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TECHNICAL SPECIFICATIONS

Chapter 2. Extension of Breakwater

2.1 General
The Contractor shall in any way propose the best-suited design and working methodology for what he
has selected for the Engineers approval.

2.2 Norm of Dredging Works


When the Contractor considers to be necessary, the Contractor shall, at his own cost, prior to the
execution of the dredging works, employ an experienced specialism company in the field of geological
survey to carry out pre-soil borings and laboratory tests under the direction of the Engineer so as to
confirm water depth, soil strata, and the characteristics of the soils. The Engineer shall point out location
of the boring holes.
Based on the boring data available at the time of designing, the layer of the granite was assumed as
suitable bearing stratum. The Contractor shall, however, keep in mind that changes in dredging depths
may be necessary, and the Engineer reserves the right to direct the Contractor to do so.

2.2.1 Preparation of Equipment for Bathymetric Survey and Standard Penetration Tests
The Contractor shall keep at the Site and during the construction period, at least one set of equipment
and tools, machinery, vessels workers and technical stuff required for carrying out the bathymetric
survey and standard penetration test under the direction and supervision of the Engineer. Such survey
and test results shall be submitted in an agreed reporting format to the Engineer within a reasonable
period of time upon completion of the test. The bathymetric survey shall be conducted by a dualfrequency echo sounder (200 kHz and 30Hz).

2.2.2 Nature of Materials to be Dredged


According to the results of boring that has been conducted, the soils to be dredged have turned out to be
mostly of soft clay, silty sand and weathered granite. However, the Contractor is required to examine the
bore hole records and carry out any additional probe he may consider necessary and he shall satisfy
himself of the nature of the soils and determine the characteristics and properties of the materials to be
dredged.

2.2.3 Area and Profile of Dredging


(1) The levels described on the Drawings, above which the soils shall be dredged, were determined
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based on Standard Penetration Test results and such levels having neither less density nor loose layer
thereunder shall be deemed as the foundation level and any materials above these levels shall be
removed completely by dredging.
The Contractor shall mobilize suitable dredgers capable of dredging any materials in the specified
dredging area so that uniformity of the specified dredged level can be obtained. Hard soil or rock may
exist in the dredging area with average SPT of value N=25 or more. The Contractor shall be responsible
for the dredging of any hard materials or rock he may encounter.
In the event where explosive is required for the dredging of such hard materials above mentioned, the
Contractor shall inform the Engineer thereof in writing asking for his direction and approval thereto.

(2) Dredging shall be completed in conformance to the depth as specified in the Drawings. Since soft
soils are deemed to be predominant in this area, the Contractor shall investigate and satisfy himself of
the nature of soils to be dredged and suitable equipment and method of dredging.
(3) The areas to be dredged are indicated on the Drawings or such other locations as the Engineer may
direct. The Contractor shall dredge these areas to the depths, slopes and berms as determined by the
methods set out in this Clause. Prior to dredging, the Contractor shall give notice in writing to the
Engineer.

2.2.4 Dumping Site of Dredged Spoil


The dumping site is located in the Tien Sa Beach approximately 10 km north of the Tien Sa Port. The
exact location of the spoil ground shall be as directed by the Engineer. The Contractor shall transport the
dredged materials and dispose of them at the dumping site.
Before entering into the Contract, the Contractor shall be fully acquainted with the distances between the
dredging area and the dumping site, and shall cover in his rates for dredging the disposal of spoil from
any part of the dredged area to any part of the dumping site. No claim will be accepted in respect of the
length of haul between the dredging area and the dumping site specified herein.
In the event where instructions are given by the Engineer or the Employer that the dredged spoil should
be dumped in other areas at a different mean distance from the dredged area, the rate for dredging of
material so disposed of shall be adjusted in accordance with the rates for longer or shorter haul named
in the priced Bill of Quantities.
No dredged spoil shall be deposited in any area other than the specified dumping site and such other
dumping site as may be subsequently directed by the Engineer or the Employer. The Contractor shall
indemnify the Employer against any claims that may be laid against him due to the Contractors default
in this respect.

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2.2.5 Plants
The Contractor shall at all times during the progress of the dredging works, provide, operate and
maintain in proper working condition all necessary dredgers, hoppers barges, tugboats, moorings,
surveying and sounding instruments, and all plants, equipment, tools, implements, tackles, and all things
whatever necessary for the execution and completion of the dredging works.

The Contractor shall at all times maintain at the Site or have access to adequate stocks of fuel,
consumable stores and spare parts. The Contractor shall at all times ensure that the plant is kept in the
best possible state.
The Contractor shall pay particular attention to the maintenance of hopper doors and suspension
equipment, to ensure their always being in the best possible state.
Where necessary, the Contractor shall provide office accommodation, shelter or other adequate
provision for record keeping on board the dredgers and other crafts for such inspectors or other persons
as are appointed by the Engineer.
2.2.6 Survey and Check Boring
(1)

Survey

The Contractor shall perform following surveys by means of dual frequency echo sounder:

Pre-dredging Survey

The Contractor shall, before dredging and according to the schedule approved by the Engineer, carry out
the bathymetric survey over the dredging and vicinity areas and shall submit to the Engineer for his
approval the results of such surveys in the form of drawings.

Survey and Inspection of Dredged Surface

The Contractor shall conduct bathymetric survey to confirm the dredged profile being in accordance with
the dredged cross sections. Inspection of the dredged contour shall be conducted immediately before
sand placement.
If the dredged profile dose not conform to the designed profile, the Contractor shall complete the profile
according to the instructions of the Engineer. Reinspection shall take place as directed by the Engineer if
the Contractor fails to place sand within an appropriate period after the initial inspection has been carried
out.

Post-dredging Survey

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A similar survey, in the stages where appropriate, shall be carried out on completion of the dredging
works.
Aside from the above, inspection shall be conducted from time to time as the Engineer so directs for the
purposes of monthly payment and taking-over by the Employer.
Should any high spots, shallower than the specified depth, be found out at the time of final inspection,
the Contractor shall at his cost and responsibility rectify it until a final approval is obtained by the
Engineer
The Contractor shall provide equipment, vessels and workers as required for surveying and sounding for
the inspection of the dredged surface as required by the Engineer, and all expenses so incurred shall be
borne by the Contractor.
The Contractor shall make sure that no unsuitable soil material of lower than the relative density or
stiffness as specified in 2.2.3 nor fluid mud shall remain upon completion of dredging works.
(2)

Check Boring (Post Sand Filling Boring and Laboratory Tests)

Geological investigation, including boring at site and laboratory tests, of the replaced sand foundation
after filling of sand, to confirm the strength and uniformity of the foundation (5 boreholes, total length
150m, SPT, laboratory tests including bulk and dry density, specific gravity, grain size, etc.).

Check boring shall be done by a well-experienced, reliable, and reputable investigation company in Viet
Nam except by the investigation company (s) that have already participated in the investigation at the
Breakwater
The selection of the boreholes, investigation company, methods and equipment, methods of laboratory
tests and analysis and other conditions shall subject to the approval of the Engineer.
.
2.2.7 Control of Dredged Profiles
The base and side slopes shall be dredged to the dimension indicated on the Drawings. The specified
depth shall be attained at all points in the dredged areas. Over-dredging exceeding the specified depth
of water shall not entitle the Contractor to claims for additional payment, unless otherwise approved by
both the Employer and the Engineer. Dredging on the side slope shall be carried out carefully so as not
to exceed the designed slope. Over-dredging on the side slopes shall not be paid for, either.
Payment shall not be made for materials dredged outside the specified tolerances for depth and side
slopes, or for approved displacement sand base materials required to replace the over-dredged material.
The quantities to be measured for payment shall be based on the approved records of surveys made
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before and after the dredging as required in this Clause.


2.2.8 Obstructions
The dredging area lies near the Piers 1 and 2 and there could possibly be such obstructions as rock
boulders, wire ropes, chains, anchors, or other artifacts. The existence of sunken wrecks can not be
denied.
The Contractor shall search the dredging area prior to dredging, locate and remove, with prior approval
of the Engineer, any objects of whatever kind that will interfere with normal dredging processes.
The Contractor shall not be allowed to claim for the cost of removal of small obstacles and/or artifacts
which can be removed by ordinary means of the Contractors dredging fleet. Sunken wrecks and other
large objects which, in the opinion of the Engineer, are not normally encountered in the area of the
dredging works shall be removed by the Contractor, the cost for which shall be paid based on the actual
cost required and approved by the Engineer.

2.3 Foundation Improvement for Breakwater


2.3.1 General

The Works in this Section consist of the furnishing and placing replacement sand, borrowing operation to
be carried out according to the Specifications and in reasonable close conformity with the lines, grades
and dimensions shown on the plans or as required by the Engineer.

2.3.2 Material
As for the Area, the formation, levels and slopes which relate to the material to be replaced are
indicated on the Drawings. The Contractor shall replace existing marine soft clay with sand as specified
below. The Contractor shall submit the sample and laboratory test result prior to the commencement of
the works.

