This document provides specifications for materials used in road construction, including granular sub-base, aggregate road base, and asphalt concrete. It defines classification systems and provides requirements for gradation, strength, durability, and other properties that materials must meet. Frequent testing is required to ensure materials comply with specifications.
This document provides specifications for materials used in road construction, including granular sub-base, aggregate road base, and asphalt concrete. It defines classification systems and provides requirements for gradation, strength, durability, and other properties that materials must meet. Frequent testing is required to ensure materials comply with specifications.
This document provides specifications for materials used in road construction, including granular sub-base, aggregate road base, and asphalt concrete. It defines classification systems and provides requirements for gradation, strength, durability, and other properties that materials must meet. Frequent testing is required to ensure materials comply with specifications.
Grading shall be one of the following classes when tested in
accordance with BS 1377: Part 2: Method 9.2. Selected class shall be as directed by the Engineer
Table 4-4. Gradation of Granular Sub Base % By Weight Passing Sieve Size / No. Class A Class B Class C 3" 100 100 100 2" 90 - 100 90-100 90-100 No. 4 35 - 70 40-90 50-100 No. 200 0 - 20 0-20 0-30
5. Materials shall conform with the following requirements:
Table 4-5. Requirements of Granular Sub Base Test Standard Limit Liquid Limit BS 1377: Part 2 : Method 4.5 max 30% Plasticity Index BS 1377 : Part 2 : Method 5 max 8% % water absorption after 24 hours submerged in water Local codes max 10% Clay lumps and friable particles in aggregates Local codes-T 113 max 10% Los Angeles Abrasion ASTM C131/C535 max 50% Compaction Test (MDD) BS 1377: Part 4: Method 3.6 2.1 Mg/m Min In-situ Density Test BS 1377: Part 9: Method 2.2 min 98% CBR at 98% MDD (96 hour soaked) BS 1377: Part 4 Method 7 min 25% Swelling of soaked C.B.R. moulds No swelling
6. Minimum Test Frequency 4-15 One sample every 1000m shall be tested for complete analysis unless otherwise approved by the Engineer. Three in-situ density tests shall be made every 1000m of granular sub base laid, unless otherwise approved by the Engineer. One in-situ density shall be carried out for every 150 linear meter of shoulder or footpath, unless otherwise approved the Engineer.
4.6.7 Aggregate Road Base
1. Hard, durable crushed gravel or crushed stone. The amount of crushing shall be such that at least 80% (by weight) of the pieces retained on 4.75mm sieve shall have at least one mechanically fractured face. Material shall consist of uniform mixtures of gravel and or crushed gravel with sand, silt and clay conforming to the following gradation limits. 2. Free of organic matter or other deleterious substances. 3. Grading shall be one of the following classes when tested in accordance with BS 1377: Part 2: Method 9.2. Selected class shall be as directed by the Engineer
Table 4-6. Gradation of Aggregate Road Base % by Weight Passing Sieve Size /No. Class A Class B Class C 2" 100 1.5" 70 -100 100 1" 55 - 85 70-100 100 3/4" 50 - 80 60-90 70-100 3/8" 40 - 70 45-75 50-80 No.4 30 - 60 30-60 35-65 4-16 No.10 20 - 50 20-50 25-50 No.40 10 - 30 10-30 15-30 N0.200 5 - 15 5-15 5-15
4. Material shall conform with the following requirements:
Table 4-7. Requirements of Aggregate Road Base Test Standard Limit Liquid Limit BS 1377: Part 2: Method 4.5 max 30% Plasticity Index BS 1377: Part 2: Method 5 max 8% Linear shrinkage BS 1377: Part 2: Method 6.5 Max 7% Organic Impurities BS 1377: Part 3: Method 3 Max 0.2% % absorption submerged in water for 24 hours. Local codes max 10% Clay lumps and friable particles Local codes T-113 max 5% Los Angeles Abrasion ASTM C131/C535 max 50% Thin and Elongated particles Local codes Max 10% Compaction Test (MDD) BS 1377: Part 4: Method 3.6 min 2.2 Mg/m In-situ Density Test BS 1377: Part 9: Method 2.2 100% CBR at 100% MDD (96 hr. soaked) BS 1377: Part 4: Method 7 min 80% Swelling of soaked C.B.R. moulds No swelling
5. Minimum Test Frequency One sample every 1000 m 3 shall be tested. Two in-situ density tests shall be made every 500 m 2 of aggregate road base laid.
