This document h a s h prepared and dmhed by COLT0 (Committee 05: Eand Tmnspwt OFficmfsJ kphnmt o f Tmnsport and is for

tfre exclusive use by S i d e Rwd Avt)rwities fw R w d ond Bridge

works.
This document is s u p p o d by h e C'M~EnginewingA d v i q Council (CEAC).

EJCopyright: The Government of the Republic d South Africa

8 All rights reserved No part of this publication may be reproduced or transmitted in any form without permission of The Government of the Republic af S o h Africa acting through CEAC or its successor.
Published by the South African Institution of Civil Enginmring (SAKE].

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Tel:

(011) 805-5947/48/53 Fax: (01I) 805-5971 SAKE e-mail: civilinfo6xrice.orq.za

Please note: That the General Conditions of Conhact For R w d and Bridge Works for S t u k Rwd Authorities document is published under a separate cover. That any other authority or organisation, which would like t o use this document, must apply to CEAC #or authorisation,

Civil Enginering Advisory Commiiiee

PO Box 16265

Lyttelton
0140

Reproduced under Government Printer's Copyright Authority 10528 dated 3 March 1 998.

STANDARD SPEClRCATlONS FOR ROAD AND BRIDGE WORKS

CONTENTS

Section

SERIES 1000 : GENEWU1100 1200 1300 1400 1500 1600 1700 Definitionsandterms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General requirements and provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contractor's establishment on site and general obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Housing. offices and laboratories for the engineer's site personnel . . . . . . . . . . . . . . . . . . . . . . . . . . Accommodationoftraffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearingandgrubbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERIES 2000 : DRAlNAGE 2100 2200 2300 2400 Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prefabricatedculverts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Concrete kerbing, concrete channelling, chutes and downpipes, and concrete linings for open drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Asphaltandconcreteberms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEWES 3000 : EARTHWORKS AND PAVEMENT LAYERS OF GRAVEL OR CRUSHED STONE Borrowmaterials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selection. stockpiling and breaking-down the material from borrow pits and cuttings. and existing pavement layers. and placing and compacting the gravel layers . . . . . . . . . . . . . . . . . . Massearthworks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pavement layers of gravel material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................................. Stabilization Crushed-stonebase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plant-mixed paver-laid pavement layers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Breaking up existing pavement layers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Patching and repairing edge breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERIES 4000 : ASPHALT PAVEMENTS AND SEALS Primecoat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Asphaltbaseandsurfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seals : Materials and general requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Singleseals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doubleseals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bituminous single seal with slurry (Cape seal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surfacingofbridgedecks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Treatment of an existing surface exhibiting certain defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sandseals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERIES 5000 : ANCILLARY ROADWORKS Pitching. stonework and protection against erosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gabions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guideblocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guardrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roadsigns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roadmarkings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Landscaping and planting plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Finishing the road and road reserve and treating old roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Foundations for structures

......................................................

Falsswork. formwork and eoncrete finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel reinforcement for structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................................................... Concrete lor slructures Prestressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No-fines concrete. joints. bearings. bolt groups for electrification. and parapets and drainage for ~tructures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structural steelwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conslruction ~olerances for strucfures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

..

SEWES TWO : SUNDRY STRUCTUFIES

Concrete psvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinforced earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Concrete block paving for roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Patented earth retaining systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testlng material and workrnanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quality control (Scheme 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CJual~ty control (Scheme 2)

Painting

....................................................... ......................................................................

SERIES 1000 :GENERAL SECTION 1100 : DEFINITIONS AND TERMS

1101

ASPHALT

CONTENTS 1101 1102 1103 1104 1105 1106 1107 1108 1109 1110 1111 1112 1113 1114 1115 1116 1117 1118 1119 1120 1121 1122 1123 1124 1125 1126 1127 1128 1129 1130 1131 1132 1133 1134 1135 1136 1137 1138 1139 1140 1141 1142 1143 1144 1145 1146 1147 1148 1149 1150 1151 1152 1153 1154 1155 ASPHALT ASPHALT SURFACING BASE BORROW AREA BORROW MATERIAL BRIDGE CARRIAGEWAY CATCHWATER DRAIN OR BANK CALIFORNIA BEARING RATIO CEMENTED MATERIAL CULVERT CUT EXCESS OVERBURDEN FILL GENERAL CONDITIONS OF CONTRACT GRADE LINE GRADING MODULUS (GM) INLET AND OUTLET DRAINS LANE LEVELLING COURSE LOT MEDIAN MEDIAN DRAIN MILLING MITRE DRAIN AND BANK OVERLAY PAVEMENT LAYERS PAVEMENT PLANING PIONEER LAYER PROJECT SPECIFICATIONS RECYCLING REHABILITATION REINFORCEMENT FOR ASPHALT RETEXTURING ROADBED ROAD PRISM ROAD RESERVE ROLLER PASSES SCREED SEAL SELECTED LAYER SERVICES SIDE DRAIN SHOULDER SHOULDER BREAKPOINT STABILIZATION SLOPE SPOIL (MATERIAL) SUBBASE SUBSOIL DRAINAGE SYSTEM TEXTURE TREATMENT TRAVELLED WAY VERGE WHEEL TRACK WORK IN RESTRICTED AREAS

A mixture to predetermined proportions of aggregate, filler and bituminous binder material prepared off the road and usually placed by means of a paving machine.

1102 ASPHALT SURFACING

The layer or layers of asphalt constructed on top of the base, and, in some cases, the shoulders.

1103

BASE

A layer of material constructed on top of the subbase, or in the absence thereof, the selected layer. A base may extend to outside the travelled way.

1104

BORROW AREA

An area within designated boundaries, approved for the purpose of obtaining borrow material. A borrow pit is the excavated pit in a borrow area.

1105

BORROW MATERIAL

Any gravel, sand, soil, rock or ash obtained from borrow areas, dumps or sources other than cut within the road prism and which is used in the construction of the works. It shall not include crushed stone or sand obtained from commercial sources.

1106

BRIDGE

A structure erected over a depression, river! watercourse, railway line, road or other obstacle for carrying motor, railway, pedestrian or other traffic or services and having a length of 6 m or more, measured between the abutment faces along the centre line of the road at girder-bed level, except that road-over-rail or rail-over-road structures are always classed as bridges.

The surface normally traversed by vehicles and which consists of one or a number of contiguous traffic lanes, including auxiliary lanes and shoulders.

1108

CATCHWATER DRAIN OR BANK

Unless inconsistent with the context, in these specifications, the following terms, words or expressions shall have the meanings hereby assigned to them.

A longitudinal drain or bank outside the road prism for diverting water that would otherwise flow into the road prism.

The Cellfornla Bearing Ratto (CBR) 07 an untreated sol! or gravel as determined by means of Method A8 o l TMHI is the load In Newtons e ~ p r e s s e d as a percentage of Californla standard values, requirsd to allow a c~rcular piston of 1 935 n m 2 to penetrate the surface nf a compacted materlal at a rate af 1,27mm per mlnuts to depths of 2.54. 5.08 and 7.62 rnrn The California standard values lor these depths are 13,344, 20,016 snd 25,354 kN respectively.

The appropriate edition of the General Conditions nl Contract far Nalional and Provinc~alRoad and Bridge Warks, fogether with the special conditions of contract form~ng part of the contract

Materlal in an exisllng pavement which cannot b e broken up with the tines of a type 14OG caterpillar or similar road grader

The grade llne Is a reference line In the drawings of the lang~tudinalsections of the road indicating at regular intervals the elevations according to which !he road is to be constructed. The grade line may refer to the level ol the completed road, base or any other layer and may indicate the elevat~ons elther along the carriagevrsy centre Ilne or along any designated position on the road cross-section

Cemented crushed stone is cemented material constructed

with crushed stone.

An e ~ ~ s t i n stabillzed g pavement layer wlll not necessarily be classlrlad as cemented materral

The cumulat~vepercentages by mass of material In a representative sample of aggregate, gravel or soil retained on the 2 00 mm, 0,425 mm and 0.075 mrn sieves. divlded b y 100

1111

CULVERT

Astructure other than a br~dge, which provides an o p ~ n i n g under the carriageway or median tor dra~nageor other purposes.

Channels lead~ng into or discharging from culverts, starmwater cendu~ts and minor bridges

1112

CUT

Cut shall mean all excavations from the road prism, including side drains, e ~ c a v a t ~ a n s tor cross-roads, Interchanges, and, where classif~ed as cul, excavalions for open dra~ns,

Part of a travelled way ~ntendedfor a single stream of traff~c tn one d~rection, which has normally been demarcated as such by road mark~ngs,

1120

LRlELLlNG COURSE

One or more layers of asphalt of varying thicknesses, but

Overburden within a borrow area which is not required or is unsuifable for u s e in construclion,
w i t h a specified minimum total thickness, which are quality of a rand so that It applied lo Improve the r ~ d i n g

wrll meet specifled standards or so that constructing the f~nal surtac~ng or resurfac~ng layer in accordance with the required standards lor levels, thickness and surface grading will be possible A levelling course is a type of averlay
That portjon of the road prrsrn consisting of approved

Imported materlal whrch lies etbove the roadbed and is bounded by the side slopes. shown on the typrcal crosssectlong on the draw~ngs runnlng downwards and outwards from !he outer shoulder breakpoint and an whrch the selected layer, subbase base, shoulders and In the case of dual carrlageways, the rned~an, ate to be constructed Material lmported to replace unsuitable as d fttr. materlal In the roadbed shall also be c l a s s ~ f ~ e

1121

LOT

b sizable portion of work or quantity of rnater~al which Is

assessed as a unit fnr the purpose of quality control and selected to represent mater~al or work produced by ess~ntlally the same process and materials.

1131

RECYCLING

The area between the two travelled ways of a dual

Tha processing of salvaged material In a plant for re-use.

carriagtway, excluding the inner shoulders.

A longitudinal drain sltuated between the innslr shoulders of a dual carriageway

Measures aimed at maintaining or Improving the conditton andlor riding comfort of an ex~sting road.

1133

REINFORCEMENT FOR ASPHALT

Excavating and removing a layer of mafarial exceeding 10

mm in thickness fram an existing pavement by means of

an approved rnllllng machine. Milling is normally used only tn asphalt and cemented layers

A cloth or grld of synthetlc rnaterlal placed underneath or between asphalt layera for slrengthening the asphalt,

1125

M r n DWUN

AND BANK
Treatment of an existing road surface to restore the texture to a specified depth of tenture or skid resistance.

A drain constructed e: an angle la the centre line of the road to divert water from a side draln. Mitre drarns ~nclude rnqtre banks placed across !ha side drains.

The natural In sltu makerla! on whlch the fill, or In the absenceof fill, any pavement layers, are to be constructed
A n additional pavement layer applied on top a1 an existing road for strengthening the pavemenl andlor for Improving the riding quality

The upper layers of the road compris~ngthe selected layers, subbase, base or gravel wearrng coucse and the shoulder layers.

That portion of the road construction includad between the or~ginalground level and the outer boundaries of !he slopes of cuttings, fills and side drains. It shall not include !he selected layer, subbase, base, surfac~ng, shoulders or roadbed

1 f 37 1128 PAVEMENT P M I N G
Planing el an e ~ l s t ~ n road q surface by the removal of a layer of material by means of a milling machine or other equipmenl

ROAD R E S E W

The entire area Included by the boundaries of a road as procla~med.

1138

R O W PASSES

1129

PIONEW LAYEF!
Unless otherwise specdied In the specificatians or the

An initial layer constructed aver a weak roadbed where select~d marerial 1 s used l o provide a stable platform for the construction of subsequent layers.

project specifimtions, an area will bs taken ta have received on0 roller pass when a roller has passed over

such area once. Additional passes made only as a tesult of nominal overlapping so as lo ensure full coverageshnlT not be taken into account.

1130

PROJECT SPECIFICATIONS

The specificalions relating to a specific project, which form part of the contract documents for such project, and which contam supplementary andlor amending specifications to the standard spec~llcat~ons.

A layer of f~ne-graded asphalt or slurry ptaced to flll f n slacks in exist~ng seals and to Improve !he r ~ d ~ n quality g of the road

1140

SEN

of the vertical difference in elevation between any two points and the- hotizontal distance between them.

The appFfcatlon of one or more layers of bitumlnous blnder with or without layers of crushed stone, sand or slurry In successiw layers on the carrlageway, shoulders o r on any other compacted layer on whlch movement of treff fc takes place.

This ratlo may also be expressed as a percentage.

The tower layer or layers of the pavement which I s constructed dlrecl onto the fill, or In some cases the roadbed, It may include roadbed material compacted in
91tu.

Material originating from construction operations and whlch is not utllized for construction purposes.

114s

SUBBASE

Tha layer of material on top of the snlectad layers or fill and below the base and shoulders. Cables, plpes or other structures to provide, inter alia, conduits for electricity, telephons and telegraph connsclions, water, sewaga, etc

An open longltudlnal drain situated adjacent to and at the bottom of cut or fill slopes,

A system OF subsoil drainage plpes (includlng any permeable material) constructed to intercept and remove subsoll water.

(a) When referring to this as a surface: The area betwatln tha outside edge of the travelled way and the shoulder breakpoint.

Treatment of an exlsting road surface to obtain a uniform texture.

(b) When referring to this as a pavement layer: The upper pavement Iayer lying between the outside edge of the base and the shoulder breakpoint.

That portion of the carriageway which includes the various traffic lanes and auxiliary lanes buf excludes the shoulders.

The line along whlch tha extended flat planes of the surface of the shoulder and the outside slope of the fill and pavement intersect. This edge I3 normally rounded to a predetermined radius.

The area between the outer edge of the road prism and the boundary of the road reserve.

1154

WHEEL TRACK

The treatment ol tha materials used in the construmion of

the roadbed, fill or pavement layers by the addition of a cementitlous binder such as lime or Portland cement or the mechanicel modification of the materFal through the addition of a so11 binder or a bitumlnous binder. Asphalt and concrete shall not be considered as materials that have been slabilizad.

The path followed by the wheels of a vehicle during normal riding movements. The wheel tracks cover approximately the outer metre w~dth on both s~des of a traffic lane.

1147

SLOPE

Unless otherwise stated, slops is given in terms of the ratio

No additional or sxrra ever payment w ~ lbe l made lor work in restricted areas, unless the atems of work to which it will apply and the pay Items under which payment wlll be effected, are ewpl~c~tly specified in these standard speclkcations or In the project spscifieat!ons and llsted in the schedule of quantities.

SHOULDER 1

1 SHOULDER

c~lnlll neo

$:

n~lkfhl

C
ROAOBED

1"
I

MEDIAN QRATN

FIGURE I
m

ROAD RESERVE
m tr. I

SHOULDER BREAKPOINT

iP
I T

ROADBED -

FIGURE 2
THE ROAD PRISM IN FIGURE 1: THE VOLUME EXCAVATED BETWEEN AOCOEFCHIA ANlg ANY F I L L CONSTRIjCTEO DN UC 6 GH T11E n O A n Pn15H I N FIGURE 2 : THE V n t U H E EXCAYATEO DETWEEEI UCnEFB AIJIJ TllE FILL ABGd

8
UI

FIGURE 1100: CROSS-SECTIONAL ELEMENTS

THE

OF A ROA'13
WHERE TO THE CONTRARY,

ThESE THO DIAGRAMS ARE INTENDED TO ILLUSTRATE THE D E F l N l T l O N S OF SECTION I f 0 0 ONLY, AND.

DEFINITIONS SHALL PREVAIL

affected by the construdlon of the works.

SECTKm f 2ME :GENEfWL REOUIREMENTS AND

PrnStONS

The employer WID, in the contract documents, provlde

information regarding the tocatlon of exlsting utility services, but the employer does not accept responsibility for the accuracy of thfs inhrmatlnn.

SCOPE
SERVICES ROAD INTERSECTIONS AND JUNCTIONS PROGRAMME OF WORK WORKMANSHIP AND QUALITY CONTROL THE SETTING-OUT OF WORK AND PROTECTION

OF BEACONS NOTICES, SIGNS AND ADVERTISEMENTS

MEASUREMENT PAYMENT CERTIFICATE OF PRACTICAL COMPLETION OF THE WORKS TRnFFlC OVER COMPLETED PAVEMENT W E R S ALTERNATIVE DESIGNS AND OFFERS VARIATION FROM SPECIFIED NOMINAL RATES OF APPLICATTON OR NOMINAL MlX PROPORTIONS CONTRACTOR'S ACTIVITIES IN RESPECT OF PROPERW OUTSIDE THE ROAD RESERVE AND OF SERVICES MOVED, DAMAGED OR ALTERED EXTENSION OF TIME RESULTING FROM ABNORMAL RAINFALL INFORMATION FURNISHED BY THE EMPLOYER PROTECTION OF THE WORKS AND REQUIREMENTS TO BE MET BEFORE CONSTRUCTION OF NEW WORK ON TOP OF COMPLETED WORK IS COMMENCED REMEDIAL WORK WATER A U T H O R I Z E D M E A S U R E M E N T S AND TOLER4NCES DRAWNGS PROVIDED BY THE CONTRACTOR THE USE OF WPLOSIVES WORK ON. OVER, UNDER OR ADJACENT TO RAILWAY LINES THE HANDING-OVER OF THE ROAD RESERVE HAUL ROADS MEASUREMENT OF DEPTH OF TRENCHES AND FOUNDATIONS EXCAVATIONS MONTHLY SITE MEETINGS LEGAL PROVlSlONS SABS CEMENT SPECIFICATIONS

The contractor shall check and determine on the site the posllions of any servlces shown on the drawings. Thls shall be done by visual inspections, using detecting apparatus, and by making excavations to expose the position of the servlce at critlcal points This shall also be done where no sewlces are shown on tha drawings but where such services are never!heless believed to be present. The positions of all services so detected shall be marked carefully and then drawn In on the drawings. These services will then be defined as known servlces. The contractor shall take all reasonable precautions not to damags the services during the search, when the onus shall rest wlth him to prove that, In the event of damags being done to such services during the search, it was not hls fault that they had been damaged
The contractor will be hsld responsible lor any damags caused by him to known servlces, unless he E m prove that he has taken air the above precautions and that the damage has nevertheless been caused becauss the posltion of the known service hed devlatwd by more than one metre from the position as may leasonably have been deduced from the Investigation made by him.

The contractor shalT take all reasonable precautions te protect erlsting services durlng construction and during W e r e prolectlvs the relocation of such services. measums involve the construction nt permanent work, the contractor shall execute the work In accordance with the engineer's Instructions, and payment shall be made as provided In the project speclficatlons.
All pipes, cables, condults or other known services of any nature whatsoever damaged as a result of the contractor's operations shall be repaired and reinstated forthwith by tha contractor or by the authority concerned, all at the expense of the contractor and t o the satisfaction of the engineer.

ll shall be clearly understood that, In ceflafn instances. e~isting rewlces can be relocated only after the contractor has advanced sufficiently on or has compFsted certain sections of earthworks or certain struclures.
W e n e v e r sewlcesareencountared whlch interfere wlth the execution of the works and which require ta be moved and relocated, the contractor shall advise the engineer, who wiFl daterm~ne the entent of the work, if any, to be undertaken by the contractor in moving, relocating and reinstating or protectlng such services.
Any work requlred to be undertaken by the contractor in protecting, moving and relocating the servlces tor whlch no provision has been made In the contract documents, or for which there are no appropriale tender fates, will be classed as a var~ation,as provided In the general mndltFons of contract The contractor shall work In close m-operatlon wlth private owners Dr public authorities controlling ssrvlcas whlch have to be protected, moved or relocated Details regarding the

This section covers matters whlch relate to the contract as a whole. Definitions, phrases or wordlng whlch would otherwise ~equire repetition In other sect~ons of the specifications are also covered by clauses In this section Matters covered by the general cenditinns of contract are not repeated In thls section, sxcapt where necessary for providing more detailed informat~on.

Thls contract may inelude certain work relating to the moving and reinstating of existing services that may be

state of negotiations concluded between the employer and n respect of the time the owner at the time of tendering I when either the owner is prepared to start moving such services or when the contcactor is requlred to or will be allowed l o start moving the services, and the duration o l such operations, will either be stated in the tender documents or be made ava~lable to tenderers. Should the owners ot services refuse t o co-operate with the contractor in a reasonabla manner in connection with the protection or moving of services betonging to them, the contractor shall refer the matter to the engineer When the contractor details hrs programme n f work as referred to In clause 15 of the general conditions of contract, he shall, E n consultation with the engineer, clearly indicate as to when he proposes to start with and conclude the movlng of each service or when ha will require the owner to start wlth and conclude the moving of each service Should It thereafter, through delays on the part of the employer or the owner of the sewlce to be moved. be imposs~bleto adhere to the programme of work, such programme shall be suitably amended by the cantractor In consullation with the engineer so as to Ilmit. In so far as is possible, the extent of any damages or delays. Should it be impossible to limit entirely the damages nr delays resulting from the amendments necessaty to the programme of work. the contractor shall be reimbursed lor any additional costs incurred or damages suffered by him

by more andlor better labour and equipment being provided on the site or by the available labour and e q u ~ p m e nbeing l ut~liz~ more d effect~vely. The approval by the engineer of any programme shall have no contractual sign~flcance other than that the engineer would be sat~sfbedH the work is carried out tn accordance with such programme and that the contractor undertakes to carry out the work in accordance with the programme, neither shall Ilimit the right of the engineer to instruct the contractor to vary the programme should circumstances so requrre The above shall not ba taken to limit the rlgh? of the contractor to claim for damages or extension of time to which he may be fa~rlyentitled In tprrns of fhe general conditions of contract for delay or d~sruptton of h ~ actlv~t~es. s Should the employer request and the contractor undertake t o finish the whole or part of the works ahead of the time oriigjnally requ~red by the contract, payment fur accelerating the work shall be made only if agreed on beforehand, in writing, and i n terms e l such agreement

(b)

Programme of work for rehabilitarion work

1ZW

fWAD INTERSECTIONS AND JUNCTlONS

Except where otherwise spec~fled,no additional ;payment over and above payment for the various items of work included In this contract wlll be made for the construction, In a confined space. of curves tapers, bellrnouths, traffic !$lands, farm accesses and other appurtenant works in connection with the construction and maintenance of road Intersections and junctions
The contractor shall be required 10 provide the safe and the unrestricted flow of public traffic at all limes d u r ~ n g construction and maintenance of such intersectmns and juncfion~.

The contractor shall note that the examination of a road with a view to rehabilitat~onis normally undertaken a considerable period of tlme before the commencement of the contract, and that cond~tions may subsequenlly change. The engineer will make further examinations during the period of contract. and, depending on the results of such exsrninations, the quantities of any items of work may be drast~cally increased or decreased. The contractor shall base hls Initial programme of work on the scope of the work as described In the project specificat~ons, and, apart from any other programme t o be submitted by him, he shall also submit a network programme in accordance with the critical-path method. This programme shall be reviewed on a regular basis, eg monthly, by the contractor in accordance with changing clrcumstances, delays and amendments to the work ordered by the engineer as a result of further exam~natiens made by h ~ m ,and the revised programme shall be submitted to the engineer for approval. The revrsed programme shall then be used by the contractor In order the necessary adaptations to the resources to determ~ne requtred by hlm for the work. ddlustments to the critical-path programme will, ~ntPr alia serve as the basis tor determining any extenston of t ~ m e to wh~ct-the contractor m a y b e ent~tled. Any d e v ~ a t ~ o from n the approved programme by the contractor w ~ l b l e at h ~ s own risk, and no claim for delay arising therefrom wrll be considered,

1204

PROGRAMME OF WORK

(a)

General requirements

Tha contractor shall base hls Inltlal programme of work on the scope of work as described In the project specifications, and, apart lrom any other programme to be submined by h ~ m ,he shall also submit a network programme in accordance with the critical-path method
Should ths contractor fall b e h ~ n dwith the approved programme !he employer may, without prejudice to the employer's rights, require the contractor to submit. w~thin seven days of the date on which he has received a notice to this effect, a revised programme, which ind~catesthe manner in which the contractor undertakes to complete the works wlthln the requlred time. k n y proposal in the revlsed programme to accelerate the rate of progress shall be accompanled by pasitlve steps to Increase productmn

12U5

W R Y S H I P AND Q U W M3W430L

The anus rests wlth the contractor to produce work whlch conforms In qual~tyand accuracy of &tall to all the requirements of the specit~cationsand drawings. and the contractor shall. at his own expense, inst~tutea qual~tycontrol system and provide experienced engineers.

foremen, surveyors, materials technicians, other technielans and other technical staff, together with all transport, instruments and equipment, to ensure adequate supenlsion and posltlve control of the works at all tlmes. The conlractor shall conduct tests or have them conducted continually on a regular basis, to check the properties of natural materials and processed natural materials and nf products: manufactured on the site, such as concrete and asphalt, Although not a requirement for the contractor to conducl regular tests on any commercially produced products such as cement, bitumen, steel and pipes, the contraclor shall remain fully responsible for any defective material or equipment provided b y him. Similarly. the quality of all elements of the works shall b e checked on a regular basis so as T o ensure compliance with the specified requiremenls. The IntensTty of control and of tests 10 be conducted by the contractor in terms of these obligations is not specifled but shalE be adequate t o ensure that proper control is being exercised,

construction operations. Ihe contractor shall establish suitable reference beacons at locations where they will not be displaced during construction. No beacon shall be covered over, displaced o r destroyed before accurate reference beacons have been established and details of the position and levels of such beacons have been The submitted to and approved by the engineer contractor's reference beacons shall be of at least the same quality and durability as the exlstlng beacons The contractor shall submit to the engineer the method of setting-out ha proposes to employ To ensure beyond all doubt that the complex elements of the road, such as traffic interchanges. structures and other important features are located truly rind correctly, the contractor shall check all setting4ut by a second method. The engineer may at any trme request the contractor t o submit proof that his setting-out has been satisfactorily checked In cases where the displacement of or damage to property
beacons or trigonometrlcal-survey beacons Is unavoidable, the conttactar shall norify the engineer in good time so that he m a y arrange ta have such beacons suitably referenced and later on refnstated. The cast of such work, i f paid for by the contractor, shall be reimbursable as extra

W e r e any natural maler~als or products made from natural

materials are supplied, and upon completion of each element of the construction work, the contractor shall test and check such materials, products andlor elements for compliance with the specified requirements and shall submlt his resulns to the engineer for approval Such submission shall include all h ~ measurements s and lest resultsand shall furnish adequare proof of compliance w ~ t h the specifiad requirements. No specific pay Items are provided as compensation far the above obligations, including the provision of all samples delivered to the engineer, the repair of places from which samples were taken, and the provision of the necessary personnel and testing apparatus and facilities, for which compensation shall be ~ncluded fn the tendered rates of the conlractor for the varrous items of work to which these obligations apply.

work, as provided In the general conditions of contract. For the purposes of this clause and nf clause 74 of !he general conditions of contract, any beacon made from a metal peg cast In concrete and any boundary beacon. whether or not cast In concrete, shall be regarded as a beacon Centre-line pegs shall not be classlfled as beacons, To protect beacons, the boundary fences of the road reserve shall be splayed at corners so as to avoid the use af corner posts in the same position as property or tr~gonometrical-survey beacons, all as shown on the drawings.

The contractor's attention is also drawn to the provlslons of clauses 8209 or 8308 in regard to Instituting specific process-control systems.

1XS

THE S E T I N E M OF WORK AND PROTECTION OF BEACONS

Accwrate control of line and level shall be provided by the contractor at all stages of construction. In respect of the road itself. control shall be at 20 m intervals or such closer intervals as may be directed for horitonZal and vertical curves Wherever necessary, but partrcularly on completion of the fill and the base, the contractor shall reestablish stake-line pegs at s u f l ~ c i ~ n t lclose y Intervals to determine accurately the position of the edges of the base. surfacing and especially kerbing, guardrails and other road elements permanently v~slble.
The setting-out of work will not be measured and paid lor directly, and compensation for the work involved in settingout will be deemed In be covered by the rates tendered and paid for the varieus items of work included in t h ~ s contract

The contractnr's attention is drawn to The requirements of clause 14 of the general conditions of contract, and he shall also comply with all legal provisions in regard to surveying and setting aut work.

The contractor shall cheek the condition of all reference

that they have and level beacons and shall satisfy h~rnsell not been displaced and are true in regard to position and level. tf beacons have been destroyed, d~splaced or damaged before the slte is handed over to the contiactor. the engineer will arrange to have new beacons installed A beacon which has been displaced shall not be used unless its true position and lever have been re-established and the! new values verified by the engineer.

12U7

NOTICES. StGNS AND ADVERTISEM!3TS

The contractor shall not erect any signs, notices or advertisements on or along the works or the slte of the viorks without the written approval of the engineer At each end of the works the contractor shall provide and erect. as part o l h ~ obligations s under section 1300, and on

Where a beacon is likely l o be displaced during

approved locations, at the starting and ending points of Ihe works, signboards of sound, weatherproof construction, painted by an approved firm of srgnwriters In accordance w~th the derails shown on the drawtngs
These signs are to be erected not later than one month after the contractor has been given access to the slte.

(iv) Structures shall be measured to the neat lines shown on the drawings and shall ~ncludeany changes ordered in writing by the englneer and. for purposes ol payment, the calculated volume of concrete structures shall incrude the volume of reinforcing steel, and minor ducts up to 150 mm in diameter

The signboards shall be painted wlth the legend allernalely in English and Afrikaans. No signboards other than those specified above will be perrn~ttedon or adjacent In the works, except that the contractor may permlt each of h ~ ss u b m n t r ~ c t o r s to d~splay one signboard, and one only, of less than 2 rn? at the works off~ce.
(a)

Conhct rates

The engineer shall have the right to have any slgn, notice or advertisement moved to a better posit~on or to have ~t removed from the site of the works If it should in any way prove unsatisfactory, inconvenient or dangerous to the general public
All advertrsements, notlces and temporary signs shall be removed by the contractor upon completion of the works

In computing the final cantract amount, payment shall be based on !he actual quantity of authorized work done In accordance wrth the specif~cationsand drawings. The tendered rates shall apply, sublect to the provisions of the general cond~tions of contract, irrespect~ve of whether the
actual quantit~erare more or less than ths scheduled quantities

M e r e no rate or price has been entered agalnst a pay item in the schedule of quantities by a tenderer. ~t shall be understood that he does not require any compensation for such work Where, however, a pay ilem described in these specillcations or In the project specifications does not appear in the schedule of quant~tres,the contractor will receive reasonable compensation for such work if requ~red, unless anything to the contrary has been determined elsewhere

(a!

'Units d measurements
(b)
Rates t o be indusive

AIE work shall be measured In accordance with the SI System of metric units.

( b 3

Schedule of q u a n t i i

The quantities set out in the schedule af quantities are estimated quantities and are used for the comparison of tenders and for awarding the contract. It must b e clearly understood that only the actual quantities of work done or mater~als supplied will be measured for payrneol and that rhe scheduled quantities may be ~ncrcased or decreased as prou~ded in the general c ~ n d ~ t i o n of s contract

The contractor shall accept the payment provided In the conlract and represented by the rates tanderad by him In the schedule of quant~t~es, as payment In fulr for executing and completing the work as specrf~ed, for procuring. furnishing, placing and install~ng all materials, lor procuring and providing labour, supervision, constructional plant, tools and equipment lor wastage, Transport, loading and off-loading. handling, maintenance, temporary work, testing, qual~ty control bncluding process conrrol, overheads, profit, risk and other obligations and lor all necessary lor the complet~on of the work other inc~denlals and rnalntenance durmg the period of maintenance. The contractor shall note that Ihe cost of all works and malerials for minor construction details at bridges, for example small quantities of caulking compound and joint tiller (other than expansran joinfs), anchor-bar covers, etc, not shown in the schedule of quantities, shall be included i n the tendered rates tor concrete.
This clause shall apply i n full t o all pay items axcept where these requirements may be spectfically amended In each case

(c)

Measurement of wmpleted work

All distances along the centre line of the road as i shown on tho drawtngs are horizontal distances which will be used in calculating the quantltles of f ~ l and l pavemenr layers lor purposes of payment. All cross-sectrons shall be taken In a vert~cal plane

All mater~als which are specifled to be measured in (111 a vehicle shall be hauled In vehicles o f such type and size that the actual volume may be readily and accurately derermrned Unless all veh~cles are of u n ~ f o r m capacity. each vehicle shall bear a plainly legible ldentrf~cat~on mark indicatrng its specific approved capacity.

(c)

The meanings of wmin

clauses

phrases in payment

(i) The quantity of bituminous and similar materials to the specified temperature. (iil)

Procuring and furnishing

... {material)

be paid by volume shall b e measured at

Where any or the words "supply". "procure", "provide". "provision of" or "furn~sh [material)' are used i n the dsscr~ption of a pay item, it shall mean the supply and

delivery to the point of use of all materials of any klnd required for the work covered by the particular pay item. Including all tax, purchase costs, clalrns, damages, royalties and transport costs Involved, but excluding overhaul. In the case of borrow materials, stone and sand. it shall also include all negotiations with the owners concerned, excavating, producing, preparing, proc~ssing, testing, hauling and delivering the material to the polnt of use: the construction, repair, maintenance and rnaklng good after completion 07 all access roads, and all work required in opening. using and finishing off borrow pits unless covered by other pay ttems rn the schedule of quantities.

clearly marked with the contractor's name, the contract number and other parlicul~rs in accordance with the engineer's instructions.

(it)

Placing material

Against an item in the schedule of quantities where no quantity is given but a rats only is requlred, the contrector shall flll In a rate or amount which will constitute payment for work which may be done in terms of this item. Such rate-only Item Is used where it Is estlrnared that little or no work will be required under the item, or where the item is to be consldered as an alternative for another item where a quantlty is gtven, or lor variattons i n rates of appl~cation ar mi%proport~ons In terms of clause 1213 of thrs section.

The phrase "placing material" shall mean tha off-loading, spreading, blending, processing, watering, miring, shaping and compactrng (where specified) of the material in the pavement layers, fills and bypasses, as well as the procuring, furnishing, applying and admixing of water: t h ~ breakingdown of oversize material, the removing of oversize materlal which cannot be broken down, correcting irregular or uneven surfaces or layers, the thickness o l which is not to speclftcation, fin~shing-oft to within the specified lalarances, the refilling of test holes and mafntstning the completed work. In the case of asphalt courses and bituminous seals, it shall also mean ?he heating and spraying of binder, the spreading of aggregate or asphalt mlntures, rolling, compactrng. l~nlsh~ng-off to within the speclfred tolerances, and rnaintarning the compleled work.

Werk under rate-only items will be paid for only if it hes been enecuted In terms of a written instruction by the
engineer.

1210

CERTIFICATE OF PRACTICAL COMFtJTiON OF

M E WOAKS
Amongst others the following sections of the works are to be duly completed to the satisfaction of the englneer to justify the issue of a certificate of practical complatlon i n
terms of clause 54 of the general conditions of contract:

(a) The gravel wearlng course, seats, asphalt or concrete pavement:

(b) all above-ground and subsoil drainage structures; all fencing: the l~nishing-off of medians and slopes of cuts and

The phrase "procuring furnishing and placing" shall maan procuring and furnishing in add~tionto placing, all as defined hereln.

(c)

Id)

Pay items

Id) fills,

The descriptions under the pay items in the various sectlons of the speclfications, indlcalrng the work for which allowance shall be made In the tendered rates for such pay items, are for the guldance of the contractor and do not necessarily repeal all the detalls of work and materials required by and described In the speclfications These descriptions shall be read in conjunction wlth the relevant specifications and drawings, and the contractor shall, when tendering, bear in mind that his rates shall be inclusive as specified E n subclause (b) above,

(e) all the necessary roed signs and road-surface markings:

(fj

all guardrails;
all structures;

(gI
(h)

the finishing-off of ail borrowpits

1211
(e)

TRAFFIC

OVER

COMPLETEU

PAVEMENT

Lwms
Matwials cm the site
Traffic over structures or pavement layers of an uncompleted road shall, i n addition to orher restrictions specltied elsewhere, be restricted 20 equipment required fur its construcf~on, wrth the proviso that traffic for hauling material over pavement layers, in so far as is possible. shall b e llmited to a mlnlmurn b y construction roads and deviations belng used Traffic over structures or the completed road will be restricted to the rnaxlmum axle load permitted i n terms of slarutory prnvisions. Any damage to structures or completed layers caused by the contractor's rraffic shall b e Payment in terms of clause 52 of the general conditions ol contract for materials on the site. which have not yet been incorporated in the works, will be calculated at BDob of the~r purchase price, or, in the case of crushed stone which has not been purchased but has been produced on the site, at BDO:. of a fair avaluatlon of such mater~al.

The englneer may at his sole discretion allow payment under "malerials on the site" in respect of artlcles such as precast beams manufactured and stored aff slte, subject la their having been completed, to proof of thelr ownership as berng that of the contractor, and to the articles being

repaired at his own cost.

foundation particularsappearlng In the contract document. Drawings for aiternative designs shall be prepared in accordance with !he provisions of clause 1221.

1212

ALTERNATIVE DESIGNS AND OFFERS

Unless anything to the contrary has been determined elsewhere in the confract documents, a tenderer may, rogerher with his tender for the orlgbnal designs contained in tha contract documents, submtt alternative designs and offers for consideration. Such alternative designs and offers shall be sublect to the following conditions and requirements

(e)

Ouantities

(a)

Tendm

An alternative offer or design will be considered only if the tender for the original items has been fully priced and completed. Unless the alternative offer stipulates to the contrary, it shall be assumed that the period for completion of the works shall be the same as for the original design. An alternative offer or design shall b e submitted together with the lender for the original items or design, otherwrse It wlll not be considered when tenders are adludicated. Calculations, drawings and a mod~fied schedule of quantities (as determined hereafter) in respect of each alternatfve offer or design shall accompany the alternative tender offer.

Each alternative offer shall be accornpanled by a modified priced schedule of quant~ties compiled in accordance with the standard specifications, in so far as at is appl~cable. which clearly shows the manner In whlch the prlce for the original schedule of quantit~es which fall away or are being changed. In addition to the schedule of quantities, a set of calculaf~ons shall be supplied to show how the quantltles have bean determined. All assumptions in regard to foundation conditions or other factors which will determine quantities shall be clearly and conspicuously marked by underlining or colouring, and shall indicate whether or not Ihe assumptions have been based on inforrnatlon furnished tn the contract documents (wlth the necessary references).

(f)

Further details

@)

Design codes

Should the engineer find that the caiculations and draw~ngs submitted for alternative designs are not complete enough for proper ~djudication of the alternative designs, it may mean that no further consideration will be given to such alternative designs The employer, however, to call on the tenderer to submit reserves to itself the r~ght such further caicuiat~ons and draw~ngs as may be required. If such further details are not submitted within ten days of having been requested, !he alternative des~gns may possibly not be given further consideration

Alternative designs shall be executed str~ctly in accordance with the appropriale deslgn codes and prescriptions of the employer. Copies of such codes and prescriptlong will be avallable for perusal at the off~ce of the engineer, but the onus rests wlth the contractor to ensure that he complies with tha deslgn requirements of the employer.

(g)

Preliminary adludication of alternative designs

Preliminary calculations tor an alternat~ve design shall b e submitted with the tender. Such calculations shall give adequate details so as to enable an assessment to be made of the general efficacy of the design and of its principal elements, aiso of the degree to whlch the design prescr~ptions and codes of the employer are being complied with. The calculations shall be clear and In a logical sequence and shall clearly reflect all the design assumptions.

The engineer will undertake a preliminary scrutiny of any elternat~vedesigns for compliance w~ththe specified requ~rements of the employer. Should he find any mlstakas or unsalisfactory aspects, he may afford the contractor the opportunity to rectify them within a period to be determined by the engineer, However, it is emphasized that the preliminary scrutiny of the design and tender by the engineer, by its very nature, cannot be comprehensive, and no guarantee can be given in this regard that all the mistakes made by the contractor will in fact bo detected, Any correction of such mistakes shall be made with the tender price of the contractor being reta~nad, and, wherever necessary, the pr~ced schedule of quantities for the alternat~ve design shall be adjusted accord~ngly.

(h)
(d)

Acceptance of alternative design

Preliminary drawings
The contraclnr shall note that the acceptance of a tender whlch indudss alternative designs shall mean that the alternat~ve designs have been approved in pr~ncep[e only. If the f~nal cdculations drawings and details do not comply with the specified requirements, such alternative designs may be rejected, unless they are suitably amended by the contraclor so as to be acceptable to the engineer.

Prelfmlnary drawings of the alternat~ve des~gns shall also be swbrnltted with the tender. These draw~ngsshall comprise adequate layout plans, elevations and sect~ons and shaH clearly Illustrate the general efficacy of the des~gn and its principal elements. Foundation depths and other elements depending on foundation conditions shall, in so far as may be applicable, be in accordance w~th

( I J Final drsnings and dculablons aml the priced schedule of quantities Where a tender with an alternative design has been accepted, the contractor shall, not less than three months before he intends starting with the construction of such design, submit to !he engineer a complete set of worklng drawings, detailed calculations and a complete schedule of quantities, for approval. Ths schedule of quanfltles shall bs based on the prellmlnary schedule of quantrtles, but with the necessary adjustments In quantitles and prices and with the tendered price for the alternative deslgn belng retained.
Wthln six weeks ot having received the above, the engineer will Indicate which drawings, calculations, quantities, prices and other particulars are acceptable to him and whlch not, with reasons lurnlshed. The contractor shall then submit to the eng.lneer in good time any rnodlfied drawings and other particulars for approval, for from the which he wit1 require two weeks. Any delay aria~ng fact that the amended particulars do not meet the requirements shall be the responstbllity of the contractor. No work whkh wlll be affected by an alternative design may be commenced, unless the drawings, schedule of quantlttes and prlces for such alternative desIgn have been approved. Should tha contractor fall to modify any drawings, calculations, quant~t~es, prlces or any other particulars to the satisfaction of the engineer, the alternative design will be rejected and the original design shall bo constructed for the same amount as has been tendered for the alternative dss~gn.

engineer

(1)

01 Eh@&ing h a t i v e designs

The contractor shall, in hls tander for each alternative deslgn, include an Item to cover the cost for checking his design. Thls Item shall be 5% of the tendered amount of the destgn wlthout any price adjustment in terms nf ctause 49 of the general conditions of contract behg considered, and the amount wlll be payable to ?heenglneer only upon an authorization issued by the employer.

(m)

Mtemalh Dflers

Alternative offers in this context shatl mean offers not relatTng to a structure, such as a bridge, wh~ch requlrss a comprehensive structural analysis. It involves, in the rnaln, offers for the use of other materials, construction programmes, alternative routes, etc. In this case The provbsions of clause 1212 wlll srlll apply, except In the case where the contractor, in consultaZion with the employer, may agree to amend or dalete certaln of the provisions, depending on the nature of the offer, but subject to a wriflen agreemant beforehand wfth the employer.

fzt3

vmnm
OF

FROM S P E ~ E D NOW RRTES APPLICATION OR NOMINAL MIX PROPORTlONS

The approval of a deslgn by the engineer shall In no way relieve the contractor of his responsibility to produca a des~gn which conforms in all respects to all the specified requirements and which wlll be suitable for the purpose envisaged.
Should It appear leter during construction or during the rnaIntenance psrlod that the design does not conform to the specified requirements, the contractor only shall be llable for any damage arising ?hersframand he shall, at his own expense, do all the necessary work ta ensure that the structure conforms to all the speclfied requirements.

The varlaus sections of these specifications spsclfy nominal rates of appllcation o r nornfnal rnlx proportlonsfor materialssuch es brturnlneus materials, aggregates, fillers, stabillzing agents, palnt and the like. Tenderers shall base Zhetr tenders on these nomlnal rates of appllcatlon and mlx proportions.

Whets such nominal rates af application or mix proportions are speclfled, provision I s made tor deviations in the quantities of material in consequence of the rates of application or mix propnrtions prescrlbed by the engineer in each aa.rticular case In consideration of the availablematerials and the conditions on the site.

Where the actual rates of application or r n l ~ proporlions used in the works vary from the specified nominal rates and mix proportions, adjustment of compensation wlll be made as a payment to the contractor F n respect of any (a) authorized Increase in quantltles whlch enceed those specified, where such Increase has been ordered, In
wr~ting, by the engineer:

(k)

Payments for alternative designs

Payments for alternative designs will be based on the finally approved schedule of quantities end rates for such designs. The lump sum fur an alternative- deslgn will remain fixed and wlfl be the final amount payabCa to the contractor in regard to such deslgn, except only for deviations arising from foundation mndltlons whlch differ from foundation (i) conditions shown In the contract documents, or in regard Zo assumptions regarding foundation conditions staled in his tender by the contractor and accepted by the englneer: changes not arlslng from any failure or fault of the (ii) contractor, but from rnodificatlons requested by the

as a refund to the empfoyet in respect of the {b) decrease In quantities w h ~ c h are less than those speclfled, Irrespective of whether such decrease results from an authorized decrease In the rates of applicatron or mix proportlonc, or from unautharfzed reductions on the part of the contractor.
Payment for a prescribed tare of appllcation or mix

proportion shall be based on the actual rate of application or mlK proportion used, provided that this does not enceed the prescribed rate of applicatlon or mix proportion. plus any tolerance in the rate of application or mix proportion allowed. If the ectual rate of applicatlon or mix proportion exceeds the prescribed rate or pmport~on, payment shall be based on the prescribed rate of applicanion or mln proportinn plus any tolerance allowed. It the actual rate of appl~cation er mls proportion is below the prescribed rate of application or mix proportion ordered, payment shall be based on the actual rate of applicatien or mix proportion regardtess of any tolerance allowed. Notwithstanding the above, the engineer shall be fully entltled to reject work which has not been constructed In accordance with the specifications or the ratesol apptlcation or mix proportfons presclibed by him

These agreements shall ba stgned b y all the parties concerned and deFlvered to the engineer.

Where the contractar cannot obtaln the owner's agreement

in wr~ting, he shall refer the matter to the engineer snd shall furnish him with details, in writing, nt any verbal agreement made.

Whare, E n addition to any agreement with the owner (c) of any property to be entered upon or temporartly occupjed or any service to be moved, It Is understood or required that the contractor shall serve notice on the owner immediately before actually entering upon or occupying the private property or moving a service, and shall give proper notice thereof in wrlting, and the engineer shall be supplied with a copy of such notice, together with acknowledgement of recelpt.

The employer shall be refunded lor any decrease in the specified rales of applicatlon ot mix proportions at the
same rate per u n ~of t measurementas that tendered by the conlractor for additlonal materials required by an increase In the rates of applicatlon or mix proportions.

On completion of hfs operations, the contractor (d) shall obtain, from the owner concerned, a written statement to the effect that the contractor has fulfilled his obligations under [I) any written agreement, or, in the absence of a written agreement,
(~i) that the owner has recelved all the curnpensatian he is entitled to and is also satisfied that all property occupied, including borrow plts, haul roads and constructinn roads, has been properly restored and ts in a satisfactory condition

1214

CCWIIWCTOR'S ACTMTIES IN RESPECT OF PRQPERXY OWSIDE THE ROAD RESERVE AND OF SERVICES MOVED, DAMAGED OR ALTERED

The contractor shall exercise any rlghts that may be (a) ceded to hlm by an authority In terms of any statutory provisions tor purposes of e~ecutingthe contract, on condition that -

(i.) the contractor complies strictly with the requirements of such statutory prevlslons, particularly In regard to the matters relating lo servlng nottce on the owner ar consultation wlth h ~ m :
in each case a written agreement is made with the (ii) engineer regarding the details of the contractor's proposed actians before the tights of the contractor in terms of Ihe statutory provisions are exercised. (b) The conttactor shall put In writlng all his agreements with owners of properly outside the road reserve or of services inside or outside the road reserve in respect of the Iollowlng matters.
The lacat~on,extent and use of borrow pits, haul i roads. construction roads and bypasses outside the road reserve.

In respect of services moved, altered, damaged or affected In any way, the contractar shall strnllarly obtaln a written statement from the owner !hat the services have been taken over [n a satisfactory condftion. All such statements shall be slgned, dated and delivered to the engineer. Should the contractor wish to use land outside the (e) area provided by the employer for storing or keeping material or equipment required for the construction nf the permanent works, it wftl be subject ta the tollow~ng

That the engineer approve any area seledsd tor (I) thls purpose.
That such land be physically separated from a n y (ii} production plant or actlv~tiss and sultably fenced In,

Compensat)on, if applicable, tor land or materials taken or for land temporarily used or occupied
(li)

(iii) The reinstatement of property occupied. used, damaged o r destroyed,or compensatEontherefor in lieu of
reinstatement

(iii) That the area used for the aforesaid purpose be surveyed, and, where the land does not belong to the contractor, he shall enter Into a contract of lease with the owner of such land in respect of the full period for which such land shall be used for such purpose, which contract shall stipulate that the owner shall not have any right whatsoever to any matarral stockpiled on such land during the currency of the contract of lease

(tv) The procedure for the moving of services and details as to how and when thls is to be done,
(Iv) That sultable, permanent reference beacons. approved by the engineer, be placed next to the area, at the cost of the contractor, lor use by the englnser with a view fo, i f applicable, taklng cross-sectfonsfor determining quantities.

(v) Any sirnllar matter directly relaled to the contractor s activitieson or in respect of private property or sewicel.

That only rnaterlal used for thls contract shall be (v) stored on such land.

project speciflcatlons.

X
1215

20, unless otherwise provtded in the project specifications. 10, unless olhewise provided In the project specilicat~ons.

BTENSION OF T1ME A B N O R W RAlMFALh

RESULTING

W M
Y =

Extension of time in terms of clause 45 of the general conditions of contract in respect of abnormal rainfall shall be determined In terms of method (i) below, unless the determine that method [liJ shall be project spec~f~calidns used. The extension of time that will be considered for a glven calendar month shall not exceed the number of calendar days in that month less the average number of days In that month on which a ralnlall of Y mrn or more per day has been recorded, as derived from enisling ralnfall records.

The total delay that will be taken into account lor the determination of the total extension of tlme for the contract shall be the algebraic sum o l the monthly totals for the period under considerat~on. But rf the grand total is negative, the time lor compTetion shall not be reduced on account of abnormal rainfall. The total extension of time for any calendar month shall no2 exceed {Nc - Nn) calendar days, where Nc = number of calendar days in Ihe month under consideration
The factor (Nw - Nn) shall be considered lo represent a fair allowance for variations from the average number of days during which rainfall equals or exceeds Y mrn per day.

The formula below shall be used to calculate separately

the delay for each calendar month or part thereof. It shall be calculated each month during the period referred to in the general conditions of contract as the time for cornptet~on of the works (including any extension thereof that n a y have been granted), or until the Issue data of the certiftcate 01 practical cornpietian, whichever 1 s the shorter period. The delay calculated for a given month shall be used to determine the Interlm extension of timegranted for referred to that month. At the end of the applicable p e r ~ o d above, !he aggregate of the rnonlhly delays will be taken into accounl for the final determination of the total extension of time for the contract

The factor (Rw - Rn) t X shall be considered l o represent a fair allowance for variations from the average lor the number of days during which rainfall does not equaf or exceed Y mm per day, but when wet conditions prevent or disrupt work
This formula daes not take into account any flood damage, which could cause further or concurrent delays and whlcfr should be treated separately In so far as emtension of time is concerned.
Accurate rain gaugings shall be taken at a suitable point on the site daily at 08'00 unless otherwise agreed to by the engineer, and the contractor shall, at his own expense, take all necessary precaurlons to ensure that the rain gauges csnnot be Interfered wlth by unauthorized persons,

(Nw

- Nn)

-I-

jRw

- Rnl
X

If any value of Y Is negative and its absolute value exceeds Nn, then V shall be taken as equal ta rnlnus Nn

The delay for a part of a month shall be calculated by substituting pro rata values for the variables In the equation

The symbols shall have the lollow~ng meanings:

V =
Delay due to rain in calendar days in respect ol the calendar rnonrh under consideration

Information regarding exisring rainfall records. if available from a su~table rainfall station near the slte, wlll be supplhed in the prolect speclflcations, together with calculat~ons of rain delays for prevlous years In accordance with the above formula The average of these delays w ~ l l be regarded as normal raln delays which the contractor shall accommodate in t719 programme, and for w h ~ c h no extension of time will be consrdared.
If no suitable rainfall records are available, the above formula will not apply.

Nw = Actual number of days during the calendar month

on which a rainfall of Y mm or more per day has been recorded. Where !he critical-path method is specified in the p r o j ~ c t specifications for determining extenslon of lime resullrng from abnormal rainfall. it shall be applted as follows:

Rw = Actual rainfall in mrn lor the calendar month under consldefatlon.

Nn = Average number o l days In the relevant calendar ralnlall records month (as derived from ert~st~ng provided in the project specif~catinns)on which a rainlalt of Y mrn or more per day has been recorded. RR

Average rainfall in mrn for the calendar month, as derived from the rainfall records supplied in the

A delay caused by Inclement weather condltlons will be regarded as a delay only if,in the opin~on ol the engineer, all progress on an Item or items of work on the critical path of the working programme of the contractor has been brought to a hall. Delays on wofking days only (based on a Itve-day work~ng week) will be taken into account for the extenslon of tlme, but the contractor shall make provision in h ~ s programme of work for an expected delay of "nu working days caused b y normal rarny weather, for which

he will not receive any exteasion of tima, The value of "n" shall be given In the project specifications.
Extension of time during workkng days will be granted to the dagree to which actual delays, as defined above, exceed the number of "nu workings days as mentioned in the project specificatians.

drains, open channels, banks, etc, and providing and operating temporary pumps and such other equipme~t as may be necessary for adequately protecting, draining and dewatering the works and temporary works. This will be In additron to any permanent drainagm works specified snd n addit~on l o any temporary drainage works installed, and F specitically pald for separately as in the case of d~versions. In case of rehabilitallon work the contractor shall plan the relevant excavation and backfill in detail and obtain the engineer'sapproval before commencing excavationsIn the existing pavement on any section of the work. The confractar shall be fully responsible for the protection of underlying pavement layers and the draining andlor keeplng dry of such excavations, and hls planning shall make provislon for the speedy backfilling and drainage of excavations during wet per~ods Unless otherwise directed by the engineer, the contractor shall1 make use of temporary drainage pipes andfor pumps for draining excavations in the pavement Where temporary pipes are placed In completed pavement layers or in ensting pavement layers that will not be broken up, the road shall be repaired in such a manner that the pavement will not be weakened thereby. In case of rehabililation work payment under any ilem that makes prwlslon for measures for drainlng pavement encavatlons, shall apply only where the engineer has ordered. in writlng, that such measures be taken and the contractor has executed the work Furthermorethe contractor shall. at his own cost, be responsible for the repalr of any pavement layers damaged as a result of water being impounded or of saturation should he have failed to submil his planntng to the engineer or to comply duly w~th the approved measures.

1216

MFORMATDN FURNISHED BY THE MPLOYER

Certain infotmatloncontained In these contract documents or provided separately Is belng offered in good faith but, In the circumstances pertalnlng to the type of information furnished, no guarantee can be given that all the inforrnat~on is necessarily correct or representative of the In sltu conditions.

This applies more specifically to aft sol1 tests, soil mapping, drilling results, geophysical surveys, qeologlcal reports, borrow-plt Informstlon, material surveys and Information, the accuracy of whFch Is reports, and slm~lar necessarily subject to the llm~tations of testing, eampting, the natural variation of material or formarions belng Investigated and the measure a l certainty wtth which conclusions can be drawn from any invest~gations made. R also applies to any materials-utilization diagram provided, as tha dlagram may be subject to major alterations durlng the progress of the work, depending on site conditions.

The employer wlTl not accept any llability for the

correctness nr otherwise of the inlotmatian furnished Q r for any resulting damage, whether direct or consequential, should It appear, during the course of the contract, that the Information supplied Is either ~ncorrect or not representative.

Any reliance placed by the contractor on this information shalt be at hfs own risk.
Notwithstanding the above, the employer will accept responsibttlty for the correctness of the following.

Care shall b e taken not to allow material in borrow (b) pits to become excessively wet, to keep all completed layers properly drained, not to cause dumps of material on completed layer work to inhibit surface drainage or to form wet spots under and around dumps, and to protect all parts of the works against erosion by floods and rain.
Material shall not be spread on a layer that Is so wet as to result in the danger of any damage berng caused to the layer durlng compaction of a subsequent layer, or when opened to traff~c

Any rock cores purported to be recovered from (a) des~gnated test-drill holes
VEsual tnformation apparent from the inspection of (b) open trial pits.

When material Is spread out on the road, the contractor shall ensure that, during wet periods, r l will have a good cross-falland a light compaction on the surface in order to fac~l~tate run-aff durlng rainy weather.

The results only of any centre-line, borrow-area or (c) other sol! lests given in the drawings or schedules forming part of the contract documents.

1217

PROTECTION OF THE WORKS AND REQUIREMENTS TO BE MET BEFORE CONSTRVCTlON OF NEW WORK ON TOP OF COMPLETED WORK IS COMMENCED

fill and cut slopes shall be repaired immediateTy (c) whenever damaged by surface water Where eroslon occurs on high fills, the slopes shall be repaired by cutting back to form benches and by compacting the backfill controlled densities, using mechanically to the spec~f~ed suitable light equipment
E~cavations for pipe drains, culverts, service ducts (d) and s~m~lar structures shall be adequately protected raln-storms, against the possrbie ingress of water dur~ng

The general obligations of the contractor in terms of clause 35 of the general conditions of contract, shall, inter alia, include the following:
(a)

The provTsion of temporary drainage works such as

All completed layer work shall be protected snd (0) maintained until the following layer is constructed Maintenance shall include immediate repairs to any damage or defects which may occur and shall b e repeated as often as may be necessary to keep the layer

continuously Intact and F n a good condition.

(I) Before any completed Tayer Is primed or a succeeding layer Is constructed thereon. eny damage to the ex~stlng layer shall be repalred, SO that, after repair or reconstruction i f necessary, it will conform in all respects to the requirements specifled for that layer. All repair work other than minor surface damage repairs shall be submitted to the engineer for inspection before it fs covered up.

Where the Roor of a cutting has been taken too [ii) deep, it will normally require backfilling and recornpaction with selected gravel In the case of sol! or gravel excavation, and with crushed stone or suitably sized rock in the case of hard excavations. All necessary measures shall be taken to dram away groundwater that may accumulate in backfilled sections. (iii)

Excess width of fills wlll have to be trimmed down.

The previously construcfed layer shall be thoroughly cleaned by the removal of all loreign material before construction of a succeeding layer ar application of a prtme coat, surfacing or surface treatment. In the case of all bitumlnouswork in particular, the existing layer shall be thoroughly broomed and all dung, clay, mud and other Whera deleterious materlal completely removed, necessary, the surface shall be sprayed with water before. during and after broomlng to remove all foreign material.
Work performed as part af the above obligations (g) shall no! be measured and paid far separately, and the cost thereof shall be included in the rates tendered for the various items of work requiring protection and the ilemsfor the contractor's establishment on the site, ets spec~ffed in sectlon 1300

Where erosion has damaged the surface of cuts or [iv) fllls, Ihe damage shall be made good by backflll~ng wlth suitable material and retrimming. In more serious cases, the slopes may have to be cut back by benching, backfilled and compacted to the required standard of compaction with sultable light equipment, and then retrimmed.

@)

Stabilizing

Any sections falling to meet the requirements specified or damaged to the exten! that they require breaking-up and recornpaction will have to be restabllized wtth the type and quantity of stabilizing agent ordered by the engineer. The engineer may also order that the layer be removed entirely and replaced with fresh material to be stabilized

1216

REMEDIAL WOW

(cJ

LDcal defecls In pavement laym

When any part of the works or any equipment or materlal Is found, upon examination by the engineer, not to conform ta the requirements or at any stage before f~nal acceptance is damaged so that it no longer conforms to fhe requlrements of the speclficatlons, the englneer may order its complete removal and replacement. at the contractor's expense, with satisfactory work, equipment ar material, or he may permit the contractor to apply remedial measures In order ta make good any such defects or damage. The actual remedial measures taken shall at all times be entirely at the conlractor's own initiative, risk and cost, but subject to the engineer's approval regarding the detalls thereof.
In parti~ular remedial measures shall ensure full compliance with the requirements of the spec~ficat~nns of the final product, shall not endanger or damage any other part of the works, and shall be careluHy controlled and submittedtotha engineer forexamination when completed or at any Intermediate stage as may be! required. For the guldance of the contractor, an indication is given below of what would normally be required In the more common cases of defects or damage, but the engineer will In na way b e bound to accept or approve !he mensures given below. as the actual remedral measures will be dictated by the circumstances of each particular case.

M e r e remedTal measures are taken to make good local defects, the width of the area to be repaired by machlnes shall be such as w ~ lbe l necessary to accommodate the full width of the machines used, and iE shall be of a reasonabre length to ensure effective operation by the machinery. The depth to whlch material wlll have to be removed will depend on the type of material. Gravel wlll require breaking up to a depth of at Ceast 75 rnm and crushed stone will usually require breaking up over its full depth. Asphalt material wlll normally require removal over Its full depth.

(d)

Concrete

Concrete work will normally require the cuttlng.back and complete removal of any weak or honeycombed sections and making good by usmg speclal epoxy adhes~ves to blnd fresh cgncrete Io old concrete. Cracks, when permitted to rernaln, shall be injected with suitable epoxy compounds, and test cores shall then be drllled lor testing the effjcacy of the injection process.

1219

WATER

The contractor hfmself shall make arrangements for

Where a cut slope has been over-excavated or [i) undercut, backtllllng wlll not normally be allowed and the entlre slope may have to be retrimmed to obtain a uniform slope.

procuring, transporting, storing, distributing and applying the water needed for construction and other purposes. except where otherwise specified No direct payment w ~ l l be made for providing water, the cost of which shall be included in the rates tendered for the various items of work for which water is needed. Only clean water, free from undesirable concenfratTons of

deleterious salts and other metsrlals, shall bs used. All water sources used shall be subject to the engineer's approval,

7221

DRRWlNGS PRaVIOED BY THE CQNTWGTOFI

1220 A U T H O R r Z E D TOIEFWCES

MEASUREMENTS

AND

Where [he cantrattar I9 raqulrad to prapere any drawlngs for the purpose of thls contract, they shall be prepared as specified below and In accordance wlth rrny further requlrements specifled by the engfneer.

The work specified In the varlous sections of these speclficatlonfi shall comply with the various dimensional and other tolerances specifled fn each case Whera no talerencss ate spwclfled, the standard of workmanshlp shall be in accordance wlth normal good practice. No representation Is made that the tull specified tolerances wlll be avaltable Independently of each other, and the conlractor Is cautioned that the llberal or full usa of Any one or mora tolerances may deprlvs hlm of the full or any use of tolerances relatlng to other aspects of the work. The latter would spply particularly In respect of level tolerances on layer work and the relatad requlrsments ragarding layer thlcknssses.

The contractor shall be pravlded wlth one transparent polyester standard drawing sheet and ona steel schedule sheet, whlch shall be used as masters tor all drewings preparod by him and submitted to the englneer for
conslderatlon,

Tha contractor shall subrnlt to the ~nglnmer for hls ad]udieation one transparent polyester prlnt, 0.050 mm thick, o l each drawlng prepared by hlm. The standnrd of detalFlng and quallty of print shall bs the same as those of tho drawlngs suppllad to the contractor under the contract.
The drawlngs shall be cornplled In the nTfFclal hnguege of the contract and shall cnmpTy In all respects wlth the requlrements of ths employer. Accepted drawlngs shall form an integral part of the contract documents, and any drawTng not accepted and signed will not be psrm~tted on the slte ot the works for constructlon purposes andlor used for the rnanufactura of any Item. Notwllhstnndlngthe approval sndtor acceptancm and slgnlng of the drawlngs, tho contractor ahst1 take tull responslbllity for all deta~ls, dlscrepancles, omlsslons, errors, atc, In respect of the sald drawlngs 89 wall as for the consequences thereof. The contractor shall subrnlt only fully cornplatad drawlngs In eccordance wlth thls spaeification and shall not be entitled to clalm tor delays resulting from the submlsslon of incernptstedrawings The englneer wlll requlre a perlod of four to sight weeks,depend~ng on clreumstances, lor reviewing t h e complete drawlng(s). No direct payment For deslgn, praparatlon and submlsslon of drewlngs wlll be made and all coats shall be Included In the rates tendered Inr the relevant pay Items as lprovlded In the schedule of quantitles. The co2l of revlewlng the deslgnldrawlngs shall be for the contractor's account.

In tho dsscrlptlon of certaln pay Items, whetn It I s stated that quantities wTll be determined from the authorized dlmenslons, thla shall be taken to mean the dlmmnslans as specltlsd or shown on the drawlngs or. H changed, a9 tlnatty instructed by the engfneer, wrthout any altowance for tolerances betng specifled If the work is therefore constructed In cnmpllance wlth the authorlzed dimsnslons. plus or mlnus any tolarances allowed, quantltles will ba based on the suthorlzed dimenslons rsgsrdless of the actual dlmenslons to wlh~ch the work in constructed.
Whero the work Is not constructed In accordance wTth the autharlzsd dlrnanslons, plus or mlnus any tolerances allowed, tho snglneer may nevertheless, In his sole dlscretton, accept tha work for payment. In such cases no payment wlll be made In respect of quanllties of work or material in encesa of those caFcufated from the authorlzed dlrnenslons and where the actual dlrnenslons are lass than the authorized dimensions, minus any tolerance allnwsd. quantltlss for payment shall be based nn the actual dimensions as constructed

The rneanlng of the specllled tolerances shall be as shown in table 122011.

Q = Actual dlmenslon of completed work

1222

USE OFMJLOSnrES

D , = Authorized dimendon of the work

t = Spsclfled tolerance Generally the contractor will be parrnlttsd to use nxploslvea for breaking up rock and hard materlal during sncavation, lor dernolishlng existing structures, and 'lor such other purposes for whtch it may normally be rwqulred, sublect to the following conditions:

2 2 0 ! 1 Table 1
TOLERANCES

+t
(01

Spectflsd tolerance t)

(0, + t)

D 2 (Da - t)

tt

( D , +
Da 2

t)

z D r D~
5 {D,-t)

-t

The englneer wlll have the rlght to prohibit the use (a3 of explosives In cases where, E n h~s opinion, the rlsk of injury to persons or damsge to property or adloinlng structures is too high. Such actinn by the englneer shalF not entitle t h e contractor to any addltlonal payment tar having l o resort to other less economical methods of constructkon unless otherwise provided In the project specifications or the schedule ol quantities

(b) The prevlslons of subclause 3308(g) shall be complied with.

contractor's use and oe~upatlon of ths road reserve.

Legal provlslons In regard to the use of e~plosives (c) and the rsqulrements of the lnspedor of Explosives shall be strictly compiled wlth.
(d) The contractor ahall, at hla own cost, meke arrangements fur supplying, transporting, storlng and ustng exploslvas.

1225

HAUL

Belore any blastlng T s undertaken, the contractor, a) together wlth the englneer, shall exarnlne and rneaaure up any buildings, houses or structures In the vlclnlty of the proposmd blastlng and cretabllsh and record, together with the ownar thereof, the extent ot any cracks or damage that may exlat before blasting operallons are commenced It shall be the responslbllity of the contractor to make good, at hls own sxpense, any furthar damage to such houses, bulldlngs or struelures which la a result of the blaating
operations.

The contractor shall aubmlt to the englneer for approval full detalls of any haul and construction roads he proposes to bulld. Such detalls shall be submltted well In ndvence In order to afford the engineer sufficient time 2 0 InvostEgats thelr lrnpllcatlons. Haul roads may not be bullt without the englnssr's prlor wrltten approval, 8nd shall be kept to a mlnlmum, parlicularly In areas where thelr Impact on Zha envlrenrnent may be serious.

Where the Contractor constructs temporary davlatlons, haur

andlor construetion roads for accommodating construct7on traffic, he shall construct and maintaln them at hfs awn cost and tn accurdance wlth detafls previously agreed on wlth the englneer, In wrltlng. Such roads shell be oblltarated and Zhalr aurisees properly relnetated when no longer requlred, all at the contractor's own cost, Haul roads shall comply with the requlremsnts sf clauses 3104 and 3105, 1228 ~ O F r n O F T R M C H E S A N D FOUNDATION MCAVATIONS Whera trenches or foundation excavatlons are raqulrad below tho level of mass excavatlons for the road prlsm, the depth of excavatlon of the trenchea or loundatlons shall be msasured from ground leva1 after cornpletlon of the mass ancavetton, unless the englnear la setlsfled that the encavatlon of the trenches or loundatlons from the orlglnal ground level or any lower lsvsl was unavaldable. Where trenches are excavated In accordance wlth the 1111 method in the completed or partly completed road prism, the depth of sxcavation ahall be measured from the levels at which Ihs engineer Instructed the contraeror to commence trench excavatlons. The contractor shall snsure that ha obtains such lnstructlons In good tlme end, where raqulred, shall submit proposals to the englnser for approval.

Where there Is consldsrable danger of damage to (f) power or telephone llnes or underground or other services or any other property, the contractor shall sultably adapt his methnd of blastlng and the slze of the charges, and shall take edequate protectlve measures, such as cover blastlng, in order to llmlt the risk of damage as fnr as poaslbls.
The englnesr shall, twenty-lour hours before each blasting operation Is earrled out, be advlsed thereof, In wrltlng, unless stharwlse sgrned on wlth the engineer,
(g)

1223 W R K ON,OVER, UNDER RAllWAY LINES

OR

CUUAENT TO

All work carrled out on, aver, under or adlacent to rallway 31nes of a statutory authorlty shall be- carr~ed out strictly in accordanca wlth tho latest edltlon of the officlal specifications of such authorlty, a copy of whlch wlll normally be lncluded In the project ~pecll~catlons. Where no such copy Is Included In the project spscllleatlons or 9 where the copy lncluded In the prolea spectflcations 1 amended or superseded by another, the contractor tihall obtain the latest edltlon, whleh shall be kept on tha alte, before any work of thls nature Is commenced. The attention is drawn particularry to Zha requirements eontalned In the specifications regarding ths approval that must be nbtained from the relevan?statutory authorlty for a work permit or occupation of Its property and the approval of falsework and formwork plans.

The cantractor or hla authorlzad reprssentatlveshall attend monthly meetings an the ~ l t e wlth reprasenZatlves of the employer and the englneer, at dates and times to be determined by the employer. Such rnsetlngs wlll be held tor evaluaZlng the progress of the contraFt and lor dlacusslng matters pertaining to the contract whleh any of the parties represented may wlsh to raise. Such meetings are not Intended for discussing matters concerning the normal day-te-day running of the cantract.

1224

M E

M O I N G O V E R OF THE W A D RESERVE
1228

LEGAL PRMIISIOMS

The road reserve will be handed over to the contractor for eonsrructlon, subject to such conditions as may be specified in the project specifications regard~ngmatters such as the sequence In which sections will be handed over and must be complsted, the rnaxlmurn total length of that w~ll be allowed to be in operation temporary deviat~ons at any time, and any other matters relating to the

The contractor ghall keep himself fully conversant with ttre latest enactments, provisions snd regulations of all legislative and statutory bodtes, and, In all respects and at all t~mes, shall compty with such enactments, previsions and regulations In regard lo executing the contract.

t Z29

SABS CEMENT SPECRCATFONS

Common cements are formulated prlrnarlly for use In

concrete.

!&hen Zhe European standard for cements Is adopted by

the SABS as the new South Afrfcan standard, the enistfng four SABS cement speclficalions will be replaced by two new spec~fications, namely:

Masonry cements are formulated to obtain mixes with a good workability tar rendering, plastering and masonry work. Masonry cement may not be used In concrete.

SABS 'ENV 197-1 for common cements

and
SABS EM, 413-1 for masonry cement.

As soon as the new SABS cement specifications become operative, the SABS cement speclflcatEons and the cement types specified in the projscl specifications or prescr~bed by the engrneer in writing shall apply to the contract.

SCTM3N 1300 : WNYRACTOFTS ESTABUSFM3T ON S m AND GENEFW Ot3UGATIONS

13.01 The c m l r d o r ' s general obligations:

(a)
130f SCOPE 1302 GENERAL REOUIREMENTS 1303 PAYMENT

Fixed obfigatlons

. . . . . . . . . . . . . . . .lump sum
sum

(b)
(c)

Valusrelsted obligations . . . . . . . . . lump

Time-related obligatlons . . . . . . . . . . . . . month

This section covers the establishment of the contractor's organization, camp and constructional plant on the site and their removal on completion of the contract. It also covers payment for certain general obligations, risks and liabilities and general (ternsof cost not covered elsewhere.

Payment of the lump sums tendered under nubitems (a) and (b), and the rate per month for subitem (c) shatl, for the three sublterns together, include full compensation for all the contractor's charges In respect of the following Items, collectively termed the "contractor's general obligations".

(I) Setting up and maintaining his organization, personnel, camps, accommodation, ablut~onand other facil~lies, offices, stores, workshops, ather temporary atrudures, fencing, testing facilities and constructional plant on the slte and their removal on completion of tha contract.
Complying with the requirements of the general (ii) conditions of contract and sectlon 12tM of the specifications, Including the effecting of insurances and prnvfding the sureties required. oil) All gsneral site and Office overheads, profit, financing costs, risks, legal and contractual responsibilities of a preliminary or general and other costs and obl~gations are not specifically measured for payment nature wh~ch under any other items of payment.
The lump sum tendered under subitem 13 01(a) above shall represent full compensation for the fixed part of the contractor's general obligat~ons,ie that part which is substantially fixed and is not a function of the time requ~red for the completron of the contract or of the value of the work.

(a)

m p s , mmlm3hmal plant a r ~ testing I facilities

The contractor shall establish his construction camps, offices, stores, workshops and testing factlltles on the site. The exact location of these faclllties shall be approved beforehand by the engineer. Accommodation, ablution and other facrlltles for site staff shall also be provided as required and the standard of rtccommodation and the location of all facifities shall comply with the requirements of the, aulhorlties cancerned and those of the engineer. Prlar to stanlng with con~truction, the contractor shall also move all constructional plant and personnel to the site. On complet~on of the work, all conslructlonal plant, buildings. fencing and other temporary structures shall be removed and the camp slte be restored to its original condition and left neat and tidy.

@)

MBinhnanoe during wnstnsStian

During constcuclfon the conrractor's camps, staff living quarters and other lacilitles shall be maintained In a neat and tidy condition,

(c)

Legal

and

contractual fequlrements

and

respbnsibilii t u the- public

The contractor shall lake all the necessary steps to comply with the general conditions of contract, particularly in respect of the Insurances and sureties required and his general obligations to the public end the employer. He shall comply with all the regulations of statutory bodies.

Should the final value of the work (excluding any payments in terms al clause 49 of the general conditions of contract) Increase or decrease by twenty (20) per cent or less in relation to the tendered amount (less any allowances, if sny, in the tender for price adlustrnenls in terms ot clause 49 of the general mnditlons of contract). the lump sum tendered for subitem 13 01 (a) shall not be subject to any variation whatsoever. However, should the said vncrease or decrease of the linal value ol tha work per cent of the tendered amount, the exceed twenty (20) provisions of clause 53 of the general crrndttions of contract shall apply lo that portion of the said increase or decrease wh~ch Is in excess 01 twenty (20) per cent of the tendered amount. Payment at the lump sum tendered under subitem 13.01(a) will be made In lhree instalments, as follows:

The first Instalment, 50% of the lump sum, will be (1) paid in the fitst payment cert~f~cate after the contractor has met all his abligat~ons under this section and has made a substantial start with construction in accordance with ths approved programme,
The second instalrnent, 35% of the Pump sum, will (2) be paid when the value of the work done reaches one half of the tendered amount, ekcludingcontingenc~es and price adjustments in terms of clause 49 of the general conditlons of contract.

However, should tha said increase or decrease in the final value of the work exceed twenty (20)per cent of the tendered amount, the above-mentioned pro rara Increase or decrease- in the lump sum tendered under subitem 13.01{b) shall apply up to the limit 01 twenty (20) per cent, and the provisrons of clause 53 of the general conditions of contract shall apply to that portion of ths said increase or decrease which is in excess of the said limit of twenty (20) per cent of the tendered amount.

The third and final instalment, 15% of the rump (3) sum, wllt be paid when the works have been completed and Ihs contractor has fulfilled all the requirements of th~s

The lump sum tendered In subitem t30l(b) will be payable monthly In instatrnentr In relation to the value of work done (encluding the value of any p i c e adjustments In termsof clause 49 nf the general conditions of contract). The tendered tale per month for subitem 13.01(c) represents fwlf cornpensailon for that part of tho contractor's general obligations which are mainly a funct~onof construction time. The tendered rate wit1 bs paid monthry, pro vata for parls of a month, from the date on which the contractor has recelved the Better of acceptance in terms of clause 12 of the general conditions of contract, until the end of the period for cornplst~on of the works, plus any extension thereof as provlded In clause 45 of t h general ~ condttlons of contract, provided that (a) should the works be- certlffed as having been completed before the contractual date tor cornp!etiun of the works, the contractor will tQen be entitled to payments In regard to the unexpired per~od lor completion.
should the progress of the contractor In terms of (b) the value of work done be in arrear in regard to his approved origlnal programme, payments in respect of this item may be limited lo payments for !his period, which, in h~s original programme (after suitable adjustments in respect of the extensron of time granted) agree wlth the actual value of work done.

section.
Before any payment is made under thfs subitem, the contractor shall satisfy the engineer that he has provided camps and construcrional plant of good quality on the sire, the value of wh~ch exceeds that of the flrst instalment.
The contractor may also be required to furnish documentary proof that he owns the camps and constructional plant on the site, ths value of which shall exceed that of the first instalment In the event of the contractor not being able to satisfy the engineer as to the ownershTp of tho camps and constructional plant, the engineer shall have the r ~ g hto l wrthhold parts of any payments to be made under thls subitern, until the works have been completed.

The lump sum tendered under subitem 13.01(b) shell represent full compensation for that part of the contractor's of only the value of general obligations, which is a funct~on the work, but not of the perlod of complet~on.Should the f~naE value of the work (excluding any payments In tsrrns of clause 49 of the general conditions of contract) increase or decrease by twenty (20) per cent o r less In relation to the tendered amount (less any allowances, if any, in the tender for price adjustments in terms of clause 49 of the general conditions of contract), the lump sum tendered for subrtem 13 011b) will be increased or decreased pro rata In full settlement of any dffference in value-relaled general obligations resulting from an increased or decreased value of the work.

Any payment made under item 13.01 will not be taken lnta account when determlnlng whetfier the value of a certificate compfies with the "minimum amount of Enterlm cert~ficate", as laid dawn in the appendix to tender. The sdrustments specified In subitems (a), (bl and (c) wlll be made only If the value of the work or the period for completion were to change and it is agreed that such adjustments wlll be in full settlement of the changed compensation for emended general nbllgatlons.

SfRfES 1000 : GENERAL

SECTION 1400 : HOUSING, OFFICES AND M D R P c TORIES FOR THE ENGINEFR'S S m PERSONNEL

be constructed in accordance with the details as shown on by the engineer. the drawings or prov~ded

CONTENTS
140t 1402 1403 1404 1405 1406

SCOPE
OFFICES AND LdBOR4TORIES HOUSING

SERVICES
GENERAL MEASUREMENT AND PAYMENT

The s ~ t l n g and orientatton of all oltlces, laboratories. housing lor other accommodation shall b e to the engineer's satisfaction and shall be d e c ~ d e d on in consultation wilh h ~ m and confirmed in writing before erection, All accommodation shall include the pmvlsion ol 220 +volt electricity, and where required, fresh clean potabla water and sewerage, including s e p t ~ c tanks, i f necessary, which will be considered as part and parcel of the accommodation provided and w ~ t l not be paid for separately, except in so far as the cost thereof shall be covered under item 14 08 Seruices.
The clear helght of all offices between floor and ceiling shaTl be 2,d m minlrnum. All windows shall be of the type that can open over the lull window area. All accornmodatlon shall meet with the approval of the engineer.

1401

SMPE

This section covers the provision of accommodation for the engineer's supervisory staff. This accommodat~onshall include the necessary o f f i c e a n d laboratory accommodation, houses and quarters for employees, the provision of all ?he necessary servlces, as well as all the arrangemenrs in connection w ~ t h the land on which the accommodatron is to be provtded.

The varlous types of offices required shall be as shown on the drawings and schedules. Unless otherwise specified or detailed, the liltings, furniture and equipment provided in accordance w ~ l h the schedule of quantities shall conform to the following requirementsm
Each affice desk shall have a surface arsa of at (I) least 1.5 m2 and shall be provlded with at least three drawers, ane of which can be locked. General-purpose steel cabinets shall have at least 1,5 rn7 shelf area and a volume of 0.70 ma each. Each cabinet shall have a lock w ~ l h two keys. (11)

(a)

General

Bulldings for offices and laboratories shall be constructed from timber. fibre-cement. or other approved materials shall have double walls filled wtth insulating The build~ngs material and lined on the Inside with timber or other approved rnaterjal Cell~ngs shall b e provided for both offlce and laboratory buildings Office buird~ngs rhall have timber floors or concrete floors with vinyl floor tlles and laboratory buildings shall have cancrete floors Window areas af these bulldlngs shall be at least equal to 258 of the floor area. Each b u i l d ~ n g shall be provided with a verandah on one s~de,running for the full lenglh of the build~ng. The verandah shall be 1,5 m w ~ d e and shall I.raue a 100 rnm thlck concrete floor. All buildings fur off~ces and laborator~es s h ~ l lbe provided wrth approved burglar proofing Stores shall be provlded. installed and furnrshed in the laboratory building. The s~des of the stores shall be fenced off from floor level t o the ceiling with 50 mm dramond-mesh wlre Each store shall have one lockable door. Fire extinguishers shall be provided for o t f ~ c e and laboratory accommodation on the basis of ane g kg all extinguisher lor every 24 m', or purpose dry powder f ~ r e portion thereof, of Iloar Space provided.

Steel tiling cabinets shall each be fitted wilh four (iii) drawers on runners. Each cabinet shall befitted with a lock 460 rnm wide and 600 mm and shall be 1 300 mm h~gh, from front to back.
liv) Shelves shall be suitahre for storing all the contract drawings or shall else be as detailed on the drawings.

Each wash-hand basin shall be fitted with taps and (v) a dra~n.

(vi) Alr-cond~t~aning units and heaters shall be as specified in subclause 1402(f).

[vii) Lights shall be of the Iluorescent type, either double

80 watt. single 80 watt or double 55 watt. of of the

incandescent type according to that whlch is required or specified (v~ii) Each draughtsman" stool shall be fitted with a padded seal wlth an adlustable seat height. Electric power plug polnts shall be provided Each (ix) off~ce shall have al least two 15 ampere plug points. Each drawing table shall have either an Inclined or (K) a har~zontald r a w ~ n gsurface as may be required and a smooth lop bull1 to the dlmenslons shown on Ihe

Mfics and laboratory burldings shall be painted with an approved palnt after erection The paintwork shall be rna~ntained during the contract p e r ~ o d
Each door shall be provided with a lock and two keys.
The various u n ~ t s of accommodat~on and the tlttlngs shall

drawings.

(xi)

Chairs shall be robust and comfortable.

(2) With concrete topsmThe tops shall be at leest 75 mrn Ihick concrete slabs wilh a smooth, hard steeltrowelled finish.

R complete telephone servlce, together with an {nil) exchange llne and the number of extensions specfied shall be provtded, The prime cost sum shall also include the cost of all telephone calls in connectran with contract adrnlnlstratlon,

All work-benches shall 'be robust and their upper surfaces shall be 920 rnm above floor level, Gas lnstallat~ons shall conslst of the necessary gas (iv) cyifnders, regulators, tubing and laps.
High stools for uss at work-benches shall be robust (v) and, if of fixed height. shall be 800 mm high.

The englneer shall be provided with a dired fndependent

telephone line that Is not connected to the mntractorhs telephone exchange. (xiil) Each conference table shall be large enough to seat twelve persons, and shall have an area of at least 4 mz.
( K ~ v ) Blinds shall be one of two types, as may be required:

Where required, a 380 volt 3-phase electric power (vi) supply shall be provided Power points for ovens and a crusher shall be suitable for the purpose. Power polnts In oven rooms shalF be 1-2 rn above floor level.
Concrete working floors shall be at least 125 rnrn (vli) thick and provided with a hard smooth finish. The working areas shall be either sntirely open or under a shelter as may be required. (vill) Wash bas~nsshall be a3 prescribed elther of stainless steel or precast concrete with an area of at least 0,s my and a mlnfmum depth of 0,3rn. They shall be provided with swan-neck type laboratory taps and drain pipes.

Adjustable venetian blinds to permit Itght to enter (1) the room, but which wlll exclude direct Ilghl;

(2)

Opaque roller blinds

Notlee boards shall be supplled In accordance with (xv) the spsclfications, the drawings or the schedule of quant~ties.
Bookcases shall comply with !he details in the [xvl) specifications or the schedule of quantitles.
(rtvil)

Fax apparatus shall be supplled as spec~tled

A supply nf fresh clean potable water at a constant (ix) head of not less than 3 rn at the taps shall be provided. Storage capacity in respect of the laboratorywater suppiy shall be not less than 700 Iltres.
Fire extinguishers shall be of the all purpose dry (n) powder type manufactured to BS 1721 and su~tablwfor types A, 8 ,C and E fires, The extinguishers shall contain not Tess than 9,0 'kg of extinguishing chemical and shall be fitted to the wall at suitable pos~tions by means of quickrelease brackets. They shall be freshly charged and the seals shall be unbroken. Extractor fans. where required,shalt be so mounted (xi) as to operate noiselessly, They shall have a capacity of at least 0.15 kW each. hiractor fans shall be spark proof (~11) Fume cupboards shall be constructed accordance with the deta~ls shown on the drawings in

All or any of four types of laboratories may b e required:

sollo laboratories, biturnlnous-materials laboratories, chemfcal labora!orles, and concrete-testing laboratories

The sites, layout and other details of the laboratories shall be as shown on the drewlngs and schedules of fittings, equlpmenl and furnlture. The laboratories, linings, furnlture and equipment shall be as follows:
Ordlnary chairs, telephone extens~ons, 15 ampere (1) 220 volt electricTty plug po~nts,air-conditloners, heaters and lights shall meet the same requirements as specifled lor oftrces. Shelf space provided against walls shall be of (11) robust construction and shetv~ng shall be olsuitablel~rnber or fibre-cement materiat, depend~ng on requirements. Shelving below work-tables shall be 390 rnrn above floor level, and above working areas, 1 980 mm above floor level. Work-bench areas shatt be of two types a3 may be (Ill) required:

(uiii) W e r e required. concrete footings and pades?als shall be constructed to the dimensions indicated by the engineer for ~nstalllng certain testlng equipment. (xiv) When required, baths for curTng concrete test cubes, beams and cylinders shall be provided The baths shall be recfangular in shape and regarding the ins~de drmensions rhe w~dthshall not exceed 1.0 m and the depth shall not exceed 0,6m, The baths shall have automat~c temperature control

M e n required, an 0.3 m ycapacity refrigerator shall (xv) be supplied.

