PART 2

MATERIALS
2.01

Quality of Materials
All materials used in the Works shall be new and of the types and qualities specified and shall be
approved by the Engineer. They shall comply with the requirements, unless modified herein, of the
current amended editions, at the date of invitation to Tender, or the British Standard Specifications
(hereinafter abbreviated to B.S.S) published by the British Standards Institution, or any other recognised
Standards which may be quoted. All materials may be checked both at the source and on site and
approval of any materials at its source does not necessarily imply that it will be approved on Site.

2.02

Approval of Source of Supply

At least 14 days before it is proposed to use materials, and before ordering any materials, the Contractor
shall submit, for the approval of the Engineer's Representative, the name of the Supplier, the source of
supply and relevant test results, for any materials to be used in the Works. The approval in writing of the
Engineer's Representative must be obtained before relevant items are obtained. The information
concerning the names of Suppliers may be submitted at different times for different materials, as may be
convenient, but no source of supply shall be changed without the Engineer's Representative's prior
approval.

2.03

Samples
In addition to any special provisions made hereinafter as to sampling and testing of materials by particular
methods, samples of all materials and workmanship proposed to be employed in the execution of the
Works comprised in this Contract may be called for at any time by the Engineer's Representative and are
to be furnished free by the Contractor. Samples of the material approved will be retained by the
Engineer's Representative until the completion of the Contract and he shall reject all materials and
workmanship not conforming in quality and character with the approved samples. Suitable labelled
receptacles for the storage of samples are to be provided by the Contractor without additional charge.

2.04

Additional Tests
In addition to the tests required under other Clauses hereof, the Engineer's Representative shall have
power to order independent tests of all materials to be carried out by some person appointed by him at
such place as he may determine.

2.05

Inspection and Testing

Whenever considered desirable by the Engineer's Representative, Inspectors may be sent to the Supplier's
premises to test the materials or to monitor their manufacture. Materials shall be tested before leaving the
premises and the Engineer's Representative shall be at liberty to reject materials notwithstanding
favourable preliminary test results at the Supplier's premises. Should the Engineer's Representative not
decide to send an Inspector to a Supplier's premises, the Contractor shall obtain from the Supplier
Certificates of test showing that the materials have been tested in accordance with the requirements of this
Specification relating thereto but neither the omission of the Engineer's Representative to send an
Inspector nor the production of Supplier's Certificate of Test shall affect the liberty of the Engineer's
Representative to reject after delivery materials found to be unsuitable or not in accordance with this
Specification.

Specification Part 2 - Materials , page 1

2.06

Defective Materials
All materials which do not comply with the requirements of the Specification will be rejected and all such
materials, whether in place or not, shall be immediately removed from the Site by the Contractor at his
own expense.

2.07
(a)

Aggregates
Aggregates shall consist of clean, dry, hard, tough, sound, crushed stone or crushed gravel of uniform
quality, free from dust, clay, dirt, sulphates, chlorides and other deleterious matter. Aggregates shall be of
such a nature that when thoroughly coated with the asphaltic material proposed for the work and
immersed in water for a period of 48 hours, no loss of binder film will be apparent.
If the use of limestone aggregates is contemplated, then it may become necessary to introduce fine sand
into the mix to make it more workable and reduce unevenness in the initial rideability of the newly laid
road surface. This addition of sand shall be considered incidental to the work and allowed for by the
Contractor in his bid prices.
Aggregate grading shall be with the following limits:-

(b)

(c)

ASPHALTIC CONCRETE OVERLAY AND REGULATION

TABLE 2.1

Mix Classification

ASTM SIEVE SIZE

Passing 50mm (2 ins)

4b

4a

Total Percentage Passing Including Filler

(by weight)
100

Passing 38mm (1 1/2 ins)

90-100

100

Passing 25mm (1 in)

75-90

100

90-100

Passing 19mm (3/4in)

80-100

82-100

100

55-75

60-80

72-90

80-100

100

70-90

80-100

Passing 4.75mm (4 mesh)

36-56

36-56

52-70

50-70

55-75

Passing 2.36 (8 mesh)

28-44

28-44

40-56

35-50

35-50

Passing 1.18mm (16 mesh)

20-34

20-34

32-46

Passing 600Fm (30 mesh)

15-27

15-27

24-36

18-29

18-29

Passing 300Fm (50 mesh)

10-20

10-20

16-26

13-23

13-23

Passing 150Fmm (100 mesh)

5-13

5-13

10-18

8-16

8-16

Passing 75Fm (200 mesh)

2-6

2-6

6-12

4-10

4-10

Passing 12.5mm (1/2 in)