4-17 4.6.8 Materials for Asphalt Concrete 1. Mineral aggregates for bituminous paving course shall consist of coarse aggregates, fine aggregates and filler material all complying with the following requirements. 2. Prior to the production of aggregates or delivery of aggregates the Contractor shall notify the Engineer of the source of aggregates for inspection of the borrow or quarry area. All sources of aggregates shall be approved by the Engineer prior to the processing of material. 3. The properties of aggregates specified in this section shall be for aggregates from individual sources or individual stockpiles. 4. If the grading and other specified properties of the material delivered to the site does not conform to the same properties of originally approved samples or does not comply with the specification, the Engineer reserves the right to reject such materials at the site of the work. If required by the Engineer the Contractor shall submit to the Engineer the original invoices for any delivery of mineral aggregates including filler. 5. Coarse Aggregates (those retained on a 4.75mm sieve) Shall consist of crushed rock or crushed gravel. Shall be clean, hard, tough, durable and sound. Shall be of uniform quality and free from decomposed stone, shale, clay lumps and other deleterious substances. Mineralogical tests shall be carried out on the aggregates, if requested by the Engineer Crushed gravel. Consists of products obtained by crushing material that has first been screened in such a manner that not less than 90% of the material to be crushed is retained on an ASTM 9.5 mm sieve. 100% (by weight) of each stockpile of aggregate retained on 2.36mm sieve shall have at least one crushed face. 4-18 At least 85% (by weight) of each separate stockpile of aggregate retained on 2.36m sieve shall have all faces crushed, unless otherwise approved by the Engineer. Coarse aggregate in each individual stock pile shall have properties which comply with the following values:
Table 4-8. Requirements of Materials for Asphalt Concrete Test Standard Binder Course Wearing Course Los Angeles Abrasion ASTM C131/C535 max 40% max 40% Thin & Elongated particles Local codes max 10% max 10% Clay lumps and friable particles Local codes 0%* 0%* % water absorption Local codes max 5% max 5% Organic Impurities BS 1377 Max 0.05% Max 0.05%
6. Fine aggregate shall be obtained from 100% crushed gravel or crushed rock, unless otherwise approved by the Engineer. If approved by the Engineer, a maximum of 25% (by weight) of fine aggregate may be uncrushed if it is separately fed into the plant. Use of dune sand shall not be permitted. Fine aggregates shall be Non-Plastic when tested for Plasticity Index:
7. Filler Material When the combined grading of the coarse and fine aggregates is deficient in material passing the ASTM No. 200 sieve, external mineral filler shall be added as approved by the Engineer at the Contractors expense. Mineral filler shall consist of finely ground non- plastic particles of limestone or cement. 4-19 Mineral filler shall be thoroughly dry and free from organic substances and clay. Test frequency is as directed by the Engineer.
8. Bitumen Binder Shall be penetration grade 40/50 or 60/70 as directed by the Engineer. Bitumen shall be prepared by refining crude petroleum. Shall be homogeneous and free from water. Shall not foam when heated to 175C. Shall conform to the following requirements, unless otherwise accepted by the Engineer. Bitumen heated 100C above the maximum temperature obtained form viscosity temperature relationship shall be considered over-heated and shall be removed from site and disposed of by the Contractor at his own expense. Bitumen shall be heated only in approved boilers or bulk storage containers equipped with adequate and accurate thermometers. When filling the bitumen from distributors boilers or bulk containers, the bitumen shall be passed through a filter of fine wire gauge. The Contractor shall take every reasonable pre- cautions to avoid fire or heath hazards. A sample of bitumen that the Contractor propose to use in the work together with a statement as to its source and properties shall be submitted to and approved by the Engineer at least 45 days before Construction begins. 4-20 The properties of bitumen shall be as specified by the Local code unless otherwise approved by the Engineer. Only the bitumen represented by the approved sample shall be used by the Contractor. Blending of bitumen from different refineries will not be permitted. Test Frequency. One full analysis shall be carried out on a sample from every 80ton.
