to avoid segregation of mixed materials
and to ensure that they do not become contaminated with dust or foreign matter. Covers
such as water-proof canvas and other insulation shall be provided when directed.

XI. Preparation of Area to be Paved

The area to be paved shall be true to line and grade, having dry and properly prepared
surface prior to the start of paving operations. The area to be paved shall be free from all
screenings, and other loose or foreign material.
Where a base is rough or uneven, a levelling course shall be placed by use of a motor
grader or spreader and shall be properly compacted before the placing of subsequent paving
courses. When a levelling course is not required, all depressions and other
irregularities shall be patched or corrected in a manner satisfactory to the Engineer.
All fatty and unsuitable patches, excess crack or joint filler, and all surplus bituminous
material shall be removed from the area to be paved. Blotting of excessive deposits of
asphalt with sand or stone shall not be permitted.
Where the area to be paved is an untreated soil or aggregate, it shall be primed. The
prime coat shall consist of an application of the asphaltic material indicated, and at the rate
specified in clause 6370. The prime coat shall be allowed to cure properly before any further
operations are permitted on the primed area.
A tack coat shall be applied when the surface to be paved is an existing Portland Cement
concrete or dry asphalt pavement. When a tack coat is required, it shall consist of an
application of the asphaltic material indicated, and at the rate specified in clause 6370.
In all cases the emulsion shall be allowed to break before laying. Prior to application of
the tack coat, all loose or objectionable material will be removed from the surface by
brooming or other approved method. After cleaning, the surface shall be inspected by the
Engineer before the tack coat is applied. The tack coat will be applied evenly and by
mechanical sprayer of approved type which is to comply with BS 1707.
Where the time between the completion of one surface course and the laying of the
subsequent surface course exceed 72 hours, a tack coat shall be applied to the preceding
course as above but at a rate of spread of 4- 4.5 square meter per litre. Such tack coat shall
be at the Contractors expense unless compliance with the 72 hours limit was impracticable.
Tack coats shall be applied 24 hours in advance of bituminous surfacing work, or such longer
period as is necessary to ensure complete breaking of the bitumen emulsion
before bituminous surfacing are laid thereon. Traffic shall not be allowed on the tack coat
before surfacing work begins.
Concrete kerbs, channels, and similar objects shall be adequately masked and
protected during the application of tack coats.
The surface of kerbs, gutters, vertical faces of existing pavements and all structures in
actual contact with asphalt mixes shall be painted with a thin uniform coating of asphalt
material to provide a bonded water-tight joint.

XII. Trial Areas

The first 30 metres of the approved bituminous mixture which is laid by each spreader shall
be regarded as a trial area in order to establish a rolling procedure which will produce
the required field density.
At least four samples of the material after rolling will be taken in accordance with part 1
section 3 of B.S. 598; when the work is at least 12 hours old in order to determine the
degree of compaction.
If the required density determined in accordance with clause 6381 is not obtained, the field
rolling procedure will be changed so as to achieve the desired field density and the trial area
will be cut out and replaced to the satisfaction of the Engineer.
After mixing, the material must not be reheated other than by the means provided in or
on the spreading machine.
Materials must not be laid when the surface on which it is to be placed is wet or when rain
appears imminent.
It is essential that the material is laid at a temperature not less than 121C and not more
than 163C. The Contractor is to provide at each spreader and finisher a suitable
thermometer for testing the temperature of the material as it is being spread and is to take
such temperature readings continually and record them hourly throughout each days laying.
This record shall be available for inspection by the Engineer who will himself make such
additional temperature checks as he considers desirable.
The materials shall be laid by approved mechanical pavers in accordance with clause
6384. The spreader paver shall be in good mechanical condition and shall be capable of
laying to the required width and profile without causing segregation, dragging burning,
irregularities or other surface defects. When not operated on side forms the paver will
employ equalizing runners, evener arms or other automatic compensating devices to adjust
the profile and confine the edges of the course to true lines.
As soon as the first load of materials has been spread the texture of the unrolled surface
shall be checked to determine its uniformly. The adjustment of the screed, tamping bars,
feed screws, hopper feed, etc., shall be checked frequently to ensure uniform spreading of
the mix to proper line and grade and adequate initial compaction. Segregation of materials
shall not be immediately suspended until the cause is determined and corrected.
Any irregularities in alignment left by the paver shall be corrected by trimming directly
behind the machine. Immediately after trimming, the edges of the course shall be
thoroughly compacted by tamping. Distortion of the pavement during this operation shall be
avoided. Edges against which additional pavement is to be placed shall be vertically formed
to true line. A rake shall be used immediately behind the finisher, when required, to obtain a
true line and vertical edge. Any irregularities in the surface of the pavement course shall
be corrected directly behind the paver. Excess material forming high spots shall be
removed by a shovel. Indented areas shall be filled with hot mix and smoothed with the
back of shovel being pulled over the surface. Fanning of materials over such areas shall not
be permitted.
The mixer capacity and the operating speed of the spreader shall be so adjusted as to
ensure continuous laying and to avoid intermittent stopping of the spreader as far as is
practicable. Hand spreading will not be permitted for general work, but will only be
allowed for filling localized depressions, or as directed by the Engineer.
Hand laying of any bituminous material will only be permitted in the following circumstances.
* for laying regulating courses of irregular shape and varying thickness.
* in confined spaces where it is impracticable for a paver to operate.
* for footways.
* at the approaches to expansion joints at bridges or viaducts.
When a paver laying base material approaches an expansion joint at a bridge or viaduct it
shall be taken out of use as soon as there is a danger of the material being laid fouling the
joint. In laying the remainder of the pavement up to the joint and the corresponding area
beyond it by hand, the joint or joint cavity shall not be fouled with surface material.
Hand-raking of wearing course material which has been laid by a paver and the addition
of such material by hand-spreading to the paved area for adjustment of level will only be
permitted at the edges of the layers of materials or where otherwise directed by the
Engineer. Where hand spreading and tamping is permitted, the mixed material is to be
dumped on delivery upon existing hard clean surface or on approved metal sheets outside
the area where it is to be spread and shall be distributed in to place immediately by means
of hot shovels. It shall be spread with hot rakes in a uniformly loose layer to the full depth
required.
Materials are to be laid to the depths necessary to give the required thickness after
compaction and they are to be finished true to profile, and where. concrete fails to meet the
specified requirements for asphaltic concrete surfacing.
If for any reason the quality, grading or supply source of aggregates or the quality or source
of bitumen is changed, or at any time the cause of variations outside the permissible
limits cannot be corrected for reasons beyond the Contractors control, the Engineer may
require the Contractor to carry out additional laboratory tests and/or the construction of
additional trial areas depending on the extent of the change or variation.

