Method Statement for Placing of Bituminous Pavement

REVISION HISTORY
Rev. CONTRACTOR: MAK Status of
No. Date Revision History ENGINEER Approval
Prepared Reviewed Approved
First Submission
following award of
0 2016 Contract

CONTENTS

1.0 Scope

2.0 Purpose

3.0 Responsibilities

4.0 References

5.0 Safety

6.0 Procedures

7.0 Inspection and Testing

1.0 Scope

1.1 This method of statement covers the placing of bituminous pavement areas
shown on approved drawings.

2.0 Purpose

2.1 This method statement defines the responsibilities and describes the activities
and procedures to be implemented for the placing of bituminous pavement for
the Construction, Completion and Maintenance of Roads, Bridges, Storm
Water Drainage, Sewers and Other Services for Roads Connecting Sabah al
Ahmad and Khiran New Towns -RA239 Project to comply with the contract
drawings and specification.

3.0 Responsibilities

3.1 The Site Engineer (SE) will ensure that the site preparation activities are
conducted according to the approved Method Statement, and HSE plan.
3.1.1 Ensure all necessary approvals and work permits are obtained prior to
start the work.
3.1.2 Convey all technical data to road foreman and to ensure that the
foreman understood the activities to be executed.
3.1.3 Arrange & ensure the required manpower to execute the work.
3.1.4 Ensure safe working procedures are followed in accordance with the
site safety plan.
3.1.5 Prepare the necessary Request for Inspection (RFI's) to arrange the
consultant Engineer for inspections.
3.1.6 Organize the work in a safe manner to ensure that safety and protective
equipment are properly utilized.

3.2 The Material Engineer (ME) will ensure that the materials being used are in
accordance with the Project Specifications and approved Material Submittals.
He will be in charged with the field laboratory and will undertake the
 necessary tests as required for the project with the assistance from Laboratory
Technicians.

3.3 Quality Control Engineer

3.3.1 Review all documents and test reports.
3.3.2 Ensure that all other discipline activities that must be inspected within
the asphalt pavement construction program have been inspected and
ready for operating safely.
3.3.3 Ensure that all in-situ tests, as required on the Inspection and Test Plan
(ITP) are implemented.
3.3.4 Organize and allocate inspection works.
3.3.5 Perform pre inspection to determine acceptability prior to inspections
or tests.
3.3.6 Co-ordinate with the consultant inspectors.

3.4 Laboratory Technician

3.4.1 Perform sampling and conduct test as per direction from the Material
Engineer.
3.4.2 Review all laboratory results and prepare reports.

3.5 Road Foreman

Road Foreman will report directly to Site Engineers, their
responsibilities include, but are not limited to the following:
3.5.1 Conduct the toolbox meetings and briefing for his crew workers the
potential hazards and precautionary measures to be taken during the
excavation process.
3.5.2 Ensure that all engaged personnel have right PPE and all equipment are
experienced enough to execute hand excavation, and backfilling
activities.
3.5.3 Supervision the asphalt different activities (prime coat, tack coat, base
course, binder course and wearing coarse works) during the
construction process.
3.5.4 Control the workmanship quality by directing and instructing his crew
workers and his operators during the execution work.
3.5.5 Responsible for proper execution of the pavement levels and
dimensions as per drawings.
3.5.6 Ensure that, all the tools & equipment are available at site to execute
the different activities.

3.6 Safety Officer

3.6.1 The Safety Officer shall be responsible for safe execution of work
activities in compliance with the approved HSE plan & project HSE
requirements.
3.6.2 Ensure that all HSE requirements are applied and implemented
according to the MPW requirements while executing the works.
3.6.3 Ensure that the approvals of work permits are obtained prior to start
activities.
3.6.4 Ensure that recommendations of workplace precautions are followed
up strictly.
3.6.5 Stop any/or all works in case of specified recommendations/
observations are not applied by the construction team.
 3.6.6 Inspect & ensure that all engaged personnel have got correct PPE and
all equipment are perfect and certified to execute the works.

4.0 References

4.1 Specifications:
4.1.1 Project Drawings and Specifications.
4.1.2 MPW General Specifications
4.2 Drawings : Document III Volume 3
4.3 BOQ : Bill No. 4

5.0 Safety

The Site Engineer and Road Foreman, in coordination with the Safety Officer,
shall be ensuring compliance with all safety requirements during the
implementation of this work which shall include, but not limited to the
following:

5.1 Ensuring all equipment are in good operating condition.

5.2 Provision and proper use of safety paraphernalia.
5.3 Maintaining cleanliness at work areas.
5.4 Proper disposal of excess and waste construction materials.
5.5 Providing visible warning signs and/or barricades at work areas when
necessary.

