INSPECTIONS AND TESTING PLAN

FOR

ROAD WORKS PROJECT

Disediakan Oleh:-

Bahagian Jalan
Ibu Pejabat JKR Perak Darul Ridzuan
Jalan Panglima Bukit Gantang Wahab
30000 Ipoh
 CONTENT PAGE

1. EARTHWORKS

1.1 BORROW PIT SOURCE 3

2. FLEXIBLE PAVEMENT

2.1 GRANULAR SUBBASE MATERIAL 4

2.2 QUARRY / AGGREGATE SOURCE 5

2.3 CRUSHER RUN (ROADBASE) 5

2.4 BITUMINOUS PRIME COAT (SK – 1 – SK – 1K) 6

2.5 BITUMINOUS TACK COAT (RS – 1 – RS – 1K) 6

2.6 ASPHALTIC CONCRETE WEARING COURSE 7-8

2.7 ASPHALTIC CONCRETE BINDER COURSE 8-9

3. CONCRETE

3.1 MINIMUM RATE OF SAMPLING 10

1
 APPENDIX:- PAGE

1. TABLE 4.1

- GRADATION LIMITS FOR SUBBASE MATERIAL 11

2. TABLE 4.3

- GRADATION LIMITS FOR CRUSHED ROADBASE 11

3. TABLE 4.8

- GTRADATION LIMITS FOR ASPHALTIC OCNCRETE 12

4. TABLE 4.9

- DESIGN BITUMEN CONTENTS 12

5. TABLE 9.5

- PRESCRIBED MIXES FOR GENERAL USE

PER CUBIC METRE OF CONCRETE 13

2
1. EARTHWORKS

1.1 BORROW PIT SOURCE

Activity Testing Requirement Frequency

a). Determine i). Lab Compaction i). To determine Initial Stage

Suitability Test (Proctor) BS moisture content /
1377 dry density
relationship

ii). Soaked CBR ii). > 3.0 %

Approving Officer Remark

Engineer JKR / SPJ / 1988
Lab test for every different variable materials

Activity Testing Requirement Frequency

b). Earthfilling i). In Situ Density i). >95% Max. Dry i). Minimum 1 test /
Test (Top 300 mm) Density / CBR > 500 sq.m of each
5% layer compacted

ii). Below 300 mm ii). > 90% Max. Dry ii). Ditto
Density

c). Cut Area i). In Situ Density i). >95% Max. Dry i). Ditto but every 300
Test (Top 300 mm) Density / CBR > sq.m
5%

d). Disposal Area / i). Field Density Test i). > 85% Max. Dry i). Min. 1 test / each
Dumping Ground Density layer compacted

Approving Officer Remark

Engineer / Technician JKR / SPJ / 1988 CI. 2.2.4
Max. compacted thickness of fill shall be
limited to 300 mm

3
2. FLEXIBLE PAVEMENT

2.1 GRANULAR SUB-BASE MATERIAL

Activity Testing Requirement Frequency

a). Determine i). Sieve Analysis i). Envelope ‘A’ to ‘E’ Initial Stage
Suitability of Table 4.1

ii). Lab Compaction ii). For Field Density

iii).Soaked CBR iii).>30%

iv). Liquid Limit iv). Not more than 25%

v). Plasticity Index v). Not more than 6

Approving Officer Remark

Engineer JKR / SPJ / 1988 CI. 4.1.2
Based on 1 test / 750 cu.m of material supplied
(Envelope dependent on sub-base designed)

Activity Testing Requirement Frequency

b). Laying i). Sieve Analysis i). Envelope ‘A’ to ‘E’ of i). 1 test / 750cu.m
Table 4.1 stockpile or
laid

ii). In Situ Density ii). > 95% Max. Dry ii). 1 test / 500
Test Density sq.m of Each
layer laid

Approving Officer Remark

Engineer / Technician JKR / SPJ / 1988 CI. 4.1
Based on 1 test / 750 cu.m of material supplied
(Not all sandy material conform to envelope)