XIII. Compaction
After spreading, the mix shall be thoroughly and uniformly compacted by rolling.
The initial breakdown rolling shall be done with three wheel smooth roller, followed by
intermediate rolling with high- pressure tyred pneumatic roller. During the rolling wheels
shall be kept moist with only sufficient water to avoid picking up material.
Heavy equipment or roller shall not be permitted to stand on finished surface until it has
thoroughly cooled. In the initial rolling the three-wheel smooth roller shall proceed on to the
fresh material with the rear or driven wheels leading. The rolling shall start as soon after
laying as conditions permit and when the material is still at a temperature of not less than
99C. The weight per unit width of the rear wheel shall be between 45-65 Kg per centimetre
width.
After the longitudinal joints and edges have been compacted rolling shall start
longitudinally at the sides and gradually progress towards the centre of the pavement,
except on super- elevated curves where rolling shall begin on the low side and progress to
the high side. Each pass of the roller shall overlap the preceding one by about one width of
the rear wheel. The roller should move at a slow but uniform speed not exceeding 8
kilometres per hour. The roller shall be in good condition, and capable of being reversed
without back lash, and the line of rolling shall not be suddenly changed or the direction or
rolling suddenly reversed, thereby displacing the mix. If rolling causes displacement of the
materials the affected areas shall be loosened at once with shovels or rakes and restored
to the original grade of loose material before being re-rolled.
The intermediate rolling shall be done with a pneumatic roller exerting compactive ground
pressures between 5.6-8.4 kg per sq. cm. The Contractor shall furnish to the Engineer
charts or tabulations showing the contact areas and contact pressures for the full range of
type inflation pressures and for the full range of tyre loadings for each type and size
compactor tyre furnished. The intermediate rolling shall follow the break down rolling as
closely as possible and while the mix is still at a temperature of 70C - 85C. Rolling shall be
continuous until the mix is thoroughly compacted and the density specified in clause 6381 is
achieved. Turning of pneumatic roller on the hot mix which causes undue displacement shall
not be permitted.

XIV. Joints
All joints shall be vertical, properly formed to the correct line and level; if necessary they
shall be cut back to achieve this. A template made to the shape of the true line and width
may be placed at each end of the construction joint line and width may be placed at each
end of the construction joint to create vertical straight finish. Joints in the surface course
should be staggered with those in the binder course and must be kept straight, when the
abutting lane is not placed the same day or if the edge of the first strip has been distorted
by trafic the joint shall be cut back to an even line and then be coated with bitumen before
laying the adjoining strip. All joints on completion are to present the same texture, density
and smoothness as other sections of the course.

XV. Field Density of Rolled Asphalt

Density tests of the asphalt surfacing after compaction shall be taken from the trial area and
later at intervals throughout the course of the work and compared with the density of-
control
specimens taken from the same material before laying all in accordance with the following
procedure:
A sample of mixed material will be taken from a lorry before the material is delivered to the
spreader, and three specimens shall be made and their density measured by the Engineer by
the immersion method.
The average of the two close specimens will be taken as the control density of that
particular batch.
The pavement will be marked to show where the lorry load of material (from which the
sample was taken) is laid, so that field density samples can be taken for comparison
with the control specimen.
After completion of rolling, three samples are to be cut from each area so marked in
positions indicated by the Engineer.
The samples shall be taken in accordance with part 1 section 3 of B.S. 598 (1974) and the
density calculated by weighing in air and weighing in water in accordance with part 6 of
B.S.
593 (1974). The average of two close results of the samples will be taken as the density of
the compacted material in that area.
This density will not be less than 100% of the control density determined as above.

When an approved rolling procedure has been established, each course will be sampled in
accordance with the above at the rate of one sample area for each 84 square metres placed
or one sample area every 2 hours (whichever is more frequent). Material which does not
achieve the required density will either be cut out and replaced or be further compacted
until the required density is obtained.

XVI. Finished Levels

The surfacing will be finished to the required levels shown on the drawings. Any deviation
exceeding 5 mm from these levels will be corrected at the contractors expense by
scarifying, cutting out and removing all loosened materials, adding new materials, as
required, re- shaping and rolling. No materials loosened by scarifying or cutting out will be
left in position or otherwise re-used.
Except across the crown of a camber, the finished surface shall be such smoothness that
when tested with a 3 metre straight edge placed anywhere and in any direction on the
surface, there shall not be gap greater than 3 mm between the bottom of the straight edge
and the surface of the pavement anywhere
Should the new asphalt surface be dragged, churned up, become soft, show signs of
segregation, show that stripping of the binder form the aggregate has occurred, or
suffer other damage during or after being laid the contractor will remove the damaged or
faulty work at his own expense and replace with fresh material, laid and compacted to the
correct level and density to the approval of the Engineer.

XVII. Material for Surface Dressing

Materials for blinding the first wearing coat surface dressing on the carriageway, shall
consist of clean crushed rock or clean crushed or uncrushed gravel from an approved
sources, as specified, graded into single sizes as defined in BS 63 latest edition Single Size
Road Stone and Chipping or in BS1984 latest edition Single Size Gravel Aggregate for
Road as appropriate. Two single sizes 19mm and 12mm shall be used for blinding on the
carriageway while 10 mm single size material may be allowed for non trafficked surface
(like verges) by only with the written approval of the Engineers Representative
The grading of the materials shall be carried out by means of an approved mechanically
operated screening plant, fitted with screens having square perforations corresponding to
the BS sieve size of the material it is intended to produce. Screens with circular
perforations will be permitted provided the diameter of the perforations is increased so as to
be equivalent to the corresponding BS sieve size.
The different sizes of material shall be stored in separate stockpile and shall not be mixed.
If the Engineers Representative considers it necessary the blinding materials shall be
washed before use. The aim of the contractor shall be to obtain the maximum production
of 19 mm and 12 mm single sized material from the plant and either size may be used in
blinding a continuous section of surface dressing of not less than 2 kilometres in length.
The crushing aggregate value of all material used for surface dressing shall not exceed
30% and its abrasion test result not more than 25%. All samples shall be tested as
described in BS 882. Samples of all blinding materials to be used in the work shall be
submitted to the Engineers Representative for approval prior to being used.
Prior to the commencement of surface treatment work the contractor will carry out tests
under the direction of the Engineer for the purpose of assessing the adhesive qualities which
are to be used in the works. As a result of these tests the Engineer may decide that it is
necessary to use an additive to the bitumen for the prevention of stripping of the stone
surfacing and the Contractor shall comply with the directive of the Engineer in this
respect. Strip test is recommended. Materials used in surface dressing are summarized in
the Table XIII shown below.

Table XIII: Material for Surface Dressing and their Description

Name Description
Cut-Back Bitumen Cut-Back Bitumen for Wearing Coat

for Prime Coat

Straight Run Bitumen Blinding Materials
Either a cut-back 100/150 seconds at 40C as measured by the standard tar
bitumen known as M.C- viscometer, or a cut Back bitumen having a viscosity of 300/400
O, having a viscosity of seconds viscosity at 40C as measured by the standard tar
75/150 seconds at viscometer.
25C as measured by Straight run bitumen for first wearing Coat shall have a
the furol viscosimeter, penetration grade
or a cut-back bitumen 180/100 at 25C and a flash point (open) of 107C (Minimum)
known as M.C-1 having Sand for blinding prime coat surface shall consist of clean sharp
a viscosity of 75/100 sand of
seconds at 50C as 6mm maximum size with not more than 20% passing 600 m.
measured by the furol Sieve and shall be approved by the Engineers Representative.
viscosimeter. Alternative grit arising from the crushing of the rock may be used
(For first wearing coat provided it is approved by the Engineers Representative and the
Either a cut-back grading complies with the specification for sand earlier discussed.
bitumen having a
viscosity of
Bituminous Emulsion
Bitumen emulsion shall Contain 30% 0f bitumen and shall comply in all other respects
with
B.S. 434 (latest edition and amendment thereto) except that the basic bitumen used in
the manufacture may have a penetration of 80/100. Bitumen emulsion containing 30% of
bitumen may be made by mixing thoroughly together in the correct proportions emulsion
complying with U.S. 434 (amendment thereto) with clean soft water.

Heating of Cut-Back Bitumen

The cut-back bitumen shall be heated in a bitumen heater complying with B.S. 167 which
shall have a capacity commensurate with the output required. The heater shall be so
operated that the temperature of the bitumen applied to the road shall be within the
specified range.