2.3.2-1 Replacement Sand


The grading percentage and grain size of sand shall lie within the limit curves shown on Fig. 2.3.2-1-1 in
the next page for foundation improvement. Sand after being placed shall contain no more than 10%
material finer than JIS sieve 74m.
Prior to work, the Contractor shall submit to the Engineer for his approval the samples and the
certificates by a third authorized agency.
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The sand shall be free from vegetation, roots, organic matter, logs or other materials which are
combustible or which can decay.

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2.3.3 Replacement Sand Works


In connection with sand borrowing operation, the Contractor shall take all responsibilities including, but
not limited to obtaining all necessary permits and approval, payment of royalties, provisions on
maintaining necessary detours on its borrowing site, anti-pollution control and maintenance of safety
measures and other temporary facilities which may be required for the safe and effective operations in
compliance with the regulations or requirements of the related authority having jurisdiction over any part
of the operation.
The Contractor shall be required to submit their work methodology and the sequence of the replacement
work to the Engineer for his approval prior to the commencement of the work.
The dredging depth and slopes shall be controlled as to the levels, or elevation described in this Chapter
and shown on the Drawings for the Engineers approval prior to the commencement of replacement
works. The replacement sand works shall commence immediately after survey works have been
finished. The sectional areas shall be specified on the Drawings and accepted by the Engineer.

2.3.4 Survey Works


Prior to sand replacement, the Contractor shall perform pre-sand filling over the area to be filled by sand
and its adjoining areas to confirm the designed profile and to provide a basis for measurement of fills.
The Contractor shall perform sounding works under the supervision of the Engineer and shall ask for his
approval on the result of the surveys. On completion of underwater fill in any one section, the Contractor
shall perform a sounding survey over the filled area to verify whether the fills have been placed to the
section shown on the Drawings.
Sand replacement shall be inspected and measured by the Engineer as the work progresses. The
Contractor shall attend such inspection, measurement and judgment operation and shall make records
as required by the Engineer.
Post-sand filling boring and laboratory tests shall be also performed by the Contractor for verification of
strength and uniformity of sand filled.

2.3.5 Tolerance of Top Surface Level


The top surface level of the replacement sand shall be placed to an accuracy of 50cm.
However, any shortage below zero shall be filled with sand so as to reach the specified level as directed
by the Engineer and at the cost of the Contractor, to avoid surplus materials for rock mound.
No additional cost shall be paid for over placement of replacement sand.
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2.4 Superstructure of Breakwater


2.4.1 General
This Section is related to the superstructure of the Breakwater.

2.4.2 Material
2.4.2-1 Concrete
The concrete grade to be used are specified as shown in the Table 1.3.1-2-1.

2.4.2-2 Rocks
(1) Quality
Rocks to be used for the construction of the Works shall be granite, sound and durable, free from flaws
and soft, weathered or decomposed parts. Rocks that are laminated, fractured, porous or otherwise
physically weak will be rejected.
(2) Properties
The properties shall conform to the requirements in the Table 2.4.2-2-1.
Table 2.4.2-2-1 Quality of Rocks (JIS A 5006)
Item
Dimension

Compressive strength kgf / cm2{N/cm2}


Water absorption (%)
Specific gravity

Quality
The ratio of the least lateral dimension
to the maximum length of each rock
measured at right angles shall not be greater
than 1:2
500 {4903.3 } min
5 max
2.7 to 2.5

(3) Grade of Rocks


Rocks to be used for the construction of the Slope Mound Type Breakwater are classified into the
following grades:

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1)

Grade A
Grade A rocks shall be used for the construction of the mound body of the Breakwater.
The rocks shall be evenly graded 10 kg to 200 kg.

2)

Grade B
Grade B rocks shall be used for filling-up the gap of surface of mound so as to avoid leak of the
crown concrete which will be placed in situ.
The rocks shall be evenly graded 50 mm to 100mm.

3)

Grade C
Grade C rocks shall be used as 1.0 ton armour stones.

4)

Grade D
Grade D rock shall be used as 1.5 ton armour stones.

(4) Tests
The Contractor shall carry out all tests on rock samples required by the Engineer to assess its quality
and suitability for use in the works, the cost of which shall be borne by the Contractor.
(5) Supply
The Contractor shall make his own arrangements to secure sufficient supply of specified rocks for the
works. The quality of the rocks at a quarry shall be uniform to such an extent that the necessary rate of
delivery will not be adversely affected by testing and /or production delay.
Approval of the source of rock supply shall not be construed as relieving the Contractor of his obligations
to supply materials in the finished works which shall be in conformity with the requirements of this
Specification and the compliance therewith.
(6) Rock Sample Display
A bulk sample of 8 to 10 tons total weight, or such other size as the Engineer may determine, for each
type of graded rock shall be displayed in a prominent place for reference in assessing quality of rock
delivered to the Site.
The sample shall be first separated into various sizes and average length, breadth and height
determined for each size. The rock for each average size shall be weighed and its proportion of the
weight of the whole sample determined.
The various sizes shall then be re-mixed, placed on a level concrete pad and round with a label
indicating the rock grade prominently displayed. The grading by weight and by average size shall be
notified to the Engineer.
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2.4.2-3 Asphalt Mat


Friction increasing asphalt mat shall be laid under concrete caisson. Materials shall meet the following
requirements in Table 2.4.2-3-1below.
Table 2.4.2-3-1 Minimum Property of Asphalt Mat
Thickness of mat
8 cm
Specific gravity
2.2 and above
Bending strength
2.0N/mm2 and above
Compressive strength
2.0N/mm2 and above
Note: When air temperature is 200C.
The Contractor shall submit the detailed drawing of this mat and its laying method for an approval of the
Engineer.
2.4.2-4 Expansion Joint of Crown Concrete
Joint fillers for concrete shall be used in accordance with the manufactures recommendation as
appropriate to the joint locations shown on the Drawings.

2.4.3 Laying of Asphalt Mat


The mat shall be laid on floating dock or the likes under concrete caisson shown on the Drawings.
2.4.4 Rock Mound Work
2.4.4-1 Transportation and Placement of Rocks at the Site
The method of transportation and placement of rocks shall be proposed by the Contractor for the
Engineers approval. It shall not interfere with transportation works of any other construction materials
from either land or offshore. The Contractor shall obtain the prior approval of the Engineer on his
methods.

2.4.4-2 Discharging Mound Rocks (Graded Rock) into the Sea


The Contractor shall not place the rocks until the inspection of replacement sand and placing mats have
been completed and approval given by the Engineer.

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2.4.4-3 Leveling Work of Mound (Graded Rock) and Armour Stone


Leveling work of the surface of rocks are classified into the following grades:
(1)

Grade A
Grade A leveling shall be applied, 50cm wider to the surface of Grade A rocks where the
concrete blocks and /or in-situ crown concrete will be placed.
The tolerance of work shall be 5.0cm.

(2)

Grade B
Grade B leveling shall be applied to the surface of Grade A rocks where the irregular
concrete blocks will be placed.
The tolerance of work shall be 30.0cm.

(3)

Grade C
Grade C leveling shall be applied to the surface of Grade C rocks.
The tolerance of work shall be 30.0cm.

(4)

Grade D
Grade D leveling shall be applied to the surface of Grade D rocks.
The tolerance of work shall be 30.0cm.

2.4.4-4 Measurement of Rock Mound


Measurement on the finished levels of each rock grade shall be based on the finished works of
replacement sand and rock mound. Slope surveys shall be carried out to confirm the accuracy within the
limits of tolerances. The surveys shall be carried out by the Contractor after each grade of rock has been
placed, taking into account specified tolerances.
The quantities of each grade of rock so determined shall be paid for at the rate given in the Bill of
Quantities. Cost of rocks used in rectifying the surface of rock mound or any excess over the tolerances
specified shall be borne by the Contractor.

2.4.5 Concrete Blocks


2.4.5-1 Metal Moulds
Irregular concrete blocks could be fabricated and pre-cast by the Contractor in accordance with the
design Drawings and Specifications. The Contractor may order provision of forms or moulds form any
reputable manufacturing company experienced in fabrication of the approved irregular concrete block in
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2 tons ( Beehive type), 3 tons, and 4 tons (Stabick type) type of forms, subject to a written approval of
the Engineer. Concrete block yard shall be referred to 1.3.5.

2.4.5-2 Transportation of Concrete Blocks


All units shall be securely located when being transported to avoid rocking and to prevent unit to unit
impact.

2.4.5-3 Placing of Concrete Blocks


(1) Units shall not be placed until 21 days have paused after casting and test result has demonstrated
that the required strength has been achieved. Units shall be placed in position and not be dropped.
(2) Placing work of concrete blocks shall be carried out with much care so as to prevent any damage on
the structure. The Contractor shall utilize a crane of appropriate capacity for this purpose.
(3) Units shall be handled with care. All units shall be inspected for cracking. All cracked and damaged
units shall be rejected and units shall be removed and replaced by the Contractor at his own expense.
(4) The wave dissipating concrete blocks shall be placed in two layers by orderly manner in accordance
with the recommendations of the manufacturer. The crown width is sized to accommodate a minimum of
two (2) units.

2.4.6 Crown Concrete Work at Area C


2.4.6-1 Front Line of Crown Concrete
The crown concrete shall be placed in-situ. The concrete for each block shall be slightly departed to
compensate for settlement and forward tilt. In particular the correction to the joint of the crown shall be
made so that the front concrete face line of the crown concrete is finished straight. The details of
finishing shall be confirmed and directed by the Engineer. Crown concrete shall not be placed until rock
mound settlement has ceased or has decreased to a degree acceptable to the Engineer.