4
 2.2 QUARRY / AGGREGATE SOURCE

Activity Testing Requirement Frequency

c). Determine i). Flakiness Index i). Less than 30 i). Initial Stage
Suitability
ii). Aggregate Crushing Value ii). Less than 30%

iii).Sodium Sulphate Soundness iii).Not more than 12%

iv). Los Angeles Abrasion iv). Less than 40

Approving Officer Remark

Engineer JKR / SPJ / 1988 CI. 4.1.1

2.3 CRUSHER RUN (ROAD BASE)

Activity Testing Requirement Frequency

a). Determine i). Sieve Analysis i). Type 1 of Table 4.3 Initial Stage
Suitability
ii). Lab Compaction ii). To determine moisture
Test content / dry density
relationship

iii).Plasticity Index iii).Not more than 6

iv). Soaked CBR iv). >80%

Approving Officer Remark

Engineer / Technician JKR / SPJ / 1988 CI. 4.1.4
Based on 1 test / 750 cu.m of material supplied

Activity Testing Requirement Frequency

a). Laying i). Sieve Analysis i). Type 1 of Table 4.3 i). 1 test / 750
cu.m supplied

ii). In Situ Density ii). > 95% Max. Dry ii). 1 test / 2500
Test or In Situ CBR Density sq.m of each layer
laid or every 100 m
laid

Approving Officer Remark

Engineer / Technician JKR / SPJ / 1988 CI. 4.14.2
Based on 1 Test / 750 cu.m of material
supplied. Thickness of material laid should be
checked together with the in-situ compaction
test.
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 2.4 BITUMINOUS PRIME COAT (SS – 1 or SS – 1K)

Activity Testing Requirement Frequency

a). Determine i). Test Conforming to i). MS 159 (Cut Back) to i). Initial Stage
MS 161 MS 161 (Emulsion)

b). Application i). Tray Test i). Between 0.5 to 1.0 litres i). 1 test / 16,000
/ sq.m sq.m covered

ii). Spraying Temperature ii). Between 25° C to 45° C ii). Daily Operation
covered

Approving Officer Remark

Engineer / Technician MS 161
JKR/SPJ 1988 CI. 4.2.1

2.5 BITUMINOUS TACK COAT (RS – 1 or RS – K)

Activity Testing Requirement Frequency

a). Determine i). Test Conforming to i). MS 161 i). Initial Stage
MS 161

b). Application on i). Tray Test i). Between 0.25 to 0.55 i). 1 test / 16,000
site litres / sq.m sq.m covered

ii). Spraying Temperature ii). Between 25° C to 45° C ii). Daily Operation
covered

Approving Officer Remark

Engineer / Technician MS 161
JKR/SPJ 1988 CI. 4.2.2

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 2.6 ASPHALTIC CONCRETE WEARING COURSE

Activity Testing Requirement Frequency

a). Lab Mix i). Aggregates Grading i). Table 4.8 i). At initial stage
Design or any change of
ii). Binder Content ii). Table 4.9 aggregate source
(5.0 % - 7.0 %0

iii). Marshal Method:-

- Stability - >500 kg
- Flow - 2.0 – 3.0 mm
- Voids in Mix - 3% - 5%
- Voids in aggregate - 75% - 85%
filled with bitumen

Approving Officer Remark

Engineer JKR/SPJ 1988 C 1.4.1

Activity Testing Requirement Frequency

b). Trial Lay i). Aggregates Grading i). Table 4.8 i). Initial stage or
any change of lab
ii). Binder Extraction ii). Table 4.9 mix design
(5.0 % - 7.0 %0

iii). Marshal Method:-

- Stability - >500 kg
- Flow - 2.0 – 3.0 mm
- Voids in Mix - 3.0% - 5.0%
- Voids in aggregate - 75% - 85%
filled with bitumen