Accurate thermometer shall be incorporated in the heater to give a clear indication of the
bitumen temperature. Should the temperature be in excess of that specified, the
Engineers Representative may direct that this overheated bitumen be disposed of at the
Contractors expense.

Cut-back Bitumen Prime Coat

The prime coat shall be of medium curing cut-back bitumen of either M.C.O. Grade or MC.1
Grade as specified. The actual grade to be used shall be determined by the Engineer after
carrying out site tests to determine the penetration of each grade. The bitumen shall
be applied strictly in accordance with the provisions of the relevant clauses of this
specification on an approved Base course free from all dust and loose material slightly
damped prior to applying the bitumen.
After spraying the surface shall be left for a minimum of three hours before blinding is
applied,
or longer if considered necessary by the Engineer s Representative to effect the
maximum penetration. Blinding consisting of sand or grit complying with the provisions of
the relevant clauses of this specification shall be applied so that a uniform covering of
suficient thickness is obtained to ensure that no bare or fat patches of bitumen are showing.
The blinding shall then be rolled in with not more than two passes of a roller.

Spraying of Cut-Back Bitumen Prime Coat

The prime coat as specified shall be evenly applied to the prepared Base course by means
of an approved pressure feed mobile distributor and complying with the requirements of
B.S.
1707: Binder distributors. In addition to the special requirements detailed in section three
of
B.S. 1707, the pressure feed mobile distributor shall be fitted with a spray bar through which
the hot bitumen can be circulated while the distributor is not spraying. The jets shall be
so arranged in the spray bar that they are efectively preheated to the same temperature as
the circulating bitumen.
The Contactor shall provide as set of 50mm wide troughs as described in Appendix A of
BS.1707 and shall carry out depot tray test A in the presence of the Engineers
Representative to demonstrate that the lateral distribution is in accordance with B.S.1707.
This test shall be carried out prior to using the spraying plant for the first time on
the contract and subsequently at the discretion of the Engineers Representative. In the
event of the quantity of bitumen in any trough or troughs being found to lie outside the
prescribed tolerance from the average, the faulty jet shall be located and cleaned or
replaced.
The bitumen shall be applied at a temperature in accordance with the Table given below
and at a rate of spray of between 0.8 and 1.2 litres per square meter depending on the
texture of the surface. From the calibration charts and tests made on the distributor, the
spraying speed shall be determined to give the required rate of spray.

Or
Alternatively rate of spray may be checked as follows: -
Check the initial and final quantity of cut back and record. The difference between initial
reading divided by the area sprayed can he used to check compliance with approved rate of
spraying.
Note: - Initial and final reading shall take place at same position.

Table XIV: Sealing Coats Temperature of Application

Bitumen Grade Temperature of Application

Min Max
M.C.0. 38C 66C
M.C.1 54C 79C
The Contractor shall carry out trial sections, as directed by the Engineers Representative
to determine the most suitable grade and rate of application of bitumen.
Immediately before any spraying run is begun, the spray bar shall be tested by allowing all
the jet to discharge simultaneously for about half a minute with a slotted metal tray placed
beneath the spray bar whilst a visual inspection is made. Any jet which is seen not delivering
a uniform spray cone shall be cleaned or replaced. After testing the spray bar, the distributor
shall proceed with the spraying run without delay. No spraying shall be carried out when rain
appears imminent, during rain, or after rain, until the surface has dried. The Contractor shall
ensure that joints between spraying strips are straight and without excess or deficiency of
bitumen which would cause either fattening up or scabbing along the joint.
The Contractor will be required to respray at his own expense any section which show
deficiency of binder or to burn of and re-sprayed at his own expense any sections which
show an excess of binder and which subsequently fat up.

First Coat Surface Dressing

The wearing course of the surface dressing shall not be laid until at least 10 days after
the application of the prime coat. During this period additional blinding sand shall be added
if directed and brushed over the surface to prevent damage. After such period all damaged
or weak spots shall be cut out, refilled, and recompacted flush with the existing surface,
sealed and blinded as specified and rerolled to the satisfaction of the Engineers
Representative. After all repair work has been allowed sufficient time to harden, the
surface shall be swept clean of all loose material immediately prior to the application of the
wearing coat. Before spraying is begun the surface shall be dry.
Bitumen for the wearing coat of the surface dressing shall be an approved cutback bitumen
or straight run bitumen as specified in the relevant clauses of this specification. The bitumen
as specified shall be evenly sprayed on the surface by means of an approved mechanical
spraying machine as specified. The temperature of the bitumen at time of spraying shall be
in accordance with the table given below. The grade of bitumen to be used shall be
determined by the Engineer.

Table XV: Bitumen Viscosity and Temperature of Application

Bitumen Viscosity Temperature of Application
STV AT 40C Min Max
100/150 SEC 132C 160C
300/400 SEC 149C 177C

The rate of spray of the bitumen shall be determined according to the type of base, type and
size of chippings which are to be used as detailed in the table given below, and the
Contractor shall carry out trial sections, as directed by the Engineers Representative to
determine the most appropriate rate of application of bitumen.
Table XVI: Size of Chipping and Rate of Spray of Bitumen

Nominal Size of Chipping Rate of Spray of Bitumen

10 mm 0.60-0.90
litre/sq.m.
12 mm 0.75-1.20
20 mm 1.2-1.50

Immediately after spraying the surface shall be blinded with approved single size chipping
as specified. The chipping shall be distributed on the sprayed surface by means of
mechanical spreader or tailboard gritters so that a single layer of closely packed chipping is
obtained any bare or lean areas shall be made good by follow-on gang using hand blinding.

Rolling shall be carried out immediately after the chippings have been spread with
an approved roller weighing not less than 3,629 kilograms or more than 5,443 kilograms.
The minimum number of passes of the roller shall be used to press the chippings into the
film of bitumen. Two passes of the roller should generally be sufficient. Pneumatic tyred
rollers are preferable to smooth wheeled rollers.
Prior to the commencement of spraying a section of the road for the first coat a 2 metres
wide paper strip shall be laid over the end of the previous section. The bitumen sprayer shall
then commence its run from over this paper strip.
Final Surface Dressing
The finished surface of the carriageway shall be left as smooth as possible and the accuracy
of finish in the longitudinal direction shall not vary at any point by more than 6mm from
a 3 metre straight edge, placed in any position on the finished surface parallel to the centre
line. The transverse profile shall conform to the same accuracy, using a correctly shaped
template instead of the straight edge. The surface shall be evenly textured and show no
lean or fat areas and shall not have any low or flat spots where water will collect.

Wet Weather
No surfacing work shall be done in wet weather or when rain is imminent. Only dry chippings
shall be used.

Job-Mix Formula
The exact job mix formulae will depend on the nature and grading of the aggregate and the
type of bitumen. The exact job-mix formulae for the respective courses will be determined
by the Engineer.

Regulating of Trafic over Surface Dressing

After laying the prime coat surfacing, barriers shall be erected to keep the area surfaced free
from traffic. It shall remain free from trafic for such a period as the Engineers
Representative may direct after which it shall be opened to trafic for not less than 3 days
and for not more than 7 days. During this period additional blinding material shall be added
and all damage by trafic made good. After application of the first coat surfacing, the area
surfaced shall be kept free from traffic for at least 24 hours.
The section shall be opened to trafic and suitable trafic notices and barriers shall be
erected for a period of one week restricting trafic speeds to 25 KPH. During this
period empty bitumen drums or other obstacles, which shall be well lighted, or alternatively
removed during the hours of darkness, shall be placed on the newly surfaced areas for the
purpose of limiting the speed of trafic, and shall be moved to different positions from day to
day in such a way that the whole width of the surface receives equal wear and compaction
from the wheels of vehicles.