4.6.9 Asphalt Concrete 1. When tested according to ASTM C117 and ASTM C136, the combined aggregates shall conform to the following grading having a smooth curve to the appropriate limits and shall not vary from the low limit on one sieve to the high limit on the adjacent or vice-versa.
Table 4-9. Gradation of aggregate to used in asphalt concrete Sieve size/No. % By Weight Passing Binder Course Wearing Course 1" 100 100 3/4" 75-100 80-100 1/2" NA NA 3/8" 45-70 60-80 No 4 30-50 48-65 No 8 20-35 35-50 No 30 5-20 19-36 No 50 3-12 13-23 No 80 2-8 7-15 No 200 0-4 3-8
2. Combined mineral aggregate shall be non-plastic. 4-21 3. Coarse aggregate, shall show no detrimental amount of stripping when tested in accordance with ASTM D 1664. The area coated shall be evaluated not only at 25C but also after the aggregate has been soaked in water at 40C and 60C. Minimum value of non-stripped area shall be 95%. If stripping occurs, the aggregate shall be rejected unless: a. An approved method of treatment shall be carried out as specified to change the material from a hydrophilic to a hydrophobic state. b. Only approved additives shall be used with the bituminous binder. 4. When necessary to change the hydrophilic character of aggregates to hydrophobic, additives of approved type will be added to the bituminous material in such percentage as required to obtain satisfactory results from the test performed in accordance with ASTM D1664. Approved additive will be used in accordance with Technical Specifications issued by the manufacturer and approved by the Engineer after appropriate testing. No extra payment will be made for required anti-stripping additives.
5. Design Criteria: The following table summarizes the design criteria of asphalt concrete. However, the exact percentage of bitumen to be used shall be fixed by the Engineer based on the laboratory mix and full- scale plant trial mix results.
Table 4-10. Design Criteria of Asphalt Concrete Properties Binder course Wearing course Bitumen Content (% of total mix) Marshall Specimens: 3 - 6 4 - 7.5 Number of Compaction blow at each end of specimen. 75 75 Air voids in total mix (VIM %) 3 - 8 3 - 5 Voids in mineral aggregate (VMA %) Min. 14 Min. 15 Stability (kg) Min. 700 Min. 900 4-22 Flow (mm) 2 - 4 2 - 4
6. Job mix for Bituminous Paving Courses: field trials with the following recommendations shall be taken into account. Combined aggregate gradation should be adjusted within the allowable limits to achieve maximum stability whilst not going below the minimum requirement for void content. Minimum bitumen binder content should be used according to the results of the Marshall Method of Mix Design, if it will still satisfy all the specified requirements. Final job mix must display all characteristics as specified for Asphalt Concrete mixes. After receiving approval of the aggregates and bitumen from the Engineer, the Contractor shall make a written request for the approval of the job-mix formula from the Engineer at least thirty, (30) days prior to the date he intends to begin production of plant-mix Bituminous Paving Course Mixes. Formula will be prepared by the Contractor under the supervision of the Engineer in the Laboratory. The laboratory job mix formula shall define: a. Percentage of aggregate passing each required sieve size. b. Percentage of bitumen binder to be added to the aggregate. c. Temperature at which the mix is to be emptied from the mixer. d. Temperature at which the mix is to be delivered to the works site. Before the start of the permanent work, mock- ups or trial areas having lengths of at least 30 m shall be laid to the specified layer thickness 4-23 a. Materials used in the trials shall be those approved for use in the bituminous paving courses. b. Equipment used shall be that according to the Contractors approved method statement and the program of work. c. The object of these trials is to determine adequacy of the Contractors equipment, loose depth measurements necessary to result in the specified compacted layer depths, and relationship between the number of compaction passes and the resulting density of the material. d. Additionally at least two samples of non- compacted material and two cores of specified diameter shall be taken from the trial area in accordance with AASHTO T-168 and analyzed in the presence of the Engineer to determine aggregate grading, binder content, stability, flow, bulk density, and voids. Results shall be submitted to the Engineer for approval before further mixing and laying are carried out.