3.4.6-2 Formwork for Crown Concrete


The formwork of the crown concrete shall conform to the Specification 1.3.2-2 Class F2.
The Contractor shall submit drawings of forms to the Engineer for his approval not later than four (4)
weeks before the commencement of formwork of crown concrete on the drawings.

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2.4.6-3 Grade of Crown Concrete


The crown concrete shall comply with 2.4.2-3 (2) above for Grade B-1 mixing requirement.

2.4.6-4 Surface Finish of Crown Concrete


The surface finish of the crown concrete shall comply with above 1.3.2-8 for Type U3 Steel Trowel
Finish.
2.4.6-5 Expansion Joints in Crown Concrete
The joint filler to be used as for the expansion joint shall be of bituminous fiber of 10 mm thickness and
shall comply with 2.4.2-4.

2.4.6-6 Concreting at Seawater Level


When concrete is to be cast to the structure at the seawater level, the Contractor shall make every effort
to complete concrete casting before seawater rises and contact with fresh concrete prior to hardening.
No concrete shall be mixed or disturbed after seawater makes contact with fresh concrete. The
Contractor shall obtain approval of the Engineer on the method of foregoing at seawater level.
2.4.7. Concrete Caisson
The Contractor shall select and dispatch to the site several foreign (Japanese) skilled labours who have
experienced abundant similar projects in construction of caisson. Especially, in the beginning of the
work, these skilled labours shall be mobilized to the Site and to transfer technical matters to the local
labours.
2.4.7- 1 Sand Fill for Caissons
2.4.7-1.1 Sand Fill
Sand fill placed inside caisson shall be the same grade of materials to be used for sand replacement as
specified in Clause 2.3.2-1.
2.4.7-1.2 Contamination
The sand fill shall be free from vegetation, roots, organic matter, logs or other materials which are
combustible or which can decay.
2.4.7-2 Caisson Yard
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2.4.7-2.1 General
The Contractor may select, subject to the approval of the Engineer, a method of construction and
launching of concrete caissons to be used for the Breakwater.
The methods chosen shall be acceptable only if it can be shown that caissons of the specified quality
can be produced and placed in adequate numbers to meet the specified construction programme.
Approval of any method by the Engineer shall not relieve the Contractor any of his obligations under the
terms of the Contract.
2.4.7-2.2 Submission of Execution Plan
The Contractor shall present a statement, supplemented by drawings and calculations, of the methods of
construction, launching and placing caissons which he proposes to use.
The following items shall be included in the proposals:
(1)

Description of methods of construction, launching and placing of caissons in writing.

(2)

Drawings and calculations related to caisson manufacturing yards, launching equipment and
means of placing.

(3)

Detailed time schedule related to construction and launching of caissons.

(4)

Drawings to indicate proposed location of the caisson yard and all necessary approvals by
constituent authorities given in writing.

(5)

Outline drawings, specifications, dimensions and capacities of various equipment related to


caisson yard and names or designations, if any, of large constructional plants.

The proposal for construction of caisson building yard shall be set out on paper of A4 size (210 x 297
mm). Drawings to be attached shall be set out on paper of A3 size (297 mm x 420 mm). The proposal
shall be submitted in triplicate.
2.4.7-3 Construction of Caissons
2.4.7-3.1 General
Structure of caisson type is indicated on the Drawing. The Contractor shall submit for the Engineers
approval a programme and a method of construction of such a caisson.
2.4.7-3.2. Concrete Grade for Caisson
The concrete for caissons shall be Grade A in the Concrete Mix 1.3.1-2.1.
2.4.7-3.3. Grade of Steel Reinforcement
The steel bars to be used for reinforcement for caisson shall be SD 345 as specified in 1.2.2.
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2.4.7-3.4. Limit in Height of One Lift of Side Wall Concrete


Placing of concrete for each caisson is in four lifts, and the maximum height of placing of concrete shall
be limited to 3.0 m per lift as follows.
1st lift

: 1.5m

2nd to 4th lift


Total

: 3.0 m each

: 10.5 m

2.4.7-3.5. Insulation between Caisson and Casting Base


Insulation materials such as waterproof paper shall be placed between the bottom plane of each caisson
and the casting base to prevent adhesion between the surfaces and to facilitate separation of the
caisson from the base for launching and floatation.
2.4.7-3.6. Prevention of Segregation of Concrete
The Contractor shall pay particular attention to prevention of segregation of concrete when conveying
and placing concrete for caissons. The Contractor shall adopt the methods approved by the Engineer.
2.4.7-3.7. Placing of Concrete
Placing of concrete shall be made as specified in Clause 1.3.1-12 over the entire perimeter so that the
height of the concrete surface may rise equally over the entire side walls and partition walls, so that the
surface of the fresh concrete can be leveled off in case of a stoppage in the concreting process.
2.4.7-3.8. Temporary Platform for Concreting Each Lift of Side Walls
The Contractor shall provide temporary platforms for concreting each lift of concrete for side walls and
partition walls of caissons.
2.4.7-3.9. Limit in the Use of Diagonal Chutes
Concrete shall not be placed through a diagonal chute directly into the form. The concrete shall flows out
of a chute shall be received on steel plate, and then shall be carefully placed in the form to avoid
segregation of the concrete materials.
2.4.7-3.10. Limit in the Use of Concrete Pump
If the Contractor desires to carry out concreting of caisson using concrete pumps, the Contractor shall
apply to the Engineer in advance for his approval.
2.4.7-3.11. Compaction of Concrete

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Internal vibrators shall be used generally for compacting concrete. Form vibrators shall be used for thin
walls and the like when the use of internal vibrators may be restricted.
Concrete shall be thoroughly compacted immediately after being placed so that concrete can be fully
filled around reinforcement steel bars and in every corner of the form.
It is desirable that manual compaction by long bars is jointly applied with other method for production of
watertight concrete walls of caissons.
2.4.7-3.12. Joint in Concrete
At every construction joint laitance shall be removed and the concrete surface roughened, cleaned and
sufficiently moistened before the next lift or panel of concrete is cast against it. When necessary a bed of
mortar of the same proportions as the cement mortar for the concrete being cast and of a thickness to be
agreed with the Engineer shall be placed on the moistened surface of the set concrete to allow complete
bonding of new and old concrete.
2.4.7-3.13. Concrete in Hot Weather
At the concrete mixing plant, the aggregate shall be shaded from direct sunlight with appropriate covers.
The water tank shall be of such construction that the water temperature is maintained as low as
possible. Transport plant for the concrete shall be suitably protected not to allow evaporation of moisture
from concrete during transportation. In addition, form surfaces shall be thoroughly sprayed with water
prior to placing of concrete. The Contractor shall obtain approval of the Engineer for his measures for
controlling temperature and evaporation of water from concrete.
2.4.7-3.14. Removal of Forms
The Contractor shall obtain the approval of the Engineer regarding the timing and procedures for
removal of concreting forms.
2.4.7-3.15. Inspection of Arrangement of Reinforcement Bars
In each stage of the caisson construction process the Contractor shall not place concrete prior to the
Engineers inspection of the fixed reinforcement bar.
2.4.7-3.16. Tests on Caisson Concrete
Test on concrete used for caisson construction shall be conducted in accordance with the provisions of
Clause 1.3.
The specified slumps shall be 12 cm 2.5 cm. The number of test samples shall be as directed by the
Engineer .
2.4.7-3.17. Tolerances in Construction of Caissons
Caissons shall be constructed within the following tolerances using a steel tape for measurement.
(1) Tolerance in wall thickness

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: 01cm

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(2) Tolerance in length, width and height

: + 03 cm, - 01cm

(3) Tolerance in width and height of slit wall

: 01 cm

(4)

Deviation from verticality of walls measured at right angles to underside of caisson base shall be
not greater than 05 cm over the full height of wall.

(5)

Deviation in plane of cross wall measured at right angles to front face of caisson shall be
measured over the full width of caisson as follows.
External (end) walls not greater than 05 cm

2.4.7-3.18. Mooring of Caisson


If the Contractor intends to moor or float caisson in Tien Sa Port, he shall obtain an approval thereof
from the Employer or government agency concerned and he shall exercise meticulous care to secure
safety of the port operations in so doing.
2.4.7-3.19. Temporary Deposit of Caisson
(1)

Deposit Caisson
If the Contractor intends to temporarily deposit caissons and tow them to the designated
place for final setting, he shall submit for the Engineers approval such a method of works
expressing the proposed place and period of deposit, and means of floating, towing and
sinking.

(2)

Installation of Lifting Bar


The Contractor is required to submit in advance for the Engineer approval setting layout of
lifting bar to the surface of caissons in compliance with the requirements of the Drawings.