Table XVII: PRIME COAT & TACK COAT [MC1 & S125]

For Priming Base M C-O or M C-I shall be used at the rate of 1.0 - 2.0
Litres/ sq.m
For Applying
emulsion
Tack Coat quick breaking type applied at the rate of 0.25 - 0.70
Litres/sq.m
Tack coat shall be applied in areas to take the binder
course if warranted by surface conditions and directed
by the Engineer Representative.
XVIII. Tests for Bitumen
The Contractor shall produce manufacturers test certificate if requested, otherwise the
Engineer may require the Contractor to carry out the following tests as described in
standard methods for testing petroleum and its products published by the Institute of
Petroleum, 26
Portland Place, London W.1. Penetration of bitumen IP.49/56
Soluble bitumen content: bitumen and asphalt IP.47/55
Flash-point by means of the elevated apparatus IP.36/55
Specific gravity IP.59/57. Method C
Specific gravity of liquids or solids pycnometer method. Specific gravity of liquids or solids
method F.
The determination of viscosity by the standard tar viscosimeter or the furol viscosimeter
may
also be required by the Engineer.
The cost of carrying out these tests if required by the Engineer shall be deemed to be
included
in the tendered rates and prices.

XIX. Tests for Aggregates for Road Stone and Chippings

In determining the suitability of aggregates for use as road surfacing material the
Engineer may require the Contractor to carry out any of the test specified in B.S. 812
Mineral aggregates sands and fillers, B.S. 882, 1201 Concrete aggregates from natural
sources, B.S.
1881 Methods of testing concrete, B.S. 1200 building sands from natural sources, B.S. 63
Single-sized road-stones and chippings. The cost of carrying out these tests if required by
the Engineer shall be deemed to be included in the tendered rates and prices.

XX. Tests for Binder Distributors

The Contractor shall provide a set of 50mm wide troughs as described in Appendix A of
B.S.
1707 and shall carry out depot tray test A in the presence of the Engineers Representative
to demonstrate that the lateral distribution is in accordance with B.S. 1707.
This test shall be carried out prior to using the spraying plant for the first time on the
contract and subsequently at the discretion of the Engineers Representative. In the event of
the quantity of bitumen in any trough or troughs being found to lie outside the prescribed
tolerance from the average, the faulty jet shall be located, cleared or replaced and a further
test carried out if required by the Engineers Representative

XXI. Tests for Rate of Application

The Contractor shall test the rate of application of bitumen at regular intervals, as directed
by the Engineers Representative by means of the tray test as described in Road Note
No.11: Binder distributors for surface dressing, issued by the Road Research Laboratory,
England

XXII. Bituminous Macadam Surfacing

Bitumen Macadam General
The manufacture and grading of the bitumen macadam shall be in accordance with B.S.
1621 bitumen macadam with crushed rock or slag aggregate except where stated
otherwise in these specifications.

XXIII. Bitumen Macadam Materials

(a) Aggregate: Coarse aggregate shall be hard cleaned and durable crushed igneous rock
from a source to be approved by the Engineer and in accordance with B.S. 812. Fine
aggregate shall be quarry fines produced from the crushing of igneous rock in a secondary
plant. They are to consist of hard non-absorbent moderately sharp particles and to be free
from clay, loam, and other foreign matter.
If filler is used it shall consist of finely ground particles of hydrated lime, Portland cement
or
crushed rock and at least 75% of the filler shall pass 75m sieve.
(b) Binder: The binder shall be a straight-run bitumen with a penetration ranging from
40/50,
60/70, 80/100 at 25C.
XXIV. Bitumen Macadam Approval of Materials
Representative samples of all materials proposed for use under these specifications shall be
submitted to the Engineer by the Contractor at the Contractors expense for test and for
preparation of trial mixes to determine job-mix formula. The Engineer shall make tests of the
proposed materials and inform the Contractor if the tests indicate compliance with the
specifications.
XXV. Macadam Composition of Mixes
The grading of the combined aggregate to be used in the respective mix for each course
shall be within the limits stated below and when plotted graphically with the particle size to
a logarithmic scale shall lie on a smooth curve within the envelope of these limits.

Table XVIII: Grading Envelope for Bituminous Binder Course

50 mm Binder Course Sieve Size Passing
38 mm 100
25 mm 50-100
12.5 mm 26-50
6 mm 18-30
2.8 mm 12-22
1.25 mm 8-17
600 m 7-14
300 m 4-11
150 m 2-8
75 m 0-5
BITUMEN 4-5.5% BY WT.
OF AGGREGATE OR AS PER DESIGN

Table XIX: Grading Envelope for Bituminous Binder Course

40 mm Binder Course Sieve Size Passing
25 mm 100
19 mm 95-100
12.5 mm 70-90
9.5 mm 55-75
6.4 mm 40-60
3.2 mm 25-40
1.25 mm 15-30
600 m 12-24
300 m 8-18
150 m 5-12
75 m 3-6
BITUMEN 4-7% BY WT.
OF AGGREGATE OR AS PER DESIGN
The exact job mix formulae will depend on the nature and grading of the aggregate and the
type of bitumen. The exact job-mix formulae for the respective courses will be determined
by the Engineer

Workmanship
XXVI. Bitumen Macadam Mixing plant
The material shall be mixed in an approved mixer of batch or continuous type from which
mixed materials can be delivered and laid hot the mixing plant shall be maintained in
good working condition and shall be subject to inspection by the Engineers Representative.
The weighing measuring and recording apparatus shall be checked at frequent intervals and
maintained in perfect adjustment throughout the contract.

XXVII. Bitumen Macadam Mixing

The aggregate and binder shall be heated separately, aggregate to a temperature range
of
121C-149C and the binder to 135C-163C. The respective temperature of the aggregate
and the binder are to be within 14C on each other at the time of mixing.
Prolonged and excessive heating of the materials is to be avoided and particular care is to
be taken with binders. A dry mixing period of at least 10 seconds - shall precede the addition
of bitumen to the wet. Wet mixing shall only continue as long as is necessary to
obtain a thorough blend.
Aggregates, including fillers, if any shall be thoroughly dry immediately before mixing. When
moisture is detected in the mixed materials all aggregates in the hot bins are to be removed
and replaced in their respective stock piles.

XXVIII. Bitumen Macadam Transporting Mixed Material

The mixed materials shall be transported from mixing plant to site in clean metal
lined vehicles. Every precaution is to be taken to avoid segregation of mixed materials
and to ensure that they do not become contaminated with dust or foreign matter.
Should any load be wetted excessively by rain, they will be rejected by the
Engineers
Representative.

XXIX. Bitumen Macadam Preparation of Surfacing Prior to Laying

Before the macadam is laid on the newly constructed base course, the surface will
be
inspected by the Engineers Representative and testing using an. Engineers level 3 metre
straight edge or any other means to ensure that the surface conforms with the
requirements of this specification. Any irregularities in the surface shall be corrected to the
satisfaction of the Engineers Representative before surfacing work will be allowed to
proceed.