(xvi) Approved voltage stabilizers shall be Wed t o all electrical power points

Of wooden construction: The tops shatr be hard (1) end srnuoth and free from warping or other defects.

Car parts shall be so constructed as to protect vehicles parked in them at all ilmes against the direct rays of the sun. The car pons shall be at least 20 rnZin area and the floors shall consist of a layer of broken stone to alleviate dusty and muddy conditions Each car port shall be at least 3 m wlde and shall have a headroom of at least 2 m. The roofs of all car ports shall be water proof.

A n approved two-way communication system shell ba provided and maintalnsd.

The access and other roads around the officas shall be treated to make them dust free either by crushed stone, suitable dust-laying olls, or bituminous surfacing being used or other approved means being adopted. They shall be well drained and kept trawicable and free from mud at all times. Footpaths shall be similarly treated to provlde convenient access to ell buildings. The offlces shall be fenced with a 2,4 m h ~ g h diamond mesh security fence with a single overhang ~nmrporating one 2,4 m high by 5 m wide double leaf security gate fitted with a padlock and chain.

Prefabricated houses shaft be constructed of wood, librecement or other approved material and shall have double walls filled with insulating material. Each house shall have a clear heeght from floor to ceillng of at least 2,74 rn.

Glass-l"oe insulating material shall also be provided on top of the ceilings. Floors shall be of timber or alternatively of concrete covered with suitable carpeting or vinyl tiles.
Each house shall have a floor area of at least 720 ml, wlth three bedrooms,a livlng-room, dinfng-room,bathroam and kitchen, In addition, the house shall have an enclosed stoep of approxtrnately 20 ma in area,

The main frame of each house shall be of ateel o r light

(f)
Alrcanditloning units a M h e m Where requlred by the engfneer, Ihe contractor shall units and heaters. provide and InstaFl air-condit~an~ng aFloy, All tlmbsr used shall be of a good quality, properly oven dried and treated against pests All fittings shal! be accurately Installed.

The air-conditioning units shall be at the electriealry operated compressor type with closed circuit and no1 of !he evaporation type, The capacity of rhs alrconditlonlng units shall be at least 2.2 kW each.
Heaters shall preferable be of a space-heatingtype wlthout exposed elements and shall have a capacity of not less than 1,5 kW each. The contractor may also be required to install airconditioning units in any housing accommodation provided.

Each house shall, after erection, ba properly painted Inside and outside with an approved paint, and the paintwork the contract period. shall be maintained dur~ng

Each house shall be provlded wlth the following:

(i) (ii)
A bath and shower with draln and inside Rush toilet.

R wash bash with drain pipe.

A metal kltchen-sink untt with staintess steel basin (iii) and drainlng boards and a cupboard wrth shelves

A kitchen dresser, linen cupboard, and built-in (iv) wardrobes in the bedrooms.
@)
AblutiDn units

Ablution units shall be well-ventilated units constructed in aceordance with the details shown on the drawings They may be constructed from fibrecement sheeting with steel frames or from other suitable approved materials, and the floors shall be of concrete with vinyl floor tiles. Latrines shall be provided with vitreous snamel WC pans with PVC seats and covers and flush cisterns. Wash basins shall be of vitreous enamel. complete with taps and drarns Provis~on shall be made for sultable sewerage as specified In clause 1404

A su~table geyser, a kltchen stove and refrigerator, (v) The geyser shall have a capacity of approximately 140 1 with a weter supply from an outside tank or from a water main. The stove shall be a four-plate stove complete wlth grill, oven and splash plate. Tha refrigerator shall have a volume of a! least 0,3m3.

Cold-water plpes from a sultable source to the bath. (vl) shower, wash basin, toile? and sfnk units, complete with taps where requited.
(vH) Hot-weter plpes from the geyser to the bath, shower, wash basin and sink unit, complete with taps.

Where requlred, a separate shower and change room shall be provided, complete with shower, hot and cold running water and drains
Each tatrine or shower shall be provided wlth a door fined with a latch. Each ablution unit shall be provided wlth an outside door with a lock. At least two keys shall be provided tor each lock,

1 7 rooms and passages, with plug (viii) Electric lighfs In a paints in the kitchen, living-room and all bedrooms. The house shall be fully wired and connected to a 2201250 volt AC power source.

(in)

Goodquality locks on all doors.

(K) Where the water supply of the houss Is not connected to a water main, an external elevated cold-water storage tank wlth a capaclty of et least 3 000 1 shall be provided In order to obta~n a minimum head equal to 3 rn of water at the taps, together wlth the pfpes teadfng to the supply tank

mads between alternative accommodation offered by hlm In terms of subclause ti) above and accommodatien he Is ordered to provlde In terms of subclause (H) abava, In so far as the method of payment, hls obllgatlon and rlsks and Ihe perlod for whlch the accomrnodatlon Is to be provlded and paid for are concerned,

(d)

dceorndmlian for tabourem

A cat port as described In subclause 1402(d) for one or twa cars shall be provlded with each house. A servant's room wfth a rninlrnum area of 12 rn', constructed as specified for ollices and laborstories, shall be provided wlth esch house. A lsrrina with flush toilet and separate shower shall also be provided.

i Instead of the houses described above, tha contractor m a y provide suitable rented or purchased houses, approved by the englnaer, whlch will pravide at least the same standard of comlort as that of the prsfabrlcated houses described above, in the nearest town or elsewhere.
The terms, of any lease for such accommodation shall be subject to the engineer's approval and shall contain provlslon, where the owner agrees, for an extension of the lease- an pre-agreed terms during any extended tlme for completion of the contract, as well as provision tor the lease to be taken over by the englneer or another contractor In the event af default by or Insolvency of the contractor. Notwtthstandlng the eng~neer's approval ol the condifions of the lease, the contractor shall be salely responsible for provldlng the accommodation for the full period requlrsd and for sultable substitute accommodatfon should the alternative accommodat~on ha no longer available

Accommodation for labourers employed by tha engineer shall be provided on the slte or, H Zhls Is not possible, In the neatest town. In the latter case, the contractor shall make prsvlsion for daily providing the labourers wlth and departing from transport arriving on the site at 07*00 the slte at 17:30, The accommodation shall be constructed as specified tor offices and laboratorleg In housfng unfts In mccordance wlth the detalls shown on the drawtngs. Each unlt shall be provlded wlth opaque windows, all of which can be opened at least halfway, and a steel door with lock or padlock, Provision shall be made tor 8 m2 of floor area for each labourer, in sddition to a sturdy bedstead, a new mattress of acceptable quality, a steel locker not less than a,? m3 in slze with hanging and shslf space, and which can be locked, and a sturdy steel chair. A bedside chesl wlth a top surface of at least O,75 m' shall be provlded for each labourer. H shown on the drawlngs, the vnlts shall be provided with approved heaters Each unit shall be provldsd wlfh electricity, plug polnts and electrical llghts In sccordence wlth the detafls on the drawings The size, layout snd number of fixtures and Items of furnlture In each unit shall b w as specified or shown on the drawings

For every five labourers one ablution unit shall be pravided.

The contractor shall aiso be respunslbla for the cost of any addltlonal travelling expenses, H any, arising from the use of alternative or sub~titute permanent housing. Such costs may be subtracted from any moneys owing to the contractor for providing housing
The engineer may also order the contraclor to pay (ii) lor any hotel or other accommodatlon or leased houses required and availabla This accommodation may ba in addition to or instead of the accommodation specitled The contractor shall enter into the necessary contracts tor the lease a! such accommodation as may be requ~redand shall not unreasonably object to the terms and conditions of such leases to be negotiated by the engineer

An ablution unlt shall consist of one well-vantilatad eection containing a flush-typa Iatrlne complete with WC pan and PVC seat and cover, and another seetlan contalnlng a shower and a wash basin, all ~ o r n p l e t e with the necessary running hot snd cold water, taps, drains and sewerage. The hut shall be of robust construction with a concrete floor and may be steel or tirnbar-framed and clad w ~ t h galvanised-Iron or f~bre-cementsheetlng, It shall have a
roof snd only nne outer door provlded with a lack and two keys Each lalrlne shall have a door fitted with B slidlng bolt.

A cooklng unit shall conslst of a hut as dstalled on the

drawings. The hut shall be of the same constructlon as specilied for the ablution unit. It shall be provided with an approved four-plats stove, two outside wash basins each at least 0.5 m v n area and 300 m deep suitable for washing clothes, a single: k i t c h ~ n sink, and at least 1,0 ma of concrete working slab and 1,s my of shelving. All the necessary taps, dralns, sewerage, and a hot and cold-water supply shalt be prouided. tn case approved stoves other than electrical stoves arw provided, an adequate supply of fuel shall be provlded for cooking and water heating pu rpores.

The cost of drawing up and entering into such leases shall be refundable If paFd by the contractor Where such accommodazion Is contemplated In advance, allowance shall be made for the cost thereof by inclusion of a suitable provisional sum. The prov~sion of such accommodation shall be classed as a variation and payment therefor shall be made as specified in subclause 40(1) of the general c o n d ~ t ~ o n of s contract
(iii) The contractor'sattention is drawn to the distinction

A latrine shall consist af a single well-ventilated hut of the same constructi~n as speclfled for ablution huts and containing a flush-type latrine complete wlth WC pan and PVC seat cover.

(xvii) Bookcases
14.03 Wee and labodmy fittings. imtallations and equipment:

...................

number (Nu) number {No)

(xv~~ Voftage i) stabilizers

., , .

..

The unit of measurement shall be the authorised number

of un~ls supplied and Installed, complete end in accardance w ~ t h the specifications and drawings, together w~th all rnlner fittings, brackets, connections, leads. mountings, etc

(a)
(1)

Hems measured by number:

2201250 volt power points

407231 volt 3-phase power points . . . .

........

number (No)

(71)

(b)

. . . . . . . . . . number

(No)

Prime-cost items and items paid far in a lump sum:

(ill)

Double 80 watt fluorescentlight fittings compfete with ballast and tubes . . . . . .

(i)

.....

number (No)

(Iv)

Double 55 watt fluorescentllght finings complete with ballast and tubes . . . . . . . . . . . . . number (No)

The provlsinn of telephone service, lncludlng the cost of calls in connectian with contract admlnistratlon and telephone rental . . . prime cost (PC) sum
Handling costs and profit in respect of subsubitem 14 03(b)(i)above . . . .

(ii)

(v)

Single incandescent-!fght fittings complete with 1 W3 watt globes . . . . . . . . . . . . . . . .

. . . .

percentage (%)

. . . . number .. (No)

(iii)

(vi)

Washhand basins complete with taps and dralns . . . . . . . . . . . . number (No) Laboratory baslns complete with swan-neck taps and drains . . . . . . . . . . . . . . . . . . . . . number (No) Extractor fans installed cornpiets wi!h own power connection . . . . . . . . . .

(vli)

The provision of a dlrect independent telephone tine for the engineer, including the cost of calls in connection w~th contract adm~nislration and telephone rental . . , prime cost (PC) sum
Handl~ng costs and proflt in respect of subsubitem 14 03(b)tiii) above . . , , .

(iv)

(viii)

percentage (%)

. . . . . . . . number (No) .......

number (No)

(v)
(vtJ

The provlsion of a law apparatus as spec~f~ed ,

. .

prime cosf (PC) sum

{in)

Fume cupboards complete according to the drawlngs

( )

Fire extinguishers, 9.0 kg. a 1 1 purpose dry powder type, complete, mounted on wall with brackets . . . . . . . . . . . . . . . . .

Handl~ng costs and prof~t in respect of subsubitern 14 03(b)(v) above ..... The provision of 400f231 volt 3-phase electrical power installattan, lncludlng all wiring, switchboards. mains connect~wns, e2c . .

...

percentage (96)

(vii)

...

number (No)

(xi)

Air-conditioning units with. 2.2 kW minimum capacity. mounted and with own power connection . . . . . . . . . . . . . . . . . . . number (No) Heater, spaceheafing type, minimum capacity t , 5 kW

lump sum

(nli)

...

number (No)

{v~ih) The provis~on of gas installations, including gasstorage cylinders, tublng regulators, gas burners and shuf-off cocks , , , ,

..

, , , ,

.,.

lump sum

(xiii]

Curing chamber for UCS specimens, complete w~th water connection, including the provision of brick partitions, plaster, paint and shelving, all complete according the drawings . . . . . . . . . number (Nnl

(K~v)General-purposesteel cupbaards with shelves

number (Nu)

The prtme-cost items shall be pald lor in accordance vrilh the provisions nf the general condirions of contract The tendered percentage is a percentage ol the amount actually spent under the relevant prime-cost item, w h ~ c h shall include lull compensation for the handling costs of the contractor, and the prof~f In connection with providing sewrce. the specli~ed

(XV)

Steel ffling cabinets with drawers. . . . . . . . . . . . . . . . . . number {No) Refrigerators

(xvl)

. . . . . . . . . . . . . . . . . number (No)

The tendered rump sums shall be in full compensation for providing the complete service or installation and the use thereof, Including any fired and usage charges payable to local or other author~ties.

(c)
(I)

Items measured by area:

Shelvlng as specllfed, complete wlth brackets
Work-benches complete wlth concrete slab top, minimum thickness 75 rnm

(c)

square metre (rn')

Cooklng unit, complete wlth stove, basin, concrete working table, shelving, aink and fuel (where sppllcablal Latrine unit as speclfisd

(il)

(dl

...... .........

number

(No)

number (No)

..

square metre (m')

(Ill)

Work-benches complete wlth wooden top, mlnfmum thlckneas 25 mm . . . . . . . . . . square metre (m2) Constant-temperature baths of concrete and/or plastered brlck . . . . . . .

Tha unit of measurement shalt be the number of complete units supplled and erected according to the npeeifications and drawings.

(Iv)

. . . . . squera metra (m2)

Pretabrlcated houses wlth outbutldlngs as speclfied In subclauses 1403(a) and 14031b)

(v)

FoundaFlons lor laboratory equipment Roller bllnds, opaque type . . . . . . . . . . . . Venetian blinds

. . . . . . . . . . . . . . . square rnstre (m2)

. . . . . . . . square
metre (m')

...........

number (No)

(vl)

The unlt of measurement shall be thn number of prefabricated houses carnpleter as specified which are provided on the engineer's instructions.

(vll)

. . . . . . . . . . .square metre (m2)

(vlfl) Not~ce boards as specified . . . . .

. . . . . . . . . . squara .

metre (m'}

The unit of measurement shall be the square metre of the Item supplied and Installed The area shall be determined from the authorised outside dlmansCons in plan, except the constant-temperature baths, whfch shsll be measured per square metra of water surface area irrespective of their depth, and the bllnds, whlch shall be measured by The width multrplled by the helght.

14.07 Rented, hotel w d other aocomrnodation:

(a)

Provisional sum for provldlng rented housing, hotel or other

aecommodation as described In subsubclause 1403(c)(ii) ,

., , , ..

provisional sum

(b)

Handllng costs and prollt In respect el subitem 74 07(a)

percentage (96)

h
14.M Car ports:
Car ports, as specklied, at offices and laboratory buildings . . . . . .

Unit
Expenditure under this item shall be made In accordance with the general condlrlons of contrect. The tendered percantage Is a percentage of the amount actually spent under subrtam 14.OJ(a),whlch shall lneluda full compensation for the handling costs of ths contractor, and the profit in connection with providing the rented accommodation.

......

number (No)

The unit of measurement shall be the number of eat ports prov~ded,

Unit
The provision of water, elsctrlclty. low-pressure gas, sewerage, septic tanks, sewage and rubbish removal, cleantng services, maintenance and repairs, all as specified In clause 1404, includtng the construction and maintenance of the access roads, footpaths, etc
(a)

(a)

Housing as specified including beds. mattresses, beds~da chest, cha~rs, tables, lockers, electricity, plug points, electrical light f~tt~ngs and burglar proofing . . . . . . . . . number of persons

r h e unit of measurement in urban areas shall be a man month.)

(b)
Ablution unit, as specified, including latrines. wash baslns, showers and taps .

Servlces at offices and laboratories:

(i)

Fixed costs

. . . . . . . . . . . . . . . . . . . .lump sum
. . . . . . . . . . . . . . . . . . . . month .

. . . .

number

(No)

(il)

Runnlng costs

The contractor may offer the use o l already available eccammodation of equal standard In lleu of any of the accommodaZfon specified above, Where the accornmodatron offered Is not of equal or better standard, the englneer may neverthalesa accept such accommodarion at prlces rnututtlly agreed an between hamself and the contractor. Where alectrtcity Is avallable, the contractor shall supply efedrlc lights in all housing units. A reasonable supply of fuel shall be provlded lor flring stoves for cooking and hot water. The contractor shall ba responsible for obtaining the necessary approval from any state department or any local n the matter for authority havlng jurlsdictlon E
(I)

and houslng. The power source shall be sultebls lor dornestlc, office and laboratory use wlth an anticipated large varlance In load factor Thrse-phase power shalt be aupplled at a nominal voltage of 4001237 volts and a nornlnal frequency of 50 Hz. The sourca of power shall be elthsr from a recognized power-supply authority or by an on-slte alternator.

the siting of the aceommodation; the plans according to which Ihe aceornrnedatlon

I (HI)

The electrlcal load shall be determlned by an appropriate dlvsrsity faclor baing applied to the sum of the connected load, due allowance belng had for the startlng load. efflclency snd power factor of motors, or shall be estimeted on the basis of 10 CVA slngle phase per house, 1,2 CVA per mZ of laboratory floor area (three phase) and 0,35kVA per m' of oflfce area. Allowance shall be made for a spare capaclty of 15% with a rnlnlrnum of 15 kVA. A detalled load estimate shall be submlttsd te the engfnser tor approval prlor to any final arrangements being made for a source of power,
In the event of alettriclty belng generated by the contractor, the motor-alternator shall be suitable to maintaln the voltage so that it will not deviate by more than 5% from the nominal voltage, and to rnalntaln the frequency so that it wlll not deviate from the nomlnal frequency by more than -c 2 Hz over the entire load ranga from 0% te 100% of full load, also In the event of swltching on and off all normal loads cannecFed to the supply, to the houslng, officsa and the Power shall be ~tvallable laboratory for 24 hours per day snd between 06:00 and 22:00 far other aecornrnodatton.

l s to be constructsd:
the accomrnodatlon as constructed.

The proposals by the conlractor, which In rmgard ta (I), (ii) end (Ill), are to be submitted to the authorities concerned for approvaf, shall be drafted in consultatlon with the land owner.

The approval for (i)end (ii) above shall be obtained prior

to constructlon and for (llij prior to tha handing-over for occupation,

All accommodatlon for labourers shall be fitted with

approved burglar prooflng.

1404

SERVICES

Power shall be distributed by rnesns of enclosed distribution boards with adequate weather and tamper protectton, suitably rated c~rcultbreakers, earth-leakage unlts or fuses, and ;by means of adequately slzed undergroundcables and earth conductors. Slzlng of cables and rating of protective and control devices shall taka Into account the load and fault currents that can occur on the system.
The reticulation network and the wirtng lnstallation of all bulldlngs and structures shall be Installed and malntalned to ensure absolute salety and a high standard of rellabillty, with partlculat reference to the earthlng installatlon and safety and protective devices The installations shall comply with the requirements of SABS 0142 and SABS 1500.
The contractor shall at all tlmesmaintaln the power supply,

The contractor shall ba rssponslble for providlng all sanltary servlces necessary lor keeplng latrlnes In a clean, neat and hygienic condltlon.

When no munlclpal ssvrage treatment Is avallable, the contractor shall provlde the necessary septic tanks for all latrlnes, Waste watet and septic-tank effluent shall be taken Into properly designed French drams. The contractor shall also make provis~on for the removal of all rubbish

the distribution network and the wirlng lnstallation of all

bulldings and structures at the hlghest standard at safety and usability. The contractor shall atso supply liquid petroleum gas for the burners used in t h e laboratories.

Where the construction of septlc tanks or a water-borne sewerage scheme is unfeas~ble, the contractor shall construct conservancy tanks and make arrangements for the removai and disposal of sewage

(b)

Water, elecbicity and gas

The contractor shall provlde a constant supply of clean potable water surtable for human consumptron as well as !he necessaryelectric power at 22012510 volts together whlh the requlred electrlcal network to the offlces, leboratories

The contractor shall provide all labour, eqvlpmsnt and material whrch may be necessary lor keep~ngall the buildings In a neat and clean condition, and any repalrs shall be made immediately at the request of !he englneer. The contractor will not be responsible for keepmg prelabr~catedand rented houses In a clean and neat

condition, and for tending to or caring for !he gardens.

1406

M E A S U R E M W AND PAYMENT

(d)

M n g fadlies

Unit
14.0t OKce and laboratory auwmmdation: The provision of accornrn~dation as specified, lncludlng mof, external and internal walls. windows complete with glazing. doors with locks and fittings, burglar proofing, paintlng, floors, fencing, the provision of a 2201250 volt electrical Installation with wlring. switchboards, etc, water and sewerage installation, and stores, complete, In accordance with the drawings and specificattons, except for Items scheduled elsewhere (a) Offices (Interior floor space only) . . . . . . . . . .
bboratories (interior floor space only) . . .

Ths contractor shall make available a kitchen with suftable cooking facllities for tho engineer's labourers near the engineer's laborator~es and shall supply fuel For cooking purposes.

At the tlme when The contract is swarded, the (a) engineer shall furnish the contractor wfth full details, in writing, regarding the number, type and laynut of all accommodation required, ineludlng details of the fittings, furniture and equipment required. The contractor shall not order any accomm~dation, materials, equipment or fillrngs on the basls of what Is specified or scheduled without written confirmation by the englneer. Ne buildings shall be erected without the englneer's wr[tten instructionsas to the exact position and orientation of the buiFdings
(b) Unless otherwise agreed on, the offices and laboratories shall be erected in close proximity to the contractor'soffices and laboratories. Should the contractor declde to move his own off~cesandlor laboratories to a new site, the olflces, laboratorfes and other buildings erected for the use of the engineer shall be moved to the new site and re-erectedIf required, at no addttlonal charge. Accommodation supplied by the contractor shall be (c) ready for use within six weeks of the date of such instruction, but the contractor may not proceed with the permanent works before the required offices and taboratories have been erected by hrm, If the houses lor the engineer"^ slte personnel are not ready for occupat~on when Ihe permanent works are commenced, the contractor shall provide swttable temporary beard and lodglng at hls own cost

...

square metre

{m2)

[b)

. . . . . . . square metre (m') . . . . . . square metre { m ' ) . . . . . . square metre {m2)

square metre {m')
, , ,

(c)

Open concrete work~ng floors. 150 mm th~ck

(dl

Roofs over open concrete working floors . dblution units Stores

(e)
(f)

............. .
,

.. .. . . , . . . . . .

square metre (m2)

The unit of measurement and payment shall b e the aquare

metre of each item provided. measured in accordance with the authorised Inner dlmenslons

If any further accommodalion is required during the h a F F inform the currency of the contract, the engineer s contractor at least three months before such additional accommodation Is to be ready for use. The ownership of all oftices, laboratories. housing, (d) sanitary facllities, laboratory equiprnenl and other Items provided by the contractor shall, when they are no longer required by the anginear, revert to the contractor upon wfitten advice by tha engFneer and shall be dismantled and removed from the site. The contractor shall take all reasonable precautions to prevent unawthorised entry ta the olf~ces and laboratories and to ensure the general security of the offices and laboratories.
e

14.02 O K * and l a h a t m y furniture:

(a)

Chairs

. ., .. .... ............ . . ... .

,

number (No)

(b)
(c)

Draughtsrnan's stools

number {No)

High chairs for laboratory . . . . . . . . number (No)

Desks. complete with drswers and locks ,
Drawing tables

(dl

number (No)

{e)

...

..

number (No) number (NO)

(I)

Conference tables

.............

Tha contractor shall ensure that all accommodation (f) complies with the appropriate statutory provistons operative In the area concerned.

The unit of measurements shall be the number of untts supplled in accordance wlth !he specil~ca!ians.drawings and the englneer's instructions.

(b)

Services for prefabricated houses: Fixed costs

kern

Unit

(i) (ii) (c) (d)

...........

lump sum

14.10 Provision of photostat facilities . . . . . . . . . .

. . . . . . . . . . . . . . . month .

Running costs

. . . . . . . . . . . . . . . . . . . . . month
. . . . . . . . . . . . month

Services for rented houses

Services for labourers' accommodation on the site: Fixed costs

The tendered rate per month shall include full provision for providing and maintaining an approved photocopier (capable of making A3-sized copies) and its use, including all accessories such as paper, etc, for making a maximum number of 1 000 A4 copies per month.
General : Method of payment

(i) (ii)

. . . . . . . . . . . . . . . . . . . .lump sum
. . . . . . . . . . . . . . . . . . . . .month
Payment under items 14.01 up to and including 14.06 and for item 14.09 will be made as follows: 80% of the amount will be paid when the item is provided and erected, fitted or installed to the engineer's satisfaction. A further 10% will be paid when the value of all permanent work done, excluding escalation, exceeds one-half of the tendered amount, and the remaining 10% will be payable in the certificate which follows the removal of the items from the site. Payment for expenditure under item 14.07 will be made In full as and when the money is expended subject to written proof by the contractor of payment of the amounts. The lump sums tendered under item 14.08 shall include full compensation for all fixed expenditures required in connection with these services, and will be payable upon completion of the work in respect of each subitem. The tendered rate per month will be payable monthly for so long as the services are required, but not in respect of any period after the tendered date of completion of any extension thereof which may have been granted. The tendered rates for the various items scheduled in this section shall include full compensation for providing, procuring, erecting, installing and/or fitting the item or service, as may be required or specified, for the use of the item or service, Including replacements when defective, and finally the dismantling and removal of each item, including all transport, handling and other costs. Payment for alternative accommodation provided in terms of subclause 1403(c) shall be adjusted pro rata in accordance with the time it is required during the period of construction of any extension thereof for which an extension of time shall have been granted.

Running costs

The lump sum and the rate per month tendered for each subitem shall collectively include full compensation for providing the specified services to the total number of units which fall in the corresponding category of accommodation.

Unit
14.09 Combined office and laboratory accommodation: (Alternative to the use of items 14.01 up to and including 14.05 when so required in the project specifications)

Office and laboratory accommodation, including fittings, furniture and equipment, car ports and housing for labourers in accordance with the details given in the project specifications and on the drawings . . . . . . . . . . . . . . .

. . . . . . . lump sum

The tendered lump sum shall be in full compensation for supplying and erecting the accommodation, fittings and furniture as specified in the project specifications and shown on the drawings, and for the proper maintenance and the subsequent removal thereof from the site on completion of the works.

The contractor may not commence wlth any part of the works before he has made adequate provision For the accommodation of traff lc.

CONTENTS
SCOPE

H work has to be done under traffic, the contractor shall see to It that his employees are elearly visfbfe.

GENERAL REQUlREMENTS
TEMPORARY TRAFFIC-CONTROL FAClLlTlES WIDTH AND LENGTH OF TEMPORARY DMATIONS TEMPORARY DRAlNAGE WORKS EARTHWORKS FOR TEMPORARY DMATIONS GRAVELLING OF TEMPORARY DMATIONS OR OF EWSTlMG ROADS USED AS TEMPORARY DRrlATIONS SELECTED-GRAVEL LAYERS, CRUSHED-STONE OR ASPHALT BASS, STAEIILIZATION, AND ROAD MARKING REQUIRED FOR BITUMEN-SURFACED TEMPOMRY DR/lATlONS BITUMEN-SURFACEDTEMPOWRY DEWATIONS MlSTlNG ROADS USED AS TEMPORARY DEVIATIONS MAINTENANCE QF GRAVEL TEMPORARY DNlATlONS AND EXfSTINGGRAVEL ROADS USED AS TEMPORARY DEWATIONS MAINTENANCE OF TEMPORARY DEVlATlONS WITH BITUMINOUS SURFACING AND EXISTING ROADS WITH BITUMINOUS SURFACING USED AS TEMPORARY DEVIATIONS ACCOMMODATION OF TRAFRC WHERE THE ROAD IS CONSTRUCTED IN HALF WIDTHS TEMPORARY FENCING AND GATES THE USE OF TEMPORARY DEVIATIONS BY THE CONTRACTOR OBLITERATION OF TEMPOWRY DEVIATIONS MEASUREMENT AND PAYMENT Ewcept where the exlsting road I s to ramaln In use for through trafflc, the contractor shall provlde, construct or put in order such temporary devlatlonsas may be reqwfred for devlatlng traffic from such sectlons of the road as are handed over to him, as spaclflsd. Should the contractor prefer to build temporary devlations at his own Enitlative in stead of complying with the requirements of the speciflcatfons, he shall obtain the engineer's prior written approval. M fhe engineer's prior written approval has been obtained, the contractor will be remunerated lor the a~zornrnodatlonof traffic up to an amount that does not exceed the tendered amount for the accommodation of traffic In accordance with the spedficatfons.

The rnlnlmurn vertical clearance over any section of a temporary deviation shall be 5,2 rn. II the rnlnlmurn clearance available Is less than 5-2 m, the minimum clearance shall be Indicated on approved slgns at approved locations on and in advance o f the obstruction.

(d)

R o wand survqr hems

This sectlon covers the consiruetlen and maintenance of the necessary temporary devlattons and detours. barricades and slgns, and everythhg necessary for the safe and easy passage of all public traffic during the conslrwcflon and rnalntenance periods, and also the obllterallon of temporary deviations a3 they becomeredundant. This section also covers the acmmrnodation of traflc on exlstlng roads wlthout the deviation of traffic onto temporary deviations

Where posslble, temporary davf~tlons shall be constructed r so as not to damage or dlsplace property o trlgonometrical-suruey beacons. In exceptional cases where this Is not posslble, the contractor shall notlfy the engineer in good time so that he may arrange to have them suitabSy referenced before they are displaced.

The contractor shall also provfde and grant access to persons whose propertiesfall wlthln or adjoin the area over which he is working, and in this respect the contractor's attention Is drawn to the general oonditians of contract. No separate payment wlll be made tor the provision and maintenance of such accesses and faclllties, except where it may be required outslde the road resews.

The contractor shall be responsible lor the safe and easy passage of public traff7c past andlor over sectlons of roads of whlch ha has occupation. The contractor shall at all times In all hls operations end In using his constructional plant take the necessary care to protect the public and to facilltata the flow of trafflc.

The need for and detalls concerning all temporary deviations shall be approved by the engineer before the constructlon of such temporary deviations mmmeneRs, and the contractor shall satisfy hlrnselt before tendering that he can make arrangements in respect of any temporary deviationsas may be necessary tar the safe and

convenient passage OF trafflc.

which are in any way connected with construdion activities, and draw up accident reports {including amongst others photographs): attend to the training and performance of flagmen (vii) and all other personnel involved in the control of traffic; (viii) attend to all complaints and cla~ms from the public with regard to traffic safety and report on such matters to the engineer.

(g)

Temporary works

The temporary deviations prov~ded by the contractor shall Include the construction of temporary gates, fences. drainage works, and other ~ncidentars considered by the engineer to be necessary.

Public services affected by temporary deviations shaH be treated tn a similar manner as serv~cesaffected by the permanent works and payment shall be made in the provisions of section 12M3 of these accordance w~th specifications.

The safety of the travetltng public Is of utmost fmpnlrtance and every effort must be made to ensure that sll road signs, barricades, del~neators, flagmen and speed controls are maintained and effective and that courtesy is extended to the pwbflc at aH times.

The contractor shall provide, erect and rnafnlaln the necessary!ralfic-control devices, road signs, channeltrailon devices, barricades, warning devices and road markings to as traffic-control facilities),es shown (hereinafter~eferred on the draw~ngsand in the Soulh Afr~canRnad Traffic S~gnsManuel, and shall remove them when no longer required. It shall be tncurnbent upon the contractor In see to it that the above-mentioned traffic-control facitities are present at all times and are functioning properly, but, prior to any section of the road which requires the above facrllties being opened to traffic, the contractor shall submtt his proposals in this connection to the englneer for his information and comment.

The contractor shall nomlnate a knowledgeabfe member of hfs staH on site who shall be the responsible person for
the arrangements and maintenance of all accommodetion of traffic measures required for the duration of the contract. The responsible person shsll liaise dally w~!hthe n order to malntain proper traff~c resident engineer F arrangements. The traffic safety officer will be requlred to perform the following duties and this list shall not be deemed to be comprehensive. He shall:

be responsible for keeping the temporary traffic (i) 24 hours accornmodatlan requirements up to Ppectflcat~on a day J days a week;
(if) compile and maintain s complete daily record of trafficsigns ~nstalled and !he traffic signs sequence at each location during the execution of the contract:
inspect and report to the engineer on the state ol (iii) all required road signs as often as the engineer may require but In any event not less than once a day or at such other tntewals as may be specified, exercise control In terms of traflic safety over the (iv) sate movement of personnel, visitors and plant on sita Includ~ng !he wearing of high v~slblllty clothing, the operation of amber flicker lights. and the display and ~lesnliness of "constructtonvehicle" signs, all as spec~fted:

The contractor shall Immediately make good any shortcomings lo the temporary traffic-control facilities The contractor shell indemnify the employer agalnst all proceedings, ctalms, actions, damages and costs which may arise from or be related to the absence or improper functioning or placement of road-traffic signs. barricades, traffic-control facilities, channelization devices, warning dev~ces and road-traffic marks Road signs,channelization devices and barricades R O longer required rney be moved for re-use, and, if no longer suitable for use, replaced without any additional compensation If they are required for re-use. The type of construction, spacing and placement of Iratficcontrol facilities, shall be in accordance with the prescriptions and recommendation of the latest edition of the South African Road Traffic 51gns Manual, and In accordance with the instructions and drawlngs of the engineer. Thevarious traffic-control facilities which may be required are the Followtng:

(a)

TraWwntrol &vices

Traffic-controldevices Include the use of flagmen, portable STOP and GO-RY signs, and Iralf~c signals, whichever may be the most suitable method under prevailing signals shall be erected only i f so circumstances. Traff~c specified in the project specifications or upon an instruction in writing, by the engineer If the road is partially closed and one-way traffic only is allowed over a section of road of whfch the length exceeds 250 rn, the traff~c shall be regulated by flagmen and STOP and GO-AY signs at both ends of such section, H It is necessary for effective communication between the flagmen, an approved two-way communication system shall be in operation at the control polnts

be responsible for keeplng all road slgns and traffic (v) cones clean and visible at all times The contractor shall remove all bituminous and other foreign matter from road sfgns and traflic cones or provlde new road signs and traffic cones all at the contractor's own cost. and all as directed by and to the satisfact~on of the engineer.
(vi)
compile completa records of trafflc accident scenes

Temporary traffic-control facilities, if applicable, shall be provided wifh portable stands adequately ballasted wlth sandbags to prevent the sFgns form being blown over by wind or wind turbulence from moving traffic, whenever they are used i n a situation where the temporary signs must be relocated frequently

15W

WIDTH AND DEVlATIONS

LENGTH

OF TEMPORARY

@)

b a d signs and barrimdm

The roadway wldth of gravel temporary deviations accommodating two-way traffic shall be not less than f 0 rn. Where temporary deviations consist of two separate one-way lanes, the minimum usable width of each lane shall be not less than 5 m.

Road sfgns shall include all the statutorily required road signs in the permanent or temporary series, which shall also include dellnealors and moveable barricades (the barricadelsign cornbinalion type), or an appropriate combination thereof,

In the case of a two-lane temporary deviation the total width of the carriageway shall be 8,5 rn and, if a bitumlnous surface Is provided. It shall comprise two lanes of 3,5 rn wldlh each and centrally located on the roadway. A single lane temporary deviation shall have a 5,Om wide carriageway and, if required, a centrally located 3,sm wide surfaced lane
Because of the llrnltation on overtaking in the case of single lane temporary deviations, such deviations shall be as short as possible with B rnaxrmum length of 1.0 km. If wlder temporary deviations are required. such widths shall be specified in the prejecl specll~cationsandlor on the drawings.

Road signs shall comply with the requirements of section 5600,

(c)

Channelization devtms and barricades

ChannelIralion devlces shall include delineators, cones. barricades, guardra~ls, barriers, roadstuds or roadmarkings. or any appropriate combination of these devtces.

151J5

TEMPORARY DRAINAGE WORKS

(d)

Barriers
The contractor shall construct the necessary temporary drainage works such as side drains, catchwater drains, mitre drains, culverts, elc, to deal adequately with any surface run-oil.
Temporary culverts of the type and size required by the engineer shall be installed on existing drainage channels Any suitable wherever requlred by the engfneer. prefabricated culverts salvaged from an existing raad or an abandoned temporary deviation may be re-used if in a good condition and approved by the engineer Any damage caused to temporary deviations on account of tempotary culverts Installed and maintained i n accordance with the engineer's instructions being unable to cope with floods effectrvefy shall be repalred. The contractor will be paid for tha cosl of such work at appl~cable rates or, where no such rates exist, i n accordance wlth the provisions of clause 40 of the general cond~trons of contract.

Barriers for preventing vahlcles from leaving the permitted lanes may consist ol movable barriers (far example the New Jersey type) of approved construct~on for separating two opposite traffic streams, or ordinary guardrails that comply with the prov~sions of section 5400

(e)

Warning devices

If specified In the project specifications all conslruct~on vehicles and plant used on the works shall be equipped with rotating amber flashing lights. All lights shall be visible at all times and from all s ~ d e s The flashing lights shall be switched an at all times when the vehicles and plant are used on the site for the execution of the works

If specifled In the project specif~cationswarnlng bosrds shall be mounted on construction vehicles and plant and The words shall be clearly vislble. KONSTRUKSIEVOERTUIG or CONSTRUCTION VEHICLE shall be displayed on these boards i n 250 rnm hrgh red letters on a white background

No separate payment w ~ l lbe made tor the supply of flashing lights and warning boards and the inslallation thereof on construction vehrcles and plant

Payment for the construction of temporary culverts will be made under the approprtate ifems provided In this section and payment for the consttuctlon o f the other dratnage works lor temporary deviations and for the maintenance of all dramage works shall bs included in the rales tendered for rtem 15,Ol. Accornmodatrng traffic and rnaintainlng temporary deviations.

fl

Road markings

Road markings. as specltied in section 5700. may be required on b~luminousand concrete surfaces and will include road-marking studs wherever necessary. The road markings shall be made In accordance with the prov~sions of section 5700 Any painted raad markings which no longer apply shall be removed. Road-markrng studs shall be removed completely.

The contractor shall shape and grade the temporary devlallons and shall make full use of all material that can be obtained from alongside the temporary deviations, from slde cuts or from the Immedlate vtcinlty If an adequate

quantity d material cannot be obtained in this manner, he shaft import materlel from other sources. Where necessary, cutilngs shall be made to obtain a satisfactory vartfcal sFlgnment The contractor shell also parlorm the nneessary clearkng and grubbing, Including the removal of all trees and stumps. Where ths subgrade is not sufnciantly dense in Its natural state, It shall be scarified to a depth of 200 rnm, mixed, watemd, and compacted to 90% of modlfied AASHTO densliv.

be prescribed by the engineer.

7570 WSTING ROADS DEVLATlONS

USED AS TEMWRARl

Any fllls which mey be neesssaryfor any reason, eg: for the constrmtlon 01 fords, shall be constructed and EompaFted by the contractor as descrlbed above. Wherever possible, fords shall be constructed from rocMlll o r marsa materlal so as In limit, In so far as $9 possible, damage caused by flood waters. The contractor shall construct cuttings where requfred.

Where existing roads are to be used as temporary deviations, the contractor shall, after consultation wlth tha owner or authority having control of such mad, carry out any repairs, afteratlons or sddltlons to such roads as may be required to bring them In a condition suitable- for traffic. This work wlll be paid for as stipulated hereinafter.

1511

MAINTENANCE

OF

GRAVEL

TEMPORARY

lEVIAT1ONSAND W m G GFMMLROADS USED AS TEMPORARY EUWTIONS

All gravel ternporary devlatlons and exlstlng gravel roads used as temparary deviations shall be naintainwd by Zha contractor in a safe traff icable condition. Whenever required by the engineer, the roads and temporary road deviations shall be bladed by means of swlf+propelled graders to provlde B srnoofh rldlng surletce free from corrugations. All potholes shall be repaired immedlateFy

1S[R G R A ~ W F T E M P O R A R T ~ I I O N S O R O F W S T l N G ROADS USED A S TEMPOWWY DEWATIONS

When the earlhworks tor temporary davlations as descrlbed in clause I506 have been completed, those sectlons of the temporaw deviations and of existing gravel roads weed as temporary deviatlons, as Indtcated by the engineer, shall be provided with a wearing course of suitable gravef approved by the snglnesr.

The contractor shall provlde, spread, water, mix and mrnpeet such material to a density equal to 93% of
modified MSHTO denslty.

bhe engineer may also Instruct the contractor to water the temporary deviations to keep down dust or l o facilitate the proper bradtng of the surface. All dralnage works shall be rnarntained In a good working order,
The bladlng of surfaces of tsrnporary dsvlatlons and the appllcatlon of gravel and water shall be measured and pald for separately, but all other maintenance shall be deemed to be! included in the rate tendered for item 15.07 * Accommodating Irafflc and rnalntalning temporary devtatlons.

i f gravel shoulders are to be used for the accommodation of traffTc and If the axlstlng shoulders are unsafe for traffic, ths shoulders shall be reconstructed as specltisd. All grass end much grass shall be bladed from the surtace. Approved grevel metmrial shall be imported from the road reserve or from borrow pits. The rnaterlsl shall be spread, wetersd, rntxsd snd compacted to 93% of modified A4SHTO density In leysrs of the specflied thickness.

1512

t m SEECIEDGMVEL LAVERS, CWSHEaSTONE OR ASPHALT W E , 5 T ~ I ~ T I O AND N, KMO MAWING REWIRED FOR BrnMEKSUWACFD m p o R B R y DE\IIATrnS

MMMEWWE OF EWOlWW DEVIATKMS W H BmMINQUS SURFACING M I 3 mSTING ROADS WmH BRUMINOUS SURFACING USED AS TEMPORARY DEVLdTlONS

W a r s specfffed In tho profeet speclffeati~ns or required by the snglneor, gravel tayers of selected subgrade or subbase quallty, crushed-stone basa, ssphalt base or stablllrad gravel layers shall be constructed snd road marklng shall be done by the contractor, all in accordance with the requirements of the relevant sections of these specltlcations and the engineer's Instructions.

P S I roads wlth bltumlnous surfacing used by publie traffic bypassing constructton shall be malntained In a good snd safe trafficable condition lor the entire period during whlch such roads are used. Maintenance shall Include the patching and repair of the bltumlnous surfacing, the clearing of shoulders, the clearing of all drafns, ineludlng culvert Inlet and outlet drains, and other Fncidentals and, unless othsrwlse specifled in the project specifications, also rhe cara and maintenance of all road markings, road slgns, dellneadors and guardralts.

Where requl;nd in the projeci spec(flcations or by the snglneer, temporary dsvlalions shall be provided with bltumlnous surieelng In accordance wlth the requirements of series 4 OW or of the project specifications, or as may

The cost of all maintenance to temporary deviafions wlth bituminous surfacing shall be Included in the rates tendered under item 15.01, Accommodating traffic and rnaintainlng temporary deviatlons, except for the cost of repalrs to the bituminous surfaclng and pmement, which shaft be paid for separately under Item 75.09.

1513

ACCOMMODAnON OF TRWFlC WHERE THE ROAD IS CONSTRUCTED IN W WIDTHS

Where, by reason of difficult terrain or lor any other reason, the construction of temporary devialions Is unfeasible, the contractor shall, upon !he written instruclion of the engineer, construct the road in half wfdths to allow traftic to use that half of the road not under construcl~on. The length of the half-wfdth conslruction shall not enceed the length specified In the project spedflcatlons or on the drewlngs, or the length of the section of road that can be constructed and completed in one day, whichever is the shortest. Provision shall be made for traffic travelling in oppos~te directions to pass at frequent inlervals.

where his own traffic causes excessive damage or wear to such mads or constitutes a cond~tion hazardous to public traffic, the engineer shall have the right to regulate the contractor's trafftc over such temporary devlatlons and require the contractor lo provide, at his own cost, such marntenance, includ~ng wearing-course gravel and watering, as in the engineer's opinion will be necessary in addition to that which would be required ta maintain the ternporaty deviations properly when not used by the contractor's construction traffic.

The contractor shall arrangs his work so as to allow traffic to have free one-way access to at least half the width of the roadway at all tlmes during the cwnslruction perlod, He shall rnaintatn that half of the road, which is being used for traffic for the time being, in a trafficable condit~on, lo the satisfaction of the engineer
Where gravel or sealed shoulders are used as temporary devlatians, the confinuous length of road under constructlon at any time shall be llrnited to 4 km unless otherwise S D @ C I ~ I @ ~ The number of sectlons undar constructlon at any tlme sharl not exceed four, and spaces of at least 2 krn in length In which the entlre road wldth is open for trafflc shall be provided between the construction areas to allow traffic to pass slow moving vehicles.

When traffic is routed permanently onto the new road, and on the written instructions of the engfneer, the contractor shall obliterate the temporary deviations and all designated sections of obsolete roads and road markings tn accordance with section 5WQ.

1517

MEASUEMENT AND P A Y M E N

Unit

15.01 kcurnmoda'ting baffic and maintaining temporary deviations . . . ..

k~lometre (km)

The contractor shall ensure that the entire road width shall be open at nlght and shall be left, at the end of each day's work, In a good and sale trafficable conditron to the satisfaction of the englneer.
During the day the traffic shall be controlled by a STOP snd RVlGO system, Should the road be not In a safe trafflcable condltlon for two-way tralfic over the entire width at the end of each day's work, the contractor shall provide adequate flagmen, signs,barricades, lights and the necessary staft at hFs own cost to ensure a reasonably free flow of traffic alternately in each direction throughout the entire period when the madway is open to one-way tralllc only

The unit of measurement shall be the kllometre, measured along the centre lines of temporary devlatlons. existing roads used a3 temporary deviations, and roads constructed In hall-widths. R shall net include sections along which the traff~c Is dlverted onto existing roads where the contractor is not responsible for the maintenance of such enisting roads. The tendered rate shall include full compensation for accommodating tralftc and maintaming temporary deviations, including reads constructed in half-widths and e ~ ~ s t ~roads ng used as temporary deviations during construct~on and maintenance per~ods,but excluding maintenance and repair work for which payment is specifically made under the other pay Items provlded in section 1500 The tendered rate shall also Inzlude full compensation lor the provision of a full-(ime traffic safety officer and for all the duties performed by him, The tendered rate shall also Include full cornpensatfun for the provision of communications equipment requlred for regulating the traff~c, arranging lor the rnovlng of services, solving traff~c problems, complying with the legal requirements of all authnrltfes concerned, for prov~ding temporary access to private property. and for the provision and maintenance of temporary drainage, but excluding the work specifically paid for under item 15 12. The tendered rate shall also include full compensation for the specified general requlrements and all lncldental ilerns of cost whrch are required under the provisions of section 1500 and which are not specifically paid for under the other pay items provided in sectlon 1500.
Payment will ba made in two equal instalrnents in respect of each section. The firs! instalment w ~ lbe l made when suitable temporary deviations have been approved for use or when traffic is taken over half-width construction. The

W e r e ordered by the engineer or specified on the drawings or in fhe project specifications. the contractor shall make his own arrangements for providing eithnr new fencing and gates or rnovlng and subsequently reinstating e~istingfencing and gates i n accordance with the provisions of clause 5512.

1515 THE USE OF TEMPORClRY DWMTlONS BY THE

mtmtAcTOR

The contractor shall have the right to use public roads, Including temporary devlutlons open to public traffic, but

second lnstalment wlll become due when the traffic can be accommodated on the new road, all temporary devlatlons have been obliterated and all general obllgatlons of the contractor have been complled wlth, all to the satisfaction of the engineer.

Item
15.03 Temporary trafflc-contml

Unit
fadltlies:

(a) (b)

flagmen

.......................

man-day

Portable STOP and GO-RY signs.

. . . . . . . . . . . . . . . . . . . . . .number (No)

1 5 . M Eerthworksfor temporary deviations:

(c) (a) Shaping of temporary devlatlons . . . . . . . . . . . . . . . . . . kllometre (km) (d) (e) (f)

The unit of measurement shall be the kllometre of temporary devlations shaped, compacted and constructed In accordance with the provislons of clause 1506 of thls section. Where the contractor has to provlde access roads to private property, the length of such access roads outslde the road reserve shall also be Included In the quantity measured for payment. The tendered rate shall lnclude full compensation for clearlng and grubbing where necessary, the removal of small trees and stumps, the shaplng and gradlng, watering, mlxlng and compacting of the materlal and all cuts and fllis constructed from materlal obtalned from alongside the temporary devlatlons or side cut, but lncludlng only such portlons of the fllls which are less than 0,5 m In helght.

. . . . . . . . . . . . . . number (No) Amber flicker lights . . . . . . . . . . . . number (No)

Road signs, R- and TR-serles, (slze Indicated) Road slgns, TW-series, (slze Indicated)

Temporary trafflc-control slgnals as specified or as shown on the drawings

. . . . . . . . . . . . . . .number (No)

. . . . . . . . . . . . . . . number (No)

(g)

Road signs, STW-, DTG-, TGS- AND TG-series (excluding dellneators and barricades) Dellneators (DTGSOJ) (slze Indicated): Slngle

. . . . . . . . . . . . . .square metre (ma)

(h)

@)

Cut and borrow to fill

. . . . . . . cubic metre (ma)

(I) (li)

......................

number (No) number (No)

Mounted back to back.

.........

The unlt of measurement shall be the cublc metre of flll measured in sltu from levelled cross-sectionstaken before and after construction where such material is either Imported from a locality more than 100 m from the point of use or Is utlllsed In a portion of a fill which is in excess of 0,5 m above the original ground level. Where measurement by cross-sections is Impractical, the volume can be assumed to be equal to 70% of the loose volume measured in trucks in the case of soil and gravel materlal, and equal to 60% of the loose volume in trucks In the case of hard material consisting predominantly of particles of whlch the maxlmum dlmenslon exceeds 100 mm. The tendered rate shall lnclude full cornpensatlon for procuring, furnishing and the placing all the classes of material, including transportingover a free-haul distance of 0,5 km. (c) Cut to spoil

(I)

Movable barrlcadelroad sign comblnatlon (size Indicated)

(j)

..... Trafflc cones (slze Indlcated) . . . . .

Slngle guardralls attached to posts

number (No) number (No)

(k)

(I) (m) (a)

. . . . . . . . . . . . . . . . . . .. . . metre (m) Movable barriers (type indicated) . . . . metre (m) Two-way communlcatlon devices . . number (No)
Flagmen

The unit of measurement shall be a day worked by a flagman. The tendered rate shall lnclude full compensation for a flagman who Is required to control traffic by way of flags or portable STOP and GO-RY signs and shall include the provision of flags and safety jackets.

. . . . . . . . . . . . . . . cubic meter (ml)

The unit of measurement shall be the cublc metre of authorized excavation taken from cut In temporary devlations or removed from fill in temporary deviations which are no longer required and carted to spoil on the lnstructlons of the engineer, all measured in sltu before excavation by means of levelled cross-sections. The tendered rate shall include full compensation for excavating In all classes of material, loading, transporting, off-loading, Including the shaping and levelling of spoil material and transporting over a free-haul distance of 0,5 km.

The unit of measurement shall be the number of each sign provided, and, as may be applicable, completely erected.

The tendered rates shall include full cornpensatlon for providing, and where applicable, erectlng each slgn complete. In the case of subitem (b) It shall also Include moving the sign as may be necessary.

The unit of measurement shall be the square metre (g) of sign face, measured on the face of each item provided. The tendered rate shall include full compensation for providing and erecting each sign, complete with posts. The unit of measurement shall be the number of (i) movable barricades, complete with road signs provided. The tendered rate shall also include full compensation for moving the barricades to fresh positions as and when necessary. The unit of measurement shall be the number of () cones provided and the measured quantity shall be the maximum number in use at any one time in accordance with the layout shown on the drawings or as directed by the engineer. The tendered rate shall also include for all moves to new positions for the duration of the contract. The unit of measurement shall be the metre of (k) straight or curved temporary guardrails erected, complete with end units, posts, reflective plates, etc. The unit of measurement shall be the metre of each (I) type of movable barriers provided and shall include the initial erection. The unit of measurement shall be the number of (m) two-way communication devices ordered by the engineer for the duration of the contract. The tendered rate shall Include full compensatlon for the supply of two-way communication devices suitable for the control of one-way traffic when half the width of the roadway is closed for construction purposes. The tendered rate shall also include full compensation for the maintenance of the devices and for the provision of operating staff for the duration of the contract.

15.05 Gravelling and repair of temporary deviations and existing gravel shoulders used as temporary deviations: (a) (b) Temporary deviations

. . . . . . . cubic metre (m3)

. . . . . cubic metre (ma)

Existing gravel shoulders

The unit of measurement shall be the cublc metre of gravel provided as wearing course for the surfacing of temporary deviations and existing gravel shoulders, computed from the dimensions of the layer as actually constructed in place, in accordance wlth the engineer's instructions. Where measurement by the above method Is considered to be impracticable by the engineer, the volume may be computed by taking 70% of the loose volume of the gravel as measured in the hauling vehicles. The tendered rate shall Include full compensation for procuring, furnishing, placing and compacting the gravel wearing course, including a free-haul distance of 1,O km, and the repair of local sections of the temporary deviations and gravel shoulders.

UnH 15.06 Watering of temporary deviations . . . . . . . . .

. . . . . . . . . . .kilolitre ( k l )

General: The tendered rates for the respective traffic control facilities shall include full compensation for the supply and initial erection complete with posts, stakes, portable stands and sandbags as may be required, for cleaning and maintenance, for covering with non-transparent material when temporarily not required and removal off the site when no longer required. 75% of the tariff will be payable when the items have been provided and erected in position for their first use on site and 25% when finally removed from the site. Facilities which become unserviceable or are damaged by vehicles or stolen, in particular delineators, shall be replaced promptly at no additional cost.

The unit of measurement shall be the kilolitre of water applied to the temporary deviations on the written instruction of the engineer. Water required for the construction of temporary deviations will not be measured for payment. The tendered rate shall include full compensatlon for the supply, transport and application of the water. Overhaul shall not apply to transporting the water used for the watering of temporary deviations.

Item 15.07 Blading by road grader of: (a) Temporary deviations

UnR

.........

kilometre-pass (km-pass)

(b) Item

Existing roads used as temporary deviations . .

. . . . . . . . kilometre-pass
(km-pass)

Unit
(c)

15.04 Relocation of traffiocontrol facilities . . . . . . . . . . . . . . . . . . . . . . lump sum

Existing gravel shoulders used as temporary deviations . . . . . . . kilometre-pass (km-pass)

The tendered lump sum shall include full compensation for dismantling, storing if necessary, transporting, re-erecting and inspecting the traffic-control facilities, and for all labour, equipment, constructional plant and incidentals necessary to execute the work complete as specified or shown on the drawings.

The unit of measurement for using a road grader to blade the surfaces of temporary deviations, existing roads and existing gravel shoulders used as temporary deviations shall be the kilometre-pass, that is, each kilometre of the full width of the temporary deviation, the entire surface of

which has been bladed by one pass of the road grader. In the case of temporary deviations constructed as two separate one-way roads, they shall be considered as one full width of the temporary deviation for purposes of measurement. Only the number of kilometre-passes actually authorized by the engineer, in writing, will be measured. Where the blading of temporary deviations has not been carried out satisfactorily and the surface has not been improved as much as can reasonably be expected from such an operation, the contractor shall carry out further grading work at his own expense until a satisfactory result is obtained. The tendered rate shall include full compensation for providing the road graders and operators, flagmen, guards, barricades, signs and all other costs incidental thereto and for blading the temporary deviations to a smooth surface free from corrugations.

constructed in half-widths on the written instructionsof the engineer. The tendered rate shall include full compensation for providing all plant, equipment, tools, transport, labour, supervision, flagmen, guards, road signs, lights, barricades and all other incidentals necessary for the proper and safe handling of traffic as specified and shall also include full compensation for all additional costs and work resulting from constructing the road in half widths.

Item 15.11 Traffic signals

Unit

. . . . . . . . . . . . . . provisional sum

The provisional sum provided to cover the cost of providing traffic signals shall be expended in accordance with the provisions of clause 48 of the general conditions of contract.

Unit b m Unit 15.12 Temporary culverts: 15.08 Repairs, alterations andlor addions to existing roads used as temporary deviations . . provisional sum The provisional sum provided to cover the cost of work ordered by the engineer in terms of clause 1510 of the specifications shall be expended in accordance with the provisions of clause 48 of the general conditions of contract. Where the exact nature of the work can be determined in advance, provision may be made in the project specifications for suitable rates to be tendered in lieu of providing a provisional sum. (a) Provision and laying of temporary prefabricated culverts complete (state size, type and bedding) . . . . . . . . . . . . . . . . . . . . . . metre (m)

The unit of measurement shall be the metre of culvert provided and installed by the contractor. The tendered rate shall include full compensation for procuring and furnishing new culverts, all excavations, bedding, laying the culverts and backfilling. (b) Re-use of prefabricated culverts complete (state type, size and type of bedding) . . . . . . . . . metre (m)

item

Unit

15.09 Maintenance of the biiminous surfacing and pavement of temporary deviations with bituminous surfacing and existing roads with biiminous surfacing used as temporary deviations . . . . . . . . . . . . . . . . . provisional sum The provisional sum provided to cover the cost of work ordered by the engineer in terms of clause 1512 for repairing and maintaming the bituminous surfacing and pavement of existing and temporary roads with bituminous surfacing used as temporary deviations, shall be expended in accordance with the provisions of clause 48 of the general conditions of contract.

The unit of measurement shall be the metre of culvert installed. The tendered rate shall include full compensation for taking up the culverts from their previous positions and installing the culverts in fresh positions, including all excavations, backfilling and bedding, the loading and transporting and off-loading of the culverts. (c) Eventual removal of prefabricated culverts

............

metre (m)

The unit of measurement shall be the metre of culvert removed. The tendered rate shall include full compensation for the eventual removal of prefabricated culverts that are not to be re-used, including excavation, taking up the culverts, loading, transporting, off-loading and stacking the culverts at an approved location, including a free-haul of 1,O km, and the reinstatement ofsurfaces. The culverts remain the property of the employer. (d) Overhaul on excavated material carted to spoil, backfill material (but

Item

Unit

15.10 Accommodation of traffic where the road is constructed in half-widths . . . . . . . . . . . . . . .kilometre (km) The unit of measurement for accommodating traffic where the road is constructed in half-widthsshall be the kilometre measured along the centre line of the road which road is

excluding portland cement), prefabricated culverts removed and reinstalled, and prefabricated culverts removed and stacked, for haul In excess of a freehaul distance of 1,O km cubic metre-kilometre (ma-km)

equipment, constructionalplant and incidentals necessary to execute the work as speclfied or shown on the drawings.

..

General notes:
The following pay items described in other sections will be listed under this section In the schedule of quantities where they relate to work executed under this section. (1) Overhaul as specified in section 1600. The clearing and grubbing of large trees as specified in section 1700. The removal of overburden as specified in section 3100. The constructionof mass earthworksand pavement layers as specified in series 3000. Bituminous seals as specified In series 4000 or in the project specifications. Temporary fencing as specified in section 5500. Road markings as specified In sectlon 5700.

Measurement and payment for overhaul shall be made in accordance with the provisions of section 1600. In the case of culverts, the outer volume of each culvert shall be measured.

(2)
15.13 h situ preparation and compaction of existing gravel shoulders to 93% of m o d i AASHTO density

(3)

.. . . cubic metre (m')

(4)

The unit of measurement shall be the cubic metre of shoulder material prepared and compacted as specified.

(5)

The tendered rate shall include full compensation for ripping, shaping, mixing, watering, compacting to a depth of 150 mm below the final road surface, and for all labour,

(6)
(7)

SERIES 1000 : G E N E M SECTION 1600 :OVERHAUL

in respect of the same hauling operation. Restricted overhaul shall apply to fill material from cut and borrow and to spoil material from excavations when hauled in excess of the free-haul distance of 0,5km in respect of haul up to and including 1,Okm, and shall be measured and paid for b y the cubic metre of material hauled between or over these distances.

CONTENTS

1601 SCOPE 1602 DEFINITIONS 1603 MEASUREMENT AND PAYMENT

1601 SCOPE

Ordinary overhaul shall apply to all overhaul material in respect of haul in excess of 1,Okm, and shall be measured by the product of the volume of material hauled, measured as specified hereafter, and the overhaul distance as defined in clause 1602(e)hereof.

This section covers the hauling of overhaul material as defined herein from the place of excavation or stockpile to the position of placement, where such haul distance is in excess of the free-haul distance as defined herein.

Both restricted and ordinary overhaul shall be paid in respect of material having a free-haul distance of 0,5km when hauled in excess of 1,Okm.

(c)

Haul distance

(a)

Overhaul material The haul distance for cut to fill shall be the distance between the centre of volume of the overhaul material In the cut before excavation and the centre of volume of the portion of the fill constructed with the overhaul material.

Overhaul material shall be transported material to which overhaul shall apply when hauled in excess of the free-haul distance and shall include only the following materials: (i) Gravel, soil or rock materials used In the construction of fills, pavement layers, banks and dykes. (ii) Topsoil, gravel prescribed b y the engineer as wearing course for temporary deviations, and selected gravel material used for backfilling drain and culvert excavations, but excluding permeable material used in filter drains. (iii) Spoil material resulting from the authorized excavations of the road prism, drains, culverts and other structures and from fills in temporary deviations which are no longer required. Crushed stone used in the construction of subbase (iv) and base, but only when overhaul applies in the circumstances specified in item 36.01 of clause 3608. Materials (irrespective of the type of material) cut (v) from existing pavement layers and transported to spoil, or direct to fill elsewhere on the site, or to approved stockpiles, or from stockpiles to the point of application. Materials and products specified elsewhere in the (vi) contract.

The distance between the centres of volume shall be measured along the centre line of the road, and any additional distance of haul ascribed to the following of a different haul route will not be considered. Cut and fill volumes for ramps, road approaches and connections on either side of the road shall be considered as concentrated at the centre line of the main roadway under construction for computing overhaul quantities for payment, unless otherwise specified in the project specifications.

The haul distance for borrow material and cut to spoil material shall be measured along the shortest route determined by the engineer as being feasible and satisfactory. Should the contractor choose to haul material over some other longer route, computations for payment shali nevertheless be based on the haul distance measured along the shortest route designated by the engineer. The haul distance for borrow materials and cut to spoil shall be measured to the nearest 0,lkm.

(d)

Freehaul distance

After reprocessing ordinary overhaul only shall apply to asphalt or any other material that has been reprocessed in a plant for recycling, and no restricted overhaui shall apply.

The free-haul distance shali be the distance up to which overhaul material may be hauled before overhaul becomes payable. This distance shall be 1,Okm in the case of all overhaui materiais, except cut and borrow to fill and cut to spoil material where the free-haul distance is 0,5km.

(e)

Overhaul distance

@)

Overhaul The overhaul distance applying to item 16.02shall be the haul distance as defined above, less 1,Okm, measured to the nearest 0,lkm.

Two types of overhaul shali apply to this contract, and, depending on circumstances, any one or both may apply

1 -

MEASUREMENT AND PAYMENT

Overhaul will be the total haul, minus the 1,O km free-haul.

(2)

Quantity of material

Crushed-stone (section 3600)

base

or

subbase

material

The quantity of material overhauled shall in all cases be measured in the same manner as the item to which the overhaul applies.
Item 16.01 Overhaul on material hauled in excess of a free-haul distance of 0,5 km, for haul up to or through 1,O km (restricted overhaul) . Unit

The following applies to crushed-stone base or subbase material as specified in section 3600 to which overhaul applies, ie material not obtained from commercial sources. The haul distance shall be measured from the approved borrow pit to the crusher site and thence to the point where used on the road. The quantity shall be the actual quantity only of subbase or base material measured for payment and does not include material excavated but discarded or lost at the crusher.
(3)

. ......

cubic metre (m3)

Oversize material (clause 3210)

removed from

the

road

The unit of measurement shall be the cubic metre of overhaul material hauled over the distance given above.

Unit 16.02 Overhaul on material hauled in excess of 1,O km (ordinary overhaul)

The haul on all oversize material removed from the road and taken to spoil shall be considered as two haul operations, and overhaul shall be calculated separately as follows: Haul from the point of procurement of the oversize (a) material to the point where it is deposited on the road Haul and overhaul shall be calculated in the normal manner, but no overhaul will be payable on the first portion of the oversize material which does not qualify for payment under any item for the "removal of oversize material". Haul from the point where it is bladed of the road (b) to the point of disposal The haul distance shall be from the point alongside the road where the oversize material is bladed off to the point where it is finally deposited. Overhaul shall apply to all oversize material removed, including material not paid for under any item for the "removal of oversize material". Overhaul shall be the haul distance minus the 1,O km freehaul.

.......

cubic metrekilometre (m3-km)

The unit of measurement shall be the cubic metre of overhaul material hauled in excess of 1,O km, multiplied by the overhaul distance.

Note:

Both restricted and ordinary overhaul shall be payable on material having 0,5 km free haul when this material is hauled in excess of 1,O km. Overhaul of material in excess of that required or for a further distance as may be necessary for the completion of the works or otherwise not authorized by the engineer will not be measured for payment purposes. The tendered rates for overhaul shall include full compensation for hauling material in excess of the freehaul distance.

(4)

Pavement layers constructed from materialsmixed in a mixing plant and placed by paver

Notes:

In the special cases detailed below, overhaul shall be measured as follows:

(1) Gravel crushed andlor screened (section 3200)

The haul distance on crushed and/or screened gravel shall be taken from the point of excavation or borrow to the crushinglscreening plant and thence to the point of final use in the road or, in the case of material sieved out and discarded, to the point where finally placed.

Measurement of and payment for overhaul in regard to material used in pavement layers, which has been mixed in a mixing plant and placed by paver, shall be the same as that in regard to material in pavement layers not mixed in a mixing plant or placed by paver, excepting that the haul distance shall be measured along the shortest direct route from the approved source to the locality where the material is placed on the road, irrespective of whether the material has been handled by a longer route from the source to the mixing plant and thence to the location where it was placed on the road. The tendered rates for item 37.01 and 37.02 shall also include full compensation for handling the material for that distance by which the actual route is longer than the shortest direct route.

SERIES 1000 : GENERAL SECTION 1700 : CLEARING AND GRUBBING

Except at borrow areas, the cavities resulting from the grubbing shall be backfilled with approved material and compacted to a density of at least the density of the surrounding ground.

(c) 1701 SCOPE 1702 DESCRIPTION OF WORK 1703 EXECUTION OF WORK 1704 MEASUREMENT AND PAYMENT

Conservation of topsoil

1701 SCOPE

This section covers the clearing of the site and the grubbing necessary for construction of the works covered by the contract, in accordance with these specifications. This section also covers the cleaning out of existing hydraulic structures and the clearing and grubbing of vegetation from the inlets and outlets of these structures, the removal, storage and replanting of selected plants, as well as clearing to improve sight distances.

Where suitable topsoil occurs within the limits of the area to be cleared and grubbed, the contractor shall, if so ordered by the engineer, remove the topsoil together with any grass and other suitable vegetation. If not used immediately, the topsoil shall be transported and deposited in stockpiles for later use. The contractor will not be required to remove topsoil to an average depth of less than 150 mm, or more than 400 m m in depth, from any particular area. This work shall be measured and paid for under section 5800. Where topsoil can be removed without the necessity of first doing clearing and grubbing, no payment will be made for clearing and grubbing under this section.

(d)

Consewation of vegetation

1702 DESCRIPTION OF WORK

(a)

Clearing

Where provided for in the project specifications, certain designated plants encountered in the road reserve and borrow areas shall be carefully protected by the contractor. Provision will be made for separate payment for the careful removal and planting of the plants in a protected and fenced off area.

Clearing shall consist of the removal of all trees, brush, other vegetation, rubbish, fences and all other objectionable material, including the disposal of all material resulting from the clearing and grubbing. It shall also include the renioval and disposal of structures that obtrude, encroach upon or otherwise obstruct the work and which can be cleared by means of a bulldozer with a mass of approximately 20 tons and an engine developing approximately 145 kW at the flywheel. Structures which cannot be cleared in this manner shall be broken down in accordance with the requirements of the project specifications for the removal and disposal of structures. No payment will be made for the moving of a certain amount of soil or gravel material which may be inherent in or unavoidable during the process of clearing. Clearing shall also include the removal of all rocks and boulders of up to 0,15 m3 in size which are exposed or lying on the surface. Payment for fences which have to be taken down and the material sorted, coiled and stacked shall be made under section 5500.

1703

EXECUTION OF WORK

(a)

Areas to be cleared and grubbed

Normally the portions of the road reserve falling within the limits of the road prism and certain borrow areas shall be cleared and grubbed. The engineer shall designate the areas to be cleared, which shall not necessarily be limited to those mentioned above. The areas occupied by an existing road prism will normally be excluded. No clearing and grubbing shall be done other than on the written instructions of the engineer, who shall designate in detail the exact areas to be cleared and grubbed and the time when it shall be done. The contractor shall note that, in order to avoid reclearing, the clearing and grubbing may have to be done at the last practicable stage of construction. Individual trees designated in writing by the engineer shall be left standing and uninjured. A penalty equal to the amount specified in the project specifications shall be imposed for every such tree which is unnecessarily removed or damaged.

@)

Grubbing

In the roadway all stumps and roots exceeding 75 m m in diameter shall be removed to a depth of no less than 600 m m below the finished road level and a minimum of 75 m m below the original ground level. Where the roadbed has to be compacted, all stumps and roots, including matted roots, shall be removed to a depth of at least 200 m m below the cleared surface.

@)

Cutting of trees

The contractor shall take the necessary precautions to prevent damage to structures and other private or public

property. If necessary, the trees shall be cut in sections from the top downwards. The branches of trees to be left standing shall be trimmed so as to leave a 7 m clearance above the carriageway.

1704

MEASUREMENT AND PAYMENT

Unit

17.01 Clearing and grubbing

. . . . . . . . . . hectare (ha)

Where clearing and grubbing on government property would involve the cutting down of indigenous forest containing a significant number of trees with a trunk diameter exceeding 200 mm, the contractor shall inform the Director-General of Environment Affairs at least two months in advance before commencing with clearing and grubbing of such areas so as to enable the Department of Environment Affairs to salvage any usable timber and to identify the trees before they are removed.

The unit of measurement for clearing and grubbing is the hectare. The quantity shall be taken as the area in hectare (to the nearest 0,01 ha) designated by the engineer and cleared and grubbed in accordance with these specifications. The tendered rate shall include full compensation for all work necessary for the clearing of the surface, the removal and grubbing of trees and tree stumps (except large trees and stumps as defined below), cutting of branches, backfilling of cavities, demolishing and disposal of structures except where otherwise provided in the proiect . , specifications, and the removal, transporting and disposal of material, all as specified in this section.

(c)

Disposal of material

Material obtained from clearing and grubbing shall be disposed of, as indicated by the engineer, in borrow pits or other suitable places and covered up with soil or gravel. The burning of material will not normally be permitted and may be done only with the prior written approval of the engineer. All statutory provisions in regard to air pollution shall be carefully obsewed.

Unit
17.02 Removal and grubbing of large trees and tree stumps:

(a) All tree trunks and branches in excess of 150 m m in diameter shall be cleaned of secondary branches, sawn into lengths not exceeding 4,O m and stacked at sites indicated by the engineer. All crops and trees which have a saleable value shall remain the property of the employer unless otherwise provided for in the project specifications.

Girth exceeding 1 m up to and including 2 m . . Girth exceeding 2 m up to and including 3 m . . . . . . .

number (No)

(b)

. . . . number (No)

Etc, in steps of 1 m girth.

Fencing wire shall be neatly wound into reels and all such wire, together with all fence posts and other usable material from structures, etc, shall be stacked at sites indicated by the engineer.

The girth of trees or stumps shall be measured at the narrowest point of the tree or stump in the first metre of its height above ground level. Trees and stumps with a girth exceeding 1 m shall be measured individually and classified according to size in increments of 1 m as indicated above.

(d)

Reclearing of vegetation The tendered rates shall include full compensation for all work necessary for the clearing and grubbing of trees and stumps of all sizes, the backfilling of holes and the removal and disposal of material, all as described in this section.

When portions of the road reserve, borrow or other areas have been cleared in accordance with the specifications, but vegetation grows again in the course of time during construction, the engineer may, if he considers it necessary, order that the area be recleared.

Such reclearing of areas previously cleared includes the removal and disposal of grass, shrubs and other vegetation in the same manner as for the first clearing operation.

(e)

Cleaning out of hydraulic structures

Where construction is carried out through plantations or where the number of trees with a girth exceeding 1 m renders individual measurement impracticable, the project specifications shall provide that the clearing and grubbing of trees in such areas be measured in hectares. If this method of measurement is used, the areas where it applies will be shown on the drawings, stated in the project specifications, or indicated to tenderers during site inspection. Where the project specifications provide payment for the clearing and grubbing of large trees per hectare in certain specific cases, the tendered price shall include full compensation for all work as described in connection with individual trees above.

After the instruction for the cleaning out of hydraulic structures has been executed, the contractor shall be responsible for maintaining the hydraulic structures in a clean condition for the duration of the contract.

Item

Unit

(b)

Pipes with an internal diameter exceeding 750 m m . . . . . . . . . cubic metre (m')

17.03 Reclearing of surfaces (on the written instructions of the engineer only) . . . . . . . . . . . . hectare (ha)

(c)

The unit of measurement for reclearing areas which have previously been cleared shall be the hectare. The quantity shall be measured to the nearest 0,l ha. (d) The tendered rate shall include full compensation for all work necessary for the clearing of the surface, grubbing if necessary, backfilling of holes and the removal and disposal of material, all as described in this section.

Box culverts up to and Including 1,5 m vertical dimension . . . . . . . . . .

. . . . . . cubic metre (m3)

Box culverts exceeding 1,5 m vertical dimension . . . . . . . . . . cubic metre (ma)

Item

Unit

The unit of measurement shall be the cubic metre of material removed from hydraulic structures where instructed by the engineer so that the structures are cleaned as specified.

17.04 Clearing and grubbing at inlets and outiets of hydraulic structures . . . . . . . . . . . . . . . square metre (mZ)

The unit of measurement shall be the square metre measured within the limits of the areas designated by the engineer, which are cleared and grubbed in accordance with these specifications. The tendered rate shall include full compensation for all work necessary for clearing the surface, removing and grubbing trees and tree stumps (except large trees and stumps defined in this section), sawing off branches, backfilling holes, removing, transporting and disposing of materials, and all additional costs due to inaccessibility, all as specified in this section

The tendered rates shall include full compensation for all work necessary for removing all undesirable materials from structures, transporting and disposing of these materials, as well as additional costs necessary for gaining access to such structures, all as specified in this section. Payment under this item will normally only be made once during the duration of the contract.

Item
17.06 Removal and storage of

Unit

selected vegetation:

(a) Item
17.05 Cleaning out of hydraulic structures:

Unit

Cost of removal, storing, protection and replanting in a protected and fencedoff area of selected vegetation . . . . . . . . . . . .

.....
....

provisional sum

(a)

Pipes with an internal diameter up to and including 750 m m . . . . . . . . . . cubic metre

(m3)

(b)

Charge on provisional sum

percentage (%)

SERIES 2900 : DRAlNAGE

SECTKIN 2100 :DRAINS

Open drains shall be constructed true to line, grade (c) and cross-section and shall be so maintained for the duration of the contract. Care shall be taken to avold excavation below the required grades for the open drains and any excavation carrled beyond the required grade shall be backfilled with suitable material and compacted to at least 90% of modified AASHTO density by the contractor at his own expense. Material resulting from the excavations for open (d) drains shall be used in the construction of fills, banks and dykes, or for other purposes, or shall be disposed of to spoil, all as directed b y the engineer. In respect of material resulting from open-drain excavation and not taken to spoil but used elsewhere in the construction of the works, payment will be made for opendrain excavation as well as for any item of permanent construction built from such material. Material from opendrain excavation which is taken to spoil will be paid for as open-draln excavation only. If ordered b y the engineer, all existing open drains, (e) but excluding open drains constructed by the contractor himself, shall be cleared and, where necessary, shaped by removing the sediment and trimming the floors and sides. The specified requirements for constructing open drains shall apply mutatis mutandis to clearing and shaping the open drains. Measurement and payment In respect of the clearing and shaping of existing open drains not classified as cut in accordance with the classification instructions in subclause 2102(b), shall be made under item 21.02, and those in respect of existing open drains classified as cut under the appropriate items in section 3300. (f) Any pitching of open drains ordered by the engineer shall be done in accordance with the requirements of section 5100. The concrete lining of open drains shall be done as specified in section 2300. (g) All culverts indicated b y the engineer shall be cleared. The contractor shaii remove all undesirable materials, such as amongst others all silt, sediment, driftwood, debris and rubble that have accumulated in and around the culvert inlet and outlet structures and In the culvert barrels. All materials resulting from the clearing operations shall be disposed of at locations approved by the engineer. The clearing shall preferably be done by means of hand tools in order to prevent damage to existing drainage and other structures. The contractor shall repair all structures damaged by him at his own cost, and to the satisfaction of the engineer.

CONTENTS

2101 2102 2103 2104 2105 2106 2107

SCOPE OPEN DRAINS BANKS AND DYKES SUBSOIL DRAINAGE CLASSIFICATION OF MATERIALS MANHOLES, OUTLET STRUCTURES CLEANING EYES MEASUREMENT AND PAYMENT

AND

2101

SCOPE

This section covers all work in connection with the excavation and construction of open drains, subsoil drainage and banks and dykes at the locations and to the sizes, shapes, grades and dimensions as shown on the drawings or as directed by the engineer, and the test flushing of subsoil drains.
It also covers the cleaning of open drains and the repairing of subsoil drainage. In special circumstances this work may be executed outside the road reserve. It also covers the clearing of existing culverts, including amongst others the removal of all undesirable materials that have accumulated in and around inlet and outlet structures and in the barrels of the culverts.

Open-drain excavation shall involve the excavating (a) of open drains and channels, including channels to direct the course of streams, all as shown on the drawings or as directed by the engineer. Open-drain excavation shall include all excavation (b) required for constructing a channel with a bottom width of less than 4 m or a V-shaped channel with side slopes steeper than 1:4, and total width at the top of less than 5 m. Any excavation required for constructing a channel with a bottom width of 4 m or more, or a V-shaped channel with side slopes equal to or flatter than 1:4, or where the width at the top exceeds 5 m, shall be classed as "cut" and shall be measured and paid for under section 3300. Open drains wlthln the road prism, such as median drains, side drains and open drains on excavation-slope benches, shall be classed as "cut" and shall be measured and paid for under section 3300, except where, on account of the shape of such open drains, excavation b y bulk excavating equipment would not be feasible and either hand excavation or special excavating equipment, such as backactors, draglines or similar equipment, would be required, in which case such excavation shall be paid for as opendrain excavation.

21W

BANKS AND DYKES

Mitre banks, catchwater banks and dykes shall be constructed of approved soil or gravel obtained from opendrain excavation or, if no suitable material can be obtained from that source, from suitable alternative sources, and be placed in such a way that the water will flow on the natural ground and against the bank.

The banks and dykes shall be properly compacted to 90% of modified AASHTO density in layers not exceeding 150 mm in thickness, unless thicker layers have been approved by the engineer. If so preferred by the contractor and approved by the engineer, mitre banks may also be constructed of handpacked stone, provided that the interstices are filled with an approved coheslve soil.

Table 2104/1 NATURAL PERMEABLE MATERIALS : SAND Grade Coarse Medium Fine Nominal maximum particle size (mm)

0,20

21W

SUBSOIL DRAINAGE
Crushed stone shali comply with the requirements given in SABS 1083 : Table 5 : Stone for Concrete, and shall be either coarse (19,O mm nominal size) or fine (13,2 mm nominal size) as speclfied. The aggregate shail be evenly graded. The aggregate crushing value of the stone shall not exceed 30 when tested in accordance with TMHI method B1. When no suitable sand and/or crushed stone is available from borrow pits, the engineer may require that it be procured from commercial sources outside the site.

(a)

Mawrials
Pipes

(i)

Pipes for subsoil drainage shail have the specified internal diameter, which shall be not less than 100 mm, and shall be one of the following types: Perforated pitch-flbre pipes complying with SABS 921; Perforated or slotted unplasticized PVC pipes complying wlth SABS 791; Perforated high-density polyethylene pressure pipes complying with the requirements of SABS 533, Part II. The size of perforations in perforated pipes shall in ail cases be 8 mm in diameter r 1,5 m m and the number of perforations per metre shall be not less than 26 for 100 mm pipes and 52 for 150 m m pipes. Perforations shall be spaced in two rows for 100 mm pipes and as shown on the drawings for 150 m m pipes. Slotted pipes shall have a slot width of 8 m m c 1,5 mm. The arrangement of slots shall be subject to the engineer's approval, but the total slot area shall be not less than that presented for perforations. Pipes without slots or perforations required for conveying ground water from the subsoil drainage proper to the point of discharge, shali be unperforated pitch fibre, PVC or polyethylene pipes of the types specified above, or concrete pipes complying with the requirements of SABS 677. (ii) Natural permeable material

The engineer shall indicate the grades of sand and crushed stone to be used in each case to comply with the requirements.

In the case of any sand and/or crushed stone, not more than 5% of the material shali pass through the 0,075 m m sieve. (iii) Synthetic-fibre filter fabric

Should the use of synthetic-fibre filter fabric in subsoil drainage, or as filter blankets, or for any other purposes, be specified, it shall comply with the requirements as specified hereinafter. (I) Composition and manufacturing

The synthetic-fibre filter fabric, or geotextile, shail be manufactured from a synthetic polymer processed into a permeable, homogeneous sheet. The sheet shall be either of a woven, non-woven or knitted construction.

Natural permeable filter materials for subsoil drainage shall consist of sand and/or crushed stone of suitable gradings. Natural permeable materials shail conform to the following requirements: Sand shall be clean, hard sand obtained from approved borrow pits. The sand shall comply with the requirements of SABS 1083, Table 1 : Sand for concrete, and shall be either coarse, medium or fine grade as specified. The nominal maximum particle size for the various grades shall be as shown in table 210411.

On account of the temperature and moisture susceptibility of polyamide, this synthetic product is not considered acceptable.
(2)

Classification

The geotextile is classified according to the mechanical properties thereof, viz its penetration load, puncture resistance and the minimum water-percolation rate as measured in the permeability test. Table 210412 shall be used for determining the grade of a geotextile.

Table 210412 GRADE CLASSIFICATIONS OF GEOTEXTILES GRADE PROPERTY Penetration load (minimum) , N Puncture resistance (maximum), mm Water percolation (minimum), llm21s TEST METHOD

geotextile he proposes to use, so that the engineer may carry out the appropriate tests specified in table 210412 and in clause 8114,and confirm the use thereof if he is satisfied that the geotextile meets the specified requirements. No extra payment shall be made for providing the samples for testing. (iv) Composite in-plane draining fabric

3.5 of SABS 02212400 1500 1988

The make and class of fabric shown on the drawings or approved by the engineer shall be used.

26

32

Clause 8114 (v)

3.7 of SABS 0221-

Concrete

20

20

1988

Notes:

All concrete work shall be carried out in accordance with the requirements of sections 6200,6300 and 6400 and with the details shown on the drawings. (vi) Galvanized woven wire mesh

The standard atmosphere for testing and the preconditioning atmosphere for all geotextile tests (SABS tests and other) shall have a relative humidity falling within the range of 0 to 80 per cent and a temperature within the range of 15C to 35C. The resistance of a geotextile to puncture is the average diameter of the hole formed when a 45" cone with a mass of 1 kg is dropped through 500 m m onto the geotextile fixed in the holding device.

Galvanized woven wire mesh manufactured from 3,sm m dia wire, 250 mm x 250 m m in area, with a 12 mm x 12 mm maximum mesh size, shall be built into the outlets of subsoil drainage systems in accordance with the details shown on the drawings.

@)

Consfmction of subsoil drainage systems With natural permeable material

(i)

(3)

Durability Trenches for subsoil drainage systems shall be excavated to the dimensions and gradients shown on the drawings or as directed by the engineer.

A geotextile is required to comply with the following specification: Resistance to chemical attack The geotextile shall withstand the level of aggressiveness of the soil and ground water given below without significant loss of its strength and hydraulic properties during its design life of 25 years: Soil and ground water with a pH in the range of 4 to 12 (pH to be determined by Method N O ,TMH1, 1986). Soil (as paste) and ground water containing salts with a conductance of up to 1,O Slm (conductivity to be determined by Method N I T , TMH1, 1986).

A layer of natural permeable material of the grade and thickness as shown on the drawings shall be placed on the bottom of the trench and be lightly tamped and finished to the required gradient.
Pipes of the type and size required shall then be firmly bedded on the natural material, true to level and grade, and be coupled in accordance with requirements. Thereafter the trench shail be backfilled with natural permeable material to such height above the pipes as shown on the drawings or as directed by the engineer. The natural permeable material shall be lightly compacted and trimmed to the required level. Further layers of finer natural permeable materidl shall then be placed, lightly compacted and finished to an even surface, as directed by the engineer. The remainder of the trench, if any, shall be backfilled with approved impermeable material and as required by the engineer, in layers not exceeding 100 mm, and compacted to at least the same density as the surrounding material. The trench shall be specially protected against the ingress of water until the impermeable layer has been completed. The width of the backfill that will be measured for payment shall not exceed the specified width of the trench. Natural permeable material shall be placed in layers not exceeding 300 mm in thickness at a time and be lightly compacted. The total thickness of each type of natural permeable material shall be carefully controlled, and when the thinner layers are placed, suitable spacers shall be used. When successive layers are placed, the lower layer shall not be walked on and, as far as possible, shall not be

Resistance of ultra-violet light

The geotextile shall maintain at least 8046 of its original strength after direct exposure to sunlight of 1 500 hours. Resistance to rot The geotextile shall be entirely rot-proof and shall not support the growth of algae.

(4)

Selection

The geotextile required shall satisfy the criteria for a grade 2 and 3 geotextile as specified in the schedule of quantities or project specifications. The contractor shall, at least 45 days before the installation of the geotextile, submit to the engineer samples of the

disturbed. Care shall be taken to prevent the contamination of natural permeable material during construction of the subsoil drainage system and all natural permeable material contaminated by soil or silt shall be removed and replaced by the contractor at his own expense.