2.4.7-3.20. Towing of Caisson


The Contractor shall obtain an approval of the Engineer on the method and schedule of towing of
caisson.
The Contractor shall mobilize two units of tug boats when necessary to secure safety manoeuvre of
vessel and caisson during towing operation taking account of congestion of the port.
2.4.7-3.21. Ballast Sand for Caisson
When directed by the Engineer, the Contractor shall fill the caisson with ballast sand in order to secure
buoyant stability. Water shall be added prior to launching the caisson to saturate the sand until its
apparent unit weight has reached to 1.8 t/m3.
2.4.7-3.22. Installation of Caissons
Floating crane with sufficient lifting capacity shall be utilized for installation of caissons and lifting frame
shall be used during lifting operation.
Hoisting of caisson shall take place when it has become stabilized after ballast sand is filled and water
poured and then to be transported to the specified location for final setting.

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The lifting bar at the surface of the lower caisson shall be taken away be the gas cutting to receive upper
caisson.
2.4.7-3.23. Formwork for Concrete Caisson
The formwork for concreting of caisson shall conform to the specification Clause 3.2.2, Class F.3
Finish.
2.4.7-3.24. Surface Finish of the Caisson
The surface of the concrete caisson shall be finished conforming to the Specification 1.3.2-8, Type U-2
Wood Trowel Finish.

2.4.7.4

Caissons Breakwater Works

2.4.7-4.1. General
This section is related to the Breakwater caisson.
2.4.7-4.2. Steel Survey Platforms
The Contractor may provide and maintain three steel turret type survey platforms prior to
commencement of the marine survey works. He shall operation them as required by the Engineer and
remove them from the Site after completion of the Works.
The platform height shall be sufficient to allow for the depth of water as high tide plus an appropriate
allowance for waves.
Platforms shall be transported by a floating crane and fixed rigidly on the seabed and rigidity of the
platform.
The platform shall have a secure timber floor of minimum size 2 m x 2 m.
A ladder shall be furnished extending from low tide level to the platform. Navigation lighting shall be
provided, as required.
Survey platforms with piled foundations may be used instead of turret type platforms transferable by
floating crane if the Contractor is so desires. All survey platforms shall be relocated or removed by the
Contractor at any time upon direction by the Engineer.
2.4.7-4.3. Survey for Face Line of the Breakwater
After leveling of the graded rock base by divers, the Contractor shall survey the face line and shall
present the results to the Engineer for his approval, indicating the compacted zone relative to the face
line.

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Appropriate Reference Points for the line of the Breakwater shall be established on land. The Contractor
shall notify the Employer of the positions of survey platforms.
2.4.7-4.4. Leveling for Marine Construction
Prior to commencement of any marine construction work, the Contractor shall establish a benchmark
near the site of construction, referred to the Site Datum, and shall agree on the level of the B.M. with the
Engineer.
The Contractor shall install at least two tide gauges so that one gauge is visible from each survey
platform or survey point on land, and shall keep them in good condition during the construction period.
Their accuracy and any variation between gauges shall be checked at frequent intervals.
2.4.7-4.5. Installation of Caissons
Before installation of caissons, the Contractor shall prepare a plan on the method of installation, plant
and vessels to be used, number of workers and so forth, and shall apply to the Engineer for his
approval.
For the sinking, each caisson shall be filled with water evenly in each cell of the caisson, and the
difference in water level shall not exceed 1.0m.
At least two divers shall be provided for the installation of each of the caisson. Any obstruction at the
grounding area of the caisson shall be removed prior to the installation.
Following the installation of caisson, the Contractor shall conduct an observation to confirm whether
vibration is noticeable or not under the supervision of the Engineer. Should any vibration is encountered,
the Contractor shall rectify such defect at his own expense.
2.4.7-4.6. Tolerances of Installation
The required tolerances of installation of caisson shall be as follows.
(1) Space between caissons
(2)

(3)

: Maximum deviation

= 100 mm

Difference from seaward faceline


or landward directions

: Maximum deviation = 100 mm

Difference from specified height


of installation

: Maximum deviation = 100 mm

2.4.7-4.7. Filling Works to Cell of Caissons


The Contractor shall comply with the following requirements on the filling works to the cell of the
caissons.

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1)

Clean coarse sand shall be filled as specified in Clause 2.4.7-1. The sample of sand shall be
submitted to the Engineer for his approval.

2)

The sand shall be immediately filled upon installation of the caissons. The Contractor shall obtain
an approval of the Engineer on the method of the sand filling.

3)

Sand shall be filled evenly in each of the cell of the caissons, the difference of which level shall not
exceed 2.0 m.

Casting of mass or plain shall be made continuously up to the specified level in still water and free drop
of concrete shall in no way be approved. Should such concreting be obliged to suspend in the midst of
the operation, such concreting works cannot be resumed unless laitance has been removed completely.
Concrete casting shall be executed in such manner as will reduce the creation of laitance at its minimum
by attempting not to disturb the concrete while being cast. Further attention has to be paid so as not to
produce flow of water until finally hardened.
It is recommended to use tremie or concrete pump for casting operation. Concrete finish shall comply
with the requirements of the Finish Type U-1.
The Contractor shall submit to the Engineer for his approval a method of mass or plain casting prior to
start concreting.
2.4.7-4.8. Surveying of Caissons after Completion of Installation
It is anticipated that settlement will occur in each caisson to a limited extent causing slight forward
movement and tilting as construction work progress. The Contractor shall survey the following items
once a day from the date of installation of each caisson, plot the figures on graphs to a time base of
days, and submit them to the Engineer on the following day of survey.
Level survey of four corners of each caisson.
Survey of movement of the face line of each caisson (Observation of daily movement of both ends of
each caisson from the reference line).
2.4.7-4.9. Face Line of Crown Concrete
The shape of the crown concrete placed in-situ for each caisson shall be slightly changed to compensate
for the settlement and forward tilt. In particular the correction to the joint of the crown concrete with the
front face of caissons shall ensure that the face line of the Breakwater is finished straight. The details will
be directed by the Engineer. Crown concrete shall not be placed until caisson movement has ceased or
has decreased to a rate acceptable to the Engineer.
2.4.7-4.10. Formwork for Crown Concrete
The formworks of the crown concrete shall conform to the specification Clause 1.3.2-2 Class F.3 Finish.
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The Contractor shall submit to the Engineer for his approval not later than four (4) weeks before the
commencement of formworks of crown concrete, detailed design on formworks, detailed design on
formworks covering the structures on the followings.
2.4.7-4.11. Grade of Crown Concrete
The crown concrete shall comply with Specification Grade B-1 in Table 1.3.1-2.1 Concrete Mix.
2.4.7-4.12. Surface Finish of Crown Concrete
The surface finish of the crown concrete shall comply with Clause 1.3.2-2 Type U.3 Steel Trowel Finish.
2.4.7-4.13. Expansion Joints in Crown Concrete
The joint filler to be used as for the expansion joint shall be of bituminous fibre of 20 mm thickness and
shall comply with Clause 1.3.1-14.

2.4.8

Removal of Existing Structure

As indicated in Drawings, a part of wave dissipating concrete block 25T at tip Breakwater, all of irregular
concrete block 2T at port-ward side mound in Area A & B, and a light beacon on crown concrete at tip
Breakwater shall be removed carefully so as not to damage them for re-use as specified below.
1)

The removed wave dissipating concrete block 25T shall be removed and stocked tentatively in
work yard and transported and placed for superstructure in Area C Breakwater.

2)

The removed irregular concrete block 2T shall be removed and stocked tentatively in work yard
and transported and placed for amour concrete block for port-ward side mound in Area A to D
Breakwater.

3)

The removed light beacon shall be reinstalled at crown concrete on head caisson. Holes will be
drilled into crown concrete for inserting of anchor bolt, void space in holes shall be filled with mortar
or the specified materials in the same method in Phase 1 original, or as instructed by the
Engineer.

2.4.9

Pavement Work

This section deals with construction of pavement for Pavement of Area A, B and C and Approach
Road to the Breakwater.
2.4.9-1 Topographic Survey
The Contractor shall carry out the topographic survey to prepare topographic map to understand the
present land situation and elevation for area of Approach Road to the Breakwater. The Contractor shall
submit the detailed drawing of based on the above topographic map for an approval of the Engineer.
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2.4.9.2

Earth Works

2.4.9.2.1
General
This Clause covers all earthworks including filling, banking, ground preparation, and backfilling, etc.
required for the permanent works of the Breakwater and Access Road to Breakwater.
The Contractor shall establish for himself accurate ground level by route survey carried out by him and
shall indicate such levels on the Drawings for the approval of the Engineer.
2.4.9.2.2
Earthwork Requirement
The Contractor shall select the most suitable equipment for excavation, filling, hauling, levelling,
compaction, etc. A list of these equipment showing types, capacities numbers and other information
shall be submitted to the Engineer for approval.
2.4.9.2.3
Borrow Pits
The Contractor shall make his arrangements for borrow pits, sand pit for sand replacement, when
necessary, and shall ascertain by conducting surveys , boring and tests that adequate supplies of
specified materials can be obtained for the works. The Contractor shall proposed for the Engineers
approval the locations for such borrow pits.
2.4.9-2.4

Quality of Fill

The materials to be used for filling works shall be a mixture of properly graded sand and gravel,
containing an appropriate amount of quality clay for bonding. The fill shall conform to at least A-2-7 or
higher in accordance with the US Public Road Classification.
Any material containing a deleterious amount of organic substances, pumice or mica shall not be used.
Fined sand of uniform grain, silt, bentonite, serpentine rock or humus soil shall not be used. The fill
materials must in all circumstances not contain any stones, gravel or other solid substances larger than
100mm in diameter.
2.4.9-2.5 Filling Work
The material form the borrow pits approved by the Engineer shall be spread and leveled in loose layers
not exceeding 300mm before compaction and consolidated with compacting machines approved by the
Engineer.