6.0 Plant & Equipment

6.1 Asphalt Mixing Plant

6.2 Surveying Instruments
6.3 Light Vehicles
6.4 Tipper Trucks
6.5 Asphalt Paver
6.6 Asphalt Distributor
6.7 Steel Rollers
6.8 Pneumatic Tire Rollers
6.9 Bitumen sprayer Tanker
6.10 Water Tanker
6.11 Flagging Tape/ Warning Tape
6.12 Personal Protective Equipment
6.13 Thermometer

7.0 Prior Activities

7.1 Job Mix

7.1.1 Job Mix Formula shall be submitted for approval to the Engineer for
the Bituminous Base Course, Binder Course and Wearing Course.
7.1.2 The Marshall Method of Mix Design (Asphalt Institute Manual Series
MS 02) will be used in designing the asphaltic concrete mixes.
 7.1.3 Prior to finalization of the Job Mix, a trial section at location approved
by the Engineer shall be laid for each Job Mix. The trial section shall
be 2 lanes wide by 50 m long.
7.1.4 The trial section shall be laid to demonstrate the adequacy of hauling,
spreading and compaction equipment and the suitability of the
construction methods and organization proposed and it shall be offered
to the Engineer for inspection and approval.

7.2 Prime and Tack Coat Materials

7.2.1 Prime and Tack Coat materials shall conform to GS sections 405 and
406, respectively.
7.2.2 Approval of the material from the Engineer is required prior to use.

7.3 Asphalt Mixing Plant

7.3.1 The plant shall be capable to continually produce asphalt mixes within
the job mix tolerances specified at an automatically controlled
operation.
7.3.2 The plant shall be offered to the Engineer for inspection and approval
prior to any asphalt paving activities.

7.4 Other Equipment

7.4.1 All other equipment such as haulers, rollers, asphalt distributor,
spreading and finishing equipment shall be offered to the Engineer for
inspection and approval.

8.0 Procedures

8.1 Hauling of Materials

8.1.1 Sufficient plant capacity, haul vehicles and storage shall be provided so
that adequate supplies of mixture are delivered to ensure continuous
paving can be achieved.
8.1.2 The dispatching of the hauling vehicles to the job site shall be so
scheduled that all material delivered may be placed in daylight, unless
the Engineer approves the use of artificial light.
8.1.3 Delivery of material shall be at a uniform rate and in an amount well
within the capacity of the paving and compacting equipment.
8.1.4 All precautions shall be taken to protect the mix from the weather
during transit and whilst waiting to discharge.
8.1.5 The mix shall be delivered to the paver at a temperature between 145C
and 165C.

8.2 Surface Preparation

8.2.1 Examine the sub-base/base course and adjoining construction, and the
conditions under which the bituminous primer will be applied. Do not
proceed with the work until unsatisfactory conditions detrimental to the
proper and timely completion of the work have been corrected.
8.2.2 All base and sub-base courses will be cleaned and prepared by removal
of dust and deleterious materials by air jetting or mechanically
sweeping or any other approved means. A light application of water
 will be made just prior to the application of liquid asphalt to facilitate
penetration.
8.2.3 Prior approval of the surface by the Engineer is required before
application of prime coat.

8.3 Prime Coat Application

8.3.1 Prime coat will be applied initially on a trial section at a location
approved by the Engineer, using the same materials, mixing and
spraying equipment, and construction procedures, proposed for use in
the works.
8.3.2 Only after approval of the Engineer on the trial section can the
application of prime coat proceed.
8.3.3 Prime coat shall be applied with same methods and procedure as that of
the approved trial section.
8.3.4 Prime coat shall not be applied when the ambient temperature is less
than 10C nor during rain, fog, dust-storms or other unsuitable weather.
8.3.5 The application rate shall be between 0.8 and 1.75 kg/m2 at application
temperature between 45C and 80C.
8.3.6 The prime coat shall usually be applied to 1/3 or 1/2 of the road width
at a time. When applied in two or more lanes, there shall be a slight
overlap of asphalt material along adjoining edges of the lanes.
8.3.7 The completed primed surface shall be maintained in a good clean
condition and prior to the application of the next course, any surface
irregularities shall be corrected and all excessive blotter material, dirt
or other objectionable materials shall be removed.

8.4 Tack Coat Application

8.4.1 Tack coat will be applied initially on a trial section at a location
approved by the Engineer, using the same materials, mixing and
spraying equipment, and construction procedures, proposed for use in
the works.
8.4.2 Only after approval of the Engineer on the trial section can the
application of tack coat proceed.
8.4.3 Tack coat shall be applied with same methods and procedure as that of
the approved trial section.
8.4.4 Tack coat shall not be applied when the ambient temperature is less
than 10C nor during rain, fog, dust-storms or other unsuitable weather.
8.4.5 The application rate shall be between 0.15 to 0.75 kg/m2 at application
temperature between 25C and 65C.
8.4.6 The tack coat shall usually be applied to 1/3 or 1/2 of the road width at
a time. When applied in two or more lanes, there shall be a slight
overlap of asphalt material along adjoining edges of the lanes.
8.4.7 The completed tack coated surface shall be maintained in a good clean
condition and prior to the application of the next course, any surface
irregularities shall be corrected and all excessive blotter material, dirt
or other objectionable materials shall be removed.