XXX. Bitumen Macadam Laying

After mixing the material must not be reheated other than by the means provided in or on
the spreading machine.
Material must not be laid when the surface on which it is to be placed is wet or when rain
appears imminent.
Immediately prior to laying the bitumen macadam, the surface of the Base course shall be
swept clean of all loose and caked dirt. The macadam as specified shall be laid by approved
means to compacted thickness of 50mm binder course and 63mm wearing course, subject
to design.
It is essential that this is laid at temperature not less than 107C and not more than 149C.
The Contractor is to provide at each spreader and finisher a suitable thermometer for testing
the temperature of the material as it is being spread and is to take such temperature
reading continually and record them hourly thoroughly each days laying. The record shall be
available for the Engineer or his Representative who will himself make such additional
temperature checks as he considers desirable.

XXXI. Bitumen Macadam Spreader or Finisher

The materials shall be laid by approved mechanical spreaders and finishers. The spreader
and finisher shall be in good mechanical condition and shall be capable of laying to the
required width and without causing segregation, dragging, burning. irregularities or other
surface defects and it shall be capable of being operated at a consistent with the character
of the mixture and the thickness of the course being laid, so as to produce a surface having
a uniform density and surface texture. When not operated on side forms the spreader will
employ equalizing runner evener arms or other automatic compensating devices to and
confine the edges of the course to true lines.
The mixer capacity and the operating speed of the Spreader shall be so adjusted as to
ensure
continuous laying and to avoid intermittent stopping of the spread as far as is practicable.

XXXII. Hand Spreading Not Allowed

Hand spreading will not be permitted for general work, but will only be allowed for filling
localized depressions, or as directed by the Engineer or his Representative.
Where hand spreading and tamping is permitted by the mixed material is to be dumped on
delivery upon an existing hard clean surface or on approved metal slice is outside the
area where it is to be spread and shall be distributed in to place immediately by hot shovels.
It shall be spread with hot rakes in a uniformly loose layer to the full depth required.
If the required specified density determined in accordance with the foregoing clause is not
obtained the field rolling procedure is changed so as to achieve the desired field density and
the trial area will be cut out and replaced to the satisfaction of the Engineer or his
Representative.

XXXIII. Bitumen Macadam Finished Levels

The surfacing will be finished to the required levels shown on the drawings. The surface
shall be of such smoothness that when tested with a 3 metre straight edge placed anywhere
in a longitudinal direction on the surface there shall not be greater than 5mm between the
bottom of the straight edge and the surface of the pavement anywhere along the pavement.
Any deviation exceeding 5mm will be corrected at the Contractors expense by scarifying
cutting out and removing all loosened materials, adding new materials as required, re-
shaping and rolling. No materials loosened by scarifying and cutting out, will be left
in position or otherwise reused. The surface shall be similarly tested, and corrected if
necessary in a transverse direction using a correctly shaped template instead of straight
edge.
It is essential that the surface of the road is free from waves any depression which
retain water on the surface are immediately to be corrected as described above to the
satisfaction of the Engineers Representative.

XXXIV. Bitumen Macadam Joints

All joints shall be vertical, properly formed to the correct line and level; if necessary, they
shall be cut back to achieve this. The exposed edges of the bitumen macadam already laid
shall be coated thinly with bitumen emulsion containing 30% to 50% bitumen before laying
adjoining work. All joint completion shall present the same texture, density and
smoothness as other sections of the surface. Surfaces and projection which the new paving
will abut shall be thoroughly cleaned and coated with bitumen emulsion containing 30% -
50% bitumen. The new paving shall then be tamped around at against the projection to
such a depth that, on completion of compaction the finished surface of the wearing course
is level with the top of the projection.

XXXV. Bitumen Macadam Damaged Work

Should the new bitumen macadam be damaged, churned up, become soft show signs of
segregation, show that stripping or the segregation of the aggregate has occurred, or suffer
other damage during or after being laid, the Contractor will remove the damaged or faulty
work at his own expense and replace with fresh material laid and compacted to the correct
level to the satisfaction of the Engineers Representative.
Tests
XXXVI. Bitumen Macadam Tests
The Contractor shall provide equipment, labour and such trained staf as may be required
by
the Engineers Representative for carrying out the following tests on material to be used in
the manufacture of bitumen in accordance with the following standards. Grading tests on
aggregates in accordance with B.S. 812: sampling and testing of mineral -aggregates
and fillers.
Determination of binder content of mixed materials in accordance with hot extraction BT
1 described in BS 598 Sampling and Examination of Bituminous Road Mixtures.
The Contractor is required to comply to the requirement of BS 598.

XXXVII. Frequency of Test Bitumen

Aggregates shall be sampled and tested at source on delivery to the mixing plant and
after each extraction test and the result of each test shall be submitted to the Engineers
Representative within 24 hours of the sample being taken. The numbers such tests shall
be adequate for proper control of the material and shall not be limited to those made on
specific instructions of the Engineers Representative. Samples of mixed materials shall be
taken and tested during the first days mixing and throughout the work to confirm that the
grading and binder contents are as specified.
Such samples shall be taken either at the place and time of mixing or at the place of
laying both may be necessary as the results will complement one another as directed
by the Engineer s Representative. Samples for testing shall also be cut from the
surfacing as laid when directed by the Engineers Representative.
The frequency of sampling mixed materials shall be at least once per day or once each 90
tonnes of material mixed whichever is the most frequent. The result of each test on
mixed material shall be submitted to the Engineers Representative within 24 hours of the
sampling and any adjustments shown to be necessary shall be made and Until such
adjustments have been made and until a certificate to the effect has been forwarded to the
Engineers Representative no further batches of mixed material shall be made.

XXXVIII. Independent Tests Bitumen Macadam

Independent sampling and testing may be carried out by the Engineer
Representative
throughout the contract period and for this purpose the Contractor shall grant free access to
the mixing plant and storage depots, supply materials and provide every facility for the
Engineers Representative to take sample whenever required.
In Particular throughout the contract, The Engineers Representative will carry out control
test on the plant mix as he requires.
 The Engineers Representative shall be supplied with all necessary equipment labour
materials to perform any additional test he may wish to carry out.

The asphaltic concrete shall be laid in two courses surface and binder courses with or
without wedge of levelling course or any combination of these as shown on the drawings.
Unless specified in volume-III or on the drawing, the compacted thickness or each course
shall not be less than 60mm for the binder and 40mm for the surface course. The
compacted thickness of any single constructed course shall not exceed 75mm binder or
levelling course or 60mm for surface course.

Table XX: Aggregate Specification for Dense Bitumen Macadam, Asphaltic Base and
Wearing Courses
rse Aggregate Crushing Value Flakin Absorption Factor
ess
Index
Dense Bitumen Macadam Base 30 35 1.5
Dense Bitumen Macadam Wearing 30 35 0.5
course
Asphaltic Concrete Base course 30 35 0.5
Asphaltic Concrete Wearing Course 30 35 0.5

Fine aggregate shall be the portion of the aggregate passing the No. 5mm opening sieve and
shall be quarry fines produced from the crushing of igneous rock. They shall be composed of
clean, tough, rough surfaced and angular particles, free from lump or ball of clay, loam and
other deleterious substances.