iv). Lab Compaction Test iv). To determine lab

density

v). In-situ Density Test v). > 98% lab density

vi). Rolling Pattern vi). To select most suitable

pattern

Approving Officer Remark

Engineer JKR/SPJ 1988 CI 4.2.2

7
 Activity Testing Requirement Frequency

b). Laying i). Sieve Analysis i). Table 4.8 i). 1 test / day of
(Gradation Analysis) production

ii). Binder Extraction ii). 4 % - 6 % ii). 1 test / 200 tons

produced

iii). Marshal Method:- iii).1 test / 200 tons

- Stability - >500 kg produced
- Flow - 2.0 mm
- Voids in Mix - 3.0% - 5.0%
- Voids in aggregate - 75% - 85%
filled with bitumen

iv). In-situ Density Test iv). To determine lab iv). One sample /
density 500 sq.m of area
laid or daily

v). Rolling Temperature v). > 98% lab density v). Every initial
(RT) rolling
vi). To select most suitable
pattern

Approving Officer Remark

Engineer / Technician JKR/SPJ 1988 CI 4.2.4

2.7 ASPHALTIC CONCRETE BINDER COURSE (ACB 28)

Activity Testing Requirement Frequency

a). Lab Mix i). Aggregates Grading i). Table 4.8 At initial stage or
Design any change of
aggregates source
ii). Binder Content ii). Table 4.9
(4 % - 6 % )

iii). Marshal Method:-

- Stability - >450 kg
- Flow - 2.0 mm
- Voids in Mix - 3.0% - 7.0%
- Voids in aggregate - 65% - 80%
filled with bitumen

Approving Officer Remark

Engineer JKR/SPJ 1988 CI 4.2.4

8
 Activity Testing Requirement Frequency

b). Trial Lay i). Aggregates Grading i). Table 4.8

ii). Binder Extraction ii). Table 4.9 (4 % - 6 % )

iii). Marshal Method:-

- Stability - >450 kg
- Flow - 2.0 mm
- Voids in Mix - 3.0% - 7.0%
- Voids in aggregate - 65% - 80%
filled with bitumen

iv). Lab Compaction Test iv). To determine lab density

v). In-situ Density Test v). >95% lab density

vi).Rolling Pattern vi). To select most suitable

pattern

Approving Officer Remark

Engineer JKR/SPJ 1988 CI 4.2.4

Activity Testing Requirement Frequency

c). Laying i). Sieve Analysis i). Table 4.8 i). 1 test / day of
(Gradation Analysis) production

ii). Binder Extraction ii). 4 % - 6 % ii). 1 test / 200

tons produced or
each plant
operation
iii). Marshal Method:-
- Stability - >450 kg iii).1 test / 200
- Flow - 2.0 mm tons produced
- Voids in Mix - 3.0% - 7.0%
- Voids in aggregate - 65% - 85%
filled with bitumen

iv). In-situ Density Test iv). > 95% lab density iv). One sample /
500 sq.m of area
laid or daily

v). Rolling Temperature (RT) v). Immediately RT > 110° C v). Every initial
rolling

Approving Officer Remark

Engineer JKR/SPJ 1988 CI 4.2.4

9
3. CONCRETE

Activity Testing Requirement Frequency

a) Concreting i). Strength i) Prescribed Mix As per Table 9.5

28 days strength must satisfy i) 3 cube / sample

at least one of the foolowing
1 nos – 7 days
a) fcu of each the two 2 nos – 28 days
cubes ≥ specified
compressive strength
b) average fcu of the two
cube ≥ specified
compressive strength
and the different
between the two
strength > 20% of
average strength

ii) Designed Mix

a) mean of 4 consecutive
sample > fcu + 0.5
current margin
b) individual sample fcu
> 0.85 x specified
compressive strength

3.1 MINIMUM RATE OF SAMPLING

Rate Volume of concrete from which

a sample shall be taken

Rate 1 Every 10 cu.m

(Pre-stressed Concrete) or every group of 10 batches*

Rate 2 Every 20 cu.m

(Ordinary Structural or every group of 20 batches*
Concrete)