8.5 Placing of Bituminous Material (Base Course, Binder Course, Wearing

Course)
8.5.1
 9.0 Inspection and Testing

Required tests and inspections shall be carried-out as per approved Inspection

and Test Plan (ITP) and enough time in the daily work program shall be
allocated to permit the performance and checking with the consultant before
proceeding with any subsequent work.

CONTENTS

1.0 Scope of Work

2.0 Definitions

3.0 References

4.0 Subcontractors

5.0 Materials

6.0 Plant & Equipment

7.0 Safety

8.0 Prior Activities

9.0 Procedure

10.0 Responsibilities
 11.0 Attachments

1. Scope:

1.1 This Method Statement describes the procedures to be followed in the placing of the
following asphalt concrete courses:
Bituminous Base Course
Bituminous Binder Course
Bituminous Surface Course

2. Definitions:

2.1 MS: Method Statement

2.2 ITR: Inspection & Testing Request

3. Reference

4. Subcontractors:

4.1 None

5. Materials:

5.1 Mineral aggregates

5.2 Bitumen

Aggregates, bitumen and mix design will be submitted for approval as per clause 331.21

6. Tools & Equipments:

6.1 Surveying Instruments

6.2 Light Vehicles
6.3 Tipper Trucks
6.4 Paver
6.5 Steel Rollers
6.6 25 Ton and 35 Ton Pneumatic Tire Rollers
6.7 Bitumen sprayer Tanker
6.8 Water Tanker
6.9 Flagging Tape/ Warning Tape
6.10 Tool box
6.11 Personal Protective Equipment
6.12 Thermometer
7. Safety

8. Prior Activities:

8.1 Submit mix design and aggregates for Engineers approval as per clause of the
specifications. The job mix shall be made for the Base, Binder and Surface Courses
respectively.

8.2 Prepare calibrated Surveying equipment.

8.3 Prepare Testing equipment.

8.4 Preparation of all safety procedures.

8.5 Notice in writing to the Engineer.

8.6 Trial Area of each pavement material, sampling the permanent works will be laid to the
extent and at locations to be agreed upon with the Engineer as per clause .

8.7 Compaction methods will be subject to approval by the Engineer prior to

commencement of permanent works by means of demonstrative trials as per clause
331.29. Tests will be conducted according to Specs and approved compaction
methods will be adopted for the Project. Any modification will be subject to the
Engineers approval.

8.8 Batching Plant for asphalt production are located in Amghra and another one will be
erected on Site to ensure the required capacity for the Project. All plants will be
calibrated and checked before being put into operation. Regular checks will be
carried out as per clause .

8.9 Bitumen and aggregates shall not be heated to above 150C and 170C
respectively, and the temperature difference between them at the time of mixing
shall not exceed 15C.

9. Placing procedure:

All activities carried out will comply with the Inspection Test Plan which reflects the testing requirements of
the Contract

9.1 Surface Preparation:

a) All base and sub-base courses will be cleaned and prepared by removal of
dust and deleterious materials by air jetting or mechanically sweeping or any
other approved means. The cleaned course will be afterwards lightly made wet
 Prior to the application of the prime coat.

b) An approved priming coat of grade MC60 or other approved will be applied to

non-bituminous sub-base and base layers at the rate of to . litres per m
as per clause . Similarly, approved bitumen tack coat of grade MC 60 cut-
back bitumen or SS1H emulsion or other approved will be applied to binder
courses at the rate of 0.25 to 0.35 litre per m as per clause .. Spraying of
the prime and tack coats will be done by a tanker fitted with nozzles at the
back of the tank to allow even spreading of bitumen. The bitumen will be pre-
heated to a temperature of 120 oC in the tanker prior to the spraying. The
accuracy of rate of application will be adjusted during the trials.

Note: Enough time will be allowed for the curing of the prime and tack coats
before laying the binder course or the wearing course.

9.2 Bituminous pavement material transportation:

a) Transportation of asphalt concrete from the mixing plant to the pavers will be
via 30 ton tipper trucks designated for this use only. The trucks vehicles will be
treated by oil or water or any other approved means to facilitate the discharge.
Moreover, they will be specially modified to prevent any spills during the
downloading into the paver.