Mineral filler shall consist of finely ground particles of hydrated lime, Portland cement or
other non mineral matter approved by the Engineer. It shall be free from foreign or other
objectionable material, and shall meet the following grading requirements:

Table XXI: Specifications for Mineral Filler

SIEVE % BY WEIGHT PASSING
300 m 100
200 m 95-100
75 m 85-100

XXXIX. Bituminous Material

Table XXII: Quality of Asphaltic Cement
PROPERTY ASPHALTIC CEMENT
80-100 PEN 60-70 PEN
Specific Gravity @ 25C 1.00-1.05 1.01-1.06
Softening Point R and B (C) 45-52 48-56
Penetration @ 25C 0.1 mm 80-100 60-70
Ductility @ 25C CMMinimum 100 100
Loss on Heating for 5 Hours at 163C % Weight Max 99 99
Solubility in CS % WT.. MIN
Drop in Penetration after Heating % Original . 20 20
MAX
Flash Point (Open Cup) C MIN. 225 250
Ash. % by WT. MAX. 0.5 0.5
Bitumen emulsion for tack coat shall be emulsion quick breaking type containing 30-
50%
bitumen.
Cutback bitumen for priming shall be MC-O or MC-1.
XL. Approval of Materials
Representative samples of all materials proposed for use under these specifications shall be
submitted to the Engineer by the Contractor at the Contractors expense for test and for the
preparation of trial mixes to determine the job mix formula. The Engineer shall make tests
of the proposed materials and inform the Contractor if the tests indicate compliance with
the specifications.

Suitable sizes of aggregate shall be stored in bins at each point where bituminous
materials are mixed. The bins shall be in such numbers and of such capacities as to ensure
that an uninterrupted supply of all the necessary sizes of aggregates is available at the
mixer.

If aggregates are stockpiled prior to their transference to the bins, the stockpiles shall be
formed on concrete floors laid to falls sufficient to permit drainage at the base of
the stockpiles. Aggregates shall be handled to and from the stockpiles in a manner such that
they are not contaminated by the ground or by extraneous matter and also in a manner such
that segregation is prevented. In as much as possible the bins shall be covered to
prevent dampness of aggregate by rain.

Coarse and fine aggregates and aggregates from different sources shall be
stockpiled separately and if aggregates of different grading or from different sources are
stockpiled in close proximity the stockpiles shall be separated by partitioning.

All aggregates produced or handled by hydraulic methods and all washed aggregates shall
be stockpiled under cover for draining for at least 24 hours before use.

Material used as filler shall be stored in dry conditions to the satisfaction of the
Engineers
Representative.
No material shall be used until it has been approved by the Engineer. Permission to use
material shall not be construed as an approval of its source nor any acceptance as continued
acceptance.
XLI. Sampling
The Contractor shall provide equipment, labour and such trained staf as may be required by
the Engineer for carrying out the following tests on materials to be used in the manufacture
of hot asphaltic concrete in accordance with the following standards:
Grading tests on aggregates in accordance with the latest B. S. 812 - Sampling and testing
of mineral aggregate and fillers.
Determination of binder content of mixed materials in accordance with either:
Hot extraction method BT 1 described in B.S. 598 (1974) - Sampling and examination of
bituminous road mixtures. The Contractor is to comply with the requirements of B.S. 598:
and to the need of providing results in duplicate Or By reflux extractor method.

Aggregates shall be sampled and tested on delivery to the mixing plant and after each
extraction test and the result of each test shall be submitted to the Engineer or his
Representative within 24 hours of the sample being taken.

The number of such tests shall be adequate for proper control of the materials and shall
not be limited to those made on specified instructions of the Engineer or his Representative.
Samples of mixed materials shall be taken and tested during the first days mixing and
throughout the work to confirm that the grading and binder contents are as specified. Such
samples shall be taken either at the place and time of mixing or at the place of laying as
directed by the Engineer or his Representative. Samples for testing shall also be cut from the
surfacing as laid when directed by the Engineer or his Representative.

The frequency of sampling mixed materials shall be at least once per day or once for each
90 tonne of material mixed whichever is the more frequent. The result of each test on mixed
materials shall be submitted to the Engineer or his representative within 24 hours of the
sampling and any adjustment shown to be necessary shall be made immediately. Until such
adjustment have been made and until a certificate to the effect has been forwarded to
the Engineer or his representative no further batches or mixed material shall be made.

Independent sampling and testing may be carried out by the Engineer throughout the
contract period and for this purpose the contractor shall grant free access to the mixing
plant and storage depots, supply materials and provide every facility for the Engineer or his
representative to take sample whenever required.

In particular, throughout the contract, the Engineer will carry out control test on the plant
mix material using the marshal test apparatus.

A certificate is to be obtained from the supplier with each consignment of bitumen delivered;
stating the grade of material being supplied, and these certificates are to be handed to
the Engineers Representative.
If the Engineer so requires, the Contractor shall arrange for the testing in an approved
manner of all materials used throughout the contract to ensure that they are up to the
standard specified, i.e. aggregates, bitumen and such other materials as specified or decided
by the Engineer. The Contractor shall arrange for the testing of materials incorporated in
the works to ensure that they have been manufactured as specified, or as ordered by the
Engineer.

Whenever the Contractor intends to carry out any of the above tests, he shall give the
Engineers Representative sufficient notice to enable him, should he so wish, to be present
during the test.

Whenever the Contractor takes samples for testing, and where so directed he is to take
duplicate samples and hand them to the Engineers Representative. Such samples are to be
properly packed and labelled as directed.

The Engineers Representative shall be given the results in writing of all tests, as soon as
they are available, and in any case not later than 24 hours after samples have been taken.

The Engineer shall be supplied with all necessary equipment, material and labour to perform
any additional tests he may wish to carry out himself.

The cost of these tests including the provision of samples will be deemed to have been
included in the bill of quantities under the appropriate item.

XLII. Composition of Mixes

Asphaltic concrete prepared under these specifications shall be composed of
graded aggregate and asphalt cement within the limits set forth below. When plotted
graphically the aggregate grading shall lie on a smooth curve within the envelope.

Table XXIII: Grading Envelope for Binder and Wearing Courses

Sieve Size % by Weight Passing
40mm - 65mm Binder 40mm-50mm Wearing
Course
31.8mm 100 100
25mm 90-10 100
19.0mm 70-90 100
12.5mm 55-80 85-100
9.5mm 47-70 75- 92
6.4mm 40-60 65- 82
2.8n 27-45 50- 65
1.25mm 20-34 36- 51
600m 14-27 26- 40
330m 8-20 18- 30
150m 5-15 13- 24
Bitumen Content % by weight of 4.5-6.5 5-8.0
aggregate
Asphaltic concrete mixes designed by the Contractor prior, to the selection of Job-Mixes
(see below) shall have combined above and shall comply with the following requirements.

Table XXIV: Properties of Compacted Asphaltic Concrete

Property Base-Course Wearing Course
Optimum Bitumen Content 4.5% - 6.5% 5.0% - 8.0% Stability,
not less than 3.5KN 3.5KN
Flow 2mm - 6mm 2mm - 4mm Voids in
total mixture 3% - 8% 3% - 5% Voids filled
with bitumen 65%-72% 75% - 82%

The exact job-mix formula will depend on the nature and grading of the aggregate and
the grade of bitumen and will be determined by the Engineer using the marshall method of
mix design. For this purpose the Contractor shall supply to the Engineer without charge
adequate samples (in separate containers) of coarse and fine aggregates and bitumen
which he intends to use. The Engineer will, after testing, furnish the Contractor with the
exact job-mix formula, which will be within the specified limits.

Before any asphalt concrete is laid, the Contractor shall produce sufficient dry mixes in
the plant and carry out sieve analysis to ensure that the correct grading is being obtained. In
addition, he shall produce a number of trial mixes to which the specified quality of
bitumen has been added. He will then carry out extraction tests on this material and further
sieve analysis on the aggregate in accordance with clause 6373 of the specification. The
results of these tests on both the dry and wet mixes shall be approved by the Engineer
before any surfacing is laid in the permanent works.