Rate 3 Every 50 cu.m

(Mass Concrete) or every group of 50 batches*

10
 APPENDIX

TABLE 4.1 – GRADATION LIMITS FOR SUBBASE MATERIAL

B.S SIEVE
SIZE % PASSING BY WEIGHT

A B C D E F
50.00 mm 100 100 - - - -
25.00 mm - 79 – 95 100 100 100 100
9.50 mm 30 – 65 40 – 75 50 – 85 60 – 100 - -
4.75 mm 25 – 55 30 – 60 35 – 65 50 – 85 55 – 100 70 – 100
2.00 mm 15 – 40 20 – 45 c 25 – 50 40 – 70 40 – 100 55 – 100
42.50 mm 8 – 20 15 – 30 15 – 30 25 – 45 20 – 50 30 – 70
7.500 mm 2 – 8.0 5 – 20 5 – 20 5 – 20 6 – 20 8 – 25

TABLE 4.3 – GRADATION LIMITS FOR CRUSHED AGGREGATE ROADBASE

B.S SIEVE SIZE % PASSING BY WEGHT

TYPE 1 TYPPE II
50.00 mm 100 100
37.50 mm 95 – 100 85 – 100
28.00 mm - -
20.00 mm 60 – 80 70 – 100
10.00 mm 40 – 60 60 – 90
5.00 mm 25 – 40 40 – 65
2.36 mm 15 – 30 30 – 5.0
2.00 mm - -
600 mm 8 – 22 20 – 40
425 mm - 10 – 25
75.00 mm 0 – 8.0 2 – 10

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 TABLE 4.8 – GRADATION LIMITS FOR ASPHALTIC CONCRETE

MIX TYPE WEARING COURSE BINDER COURSE BINDER COURSE

MIX DESIGNATION ACW 14 ACB 14 ACB 28

B.S SIEVE SIZE % PASSING BY WEIGHT

37.50 mm - - 100
28.00 mm - - 80 – 100
20. 00 mm 100 100 72 – 93
14.00 mm 80 – 95 70 – 95 58 – 82
10.00 mm 68 – 90 56 – 81 50 – 75
5.00 mm 52 – 72 40 – 65 36 – 58
3.35 mm 45 – 62 32 – 58 30 – 52
1.18 mm 30 – 45 20 – 42 18 – 38
425 mm 17 – 30 12 – 28 11 – 25
150 mm 7 – 16 6 – 16 5 – 14
75.00 mm 4 – 10 4–8 3–8

TABLE 4.9 – DESIGN BITUMEN CONTENTS

CLASS OFMIX NORMAL RANGE OF DESIGN BITUMEN

CONTENTS BY WEIGHT OF MIX

ACW 14 - WEARING COURSE 5.0 - 7.0 %

ACW 14 - BINDER COURSE 4.5 - 6.5 %

ACW - BINDER COURSE 4.0 - 6.0 %

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 TABLE 9.5 – PRESCRIBED MIXES FOR GENERAL USE
PER CUBIC METRE OF CONCRETE

Nominal
size of
40 20
aggregate
28 days
(mm)
characteristic
Grade of
strength of
concrete
concrete
Workability Medium High Medium High
(N/mm2)

Slump limits 50 – 100 100 – 150 25 – 75 75 – 125

(mm)

15P 15 Cement (kg) 250 270 280 310

Total
aggregate 1850 1800 1800 1750
(kg)

Fine
aggregate 30 – 45 30 – 45 35 – 50 35 – 50
(kg)

20P 20 Cement (kg) 300 320 320 350

Total
aggregate 1850 1750 1800 1750
(kg)

Fine
aggregate 25 – 35 25 – 40 25 – 40 20 – 45
(kg)

25P 25 Cement (kg) 340 360 360 390

Total
aggregate 1800 1750 1750 1700
(kg)

Fine
aggregate 25 – 35 25 – 40 45 – 40 30 – 45
(kg)

13