Passing 9.5mm (3/8in)

Specification Part 2 - Materials , page 2

(d)

(e)

(f)

(g)

(h)

For each mix type the Contractor shall establish a job mix formula which shall state a single percentage of
aggregate passing for each sieve size. The grading curve of the aggregates, as prescribed by the job mix
formula, when plotted shall give a smooth curve throughout the whole range designated grading band
limits shown in Table 2.1. The maximum size of the coarse aggregate shall not be greater than forty
percent (40%) of the surfacing layer thickness and fifty percent (50%) of the levelling layer thickness after
compaction. Should the Engineer consider it desirable or necessary he shall be empowered to request the
Contractor to test, mix and lay alternative asphaltic mixes at rates to be agreed.
Cover aggregates shall conform with B.S. 63 Part . Specification for Single Size road stone and chippings.
Generally the surface treatment shall be a Double Bituminous Surface Dressing (DBSD). However should
the Engineer consider it necessary to improve the pavement riding quality and to further protect the base
course he may instruct a Triple Bituminous Surface Dressing (TBSD). The nominal size of aggregates
used for surface treatment shall be as follows:
Size No. 1.
Size No. 2.
Size No. 3.
Size No. 4.

Nominal Size
Nominal Size
Nominal Size
Nominal Size

19mm (3/4)
12mm (1/2)
9mm (3/8)
6mm (1/4)

Notes:

i)

Bituminous material types are

a)
asphalt cement

ii)

Quantities of bituminous materials may be varied by the Engineers Representative by

+/- 15% depending on the site conditions and in accordance with Overseas Road Note 3
(ORN 3) published by the Transport Research Laboratory (TRL).

iii)

Prime coat shall be applied prior to the surface treatment on non-bituminous surfaces or
as directed by the Engineers Representative.

General
For all aggregates, the Flakiness Index should not exceed 35 and the aggregate crushing value should not
exceed 25%. For crushed gravel at least 75% by weight of the particles retained on 9.5mm (3/16") sieve
shall have at least one fractured face.
Water Absorption
The water absorption as determined in accordance with B.S. 812, or alternatively AASHTO test
specifications T84 and T85, shall not be more than 2%.
Plastic Fines in Blended Aggregate
The portion of the blended aggregate, including filler, passing a 4.75mm (No. 4 mesh) sieve shall have a
plasticity index not exceeding 4 when tested in accordance with AASHTO T 90-70. When either hydrated
lime or Portland cement are used as filler they shall not be included with the other fine materials for the
determination of plasticity index.

Filler
If filler material additional to the normal crushing plant production is required to meet aggregate grading
requirements, it shall consist of finely divided mineral matter such as crushed rock, hydrated lime,
Specification Part 2 - Materials , page 3

2.08
(a)
(b)
(c)

2.09

Portland cement, or other approved material. It shall be sufficiently dry to flow freely and shall be free
from agglomerations. Not less than 70% shall pass a 75:m (No. 200 mesh) sieve.
Asphalts
Penetration graded asphalt shall conform with the requirements of B.S.S. 3690, Bitumen for Road
Purposes, and shall be of penetration grade 60-70.
Cutback asphalts shall conform with the requirements of B.S.S 3690, Bitumen for Road Purposes.
Asphaltic Emulsions shall conform with the requirements of B.S.S 434, Bitumen Road Emulsion
(Anionic). Cationic emulsion may be used provided its affinity to the aggregates used is established to the
satisfaction of the Engineer's Representative.
Asphaltic Concrete
Asphaltic concrete shall be manufactured from aggregate, penetration grade asphalt and filler conforming
with Table 2.2 and Clauses 2.07 and 2.08 of this Specification.
Unless otherwise ordered by the Engineer the mix classifications are per Table 2.2 for the various road
items shall be:(i)
Machine laid overlay course of
....
Class 4b 6.0 to 7.5% bitumen
compacted thickness 30mm (13") min.
to 55mm (23") maximum.
(ii)
Machine or hand laid regulating of....
Class 4a 6.0 to 8.0% bitumen
compacted thickness not exceeding 50mm (2").
The asphaltic concrete mixes shall conform with the values of the Standard Marshall mix design method
criteria specified in Table 2.4 for test specimens compacted using the 75 blows per face standard.
MARSHALL TEST CRITERIA
TABLE 2.4

Mix Classification

4b

4a

Stability lbs. (75 blows compaction)

750+

1,800+

750+

Flow 0.01 in.

8-20

8-14

8-16

Percent Voids in Mix

3-5

3-5

3-5

65-80

65-75

75-85

Percent Voids filled with bitumen

Voids in Mineral Aggregate
*R

13% Min
90+

125+

125+

*R = Marshall Stability (lbs.)