Job Mix Formula The job-mix formula is the single definite percentage of aggregate
passing each required sieve size, a single definite bitumen content to be added to the
aggregate, a single definite temperature at which the mixture is to be emptied from the
mixer and a single definite temperature at which the mixture is to be delivered on the road.
Unless specifically changed in writing by the Engineer, the maximum variation from the
job- mix formula shall be as follows:
Table XXV: Permissible Variation Percent by Weight of Total Mix
Material Passing Permissible Variation % By Weight of
Total Mix Passing Sieve 9.5 mm and layer
5% Passing Sieve 9.5 mm
600 m 4% Passing Sieve 600 m
150 m 3% Passing Sieve 150 m
75 m 0.1% Bitumen Content
0.3%
Notes:
Temperature of Mixture when emptied from mixer 145C 5C
Temperature of Mixture on delivery on the road 130C 5C
The job mix formula is liable to alternation by the Engineer Throughout the progress of
the work but at all times it will be within the specified limits.

Preparation
XLIII. Preparation of Aggregates
The coarse and fine aggregate shall be separately fed by feeder to the cold elevator
or elevators in their proper proportions and at a rate to permit correct and uniform
temperature control of the heating and drying operation.
The aggregate shall be heated before entering the mixer to a temperature range of 120C
-
149C. All aggregates in the bins of a temperature that will produce a mix outside the limits
stated above or that contain moisture or expanding gases to cause Foaming in the
mixture, shall be removed and replaced in their respective stock piles. All aggregates that
have been overheated shall be cooled before being deposited in the feeder. All unsuitable
aggregates that may be in the weigh box or that become combined in the process of
Pulling the bins shall be discarded.
The screening efficiency shall be maintained within the limits set forth in Clause 6383. When
these limits are exceeded, the material shall be discarded and the cause for such
condition skill be corrected

XLIV. Preparation of Asphalt Cement

The asphalt cement shall be delivered to the asphalt bucket at a temperature between
135C and 163C. All asphalt cement heated beyond 177C at the plant before mixing or
heated beyond 163C during the mixing shall be rejected. No asphalt shall be used while
foaming.

XLV. Preparation of Mixtures

The exact proportions within the limits specified for each mix shall be regulated so as to
produce a satisfactory mixture with all particles uniformly coated with bitumen.
When batch mixing is used, the aggregate at the temperature specified, shall be mixed dry
for a minimum of 15 seconds; the asphalt cement shall be added in an evenly spread sheet
Over
the full length of the mixer. The mixing shall be continued for a minimum of 30 to 45
seconds for all mixtures.
The initial time of mixing shall be the interval of time between the opening of the weigh
box and the opening of the mixer gate. The number of batches produced in one hour
from the mixer shall not exceed 60.
When continuous mixing is used the dry aggregates shall be thoroughly mixed before the
addition of the asphalt cement. The asphalt cement shall then be added in an evenly spread
sheet over the full width of the mixer by means of spray bars. The mixing shall be
continued for a period of not less than 30 seconds. The total time for mixing shall be the
ratio of the
dead load in the mixer to the kilograms per minute delivered. The kilograms per minute
delivered shall be determined by timing and weighing a load of mixed material. The dead
load shall be determined by weighing the Mixer-full of material. The dry mixing shall be
the product of the ratio of dry mixer length to the total mixer length and total mixing time.
The Engineer may vary the length of the dry and wet mixing periods, but under no
circumstances shall the total mixing time be less than 45 seconds:
The mixture shall be loaded into trucks in such a manner that segregation will not occur.
The temperature of the mixture on arrival at the project site shall be as determined by
the Engineer in keeping with the temperature range set for the mix design and heat losses
in transit.

XLVI. Transporting Mixed Materials

The mixed materials shall be transported from mixing plant to site in clean metal
lined vehicles. Every precaution is to be taken to avoid segregation of mixed materials
and to ensure that they do not become contaminated with dust or foreign matter. Covers
such as water-proof canvas and other insulation shall be provided when directed.

XLVII. Preparation of Area to be Paved

The area to be paved shall be true to line and grade, having dry and properly prepared
surface prior to the start of paving operations. The area to be paved shall be free from all
screenings, and other loose or foreign material.
Where a base is rough or uneven, a levelling course shall be placed by use of a motor
grader or spreader and shall be properly compacted before the placing of subsequent paving
courses. When a levelling course is not required, all depressions and other
irregularities shall be patched or corrected in a manner satisfactory to the Engineer.
All fatty and unsuitable patches, excess crack or joint filler, and all surplus bituminous
material shall be removed from the area to be paved. Blotting of excessive deposits of
asphalt with sand or stone shall not be permitted.
Where the area to be paved is an untreated soil or aggregate, it shall be primed. The
prime coat shall consist of an application of the asphaltic material indicated, and at the rate
specified in clause 6370. The prime coat shall be allowed to cure properly before any further
operations are permitted on the primed area.
A tack coat shall be applied when the surface to be paved is an existing Portland Cement
concrete or dry asphalt pavement. When a tack coat is required, it shall consist of an
application of the asphaltic material indicated, and at the rate specified in clause 6370.
In all cases the emulsion shall be allowed to break before laying. Prior to application of
the tack coat, all loose or objectionable material will be removed from the surface by
brooming or other approved method. After cleaning, the surface shall be inspected by the
Engineer before the tack coat is applied. The tack coat will be applied evenly and by
mechanical sprayer of approved type which is to comply with BS 1707 Where the time
between the completion of one surface course and the laying of the subsequent surface
course exceed 72 hours, a tack coat shall be applied to the preceding course as above but at
a rate of spread of 4- 4.5 square meter per litre. Such tack coat shall be at the Contractors
expense unless compliance with the 72 hours limit was impracticable.
Tack coats shall be applied 24 hours in advance of bituminous surfacing work, or such longer
period as is necessary to ensure complete breaking of the bitumen emulsion
before bituminous surfacing are laid thereon. Traffic shall not be allowed on the tack coat
before surfacing work begins
Concrete kerbs, channels, and similar objects shall be adequately masked and
protected during the application of tack coats.
The surface of kerbs, gutters, vertical faces of existing pavements and all structures in
actual contact with asphalt mixes shall be painted with a thin uniform coating of asphalt
material to provide a bonded water-tight joint.