(iv)

With composite in-plane drainage fabric

Perforated and slotted pipes shall be jointed by means of couplings. Perforated pipes shall be laid with perforations at the top or bottom as may be prescribed. The higher end of each subsoil drainage pipe shall be sealed off with a loose concrete cap of class 20119 concrete, as shown on the drawings, and at the lower end the pipe shall be built into a concrete head wall providing a positive outlet or it shall be connected to stormwater pipes or culverts. The complete system, together with head walls, shall be constructed in one process starting at the lower head wall. Any section of a subsoil drainage system constructed of pipes without perforations or slots shall be backfilled with impermeable backfill material as described herein. Where suitable, the excavated material may be used for backfilling. (ii) With polyethylene lining to trenches for subsoil drainage systems

Wherever specified, composite in-plane drainage systems shall be constructed in accordance with the details shown on the drawings. The elements of the system shall be assembled above ground in manageable lengths, and all exposed surfaces shall be sealed with an approved geofibre seal. The trench sides shall be vertical, and the composite in-plane system shall be installed against the side through which the subsoil flow is expected. The trench shall then be backfilled with sand, which shall be saturated with water after placement, up to the prescribed level. The upper part of the trench shall be backfilled with impermeable material which shall be compacted to the density of the surrounding material, in layers not exceeding 100 m m in thickness.

(c)

Test flushing

Final acceptance of longitudinal subsoil drains will be subject to satisfactory test flushing after completion and installation of the rodding eye inlets. Flushing tests shall be carried out in the presence of the engineer's representative by flushing the drain and metering the outflow to ensure the drain is clear of blockage. Should blockages be apparent the contractor shall locate and clear the obstruction and repeat the test.

Where shown on the drawings or directed by the engineer, trenches for subsoil drainage systems shall be lined with approved polyethylene sheeting 0,15 m m thick. The polyethylene sheet shall cover the bottom of the trench and shall extend upwards on both sides for as far as may be directed by the engineer in each particular case, in order to form a waterproof channel. At joints the polyethylene sheeting shall be heat-welded together or lapped by a minimum of 200 mm. When backfilling the trench with natural permeable material, care shall be taken not to displace or damage the polyethylene lining in any way. The use of plastics other than polyethylene will be considered, provided that the material is of equal quality and is approved by the engineer. (iii) Wth synthetic-fibre filter fabric

2105

CLASSIFICATION OF MATERIALS

All excavations for open drains and subsoil drainage systems shall be classified as follows for payment purposes:

Hard material: Material which cannot be excavated except by drilling and blasting, or with the use of pneumatic tools or mechanical breakers

and

boulders exceeding 0,10 material.

d3 shall

be classified as hard

Where specified that synthetic-fibre filter fabric shall be used for lining in subsoil drainage systems, it shall be procured, furnished and installed as specified and shown on the drawings. The lining shall not be displaced or damaged in any way when the trench is being filled with natural permeable material. The filter fabric shall be lapped both longitudinally and transversely by at least 300 m m or as instructed by the manufacturers. The transverse lap shall be positioned on top of the box forming the drain and shall be stitched together with plastic/galvanised wire or strong synthetic thread at metre intervals. The longitudinal lap shall be in the direction of flow. Filter fabric shall be stored under suitable cover and shall not be exposed to direct sunlight for prolonged periods and shall be protected from mechanical damage during installation and construction.

Where more than 40% of any material (by volume) consists of boulders each exceeding 0,10 m' in size, the material shall be classified as hard material.

Soft material: All material not classified as hard material shall be classified as soft material.

2106

MANHOLES, OUTLET CLEANING EYES

STRUCTURES

AND

Manholes, outlet structures and cleaning eyes for subsoil drainage systems shall be constructed in accordance with the details shown on the drawings or in positions as instructed by the engineer.

2107

MEASUREMENT AND PAYMENT

21.03 Ercavation for subsoil drainage systems: (a) Excavating soft material situated within the following depth ranges below the surface level: 0 m up to 1,5 m

Unit
21.01 Excavation for open drains: (a) Excavating soft material situated within the following depth ranges below the surface level:

(i) (ii)

...........

cubic metre (m')

(i) (ii)

0 m up to 1,5 m

. . . . . . . . . . . cubic metre (rn3)

Exceeding 1,5 m and up to 3,O m . . . . . . . . . . . . . . . . . cubic metre (m') Etc, in increments of 1,5 m Extra over subitern 21.03(a) for excavation in hard material irrespective of depth . . . . . . .

Exceeding 1,5 m and up to 3,O rn . . . . . . . . . . . .

. . . . . cubic metre

(m3)

(iii) (b)

(iii)
(b)

Etc, in increments of 1,5 m Extra over subitem 21.01 (a) for excavation in hard material, irrespective of depth . . . . . . . . cubic metre (m3)

. cubic metre (m3)

The unit of measurement shall be the cubic metre of material excavated in accordance with the authorized dimensions, measured in place before excavation. Excavation for open drains only as defined in subclause 2102(b) shall be measured.

The unit of measurement shall be the cubic metre of material excavated in accordance with the authorized dimensions, measured in place before excavation. Irrespective of the total depth of excavation, the quantity of the material in each depth range shall be measured and paid for separately. The tendered rates shall include full compensation for the excavation of the material to the required lines, levels and grades, all temporary shoring and strutting, and the disposal of the material as directed, including a free haul of 1,O km. For payment purposes a distinction shall be made between soft and hard material, as defined in clause 2105. Where subsoil drainage systems are adjacent to structures such as culverts, that part of the excavation for subsoil drainage systems which can be made by widening the excavation for the structure shall be measured and paid for under excavation for such structure, and not under excavation for the subsoil drainage systems.

lrrespective of the total depth of the excavation, the quantity of material in each depth range shall be measured and paid for separately.

The tendered rates shall include full compensation for the excavation of the material to the required lines, levels and grades and the disposal of the material as directed, including a free haul of 1,O km.

For payment purposes a distinction shall be made between soft and hard material, as defined in clause 2105.

Item
Item

Unit Impermeable backfilling to subsoil drainage systems . . . . . . . . . . .

Unit

21.04

21.02 Clearing and shaping existing open drains . . . . . . . . cubic metre (m3)

. . . . . . cubic metre

(m3)

The unit of measurement shall be a cubic metre of sediment removed, measured in place before removal.

The unit of measurement shall be the cubic metre of completed backfill, measured in place in the subsoil drainage systems and calculated in accordance with the authorized dimensions. The tendered rate shall include full compensation for procuring, furnishing, placing and compacting the backfilling and a free haul of 1,O km.

The tendered rate shall include full compensation for excavating the material, protecting the existing drainage structures, trimming the floors and sides of the open drains and disposing of material as prescribed, including free-haul over a distance of 1.0 km.

Item
21.05

Unit
Banks and dykes

...........

cubic metre (m3)

The clearing of existing concrete side drains will be measured and paid for under item 21.18.

The unit of measurement shall be the cubic metre of material, measured in place in the banks or dykes, and calculated in accordance with the authorized dimensions.

The tendered rate shall include full compensation for procuring, furnishing, placing, watering, compacting, shaping and trimming the material in the banks and dykes and a free haul of 1,O km.

The tendered rate shall include full compensation for procuring, furnishing, transporting from the borrow areas over a free-haul distance of 1,O km, and placing the sand as specified. For payment purposes a distinction shall be made between the different grades of sand. (b) Sand from commercial sources (state grade) . . . . . . . . . . . . . .cubic metre (m3)

Item 21.06 Natural permeable material in subsoil drainage systems (crushed stone): (a)

Unit

Crushed stone obtained from approved sources on the site (state grade) . . . . . . . . . . . cubic metre (m3)

The unit of measurement shall be the cubic metre of sand in place in the drains, calculated in accordance with the authorized dimensions. The volume occupied by the pipes shall be deducted when calculating the volume of the permeable material. The tendered rate shall include full compensation for procuring, furnishing and transporting approved sand from commercial suppliers, including the cost of transporting the material to the site, and placing the material as specified.

The unit of measurement shall be the cubic metre of approved crushed stone in place in the drains, calculated in accordance with the authorized dimensions. The volume occupied by the pipes shall be deducted when calculating the volume of the permeable material.

The tendered rate shall include full compensation for procuring, furnishing and transporting from the borrow areas over a free-haul distance of 1,O km and placing the material as specified. For payment purposes a distinction shall be made between the different grades of crushed stone. (b) Crushed stone obtained from commercial sources (state grade) . . . . . . . . .

21.08 Pipes in subsoil drainage systems: (a) Pitch-fibre pipes and fittings complete with couplings (state size and whether or not perforated) . . . . . . . . Unplasticized PVC pipes and fittings, normal duty, complete with couplings (state size and whether or not perforated or slotted) . . . . . . . . . .

metre (m)

. . . . . cubic metre

(m3)

(b)

The unit of measurement shall be the cubic metre of crushed stone in place in the drains, calculated in accordance with the authorized dimensions. The volume occupied by the pipes shall be deducted when calculating the volume of the permeable material. The tendered rate shall include full compensation for procuring, furnishing and transporting approved crushed stone from commercial suppliers, including the cost of transporting the material to the site, and placing the materials as specified. For payment purposes a distinction shall be made between the different grades of crushed stone.

. . . . . . metre (m)

(c)

High-density type polyethylene pressure pipes and fittings, complete with couplings (state size, type and class and whether or not perforated) . . . . . . . . . metre (m) Concrete pipes (state type and diameter) . . . . . . . . . . . . . . metre (m)

(d)

Item 21.07 Natural permeable material in subsoil drainage systems (sand): (a) Sand obtained from approved sources on the site (state grade) . . . . . . . . . . . .

Unit

The unit of measurement for pipes shall be the metre of pipe, measured in place along its centre line, including the length of fittings. The tendered rate shall include full compensation for procuring, furnishing, laying and jointing the pipes and fittings as specified.

Item

Unit

. . cubic

metre (m3) 21.09 Polyethylene sheeting, 0,15 mm thick, or similar approved material, for lining subsoil drainage systems . . . . . . . . . . . .

The unit of measurement shall be the cubic metre of approved sand in place in the drains, calculated in accordance with the authorized dimensions. The volume occupied by the pipes shall be deducted when calculating the volume of the permeable material.

...

square metre (m2)

The unit of measurement shall be the square metre of

polyethylene sheeting Installed, measured net from the specified dimensions. The tendered rate shall include full compensation for procuring, supplying, cutting, overlapping, jointing, placing and protecting the sheeting as specified, as well as for wastage.

providing, erecting and removing formwork, mixing, transporting, placing and curing the concrete, and all labour and constructional plant required for constructing the concrete outlet structures, manhole boxes, junction boxes and cleaning eyes, complete as specified.

Item
21.13 Concrete caps for sub soil drain pipes 21.10 -fibre fitter fabric (describe type, grade, etc) . . . . . . . . . . . . . . square metre (m2)

Mi

. . . . . . . . . . . . . . .number (No)

The unit of measurement shall be the number of caps supplied, and the tendered rate shall include full compensation for supplying and Installing the caps.

The unit of measurement shall be the square metre of filter fabric supplied and installed as specified. Item The tendered rate shall include full compensation for furnishing, procurlng, cutting, overlapping, jointing, placing and protecting the filter fabric as specified, as well as for wastage.
21.14 Repairing or repladng existing drainage systems

UnH

. . . . . provisional sum

Item

Unit

The provisional sum given for repairing or replaclng existing drainage systems shall be expended in terms of the general conditions of contract.

21.1 1 Composite inplane drainage systems (state size, type, grade, etc) . . . . . . . . . . . . . . . . . . . . metre (m)

ttem
21.15 Overhaul for material hauled i n excess of 1,O km M a u l (normal ovehaul)

UnR

The unit of measurement shall be the metre of composite in-plane drainage system measured in place along the centre line of the system. The tendered rate shall include full compensation for procuring, furnishing, assembling, installing and jointing the composite in-plane drainage system, including perforated or other types of pipes, complete as specified.

......

cubic metrekilometre (m'-km)

The measurement and payment for overhauling materlal referred to in items21.01,21.02,21.03,21.04,21.05, 21.06, 21.07 and 21.16 shall be in accordance with section 1600, and the overhaul quantities shall be listed in clause 2107.

Item
21.12 Concrete oullet structures, manhole boxes, junction boxes and cleaning eyes for subsoil drainage systems:

Unit
21.16 Backtilling existing eroded side drains . . . . . . . . . . . . . . cubic metre (m3)

(a) (b) (c) (d)

Outlet structures Manholes boxes Junction boxes Cleaning eyes

. . . . . . . . . . . . . . number

(No)

The unit of measurement shall be the cubic metre of approved granular material placed and compacted to 93% of modified AASHTO density, measured in place afler compaction, where instructed by the engineer.

. . . . . . . . . . . . . . number (No)

. . . . . . . . . . . . . . number
. . . . . . . . . . . . . . . .number

(No) (No)

The tendered rate shall include full compensation for trimming the side drains disposing of the resulting material and procuring, furnishing, transporting, placlng and compacting the granular material and a free-haul of 1.0 km.

The unit of measurement shall be the number of outlet structures, manhole boxes, junction boxes and cleaning eyes for subsoil drainage systems constructed In accordance with the details on the drawings and the engineer's instructions. The tendered rates shall include full compensation for all excavation, backfilling, compacting to 90% of modified AASHTO density, disposing of surplus excavated material, keeping the excavations safe, dealing with any surface or subsurface water, procuring and furnishing all materials.

Item
21.17 Test flushing of pipe subsoil drains . . . . . . . . . . . . . . . .

Unit

...... number

(No)

The unit of measurement shall be the number of tests satisfactorily completed on unblocked sections of drain. No payment will be made for tests which have to be repeated due to blocked pipes or faulty workmanship.

The tendered rate shall include full compensation for the provision of a water tanker, water, equipment and labour necessary to carry out the tests, complete as specified.

and disposing of the excavated material, including shaping and levelling-off piles of spoil material. The tendered rate shall also include full compensation for transporting the excavated material for a free-haul distance of 1,O km.

Unit Unit
21.18 Excavation for the dearing of existing drainage systems:

(a)

Manholes and inlet and outlet structures . . . . . . . . . . . . . . . Culvert barrels

cubic metre (m3) cubic metre (m3) cubic metre (m3)

21.19 Selected backfill material under concrete-lined side drains compacted to 93% of modified AASHTO density . . . . cubic metre (m3)

(b) (c)

. . . .. . . . . . . . .....

Concrete side drains

The unit of measurement shall be a cubic metre of compacted material and the quantity shall be calculated from the authorised dimensions given on the drawings.

The unit of measurement shall be the cubic metre of material excavated and removed, measured in place before excavation. The tendered rate shall include full compensation for excavating the material, protecting the existing drainage structures, dealing with any surface or subsurface water,

The tendered rate shall include full compensation for procuring, as if from soft excavation or borrowpits, breaking down, placing and compacting the material in 150 mm layers, transporting for a free haul distance of 1,O km, and for shaping the top surface in accordance with the drawings.

2203 MATERIALS SECTION 2200 : PREFABWCATED CULVERTS

The prefabricated culvert units shall be factory produced by a reputable manufacturer of these articles and shall comply with the following requirements: SCOPE TYPES OF CULVERTS MATERIALS CONSTRUCTION METHODS EXCAVATION FOR CONSTRUCTION BY TRENCH METHOD PREPARATION FOR CONSTRUCTION BY THE EMBANKMENT METHOD UNSUITABLE FOUNDING CONDITIONS CLASSIFICATION OF EXCAVATION DISPOSAL OF EXCAVATED MATERIAL LAYING AND BEDDING OF PREFABRICATED CULVERTS BACKFILLING OF PREFABRICATED CULVERTS INLET AND OUTLET STRUCTURES, CATCHPITS AND MANHOLES REMOVAL OF EXISTING WORK JOINING NEW WORK TO OLD SERVICE DUCTS CULVERTS ON STEEP GRADIENTS STORMWATER DUCTS, TREMIES AND OTHER CLOSED CONDUITS MEASUREMENT AND PAYMENT

(a)

Prefabricated concrete pipe cuhrert units

Prefabricated concrete pipe culvert units shall comply with the requirements of SABS 677. Pipes with ogee joints shall be provided, unless otherwise specified.

@)

Portal and rectangular prefabricated concrete culvert units

Portal and rectangular prefabricated concrete culvert units shall comply with the requirements of SABS 986.

(c)

Corrugated metal culvert units

Corrugated metal culvert units shall comply with the requirements of CKS 176 for riveted and nestable pipes and pipe arches, and CKS 437 for multiplate pipes and pipe arches. Metal culverts shall be supplied with inlet and outlet ends finished by one of the following two methods, whichever is shown on the drawings or has been prescribed by the engineer: Where no concrete inlet and outlet structures but (i) bevelled pipe ends are required, inlet and outlet units shall be bevelled to suit the skew angle of the culverts and the side slope of the fill and pavement. (ii) Where concrete inlet and outlet structures are required, the ends of the culvert units shall be cut to the required plan skew angle (if any) and provided with anchor bolts projecting radially around the edge as shown on the drawings for bonding the metal culvert into the concrete inlet and outlet structures. The contractor shall not store any nestable culvert units on the site in such a manner that moisture can accumulate between the contact faces of the nested units, as this may adversely affect the spelter coating and render the units liable to rejection. Any units damaged by corrosion shall. if not rejected, be repaired by cleaning all affected areas and applying at least two coats of an approved zinc-rich epoxy primer which complies with the. requirements of SABS 926, in accordance with the manufacturer's instructions, or as directed by the engineer.

2201

SCOPE

This section covers work in connection with the construction from prefabricated units of culverts and other closed conduits such as stormwater ducts, tremies and service ducts, together with inlet and outlet structures, manholes and other appurtenant structures.

2202

TYPES OF CULVERTS

For the purposes of this specification, the term "prefabricated culverts" shall mean culverts constructed from -

prefabricated concrete pipes with circular sections, (a) hereinafter referred to as "concrete pipe culverts";

(b) prefabricated concrete culverts other than pipe culverts, hereinafter referred to as "portal culverts" or "rectangular culverts";

(d)

Fine granular material

(c) prefabricated corrugated metal pipes and pipe arches, hereinafter referred to as "metal culverts"; Other types of prefabricated culverts not mentioned above, if required, will be specified in the project specifications or schedule of quantities or on the drawings.

Wherever the use of fine granular material is specified in this section for the bedding of culverts, it shall mean sand or other cohesionless material, all of which shall pass through a 6,70 m m sieve and not more than 10% of which m m sieve. shall pass through a 0,15

(e)

Protective coating for metal culverts

Where sol1 or water condltlons are likely to cause excessive corrosion of metal culverts, the engineer may order that prefabricated units be protected by the application of a mastlc asphalt protective coating. The coating shall be applied to either the inside, the outside or to both sldes of the metal culvert units as may be directed by the engineer. The mastic asphalt shall bear a reglstered trade mark, and shall contain asbestos fibres and filler such as Bltuseal or an equal approved material and shall be supplied as a spray or brush-grade material as prescrlbed. The surfaces to be protected shall be cleaned to remove all moisture, dirt, oil, paint, grease, alkalis, rust, mlll scale or other deleterious matter. The material shall be mixed until all asbestos fibres and filler are uniformly distrlbuted. Spray-grade mastlc shall be applied by means of an airless gun and shall be of a suitable conslstency without the addition of a harmful amount of thinners. Brush-grade rnastlc shall be applied wlth an ordinary roofing brush, wlth the second coat being applied at right angles to the first coat. The final film thickness measured on the crest of corrugations shall be a minimum of 1,30 m m or such other thickness as may be specified. Care shall be taken not to damage the protective coating, and all damage to the coating shall be repaired before the culvert Is put to use.

The following defects will be regarded as poor work, and the presence of any of or all such defects or any other defects In any Individual unlt or In general shall constitute adequate reason for rejection: Uneven jolnts, distorted shapes, devlatlons from a straight centre line, irregular or dlagonaily ruptured sides, loose rlvets, rivets not In line or irregularly spaced, poorly finished rivet heads, illegible trade marks, or a lack of rigidity.

(h)

Materials at joints

Joint filler and joint sealing materlal shall comply wlth the requirements of clause 6603.

(i)

In situ concrete

All concrete work shall be carried out In accordance wlth the requirements of sections 6200, 6300 and 6400.

2204

CONSTRUCTION METHODS

Prefabricated culverts shall be Installed by either

the "trench method", where the unlts are lald In a (a) trench excavated below the existing ground level or In a trench excavated In previously constructed subgrade and, If necessary, subbase layers; or the "embankment method", where the units are lald (b) approximately on the existlng ground surface and the subgrade is then constructed on either side and over the culvert. Culverts shall be constructed by the method shown on the drawings or specified in the project specifications. The larger sizes of metal culverts and the larger portal or rectangular culverts shall normally be constructed by the embankment method. Surface drainage shall be controlled by the construction of temporary earth berms and drainage channels. The contractor shall comply strictly with all the approprlate statutory provisions in regard to trench excavations.

(1)

Skewed ends

Where culverts are to be constructed at a skew angle, the culvert units at the inlet and outlet of the culvert shall be supplled with skew ends by the manufacturer, if required. The cutting of skew ends on the site shall not be allowed. Portal and rectangular units shall be provided with square ends and any portions that would otherwise be cut off, shall project beyond the culvert head walls. Where Instructed by the engineer, portal and rectangular culverts shall be provided with skewed ends constructed from cast in sltu reinforced concrete in accordance with the details shown on the drawings.

2 2 0 5 EXCAVATION FOR CONSTRUCTION BY TRENCH

METHOD

All broken, bent, chipped, cracked, dented, corroded or otherwise damaged units shall be repaired to the engineer's satisfaction or, where this is not possible, they shall be removed and replaced with undamaged units. Culvert units which are thinner than the specified thickness, or the spelter coating of which has been bruised or broken, or which may exhibit signs of faulty work, will be rejected.

(a)

Depth of excavation

In the case of culverts to be constructed by the trench method, the contractor shall first construct the fill, subgrade and, if necessary, the subbase to such level as will provide a minimum cover, above the proposed level of the top of the culvert, as described hereinafler for the various types of culvert. The contractor may then commence excavating the trench for the culvert.

The amount by whlch the excavation Is to exceed the proposed level of the lnvert of the culvert shall be sufficient to allow the type and thickness of bedding materlal to be placed as specified or as shown on the drawings. The minimum cover above the top of the culvert and mlnlmum depth of excavatlon below the bottom slde of the culvert shall be as speclfled In subsubclauses 2205(a)(I), ( 1 1 ) and (Ill). Notwithstanding the provlslons of subsubclauses 2205(a)(l), ( 1 1 ) and (ill), the base shall not be constructed before the culvert and the backfill have been completed. (I) Concrete pipe culverts

trench sllpplng or collapslng, the contractor shall immediately Inform the englneer and shall not proceed with any further laying of culverts or backfilling until the engineer has reviewed the clrcumstances and has glven Instructions as to the need for altering the class of culvert or type of bedding.

2206

PREPARATION FOR C0NSTRUCTK)N BY THE EMBANKMENT METHOD

The mlnlmum helght of embankment construction over the top of the proposed plpe culvert before excavation may be commenced, shall be the mlnlmum cover specified on the drawlngs for the type of pipe and bedding onto whlch It shall be laid. The minlmum amount by which the excavatlon shall be deeper than the proposed level of the bonom slde of the plpe shall be 75 m m or such other amount as may be requlred for accommodatlng the type of bedding requlred for the plpe In each case. (ii) Portal and rectangular culverts

Where culverts are to be constructed by the embankment method as defined In clause 2204 above, the contractor shall level the existing ground by excavating, fllllng and compacting as may be necessary so as to provlde exactly the requlred slope and a unlform density over the entire length of the culvert. The finlshed level of the ground for the beddlng of the culvert shall be the same depth below the proposed bottom level of the culvert as speclfied above in clause 2205 for the various types of culverts.

2207

UNSUITABLE FOUNDING CONDITIONS

The mlnlmum height of embankment constructlon over the top of the proposed culvert before excavation may be commenced, shall be 100 m m or such greater helght as may be shown on the drawlngs, whlchever Is the greater. The minimum amount by which the excavatlon shall be deeper than the proposed level of the bottom of the culvert Invert slab shall be 75 rnm In the case of culverts with precast invert slabs. In the case of culverts with cast in sltu lnvert slabs, the excavatlon shall exactly accommodate the invert slab. (Ill) Metal culverts

Where the bottom of the trench does not provlde a sultably firm foundation for the culvert on account of soft, mucky or otherwise unsultable materlal belng encountered, the unsuitable materlal shall be excavated to a depth below the bottom of the culvert as may be indicated by the englneer. The contractor shall excavate the unsultable material to the depth lndlcated and shall replace It with gravel or other approved materlal properly compacted to provide a firm earth cushlon. The width of the excavatlon and earth cushion shall be as prescrlbed by the englneer, but In the case of culverts to be constructed by the embankment method, the wldth shall be at least one diameter or span, as the case may be, wider than the culvert on each side. Other special construction methods may be shown on the drawings or specified in the project specifications in specific cases.

The minimum helght of embankment constructlon over the top of the proposed metal culvert before excavatlon may be commenced, shall be the minlmum cover speclfied on the drawingsfor the type of metal culvert, or 0,25 times the diameter of pipes, or 0,25 times the span of pipe arches, whlchever is the greatest. The minimum amount by which the excavation shall be deeper than the proposed level of the bottom of the pipe shall be 75 m m or such other amount required for accommodating the type of bedding required for the culvert in each case.

2208

CLASSIFICATION OF EXCAVATION

All excavations for prefabricated culverts shall be classified as provided in clause 2105 for payment purposes.

@)

Wdth of excavation
Where excavated material does not comply with the requirements for backfilling material as specifled hereinafter or is surplus to backfilling requirements, such excavated material shall be removed from the site and disposed of In disused borrow pits or at other places as directed by the engineer. Material suitable for use in the works, however, shall be

The widths of excavations shall be sufficient to allow the proper laying, bedding and backfilling of culverts. The widths of the excavation for each type and size of culvert shall be as shown on the drawings or as may be prescribed by the engineer in writing.
If the width of an excavation is increased by the side of the

used as prescribed by the engineer. Payment for such material will be made as for excavation under item 22.01, and also under the appropriate item for such part of the works as may be constructed from such material. All excavated material shall be subject to a free-haul distance of 1,O km.

(iv)

Rock foundation

Where rock, shale or other hard material is encountered on the bottom of excavations, the installation of pipes on class B bedding shall proceed as follows: The material below the pipe shall be excavated and replaced with a bed of sand or approved gravel or soil to a depth as shown on the drawings or prescribed by the engineer. Such rnaterial shall be classed as backfill for purposes of payment. The backfill material shall be watered and compacted to provide a firm earth cushion. Class B bedding shall then be prepared as described in subsubclause 2210(a)(ii). (v) Concrete casing

2210

LAYING AND BEDDING OF PREFABRICATED CULVERTS

(a)

Concrete pipe culverts

Concrete pipe culverts shall be laid on Class A, B, C or D bedding as shown on the drawings or as directed by the engineer. The pipe ends shall be laid hard up against each other so as to obtain tight joints. Ogee pipes shall be laid with their spigot ends pointing downstream. The joints shall be sealed on the outside with two layers of bitumen-impregnated burlap as specified in subsubclause 2210(b)(iii).

The insides of the culverts shall be smooth and without any displaced joints. All pipes shall be laid true to line and level. (i) Class A bedding

Where shown on the drawings or ordered by the engineer, pipes shall be fully encased in concrete according to class and dimensions as shown on the drawings or as ordered by the engineer. Supports shall be provided close to the pipe ends to support the pipes during the placing of concrete. The concrete shall be so placed as to fill all spaces below the pipe completely. Poker vibrators shall be used to ensure the proper filling of all spaces below and around the pipes with concrete. Concrete casing shall be cast in one continuous operation until completed.

@)
(i) The pipe shall be laid with its bottom part on a 20 MPa concrete bedding cradle of specified thickness below the lower part of the pipe, which concrete shall extend upwards on both sides of the pipe to a specified portion of its height, as shown on the drawings.

Portal and rectangular culverts

Cast in situ floor slabs

Before concreting, the pipes shall be supported on suitably shaped cradles at the correct level. No longitudinal construction joints on the horizontal plane will be permitted. (ii) Class B and class C beddings

Cast in situ floor slabs shall be constructed to the dimensions and at the locations as shown on the drawings or as may be prescribed by the engineer. They shall be reinforced with steel reinforcement as detailed on the drawings. Joints of the types detailed on the drawings shall be formed in the floor slabs, and between the floor slabs and the inlet and outlet structures. (ii) Prefabricated floor slabs

The pipe shall be laid on a bedding cradle of compacted selected granular material as specified. The bedding shall extend upwards on both sides of the pipe to a specified portion of its height, as shown on the drawings. Joint holes shall be formed in the bedding cradle for pipe sockets and couplings, to ensure that each pipe is fully supported throughout the length of its barrel on the bedding cradle. (iii) Class D bedding

A layer of fine-grained material at least 75 rnm thick shall be placed on the bottom of the excavation, levelled, compacted and trimmed to line and grade, to form a bed to receive the precast slabs.
The slabs shall be carefully placed on the prepared bed, true to line and grade, and so bedded that they will be uniformly supported over their whole area on the bedding. (iii) Placing the portal portions of culverts

The pipe shall be laid on the in situ rnaterial in the excavation bottom after the bottom has been handtrimmed to support the pipe along the entire length of its barrel in accordance with the details shown on the drawings. Wherever necessary, the in situ material shall first be stabilized in accordance with the details shown on the drawings or as prescribed by the engineer. Joint holes shall be formed in the trench bottom for pipe sockets and couplings.

The portal portions of portal and rectangular culverts shall be placed accurately and symmetrically on the floor slabs, with a thin layer of mortar of one part of cement and six parts of sand between the contact surfaces to ensure a firm and uniform support. The units shall be butted end to end with butt joints, which joints shall be covered with two layers of burlap of 340 g/mZ,pre-impregnated with a bituminous emulsion, or a similar approved material. The strip of burlap shall be at least 150 m m wide and placed symmetrically over the joint. The units shall first be treated with a primer of 60%

bitumen emulsion over the width of the strip of burlap. Where two or more culverts are placed side by side to form a multi-barrel culvert, the space between the culverts shall be filled with concrete up to the level of the top of the culvert. Where prescribed, filter fabric shall be applied to the vertical outer faces in accordance with the details shown on the drawings.

(e)

Construction of culverts in haH widths in existing roads

If necessary for taking up traffic or for any other reasons, or if so instructed by the engineer, culverts shall be constructed in half widths. Unless otherwise prescribed, the downstream section shall be constructed first. The end of the excavation adjoining the traffic lane shall be properly supported to prevent displacement from occurring. The necessary warning signs shall be erected in accordance with the requirements of section 1500. Where the culvert is constructed in an existing road and it has been so prescribed by the engineer, the pavement layers at least shall be benched and recompacted during backfilling. The depth of benching shall equal the respective layer thicknesses, and the width shall be at least 150 mm.

( c )

Metal culverts

The excavation shall be trimmed to the shape of the invert of the culvert and a bed of fine granular material not less than 75 m m thick shall be placed, compacted and shaped to enable the culverts to be bedded as shown on the drawings. Where rock is encountered, the depth of excavation shall extend to a depth of at least 200 m m below the invert of the culvert, and shall be filled with granular material as before. The culverts shall be installed in accordance with the manufacturer's recommendations as approved by the . . engineer. Where these specifications are inconsistent with the manufacturer's recommendations, these specifications shall have preference. Anchor bolts shall be installed at the ends of metal pipe culverts in accordance with the manufacturer's instructions to bond them into inlet and outlet head walls, which head walls shall be constructed as soon as possible after installation of the culverts.

(9

General

The construction of culverts shall be commenced at one end of the culvert, the position of which shall be fixed as shown on the drawings or as prescribed by the engineer. Units which have been deformed or cracked, or which are not constructed to the required lines, levels and grades, or which become displaced in the process of the work or during the maintenance period, shall be removed and replaced by the contractor at his own expense. Prefabricated units shall be lifted and handled by means of approved lifting devices only. Lifting eyes shall be caulked with a suitable mortar after the units have been installed. The contractor shall exercise due care not to damage, overstress or displace any prefabricated culverts with his own traffic or compaction equipment. Where loads exceeding those prescribed in the appropriate statutory provisions are likely to pass over completed culverts, the contractor shall provide additional cover over the culverts so as to ensure that the design stresses on the culverts will not be exceeded. All concrete work shall be carried out in accordance with the provisions of series 6000 of these specifications. When the contractor is required to supply and install culverts at a slope exceeding 1:4, the work shall be carried out as specified in clause 2216.

No concrete bedding or casing shall be used in the installation of metal culverts.

Where prescribed, the invert of metal culverts with diameters or spans exceeding 1 500 mm which are laid on steep grades shall be protected with a layer of concrete with dimensions and class as shown on the drawings.

(d)

Extension of exisling

culverts

Where an existing culvert requires extension or portal replacement, the new section shall be placed at the same grade and, where it joins the existing structure, at the same level as the existing structure.

Any sections of existing wing walls, approach slabs and head walls which may obstruct any new work shall be demolished and removed. Existing culvert ends shall not be damaged, but, should damage occur, the repair work shall be done before the placement of any fresh concrete or new culverts. Loose material shall be removed and joint faces thoroughly cleaned to the satisfaction of the engineer. Jointing shall be done in accordance with clause 2214. After completion of the extension or partial replacement of a culvert, new approach slabs, head walls, wing walls, catchpits, etc, shall be constructed in accordance with the drawings and clause 2212.

2211

BACKFILLING OF PREFABRICATED CULVERTS

After the culverts have been firmly laid on the required bedding as described in clause 2210, backfilling shall be carried out as follows: The material used for the backfilling of those portions of culverts subject to traffic loads shall be selected material of at least subbase quality or such other lower quality as may be permitted by the engineer. Where the excavated

material is not of adequate quality, selected material shall be imported for this purpose. The contractor shall, in advance, ascertain from the engineer as to which portions will require selected-quality material for backfilling. In the case of concrete pipe culverts on class B and class C beddings and metal culverts, the backfilling material shaii be thoroughly tamped in under the flanks of the cuiverts to provide a uniform bedding, all to the engineer's satisfaction. Metal culverts shaii be temporarily ballasted during backfilling to prevent them from lifting. Backfiillng alongside and over all culverts shail be placed at optlmum moisture content and compacted In layers not exceeding 150 m m after compaction, to a density of at least the density required for the material In adjoining layers of fill, subgrade and subbase. The density of backfilling in excavations made in natural ground shail be at ieast 90% of modified AASHTO density. Backfilling shail be carried out simultaneously and equally on both sides of a culvert to prevent unequal lateral forces from occurring. Where the engineer so directs, metal culverts with large diameters or spans or multi-barrel culverts shall be constructed by the embankment method as defined in subclause 2204(b). In such cases the backfilling shali be carried out to the same standard as described above, simultaneously and equally on both sides of the culvert and placed over the culvert until the minimum specified cover is obtained, The width of backfill on each side of the culvert, after completion, shall be at least equal to the diameter (or span) of one of the openings of the culvert. Metal cuiverts shall be backfilled symmetrically to prevent distortion of the units, and the contractor shall also ensure that the required cover as specified in subsubclause 2205(a)(iil) is provided over the culvert before routing his construction equipment over it. Whenever specified or as may be instructed by the engineer, the backfilling shall conslst of concrete placed between the side of the culvert and the excavation up to the top of the culvert. When specified or ordered by the engineer, the backfilling of culverts shali be done using a wet or a stiff mixture of soil cement in lieu of a compacted gravel or lean concrete. A wet mixture of soil cement shali consist of an approved soil or gravel mixed with 5% of Portland cement and only sufficient water to give a consistency that will permit the soil cement to be placed with vibrators, so that all voids between the pipes and the sides of excavations and between culverts in the case of multi-barrel culverts will be properly filled. A stiff mixture of soil cement shall contain 3% of Portland cement and just sufficient water for it to be placed and compacted like ordinary backfill material. The height to which the soil cement backfill shall be taken shall be as prescribed by the engineer or shown on the drawings, and any remaining backfill shall be carried out as described above with a granular material. The aggregate used for soil cement shall preferably be a sandy material but may contain larger particles up to 38 mm, and it shall not have a plasticity index exceeding 10. Detrimental percentages of silt or clay shali be

avoided, and the aggregate shall be obtained from an approved source. The soil cement shall be mixed on the site with suitable concrete mixers, and the water and cement contents shall be carefully controlled. The material shall be placed and then thoroughly compacted so that all voids are filled as described above. At culvert ends stones shall be packed to prevent the soil cement from flowing beyond the required limits. Soil cement shali not be used for backfilling corrugated metal culverts. Afree-haul distance of 1,O km shall apply In respect of all imported materials used for backfilling the culverts but no overhaul shall be paid on any cement, water or concrete aggregates used.

2212

INLET AND OUTLET STRUCTURES, CATCHPITS AND MANHOLES

Inlet and outlet structures for prefabricated culverts as well as catchpits and manholes shali be constructed in accordance with the details shown on the drawings.

(a)

Ewcavation and backtilling

The specifications given elsewhere in this section for excavating and backfilling the culverts shall apply mutatis mutandis to inlet and outlet structures, catchpits and manholes. No backfilling of a concrete structure may be done for a period of at ieast 7 days after the structure has been completed, unless otherwise specified or directed by the engineer.

@)

Concrete work

Concrete work shall be carried out in accordance with the provisions of series 6000 of these specifications and the drawings.

(c)

Brickwork

Bricks shall be engineering bricks conforming to the requirements of SABS 227. The limit for water absorption in the 24 hour immersion test shall be 8%. Brickwork shall be built in English bond in a mortar consisting of one part of cement and six parts of sand, or in stretcher bond where its thickness does not exceed 115 mm. it shall be well and regularly bonded without any false headers. Ail bricks shali be unbroken, except where required as closers. Bricks shall be well wetted before laying and each brick shall be pressed into its bed so as to leave a finished joint not exceeding 10 m m in thickness. All joints shall be filled solid with mortar, and joints for exposed faces shall be pointed as the work proceeds.

Where pipes enter brickwork, they shall be thoroughly caulked into the wall and rendered with mortar.

dimenslons as shown on the drawings. All concrete work shall comply with the requirements of series 6000.

(d)

Plaster

2213

REMOVAL OF WSTING WORK

Where the plastering of brickwork is requlred, all jolnts shall be well raked out and the brick face thoroughly wetted before plaster Is applied. Plaster shall not be less than 12 mm neither more than 20 m m thick. Plaster finlsh shall be smooth and even and shall not show any trowel marks. Unless otherwise specified, all plaster shall be finished wlth a steel trowel. Plaster shall consist of one part of cement to four parts of approved fine sand. Plaster shall be cured for at least 48 hours.

Where shown on the drawings or directed by the engineer, existing inlets or outlets to pipe culverts shall be demolished and debris or rubbish disposed of as directed by the engineer. Existing pipes shall be removed where necessary and saved for later use. All such work shall be carried out so as to prevent damage belng done to former work which is to remain. The contractor's attention Is directed to the provisions of section 1700 that specifies which structures have to be removed as part of the clearing and grubbing operations, the removal of which will therefore not be measured and paid for under this section. Pipes shall be carefully removed from existing culverts and thoroughly checked. Undamaged pipes shall be re-used in the works where indicated by the engineer. Pipes whlch cannot be re-used shall remain the property of the employer and shall be stacked within the road reserve or where directed by the engineer.

(e)

Manhole covers, grid inlets, etc

Manhole covers and frames, grid inlets and other metal accessories shall be supplied and/or manufactured in accordance wlth the details shown on the drawings. Road and pavement manhole covers and frames shall comply with the requirements of SABS 558 and shall be of the size and type Indicated. Before fixlng manhole covers and frames, they shall be dlpped In an approved preservative and gratings and frames painted wlth two coats of bituminous paint. Manhole frames shall be set firmly in a cement mortar to leave the covers flush with the final surface.

2214

JOINING NEW WORK TO O D

(f)

Retabrlaite~~I wncreh, chambers and shafts

Prefabricated chambers and shafts shall be constructed from non-pressure concrete pipes which comply with the requirements of SABS 677. Pipes wlth ogee joints shall be provided unless otherwise specified. The pipes shall be to the diameters specified. All chambers and shafts shall be Installed with the spigot ends pointing upwards and shall be bedded In mortar thoroughly caulked to ensure watertight joints.

Where partial demolition is required for extension work to existing structures, the contact face shall be cut to predetermined lines and levels, any loose and fragmented material shall be removed, and projecting steel cleaned and bent as directed by the englneer. Where partlal demolition is not required but extension work only, the contact surface shall be roughened and cleaned of all dirt and loose particles. If dowels are required, they shall be Installed In holes drilled into the existing structure, in accordance with the details shown on the drawings, and secured by means of an approved type of epoxy resin grout. Fresh concrete shall be bonded to the old concrete In accordance with the requirements specified in section 6400. Reinforced or plain concrete removed in the process of partial demolition shall be measured and paid for under item 22.12 and the installation of dowels and those surfaces treated with an epoxy bonding compound will be paid for separately, but no separate payment will be made for any other work described above, the cost of which shall be deemed to be included in the rates tendered for the concrete supplied for the extensions to the existing structures.

(g)

Benching

All benching shall be rendered in 20 mm granolithic plaster and finished smooth and true with a steel trowel. Corners shall be rounded to dimensions shown on the drawings.

(h)

Prefabricated inlet and outlet sbuctures

Where specified for use, prefabricated inlet and outlet structures shall be manufactured in accordance with the dimensions shown on the drawings. The units shall be laid and jointed generally as specified for prefabricated concrete pipe culverts.

( i ) Prefabricated energy dinipators in outlet structures

2215

SERVICE DUCTS

Where shown on the drawings, the contractor shall supply and install in the outlet structures, prefabricated reinforcedconcrete energy dissipators of class 25/19 concrete with

Where required, the contractor shall construct service ducts

for the easy installation and maintenance of existing, new and future cables and other services. Service ducts shall be constructed from one or more of the following materials: (i) Normal-duty uPVC pipes in accordance with SABS 791. Pitch-fibre pipes in accordance with SABS 921 Fibre-cement pressure pipes in accordance with SABS 1223. Class C pipes shall be used unless other types are specified. Reinforced-concrete pipes in accordance with SABS 677.

2216

CULVERTS ON STEEP GRADIENTS

Where culverts are constructed on gradients exceeding 1 in 4 , they shall be referred to as inclined culverts. Inclined culverts shall be constructed from the type of unit required, normally either circular concrete pipe units or metal culvert units as described in clause 2203. Particular care shall be taken to protect excavations against stormwater damage. The trenches shall be excavated down to firm ground, and backfilled with selected gravel or concrete if it is necessary to overexcavate for obtaining a firm floor. After the outlet structure has first been completed, the culvert units shall be laid in the normal manner by starting from the lower end and placing successive units firmly against each other to prevent subsequent movement. The lower unit shall be securely cast into the outlet structure, and metal culverts shall be provided with the necessary anchor bolts at both inlet and outlet structures and also at all thrust and anchor blocks. Thrust and anchor blocks shall be constructed from concrete as required in accordance with the drawings and details furnished by the engineer. Anchor bolts, straps and other anchoring devices required at anchor and thrust blocks shall be provided. The backfilling of trenches shall be done in horizontal layers starting at the lower end.

(ii) (iii)

(iv)

Where required, the pipes shall be cut lengthwise and accurately in two halves. The actual type of pipe required shall be in accordance with the specifications, The pipes shall be installed in the required positions, and accurate record shall be kept regarding the depth, position and number of pipes installed in each duct. Pipes shall be laid at the grades shown on the drawings to facilitate flushing with water and shall, where required, be encased in concrete or soil cement. The width of excavation for service-duct trenches shall be equal to the nominal inside diameter of the pipe, plus 150 m m on each side of the duct. Where ducts consist of two or more units, the minimum spacing between the units shall be 75 mm, and the 150 m m side clearance specified above shall apply to the outside units of the group. Below the carriageway the depth of excavation shall accommodate a minimum cover of 1.0 m above the upper side of the installed service duct.

2217

STORMWATER DUCTS, TREMIES AND OTHER CLOSED CONDUITS

All pipes shall be joined with watertight couplings made from the same material as the pipe. Fibre-cement couplings shall be of the rubber-ring type.
Split pipes shall normally be used only for providing ducting for existing services which cannot be severed and threaded through the ducts. The pipes shall be accurately cut longitudinally in two halves and opposite halves shall be matched as sawn. Split pipes shall be placed around the service as required, firmly bound by steel straps and finally encased in concrete if required. Excavating, laying and bedding the pipes shall be in accordance with the specifications for prefabricated culverts with any modifications as may be necessary or specified here. Duct ends shall be provided with suitable conical wooden stoppers to prevent dirt from entering the ducts. Two strands, 2,5 m m in diameter, of galvanized steel wire shall be threaded through each unit and shall extend 2 m beyond each end and firmly wedged into position with the wooden stoppers. The end of each duct shall be marked with a marker block constructed to the details shown on the drawings. Each duct marker block shall be at least 50 rnm proud of the finished surface level.

The specifications given in this section for culverts, including the method of measurement and payment, shall apply mutatis mutandis to the construction of stormwater ducts, tremies or any other closed conduits constructed from the prefabricated units described in clause 2203, whether intended for drainage or for any other purpose. No distinction will be made in the schedule of quantities between the construction of culverts as defined in section 1100 and that of the other closed conduits described above, all being classed as culverts. Trernies constructed from prefabricated units shall be classed as inclined culverts where laid to a grade steeper than 1 in 4.

2218

MEASUREMENT AND PAYMENT

Unit
22.01 Excavation:

(a)

Excavating soft material situated within the following depth ranges below the surface level:

(i) (ii)

0 m up to 1,5 m

...........

cubic metre (m3)

Exceeding 1,5 m and up to 3,O m . . . . . . . . . . . . . cubic metre (m3)

. . ..

The unit of measurement shall be the cubic metre of material in place after compaction. The quantity shall be calculated from the leading dimensions of the backfilling as specified or as authorized by the engineer.
If excavations were carried out in excess of the dimensions authorized by the engineer, the quantity of backiilling will nevertheless be based on the authorized dimensions. The volume occupied by the culvert shall be subtracted when calculating the volume of backfilling.

(iii)

Exceeding 3,O m and up to 4,s m . . . . . . . . . . . .

cubic metre (m3)

Etc in increments of 1,5 m. (b) Extra over subitem 22.01(a) for excavation in hard material, irrespective of depth . . . . . . . . . . . . . . . . . cubic metre (m3)

The unit of measurement shall be the cubic metre of material excavated within the specified widths over the lengths and depths authorized by the engineer in each case. Excavation in excess of the widths specified or authorized by the engineer shall not be measured for payment. Irrespective of the total depth of the excavation, the quantity of material in each depth range shall be measured and paid for separately. When measuring excavation for the removal of existing culverts, the volume occupied by the culvert shall not be subtracted from the calculated volume of excavation. In the case of manholes, catchpits and inlet and outlet structures, the dimensions for determining the volume of excavation shall be the neat outside dimensions of the structure, plus an allowance of 0,5 m of working space around the structure. The tendered rates shall include full compensation for all excavation, temporary timbering, shoring and strutting, for preparing the bottom of the excavation for the culvert beds, the disposal of excavated material unsuitable for backfilling, keeping excavations safe, dealing with any surface or subsurface water, and for any other operations necessary for completing the work as specified. Payment shall distinguish between soft and hard material as specified in clause 2208. The tendered rates shall include full compensation for transporting the excavated material for a free-haul distance of 1,O km.

The tendered tariffs shall include full compensation for backfilling under, alongside and over conduits, for watering, and for compacting the backfill material to the specified density. The tendered rate for subitem 22.02(b) shall, in addition, include full compensation for supplying selected material of subbase quality from approved sources, including a free haul of 1,O km. The tendered rate for subitem 22.02(c) shall be additional to the rates tendered for subitems 22.02(a) and (b) and shall include full compensation for all incidentals required for the complete backfilling with soil cement as specified.

kern

Unit

2 2 . 0 3 Concrete pipe culverts:

(a)

On class A bedding (type and diameter indicated) On class B bedding (type and diameter indicated) On class C bedding (type and diameter indicated) On class D bedding (type and diameter indicated)

..... . ......

metre (m)

(b)

metre (m)

(c)

. . . . . . metre (m) . . . . . . metre (m)

(d)

The unit of measurement for concrete pipe culverts shall be the metre of culvert laid as shown on the drawings or ordered by the engineer. The length shall be measured along the soffit of the culvert. The tendered rates shall include full compensation for providing, testing, loading, transporting and unloading the culverts, for providing and placing the selected granular material, where required, and for the installation, laying and jointing of the culverts, as specified. Should it be inevitable for a section to be cut off from a concrete pipe unit of standard length, the full standard length of the unit shall be measured for payment. No additional compensation for cutting and disposing of such section will be paid. Where a half-length pipe unit is required, ie a pipe unit of which the length is equal to half the standard length, and provided that such half-length pipe units are iormally supplied by the manufacturers, the actual length of such half-length pipe unit will be measured for payment, and no additional compensation will be paid in respect of such half-length pipe unit.

h
22.02 Backfilling: (a) Using the excavated material . . . . . . . . .

Unit

. . . . . . . . cubic metre (m3)

@)

Using imported selected material .. ......

.. ...

....

cubic metre (m3)

(c)

Extra over subitems 22.02(a) and (b) for soil cement backfilling (percentage of cement indicated) . .

. . cubic metre (m')

Upon payment, differentiation shall be made between the various types and sizes of culverts and between the culverts placed on A, B, C and D classes of bedding.

supplying, testing, loading, transporting and off-loading all culverts, providing and placing the fine-grained material where required for installing the culverts, and installing, laying and jointing the culverts as specified, including cutting them on the site, and waste. Payment will be made separately for floor slabs of cast in situ concrete. Payment shall distinguish between the different sizes and types of culverts and between culverts installed with or without prefabricated floor slabs.

ltem
22.04

Unit Metal culverts: Size, wall thickness and type indicated . . . . . . . . . . . . . . . . . . metre (m) Cutting off bevelled and/ or skew ends (size and type indicated) . . . . . . . . . . . . . Anchor bolts

(a)

(b)

. . . . . . number

(No) (No)

ltem
22.06 Extra over items 22.03, 22.61 and 22.05 for conshucting indined culverts . . . . . . . . . . .

Unit

(c)

. . . . . . . . . . . . . . . . . number

The unit of measurement shall be the metre of culvert laid as shown on the drawings or ordered by the engineer. In the case of a metal pipe, the culvert length shall be measured along the pipe centre line. In the case of a metal pipe arch, the culvert length shall be measured along the bottom of the pipe arch. In both cases the length of bevelled and/or skew ends shall be included. The tendered rates shall include full compensation for providing, testing, loading, transporting and off-loading the culverts, for providing and placing fine-grained material where required for the installation of culverts, and for installing, laying and jointing the culverts as specified. Upon payment, a differentiation shall be made between the various types and sizes of culverts and also between culverts with differing wall thicknesses. Payment shall be made separately for the cutting of bevelled and/or skew ends, and the tendered rate shall include full compensation for all work in connection with the cutting of ends. The tendered rate per anchor bolt shall include full compensation for procuring, providing and installing the bolts.

. . . . . . . . . . . .metre (m)

The unit of measurement shall be the metre of culvert installed at a grade steeper than 1:4 as specified in clause 2216. The tendered rate shall include full compensation for additional or more difficult work of any nature in regard to laying, excavating and backfilling as may be required for installing the culverts at a grade steeper than 1:4.

Item
22.07 Cast in situ concrete

Unit

and formwork: (a) In class A bedding, screeds and the encasing for pipes, including formwork, (class of concrete indicated) . . . . . . . . . cubic metre (my) In floor slabs for portal or rectangular culverts, including formwork, joints and class U2 surface finish (class of concrete indicated) . . . . . . . . . . . . . . . . cubic metre

(b)

(rn3)

ltem
22.05 Portal and rectangular culverts:

Unit (c) In inlet and outlet structures, skewed ends, catchpits, manholes, thrust and anchor blocks, excluding formwork but including class U2 surface finish (class of concrete indicated) . . . . . . . . . . . . . . . . cubic metre (m3) Formwork of concrete under subitem 22.07(c) above (type of finish indicated) . . . . square metre (m2) In concrete linings for the inverts of metal culverts, including formwork and class U2 surface finish (class of concrete indicated) . . . . . . .

(a)

Complete with prefabricated floor slabs (size and type indicated) . . . . . . . . . . . . . . Without prefabricated floor slabs (size and type indicated) . . . . . . . . . . .

. . . . . . . metre (m)
(d)

(b)

. . . . . . . . . . metre (m)
(e)

The unit of measurement for prefabricated portal or rectangular culverts shall be the metre of culvert laid as shown on the drawings or as directed by the engineer. The length shall be measured along the soffit of the culvert. The tendered rates shall include full compensation for

. . cubic metre

(m3)

Measurement of formwork and cast in situ concrete shall be as specified in sections 6200 and 6400 of these specifications.

Payment for formwork and cast in situ concrete shall be made as provided in sections 6200 and 6400 of these specifications, except that payment for the formwork for concreting in subitems 22.07(a), (b) and (e) shall not be made separately, and the contractor's rates for concrete shall include full compensation therefor. No separate payment shall be made for the construction of joints in culvert floor slabs or at inlet and outlet structures, and the tendered rates for concrete shall include full compensation for forming the joints complete in accordance with the details shown on the drawings.

dowels installed.

The tendered rate shall include full compensation for supplying all materials, all cutting, drilling and grouting, and any other operation or thing necessary for the proper execution of the work.

Itern
22.12 Removing existing concrete:

Unit

Item

Unit

(a) (b)

Plain concrete

. . . . . . . . . . . . . cubic metre (m3)

22.08 Concrete backfill for culverts (class indicated) . . . . . . . . . . . . . . . . cubic metre (m3) The unit of measurement shall be the cubic metre. The quantity shall be calculated from the dimensions of the excavation as specified or as may be authorized by the engineer, minus the volume taken up by the culverts, irrespective of whether the actual excavation to be backfilled exceeds the specified or authorized dimensions. Payment shall be made as for concrete in item 22.07(a) above.

Reinforced concrete

........

cubic metre (m3)

The unit of measurement shall be the cubic metre of existing concrete removed. The tendered rates shall include full compensation for all demolition and for loading, transporting and disposing of the products of demolition, including a free haul of 1,O km. Payment shall distinguish between plain and reinforced concrete. For the purposes of this item, relnforced concrete shall be defined as concrete containing at least 0,2% of steel reinforcement measured by volume. The tendered rates shall also include full compensation for cutting straight grooves of the specified depth at joint positions where shown on the drawings.

ttem

U n i t

22.09 Refabricated concrete inlets and outlets to culverDr (size and type indicated) . . . . . . . . . . . . . . . . . . . number (No) Prefabricated concrete inlets and outlets for concrete pipe culverts shall be measured per inlet or outlet, complete in position. The tendered rate shall include full compensation for procuring, providing, loading, transporting, off-loading and installing the inlets or outlets as specified.

Item
22.13 Removing and relaying

Unit

existing pipes (size and type of bedding indicated)

........

metre (m)

The unit of measurement shall be the metre of existing pipe removed and re-laid. The tendered rate shall include full compensation for lifting, loading, transporting for a free-haul distance of 5,Okm, off-loading, and laying pipes according to the specifications. Payment for any excavation and backfilling required for the removal and relaying of existing pipes shall be made separately under items 22.01 and 22.02. Where existing pipes are loaded, transported and used in temporary deviations, they shall not be measured for payment under this item, but payment therefor shall be made in terms of section 1500.

ltem
22.10 Steel reinforcement:

Unit

(a) (b) (c)

Mild steel bars . . . . . . . . . . . . . . . . . . . .ton (t) High-tensile steel bars Welded steel fabric

. . . . . . . . . . . . . . . ton

(1)

. . . . . . . . . . . . kilogram (kg)

Measurement and payment for steel reinforcement shall be made as specified in section 6300 of these specifications. Item Item
22.11 Dowels for joining old and new concrete . . .

uni
existing prefabricated wiverts (type and size indicated) . . .

Unit

22.14 Removing and stacking

. . . . . . . . . . kilogram

......

metre (m)

(kg) The unit of measurement shall be the metre of existing prefabricated culverts removed and stacked.

The unit of measurement shall be the kilogram of steel

The tendered rate shall include full compensation for lifting, loading, transporting to stack, off-loading, and stacking the prefabricated culverts. Payment for any excavation and backfilling required for removing and stacking the existing prefabricated culverts shall be made separately under items 22.01 and 22.02. The free-haul distance shall be 5,O km.

(e)

Extra over or less than subitem 22.17(b) for variations in the depths of catchpits from the standard depth designated for tendering purposes (standard depth and type of catchpit indicated) . . . . . . . . . . . .

. . . . . . metre (m)

Item

Unit

The unit of measurement, in the case of subitems (a), (b) and (c) above, shall be the complete unit as shown on the drawings, including all concrete, brickwork, covers, frames, grids and other accessories. The tendered rates shall include full compensation for procuring, furnishing and installing, and laying where applicable, the complete units except for excavation and backfilling, which shall be measured separately. The tendered rate shall also include full compensation for connecting up to and building any conduits into the walls of the various structures. The unit of measurement in the case of subitems (d) and (e) above shall be the metre of increased or decreased depth of the manhole or catchpit measured in relation to the standard depth furnished for tendering purposes. The tendered rates per metre shall be an adjustment to the compensation for the standard item, payable either as an increased compensation to the contractor in the case of an increased depth, or as a decrease in compensation in the case of a decreased depth in relation to the standard depth. Where the above items of work cannot be conveniently standardised for payment according to complete units, the various types of work and items of material provided shall be measured separately in accordance with items 22.18 to 22.21 and such other items as may be necessary. Concrete and formwork shall be measured and paid for under subitems 22.07(c) and (d) respectively, excavation under item 22.01, and backfilling under item 22.02.

22.15 Treating surfaces with epoxy resin for joining new to old concrete (type of epoxy resin specified) . . . . . . . . . . . . litre (I)

The unit of measurement shall be the litre of epoxy-resin compound used at the specified rate of application.

The tendered rate shall include full compensation for providing and applying the epoxy-resin compound.

Item

Unit

22.16 Pmtective mastic asphalt coating for corrugated metal culvert units (state whether to be applied by brush or by spray gun) . . . . . . . . . . . . . . square metre (mZ)

The unit of measurement shall be the square metre of protective coating applied as specified and as directed by the engineer. When both inside and outside surfaces are treated, both surfaces shall be measured. The tendered rate shall include full compensation for procuring and furnishing the mastic asphalt, applying the material, and for all other additional work and incidentals required for providing the protective coating as specified.

Item 22.17 Manholes. catchpits, precast inlet and outlet structures complete:

Unit

Item
22.18 Brickwork:

Unit

(a)

115 m m thick 230 m m thick 345 m m thick

. . . . . . . . . . . . square metre (m2)

(a) (b) (c)

Manholes (type indicated) Catchpits (type indicated) Precast inlet and outlet structures (type indicated)

. . . . . . . number (No) . . . . . . . number (No)

(b) (c)

. . . . . . . . . . . . square metre (m2)

. . . . . . . . . . . . square metre (m2)

. . . . . . . number (No)

(d)

Extra over or less than subitem 22.17(a) for variations in the depths of manholes from the standard depth designated for tendering purposes (standard depth and type of manhole indicated) . . . . . . . . . . . . . . . . . . . . . metre (m)

The unit of measurement shall be the square metre of brickwork built, calculated from the leading dimensions of the brickwork. Areas in walls occupied by conduits, shall not be included in the areas measured, and corners and intersections common to more than one brickwall shall be measured only once. The tendered rates per square metre shall include full compensation for the brickwork complete as specified, including pointing and the building-in of conduits.

22.19 Plaster . . . . . . . . . . . . . . . . . square metre (m2)

2 2 . 2 3 Service ducts:
(a) Ordinary pipes (type and diameter indicated) Split pipes (type and diameter indicated) .

The unit of measurement shall be the square metre of plasterwork provided. (b) The tendered rate shall include full compensation for raking out joints in the brickwork and applying a 1:4 plaster, as specified, to all surfaces where required.

..........

metre (m)

. . . . . . . . . . . . . metre

(m)

The unit of measurement shall be a metre of service duct laid. The tendered rates shall include full compensation for procuring, providing and laying the pipes, including end stoppers, draw wires and complete installation, but shall exclude excavation, backfilling, and encasing with concrete, which shall be measured for payment under the appropriate items of payment of this section.

Item
22.20 Benching

Unit

. . . . . . . . . . . . . . . square metre

(mZ)

The unit of measurement shall be the square metre of benching, measured in plan, constructed in class 20119 concrete with granolithic rendering.

Hem
22.24 Duct marker blocks (type indicated) . . . . . . . . . . .

Unit

The tendered rate shall include full compensation for procuring and furnishing all materials, placing the concrete benching, and rendering with the specified granolithic rendering.

. . . . . . . . number

(No)

The unit of measurement shall be the number of marker blocks installed, and the tendered rate shall include full compensation for manufacturing, delivering and installing the marker blocks, complete as shown on the drawings.

ltem 22.21 Accessories: (a)

Unit Hem Unit

Manhole covers including frames (description) . . . . . . . . . . . number (No) Inlet grids including frames (description)

(b)

...........

number (No)

(c) (d)

Step irons (description)

. . . . . . . . . number (No)

Etc for other accessories

........

number (No)

The unit of measurement shall be the number of each type of accessory delivered and installed.

22.25 Overhaul on excavated material carted to spoil, backfill material (but excluding Portland cement in the case of soil cement), existing structures demolished and remwed to spoil, and removing and relaying, and removing and stacking existing prefabricated culverts, for haul i n excess of the free-haul distance . . . . . . . . . . . . . cubic metrekilometre (m3-km)

The tendered rates shall include full compensation for procuring, furnishing and installing the accessories.

Measurement and payment for overhaul shall be made in accordance with the provisions of section 1600, except that the free-haul distance shall be as specified in each item. In the case of pipes, the outer volume of each pipe shall be measured.

ltem

Unit

22.22 Anchors for pipes

(description)

. . . . . . . . . . . . . . . . . number

(No)
22.26

Unit Hand excavation to determine the positions of existing services . . . . . . . . . . . . . . . . cubic metre (m3)

The unit of measurement shall be the complete anchor installed, including straps, bolts, etc, but excluding any concrete work, which shall be measured under subitem 22.07(c) and (d).

The tendered rate shall include full compensation for procuring, providing and installing the anchors.

The unit of measurement shall be a cubic metre of material excavated within the lengths and widths authorized by the engineer and the depth required to expose the service. Excavation in excess of the authorized dimensions shall not be measured for payment.

The tendered rate shall include full compensation for all excavation, backfilling, compacting to 90% of modified AASHTO denslty, disposlng of any surplus excavated material, keeping the excavations safe, dealing with any surface or subsurface water, taklng special care to ensure that services are not damaged In any way and any other operation necessary for completing the work. The tendered rate shall also Include the transporting of surplus excavated material for a free-haul dlstance of 1,O km. Any damage to a service caused by the contractor shall be repaired at his own cost, to the satlsfactlon of the owner of the service and the englneer. No distlnctlon will be made between hard and soft material, neither will distinction be made between the various types of services to be exposed or the depths to which excavations are taken.

The unit of measurement for subltem (e) shall be the metre of kerbing replaced due to trench excavations where instructed by the engineer.

Any relnstaternent required beyond the agreed or instructed dimensions owing to damage caused by the contractor will not be measured for payment. The appropriate sections of the specifications shall also be applicable to the reinstatement of the trenches. The tendered rates shall include full con?pensation for procuring, furnishing, placing, compacting and finishing all materials, providing all labour and constructional plant, cutting and preparing the edges of the existing surfacing, and protecting and maintaining the completed relnstaternent as specified.

Item

Unit
Item

Unit

2 2 . 2 7 Reinstating trenches crossing roads:

(a) (b) (c) Selected layers Subbase

22.28 Prefabricated r e i n f o r c e d ~ n c r e t e

..........

square metre (m2) square metre (m2)

...............

skew end units for concrete culverts constructed at a skew angle (type and dimensions of unit and class of bedding indicated) . . . . . . . . . . . . . . .

. . . . number (No)

Base (including prime coat) . . . . . . . . . . . . . . . . . . square metre (m2) Bituminous surfacing (including tack coat) Kerbing

(d)

The unit of measurement shall be the number of each type and size of prefabricated reinforced-concrete skew end unit provided and installed, irrespective of the angle of skew. The tendered rates shall include full compensation for providing, testing, loading and unloading the units, constructing the prescribed class of bedding, and for installing, laying and joining the units, complete as specified and in accordance with the details shown on the drawings.

. . . . . . square metre (m2)

(e)

. . . . . . . . . . . . . . . . . . . . . . .metre (m)

The unit of measurement for subitems (a) to shall be the square metre of the layer reinstated where'instructed by the engineer. .

(b)

SERIES 2000 : DRAlNAGE SECTION 2300 : CONCRETE KERBING, CONCRETE CHANNELLING, CHUTES AND DOWNPIPES, AND CONCRETE UNINGS FOR OPEN DRAlNS

Concrete may also be prescribed as bedding material, in which case It shall comply wlth the requirements of section 6400 of these specifications.

2303 TYPES OF STRUCTURES CONTENTS

2301 2302 2303 2304 2305 2306 2307 SCOPE MATERIALS TYPES OF STRUCTURES CONSTRUCTION INLET AND OUTLET STRUCTURES AND TRANSITION SECTIONS CONSTRUCTION TOLERANCES AND SURFACE FINISH MEASUREMENT AND PAYMENT Kerbing shall Include barrier kerbs, mountable and semimountable types, All these elements may be prefabrlcated units o constructed In a contlnuous operatlon using silpforms. Channelling may be cast in situ, prefabricated units or else of slipform construction. Chutes may be either prefabricated units or cast in situ, and the concrete lining of open channels shall be cast in situ only, except that side slabs may be precast. Downplpes shall be prefabricated units.

2304

CONSTRUCTION

2301 SCOPE

(a)
This section covers the constructlon of concrete kerbing and channelling, kerb inlets, chutes and downpipes, and concrete linings for open drains at the locations and to the details as shown on the drawings or as directed by the engineer. (i)

Excavation, and preparation of bedding Kerbs and channels

2302 MATERIALS
(a)

Trenches for kerbs and channels shall be excavated to the required depth and all unsuitable material shall be removed and replaced with a layer of approved bedding material at least 75 m m thick. The bedding shall be compacted and accurately shaped to the required grade. No concrete or precast concrete units shall be placed on uncompacted or disturbed material. (ii) Concrete linings

Concrete

All concrete work shall be carried out in accordance with the requjrements of sections 6200,6300 and 6400 of these specifications.

The excavation work for open drains shall be executed and paid for in accordance with the provisions of section 2100. The excavations shall then be neatly trimmed to the lines and levels specified so as to permit the accurate construction of the concrete linings. All loose material shall be compacted to a density of not less than 93% of modified AASHTO density.

@)

Kerbing and channelling

Prefabricated kerbing and channelling shall comply with the requirements of SABS 927. Cast in situ kerbing and channelling shall be of the class of concrete indicated.

(c)

Joint sealant

(i) Cold-applied joint sealant shall be a two-part polysirlphide sealing compound conforming to the requirements of BS 4254. Polyurethane-basedjoint sealants shall complywith (ii) the requirements of SABS 1077. Silicone-based joint sealants shall comply with the (iii) requirements of the project specifications.

Where the in situ material is unsuitable, the engineer may order that it be removed to the required depth and replaced with selected material compacted to a density of 93% of modified AASHTO density.

Where excavations for open drains are in rock, overbreak shall be backfilled as ordered, either with mass concrete or with selected natural gravel or soil compacted to a modified AASHTO density of at least 93%. (iii) Chutes

(d)

Bedding material

The material on which concrete kerbs and channels are to be bedded shall consist of crushed stone, cinders, slag, sand or other approved porous material with a maximum particle size of 13,2 mm.

Excavations for chutes shall be neatly trimmed. All loose material shall be thoroughly compacted, and where overbreak occurs in hard material, the excavations shall be backfilled with mass concrete. If required by the engineer, the excavations shall be taken deeper to accommodate a concrete screed cast to act as a working platform for the construction of the chutes.

@)

Prefabricated concrete kerbing and channelling

right angles to the edge of the road. After concrete has been placed in the forms, it shall be tamped and worked until mortar entirely covers any exposed faces. Exposed faces shall then be finished to smooth and even surfaces and edges shall be rounded to the radii shown on the drawings. Forms shall be removed from any concrete surfaces that will be exposed, within a period of 24 hours of the concrete having been placed. Minor defects shall be repaired with a 2 : l sand:cement mortar. Plastering shall not be permitted on exposed faces and all rejected portions shall be removed and replaced at the contractor's expense. When completed, the sections shall be cured in accordance with the requirements specified in clause 6409. The completed kerbs and channels shall be true to line and elevation and shall have an even and neat appearance.

Prefabricated concrete kerbing and channelling shall be laid on the approved bedding with close joints filled with 3:l sand:cement mortar not exceeding 10 m m in thickness and neatly pointed with a pointing trowel. The exposed faces of kerbs and edging shall be constructed true to line and elevation. Kerbing around curves shall first be laid along the full curve length before the joints are filled, unless otherwise allowed by the engineer. Kerbs shall be temporarily propped during construction. Unless otherwise instructed by the engineer, prefabricated concrete kerb units shall be 1,O m in length, except at curves at road junctions, where they shall be 0,3 m in length. Prefabricated concrete kerbs shall be laid with a class 1:4:8/25 cast in situ concrete support behind the kerbs in accordance with the details shown on the drawings.

(c)

Prefabricatedchutesand downpipes on side slopes of fills and cuts

(9

Cast in situ chutes on cut slopes

Prefabricated chutes and downpipes shall be manufactured in accordance with the dimensions shown on the drawings, and the units shall fit neatly into each other as shown. The bottom unit shall rest against the outlet structure or footing as shown on the drawings. The units shall be laid true to line and grade from the bottom up so that each unit fits neatly into the previous one.

Cast in situ concrete chutes on cut slopes, together with the inlet and outlet structures, shall be constructed in accordance with the drawings. The class of concrete shall be as indicated on the drawings. Where required by the engineer, a concrete screed shall first be cast on excavations that cannot be trimmed accurately. The screed shall be accurately finished to the level of the underside of the chute floor slab and allowed to set before the floor slab is cast. Where the material being excavated cannot be accurately trimmed or where the chute sides have to extend above the surface of cut slopes, the outer faces of the sides shall be cast against formwork.

A transition section shall be constructed at the inlet to lead the water into the chute or downpipe as shown on the drawings.

(g) (d) Slipform kerbing

Concrete-lined open drains

Slip-form kerbs and channels shall be placed on an apbroved bedding by a continuous process with an approved machine. Contraction joints shall be sawn at .. intervals shown on the drawings or prescribed by the engineer in a manner so as not to cause the concrete to spall at the joint. The concrete shall be cured in accordance with the requirements of clause 6409. The kerbs and channels shall be constructed true to line and elevation and shall have a neat appearance. Where transverse cracks occur, the contractor shall replace the entire section between the contraction joints at his own cost.

The exposed surfaces of the concrete linings of open drains shall be given a class U2 surface finish. Concrete shall be cured in accordance with the requirements of clause 6409. Sealed joints in concrete shall be in accordance with the details indicated on the drawings and the provisions of section 6600. Cold joints shall be painted with a coat of approved bituminous emulsion containing 60% of pure bitumen by mass, or with an approved anti-adhesive before any adjoining slabs are cast. Expansion joints shall be made in accordance with the drawings. Where required, the surfaces on which concrete lining is to be cast shall, after having been trimmed, be covered with polyethylene sheeting 0,15 m m thick and all joints in the sheeting shall be overlapped by at least 150 mm.

(e)

Cast in sihr kerbs and channels

Forms for kerbs and channels shall be accurately set to line and elevation and shall be firmly held in position during the placing of the concrete. Stops and jointing material at the ends of sections shall be accurately placed so as to ensure that joints between adjacent sections are truly perpendicular to the surface of the concrete and at

(h)

Backlilling

After completing the concrete work, the spaces at the backs of kerbs shall be backfilled with approved material

to pavement or road shoulder level. Spaces adjoining chutes shall be backfilled level with the side slope. Such backfill shall be placed in layers not exceeding 150 m m and each layer shall be thoroughly compacted at optimum moisture content before the succeeding layer is placed thereon. Where kerbs and channels are laid after construction of the base, the spaces between the concrete and adjoining base shall be backfilled with premixed bituminous material.

(k)

Cutting existing pavement layers

bituminous

surfacing

and

( i )
(i)

Construction sequence Where kerbs and channelling are constructed before the base

In this case slip-form units or cast in situ units may be constructed. During working and constructing the base, precautionary measures shall be taken to prevent the concrete work from being damaged or shifted. (ii) Where kerbs and channelling are constructed after the base

Where the engineer instructs kerbing, channelling or concrete-lined drains to be constructed against existing bituminous surfacing, the full depth of the bituminous surfacing, and the base and subbase if necessary, shall be accurately cut with a mechanical saw to the required line before the kerbing, channelling or concrete-lined drain is constructed. The cut edge shall be vertical for kerbing and channelling. The concrete shall then be placed directly against the cut edge without formwork. All material outside the cut edge shall be removed to the required depth before the concrete is placed. The debris shall be disposed of at a dumping site to be provided by the contractor subject to the approval of the engineer. The bituminous surfacing shall be protected and kept clean to the engineer's satisfaction.

2305

INLET AND OUTLET TRANSrrlON SECTIONS

STRUCTURES

AND

The base shall be constructed wider than the specified width, after which a neat trench shall be dug for the kerbing or channelling. Any over-excavation shall be filled with concrete cast simultaneously with the kerbs and channelling. (iii) Where kerbs and channelling are constructed after the asphalt base and/or asphalt surfacing

Transition sections on kerbing, kerbing-channelling combinations and concrete-lined open drains shall be constructed to the same standards and by the same methods as described for the uniform sections, but with the required modifications. Sections may be either precast or cast in situ units. Inlet and outlet structures may be either precast or partially precast concrete units or of cast in situ concrete. Where shown on the drawings or instructed by the engineer, the contractor shall supply and install in the outlet structures energy dissipators consisting of prefabricated reinforced-concrete blocks of class 20119 concrete of the dimensions shown on the drawings or listed in the schedule of quantities. All concrete work shall comply with the requirements of series 6000. Components such as grids, covers and frames shall be in accordance with the details shown on the drawings and the requirements of subclause 2212(e).

The asphalt base and/or asphalt surfacing shall be constructed wider than the specified width and shall then be cut back accurately with a mechanical saw to a marked line to give a neat joint line between the kerbs or channelling and the asphalt layer. The base shall then be removed to the required depth. Any concrete spilt onto the asphalt surface shall be removed. Where so required by the engineer, the contractor shall, without any additional compensation, paint emulsion over the stained surface.

2306 CONSTRUCTION TOLERANCES AND SURFACE

FINISH During transporting and laying care shall be taken to protect all precast units against chipping or breakage.
(a)

Concrete kerbing and channelling

Concrete kerbing and channelling as well as any other structures adjacent to the road shall be protected against staining by bitumen being sprayed or premix being placed. Where bitumen is to be sprayed, all such work shall be completely covered with polyethylene sheeting at least 0,25 mm thick, specially reinforced paper or other approved material, properly secured to prevent the sheeting from lifting during windy conditions. Any work stained by bitumen shall be broken down and replaced, unless all such bitumen is completely removed so as not to show any stains. Painting over stained work is strictly prohibited.

Concrete kerbing and channelling shall be constructed to within the following dimensional and alignment tolerances: (i) Horizontal alignment

The maximum deviation of edges, centre line, or vertical surfaces from the specified position shall be 25 mm. The maximum deviation of edges, centre line, or vertical surfaces from the specified alignment, shall be 1:500when taken over any section exceeding 10 m in length.

(ii)

Vertical alignment and level

2XV

MEASUREMENT AND PAYMENT

The inside edge of channelling shall nowhere be above the finished road level nor more than 10 m m below the finished road level. The invert level of channels and open drains and the top of kerbing shall nowhere deviate by more than 10 m m from the required level and nowhere shall channels or drains have any adverse grade.

Item 23-01 Concrete kerbing (class of concrete indicated for in situ concrete): (a)

Unit

(iii)

Trueness of exposed surfaces (b)

(Description of type with reference to drawing) . . . . . . . . . . . . metre (m) Etc for other types.

When tested with a 3 m straight-edge, no surface irregularities shall exceed 6 mm.

Item (iv) Cross-sectional dimensions 23.02 All cross-sectional dimensions shall be within 6 m m of the specified dimensions except that the underside of channelling may extend up to 25 m m below the level at which it would have the required thickness. (a)
@)

Unit Concrete kerbing-channelling combination (class of concrete indicated for cast in situ concrete): (Description of type with reference to drawing) . . . . . . . . . . . . metre (m) Etc for other types.

Conwetdined open drains, chutes and downpipes (b)

Concrete-lined open drains, chutes and downpipes shall be constructed to within the following tolerances:

The unit of measurement shall be the metre of concrete kerbing or kerbing-channelling combination complete as constructed, measured along the front face of the kerb. The tendered rate for each metre of concrete kerbing and/or kerbing-channelling combination shall include full compensation for the necessary excavation and preparation of bedding, backfilling, formwork, finishing, and for procuring, furnishing and installing all materials, kerbing and channelling, protecting it against staining, supporting the kerbs with in situ cast concrete, and filling and pointing all joints, all complete as specified.

(i)

Horizontal alignment

The maximum deviation from the true position of the edges or centre line shall be 25 mm.

(ii)

Vertical alignment

The invert level shall nowhere deviate by more than 25 m m from the required level and nowhere shall the inverts have an adverse grade.

Hem (iii) Trueness of exposed surface 23.03 Concrete chutes (typical designsj: (a) (Description of type with reference to drawing. State whether prefabricated or cast in situ and class of concrete) . . . . . . . . . . . . . Etc for other types.

Unit

When tested with a 3 m straight-edge, no exposed surface shall show surface irregularities exceeding 10 mm.

(iv)

Cross-sectional dimensions (b)

........

metre (m)

All cross-sectional dimensions shall be within 10 m m of the specified dimensions, and the average thickness of a floor or side slab shall not be less than the specified thickness when considering any complete slab or a slab section with a surface area of 10 m2 or more, and disregarding a thickness exceeding 10 m m of the specified thickness.

The unit of measurement shall be the metre of completed chute as constructed, including any overlap, measured along the slope as laid but excluding transition sections and inlet and outlet structures measured separately.

(c)

Surface finish

All unformed exposed concrete surfaces shall have a class U2 surface finish and all formed exposed concrete surfaces shall have a class F2 surface finish.

The tendered rate per metre shall include full compensation for procuring, furnishing and installing the completed chutes as specified and for all excavation and the preparation of bedding, backfilling, formwork and finishing required.

23.04 Cast i n situ concrete

c h m (measured by components):
(a) @) Concrete (class indicated)

23.07 Trimming of ex--ons for conwetdined open drains:

....

cubic metre (m3) (a) In soft material In hard material

...........

square metre (m')

Formwork (surface finish indicated) . . . . . . . . . . square metre (m2)

(b)

. . . . . . . . . . . square metre (m2)

Measurement and payment for formwork and concrete shall be as specified in sections 6200 and 6400, except that payment for excavation and gravel or soil backfilling shall be deemed to be included in the rates tendered for concrete and shall not be measured and paid for separately.

The unit of measurement shall be the square metre of excavation trimmed to receive concrete lining.

Item
23.05 Inlet, outlet, transition

unit

and similar sbuchrres (typical designs): (a) (Description of structure, type, etc, with reference to drawing and class of concrete) . . . . . . . . . . . . . . . . . . . number (No) Etc for other types.

(b)

The tendered rates shall include full compensation for all labour, plant, materials and other additional work and incidentals necessary for trimming the excavations for open drains to the standard of finish required for the construction of concrete linings. All excavation, includlng the removal of unsuitable ground and backfilling with suitable material, shall be measured and paid for under section 2100. Payment shall distinguish between trimming In soft material and trimming in hard material as defined in clause 2105. No extra payment shall be made in respect of any soil or gravel backfilling, additional concrete or mass-concrete backfilling required on account of overbreak or unavoidable unevenness of the excavations in difficult ground, the cost of which shall be deemed to be included in the tendered rates for trimming in hard material.

The unit of measurement and payment shall be the number of completed units of each type of structure constructed, and payment shall include full compensation for all formwork, concrete, excavation, trimming and backfilling, including such accessories as grids, etc, as may be specified on the typical drawings.

Item 23.08 Concrete lining for open drains: (a)

Unit

Item
23.06 Inlet, outlet, transition and similar sbuctures (measured by components):

Unil

Cast in situ concrete lining (class of concrete and type of open drain indicated) . . . . . . . . . . . . . . . . cubic metre (m3) Class U2 surface finish to cast in situ concrete (type of open drain indicated) . . . . . . . . . . . . . . . square metre (m2)

(b)

(a) (b)

Concrete (class indicated)

. . . . cubic metre (m3)

Formwork (surface finish indicated) . . . . . . . . . . . . . . . square metre (m2) Other components

(c)

. . . . . . . . . . . . number (No)

The measurement and payment for formwork and concrete shall be as specified in sections 6200 and 6400, except that excavation, trimming and backfilling shall not be measured and paid for separately, the cost of which shall be deemed to be included in the rates tendered for concrete. The unit of measurement for other components such as grids shall be the number of each type of component installed. The tendered rates shall include full compensation for procuring, furnishing and installing the components, including any painting or protective coating specified in the project specifications or as shown on the drawings.

Measurement of and payment for concrete shall be as specified in section 6400, but the tendered rate shall include full compensation for painting open joint surfaces as specified.

The unit of measurement for surface finish shall be the square metre of finished surface.

The tendered rate for surface finish shall include full compensation for all labour, plant, material and other additional work and incidentals required for trimming the concrete lining as specified.

Item
23.09 Formwork to cast in situ conaete lining for open drains (class F2 surface finish): (a) To sides with formwork on the internal face only

Unit

ttem
23.12 Steel reinforcement: (a) (b) Mild steel bars

Unit

. . . . . . . . . . . . . . . . . . . . ton

(t) (t)

High-tensile steel bars Welded steel fabric

. . . . . . . . . . . . . . . ton

....

square metre (m2)

(c)

. . . . . . . . . . . . kilogram (kg)

(b)

To sides with formwork on both internal and external faces (each face measured) . . square metre (m2) To ends of slabs

Measurement and payment shall be in accordance with the provisions of section 6300.

(c)

..........

square metre (m2)

Item 23.13 Polyethylene sheeting (0,15 mm thick) for concrete-lined open drains . . . . . . . . . . . .

Unit

Measurement of and payment for formwork shall be as specified in section 6200. Formwork under item 23.09(a) shall be measured and paid for only when the side slope of the slabs exceeds 1 in 2 and the slabs cannot be constructed without formwork even when a stiff concrete mix is used. When the contractor elects to use precast side slabs, payment will be made for formwork as if cast in situ concrete had been used.

. . . . . . square metre (m2)

The unit of measurement shall be the square metre of area covered with polyethylene sheeting. The tendered rate shall include full compensation for procuring, furnishing and installing the polyethylene sheeting, including wastage and overlap.

Item
23.10 Sealed joints in concrete linings of open drains (description of type with reference to drawing) . . . . . . . . .

Unit

Item 23.14 Cutting biminous surfacing and pavement layers for concrete kerbing, channelling or concretelined drains . . . . . . . . . . . . . . . .

Unit

. . . . . . . . . . . . . metre

(m)

The unit of measurement shall be the metre of completed joint of each size and type. The tendered rate shall include full compensation for the supplv . . . of all materials and for all labour, formwork and incidentals necessary for sealing the joint as shown on the drawings or specified in the project specifications.

. . . . metre

(m)

The unit of measurement shall be the metre of bituminous surfacing and pavement layers cut where instructed by the engineer, irrespective of the depth cut. The various layers shall not be measured separately for payment. The tendered rate shall include full compensation for all labour, constructional plant and materials required for cutting the surfacing and pavement layers to the required depth, removing and disposing of the debris, and protecting and keeping the surfacing clean, all as specified.

Item
23.1 1 Conaete screed or bacMill below chutes (class of concrete indicated) . . . . . . . . .

Unit

. . . . . . . . cubic metre (m3)

ttem Unit 23.15 Precast concrete blocks in outlet structures . . . . . . .

The unit of measurement shall be the cubic metre of concrete screed or backfill as may be instructed by the engineer to be placed below chutes. The tendered rate shall include full compensation for furnishing, procuring and placing the concrete in screed or backfill.

.......

number (No)

The unit of measurement is the number of precast concrete blocks provided and installed as shown on the drawings or directed by the engineer.

2403 COMPOUNDING. MWNG AND TRANSPORTING

ASPHALT MDCES

SECTKM 2400 :ASPHALT AND CONCRETE BERMS

(a)
Compounding the mixture

SCOPE MATERIALS COMPOUNDING, MIXING AND TRANSPORTING ASPHALT MIXES 2404 PREPARING THE BERM FOUNDATION 2405 PLACING 2406 TRANSITION SECTIONS FOR NJ TYPE OF RAILS 2407 MEASUREMENT AND PAYMENT
2401 2402 2403

Asphalt containing penetration-gracie bitumen shall contain, by mass of the dry aggregate, 7% of net 60/70 or 801100 penetration-grade bitumen and 1% of active filler. Asphalt containing mix-grade bitumen emulsion shall contain, by mass of the dry aggregate, 7% of net bitumen. The asphalt mix shall be in accordance with the requirements of the project specifications. The composition of the asphalt mix shall In all cases be subject to the prlor approval of the engineer.

2401 SCOPE

@)
This section covers the construction of asphalt or concrete berms at the outer edge of paved shoulders. Berms shall be cast in situ in moulds or by means of a suitable machine to the dimensions shown on the drawings or as directed by the engineer.

Mixing plant

The mixing plant shall be in accordance with the requirements of clause 4204 for asphalt with penetrationgrade bitumen, and clause 4303for asphalt with mix-grade bitumen emulsion.

(c)

Mixing, transporting and placing

(a)

Bituminous binder

Bituminous binder shall be a penetration-grade bitumen or a mix-grade bituminousemulsion as may be prescribed by the engineer. Spray-grade emulsion may be used as primer and tack coat.

Asphalt with penetration-grade bitumen shall be mixed, transported and placed in accordance wlth the requirements of section 4200, and asphalt with mix-grade bitumen-emulsion in accordance with the requirements of the project specifications.