Note: The number of trucks to be used for hauling the asphalt will be sufficient
to avoid any interruption in the paving operation.

b) The flow of delivery will be uniform to assure the best quality of asphalt
finishing.

c) All mixed material will be delivered to the paver in time to permit completion of
spreading and finishing of the mixture during the day working hours. Should
the bituminous material be placed at night, adequate lighting will be provided
and request for approval will be sent to the Engineer.

d) Maximum care will be taken to avoid delivery interruption. However, in case

there is a long stoppage between trucks, a joint will be cut in the fresh layer,
loosened material discarded and a very light coat of hot bitumen will be applied
before the next strip is placed.

9.3 Surveying work

a) Base course, binder course and wearing course levels will be determined from
the finished pavement surface as shown on the approved shop drawings and
will be submitted for the Engineers approval.

b) The strip width shall not be less than 3 meters. Paver guideline levels will be
 set using steel wires stretched and adequately supported to prevent any
sagging on both sides.
9.4 Placing of bituminous material:

a) Spreading of bituminous mixtures shall be done by automatic controlled

pavers. ABG pavers will be used in this job. The ABG pavers are equipped with
automatic sensors that control the grades and cross slopes. The sensors are
mounted on either side of the paving legs and are individually controlled.
Crowns or continuous grades can be established on an ABG Finisher. All
machines involved in asphalt operation shall be in good condition and will be
checked before and during the operation.

b) The thickness of asphalt shall be controlled on both sides by the elevation of

the steel wires. The thickness of asphalt laid is determined by measuring
height from top of wire and by a measuring gauge (a steel rod fitted with a
circular steel plate which can be adjusted for depth) throughout the laying
period. The length of each pass shall not exceed a one truck load.

c) The material temperature should be more than 120C and will be checked
directly before its discharge according to clause . of the specifications.

d) Longitudinal joints in successive layers shall be offset by at least 300mm from

parallel joints in the layer beneath. Transverse joints in successive layers
and/or adjacent lanes shall be offset by at least 3 meters.

e) The material discharge will take place without delay. Rolling shall commence
immediately after placing of asphalt and will stay as close as possible to the
Paver. However, all loose material shall be removed prior to compaction.

f) The paver shall operate at a speed which will give the best results
coordinating with the rate of delivery of material.

g) Initial rolling shall be carried out with the Steel Roller at speeds slow enough
to avoid displacement of asphalt.

h) Excess binder/base course material will be removed by brooming or light

raking and will be discarded. Adjustment of surface course level by hand-
raking or hand spraying will be carried out after getting the Engineers
approval as per clause 331.29

i) Rolling shall be longitudinally, beginning at low side towards the high side of
pavement. Adjacent rolls shall be shorter as progressed and finally semi
diagonal steel rolling is applied.

j) The asphalt shall then be rolled with the 25 Ton tire Rollers and shall stop short
of any cracks that might appear.

k) The high powered 35 Ton Pneumatic Tire Rollers shall then be applied to
achieve the required compaction.
 l) Final rolling shall be done by the Steel Roller especially at joints and points of
deficiencies.

m) All Rollers shall be equipped with water reservoirs and scrapers to avoid any
breaking of the asphalt surfaces. The tires of the rollers shall be sprayed with
oil/diesel to prevent any fine particles from asphalt getting stuck to the tires.

n) The smoothness of the course will be checked by means of 3 meters

straightedge as per clause 331.37 and will be measured by the gap between
bottom of straightedge and pavement at any points and in any direction.

9.4 Tolerances (Clauses..)

a) Horizontal Alignment
15mm from Drawings
Rate of deviation not to exceed 1 in 1000

b) Vertical Alignment
10mm for base course
6mm for binder course
6mm for surface course

c) Layer Thickness
5mm for any individual layer
min(10% of combined thickness; 15mm) for combined thickness

d) Smoothness
3mm for surface course
10mm for binder course

10. Responsibilities:

10.1 The CM will coordinate with SE and ensure that the necessary resources to implement
the approved method statement, Job and Activity Hazard Analysis have been allocated
to the task.

10.2 It is the Site Supervisors duty to organize the work in a safe manner to ensure that
safety and protective equipment are being properly utilized. He must also assure the
AHA & JHA are implemented and the method statement procedure is followed and the
ITP applied.

10.3 It is the workers duty to properly wear the protective equipment provided and obey all
safety rules. They must also perform the work as described in the method statement
procedure.

10.4 The SE will ensure that the site preparation activities are conducted according to the
Approved method statement, JHA, AHA and all in-situ tests as required in the ITP are
implemented.

10.5 The ME will ensure that the materials being used are in accordance with the Project
 Specifications, the approved method statement and the ITP.

11. Attachments:

11.1 Job Hazard Analysis

11.2 Activity Hazard Analysis
11.3 Inspection and Testing Plan