Flow (0.01 ins.)

After having obtained a consistent production from the Supplier's crushing plants, the Contractor shall
propose a job mix formulae. In order to attain optimum quality of the mixture, the job mix formulae shall
be prepared on the basis of testing several aggregate grading within the limits set by this Clause at an
appropriate range of asphalt contents.
Samples of mixtures conforming to the job mix formulae shall be subjected to a comprehensive Marshall
test and analysis as follows:(i)
Preparation of specimens for the standard stability and flow test in accordance with AASHTO T
245-74 using the 75 blows per face compaction standard.
Specification Part 2 - Materials , page 4

(ii)
74.
(iii)

Determination of the bulk specific gravity of the specimens in accordance with AASHTO T 166-

Determination of the stability and flow values in accordance with AASHTO T 245-74.
(iv)
Analysis of the density and voids parameters to determine the percentage of voids in the
compacted aggregate, the percentage filled with bitumen, and hence the percentage of voids in the
compacted mix.
All criteria shall comply with the requirements of Table 2.4.
Air voids shall be defined as the small pockets of air between the coated aggregate particles in a
compacted paving mixture. The portion of the asphalt cement absorbed into the aggregate particles must
therefore be allowed for when calculating the air voids. For blended aggregate the asphalt absorption
shall be determined in accordance with AASHTO test method T 209-74 (the vacuum saturation method)
or by such other satisfactory test procedure as the Engineer's Representative shall approve.
Voids in the mixed aggregate shall be calculated on the basis of the aggregate's bulk specific gravity on an
oven dried basis as determined in accordance with B.S. 812 or alternatively AASHTO tests specifications
T 84 and T 85 as applicable.
The job mix formulae shall be submitted for the Engineer's approval and he may change the grading or
the asphalt cement content or both, to attain optimum quality of the completed mixture. Such approval
may not be given until sufficient quantities of the material have been laid and its performance assessed
under traffic for a short period. Any resulting adjustments, which may overrule the above mentioned
grading and asphalt cement content requirements, shall be considered incidental to the work and allowed
for by the Contractor in his bid prices.
The approval of such job mix formulae shall bind the Contractor to furnish mixtures not only within the
general ranges prescribed herein, but meeting the precise job mix formulae within the following
tolerances, based on the weight of the total mix.
TABLE 2.5
Aggregates larger than 4.75mm (3/16")
Aggregate passing 4.75 (3/16") and
retained on 150:m (No. 100)
Aggregate passing 75:m (No.200)
Bitumen content

2.10
(a).

(b).

Tolerance
+ 5%
+ 4%
+ 2%
+ 0.3%

If for any reason it is necessary to amend the specified temperatures at which the asphalt cement and
aggregates enter the pug mill from the values prescribed in Clauses 5.06 and 5.07 respectively, all such
amendments shall be included in job mix formulae, and approved by the Engineer's Representative.
Base Material and Crushed Stone
This work shall consist of supplying, laying and compacting base material at locations and to lines,
grades and cross sections shown on the drawings or as directed by the Engineer's Representative, all in
conformity with the requirements of this specification and other contract documents.
Base material for this work shall consist of a natural mixture of hard rock fragments and soil binder free
from soft particles of clay. The material should be obtained from a quarry approved by the Engineer and
should conform with the following physical properties:

Specification Part 2 - Materials , page 5

TABLE 2.6
(i) GRADATION
ASTM Sieve Size

Percentage by Weight Passing

Base

Sub-base

75mm (3")

100

38mm (1 1/2")

100

80 - 100

19mm (3/4")

85 - 100

60 - 80

4.75mm (No. 4)

40 - 60

30 - 50

2mm (No. 10)

25 - 55

0.425mm (No. 40)

10 - 25

10 - 25

75:m (No. 200)

5 - 15

5 - 15

The fraction of marl material passing the 75:m sieve must not be greater than two thirds of the
fraction passing the 0.25mm.
(ii) PROPERTIES

Description

Limits
Sub-base

Base

Co-efficient of Uniformity

10 - 40

Los Angeles Abrasion Test

50%

50%

18%

30%

80%

25%

10%

6%

0.3%

Soundness Test (MgSO4.5 cycles (Max))

C.B.R. 4 day soaked (Min)
Liquid Limit (Max)
Plasticity Index (Max)
Linear Swell (Max)

(c).

The prepared foundation for the base shall be shaped carefully to the required cross-section and
compacted thoroughly by approved earth compacting plant to the densities required in this specification.

Specification Part 2 - Materials , page 6