2404 PREPARING THE BERM FOUNDATION

The various bituminous materials shall comply with the following specifications:

If shown on the drawings, the prime coat sprayed onto the base and shoulders shall extend over a wider area to allow space for the berms to be placed. Where the engineer so instructs during construction that berms shall be constructed, the specified width of the base projecting beyond the sides of the paved shoulder shall be thoroughly cleaned. The shoulder material adjacent to the base shall be compacted and trimmed to the upper level of the base and all loose material removed. A prime coat consisting of 30% bitumen-emulsion shall be applied at a rate of 0,40 litres per square metre onto that part of the berm foundation falling outside the paved surface of the road. In the case of asphalt berms, a tack coat of 30% bituminous emulsion shall be applied at a rate of 0,40 litres per square metre over the entire berm foundation. The tack coat shall be left to break before the berm is placed.

Penetration-grade bitumen: Bituminous emulsions:

SABS 307 SABS 309 and 548

The material of asphalt which contains penetration-grade bitumen shall comply wlth the requirements of section 4200. The aggregate grading shall lie between the limits indicated in table 4202/7 for a fine continuously graded mix. The material of asphalt which contains mix-grade bitumen emulsion shall comply with the requirements of the project specifications. The grading of the aggregate shall be subject to the prior approval of the engineer.

2405

PLACING

All concrete work shall be carried out in accordance with the details shown on the drawings and the requirements of sections 6200 and 6400.

When the berms are placed, proper care shall be taken at all times to ensure that the toe of the berm does not encroach on the side of the carriageway or shoulder by more than 25 mm.

(a)

Placing by hand

2407

MEASUREMENT AND PAYMENT

The mixture shall be placed and shaped in situ in a rigid portable mould to form a trapezoidal kerb of the dimensions indicated on the drawings.
24.01 Asphalt berms:

Unit

(a) In the case of asphalt berms the mixture shall be thoroughly compacted to form a hard unyielding berm, true to level, shape and line, within the specified tolerances. The moulds may be removed as soon as the material has cooled to air temperature, or, in the case of a cold asphalt mix, as soon as it has hardened.

Placed where there are no guardrails (types of asphalt and binder indicated) . . . . . . . . . . . . metre (m) Placed at existing guardrails (types of asphalt and binder indicated) . . . . . . . . . . . . . . . . metre (m)

(b)

@)

Placing by machine

The unit of measurement shall be the metre of asphalt berm placed as specified. The tendered rates shall include full compensation for procuring, furnishing, mixing and placing the'material, and all other work necessary for completing the asphalt berms as specified. The prime and tack coats shall be paid for under item 24.03.

A machine of approved design may be used for placing the berm. In general, machine-placed work will not require any additional compaction. In areas where, in the opinion of the engineer, the compaction is inadequate, the machine shall be weighted with additional mass, or other measures shall be taken to ensure that adequate compaction is obtained.

(c)

Placing under guardrails

Item 24.02 Concrete berms:

Unit

Should the berm be placed first, the holes for the guardrail posts shall be excavated with care to prevent damage being done to the berm. Where chutes are required against fills, the berm shall be discontinued for the width of the top of the chute and finished to form a proper inlet for the water into the chute, as indicated on the drawings.

(a)

Placed where there are no guardrails . . . . . . . . . . . . . . . . . . . metre (m) Placed at existing guardrails . . . . . . . . . . . . . . . . . . . . . . . . . metre (m)

(b)

(d)

General requirements

The unit of measurement shall be the metre of concrete berm placed as specified.

The berms shall be placed true to level, shape and line. All berms deviating more than 10 m m from the specified line when measured at the inner edge of either their crests or their bases, or of which the height or width, measured at the crest, varies by more than 5 m m from the specified height or width, will be rejected and shall be removed and replaced at the contractor's own expense.

The tendered rates shall include full compensation for procuring, furnishing, mixing and placing the material, and all other work necessary for completing the concrete berms as specified. The prime coat shall be paid for under item 24.03.

Unit

The surfaces of concrete berms placed by machine, and all unformed surfaces, shall be given a class U2 finish, and formed surfaces a class F2 finish. Joints shall be provided at 3 m intervals in all concrete berms, either by casting in alternate sections or by cutting machine-placed sections. All such joints shall be neatly formed and finished so as not to leave any irregularities or loose concrete at the joints.

24.03 Prime and tack coats:

(a) (i)

Prime coat: Under asphalt berms (primer indicated) . . . . . . . . . square metre (m2) Under concrete berms (primer indicated) . . . . . . . . . square metre (m2) Tack coat (type indicated) . . . . . . . . . . . . . . . . square metre (m2)

(ii)
2406

TRANSITION SECTIONS FOR NJ TYPE OF RAlLS

(b)

Where transition sections for New Jersey type of bridge rails are required to be constructed from asphalt, the instructions for asphalt berms shall apply in regard to the asphalt composition and the preparation of the foundation.

The unit of measurement shall be the square metre of completed prime coat or tack coat applied in accordance with the specifications.

The tendered rates shall include full compensation for procuring and providing all material and for mixing and applying the adhesive and primer complete as specified, including cleaning, compacting and trimming the coat being primed. Payment shall be made under this item for the prime coat if, as instructed by the engineer, it is applied in a separate strip independently from the prime coat of the road or shoulder surface. If applied as an integral part of the prime coat of the road or shoulder surface by the prime coat being sprayed over a wider area to provide space for the berms, payment for the prime coat will not be made under this item.

Item

Unit

24.04 Transition sections for NJ type of rails . . . . . . .

. . . . . . . . number (No)

The unit of measurement shall be the number of completed asphalt transition sections constructed to the details shown on the drawings.

The tendered rate shall include full compensation for procuring, providing, mixing and placing all materials, and for all labour, formwork and incidentals reauired for constructing complete transition sections as spdcified.

SERIES 3000 :

EARTHWORKS AND PAVEMENT LAYERS OF GRAVEL OR CRUSHED STONE

(b)

Borrowpit plans

SECTION 3100 : BORROW MATERlALS

SCOPE NEGOTIATIONSWITH OWNERSAND AUTHORITIES OBTAINING BORROW MATERIALS OPENING AND WORKING BORROW PlTS AND HAUL ROADS FINISHING-OFF BORROW AREAS AND HAUL ROADS DISPOSAL OF BORROW MATERIAL CLASSIFICATION OF BORROW PlTS FOR GRAVEL MATERIALS FOR PAVEMENT LAYERS MEASUREMENT AND PAYMENT

Borrow-pit plans are included in the contract documents. The information shown on the borrow-pit plans reflects the results of site investigations and laboratory tests conducted by or for the employer and is supplied in good faith as to the sufficiency in quantity and quality of the material for the due and proper completion of the works. The provision of these borrow-pit plans shall not in any way be construed as limiting the obtaining of borrow material to the borrow areas and/or to the depth of working specified pits shown on the plans or as necessarily limiting the use of the rnaterial to that described on the plans. If. at any time during construction, it appears that the quality or quantity of material available in a borrow pit is inadequate or insufficient. the contractor shall make use of other borrow areas approved by the engineer. irrespective of whether or not such other borrow areas are shown on the borrow-pit plans. The contractor shall provide all assistance in the form of plant, trained personnel. labour and fencing material as may be required by the engineer for prospecting for and testing further borrow pits. The cost of such assistance will be for the employer's account.

3101

SCOPE

This section covers the work involved in obtaining borrow materials for work under this contract. including negotiations with owners of the land on which borrow areas are situated, clearing the site, stripping and disposing of excess overburden. excavating selected material for use in the works, and finishing-off the borrow areas.

(c)

U s e of b o r n materials

3102

NEGOTIATIONS WrrH OWNERS AND AUTHOR lTlES

With regard to borrow areas that are identified and (a) prescribed by the employer for the execution of the works. the contractor is exempted from all obligations and costs in respect of negotiations with and compensation of the owners of the land on which the borrow areas are situated. unless otherwise specified.

The decision as to which source of supply the contractor shall use at any time shall rest with the engineer. and the contractor shall at any stage of the work use that approved source of supply which in the opinion of the engineer is the most suitable in regard to the quality and quantities of the various types of available materials and the ultimate cost of the work to the employer. Unless otherwise determined elsewhere. payment will not be made for moving the contractor's plant from one location to another at any of the individual sources shown on the plans or subsequently approved by the engineer. Should the contractor elect to obtain material from sources other than those shown on the borrow-pit plans, he shall excavate the necessary trial holes, take such samples and conduct such tests as are deemed to be necessary by the engineer. The contractor shall submit the results and sufficient details to the engineer to satisfy him that the quality and quantity of the material available in the proposed borrow area are acceptable for the intended use. all at the contractor's own expense. Compensation to owners and arrangements for taking any material shall be in terms of the project specifications. Approval of borrow pits or borrow areas shall apply only to those portions of the pit or area from which acceptable material can be obtained or produced. The contractor shall organize his operations in any approved pit or borrow area or portions thereof with a view to using the material for the purpose envisaged.

(b) The attention of the contractor is drawn to the provisions of clause 1214 as regards his activities on private land.

The contractor shall observe all the legal provisions (c) and the provisions of the project specifications in respect of his activities at borrow pits and when finishing off the borrow pits.

3103

OBTNNING BORROW MATERIALS

(a)

General

Borrow materials shall be obtained from approved sources of supply listed and described on the borrow-pit plans. or from such other sources as may from time to time be tested and approved by the engineer. Borrow-pit material complying with the requirements of the specifications for the use for which the material is intended. shall be selected from these approved sources.

The contractor shall plan his exploitation of the borrow pits in such a manner that the various types of materials excavated can be selected and loaded directly for use. When this is unfeasible for reasons beyond the contractor's control. rnaterial to be stockpiled for later use shall be loaded, transported and temporarily stockpiled as ordered by the engineer and as determined in clause 3203. No material resewed for a specific purpose shall be used for any other purposes without the written approval of the engineer.

(d)

Bomm materiala obtainable in the mad prism or within the mad reserve boundaries

possible at that stage, replaced into the borrow pits as described in clause 3105. Excess overburden will also be measured for payment where the borrow material shall be stone or sand used for stone pitching, concrete work, crushed-stone subbase and base, permeable material in subsurface drainage systems. and asphalt pavements and seals.

Where suitable sources of materials are available in existing cuttings and side drains, or anywhere else in the road prism or within the road reserve boundaries. such materials may be used for the construction of fills. pavement layers and shoulders, if so ordered by the engineer.

(d) 3104

Excavating borrow material

OPENING AND WORKING BORROW HAUL ROADS

Prrs

AND
Borrow material shall be excavated within the limits of depth and area shown on the borrow-pit plans or directed by the engineer. and in a manner that will not prejudice the use of the material for the intended purpose. Where any borrow pit contains different types of materials in separate layers which require to be mixed to produce a suitable product, the materials shall be excavated over the full depth of the approved working face in one operation without the different types of materials being separated. The contractor shall take all reasonable precautionary measures so as to avoid contamination of the suitable borrow material by the inclusion of clayey or otherwise unsuitable material from the floor of the borrow pit, the overburden, any unsuitable layers, or areas beyond the approved limits of the borrow area. During loading, any hard oversize material which will not break down during processing on the road shall be excluded as far as is practicable. During borrow operations, and especially when excavating material near the floor and outer boundaries of the borrow areas, the contractor shall plan his operations so as to reduce. in so far as is possible, the amount of earth moving work that will be necessary for finishing-off the borrow pits. lndiscrimlnate excavation without due regard being given to the desired final shape of the borrow pit will not be permitted. The material in borrow pits shall be blasted or ripped and excavated in a manner that will ensure the effective breaking-down of the material in the borrow pit before it Is loaded.

(a)

Removing topsoil

Prior to opening a borrow pit, the contractor shall ascertain from the engineer whether the removal of topsoil is required and shall then remove and stockpile such topsoil as instructed by the engineer. This work shall be carried out, measured and paid for in accordance with the provislons of section 5800.

@)

Clearing and grubbing

Clearing and grubbing of borrow areas will be measured for payment In accordance with the provisions of section 1700 before excavation is commenced, but only in the following cases, unless otherwise directed by the engineer: (i) In borrow areas located in plantations

(li) In borrow areas where large trees with trunks exceeding 1 m in circumference as defined in section 1700 are found. In borrow areas without any excess overburden but (iii) where the removal of grass, shrubs and roots is required. Unless the clearing and grubbing of a borrow area have been prescribed by the engineer in writing, no payment will be made for clearing and grubbing such borrow area.

(c)

Excess overburden
(e)

Control at b o r n pH

The contractor shall advise the engineer in good time. before any excavation at such borrow area is commenced. of his Intention of starting to use a borrow area in order that a survey of the site can be made for the purpose of computing the quantity of excess overburden, if any. to be removed. No removal of overburden or other quarrying operations shall be proceeded with until agreement has been reached between the engineer and the contractor in regard to the quantity of such overburden. Unless, under exceptional circumstances. the clearing and grubbing of the borrow area is required to be done first. the excess overburden shall be measured only after this work has been completed. As instructed by the engineer, excess overburden shall be moved to the outer limits of the proposed borrow area. and, if this area is enlarged later on. the excess overburden shall be moved further to the new outer limits, or. where

The contractor shall be responsible for controlling his operations at every borrow pit where material is being excavated to ensure compliance with all the requirements of subclause 3104(d). He shall conduct sufficient tests on the materiai being excavated from the borrow pit to satisfy himself that the quality of the material will comply with the specified requirements for the particular layer for which it will be used. If there is any doubt concerning the quality of the borrow material being excavated at any time, the contractor shall notify the engineer immediately, and in any case before such material is brought onto the road. The results of all the tests which are conducted by the contractor shall be submitted to the engineer on request. The engineer will. after further testing or inspection if necessary, instruct the contractor regarding the use of the material in the borrow area. or he may order the borrow pit to be finished off and

abandoned.

(1)

Protecting borrow pits

satisfaction of the engineer, and the contractor shall furnlsh the engineer with a signed certificate from the landowner stating that he is fully satisfied with the finishing-off of any borrow area. The contractor's attention is drawn to the provisions of clause 1214 in this respect.

Borrow pits shall be continuously protected against the ingress of surface water, and the contractor shall construct such temporary banks as may be required for diverting surface water, and, in so far as is possible, his operations shall be planned in such a way that the borrow pit will be self-draining. Where this is unfeasible. borrow pits shall be dewatered by pumping. The contractor shall be solely responsible for keeping borrow areas dry and ensuring that borrow material is sufficiently dry when required for use.

@)

Haul roads

All haul roads shall be obliterated and their surfaces scarified, earth banks shall be constructed to prevent erosion, and all damaged fences and other structures shall be reinstated, unless otherwise specified. Where materials from a borrow pit are hauled on unproclaimed private access roads, such roads shail be restored to their original condition to the satisfaction of the engineer and the owner when borrow operations at the borrow pit are completed, unless otherwise specified. No additional payment will be made for this work, and full compensatlon for restorlng unproclaimed private access roads used as haul roads will be regarded as being included in the rates tendered and paid for the various items of work where the materials are used. The restoration of proclaimed roads shail be done in accordance with the instructions of the engineer and payment will be made in accordance with applicable unit rates.

(g)

Unproclaimed private access roads

Where materials from a borrow pit are hauled on unproclaimed private access roads, such roads shall be maintained properly to the satisfaction of the engineer and the owner during borrow operations at the borrow pit. No additional payment will be made for this work, and full compensation for maintaining unproclaimed private access roads used as haul roads will be regarded as being included in the rates tendered and paid for the various items of work where the materials are used.

3105

FINlSHlNGOA BORROW AREAS AND HAUL ROADS 3106 DISPOSAL OF BORROW MATERIAL

(a)

Bormw areas
The contractor shall not have the right to use material obtained from borrow pits for any purpose other than for the execution of this contract. He shall not dispose of any borrow material whether processed or not either by sale or donation to any person without the written authorization of the employer.

On completion of his operations in a borrow area, the contractor shall reinstate the entire area so as to blend it with the surrounding area and to permit the reestablishment of vegetation. For this purpose the borrow area shall be shaped to even contours without any slopes being steeper than 1 In 3, except where the engineer so permits in specified cases. All material in and around the borrow area, whether spoil from road-building operations, excess stockpiled material, oversize material left in the borrow pit, material resulting fmm etearing and grubbing opemths or excess overburden, shall be used or disposed of as directed by the engineer. Material incapable of supporting vegetation shall be buried and used for shaping the borrow area and shall subsequently be covered with soft material. All available soft material shall be spread evenly to the prescribed thickness, and where sufficient material is not available for so covering the entire area, the remaining portions shail be scarified along the contours so as to avoid undue erosion. The shaping and finishing-off of the borrow pit shall be done in such a manner that the borrow pit will be properly drained wherever practicable, and, where required, the contractor shall place earth banks to divert surface water from the borrow area. If so directed, the borrow area shail be fenced off and provided with gates as specified in section 5500, and topsoiled and/or hydroseeded as specified in section 5800. The finishing-off of the borrow areas shall also comply with ail legal provisions, which require, inter alia, that rehabilitation shall be approved. (See also Act 50 of 1991.) The finishing-off of any borrow pit shall be to the entire

31

C~;~~~S~CA OF T BORROW ION Prrs FOR GRAVEL MATERlALS FOR PAVEMENT LAYERS

Borrow pits for the exploitation of gravel materials shall be classified in accordance with the same classification as that described in clause 3303 for mass earthworks. Borrow pits for exploiting stone for piLching or crushing, and borrow pits for sand shall not be classified for purposes of payment. The engineer shall have the right to decide which borrow pit shall be operated by the contractor at any particular stage of the work and to approve new borrow pits during the construction period.

3108

MEASUREMENTAND PAYMENT

Item 31.01 Excess weburden

Unit

. . . . . . . . . cubic metre

(m')

The unit of measurement shall be the cubic metre of excess overburden measured in place before stripping. Such measurement shall be based on the depth of overburden as measured in the trial pits.

The tendered rate shall include full compensation for stripping, removing and stockpiling the excess overburden prior to the borrow material being excavated, for replacing the excess overburden in the borrow pit after completing the excavation, of borrow material. and for levelling-off the excess overburden in the borrow area. Where the stockpiled excess overburden has to be moved to beyond the limits originally instructed by the engineer. it shall be measured once more for payment. Where overburden material is used for filling or for other purposes, payment will not be made for removing such overburden material, but will be made in accordance with the purpose for which such material will be used. No distinction will be made for purposes of payment. in accordance with the classification set out in clause 3303. between the various types of material. which have been removed as overburden. except only in regard to borrow pits for obtaining crushed stone for the subbase and base. as determined in item 31.02 below.

31.W Finishing-off borrow areas in:

(a)

Hard material

. . . . . . . . . . . . . . . . . hectare (ha)

(b)
(c)

Intermediate material Soft material

...... ... . .
. ...

hectare (ha)

. . . . . ...... .

. . hectare (ha)

The unit of measurement for finishing-off borrow areas shall be the hectare measured in accordance with the finally excavated area of the borrow pit before it is finished off. The tendered rates shall include full compensation for finishing-off the borrow pits as specified. including any further earth moving necessary for finishing. but excluding the establishment of grass. Borrow pits shall be classified in accordance with the classification of the material removed therefrom and. where more than one class of material is taken from a borrow area. the area shall be apportioned pro rata for classification purposes. in accordance with the volumes of each type of material removed.

Item
31.M Excess overburden i n borrow pits for obtaining crushed stone for pavement layers:

Unit

Notes:

(a)

Overburden in soft or intermediate excavation . . . . . . cubic metre (m') Overburden in hard excavation . . . . . . . . . . . . .

(1)

Borrow material

(b)

. . cubic metre (m')

The unit of measurement shall be the cubic metre of excess overburden measured in place before stripping. The quantity shall be based on the depth of the overburden as measured in test pits. Distinction shall be made between soft and intermediate material on the one hand and hard material on the other, in accordance l ~ i t h the classification as described in clause 3303 for excavations. The tendered rates shall include full compensation for stripping, removing and stockpiling excess overburden prior to the borrow material being excavated. replacing the excess overburden in the borrow pit after excavation of the borrow material has been completed, and levelling-off the excess overburden in the borrow area. Where the stockpiled excess overburden has to be mcved to beyond the limits originally indicated by the engineer, it shall be measured once more for payment. but only under item 31.01. Where overburden material is used for filling or for other purposes, payment will not be made for removing such overburden material, but will be made in accordance with the purpose for which such material will be used.

Apart from the existing payment items. no direct payment will be made for procuring and providing borrow material. but it will be regarded as an additional obligation on the part of the contractor to be covered by the contract prices paid for the various items of work for which the material is used as prescribed in these specifications. Payment shall, however, be made separately for certain items of work where so specified. The tendered rates for procuring and providing borrow material. shall also include full compensation for all obligations. costs, activities and work as prescribed in section 1200 of the specifications. as well as for all supervision. labour. plant, tools and incidentals required therefor. including all costs as may be necessary for conducting control tests on all materials, draining and protecting all borrow areas, and concluding all negotiations with landowners (except negotiations that are entered into by the employer himself) as specified. also for finally shaping and finishing the borrow pits. (2) Prospecting for materials

Payment will be made for excavating trial pits according to a grid pattern as ordered by the engineer over the entire borrow area. and for assistance rendered by the contractor, as may be directed by the engineer, in prospecting for additional material in accordance with the provisions of clause 40 of the general conditions of contract.

SEFUES 3000 :

S AND PAVEMENT LAYERS OF GR4VEL OR CRUSHED STONE

The contractor should note the provisions of subclauses 3103(c) and 3104(d) and (e) in regard to activities at borrow pits, and of subclause 3306(d) in regard to activities in cuttings. Where the contractor has unnecessarily contaminated or wasted suitable material, he shall supply other suitable material at his own cost.

SECTION 3 2 0 0 : SNCTION,

STOCKPIUNG AND BREAKlNG-DCWN M E M A T FROM BORROW PITS, CUrnNGS AND WSTlNG PAVEMENT LAYERS, AND PLACING AND COMPACTING THE GRAVEL LAYERS

CONTENTS

3203 STOCKPlUNG THE MAT-

SCOPE SELECTING THE MATERIAL STOCKPILING THE MATERIAL BREAKING-DOWN THE MATERIAL CRUSHING AND SCREENING CONTROLLING THE MOISTURE CONTENT OF MATERIALS LAYER THICKNESSES AND SPREADING THE MATERIALS PLACING AND COMPACTING THE MATERIALS IN LAYER THICKNESSES OF 200 m m AND LESS AFTER COMPACTION PLACING AND COMPACTING THE MATERIALS IN LAYER THICKNESSES IN EXCESS OF 200 mm AFTER COMPACTION DISPOSING OF OVERSIZE MATERIAL DRAINAGE AND PROTECTION MEASUREMENT AND PAYMENT

The contractor shall so plan his activities that materials excavated from borrow pits and cuttings, In so far as Is possible, can be transported direct to and placed at the point where it is to be used. However, where utilizing materials in this manner is impracticable, and, if so instructed by the engineer in writing, it shall be temporarily stockpiled for later load in^ and transportation to where It will be used. ~ o m ~ e n s a tfor i ostockpiling ~ materials will be payable only in regard to material stockpiled in accordance with the engineer's written instructions. The temporary stockpiling of material within the borrow area in heaps with a view to loading, or any other stockpiling method used in connection with the loading method adopted by the contractor in the cutting or borrow pit, will not be classified as temporary stockpiling. The costs for these processes will be deemed to be covered by the rates for the various items of work for which material so stockpiled is used. Stockpiling areas shall be indicated or approved by the engineer. Before any stockpiling of material may be done, the site shall be cleaned, and all loose stones or anv vegetation or other material which may cause contamination shall be removed. After the stock~iled material has been removed, the site shall be reinstatdd as closely as possible to Its original condition, and the surface shall be lightly scarified to promote vegetation growth. Payment will be made for stockpiling the material from existing pavements only if the material is intended for reuse and If its stockpiling has been approved or directed by the engineer.

3201

SCOPE

This section describes the selection of materials from borrow pits and cuttings for the various purposes for which they are required, stockpiling the materials excavated but which cannot be dumped direct where required, breaking down the material during the excavation process, when it is processed on the road, or when special processing for breaking-down by crusher is required, controlling the moisture content, placing and compacting the soil and gravel layers and constructing the rock fills. In addition this section describes the treatment of material recovered from existing pavements, and construction in restricted areas during rehabilitation work. Unless inconsistent with the context, the provisions of section 3200 relating to borrow pits or to material obtained from borrow pits shall apply mutatis mutandis to such places where material is recovered from an existing road, and to the material recovered from an existing road respectively.

3204 BREAKlNGDOWNTHE MATERUU

Initial breakingdawn of the material in arttine, borrow pits and existing pavement layers

(a)

3202 SELECTING THE MATERM

The contractor shall use materials strictly in accordance with the purpose for which they have been approved and in accordance with the details as indicated on the drawings or as directed by the engineer. During his activities in borrow pits, cuttings and existing pavement layers, he shall ensure that approved materials are not unnecessarily polluted with unsuitable material or that approved materials are not unnecessarily wasted.

The material from cuttings and borrow pits shall be broken down in the cuttings or borrow pits to the maximum sizes as set out below, depending on the use envisaged for the material, before it is loaded and hauled to the road. Rock fills Normal fills Pavement layers 750 m m maximum dimension 500 m m maximum dimension 300 m m maximum dlmenslon

Spoil material need be broken down only sufficiently for convenient loading and transporting, but the engineer may require sufficient material to be broken down to a maximum size of 500 m m with a view to effectively trimming the spoil areas.

Material intended for crushing need only be broken down sufficiently to permit acceptance by the crusher. In order that the material can be broken down to the above-mentioned sizes, the contractor shall adjust and control his blasting, ripping, excavating and other operations so that the desired result can be achieved as effectively as possible. In so far as may be practicable, drilling and blasting patterns shall be such as to break down the material to the desired sizes, and, where this is impracticable, secondary blasting or other methods shall be used for breaking down oversize materials. If, in the opinion of the engineer, the working methods of the contractor are such that unnecessarily large quantities of oversize material are produced, he may instruct the contractor to change his methods in order to produce less oversize material, and the contractor shall not be entitled to any additional compensation for carrying out such instructions. Care shall be taken not to load oversize material and to bring it onto the road. However, where this is nevertheless done, the contractor shall, at his own cost, remove such oversize material from the road or break it down further to the required size on the road. Where surplus material is available and the engineer so agrees the contractor, instead of breaking down any oversize materials, may work it out or leave it in the borrow pits, or in the case of materials from cuttings, spoil it, but in the latter case not without the written approval of the engineer. The engineer may also require oversize materials to be used for other purposes, such as for rock fills instead of breaking it down.

Any oversized material shall be removed by hand, (4) and/or constructional plant as provided in clause 3210. The broken-down material shall be placed In a (5) windrow to the opposite side of the material still to be broken-down. (6) Repeat steps (2) to (5), but place the second windrow next to the first. To mix the material, the two windrows formed in (7) steps (2) to (6) shall then be bladed Into a single windrow to the side of the road. If so ordered by the engineer repeat steps (2) to (7) (8) until all the material that needs to be broken-down has been treated. (iii) However, should too much oversize material continue to be produced by normal grid-rolling, the engineer may instruct that any one of the following be done: That additional normal grid-rolling or its equivalent be done; That, instead of attempting to break down the material on the road, It be crushed as described In clause 3205; or That the contractor and engineer agree on the use of any other methods and equipment which may be more suitable, and determine compensation for such work in terms of clause 40 of the general conditions of contract. (iv) Any oversize materlal still remaining after processing in accordance with any of the processes described above shall be removed from the road as provided in clause 3210.

@)

Further breakingdown of pavement material

Pavement material shall be further broken down to (i) the sizes as specified for each layer by using grid rollers, and other suitable equipment, subject to the approval of the engineer. The contractor shall be at liberty to employ any methods and equipment he may prefer, but, where any difference of opinion may arise in regard to the practicabilityof the breaking-down process or the suitability of the methods and equipment employed by the contractor, the engineer may require normal grid-rolling to be done as described below. The results so obtained will then serve as the norm for the degree of breaking-down to be attained by any alternative method. For the purposes of this specification, normal grid(ii) rolling shall mean the following: The material shall be placed or bladed to the one (1) side of the road to provide working space for breakingdown the material. Subject to the approval of the engineer a portion of (2) the material shall be spread in a thin layer on a compacted surface to promote effective breaking-down of the material, and to a width which the grid roller shall be able to cover in a single pass. The grid roller, which shall proceed at a speed of at (3) least 12 kmlh and shall have a minimum mass of 13,5 tons, shall do four complete roller passes over the material.

(c)

Further breaking-down of fill on the mad

After fill material in borrow pits and cuttings has been broken down to the maximum size specified in subclause 3204(a) and then spread on the road, it shall be further broken down by means of suitable equipment such as grid rollers, subject to the approval of the engineer. In many cases breaking down by the normal compaction process should be adequate, and no special effort should be necessary for breaking down the material, but, In the case of hard and coarse material, the engineer may require that the material receive at least a light grid-rolling, and the degree to which breaking-downwill occur by means of the light grid-rolling process will then serve as norm of what may be required in regard to alternative methods the contractor is permitted to employ. For the purposes of these specifications light grid-rolling is defined as follows:

The material shall be spread in a layer, the uncompacted thickness of which shall be more or less equal to the average maximum fragment size, but with a minimum of 200 mm. It shall then be rolled by means of at least two complete passes per 200 mm of uncompacted layer thickness by a grid roller with a mass of not less than 13,5 tons, moving at a speed of at least 12 kmh, Should the uncompacted layer thickness be in excess of 200 mm, the number of roller passes shall be increased pro rata.

Compensation for light grid-rolling processing will be regarded as being included in the price paid for providing and compacting the material, which processing will not be included in the number of roller passes whlch may be paid for compacting the material.

For all stages of crushing plant, precautionary measures required in terms of the Occupational Health and Safety Act (Act 85 of 1993) and the Minerals Act (Act 50 of 1991), and the latest amendments thereof shall be deemed included in the rates tendered for the relevant products.

(d)

Milled material

3206

CONTROUJNG THE MOISTURE CONTENT OF MATERIALS

Milled material need not normally be broken down further unless so specified or instructed b y the engineer. The contractor shall take all reasonable precautions to prevent material in borrow pits, excavations, stockpiles and on the road from becoming excessively wet as a result of rain or groundwater or stormwater. In view hereof, the excavation of borrow pits and cuttings shall, as far as possible, be so planned and executed as to prevent the damming-up of water in the borrow pits or cuttings, and the contractor shall also provide the necessary temporary drainage for this purpose. During the rainy season, material spread over the road shall be spread with a proper cross slope, and, if not directly compacted, it shall be rolled several times with a flat-wheeled roller in order to let the water run off and not penetrate the material unduly. Care shall also be taken not to allow the water to dam up against material heaps, windrows, or any spread material.

(0)

Existing cemented layers

layers to be broken down and reprocessed either where it is to be hauled to a crusher for processing, been specified or instructed by the

Existing cemented reprocessed may be placed, or it may be whichever may have engineer.

3205

CRUSHING AND SCREENING

Where the material Intended for use in the pavement layers can not be suitably broken down by the methods set out in subclause 3204(b), the engineer may direct that the material be crushed, screened, or crushed and screened, or be modified b y screening out certain fractions. A single-stage crushing plant implies the utilization of a primary crushing unit in which only one size reduction stage occurs, irrespective of the magnitude of the reduction ratio possible by nature of its construction. The single stage crushing plant, shall be capable of breaking down oversize material to the maximum size specified for the layer concerned. A second crushing stage, while not always necessary to achieve the required reduction ratio, is required by utilizing a secondary crushing plant in addition to the primary crushing unit, to control the grading of the product to fall within the broader specified envelope for G4, G5 and lower quality selected materials, as well as yielding specified shape characteristics as appropriate. This shall be termed a two-stage crushing plant. A third crushing stage and where appropriate a fourth crushing stage utilizing in addition to the earlier stage crushing plant, tertiary and quaternary crushing plants, as appropriate, to control the grading and shape of the higher quality materials G I , G2 and G3, as well as grades 1 to 3 surfacing aggregate and concrete aggregates, shall be termed a multi-stage crushing plant. For the single-stage and two-stage crushing plant, selective screening may be ordered by the engineer. Screening only of material involves screening the material into various fractions through a series of screens, the smallest of which need not be smaller than 6,7 mm. For the multi-stage plant, all screening and/or any other required activity and concomitant equipment required to produce the specified end product, shall be considered to be included.

Where material, despite proper precautionary measures, on account of its in situ moisture content, is nevertheless too wet to comply with the requirements in regard to moisture content during compaction, the contractor shall dry out the material until it is adequately dry for compaction, but, in the first instance, he shall, in so far as is practicable, so plan his construction programme that material with a high natural moisture content will be used in the dry season and not in the wet season. No prescriptions apply in regard to drying out the material, and the contractor himself shall decide on the best methods. No additional payment will be made for keeping dry and drying out the material, but the cost of such work shall be included in his tender rates for the various items of work for which the material is to be used, unless provision for additional compensation of this nature has been made in the project specifications. However, where the contractor has taken all reasonable precautions to keep the material dry and to dry it out where necessary and it is nevertheless impracticable to dry out the material as required, the engineer shall permit the material to be compacted at a higher (a) moisture content, subject to the required dry density being achieved; or declare the material to be unsuitable and instruct (b) that it be not used, and, if already on the road, be removed at the appropriate compensation and replaced with suitable material; or further instruct the contractor as he may deem (c) necessary under circumstances and compensate him for any additional expenses brought about theieby, but only to the degree to which the additional costs have not arisen through the failure of the contractor to comply with the provisions of this clause.

3207

LAYER THICKNESSES AND SPREADING THE MATERIALS

(a)

Fills

The layer thickness of fills will generally be determined by the maximum size to which the material can be b~oken down in the borrow pits and cuttings. and thereafter when it is processed on the road itself. The layer thickness will therefore normally be based on the pre-estimation of what the maximum size will be to which the material can be broken down, and shall be such that the maximum size of the fragments will be more or less equal to the layer thickness after compaction. The maximum layer thickness (after compaction) required from the contractor shall be 200 mm, but layer thicknesses as little as 100 m m will be permitted. In order to prevent the layer thicknesses from being determined by the presence of isolated large fragments. the engineer may require such isolated fragments to be removed from the road, as determined in clause 3210. The engineer may also agree to the material being compacted in layers in excess of 200 m m or the maximum fragment size, provided that he is satisfied that the material will be properly compacted. Layer thicknesses shall be agreed on in advance between the engineer and the contractor. Where a new layer is constructed on an existing or already constructed fill and the new layer will be less than 100 m m in compacted thickness, the existing fill shall be scarified to such a depth as will give a layer thickness after compaction of not less than 100 m m of the new plus the scarified material together. No additional payment will be made for this. Where coarse material is to be processed in layer thicknesses which make mixing by road grader impracticable, the material shall be so excavated. transported and dumped that it will be properly mixed after dumping and exhibit a minimum segregation of fine and coarse material. Such material shall be placed to the correct thickness by end tipping, and the surface levelled by bulldozer, after which some fine material shall be spread on top of the layer and worked into the depressions on the surface.

Where the thickness of any existing pavement layer (iii) requires to be supplemented and the thickness of the added material after compaction will be less than 100 mm, the existing layer shall be scarified to a depth that will give a layer thickness of at least 100 m m after compacting together the loosened existing and added material. In the case of gravel or crushed-stone bases and subbases. the engineer may direct the existing layer to be broken down to its full depth. The composite layer shall be watered. mixed and compacted as determined in clause 3208. Payment for adding the material will be made as determined for the respective pavement layers.

3208 PLACING AND COMPACTING THE MATERIALS IN LAYER THICKNESSES OF 200 mm AND LESS AFTER COMPACTION

When the layer thickness after compaction is 200 m m or less. any oversize material which cannot be broken down to the required size shall first be removed from the road and then disposed of or used as may be prescribed by the engineer. Tt~e material shall then be sprayed with water, niixed. and compacted as described hereafter.

(a)

Spraying and mixing

General requirements

(i)

Before the material is compacted. it shall first be thoroughly mixed by grader or other suitable plant so as to obtain an even mix of the various types of materials and to spread the fine and coarse material evenly throughout the mixture. If necessary during the mixing process, water shall also be sprayed evenly over and mixed into the material to bring it to the correct uniform moisture content. The moisture content to which the material shall be brought shall be just sufficient to bring the material to the optimum moisture content for the compacting equipment being used and the compaction required. provided that, should the moisture content of the material be in excess of 2% above the optimum moisture content for modified AASHTO density. it shall be compacted only when so approved by the engineer. If not, it shall first be dried out to the required moisture content even where it had been too wet initially. (ii) Additional requirements in respect of work in restricted areas The engineer may. in restricted areas. permit the contractor to spread. water and mix the gravel or crushed stone in a windrow next to the pavement excavation. Care shall be taken not to damage existing surfacing and not to pollute the mixed material with other deleterious material. Where this method of mixing is impracticable or impossible. the contractor shall make use of concrete mixers or any other equipment or method acceptable to the engineer. Irrespective of the layer concerned, the mixing shall be of such quality that a uniform mix will be obtained at all times to the satisfaction of the engineer.

@)

Pavement layers

All material placed in position before compaction (i) shall be spread evenly over the entire surface of the layer concerned, and the quantity of material spread shall be such that every layer will comply with the specified requirements for thickness when measured after compaction. The layer thickness shall comply with the requirements as indicated on the drawings and in the project specifications. Spreading material in restricted areas may be done (ii) in any manner approved by the engineer, on condition that the required level and grading standards can be attained. Where the compaction apparatus used is of such a nature that the material in thicker layers can not be properly compacted, the engineer may instruct that material be placed and compacted in layers of as thin as 75 mm.

@)
(i)

Compaction
General requirements

density being achieved over the full depth of the layer. In this case efficient vibratory rollers shall be used for compacting the sand.

Compaction shall be carried out in a series of continuous operations covering the full width of the layer concerned, and the length of any section of a layer being compacted shall, wherever possible, be not less than 150 m nor more than can be properly compacted with the available equipment. The engineer reserves the right to order the contractor to reduce the length of any layer compacted in any single operation if the proper compaction of such layer is not being achieved. The types of compaction equipment to be used and the amount of rolling to be done shall be such as to ensure that specified densities are obtained without damage being done to lower layers or structures. During compaction the layer shall be maintained to the required shape and crosssection, and all holes, ruts and laminations shall be removed. (ii) Additional requirements in respect of work in restricted areas Suitable equipment and methods acceptable to the engineer shall be used in restricted areas so that the required densities will be obtained throughout the thickness of the layer. If necessary, the layers shall be placed in thicknesses which are less than the specified layer thickness, as determined in subsubclause 3207(b)(ii). Work that has to be done in restricted areas as a result of the actions of the contractor, will not be regarded as work in restricted areas for payment purposes.

@)

Hardmaterialfills

Should the material used for fills be of such a nature that. during the breaking-down effort as described in subclause 3204(b), it does not readily break down to a maximum size of 200 m m or less, the material shall be spread as described in subclause 3207(a) and processed as follows: The material shall be sprayed and mixed as described in subclause 3208(a), but, should this be impracticable on account of the thickness of the layer, these processes may be omitted on condition that the material be thoroughly mixed and placed as described in subclause 3207(a) (last paragraph). The material shall subsequently be compacted in accordance with one of the methods described in section 3300, depending on the method directed by the engineer.

(c)

Rock fill

Rock-fill processing and compaction shall apply to material consisting predominantly of stone and boulders, with some fine material in between, which, on account of the mechanical interlock of the rock, cannot be effectively compacted by construction methods normally used for soils and gravel. When the layer thickness after compaction is 500 m m or less as instructed by the engineer, the processing and compaction of such material shall not be classified as rockfill processing and compaction, and the engineer may prescribe that the material be compacted as described in subclause (b) above. The maximum size of rock which may be used in rock fill is 750 mm, and the layer thickness before compaction shall not be in excess of one and a half times the average actual size of the rock. The engineer may prescribe that 5% of the oversize material shall be bladed off the road after the material has been dumped onto the road, and it shall be disposed of as described in clause 3210, so that the layer thickness will not be determined by the presence of isolated large rock fragments. The compacted layer shall not contain any rock fragments the largest dimension of which exceeds the thickness of the compacted layer. The material to be compacted shall be off-loaded by the end-tipping method. The material shall then be spread by bulldozer or other suitable plant and shall be so bulldozed and levelled as to properly mix the fine material with the rock. The rock fill shall contain sufficient fine material to fill the voids. The routes to be followed by hauling, spreading and compaction equipment shall be uniformly distributed over the entire width of the layer to be compacted. The material shall be broken down and compacted during the spreading and compacting process by grid or other suitable rollers and finally compacted with vibratory rollers in accordance with the following formula to achieve a good mechanical interlock of the rock and the maximum compaction of the finer material in the spaces between the rock.

(c)

In place reworking of pavement layers

Where so specified in the project specifications and/or instructed by the engineer and the material in any existing layer complies with the requirements for the new layer, the contractor shall scarify the layer to the specified depth, add extra material if necessary, and reprocess the layer in place. Reprocessing includes watering by spraying, mixing, and compacting the layer to the density specified for the layer concerned. Payment will be made as determined for the respective pavement layers.

3209 PLACING AND COMPACTING THE MATERWS IN

LAYER THICKNESSES IN MCESS OF 200 mm AFTER COMPACTION (only applicable in the case of fills)

(a)

Softmaterial fills

Materials which readily break down to a maximum size of 200 m m shall be compacted in layers not in excess of 200 mm after compaction, and spraying, mixing and compacting the material shall be executed as described in clause 3208 for pavement layers. In the case of cohesionless sand, the layer thicknesses may however be increased to as much as 400 mm, and spraying and mixing the material may be omitted or limited in so far as is practicable, all subject to the required

The type of vibratory roller used. the operating speed. the number of passes and the layer thickriesses are determined by means of the following formula:

Pe - 1 500 (minimum) hxv

where Pe
=

"

the adjacent existirig layer, for example in the case of a stabilized or bitumen-treated layer next to an untreated layer. it may be specified. or the engineer may instruct that pavement subsoil drainage be installed in accordance with the details indicated on the drawings or determined by him. The installation of subsoil drainage will be measured and paid for under the pay items of section 2100.

n h v

= = =

total static and dynamic force per metre width generated by the vibratory roller at the operating frequency given by the manufacturer (kN/m) number of passes required thickness of the compacted layer in metres roller speed in metres per second.

3212

MEASUREMENT AND PAYMENT

Operating frequencies shall be between 18 Hz and 30 tiz and Pe shall be at least 120 kN/m.

Where provided in the various sections of these specifications that a payment item shall include compensation for placing or for placing and compacting the materials, the terms placing or placing and compacting shall include compensation for all work described and costs given In this section, excepting work covered by the payment items below. for which separate payment will be made, as follows:

3210

DISPOSING OF OVERSIZE MAlERlAL

Unit
All oversize materials removed from the road in terms of subclause 3204(a) and all excess fill removed from the road in terms of subclause 3207(a) shall be disposed of at the contractor's cost or. with the approval of the engineer. may be used for other suitable purposes. Oversize pavement material left over after application of the provisions of subclause 3204(b) and removed from the road in terms of clause 3208, shall be loaded and disposed of as determined by the engineer and will be paid for subject to the provisions of payment item 32.04. Where. however, such material is used direct for any construction work, the contractor will be entitled only to compensation at the rate in respect of the construction item in question. Notwithstanding the methodsof payment described above. the tender rates for constructing all pavement layers shall include full compensation for the removal of up to 5% by volumeof oversize material without any additional payment being made to the contractor. The limit of 5% will apply to individual layers and not to all the layers together. The contractor shall take all reasonable precautions not to place on the road any material which cannot be broken down on the road itself to the required size by processing This shall be avoided by proper selection during excavation in the cuttings or borrow pits. If such material is encountered in cuttings. it shall be spoiled directly or used as prescribed by the engineer.

33.01 Providing a crushing andlor screening plant:

(a) (b) (c) (d) Single-stage crusher Two-stage crusher

. . . . . . . . . . number (No)
number (No)

.............

Screening plant . . . . . . . . . . . . . . . number (No) Multiple-stage crusher and screening plant . . . . . . . . . . . . . . . number (No)

The unit of measurement shall be the number of complete plants supplied as ordered by the engineer. The tendered rates shall include full compensation for providing the plant. transporting it to the site. erecting. commissioning and finally dismantling it, and loading and transporting it away from the site or to the point where it is to be re-erected. regardless of the number of types of material treated.

ttem

Unit

32.02 &erecting the crushing and/or screening plant:

(a) Single-stage crusher . . . . . . . . . . . number (No) Two-stage crusher

3211

DWNAGE AND PROTECTION

(b) (c)

. . . . . . . . . . . . number (No)

Screening plant . . . . . . . . . . . . . . number (No) Multiple-stage crusher and screening plant . . . . . . . . . . . . . number (No)

The compacted layers shall be adequately drained and shaped to prevent water from standing on or along or scouring the completed work. Windrows shall be removed to facilitate the drainage of water from the surface. No material for a subsequent layer may be placed if the underlying layer has been softened by excessive moisture. In cases where pavement layers are replaced over a section of the road width, or where pavement layers are widened and the new layer is more or less permeable than

(d)

The unit of measurement shall be the number of times each plant is dismantled. transported and re-erected as ordered by the engineer. regardless of the number of types of material treated. The tendered rates shall include full compensation for dismantling the plant. loading, transporting. off-loading and

re-erecting it at new positions as ordered b y the engineer. and recommissioning it.

32.03 Crushing and screening:

(a) (b)
(c)

Single-stage crushing . . . . . . . cubic metre (m') Two-stage crushing Screening

The tendered rate shall include full compensation for the excavation of material in all classes of excavation, loading and transporting it to the road, placing. and any breakingdown treatment given or attempted. blading all oversize pavement material off the road, loading. transporting it to the point of disposal or subsequent re-use. including a free-haul of 1.0 km, and off-loading and spreading of the material.

'

. . . . . . . . cubic metre (ni')

Item

. . . . . . . . . . . . . . . cubic metre h i ' )

M i

(d)

Multiple-stage crushing and screening . . . . . . . . . . . . . . . . cubic metre (ni')

37.05 Addiional normal grid rolling . . . . . . . . . . . . . . . . . . . cubic metre (my)

The unit of measurement shall he a cubic metre of material crushed or screened or crushed and screened and finally used in construction, measured in place after compaction. No allowance will be made for waste. except in the case of subitems (c) and (d), where the quantity measured as above for payment shall be increased b y including 70% of the loose volume, measured in stockpile. of the material screened out and discarded. The tendered rates shall include full co~npensation for crushing in the case of subitems (a) and (b), or screening in the case of subitem (c), or crushing and screening the material in the case of subitem (d). including all labour. plant, fuel, handling, processing. stockpiling if necessary. loading for transportation to the point of final use, and for disposing of any material screened out and discarded. Item

The unit of measurement shall be the cubic metre of compacted material upon which an additional "normal gridrolling operation" as described in subclause 3204(b) is performed in accordance with the instructions of the engineer.

The tendered rate shall include full compensation for performing one additional normal grid-rolling operation in addition to the initial normal grid-rolling operation. the cost of which has been included in the tender rates for pavement layers.

Unit
32.06 -piling

of material . . . . . . . cubic metre (my)

32.04 Rernwal of wersize pavement material . . . . . . . . . . . . . . . . . cubic metre (m')

The unit of measurement shall be a cubic metre of oversize pavement material from cut and borrow. which cannot be broken down as specified. and is removed. The volume shall be determined as prescribed by the engineer and shall be the loose volume in stockpiles or its equivalent measured in hauling vehicles. Only that volume of oversize pavement material in excess of 5% of the compacted volume of pavement layers will be measured for payment. all as specified in cla1.1se3210.

The unit of measurement shall be the cubic metre of material temporarily stockpiled on the instruction of the engineer.

The tendered rate shall include full compensation for cleaning and preparing the stockpiling sites and also for levelling and reinstating of the site after completion of the work. for off-loading and spreading the material if necessary. and for loading when required for use.

SERIES 3000 :

EAATHWORKS AND PAVEMENT LAYERS OF GRAVEL OR CRUSHED STONE

to the rock fill and placed as specified in subclause 3307(j). The addition of approved fines will be paid for separately. Where it is possible by virtue of the quality of the (ii) available material. the minimum CBR at the specified compaction shall be as follows: Depth below final road surface Less than 1.2 m

SECTION 3300 : MASS EARTHWORKS

CONTMS SCOPE MATERIALS CLASSIFICATION OF CUT AND BORROW EXCAVATION CLASSIFICATION OF COMPACTION TREATING THE ROADBED CUT AND BORROW FILLS FINISHING THE SLOPES PROTECTIONOF ROAD PRISMAND STRUCTURES CONSTRUCTION TOLERANCES QUALITY OF MATERIALS AND WORKMANSHIP MEASUREMENT AND PAYMENT

Minimum CBR 3% at 90% of modified AASHTO density 3% at 100% of modified AASHTO density

Should the depth below the final road surface exceed 9 m, or should the material be not in accordance with the said requirements. the material shall conform to the requirements as set out in the project specifications or as prescribed by the engineer. If provision is made for it in the project specifications, the engineer may allow the use of material not meeting these requirements. ie clay or clayey material with a CBR less than 3% at 100% modified AASHTO density, subject to the requirements specified in the project specifications. (iii) Compaction requirements. minimum in situ dry density

3301

SCOPE

This section covers all work in connection with the construction of cuts and fills. the removal to spoil of material unsuitable for use. the construction and compaction of fills with cut material from the road prisrn or borrow material from approved borrow pits. the compaction of the roadbed and finishing off cuts and fills. up to the stage where fills are ready for placing the pavement layers. This section also covers the widening of existing cuttings. fills and roadbeds.

When the material is compacted to a percentage of modified AASHTO density. 90% or 93% (as required). Sand which for the purposes of this requirement is specified as non-plastic sand with not less than 95% passing through the 4.75 m m sieve, but with not more than 20% passing through the 0.075 mm sieve, shall be compacted to lOOSb of modified AASHTO density. Should more than 20% pass through the 0.075 m m sieve. the sand shall be compacted to 95% of modified AASHTO density. Where existing fills are to be widened. or where new fills are to be constructed adjacent to existing fills. the material so placed shall be compacted to at least 93% of modified AASHTO density in order to minimise differential settlement. For sand. the compaction shall be at least 95% or 100% of modified AASHTO density. as specified. (iv) A maximum swell as specified In the project specifications shall apply.

(a)

Roadbed and cut

Roadbed and cut materials which occur along the route of the roadway have been tested and the results of the tests are shown on the drawings. The test results. read in conjunction with these specifications, give a preliminary indication as to the purpose for which the cut material may be used as well as the treatment. if any. which the roadbed shall receive. The engineer shall give final instructions during construction regarding the use of cut material and the treatment of the roadbed.

3 3 0 3 CLASSIFICATION
EXCAVATION

OF

CUT

AND

BORROW

@)

Fill
(a)

Classes of excavation

Unless otherwise specified in the project specifications. fill material shall conform to the requirements specified below: The material shall not contain any rock fragments (i) with a maximum dimension exceeding 500 mm, except in the case of rock fills. when it may be 750 rnrn. In the case of rock fills the material shall contain sufficient finer fractions to fill the voids in order to obtain the maximum density. The engineer has the right to verify the result by means of random trenching. If the rock fill material is deficient in fines. approved fines shall be added

The excavation of material from cut or borrow for fills (including excavations in existing roads where specified or agreed) shall be classified as follows for purposes of measurement and payment:

(i)

Soft excavation

Soft excavation shall be excavation in material which can be efficiently removed or loaded by any of the following plant without prior ripping:

A bulldozer with a mass of at least 22 tons, (whlch Includes the mass of a ripper If fitted) and an engine developing approximately 145 kW at the flywheel.

A tractor-scraper unit wlth a mass of at least 28 tons and an englne developing approximately 245 kW at the flywheel, pushed during loading b y a bulldozer as specified In subsubclause 3303(a)(li).

shall be in a good mechanical order. The expressions "efficlently ripped", "efficiently removed" or "efficlently loaded" as used in this subclause shall in this context mean ripped, removed or loaded (as the case may be) in a manner which can reasonably be expected from the equipment in questlon, with regard to the production achieved.

@)

Method of dassifying

A track-type front-end loader wlth a mass of at least 22 tons and an engine developing approximately 140 kW at the flywheel.
(il) Intermediate excavatlon

The contractor shall be at liberty to use any method he wishes to use for excavating any class of material, but the method of excavating the materlal shall not dictate the classification of the excavation. The engineer shall decide under which one of the above classes any excavation shall be classified for purposes of payment. In the first instance the classlflcation shall be based on an inspection of the material to be excavated, which classlflcation shall be agreed on before excavatlon may be started. In the event of a disagreement between the contractor and the engineer, the contractor shall, if required, make available such mechanical plant as specified In subclauses 3303(a)(i) and (ii) at his own cost, in order to determine whether or not the material can reasonably be removed. The declslon of the englneer as to the classification shall thereafter be final and bindlng, subject to the provisions of clause 2 of the general conditions of contract. The contractor shall immediately inform the engineer if and when the nature of the material being excavated changes to the extent that a new classlficatlon for further excavation is warranted. Failure on the part of the contractor to advise the engineer thereof in good time shall entitle the engineer to classify, at his discretion, such excavation as may have been executed in material of a different nature.

lntermediate excavation shall be excavation (excluding soft excavatlon) in material which can be efficiently ripped b y a bulldozer with a mass of at least 35 tons when fitted with a single tine rlpper and an engine developing approximately 220 kW at the flywheel. (iil) Hard excavation

Hard excavatlon shall be excavatlon (excluding boulder excavation) in materlal which cannot be efficiently ripped by a bulldozer with properties equivalent to those described in subclause 3303(a)(ii). This type of excavation generally includes excavation in material such as formations of unweathered rock, which can be removed only after blasting. (iv) Boulder excavation class A

Boulder excavation class A shall be excavation in material containing In excess of 40% by volume of boulders between 0,03 m' and 20 m3 in size, in a matrix of softer material or smaller boulders. Excavation In dolomite formations other than solid dolomite shall also be classed as class A excavation if the formations contains in excess of 40% by volume of lumps of hard dolomite between 0,03 m3 and 20 m3 in size, in a matrix of softer material or smaller lumps of hard dolomite. Excavation of solid boulders or lumps of hard dolomite each in excess of 20 m3 in size shall be classed as hard excavation. Excavation of fissured or fractured rock shall not be classed as boulder excavation but as hard or intermediate excavation according to the nature of the material. (v) Boulder excavation class B

(c)

Classes of excavation for exanrations in existing roads

The system for classifying excavations in existing roads depends on the clrcumstances in each case, and therefore on the construction methods which may be applied. Unless otherwise specified, and prior to any excavations being made in existing roads, the contractor and the engineer shall agree as to which classification system will be used and also as to the classification of the materials themselves. The two systems of classification are, firstly In accordance with clause 3803, and secondly in accordance with subclauses 3303(a) and (b) and the considerations for determining the classification system are as follows: (i) Classification In accordance with clause 3803

Where material contains 40% or less by volume of boulders or lumps of hard dolomite ranging from 0,03 m3 to 20 m3 In size, in a matrix of soft material or smaller boulders or lumps of hard dolomite, then those boulders or lumps of hard dolomite between 0,03 m3 and 20 m3 in size shall be classed as class B boulder excavation. The excavation of the rest of the material shall be classed as soft or intermediate excavation according to the nature of the material. All the equipment specified in subclauses (i) and (ii) above

This method of classification shall apply where the excavation is subject to the provisions of clauses 3804 and 3805, that is, where the excavation requires strict control so that underlying layers will not be damaged, or so that only material from a specified layer will be removed without being contaminated with material from other layers, and also where only part of a layer requires to be removed. (ii) Classification 3303(a) and (b) in accordance with subclauses

This method of classification shall apply where excavations are not subject to the restrictions of section 3800, but only

to those of section 3300. Where excavations can therefore be made In the normal manner as in new construction, even In a restricted area, the classification of subclause 3303(a) shall apply. For excavations In borrow plts, subclause 3303(a) shall always apply. Where extra over items of payment are provided for excavations in various classes of materlal, only those extra over items relating to the appropriate classification system as determined above shall apply.

(i)

Vibratory roller

The vlbratory roller shall be capable of exerting a comblned static and dynamic force of not less than 120 kN1metre-widthfor every metre of loose-layer thickness at an operating frequency not exceeding 25 Hz and shall move at a speed not exceeding 4 k m h . (ii) Oscillatory roller

33W

CLASSIFICATION OF COMPACTION

The oscillatory roller shall be capable of exerting a combined static and dynamic force of not less than 120 kN/metre-width for every metre of loose-layer thickness at an operating frequency not exceedlng 50 Hz and shall move at a speed not exceedlng 4 k m h . (Ill) Grid roller

The method of processing and the compaction of fill material shall be classified as described below for purposes of measurement and payment. The engineer wlll decide in advance as to which classlficatlon of compactlon shall be employed and the classification of materlal for purposes of excavation shall not In any way be taken into consideration In respect of the classification of the compaction of material.

The grid roller shall have a mass of not less than 13,5 tons when ballasted, shall be loaded to thls mass, and shall move at a speed of not less than 12 kmlh. (iv) Tamping roller

(a)

Compactionto a minimum percentage of modilied AASHTO density

Wherever a denslty requlrement in respect of a fill or pavement layer is specified In these specifications, on the drawlngs or In the project specifications or is prescribed by the engineer In terms of a percentage of modified AASHTO denslty, the contractor shall be at liberty to employ any type of compactlon equipment he may choose so as to achieve such denslty over the full specified depth of the layer, provided always that he complies in all respects with the general requirements of these specifications and that the equipment employed is adequate and suitable for the purpose and wlll not in any way be detrimental to any part of the already completed works.

The tamplng roller shall conslst of a cylindrical drum fitted with specially deslgned tamping feet, and shall have a total mass of not less than 13,5 tons, and shall be towed at a speed of not less than 12 k m h . The feet shall be rectangular in shape and shall have two or three consecutive rolling faces, and shall be designed so as not to loosen any materlal during the process of rolling.

When so directed by the engineer, the rock fill shall be constructed as determined In subclause 3209(c).

3305

TREATING THE ROADBED

@)

EigM roller passes compaction

(a)

Removing unsuitable material

Where the degree of compaction cannot be satisfactorily controlled by way of testing the in situ density on account of the nature of the material, the engineer may instruct that the material be placed and compacted by eight passes (for every 200 m m of compacted layer thickness) by a combination of various items of compaction equipment. The engineer may also instruct that the required number of passes be increased or decreased and that the payment be adapted accordingly. The contractor shall use a combination of all or any of the following items of plant: grid rollers, sheep's-foot rollers, tamping rollers, flatwheel rollers, vibratory rollers, oscillatory rollers, or any other item of plant deemed by the engineer to be suitable. The contractor shall base his tendered rates on the inclusion of four passes b y a vibratory roller or an oscillatory roller, two passes by a grid roller, and two passes by a tamping roller in every eight passes by the combination of rollers. Equipment The plant shall be of any size and type as may be deemed, to be suitable by the engineer, except that the following items of plant shall comply with the requirements stated below:

Any roadbed material which is considered by the engineer to be of a quality that would be detrimental to the performance of the completed road shall be removed to such widths and depths as may be instructed by the engineer and shall be disposed of as prescribed. The excavated spaces shall then be backfilled with approved imported material compacted to the required denslty. The engineer may also order that material which is too wet to provide a stable platform for the construction of the fill be removed and replaced with suitable dry material, and the contractor shall be paid for this work, provided that the engineer is satisfied that, despite adequate temporary drainage installed b y the contractor and permanent drainage that the contractor may have installed on the engineer's instructions, the wet condition is unlikely to be remedied within a reasonable time and could not have been reasonably foreseen and avoided by proper advance planning for construction being done during a dry period. The removal of unsuitable material shall be paid for under item 33.07. For payment a distinction shall first be made in respect of the depth of the material removed and secondly in respect of the stability of the material and the construction plant to be used. For removing any stable material, payment will be made under this item should

the instruction to remove be given after completion of the excavations in accordance with the original instructions or should the thickness of the layer to be removed be less than 200 mm. If not. payment will be made therefor under item 33.04 as for ordinary excavated material which is taken to spoil. For the purposes of this clause and of payment item 33.07. stable material shall be defined as material which can be removed effectively by means of normal road-construction equipment such as bulldozers. road graders. scrapers. mechanical shovels, back hoes or excavators, whereas unstable material shall be material which can be removed effectively only by means of dragline scrapers or similar equipment.

directed by the engineer. If necessary, roadbed material may have to be temporarily bladed off to windrow in order to achieve the necessary depth of compaction. Where any additional material has to be imported to obtain the required level and layer thickness. and where the thickness of the layer of imported material would be less than the specified layer thickness after compaction, then the roadbed material shall be scarified. the necessary imported material placed, and this combined material mixed and compacted to the full specified depth of the layer. The imported material shall be measured and paid for under "Cut and borrow to fill" and the roadbed material shall be measured and paid for under "Roadbed preparation and compaction of material".

@)

Three roller passes compaction

(d)

In silu treatment of roadbed

Any portion of the roadbed which, by reason of its inadequate in situ density is shown on the drawings or is specified or is prescribed by the engineer to be given three roller passes compaction, shall be prepared by shaping if necessary and then compacting with a pneumatic-tyred roller with a load of at least 2.0 t per wheel. or a vibratory roller which complies with the requirements specified in subclause 3304(b), or with an impact roller. The impact roller shall be a single multi-faced roller with a maximum of five flat or nearly flat faces and a roller mass of between 8 and 10 tons. The roller and towing mechanism, which shall be of the free-fall type, shall be so designed that all the energy applied in lifting the roller. when the roller is supported on the ridge between adjacent faces, will be available for application on impact when the roller drops down again. The roller shall be towed at a speed between 8 km and 12 kmlh. Except where otherwise authorized by the engineer. compaction shall comprise not less than three complete coverages by the wheels of the roller. specified or ordered. over every portion of the area being compacted. Although it is not the intention that water be applied to the roadbed by the contractor under this class of compaction and no rigid control of the moisture content will be exercised during compaction, the contractor shall nevertheless satisfy the engineer that every possible endeavour is being made to take advantage of favourable soil-moisture conditions and to carry out such compaction in so far as is possible during periods when the roadbed is neither excessively dry nor excessively wet. The engineer shall be fully authorized to decide as to when conditions are favourable for compaction and where such compaction shall be done at any particular time and he is authorized to instruct the contractor to water the roadbed at the contractor's expense where, in the opinion of the engineer, the contractor has failed to comply with these requirements. Where required. three roller passes compaction shall be followed up by the process described in (c) be!ow.

Wherever shown on the drawings or as may be directed by the engineer, the roadbed shall be treated in situ by undesirable formations of hard or rocky materials being broken up in order to achieve a uniform standard of compaction or to improve drainage. Treatment in situ shall consist of ripping or blasting the roadbed to depths which. on normally cambered sections, shall increase from the centre of the roadbed to the edges. Unless otherwise indicated on the drawings or directed by the engineer. the depth of ripping in the centre of the roadbed shall be not less than 300 m m and at the edges of the roadbed not less than 500 mm. Similarly the depth of drilling and blasting shall be not less than 700 mrn at the centre of the roadbed. and shall slope outwards to not less than 1 000 m m at the edges of the roadbed. On superelevated sections the treatment shall, if so directed by the engineer or shown on the drawings. have a uniform crossfall and a minimum depth of 400 m m in the case of ripping and 850 rnm in the case of blasting. After ripping or blasting the material shall be processed as follows: Where the engineer instructs the contractor to rip the in situ material. all the material shall be sized by rolling or knapping until the maximum dimensions of any clod or spall do not exceed two-thirds of the thickness of the layer after compaction. The material shall then be compacted as described in section 3200 and in subclause 3304(b) by means of eight passes by an approved combination of various rollers. Where instructed by the engineer, the contractor shall blast the in situ material, and all the material shall be processed and compacted as described in subclause 3209(c). In both cases surplus material resulting from bulking after treatment in situ shall be removed and disposed of or utilized elsewhere as directed by the engineer.

(e)

Draining of roadbed

(c)

Reparing and compacting the roadbed Any drainable waterlogged roadbed. such as saturated material overlying less pervious strata, shall first be drained by the installation of all permanent surface or subsoil drainage shown on the drawings or as directed by the engineer. before any other construction may be started on these sections.

Any part of the roadbed which is classified as being suitable for use in situ, save that it fails to meet density requirements, shall be scarified, watered and compacted to a percentage of modified MSHTO density. The type of compaction and the depth of compaction shall be as

Such drains shall be constructed, measured and paid for in accordance with the requirements of section 2100 of these specifications.

(1)

Wdening the roadbed

Where the road is to be widened, and where so instructed by the engineer, the roadbed shall be treated in accordance with the provisions of clause 3305. Where uncompacted roadbed material occurs below the outer part of the fills, the fill material shall be cut back or cut away to expose the full width of the roadbed widening to be treated.

The engineer shall have full control of the use of all material obtained from cut excavations, but the contractor shall plan his operations and particularly his cut-to-fill operations in such a manner that all cut material may be used to the best advantage of the employer. This would mean that no material shall be unnecessarily spoiled, borrowed or hauled. The contractor shall neither borrow nor spoil any material without the engineer's approval and without satisfying the engineer that this is necessary and the most economical method of constructing the works.

3306 CUT AND BORROW

(a)

No material other than that originating from cuttings, the excavations for culverts, foundations, drains and the shaping of the roadbed may be excavated from within the road reserve unless so authorized by the engineer. Where sufficient quantities of suitable cut material are not available, additional material shall be excavated from borrow areas shown on the drawings or as directed by the engineer. In lieu of borrow, cuttings may be widened or their slopes flattened, provided that the engineer determines the need for such action before the contractor starts work on any particular cutting. If the engineer requires existing cuttings or completed or partly completed cuttings to be widened, such widening shall be measured and paid for separately as provided in subclause (a) of this clause. Additional material required for the construction of the work shall, wherever possible, be obtained by the shortest haul distance from approved borrow areas being used. The engineer shall have the right to decide which sources of supply of approved material shall be used by the contractor at any particular time. Where satisfactory material is obtainable at shorter haul distances and the contractor elects to use material which will require longer hauls, the contractor will be paid at the rate for the shorter haul.

Dimensions of cuts

The dimensions of cuts shall be generally in accordance with the details of the typical cross-sections, and of the interchange and intersection as shown on the drawings and shall further be defined or amended during the course of construction by instructions from the engineer. The contractor shall first obtain instructions from the engineer regarding the slope of the sides of cuttings and the depth to which cuttings are to be taken, including the dimensions of any in situ treatment of cuts that may be required. All cuts carried below the specified levels shall be backfilled with suitable material and compacted to the satisfaction of the engineer at the contractor's own expense. In the case of cuttings made in hard or boulder material, where a certain amount of overbreak would be inevitable, the contractor is, however, afforded the opportunity of pricing an item to cover his costs in respect of unavoidable overbreak on the floor and backfilling in such sections. The engineer may, when he considers it necessary, instruct the contractor to widen existing, completed or partly completed cuttings either uniformly or by altering the slope of the sides of the cutting, or by cutting benches, or in any other way. Those parts of cut slopes exceeding 2,5 m in depth and widened by less than 4 m measured horizontally shall be measured and paid for as specified in clause 3312, item 33.08. Those parts of widened cut slopes which are less than 2,5 m in depth, and parts widened by more than 4 m measured horizontally, shall be measured and paid for as cut to fill or cut to spoil as the case may be.

(d)

Selection

The engineer may order that particular materials in borrow pits or in cuts be selected for a specific purpose. Where selection is ordered, the method of excavation and the programme of work shall be so arranged as to avoid, in so far as is possible, double handling and to meet the requirements of the engineer. In general the excavated materials shall be placed direct in their final positions in the fill. When ordered by the engineer, the better class fill material shall be selected for use in the top layer of the fills and in the lower layers of high fills.

@)

The use of cut material

All suitable and approved materials excavated from the road prism shall, in so far as is practicable, be used for the construction of fills, pavement layers and mitre banks and for such other purposes as shown on the drawings or as directed by the engineer. Coarse rock encountered in cuttings shall be utilized for the construction of the lower layers of fills high enough to accommodate thick layers, or, where so required, shall be consewed and used as directed for constructing the sides of embankments or for sewing as protection against embankment or channel erosion.

(e)

The temporary Hockpiling of materials

Where the earthworks pattern is such that selected materials cannot be placed direct in their appropriate positions, the engineer may authorize their removal to temporary stockpiles as described in clause 3203.

The dispwal of surplus material Any surplus material resulting from excavations, including any waste or oversize material bladed off the road, shall be disposed of as directed b y the engineer. However, no material shall be disposed of without the written instructions of the engineer. Spoil material shall not require compaction but shall, if required, be spread, shaped and given a smooth surface as may normally be obtained by careful bulldozer operations.

Where a local surplus of cut material occurs or of material which, for the above reasons, is unsuitable or oversize, payment will nevertheless be made for the removed material as for the disposing of cut material to the extent in which such material or an equal volume of other material would in any case have to be spoiled. All material used for the construction of fills shall, during excavating, placing and compacting, be broken down, placed and compacted as described in section 3200. The density of fill shall comply with the requirements of subsubclause 3302(b)(iii) unless otherwise authorized b y the engineer, as in the case of the bottom layer of a fill on marshy ground or in rock fill. The layer thickness used for the construction of the fills will depend on the type of material used. The engineer shall first determine the layer thicknesses with reference to the provisions of clauses 3207, 3208 and 3209, and shall also determine the type of compaction to be employed. Wherever practicable, fill shall be placed in successive layers parallel to the final road surface, and the construction of wedge-shaped layers shall be restricted to the bottom layers of fill where this may be unavoidable on account of crossfall, the tapering out of fills, or the superelevation of the final road surface.

@)

General

The contractor shall take proper care when excavating cuts not to loosen, where it can be avoided, any material outside the specified cut line, whether by ripping, blasting or b y other means, which would endanger the stability of the slopes or which would subsequently cause undue erosion or disintegration of the batters. This would normally entail modifying the methods of excavating when work is done in the vicinity of the final cut surface. Care shall also be taken not to undercut any slopes, and proper control shall at all times be exercised b y regular survey checking and by using batter poles at close intervals. Where the batters are nevertheless undercut, backfilling and compacting with imported material will not normally be considered to be a suitable remedy, and the engineer may order such remedial measures as he may consider to be necessary to be implemented at the contractor's expense, which, in serious cases, may include cutting back the entire or large sections of the batter to a uniform slope.

@)

Placing the rock

Rock material containing rock particles In excess of 300 m m in size shall not be used at a depth of less than 150 m m below the top of the fill unless otherwise authorized b y the engineer. The contractor shall, b y the judicious planning of layer thicknesses and by selecting the smaller sized material for placing in the thinner fill layers, avoid unnecessary spoillng of the larger sized rock material and shall ensure its fullest practicable utilization in fills.

3307

nus
General

(a)

The dimensions of fills shall be in accordance with the typical cross-sections and the interchange or intersection details shown on the drawings, as further defined or amended by the engineer during the course of construction. Before starting construction, the contractor shall obtain instructions regarding the required slope of each fill, any roadbed preparation or subsoil drainage required, details of earthworks at interchanges and Intersections, the selection of materials, the method and classification of compaction, and any other matter that may affect the construction of the fill or sequence of operations.

(c)

Canstructing a pioneer layer

Where, for one of the following reasons, material is oversize or otherwise unsuitable for use because it was not properly broken down, during (i) the excavation process, to the maximum size as described In clause 3204: (ii) because it was not properly selected or was contaminated as described in clause 3202; because it was excavated in a manner detrimental (iii) to its intended use as described in subclause 3104(d); such material shall be removed from the road and disposed of, and its removal and disposal shall not be paid for.

Where fill is to be constructed across water-logged or soft clayey ground exhibiting excessive movement under normal compaction equipment and haulage trucks, and such conditions preclude the effective compaction of the bottom fill layers, the engineer may direct that a pioneer layer be constructed on the unstable ground. This layer shall be constructed by successive loads of suitable coarse material being dumped and spread in a uniform layer with a thickness just sufficient to provide a stable working platform for constructing the further fill layers which are to be compacted to a controlled density. Light hauling equipment shall be used, and, where necessary, end tipping for placing the material, and the layer shall be compacted b y light compaction equipment being used, which will glve the most effective compaction without the roadbed being overstressed. Pioneer layers will not require compaction to a controlled density. The distinction between the construction of a pioneer layer and a rock flll as described in clause 3209 will be determined by the purpose for which it is constructed. The compacted volume of material used may be determined by 70% of the loose volume in trucks being taken as an alternative to taking cross-sections before and after construction.

(d)

Benching

( 1 )

Sand filter blankets

Where the natural crossfall of the roadbed exceeds 1 in 10. the fills shall be bonded to the roadbed b y means of benches excavated in the roadbed. The height of the benches shall be determined b y the engineer. Benches in hard material may normally be smaller than those in soft material. Where benches are cut into rock, the toe of the fill shall preferably also b e constructed from rock material. and the benches shall be at least as high as the largest boulders in the fill material. The floor of the first bench in rock material shall also be serrated in order to resist horizontal forces effectively. Benches in rock material shall also be excavated to slope slightly inwards so as to obtain a better bond. The benches may be constructed in either one of the following two ways:

At the bottom of fills, and sometimes at intermediate levels, the construction of sand filter blankets may be required to facilitate the drainage of fills. Sand filter blankets shall be constructed in accordance with the details on the drawings and shall normally consist of a layer of selected sand with a suitable grading to provide effective drainage and to prevent the infiltration of fill or roadbed material into the sand filter blanket. The surface on which the sand filter blanket is to be constructed, shall b e smooth and even and the sand shall be spread evenly to the required thickness and be given a light compaction with suitable rollers. The final surface of the sand filter blanket shall be finished off true to line and level. The engineer may require the layers immediately below and above the filter blanket to be constructed from selected soil or gravel. Sand filter blankets will be measured and paid for separately.

Method A
(g) This method requires the cut of the first bench in the existing roadbed to be of adequate width for accommodating normal-width self-propelled construction equipment. The widths of successive benches shall be determined b y the width of the fill at the relevant height. The width of benches shall decrease gradually u p to the stage where the fills in any case are wide enough for accommodating normal-width self-propelled construction equipment. Construction of fills near structures

Method B
This method does not require the benching in the toe of the fill to b e cut back adequately for accommodating normal construction equipment. but less. and requires the fills then constructed to be so much wider as may be necessary for accommodating such equipnierlt u p to the height where the fills are sufficiently wide in any case. In this case the engineer shall determine the width of the lowest bench to be cut in the fill. The position of the first bench at the toe of the fill shall be properly measured and clearly set out. All suitable material obtained from the excavations for benching shall. in so far as is possible, be re-used for constructing the fills. Measurement of and payment for constructing the benches shall be treated as "cut to fill" or "cut to spoil" as the case may be, unless otherwise determined in the project specifications. In the case of method B construction. the engineer may require excess width at the toe of the fill to be removed later on. in which case it shall be classified as soft excavation material.

At all fills adjoining uncompleted structures such as bridges and large culverts. where the construction of the fill and the backfilling behind the structure cannot b e done simultaneously, the fills shall b e so constructed that the longitudinal slope of the surface of the fill at all stages will form a continuous plane sloping towards ground level at the structure at a gradient not exceeding 10%. When the structure is completed, the remaining portion of the fill shall b e similarly completed simultaneously with the backfilling behind the structure, while the backfill behind the structure is being maintained at the same elevation as the adjoining fill. No additional payment will b e made for constructing fills in this manner outside the restricted areas as defined in clause 6108.

(h)

Constructing toes for rock fill embankments

Where required. rock fill embankments shall be protected b y special toes. which shall b e installed as shown on the drawings and as directed b y the engineer. The toe shall b e constructed simultaneously with the rest of the fill and shall consist of selected rock material varying in size between 150 m m and 750 m m . If shown on the drawings, a layer of synthetic-fibre filter material and a sand blanket shall be installed at the interface between the normal fill and the rock protection. Care shall b e taken not to damage or tear such material. The toe shall be constructed and compacted as described in clause 3209 for rock fill, but the following additional requirements shall be taken into consideration: The outer part of the toe shall consist of larger boulders properly bedded b y means of smaller fragments so as to form a stable interlocking surface. If placing with mechanical construction equipment does not achieve the required results, the equipment shall be supplemented b y manual labour to select. bar and place keystones in between the larger boulders until the correct placing is achieved and the rocks are firmly interlocked. No additional payment will b e made for the supply and installation of synthetic-fibre filter material and sand blankets.

(e)

Construction of high fills

The construction of high fills may require special techniques to prevent the development of excessive pore pressure and ensure the stability of such fills during and after construction. These may include. inter alia, the selection of better class material for use in the bottom layers of the fill, the construction of sand filter blankets and the strict control of moisture content during compaction. Where these measures are required. such fills shall be designated as high fills. which shall be constructed in accordance with the project specifications.

(i)

Wdening of Rlls

Where existing fills are to be widened. the existing fill slopes and the roadbed onto which the new fills are to be constructed, shall be cleared and grubbed, if so ordered by the engineer in writing. The clearing and grubbing shall be done in accordance with the provisions of section 1700. Subsequently the new roadbed shall be treated in accordance with the provisions of clause 3305. Where existing fills are required to be widened or where already constructed fills are required to be widened or flattened, it shall be done by way of bench construction as described in subclause 3307(d) in order to form a firm bond. During these operations there shall be close liaison between the engineer and the contractor. Benches of not more than 500 m m deep shall be cut into the existing fill. In the case of fills of less than 1 m in height, and in the upper metre of any fill, the benches shall not be deeper than the layer thickness prescribed for constructing the widening, depending on whether or not uncompacted fill material occurs in the side of the existing fill. The benches shall extend into the properly compacted portion of the original fill material to the satisfaction of the engineer.

The fines shall be uniformly distributed over the surface of the rock fill with stiff brooms, and watering, rolling and brooming shall continue until all areas deficient in fines have been satisfactorily corrected. All excess fines shall be removed from the surface of the rock fill.

3308 FINISHING THE SLOPES

(a)

Cut slopes

The slopes of cuttings shall be trimmed to neat lines and to a standard which. with proper care and workmanship, is generally attainable with proper care and workmanship in the type of material concerned. All loose rocks. stones and nests of loose material shall be removed. especially in solid-rock cuts. which must be completely free from such material. The final surface of side slopes shall have a slightly roughened surface which will be suitable for subsequent grassing or for establishing natural vegetation.

@)

Fill slopes

All suitable material from benches shall be used in the construction of the widened section of the fill. Unsuitable material shall be removed as instructed by the engineer. Benches shall be compacted together with the fill widening during the construction of the fill.
Material from benches used in fill will be paid for as "cct to fill". Spoil material from the benches will be paid for as specified in item 33.17. Where the existing fill consists of rock fill. the new section shall consist of rock fill, unless otherwise approved by the engineer. Where a rock fill is widened by adding soil or gravel material, the contractor shall obtain prior instructions from the engineer as to the type of subsoil drainage to be provided and other measures to be taken. Benching in rock fills shall be planned in consultation with the engineer.

Fill slopes shall be finished to neat lines with all loose rocks and uncompacted material removed. The degree of finish required shall depend on the nature of the material used for the fill slope but shall be as smooth as is consistent with the material involved and good workmanship. No individual boulders occurring in otherwise smaller sized material shall be allowed to project beyond the surface. All excess fill shall be removed immediately. In the case of rockfill. soft material shall be dumped over the sides of fills and worked into the interstices between the rock on the surface of the slope. Any soft material ordered by the engineer to be dumped over the sides of rock fills without any further shaping or trimming shall be classified as "cut to spoil", but if shaping and finishing have been ordered. the material shall be classified as "cut to fill", and all such material shall be measured for payment additional to fill. which is measured in accordance with the net specified dimensions of the road prism. The volume of such material shall be taken to be equal to 70% of the loose volume measured in the trucks.

An extra over payment for the widening of existing fills will apply as specified under item 33.16. Rock fills will not be required to be widened by less than 4.0 m. 1Vhere narrower widenings of rock fills are required. the construction thereof and payment therefor shall be made in accordance with the provisions of the project specifications.
For the subsoil drainage required by the engineer in the widening of fills, payment will be made in accordance with section 2100.

(c)

Median slopes and interchange areas

Median slopes shall be finished to the same level tolerances as specified in subclause 3310(a) for the top layers of fills. This tolerance shall apply to both the top layer of the fill and the final surface of the topsoil. The area between interchange ramps shall be finished to the same tolerance as that specified for median slopes. For the sides of fills steeper than 1 in 4. the provisions of subclauses 3308(b) and (d) will apply.

0)

Correcting rock fills that are deficient in fine

material

i f a rock fill does not comply with the requirements of subclause 3302(b) In respect of the fines content. additional approved material that passed through the 4,75 m m sieve shall be spread over the surface of the rock fill. The material shall then be well watered over short sections at a time, and rolled preferably with dynamic equipment as specified in subsubclauses 3304(b)(i) and (ii).

(d)

General

Except in solid rock. the tops and bottoms of all slopes, including the slopes of drainage ditches. shall be rounded as indicated on the drawings or as ordered by the engineer. Slopes at the junctions of cuts and fills shall be adjusted and so warped as to flow into one another or into

the natural ground surfaces without any noticeable break. When so directed by the engineer, adjustment to the slopes shall be made so as to avoid damage being done to standing trees and so as to harmonise with existing landscape features. The transition to such adjusted slopes shall be gradual. Cut and fill slopes shall be finished to a uniform appearance without any noticeable break which can be readily discerned from the road. The degree of finish required for all fill slopes and for cut slopes flatter than 1 in 4 shall be that normally obtainable by grader or handshovel operations. The slopes of cuts and fills which are designated for grassing shall, after finishing, be prepared for grass planting and/or for topsoil being placed for grass planting as specified in section 5800 of these specifications. All trimming of cut slopes shall be completed before any work on the subbase is commenced inside such cuttings. No extra over payments will apply to the finishing of slopes in restricted areas.

layer of the fill:

H ,,
,H ,

= =

* 25 m m * 33 mm.

(i)

Common fill

The horizontal measurement taken from the centre line of the road to the side of the fill, shall nowhere be more than 125 m m less or 250 m m more than the specified dimension when measured at any level. (ii) Rock fill

The horizontal measurement taken from the centre line of the road to the side of the fill, shall nowhere be more than 250 rnm less or 500 m m more than the specified dimension when measured at any level. (iii) Cut slopes

3309

PROTECTIONOF ROAD PRISMAND STRUCTURES

During construction, the road prism shall be kept welldrained and protected at all times as specified in clause 1217. All windrows shall be cut away after construction to prevent the concentrated flow of water on completed fill layers, but, where necessary, flat berms shall be constructed to prevent the undue erosion of fill slopes. All permanent drains shall be constructed as soon as possible, plus sufficient additional temporary drains as may be necessary to protect the road prism, and shall be maintained in a good working order. Ruts and potholes developing in the fills after completion shall be repaired, and damaged portions of the fills shall be reshaped and recompacted at the contractor's own cost. All cut and fill slopes shall be maintained by the contractor until the road has been certified as being finally completed. All erosion and flood damage to slopes shall be promptly repaired as specified in clauses 1217 and 1218. Side drains discharging water from cuts and all other drains shall be so constructed as will avoid damage to the fills by erosion. Proper precautionary and temporary measures shall be taken in all cases to ensure that the method or procedure by which the fills are constructed will not impose loads on structures, especially on uncompleted structures, which may damage or overstress such structures.

The cut slopes shall be finished to a standard generally attainable with proper care and workmanship, where the nature of the excavated material is borne in mind. Care shall also be taken not to undercut any slopes which would cause sections to have a steeper slope than specified. All loose material shall be removed.

3311

QUALITY OF MATERIALS AND WORKMANSHIP

Routine inspection and tests will be made by the engineer to determine whether the quality of materials and the workmanship comply with the requirementsof this section. Fills comply with the requirements of clause 3302 in cases where the results of at least 75% of in situ density tests on any lot are equal to or exceed the specified values and no single density is more than 5 percentage points below the specified value.

3312

MEASUREMENT AND PAYMENT

General directions (1) Determining the quantities

3310

CONSTRUCTION TOLERANCES

The work described in this section shall be constructed to the dimensional tolerances given below.

(a)

Levels

The level tolerances referred to in clauses 8205 and 8305 shall be as follows for fill, but shall apply only to the top

Upon completion of all work in connection with clearing and grubbing and working the roadbed, and where the classification of the excavations change, the contractor, at his own cost, shall take cross-sections at 20 m intervals so as to determine quantities, and shall submit the results so obtained to the engineer for approval. The engineer will take control measurements to determine the accuracy and adequacy of the cross-sections, and may instruct the contractor to correct any faulty work and to take such additional measurements and cross-sections as may be deemed necessary by him. Such cross-sections shall be taken before any cut or fill work is done. Where the contractor proceeds with such work before final approval of the cross-sections and before the contractor and the engineer have agreed on the cross-sections, the engineer's decision regarding the cross-sections to be used shall be final and binding on the contractor.

Where there is valid reasons for believing that the roadbed is subsiding as fills are being constructed, and after the roadbed work has been completed and cross-sectionshave been agreed on, the contractor may request that the fill quantities shall be adjusted accordingly. Such request shall be lodged'without delay, and the contractor shall submit the required supporting evidence to the engineer. Where the engineer Is satisfied that significant subsidence is occurring, he, together with the contractor, shall decide as to how the extent of the subsidence is to be determined, and, where no agreement can be reached, the decision of the engineer shall be final. Any adjustments of this nature shall be made only where the average subsidence exceeds 50 mm. (2) Material from commercial sources

(e)

Pioneer layer (as speclfied in subclause 3307(c))

.......

cubic metre (ma)

(1)

Sand filter blanket (as specified cubic metre (ma) In subclause 3307(f)) .

.... ...

If specified In the project specificatlons, material from commercial sources shall be used for the construction of fills. In such cases the items listed below shall be applicable, except that the tendered rates shall also include full compensation for all transport costs, and no overhaul shall be measured and paid for. (3) Work in restricted areas

The unit of measurement shall be the cubic metre of material measured in the compacted fill. For subitems (a), (b) and (c) the quantity measured shall be computed by the method of average end areas from levelled crosssections prepared from the ground line after clearlng and grubbing and the removal of topsoil and the completion of any preparatory roadbed treatment which may have been ordered by the engineer, but prlor to the construction of the fill, and the final specified or authorized fill crosssection superimposed thereon at 20 m intervals along the centre line of the road. All measurement shall be neat, and that part of the fill placed in excess of the authorized crosssection shown on the drawings or directed by the engineer, will not be paid for irrespective of the tolerances in workmanship allowed under the contract. Where the roadbed has subsided under the fills, the quantities shall be adjusted to make allowance for such subsidence, as set out in the note at the commencement of this clause. Measurement of fill shall distinguish between the alternative methods of processing and compacting.