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The fill shall be compacted to 90% of the maximum dry density as determined by JIS A 1210 except for
fills to be used in hillsoil defined in 2.4.10-4.1 of the Specification.
In addition, the Contractor shall carry out proof rolling in the presence of the Engineer to check the
compaction of the fill. The fill shall be placed and compacted only when the weather allows it. Operations
shall be suspended if rain causes the fill to become too wet for proper compaction.

2.4.9-2.6 Protection of Fill from Rain


The Contractor shall take adequate measure to prevent the filled surfaces from turning soft due to rain
during earthwork. Care shall be taken not to leave fill materials in heaps, or to leave material brought into
the site without compaction.
The compaction surface shall have an appropriate slope to the horizontal and the whole of the top
surface of the filled area shall be provided with temporary surface drainage and covered with tarpaulins,
where necessary.
The Contractor shall protect the side slope around the edge of the filled areas to minimize the possible
damage of the slopes by rain and provide temporary perimeter drains where directed by the Engineer.

2.4.9-2.7 Excavation
(1) Excavation in General
All excavations for drains, services trenches, retaining walls, urban storm water drainage, etc. and
cutting in the planned Container Yard shall be carried out accurately to the levels, cross sections and
slopes shown on the Drawings.
Where the limits or excavation of cutting area is not indicated on the Drawings, the Contractor shall use
his own judgment and establish the limits of excavation or cutting for himself and shall indicate such
limits on his drawings for the approval of the Engineer.
All excavations shall be carried out in such a manner as will not disturb adjacent unexcavated ground.
The Contractor shall be held responsible for the safe operation of all excavations and damage to the
buried facilities, adjoining works and properties.
Unless otherwise specified in the Contract, all excavation works shall be carried out under dry condition.
If the Contractor excavates more material than called for on the Drawings or instructed by the Engineer,
he shall refill the area to the correct level or to the required level to be approved by the Engineer with
excavated material or similar equivalent materials at his own cost.
The state of the completed excavation shall be inspected and approved by the Engineer prior to the
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commencement of any subsequent works.


(2) Excavation for Pavement
When excavating the existing pavement to provide a new pavement, the portion of the pavement below
the planned level of granular subbase (or the bottom of base layer) shown on the Drawings may not be
excavated subject to the consent of the Engineer.
When the existing pavement lies within the planned granular base course and the top of existing
pavement is deeper than 2/3 of the height of planned granular base course, the Contractor needs not
excavate the existing pavement subject to the consent of the Engineer. However, the top asphalt must
be stripped even when excavation of the existing pavement is not required.
When rock is encountered, during excavation, below the planned the top of subbase shown on the
Drawings, the Contractor may not excavate any further subject to the consent of the Engineer.
When rock is encountered above the planned top subbase, the Contractor shall remove it and excavate
to the planned top of subbase using the method and equipment approved by the Engineer.

2.4.9-2.8 Temporary Support


The Contractor shall provide, fix and remove all necessary open or close timbering, strutting and shoring
whenever excavations require temporary support. The Engineer may order such temporary support to be
strengthened or altered if he considers it necessary in the interests of the Works or as a safeguard
against accidents to the workmen, but this shall not relive the Contractor of any of his responsibilities or
liabilities under the Contract.
Where the provision of temporary supports is deemed necessary from an engineering point of view or
directed by the Engineer, the Contractor shall submit drawings of temporary supports together with
calculations, if necessary, to the Engineer for his approval not less than one week prior to
commencement of the Work.

2.4.9-2.9 Test for Filling Work and Excavation


When in-situ density tests or CBR tests of filled or excavated ground are required by the Engineer in the
course of the works, these shall be carried out in accordance with JIS A 1214, JIS A 1211 or equivalent
standards in the presence of the Engineer.

2.4.9-2.10 Treatment of Foundations


When structures are to be placed on excavated plane of foundation, final trimming shall be done by hand
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to ensure that undisturbed material is uncovered.


When the foundation below the excavated layer is determined by the Engineer to be insufficient in
bearing capacity for the planned structure, the foundation shall be given necessary treatment such as
compaction as directed by the Engineer.
2.4.9-2.11 Backfilling
Where indicated on the Drawings or instructed by the Engineer, the Contractor shall backfill and compact
the fill on and around the completed structures and behind walls with material indicated on the Drawings
or, in the absence of instructions on the Drawings, with suitable material from excavation.
Such material shall be free from large boulders or lumps of soil, rubbish, organic matter or other
substances and shall be subject to the approval of the Engineer. The material shall be placed
simultaneously as practically as possible over and around the completed structure.
All backfill material shall be spread in layers not exceeding 250 mm thickness in the loose state and shall
be compacted by equipment to obtain a density of at least 95% of the maximum dry density as defined
by JIS A 1210 at a moisture content 2% of the optimum moisture content.

2.4.9-2.12 Drainage of Ground Water


Suitable drainage shall be prepared to ensure that ground water, if any, welling out of the excavation
shall be channeled into collection pits and removed by pumping or bailing.

2.4.9-2.13 Disposal of Excavated Materials and Others


Excavated soils or asphalt excavated from existing pavement may be used as fills or backfill material or
for any other purposes only when such materials have been determined by the Engineer as suitable for
purpose. Spoils determined by the Engineer as suitable fill materials shall be stockpiled at the place
designated by the Engineer. Spoils form excavation determined unsuitable for any purpose shall be
disposed of at the ground approved by the Engineer.

2.4.9-3 Pavement and Hillsoil


2.4.9-3.1 General
(1)

General

This Clause shall apply to all the paving works as pavement for Pavement Area A, B, and C on the
Breakwater and Approach Road to the Breakwawter.
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(2)

Setting Out

The Contractor shall properly set out positions of various surfaces and structures and establish benchmarks to indicate the levels of surface, all as necessary and approved by the Engineer. Such setting out
and Bench Marks shall be effectively protected until the pertinent works have been completed in a
manner to be approved by the Engineer.

2.4.9-3.2 Composition of Asphalt Concrete Pavement


There shall be two types of asphalt concrete pavement structure as shown on the Drawings and Table
2.4.9-3.2.1 in the next page.
The pavements shall consist of a crusher-run aggregate subbase with CBR30, a mechanically stabilized
granular base course with CBR80.
Table 2.4.9-3.2.1 Composition of Asphalt Concrete Pavement Structure
Type

Total
Thickness
(cm)

Asphalt
Concret
e
(AC)
(cm)

Asphalt
Treated Base
(ATB)
(cm)

Granular
Subbase
(CBR 30)
(cm)

30-thick
Compacted
Hillsoil
Strength

Granula
r Base
Course
(CBR
80)
(cm)
20

Pavement on
Breakwater
Approach Road

32

K98

62

30

30

2.4.9-4 Hillsoil Work


2.4.9-4.1 Definition
The term hillsoil referred to herein means the soil layer of one (1) meter in thickness immediately below
the subbase, whether or not the pavement is provided on soil fill materials or on existing ground after
removal of top soil and unsuitable soils.

2.4.9-4.2 Material
Where the pavement is provided on fill, the hillsoil fill material shall be as specified in 2.4.10-2.4 .
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2.4.9-4.3 Compaction
The hillsoil fill material or the existing hillsoil soil shall be compacted to a dry density of not less than
95% of the maximum dry density as determined by JIS1210 at a moisture content1% of the optimum
moisture content. Compaction shall achieve CBR values not less than those shown in the Table 2.4.93.2.1 above.
Compaction shall be carried out by means of compaction equipment as approved by the Engineer to
ensure uniform compaction over the whole area. Where the required CBR value cannot be obtained, the
Contractor shall excavate to a depth as directed by the Engineer, refill with suitable materials and
compact to require density in layer of thickness approved by the Engineer.
Where suitable material cannot be obtained, the Contractor shall increase the total thickness of the
pavement to achieve the required stability at his own cost.
CBR tests shall be conducted once in every 1,000 m 2 for each compacted layer of soil and if the results
are unsatisfactory, two additional tests shall be conducted in the vicinity of the original site. If both tests
satisfy the Specification, the area represented by the tests shall be accepted. If either one or both of the
additional tests fail, then the Contractor shall carry out such remedial works as the Engineer may direct.

2.4.9-4.4 Finish
The hillsoil shall be finished to within 5 cm of the levels determined by subtracting the thickness of
pavement from the level of pavement surface indicated on the Drawings, after removing debris from the
surface of the hillsoil.

2.4.9-4.5 Conditions before Proceeding to Subbase Work


The hillsoil shall be prepared and completed for at least 50m ahead of the placing of granular subbase
material. Notwithstanding any earlier approval by the Engineer of hillsoil, any damage to or deteriorating
of hillsoil shall be made good before any subbase is laid.
If any settlement of the hillsoil occurs prior to the commencement of subbase preparation, the Contractor
shall at his expense rework the hillsoil to conform to the specified level and compaction and shall obtain
the Engineers approval. Before the construction of subbase, the earthwork, drains, etc. for the related
area shall be completed.