If the laboratory job mix formula fails to produce a satisfactory trial, the mix proportions may be modified by agreement with the Engineer, within the applicable specification requirements to produce a mix of satisfactory workability and acceptable surface finish. 4-24 All mixes produced shall conform to the properties of Job Standard Mix approved by the Engineer, within the ranges of tolerance specified in Table 22. Should a change in a material be encountered or should a change in a source of material be made, a new Job-Standard Mix shall be submitted by the Contractor and approved by the Engineer before the mix containing the new materials is delivered. Job materials will be rejected if they do not possess the same characteristics of the approved Job Standard Mix.
Table 4-11. Job Mix Tolerance Aggregate retained on 4.75 mm sieve or larger + 5% Aggregate passing 4.75 mm sieve and retained on 0.075 mm sieve + 4% Aggregate passing 0.075 mm sieve + 2% Bitumen Binder + 0.25% Temperature for mixing and placing 10C
7. Samples of Bituminous paving course mixes shall be taken from the mixing plant and/or behind the paver prior to compaction, as decided by the Engineer, to check compliance with the approved job mix requirements. Density of the compacted mixes shall be related to the job standard density or the daily Marshall Density at the option of the Engineer, which shall be determined by making four Standard Marshall specimens from samples of the mix taken from the mixing plant or paver. Density of each sample shall be determined and compared with the mean value. Any individual result, which varies from the mean by more than 0.015 g/cc, shall be rejected. 4-25 Marshall tests shall be repeated on a daily basis to establish the daily Marshal Density for that particular days production. Daily Marshall Density shall not vary from the Job Mix Design Density by more than + 1%.
8. Assistance of the Engineer in the preparation of the job standard mix shall in no way relieve the Contractor of his responsibility for producing a bituminous mix meeting the requirements of the Specifications.
9. Preparation of Bitumen Binder Temperature of the bitumen binder for mixing and compacting shall be in accordance with ASTM D1559. The Contractor shall submit a temperature / viscosity chart for each grade of bitumen to be used.
10. Preparation of Mineral Aggregate for Bituminous Mix Coarse and fine aggregate shall be stored at the asphalt plant in such a manner that separate stockpiles will not become intermixed. a. Stockpiles shall be of sufficient size to provide a minimum quantity of one weeks continuous production of asphalt mix. b. Aggregates brought to the asphalt plant to supplement stocks should be tested and approved prior to placing in the existing approved stockpiles. Cold bins shall be calibrated with the materials to be used and the settings shall be such as to produce a combined gradation in accordance with the job mix formula. a. Proportioning shall be such that surpluses and shortages in the hot bins will not occur. b. Neither the dryer nor the screens shall be overloaded. 4-26 c. All the above shall be as approved by the Engineer. Materials shall be thoroughly dried and heated so that their temperature is within 8C of the temperature needed to satisfy the viscosity requirements of the asphalt cement. a. Moisture content of the heated and dried materials shall not exceed 0.5%. b. Quantity of materials fed through the drier shall in all cases be held to an amount, which can be thoroughly dried and heated within the limits specified. Immediately after heating, the aggregates shall be screened into at least five sizes and conveyed into separate bins ready for batching and mixing with bituminous materials. When the aggregates supplied are of such size and grading that separating into five bins is impractical, the number of required separations may be reduced to four or to three with the approval of the Engineer. Efficiency of the screening operations shall be sufficient to produce (at plant operating capacity) gradations (in all sizes of heated and dried aggregates) which are reasonably uniform and result in the production of a mix complying with the limits specified for the aggregate gradation.