Items 33.15 and 33.18 are applicable solely to work that has to be executed in a restricted area of which the wldth is less than 3,O m or the length is less than 150,O m.

The quantities for subitems (d) and (1) shall be calculated from the authorized dimensions. For subitem (e) the compacted volume of the material In the pioneer layer may be taken as equal to 70% of the loose volume of the material in the trucks as an alternative to taking cross-sections before and after construction.

kern
33.01

Cvt and b o r n to fill,

induding free-haul up to 0,5 krn: Material In compacted layer thicknesses of 200 mm and less: Compacted to 90% of modified AASHTO density Compacted to 93% of modified AASHTO density Eight roller passes compaction . . . .

(a)

(1)

.... ....

cubic metre (ma)

(ii) (iii)

cubic metre (ma)

Material excavated for the construction of open dralns, subsoil drains, culverts, bridge foundations and other structures, shall, if suitable and if so directed by the engineer, be used for the constructlon of fills, and payment shall be made under item 33.01 irrespective of any payment made previously for the excavation of such material. All such material shall be classified as soft excavation.

. . . . . . . ....

cubic metre (m3)

(b)

Material in compacted layer thicknesses exceeding 200 mm: Compacted to 90% of modified AASHTO density Compacted to 93% of modified AASHTO density Eight roller passes compaction . . . . . .

(1) (ii)

....
... .

cubic metre (m3)

cubic metre (ma)

The tendered rates shall include full compensation for procuring, furnishing and placing the material, including excavating as if in soft excavation, the cuttina of benches. for transporting the material for a free-haul distance of 0,5 km; for preparing, processing, shaping, watering, mixing, and compacting the materials to the densities or in the manner specified herein and for removing and disposing of up to 5% oversize material from the road after processing, including transport for a free-haul distance of 1,O km.

(iii)

. . . . .... . . ..... . ..

cubic metre (ma)

(c)

Rock fill (as specified in subclause 3209(c))

The tendered rates shall also include full compensation for the supply and installation of synthetic-fibre filter material where specified or indicated on the drawings.

cubic metre (m3) Payment shall distinguish between the various materials and methods of processing and compacting specified, as itemized above.

(d)

Toes for rock fill embankments (as specified in subclause 3307(h)) . . . . .

cubic metre (m3)

33.02 Sand fills (asdescribed in clause 3302,induding free-haul up to 0,5 km):

The extra over payment shall distinguish between intermediate, hard, boulder class A and boulder class B excavation.

(a)

Non-plastic sand with up to 20% passing through the 0,075 m m sieve, compacted to 100% of modified AASHTO density . . . . . . . . . . . . . . . . . . cubic metre (m') Non-plastic sand with more than 20% passing through the 0,075 m m sieve, compacted to 95% of modified AASHTO density . . . . . . . . . . . . . . . . . . cubic metre (rn3)

33.04 Cut to spoil, including freehaul up to 0,5 km. Material obtained from:
(a) (b) (c) (d) Soft excavation

............

cubic metre (m3) cubic metre (m3)

(b)

Intermediate excavation Hard excavation

......

. . . . . . . . . . . cubic metre (m3)

Boulder excavation class A . . . . . . . . . . . . . . . . . . cubic metre (m3) Boulder excavation class B . . . . . . . .

The unlt of measurement shall be the cubic metre of sand measured in fills as determined in item 33.01. but with the dlfference that no distinction will be made between different layer thicknesses in which the material is placed and compacted. The tendered rates shall include fuil compensation for procuring, placing and compacting the sand fills, as well as 0,5 k m free-haul.

(e)

cubic metre (m3)

Item

Unit

The unit of measurement shall b e the cubic metre of material measured in its original position in cut and computed b y the method of average end areas from levelled cross-sections taken along the ground line after clearing and grubbing and the removal of topsoil, if any, but prior to excavating the cut, with the final specified or authorized cross-section of the cut super-imposed thereon at intervals not exceeding 20 m along the centre line of the road. Measurement of boulder excavation class B shall be b y the volume of individual boulders being measured after removal, or, where this is considered to be impracticable, b y taking the in sltu voiume of boulder excavation to be equivalent to 50% of the loose volume in the hauling vehicles. Where measurement b y cross-sections is considered b y the engineer to be impracticable, cut to spoil may be measured in the hauling vehicles, b y taking the in situ volume of the material in the case of soils and gravel to b e the equivalent of 70% of the loose volume in the haul vehicles. and, in the case of boulder material, as equal to 50% of the loose volume in the haul vehicies. The tendered rates for cut to spoil shall include full compensation for excavating from the road prism and roadbed in the various classes of excavation. for loading, transporting the material for a free-haul distance of 0.5 km, off-loading and disposing of the material as specified, including shaping and levelling-off any piles of spoil material. This payment item will also apply to the removal of unsuitable roadbed material, provided that it is stable material, and that instruction in respect of its removal be given before the excavations reach the level of the roadbed material to be removed, all as described in subclause 3305 (3).

33.03 Extra over item 33.01

for excavating and breaking down material In:
(a) (b) (c) Intermediate excavation . . . . . . cubic metre (m')
-.

Hard excavation

...........

cubic metre (m3)

Boulder excavation class A . . . . . . . .

. . . . . . . . . .cubic
.........

metre (m3)

(d)

Boulder excavation class B . . . . . . . . .

cubic metre (m')

The unit of measurement shall be the cubic metre of material removed as specified. Measurement of items (a). (b) and (c) shall be in the original position in the cut or borrow pit.,and the quantity shall b e computed b y the method of average end areas from levelled cross-sections at intervals not evceeding 20 m measured along the centre line of the road in the case of cuts and at intervals not exceeding 10 m and parallel to one another in the case of borrow pits. before and after the removal of the materiai. Measurement of boulder excavation class B shall be b y the voiume of individual boulders being measured after removal, or. where this is considered to be impracticable. by taking the in situ volume of boulder excavation to be equivalent to 50% of the loose voiume in the hauling vehicies.

The tendered rates shall be paid as extra over the rates applying to soft excavation in item 33.01 and shall include full compensation for additional costs to excavate and break down the various classes of material. including the cost of all the necessary additional effort. plant. tools. materials, labour and supervision.

Except where the temporary storage of spoil material is ordered b y the engineer, the tendered rates shall also include fuil compensation for the temporary storage of spoil material. the later loading, transporting. off-loading and grading of the spoil material within the borrow areas, and for reinstating the storage site to its original condition.

Item

Unit
33.07 Fkmoval of unsuitable material (induding free-haul of 0.5 km): (a) In layer thicknesses of 200 m m and less: Stable material . . . . . . . . . . . . cubic metre (m3) Unstable material . . . . . . . . . . cubic metre (m3) In layer thicknesses exceeding 200 mm: Stable material . . . . . . . . . . . . cubic metre (m3) Unstable material . . . . . . . . . . cubic metre (m3)

33.05 Overbreak in hard and boulder dass A excaration . . square metre (m7)

The unit of measurement shall be the square metre of exposed roadbed in completed hard and boulder class A cuttings.

(i) The tendered rate for overbreak in hard and boulder class A cuttings shall include full compensation for unavoidable overbreak which may occur during excavation and for the cost of backfilling with suitable rock material and compacting it to the lines and levels specified for the excavation. This item shall not apply when item 33.12 is applied in respect of the same area. (ii) (b)

(i) (ii)

Item
33.06 Variations i n the number of roller passes (applicable to subsubitems 33.01 (a)lii) and 33.01 @)(iii) and item 33.1 1): (a) (b) (c) (d) (e) (f)

Unit
The unit of measurement shall be the cubic metre of unsuitable material removed by the contractor in accordance with the engineer's instructions. and it shall be the in situ volume of the material calculated in accordance with its authorized dimensions.

Vibratory rollers . . . square-metre-pass (m'-pass) Oscillatory rollers Grid rollers

square-metre-pass (m7-pass) square-metre-pass (m7-pass) square-metre-pass (m7-pass) square-metre-pass (m7-pass)

Subsubitems 33.07(a)(i) and (b)(i) shall apply only in circumstances as specified in subclause 3305(a) and item 33 04.

...... ...

Tamping rollers Impact rollers

For the purposes of this clause the definitions of stable and unstable material shall be as set out in subclause 3305(a).

....

Pneumatic-tyred rollers . . . . . . . . . square-metre-pass (m7-pass)

The unit of measurement shall be the square-metre coverage, and shall be computed by multiplying the number of square metres to which the changed pass efforts apply by the increased or decreased number of roller passes. In the case of item 33.01. it will be computed on the basis of a 200 m m layer thickness.

The tendered rates shall include full compensation for the removal of all classes of unsuitable material and shall distinguish only between stable and unstable material and layer thicknesses of less than and exceeding 200 mm. It will also include compensation for free-haul of 0.5 km.

Item

Unit

33.08 Wdening of cuts (extra

over items 33.01,

33.02and 33.04):
Where a change in the compaction effort is requested, the contractor will be compensated at the tendered rates for the above items in respect of the increased number of square-metre roller passes of each type of roller required over and above that specified in the relevant standard effort. His compensation will be decreased sirnultaneously, at the applicable rates. by the number of square-metre roller passes of each type of roller which is either decreased or completely left out. (a) (b) In hard material . . . . . . . . . . . . cubic metre (m3) In boulder material class A or class B . . . . . . . . . . cubic metre (m3) In all other materials . . . . . . . . cubic metre (m')

(c)

The tendered rate for each additional square metre-pass ordered by the engineer over and above the specified number of passes, shall include full compensation for all supervision, labour, plant, equipment, fuel. materials. work and incidentals necessary for completing the work. The same rates shall be accepted by the contractor during computation of a decrease in his compensation where the number of roller passes for each specific type of roller is decreased.

The unit of measurement shall be the cubic metre of material excavated during the widening of cuts where they are more than 2.5 m deep (measured vertically from the top of the cut to the shoulder breakpoint). and where the cut is widened by less than 4 m. Measurement of the material shall be in the original position in the cut. and the quantity shall be compvted by the method of average end areas from levelled crosssections at intervals not exceeding 20 m measured along the centre line of the road before and after removal of the material.

The tendered rates for widening the cuts shall be paid extra over the rates tendered for items 33.01. 33.02 and 33.04 and shall include full compensation for the additional costs involved (over and above those for excavating new cuttings) for excavating material during the widening of a cut where the cut exceeds 2,5 m in depth and is widened by less than 4 m.

(c) (d) (e) (f)

Grid roller

. . . . . . . . . . . . . . . square metre

(m') (m2) (rn2)

Tamping roller Impact roller

. . . . . . . . . . . square metre

. . . . . . . . . . . . . square metre

Pneumatic-tyred roller . . . . . . . . .

. . . . . . . . . . square metre (m2)

ltem
33.09 Material bladed to windrow

Unit

...

cubic metre (m3)

The unit of measurement in respect of material temporarily bladed to windrow as specified in subclause 3305(c) shall be the cubic metre of material to be bladed off. measured in the original position before blading off, in accordance with the method of average end areas. The tendered rate shall include full compensation for the temporary removal of such material and its later replacement, and for all clearing work which may be necessary afler replacement of the material. Only material bladed to windrow on the instructions of the engineer for exposing the underlying roadbed material for treatment will be measured and paid for as described above.

The unit of measurement shall be the sauare metre of roadbed compacted in accordance with thk provisions of subclause 3305(b). The quantity will be computed in accordance with the authorized dimensions of the area to be treated. The tendered rates shall include full compensation for shaping, providing the rollers, keeping the rollers ready for use when soil-moisture conditions are favourable as specified, and compacting the roadbed by three roller passes.

33.12 In situ treatment of roadbed:

(a)

In situ treatment by ripping . . . . . . . . . . . . . . . . . . cubic metre (my) In situ treatment by blasting . . . . . . . . .

ltem
33.10 Roadbed preparation and the compaction of material:
(a) Compaction to 90% of modified AASHTO density Compaction to 93% of modified AASHTO density

Unit

(b)

. . . . . . . . . cubic metre (m')

...

cubic metre (m3)

The unit of measurement shall be the cubic metre of in situ material treated in situ as specified in subclause 3305(d). The quantity shall be calculated from the authorized dimensions of the in situ treatment. The tendered rates shall include full compensation for ripping or blasting, shaping. scarifying, sizing. knapping, rolling. mixing of in situ and imported material if required, and preparing and compacting the material as specified. Payment shall distinguish between in situ treatment by ripping and in situ treatment by blasting. Surplus material shall be measured and paid for as in item 33.01 if placed in fill and item 33.04(a) if taken to spoil. and no payment shall apply under item 33.03.

(b)

....

cubic metre (m')

(c)

Compaction of sand roadbed to 95% of modified AASHTO density . . . . . . . . . . . . . . . .

. . cubic metre (m')

(d)

Compaction of sand roadbed to 100% of modified AASHTO density . . . . . . . . . . . cubic metre (m3)

The unit of measurement shall be the cubic metre of roadbed material prepared and compacted as specified in subclause 3305(c). The quantity shall be computed in accordance with the authorized dimensions of the completed layers.

Item
33.13 F i n i s h i n g d cut and fill slopes, medians and interchange areas:

Unit

(a) The tendered rates shall include full compensation for shaping, scarifying, mixing of in situ and imported material if required, and preparing and compacting the materia! as specified. (b) (c)

Cut slopes . . . . . . . . . . . . . . square metre (m2) Fill slopes . . . . . . . . . . . . . . . square metre (m') Medians and interchange areas . . . . . . . . . . . . . . . . . . square metre (m2)

Unit

33.11 Three roller passes compaction:

(a) (b) Vibratory roller . . . . . . . . . . . square metre (m7) Oscillatory roller . . . . . . . . . . square metre (m')

The unit of measurement shall be the square metre of cut or fill slopes or medians and interchange areas finished off as specified. The areas shall be measured from levelled cross-sections taken at 20 m intewals measured along the centre line of the road and shall be the sloping area between the shoulder breakpoint and the toe of the fill in the case of fill slopes. and the sloping area between the top of the cut slope and the toe in the case of cut slopes.

The medians shall include the full width of the median between the inner edges of the shoulders. The area of median areas which are to be finished off shall be determined in accordance with the drawings. The area of the side slopes and channel bottoms of any open channels that are not classified as open drains in terms of clause 2102, shall be included in item 33.13. All areas required to be covered by cast in sit11or precast concrete linings, kerbing. channelling or shutes. as specified and paid for under section 2300. shall not be measured and paid for under item 33.13. All cut and fill slopes and channel bottoms of open drains resulting from open-drain excavations as defined in clause 2102, as well as the floors and sides of existing open drains that are trimmed during the clearing and shaping of existing open drains, that are measured and paid for under items 21.01 and 21.02. shall not be measured and paid for under item 33.13. The tendered rates for finishing cut or fill slopes. medians and interchange areas shall include full compensation for all labour, plant, materials and other incidentals and work required for finishing as specified, including the loading. transporting and disposal of any material brought down during the finishing operations.

dimensions and the layer thickness to be excavated. The tendered rate shall include full compensation for the additional work for making excavations in restricted areas. This item does not apply to the widening of cuts.

ltern 33.16 Wtdening of fills as specified in subdause 3 3 0 7 ( i )extra over: (a) (b) (c) (d) Item 33.01(a) . . . . Item 33.01(b) ltern 33.01 (c) . ltem 33.02 .

. . . . . . . . . . cubic metre (m3)

. . . . . . . . . . . . . cubic metre (m3) . . . . . . . . . . . . . cubic metre (m3)

. . . . . . . . . . . . . . . cubic metre (m3)

The unit of measurement shall be a cubic metre of material placed in the widening of existing fills. The tendered rates shall be paid extra over applicable to normal full-width construction. include full compensation for all additional equipment. labour. supervision as well as any costs for the widening of fills, including the benches. the rates and shall transport, additional cutting of

Item 33.14 Extra over item 33.01 for excavating material from me pavements and fills of existing roads: (a) (b) Non-cemented material . . . Cemented material

Unit

The tendered rates shall also include full compensation for widening fills in restricted areas.

Item

lhlit

. . . cubic me!re (m3) . cubic metre

( 9 7 ' )

....

. . .

33.17 Exba over item 33.04 fof spoiling material excavated from benches wnshcted for widening existing fills . . . . . .

. cubic metre (my)

The unit of measurement shall be a cubic metre of material removed from the pavements and fills of existing roads. and the quantity will be based on the authorized dimensions and layer thickness to be excavated. The material shall be classified as specified in subclause 3303 (c). The tendered rate will be paid extra over the rates applicable to soft excavation under item 33.01 and shall include full compensation for all additional costs for making excavations in existing pavements in accordance with the provisions of section 3800.

The unit of measurement shall be a cubic metre of material excavated from benches in the widening of existing fills and which is spoiled on the instructions of the engineer. The quantity shall be calculated in accordance with the authorized dimensions of the benches. The tendered rate shall be paid extra over the rates applicable to item 33.04, and shall include full compensation for all additional costs for spoiling the material. including amongst others all additional work. construction equipment. labour and supervision, irrespective of the size and depth of the benches and the class of material. No extra-over payment will be made for work in restricted areas.

Item 33.15 Extraover item 33.14 for exmvating in pavements and fills of existing mads in resbicted areas in: (a) (b) Non-cemented material Cemented material

Unit

. . . . . . cubic metre (my)

. . . . . . . . cubic metre (m')

33.18 Extra over items 33.10.33.1 1 and 33.12 for preparing andlor treating the roadbed and compacting material in restricted areas: (a) ltem 33.10 for roadbed preparation and the compaction of material . . . . . . . . . . . . . . . cubic metre (m3)

The unit of measurement shall be a cubic metre of material removed from existing pavements and fills in restricted areas, and the quantity will be based on the authorized

(b)

hem 33.1 1 for three roller . . . . square metre (m2) passes compaction . .

..

(c)

ttem 33.12 for in situ treatment of roadbed . . . . . . . . . . .

....

cubic metre (m3)

The following payment items, where they relate to work under this section, will be listed in the schedule of quantities.

The unit of measurement shall be the cubic metre or square metre of prepared and/or treated roadbed or compacted material, depending on the type of work required, as indicated for the various items where such work is required to be done in restricted areas. The quantities shall be calculated as specified under items 33.10, 33.11 or 33.12, whichever may be the case. The tendered rate shall include full compensation for the additional cost of executing the work in restricted areas. No distinction in payment will be made between the various density requirements, the various types of rollers, and between ripping and blasting.

Item 16.01 & 16.02 ltem 31.01 ltem 32.04 ltern 32.06 ltem 35.01 ltem 35.02 ltern 35.03 ltern 35.04

Overhaul (extra over items 33.01, 33.02, 33.04 and 33.07) Excess overburden at borrow pits Removal of oversize pavement material Stockpiling of material. Chemical stabilization Chemical stabilizing agent Mechanical modification Provision and application of water for curing Curing by covering with the subsequent layer

Unit

33.19 Exb-a over subiirn 33.01(c) for cmmcling rock fills that are deficient in fine material . . . . . cubic metre (m3)

ltem 35.05 The unit of measurement shall be the cubic metre of corrected rock fill. The tendered rate shall include full compensation for procuring and furnishing approved material that passed through the 4,75 m m sieve, including all transport, for placing and spreading, watering and rolling, for removing all excess fines from the surface of the rock fill, and for all other Incidentals necessary for completing the work as specified. ltem 35.06 ltern 35.07 ltern 35.08 Item 35.09

Curing with a bituminous membrane Bituminous stabilization Bituminous stabilizing agent Additive for bituminous stabilization.

SERIES 3000 :

EARTHWOWS AND PAVEMENT LAYERS OF GRAVEL OR CRUSHED STONE

SECTION 3400 : PAVEMENT LAVERS OF GRAVEL MATERIAL

Materials from existing pavements will be classified for the purposes of this section as non-cemented material or cemented material (as specified in clause 3803), or as material mixed with bituminous surfacing material. For payment purposes material mixed with bituminous surfacing material will be defined as material containing more than 10% of surfacing material b y volume. Mixtures of surfacing and other material used in pavement layers shall not contain more than 30% of such surfacing material by volume, unless otherwise specified. The material shall not contain fragments of surfacing material exceeding 37.5 m m in size, and any such larger fragments shall be removed by hand at the expense of the contractor.

3401 3402 3403 3404 3405 3406 3407

SCOPE MATERIALS CONSTRUCTION PROTECTION AND MAINTENANCE CONSTRUCTION TOLERANCES QUALITY OF MATERIALS AND WORKMANSHIP MEASUREMENT AND PAYMENT

@)

Compaction requirements

3401

SCOPE

The minimum in situ dry density of gravel material shall be as specified hereinafter for the respective layers in terms of a percentage of modified AASHTO density. Selected layer (see note 1 below) Lower selected layer: 93% or 95%. as required Sand : loo'%
93% or 95%. as required.

This section covers the construction of selected layers. subbases, bases and shoulders with natural gravel and/or crushed or partially crushed material. and also gravel wearing courses. Crushed-stone base is specified in section 3600. This section also covers the rehabilitation of existing pavements layers over part of or over the full road width as well as the widening of existing pavement layers. It also covers the addition of material to existing layers as specified in subsubclause 3207(b)(iii).

Upper selected layer :

Sand : 100% Subbase 95% or 97%. as required for material not cher?ically stabilized. 95% or 96%. as required, for chemically stabilized material. 98% or 100%. as required, for material not chemically stabilized. 97% or 98%. as required. for chemically stabilized material. 93% or 95%. as required.

Base

(a)

General

Gravel material shall be obtained from approved sources in borrow areas. cuts or existing pavement layers. Tests have been made on potential borrow pits, cuts and on the roadbed along the centre line of the route envisaged. and the results are reflected on the drawings. which also show the use for which the material could possibly be suitable. The type of material prescribed and used for the construction of each pavement layer shall comply with the requirements set out in tables 340211. 340212. 340213 and 340214, unless otherwise specified in the project specifications. Notwithstanding the indications on the drawings regarding the possible use of the sources of natural material tested. it shall be incumbent on the contractor to use only material which complies with the prescribed requirements for use in the relevant pavement layers. Where natural gravel does not fully comply with the requirements in respect of maximum size after having been broken down as determined in clause 3204. oversize material shall be removed as specified in clause 3210. Gravel material for pavement layers may also be material recovered from existing pavement layers. or imported material approved by the engineer. Crushed stone reclaimed from existing pavements and processed as gravel material will be paid for as gravel material and not as crushed stone.

Shoulder & wearing course:

In restricted areas pavement layers constructed with gravel material shall comply with the density requirements as specified in the project specifications.

(c)

Soluble salinily

When specified in the project specifications. the soluble salinity of base material shall be subject to the requirements of subclause 3602(b).

Notes:

The requirements of subclause 3302!b) shall apply (1) to sand used for the construction of selected layers.

In the case of very coarse material. the in situ dry (2) density of which cannot be easily determined. the engineer may order that selected layers be compacted by eight roller passes as described in subclause 3304(b). in which case no definite in situ dry density shall apply.

Table 340211

REQUIREMENTS FOR TYPES G 4 T O G6 MATERIALS

TYPE OF MATERIAL PROPERTY G4 Natural gravel, or natural gravel and boulders which may require crushing. May contain approved additional fines not obtained from parent rock. Added fines shall have a liquid limit (LL) not exceeding 25 and a plasticity index (PI) not exceeding 6. (i) (il) Uncruslied material : 53 mm Crushed material : 37.5 mm or 26.5 mm (unless otherwise specified In the project specifications) G5 Natural gravel, or natural gravel and boulders whlch may require crushing, or crushed rock. May conlaln approved natural fines not obtalned from parent rock. G6 Natural gravel, or natural gravel and boulders whlch may require crushing, or crushed rock. May conlaln approved natural fines not obtalned from parent rock.

DESCRIPTION OF MATERIAL

ADDITIONAL FINES

NOMINAL MAXIMUM SIZE

(i) (li)

Uncrushed material : 63 m m Crushed rnaterial : 53 mm before compaction (unless otherwise specified In the prolect specifications)

(I)

Uncrushed material:

Two thlrds of the compacted layer thickness (unless otherwise specified In the project speclficatlons) (ii) Crushed material:

83 mm before compaction (unless otherwise specified in the project specifications) FLAKiNESS INDEX Flakiness Index, determined in accordance with TMHl method 83, shall not exceed 35 on each of the -26.5 + 19 mm fraction and the -19 + 13,2 mm fraction. Alluvial and colluvial gravels shall be crushed so that at least 50% by mass of the fractions retained on each standard sieve 4,75 mm and larger shall have at least one fractured face. Percentage passing through sieve by mass GRADING Crushed rnaterial Nominal aperture size of sieve (mm) Uncrushed material All alluvial and colluvlal material shall be crushed so that at least 50% by mass of the fraction retained on the 4,75 mm sieve shall have at least one fractured face.

FRACTURED FACES

Nominal maximum size 37.5 mm

Nominal maximum size 26,5 mm

53,O 37.5 26,5 19,O 13,2 4,75 2,OO 0,425 0,075 GRADING MODULUS (GM) 1W 84 - 94 71 - 84 59 - 75 36 - 53 23 - 40 11 - 2 4 4 - 12 100 85

100 65

The percentage by mass passing the 2.00 mm sleve shall not be less than 20% nor more than 70%.

- I00

- 95 - 60

60 - 90

71 - 84 42 30 - 65 20 - 50 10 - 30 5-15 2,s t GM 2 1.5 2,6 a GM r 1,2 PI shall not exceed 12 or a value equal l o 2 times the GM plus 10, whlchever is the higher value. LS shall not excsed 5%. In the case of calcrete the PI shall not exceed 15 provlded the LS does not exceed 6% and (% passing 0,425 mm sieve) LS s 320.

27 - 45 13 - 27 5 - 12

(a)

All met&

except cakrrte:

(a)

All msterlals ex+

dcmte:

ATTEREERG LIMITS FOR NATURAL MATERIAL (-0,425 mm FRACTION)

LL shall not exceed 25. Pi shall not exceed 6. Linear shrinkage (LS) shall not exceed 3%.

LL shall not exceed 30. PI shall not exceed 10. LS shall not exceed 5%.

(b) chkfete: LL s 25 PI S 8 (% passing 0,425 mm sieve) LS s 170

The material shall comply with the requirements in table 3402/3.

(b) Calacte: LL s 30 PI s 15 LS s 6 (% passing 0,425 mm sieve) LS

s 320
Mudrock shall have a wet 10% FACT value of not less than 80 kN, and a weVdry Venter test class of I or 11.

DURABlLlN SOLUBLE SALTS STRENGTH (CBR) SWELL (MAXIMUM) COMPACTION REQUIREMENTS

Mudrock shall have a wet 10% FACT value of not less than 90 kN, and a weVdry Venter test class of I or II.

The materials shall comply with the requirements of clause 3602. CBR at 98% of modified AASHTO density shall not be less than 60%. Swell at 100% of modified AASHTO density shall not exceed 0.2% for all materials except calcrete for which the swell shall not exceed 0.5%. 96% or 100% (as specified) of modified AASHTO density for natural materials CBR at 95% of modified AASHTO density shall not be less than 45%. Swell at 100% of modified AASHTO density shall not exceed 0.5%. CBR at 95% of modified AASHTO density shall not be lass than 25%. Swell at 100% of modified AASHTO density shall not exceed 1,0%.

The density requlrements of the layer In whlch the materlal Is used, shall be applicable. (See subclause 3402(b).) In restrlcted areas the In sltu dry density of gravel materlal shall comply with the requlrements In the project specifications.

Table 340212 REQUIREMENTS FOR TYPES G7 T O G9 MATERIALS

TYPE OF MATERIAL
PROPERN G7 Natural material (soil, sand or gravel) DESCRIPTION OF MATERIAL ADDITIONAL FINES NOMINAL MAXIMUM SIZE (i) (ii) GRADING MODULUS (GM) ATTERBERG LIMITS FOR NATURAL MATERIAL (-0,425 mm FRACTION) Not applicable Uncrushed material : Two thirds of the compacted layer thickness Crushed material : 75 mm 2.7 n GM a 0,75 The Pi shall not exceed 12 or a value equal to 3 times the GM plus 10, whichever is the higher value. In the case of calcrete the PI shall not exceed 17 provided that the LS does not exceed 7% and (% passing 0.425 mm sieve) LS s 320. Mudrock shall have a wet 10% FACT value of not less than 60 kN, and a wetldry Venter test class of I, II or Ill Not apptlcable Two thirds of the compacled layer thickness Nol applicable Two thirds of the compacted layer thickness G8 Natural material (soil, sand or gravel) G9 Natural material (soil, sand or gravel)

2,7 2 GM r 0,75 The PI shall not exceed 12 or a value equal to 3 times the GM plus 10, whichever Is the higher value. In the case of calcrete the Pi shall not exceed 17 provided that the LS does not exceed 7%. Mudrock shall have a wet 10% FACT value of not less than 60 kN, and a weVdry Venter test class of I. II or Ill

2,7 5: GM 5: 0,75 The PI shall not exceed 12 or a value equal to 3 times the GM plus 10, whichever is the higher value. In the case of calcrete the PI shalt not exceed 17 provided that the LS does not exceed 7%. Mudrock shall have a wet 10% FACT value of not less than 60 kN, and a weVdry Venter test class of I, II or Ill

DURABILITY

SOLUBLE SALTS STRENGTH (CBR) SWELL (MAXIMUM) COMPACTION REQUIREMENTS

The materials shall comply with the requirements of clause 3602. CBR at 93% of modified AASHTO density shall be at least 15% Swell at 100% of modified AASHTO density shall not exceed 1.5% CBR at 93% of modified AASHTO density shall be at least 10% Swell at 100% of modified AASHTO density shall not exceed 1,5% CBR at 93% of modified AASHTO density shall be at lead 7% Swell at 1W% of modified AASHTO density shall not exceed 1,5%

The density requirements of the layer in which the material is used, shall be applicable. (See subclause 3402(b).) In restricled areas the In silu dry density of gravel material shall comply with the requirements in the prolect specifications.

Table 3402/3 DURABILITY REQUIREMENTS FOR G4 MATERIAL

GROUP Basic crystalline rock

MEMBERS OF GROUP Basalt Dolerite Gabbro Gneiss Granite Cherl Hornfels Quartzite Arkose Conglomerate Sandstone Siltstone Mudrock Phyllite Shale etc Dolomite Limestone Marble Greywacke Tillite Calcrete Ferricrete Silcrete

DURABILITY MILL INDEX (MAXIMUM) 125

%PASSING 0.425 mm SINE AFTEA THE DUFlABlLlTY MlLL TEST (MAXIMUM) 35

Acid crystalline rock High sil~ca rock

420 420 (clay mineral kaolin) 125

35 35

Sandstone

35 (increase from original not more than 15%)

Mudrock

125

35

Carbonate rock

not applicable

no! applicable

Diamictites Pedogenic material

125 480

35

40

Table 340214 REQUIREMENTS FOR GRAVEL WEARING COURSE

PARAMETER TYPE t Maximum size, mm Ovenlze index ( I . ) (maximum). % Shrlnkage product (SJ 37.5
6

LIMIT TYPE 2 37.5 0 t 00 - 240

100 - 365 (maximum of 240 preferable) 16 - 3 4

Gradlng coefficient (GJ CBR at a 95% modified AASHTO Compaction (soaked value) (minlmum), % I , S ,

16 - 34

15

z 15

Oversize index (per cent retained on 37,s mm sleve) Llnear shrinkage x (per cent passing 0,425 mm sieve)

GJ = (Per cent passlng 26.5 mm - per cent passing 2,O mm) x per cent passing 4.75 mm/100

Note: All the parameters In table 340214 are defined in TRH 20

Table 3402/5 REQUIREMENTS FOR CHEMICALLY STABILIZED PAVEMENT LAYERS

CRiTERlA Material before treatment Atterberg limlts after treatment Design strength (MPa) (Laboratory unconfined strength) (a) at 100% of modified AASHTO density

Cl At least G2 quality Si~ghtiy plastic

C2 At least G4 quallty Slightly plastic

C3 At least G6 quality PI shall not exceed 6

C4

minimum : 6 maximum : 12 minimum : 4 maximum : 6

minimum : 3 maxlmum : 6 minimum : 2 maximum : 4

minimum : 1.5 maximum : 3 minimum : 1 maximum : 2 Mlnimum : 250

minimum : 0.75 maximum : t,5 minimum : 0.5 maximum : 1 Minimum : 200

(b)

al 97% of modified AASHTO density

lndlrect tensile strength at 100% of modified AASHTO density (kPa) Durability : Fines lost Wet-dry Freeze-thaw

All characteristics, including amongst others the carbonated values wlth regard to durability, shall comply with the requirements in the project specif~cations.

(a)

Requirementsapplying prior to me construction of the layer

Pavement layers shall be constructed only where the underlying layer meets all the specified requirements and has been approved by the engineer. Before the construction of any pavement layer, and also before any material for a pavement layer is dumped on the road. the contractor shall check the underlying layer to establish whether there is any damage, wet spots or other defects. which shall be rectified in accordance with the instructions of the engineer before the next layer is constructed. Where a layer is constructed on the floor of a pavement excavation, ie, where the underlying layer has not been reworked or reconstructed. the floor of the excavation shall first be watered and rolled if directed by the engineer. The contractor shall base his tender price on 5 roller passes with rollers specified in clause 3304. The engineer may increase or decrease the number of roller passes or order the use of other rollers. Where the in situ material is classified as being suitable for a selected layer, it shall be treated as specified in subclause 3305(c) and paid for under item 33.10 in section 3400 of the schedule of quantities. and not under item 34.01.

Where a base is to be constructed from crushed stone. the shoulders shall first be constructed and then neatly cut to the required line to provide lateral support for the crushed stone. Care shall be taken not to pollute the base material with the shoulder material. In the case of asphalt bases, the shoulders may be constructed after completion of the base. Shoulder material shall be spread, broken down. watered, processed and compacted in accordance with the specifications. Work shall be so constructed that the road will be adequately drained at all times by means of temporary drainage pipes passing through the shoulders. The contractor shall not start constructing the final bituminous surfacing of any part of the road before he has completed the shoulders of such section and the engineer has approved it.

(c)

Crushing and screening

Where pavement material cannot be suitably broken down to the required size in excavation and during processing on the road. the engineer may prescribe that the material be crushed and screened or crushed only. all as specified in section 3200.

(d) Stabilization @)
Placing and compacting
When specified or required by the engineer. pavement layers shall be stabilized as specified in section 3500.

The material for a pavement layer shall be placed. spread. broken down, watered if necessary and mixed. and oversize material shall be removed and the layer compacted, all in accordance with the requirements of section 3200. The following additional requirements in regard to placement and compaction shall apply to specific pavement layers:

(e) Classification of layers for payment purposes

Payment for pavement layers constructed from gravel material. shall distinguish between layers constructed with material from borrow pits, cuts or existing pavement layers, and in situ recompacted layers with or without the use of additional material. Layers constructed from crushed-stone material recovered from existing crushed-stone pavement layers shall be placed and paid for as gravel material. unless otherwise determined by the engineer. Where the engineer determines, in writing. that the material shall be processed and placed as crushed stone, section 3600 shall apply in respect of the placing of and payment for the material.

(i) Gravel base

Coarse gravel containing non-plastic or slightly plastic soil fines and used in the construction of the gravel base will usually require slushing and rolling in addition to the compaction specified in clause 3208, in order to obtain a firm, well-knlt surface. If so directed by the engineer. the base, after being processed and compacted as specified above, shall be well watered by the contractor over short sections at a time, slushed and rolled with compactors and/or heavy flatwheel rollers of a mass of not less than 10 tons each. Watering and rolling shall continue over a section until all excess fines have been brought to the surface of the layer. Such excess fines shall be uniformly spread over the entire surface of the layer by means of stiff brooms, and watering, rolling and broorning shall continue until all areas deficient in fines have been suitably corrected. All excess fines shall finally be removed from the surface of the layer.

3404

PROTECTlON AND MAINTENANCE

The contractor shall protect and maintain the completed pavement layers in accordance with the provisions of clause 1217. Protection includes protection against rain and flood water and against any undue wear and tear of. or damage to unsealed layers by construction or other traffic. In addition, payment may be withheld at the sole discretion of the engineer for any pavement layers on a particular section of the road. until the trimming of the sides of cuts and fills. the construction of side drains. including subsurface drainage where specified through cuttings. the installation of culverts other than lowheight culverts, etc, have all been completed for that section.

(ii)

Shoulders

Where the shoulders are to be constructed from the same material as the base, they shall be constructed simultaneously with the base.

Where paved side drains are specified and the geonletric shape of such drains do not permit the completion thereof before the construction of the subbase or subsequent layers a temporary profile will be permitted for the side drain provided that such profile shall effect positive drainage of the surface water with no water allowed to pond on and/or against structural layers of the pavement. Maintenance shall include, inter alia, the immediate repair of any damage or defects that may occur, excluding the normal wear and tear of bases and wearing courses. and shall be repeated until the end of the maintenance period.

Use the following formula for other lengths

3405

CONSTRUCTION TOLERANCES

The average width of the layer shall not be less than the specified width, and nowhere shall the outer edge deviate by more than the following from the edge lines shown on the drawings: Selected layer . . . . . . . . . . . . . . . . . . . . . . . . . . 80 m m Subbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75mm Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 0 m m Shoulders and wearing course . . . . . . . . . . . . . .75 m m

The completed pavement layers shall comply with the construction tolerances given below. The values specified below apply to a layer thickness of 150 m m or more. For layers with a thickness less than 150 mm, more stringent values shall apply as specified in the project specifications.

(e) (a)

Cross-section

Level

The level tolerances referred to in clauses 8205 and 8305 shall be as follows:

When tested with a 3 m straight-edge laid at right angles to the road centre line, the surface shall not deviate from the bottom of the straight-edge by more than 6 mm. At any cross-section the difference in level between any two points shall not vary from their difference in level computed from the cross-sections shown on the drawings by more than 15 mm.

Selected layer Subbase Base Shoulders and wearing course

25 m m 20 m m 15mm

33 rnm 25 mrn 20rnm 25 m m

(f)

Surface regularity

@)

Layer thicknesses

When testing the base with a rolling straight-edge as described in subclause 81 11(c), the number of surface irregularities shall not exceed those given below: (i) Average number of irregularities per 100 m equal to or exceeding 5 m m when taken over 300 m - 600 m lengths . . . . . . . . . . . . . . . 4 Number of irregularities equal to or (ii) exceeding 5 m m when taken over 100 m sections

The thickness tolerances referred to in clauses 8205 and 8305 shall be as follows:

Selected layer Subbase Base Shoulders and wearing course

30 m m 21 m m 21 m m

40 m m 27rnrn 27mm 30 m m

10 m m 5mm 5rnrn -0 rnrn

...

The maximum value of any individual irregularity measured with the rolling straight-edge or a 3 m straight-edge laid parallel to the road centre line shall not exceed 10 mm.

(c)

Grade

(g)

Construction tolerances for rehabilitation work

Deviations from the specified longitudinal grade shall not exceed the following in respect of the specified grades on the completed base:

of Length (1) section under review (m)

Maximum deviation (g) of specified slope (%)

The construction tolerances of clause 3405 shall be applicable to rehabilitation work, except that where a gravel layer is placed on top of an existing layer without it being required that the existing layer be trimmed first to prescribed levels, the thickness tolerances of subclause 3405(b) shall not apply.

3406

QUAUTY OF MATERIALS AND WORKMANSHIP

The engineer will do routine inspections and conduct routine tests to determine whether the quality of material and workmanship provided comply with the requirements of this section.

The test results and measurements will be assessed in accordance with the provisions of sections 8200 or 8300 according to which section has been designated in the project specifications as being appropriate.

(f)

Gravel base (chemically stabilized material) compacted to: 97% of modified AASHTO density (specify compacted layer thickness) . . . . . . . . . . . cubic metre (ma) 98% of modified AASHTO density (specify compacted layer thickness) . . . . . . . . . . . cubic metre (m3) Gravel shoulders compacted to: 93% of modified AASHTO density (specify compacted layer thickness) . . . . . . . . . . . cubic metre (ma) 95% of modlfied AASHTO density (specify compacted layer thickness) . . . . . . . . . . . cubic metre (m3) Gravel wearing course compacted to: 93% of modified AASHTO density (specify compacted layer thickness) . . . . . . . . . . . cubic metre (m3) 95% of modified AASHTO density (specify compacted layer thickness) . . . . . . . . . . . cubic metre (mJ)

(i)

3407 MEASUREMENT AND PAYMENT

(ii) Items 34.08, 34.09 and 34.13 are applicable solely to work that has to be executed in a restricted area of which the width is less than 3,O m or the length is less than 150,O m. Item 34.01 Pavement layers constructed from gravel taken from cut or bonow, induding free-haul up to 1,O km: (a) Gravel selected layer compacted to: 93% of modified AASHTO density (specify compacted layer thickness) . . . . . . . . . . . . cubic metre (m3) 95% of modified AASHTO density (specify compacted layer thickness) . . . . . . . . . . . cubic metre (m3) Sand selected layer compacted to 100% of modified AASHTO density (fraction sand < 0,075 mm less than 20%) (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) Gravel subbase (unstabilized gravel) compacted to: 95% of modified AASHTO density (specify compacted layer thickness) . . . . . . . . . 97% of modified AASHTO density (specify compacted layer thickness) . . . . . . . . Unit

(g) (i)

(ii)

(h)

(i)

(i)

(ii)

(ii)

(b)

The unit of measurement shall be the cubic metre of compacted pavement layer, and the quantity shall be calculated from the authorized dimensions of the completed layer.

(c)

(i)

. . . cubic metre (m3) . . . cubic metre (m3)

(ii)

The tendered rates shall include full compensation for procuring, as if from soft excavation or pits, breaking down, placing and compacting the material, including transporting the material for a distance of 1,O km and its removal, disposal and transporting for a distance of 1,O km, of up to 5% by volume of oversize material, and the protection and maintenance of the layer and the conducting of control tests, all as specified.

(d)

Gravel subbase (chemically stabilized material) compacted to: 95% of modified AASHTO density (specify compacted layer thickness) . . . . . . . . . 96% of modified AASHTO density (specify compacted layer thickness) . . . . . . . . Gravel base (unstabilized gravel) compacted to: 98% of modified AASHTO density (specify compacted layer thickness) . . . . . . . . . . . cubic metre (m3) 100% of modified AASHTO density (specify compacted layer thickness) . . . . . . . .

Item 34.02 Extra over item 34.01 for excavation of material in:

Unit

(i)

. . . cubic metre (m3)

(a)

Intermediate excavation . . . . . . cubic metre (m3)

(ii)

...

cubic metre (m3)

(b)

Hard excavation

. . . . . . . . . . . cubic metre (m3)

(e)

The unit of measurement shall be the cubic metre of material obtained from intermediate or hard excavation.

(i)

(ii)

. . . cubic metre (m3)

The tendered rates shall include full compensation for the additional costs involved for taking material from classes of material harder than soft excavation and for the additional costs, if any, for processing such material in the pavement layers.

34.03 Pavement layers constructed from gravel o p i n e d from existing pavement layers: (i) (a) Gravel selected layer compacted to 93% of modified AASHTO density, using: (ii) (i) Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) (h) (ii) Cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . cubic metre (m3) Gravel selected layer compacted to 95% of modified AASHTO density, using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) Cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . cubic metre (m3) Sand selected layer compacted to 100%of modified AASHTO density (specify compacted layer thickness) . . . . . . . . . . . . cubic metre (m3) Gravel subbase (unstabilized gravel) compacted to 95% of modified AASHTO density, using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m') Cemented material (specify compacted layer thickness) . . . . . . . . . . (i)

Gravel subbase (chemically stabilized material) compacted to 96% of modified AASHTO density, using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . .

. . . . . cubic metre (m3)

Cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . cubic metre (m3) Gravel base (unstabilized gravel) compacted to 98% of modified AASHTO density (unstabilized gravel), using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . .

(b)

. . . . . cubic metre

(m3)

(i)

(ii)

Cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . cubic metre (m3) Gravel base (unstabilized gravel) compacted to 100% of modified AASHTO density (unstabilized gravel). using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . Cemented material (specify compacted layer thickness) . . . . . . . . . .

(ii)

(i)

(c)

(i)

.....

cubic metre (m3)

(d)

(ii)

. . . . . cubic metre (m3)

(i)

li)

Gravel base compacted to 97% of modified AASHTO density (chemically stabilized material), using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) Cemented material (specify compacted layer thickness) . . . . . . . . . .

(ii)

. . . . . cubic

metre (m3)

(e)

Gravel subbase (unstabilized gravel) compacted to 97% of modified AASHTO density, using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . Cemented material (specify compacted layer thickness) . . . . . . . . . . .

. . . . . cubic metre (m3)

(i)

. . . . . cubic metre (m3)

(ii)

Gravel base compacted to 98% of modified AASHTO density (chemically stabilized material). using: (i) Non-cemented material (specify compacted layer thickness) . . . . . . . . . . .

.....

cubic metre (m3)

(1)

Gravel subbase (chemically stabilized material) compacted to 95% of modified AASHTO density, using:

. . . . . cubic metre (m3)

(ii)

Cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . cubic metre (m3) Gravel shoulder wearing course compacted to 93% of modified AASHTO density. using: Non-cemented material

( i ) Noncemented material
(specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) (ii) Cemented material (specify compacted layer thickness) (1)

. . cubic metre (m3)

(i)

(specify compacted layer thickness) . . . . . . . . . . . (ii)

cubic metre (m')

measuring and marking-off of the excavation, and the protection of the adjacent existing pavement and its repair should it be damaged. The tendered rate for cemented material shall include full compensation of breaking down the material to comply with the specified grading requirements.

Cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . cubic metre (m3) Gravel shoulder wearing course compacted to 95% of modified AASHTO density, using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . Cemented material (specify compacted layer thickness) . . . . . . . . . .

(m)

(i)

34.04 In situ reconstruction of existing pavement layers as:

.....

cubic metre (m3)

(a)

(ii)

Gravel selected layer compacted to 93% of modified AASHTO density, using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . Cemented material (specify compacted layer thickness) . . . . . . . . . .

. . . . . cubic metre

(m3)

(i)

(n)

Gravel wearing course compacted to 93% of modified AASHTO density, using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) Cemented material (specify compacted layer thickness) . . . . . . . . . .

. . . . . cubic metre

(m3)

(ii)

(i)

. . . . . cubic metre (m3)

(b)

(ii)

Gravel selected layer compacted to 95% of modified AASHTO density. using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) Cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . cubic metre (m3) Gravel subbase (unstabilized gravel) compacted to 95% of modified AASHTO density, using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) Cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . cubic metre (m3) Gravel subbase (unstabilized material) compacted to 970A of modified AASHTO density. using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) Cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) Gravel subbase (chemically stabilized material) compacted to 95% of modified AASHTO density. using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3)

. . . . . cubic

metre (m')

(i)

(0)

Gravel wearing course compacted to 95% of modified AASHTO density, using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) Cemented material (specify compacted layer thickness) . . . . . . . . . . .

(ii)

(i)

(c)

(ii)

. . . . . cubic metre (m3)

(i)

The unit of measurement shall be the cubic metre of compacted pavement layer, the quantity of which shall be calculated in accordance with the authorized dimensions of the completed layer if the underlying layer has also been reconstructed or reworked. Where the underlying layer has not been reconstructed or reworked but only rolled. or where no work has been done on it, quantities shall be calculated with the aid of cross-sections taken of the layer before and after construction. subject to the provisions of clause 1220. Where the material consist of recovered pavement material in part and imported material in part. the quantity of imported material obtained from cut or borrow shall be paid for under item 34.01,calculated in accordance with the volume relation of the respective materials. The tendered rate shall include full compensation for breaking up the existing pavement layer, excavating the material in the existing pavement, procuring. breaking down, placing and compacting the material, including haul for a free-haul distance of 1,O km, and for the protection and maintenance of the layer as well as for the performance of control tests, all as specified. Where excavation is executed over sections of the road. payment shall also include compensation for the proper

(ii)

(d)

(i)

(ii)

(e)

(i)

Cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) Gravel subbase (chemically stabilized material) compacted to 96% of modified AASHTO density, using: (i) Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . Cemented material (specify compacted layer thickness) . . . . . . . . . .

(i)

Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . . cubic metre (m3) Cemented material (specify compacted layer thickness) . . . . . . . . . . . . . . . cubic metre (m3) Gravel shoulder wearing course compacted to 95% of modified AASHTO density, using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . Cemented material (specify compacted layer thickness) . . . . . . . . . .

(ii)

(I)

.....

cubic metre (m3) (i)

(ii)

. . . . . cubic metre (m3)

. . . . . cubic metre

(m3) (ii)

(9)

Gravel base compacted to 98% of modified AASHTO density (unstabilized gravel), using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . .

. . . . . cubic metre (m3)

(i)

. . . . . cubic

metre (m3)

The unit of measurement shall be the cubic metre of compacted pavement layer reworked in situ, the quantity of which shall be calculated in accordance with the authorized dimensions of the completed layer. The tendered rate shall include full compensation for breaking up the existing pavement layer to the specified depth, breaking down and preparing the material, placing and compacting the material as well as the protection and maintenance of the laver, conducting - control tests, measuring and demarcating the work where layers are reprocessed partly. protecting the adjacent pavement and its repair should it be damaged The tendered rate shall also include full compensation for spreading and mixing in any additional material should the existing layer thickness be inadequate and it be specified or instructed by the engineer that the thickness be increased. Material which is temporarily bladed to windrow for the removal of an underlying layer and then bladed back and compacted. will be classed as in situ reconstruction and paid for under this item. The temporary blading of the material to windrow will be paid for under item 34.07. The tendered rate for cemented material shall include full compensation for breaking down the material to comply with the specified grading requirements.

(ii)

Cemented material (specify compacted layer thickness) . . . . . . . . . . . . Gravel base compacted to 100% of modified AASHTO density (unstabilized gravel), using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . Cemented material (specify compacted layer thickness) . . . . . . . . . . . Gravel base compacted to 97% of modified AASHTO density (chemically stabilized material), using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . Cemented material (specify compacted layer thickness) . . . . . . . . . . Gravel base compacted to 98% of modified AASHTO density (chemically stabilized material), using: Non-cemented material (specify compacted layer thickness) . . . . . . . . . . . Cemented material (specify compacted layer thickness) . . . . . . . . . . . Gravel shoulder wearing course compacted to 93% of modified AASHTO density, using:

cubic metre (rn3)

(h)

(i)

cubic metre (rn3)

(ii)

cubic metre (m3)

(i)

cubic metre (m3)

cubic metre (m3)

34.05 Extra over subitems M.W(a), P I , (dl, (el, 0, @I. 0) and (m), and 34.W(a), @I, (c), (dl, (4, 0, (kl and (I) for the construction of gravel pavement layen from recovered pavement material mixed with existing bituminous surFacing material . . . . . . . . . . . . . . . . . cubic metre (m3) The tendered extra-over rate for constructing the pavement layers from material recovered from existing pavements and mixed with existing bituminous surfacing material shall include full compensation for breaking down the surfacing material into fragments not exceeding 37,5 m m in size, uniformly mixing it with the other material, manually removing any over-sized fragments, and for any other incidentals.

cubic metre (m3)

cubic metre (m')

thickness of the layers excavated.

34.06 Extra over .item 34.04 for adding extra material as specified in subsubdause 3207@)(iii):
(a) (b) (c) (d) (e) Gravel selected layer Gravel subbase

The tendered rate shall include full compensation for all additional costs for excavating the material in restricted areas.

........

cubic metre (mJ) cubic metre (m')

Item
34.09 Extra over items 34.03 and 34.04

Unit

............

Gravel base . . . . . . . . . . . . . . cubic metre (m7) Gravel wearing course . . . . . . cubic metre (m3) (a) Gravel shoulder wearing course . . . . . . . . . . . . . . . . . . cubic metre (m3) (b)

for placing and compacting gravel pavement layers in restricted areas:

Non-cemented material . . . . . . cubic metre (m3) Cemented material

....

cubic metre (m3)

The unit of measurement shall be a cubic metre of material added on the instruction of the engineer, which quantity shall be taken as 70% of the loose volume measured in trucks, unless instructed by the engineer that the quantity be determined by way of cross-sections. The tendered rate shall include full compensation for procuring and adding the material to the in situ brokendown pavement layer. and for haul over a free-haul distance of 1,O km.

The unit of measurement shall be a cubic metre of pavement layer placed and compacted in restricted areas. Payment will not distinguish between the various pavement layers. neither between material mixed with bituminous surfacing material and material without bituminous surfacing material. The tendered rates shall include full compensation for all additional costs for placing and compacting the material in restricted areas. This item shall also apply where pavement layers are widened and work is performed in restricted areas.

ttem

Unit

34.07 Extra over item 34.04 for temporarily blading the material to windrow . . . . . . . . . . . . . . . cubic metre (m3)
The unit of measurement shall be a cubic metre of material from an existing pavement layer, temporarily bladed to windrow and measured in its original position before removal. The tendered rate shall include full conlpensation for all additional costs involved in temporarily blading the material to windrow and later blading back and also for all clearing-up work which may be necessary after the material has been bladed back. Only material bladed to windrow on the instruction of the engineer in order to expose the underlying layer shall be measured and paid for. Material bladed or cut from restricted areas to windrow. and material temporarily stockpiled. will not be paid for under this item.
34.10 Conipacting the flwrs of pavement excavations (5 roller passes) with:

(a) (b) (c) (d) (e)

Vibratory rollers . . . . . . . . . . . square metre (m2) Oscillatory rollers . . . . . . . . . square metre (m2) Grid rollers . . . . . . . . . . . . . . square metre (m7) Flat-wheeled rollers

. . . . . . . square metre (m7)

Pneumatic-tyred rollers . . . . . square metre (m2)

The unit of measurement shall be a square metre of floor of pavement excavations compacted by 5 roller passes. Payment will differentiate between the above types of rollers. The tendered rate shall include full compensation for supplying the roller. applying 5 roller passes. and removing the roller after completion of the compacting process. The engineer may increase or decrease the number of roller passes, in which case payment will be adjusted in accordance with item 34.12.

Unit 34.08 Extra over item 34.03 for excavating material in existing pavement layzrs in resbicted areas:
(a) (b) Non-cemented material . . . . . . Cemented material cubic metre m3)

Item
34.1 1 Watering the pavement excavation

Unit

. . . . . . . . cubic metre (m3)

floor . . . . . . . . . . . . . . . . . . . . . . . . kilolitre ( k l )
The unit of measurement shall be kilolitre of water applied to the floor of the excavation to be compacted on the instruction of the engineer.

The unit of measurement shall be a cubic metre of material excavated in a restricted area, the quantity of which shall be calculated in accordance with the area and the average

The tendered rate shall include full compensation for procuring and applying the water. including all haul. Where the following items of work are required in connection with constructing the pavement layers, the appropriate payment items shall appear in section 3400 of the schedule of quantities. ltem16.02 Overhaul of material for exceeding 1,O km Excess overburden Finishing-off borrow areas Provision of crushing and/or screening plant Re-erection of crushing and/or screening plant Crushing and screening Removal of oversize pavement material Chemical stabilization Chemical stabilizing agent Mechanical modification Provision and application of water for curing Curing by covering with the subsequent layer Bituminous stabilization Bituminous stabilizing agent Additive for bituminous stabilization. a distance

Item
34.12 Variations in the number of roller passes applicable to item 34.10:

Unit

(a)

Vibratory rollers

square metre-pass (m7-pass)

ltern 31.01 ltern 31.03 ltern 32.01

(b)

Oscillatory rollers

.... . . ..

square metre-pass (m7-pass) square metre-pass (m2-pass)

(c)

Grid rollers

. .... . . . .. . . . ...... ....

ltem 32.02 (d) Flat-wheeled rollers square metre-pass (m'-pass) ltem 32.03 (e) Pneumatic-tyred rollers square metre-pass (m7-pass) ltem 32.04 ltern 35.01 ltem 35.02

The provisions of item 33.06 shall apply

Item

Unit
ltem 35.03

34.13 Extra over item 34.10 for compacting pavement excavation floor in restricted areas . . . . . square metre (m')

ltern 35.04

ltem 35.05 The unit of measurement shall be a square metre of pavement excavation floor compacted in restricted areas. ltern 35.07 The tendered rate shall include full compensation for all additional costs for compacting the pavement excavation floor in a restricted area irrespective of the compaction plant used. ltern 35.08 ltem 35.09

SERlES 3000 :

EARTHWORKS AND PAVEMENT LAYERS OF GRAVEL OR CRUSHED STONE

requirements of SABS 1491 : Part I. Ground granulated blast-furnace slag shall have a specific surface of not less than 0,35 m2/g and the residue on a sieve with 75 micron openings shali not exceed 10% by mass. Ground granulated blast-furnace slag shall not be used on its own as a stabilizing agent but shall be mixed either with Portland cement to form a cement-slag mixture, or with lime to form a lime-slag mixture. The ratio by mass of the ingredients of each mixture shall be indicated by the engineer. Cement-slag and lime-slag mixtures shall be intimately mixed by means of approved mixers and/or spreaders prior to their application onto any layers to be stabilized, or they may be mixed on the road, at the discretion of the engineer. (v) Portland fly ash cement

CONTENTS
SCOPE MATERIALS CHEMICAL STABILIZATION MECHANICAL MODIFICATION BITUMINOUS STABILIZATION TOLERANCES CONSTRUCTION OF TRIAL SECTION STABILIZATION WORK IN RESTRICTED AREAS QUALITY OF MATERIALS AND WORKMANSHIP MEASUREMENT AND PAYMENT

3501

SCOPE
Portland fly ash cement shall comply with the requirements of SABS 1466.

This section covers the stabilization of materials used in the construction of the roadbed, fill or pavement layers by the addition of a chemical stabilizing agent or by the mechanical modification of the material by mixing various materials or by treating the material with a bituminous stabilizing agent. It includes the furnishing, spreading and mixing-in of the stabilizing agent or soil binder. In the case of chemically stabilized material the layer is given a curing treatment. For the purposes of this section, chemical stabilization includes the mere modification of material properties by the addition of stabilizing or modifying agents, without necessarily envisaging or requiring the cementation of the material by such process.

(vi)

Other chemical stabilizing agents

Other chemical stabilizing agents such as fly-ash may be used if specified in the project specifications or if approved or so instructed by the engineer. Ry ash shall comply with the requirements of SABS 1491 : Part II.

@)

Soil binder

Soil binder for mechanical modification shall be taken from within the limits of an approved source and shall be subject to such requirements regarding grading, plasticity index or other properties as may be Indicated on the borrow-pit plans, or prescribed by the engineer.

(c) (a) Chemical stabilizing agents (i)

Material for bituminous stabilization

Bituminous stabilizing agents

The stabilizing agent shall be either one or more of the following agents specified on the drawings, in the schedule of quantities or in the project specifications or ordered by the engineer. (i) Road lime

For the purposes of this contract the bituminous stabilizing agent shall be one or more of the following agents specified on the drawings, in the schedule of quantities or in the project specifications, or as may be instructed by the engineer, and shall comply with the appropriate SABS specification given below: Stable-grade bituminous emulsion (60% net bitumen)

Road lime shall comply with the requirements of SABS 824 and shall bear the SABS mark. (ii) Ordinary portland cement

SABS 309 (anionic) or SABS 548 (cationic)

(ii) Portland cement shall comply with the requirements of SABS 471. Rapid-hardening portland cement shall not be used. (iii) Portland blast-furnace cement

Fillers

Fillers such as road lime, portland cement and ground granulated blast-furnace slag added for improving adhesion and/or stability shali comply with the requirements of subclause 3502(a) above. (iii) Aggregate

Portland blast-furnace cement shall comply with the requirements of SABS 626. (iv) Ground granulated blast-furnace slag

Ground granulated blast-furnace slag shall comply with the

Material for bituminous stabilization shall be subject to the requirements prescribed for chemically stablllzed gravel or crushed-stone base, with the proviso that the plasticity index shall not exceed 6 after the addition of chemical

stabilizing agent (if required) and before stabilization In the case of gravel material, the percentage of material smaller than 0,075 m m shall not exceed 12%. No gravel from weathered igneous rock may be used. unless it is prescribed in the project specifications. Where gravel material or crushed stone has been recovered from existing pavements. the engineer may allow up to 15% material smaller than 0.075 m m to be present in material intended for bituminous stabilization. Where specified in the project specifications, material from existing pavements mixed with existing bituminous surfacing material may be used in bituminously stabilized base where so approved by the engineer, in writing. The restrictions in subclause 3402(a) in regard to the percentage of existing bituminous material and the size of fragments of such material shall. however. still apply.

obtained (c) Slaking and applying unslaked lime

When unslaked lime is used. it stiall be slaked as follows: The material to be treated shall be spread over the road in a layer of uniform thickness and shall then be lightly rolled with a flatwheel roller. The lime shall then be spread on the layer as described in subparagraph (b) above. after which it shall be ploughed in and thoroughly mixed with the material. The mixture shall then be watered and the moisture mixed in. The wetness of the mixture shall exceed optimum moisture content (approximately 2% additional moisture) so as to produce a sufficient quantity of rnoisture for slaking the lime. The mixture shall then be allowed to slake completely, normally for a period of at least 24 hours. The contractor shall keep in mind that unslaked lime can cause serious burns. and also injury to eyes, mouth and nose. Workers exposed to unslaked lime shall therefore be supplied with approved protective apparel and masks. and no person without such apparel and masks may be permitted to work with or be exposed to the lime. Precautionary measures shall also be taken to ensure that the public will not be exposed to unslaked lime blown by the wind or under similar circumstances.

(d)

General

From the time of purchase to the time of use, all chemical stabilizing agents shall be kept under proper cover and protected from moisture. Consignments of these materials shall be usedsin the same sequence as that of their delivery at the works. Stocks stored on the site in excess of three monttis shall not be used in the work unless authorized by the engineer.

(d)

Mixing in the stabilizing agent

(e)

Water

Water used for diluting emulsions shall be clean and free from so many salts as will break the emulsions during dilution, and shall be tested for compatibility with the prescribed stabilizing agent.

Immediately after the stabilizing agent has been spread. it shall be mixed with the material for the full depth of t~eatment. Care shall be taken not to disturb the cornpacted layer underneath, nor to mix the stabilizing agent in below the desired depth. Mixing shall be continued for as long as necessary and repeated as often as required to ensure a thorough, uniform and intimate mix of the soil or gravel and the stabilizing agent over the full area and depth of the material to be treated. Mixing shall be done by grader, disc harrow, rotary mixer or equivalent plant. working over the full area and depth of the layer to be stabilized by means of successive passes of the equipment. Mixing may also be done in central batch-mixing plants, but the contractor will not be entitled to payment for additional overhaul or incidentals resulting from such procedure.

3503

CHEMICAL STABILIZATION

(a)

Preparing the layer

The material to be stabilized shall be prepared and placed as specified in section 3200, and given at least one pass with a flatwheel roller. The material shall be damp.

@)

Applying the stabilizing agent

After the layer of soil or gravel has been prepared. the stabilizing agent shall be spread uniformly over the full area of the layer by means of an approved type of mechanical spreader at the prescribed rate of appiication in a continuous process. or it may be spread by hand When spreading is done by hand, pockets or bags of stabilizing agent shall be accurately spaced at equal intervals along the section to be stabilized so that the specified rate of application can be achieved The stabilizing agent shall be spread as evenly as possible. snd shall then be uniformly distributed over the entire surface to be treated. The engineer may permit spreading of the hand-spaced stabilizing agent by motor grader. provided that he is satisfied that an even distribution of the stabilizing agent is

(e)

Watering

Immediately after the stabilizing agent tias been properly mixed with the soil or gravel, the moisture content of the mixture stiall be determined. and the required amount of water as specified in section 3200 shall be added. Each application or increment of water shall be well mixed with the material so as to avoid the concentration of water near the surface or the flow of water over the surface of the layer. Particular care shall be taken to ensure satisfactory ~oisture distribution over the full depth. width and length of the section being stabilized and to prevent any portion of the work from getting excessively wet after the stabilizing agent has been added. The moisture content of

the material during compaction shall never exceed 8096 of the saturation moisture content of the natural material without stabilizing agent, calculated at maxirnum dry d$nsity in accordance with subclause 8107(d). Any portion of the work that becomes too wet after the stabilizing agent has been added and before the mixture has been compacted, will be rejected, and such portions shall be allowed to dry out to the required moisture content and shall then be scarified, restabilized, recompacted and again finished off in accordance with the requirements specified herein, all at the expense of the contractor. The water supply and watering equipment shall be adequate to ensure that all the water required will be added and mixed with the material being treated within a short enough period to enable compaction and finishing to be completed within the period specified in subclause 3503fi).

The stabilized layer shall be kept continuously wet (i) or damp by watering at frequent intewals. This method will be permitted for up to a maximum period of 24 hours. but one of methods (ii). (iii), (iv), or (v) shall be applied as soon as the moisture content of the stabilized layer so permits. Work which is not kept continuously wet or damp to the satisfaction of the engineer, but is subjected to consecutive wet-dry cycles, may be rejected by the engineer should he consider the layer to have been adversely affected. (ii) The stabilized layer shall be covered with the material required for the next layer while the stabilized layer is still in a wet or damp condition. The material forming the protective layer shall be watered at such intervals as may he required to keep the stabilized layer continuously wet or damp, and in dry weather this shall be done at least once in every 24 hours. The stabilized layer shall be covered with a curing (iii) membrane consisting of a spray-grade emulsion or cutback bitumen applied at the rate instructed by the engineer. The provisions of section 4100 shall apply mutatis mutandis to the application of a curing membrane. Where a prirne coat is specified on top of the (iv) stabilized base or subbase, the prime coat may be utilized as a curing membrane and shall be applied as specified in section 4100. The stabilized layer shall be kept continuously wet (v) for seven days by an effective fog-spraying system which will not damage the surface of the layer. During this period. the application of water shall be so controlled that it will not unduly wet the layer but, at the same time, will not allow the layer to dry out. Layers allowed to dry out may be rejected if damaged thereby. In regard to this method. payment will be made only for the application of water. No additional payment will be made for curing as described above. except that the application of a curing membrane or water in accordance with method (v) above will be paid for when the application of such methods has been ordered by the engineer.

(f)

Compaction

The provisions of section 3200 shall apply. During compaction loss of moisture by evaporation shall be corrected by further light applications of water. During compaction of the stabilized layers. the coritractor shall lightly harrow or scarify the crust before final rolling. if so required by the engineer, in order to prevent the formation of laminations near the surface of the layer. Final rolling shall be done with equipment that will give a smooth surface finish which conforms to the surface tolerances specified. Low patches on the surface may not be filled after compaction. The minimum compaction requirements shall be as specified for the particular layer in the various sections of these specifications.

A sufficient number of compacting units shall be employed

on the work to ensure that, from the time when the stabilizing agent is first applied to the layer, the mixing process, watering, compacting, shaping and final finishing will be completed within the periods specified in subclause 3503(i) below.

@)

Finishing at junctions

Any finished portion of the stabilized layer adjacent to new work, which is used as a turn-round area by equipment in constructing the adjoining section. shall be provided with a protective cover of soil or gravel of at least 100 mm thick over a sufficient length to prevent damage to work already completed. When the adjoining section is being finally finished, such cover shall be removed to permit the making of a smooth vertical joint at the junction of the different sections. Material in the vicinity of the joint which cannot be processed satisfactorily with normal construction equipment shall be mixed and compacted by hand or with suitable hand-operated machines.

6)

Conshuclion limitations

For cemented layers the stabilizing agent shall be applied only to a surface the size of which will permit all processing, watering. compacting and finishing to be completed withiri the period given in table 350311. For any special surface finishing operations the maximum period may be fractionally increased by the engineer. For modification only. the niaximum period allowed from the time the binder comes into contact with the layer being modified until the completion of compaction shall be 48 hours in the case of slaked or unslaked lime. The starting time shall be the median time taken to complete the spreading of the lime. No stabilization shall be done during wet weather or when, in the opinion of the engineer, windy or freezing conditions may adversely affect the stabilizing operations. Any rain falling on the working area during the process of stabilization may be sufficient cause for the engineer to order any affected areas to be reconstructed at the contractor's own cost.

(h)

Curing the stabilized work

The stabilized layer shall be protected against rapid dryingout for at least seven days following completion of the layer.

The methods of protection may be any one or more of the following subject to the provisions of the project specifications or the approval of the engineer:

Table 350311 CONSTRUCTION LIMITATIONS FOR CEMENTED LAYERS Maximum continuous period allowed from the time the stabilizing agent comes into contact with the layer being stabilized until the completion of compaction (see note)

roller. The materia! from the second source shall then be dumped onto the road, prepared, broken down and evenly spread, after which the two materials shall be thoroughly mixed as described in subclause 3208(a): Spraying and mixing.

Stabilizing agent

Ordinary portland cement, and/or approved portland cement blends Slaked lime Unslaked lime

The mixing of materials from different sources wlll apply only when the smallest component of the mixture exceeds 20% of the total mass of the mixture. If not, the process will be regarded as the addltlon of a soil blnder as described above in subclause (a).

(c)

Recombining recovered material

8 hours 10 hours 10 hours

Where specified in the project specifications or required by the engineer, recovered material shall be recombined to comply with the requirements of the layer for whlch it Is destined.

Note: The starting time shall be the median time taken to complete the spreading of the stabilizing agent. No traffic nor any plant not actually used for processing the layer may be allowed to pass over the freshly spread stabilizing agent. Only equipment required for curing or priming may be allowed over the treated layers during the specified curing period, unless otherwise specified in the projects specifications or approved by the engineer. Where specified in the project specifications, watering shall be done by side-spraying tankers travelling off the stabilized layer.

3505

BITUMINOUS STABILIZING

(a)

Reparing the material

The material to be stabilized shall be prepared and placed as specified In section 3200, and shall be ploughed into furrows. The moisture content of the material shall be just below the optimum molsture content during mlxlng-in of the stabilizing agent. Immediately before the stabilizing agent is applied, the material shall again be lightly wetted. No dry material whatsoever may then be present.

3504

MECHANICAL MODlFlCAllON

@)

Mixing in the a d d i i

Mechanical modification shall consist of the addition of an approved soil binder to material to improve its properties, or the mixing of material originating from various sources, as described hereafter.

Where an additive (lime, cement, etc) has been specified, or if so required by the engineer, it shall first be spread and mixed in as described in subclause 3503(b). Separate payment will be made for providing, applying and mixingin the additives.

(a)

W i n g soil and gravel by the addition of a soil binder

(c)

Heating and diluting the bituminous stabiliing agent

This process involves the addition and mixing of an approved soil binder, which shall not exceed 20% by mass of the total mixture, to the material to be improved. The material to be treated shall be prepared, broken down and spread to the required loose thickness, all as specified in section 3200. An approved binder material shall then be spread over the prepared material at the required rate, and the materials shall be mixed by a suitable method by motor grader, disc harrow and/or other sultabie plant until the binder material is uniformly and intimately mixed with the material being treated. The mixed materials shall then be watered, mlxed and compacted as described in section 3200.

The bituminous stabilizing agent shall be heated as specified In clause 4305.

During dilution of the bituminous emulsion with water, care shall be taken to prevent Its breaking. This will mean that clean water shall be added gradually during constant stirring of the emulsion or its circulation by pumps.

(d)

Applying the stabilizing agent

@)

Mixing materials from various sources

The mixing of materials from various sources requires the material from the first source to be dumped onto the road, prepared, broken down and spread in a layer of uniform thickness, after which it is lightly rolled with a steel-wheeled

After preparing the material, the stabilizing agent shall be uniformly applied by an approved binder distributor (in accordance with subclause 4103(a)) in a continuous process at the prescribed rate of application over the full area of the layer. Multiple applications may be necessary. In such cases it shall be ensured that the molsture escaping on account of drying-out is replaced by water being applied. Care shall be taken not to allow the stabilizing agent to run from the layer before it has been mixed in.

The stabilizing agent shall be diluted with water to obtain a better distribution. In cases where, in the opinion of the engineer, it is impracticable to apply the stabilizing agent b y mechanical binder distributor, hand distributors m a y b e used. Where so required by the engineer, a certain part (not more than 10% of the total quantity) of the stabilizing agent shall b e sprayed onto the surface in a diluted form (with a maximum of 2 parts of water to 1 part of bituminous stabilizing agent) immediately. before the final finishing of the layer. The stabilizing agent shall. immediately after each application, be mixed with the loose material. to the full depth of the treated layer. This work shall be done carefully so as not to disturb the underlying compacted layer and as not to mix in the stabilizing agent deeper than the required depth. During mixing-in, the moisture content of the material shall b e immediately below or at optimum moisture content. Mixing shall be proceeded with for so long as m a y be necessary and shall be repeated as frequently as may be necessary to ensure the thorough. uniform and proper mixing of the gravel or the aggregate and the stabilizing agent over the full surface and depth of the material to b e treated, until the resulting mixture is homogeneous and has the same appearance throughout without any individual spots of the stabilizing agent being visible, and until the mixture has reached the r ~ q u i r e d moisture content of compaction. Mixing shall be done b y road grader. disc harrow. rotary mixer or similar plant, which will work the layer to b e stabilized b y way of successive passes over its full surface and depth. Mixing may also b e done in a central batch-mixing plant. but the contractor shall not be entitled to payment for extra overhaul or other costs arising from this method of work.

location. or a representative sample of the aggregate without any addition of bituminous stabilizing agent, and the value thus obtained shall b e adjusted to make provision for the specified percentage of bituminous stabilizing agent to b e added, but no adjustment shall be made for making provision for the presence of bituminous stabilizing agent in regard to such values as are obtained for field densities.

(1)

Finishing at junctions

The junctions of sections shall be finished in accordance with subclause 3503(g) for obtaining an even and wellcompacted joint and so as not to cause damage to the adjacent parts of the sections.

(g)

Construction limitations

When gravel is being stabilized with a bituminous emulsion. the layer shall b e mixed and compacted within 24 hours. Limited slushing shall b e done within 48 hours. Where crushed stone is stabilized with bituminous emulsion and used for repairing subbase or base layers, it shall be mixed in. placed. and compacted within 5 hours.

3506

TOLERANCES

(a)

FIale of application
Chemical stabilizing agents

(i)

(e)

Compaction

The provisions of subclause 3503(f) shall apply. The moisture content during the compaction of stabilized layers shall not exceed the optimum of the gravel or aggregate. However, the engineer m a y amend these required moisture contents. The engineer m a y prescribe or permit a limited amount of slushing as specified in subclause 3604(c) so as to ensure a higher density and/or better finish. However, slushing, preferably after an initial drying out period, shall be limited so as to bring just sufficient fine material to the surface for improving rough spots. but not in excess. Fine material m a y not b e swept from the road. Where the required densities for a pavement layer in accordance with the modified AASHTO density is specified. the standard density as well as the field densities shall be determined on the material as obtained from the road, and the standard density or the field densities shall not be adjusted o n account of the presence of bituminous stabilizing agents. Where, however, the required density has been specified in accordance with the apparent density of the material. the apparent density shall be determined at a specified testing

The average rate of application of a chemical stabilizing agent. when applied b y mechanical bulk-spreading equipment and measured b y the canvas-patch method, shall b e equal to the specified rate of application ? 5% of the rate of application measured over any section not exceeding 1.0 k m in length, and no single measurement shall show a value deviating b y more than 20% from the s~ecified rate. When hand spotted. stabilizing agents shall be spread exactly to the specified rate of application. (ii) Bituminous stabilizing agents

The average rate of application of bituminous stabilizing agent as measured in the binder distributor shall b e within 5% of the specified rate of application.

@)

Uniformity of m i x (chemical stabilization)

One of the following test methods. as prescribed in the project specifications. shall b e applied to assess the uniformity of mix:

(i)

The quantity of cementitious binder in the mixed material as determined during sampling and testing as specified in subclause 81 lO(a). shall b e within the limits specified in the statistical judgement plan described in clauses 8206 or 8305.

Samples for the determination of the uniformity of mix shall be taken immediately after the material has been mixed with the water and stabilizer and spreaded, but before the layer is compacted, and the contractor shall therefore make the necessary arrangements timeously and allow for the time to collect the samples. As described in clause 81 10(a), test results shall be adjusted to make allowance for the presence in the material to be stabilized. of minerals which affect the test results. The above requirements for uniformity of mix shall be applied only on condition that the variation in these adjustments falls within the limits specified in clause 81 10. The coefficient of variation may not exceed 0.3 (30%) for material mixed on the spot, and 0.2 (20%) for material mixed in a mixing plant. (ii) The quantity and distribution of the effective cementitious binder in the mixed material shall be deemed acceptable if the resultant unconfined compressive test results of samples randomly selected immediately prior to the compaction of a stabilised construction lot, and covering the area on either side of the diagonal dividing such a lot. satisfy the statistical assessnient criteria for the method outlined in the project specifications. The target value for the primary variation, required to perform the relevant calculations, shall be agreed based on the outcome of an acceptable trial section, and shall fall within the following applicable ranges: Number of Stabilizer type traffic lanes Permissible range for setting target v a l u e of t h e primary variation for cementation 0.3 to 0.3 to 0.4 to 0.5 to 0.7 0.7 1.0 0.9

The trial section shall be paid for separately only when It complies with all the requirements of these specifications and has been approved by the engineer. After approval has been obtained the mixing process and equipment shall remain unaltered unless otherwise approved by the engineer.

3508

STABILIZATION WORK IN RESTRICTED AREAS

(a)

General requirements

The provisions of subsubclauses 3208(a)(ii)and 3208(b)(ii) in regard to work in restricted areas shall apply mutatis mutandis. Where existing and new work are joined (longitudinal joints and others), material shall be satisfactorily mixed and compacted without any permeable or loose patches. Subclause 3503(g) shall apply. In regard to the curing of stabilized layers in restricted areas, the construction of the subsequent layers may be commenced as soon RS practicable with the permission of the engineer.

@)

Chemical stabilization

Where pavement layers are to be widened. no chemical stabilizing agent may be spread or mixed beyond the required width. The contractor will not be permitted to mix material for stabilization on adjacent surfaces unless he has obtained prior permission from the engineer. in writing. Where the existing surfaces of the road may not be used for this purpose, the contractor shall apply other approved methods of mixing.

2 3 2 3

LIME LIME OPC (or blends) OPC (or blends)

Payment over and above payment for work In restricted areas will not be considered for additional overhaul or other costs arising from this manner of mixing or working.

Where the primary variation obtained for the trial section, falls outside the specified range. a new trial section will be required.

(c)

Bituminous stabilization

3507 C0NSTRUCTK)N OF TRIAL SECTION

Before the contractor commences with the construction of stabilized layers he shall demonstrate by constructing a trial section that the equipment and procedure he proposes to use will result in him constructing the layers in accordance with these specificatiocs.

No mixing of material with bituminous stabilizing agent will be permitted on the existing surfacing without the written permission of the engineer, and then only where such surface is required to be resealed or provided with a resurfacing layer. Where restricted areas are such that mixing in them will not be practicable and/or mixing on adjacent surfaces is not permitted. mixing shall be done in a central mixing plant. In the case of smaller quantities, approved concrete mixers may be used. Payment over and above payment for work in restricted areas will not be considered for additional overhaul or other costs arising from this manner of mixing or working.

The trial section shall be at least 2 000 m 2 in area and shall be constructed in its proper position in the pavement. Only when such a trial section has been satisfactorily constructed and accepted will the contractor be permitted to proceed with the stabilized layer in the permanent work.

3509

QUALITY OF MATERMS AND WORKMANSHIP

In the event of the trial section being unsuccessful the contractor shall remove the trial section should the engineer so require.

Routine inspection and testing will be made by the engineer to determine the quality of materials and workmanship for compliance with the requirements of this section.

The test results and measurements will be Judged in accordance with the provisions of section 8200 or 8300, depending on which section is indicated as the appropriate section in the project specifications. Only the lower limits and not any upper limits for cementitlous binder content have been laid down In clauses 8206 and 8208 (alternatelyclauses 8305 and 8307). Nevertheless, the binder content as determined by the sample mean of a lot shall be not more than 0,5% above the value specified or ordered by the engineer. Compliance with the requirements for the compaction of stabilized materials shall be as specified in the relevant section for each layer, or in the project specifications. When the tests for uniformity of mix are not applicable as stated In subclause 3506(b), the material shall be visually appraised for uniformity of mix.

(b)

Portland blast-furnace cement . . . . . . . . . . . . . . . . . . . . . . . . . . ton (t) Road lime (type indicated)

(c)

. . . . . . . . . . . . . . . . . . . . ton (1)

(d)

Ground granulated blast-furnace slag . . . . . . . . . . . . . . . . . . ton (t) Unslaked lime (dry)

(e) (1) (g)

. . . . . . . . . . . . . . . . . ton (t)
..............
ton (1)

Portland fly ash cement Other stabilizing agents (type specified)

..............

ton (t)

3510

MEASUREMENT AND PAYMENT

The unit of measurement shall be the ton of stabilizing agent. Measurement shall distinguish between the various stabilizing agents used. When mixtures of slag and cement or lime are used, the quantity of each constituent shall be measured separately and not the mixture as a whole. In the case of unslaked lime, the mass for purposes of payment shall be the mass of the lime before slaking, therefore, the mass of the calcium oxide. Subject to the provlsions of clause 1220, the quantity will be determined in accordance with the authorized rate of application. The tendered rates shall Include full com~ensationfor providing the stabilizing agent at the works, irrespective of the rate of application specified or ordered by the engineer, but shall make allowance for the differences in mixing and compaction times specified for various stabilizing agents. The rate for ground granulated blast-furnace slag shall include full compensation for premixing the blast-furnace granulated slag with other stabilizing agents in the required proportion, and the rate for unslaked lime shall also Include f~ll'com~ensation for its slaking, Including the supply end application of water.

Items 35.10, 35.11 and 35.12 are applicable solely to stabilization work that has to be executed in a restricted area of whlch the width Is less than 3,O m or the length Is less than 150,O m.

ttem
35.01 Chemical stabilization (layer thlckness indicated) extra over unstabilizedcompacted layers (layer to be stabilized Indicated)

Unit

. . . . . . . . cubic metre (m3)

The unit of measurement shall be the cubic metre of stabilized material, the quantity of which shall be determined in accordance wlth the authorized dimensions of the layers treated as instructed by the engineer. The tendered rates for chemical stablllzation shall be paid as extra over the rates tendered for constructing the unstabiilzed layers. The tendered rates shall therefore include full compensation for spreading and mixing the stabilizing agent, curing the stabilized sections, any extra water required, and all materials, supewision, labour, plant, equipment, tools and incidentals (extraover those provided for in the rates tendered for constructing the unstabilized layer) necessary for completing the specified work, but excluding the cost of supplying the stabilizing agent. No distinction will be made in respect of the type of stabilizing agent used, the time for completion or the specific layer being stabilized, and the extra over rate tendered shall apply to any combination thereof. The engineer reserves

Item
35.03 Mechanical modiication (exira over unlreated layer):

Unit

(a) (b)

By adding a soil binder By mixing materials from different sources

......

cubic metre (ma)

.......

cubic metre (m3)

to himself the right to vary the thickness of the layer to be stabilized by up to 20 mm, and the contract rate for this work shall not be amended by such change.

The unit of measurement shall be the cubic metre of compacted material that has been mechanically modified as specified in clause 3504, and the quantity shall be calculated in accordance with the authorized dimensions of the mechanically modified layer.

Unit
35.02 Chemical stabilizing agent:

(a)

Ordinary portland cement

. . . . . . . . . . . . ton (1)

The tendered rates for mechanical modification shall be paid as extra over the rate for the construction of an untreated layer and shall include full compensation for all the work, plant and other incidentals necessary for supplying and hauling the material for a distance of 1,O km, and for spreading the soil binder and mixing it with the material to be treated or for mixing materials from different sources as specified.

The addition of material during a crushing or screening process, whether it is specially imported material which is not the product of the crushing process or whether it is crushed material screened out and then replaced in part or as a whole, will not be regarded as treatment with soil binder for measurement and payment purposes. but will be regarded as part of the process of producing crushed stone for subbase, base or other construction work. the cost of which shall be included in the tendered rates for those items of work.

and maintaining the surface as specified.

.75.07 Bituminous stabilization (extra over the untreated layer) . . . . . . . . . . . . . . . . . . . cubic metre (m3)

k m

Unit

The unit of measurement shall be the cubic metre of material stabilized: the quantity shall be determined in accordance with the authorised dimensions of the completed layer. The tendered rate for bituminous stabilization shall be paid extra over the rates for constructing the untreated layer and shall include full compensation for all incidentals, excepting the compensation covered b y items 35.08 and 35.09. which are necessary for treating the material as specified. No distinction shall be made in regard to the type of bituminous stabilizer used, the time for completion, and the particular layer to be stabilized. and the tendered extra rate shall apply to any combination thereof. The engineer reserves to hin~self the right to alter the thickness of the layer to b e stabilized, and the contract rates will remain applicable to all layer thicknesses between the limits of 100 m m and 200 m m .

35.04 Provision and application of water for curing . . . . . . . . . . . . . . kilolitre ( k t )

The unit of measurement shall be the kilolitre of water provided and applied in accordance with the engineer's instructions for curing the stabilized layer as specified in subclause 3503(h)(v)r The tendered rate shall include full con~per~sation for furnishing, transporting and applying the water and for the provision of spraying equipment. Water applied within the first 24 hours of completion of the stabilized layer will not be calculated for payment.

Unit 35.05 Curing by covering with the subsequent layer . . . square metre (m') The unit of measurement shall b e the square metre of stabilized pavement layer being cured b y covering it with the subsequent layer as specified in subclause 3503(h)(ii). The quantity will b e deterrnined by the authorized dimensions of the layer to be treated. The tendered rate shall include full compensation for incidentals in respect of applying the subsequent layer for curing as specified. including the cost of regularly supplying and applying water.

ttem
35.08 Bituminous stabilizing agent:

U l i

(a)

Anionic stable grade bituminous ernulsion (60% net bitumen) . . . . . . . . . . litre (1) Cationic stable grade bituminous emulsion (60% net bitumen) . . . . . . . . . . litre (1) Other (specify) . . . . . . . . . . . . . . . . . . . . litre (1)

(b)

(c)

The unit of measurement shall b e the litre of bituminous stabilizing agent applied on the instruction of the engineer. The tendered rates shall include full compensation for providing. diluting and applying the stabilizing agent, irrespective of the prescribed rate of application.