2.4.9-5 Subbase Work

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2.4.9-5.1 Preparations
All drains, manholes, kerbs, foundations of structures etc. adjacent to the pavement shall be completed
to the satisfaction of the Engineer before the subbase is laid. Small areas around the completed
structures shall be compacted by hand or power-operated hand rammer so that a density of not less
than 95% of the maximum dry density as stipulated in JIS A 1210 is achieved throughout.
Attention shall be paid to the compaction of filling material placed on each side of open drainage or
service trenches, etc. within a distance three times greater than their width, so that 100% of the
maximum density may be achieved throughout.

2.4.9-5.2 Material
The material for subbase with CBR>30 shall be of crushed-run material free from unsuitable materials
such as vegetable and deleterious substances and conforming to the requirements stated herein below
and JIS A 5001 standard. The subbase material shall be approved by the Engineer prior to its use in the
work.
Grading requirements for crusher-run material by nominal size are shown in Table 2.4.9-5.2.1. Crushed
stones not meeting the requirements may be used in combination with other aggregates, such as
crushed stones, sand or mineral fillers, provided that the combined grading complies with the
requirements.
2.4.9-5.3 Construction
The material for subbase shall be spread uniformly with such equipment as bulldozers, graders,
aggregate spreaders, etc. approved by the Engineer so as to obtain a maximum thickness of 200 mm for
one layer after compaction. Care shall be taken to prevent contamination by deleterious substances and
segregation of the material.
Immediately after each layer is spread and shaped satisfactorily, the layer shall be thoroughly compacted
with compaction equipment approved by the Engineer. Rolling operations shall begin at the lowest level
of cross section and progress towards the highest level.
Each layer shall be compacted to achieve a CBR 30 or higher and the dry density shall not be less than
95% of the Maximum Dry Density as determined by JIS A 1210 at a moisture content of 1% of the
optimum moisture content.
Subbase materials, which do not contain sufficient moisture in accordance with the requirements of this
Section, shall be sprinkled with water as directed by the Engineer. Subbase materials containing excess
moisture shall be performed by the methods approved by the Engineer.
During the construction of subbase, the Contractor shall ensure that the subbase already spread and
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rolled is properly drained.


Table 2.4.9-5.2.1 Grading Requirements for Crusher-Run Material by JIS A 5001
Designation

Nominal
Size
(mm)

C-40

40 to 0

C-30

30 to 0

C-20

20 to 0

50m
m
100

Amount Finer than Each Laboratory Sieve


(Weight Percentage)
40mm
30m 25mm
20m 13mm
5mm
m
m
95
50
15
to 100
to 80
to 40
100
95
55
15
to
to 85
to 45
100
100
95
60
20
to
to 90
to 50
100

2.5mm
5
to 25
5
to 30
10
to 35

Notes:
(1) The sieves in this Table correspond to the Standard Sieves designated in JIS Z 8801: 50.8mm,
38.1mm, 31.7 mm and 25.4 mm in that order.
(2) The plasticity index, PI, of the fraction of the subbase material passing the 0.4 mm sieve should not
be greater than 6 when tested in accordance with JIS A 1206 or equivalent standard.
(3) The maximum particle size should preferably be smaller than 50mm.

2.4.9-5.4 Finish
The finished subbase shall not vary more than 4 cm above or below the planned level of pavement
indicated on the Drawing, minus the total thickness of the surface (asphalt treated base and asphalt
concrete) and the granular base course. The subbase which doses not conform to the above
requirements shall be reworked, watered and thoroughly recompacted to conform to the Specifications.
At the junction of subbase layer of different thicknesses due to different pavement types, or where the
thickness has been changed by order of the Engineer, the bottom surface of such subbase shall be
formed by an even slope of 1:5.

2.4.9-6 Base Course Work


2.4.9-6.1 Material

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The material for the mechanically stabilized granular base course of CBR>80 shall be a mixture of one,
two or three aggregates, which include crusher-run with or without sand in a proper ratio, free from
unsuitable materials such as vegetables and deleterious matters, and conforming to the following
requirements and JIS A 5001.
The grading shall conform to the requirements of Table 2.4.9-6.1.1. The material shall be obtained as a
product of the stone crushers with the grading requirements or alternatively, two or three kinds of
aggregates shall be blended to produce a mechanically stable grading.

Table 2.4.9-6.1.1Grading Requirements for Mechanically Stabilized Base Course


by JIS A5001

Desig
nation

Nominal
Size
(mm)

50
m
m

40
mm

M- 40

40 to
0

10
0

95
to
100

Amount Finer than Each Laboratory Sieve,


(Weight Percentage)
30
25
20 13
5
2.5
1.
mm
m
m mm
mm
mm
2
m
m
m
m
60
30
20
to
to
to

M - 30

30 to
0

100

95
to
100

M - 25

25 to
0

100

95
to
10
0

90
60
to
90

55
to 85

65
30
to
65
30
to
65

50
20
to
50
20
to
50

0.4
m
m

0.07
4
mm

10
to
30
10
to
30
10
to
30

2
to
10
2
to
10
2
to
10

Notes:
1) The sieves in this Table correspond to the Standard Sieves designated in JIS Z 8801: 50.8 mm,
38.1mm, 31.7 mm, 25.4 mm,19.1mm, 12.7 mm, 4,760, 2,380,1,190, 420and 74in that order.
2) The Plasticity Index, PI, determined by JIS A 1205 and JIS A1206 or equivalent standard of the
fraction of the base materials passing the 0.4mm sieve should not be greater than 4.
3) The maximum particle size of aggregates should be neither greater than 40 mm nor greater than one
half (1/2) of the finished thickness of a single construction layer.

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2.4.9-6.2 Blending of Material


The material for the base shall be graded and shall satisfy the grading requirements specified throughout
in this Clause. The method of mixing and the type of mixer for the grading shall be subject to the
approval of the Engineer. Care shall be taken to prevent segregation of material.

2.4.9-6.3 Construction
After the materials are uniformly mixed, they shall be spread evenly and leveled to the specified level
and profile by means of motor grader, or an aggregate spreader or manually where such cannot be
used. The spreading and leveling shall be done in layers with uncompacted thickness of maximum of
15cm and the layers shall be nearly equal in thickness.
Care shall be taken to prevent segregation of materials. When directed by the Engineer, all segregated
materials shall be corrected, or removed and replaced with well-graded materials.
When the granular base course is spread contiguous to other completed works, extreme care shall be
exercised not to damage other completed works. Any damage of other completed works resulting from
careless or negligent construction methods by the Contractor shall warrant the removal and replacement
of said other completed works at the Contractors expense.
Immediately after each layer has been spread and shaped satisfactorily, the layer shall be thoroughly
compacted with suitable compaction equipment approved by the Engineer. Rolling operations shall begin
at the lowest level of the cross section and progress towards the highest level.
Each layer shall be compacted to achieve a CBR= 80 or higher and the dry density shall be not less than
95% of the Maximum Dry Density as determined by JIS A1210 at a moisture content 1% of the
optimum moisture content. JIS A1214 shall determine density of the compacted granular base course.
The base material which dose not contain sufficient moisture to be compacted in accordance with the
requirements of this Section shall be sprinkled with water as directed by the Engineer.
Base material containing excess moisture shall be dried prior to or during compaction. Drying of wet
material shall be performed by methods approved by the Engineer. Any irregularities which may develop
in the surface during or after construction shall be corrected by removing or loosening the surface and
adding materials as required.

2.4.9-6.4 Finish
The base shall be finished to 6 mm of the levels and profiles indicated on the Drawings. The base which
does not conform to the specified requirements, shall be reworked, watered and thoroughly rePACKAGE 1 CIVIL WORKS FOR TIEN SA PORT

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compacted to conform to the Specification.

2.4.9-7 Tests for Subbase and Base Course


Before or during the paving works, the Engineer may inspect and carry out tests, where necessary, to
ensure that the required compaction is maintained on the subbase and the granular base course. The
Contractor shall not proceed with the subsequent stages of the work without the approval of the
Engineer. The Contractor shall provide all equipment and devices necessary for the tests given below,
and carry out the tests in the presence of the Engineer.
- Test on moisture contents and density
- Measurement of density in-situ
- CBR tests
These tests shall be conducted in accordance with JIS A 1203, JIS A 1214 and JIS A 1211 at least once
in every 1,000m2 of subbase and granular base course in the area to be paved.
When the Engineer has any doubt as to the quality of materials being used for subbase or granular base
course, he may instruct the Contractor to conduct the following tests. In such case, the Contractor shall
carry out the tests in accordance with JIS A 1204, JIS A 1205 and JIS A 1206 at his own expense.
- Mechanical analysis
- Plasticity Index test

2.4.9-8 Prime Coat and Tack Coat Work


2.4.9-8.1 Purpose of Coating
Prime coat and tack coat shall be applied to the granular base course and binder coarse of asphalt
concrete, respectively, to provide better bonding of asphalt treated base and asphalt concrete. The
bituminous material of both the primer and the tack coat shall be asphalt emulsion, cutback asphalt or
other materials approved by the Engineer.
The bituminous material of both primer and tack coat shall be asphalt emulsion, cut back asphalt or
other materials approved by the Engineer. The cut back asphalt used as bituminous material of prime
coat shall be Type MC-70 specified by the Japan Road Association (to be referred to as JRA hereinafter)
or the equivalent and the asphalt emulsion shall be Type PK-3 specified by JIS K 2208 or the equivalent.
The cut back asphalt to be used as bituminous material of tack coat shall be Type RC-70 specified by
JRA or the equivalent.
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The asphalt emulsion of more than 60 days after manufacturing shall not be used. The Contractor shall
submit certificates of quality for both prime coat and tack coat for the approval of the Engineer prior to
their use.