11. Preparation of Bituminous Mix Asphalt concrete shall be prepared in a central mixing plant conforming to the requirements of ASTM D995. a. The plant shall be equipped with an efficient mechanical dust extraction system and storage silos. 4-27 b. Its design shall be provided for the controlled return of some of the filler to the mix, when necessary, by means of filler weighing bin discharging in to the pugmil. c. The dust collection system shall be powerful enough to keep the mineral filler contents the in hot sand bin below 2%. d. The plant settings once established shall not be changed without the approval of the Engineer. e. The minimum mixing time shall not be less than that recommended by the manufacturer. The mixing time may be increased by the Engineer if additional time is necessary to obtain a homogeneous mix and satisfactory coating. f. Bitumen binder shall be introduced into the mix in the proportion specified by the job-mix formula. Initial mixing time will be designated by the Engineer. Mixing time may be increased by the Engineer if additional time is necessary to obtain a homogeneous mix and satisfactory coating. Timing at the batch plant for mixing shall begin at the start of the introduction of the bitumen into the pugmill. Temperature of the aggregate immediately prior to mixing shall be within + 8 C of the temperature of the bitumen binder. a. Temperature of the aggregate and asphalt prior to mixing shall be approximately that of the completed mix as defined in the job mix formula approved by the Engineer. b. Mix temperature shall be within the limits set out in the job mix formula when emptied from the mixer. 12. Minimum test requirements for bituminous courses Bitumen material: One sample shall be tested for penetration and Ring ball test for every 80 tons or part thereof, unless otherwise agreed by the Engineer. 4-28 Aggregate: One sample for each stockpile or every 1,000 m. Perform all the required tests. Bituminous mix: one sample of mix shall be obtained from at least every 200 tons. Perform all the required tests.
4.6.10 Prime and Tack coats 1. Prime coat shall be a medium curing cut back asphalt (MC-70) . Sampling shall be in accordance with ASTM D140. Frequency of the testing shall be as directed by the Engineer. 2. Tack Coat shall be Rapid Curing cut back asphalt ( RC-250 ). Sampling shall be in accordance with ASTM D140. Frequency of the testing shall be as required by the Engineer. 3. Depending on the possibilities of obtaining Bituminous materials, the Engineer may modify the type and gradation of the materials for the prime coat and tack coat. 4.6.11 Road marking materials 1. Thermoplastic Materials shall comply with BS3262 hot-applied thermoplastic road marking materials and shall be suitable for road surface temperature of up to 80C, unless otherwise approved by the Engineer. Proportions, testing requirements and type of materials used shall be as mentioned in the Contractors approved method statement. 2. Road marking paint shall be either chlorinated rubber, one pack epoxy or 4-29
4.6.12 Traffic signs 1. Permanent traffic signs shall be reflector and shall comply with the following requirements except as modified here under or as directed by the Engineer. 2. Sign plates shall be manufactured from sheet aluminum with a minimum thickness of 3mm, unless otherwise approved by the Engineer. 3. Information on signs shall be constructed in extruded aluminum plank sections, which will either be self-locking or rear fixing, and the aluminum shall be BS EN 485, or BS 1490 or other approved equivalent International Standard. 4. All sign plates shall have clean, smooth edges cut to the required shape of the sign and shall be etched 4-30 5. Sign shall be covered with High Intensity reflective sheeting. Sheeting must have the manufacturers guarantee for a period of not less than 5 years for Engineering Grade and 7 years for High Intensity. Rear faces shall be non-reflective grey and should give a similar life span to the sign face. Reflective sheeting shall be fixed to the sign plate either with a heat activated adhesive using vacuum applicator or with a pressure sensitive adhesive using a pressure roller in accordance with the sheeting manufacturers instructions. Sign faces shall be formed from a single piece of reflective 4-31 Sheeting, after application to the sign base, will not come off at the edges nor shall it peel off or warp. Surface shall be smooth, flat and free from any bubbles, pimples, edge chipping or edge shattering. Surface 4-32 Corners of all direction signs shall be rounded to a radius of 75 mm. 6. Stiffening and Framing All stiffening and framing shall be of hot dipped galvanized steel. Signs constructed of aluminum sheet shall, when recommended by the Traffic Sign Manual, be framed on all edges using hot dipped galvanized steel angle. Stiffening to signs constructed of aluminum sheet, having an area exceeding 0.10 sq.m. shall be confined to horizontal lengths at the top and bottom edges of the sign plate. 7. All rivets or other devices fixing sign plates to their framework shall be of non-staining steel or other materials approved by the Engineer and shall 4-33