XLVIII. Trial Areas

The first 30 metres of the approved bituminous mixture which is laid by each spreader shall
be regarded as a trial area in order to establish a rolling procedure which will produce
the required field density.
At least four samples of the material after rolling will be taken in accordance with part 1
section 3 of B.S. 598; when the work is at least 12 hours old in order to determine the
degree of compaction.
If the required density determined in accordance with clause 6381 is not obtained, the field
rolling procedure will be changed so as to achieve the desired field density and the trial area
will be cut out and replaced to the satisfaction of the Engineer.
After mixing, the material must not be reheated other than by the means provided in or
on the spreading machine.
Materials must not be laid when the surface on which it is to be placed is wet or when rain
appears imminent.
It is essential that the material is laid at a temperature not less than 121C and not more
than
163C. The Contractor is to provide at each spreader and finisher a suitable thermometer for
testing the temperature of the material as it is being spread and is to take such temperature
readings continually and record them hourly throughout each days laying. This record shall
be available for inspection by the Engineer who will himself make such additional
temperature checks as he considers desirable.
The materials shall be laid by approved mechanical pavers in accordance with clause
6384. The spreader paver shall be in good mechanical condition and shall be capable of
laying to the required width and profile without causing segregation, dragging burning,
irregularities or other surface defects. When not operated on side forms the paver will
employ equalizing runners, evener arms or other automatic compensating devices to adjust
the profile and confine the edges of the course to true lines.
As soon as the first load of materials has been spread the texture of the unrolled surface
shall be checked to determine its uniformity. The adjustment of the screed, tamping bars,
feed screws, hopper feed, etc., shall be checked frequently to ensure uniform spreading of
the mix to proper line and grade and adequate initial compaction. Segregation of materials
shall not be immediately suspended until the cause is determined and corrected.
Any irregularities in alignment left by the paver shall be corrected by trimming directly
behind the machine. Immediately after trimming, the edges of the course shall be
thoroughly compacted by tamping. Distortion of the pavement during this operation shall be
avoided. Edges against which additional pavement is to be placed shall be vertically formed
to true line. A rake shall be used immediately behind the finisher, when required, to obtain a
true line and vertical edge. Any irregularities in the surface of the pavement course shall be
corrected directly behind the paver. Excess material forming high spots shall be removed by
a shovel. Indented areas shall be filled with hot mix and smoothed with the back of shovel
being pulled over the surface. Fanning of materials over such areas shall not be permitted.
The mixer capacity and the operating speed of the spreader shall be so adjusted as to
ensure continuous laying and to avoid intermittent stopping of the spreader as far as is
practicable Hand spreading will not be permitted for general work, but will only be
allowed for filling localized depressions, or as directed by the Engineer.
Hand laying of any bituminous material will only be permitted in the following circumstances.
* for laying regulating courses of irregular shape and varying thickness.
* in confined spaces where it is impracticable for a paver to operate.
* for footways.
* at the approaches to expansion joints at bridges or viaducts.

When a paver laying base material approaches an expansion joint at a bridge or viaduct it
shall be taken out of use as soon as there is a danger of the material being laid fouling the
joint. In laying the remainder of the pavement up to the joint and the corresponding area
beyond it by hand, the joint or joint cavity shall not be fouled with surface material.
Hand-raking of wearing course material which has been laid by a paver and the addition
of such material by hand-spreading to the paved area for adjustment of level will only be
permitted at the edges of the layers of materials or where otherwise directed by the
Engineer. Where hand spreading and tamping is permitted, the mixed material is to be
dumped on delivery upon existing hard clean surface or on approved metal sheets outside
the area where it is to be spread and shall be distributed in to place immediately by means
of hot shovels. It shall be spread with hot rakes in a uniformly loose layer to the full depth
required.
Materials are to be laid to the depths necessary to give the required thickness after
compaction and they are to be finished true to profile.
The Contractor shall break out and remove at his own expense any asphaltic concrete laid in
trial areas if such asphaltic concrete fails to meet the specified requirements for asphaltic
concrete surfacing.
If for any reason the quality, grading or supply source of aggregates or the quality or source
of bitumen is changed, or at any time the cause of variations outside the permissible
limits cannot be corrected for reasons beyond the Contractors control, the Engineer may
require the Contractor to carry out additional laboratory tests and/or the construction of
additional trial areas depending on the extent of the change or variation.

XLIX. Compaction
After spreading, the mix shall be thoroughly and uniformly compacted by rolling.
The initial breakdown rolling shall be done with three wheel smooth roller, followed by
intermediate rolling with high- pressure tyred pneumatic roller. During the rolling wheels
shall be kept moist with only sufficient water to avoid picking up material.
Heavy equipment or roller shall not be permitted to stand on finished surface until it has
thoroughly cooled. In the initial rolling the three-wheel smooth roller shall proceed on to the
fresh material with the rear or driven wheels leading. The rolling shall start as soon after
laying as conditions permit and when the material is still at a temperature of not less than
99C. The weight per unit width of the rear wheel shall be between 45-65 Kg per centimetre
width.
After the longitudinal joints and edges have been compacted rolling shall start
longitudinally at the sides and gradually progress towards the centre of the pavement,
except on super- elevated curves where rolling shall begin on the low side and progress to
the high side. Each pass of the roller shall overlap the proceeding one by about one width of
the rear wheel. The roller should move at a slow but uniform speed not exceeding 8
kilometres per hour. The roller shall be in good condition, and capable of being reversed
without back lash, and the line of rolling shall not be suddenly changed or the direction or
rolling suddenly reversed, thereby displacing the mix. If rolling causes displacement of the
materials the affected areas shall be loosened at once with shovels or rakes and restored
to the original grade of loose material before being re-rolled.
The intermediate rolling shall be done with a pneumatic roller exerting compactive ground
pressures between 5.6-8.4 kg per sq. cm. The Contractor shall furnish to the Engineer
charts or tabulations showing the contact areas and contact pressures for the full range of
type inflation pressures and for the full range of tyre loadings for each type and size
compactor tyre furnished. The intermediate rolling shall follow the break down rolling as
closely as possible and while the mix is still at a temperature of 70C - 85C. Rolling shall be
continuous until the mix is thoroughly compacted and the density specified in clause 6381 is
achieved. Turning of pneumatic roller on the hot mix which causes undue displacement shall
not be permitted.

L. Joints
All joints shall be vertical, properly formed to the correct line and level; if necessary they
shall be cut back to achieve this. A template made to the shape of the true line and width
may be placed at each end of the construction joint line and width to create vertical straight
finish. Joints in the surface course should be staggered with those in the binder course and
must be kept straight, when the abutting lane is not placed the same day or if the edge of
the first strip has been distorted by traffic the joint shall be cut back to an even line and
then be coated with bitumen before laying the adjoining strip. All joints on completion
are to present the same texture, density and smoothness as other sections of the course.

LI. Field Density of Rolled Asphalt

Density tests of the asphalt surfacing after compaction shall be taken from the trial area and
later at intervals throughout the course of the work and compared with the density of-control
specimens taken from the same material before laying all in accordance with the following
procedure:
A sample of mixed material will be taken from a lorry before the material is delivered to the
spreader, and three specimens shall be made and their density measured by the Engineer by
the immersion method.
The average of the two close specimens will be taken as the control density of that
particular batch.
The pavement will be marked to show where the lorry load of material (from which the
sample was taken) is laid, so that field density samples can be taken for comparison with the
control specimen.
After completion of rolling, three samples are to be cut from each area so marked in
positions
indicated by the Engineer.
 The samples shall be taken in accordance with part 1 section 3 of B.S. 598 (1974) and the
density calculated by weighing in air and weighing in water in accordance with part 6 of
B.S.
593 (1974). The average of two close results of the samples will be taken as the density of
the
compacted material in that area.
This density will not be less than 100% of the control density determined as above.
When an approved rolling procedure has been established, each course will be sampled in
accordance with the above at the rate of one sample area for each 84 square metres placed
or one sample area every 2 hours (whichever is more frequent). Material which does not
achieve the required density will either be cut out and replaced or be further compacted
until the required density is obtained.

LII. Priming of untreated base and application of tack coat existing paved surfaces
shall be done as follows:
All materials and method of preparation and construction shall conform with
the requirements of these specifications. The finished pavement shall conform in all respects
with the hues, grades, dimensions and cross sections shown on the drawings or as
may be otherwise specified or directed by the Engineer

LIII. Equipments
The type of equipment used should be the appropriate equipment for specific operation and
should not create any hazard to the adjoining properties along the project areas
most especially plants that can induce vibration. Notwithstanding that all test, piece of
equipment or apparatus is not specifically mentioned or described in the various pages
hereof, nevertheless if directed by the Engineer the Contractor is to supply at his own
expense all apparatus and equipment of whatever kind necessary to carry out any test
mentioned in or required by the provisions of the various clauses in this specification and the
British Standard Specifications incorporated in this Specification.

The Engineer shall be the final arbitrator on which tests are necessary for the
proper execution of the works.