2.4.9-8.2 Amount to be Applied


The amount of prime coat to be applied shall be of the order of 1.0 liter/m 2 to 1.5 liters/m2. However, the
Contractor shall make a thorough study of the condition of the granular base course and the working
condition and determine the optimum amount, which makes prime coat exhibit its inherent
characteristics and which would not cause bleeding or rutting. The amount of tack coat to be applied
shall be of the order of 0.6 liters/m2. The Contractor prior to their use shall obtain the Engineers approval
on the amount of both prime coat and tack coat to be applied.

2.4.9-8.3 Application
(1) Prime Coat
Prior to the application of prime coat, the surface of the granular base course shall be properly dried,
leveled and cleaned of loose stones, rubbish and other foreign materials. Where the surface of granular
base course is excessively dry, a small quantity of water shall be sprinkled over the entire surface prior
to coating. In this case, the bituminous material shall not be applied until the water on the surface of the
granular base course dries up.
A proper viscosity shall be given to the prime coat under normal temperature or by heating it if
necessary. The primer shall be sprayed evenly by means of distributors approved by the Engineer.
Where the amount of primer is not sufficient after penetration, additional amount of primer shall be
applied. Where the primer has been applied in excess, an appropriate amount of sand shall be spread
over to absorb the excess.
When vehicles are allowed on the coated base due to unavoidable reasons after the spraying of the
primer, a layer of coarse sand shall be spread over the surface for protection. Any prime coat damaged
by the traffic shall forthwith be made good by spraying another coat.
Any loose sand on the primer shall be completely removed prior to the paving of the base.
The application of prime coat shall be stopped immediately when it rains. The portion of prime coat
affected by the rain shall be made good with another coat as directed by the Engineer.
(2) Tack Coat
Prior to the application of tack coat, the surface of asphalt treated base shall be dried and swept
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thoroughly and cleaned of all loose dirt and other foreign materials. In applying, attention shall be paid to
the proper temperature of tack coat, and the specified amount of tack coat shall be sprayed uniformly
with distributors or sprayers approved by the Engineer. The amount of tack coat exceeding the special
amount shall, if considered to be deleterious, be removed as directed by the Engineer and the affected
portion of the asphalt treated base shall be given another coat.
The tack coat shall be protected from damage in a manner approved by the Engineer until it is
completely cured and stabilized. Application of tack coat shall be stopped immediately when it rains. Any
tack coat damaged by traffic shall be made good by spraying another coat as directed by the Engineer.

2.4.9-9 Surface Pavement Work


2.4.9-9.1 Materials for Asphalt Concrete
(1) Quality of Asphalt
The quality of asphalt to be used shall meet the requirement of straight asphalt type 80-100 (penetration
grade in AASHTO standard specification is 80-100) specified by JIS 2207 or the equivalent. Prior to use
of asphalt, the Contractor shall submit a certificate of quality and a statement showing a specific gravity
and temperature characteristics of viscosity for the approval of the Engineer.
(2) Quality of Aggregates
Both the coarse aggregates (particles retained on a 2.5 mm test sieve) and the fine aggregates shall be
hard, durable and clean, and free form clay and organic matter or other impurities. In the coarse
aggregates retained on 5 mm test sieve, the content of flat or oblong pieces shall not exceed 10 percent
by weight.
The quality of coarse aggregates shall meet the requirement for specific gravity absorption and abrasion
loss as specified by JIS A 5001. These tests shall be carried out according to JIS A 1110 and JIS A1121
or equivalent standard. If screening is to be used for fine aggregates, it shall be of particle size meeting
the requirement specified by JIS A5001. Fillers used in asphalt concrete shall be limestone powder
meeting the requirement specified by JIA A5008. For all of the above mentioned aggregates, the
Contractor shall submit for the approval of the Engineer a statement or certificate showing the test result
meeting the required quality standard prior to their use.

2.4.9-9.2 Storage of Materials for Asphalt Concrete


For temporary storage of asphalt in a tank lorry, temperature of asphalt shall be maintained at
appropriate levels with the use of heaters if necessary. The asphalt transported in drums shall be stored
separately according to the delivery date and manufacture, and in such manner as to permit easy
inspection and shall be issued in the order of delivery. Aggregates in storage shall be separated by type
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or grade.
In storing aggregates, necessary measures shall be taken to minimize segregation and intermixing of
deleterious materials. The Contractor shall also provide adequate drainage of the entire storage area.
Fine aggregates containing fine particles shall be covered with a tarpaulin, etc., for protection from
rainwater. Fillers shall be stored at the place of low humidity and shall be issued in the order of delivery.
Fillers in bags shall be stored in a warehouse with floors raised at least 30cm above the ground.

2.4.9-9.3 Asphalt Mixture and Mix Design


Hot asphalt mix shall be used for both asphalt treated base and asphalt concrete. Coarse graded asphalt
concrete shall be used for asphalt treated base, and dense graded asphalt concrete shall be used for the
asphalt concrete, on which the open graded asphalt concrete shall be used.
Aggregates used for those asphalt mixtures shall meet the standard of the maximum particle size and
grain size distribution shown in the Table 2.4.9-9.3.1 and shall be approved by the Engineer prior to their
use.

Table 2.4.9-9.3.1 Gradation Range of Coarse and Fine Aggregates

Max. Particle
Size (mm)

Coarse Graded
Asphalt Concrete

Dense Grade
Asphalt Concrete
20
13

20

Weight
Percent
Passing
Sieve

25
20
13
5
2.5
0.6
0.3
0.15
0.0715

100
95-100
70-90
35-55
20-35
11-23
5-16
4-12
2-7

100
95-100
75-90
45-65
35-50
18-30
10-21
6-16
4-8

100
95-100
55-70
35-50
18-30
10-21
6-16
4-8

Open Graded
Asphalt Concrete
13

100
95-100
23-45
15-30
8-20
4-15
4-10
2-7

Prior to the manufacture of hot asphalt mixture, the Contractor shall make a laboratory mix design
according to standard Marshall Methods as specified in ASTM D15596-89 and shown in the Table 2.4.99.3.2. In laboratory mix design, the amount of asphalt shall be determined so as to prevent rutting of the
pavement especially in the Container Yard. The method and mix proportion of the laboratory shall be
approved by the Engineer.

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Table 2.4.9-9.3.2 Kinds and Materials of Asphalt Concrete


Kind
Use
Number of blows for
Marshall Method
Minimum Marshall
stability (KN)
Flow value (1/100 cm)
Voids (%)
Voids filled (%)

AC I
Surface
50

AC II
Surface
75

AC III
Base
50

AC IV
Base
75

4.9

8.8

4.9

8.8

20 - 40

20 - 40

15 - 40

15 40

3-5

2-5

3-6

36

75 - 85

75 - 85

65 - 80

65 - 85

Remarks: Where the number of blows is 75, it shall be applied to the cases that the contact pressure of
design load of tire is equal to or more than 70 N/cm2, or when rutting effect is expected due to heavy
traffic.

2.4.9-9.4 Mixing Plant


The asphalt mixing plant shall be designed and adjusted to produce the required amount of mixture of
uniform grade and shall, in principle, be more than 30 ton/hour in the capacity of the mixer.
The plant shall, in principle, be a batch mix plant and shall be equipped with all functions required. The
type of plant and the capacity of each equipment of the plant shall be approved by the Engineer prior to
the operation.

2.4.9-9.5 Mixing Operation


Prior to the commencement of mixing operation, the Contractor shall obtain the approval of the Engineer
as to the conformity of asphalt mix materials to the specified requirement. The Contractor shall
determine the weighing value for each hot bin to match the grain size of job mix.
The asphalt material shall be heated to the specified temperature in kettles or tanks so designed as to
avoid local overheating and provide a continuous supply of the asphalt material to the mixture at a
uniform temperature at all times. Asphalt cement shall be heated to the specified temperature between
135 and 160 based on the instruction of the Engineer. The temperature variation shall be within
15 of the approved temperature.
The mineral aggregates shall be heated to a temperature between 150 and 170. When a batch

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mixer is used, aggregates and fillers shall be placed and mixed in the mixer for five seconds or more and
then asphalt shall be poured into the mixer and mixing shall continue for more than 30 seconds until the
uniform mixture is obtained.
The mixing time for batch mixer shall be determined after trial mixing in consultation with the Engineer.
The standard temperature of mixture when discharged from the mixer shall be determined in
consultation with the Engineer. The variation shall be limited to within 25 of the approved
temperature.