Item
35.06 Curing with a bituminous membrane:
(a) (b) (c) (d)

Unit

MC 30 cut-back bitumen . . . . . . . . . . . . litre ( I ) MC 70 cut-back bitumen . . . . . . . . . . . . litre ( I ) Invert bitumen emulsion . . . . . . . . . . . . litre ( I ) (a) 60% spray-grade anionic bitumen emulsion . . . . . . . . . . . . . . . . . . . . . . . litre ( I ) (b)
35.09 A d d i for bituminous stabilization:

lhlii

Ordinary portland cement . . . . . . . . . . . . ton (1) Ground granulated blast-furnace slag

ton (1)

(e)

65% spray-grade cationic bitumen emulsion . . . . . . . . . . . . . . . . . . . . . . . . litre ( I )

(c)

Road lime . . . . . . . . . . . . . . . . . . . . . . . . ton (1)

The unit of measurement shall be the litre of bituminous material conforming to the relevant SABS requirements measured at spraying temperature and sprayed as required in section 4100. The tendered rate shall include full compensation for supplying the material, preparation of the surface before applying the bituminous membrane. applying the material

The unit of measurement shall be the ton of additive applied on the instruction of the engineer. The tendered rates shall include full compensation for providing and spreading the additive and for the incidentals required for mixing it in. The tendered rates shall apply irrespective of the percentage of additive prescribed between the limits of 0.5% and 1.5% b y mass.

35.10 EKba over item 35.01 for chemical stabilization in restricted areas: (a) Mixing in mechanical mixers . . . . . . . . . . In situ mixing

. . . . . . . . cubic metre

(m3)

The tendered rates shall include full compensation for all additional costs for executing the.work in restricted areas, and shall amongst others include full compensation for the additional costs for applying stabilizing agents or soil binders in restricted areas, as well as for curing chemically stabilized layers in restricted areas (irrespective of the method of curing), and the application of additives for bituminous stabilization in restricted areas.

(b) (c)

.............
...

cubic metre (m3) Payment under item 35.10 will not distinguish between the various types of chemical stabilizing agents.

Mixing as for in situ mixing but on adjacent surfaces .

cubic metre (m')

Item 35.11 Extra over item 35.03 for mechanical modification in reslricted areas: (a) Mixing in mechanical mixers . . . . . . . . . . In situ mixing

Unit Payment under item 35.1 1 will not distinguish between the addition of soil binder and the mixing of material from various sources.

. . . . . . . . cubic

metre (m3)

Payment under item 35.12 will not distinguish between the various types of bituminous stabilizing agents or various types of additives.

(b) (c)

.............

cubic metre (m")

Mixing as for in situ mixing but on adjacent surfaces . . . . . cubic metre (m3)
35.13 Extra over items 35.01 and 35.07 for Ma1 sections . . . . . . . . . . . cubic metre (m3)

Item
35.12 Exira over item 35.07 for biminous stabilization in restricted areas: (a) Mixing in mechanical mixers . . . . . . . . . . In situ mixing

Unit

The unit of measurement shall be the cubic metre of compacted stabilized layer that has been placed as a trial section and approved by the engineer.

. . . . . . . . cubic

metre (m3)

(b) (c)

............. ...

cubic metre (m3)

Mixing as for in situ mixing but on adjacent surfaces .

The tendered rate shall include full compensation for all additional work, testing and incidentals associated with the construction of an approved trial section as specified. It shall also include full compensation for trial sections removed as excess/unsatisfactory material.

cubic metre (m3)

The unit of measurement shall be a cubic metre of chemically stabilized or modified material, mechanically modified material, or bituminous stabilized material in restricted areas measured in place after placement irrespective of the layer treated. Payment shall apply only to bases, subbases and selected layers.

Note:
Where soil binder requires haulage in excess of 1 km, item 16.02 shall be included in this section of the schedule of quantities to make provision for overhaul.

SERIES 3000 :

EAATHWORKS AND PAVEMENT LAYERS OF GRAVEL OR CRUSHED STONE

part of or over the full width of the existing layer.

3602 MATERIALS
SECTION 3600 : CRUSHEDSTONE BASE (a) CONTENTS SCOPE MATERIALS TRIAL SECTION AND OTHER REQUIREMENTS BEFORE THE CRUSHED-STONE LAYER MAY BE CONSTRUCTED CONSTRUCTION PROTECTION AND MAINTENANCE CONSTRUCTION TOLERANCES QUALITY OF MATERIALS AND WORKMANSHIP MEASUREMENT AND PAYMENT The aggregate used for crushed-stone base shall comply with the requirements specified in tables 360211 and 360212 and in subclause 3602(b). It shall not contain any deleterious material such as weathered rock, clay, shale or mica. Argillaceous rocks may only be used if specified in the project specifications, or with the engineer's written approval. Requirements for crushed aggregate

@)

Soluble salts

The percentage of soluble salts in the material shall (i) be subject to the following provisions:
3601

SCOPE Untreated material (c 6,7 m m fraction)

This section covers the procuring, furnishing and placing of approved crushed stone on top of the completed subbase, and constructing a crushed-stone base in accordance with the requirements of these specifications.

Witwatersrand quartzite: Crushed stone and mine sand. Where the p H < 6,0, it shall be treated with lime until p H r 10, and then used. (The aggregate is normally treated at the crusher, and if the pH exceeds 10 at that stage, the decrease which will occur later on, shall be ignored should it remain r 8,O.) Where the pH r 6,0, the material is used as it is.

This section also covers the replacement or the reprocessing of existing crushed-stone layers (with or without the addition of approved fresh crushed stone) over

Table 360212 10% FINES AGGREGATE CRUSHING VALUES Wet min

Rock type Arenaceous rocks

Matrix Non-siliceous cementing material Siliceous cementing material

Dry min 140 kN

Wetldry relationship min 75% 75% 70%

110 kN 200 kN

Diamictites (tillite) Argillaceous rocks Other rock types

180 kN 110 kN Table 360213 AGGREGATE CRUSHING VALUE

125 kN

75%

Rock type Arenaceous : without siliceous cementing matrix Arenaceous : with siliceous cementing matrix Diamictites (tillite) Argillaceous rocks Other rock types

ACV, max 27% 29% 21% 24% 29%

Table 3602/1 CRUSHED STONE BASE AND SUBBASE : MATERIAL REQUIREMENTS TYPE OF MATERIAL MATERIAL CHARACTERISTIC PARENT MATERIAL G1 Sound rock from an approved quarry, or clean, sound mine rock from mine dumps, or clean sound boulders Only fines crushed from the same sound parent rock may be added for grading correction provided that added fines shall have a LL not exceeding 25 and PI not exceeding 4. G2 Sound rock, boulders or coarse gravel G3 Sound rock, boulders or coarse gravel

ADDITIONAL FINES

May contain up to 10% by mass of approved natural fines not necessarily obtained from parent rock. Added fines shall have a LL not exceeding 25 and PI not exceeding 6.

May contain up to 15% by mass of approved natural fines not obtained from parent rock. Added fines shall have a LL not exceeding 25 and PI not exceeding 6.

STRENGTH

10% Fines Aggregate Crushing Value (10% FACT), determined in accordance with TMHl method 82, shall be not less than the appropriate value in table 360212, column 3. The Aggregate Crushed value (ACV), determined in accordance with TMHl method 81, shall not exceed the appropriate value in table 360213. The material shall comply with the requirements in columns 3, 4 and 5 of table 360212. Flakiness Index, determined in accordance with TMHl method B3, shall not exceed 35 on each of 19 m m fraction and the -19 + 13,2 m m fraction. the -26,5

DURABILITY FLAKINESS INDEX FRACTURED FACES

All faces shall be fractured faces. For crushed materials at least 50% b y mass of the fractions retained on each standard sieve 4,75 m m and larger shall have at least one fractured face. LL shall not exceed 25. PI shall not exceed 5. LS shall not exceed 2%. In addition the arithmetic mean of the Pl's for a lot (min 6 tests) shall not exceed 4.

FRACTION (mm) ATTERBERG LIMITS

LL shall not exceed 25. PI shall not exceed 6. In addition the arithmetic mean of the Pl's for a lot (min 6 tests) shall not exceed 43. LS shall not exceed 3%.

LL shall not exceed 25. PI shall not exceed 6. LS shall not exceed 3%. In the case of calcrete the PI shall not exceed 8. (% passing 0,425 m m sieve) LS 5 170

-0,075

The PI shall not exceed 12. If the PI exceeds 12 the material shall be If chemical modification is required, chemically modified. After chemical modification the PI of the minus the PI of the -0,075 mm fraction after modification shall not exceed 0,075 mm fraction shall not exceed 8. 10. See additional requirements. 37,5 m m Percentage passing sieve, by mass 37,5 m m Percentage passing sieve, by mass 37,5 m m 26,5 mrn Percentage passing sieve, by mass

SOLUBLE SALTS NOMINAL MAXIMUM SIZE Nominal aperture size of sieve (mm) 37,5 26,5 19,O GRADING 13,2 4,75 2,OO 0,425 0,075 COARSE SAND RATIO (SEE DEFINITION IN SUBSUBCLAUSE 3602(c)(i)(5)) COMPACTION REQUIREMENTS

100 84 94 71 - 84 59 - 75 36 - 53 23 - 40 11 - 24 4 - 12 Shall not be less than 35% and shall not exceed 50% in respect of the target grading. Minimum of 88% of apparent relative density.

100 84 - 94 71 - 84 59 - 75 36 - 53 23 - 40 11 - 2 4 4-12

100 84 - 94 71 - 84
59 - 75

100 85 - 95 71 - 84 42 - 60 27 - 45 13 - 27 5 - 12

36 - 53 23 - 40 11 - 2 4 4 - 12

Shall not be less than 35% and Shall not be less than 35% and shall not exceed 50% in respect of shall not exceed 50% in respect of the target grading. the target grading. Minimum of 85% of bulk relative density. 98% or 100% of modified AASHTO density (as specified).

OIher materials such as natural gravel and other crushed

stone

relating to the crushing charatteristlcs of the parent rock and its impact on the shear characteristics and compatibility of the structural layer: (i) For 37,5 m m maximum size aggregate the requirements are as follows (percentage b y mass): (1) 9%.
(2)

Where the electrical conductivity (EC) s 0,15 Sm-', the material may be used. Where the EC > 0,15 Sm", the p H shall be determined.

The -0,075 m m fraction shall be between 7% and

Where the p H < 6,0, the material shall be treated with lime until the pH 2 10. The material may then be used. (Any later decrease of the p H shall be ignored should it remain 2 8,O.) Where the pH 2 6,0, it may be used, but special attention should be given to design and construction measures. Material being stabilized (for example with lime or cement) Where the pH r 6,O and the EC < 0,02 Sm" and the qualitative test shows that sulphates do not pose a problem, the material may be used. If not, the material shall be further analysed by the engineer in accordance with the employer's instructions, and the proposals for its use shall be submitted to the employer for approval. The tests conducted for determining the above (ii) judgement parameters shall include the following: Electrical conductivity (EC)

The -0,425 m m fraction shall not exceed 22%. The -2,OO m m fraction shall not exceed 34%.

(3)

The -4,75 m m fraction shall be between 40% and (4) 45%. For aggregate with a flakiness index in excess of 25 and which is assessed visually to be of a needle-like shape the target value shall be 45%. With the written permisslon of the engineer this upper value may be exceeded if the trial section indicates that it is necessary in order to achieve the required bulk density. The -2,00 m m +0,425 m m fraction shall be not less (5) than 35% nor more than 50% of the -2,00 m m fraction. This shall be termed the coarse sand ratio requirement. (ii) For 26,5 m m maximum size aggregate the requirements are as follows (percentage b y mass): (1) 9%. The -0,075 m m fraction shall be between 7% and

. . . . . . . . . . method A21T of
TMHl ( < 6,7 m m fraction)

Qualitative sulphate test . . . . . . . . . . . . . . . . . . . . . . . NlTRR method CA21 ( < 6,7 m m fraction) pH

. . . . . . . . . . . . . . . . . . . . . . . .NlTRR method CA 21
( < 6.7 m m fraction)

The -2,OO m m +0,425 m m fraction (ie the coarse (2) sand ratio) shall not be less than 35% nor more than 50% of the -2,OO m m fraction (3) 50%. The -4,75 m m fraction shall be between 45% and

Acid-soluble sulphate content

........

BS 1377 of 1975, test No 9, made on a full sample crushed to < 2,00 m m

The selected target values shall produce a gradual (iii) change from the coarse to the finer fractions without any marked gaps or excessive quantities at a particular size. In order to satisfy the aforementioned requirements, (iv) the mean grading of the approved trial section may not necessarily represent the target grading finally approved for quality assessment (eg the variability actually obtained for particular fractions will dictate the setting of the target grading). For G I , G2 and G3 base material the mean grading of each lot (mlnimum of 4 but preferably 6 test points per lot) determined from samples obtained in a stratified random sampling procedure shall conform to the approved target grading within the tolerances specified in table 360214.

Water-soluble sulphate content

. . . . . . . . BS 1377 of

1975, test No 10

Where the salinity of the water used for compaction (iii) purposes is so high as to cause an increase in the salinity of the material, the engineer shall be entitled to determine the soluble salinity from samples taken from any section of the compacted layer within 24 hours, and also before the prime coat is applied.

(c)

Grading requirements

After compaction, the individual fractions making up the grading of the material in place in the road shall conform to the proportions in table 360211, subject to the following requirements. The target grading after compaction shall be as near as possible to the mean of the specified grading envelope shown in table 360211. The approved target grading shall be based on test results obtained from a trial section constructed in accordance with clause 3603 and subject to complying with the following requirements unless otherwise approved, where such approval shall be based on substantive evidence

(d)

Material from existing pavements

Where existing crushed-stone material is to be reprocessed, the engineer will inspect the material and instruct the contractor to reprocess it as gravel subbase or base, or as crushed-stone base or subbase. The compaction requirements specified in table 360211 shall apply to crushed-stone layers constructed from recovered material. Payment for crushed-stone layers constructed from recovered material, will differentiate between the varlous types of material and their preparation.

Table 360214 TOLERANCES ON TARGET GRADING Permissible deviations for mean values (% by mass) Nominal Nominal maximum maximum size size 37,5 m m 26,5 m m Permissible deviations for individual values (% by mass) Nominal Nominal maximum maximum size size 37,5 m m 26,5 m m

No payment will be made for trial sections removed as excess/unsuitable material. The crushing of aggregate for the base from any source, or the stockpiling of crushed stone in stockpiles, shall be restricted to 5 000 m 3 until the material has been approved by the engineer. Material shall be furnished only from sources approved by the engineer, who may cancel his approval should in his opinion, the particular source, have become unsuitable. Approval of the crushed-stone material for the base will not relieve the contractor of his responsibility to produce a finished crushed-stone base constructed according to the specifications. (b) The underlying layer shall comply with the requirements for the layer concerned. The provisions of subsubclause 3403(b)(ii) shall (c) apply to the construction of a crushed-stone base. (d) No crushed-stone layer shall be rolled if the underlying layer, either on account of rain or by any other cause, is so wet as to constitute a danger of the underlying layers being damaged.

Sieve size (mm)

26,5 19,O 13,2 4,75 2,oo 0,425 0,075

+5
2 5 * 5
f5

+5
'5

+
2

*4
+3
2

a4

'4
+3

+7 2 7 +7
+5 +3
+5

+7
7 2 7 5 2 5 5 3
2

+2

3603

TRIAL SECTION AND OTHER REQUIREMENTS BEFORE THE CRUSHEDSTONE IAYER MAY BE CONSTRUCTED

3604

CONSTRUCTION

Before any crushed-stone layer is constructed, the following requirements shall be met: (a) Approval of base material will be granted only after (a) the successful construction of a trial section or sections complying in all respects with the specifications, including density and grading. No base material, except for the trial sections, shall be placed on the road unless the engineer has approved the base material in writing. A trial section shall be constructed from material from a proposed source (before 5 000 my has been produced), to prove the quality and compactibility of the material and to agree to a target grading for future construction lots where essentially the same material is used and it is processed essentially in the same manner. The trial section shall be constructed on a layer of the specified subbase standard and shall be placed as instructed by the engineer with due regard to the approved construction programme. The trial section shall be between 150 m and 200 m in length, or as otherwise ordered by the engineer. The width shall be as ordered by the engineer, whilst the thickness shall be the same as the base thickness specified for the pavement structure. The trial section shall be adequately assessed by the engineer prior to proceeding with the next one where so ordered, in order to rectify identified shortcomings. If a trial section fails, it shall be removed as excesslunsuitable material, unless it is structurally acceptable to the engineer to be retained as subbase. Where further trial sections are required for approval, the failed sections shall be removed before further trial sections may be constructed. Only trial sections in which the base material complies with all the requirements of the specifications shall be paid for. Payment for the construction of base will be made under the relevant Items of section 3600. Spreading and mixing

The contractor may elect to mix and spread crushed-stone material by means of a mixing plant and paver unit respectively, in which event the requirements of subclauses 3704(a) and (b) shall apply mutatis mutandis. Crushed-stone material complying with the requirements specified above shall be dumped in quantities sufficient to ensure that the completed layer will comply with all the requirements in regard to layer thickness, level, crosssection and density. Allowance shall also be made for sufficient extra material to enable the layer to be properly formed. The maximum compacted thickness of any layer of crushed-stone base compacted in one process shall be 150 mm, unless otherwise specified or permitted by the engineer. The dumps of material shall be spread out to a layer with a thickness which will be suitable for mixing. The required quantity of water shall then be added and the material mixed until a homogeneous mixture is obtained.

(b)

Compaction

After mixing, the crushed-stone material shall be placed ::, the correct thickness and level and thoroughly compacted by suitable equipment so that the specified density is obtained throughout the entire layer after slushing (except where the multi-stage process in subsubclause 3604(c)(ii) is prescribed). When required by the engineer, the density of the layer shall be tested at various prescribed depths.

The finally compacted layer shall be free from surface laminations, portions exhibiting segregation of the fine and coarse aggregate, corrugations, or other defects that may adversely affect the performance of the layer.

(c)

SurPace preparation of the base

Continuous process (watering and slushing)

plastic base. The completed layer shall be firm and stable with a closely knit surface aggregate exposed in mosaic and free from nests of segregated material, laminations or corrugations. During surface preparation of the base, care shall be taken not to-roll the surface out of shape,

(i)

Immediately after completion of the compaction described above, short sections of the surface shall be thoroughly watered, rolled and slushed by means of steel-wheeled rollers with a mass of not less than 12 tons each, and/or with pneumatic-tyred rollers. The process shall continue until all excess fines are brought to the surface. The grout thus formed shall be uniformly broomed over the surface with stiff brooms to correct any areas still deficient in fines, whereupon the excess fines shall be broomed from the surface of the layer. This process shall continue until all excess fines in the mixture have been brought to the surface of the layer and Its specified density has been reached. Excess fines and loose aggregate shall then be swept from the surface while the surface is still damp, and the layer shall then be allowed to dry out. During slushing operations, care shall be taken not to roll the surface out of shape. The slushing process shall be carried out on each section in one continuous process, and each section shall be completed before the next is proceeded with. After completion of the slushing and brooming process, when the layer is wind-dried, the surface shall be finally rolled with a steel-wheeled roller. The completed layer shall be firm and stable with a closelyknit surface of aggregate exposed in mosaic and free from nests of segregated material, laminations or corrugations. The engineer may permit omission of the slushing process in the lower layer of a two-layer base, provided that the specified density Is obtained in each of the layers. (ii) Multi-stage process (water or slurry rolling)

(d)
(i)

General Kerbing and channelling

Care shall be taken during rolling to ensure that concrete edging, kerbing and channelling already laid are not displaced or damaged. Any concrete edging, kerbing and channelling damaged during construction shall immediately be replaced or repaired by the contractor at his own expense. (ii) Excess crushed-stone material

Excess crushed-stone material shall not be spread over the shoulders or side fills, but shall be loaded and removed from the road. It shall not be re-used unless it has been rescreened, retested and again approved for use. It shall not be mixed with approved material unless screened, tested and again approved for use on its own. (iii) Junctions with existing bituminous surfaces

At junctions with existing bituminous surfaces, the new base shall not be feathered-off to obtain continuity of grade, but the existing work in the vicinity of the joint shall be cut back so as to ensure an overall compacted thickness of new base and surfacing of not less than 100 mm.

(e)

Breaking down existing crushed-stone layers

After the base has been compacted to the required density at optimum moisture content and has then been allowed to dry out to less than 50% of the optimum moisture content, the final surface of the base shall be watered and subjected to additional rolling (the so-called "slurry" or "water" rolling) in order to obtain a firm, even, well-knit surface. Watering, rolling with suitable rollers, and sweeping with stiff brooms shall continue until all excess fines on the surface have been distributed over the surface of the base.

The requirements of clause 3805 shall apply.

(f)

In sih~reconstruction of existing aushed-stone layers

Any areas deficient in fines shall be corrected by the addition of fine aggregate from the same source of supply as the crushed aggregate, and by brooming such fine aggregate into the surface voids of the layer until a firm base with a closely knit surface is obtained, free from nests of segregated materials, loose aggregate or other irregularities. All excess fines which cannot be redistributed shall be removed by brooming whilst still wet from the slurry roll watering, and the base shall then be allowed to dry out once again to less than 50% of the optimum moisture content so as to present an exposed mosaic of regular stone faces free from fine aggregate and foreign matter before any further treatment of the surface may be carried out. When using entirely non-plastic bases, it may be necessary to remove the final portions of excess fines from the surface after the base has been allowed to dry out to a degree which will be determined only by practical trial and error in each specific case of such a non-

Where specified in the project specifications and approved by the engineer, existing crushed-stone layers shall be reconstructed in situ in accordance with the requirements of subclause 3208(c). Where the existing layer thickness Is insufficient, additional material shall be added as specified in subsubclause 3207(b)(iii). The material added shall be GI,G2 or G3 material, depending on which type has been specified. Where the grading requires adjustment by the addition of specific fractions (eg crusher dust), the contractor shall comply with the provisions of the project specifications.

(g)

Work in restricted areas as defined in the first paragraph of dause 3608

The provisions of clauses 3207 and 3208 shall apply to the spreading, mixing and compacting of crushed-stone layers in restricted areas. Where conventional rollers cannot be used for the surface preparation process, the engineer may order that other approved compaction equipment be used.

Where any compaction work is being done adjacent to existing surfacing, care shall be taken not to damage the surfacing.

No traffic is permitted on the completed and primed layer. Only in exceptional cases may the engineer allow a limited amount of traffic on the layer.

(h)

Joints between existing layers and new or reconstructed layers

36Of5 CONSTRUCTION TOLERANCES

The completed crushed-stone layer shall comply with construction tolerances specified in clause 3405. Where a base is to be constructed in two layers, the requirements for grade, thickness, cross-section and smoothness shall not apply to the lower layer, but the lower layer shall be constructed with sufficient accuracy to enable the construction of the combined layer to be carried out to the tolerances specified. Where a crushed-stone base is placed directly onto an existing layer without it being required that the existing layer be finished to specified levels, the requirements for layer thicknesses of subclause 3405(b) shall not apply.

Where the base is not replaced or reconstructed over the full width, any existing unsuitable material shall be removed until a firm, well-compacted material is reached. Where the subbase has also been replaced or reprocessed, and unless otherwise determined by the engineer, the joint in the base shall not be directly above the joint in the subbase, but staggered by at least 100 mm. The aforesaid provisions shall also apply where a pavement is being widened. Where it is widened, the excavated material shall be disposed of and not used for widening the base. In both the above cases, the existing surfacing shall be removed to at least 100 mm outside the working area of the base. Where the existing base consists of cemented material, the existing material at the joint shall be cut with approved sawing equipment or milled out mechanically. Payment for sawing and milling will be in accordance with the provisions of section 3800.

3607 QUAUW OF MATEWALS AND WORKMANSHIP

Routine inspections and tests will be made by the engineer to determine whether the quality of material and workmanship complies with the requirements of this section.

Unless otherwise shown on the drawings or approved by the engineer, the joints in the bases shall not fall within a wheel track.

(i)

Watering and rolling the floor of a pavement excavation

Test results and measurements shall be assessed in accordance with the provisions of either section 8200 or 8300, depending on which section is indicated in the project specifications as being the appropriate section.

Where a crushed-stone layer is constructed on the floor of a pavement excavation, ie where the underlying layer has not been reconstructed, and where the engineer so orders, the floor of the excavation shall first be watered and rolled in accordance with the instructions of the engineer. The nominal number of roller passes shall be 5 passes with rollers specified in clause 3304.The engineer may, at his discretion, increase or decrease the number of roller passes or order the use of other rollers. Variations in the number of roller passes will be paid for under item 36.13.

3608 MEASUREMENT AND PAYMENT

Items 36.09, 36.10 and 36.14 are applicable solely to work that has to be executed in a restricted area of which the width is less than 3,Om or the length is less than 150,Om.

Item
36.01 Cmshed-stone base:

Unil

Where the material in the floor of the pavement excavation consists of crushed stone, the engineer may instruct that the floor be also watered and rolled.

(a)

Constructed from type

Gl material obtained from

commercial sources and compacted to 88% of apparent relative density (layer thickness indicated) . . . . . . . . cubic metre (ma) (b) Constructed from type

3605

PROTECTION AND MAlNTENANCE

The contractor shall protect and maintain the completed crushed-stone layer at his own expense until the next layer or the seal or surfacing is applied. The crhshed-stone base shall be primed as soon after construction as possible and as soon as the moisture content of the layer is below 50% of the optimum moisture content. Maintenance shall include the immediate repair of any damage to or defects in the layer and shall be repeated as often as is necessary. Repairs shall be so made as to ensure an even and uniform surface to be restored after completion of the repair work.

GI material obtained from

approved borrow pits, crushed by the contractor, and compacted to 88% of apparent relative density (layer thickness indicated) (c) Constructed from type

... .

cubic metre (ma)

G2 material obtained from

commercial sources and

compacted to 85% of bulk relative density (layer thickness indicated) . . . . . . . . cubic metre (m3) (d) Constructed from type G2 material obtained from approved borrow pits, crushed by the contractor, and compacted to 85% of bulk relative density (layer thickness indicated) . . . . . . . . cubic metre (m3) Constructed from type G3 natural material obtained from commercial sources (nominal maximum size of stone indicated) and compacted to:

and (d) for compaction to 86% of bulk relative density . . . . . . cubic metre (m3) The tendered rates shall include full compensation for all additional costs for compacting the material to the higher density.

Item

Unit

3 6 . 0 3 Crushed-stone base trial section

(thickness indicated) constructed in accordance with the pmvisions of dause 3 6 W . . . . . . . . . . . . square metre (m2)
The unit of measurement shall be the square metre of completed trial section approved by the engineer. The tendered rate shall include full compensation for constructing the trial section complete as specified. Only trial sections in which the base material and the completed layer comply with all the requirements of the specifications shall be paid for.

(e)

(i)

98% of modified AASHTO

density (layer thickness indicated) . . . . . . . . . . . . . . . . cubic metre (m3)

(ii)

100% of modified AASHTO density (layer thickness indicated) . . . . . . . . . . . . . . . . cubic metre (m3)
Constructed from type G3 natural material obtained from approved borrow pits, crushed by the contractor (nominal maximum size of stone indicated) and compacted to:

(f)

36.04 Crushed-stone base constructed

with matwial from existing pavement layers (indicate thickness of crushed-stone base in each case):
(a)

(i)

98% of modified AASHTO

density (layer thickness indicated) . . . . . . . . . . . . . . . . cubic metre (m3)

GI material compacted to 88% of apparent density:

Material from existing uncemented crushed-stone layers screened and recombined in a plant . . . cubic metre (m3) Material from existing cemented crushed-stone layers, not milled out but crushed, screened and recombined in a plant . . . . . . . cubic metre (m3) Milled-out material

(i)
(il)

100% of modified AASHTO

density (layer thickness indicated) . . . . . . . . . . . . . . . cubic metre (m3) (ii)

The unit of measurement shall be the cubic metre of completed crushed-stone base in place as the case may be, and compacted to the specified density. The quantity shall be calculated from the authorized dimensions of the layer as shown on the drawings or prescribed by the engineer. The tendered rates shall include full compensation for procuring, furnishing and placing all materials, including the crusher fines or sand (if approved) necessary for correcting the grading of the crushed stone, for crushing and screening, for hauling the material over an unlimited free-haul distance where material is obtained from commercial sources, and over a 1,Okm free-haul distance where material is obtained from approved borrow pits, for rolling, slushing and correcting the layers, and for testing, protecting and maintaining the work as specified.

(iii) (b)

.........

cubic metre (m3)

G2 material compacted to 85% of bulk relative density:

(i)

Material from existing uncemented crushed-stone layers: Unscreened . . . . . . . . . . . . . . . cubic metre (ma) Screened and recombined in a plant . . . . . . . . . . . . . . . . cubic metre (m3) Material from existing cemented crushed-stone layers, not milled but crushed, screened and recombined in a plant . . . cubic metre (m3) Milled-out material

(1)

(2)

(ii)

Item

Unit

3 6 . 0 2 Additional compaction:
(iii) (a) Extra over subitems 36.01(a) and (b) for compaction to 89% of apparent relative density . . . . . . . . . . . . . . . . . . cubic metre (m3) Extra over subitems 36.01(c) (c)

.........

cubic metre (m3)

G3 material compacted to 98% of modified AASHTO density:

Material from existing uncemented crushed-stone layers:

(i) (b)

(1) (2)

Unscreened . . . . . . . . . . . . . . . cubic metre (m3) Screened and recombined in a plant . . . . . . . . . . . . . . . . cubic metre (m3) Materlal from existing cemented crushed-stone layers, not milled but crushed, screened and recombined in a plant . . . cubic metre (m3) Milled-out material
36.05 h situ reconstructed uncemented crushed-stone base (indicate thickness o f aushedstone base in each case):

(ii)

(a)

G I material, compacted to 88% of apparent relative density . . . . . . . . . . . . . . . . . . cubic metre (m3) G2 material, compacted to 85% of bulk relative density G3 material, compacted to 98% of modified AASHTO density . . . . . . . . . . . . . . G3 material, compacted to 100% of modified AASHTO density . . . . . . . . . . . . . .

(ill) (d)

.........

cubic metre (m3) (b)

G3 material compacted to 100% of modified AASHTO density: (c) Material from existing uncemented crushed-stone layers: Unscreened . . . . . . . . . . . . . . . cubic metre (m3) Screened and recombined in a plant . . . . . . . . . . . . (d)

. . cubic metre (m3)

(i)

. . . . cubic meter (m3)

. . . .cubic metre (m3)

(1)
(2)

. . . . cubic metre (m3)

(ii)

Material from existing cemented crushed-stone layers, not milled but crushed, screened and recombined In a plant . . . cubic metre (m3) Milled-out material

The unit of measurement shall be a cubic metre of completed crushed-stone base. The quantity shall be calculated in accordance with the authorized depth and area of the existing broken up layer. The tendered rate shall include full compensation for breaking up the existing crushed-stone layer to the specified depth, breaking down and preparing the material, spreading and mixing the crusher dust or sand necessary for correcting the grading of the material, placing and compacting the crushed-stone layer, and watering and rolling the underlying layers. The tendered rate shall also include full compensation for spreading and mixing in the additional approved crushed stone where the existing layer thickness is inadequate, and the increase of the layer thickness is specified or ordered by the engineer. Payment for breaking down, placing and compacting the material temporarily removed to windrow to expose or remove underlying material, shall be made under this Item. The operation to cut material to windrow and later to cut back such material will be paid for under item 36.06. The tendered rate for material mixed with existing surfacing material shall also include full compensation for breaking down fragments of surfacing material by hand, and for removing oversized fragments by hand.

(iii)

. . . . . . . . . cubic metre (m3)

The unit of measurement shall be a cubic metre of completed crushed-stone base. The quantity shall be calculated in accordance with the authorized dimensions of the layer. If the underlying layer has not been reconstructed or reworked, but only rolled, or where no work has been done on it, the quantity shall be calculated from the measured cross-sections before and after placing the layer, but subject to the provisions of clause 1220. The tendered rate shall include full compensation for breaking up the existing pavement layer, excavating the material from the existing pavement, loading the material, mixing in the crusher fines or sand required for rectifying the grading of the material, transporting the material for a free-haul distance of 1,O km, and placing and compacting the material, slurrying, and watering and rolling the underlying layers. The tendered rate under subsubitem 36.04(a)(i) shall also include full compensation for screening and recombining the material to comply with the specified requirements. The tendered rate under subsubitem 36.04(a)(ii) shall also include full compensation for crushing, screening and recombining in an approved plant. The tendered rates for milled-out material shall also include full compensation for loading the material at the stockpile and for hauling it to a screening plant where applicable or to the polnt of use for a free-haul distance of 1,O km, and for any additional processing required to bring the material up to the required standards, but shall not include compensatlon for milling.

ltem
36.06 Exira over item S.05 for temporarily blading the material to windrow . . . .

Unit

.....

cubic metre (m')

The provisions under item 34.07 shall apply.

The tendered rates for material mixed with existing surfacing material shall also include full compensation for breaklng down fragments of bituminous material to the specified maximum size and for removing over-sized fragments by hand.

36.07 Crusher fines or sand for improving the grading o f recovered aushed stone:
(a) Material from approved borrow pits . . . . . . . . . . . . . . . . . . . . . cubic metre (m3)

(b)

Material from commercial sources . . . . . . . . . . . . . . . . . . cubic metre (my)

(b)

Cemented crushed stone

....

cubic metre (ma)

The unit of measurement shall be a cubic metre of approved material added on the instruction of the engineer, and the quantity shall be the loose volume measured in trucks. The tendered rate for subitem (a) shall include full compensation for procuring and providing the material and hauling it over a free-haul distance of 1,Okm. The tendered rate for subitem (b) shall include full compensation for procuring and providing the material from commercial sources and hauling it from the source to the point on the site where required.

The unit of measurement shall be a cubic metre of material excavated in a restricted area, the quantity of which shall be calculated in accordance with the area and the average thickness of the layer excavated. The tendered rate shall include full compensation for all additional costs for executing the work In restricted areas.

Item
36.10 Exba over payment for placing and compacting or for in situ reconsbvction of crushedstone base in resbicted areas:

U n i t

Item
36-08 Extre over item 36.05 for using added a u s h e d d m , material:

U n i t

(a)

Extra over item 36.04for placing and compacting material from existing pavement layers . . . . . . . . . . . . . . . . . . . cubic metre (my) Extra over item 36.05for in situ reconstructing uncemented crushed-stone base cubic metre (m3)

(b) (a) Material from approved sources on the site:

........

(i) ( i ) (iii)

G1 material G2 material G3 material

..............
..............
..............

cubic metre (my) cubic metre (my) cubic metre (my)

The unit of measurement shall be a cubic metre of crushed-stone base constructed in restricted areas, the quantities of which shall be calculated as determined for the item concerned.

@) (1)
( i) (lii)

Material from commercial sources:

GI material G2 material G3 material

.............. ...............

cubic metre (my) cubic metre (my)

The tendered rates shall include full compensation for all additional costs for executing the work in restricted areas, irrespective of the density required.

..............

ltem cubic metre (m3)

36.11 Compacting the floor of pavement excavaljons (5 roller passes) with:

U n i t

The unit of measurement shall be a cubic metre of approved material added on the instruction of the engineer. The quantity shall be taken as being 70% of the loose volume measured in the trucks. Only approved freshly broken stone from a commercial source, crusher plant or stockpile shall be paid for. The tendered rate for subitem (a) shali include full compensation for the additional cost of providing the material and hauling it over a free-haul distance of 1,Okm. The tendered rate for subitem (b) shall include full compensation for the additional cost of providing the to it from the source where it was material and trans~ortina obtained to the point on-the site where it is required. Compensationfor processing and compacting the material shall be Included in the rate for item 36.05.

(a) (b) (c) (d) (e)

Vibratory rollers Oscillatory rollers Grid rollers

. . . . . . . . . . square metre (m2)

.........
square metre (m2)

. . . . . . . . . . . . . . square metre (m')

Flat-wheeled rollers

....... .....

square metre (rn2) square metre (m2)

Pneumatic-tyred rollers

The unit of measurement for compaction shall be a square metre of pavement excavation floor compacted by means of 5 passes by one of the above-mentioned rollers on the instruction of the engineer.

ltem

Unit The tendered rate for compaction shali include full compensation for supplying the rollers, compaction with 5 roller passes, and afterwards removing the rollers. The engineer may increase or decrease the number of roller passes, in which case payment will be adjusted in accordance with item 36.13.

36.09 ExGe over item 36.04for exanrating awhed stone from existing pavements in restricted

areas:
(a) Non-cemented crushed stone

cubic metre (m3)

Item
36.12 Water for compacb'ng the pavement e x d ' o n floor

U n i t

. . . . . . . . kilolitre (kt)

The unit of measurement shall be a kilolitre of water applied to the floor of the excavations to be compacted on the instruction of the engineer. The tendered rate shall include full compensation for procuring, applying and mixing in the water, and for all haul.

No payment shall be made under this item If the crushedstone material is supplled from commercial sources or from a crusher that had been erected or was in operation prior to the award of the contract, or from a crusher that is not completely or directly under the control of the contractor. In such cases payment under subltems 36.01(a), (c) and (e), 36.07(b) and 36.08(b) shall Include full compensation for the work performed In accordance with this section. The unit of measurement for establishing the multi-stage crusher and screening plant and opening the borrow pits shall be the number of times when the plant is set up and dismantled, with the approval, in writing, of the engineer, at approved sources of supply, for the purpose of supplying crushed-stone material for base. The tendered rate shall include full compensation for the provision and erection of the multi-stage crusher and screening plant complying with the requirements of clause 3205, ready for crushing, its later dismantling and removal afler completion of the crushing operations, and the work involved in opening the borrow pits, including clearing, establishing a working face, and finishing-off the borrow pit upon completion of the operations. Where item 36.15 applies in clrcurnstances as described above, and only where such circumstances shall apply, payment shall also be made for removing excess overburden and for overhaul in excess of 1,O km as indicated below. Crushed stone stockpiled on the site will only qualify for payment as "material on the site" where the engineer is satisfied that the material complies with all the speclfied requirements. Where the contractor himself produces the crushed stone, its value per cubic metre, measured loose in stockpile, will be taken as not exceeding 45% of the tendered rate per cubic metre of compacted material.

b m
36.13 Variations in the number of roller passes applicable to item 36.11:

Unit

(a)

Vibratory roller

... . . . . . . .

square metre-pass (m2-pass) square metre-pass (m2-pass) square metre-pass (m2-pass) square metre-pass (m2-pass) square metre-pass (m2-pass)

(b)

Oscillatory roller

. . . ... . . .

(c)

Grid roller

.. . ... . . ..... ....... . ...

(d)

Flat-wheeled roller

(e)

Pneumatic-tyred roller

The provisions under item 33.06 shall apply.

Item

Unit

36.14 ExGe mer 'mm 36.11 for compacting the floor of pavement excavations in resbicted areas . . . . . . . . . . . square metre (m2)

Notes:
(1)

Payment items from other sections

The unit of measurement described in item 36.11 shall apply. The tendered rates shall include full compensation for all additional costs for compacting the pavement excavation floor in restricted areas irrespective of the compacting equipment used or the density required.

Where material has been obtained from approved borrow pits on the site, whether indicated on the plans or approved afler work has started and the engineer has instructed that the borrow pits be used, the followlng payment items from other sections shall apply to crushed stone, but shall be listed under this section in the schedule of quantities. ltem 16.02 Overhaul for material hauled in excess of 1.0 km.

b m
36.15 Establishing a multi-stage crusher and saeening plant and opening bomm pits where stone is obtained fmm approved bomm pits and crushed by the contractor . . . . . . . . . . . . . . . . .

Unit

Item 31.02

Excess overburden in borrow pits for obtaining crushed stone for pavement layers.

..

number (No) ltem 31.03 Finishing-off borrow plts.

Where the material for crushod-stone base is obtained by the contractor from approved borrow pits, whether indicated on the borrow-pit plans or approved afler construction has started, the contractor shall be entitled to the compensation provided by item 36.15, provided that prior instructions have been obtained from the engineer to crush such material.

ltem 32.06

Stockpiling of material.

ltem 38.09

Removing the remaining asphalt from the underlying surface.

Overhaul shall apply to material obtained from existing pavements, and the distance is measured along the centre line of the road from the point of excavation to the point of use on the road if used directly, or from the stockpile or

processing plant if stored with the approval of the engineer or processed in a plant (see also subclause 3807(b)). Overhaul shall also apply to fines and additional crushed stone used on the instruction of the engineer. Where the fines or additional material is obtained from a commercial source, no overhaul will be payable (see items 36.07 and 36.08).

SERIES 3000 :

EARTHWORKS AND PAVEMENT LAYERS OF GRAVEL OR CRUSHED STONE

SECTION 37UO : PLANT-MIXED PAVERWD PAVEMENT LAYERS

Aggregates for stabilized pavement layers may consist of either natural gravels, crushed stone or crushed natural gravels. Aggregates for wet lean-mix concrete shall consist either of a mixture of nominal 19.0 m m sized stone and sand or it may be a graded crushed stone with or without sand. Requirements regarding the properties of the aggregates shall be in accordance with the project specifications and, where applicable, the approved source or sources of material will be indicated.

CONTENTS
SCOPE MATERIALS REQUIREMENTS TO BE MET BEFORE PAVEMENT LAYER MAY BE CONSTRUCTED CONSTRUCTION CURING PROTECTION AND MAINTENANCE TRIAL SECTION TOLERANCES ROUTINE INSPECTION AND TESTS MEASUREMENT AND PAYMENT

(c)

Wate~

Water shall not contain any deleterious materials in harmful concentrations. Only approved sources of water shall be used.

3701

SCOPE

3703

REQUIREMENTS TO BE MET BEFORE A PAVEMENT LAYER MAY BE CONSTRUCTED

This section covers the construction of plant-mixed paverlaid pavement layers for concrete pavement. The pavement layer shall consist of any of the following as may be required: (a) (b) Stabilized crushed stone Wet lean-mix concrete

Before any pavement layer is constructed. the underlying layer shall be inspected for compliance with the specifications for the layer concerned. Any damaged sections or sections which do not comply with the specified requirements shall be repaired or replaced to the satisfaction of the engineer. No construction shall commence if the underlying layer is wet enough to be damaged by the construction of the pavement layer. The underlying layer shall be free from loose or extraneous material.

Layer thicknesses shall be in accordance with the drawings, and all materials shall be mixed at a central mixing plant and laid by paver.

37W

CONSTRUCTION

(a)

Stabilizing agents

(a)

Hxing and transporting

The stabilizing agents shall be any of the following as specified in the project specifications or as directed by the engineer: (i) Ordinary portland cement complying with the requirements of SABS 471. Portland blast-furnace cement complying with the (ii) requirements of SABS 626. A mixture of ordinary portland cement and milled (iii) granulated blast-furnace slag in the proportion of 5096 ordinary portland cement to 50% granulated blast-furnace slag or as specified by the engineer. Milled granulated blast-furnace slag shall comply with the requirements of SABS 1491 : Part I and shall have a specific surface area of not less than 0,35 m21g and the residue on a sieve with square openings of 0,075 m m shall not exceed 10%. (iv) Portland fly ash cement complying with the requirements of SABS 1466

Mixing shall be done at a location off the road by means of a central mixing plant. Mixing the materials on the road will not be allowed. The stabilizing agent content and the type of stabilizing agent shall be as specified in the project specifications or as directed by the engineer. The aggregate or gravel and stabilizing agent shall be thoroughly mixed at the mixing plant either by batch-type mixing with revolving blade or rotating-drum mixers or by the continuous-mixing process with suitable pugmill-type mixers. at the option of the contractor. The aggregate or gravel and stabilizing agent shall be measured by mass. In all plants the water may be measured either by mass or by volume and provision shall be made for readily checking the quantity of water per batch or the rate of flow in a continuous-mixing plant.

Any other stabilizing agent as may be specified in (v) the project specifications.

Where mixtures of cement and milled slag are used as stabilizing agents. the mixing plant shall contain separate hoppers for the cement and the slag and the introduction of each of these materials into the mix shall be controlled so as to ensure the correct quantity of each material being added every time.

The method of introducing the various materials comprising the final mix shall be subject to the engineer's approval. He shall be entitled to reject a process which in his opinion may not consistently produce a mix with the required proportions. The mixed material shall be so loaded into the trucks used for transporting the material that segregation will not take place while the material Is being loaded into the trucks. Care shall be taken to prevent excessive loss of moisture between the time when the materials are mixed and when they are compacted on the road. Where necessary, trucks shall be provided with protective covers to limit the loss of moisture.

crushed-stone layers, and, if water Is added during or after the compaction process, it shall be carefully controlled, as the excessive application of water will not be allowed. (ii) Wet lean-mix concrete

In the case of wet lean-mix concrete, the stabilizing-agent content will generally be higher than that of stabilized crushed stone and compaction to a specified density by normal rolling techniques will not be requlred, but the paver shall be fitted with a vibrating screed capable of thoroughly compacting the material and striking it off to a smooth dense surface. (iii) Moisture content

The mixture shall be spread by mechanical paver on the underlying layer to the required width and to such thickness as will comply with the requirements specified in clause 3708 after final compaction. Segregation of the materials shall be avoided and the layer shall be free from pockets of coarse or fine materials. Immediately prior to spreading the material,the underlying layer shall be moistened and kept moist but not excessively wet.

Notwithstandingany other requirements set out elsewhere, the moisture content of the mix, whether for stabilizingagent-treated crushed stone or for wet lean-mix concrete, shall not exceed 85% of the saturated moisture content as defined in clause 8107.

(d)

Consbudon joints

At the end of each day's work, and when operations are delayed or stopped for more than two hours, a construction joint with a vertical but rough face shall be made in thoroughly compacted material, at rlght angles to the centre line of the road. Additional mixture shall not be placed until the construction joint has been constructed.

H longitudinal construction joints are necessary, they shall be constructed in the positions shown on the drawings.
(c)
(i)

Compaction
Stabilized crushed stone The stabilized pavement layers and wet lean-mix concrete pavement layers shall be of a uniform consistency. All coarse segregated areas shall be removed. The edges of the holes so formed shall be painted with a slurry of cement and water.

The spread mixture shall be compacted at or near the same optimum moisture content as that in the plant. The completed compacted layer shall have a dry density of not less than that specified in the project specifications, and the contractor may select any suitable compaction technique to achieve this required compaction, subject to the following conditions: Not more than one hour shall elapse between the time of starting the mixing process and that of starting to compact the material. The initial compaction shall be carried out with plant which will achieve a stability suitable for subsequent compaction without causing undue displacement of the material or deformation of the layer. Normally a ballasted 3-wheel steel wheel roller should be suitable for this operation. The rolling pattern shall be so designed as to retain the shape of the layers. From the time when the stabilizing agent, gravel or aggregate and water are added together and mixed, not more than three hours shall elapse until the compaction has been finally completed. Compaction equipment shall be adequate for obtaining the specified density within the specified time limits. The compaction equipment and techniques shall be capable of producing the specified surface finish and density without any interruption. The layer shall not be slushed as specified for untreated

The holes shall then be backfilled with stabilized crushedstone material or lean-mix concrete compacted to the required density and finished off to the required elevation. Such patches shall be cured as specified below. Any portion of the pavement layer which does not meet the specified requirements shall be corrected by approved methods to the satisfaction of the engineer at the contractor's cost.

3705

CURING

The pavement layer shall be cured in accordance with the requirements of subsubclause 3503(h)(v). Thereafter a curing membrane as specified in the project specifications shall be sprayed onto the layer. Before the application of the curing membrane, the surface of the layer shall be thoroughly cleaned and all loose material and dirt removed.

Alternatively, if allowed for in the project specifications, a concrete curing membrane may be applied Immediately after the completion of the stabilized layer.

3706

PROTECTION AND MAlNTENANCE

tolerances indicated in clause 3405.

The contractor shall cure, protect and maintain the completed layer until the next pavement layer is placed. Maintenance shall include the immediate repair of any damage or defects that may occur in the layer and shail be repeated as often as is necessary for keeping the layer constantly intact and in a good condition. Repairs shall be made in a manner approved by the engineer to ensure an even and uniform surface. Traffic shall not be allowed onto any completed layer unless unavoidable and if so authorized by the engineer. The next pavement layer shall not be constructed on a layer which is less than seven days old.

@)

Stabilizing-agent content and mix uniformity

The stabilizing-agent content and mix uniformity shall be subject to the provisions specified in clause 3506 for chemical stabilization.

3709

ROUTINE INSPECTION AND TESTS

Routine inspection and tests will be made by the engineer to determine the quality of the materials and workmanship for compliance with the requirements of this section. Test results and measurements will be assessed in accordance with the provisions of sections 8200 or 8300 according to which section is indicated In the project specifications as being the appropriate section.

3 7 0 7 TRIAL SECTION

Prior to commencing with the construction of the specified plant-mixed paver-laid pavement layer, the contractor shall construct a trial section of the pavement layer, in a position approved by the engineer, to demonstrate the capability of the contractor to construct the pavement layer in accordance with the specifications. The trial section shall be constructed with the same materials and equipment as those intended for use by the contractor for the pavement layer, and he shall also demonstrate the methods he proposes to use for the making of construction joints. An initial trial section of not less than 150 m in length constructed in one continuous operation shall be submitted for approval. The engineer shall also be entitled to call for a new trial section to be constructed at any stage of the contract when changes by the contractor in the approved equipment, materials, mix or rate of paving warrant the construction of another trial section. The contractor will be paid for the actual length of trial pavement layer constructed as initial trial section and trial sections constructed in consequence of changes in mixes. techniques, materials, etc. effected by the contractor, but in this respect he will not be paid for a total length exceeding 300 m. In addition. he will be paid for any trial lengths necessary as a result of similar changes required by the engineer, notwithstanding the fact that the trial section built by the contractor complied with the specified requirements. The contractor may, unless advised of any deficiencies in the trial section, proceed with the construction of the pavement layer ten days after the completion of the trial section or such earlier time as the engineer may determine. In the event of deficiencies in the trial section. the engineer may order the contractor to construct a further trial section. which will again be regarded as the initial trial section. Where required by the engineer a rejected trial section shall be removed and disposed of by the contractor at the contractor's cost.

37 10

MEASUREMENT AND PAYMENT

Item
37.01 Stabilized aushed stone

mixed in a plant and placed by paver (pavement layer, type of material and source indicated) . . . . . . . . . . . . . . . . cubic metre (rn')
The unit of measurement shall be the cubic metre of completed stabilized crushed stone. the quantity of which shall be calculated in accordance with the authorized dimensions of the layer as shown on the drawings or as directed by the engineer. The tendered rate shall include full compensation for procuring. furnishing and placing all materials, but shall exclude the provision of the stabilizing agent and a curing membrane. The tendered rate shall also include full compensation for hauling material for an unlimited freehaul distance in the case of crushed-stone aggregates obtained from commercial sources, and for a free-haul distance of 1.0 km in the case of material obtained from approved borrow pits on the site, and for compacting, curing and correcting the stabilized layers, including protecting and maintaining the work as specified.

Item

37.02 Wet leanmix concrete! pavement layer (indicate

specific pavement layer)

. . . . . cubic metre (m')

The unit of measurement shall be the cubic metre of wet lean-mix concrete pavement layer measured as specified for item 37.01 above. The tendered rate shall include full compensation for procuring and furnishing all the materials. excluding the supply of the stabilizing agent and curing membrane. The tendered rate shall also include full compensation for mixing the materials, hauling the material over an unlimited free-haul distance. for placing, compacting. curing and correcting the wet lean-mix concrete layers. including

3708

TOLERANCES

(a)

Construction tolerances

The applicable construction tolerances are the relevant

protecting and maintaining the work as specified.

ltem

unit

The unit of measurement shall be the litre of material specified conforming to the relevant specifications measured at spraying temperature and sprayed as required in section 4100 for bituminous material and the project specifications for products other than bituminous materials.

(a) (b)

Ordinary portland cement Portland blast-furnace cement . . . . . . . . . . Milled granulated blast-furnace slag

. . . . . . . . . . . . ton (1)

. . . . . . . . . . . . . . . . ton (1)
ton (1)

The tendered rates shall include full compensation for supplying the material, preparation of the surface before applying the membrane, applying the material and maintaining the surface as specified.

(c)

..................

(d) (e)

Portland fly ash cement Others (specify)

. . . . . . . . . . . . . ton (t)

37.05 Trial section of pavement layer (specify width) . . . . . . . . . . . . . . . .

. . . . . . metre . (m)

. . . . . . . . . . . . . . . . . . . . ton (t)
The unit of measurement for the trial section of the plantmixed paver-laid pavement layer shall be the linear metre of trial section of the specified width measured along the centre line of the road. Not more than a total length of 300 m of trial section will be measured for payment as described in clause 3707.

The unit of measurement shall be the ton of stabilizing agent. Measurement shall distinguish between the various types of stabilizing agent used. When a mixture of cement and slag is prepared on the site, the quantity of each constituent shall be measured separately. The quantity shall be the quantity of stabilizing agent as specified or as ordered by the engineer and actually provided within the layer concerned. The tendered rates shall include full compensation for the provision of the stabilizing agent within the works irrespective of the specified rate of application or that ordered by the engineer. The rate for milled granulsted blast-furnace slag shall include full compensation for any additional work or costs resulting from it being mixed with Portland cement.

The tendered rate shall include full compensation for constructing the trial section complete as specified.

Note:

ltem

Unit

3 7 . 0 4 Curing membrane:
(a) (i) (ii) (ili) Bituminous membrane:

Where material has been obtained from approved borrow pits on the site. whether indicated on the plans or approved after work has started and the engineer has instructed that the borrow pits be used, the following payment items from other sections shall apply to crushed stone, but shall be listed under this item in the schedule of quantities.

ltem 16.02 MC 30 cut-back bitumen MC 70 cut-back bitumen

............

litre ( I )

Overhaul of material exceeding 1,O km.

for

distance

. . . . . . . . . . . . . litre ( I )
ltem 31.02 Excess overburden in borrow pits for obtaining crushed stone for pavement layers Finishing-off borrow pits

Spray-grade bitumen emulsion . . . . . . . litre ( I ) Other (specify)

@)

. . . . . . . . . . . . . . . . . . . litre

(1)

ltem 31.03

SERIES 3000 :

EARTHWORKS AND PAVEMENT LAVERS OF GRAVEL OR CRUSHED STONE

(d)

Cemented crushed stone

SECTION 3800 : BREAKING UP WSTING PAVEMENT LAYERS

Cemented crushed stone shall be existing cemented material consisting of crushed stone. Unless specified as such in the project specifications, cemented crushed stone will not be classified as concrete.

CONTENTS 3801 3802 3803 3804 3805 3806 3807 SCOPE SELECTING THE MATERIAL CLASSIFYING THE MATERIAL PLANT AND EQUIPMENT CONSTRUCTION STORING RECOVERED PAVEMENT MATERIAL MEASUREMENT AND PAYMENT

(e)

Milled material

Milled material shall be bituminous material and/or cemented crushed stone excavated with an approved milling machine. Milled material will be classified as such only when milling is specified or ordered by the engineer, in writing. Payment will normally distinguish between milling of asphalt and of cemented crushed stone.

3804
3801

PLANT AND EQUIPMENT

SCOPE (a) Milling equipment

This section covers the breaking up and excavation of existing pavement layers by conventional means or by milling, selecting the material, and the removal thereof to spoil dumps or to stockpiles for later reprocessing or recycling.

Only approved milling plant may be used. The plant shall be so equipped that it will be able to mill out asphalt and/or cemented material to the prescribed depth in one operation over the width specified in the project specifications. The milling depth shall be controlled electronically. The direction and speed of the milling machine and the speed of rotatlon of the milling drum shall be adjustable so as to obtain the required grading of the milled material. The machine shall be capable of making a neat vertical cut at the outer edges when milling the layer and to leave the floor of the cut level and with a uniform texture.

3802 SELECTING THE MATERlAL

Material from existing pavements may only be used for purposes approved by the engineer. The material shall be so excavated that material from the various pavement layers will not be mixed unless so permitted by the engineer, in writing.

3803 CLASSIFYING THE MATERlAL

Unless otherwise specified in the project specifications, the mllling machine shall be equipped with a self-loading conveyor belt which can be easily removed and installed and adjusted for slope and direction.

Material from existing pavements shall be classified as follows for excavation and processing purposes: @) (a) Existing bituminous material General

Existing bituminous material shall be asphalt or other bituminous seal or base material removed separately from the existing layers on the instruction of the engineer. Where underlying material is broken down or excavated together with bituminous materials, the mixture will not be classified as bituminous material for payment purposes.

The equipment to be used for the conventional breakingup and excavation of existing pavement layers will be determined by the size and depth of the pavement section to be processed or excavated, taking into consideration of the fact that work may have to be carried out in restricted areas. Only approved cutting or sawing equipment may be used for cutting or sawing the asphalt layers. The equipment shall be capable of cutting the asphalt layers to the specified depth in one operation without fragmenting the material, and in straight lines within the required tolerances.
3805

@)

Noncemented material

Non-cemented material shall be existing pavement material which can be ripped with the teeth of a 140G Caterpillar or similar grader.

(c)

Cemented material

CONSTRUCTION General

Cemented material shall be existing pavement material which cannot be ripped with a type 140G Caterpillar or similar grader. Existing stabilized material will not necessarily be classified as cemented material.

(a)

Where all or a part of the existing surfacing material is to be reprocessed together with the underlying layer, the

surfacing shall be properly broken down and mixed through the full depth of the existing base material to the satisfaction of the engineer. Fragments of bituminous material shall be broken down to sizes not exceeding 37.5 mm. Where specified in the project specifications or ordered b y the engineer, the existing bituminous material shall first be removed before the underlying layers are broken up. Bituminous material may be milled out or otherwise broken up and removed to approved stockpile sites for recycling or to spoil sites, whichever is required. Where the underlying material is to be reprocessed as base, the exposed surface shall be cleaned to the satisfaction of the engineer after removal of the bituminous material. All remaining fragments of bituminous material shall be removed, and not more than 5% of the surface may be covered with bituminous material. The existing pavement material shall be broken down to the specified depth and removed, or reprocessed in place, whichever may be required. The underlying layers may not be damaged, and material from one layer may not be mixed with that of another layer. Where such mixing occurs or where the material is contaminated in any other way by the actions of the contractor, he shall remove such material and replace it with other approved material, all at his own cost. Where a layer or layers require to be broken down over part of the pavement width only, the limit of the work shall be clearly demarcated, which limit shall not be exceeded by the contractor by more than 100 mm. Pavement layers broken down outside the specified limits shall be repaired by the contractor at his own cost, to the satisfaction of the engineer.

@)
(i)

Milling
Preparing the pavement surface

Before milling may be commenced, the pavement surface shall be clean and free from soil or other deleterious material. Where only part of the pavement is to be mllled out, the milling area shall be properly demarcated. Milling may not exceed the required width by more than 50 mm. Payment will not be made for milling beyond the required width, which shall be backfilled with approved material in accordance with the provisions for the specified pavement material at the cost of the contractor. (ii) Trial milling

Where ordered by the engineer, the contractor shall execute trial milling on the various materials to be milled. During the trial work, the contractor will be expected to vary the direction and speed of the milling machine, the speed of rotation of the milling drum, and also the milling depth, in order to obtain milled material of the required grade. No payment will be made for trial milling. (iii) Asphalt

Where the asphalt and/or the cemented base must be reused, the asphalt shall be removed separately. Where the asphalt consists of layers of various mixes or grades, the engineer may instruct the separate removal of the layers to different stockpiles. Where the milled material is not conveyed directly by conveyor belt and then loaded, and the engineer so approves, the material shall first be cut to windrow and then loaded. During loading, the floor of the excavation or the underlying material shall not be damaged. The milled material shall be inspected and classified in accordance with the various types of asphalt and its suitability for recycling. Different stockpiles shall be used for the different types of material as ordered by the engineer. Contamination of the asphalt with underlying material will not be permitted, and the contractor shall adjust the depths of milling in accordance with the thickness of the layer. (iv) Milling in restricted areas

Where so ordered by the engineer, asphalt and cemented layers shall be cut or sawn'through to the specified depth along the measured limit with approved equipment. Payment will be made for sawing only where specified on the drawings or ordered, in writing, by the engineer.

Payment will not be made for sawing or cutting work where the existing layer requires removal by milling.

Extra over payment shall only apply to milling in widths of less than 1.0 m. Where existing roads have to be widened, the existing pavement layers shall be cut back to a firm, wellcompacted or cemented material. Material so broken up, if acceptable, may be used togetherwith imported material in the widening process, except in the case of crushedstone base. Where existing pavement layers are widened, separate payment will not be made for cutting back into the existing pavement layers unless so specified in the project specifications, irrespective of the type of material in the existing pavement layer. Where pavement layers are broken down over a section of the road width or where pavement layers are widened, the engineer may order, in writing, that the various pavement layers be excavated in benches in accordance with his instructions. No additional payment will be made for excavating benches. (v) Cemented material

Unless otherwise specified milled cemented material to be reprocessed on the road shall first be windrowed with a view to inspecting the underlying surface for any patches of poor or unsuitable material. Where unsuitable material is encountered in the floor of the excavation, such material shall first be removed b y further milling (where the underlying layer also consists of the cemented material), or by other approved methods, all to the satisfaction of the engineer. The unsuitable material shall be replaced with approved material of the required type, which shall be placed in accordance with the specifications for the relevant underlying layer. Where in the opinion of the engineer It may be necessary,

he may instruct the contractor to taper the ends or edges of a milled excavation for which payment will be made. provided that the tapering is not the result of defective work. Payment for the milling-out of cemented crushed stone will distinguish between the various strengths of the cemented layer. Where the engineer is of the opinion that the existing cemented layer has a compressive strength exceeding 10 MPa, he may instruct the contractor to drill cores from the layer and have them tested for compressive strength in accordance with the provisions of SABS method 865. The number of cores to be drilled out and the drilling locations will be determined on site by the engineer. (vi) General

contamination shall be removed. The site shall be graded smooth with an adequate slope to ensure proper drainage of water. Where so instructed by the engineer, the surface shall be watered and compacted to a depth of at least 150 m m to a density of 90% of modified AASHTO density. The compacted surface shall be firm without any loose patches. Where asphalt is recovered for recycling, the engineer may order the surface to be chemically stabilized to a depth of 150 mm. Upon completion, this surface shall be swept clean. Stockpile sites shall be sufficiently large to allow the placing of stockpiles of different types of material or types of recovered asphalt without the stockpiles overlapping or the limits of the prepared site being exceeded. The enlargement of the stockpile site afler the stockpiles have already been placed will not be permitted without the approval of the engineer. Stockpiles of milled material shall be shaped in a manner which will limit segregation to a minimum. The stockpiling of asphalt shall be done in a manner that will limit consolidation to a minimum. Adequate approved covers shall be provided for recovered asphalt stockpiles to prevent them from becoming wet, or being contaminated by dust. Upon completion of the work, the stockpile sites shall be broken up in accordance with the instructions of the engineer. The stockpiling of excavated material will not be paid for directly, but full compensation therefor shall be included in the rates for the various items of work in which the stockpiled material will be used. Separate payment will be made for the preparation of storage sites.

The floor of the milled excavation shall be level and with an even texture without any loose patches or patches of unsuitable material occurring. Loose patches and patches with unsuitable material shall be remedied in accordance with the instructions of the engineer. Payment for removing and replacing unsuitable material and remedying loose patches shall be as specified elsewhere in these specifications. Where such remedial work is done in restricted areas, the extra over payment concerned shall be in accordance with the provisions of the appropriate clauses. Where the floor of an excavation is tested in the longitudinal direction with a 3 m straight-edge, and in other directions with a 3 m straight-edge or a straight-edge of such shorter length as fits in between the longitudinal sides of the excavation, the surface shall not deviate by more than 7 m m from the bottom edge of the straightedge. Payment for milling will distinguish between various types of milled material and between various milling depths.

XKl7

MEASUREMENT AND PAYMENT

(c)

Treatment of pavement excavation floor

(a)
(i)

General Material to be reprocessed

The floor of any pavement excavation where material is not milled out, shall be treated and paid for as specified in the relevant clauses of sections 3400 and 3600. Milled surfaces shall be treated and paid for as specified in the project specifications.

Direct payment will not be made for breaking up and excavating existing pavement material that is reprocessed and re-used, except when the material is milled out in accordance with the provisions of the project specifications or upon the written instruction of the engineer; bituminous surfacing or other bituminous pavement layers are removed separately from the underlying material in accordance with the project specifications or the written instructions of the engineer. Full compensation for excavating existing pavement material. where the excavation thereof is not payable separately. shall be included in the rates tendered for the various pavement layers and items of work in which the material is used. as provided in the relevant specifications. (ii) Removal of bituminous layers (except milled material) Separate payment will be made for removing existing bituminous material separately from the underlying layer, when it is not milled out in accordance with the project

3806

STORING RECOVERED PAVEMENT MATERIAL

Excavated pavement material intended for reprocessing but which cannot he reprocessed in place or. in the opinion of the engineer, cannot be windrowed next to the excavation, nor placed in position directly at any other place, and material intended for recycling or reprocessing in a plant, shall be transported to approved stockpiles with the written permission of the engineer. Stockpile sites for material intended for recycling or reprocessing in a plant shall be set out at the corresponding mixing or crushing plant or at such other locations as approved by the engineer. The stockpile site shall be cleaned, and all loose stones. vegetation and other materials which may cause

specifications or the instructions of the engineer, irrespective of whether or nor it requires recycling. (iii) Material from existing pavements which is not reprocessed Existing gravel pavement material, gravel, or existing bituminous material not intended for reprocessing, shall be used for other specified purposes or taken to spoil. Payment for the excavation of such material will be made directly under item 38.04 unless it is used for other purposes. (iv) Milling

(b)

Material to be disposed of with the average depth of excavation: Not exceeding 30 m m

(i) (ii)

......

square metre (m2)

Exceeding 30 m m but not exceeding 60 m m . . . . . . . . . square metre (m2) Exceeding 60 m m

(iii)

.... . . . ..

square metre (m2)

The unit of measurement shall be a square metre layer of bituminous material excavated from existing pavements separately from the underlying material on the instruction of the engineer, and removed to approved stockpile or spoil sites. The tendered rate shall include full compensation for determining the average thickness of the layer of bituminous material to be excavated, including the excavation of holes or the drilling of cores, if so instructed, for breaking down, excavating, loading and transporting the material to approved stockpile or spoil sites for a freehaul distance of 1,O km and for loading and properly placing the material in stockpile or spoil dumps. The volume used for calculating overhaul shall be taken as 70% of the loose volume of the material measured in the hauling vehicles.

Milling will be paid for directly irrespective of whether or not the material will be re-used. (v) Measurement for excavating existing pavement material and underlying fill Where payment is made separately for the excavation of existing pavement material and underlying fill, the quantity will be calculated in accordance with the authorized horizontal dimensions of the excavated layer and the average depth of excavation. The average depth of excavation will be determined in accordance with the test holes made or cores drilled at intervals not exceeding 10 m, and which are so distributed over the surface that a realistic estimate of the depth can be obtained.

Item

Unit

@)

Overhaul

The distance for calculating overhaul on material intended for recycling or reworking in a plant will be measured from the point of excavation on the road up to the plant. Where the plant is situated outside the site of the works, the distance will be measured to a suitable location for setting up a plant closest to the centre of the site.

38.02 Milling out existing biminous material with an average milling depth: (a) (b) Not exceeding 30 m m . . . . . . . cubic metre (m3) Exceeding 30 m m but not exceeding 60 m m . . . . . . . . . . cubic metre (m3) Exceeding 60 m m

(c)

..........

cubic metre (m3)

(c)

Item 38.05 is applicable solely to work that has to be executed in a resbicted area of which the width is less than 3.0 m or the length is less than 150.0 m.

The unit of measurement shall be a cubic metre of asphalt milled out and removed to approved stockpiles. The tendered rate shall include full compensation for providing milling equipment and milling out the material to the specified depth and in accordance with the requirements for evenness and for all measurements, labour, supervision and incidentals for executing the work and obtaining milled material which will comply with the specified requirements. The tendered rate shall also include full compensation for loading and transporting the material to approved stockpiles for a free-haul distance of 1,O km irrespective of the method of loading, and for unloading the material and placing it in stockpile, also for screening out the oversize material if necessary. Separate payment will be made for preparing the stockpile site.

(d) Item

Items of payment Unit

38.01 Excavating and r e m o v i n g existing biiminous material (except milled material): (a) Material intended for recycling with the average depth of excavation: Not exceeding 30 m m . . . . . Exceeding 30 m m but not exceeding 60 m m . . . . . .

(i) (ii)

square metre (m2)

.. .

square metre (m2)

(iii)

Exceeding 60 m m

.... . . .. .

square metre (m2)

Payment for milling the material will distinguish between the various average depths of excavation, irrespective of the required number of passes by the plant for milling out the material.

for a free-haul distance of 1.0 km, off-loading, and placing the material in approved spoil dumps.

3 8 . 0 3 Milling out cemented crushed stone:

(a) Average milling depth not exceeding 50 mm: Compressive strength of 10 MPa and less . . . . . . . . . . . cubic metre (m3) Payment will not distinguish between material with or without existing bituminous material.

(i)

3 8 . 0 5 Excavating material from an

(ii) Compressive strength of 10 MPa up to and including 20 MPa . . . . . . . . . . . . . . . . . . cubic metre (m3) (a) (iii) Compressive strength exceeding 20 MPa . . . . . . . . . cubic metre (m3) Average milling depth exceeding 50 mm but not exceeding 100 mm: Compressive strength of 10 MPa and less . . . . . . . . . . . cubic metre (m3) Compressive strength of 10 MPa up to and including 20 MPa . . cubic metre (m3) Compressive strength exceeding 20 MPa . . . . . . . . . cubic metre (m3) Average milling depth exceeding 100 mm: Compressive strength of 10 MPa and less . . . . . . . . . . . . . . . . . cubic metre (m3) Compressive strength of 10 MPa up to and including 20 MPa . . cubic metre (m3) Compressive strength exceeding 20 MPa . . . . . . . . . . . . . . . . . . cubic metre (m3) (b) existing pavement andlor underlying fill in restricted areas: Extra over item 38.01 for bituminous material excavated separately . . . . . . . . . . . . . . . square metre (m') Extra over item 38.04 for other existing pavement and/or fill material: Non-cementedmaterial Cemented material

(b)

(i)

(i)

......

cubic metre (m')

(ii)

(ii)
(iii)

. . . . . . . . . cubic metre (m3)

. . . . cubic metre (m3)

Cemented crushed stone

(iii)

(c)

Upon payment being made under subitem (a) no distinction will be made between various thicknesses of bituminous material. The tendered rates shall include full compensation for incidentals for excavating material in restricted areas.

(i)

(ii)

(iii)

38.06 Extra over items 38.02and 3 8 . 0 3 for milling in restricted widths of less than 1.0 m . . . . . . . . . . . . cubic metre (m3)
The unit of measurement shall be a cubic metre of material milled out in a width of less than 1.0 m, the quantity of which will be calculated in accordance with the authorized dimensions of the area and the average depth milled. The tendered rates shall include full compensation for the additional costs for executing the milling in the restricted width. Payment will not distinguish between the various depths of milling or the various types of material.

The provisions of item 38.02 shall apply mutatis mutandis. No payment will be made under the subitems in regard to material with compressive strengths exceeding 10 MPa unless the higher strength has been proven by tests.

Item

Unit

3 8 . W Excavating and spoiling material

from an existing pavement andlor the underlying fill: (a) (b) (c) Non-cementcd material Cemented material

......

cubic metre (rn3)

. . . . . . . . . cubic metre (m3)

. . . . cubic metre (m3)
38.07 Exha over items 3 8 . 0 2 and 3 8 . 0 3for tapering the milled excavation edges or ends . . . . cubic metre (ma)
The unit of measurement shall be a cubic metre of material milled out in a tapered area. the quantity of which shall be calculated in accordance with the authorized dimensions of the taper. The tendered rate shall include full compensation for all

Cemented crushed stone

The unit of measurement shall be a cubic nietre of material, with or without existing bituminous material. excavated from the existing pavement and/or fill and removed to spoil dumps. The tendered rate shall include full compensation for excavating the material from the existing pavement and/or fill, irrespective of layer thickness, for loading, transporting

additional measurements. adjustments and costs for milling out the taper to the satisfaction of the engineer. Payment will not distinguish between the taper at the ends or along the edge of the milled excavation. No payment will be made for tapering resulting from the normal routine level adjustments of the machine neither for the taper necessitated by defective work by the contractor. Payment will not distinguish between various depths of milling or various types of material milled.

Item

Unit

38.10 Preparing stockpile sites . . . . square metre (m2)

The unit of measurement shall be the square metre of stockpile site prepared on the instruction of the engineer. The tendered rate shall include full compensation for demarcating. clearing. levelling and draining the stockpile site as specified. Payment will not be made for preparing the sites for spoil dumps unless such preparation has been instructed, in writing. by the engineer.

b m
38.08 Sawing or cutting asphalt or

Unit

cemented pavement layers: (a) (b) (c) (i) (ii) Sawing asphalt . . . . . . . . . . . square metre (m7) Cutting asphalt . . . . . . . . . . . . . . . . . metre (m) Sawing cemented layers: Cemented material
38.11 Extra over item 38.10 for

h i t

watering and compacting stockpile sites . . . . . . . .

. . . . . cubic metre (m')

. . . . . . . . square metre (m7)

. . . square metre (m')

The unit of measurement shall be a cubic metre of material watered and compacted on the instruction of the engineer on the prepared storage site. The tendered rate shall include full compensation for procuring all material. scarifying, mixing, and compacting the site as specified.

Cemented crushed stone

The unit of measurement for subitems (a) and (c) shall be the square metre of sawcut area calculated in accordance with the authorized length of sawcut and the average saw depth measured after excavation of the material. The unit of measurement for subitem (b) shall be the metre of cut measured in accordance with the authorized saw length. The tendered rate shall include full compensation for all material and sawing or cutting costs and for all incidentals for cutting or sawing the pavement in accordance with the instructions of the engineer. Payment will not distinguish between the various depths of sawing or cutting work, irrespective of the number of separate cuts which may be required for sawing or cutting the layer to the required depth. Where surfacing of less than 30 m m thickness is sawn together with a cemerted pavement, the surfacing section shall be deemed to be cemented material for payment purposes.

Item
38.12 Chemical stabilization of

lhlii

stockpile site: (a) (b) Chemical stabilization . . . . . . . cubic metre (ma) Chemical stabilizing agent
. . . . . . . . . . . ton jt)

The provisions of items 35.01 and 35.02 shall apply mutatis mutandis.

Item
38.13 Drilling cores:

Unit

(a) ltem Unit (b)

38.09 Remaring the remaining asphalt from the undertying layer . . . square metre (m7)

In asphalt . . . . . . . . . . . . . . . . . . . number (No) In cemented material

. . . . . . . . . . number

(No)

The unit of measurement shall be the number of cores drilled on the instructions of the engineer. The tendered rate shall include full compensation for setting out the core locations, and for drilling the cores.

The unit of measurement shall be the square metre of excavation floor cleaned on the instruction of the engineer. The quantity will be calculated in accordance with the authorized dimensions of the surface from which the remaining bituminous material will have to be removed afterthe existing bituminous layer has been taken off. Only surfaces of existing layers to be reprocessed as base will be paid for and only if so instvucted by the engineer. The tendered rate shall include full compensation for the removal of any remaining bituminous material from the excavation floor as specified and the disposal thereof. all to the satisfaction of the engineer.

ttem
38.14 Roviding the milling machine on

the site (size indicated) . . . . . . . . . number (No) The unit of measurement shall be the number of milling machines provided on the site, or the number of times a milling machine is brought onto the site where it had to be removed temporarily with the approval of the engineer.

Payment for returning the machine to the site after removal shall be made only where the removal was in accordance with the contractor's approved programme of work and not for any other reason. Payment will not be made for replacing any defective plant. Additional machines will be paid for only where their provision is in accordance with the contractor's approved programme of work and if all the milling machines are in use on the site simultaneously.

The unit of measurement shall be the number of times the machine Is moved for more than 1,O km, as may be approved or instructed by the engineer, in writing.

Item

Unit M n g the milling machine o n the s i t e for a distance exceeding 1.0 km (size indicated) . . . . . . .

38.15

..

number (No)

The tendered rate shall include full compensation for all costs involved in such moving (irrespective of as to whether the machine is moved to a new section of the site or returned to a previous position for further work), as well as for all delays and production losses. Payment will not be made for moving for the purpose of maintenance and repairs or for replacement with another machine.

SERIES 3000 :

EARTHWORKS AND PAVEMENT LAYERS OF GRAVEL OR CRUSHED STONE

The following items of plant and equipment shall also be available and in good working order: A vibratory roller having a mass approximately equal to that of a Bomag 905 or similar vibratory roller, with an adjustable amplitude and frequency of vibration. A mobile compressor capable of producing at least 3 m3/minute compressed air at 750 kPa. Appropriate paving breakers Manually-operated pneumatic compactors as required. Appropriate concrete mixers.

SECTION 3900 : PATCHING AND REPAlRlNG EDGE BREAKS

CONTENTS
3901 3902 3903 3904 3905 3906 3907 SCOPE MATERIALS PLANT AND EQUIPMENT PATCHING REPAIRING EDGE BREAKS IN SURFACING QUALITY OF MATERIALS AND WORKMANSHIP MEASUREMENT AND PAYMENT

3904
3901

PATCHING
Demarcation

SCOPE

(a)

This section covers the patching of existing pavement layers and the repairing of edge breaks, excluding resealing or resurfacing. Patching shall be any work to existing pavement layers (and in exceptional cases to fills and the roadbed) with the purpose of repairing local failures, and which is carried out in an area having a width of less than 1,O m, or a length of less than 25,O m, or an area of less than 100 mZ.This does not include the repair of edge breaks, pretreatment of the road surface, or the rehabilitation of concrete pavements. Patching involves excavating the existing failed sections and reconstructing the excavated fills and pavement layers with the specified pavement material. Backfilling with asphalt will be measured and paid for under section 4200. Compensation for work in restricted areas shall not be applicable to patching and repairing edge breaks.

The engineer will demarcate any failed areas to be repaired, and shall instruct the contractor in regard to the repair work to be done. The contractor shall give adequate notice to the engineer of his intention to commence with repair work on any specific section of the road so that the engineer will have sufficient time to demarcate the areas to be patched and repaired. In addition to his specified responsibilities for the accommodation of traffic, the contractor shall also be responsible for traffic accommodation during the demarcation work.

@)

Other sections of the specifications

In addition to the provisions of section 3900 the various provisions of sections 3200, 3400, 3500, 3600, 3800, 4100 and 4200 amongst others shall apply mutatis mutandis.

39M

MATERIALS
(c)

Excavating pavement material

The materials shall comply with the requirements specified for the various types of material in the appropriate sections of the specifications and the project specifications.

Unless otherwise instructed by the engineer, the patching shall have a neat rectangular shape. The existing material shall be excavated and removed to the full specified depth. Asphalt layers and surfacing shall be cut with approved sawing equipment. Excavation for patching shall be cut with sideslopes of approximately 60" to the horizontal. Where required, excavation shall be done with an approved milling plant in accordance with section 3800. Excavated material from each pavement layer shall be placed in separate stockpiles adjacent to the patch, The stockpiled material shall be re-used or spoiled in an approved manner in accordance with the engineer's instructions. After completion of the excavation to the specified depth, the engineer shall be afforded the opportunity to examine it. Where required, the floor of the excavation shall be

Herbicide shall be a non-selective herbicide approved by the engineer.

3903

PLANT AND EQUIPMENT

All equipment shall be suitable for the specified use and working areas and shall be capable of obtaining the specified results. Only approved cutting or sawing equipment may be used for cutting or sawing asphalt layers. The equipment shall be capable of cutting asphalt layers to depths of 200 m m in one operation without fragmenting the material, and in straight lines within the required tolerances.

compacted to the specified concerned.

density

for the layer

3905

REPAIRING EDGE BREAKS IN SURFACING

(d)
(i)

Backfilling excavations
Excavations shall be backfilled with pavement material as specified in the project specifications or as ordered by the engineer, and the backfilling shall be compacted and finished to the required levels. The requirements for material quality. density and finish specified in other appropriate sections shall remain applicable. Stabilized materials shall be mixed in concrete mixers or by other approved equipment. Subbase and base materials shall be stabilized as specified. Placing concrete in patches will not be permitted.

This treatment is used wherever necessary for finishing off and/or repairing the edges of the paved area, and also for repairing the edges of the road so that it lines up with the true edge of the original road or with such other edge as may be required. Where the existing edge of the surfacing is sound and undamaged but the required surfacing width is exceeded by more than 50 mm. the excess surfacing shall be cut back. parallel to the centre line of the road, to the required width. Where the edges of the surfacing is fragmented or where the surfacing is narrower than the required width, it shall be cut back to a line along which a sound edge can be obtained. These lines shall be parallel to the centre line of the road and may not exceed the required width. Where the surfaci~g. after having been cut back, is narrower than the specified width, the pavement material between the cut edge and the specified surfacing edge shall be excavated to a depth of 60 m m below the final road surface, or until firm material is found. The edges shall be restored in accordance with the requlrements of subclause 4804(e). Item 39.05 shall apply only to edge breaks with an average width of 250 m m and less. Repairing wider edge breaks will be classified as patching.

(ii)

Unless otherwise specified in the project specifications, the base shall be backfilled in accordance with the following requirements. The specified base material shall be stabilized as follows: The base material shall be placed in a concrete mixer, and water shall be added to moisten the material.

3906

Q U W OF MATERIALS AND WORKMANSW

A suitably diluted 60% stable-grade anionic or

cationic bitumen emulsion shall be added at the specified rate. Ordinary portland cement shall be added at a rate of 1,096 by mass, unless otherwise specified. During mixing the fluid content (water plus emulsion) shall not exceed the optimum moisture content of the base. Mixing shall continue until a uniform mix of the base material and the emulsion is obtained. The contractor shall place and spread the stabilized material by hand in layers of appropriate thickness. Each layer shall be compacted with a handoperated self-propelled vibratory roller to the specified density. The process of placing. spreading and compacting shall be repeated until the required total thickness of base is obtained. The engineer will do routine inspections and conduct routine tests to determine whether the quality of material and workmanship provided comply with the requirements of this section. The test results and measurements will be assessed in accordance with the provisions of sections 8200 or 8300 according to which section in the project specifications has been designated as being appropriat~.

3907

MEASUREMENT AND PAYMENT

Unit
39.01 Sawing asphalt or cemented pavement layers for patching: (a) Sawing asphalt to an average depth: Not exceeding 50 m m

The stabilized material shall be placed at a fluid content not exceeding the optimum moisture content for the base.

(i) (ii)

....

square metre (m2)

(e)

Resbictions
(iii)

Exceeding 50 m m but not exceeding 100 m m . . . . . . Exceeding 100 m m

square metre (m2) square metre (m')

Unless otherwise instructed in writing by the engineer. the excavation, backfilling and all patching work. complete as specified, for any patch shall be carried out and completed on the same day. Special attention shall be given during patching to controlling and protecting traffic. as specified.

.... . .

(b)

Sawing cemented pavement layers to an average depth:

(i) (ii) (iii)

Not exceeding 50 m m

. . . . square metre (m2)

square metre (m2)

(i) (ii)

Not exceeding 5 m2

. . ... .. ..

cubic metre (m3)

Exceeding 50 m m but not exceeding 100 mm . . . . . . Exceeding 100 mm

Exceeding 5 m2 but not exceeding 100 m2 . . . . . . Exceeding 100 m2

cubic metre (m3) cubic metre (m3)

. . . . . . square metre (m2)

(iii)

... . . ...

The unit of measurement shall be the square metre of sawcut area calculated in accordance with the authorized length of sawcut and the average saw depth measured after excavation of the material. The tendered rate shall include full compensation for all plant, equipment, labour, supervision, materials, transport and for all incidentals for sawing the asphalt and the cemented pavement layers, complete as specified and prescribed by the engineer, and also for work in restricted areas. ttem Unit pavements

The unit of measurement shall be a cubic metre of the specified chemically or bituminously stabilized pavement material placed in accordance with the specified requirements. The quantity will be computed in accordance with the authorized dimensions of the layer. The tendered rates shall include full compensation for providing all the material, irrespective of its origin, including gravel (notwithstanding the provisions of section 1600),for all mixing, placing, compacting and finishing as specified in this section and other appropriate sections of the specifications, for all transport, work in restricted areas, and also for all machinery, equipment, labour, supervision and other incidentals for executing the work as specified. The tendered rate shall also include full compensation for chemical or bituminous stabilization, including amongst others the provision and application of the stabilizing agents. ttem unit

3 9 . 0 2 Excavation in e n x s ig t
for patching in: (a) (b) (c) Asphalt layers

. . . . . . . . . . . cubic metre (m3)

Cemented layers

....... . .

cubic metre (m3) square metre (m3)

Other layers (specify type) . .

39.04 Compacting the floor of

The unit of measurement shall be a cubic metre of material excavated from the existing pavement. The quantity shall be computed in accordance with the authorized dimensions of the excavation. The tendered rate shall include full compensation for demarcating the excavation, excavating the material, placing the excavated material in temporary stockpiles, spoiling of material in the stockpiles where ordered by the engineer, including haul over a free-haul distance of 1,O km, complete as specified, and also for Work in restricted areas. Payment will distinguish between the different types of pavement material excavated. Item Unil
39.05 Cutting back the edges of the existing surfacing for the repairing of edge breaks . . . .

excavations for patching

square metre (m2)

The unit of measurement shall be a square metre of excavation floor compacted on the instruction of the engineer, and the quantity shall be computed in accordance with the authorized dimensions of the excavation floor. The tendered rate shall include full compensation for compacting the floor of excavations complete as specified, and also for work in restricted areas. Payment will not distinguish between the various methods of compaction or various density requirements. ttem Unil

39.03 Backtilling of excavations for patching with:

(a) Chemically stabilized pavement material (specify the pavement material and the stabilizing agent) for a patch with a surface area: Not exceeding 5 m2

......

metre (m)

The unit of measurement for cutting back the edges shall be a metre of pavement edge cut back and excavated as specified. This Item shall apply only to edge breaks of which the repaired width is less than 250 mm. The tendered rate for cutting back the edges shall include full compensation for cutting back the edges in accordance with instructions, excavating the material to the specified depth, removing all excavated and loose material, and compacting the surface onto which the fresh edge shall be constructed, all in accordance with the required lines and levels. The tendered rates shall also include full compensation for all transport, handling, labour, material, and all incidentals necessary for completing all the work in accordance with the specifications, and also for work in restricted areas.