2.4.9-9.6 Transportation of Mixture


The mixture shall be transported from the mixing plant to the place of use by truck. The trucks hauling
the mixtures shall have tight, clean and smooth metal beds. To prevent mixtures from adhering to the
bed, beds shall be lightly coated with a minimum amount of paraffin oil, lime solution, or other materials
approved by the Engineer. Each truck shall have a suitable cover to protect mixture from adverse
weather and an insulated bed to maintain at specified temperature. The mixture shall be delivered on the
road at a temperature within the absolute limits of 140 and 159 even allowing for tolerances.

2.4.9-9.7 Paving Equipment


The Engineer shall approve principal paving equipment, including asphalt finishers for spreading and
leveling the hot mix and compacting. Prior to paving operations, the number, condition, wear and tear of
parts and availability of spares of the equipment and tools shall be examined so that no delays of work
shall be caused by any unsatisfactory equipment during the execution of the works.

2.4.9-9.8 Placing and Spreading of Mixture


Immediately before placing the asphalt mixture, the underlying course shall be cleaned of loose or
deleterious material using a power sweeper equipped with a blower, supplemented with hand brooms if
necessary, or removed by other means as directed the Engineer. No asphalt mixture shall be placed on
the base or asphalt treated base where the prime coat or tack coat has not been sufficiently cured and
stabilized.
Asphalt mixture shall not be placed when the underlying surface is not completely dry and it is raining.
When the cut back asphalt is used for prime coat, the asphalt mixture shall not be placed within 24 hours
unless approved by the Engineer.
The temperature of the mixture, when placed, shall fall within the range of 120. Where the Engineer
considers it indispensable to mix and deliver asphalt concrete in spite of seemingly undesirable weather
condition, the Contractor shall be required to do so.

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Hauling the mixture over the materials already placed shall not be permitted until the materials are
thoroughly compacted as specified and allowed to cool to an atmospheric temperature.
Upon arrival, the mixture shall be dumped into an approved bituminous paver and immediately spread to
full width required and struck off in a uniform layer of such depth that, when work is completed, it will
have required thickness and will conform to specified grade and surface contour required.
Paver spreading shall be regulated to eliminate pulling and tearing of bituminous material. The mixture
shall be placed in strips not less than 3 meters wide. To ensure drainage, spreading shall begin along the
pavement centerline on a crowned section or on high side of pavement.
After the first strip of width is compacted, the second width shall be placed, finished and compacted in
the same manner as the first width. After the second strip is placed and rolled, 5-meter straight edge
shall be placed across the longitudinal joint approved by the Engineer, to determine if the surface
conforms to the specified grade and contour requirements. Where the new pavement joints the
pavement of existing road, the asphalt mixture shall be so placed and spread as to form a slope of less
than 5%.

2.4.9-9.9 Compacting of Mixture


After spreading, mixture shall be thoroughly and compacted with power rollers as directed by the
Engineer. Rolling shall begin as soon as possible after the spread mixtures can stand the roller without
under displacement or hair cracking and shall start at the center of first spread and continue toward
either edge. On subsequent strips laid, rolling shall start on edge adjacent to previously laid material and
continue toward the opposite edge.
The roller shall, at all times, run slowly to avoid displacement of hot mixture. Any displacement occurring
as a result of reversing the direction of roller, or from any other cause, shall be corrected at once by
rakes and applying fresh mixture where needed.
A sufficient number of rollers shall be furnished and operated to handle plant output and rolling shall
continue until all roller marks are eliminated; surfaces become of uniform texture and true to grade and
cross section; and a density of at least 96 percent of specified laboratory density is obtained. Field
density tests shall be made at least twice daily.
To prevent adhesion of mixture to roller, wheels shall be kept properly moistened, but excessive water
shall not be permitted. In areas not accessible to rollers, mixture shall be thoroughly compacted with hot
hand tampers.
Any mixture, which becomes loose and broken or mixed with dirt, or in any way defective shall be
removed and replaced with fresh hot mixture and immediately compacted to be on a level with
surrounding areas. Skin patching shall not be permitted.

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2.4.9-9.10 Joints
The mixture at joints shall comply with the surface requirements and present same uniformity of texture,
density smoothness, etc. as other course sections. For transverse joints, placing of course shall be as
continuous as possible and rollers shall not pass over the unprotected end of freshly laid mixtures,
except when discontinuing the work. Transverse joints of granular base course shall be separated by at
least 1m from the transverse joints of granular base course.
For longitudinal joints, placing of course shall be as specified in such manner that joints are exposed for
the shortest period possible. The longitudinal joints shall be positioned not closer than 25cm from any
such joints in the surfaces of base, binder or other course immediately below the surfacing course. The
position of transverse and longitudinal joints shall be approved by the Engineer.

2.4.9-9.11 Quality Control and Testing


(1) Unless specified otherwise, the Contractor shall select and subcontract with prior approval of the
Engineer adequate laboratory facilities and equipment required for sampling and tests for each of the
following. Relevant details shall be referred to Chapter 4. of the GENERAL SPECIFICATIONS hereof.
- Grading analysis of aggregates and filler
- Sand equipment of aggregates
- Flakiness Index of coarse aggregates
- Bulk specific gravity of mixed aggregates
- Compacted density of mixed aggregates (Marshall Density)
- Marshall Stability and Flow
- Density of compacted Asphalt Concrete
- Asphalt extraction, in accordance with AASHTO Test Method T170
(2) The Contractor shall provide the Engineer with the following results and records of tests carried out
on each days production in the finished work.
- Temperature of mix when sampled at the mixing plant and on the road
- Compacted density and percentage compaction of asphalt concrete
- Asphalt content and aggregate grading of mix
- Air voids in compacted mix
2.4.9-9.12 Finish of Surfacing
The finished surface of the asphalt concrete surfacing shall not deviate more than 6 mm from the levels
and profile shown on the Drawings or as directed by the Engineer.
2.4.9-9.13 Protection of Pavement

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All sections of the newly finished work shall be protected from traffic of any kind until the mixture has
cooled to 500C. Traffic shall not normally be permitted on the newly laid surface within 6 hours after
completion of the pavement.
2.4.9-9.14 Tolerance
The tolerance for all geometrical properties of pavement shall be as shown in the Table 2.4.9-9.14.1. For
the thickness of each pavement component, the average of 10 measured values shall be within the limits
shown in the bracket in the same Table.
The pavement shall be inspected for flatness with a legged direct-reading flatness meter or a profile
meter approved by the Engineer.
Table 2.4.9-9.14.1 Frequency of Inspection and Tolerance
for Each Geometrical Properties of Finished Pavement
Pavement
Component
Subbase

Mechanically
Stabilized Base
Binder
Hot
and
Asphalt
Surface
Mix

Quality

Frequency of Inspection

Grade
Thickness
Width
Thickness
Width
Thickness of Surface
Thicknessof Binder
Width
Evenness

every 20m
every20m
every 40m
every 20m
every 100m
every 1,000m2
every 1,000m2
every 100m
throughout the length of
every lane

Tolerance
4cm
-4.5cm(-1.5cm)
-5cm
-2.5cm(-0.8cm)
-5cm
-0.7cm(-0.2cm)
-0.9cm(-0.3cm)
-2.5cm
6.0mm or less

Note: Figures in parenthesis are the average of 10 measured values.

2.4.9-10 Concrete Curb


Concrete curb shall be constructed at the both sides of pavement on the surface of subbase cparse.
Concrete grade: Grade B-2
Formwork grade: Class F2
Surface Finish: Type U3
2.4.9-11 Concrete Open Channel
The Contractor shall submit the detailed drawings concrete open channel based on topographic survey
to be conducted by the Contractor prior to commencement of the work for an approval of the Engineer.
Concrete grade: Grade B-2

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Formwork grade: Class F2


Surface Finish: Type U3
2.4.10 Foot Protection Concrete Block
The Contractor shall submit the detailed drawing of foot protection concrete block having hole type.
Detail size of these block and holes shall be in accordance with Japanese Standard. The detailed design
calculation of lifting hook shall be submitted for an approval of the Engineer.
Concrete grade: Grade B-1
Formwork grade: Class F2
Surface Finish: Type U3
2.4.11

Mooring Accessories and Other Fittings

2.4.11.1

Bollard

The Contractor shall submit the detailed drawing of 35 bollard including anchor bolt to be embedded into
crown concrete, detailed size of the bollard and material requirements, and the detailed design
calculation of lifting hook in accordance with Japanese Standard for an approval of the Engineer.

2.4.11.2

Used Truck Tire

The Contractor shall submit the detailed drawing of big size tire or heavy used truck including
connecting chain and its anchor bolts to be embedded into crown concrete, for an approval of the
Engineer.
2.4.11.3

Step

Concrete steps shall be constructed as indicated in Drawing. The Contractor shall submit the detailed
drawing of formwork plan, and detailed bar arrangement for steps for an approval of the Engineer.
2.4.11.4

Concrete kerb

Concrete kerb shall be constructed as indicated in Drawing. The surface of concrete shall be painted
in tiger pattern paint (yellow and black colours),
Reforcing ar grade: SD 345
Concrete grade: Grade A
Formwork grade: Class F2
Surface Finish: Type U3
2.4.12

Works related to New Berth in Phase-2

It is anticipated that new berth will be constructed in Phase-2 Project. A part of sand replacement and
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rock mound of the new berth, where intersects with the planned breakwater shall be carried out in this
work as specified in Drawing.

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