(i) (ii)

... . . .. ... . .

cubic metre (m3)

Exceeding 5 m2 but not exceeding 100 m2 . . . Exceeding 100 m2

cubic metre (m')

(iii) (b)

. . . . . . . . cubic metre (m3)

Base material stabilized with bituminous emulsion (specify the emulsion) for a patch with a surface area:

SERIES 4000 :ASPHALT PAVEMENTS AND SEALS SECTION 4100 : PWME COAT

centres for testing binder distributors mentioned in TMH 2; (ii) not have any fuel, oil or binder leaks;

have a straight and clean spraybar, all the spray (iii) heads of which shall be of the same type which open simultaneously and shall not leak when closed; SCOPE MATERIALS EQUIPMENT WEATHER AND OTHER LIMITATIONS PREPARATION OF THE LAYER TO BE PRIMED APPLICATION OF THE PRIME COAT MAINTENANCE AND OPENING TO TRAFFIC TOLERANCES TESTING MEASUREMENT AND PAYMENT have its spray heads all spraying at the same angle (iv) to the spraybar and adjusted to the correct level so as to obtain the required overlapping: (v) (vi) have its fans not interfering with one another; have its sieve undamaged and clean;

4101

SCOPE

be under the direct control of an operator approved (vii) by the engineer on the grounds of a reference, in writing, or a certificate of competence signed by a representative of a road authority; (viii) be fitted with a suitable cut-off spray-head or fishplate.

This section covers the application of a tar or bitumen prime to a prepared pavement layer.

@)

Water sprinkler

(a)

Priming material

The water sprinkler shall have efficient spray equipment, capable of spraying a uniform film of water over the whole area to be primed.

The priming material shall be one of the following as may be specified or directed by the engineer: RTH 3112P tar prime complying with SABS 748 or RTL 3/12P tar prime complying with SABS 749. RTH 1/4P quickdrying tar prime complying with SABS 748

(c)

Rotary broom

The rotary broom shall be self-propelled and supplied together with a suitable pneumatic-tyred towing vehicle.

(d)

Other equipment

MC-30 cut-back bitumen complying with SABS 308: MC-70 cut-back bitumen complying with SABS 308: Invert bitumen emulsion complying with SABS 1260. Other equipment shall include hand brooms, mat or reinforced paper for joints, string, nails and all other ancillary equipment required to carry out the operation efficiently and neatly.

@)

Aggregate for blinding

4104

WEATHER AND OTHER LIMITATIONS

The aggregate used for blinding the primed surface shall consist of crushed rock or river sand, with 100% passing the 6,7 m m sieve and not more than 10% passing the 2,36 m m sieve. The aggregate shall be clean, hard and free from excessive dust. It shall contain no clay, loam or other deleterious matter.

No prime shall be applied under the following adverse conditions: (a) (b) during foggy or wet conditions; when rain is imminent:

when wind is blowing sufficiently hard to cause (c) uneven spraying: The following equipment shall be available and in good working order: when the surface of the layer is visibly wet, ie more (d) than damp: when the temperature of the surface immediately (e) prior to commencing with the application of the prime is below or in the opinion of the engineer likely to fall below 10C; (1) comply with TMH 2 and shall be covered by a valid (i) certificate of compliance with TMH 2 issued by one of the (g) after sundown: when at any position the moisture content of a

(a)

Binder distributor

The binder distributor used for distributing the bituminous binders shall -

granular base layer is more than 50% of the optimum moisture content as determined by the engineer. The engineer's decision on whether or not to apply the prime coat under specific conditions shall be final.

100 mm. Table 4106/1

4105

PREPARATION OF THE LAYER TO BE PRIMED

Maximum storage temperature "C

Not longer than 24 hours before spraying, the layer to be primed shall be broomed and cleaned of all loose or deleterious material by means of a rotary broom and hand brooms. Sweeping shall be done carefully so as not to cause any damage to the layer. A light spray of water, sufficient to dampen the surface, shall be uniformly applied to the layer immediately before the application of the prime. If the water is over applied the layer shall be allowed to dry until a uniform damp surface is obtained. Before any priming material is sprayed the layer to be primed shall be checked for compliance with the surface and other requirements specified. Any sections not complying with the specified requirements shall be corrected as specified in clause 1218.

Spraying temperature range "C

Type of prime

Up to 24 hrs

Over 24 hrs

Cut-back bitumens MC-30 MC-70 Tar prime RTHIRTL 3/12P Tar 10% creosote Tar 20% creosote Tar 30% creosote Quick drying tar prime RTH 1/4P 65 80 30 50 45 60 60 80

+ + +

60 60 60

40 40 40

54 - 68 45 - 55 40 - 50

4106 APPLICATION OF THE PRIME COAT

A mat, reinforced paper or other suitable approved (a) material shall be used at all joints at the beginning and end of all sprays in order to obtain a neat start and cut-off. The temperatures for storage and spraying shall be (b) in accordance with table 410611. All prime materials stored in a heated condition shall be stored in a container with a properly functioning circulation system and having a securely fitting lid. The rate of application shall be as directed by the (c) engineer after trial applications to short sections if necessary. Wherever feasible, the prime shall be applied in one (d) or more lanes evenly over the full width of the road and allowed to penetrate and cure until traffic can pass over the surface without the wheels picking up the prime. All traffic shall be kept off the surface until this condition is obtained. The total width of the primed surface shall be as shown on the drawings or as prescribed by the engineer, and the edges of the primed surface shall be parallel to the centreline of the road. Where it is not feasible for traffic to use diversions, (e) the prime shall be applied and allowed to penetrate for as long as is practicable before a blinding layer of aggregate is applied at a rate of 285 m2/m3. Care shall be exercised in this operation to avoid the aggregate being applied too soon after spraying the prime. Where practicable two to four hours shall elapse as directed b y the engineer. Any "caking" of aggregate which may take place and cause problems during the surfacing process and all loose aggregate shall be removed before the final surfacing is commenced. H the prime is applied in more than one strip, (1) allowance shall be made for overlapping of strips by

Invert bitumen emulsion

Care shall be taken to protect all kerbing and (g) channelling, guard rails and channelling from the prime by covering them with a suitable protective material when spraying. The contractor shall, at his own cost, replace all soiled items which cannot be properly cleaned. Painting of the soiled surfaces will not be accepted as a sultable remedial measure. After the prime has penetrated sufficiently, surplus (h) prime shall be covered with damp crusher sand, which shall be worked into it by means of hand brooms in order to absorb the surplus prime. As soon as it is saturated with prime, the crusher sand shall be swept off the primed surface. The process shall be repeated until no surplus prime remains on the primed surface. (i) The provisions of clause 4309 apply to the application of the prime in areas inaccessible to mechanical equipment. The prime shall be applied under the supervision of an experienced person b y means of a portable binder distributor that complies with the requirements of subclauses 4103(a) and 4309(a). The quantity of prime applied, shall be controlled so that the specified rate of application is achieved. Surplus prime shall be removed as specified in subclause 4106(h).

4107

MAINTENANCE AND OPENING TO TRAmC

Where a blinding layer has been applled to the primed surface, the contractor shall malntain the blindlng layer and the primed surface during the period when the surface is opened to traffic, and shall repair all damage caused to the blinding layer or the primed surface by such trafflc, as directed b y the engineer, at no additional payment to the

contractor.

(d) (e)

MC-70cut-back bitumen . . . . . . . . . . . . . litre ( I )

Invert bitumen emulsion

. . . . . . . . . . . . . litre ( I )

4108

TOLERANCES
The unit of measurement shall be the litre of priming material measured at spraying temperature and sprayed as required. The tendered rates shall include full compensation for supplying the priming material, cleaning and watering the layer to be primed, applying the priming material and maintaining the primed surface as specified.

The actual spray rates measured at spraying temperature shall not deviate from the required spray rate as specified or ordered by the engineer by more than 0,06I /m2. The edges of the primed surface shall be true to line with a maximum deviation of 25 m m from the specified edge line.

ttem 4109

TESTING

41.02 Aggregate for blinding

. . . . . . square metre (m2)

The contractor shall give the engineer at least 24 hours notice of his intention to spray prime material so that the actual spray rates can be prescribed and/or verified by the engineer. Unless otherwise agreed in advance the contractor shall only spray when the resident engineer or his representative is present.

The unit of measurement shall be the square metre of prime coat blinded with aggregate on the instructions of the engineer. The tendered rate shall include full compensation for procuring. furnishing and applying the aggregate for blinding where directed by the engineer, and for maintenance of the blinding layer, as specified.

4110

MEASURMEM AND PAYMENl

ttem 41.03 Extra over item 41.01 fw applying the prime coat in areas accessible only to hand held equipment . . .

Unit

Unit 41.01 Rime coat:

. . . . . litre ( I )

(a)

RTH 3/12P or RTL 3112P tar prime . . . . . . . . . . Quick drying RTH 114P tar prime . . . . . . . . . . MC-30 cut-back bitumen

The unit of measurement shall be a litre of priming material (measured at spraying temperature) sprayed in accordance with the requirements for areas accessible only to hand held equipment. litre ( I ) The tendered rate shall include full compensation for the additional costs for executing the work in areas accessible only to hand held equipment.

(b)

(c)

. . . . . . . . . . . . . litre (1)

SERIES 4000 : ASPHALT PAVEMENTS AND SEALS SECTION 42Ml: ASPHALT BASE AND SURFACING

The construction of asphalt surfacing on bridge (d) decks where shown on the drawings or ordered by the engineer.

4202

MATERIALS

SCOPE MATERIALS COMPOSITION OF ASPHALT BASE AND SURFACING MIXTURES PLANT AND EQUIPMENT GENERAL LIMITATIONS AND REQUIREMENTS AND THE STORAGE OF MIXED MATERIAL PRODUCING AND TRANSPORTING THE MIXTURE SPREADING THE MIXTURE JOINTS PRECOATED CHIPPINGS FOR ASPHALT SURFACING COMPACTION LAYING TRIAL SECTIONS PROTECTION AND MAINTENANCE CONSTRUCTION TOLERANCES AND FINISH REQUIREMENTS QUALITY OF MATERIALS AND WORKMANSHIP MEASUREMENT AND PAYMENT

(a)

Bituminous binders
Conventional binders

(i)

The various bituminous binders specified shall comply with the relevant SABS specifications stated below:

Road-grade bitumens

. . . . . . . . . . . . . . . . . .SABS 307
SABS 309 (anionic) SABS 548 (cationic) modified

Bitumen emulsions

............

(ii) Non-homogeneous binders

(heterogeneous)

4201

SCOPE

(The addition of rubber to the aggregate in the same way as filler, the so called dry method. is not included in these specifications.)

This section covers the following work: All the work in connection with the construction of (a) asphalt bases and surfacing. It includes the procuring and furnishing of aggregate and bituminous binder, mixing at a central mixing plant, spreading and compaction of the mixture, all as specified for the construction of: (i) (ii) Continuously graded asphalt base; Semi-gap-graded asphalt base;

The bitumen-rubber binder shall comply with the following specifications: (1) Base bitumen

The bituminous binder used in the production of the bitumen-rubber shall be a 812 or B8 road-grade bitumen (60170or 801100 penetration-grade bitumen respectively) or a blend of these grades to provide a product with a particular viscosity and other prescribed properties.
(2)

Rubber

(iii) Continuously graded asphalt surfacing with or without rolled-in precoated chippings; (iv) Gap-graded asphalt surfacing with or without rolled-in precoated chippings; Semi-gap-graded asphalt surfacing with or without (v) rolled-in precoated chippings; (vi) (vii) Open-graded asphalt surfacing; Stone-mastic asphalt surfacing

The rubber is obtained by processing and recycling pneumatic tyres. The rubber crumbs shall be produced by a mechanical comminuting process. Crumbs produced by cryogenic-mechanical techniques are not permitted. It shall be pulverized. free of fabric, steel cords and other contaminants. A maximum of 4% by mass of fine particle size calcium carbonate. or talc, may be added to the rubber crumbs to prevent the rubber particles from sticking together. At the time of use the crumbs shall be free flowing and dry and comply with the requirements in table 420211.
(3)

(b) The widening of asphalt bases and surfacing. placing asphalt in restricted areas and placing asphalt reinforcing where specified. The recycling of asphalt by reprocessing recovered (c) materials, adding fresh aggregate, bituminous binders and other agents for obtaining an asphalt mix which will comply with the specified requirements, and placing the recycled material. The provisions of section 4200 shall apply throughout to recycled asphalt, except where explicitly specified otherwise.

Extender oil

Extender oil shall be a resinous. high flash point aromatic hydrocarbon conforming with the requirements in table 420212. The chemical composition of the base bitumen and the nature of the rubber will dictate the need to introduce an extender oil. The bitumen and extender oil, when combined shall form a material that is chemically compatible with the rubber.

Table 420211 Property

Table 420213 Requirements

Property

Requirements

Test method Sabita BRGT

Sieve analysis, as a percentage by mass passing through the 1,18 mm sieve, % 0,60 m m sieve, % 0,075 m m sieve, % Natural rubber hydro-carbon content (minimum), % Resilience (raw) (minimum),
%

Percentage of rubber by mass of the total blend, % Percentage extender oil by mass of the total blend (maximum), % Blendinglreaction temperature, " C

18 - 2 4

100 50 - 70 0-5 BS903 Parts Bll&B12 Sabita BR7T Sabita BR7T Sabita BR9T

4 180 - 210 1-4

30

Reaction time, hours

40

Loss in resilience (maximum),

%

60 1,lo-1,25

Relative density, glcm3

A continuous record shall be kept on the site by the contractor of the percentage rubber in the mix and the reaction temperatures and times. The bitumen-rubber binder shall be sampled within five minutes prior to the mixing of the asphalt and shall comply with the requirements in table 420214. Table 420214

Table 420212

Property

Requirements

Test method

C Viscosity at 40 O (minimum) Flash point, COC, " C Compositional analysis Asphaltenes, % by mass (maximum) Aromatics. % by mass (minimum)

2 500 200

ASTMD88 ASTMD92

0,1 55,O

ASTMD2007

(4)

Bitumen-rubber blend The bitumen-rubber mixture after reaching the desired consistency shall not be held at temperatures in excess of 160C (with no extender oil) or 190C (with 4% extender oil) for more than 4 hours. (iii) Homogeneous modified binders

At least two weeks prior to commencement of the blending operation, the contractor shall state in writing to the engineer, in a method statement, that also includes details of the proposed plant, the percentage of rubber, the blendinglreaction temperature, reaction time and percentage of extender oil he intends to use, substantiated by graphs of time against ring and ball softening point and flow for the full reaction period, taking cognisance of the actual equipment and method to be used for the mass production of bitumen-binder. These shall be referred to as behaviour curves. The contractor shall not be allowed to deviate from the stated percentage of rubber crumbs by more than 1 per cent and from the stated reaction temperature by more than 10C without producing new behaviour curves. Reaction time is defined as half the time required for adding the rubber to the bitumen plus the time required for acceptable reaction between the bitumen and rubber as determined from the behaviour curves in agreement with the engineer. No bitumen-rubber blend shall be used until it has complied with the reaction time. The bitumen-rubber blend, containing where necessary extender oils, shall satisfy the requirements in table 420213. The reconstitution of the bitumen-rubber blend will not be allowed unless approved by the engineer in writing.

Homogeneous modified binders are defined as industrial blends of polymer and bitumen where the blended components form a stable microscopic dispersion, or either or both form a stable continuous phase relative to each other. The properties of the homogeneous modified binders shall comply with the requirements given in the project specifications.

The type and grade of bituminous binder to be (iv) used in each case shall be as specified hereinafter or in the project specifications.

Coarse and fine aggregate shall be clean and free from decomposed materials, vegetable matter and other deleterious substances and shall meet the requirements of

sections 3600 and 4300, unless otherwise provided in this section. (i) Resistance to crushing

Continuously and open-graded surfacing and stone-mastic asphalt surfacing . . . . . . . . . . . . . . 50 Gap-graded surfacing . . . . . . . . . . . . . . . . . . . . . . . . 45 Rolled-in chippings . . . . . . . . . . . . . . . . . . . . . . . . . 50 Aggregates with polishing values below those stated above may be approved for use by the engineer. (iv) Adhesion

The aggregate crushing value (ACV) of the coarse aggregate, when determined in accordance with TMHl method 51, shall not exceed the following values for aggregate used for: Base and surfacing

. . . . . . . . . . . . . . . . . . . . . . . . . 25

Rolled-in chipplngs, open-graded surfacing and stone-mastic asphalt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 The minimum dry 10% FACT values of the -13,2 m m +9,5 m m fraction shall be as follows: Rolled-in chippings, open-graded surfacing and stone-mastic asphalt Other surfacing and base

When tested in accordance with TMHl method C5, the immersion index of a mixture of the binder and aggregate proposed for use shall not be less than 75%. The aggregate used for the test mixture shall have a grading within the actual limits for the mix concerned. (v) Absorption

..........

210 kN 160 kN

................

When tested in accordance with TMHl methods 814 and 815, the water absorption of the coarse aggregate shall not exceed 1% by mass, and that of the fine aggregate shall not exceed 1,5% by mass, unless otherwise permitted. (vi) Sand equivalent

The wetidry ratio shall not be less than 75%, (ii) Base: The flakiness index when determined in accordance with TMHl method 83 shall not exceed 35 for the minus 26,5 m m sieve plus 19,OO m m sieve and minus 19 m m plus 13,2 m m sieve fractions respectively. In addition, at least 50% by mass of the individual fractions retained on each of the standard sieves with a square mesh size of 4,75 m m and larger shall have at least one fractured face. Surfacing and rolled-in-chippings: The flakiness index for surfacing asphalt and rolled-inchippings shall not exceed the values given in table 420215. The grades refer to the single-sized crushed stone grades as defined in subclause 4302(b). Table 420215 Maximum flakiness index % Surfacing aggregate Grade 1 19,O 13,2 9,5 67 25 25 30 30 Grade 2 30 30 35 35 Rolled-inchips (all grades) 20 20 The grading of the combined aggregate including any filler added in an approved working mix as described in subclause 4202(c) shall be within the limits stated in tables 420216 to 4202110 for the various mixes. The approved grading shall be designated as the target grading. The mean grading of each lot of the working mix (minimum of 6 tests per lot) determined from samples obtained in a stratified random sampling procedure, shall conform to the approved target grading within the tolerances specified In subclause 4213(c). The target grading requirements for crushed-stone base as specified under subclause 3602(c) shall apply to all continuously graded asphalt bases. In addition, and for tender purposes and preliminary mix design, the target grading for 37,s m m maximum aggregate size asphalt base shall be within the range derived from the formula: Shape of the aggregate The total fine aggregate used in all asphalt mixes shall have a sand equivalent of at least 50, when tested in accordance with TMHl method 519, and the natural sand where it is permitted to be mixed with the aggregate shall have a sand equivalent of at least 30. (vii) Design requirements

The contractor shall, by conducting the necessary tests, satisfy himself that he will be able to produce a mixture meeting the design requirements specified hereinafter, using the aggregate he proposes to supply, within the grading limits specified. (viii) Grading

Nominal size of aggregate (mm)

In addition, at least 9546 of all particles shall have at least three fractured faces.

where: P = d = n = D = F= percentage passing a particular sieve, % sieve size, m m exponent which determines the shape of the grading curve maximum aggregate size, m m filler content. %

(iii)

Polishing

The polished stone value of aggregate, when determined in accordance with SABS method 848, shall not be less than the following values for aggregate used for:

using values of F = 5% with n = 0,45 and F = 7% with n = 0,4 (one percent being active filler). The approved target grading shall be determined after laying a trial section on site. Where mixes with coarser and/or other grading compositions are required for asphalt bases, it will be specified in the project specifications. (ix) Additional requirements for asphalt bases

cement, fly-ash, or a mixture of any of the above materials. Individual materials shall comply with the requirements of the relevant SABS or other specifications for such material. Active filler shall have at least 70% by mass passing the 0,075 m m sieve and a bulk density in toluene falling between 0,5 and 0,9 g l m l . The voids in dry compacted filler shall be between 0,374 and 0,5%, when tested in accordance with British Standard 812. Active fillers for use in asphalt bases shall be introduced to the mix prior to wetting with the binder. An active filler content of 1% by mass shall be used unless otherwise specified. Only active filler added on the instructions of the engineer, for the purpose of improving adhesion, will be paid for. No payment will be made for filler added to improve the grading.

If approved by the engineer and if the specified requirements are met, the aggregate component may contain natural fines not obtained from the parent rock being crushed, on condition that such added material does not exceed 10% by mass, unless otherwise specified in the project specifications. The added fines shall have a liquid limit not more than 25% and a PI not more than 6. The contractor shall submit full details regarding the exact quantity and nature of such fine aggregate, before such permission will be considered. In the event of such added material being natural sand, its impact on dynamic creep properties should be assessed from laboratory briquettes and cores obtained in a trial section planned well ahead of any production runs. The addition of natural fines shall be done by using a separate cold feed bin. (x) Rolled-in chippings

(d)

Fibres

The use of fibres in asphalt mixes shall be subject to the provisions of the project specifications.

(e)

Asphalt reinforcing

Asphalt reinforcing shall be of the type specified in the project specifications and shall be obtained from an approved manufacturer. Where the use of reinforcing for asphalt has been specified, the contractor shall, at least 3 months before the material is to be used, submit samples of the type he intends to use, together with complete specifications of the material, as well as the manufacturer's instructions for use, to the engineer for approval. Where the material does not carry the SABS mark or the mark of another acknowledged authority, the engineer may instruct the contractor to have the material tested by an approved laboratory and to submit the results.

Rolled-in chippings for asphalt surfacing mixes shall comply with the grading requirements of table 420211 1. Table 420211 1 GRADING LIMITS FOR ROLLED-IN CHIPPINGS Percentage passing by mass Sieve size (mm) 19,O 13,2 985 67 0,425 19,O m m chip size 100 0 - 20 0-5 0-1 0,5 max 13,2 m m chip size 100 0 - 20 0-5 0,5 max

(9
(i)

Asphalt for hot plant mix recycling Recovered asphalt

(c)

Fillen

The engineer will test the existing asphalt in any part of the road and determine its suitability for recycling before removal. He may instruct the contractor to drill additional cores at specified points. Recovered asphalt intended for recycling shall be stored separately from other asphalt, and the engineer may also direct different types of asphalt to be stored separately. The recovered asphalt shall be free from any underlying base material and other foreign matter. Asphalt milled out shall be of a maximum size of 37,5 mm, unless another maximum size has been approved by the engineer. Asphalt not milled out shall be broken down in any approved manner so that it can be properly remixed in a plant to the satisfaction of the engineer. Mixes of recycled asphalt containing fragments of recovered asphalt exceeding 37,5 m m in size, will not be accepted. Payment for recovered asphalt will distinguish between

If the grading of the combined aggregates for asphalt surfacing mixes show a deficiency in fines, an approved filler may be used to improve the grading. Filler may consist of active filler as defined hereinafter or of inert material such as rock dust having the required grading necessary to improve the grading of the combined aggregates. In no instance shall more than 2% by mass of active filler be used in asphalt mixes, Inert filler such as rock dust used to improve grading shall not be subject to this limitation. The engineer may order the use of any active filler to improve the adhesion properties of the aggregate. Active filler shall consist of milled blast furnace slag, hydrated lime, ordinary portland cement, portland blast furnace

milled out and non-milled out material. Samples shall be taken from the recovered asphalt intended for hot recycled mixes in the stockpil~ and shall be tested for grading and quality of the aggregate, binder content, and properties of the binder.

(h)

General

All materials shall be handled and stockpiled in a manner that will prevent contamination, segregation or damage. Cement and lime shall be used in the order in which it has been received. The contractor shall, as often as necessary, test and control the materials produced by himself or the materials received by him from suppliers to ensure that the materials always comply with the specified requirements. In general the contractor will not be expected to construct layers in which the nominal maximum aggregate size exceeds two-thirds of the compacted layer thickness.

(ii)

Bituminous binders

The provisions of subclause 4202(a) shall apply. The grade of new binder used in the recycled asphalt mix shall be such that the mix of new and residual binder will comply with the requirements of the project specifications. Recycling agents such as blended oils and other additives may not be used without prior approval by the engineer.

4203

COMPOSITION OF ASPHALT SURFACING MIXTURES

BASE

AND

(iil)

New aggregate The rates of application and mix proportions of bituminous binder, aggregates and fillers which are given in tables 420216 to 4202110, are nominal rates and proportions and shall only be used for tendering purposes. The rates and proportions actually used shall be determined to suit the materials used and conditions prevailing during construction and any approved variation on a nominal mix in the bitumen content or active filler content shall be the subject of an adjustment in payment for binder or active filler variations as described in clause 4215. Before production or delivery of the asphalt the contractor shall submit samples of the materials he proposes to use in the mix, together with his proposed mix design as determined by an approved laboratory, to the engineer in accordance with table 810411, so that the engineer may test the materials and confirm the use of the proposed mix if he is satisfied that it meets the specified requirements. The engineer also reservers the right to change aggregate blends in order to allow the selection of any combined aggregate grading. within the specified grading envelope(s) for the proposed mix. As soon as the materials become available the contractor shall produce a working mix in the plant in accordance with the design mix. The working mix shall again be tested by him for compliance with the design requirements. Samples of the working mix and the test results shall also be made available to the engineer, who will authorise the use of the working mix proportions approved for use in the trial section. Final approval of the working mix will be subject to the approval of the trial section. The composition of the approved working mix shall be maintained within the tolerances given in subclause 4213(c). The nominal mix proportions (by mass) of the various asphalt mixes are set out in tables 420216 to 4202110. The design of the asphalt mixes shall be in accordance with the design guidelines of TRH8 and appropriate research results, and the mix properties and requirements shall be as specified in the project specifications. In addition to the design guidelines of TRH8, the asphalt mixes shall also comply with the requirements in table 420311 unless otherwise stated in the project specifications.

New aggregate required for use in recycled asphalt mixtures shall comply with the requirements of subclause 4202 (b).

(iv)

Combined aggregate

The aggregate mix obtained from new aggregate and the aggregate in the recovered asphalt, including any mineral filler, an approved quantity of which may be added in accordance with subclause 4202(c), shall comply with the requirements specified in the project specifications for the relevant recycled asphalt layer. (v) Storing material for recycling

The provisions of clauses 3203 and 3806 shall apply to the storing of recovered asphalt. In addition the following requirements shall apply. Stockpiles of milled or crushed asphalt shall be shaped and formed in a manner that will prevent segregation as far as possible. The stockpiling of the recovered asphalt shall be done in a manner that will prevent consolidation as far as possible, and adequate covers shall be provided to prevent the ingress of water and contamination by dust. The recovered asphalt that is placed in the stockpile(s) shall be tested, carefully controlled and recorded with regard to origin and material properties to ensure a consistent recycled end product. The preparation of stockpile sites and the stockpiling of recovered asphalt for recycling will not be paid for directly but full compensation therefore shall be included in the rates for the recycled asphalt.

@)

Hot i n situ surface recycling

With regard to new binder, recycling additives, new asphalt, new aggregate or combinations of these materials. hot in situ surface recycling shall comply with the requirements in the project specifications.

Table 420216 GRADING LIMITS FOR COMBINED AGGREGATE AND MIX PROPORTIONS FOR ASPHALT BASE SIEVE SIZE (mm)
53,000 37,500
V)

SEMI-GAP-GRADED
37.5 m m MAX 26.5 m m MAX

CONTINUOUSLY GRADED
37,5 m m MAX 26.5 m m MAX

100 85

100 100 92 84 - 94 71 - 84 59 - 75 50 - 67 100 85 - 95 71 84 62 - 78

m
4

26,500 19,000 13.200 9,500 6,700 4,750 2,360 1,180 0,600 0,300 0,150 0,075

100

Z >

c W >

75 - 95

- 100

cn

82 - 93 60 - 80 72 - 87 60 75 45

12 A

'+ ?
e
c C

- 60

50 - 64 40 - 52 36 - 47 32 - 42 22 - 35 10 - 2 0
4 - 10

36 - 53
25

42

- 60

z o
< c
LI;

40 - 52 36 - 47 32 - 42 22 - 35 10 - 2 0
4 - 10

- 42

30 - 47

18 - 3 3

21

S Z

LL:

F
LC
(L

9 - 21
6 - 17
4

- 37 15 - 30 11 - 24
8 - 19
5 - 12

- 12

9 ' S 2 = rogz

Aggregate Bitumen (grade according to project specifications) Active filler*

93,5%

95%

94,5%

&?$$
0

5,5%

4%

z-rnm2

v,

4,5%

1,0%

1 ,O%

1,096

*Active filler for tender purposes to be hydrated lime. Note: For recycled asphalt the nominal mix ratios of recovered asphalt, new aggregate, new bituminous binders, and active mineral filler to be used for tender purposes, shall be as specified in the project specifications.

Table 4202i7 GRADING LIMITS FOR COMBINED AGGREGATE AND MIX PROPORTIONS FOR ASPHALT SURFACING

SIEVE SIZE (mm) HIGH STONE CONTENT

26,500

GAP-GRADED* INTERMEDIATE STONE CONTENT LOW STONE CONTENT

SEMI-GAP-GRADED COARSE
26,5 m m

CONTINUOUSLY GRADED MEDIUM FINE

SEMI- " OPENGRADED

MAX
100

19 m m MAX
100

9
0
4

AGGREGATE BITUMEN (GRADE ACCORDING TO PROJECT SPECIFICATIONS) ACTIVE FILLER

---

92,0% 7,0%

92,0% 7,0%

92,046 7,0%

93% 6,0%

93% 6,0%

93,5% 5,5%

93,5% 55%

93,076 6,0%

903%

r;g 2
-

8,5%

1,0%

1,O%

1,0%

1,090

1,0%

1,0%

1,096

1,0%

1,0%

*THE PERCENTAGE PASSING THROUGH THE 4,750 mm SIEVE AND RETAINED ON THE 0,600 MM SIEVE SHALL NOT EXCEED 15% **DRY METHOD RUBBERIZED ASPHALT AS SPECIFIED IN THE PROJECT SPECIFICATIONS Note: For recycled asphalt the nominal mix ratios of recovered asphalt, new aggregate, new bituminous binders, and active mineral filler to be used for tender purposes, shall be as specified in
.a

the project specifications.

GRADING LIMITS FOR COMBINED AGGREGATE AND MIX PROPORTIONS FOR NON-HOMOGENEOUS MODIFIED BINDERS CONTINUOUSLY GRADED ASPHALT SURFACING Sieve size (mm) Percentage passing through by rnass Continuously graded

13.2 rnm max 19 13.2 9.5 4.75 2.36 1.18 0.60 0.30 0.15 0.075
Aggregate Modified binder (bitumen rubber) Active filler

19.0 m m max 100 84 - 96 70 - 84 45 - 63 29 - 47 19 - 33 13 - 25 10 - 18 6 - 13 4 - 10 91 .O% 7.0% 2.0%

Percentage passing through sieve by mass

100 80 - 100 50 - 70 32 - 50 13 - 25 8 - 18 4-8 91 .On& 7.0/~ 2.0%

Nominal mix proportions by mass

GRADING LIMITS FOR COMBINED AGGREGAlE AND MIX PROPORTIONS FOR CONVENTIONAL NON-HOMOGENEOUS MODIFIED AND HOMOGENEOUS MODIFIED BITUMINOUS BINDERS OPEN-GRADED ASPHALT SURFACING The target grading selected for open-graded asphalt mixes shall be such that in the case of medium open-graded asphalt mixes of type 2 and 3, the void content of the compacted mix shall he between 18 and 22 per cent. while for all other types. the voidcontent shall be between 20 and 25 per cent. Sieve size (mm) Type 1 Open graded asphalt mixes

13.2 mm noniinal
Type 2 Type 3

9.5 mm rnaximurn

19 13,2 9.5 4,75 2,36 1,18 0,60 030 0,15 0,075

Binder type Road grade bitumen

100 90 - 100 30 - 50 10 - 20 8 - 14

100 70 - 100 50 - 80 15 - 30 1 0 - 22 6 - 13

100 50 - 70 20 - 30 5 - 15

100 10 - 25 5 - 15

3-8 2-6
Polymermodified binder Bitumen ruhher

3-6
Bitumenrubher

2-5
Bitumenrubber

2-6
as for 13.2 m m type 1 mixes as for 13.2 m m type 1 mixes as for 13.2 mm type 1 mixes

Aggregate Binder content Active filler

94.5% 4.5% 1,O%

94.0% 5.0% 1 ,O%

93.51: Fi 5%
1.0'h

93.576 5.58 1.06

93.5% 5.5% 1.O%

1.096

GRADING LIMITS FOR COMBINED AGGREGATE AND MIX PROPORTIONS FOR CONVENTIONAL AND HOMOGENEOUS MODIFIED RITUMINOUS BINDERS STONE MAS1lC ASPtlALT SURFACING Sieve size (rnrn)
13,2 93 67 4,75 2,36 1,18 0,600 0,300 0,150 0,075 13.2 m m man size 100 67 - 90 41 - 65 30 - 50 21 - 32 17 - 2 7 14 - 24 11 - 23 9 - 17 7
-

9.5 mrn max size

6.7 rnm rnax size

100 50 - 80 30 - 55 22 - 32 17 - 2 7 14 - 2 3 11 - 22 9 - 19 100 80 - 100 34 - 44 24 - 34 18 - 30 13 - 25 9 - 19 7 - 12 93.5 0.3 - 0,5 6.5

12

7 -12
93.5 0.3 - 0.5 6.5

Aggregate (%) Binder stabilizer (cellulose fibres) % Binder content (%)

93.5 0.3 - 0.5 6.5

Tahle 420811 Property Base (37.5 m m aggregate) Design guidelines Voids in mix (%) Sabita manual 13 and TRH 8
3-6

Requirements Continuously graded and stone-mastic wearing courses TRH 8

3 6 2 6

ContinuouslyOpen-graded graded biturnen- asphalt wearing rubber wearing courses courses Sahita manual 16 and TRH 8
9.5 m m and type t : 20 - 25 Target 20 Types 2 and 3 : 18 - 22

Serni-gap-graded asphalt wearing courses TRH8

3-6

Voids in mineral aggregate (%)

12 minimum

Stone mastic 17 minimum Continuously graded . 14 minimum

,

17 minimum

15 minimum (19.0) 14 minimum (26.5)

Indirect tensile strength at 25 " C (kPa) Cantabro abrasion loss at 25 " C (5%) Dynamic creep at 40 " C for laboratory briquettes (MPa)

800

800

550 25 maximum (Types 2 and 3: 20 max)

800

15 minimum

15 minimum (for stone-mastic asphalt see project specifications)

10 minimum

Not applicable

12 minimum

Note: See project specifications for the dynamic creep reqriirements for cores from trial sections and from the road during construction.

4204

PLANT AND EQUIPMENT

to ensure the complete combustion of the fuel in order to prevent pollution of the atmosphere and the aggregate. (ii) Non-homogeneous modified blnders (bltumenrubber)

All plant shall be so designed and operated as to produce a mixture complying with the requirements of this specification. The plant and equipment used shall be of adequate rated capacity, in good working order and subject to the approval of the engineer. Obsolete or wornout plant will not be allowed on site. Prior to the start of the work the contractor shall supply the engineer with copies of the manufacturer's handbooks and copies of check lists prepared in terms of IS0 9002 where applicable pertaining to the mixing, remixing and paving plants, containing details of the correct settings and adjustments of the plant. Any alteration which has been or is being effected to any constructional plant, and which does not comply with the specifications of the manufacturer, shall be brought to the notice of the engineer.

In the event of on-site blending adequate and suitable heating tanks and acceptable blending equipment shall be provided in addition to the mixing plant for conventional binder. (iii) Homogeneous modified binder

In addition to the mixing plant requirements for conventional binder, refer to the reouirements of the project specifications. (iv) Recycling

(i)

Conventional binders

In addition to the requirements set out in subclause 4204(b)(i) the mixing equipment shall be specially adapted to deal with recycling and any such adjustments shall be in accordance with the instructions of the manufacturer of the mixing plant. The recovered asphalt portion of the mlx shall not be exposed directly to the heating source whilst the feeding rate and proportioning shall be accurately controlled. Before work is commenced, the contractor shall submit full details of his mixing equipment to the engineer for his approval.

Asphalt shall be mixed by means of an approved type mixer of proven suitability for producing a mixture complying with all the requirements of the specifications. The mixing plant may be either automatically or manually controlled but in the latter case, two control operators shall be provided. The heating system of the tanks storing the binder shall be so designed that the binder will not be degraded during heating. A circulating system for the binder shall be provided which shall be of adequate size to ensure the proper and continuous circulation between storage tanks and mixer during the entire operating period. Binder storage tanks shall be fitted with thermometers designed to provide a continuous record of the temperature of the binder in the tank. Copies of these records shall be supplied to the engineer on a daily basis. Satisfactory means shall be provided to obtain the proper amount of binder in the mix within the tolerances specified, either by weighing or volumetric measurements. Suitable means shall be provided for maintaining the specified temperatures of the binder in the pipelines, weigh buckets, spray bars and other containers or flowlines. In the case of a drum type mixer, the system shall control the cold feeding of each aggregate fraction and of the filler by mass, by means of a load cell or another device regulating the feed automatically, and by immediately correcting any variation In mass which results from moisture or from any other cause. The cold feed shall be regulated automatically in regard to the binder feed so as to maintain the required mix proportion. Suitable dust collecting equipment shall be fitted to prevent pollution of the atmosphere in accordance with the provisions of Act 45 of 1965 and Act 85 of 1993. The fuel chosen and control of the burner shall be such as

(c) (i)

Spreading equipment Paver

The mixture shall be laid by an approved type of selfpropelled mechanical spreader and finisher capable of laying to the required widths, thicknesses, profile, camber or cross-fall, without causing segregation, dragging or other surface defects. All pavers shall be fitted with automatic electronic screed controls to maintain the required levels, cambers and cross-falls. Where levelling beams on multiple skids or sliding beams are used they shall be at least 12,O m long, or as specified by the engineer. (ii) Chip spreader

Wherever feasible, a machine straddling the full paved width shall be used for spreading the precoated chippings. Such a mechanical spreader must be self-propelled and be able to follow immediately behind the paver. When coated chippings are spread by hand special care shall be taken to prevent bunching of the chippings.

(d)
(i)

Rollers
General requirements

Compaction shall be done by means of approved flat steelwheeled, vibratory or pneumatic-tyred rollers. The frequency as well as the amplitude of vibratory rollers shall be adjustable. Vibratory rollers shall be used only where there is no danger of damage being done to the asphalt, structures of bridge decks, or other layers. It will be Indicated in the project specifications whether vibratory

compaction equipment may be used on bridge decks and what the constraining parameters will be. The rollers shall be self-propelled and in good working condition. free from back lash, faulty steering mechanism and worn parts Rollers shall be equipped with adjustable scrapers to keep the drums clean and with efficient means of keeping the wheels wet to prevent mixes from sticking to the rollers. No leakages of any nature may occur in the rollers The mass and/or tyre pressures shall be such so as to ensure proper compaction to comply with the specifications of surface finish and density.

4205

GENERAL LIMITATIONS AND REQUIREMENTS AND THE STORAGE OF MIXED MATERIAL

(a)

Weather conditions

Asphalt may b e mixed and placed only under favourable weather conditions. and shall not be mixed or placed when rain is imminent or during misty or wet conditions. The following wind and temperature conditions are regarded as being suitable for paving work: While the air temperature is rising. work may be (i) performed at temperatures of -

(ii)

Non-homogeneous modified binder asphalt 6 C with an allowable wind velocity of less than 25 km/h

For continuously graded asphalt the use of an approved pneumatic-tyred roller shall b e assessed i n a trial section. The contractor shall take adequate precautions to eliminate pick-up. For open-graded asphalt and/or stone-mastic asphalt, only approved static flat steelwheeled rollers having a total mass of 7 to 10 tons shall be used.

10C with an allowable wind velocity of less than 55 kmlh. or for asphalt with a compacted thickness of less than 30 m m with an allowable wind velocity of less than 35 kmlh. With falling air temperatures. work must be stopped (ii) when the temperature reaches 6C regardless of the wind velocity and &ay not be restarted before the temperature is definitely rising.

(iii)

Homogeneous modified binder asphalt

The general requirements shall apply. However. for open graded asphalt and/or stone-mastic asphalt the requirements as specified for non-homogeneous modified binder asphalt shall equally apply.

@)

Moisture

The mixing and placing of asphalt will not be allowed if: the moisture content of the aggregate affects the (i) uniformity of temperature: or if

(e)

Binder di&.butors (ii) free water is present on the working surface: or if

Where bituminous binders are to be sprayed onto areas before the asphalt is placed. the binder distributors shall comply with clause 4103.

(1)

Vehicles

the rnois!i~re content of the underlying layer. in the (iii) opinion of the engineer. is too high. or if the moisture content of the upper 50 m m of the base exceeds 50% of the optimum moisture content as determined b y the engineer. No overlay shall be placed immediately after a rainy spell on an existing partly cracked and/or highly permeable e the surfacing resulting in the trapping of m o i s t ~ ~ rin pavement structure A minimum delay of 24 hours or such extended period as ordered b y the engineer shall apply.

The asphalt shall be transported from the mixing plant to the spreader in trucks having tight. clean. smooth beds and sides which have been treated to prevent adhesion of the mixture to the truck bodies. A thin film of soapy water or vegetable oil may b e used to prevent adhesion hut petroleum products shall not be used for this purpose.

(c)

Surface requirements Correction of base or suhbase in the case of asphalt

All vehicles used for transporting hot asphalt shall he fitted with canvas (transport in excess of 10 k m or cold. windy or rainy conditions prevailing) or other suitable approved covers (less than 10 k m and moderate climatic conditions prevailing) to minimise temperature loss. Such covers shall be securely fixed over the hot asphalt from the time of departure at the mixing plant until immediately prior to the discharge of the asphalt into the paver.

(i) base

@)

Massmeasuring device for asphalt mixes

Where payment per ton is specified. the contractor shall keep available at the mixing plant or on the site a suitable gauged mass-measuring device for measuring the asphalt mixes. The device shall be provided with a printer for printing the type of mix. the mass. the time and the date The printed data shall be submitted to the engineer.

The base (after the prime coat has been applied) or the subbase. as the case may be. shall be checked for smoothness and accuracy of grade. elevation and cross section. Any portion of the base or subbase. as the case may be. not complying with the specified requirements. shall be corrected with asphalt at the contractor's own expense, until the specified requirements are met. The engineer may. however. in his sole discretion. allow minor surface irregularities to remain. provided they can be taken u p in the following asphalt layer without adversely affecting that layer. The asphalt used for the correction of the base or subbase. shall be the sarrie mixture as specified for the surfacing or

as directed by the engineer. and the maximum size of aggregate used shall be dictated by the required thickness of the correction in each case. Notwithstanding these provisions for the correction of the base or subbase, the engineer reserves the right to order the removal and reconstruction of the layer or of portions of the base and subbase layers not complying with the specified requirements, instead of allowing the correction of substandard work with asphalt material. Where a prime coat is applied it shall be dry before further coats or layers are applied. The contractor shall not commence with the application of the tack coat and/or the paving without the written approval of the engineer. The contractor's programme shall allow for delays that are a function of the type of prime. rate of application, base porosity and moisture content. and climatic conditions. (ii) Cleaning of surface

Preparation where asphalt layers are to be widened (v) or where surfacing over a section of the road width requires replacement The existing asphalt shall be removed as described in section 3800. where applicable. or as instructed by the engineer. Where a road has to be widened. the overlay shall be cut hack not less than 1 0 0 m m from the existing edge. Unless otherwise indicated on the drawings or instructed by the engineer. asphalt joints may not fall within a wheel track.

(d)

Storage

Immediately before applying the tack coat, or where there is no tack coat, before the application of the asphalt. the surface shall be broomed and cleaned of all loose or deleterious material. Where the prime coat (if any) has been damaged. it shall be repaired by handbrushing or spraying priming material over the damaged portions. Where the surfacing is to be constructed on bridge decks. the concrete deck shall be thoroughly cleaned by washing and brushing to remove all loose material and allowed to dry. (iii) Tackcoat

Mixing shall not be allowed to take place more than four hours before paving begins unless provision has been made for storage. Storage of mixed material will only be p ~ r m i t t e din approved hoppers. which are capable of maintaining the temperature of the mix uniform throughout. In any case storage will not be permitted for a period longer than 8 hours after mixing. unless otherwise approved by the engineer. Open-graded mixes and stonemastic asphalt shall not be stored or mixed ahead of paving operations, but shall be laid directly following mixing.

4206

PRODUCING MIXTURE

AND

TRANSPORTING

THE

(a)

Mixing and storage temperatures of binder

Where required in these specifications or the project specifications, or where indicated by the engineer. a tack coat shall be applied to the surface to be paved. The tack coat shall consist of a stable-grade bituminous emulsion diluted to have a 30% bitumen content and shall be applied at a rate of 0.55 l / m 2 or as directed by the engineer. For bridge decks a tack coat consisting of 30% stablegrade bituminous emulsion shall be applied to the surface at a rate of 0,4 l / m 2 . The tack coat shall then be allowed to dry. The use of hand operated equipment for the application of tack coats shall be at the sole discretion of the engineer and his approval shall be timeously obtained.

Bituminous binders shall be stored at temperatures not exceeding those given in table 420611 or as specified in the project specifications. and the aggregate and bituminous binders shall be heated at the mixing plant to such temperatirres that the mixed product shall have a temperature within the range given in table 420611.

(b)

Production of the mixhrre

Using batch plants Heating the aggregate

(i)
(1)

The aggregate shall be dried and heated so that. when delivered to the mixer. its temperature shall be between 0 C and 20C lower than the maximum temperature indicated in table 420611 for the mixture. The moisture content of the mix shall not exceed 0.5%. (2) Batching

All exposed portions of kerbing. channelling and bridge

railing, shall be protected in terms of section 2300 when the tack coat is applied. The tack coat shall not be applied more than 24 hours before the paving is done. Each fraction of the aggregate and binder shall be measured separately and accurately in the proportions by mass in which they are to be mixed. If filler is used. it shall be measured separately on a scale of suitable capacity and sensitivity. The error in the weighing apparatus used shall not exceed 2% for each batch. (3) Mixing

(iv)

Preparation for placing the overlays

The provisions of section 4800 shall apply to any surface to be covered with overlays. The type of treatment to be applied, if any, will be specified in the project specifications or instructed in writing by the engineer.

The aggregate, filler and binder shall be mixed until a homogeneous mixture is obtained in which all particles are uniformly coated. Care shall be taken to avoid excessively long mixing times which can cause hardening of the

Table 420611

engineer, is provided. Any asphalt which has become wet due to rain or any other cause shall be rejected. Hauling over freshly laid material is not permitted.
(d)
<

Small quantities o l asphaH

Maximum storage temp of binder

Temperature range of mix "C

"C

Material

Over Under Continuously. 24 hrs 24 hrs semi-gap and gap graded mixes

Open graded mixes

A small quantity of asphalt shall be a quantity of less than 10 tons of a specified composition to be specially produced on occasion. For a small quantity of asphalt of less than 10 tons extra payment will be made if its use has been instructed by the engineer, in writing, and where. in the opinion of the engineer it is necessary (i) in accordance with the approved programme of the contractor. and/or working

Bitumens 40150 penetration grade (824 road-grade) 60170 penetration grade (812 road-grade) 80/100 penetration grade (88 road-grade) 150/200 penetration grade (84 road-grade)

for the safety of the work or the travelling public on (ii) account of weather conditions or abnormal traffic conditions. 145 175 140-165 110-140 No extra payment will be made where small quantities of asphalt are required in consequence of the negligence of the contractor. or of poor work or bad planning done by the contractor. or because he did not execute the works in accordance with his approved programme.

135

175

135-160

105-135

125

175

130-155

100-130

(e)

Recycled asphah

The provisions of subclauses 4206(a) to 4206(d) shall apply mutatis mutandis. 115 165 125-150 At least 4 weeks before paving with recycled material will commence. the contractor shall submit to the engineer full particulars regarding the recycling methods he intends to use. 160 - 180 Where recovered asphalt material is taken from a stockpile. it shall be done by excavating from the pile over its full depth. Where segregated material is fed into the mixing plant. the engineer will have the right to order the work to cease and to instruct the contractor to remix the stockpile. retest the mixed material and redesign the asphalt mixture all at his own cost.

Nonhomogeneous modified binders (see clause Bitumen-rubber 4202(a)(ii)(4)) Homogeneous modified binders

160 - 180

See project specifications

(ii)

Using drum-type mixer plants

The aggregate and filler shall be accurately proportioned and conveyed into the drum-mixing unit. The calibrated amount of binder shall be sprayed onto the aggregates at the correct position so that no hardening of the binder shall take place. A homogeneous mixture and uniform coating of binder must be achieved and the moisture content of the asphalt mixture shall not exceed 0.5%. Once the final mix temperature has been agreed upon it may not be altered without the prior consent of the engineer. The moisture content of the asphalt mixture shall be tested according to method C11 of TMHI.

4207

SPREADING THE MLXTURE

(c)

Transporting the mixlure

The mixture shall be delivered to the paver in such (a) a manner that the paver will never be forced to stop for lack of asphalt. The temperature of the mixture shall be controlled by measuring in a random pattern in the truck immediately before emptying. and shall not be more than 10" C below the minimum temperature specified for mixing in table 420611. The adjustment of the screed. tamping bars. feed screws. hopper feed. etc. shall be checked frequently to ensure uniform spreading of the mix. If segregation or tearing occurs, the spreading operations shall immediately be suspended until the cause is determined and corrected.

The mixture shall be transported from the mixing plant to the works in trucks complying with the requirements of subclause 4204(f). Loads shall be covered by waterproof canvas or insulated metal sheets when the haul exceeds 10 krn or during cold, windy or rainy weather. Deliveries shall be made so that spreading and rolling of all the mixtures prepared for a day's run, can be completed during daylight, unless artificial lighting. as approved by the

The addition and removal of material behind the paver shall normally not be allowed and the paver shall be capable of spreading the mixture to the correct amounts that will provide the required compacted thickness without resorting to spotting. picking-up or otherwise shifting or disturbing the mixture.

Only minimal hand-working of the open graded asphalt shall b e permitted after discharge from the paver and before rolling and shall only be carried out with wooden spreaders. Operatives shall not be permitted to walk on uncompacted open graded asphalt. Paving shall, if possible, commence at the bottom of the grades and the lower edges of superelevated curves. Paving shall be done upgrade o n grades steeper than 5?& Spreading shall b e so arranged that longitudinal joints do not coincide with joints in lower layers of asphalt base. paver laid crushed stone bases or surfacing. Continuity of placing is especially important for opengraded asphalt. Cutting of longitudinal joints shall be avoided when paving open-graded asphalt. but where cutting is essential. only sawing shall be permitted. The existing layer shall b e heated to assure adequate longitudinal bonding of the asphalt in the two lanes. Unless otherwise specified in the project specifications the control of paver shall b e equipped to provide autorr~atic levels and cross section. In the case of asphalt base construction, automatic control shall b e run off guidewires and in the case of surfacing and overlays skids or guidewires shall b e used. On restricted areas, inaccessible to the paving equipment used, the mixture may b e placed by hand or other means to obtain the specified results. Paving shall b e carried out in a manner which will avoid segregation and which will allow control of levels. The mixer capacity and the operating speed of the paver are t o b e so co-ordinated as to ensure continuous laying and to avoid intermittent stopping of the paver. Paving shall cease when rain starts falling or when the surfaces to b e paved are visibly wet. In the case of overlays, guide wires will normally not (b) b e required during the placing of the mix unless s p e c i f i ~ d i n the project specifications. In all cases. including levelling courses, the paver shall be provided with approved skid beams with electronically controlled equipment which can ensure a constant crossfall and can even out local irregularities. Asphalt shall be placed in restricted areas with the (c) aid of smaller specially equipped pavers. hand tools. or other approved equipment. The space concerned shall be properly filled with asphalt. without leaving any gaps between the fresh asphalt and the existing pavement layers. All the provisions in regard to temperature. mix composition, uniformity, etc. shall remain applicable. but layer thickness and control shall be such that the requirements for compaction and surface tolerances can still be attained.

the engineer it has resulted in a deficiency of recovered material. the contractor shall supplement such deficiency at his own cost with a quantity of similar or better material equal to the quantity wasted. as determined b y the engineer.

(e)

Surfacing of bridge decks

The type and nominal thickness of the surfacing shall be as indicated on the drawings and specified in the schedule of quantities. Before commencing with the construction of the surfacing. the actual levels of the bridge deck shall be determined by means of accurate levelling. The levels and grades to which the surfacing is to b e constructed shall b e as shown on the drawings or as indicated b y the engineer. If the levels of the concrete deck as constructed b y the contractor deviate by more than the specified tolerances from the specified levels. he shall construct a levelling layer at his own cost. Ttre nominal size of the aggregate in the levelling layer shall be 9.5 m m .

1208

JOINTS

All joints between adjacent sections of the work shall b e made b y cutting back the layer against which the material is to b e placed except for open-graded asphalt where the requirements of clause 4207 shall apply. All loose and incompletely compacted material shall be removed. A cutting wheel shall be used for cutting longitudinal joints. The joints of adjacent sections shall normally not be cut in the case of open-graded surfacing. but shall b e formed b y placing hot asphalt in the adjacent lanes. Joints shall b e either at right angles or parallel to the centre line. and unless otherwise approved-joints in the final layer of the surfacing shall correspond with the lane markings. Joints in lower layers shall be offset not less than 150 m m o n either side of the edges of the traffic lanes. Before a new layer is placed next to an existing layer. except in the case of open-graded mixes. the cut edge of the existing layer shall b e painted with a thin coat of bituminous emulsion of the same type used for the tack coat. if so directed by the engineer. Joints shall be neat and shall have the same texture and density as the remainder of the asphalt course. All joints shall b e marked out with chalk lines prior to cutting.

The outside edges of the completed asphalt layer shall b e trimmed along the shoulder, and parallel to the centre line. to give a finished width. as shown o n the drawings. within the tolerances specified.

(dl

Recycled =Ph&
Any fresh mixture spread accidentally onto existing work at a joint shall be carefully removed by brooming it back with stiff brooms onto the uncompacted work. so as to avoid the formation of irregularities at the joint. Whenever the paving operation is stopped due to lack of mixture. the contractor shall form a proper joint as specified above. if so directed b y the engineer.

The provisions of subclauses 4207(a) to 4207(c) shall apply mutatis mutandis to recycled asphalt. Where the average thickness of a completed asphalt layer exceeds the specified thickness. and/or recovered asphalt has been wasted indiscriminately. and. if in the opinion of

The requirements of clause 4208 apply mutatis mutandis to joints in recycled asphalt layers.

4209

PRECOATED CHIPPINGS SURFACING

FOR

ASPHALT

Aggregate for precoated chippings shall be coated using 1,7% + 0,396 by mass of the same bitumen used in the asphalt, provided that the bitumen shall not be softer than 60170 penetration-grade (812 road-grade).One per cent by mass of active filler shall be added to the mixture. The active filler shall be hydrated lime, and shall comply with the requirements of subclause 4202(c). The aggregate shall be dried and fed into the mixer at a temperature of between 130" C and 185C followed by the bitumen at a temperature not exceeding 175C and filler. Immediately after the aggregate has been coated and discharged from the mixer it shall be rapidly cooled to ambient air temperature by hosing down with water. Coated chippings shall be stockpiled in heaps not exceeding 1,O meter in height and protected if necessary to prevent its temperature from exceeding 60C during storage. The precoated chippings shall be spread on the asphalt at the rate of 6 to 8 kglm2when using 13,2 mm nominal size chippings, 7 to 9 kglm2when using 19,O mm nominal size chippings, depending on the relative density of the aggregate. The chippings must be laid by a mechanical spreader which straddles the paved width and follows immediately behind the paver. The chippings shall be spread to give a uniform texture free from clusters and open patches and rolled in as described in clause 4210. The desired surface texture shall be demonstrated in the trial section as described in clause 421 1, and it shall have a texture depth of between 0,6 and 1,O mm when tested according to method ST1 of TMH6, and thereafter the spread rate shall be determined by the engineer. In restricted areas the contractor may use hand tools for spreading chippings or, if so instructed by the engineer, dace a bituminous seal as specified in the contractor mav ,, subclause 4309(a) or in the project specificat/ons, after compaction, over the asphalt layer. The rate of application and requirements for evenness of the spread chippings shall remain applicable. Where extra over payment is made for work in restricted areas, no distinction shall be made between placing the conventional chippings and placing the bituminous seal as specified in clause 4309 or in the project specifications.

steelwheel and pneumatic-tyred rollers in a sequence predetermined and approved during the laying of trial sections. Such rolling shall commence and be continued only for so long as it is effective and does not have any detrimental effect. Only steelwheel rollers (non-vibratory) will be permitted for the compaction of open-graded mixtures although rubber-tyred rollers shall be on standby if required. The use of pneumatic-tyred rollers for continuously-gradedasphalt with modified binders shall be assessed in the trial section. As many rollers shall be used as is necessary to provide the specified pavement density and the required surface texture. During rolling of asphalt surfacing, the roller wheels shall be kept moist with only sufficient water to avoid picking up the material. After longitudinal joints and edges have been compacted, rolling shall start longitudinally at the sides and gradually progress towards the centre of the pavement, except on superelevated curves, or where the area to be paved has a cross-fall, when rolling shall begin on the low side and progress to the higher side, uniformly lapping each preceding track, covering the entire surface. During breakdown-rolling the rollers shall move at a slow but uniform speed (not to exceed 5 kmh) with the drive roller nearest the paver, unless otherwise specified on account of steep gradients. No movement of the asphalt layer shall occur under steelwheel rollers once the asphalt temperature has dropped to below 100 "C. Three-wheeled steel rollers, with large diameter rear wheels are preferable to tandem rollers and may be used in conjunction with pneumatic tyred rollers, provided pick-up of the asphalt on the wheels does not occur. The contractor shall take adequate precautions to eliminate pick-up. The sequence of rollers used in compaction is at the discretion of the contractor provided the completed pavement shall have a density as measured on recovered core equal to or greater than 97 per cent, minus the percentage voids in the approved production mix, of the theoretical maximum density, determined as described in TMH1 method C4. For thin layer asphalt (less than 25 mm) the compaction requirements shall be specified in the project specifications. For open graded asphalt the degree of compaction can be controlled indirectly by means of in-situ permeability tests calibrated during the trial section and by visual evaluation of the aggregate to prevent crushing. The contractor shall utilize a calibrated nuclear gauge for process control during compaction operations. (See subclause 8107(f)) Notwithstanding this requirement, the acceptance control carried out for compaction by the engineer, shall still be based on cores taken from the compacted layer. When constructing asphalt surfacing with rolled-in chippings the asphalt shall be paver compacted and thereafter precoated chippings shall be spread at the specified rate. When the asphalt has reached the correct temperature the chippings shall be rolled in so that they are firmly bedded in the asphalt. Care shall be taken not to

The provisions of clause 4209 shall apply mutatis mutandis to surfacings of recycled asphalt, but the rate of application of the stone chippings will be determined by the engineer after the grading of the recovered asphalt and the mix ratios of the recycled mix have been determined.

4210

COMPACTION

The mix shall be rolled as soon as possible after it has been laid by a combination of vibratory and static

roll the chipplngs flush wlth the asphalt but to leave them slightly proud. The procedure for compacting the asphalt and rolling In the chipplngs to produce the desired surface texture and specified degree of compaction shall be determined on a trlal section as described in clause 421 1. The portion of trlal section having the desired surface texture shall be designated as a reference for what is required In the permanent work. The following requirements shall apply to rolling and compacting generally: The materlai shall not be excessively displaced in (a) a longitudinal or transverse direction especially when changing gears, stopping or starting rollers. No cracks or hair cracks shall be formed and the (b) bond wlth the underlying layer shall not be broken. The density shall be uniform over the whole area of (c) the layer and extend over the full depth of the layer. Rollers shail not be left standing on the asphalt (d) layer before It has been fully compacted and before the layer surface temperature has dropped below 60" C. In restricted areas where the specified rollers cannot (e) be used, compaction shall be carried out wlth handoperated mechanical compaction equipment or approved smaller vibratory rollers. The prescribed density requirements remain applicable throughout over the full layer thickness irrespective of the method of compaction. Note: The provisions of clause 4210 apply mutatis mutandis to recycled asphalt.

Only when such a trial sectlon has been satisfactorily laid and finished, and complies with the specified requirements, will the contractor be allowed to commence with construction of the permanent work. If the contractor should make any alterations in the methods, processes, equipment or materials used, or if he is unable to comply consistently with the specifications, the engineer may require that further trlal sections be laid at the contractor's cost before allowing the contractor to contlnue with the permanent work. The lntentlon of this clause is to avoid any experimentation by the contractor on the permanent work. The trial sections shali be lald where indicated by the engineer. The contractor shall prepare the surface on which to lay the trial sectlon and shall also, if requlred, remove the trlal sectlon after completion and restore the surfaces on which it was constructed, all at the contractor's cost. Provision is made for payment of the first approved trial sectlon of any particular mlx type, but subsequent trial sections with the same mix type shall be at the contractor's own cost. Payment will be made for the speclfled area of each approved first trial sectlon for any particular mix type. The construction equipment and techniques as well as the mix properties applicable to the approved trlal section shail not be changed without prior approval by the engineer.

4212

PROTECTIONAND MAlNTENANCE

4211 LAYlNG TWAL SECTlONS

Before the contractor commences with the construction of any asphalt base or surfacing, he shall demonstrate, by laying a trial section of between 300 mz and 600 m Z in area, as specified, depending on the required layer thickness, that the equipment and processes that he proposes to use, will enable him to construct the particular asphalt course in accordance with the specified requirements. The engineer may require that up to 3 different binder contents be incorporated in one such trial section to verify the laboratory design phase.

The contractor shall protect asphalt base and asphalt surfacing from all damage until the work Is finally accepted by the engineer and he shall maintain the surfacing work until the issue of the maintenance certificate. Excepting fair wear and tear on surfacing any damage occurring to the completed base or surfacing during the maintenance period, or any defects which may develop due to faulty workmanship, shall be made good by the contractor at his own expense and to the satisfaction of the engineer.

4213

CONSTRUCTION TOLERANCES AND REQUIREMENTS

FINISH

(a)

Construction tolerances

(The application to overlays is specified in subclause 4213(f)) The completed sections of asphalt base and surfacing shall comply with the requirements for grade, width, thickness, cross section and smoothness stated below.
(i)

Amongst others the contractor shall submit dynamic test results obtained from the testing of cores extracted from the completed trial section in locations determined by stratified random sampling methods, and/or, if specified, dynamlc test results obtained from briquettes prepared from material obtained by stratified random sampling methods at the manufacturing plant or behind the paver as directed by the engineer.

Level and grade

The level tolerances referred to in clauses 8205 and 8305 shall be as follows:

A maximum period of 10 days shall be allowed to verify

dynamic creep test results unless otherwise specified in the project speclfications.

Deviation from the specified longitudinal grade due to deviations from the specified levels shall not exceed the values given below:

Length of variation in grade (m)

Maximum variation from specified grade

Oh

Number of irregularities equal to or exceeding the (2) specified value when taken over 100 m sections: Freeways (3 m m irregularities) Asphalt with rolled-in . chippings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Stone-mastic asphalt . . . . . . . . . . . . . . . . . . . . . . . . .6 Other asphalt layers . . . . . . . . . . . . . . . . . . . . . . . . . .5 Other roads (5 m m irregularities)

(ii)

Width Asphalt with rolled-in chippings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Other asphalt layers . . . . . . . . . . . . . . . . . . . . . . . . . . 3 (3) The maximum value of any individual irregularity when measured with the rolling straight-edge or a 3 m straightedge laid parallel to the road centre line: Freeways

The average width of both asphalt base and surfacing shall be at least equal to that shown on the drawings and nowhere shall the outer edge of the layer be inside the lines shown on the drawings by more than 15 m m in the case of both asphalt base and asphalt surfacing. (iii) Thickness

The thickness tolerances referred to in clauses 8205 and 8305 shall be as follows: D m base = 15 m m Dmax base = 20 m m Dave base = 5 m m surfacing = 5 m m surfacing 8 mm surfacing 2 mm

Asphalt with rolled-in . mm chippings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Stone-mastic asphalt . . . . . . . . . . . . . . . . . . . . . .6 m m Other asphalt . . . . . . . . . . . . . . . . . . . . . . . . . . .4. m m Other roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 m m (vi) ~ u l t i ~ l e - l a ybase er

Thickness shall be determined from carefully controlled levels taken before and after construction in exactly the same position andlor from cores drilled from the completed layer. (iv) Cross section

When tested with a 3 m straight-edge laid at right angles to the road centre line the surface shall not deviate from the bottom of the straight-edge by more than 6 m m for freeways and more than 10 m m for other roads. At any transverse section the difference in level between any two points shall not vary from their difference in level computed from the cross section shown on the drawings by more than 15 m m for freeways and 20 m m for other roads. (v) Surface regularity

Where the base is constructed from more than one layer, the requirements specified shall apply to the combined layers in respect of width and thickness. The requirements for cross section. smoothness and grade shall apply to the final layer only, but the lower layers shall be constructed so as to ensure that these requirements in the final layer can be met. (vii) Surfacing of bridge decks

The completed surfacing shall comply with the requirements for base in section 3400 in respect of surface tolerances for grade, smoothness. cross section and width.

(b)
When tested with a rolling straight-edge as described in clause 81 11 the number of surface irregularities shall not exceed those given below (applied to base and surfacing) Average number of irregularities per 100 m equal to (1) or exceeding the specified value when taken over 300 m 600 m lengths: Freeways (3 m m irregularities)

Spread rate of rolled-in chippings

The tolerance in the spread rate of rolled-in chippings shall be a lo0' of the specified spread rate.

(c)

Gradings

Asphalt with rolled-in chippings.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Stone-mastic asphalt . . . . . . . . . . . . . . . . . . . . . . . . . 4 Other asphalt layers . . . . . . . . . . . . . . . . . . . . . . . . . .3 Other roads (5 m m irregularities)

The combined aggregate and filler grading shall not deviate from the approved target grading for the working mix by more than that given in table 421311. The mean grading of each lot of the working mix (minimum of 6 tests per lot) shall be determined from samples obtained in a stratified random sampling procedure.

(d) Asphalt with rolled-in chlppings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Other asphalt layers . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Binder content

The binder content shall be within the limits specified in the applicable statistical judgement scheme in clause 8206 or clause 8305.

Table 421311 Permissible deviation from the approved target grading ("A)

4214

QUALITY OF M A T E W AND WORKMANSHIP

Size of aggregate: Material passing through the following sieves (mm) 26,500 19,000 13,200 9,500 6,700 4,750 2,360 1,180 0,600 0,300 0,150 0,075

(a)

Sampling

Sampling of asphalt mixes shall be carried out according to method MB7 of TMH5, or as prescribed by the engineer. Sampling for acceptance control for bitumen content and grading shall be carried out immediately behind the paver or as otherwise prescribed by the engineer. Sampling of bitumen shall be carried out at the discharge point of the delivery vehicle or adjacent to the discharge point into the mixer. Bitumen sampling shall comply with the relevant procedure as described in ASTM D140.

+ 5,O
r 5,O

+ 5,O
r 4,O

+ 5,O + 5,O
+ 4,O + 4,O

r 4,O 2 3,O 2.0 + 1,0*

@)

Coring of asphati layers

*When statistical methods are applied the permissible deviation for the 0,075 m m fraction is + 2,0%.

(e)

Voids

The voids in the mix shall be within the limits specified in the applicable statistical judgement scheme in clause 8206.

If required in the project specifications, the contractor shall provide suitable coring machines capable of cutting 100 m m diameter cores from the completed asphalt layers. The contractor will be paid in accordance with item 42.08 for cutting cores ordered by the engineer. The cost of extracting cores for process control shall be included in the contractor's pricesfor the construction of asphalt pavement layers and will not be paid for separately. The coring equipment, the programme, and the procedures must be approved b y the engineer. If the contractor does not adhere to the approved programme, the engineer may temporarily suspend the paving operations. All Lore holes shall be neatly repaired with asphalt and compacted to the specified density. Wherever possible the cores shall be filled with the same mix as used for the layer tested.

( 1 )

Construction tolerances for overlays

When the overlay is constructed to specified levels (i) on a layer that has also been constructed or milled to specified levels by the contractor, all the tolerance requirements of subclause 4213(a) shall be applicable.

When the overlay is constructed to specified levels (ii) on an existing layer, or on a layer which has been constructed or milled by the contractor, but which has not been constructed or milled to specified levels, all the tolerance requirements of subclause 4213(a) shall be applicable except those of subsubclause 4213(a)(iii) which relate to thickness. When the overlay is not constructed to specified (iii) levels and no guide wires are used, but an electronically controlled paver and a skid beam, the following tolerances shall apply:

(c)

mutine inspeclion and tests

Routine inspection and tests will be carried out by the engineer to determine the quality of the materials and workmanship for compliance with the requirements of this section. Tests results and measurements will be assessed in accordance with the provisions of section 8200 or section 8300 as specified in the project specifications.

4215

MEASUREMENTAND PAYMENT

The outer edges of the overlay shall nowhere be more than 15 m m inside or outside the lines shown on the drawings, and shall be parallel to the road centre line.

Items 42.13, 42.14 and 42.16 are applicable solely to work that has to be executed in a restricted area of which the width is less than 3,O m or the length is less than 150,O m.

The minimum thickness shall be the specified nominal thickness.

The maximum thickness shall be the specified nominal thickness 2 10 mm.

42.01 Asphatt base (state specified thickness, type of b i i m e n and maximum size of aggregate):

The surface regularity shall be measured with a 3,O m straight-edge in accordance with subclause 81 11(b), and no irregularity may exceed a value of 6 mm.

(a) (b)

Continuously graded Semi-gap-graded

......

square metre (m2) square metre (m2)

.. . . . .. ..

The unit of measurement shall be the square metre of asphalt base constructed to the thickness specified. When specified in the project specificatinris and/or indicated in the schedule of quantities. the unit of measurement shall be the ton of asphalt constructed as specified and measured according to certified weighbridge tickets issued in respect of mixture used. No payment will be made for material wasted.

ttem
42.03 Rolled-in chippings

Unit

(nominal size indicated) i n surfacing . . . . . . . . . . . . . . . . . . . . . . . ton (1) The unit of measurement shall be the ton of rolled-in chippings applied at the specified rate. measured loose in hauling vehicles. The tendered rate shall include full compensation for the procuring. furnishing. precoating. spreading and rollirig in of precoated chippings and for any additional costs resulting from more difficult construction of the asphalt surfacing with rnlled-in chippings

The tendered rates shall include full compensation for procuring, furnishing. heating. mixing. placing and compaction of all materials as well as process control testing, protecting and maintaining the work as specified

When the unit of measurement is a ton of asphalt. the tendered rate shall also include full compensation for supplying and installing a weighbridge. and for weighing the material.

ltern
42.04 Tack coat o f 30% stablegrade emulsion

Unit

. . . . . . . . . . . . . . .litre (f )

The unit of measurement shall be the litre of 30% stablegrade emulsion applied as specified. 42.02 Asphalt surfacing (state specified thickness and type of bitumen): (a) Continuously graded (grade stated) . . . . . The tendered rat- shall include for the procuring. furnishing and application of the material as specified.

.......

square metre (m7)

ttem

Unit

(b)

Gap-graded (stone content indicated) . . . . . . . . . . . . square metre (m7) Open-graded (grade stated) . . . . . . . . . . . . . . . . . squaw metre (rn7) Semi-gap-graded (state maximum size of aggregate) Semi-open-graded

42.05 Binder variations: (state type) . . . . . . . . . ton (t)

(c)

The unit of measurement in respect of increases or decreases in the hituminous binder from that specified in the nominal mix shall be the ton. Payment for variations shall be made as specified in clause 1213.

(d)

square metre (m7)

(e) (1)

. . . . . . . . square metre ( m 7 )

Item Stone-mastic asphalt (state maximum size of aggregate) . . . . . . . . . . . . . . square metre (rn')
42.06 Variation in active

Unit

filler conhnt: (a) Cement Lime . . . . . . . . . . . . . . . . . . . . . ton (1)

The unit of measurement shall be the square metre of asphalt surfacing constructed to the thickness specifled When specified in the project specifications andlor indicated in the schedule of quantities. the unit of measurement shall be the ton of asphalt constructed as specified and measured according to certified weighbridge tickets issued in respect of mixture used. In the case of asphalt resurfacing. measurement by ton shall he obligatory. No payment will be made for material wasted

(b)
(c)

. . . . . . . . . . . . . . . . . . . . . . . . . . ton (t)

Milled granr~lated blast-furnace slag

ton (1)

(d)

Fly-ash . . . . . . . . . . . . . . . . ton (t)

The tendered rates shall include full conipensation for procuring, furnishing, heating. mixing. placing anrl compaction of all materials as specified as well as process control testing. protecting and maintaining the work as specified. When the unit of measurement is a ton of asphalt, the tendered rate shall also include full compensation for supplying and installing a weighbridge. and for weighing the material.

The unit of meas~~rement in respect of increases or decreases iri the active filler content for base and surfacing mixtures from that specified in the nominal mix shall be the ton. Nn payment shall be made for inert filler added by the contractor.

Payment for variations shall he made as specified in clause 1213.

kern Rolled-in chippings will be paid for separately under iten1 42.03.
47.07 Trial s e c ? i o n s

Unit (nominal thickness indicated) . . . . . . . square metre (m')

The unit of measurement shall be the square metre of asphalt trial section constructed as ordered. The tendered rate shall include full compensation for the construction of the trial section of asphalt base or surfacing complete as specified, for the application of a prime coat as in item 41.01 and for the application of rolled-in precoated chippings, if specified.

(a)

Base constructed with new asphalt (state specified thickness. type of bitumen and maximum size of aggregate) Continuously graded . . . . . . . square metre (m7) Semi-gap-graded . . . . . . . . . square metre (m') Surfacing or overlay constructed with new asphalt (state specified thickness. type of bitumen and maximum size of aggregate) Continuously graded . . . . . . . square metre (m7) Semi-gap-graded . . . . . . . . . square metre (m7) Base constructed with recycled asphalt (state specified thickness) . . . . . . . . . . . . . . . square metre (m7) Surfacing or overlay constructed with recycled asphalt (state specified thickness) . . . . . . . . square metre (m7)

(i) (ii) (b)

42.08 100 mm cores i n asphalt paving . . . . . . . . . . . . .

. . . . . . . . number (No)
(i) (ii) (c)

The unit of measurement shall be the number of 100 nlrn cores drilled and recovered as instructed by the engineer for his own testing. No separate payment shall be made for cores drilled as part of the contractor's obligations under process control, the cost of which shall be included in the prices tendered for the various items of asphalt paving. The tendered rate shall include full compensation for drilling the cores as directed. for all plant. fuel. labour and other incidentals necessary and for repairing.

(d)

bm
42.09 Asphalt surfacing on bridge decks (state nominal thickness and type of bitumen): (a) Continuously graded (grade stated) . . . . .

Unit

The unit of measurement for subitems (a) and (b) shall be a square metre of asphalt base. surfacing or overlay constructed to the specified thickness. The quantity shall be calculated from the authorized dimensions. The unit of measurement for subitems (c) and (d) shall be a square metre of asphalt base. surfacing or overlay constructed with recycled asphalt consisting of recovered asphalt and new materials mixed in the prescribed ratio. The quantity shall be calculated from the authorized dimensions. The tendered rate for subitems (a) and (b) shall include full compensation for procuring. providing. heating. mixing. placing and compacting the material. process control tests. and protection and maintenance. all complete as specified. Rolled-in chippings will be paid for separately under item 42.03. and the additional cost for applying rolled-in chippings in restricted areas will be paid for under item 42.16. The tendered rate for subitems(c) and (d) shall include full compensation for supplying the new materials. taking recovered asphalt from stockpile. blending the materials in accordance with the nominal mix ratios specified in the project specifications. heating. mixing. placing and compacting the material. process control tests. and protection and maintenance. all complete as specified. Payment will distinguish between different types of recycled asphalt in accordance with the project specifications. No extra payment will be made for small quantities of recycled asphalt.

ton (1)

(b)

Gap-graded (stone content indicated) . . . . . . . . . . . . . . . . . . . . . . . . ton (1) Open-graded (grade stated)

(c) (d)

. . . . . . . . . . ton (1)

Semi-gap-graded (state maximum size of aggregate) . . . . . . . . . . ton (1) Semi-open-graded . . . . . . . . . . . . . . . . . ton (t) Stone-mastic asphalt (state maximum size of aggregate) . . . . . . . . . .

(e) (f)

ton (1)

The unit of measurement shall be the ton of surfacing completed to the nominal thickness indicated. and measured according to certified weighbridge tickets issued in respect of the mixture used. The tendered rate shall include full compensation for procuring and furnishing all materials. heating the binder and aggregate, mixing, transporting. placing and compacting the material. and the provision and application of the slurry. The rate shall also include full compensation for variations in thickness within the specified tolerance for bridge deck levels and for the application of a tack coat Rolled-in chippings will be paid for separately under item 42.03.

Item
42.11 Asphalt layer c o n w c t e d for rehabilitation purposes i n accordance with the provisions of subsubdauses 4213(f)(ii) or 4213(f)(iii): (a) Base constructed with new asphalt (state type of bitumen and maximum size of aggregate:

Unit

Itern
4210 Asphalt layer constructed for rehabilitation purposes in accordance with R e provisions of subsubdause 4213(f)(i):

Unit

(i) (ii) (b)

Continuously graded Semi-gap-graded

................

ton (1)

. . . . . . . . . . . . . . . . . . ton (t)

full compensation for all additional costs to produce and place small quantities of asphalt on the instruction of the engineer. Payment will not distinguish between various types of asphalt or various types of asphalt layers.

Surfacing or overlay constructed with new asphalt (state type of bitumen and maximum size of aggregate) Continuously graded Semi-gap-graded

(i) (ii) (c) (d)

. . . . . . . . . . . . . . . . ton (t)
ton (t)

ltem

Unit

..................

42.13 Placing and compacting asphalt in Meted areas:

(a) Extra over items 42.01, 42.02 and 42.10 . . . . . . . . . . . . . . . square metre (m2) Extra over item 42.1 1

Base constructed with recycled asphalt . . ton (t) Surfacing or overlay constructed with recycled asphalt . . . . . . . . . . . . . . . . . . . ton (t) (b)

. . . . . . . . . . . . . . . ton (t)

The unit of measurement for subitems (a) and (b) shall be a ton of asphalt placed. The quantity shall be determined by means of certified weighbridge tickets issued in respect of the asphalt mix used. No payment will be made for asphalt placed outside the tolerances specified. The unit of measurement for subitems (c) and (d) shall be a ton of recycled asphalt consisting of recovered asphalt and new materials mixed in the prescribed ratio. The quantity shall be determined by means of certified weighbridge tickets issued in respect of the asphalt mix used. No payment will be made for asphalt placed outside the tolerances specified. The tendered rate for subltems (a) and (b) shall include full compensation for procuring, providing, heating, mixing, placing and compacting the material, process control tests, and protection and maintenance, all complete as specified. Rolled-in chippings will be paid for separately under item 42.03, and the additional cost for applying rolled-in chippings in restricted areas will be paid for under item 42.16. The tendered rate for subitems (c) and (d) shall include full compensation for supplying the new materials, taking recovered asphalt from stockpile, blending the materials in accordance with the nominal mix ratios specified in the project specifications, heating, mixing, placing and compacting the material, process control tests, and protection and maintenance, all complete as specified. Payment will distinguish between different types of recycled asphalt in accordance with the project specifications. No extra payment will be made for small quantities of recycled asphalt.

The unit of measurement shall be a square metre or a ton of asphalt (in accordance with the unit of measurement for the item concerned), placed in restricted areas, the quantity of which shall be measured as specified for the item of payment concerned. The tendered rates shall include full compensation for additional costs for executing the work in restricted areas.

Item

Mi

42.14 Extra over item 42.04 for applying tack coat in restricted areas . . . . . . . . . . . litre ( I )
The unit of measurement shall be a litre of 30% stablegrade emulsion applied in restricted areas. The tendered rate shall Include full compensation for additional costs for applying the tack coat in restricted areas, irrespective of the method of application.

Item

Mi

42.15 Application of prime coat and/or tack coat to the edges of a layer . . . . . . . . . . .litre ( I )
The unit of measurement shall be a litre of 30% stablegrade emulsion applied to the edge of a layer against which asphalt has to be placed. The tendered rate shall include full compensation for obtaining, procuring and applying the material, irrespective of the layer thickness, the method of application, or the size of the area over which it has to be applied.

ltem

Unit Item

42.12 ExGa over items 42.01, 42.02, 42.10 and 421 1 for placing small quantities of asphalt of less than 10 tons specially produced as specified in subdause 4206(d) . . . . . . . . . . . . . . . . . . . . . . . . . . ton (t)
The unit of measurement shall be a ton of asphalt of a specified composition, less than 10 tons of which is produced on occasion, as specified, and measured in accordance with the certified weighbridge tickets issued in regard to the mix used. The tendered rate shall be paid as extra over the rates tendered for the items mentioned above, and shall include

Unit

42.16 Exba over item 42.03 for applying mlledin chippings in restricted areas .

...

ton (1)

The unit of measurement shall be a ton of rolled-in chippings applied in restricted areas at the specified rate. Payment will not distinguish between rolled-in chippings and bituminous seals referred to in clause 4209.

The tendered rate shall include full compensation for the additional cost for executing the work in restricted areas.

Item

Unit

42.17 Asphalt reinforcing complete (state type) . . . . . . . . . . . . . . square metre (m7) The unit of measurement shall be a square metre of asphalt covered with reinforcing placed. complete as specified and accepted b y the engineer. The tendered rate shall include full compensation for procuring, providing, placing and fixing all materials (irrespective of the quantity of reinforcing required) overlapping and cut-offs included. and for all transport. equipment, tools, labour. supervision and all other costs necessary for installing and protecting the reinforcing until the asphalt prime coat has been placed. The tendered rate shall also include full compensation for all special preparatory work required. If it is necessary to repair cracks in the underlying seal or asphalt layer, separate payment will b e made therefor under the appropriate items of payment.

qoantity of recovered material available for recycling will be determined in accordance with the authorized quantities excavated. and the contractor shall include full compensation in his tendered rates for making good losses in recovered materials at his own cost.

Item
42.19 Variations in cellulose fibre content at stone~rnastic asphnlt . . . . . . . . .

. . . . . ton (1)

The unit of measurement for an increase or a decrease in the cellulose fibre contpnt of stone-mastic asphalt in comparison with the specified nominal cellulose fibre content shall be a ton of cellulose fibres. Payment for variations shall be made in accordance with the provisions of clause 1213. Item
42.20 BacMilling o l excavations for

Item 42.18 Variations from nominal mix ratios in recycled asphalt mixes: (a) (b) (c) New binder (penetration-grade bitumen)

Unit (a) (b) ton (1)

patching with: Asphalt base . . . . . . . . . . . . . . . . . . . . . . ton (1) Asphalt surfacing

. . . . . . . . . . . . . . . . . . ton (t)

New aggregate . . . . . . . . . . . . . . . . . . . . ton (1) New active mineral filler . . . . . . . . . . . . . ton (t)

The unit of measurement shall be a ton of asphalt placed in accordance with the specified requirements. The quantity will be computed in accordance with the certified weighbridge tickets issued in respect of the asphalt mix. Payment will not be made for wasted material. The tendered rate shall include full compensation for procuring and providing all materials. irrespective of its origin. for all mixing. placing. compacting and finishing as specified. for all transport. work in restricted areas. and also for all machinery. equipment. labour. supervision and other incidentals for executing the work. complete as specified. Payment for asphalt base and surfacing will not distinguish between the various types of asphalt. ltem 42.12 for small quantities of asphalt shall not apply to patching. Screeds. where required. shall b e measured and paid for under item 4 8 . 0 4 .

The unit of measurement for an increase or decrease in the ccntent of new binder, aggregate or mineral filler in the recycled asphalt mixture in relation to the content specified in the nominal mixture, shall be a ton of binder. aggregate or filler. Where payment for recycled asphalt is per square metre. the varied quantity shall be calculated b y converting volume to mass using the average density of the asphalt layer measured after compaction. Payment for variations shall be made in accordance with the provisions of clause 1213. Payment will not be made for an increase in the quantity of new material required where this results from recoverpd asphalt being wasted. The contractor is warned that the

SERIES 4000 : ASPHALT PAVEMENTS AND SEALS SECTION 4300 : SEALS : MATERIALS AND GENEFWL REQUIREMENTS

Minimum 80 seconds Saybolt Furol at 50C.

The type and grade of bituminous binder to be used shall be as specified under the appropriate section of these specifications for each type of bituminous seal, or in the project specifications.

SCOPE MATERIALS PLANT AND EQUIPMENT GENERAL LIMITATIONS AND REQUIREMENTS HEATING AND STORAGE OF BITUMINOUS BINDERS STOCKPILING OF AGGREGATE CONSTRUCTION OF SEAL RATES OF APPLICATION AREAS INACCESSlBiE TO MECHANICAL EQUIPMENT DUST CONTROL OPENING TO TRAFFIC DEFECTS MAINTENANCE TOLERANCES AND FINISH REQUIREMENTS MEASUREMENT AND PAYMENT

(3)

Cutting back of bitumen in the distributor of bitumen will only be allowed where engineer. The cutting back of bitumen in accordance with the engineer's the provisions of TRH3.

The cutting back authorized by the shall be done requirements and

Power paraffin shall comply with the requirements in the project specifications. The temperature of the bitumen. when the power paraffin is introduced. shall not be higher than 140C. The power paraffin shall be sucked in measured quantities from 200 1 drums through the bitumen pump and circulated with the bitumen for a minimum of 45 minutes. During this process all burners shall be shut off and no open flames allowed near the distributor. The power paraffin shall not be introduced into the distributor through the manhole. which shall be kept closed. Each distributor shall at all times have two fire extinguishers in a working order available. (ii) Non-homogeneous (heterogeneous) binders (summer grade) modified

4301

SCOPE

This section covers the materials. constructional plant. construction and requirements common to the construction of all seals specified in these specifications.

4302

MATERIALS The bitumen-rubber binder shall comply with the followirlg requirements:

(a)

B i m i n o u s binders
(1)

Base bitumen

The type and grade of binder specified in the project specifications or in the schedule of quantities. or ordered by the engineer, shall be used. (i) Conventional bituminous binders

Bituminous binders shall comply with the following specifications: (1) Bitumens

The bituminous binder used in the production of the bitumen-rubber shall be a 68 or 84 road-grade bitumen (801100 or 1501200 penetration-grade bitumen respectively) that complies with the requirements of SABS 307, or a blend of approved grades to provide a product with the required viscosity properties. (2) Rubber

Road-grade bitumens Cut-back bitumens (2)

. . . . . . . . . . . . . . . . . SABS 307

. . . . . . . . . . . . . . . . . . . SABS 308

Bitumen emulsions

Anionic emulsions . . . . . . . . . . . . . . . . . . . . SABS 309 Cationic emulsions

The rubber is obtained by processing and recycling pneumatic tyres. It shall be pulverized, free from fabric, steel cord and other contaminants. A maximum of 4% by mass of fine particle size calcium carbonate, or talc, may be added to the rubber crumbs to prevent the rubber particles from sticking together. At the time of use the crumbs shall be free flowing and dry and comply with the requirements of table 430211.

. . . . . . . . . . . . . . . . . . . SABS 548
(3) Extender oils The extender oil shall be a petroleum-derived material of high aromaticity and shall comply with the requirements of table 430212.

The bitumen emulsions shall also be subject to viscosity requirements for spray-grade emulsions as follows:

Anionic spray-grade (60%) emulsion: Minimum 12 degrees Engler at 20C. Cationic spray-grade (60% 65% and 70%) emulsion: (4) Diluent

The diluent shall be a distillate of hydrocarbon.

Table 430U1 RUBBER CRUMBS Property

Table 430213 BITUMEN-RUBBER BLEND Requirements Control measures As specified by the supplier As specified by the supplier As specified by the supplier

Percentage of rubber by mass of 20% - 24% total blend Percentage of extender oil by mass of total blend

6% (maximum)

Percentage of diluent by mass of 7% (maximum) total blend BlendinglReaction 170C - 210C temperature 0,5 - 4,O hours Reaction time (Reaction time commences when all the rubber crumbs have been added to the blend)

As specified by the supplier As specified by the supplier

Table 430212 EXTENDER OILS Property Flash point Percentage by mass of saturated hydrocarbons Percentage by mass of aromatic-unsaturated hydrocarbons Requirements 180 " C (minimum)

25% (maximum)

Table 430214 BITUMEN-RUBBER BINDER

55% (minimum) Property Compression recovery: Requirements Test method BR3T (Sabita) 70% (minimum) 70% (minimum) 48% - 55% (minimum) ASTM method D36 BR2T (Sabita) ERST (Sabita)

(5)

Bitumen-rubber blend

The bitumen-rubber blend, including extender oil and/or diluent, if necessary, shall comply with the requirements of table 430213.

after 5 minutes after 1 hour after 4 hours

Ring-and-ball softening point Resilience (%)

55C (minimum) 13% - 35% (minimum) 20 - 35 dPa.s 20 m m - 75 m m

Prior to commencement of the work, the supplier shall state in writing the percentage of rubber and the blendinglreaction temperature he intends to use for his specific product. The actual percentage of rubber shall not deviate by more than 1% from the stated value and the actual reaction temperature shall not deviate by more than 10% from the stated value.

Dynamic viscosity (Haake at 190C) Flow

BR4T (Sabita)

A continuous record of both percentage rubber added and reaction temperatures shall be kept on site by the ontractor.

The contractor shall provide the engineer with timetemperature ratios in regard to the above properties of his specific product before work may start in order to determine the final process and the acceptance limits. The methods of testing bitumen-rubber material have been published in Manual 3 of the Southern African Bitumen and

The bitumen-rubber binder shall comply with requirements of table 430214.

the

Tar Association. If a supplier uses a diluent, an ageing test may be required in which the binder is placed in an oven for 5 hours at 150C, after which time it shall comply with tlie above specifications.

The properties of the modified bitumen recovered by using a rotary vacuum evaporation method or simple evaporation method as described in "Technical Guidelines for Seals using homogeneous modified Binders", Sabita Manual 15, May 1994, shall comply with the requirements of table 430216.

The contractor shall provide the performance record for three recent projects of the materials he intends to use in order to assess the successful use of the materials. The information shall include mean values obtained for the prescribed tests as well as any relevant comments. This information shall be submitted at tender stage.

If there is any discrepancy in the test results on recovered modified binder, then the results on recovered binder obtained from the rotary vacuum evaporation method shall be binding.

(v) (iii) Non-homogeneous modified binders (winter grade)

Homogeneous hot-applied (summer grades)

modified

binders

If non-homogeneous modified binders (winter grade) are required, they shall coinply with the requirements in the project specifications.

The requirements for any polymer other than the generic types listed in table 4302/7 used for the manufacture of homogeneous hot-applied modified binders will be indicated in the project specifications.

(iv)

Homogeneous cold applied modified binders

Where applicable the following details will be indicated in the project specifications:

If any polymer other than the elastomer polymers styrenebutadiene rubber (SBR) or styrene-butadiene (SBS) is required for the manufacture of cationic modified bitumen emulsions it shall comply with the requirements in the project specifications.

generic type (plastomer or elastomer) and type polymer;

Where applicable the following details will be indicated in the project specifications:

grade base bitumen (58 or 94 road grade) required, and

type elastomer polymer: SBR or SBS. Unless otherwise specified SBR shall be used for tender purposes. grade base bitumen: 58 or 84 road grade (801100 or 1501200 penetration grade). Unless otherwise specified 58 road grade shall be used for tender purposes. modified binder content: 65'/0 or 70%. Unless otherwise specified 65% shall be used for tender purposes.

The aforementioned components together with polymer content will dictate the attributes attainable.

(vi)

tlomogeneous hot-applied modified binders (winter grade)

Where applicable the requirements for homogeneous modified binders (winter grade) will be specified In the project specifications.

The aforementioned components together with polymer content will dictate the attributes attainable.

(i)

Aggregates for seals

Unless otherwise specified, the properties of cationic modified bitumen emulsion containing SBR or SBS solids shall comply with the requirements in table 430215.

The aggregate shall consist of approved crushed stone of the specified grade and size and shall comply with the following requirements in regard to grading, hardness and shape:
(1)

Gradirig

Avolatile solvent flux content of up to 3% mass by mass of the bitumen may be added to enhance eniulsion performance with regard to prevailing climatic conditions. Any expected change to specified values shall first be discussed with the engineer prior to the addition of any such enhancer.

The grading shall comply with the requirements set out in table 430218 for grades 1. 2 and 3. The grade or grades of aggregate specified in the project specifications and in the schedule of quantities shall be used.

Table 430215 CATIONIC MODIFIED BITUMEN EMULSION

Polymer modifier Grade of base bitumen Minimum modified binder content

Required properties Minimum viscosity at 50" C Saybolt Furol (seconds) 80 70 80 50 ASTM D244 Maximum residue on sieving (91100 m l ) Particle charge Sedimentation after 60 rotations

("/.I
B8 SBR 84 88 SBS 84 Test method 65 ASTM D244 65 70 70

0,25 0,25 0,25 0,25 SABS 548

Positive Positive Positive Positive SABS 548

Nil Nil Nil Nil SABS 548

Note 1: Modified binder is bitumen plus polymer.

Table 430216 RECOVERED MODIFIED BITUMEN

Polymer modifier Grade of base bitumen Minimum softening point ( " C )

Required properties Minimum dynamic viscosity at 135C (Pas) 13 1To 1,3 1,o ASTM 04402 Minimum ductility at 10" C (mm) Elastic recovery
(%)

Minimum adhesion at ("h at 5 0 " ~

(%)

B8 SBR 84 B8 SBS 84 Test method Note (1):

55 45 60 47 ASTM D36

1000 1000 500 500 DIN 52013

52 55 55 60 DIN 52013

90 90 90 90

100 100 100 100

Mod Vialit method

The dust content criteria shall be according to table 430218 grade 2 stone for the adhesion test.

Table 430217 HOT-APPLIED MODIFIED BINDERS

Test method

ASTM

ASTM
D4402

DIN
52013

DIN
52013

D36

*Mod Vialit method

The Modified Vialit method: See "Technical Guidelines for Seals using homogeneous modified Binders", Sabita Manual 15, May 1994. Table 430218 SINGLE-SIZED CRUSHED AGGREGATE GRADES 1 , 2 AND 3 Grade
26,5 m m 19,O m m

Sieve size (mm)

Percentage by mass passing

13,2 m m 9,5 m m nominal size 6,7 m m nominal size 4,75 m m 2,36 m m

nominal size
37,50 26,50 19,OO 13,20 9,50 6,70 4,75 3,35 2,36 100 85 - 100 0-30 0-5

nominal size

nominal size

nominal size

nominal size

Grades
1&2

100 85-100 0-30 0-5

100 8 5 - 100 0-30* 0-5**

100 85-100 0-30* 0 - 5**

100 8 5 - 100 0 - 30* 0 - 5**

100 85 - 100 0 - 30 0-5

100 0 - 100

Grade 3

Grading shall comply with the requirements for grades 1 and 2 with the following exceptions: * 0 - 50

**oFines content: Material passing a 0,425 m m sieve (max) Dust content: Material passing a 0,075 m m sieve (max) Grade 1 Grade 2 Grade 3 Grade 1 Grade 2 Grade 3
03 1,5 0,s 1,5

10 03 1,5 2,O 0-5 1,5 2,O 03 2,o 3.0 1-0 2,s 3,5 15,O 15,O 15,O 2,O

NIA NIA
0,s

NIA
N/A
0,s

NIA
0,s 1,5

NIA
0,s 1,5

NIA
1,O 1,5

NIA
1,O 1,5

2,O
2,O

NIA

NIA

Table 430219 SAND Percentage by mass passing 95 (minimum) 50 (minimum) 20 (maximum)

Table 430211 1 GRADING LIMITS OF AGGREGATE FOR SLURRY SEALS

Sieve size (mm)

4,75 0,425 0,075

Plasticity Index : Non-Plastic

(2)

Hardness

When tested in accordance with TMHl method 81, the aggregate crushing value shall not exceed 21 and when tested in accordance with TMHl method 82 the 10% FACT value (dry) shall be at least 210 kN and the wet to dry ratio shall be at least 75%. The polishing stone value shall be at least 50 unless otherwise specified or approved by the engineer.

(3)

Shape The sand equivalent determined in accordance with SABS 838 (TMHl method B19) shall be at least 35.

The maximum flakiness index, when tested in accordance with TMHl method 83, shall comply with the requirements in table 4302/10. Table 4302110 Maximum flakiness index % Grade 1 19,O m m 13,2 m m 9,5 m m 6,7 mm 25 25 30 30 Grade 2 and 3 30 30 35 35

The immersion index of briquettes made with slurry aggregate and road grade B8 (80/100 penetration-grade) bitumen at the specified net bitumen content for the slurry shall be not less than 75 when tested in accordance with method C5 of TMH1. In addition, unless otherwise specified, for rapid setting slurries the supplier shall assess the compatibility of the binder offered with aggregates from suitable sources nearest to the site prior to tender closure. Table 4302112 GRADING LIMITS OF AGGREGATE FOR SLURRY USED FOR TEXTURE IMPROVEMENT ONLY

Nominal size of aggregate

Sieve size (mm) If so required for special purposes, the average least dimension (ALD) shall be as indicated in the project specifications.

Percentage passing sieve by mass 100 82 - 100 50 - 70 20 - 35 7 - 15

1,180 0,600 0,300 0,150

(ii)

Aggregate for slurry seals

The aggregate for slurry seals shall be an approved crusher sand obtained from a parent rock having an ACV not exceeding 30 or a mixture of such crusher sand and an approved clean natural sand, where the mixture does not contain more than 25% of natural sand. The aggregate shall be clean, tough, durable, angular in shape, and shall comply with the grading requirements given in table 430211 1 for the slurry and the grade or type of aggregate specified.

0.075

(c)

Filler for slurry

Ordinary portland cement shall comply with SABS 471 and portland blast-furnace cement (PBFC) with the requirements of SABS 626.

Road lime shall comply with the requirements of SABS 824 (Lime for Soil Stabilization) and shall bear the SABS mark. Only one of the above materials shall be used throughout. in order to prevent undesirable colour differences in the surface.

(b)

Binder distributor

The birider distributor shall comply with all the provisions of subclause 4103(a). The binder distributor used for non-homogeneous modified binder shall be adapted to spray the rubber modified binder saticzfactorily. The contractor shall provide proof by way of a test on the site that the binder distributor has sufficient reserve power to maintain the required constant speed up the steepest incline to which spray has to be applied, and to obtain a uniform distribution of the binder. The optimal spray-bar level shall be determined during testing. and the spray-bar level shall be adjusted accordingly before each spray. The uneven application of binder will be unacceptable.

(d)

Hydrophilic aggregates

Where hydrophilic or other aggregates which may cause problems are encountered, the engineer may order that the stone chips be precoated, as described below, or that a fog spray be applied, as specified in subclause 4403(d). (i) Precoating of aggregate for stockpiling or for immediate use

This method may be used for aggregate intended for immediate use or for stockpiling. The untreated stockpile of aggregate shall be thoroughly sprayed with water, which shall be allowed to drain off. The damp aggregate shall then be loaded into the bucket of a front-end loader (1 m3) and a nominal quantity of 12 1 of an approved precoating fluid shall be sprayed evenly over the aggregate by means of a watering can. The wetting agent approved by the engineer shall be added to the precoating fluid at a rate of 0.5% of the volume of precoating fluid. The mixture of aggregate and precoating fluid shall then be dumped on a site prepared as specified in clause 4306. This process shall be repeated until a stockpile of approximately 15 m' to 20 m 3 has been built up. This stockpile shall then be turned over with the front-end loader until the aggregate is uniformly coated with the precoating fluid. Three complete turnings of the stockpile will probably be required. The time between the precoating and the placing of the aggregate shall not exceed the time specified in the project specifications or agreed on by the engineer and the contractor. (ii) Precoating constraints

(c)

Chip spreaders

The chip spreaders shall he capable of spreading stone of the specified size uniformly over widths varying between 2.4 m and 4,O m and shall be capable of adjustment to permit variation of the rate of application within the specified tolerances. and uniform spreading in both the transverse and longitudinal directions. At least two chip spreaders shall be provided, one of which shall be self-propelled. Spreaders which are not self-propelled,.shalI be of a type that can be attached quickly to the reaf of trucks, and operated while backed over the stone chippings being spread.

(d)

Rollers

Sufficient operational rollers of each of the following types shall be available on the works to maintain the required ternpo of work: (i) Pneumatic-tyred rollers

Pneuniatic-tyred rollers shall be of a self-propelled type equipped with smooth flat profile pneumatic tyres of uniform size and diameter. The mass of the roller shall not be less than 2 ton per wheel. The rollers shall be equipped with suitable devices for keeping the wheels wet and clean during operation. The wheels of the roller shall be so spaced that one pass of the roller will provide one complete coverage equal to the rolling width of the machine. The total operating mass and tyre pressure may be varied by the engineer at his discretion, Individual tyre pressures shall not differ by more than 35 kPa from one another. (ii) Rubber-soled steel-wheeled rollers

No precoating shall be applied where conventional and modified emulsion binders are used unless specifically specified or ordered by the engineer.

4303

PLANT AND EQUIPMENT

(a)

General

All plant and equipment used on the works shall be of an adequate rated capacity and in a good working condition.

All plant and equipment that will be operated on the road during construction of the seal shall be free froni ariy binder, fuel or oil leaks, and no refuelling or servicing of any equipment will be allowed to take place while such . equipment is on the road.

Rubber-soled steel-wheeled rollers shall be self-propelled, and have a mass of between 6 and 8 tons. It shall be equipped with suitable devices for cleaning and moistening the wheels. The wheels of the roller shall be so arranged as to give one complete coverage, by one passage of the roller. over a width equal to the rolling width of the roller.

(iii)

Steel-wheeled rollers

(h)

Spreader box for slurry

Steel-wheeled rollers shall be self-propelled three-wheel or tandem rollers of between 6 and 8 tons mass and shall be equipped with suitable devices for cleaning and moistening the wheels. The mass of the roller required shall be determined by the engineer. No steel-wheeled rollers shall be used without the consent of the engineer. (iv) Additional requirements

The type of spreader box used for spreading the slurry shall be submitted to the engineer, in advance. for approval. The spreader box for rapid setting slurry shall be of a proven and approved type, fitted with a proven and approved device to ensure sufficient agitation within the spreader system. The spreader box shall be so constructed as to distribute the weight onto metal skids in such a way that no damage shall be done to the surface when the box is in operation. Soft rubber belting shall be attached to the framework in such a manner as to prevent slurry from being spilt past the sides of the spreader box when the box is in operation. The spreader box shall be capable of spreading a uniform application of the slurry in adjustable widths from 1.5 m to 4.0 m , at specified rates. and it shall have efficient mechanical means of adjusting the rates and widths of application specified.

The type and number of rollers shall be subject to the approval of the engineer for each type of seal and the proposed programme.

No seal work shall continue if the required rollers are not on site or not in an operational condition.

(e)

Brooms Drag broom

(i)

The drag broom shall be of a size, type and mass which will enable the chips to be distributed evenly over the surface without dislodging any chips frorn the binder. (ii) Rotary broom

(i)

Precoating plant

The precoating of chips may be done with any suitable equipment capable of uniformly coating the chips.

An approved rotary broom, complete with towing vehicle fitted with smooth tyres, shall be available at all times on the works.

0)

Massmeasuring device

(f)

Mixer for slurry

A mobile mixer of a type approved by the engineer shall be provided. It may be either a batch mixer or a continuous type mixer. The paddles of the mixer shall be so designed as to ensure a complete blending of the constituents of the slurry.

Where payment per ton is specified, the contractor shall provide and install suitable gauged mass-measuring device on the site. in accordance with the engineer's requirements. The device shall be provided with a printer for printing the mass. the time and date. The printed data shall be submitted to the engineer on a daily basis.

(k)

Miscellaneous equipment

For the rapid setting slurry types. the mixing and application of the slurry shall be done by a mixer designed to provide a rapid mixing time, and sufficient agitation within the spreading system to prevent segregation or premature hardening. The mixer shall be capable of continuous mixing arid application.

Sufficient equipment for handling and hauling aggregate, binder and slurry. and blending units for nonhomogeneous modified binders, shall be provided to ensure prompt and continuous placing and application of bituminous materials as specified. The contractor shall have available all the necessary ancillary equipment and hand tools to carry out the work efficiently.

The purpose designed mixer for cor~tinuous type mixing of either conventional or rapid setting slurries. shall be equipped with precise metering systems to enable the various constituents to be combined continuously to the prescribed formulation.

Suitable fire-fighting equipment for dealing with bitumen fires shall be available on site. together with suitable first aid equipment for dealing with bitumen burns. (Refer to Sabita Manual 8 : Bitumen Safety Handbook.)

No central mixing plant will be allowed. Details of the type of mixer shall be submitted in advance of actual construction, for approval by the engineer.

The engineer shall be entitled to request reserve plant should there be any doubt as to the efficiency or capability of the equipment provided.

4304

GENERAL L1MlTATK)NS AND REQUIREMENTS

@)

Loader for aggregate

(a)

Weather limitations

A loader, or equivalent capacity labour force where so

required in the project specifications, compatible with the needs and capacity of the mixer unit shall be available at the stockpiling site. The minirnum road-surface rising temperatures at which the spraying of the different types and grades of binder may be done are -

(i)
(1)

Conventional binders Bitumens

When strong winds are blowing which are likely to interfere with the proper execution of the work, no sealing, especially spraying of binder, shall be done.

150/200 penetration-grade or 84 road grade bitumen . . . . . . . . . . . . . . . . . . . . . . . . . 21 " C 80/100 penetration-grade or B8 road grade bitumen . . . . . . . . . . . . . . . . . . . . . . . . . 25 " C MC-BOO cut-back bitumen . . . . . . . . . . . . . . . . . . 10" C MC-3000 cut-back bitumen . . . . . . . . . . . . . . . . . . 10" C

@)

Moisture content

(2)

Bitumen emulsions

Bitumen emulsion . . . . . . . . . . . . . . . . . . . . . . . . 10" C (ii) Non-homogeneous modified binders (summer grade)

No seal shall be placed unless the moisture content of the upper 50 m m of the base is less than 50% of the optimum moisture content as determined by the engineer. No reseal shall be placed immediately after a rainy spell on an existing partly cracked and/or highly permeable surfacing resulting in the trapping of moisture in the pavement structure. A minimum delay of 24 hours or such extended period as ordered by the engineer shall apply.

(c)

Olher constraints

Bitumen-rubber (spray application) (iii)

. . . . . . . . . . 25^C

Non-homogeneous modified binders (winter grade)

The following curing periods shall apply to the (i) various treatments listed. prior to applying a seal/reseal unless otherwise specified in project specifications: Texturing using fine slurries . . . . . . . . . . . . . . 6 weeks Rapid setting slurry (rut filling, etc) . . . . . . . 12 weeks Crack sealing . . . . . . . . . . . . . . . . . . . . . . . . 2 weeks Repair of distressed patches . . . . . . . . . . . - . . 6 weeks

As specified in the project specifications. (iv) Homogeneous cold applied modified binders 10" C 10" C binders

SBR modified cationic emulsion . . . . . . . . . . . . . SBS modified cationic emulsion . . . . . . . . . . . . . (v) Homogeneous hot-applied (summer grade) modified

(ii) Unless otherwise agreed by the engineer, and subject to the ot~tcomeof a trial section, the contractor shall programme all spraying to cease each working day at 15:OO h.

Modified binder 150/200 penetration-grade or 84 road grade base bitumen . . . . . . . . . . . . . . . . . . . . . 21 " C Modified binder 80/100 penetration-grade or B8 road grade base bitumen . . . . . . . . . . . . . . . . . . . . . . . . . . . 25C (vi) Homogeneous hot-applied modified binders (winter grade)

(iii)

Traffic limitations

The contractor shall comply with the requirements of clause 1211.

As specified in the project specifications Whenever the temperature of the road surface falls below the aforesaid temperature for the binder in question. or. in the opinion of the engineer, will probably fall below the required temperature before spraying the binder. no binder shall be sprayed. No bituminous work shall be done during foggy or rainy weather, and, when a cold wind is blowing, the above temperatures shall be increased by 3C to 6 " C as directed by the engineer. Conventional slurry shall not be applied at an air temperature of less than 7 C when temperatures are rising, or less than 13C when temperatures are dropping. Rapid setting slurry shall be sufficiently versatile to be laid in air temperatures of 4C to 40C. as well as capable of being laid under damp conditions. During hot weather slurry operations shall be suspended when aggregate is being displaced by the spreader box or squeegees. When the breaking process accelerates to such an extent that it renders the product unworkable to attain the required end result, for instance when the surface temperature is in excess of 60C. or as ottierwise prescribed by the engineer, no sealing shall be done.

(d)
(i)

Preparation o f areas to be sealed General

The areas to be sealed shall be cleaned of all dust, dirt. dung. oil or any other foreign matter that may be deleterious to the seal.

(ii)

Newly constructed seals

Where newly constructed base or shoulder areas are to be sealed. the surfaces shall be checked for compliance with the surface tolerances and all other requirements specified. Any portions that do not meet these requirements shall first be either corrected or removed and reconstructed before they are sealed.

(iii)

Existing surfaces to be resealed

Existing roads that require resealing shall, if so specified or ordered by the engineer, be given a pretreatment in accordance with one or more of the methods described in section 4800.

Any failures shall be repaired as specified in the project specifications.

(e) (i)

Demarcation of working area New work

(c)

Non-homogeneous modifiedbinders (winter grade)

The contractor shall demarcate the area of the primed base to be sealed by means of setting out string lines down each edge of the specified seal width. The intervals for setting out horizontal curves shall be as agreed with the engineer. (ii) Resealing

The contractor shall comply with the requirements specified in the project specifications with regard to the storage, heating and spraying temperatures, and with regard to the information to be provided in the tender stage, unless otherwise approved by the engineer.

(d)

Homogeneous cold applied modified binders

The centre line of the road or a reference line shall be marked immediately before the tack coat or bituminous binder is sprayed.

Modified bitumen emulsions may be stored at ambient temperature for long periods, provided that some circulationlmixing takes place from time to time. The spraying temperatures of these emulsions are the same as for conventional bitumen emulsions.

4305

HEATING AND
BINDERS

STORAGE OF

BITUMINOUS
(e)

Homogeneous hot-applied (summer grade)

modified

binders

(a)

Conventional binders

The temperature ranges between which bituminous binders are to be heated shall be as given in table 4305/1. Binders stored in a heated condition shall be kept in a container with a securely fitting lid, and the circulatory system of which is functioning properly. The container shall be provided with a built-in thermometer. Binders which have been heated above the maximum temperatures indicated in table 430511 shall not be used and shall be removed from the site. Every effort shall be made to maintain the binder temperature for spraying to within 5C of the recommended temperature. For seals the temperature limits for 80/100 penetrationgrade or 88 road grade bitumen, cut back with the indicated amounts of power paraffin in parts per 100 parts of bitumen by volume as described in subsubclause 4302(a)(i)(3), shall be as set out in table 4305/2 to prevent degradation of the bitumen.

The heat stability of modern modified bitumens is remarkably good. However, excessive temperature over extended periods will degrade all modified bitumens and negatively'affect the enhanced properties of these binders.

The temperature limits for the storage and spraying of modified hot-applied binders shall be as set out in table 430513 unless otherwise approved by the engineer.

Modified binders stored in a heated condition shall be kept in a container having a properly functioning circulation system and a securely fitting lid.

Note: Many long chain polymers have low shear stability and can be degraded by the action of a high shear rate pump such as a close tolerance gear pump.

(f)

Homogeneoushot-appliedmodifiedbinders (winter grade)

@)

NonAomogeneous (heterogeneous) binders (summer grade)

modified

After completion of the bitumen-rubber reaction, the binder shall be cooled to below 160C. The binder mixture may not be kept for more than 2 days. The mix may only be stored in tanks with circulation systems. The spray and storing temperatures of the bitumen-rubber binder shall comply with the following requirements:

The contractor shall comply with the requirements specified in the project specifications with regard to the storage, heating and spraying temperatures, and with regard to the information to be provided in the tender stage, unless otherwise approved b y the engineer.

4306

STOCKPIUNG OF AGGREGATE

(a)

General

Spray temperature, " C

..........

Must be provided by supplier

Max storing time at spray temperature, hours . . . .

. . . . . . . . . . . . . . . . . . . . . .4
35 below spray temperature but not more than 160

Sites for the stockpiling of aggregates shall be prepared in such a manner that no grass, mud, dirt or other deleterious material will be included when the aggregates are loaded for use.

Max storing temperature (up to 2 days), " C . . . . . .

Stored blnder heated to a temperature above 160C shall not be used and shall be removed from the site.

Access roads to stockpile sites shall be prepared and maintained in such a way that no dirt is conveyed by vehicle wheels onto the areas to be sealed or resealed whilst aggregate is being transported to or from the stockpiles.

Table 430511 Maximum storage temperature "C Over 24 Up to 24 hours hours

115 125 165 175

Heating and spraying temperatures "C Minimum Maximum Recommended

Materials

Road grade bitumens B4 (1501200 penetration grade) 88 (801100 penetration grade) Cut-back.bitumens RC-250 MC-800 MC-3000 Bituminous emulsions 60% 65% 70%
Table 430512

150 165

175 190

165 175

60 75 100

90 125 155

90 110 135

115 135 155

100 125 145

Air temp. Air temp. Air temp.

60 60 60

Air temp. 50 55

60 60 65

60 60 65

Quantity of power paraffin added (parts per 100 parts of bitumen by volume)

Temperature limits Lower limit "C

150 146 138 132 125

sited that dust deposited on the chips is reduced to a minimum. Where necessary, temporary deviations and access roads in the immediate proximity shall be watered or sealed. During the wet season when there is danger of the precoating fluid being washed off the aggregate, the stockpiles shall be covered with tarpaulins or similar protective coverings. During the cooler periods the engineer may order that stockpiles be covered with tarpaulins to ensure that the aggregate temperature remains compatible with the limiting temperature applicable to the specified binder type.

Upper limit "C

175 163 154 149 143

rn
Table 430513

0 23 5,O 7,5

4307

CONSTRUCTION OF SEAL

TEMPEFLATURE LIMITS FOR STORAGE AND SPRAYING (a)

General

Adequate advance notice shall be given to the engineer before the contractor proceeds with any seal work.

@)
(i)

Single and double aggregate seals

Application of tack coat and aggregate

Bituminous binders shall be applied by means of a binder distributor, unless otherwise approved. If a choice can be exercised areas inaccessible to mechanical equipment shall preferably be restricted to areas that are not subjected to traffic. Stockpiles shall be so sited that they will not be exposed to excessive contamination with dust arising from traffic on the road or access roads. Aggregates contaminated to the extent that it contains more than the allowable percentage of material passing through the 0,425 m m sieve and 0,075 m m sieve shall not be used for sealing. A bituminous tack coat consisting of the type and grade of binder specified in these specifications under each of the appropriate sections for each type of bituminous seal, or in the project specifications, shall be uniformly sprayed on the properly cleaned and prepared base or existing surface over the full specified width of the seal. Where the tank of the binder distributor could become empty during spraying against inclines, the spraying shall be done while the binder distributor is moving uphill. Should the engineer be of the opinion that the contractor

@)

Precautions

Areas used for stockpiling precoated aggregate shall be so

is unable to place the sealant over the full specified width in one movement, the contractor shall execute the spraying and the distribution of the chips in strips. The spraying of adjacent strips shall overlap b y 100 m m subject to adjustment for the particular fan angle. Chips may not be placed on the 100 mrn overlap before the adjacent strip has been sprayed. The adjacent strip may not be sprayed before the preceding strip, excluding the 100 m m overlap. has been covered satisfactorily with chips in compliance with the specifications. In so far as is practicable. the contractor shall so place the strips that the joint between two adjacent chip applications shall fall on the centre line of the road. Immediately after the binder has been sprayed. it shall be covered with clean, dry aggregate of the size specified in these specifications under each of the appropriate sections for each type of seal. The actual rates of application of binder and aggregate to b e used in the construction will b e determined b y the engineer, after he has tested the aggregates the contractor proposes to use for the seal and prior to any sealing being carried out. The aggregate shall b e applied uniformly b y means of selfpropelled chip spreaders, unless otherwise specified. The immediate application of the chips is of prime importance. The spreading of the chips shall be done as closely as possible behind the distributor. The chip spreader shall be so operated that the tack coat shall be covered with aggregate before the wheels of the chip spreader or truck pass over the uncovered tack coat. The quantity of bitumen sprayed in any single spray operation shall be governed b y the quantity of aggregate. and the number of trucks available shall be sufficient to ensure the continuous application of stone behind the distributor. In addition the available roller capacity at normal operating speed shall also govern the application rate of the tack coat and aggregate. The chip spreaders shall comply with the requirements of subclause 4303(c). Areas with varying or narrowing widths on which binder distributors can be used, shall be screened off b y means of fibre-reinforced paper, so that only the area to which the binder is to be applied, will be exposed. The binder shall then be applied at the specified rate with a binder distributor. Immediately thereafter the fibre-reinfo~ced paper shall be removed, the aggregate shall be applied. and the seal shall be completed. (ii) Initial rolling of aggregate

prevent any aggregate from being dislodged, the surface shall b e slowly dragged with a broom drag to ensure even distribution of the aggregate. If there are areas which are deficient in stone chips. additional material shall be added b y hand so as to leave a single layer of chips lying shoulder to shoulder. If there are areas with an excess of stone chips, such excess shall be removed b y hand so as to leave a single layer of chips lying shoulder to shoulder. The importance of applyirig only a single layer of chips is stressed. Every care shall be taken to avoid an over-application of stone. After completing the spreading of the aggregate, the surface shall b e rolled with a self-propelled pneuniatictyred roller with a minimum load of 2.0 t per wheel for three to four coverages. Except in the case of single seals final rolling shall then be done with a steel-wheeled roller with a mass of 6 to 8 tons working parallel to the centre line of the road from the shoulders towards the crown of the road. until every portion of the surface concerned has been covered b y at least two to four passes of the roller, provided that only a limited degree of crushing of the aggregate will take place. but if, in the opinion of the erigineer, general crushing occurs under the rollers, such rolling shall be stopped regardless of the number of passes completed b y the roller. The surface shall b e well knit and have a uniform appearance, free of roller-tyre marks; all aggregate contaminated b y fuel. oil or grease shall b e removed and replaced with clean aggregate. (iv) Joints between binder sprays

In order to prevent overlapping at junctions of separate binder applications. the previous work along the joint shall be covered with a removable protective sheet for a sufficient distance back from the joint to ensure that the sprayer is operating at the required rate before the untreated surface is reached, and also to prevent additional binder application onto the previously treated section. The same method shall b e used to ensure a neat joint at the end of the run. (v) Protection of kerbs. channels. etc

Kerbs, channels. manholes. guard rails. bridge railings and any other structures which may b e soiled b y bituniinous binders during spraying operations shall be protected in terms of section 2300 during spraying operations. The contractor shall replace at his own cost any items that have been soiled and cannot be cleaned entirely. The painting of soiled surfaces will not be accepted as a suitable remedy.

Immediately after the aggregate has been applied. rolling shall be commenced. A self-propelled pneumatic-tyred roller with a load of at least 2.0 t per wheel shall b e used in the case of single seals, and a steel-wheeled roller may also be used in the case of double seals, on condition that excessive crushing of the aggregate shall not take place. Rollers shall operate parallel to the centre line of the road. from the shoulders inwards towards the crown of the road. until the entire surface has been covered at least three times with the wheels of the roller. (iii) Broom drag and final rolling of aggregate

Whenever the terms "net bitumen" or "net quantity of bitumen" are used in these specifications to specify the rate of application of the binder for conventional or homogeneous modified binder. they shall mean net bitumen cold at a temperature of 20C. Nonhomogeneous modified binders. however, shall b e specified at spraying temperature. All binders. aggregates and slurry used in the various types

After the bituminous binder has set-up sufficiently to

of seals shall be applied at the rates of application as determined by the engineer after tests on the materials proposed for use, within the tolerances specified in clause 4314. No payment will be made for bituminous binder applied in excess of the rate ordered plus the permitted tolerance or at a rate lower than the specified rate, minus the permitted tolerance, unless, in the opinion of the engineer, such overspray or any shortages can be satisfactorily corrected in the case of a first application by the adjustment of the application rate of the second spray, and if such correction is effected. The nominal rates of application are for tendering purposes onhr and will not necessarilv be used i n consbuction. The i t e shall in all a&al rates of application be used on the s cases be as instructed b y the engineer. The appropriate conversion factors given in TRH3 (excluding the annexures) or specified in the project specifications shall be used for calculating bitumen for conventional and homogeneous modified binders at spraying temperature from bitumen net cold.

requlred, and thereafter the second layer of aggregate shall be applied, rolled and broomed. Thereafter, where applicable, the specified fog spray of bitumen emulsion shall be applied within 48 hours at the rate prescribed by the engineer. The engineer may require a slurry to be applied to areas subjected to traffic. The slurry shall comply with the requirements of clause 4302.

Where the sealing layer consists of an application of aggregate with slurry, the slurry shall be applied to the surface of the layer constructed as described above, at the rate prescribed by the engineer. This shall be done simultaneously with the final slurry application on the other portions of the work to obtain a uniform appearance.

4310

DUST CONTROL

4309

AREAS INACCESSIBLE EQUIPMENT

TO

MECHANICAL

Any temporary deviations and construction roads shall be kept watered and damp during all sealing operations and all dust shali be removed from surfaces before any binder, aggregate or slurry is applied. The supply and application of water on temporary deviations will be paid for separately as specified in section 1500, but payment for watering the haul and construction roads shall be included in the unit rates tendered for the various types of seals used.

(a)

Bituminous binders

Bituminous binders shall be applied by means of a binder distributor, unless otherwise approved. Binder for seals, and particularly bitumen-rubber binder, shall be sprayed with mechanical equipment, which, where necessary, has been specially adjusted for accurately applying the binder in restricted areas in accordance with the specified requirements. Hand-spray equipment may be used only with the written approval of the engineer, and then only in accordance with approved methods under the strict supewision of experienced personnel and with equipment suitable for performing the work in accordance with specified requirements. If a choice can be exercised areas inaccessible to mechanical equipment shall preferably be restricted to areas that are not subjected to traffic. The total application of binders shall be controlled in order to determine whether the specified application rate is being obtained. Each area that is to be sealed, shall be screened off by means of fibre-reinforced paper, so that only the area to which the binder is to be applied, will be exposed. The type of tack coat and the rate of application thereof shall be subject to the engineer's approval. The tack coat shall be applied by means of hand-spraying equipment complying with the requirements specified in subclause 4103(a). The aggregate shali be of the same size as the aggregate in the existing surrounding seal, and shall be spread by hand. The seal shall be rolled to the satisfaction of the engineer with the most effective rollers that can be used in the area in question, and thereafter the excess aggregate shall be swept off the surface with hand brooms. The specified penetration layer shall then be applied if a double seal is

4311

OPENING TO TW\FLlC

The engineer shall be responsible for determining when any sealing layer is to be opened to public traffic. The road shall not be opened to traffic until the binder has set sufficiently to retain the aggregate, or in the case of slurry seals, the slurry has set sufficiently so as not to be picked up by the wheels of passing traffic. The contractor shall not allow any construction equipment, which is likely to cause damage, over the completed seal. The contractor shall display speed restriction signs in accordance with section 1500, section 5600 and the instructions of the engineer.

4312

DEFECTS

Where, in the opinion of the engineer, any unacceptable loss of stone from or bleeding of the road surface that may occur during the course of the contract or during the maintenance period can be attributed to the contractor not observing any of the requirements of the specifications, not using the correct rates of application, or to any other omission or fault on the part of the contractor, any corrective work ordered by the engineer shall be at the contractor's cost, including the supply, precoating, stockpiling at selected sites and later removal If not used, of any aggregate resewed for corrective work during the period of maintenance or thereafter.

The contractor shall base his proposed repair method on the requirements specified in this clause, and submit it to the engineer for approval. The contractor m a y not commence with the repair work without the engineer's approval. Where the reason for bleeding or loss of stone, in the opinion of the engineer, cannot be attributed to ariy fault or neglect on the part of the contractor, the emplnyer shall pay at the tendered rates for the cost of any remedial measures taken on the instructions of the engineer.

clause 4804 to obtain a uniform surface. which shall then be covered with a single seal in accordance with section 4400. The type of aggregate and binder to be used shall be determined b y the engineer.
(3) Very severe bleeding in large sections or in circurnscribed smaller sections

(a)

Bleeding

In these sections the seal shall be rernoved from the surface of the base b y means of an approved method, e g milling or blading. The removal work shall be executed while the temperature of the road surface is below 15C. If necessary the road surface shall be cooled with water during the execution of the work. Only graders fitted with new blades shall be used. The contractor shall repair all damage to the surface of the basecourse to the satisfaction of the engineer, whereupon a surface course or a seal shall be applied in accordance with the engineer's instructions. (iii) General

Bleeding shall b e corrected b y one or more of the methods described below, as may be ordered b y the engineer: (i) Single seal with slurry

The engineer will determine the size of the aggregate to be applied to the bleeding portions, and for this purpose he may require ball penetration tests to be perfornied on the portions in question. The aggregate shall comply with the requirements of clause 4302. If the binder of the existing surface has an oxidised filrr~or if the road has been used b y traffic for some time. it shall be treated either b y brushing in power paraffin to soften the surface of the binder, or the surface shall be softened b y heating apparatus, if so ordered b y the engineer. The heating apparatus shall be an approved type that does not expose the road surface to open flames. This work shall only commence when the road temperature exceeds 30" C. The aggregate shall be applied to the surface immediately at the rate determined b y the engineer and rolled with a pneumatic-tyred roller having a mass of at least 2.0 t per wheel until the aggregate is firmly embedded. All loose aggregate not embedded shall be broomed off the road before it is opened to traffic. When opening the road to traffic, the affected areas shall be demarcated with traffic cones and speed limit signs for the first two days, care being taken to remove all loose aggregate daily. Areas where whip-off is excessive after the above treatment has been carried out. shall be retreated in accordance witti the engineer's instructions. If only half the road width is to be treated, the application of aggregate shall b e finished in a neat line on the centre line of the road. (ii) Single or multiple seals

All operations to correct bleeding shall be carried out at the correct surface temperature to promote adherence. This work shall be effected as soon as possible after bleeding occurs. Before opening any rectified work to traffic, all the loose aggregate shall be swept off the surface. It is essential to use the specified pneumatic-tyred roller on all this work. Rolling shall continue until the engineer is satisfied that all the aggregate has been properly embedded. No rolling shall be done in wet weather, cold weather or early in the morning when the surface is cold. Notwithstanding the above methods of treatment. the engineer may order any seal which has not been properly constructed to be removed and replaced. The ren~oval of the seal shall be done so as not to damage the existing base. All aggregate and binder shall be removed either b y glacier or b y hand tools and any damage done to the surface shall be repaired to the satisfaction of the engineer. @)

Loss of stone

Where loss of stone occurs, the following measures shall be applied immediately: Those sections of the road where loss of stone occurs shall be closed for traffic b y means of the statutorily required road signs. All loose stones shall be removed from the road surface. The contractor shall make sure that all the rerriaining stones adhere satisfactorily to the road surface. Depending on the engineer's opinion about the cause, degree and extent of the loss of stone. the following rectifying measures shall be applied: (i) Slight loss of stone

Where, in the opinion of the engineer. severe bleeding occurs, the engineer may prescribe one of the following treatments:
(1)

Severe bleeding in circumscribed smaller sections

These sections shall be treated as specified in subsubclause 4312(a)(i). The engineer will determine the size of the aggregate. (2) Severe bleeding in large sections

If the surface is non-uniform, ie partly bleeding and partly coarse-textured, the surface shall b e rectified b y pretreating the coarse areas in accordance with the requirements of

Slight loss of stone shall be treated in accordance with the requirements of the engineer. with the aid of fog spray. The surface to be repaired shall be clean and dry, and a 30% anionic or cationic spray-grade emulsion shall b e applied at a rate of 0.55 f/m%r such other rate as may be approved by the engineer.

Loss of stone due to low temperature : Isolated (ii) areas The areas where the remaining aggregate has to be removed from the road surface, shall be demarcated by the engineer. The remaining aggregate in these areas shall be removed with hand-equipment. Heating apparatus as described in subsubclause 4312(a)(i) may be used. Thereafter the areas shall be resealed as specified in subclause 4309(a).

(ii)

Width

The edges of the seal shall be true to line with a nlaximum deviation of 15 rnm from the specified edge line. (iii) Cross section

The requirements relating to the base on which the seal is coristr\~cted shall apply. (iv) Surface regularity

(iii)

Loss of stone due to low temperature : Large area

The requirements relating to the base on which the seal is constructed shall apply.
(v)

The remaining aggregate shall be bladed from the road surface as soon as possible. The exposed area shall be resealed with binder and aggregate as prescribed and approved by the engineer. (iv) Loss of stone due to a deficiency in binder : Isolated areas The measures specified in subsubclause 4312(b)(i) shall be applied.

General

Any areas whlch show signs of bleeding after the section has been opened to traffic shall be corrected as specified in clause 4312. Corrective work shall be carried out in such a manner as to blend in colour, texture and finish with adjacent work. The conipleted seal shall be free from corrugations or any otlier wave effect where depressions are preceded and followed by humps or ridges no matter how small the distance between the tnp of the hump to the bottom of the preceding or followirig depression.

(v)
area

Loss of stone due to a deficiency in binder : Large

As soon as the temperature of the road surface is within the prescribed limits, a fog spray of diluted bitumen emulsion shall be applied at the rate specified or approved by the engineer.

@)

Resealing work on existing surfaces

An additional layer of aggregate shall be applied with a mechanical spreader at a rate sufficient to replace the loss of stone.
The completed seal shall be roiled to the satisfaction of the engineer with pneumatic-tyred rollers as specified in subclause 4303(d). When the temperature of the road surface drops sufficiently. all surplus aggregate shall be swept off the road surface with brooms as specified in subclause 4303(e).

The completed seal shall be of uniform texture without gaps or patches and shall be free from any loose aggregate or bitumen spillage. Any areas which show signs of bleeding after the section has been opened to traffic shall be corrected as specified in clause 4312. Corrective work shall be carried out in such a manner as to blend in colour, texture and finish with adjacent work. The complsted seal shall be free from corrugations or any otlier wave effect where depressions are preceded and followed by humps or ridges no matter how small the distance between the top of the hump to the bottom of the preceding or following depressions. The ~ d g e of s the cornpleted seal shall be coritiriunusly true to line with a maximum allowable deviation from the specified edge line of 15 mm.

4313

MAINTENANCE

The contractor shall maintain the bituniinous surface until the work is finally accepted by the employer. Ariy darnage done to the surface or any defects which may develop before the issue of the maintenance certificate. fair wear and tear excepted. shall be corrected by the csntractor at his own cost and to the requirements of the engineer.

(c)

The rate of application

4314

TOLERANCES AND FINISH REQUIREMENTS

The completed bituminous work shall comply with the following requirements reqarding surface tolerances and finish:

The rnaximum perrnissible variation frorn the rates of application of bituminous binders. aggregates or slurry. as ordered by the engineer. shall be plus or minus 5% of the rate of application required for the aggregate. and plus or minus 0.06 l / r n 7 net bitumen cold (20C) for conventional or homogeneous modified binders. and within a tolerance of plus or minus 5% for non-homogerleous modified binders at spraying temperature. When the viscosity of the binder actually in use (at spraying temperature) varies from that with which the distributor was calibrated or for any other reason, the engineer may order the transverse distribution to be checked before the binder is applied by a method prescribed by the engineer. The coefficient of variation

(a) (i)

New work
Level and grade

The requirements relating to the base on which the seal is constructed shall apply.

(100.~1~) of the spray applications calculated for 100 m m strips of spraybar length, excluding the outer 300 m m on each side, shall not exceed 12 percent for any one such test ordered b y the engineer. In order to achieve the minimum lot size the engineer may combine sublots of the same population.

Where, in the opinion of the engineer, the corrective (c) work executed in terms of clause 4312 is not for the contractor's account, the contractor will be remunerated at the applicable rates as determined by the engineer in terms of the contract.

(d)

Conditional acceptance 43.01 Application of a fog spray of 30% spraygrade or approved equivalent diluted stable grade emulsion: (a) (b) Spray-grade emulsion Stable-grade emulsion

The provisions of clauses 8208 and 8307 apply to conditional acceptance.

4315

MWUREMENT AND PAYMENT

. ..... .......
....... ......

litre (1) litre ( 1 )

Measurement and payment will be made under the (a) various sections where the different seals are specified. (b) Work in areas inaccessible to mechanical equipment will be measured and paid for under the following sections: Single seals: Section 4400 Double seals: Section 4500 Aggregate with slurry : Section 4600 Sand seals : Section 4900

The unit of measurement shall be the litre of 30% spraygrade or approved equivalent diluted stable grade emulsion measured at spraying temperature.

The tendered rate shall include full compensation for providing the material and for applying the fog spray as specified.

SERIES 4000 : ASPHALT PAVEMENTS AND SEALS SECTION 4400 : SINGLE SEALS

Table 440311 Nominal rates of application

CONTENTS 4401 4402 4403 4404 SCOPE MATERIALS CONSTRUCTION MEASUREMENT AND PAYMENT

Nominal size of aggregate mm bitumen

4401

SCOPE

This section covers all the work in connection with the construction of single seals. It also covers the construction of single seals for resealing existing roads, as well as the use of modified binders in single seal resealing work and in stress-distribution layers. Note: Section 4300: Seals : Materials and General Requirements applies to this section.
(c)

Final rolling

Any areas deficient in aggregate shall have additional material added so as to leave the carpet with a single layer of chippings lying shoulder to shoulder. It is essential to ensure that only one layer of chippings is applied and every care shall be taken to avoid over-application of chippings.

4402

MATERIALS

The final rolling shall be done as specified in subsubclause 4307(b) (ii).

The materials shall comply with the requirements of section 4300. The average least dimension (ALD) of the appropriate size and grade of aggregate, where required in the project specifications, shall comply with the requirements in table 440211. Table 440211 Aggregate properties Nominal size (mm) 19,O 13,2 9-5 Minimum ALD (mm) 12,O 82 5,9

The finished surface shall be well-knit and have a uniform appearance free of roller-tyre marks. All aggregate contaminated by oil, fuel or grease shall be removed and replaced by clean aggregate.

All loose aggregate shall be broomed off the surface with a rotary broom or hard brooms as directed by the engineer.

(dl

Fog spray

When required by the project specifications or, if so directed by the engineer in writing, a fog spray of 60% or 30% anionic or cationic emulsion shall be applied to the surface of the aggregate by means of a pressure distributor at the required rate.

4403

CONSTRUCTION

(a)

Application of tack coat and aggregate

(e)

Blinding

The tack coat and aggregate, of the size and grade specified in the project specifications or ordered by the engineer, shall be applied as specified in clause 4307. The nominal rates of application given in table 440311 shall be used for tendering purposes only. The actual rates of application shall be as determined by the engineer.

If required in the project specifications or as may be directed by the engineer, a light blinding layer of washed natural or crusher sand shall be applied by the contractor to prevent chippings from being picked up by traffic. The blinding layer shall be spread evenly over the full indicated surface. Should it be required by the engineer, the layer shall be spread evenly by means of hand brooms.

(1)
@) Initial rolling

Precoating of aggregate

Initial rolling shall be carried out as specified in subsubclause 4307(b) (ii).

If required in the project specifications or as may be directed by the engineer, the aggregate shall be precoated with a precoating fluid as specified in subclause 4302(d).

@)

Bitumen-rubber seals

(d) (e)

Using 13.2m m aggregate . . . square metre (ni2) Using 19.0m m aggregate

The provisions of clause 4403 shall apply throughout. together with the following: For tender purposes, the contractor shall base his rate on the nominal rate of application indicated in table 440312. The total application of bitumen-rubber shall be applied in a single spray. Table 440312

...

square metre (m2)

The unit of measurement shall be the square metre of completed, and accepted seal.

Nominal size of aggregate (mm)

Nominal rates of application

'

Bitumen-rubber tack coat at spray temperature (1/m2)

2,7 2.1

Aggregate (m2/m')

The tendered rates shall include full compensation, inter alia. for furnishing all materials, marking the centre line or reference lines. spraying of binder, spreading of aggregate, rolling. removing of dust or deleterious material, supplying of water and spraying of haul roads and construction roads. trimming the edges of the completed surface, and all other incidentals necessary for completing the work as specified, except the application of a fog spray and precoating of aggregate, which shall be paid for separately.

Item

Unit

19,O 13,2 9,5

1,6

65 90 130

44.02 Biminous binder variations:

(a) (b)

Road grade 84 bitumen Road grade B8 bitumen

. . . . . . . . . . . . .litre . . . . . . . . . . . . .litre

(1) (1)

All the aggregate shall be applied immediately, but not more than 2 minutes after the application of the biturnenrubber tack coat.

(c) (d)

70% spray-grade emulsion . . . . . . . . . . . litre (1) 65% spray-grade emulsion . . . . . . . . . . .litre (1) 60% spray-grade emulsion . . . . . . . . . . .litre (I) MC-3000cut-back bitumen . . . . . . . . . . litre (1)

( h )

Resealing at bridge joints (e)

The seal shall not be applied closer than 300 m m from the concrete joint noses, and not under any circumstances over the joint nose itself. Where specified in the project specifications, the existing surfacing shall be cut back on both sides of the bridge joint over a width of 300 m m in a tapered shape so that the resealed surface will be flush with the surface of the concrete joint nose.

(f)

(g)

Bitumen-rubber (specify the type and composition) . . . . . . . . . . .

....... litre (I)

(h)

Homogeneous modified binder (indicate type) hot applied . . .

.......

litre (1)

All bridge joints shall be adequately protected against damage or blockage until all rolling and brooming work has been completed.

(i)

Homogeneous modified binder (indicate type) cold applied . . . . . . . . . . litre (1) Precoating fluid . . . . . . . . . . . . . . . . . . . . litre (1) Paraffin (indicate type)

(i) ( i ) Work in areas equipment

inaccessible to mechanical (k)

. . . . . . . . . . . . . . litre (1)

The provisions of clause 4309 shall apply.

4404

MEASUREMENT AND PAYMENT

The unit of measurement for bituminous binder in respect of an increase or a decrease in the specified rates of application shall be the litre measured at spraying temperature. (The contractor must note that the nominal rates of application are specified in net bitumen cold, except for bitumen-rubber.) Unit Payment for variations shall be made as specified in clause 1213.

Item 44.01 Single seals (indicate grade of aggregate and type of binder): (a) (b) (c) Using 4,75m m aggregate Using 6,7m m aggregate

. . square metre (m7)

Where paraffin is used to cut back the penetration-grade bitumen, the rate for paraffin variation under subitem (k) shall include full compensation for providing the paraffin and mixing it with the bitumen.

. . . . square metre (rn7)

Using 9,5m m aggregate . . . . square metre (m7)

ltem

Unit

approved wetting agent to the precoating fluid as specified or as directed b y the engineer. The tendered percentage of the prime cost sum shall include full compensation for handling the material. storing and introducing it into the mix. including any equipment required. and for all other charges and profit.

44.03 Aggregate variations (state grade):

(a) (b) (c) (d) (e) 4,75 m m aggregate
6,7 m m aggregate

. . . . . . . . cubic metre (m')

. . . . . . . . . cubic metre (m3)

9,5 rnm aggregate

. . . . . . . . . cubic metre (mR)

ltem Unit

13,2 m m aggregate . . . . . . . . . cubic metre (m')

11.07 Aggregate for blinding:

19,O rnm aggregate . . . . . . . . . cubic metre (m') (a) Natural sand Crusher sand
. . . . . . . . . . . . . cubic metre (m3)

The unit of measurement for aggregate in respect of an increase or a decrease in the specified rates of application shall b e the cubic metre of aggregate. Payment for variations shall be made as specified in clause 1213.

(b)

. . . . . . . . . . . . cubic metre (m3)

The unit of measurement shall be the cubic metre of sand measured in the hauling vehicles. The tendered providing the complete as stockpiling the rate shall include full compensation for material and applying the blinding coat specified. and, should it be required. sand at an approved locality.

ltem

Unit

44.04 Application of fog spray:

(a) 60% spray-grade emulsion (indicate type) . . . . . . . . . . . . . . . . . . . . . litre (1) 30% spray-grade emulsion litre (1) (indicate type) . . . . . . . . . . . . . . . . . . . . . Item Unit

(b)

44.08 Extra over item 44.01 for work in areas inaccessible to mechanial equipment . . . . . . . . . . . . square metre (m2)

The unit of measurement shall be the litre. measured at spraying temperature. The tendered rate shall include full compensation for furnishing the material and applying the fog spray as specified.

The tendered rate shall include full compensation for all additional costs for executing the work in areas inaccesible to mechanical equipment.

Payment will not distinguish between the various types of binders or various sizes or grades of aggregate.

ltem

Unit ltem Unil

44.05 Recoating the aggregate at a rate of 12 I l m 3 or as specified) (indicate precoating fluid) . . . . . . . . . . . cubic metre (m') The unit of measurement for the precoating o: aggregate shall b e the cubic metre of aggregate so treated measured in hauling vehicles or in stockpile. The tendered rate shall include full compensation for furnishing the equipment and materials and precoating the aggregate as specified. including the handling. stockpiling and protecting of the stockpiles against inclement w e a t h ~ r

44.09 Resealing at bridge joints:

(a)

Where the existing surfacing is not removed . . . . . . . . . . . metre (m) Where the existing surfacing is . . . . . . . . . . . . . . . .metre (m) removed

(b)

The unit of measurement shall be a metre of bridge joint situated in the surface to be resealed. and which has been protected in accordance with the specifications to the satisfaction of the engineer.

ltem

Unit

44.06 Addiion of wetting agent (indicate type):

(a) (b) Providing and supplying

......

prime cost sum

The tendered rate shall include full compensation for protecting the bridge joints against damage, blockage and soiling until the resealing has been completed, including the procuring. placing and removing of all covering material. and all other incidentals required for executing the work in accordance with the specifications.

Handling, applying. profit and all other costs . . . . . . . percentage of prime cost sum

Prime-cost sum will be paid for in terms of the general conditions of contract for providing and supplying an

The tendered rate for subitem (b) shall also include full compensation for cutting back in the existing surfacing. treating and backfilling it, and disposing of excavated material, all as specified and to the satisfaction of the engineer.

SERIES 4000 : ASPHALT PAVEMENTS AND SEALS SECTION 4500 : DOUBLE SEALS
Nominal size of aggregate (mm)

Table 450311

Nominal rates of application Tack coat (litres of net bitumen cold per m2) 1,o 0,8 Aggregate (m2 per m3) Bitumen rubber at spray temperature (litres per m2) 1,8 1,6

CONTENTS
4501 4502 4503 4504 SCOPE MATERIALS CONSTRUCTION MEASUREMENT AND PAYMENT

4501

SCOPE

19,O 13,2

75 110

This section covers the supplying and furnishing of materials for the construction of a bituminous double seal. The seal shall be constructed using either 19.0 m m plus 9,5 m m aggregate, or 19,O m m plus 6,7 m m aggregate, or 13,2 m m plus 6.7 m m aggregate, or 13,2 m m plus 4,75 m m aggregate, of the specified grade, whichever is shown in the schedule of quantities. If other sizes and combinations are required it k i l l be specified in the project specifications and shown in the schedule of quantities.

(d)

Second application of biminous binder and aggregate

The bituminous binder specified by the engineer shall be applied and followed by the second layer of aggregate of the size specified in the project specifications or as ordered by the engineer. The nominal rates of application given in table 450312 shall be for purposes of tendering only and the actual rates of application shall be as determined by the engineer. Table 450312

Note: Section 4300 : Seals : Materials and General Requirements shall apply to this section.

4502

MATERIALS

Nominal size of aggregate (mm)

Nominal rates of application Binder (litres of net bitumen cold per m2) 1,o 0,8 06 Aggregate (m2 per m3)

The materials shall comply with the requirements of section 4300. 9,5 6-7 4,75

45W

CONSTRUCTION

165 200 250

(a)

Application of tack coat and first layer of aggregate

The second application of binder shall preferably take place within 48 hours of the application of the tack coat when bitumen is used for the tack coat and not less than ten days of the application of the tack coat when cut-back bitumen is used in tack coat (ie new work).

The binder of the type and grade required, and the aggregate of the size and grade specified in the schedule of quantities or ordered by the engineer, shall be applied as specified in subsubclause 4307(b)(i).

The nominal rates of application given in table 450311 shall be for the purposes of tendering only and the actual rates of application shall be as determined by the engineer.

(e)

lnitial rolling of second layer

Initial rolling of the second layer of aggregate shall be carried out as specified in subclause 4307(b).

The use of cut-back bitumen in the tack coat will only be permitted under special circumstances.

(1)

Broom drag and final rolling of second layer

@)

lnitial rolling

Dragging and final rolling of the second layer of aggregate shall be carried out as specified in subsubclause 4307(b)(iii).

lnitial rolling shall be carried out as specified in subsubclause 4307(b)(ii).

(c)

Broom drag and final rolling of aggregate

Dragging and final rolling of aggregate shall be carried out as specified in subsubclause 4307(b)(iii).

When required by the project specifications or if so directed by the engineer in writing, a fog spray of 60% or 30% anionic or cationic bitumen emulsion shall be applied to the surface of the second layer of aggregate by means

of a pressure sprayer at the rate of application specified by the engineer.

(e)

60% spray-grade emulsion

(state typo)
. . . . . . . . . . .

litre ( I )

(h)

Recoating of aggregate

(f)

30% anionic spray-grade

emulsion . . . . . . . . . . . . litre ( I )

When required b y the project specifications or if so directed b y the engineer, the aggregate shall be precoated with an approved precoating fluid.

(g) (h)

MC-3000cut-back bitumen . . . . . . . . . . . litre ( I )

Bitumen-rubber (specify the type and composition) . . . . . . . . . . . . .

litre ( I )

4504

MEASUREMENT AND PAYMEM

(i) Homogeneous modified binder (indicate type) hot applied . . . . . . . . . . . litre ( I ) Homogeneous modified binder (indicate type) cold applied . . . . . . . . . . litre ( I ) Precoating fluid . . . . . . . . . . . . . . . . . . . . litre(!)

(j)
45.01 Double seals using:

(a)

19,Om m and 9.5rnrn aggregate (state grades of aggregate and types of binders to be used) . . . . . . . . square metre (m') 19.0 m m and 6.7 m m aggregate (state grades of aggregate and types of binders to be used) . . . . . . . . square metre (m7) 13,2rnrn and 6.7 mrn
aggregate (state grades of aggregate and types of binder to be used) . . . . . . . . square metre (m7)

(k)

(b)

The unit of measurement of bituminous binder in respect of variations in the specified rates of application shall be a litre. measured at spraying temperature. The contractor rnust note that the nominal rates of application are specified for net bitumen cold. except for bitumen-rubber. Payment for variations shall be made as specified in clause

1213.
(c)

Item
45.03 Aggregate variations (state grade):

Unit

(d)

13,2m m and 4.75m m

aggregate (state grades of aggregate and types of binder to be used) . . . . . . . . square metre lm7) (a) (b) (c) (d)

19.0m m aggregate . . . . . . . . . cubic metre (m3) 13.2m m aggregate

. . . . . . . . . cubic metre (my)

The unit of measurement shall be square metre of completed and accepted surface treatment. The tendered rate shall include full compensation. inter alia, for furnishing all materials. marking the centre line or reference lines, spraying of binder. spreading of aggregate. rolling, removing of dust or deleterious material, supplying of water and spraying of haul roads and construction roads, trimming the edges of the completed surface, and all other incidentals necessary for completing the work as specified, except the application of a fog spray and precoating of aggregate, which shall be paid for separately

9.5m m aggregate . . . . . . . . . cubic metre (my) 6.7m m aggregate . . . . . . . . . cubic metre (m') 4.75m m aggregate . . . . . . . . . cubic metre (my)

fe)

The unit of measurement with respect to variations in the rate of application of aggregate shall be the cubic metre of aggregate measured in the truck. Payment for variations shall be made as specified in clause

1213.

Item
45.02 Bituminous binder variations:
(a)

Unit
45.04 Application of fog spray consisting of:

Unit

8 4 road-grade bitumen or I ) 1501200 penetration grade bitumen . . . . . litre (

(a)

60% spray-grade emulsion

(state anionic or cationic) . . . . . . . . . . . litre ( I )

(b)

08 road-grade bitumen or 801100 penetration grade bitumen

(b)
. . . . . .

30" spray-grade emulsion

(state anionic or cationic) . . . . . . . . . . . litre ( I )

litre ( I )

(c)

70% spray-grade emulsion (state type) . . . . . . . . . . . . . . . . . . . . . . litre ( I )

The unit of measurement shall be the litre of emulsion sprayed as specified and measured at the application temperature The tendered rate per litre of emulsion shall include full compensation for procuring and furnishing the binder and applying the fog spray as specified.

(d)

65% spray-grade emulsion (state type) . . . . . . . . . . . . . . . . . . . . . . litre ( I )

45.05 Precoating aggregate (indicate precoating fluid)

....

cubic metre (m')

The prime cost sum will be paid for in terms of the general conditions of contract for providing and supplying an approved wetting agent to the precoating fluid as specified or as may he directed hy the engineer.

The unit of measurement for the precoating of aggregate measured shall be the cubic metre of aggregate so t~eated in hauling vehicles or in stockpile. The tendered rate shall include full compensation for furnishing the equipment and materials arid ;recoatirig the aggregate as specified, including the handling. stockpiling arid protecting of the stockpiles against inclernent weather.

The tendered percentage of the prinie cost sum shall include full cornpensation for handling the material, storing and introducing it into the rnix. including any equipment rerluired. and for all other charges and profit.

Item
45.07 &tra over item 45.01 for work in areas inaccessible to mechanical equipment

Unit

Unit
45.06 Mdiion of --ng
(state t y p e ) :

.. .

square metre (m2)

agent The tendered rate shall include full compensation for all additional costs for executing the work in areas inaccessible to mecl>anicalequipment.

(a) (b)

Providing and supplying . . . . . Handling, applying, profit and all other costs . . . . . .

prime cost sum

. . . . . . . percentage

of prime cost

Pay~nent will not distinguish between ttie various types of hinders or various sizes or grades of aggregate.

SERIES 4000 : ASPHALT PAVEMENTS AND SEALS SECTION 4600 : BITUMINOUS SINGLE SEAL WITH SLURRY (CAPE SEAL) The binder used for slurry shall be an anionic or cationic stable-grade emulsion (60% bitumen).

CONTENTS 4601 4602 4603 4604 4605 SCOPE GRADES OF BINDER TO BE USED CONSTRUCTION BEFORE SLURRY APPLICATION SLURRY MEASUREMENT AND PAYMENT

4603

CONSTRUCTION BEFORE SLURRY APPLICATION

(a)

Application of tack coat and aggregate

4601

SCOPE

The binder of the type and grade required, and the aggregate of the size specified in the schedule of quantities or ordered by the engineer, shall be applied as specified in subsubclause 4307(b)(i) at the rates as ordered by the engineer. The nominal rates of application given in table 460311 shall be used for the purposes of tendering. Table 460311 Nominal size of aggregate Nominal rates of application

This section covers the construction of a seal consisting of the application of a tack coat, spreading of 19,O m m or 13,2 m m aggregate, as specified, a further application of bituminous binder coat and the application of the slurry in one or two coats. Note: Section 4300 : Seals : Materials and General Requirements applies to this section.

net bitumen cold per m2)

(m2 per m3)

4602

GRADES OF BINDER TO BE USED

(a)

Tack coat

@)

Initial rolling

The tack coat shall consist of one of the following binders, whichever is specified in the project specifications or the schedule of quantities or as ordered by the engineer: (i) (1)
(2)

Initial rolling shall be carried out as specified in subsubclause 4307(b) (ii).

Conventional binders Road-grade bitumen (84 or 88) MC-3000 cut-back bitumen 60%, 65% or 70% spray-grade emulsion Non-homogeneous modified binders Rubber-bitumen (summer grade) Rubber-bitumen (winter grade) Homogeneous modified binders 5% latex cationic emulsion

(c)

Broom drag and final rolling of aggregate

Dragging and final rolling of aggregate shall be carried out as specified in subsubclause 4307(b)(iii).

(3) (ii) (1)

(2)

(d)

Second application of bituminous binder

The required binder shall be sprayed at the rate prescribed by the engineer. This shall be done at least 2 days after application of the tack coat and the aggregate. For tender purposes a nominal rate of 0.33 t l m 2 (net bitumen cold) shall be used for 13,2 m m aggregate and for 19 m m aggregate.

(iii) (1)

4604 SLURRY
@)

Second application of binder

(a)

Condition of surface

The second application of binder shall consist of one of the following binders, whichever is specified in the project specifications or the schedule of quantities or as ordered by the engineer: 30% or 60% spray-grade emulsion. Where further dilution of the emulsion is required, the provisions of TRH3 shall be observed.

The surface shall be rolled once with a light flat-wheeled roller early in the morning on the day of sealing to depress any loose stones that may have been displaced. The surface shall be cleaned to remove all dust, mud, leaves, etc, and shall have a uniform closely knit appearance, with edges trimmed correctly to the specified width.

@)

Timing of slurry application

(ii)

Continuous mixer

The slurry shall be applied only after the final spray has cured or dried out (which usually takes at least 2 days).

(c)

Composition of slurry

The slurry shall conslst of a mix of the grade of slurry aggregate ordered by the engineer and specified in subsubclause 4302(b)(ii) together with a 60% stable-grade emulsion, filler and water in the proportions as directed by the engineer. The following proportions shall apply for tendering purposes only: Slurry aggregate (saturated volume) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 m' Stable-grade emulsion at mixing temperature (state type) . . . . . . . . . . . . . . . . . . . . 260 1 Cement

Aggregate and filler contained in separate bins shall be fed through metering devices at controlled rates to the mixer. Water and bitumen emulsion contained in separate tanks shall similarly be pumped to the mixer at controlled rates through metering devices. The mixing of the slurry shall be at a suitable rate adjusted to ensure complete blending of the Ingredients and uniformity of mix.
(8)

Application of slurry

The method of application specified in the project specifications shall be used. Before slurry is applied, the road surface shall be thoroughly cleaned and lightly sprinkled with water but no free water shall be present on the surface when the slurry is applied. The slurry shall be applied in two layers In the case of 19,O m m chippings and in one layer in the case of 13,2 m m chippings, unless otherwise specified in the project specifications or ordered by the engineer. The nominal rate of application of slurry shall be as follows for a seal using

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.01 m3

Water (as directed by the engineer) . . . . . . . . . . . . . . . . . . . . . . . . .approx 235 1 If specified in the project specifications, the composition of the slurry shall be based on the following mass proportions for tender purposes: Slurry aggregate (dry) Stable-grade emulsion Cement Water

13,2 m m aggregate 19,O m m aggregate

...........

166 m'/m3 one layer 125 m2/m3total for two layers

. . . . . . . . . . . . . . . . . . . . . . 100
. . . . . . . . . . . . . . . . . . . . . . . 20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1,5
15

If speclfied In the project specifications, the nomlnal rate of application of the slurry on a mass basis shall be taken as

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .+

13,2 m m aggregate The saturated volume of slurry shall be determined by applying a correction for bulking of moist aggregate, as described in item 46.05. 19,O m m aggregate

. . . . . . . . . . . . . . . . . . . 7,5 kg/m2

...................

9,5 kg/m2

(d)

Mixing of slurry

The rate of application of slurry shall be measured in cubic metres of fine aggregate (saturated volume) contained in the slurry applied, per square metre of surfacing. The nominal rates of application given above are intended for tendering purposes only and the actual rates of application on the site shall be as directed by the engineer. The slurry shall be placed in accordance with the requirements of TRM, unless otherwise specified. When the slurry is applied in two layers, the first layer of slurry shall be struck off level with the tops of the stones in the aggregate layer so that, after application, the tops of the stones will be just visible. The second layer of slurry shall not be applied until the first layer has dried. If required by the engineer, the contractor shall open the road to traffic before the second layer of slurry is applied. Rolling of the slurry shall commence after the slurry has dried sufficiently unless otherwise approved by the engineer. Each layer of slurry shall be roller compacted by at least three roller passes with a 27 t pneumatic-tyred roller. However, the second layer shall be compacted until the required in situ water permeability is less than 1,O 1 l h when measured by means of an approved method. The second layer shall be applied only after sufficient time has been allowed for the first layer to cure. The engineer will decide on the time

A mixer of a type approved by the engineer shall be provided in a good working order capable of producing a uniform slurry of the constituent materials. It may either be a batch mixer or a continuous type mixer. Material which, in the opinion of the engineer, is not properly mixed or in which the emulsion shows signs of having broken during mixing shall not be applied to the road. The slurry consistency when measured in accordance with ASTM D3910 section 6.1 shall be between 30 m m and 40 m m in order to achieve the required workability. (i) Batch mixer

The slurry shall be mixed in an approved type of mixer as specified in subclause 4303(f). All the constituents of the slurry shall be accurately proportioned and due care and attention shall be given to the sequence in which the ingredients are introduced into the mixer and to the period of mixing. Mixing shall be continued until the materials in each batch are thoroughly blended.

necessary for proper curing, which will in any case be not less than 24 hours. The surface shall be thoroughly cleaned of all dust, dirt or foreign materials before the second layer of slurry is applied. For seals using 13,2 mm nominal sized chippings, the slurry shall be applied In one layer only. The slurry shall also be struck off so that the tops of the stone chippings will be just visible after the emulsion has set and cured. When the slurry is applied, the squeegee squad shall be allowed to complete the spreading of each batch discharged onto the road, using squeegees, before the next is discharged. Slurry shall be spread only by hand and not with a spreader box. In order to adequately fill the volds with slurry, the squeegees shall be applied in a multi-directional fashion. The contractor shall ensure that either edge of the road surface is finished to the specified widths and lines. All stones dislodged in the process of applying the slurry shall be removed on the same day on which the slurry seal has been applied. All spillage of slurry or excess slurry shall be neatly removed form the road and buried. The second layer of slurry shall extend to the edge of the primed surface as indicated on the drawings. 46.02 Bituminous single seal with 13,2 mm aggregate and slurry (indicate type and grade of binder and grade of aggregate) . . . . . . . . . . . . square metre (m2) The unit of measurement for the complete bituminous single seal with aggregate and slurry shall be the square metre. The tendered rates shall include full compensation, for furnishing all materials, demarcating the working area, spraying the binders, spreading the aggregates, rolling, mixing and applying the slurry, and all other incidentals necessary for completing the work as specified, including the watering of haul and construction roads in and about the site.

ltem
46.03 Bituminous binder variations: (a) (b) (c) (d) The slurry batch shall be discharged onto the road in small increments by means of a chute. The rate of application shall be measured by mass in kilogram of fine aggregate, contained in the slurry applied, per square metre of surfacing. (0) 84 road-grade bitumen
08 road-grade bitumen

Unit

. . . . . . . . . . . . . .litre (1)

. . . . . . . . . . . . . .litre (1)
. . . . . . . . . . .litre (1)

MC-3000 cut-back bitumen

Spray-grade emulsion (30% bitumen) Spray-grade emulsion (60% bitumen) Spray-grade emulsion (65% bitumen) Spray-grade emulsion (70% bitumen) Anionic stable-grade emulsion (60% bltumen)

. . . litre (1)
. . . litre (1)

(1)
(g)

. . . litre (1)
. . . litre (1)

The slurry shall be worked from side to side and criss-cross with the aid of squeegees so as to fill as many spaces as possible. In this case the final layer of slurry shall be struck off flush with the tops of the stone chippings so as to leave the chippings to be visible after the emulsion has stiffened and hardened.

(h)

. . . . . . . . . . . . . . . . . . . .litre (1)

(i)

Cationic stable-grade emulsion (60% bitumen)

. . . . . . . . . . . . . . . . . . . .litre (1)
. . . . . . . litre (1)

0)
The slurry shall be applied to the full road width in one application. If so ordered by the engineer, the slurry may be applied in half-widths of road, provided that the work is so programmed that the slurry is applied to both halfwidths on two successive days in order to complete a section of full road width in two days. (k) (I)

Rubber-bitumen (summer grade) Rubber-bitumen (winter grade) 5% latex cationic emulsion

. . . . . . . . litre (1)

. . . . . . . . . . .litre (1)

The unit of measurement in respect of variations shall be the litre of binder measured at spraying (or mixing) temperature. Payment for variations shall be made as specified in clause 1213.
Item Unit

Any damage to the slurry seal by rain or traffic before the slurry has cured shall be rectified by the contractor at his own expense.

4605

MEASUREMENT AND PAYMENT

46.04 Aggregate variations:

(a)
Unit
46.01 Bituminous single seal with 19,O mm aggregate and

13,2 mm nominal sized aggregate . . . . . . . . . . . . . . . . cubic metre (m3) 19,O mm nominal sized aggregate . . . . . . . . . .

(b)

. . . . . . cubic metre (m3)

slurry (indicate type and grade of binder and grade of aggregate) . . . . . . . . .

. . . square metre (mZ)

The unit of measurement in respect of variations shall be the cubic metre of aggregate, measured loose in the truck.

Payment for variations shall be made as specified in clausp 1213.

True (saturated) volume carried by the truck hopper:

h m

Unit Item
46.06 Slurry application rate variations . . . . . . . .

46.05 Variation in the rate of application of the slurry . . . . cubic metre (m') The unit of measurement for slurry variations shall be the cubic metre of saturated fine aggregate. Payment for variations shall be made as specified in clause 1213. Every load of fine aggregate used for the slurry shall be struck off with a straight-edge at the stockpile. and the volume shall then be measured. and corrected for bulking. The following method shall be used for calculating the corrected volume of fine aggregate when determining the application rate of slurry: The volume of a truck hopper filled with fine aggregate shall be carefully measured in cubic metres (say A cubic metres).

Unit

ton (1)

The unit of measurement for variations in the slurry application rate shall be a ton of aggregate contained in the slurry. Payment for variations shall be made as specified in clause 1213.

Item
46.07 Variation in active filler

U n i t

content (specify active filler)

. . . . .. . . ..

ton (1)

A representative sample of aggregate shall be obtained from the conveyor belt feeding the mixer. 1 000 m l of the sample shall be placed in a plastic measuring cylinder and dropped ten times through a height of 50 m m onto a wooden table, after which the volume of aggregate in the cylinder shall then be measured in millilitres (say B millilitres).
The sample in the cylinder shall then be saturated with water and water shall be added until it covers the aggregate by 50 mm. The mixture shall be shaken well. and the cylinder containing the aggregate and water placed on a horizontal surface allowing the aggregate to settle until the liquid above the aggregate clears sufficiently for a reading to be taken of the volurne of the saturated aggregate, in millilitres (say C rnillilitres). The saturated volume of the aggregate in the hopper of the truck shall be calculated from the following formula, and payment for the slurry application variations shall be made in accordance with this formula:

The unit of measurement in respect of increases or decreases in the active filler content from that specified in the nominal mix for tender purposes shall be the ton. No payment shall be made for inert filler added by the contractor. Payment for variations shall be made as specified in clause 1213.

Item
46.08 Extra over iterns 46.01 and 46.02for work in areas inaccessible to medranical equipment . . . . . . . . . . . . .

U n i t

square metre (m')

The tendered rate shall include full compensation for all additional costs for executing the work in areas inaccessible to mechanical equipment. Payment will not distinguish between the various types of binders or various sizes or grades of aggregate.

SERIES 4000 : ASPHALT PAVEMENTS AND SEALS SECTION 4700 : SURFACING OF BRILKiE DECKS
Irrespective of the type of seal applications on the road on both sides of the bridge, asphalt surfacing shall be constructed in accordance with section 4200, and seals for bridge decks in accordance with section 4300.

CONTENTS
4701 4702 4703 4704 4705 4706 4707 SCOPE MATERIALS PREPARATION OF SURFACE TYPE AND THICKNESS OF SURFACING CONSTRUCTION SURFACE TOLERANCES MEASUREMENT AND PAYMENT

4706

SURFACE TOLERANCES

The completed surfacing shall comply with the requirements for base of clause 3405 in respect of surface tolerances for grade, smoothness, cross section and width.

4701

SCOPE
4707

MEASUREMENT AND PAYMENT

This section covers the construction of a bituminous surfacing on bridge decks where shown on the drawings or ordered by the engineer. Asphalt surfacing of bridge decks is specified in section 4200

47.01 Surfacing on bridge deck (indicate type and thickness)

..........

ton (1)

4702

MATERIALS

The unit of measurement shall be the ton of surfacing completed to the nominal thickness indicated.

Bituminous binders and aggregate shall comply with the requirements of section 4200 for asphalt surfacing and section 4300 for other bituminous seals.

4703

PREPARATION ON SURFACE

The tendered rate shall include full compensation for procuring and furnishing all materials, heating the binder and aggregate. mixing. transporting, placing and compacting the material, and the provision and application of the slurry. The rate shall also include full compensation for variations in thickness within the specified tolerance for bridge deck levels and for the application of a tack coat.

Before the surfacing is constructed. the concrete deck shall be thoroughly cleaned by washing and brushing to remove all loose material. After drying. a tack coat consisting of 30% bituminous emulsion shall be applied to the surface at a rate of 0,4 Llm2. The tack coat shall then be allowed to dry.

Rolled-in chippings will be paid for separately under item 47.02. Asphalt surfacing of bridge decks will be paid for under section 4200.

4704

TYPE AND THICKNESS OF SURFACING

Item

Unit

The type and nominal thickness of the surfacing shall be as indicated on the drawings and specified in the schedule of quantities. Before commencing with the construction of the surfacing. the actual levels of the bridge deck shall be determined by means of accurate levelling. The levels and grades to which the surfacing is to be constructed shall be as shown on the drawings or as indicated by the engineer. If the levels of the concrete deck as constructed by the contractor deviate by more than the specified tolerances from the specified levels, he shall construct a levelling layer at his own cost. The nominal size of the aggregate in the levelling layer shall be 9.5 rnm.

47.02 Rolledin chippings (nominal size indicated) in surfacing . . . . . . . . . . . . . . . . . . . . . . . . . ton (1)

The unit of measurement shall be the ton of rolled-in chippings applied at the specified rate, measured loose in hauling vehicles.

The tendered rate shall include full compensation for the procuring. furnishing. precoating. spreading and rolling in of precoated chippings and for any additional costs resulting from more difficult construction of the asphalt surfacing with rolled-in chippings.

SERIES 4000 : ASPHALT PAVEMENTS AND SEALS SECTION 4800 : TREATMENT OF AN WSTING SURFACE EXHIBITING CEATAJN DEFECTS

the binder will have a net rubber content equal to 10% of the net bitumen content. (iv) Fog spray

CONTENTS
4801 4802 4803 4804 4805 4806 4807 SCOPE MATERIALS PLANT AND EQUIPMENT CONSTRUCTION OPENING TO TRAFFIC JOINTS AND THE PROTECTION OF KERBS MEASUREMENT AND PAYMENT

30%, 40%. 50% or 60% cationic or anionic spray-grade emulsion shall be used in accordance with the requirements. (v) Tack coat for texturing

60% anionic or cationic spray-grade emulsion shall be used. (vi) Slurry-seal

The following shall be used:

4801

SCOPE
Tack coat
: :

30% stable-grade emulsion 60% slurry-grade emulsion

This section covers the work in connection with the treatment of existing road surfaces exhibiting certain defects. It covers the treatment of existing seals where: (a) The existing surface is deficient in binder

Slurry seal (vii)

Screed

(b) Marked differences in texture occur over the surface. (c) (d) etc. (e) The existing surface is open-textured. The surface is uneven on account of bumps. slacks.

30% bitumen emulsion shall be used for the tackcoat, and the binder for the asphalt shall be 80/100 penetration-grade (88 road grade) bitumen unless otherwise specified in the project specifications. (viii) Binder in asphalt for patching

Tack coat Asphalt

: :

60% stable-grade emulsion 801100 penetration-grade (BE road grade) bitumen

Edges require trimming and/or repairs. (ix)

It also covers planing of the road surface, fog spraying. texturing, slurry sealing, screeding, sealing cracks and building up broken edges with asphalt.

Bitumen rubber

Bitumen rubber shall comply with the requirements of clause 4302. The softening point shall be at approximately 65 "C.

Note: Section 4300 : Seals : Materials and general requirements shall apply to this section.

@)

Rubber crumbs

48M

MATERIALS

Rubber crumbs used for crack sealing shall be obtained by processing rubber tyres. The rubber shall be granulated and free from fibres. steel wire and other impurities. The rubber crumbs shall pass through a 2.0 m m sieve.
(c)

(a)

Biminous binders

Herbicide

(i) The type or grade of binder used shall be as specified in the project specifications or the schedule of quantities or as ordered by the engineer. Bituminous binders shall comply with the appropriate requirements of section 4300. (ii) Primer for sealing cracks

Herbicide shall be Hyvar X or a similar non-selective herbicide approved by the engineer.

4803

PLANT AND EQUlPMENl

(a)
The primer shall be an invert bitumen emulsion manufactured from 80/100 penetration-grade bitumen such as MSPI1 or similar. (iii) Emulsion for crack treatment

Planing machine

The machine shall be of a design which will be suitable for planing the existing surfacing in order to remove any irregularities and to leave an even surface without tearing the underlying material. An approved milling machine may be used. Before planing may start, the contractor shall demonstrate to the engineer that the machine is in fact capable of executing the work in accordance with the specifications.

Anionic stable-grade bitumen emulsion shall be used. Unless otherwise specified in the project specifications. synthetic modifiers shall be added to the emulsion so that

@)

Equipment for crack-sealing

Aggregate

.. . . . . . . . . . . . . . . . . . . ...

0,0045 m3/m2

Over and above the equipment normally used for surface treatments, the following additional equipment will be necessary for the sealing of cracks:

The actual rates of application shall be as instructed by the engineer. It is anticipated that spraying and spreading may have to be carried out in narrow strips varying in width from 0,5 m to 2,O m. The emulsion shall be allowed to break before the aggregate is applied. As soon as the aggregate has been spread, patches where it has not been spread evenly shall be corrected by brooming the patch with a hand broom or a llght dragbroom. Rolling shall be done as specified in subsubclause 4307(b)(ii). Any excess aggregate remaining on the road after it has been opened to traffic for two days or more shall be removed. This treatment, or a sand seal as specified In section 4900, is intended for application where marked differences in texture occur In the existing surfaclng, in order to obtain a uniform texture before resealing.

A vibratory roller having a mass approximately (i) equal to that of a Bomag 905 or similar, with an adjustable amplitude and frequency of vibration.
A mobile pneumatic pump capable of producing at (ii) least 3 m31minat 750 kPa for blowing out cracks.
(iii) Special spraying equipment with 2 mm nozzle openings and provided with resewe nozzles. Special heating equipment where appropriate for (iv) cleaning cracks, and custom-built applicators for applying sealants to cracks.

(c)

Mher equipment

All equipment shall be suitable for the specified use and working areas and shall be capable of obtaining the specified results.

(c)

Slurry seal

4804 CONSTRUCTION
Before any treatment is carried out, the area to be treated shall be cleaned and prepared as specified in subclause 4304(d), and any major failures shall be repaired as specified In this section and in the project specifications.
(a)

Slurry seal shall comply with the requirements of section 4600. This treatment shall be used when an exlsting surface treatment, which is open-textured, requires treatment with bituminous slurry.

Treatment with diluted biiminous emulsion (fog spray)

Prior to treatment with a slurry, the surface shall be sprayed with a tack coat of 30% bitumen emulsion of the type and at the rate prescribed by the engineer.

This treatment will be applied where In the opinion of the engineer the existing surface is deficisnt in binder. The treatment shall consist of the application of a fog spray of the specified grade of bituminous emulsion to the existing surface by means of a pressure distributor at the rates of application as directed by the engineer, in widths that may vary from 0,5 m to 4,O m. A 30%, 40%, 50% or 60% cationic or anionic spray grade emulsion, as specified, shall be used.

A distinction shall be made In respect of payment for the following two methods of construction:
Where the slurry can be applied by hand methods (i) only or where the engineer so directs or where it is specified that the slurry shall be applied by hand methods. Where the slurry can be applied mechanically with (ii) a spreader box. The slurry shall be prepared, mixed and applied as specified in subclauses 4604(c), (d) and (e), except that slurry to be applied by hand can be mixed in a suitable concrete mixer and worked into cracks or other open patches with brooms or squeegees until the surface is smooth and even; and where a spreader box is used for applying the slurry, it shall be applied in one layer.

@)

Texturing
1

A tack coat of cut-back bitumen, 84 or B8 road-grade bitumen, or the specified type and grade of emulsion shall be applied to the surface as specified In subsubclause 4307(b)(i) followed by an application of double-washed crusher sand. The crusher sand shall be the medium grade specified for slurry in subsubclause 4302(b)(ii), but shall be on the coarse side of the grading envelope, and shall be subject to the engineer's approval.

A nominal rate of application of 0,0040 m'/m2 shall apply for tender purposes.

The nominal rates of application shall be: Cut-back bitumen : 0,70 1of net bitumenlm2 84 or BE road grade bitumen : 0,70 1of net bitumenlm2 Emulsion This treatment is used where the road surface is uneven and where depressions, humps or small grooves occur, which, in the opinion of the engineer, are the result of the deformation of the pavement layers, but not of structural failure of the pavement.

.... .......... .. .

0,70 1net bitumenlm2

Where both planing and screening are specified, the screed shall be placed after the planing has been completed. Where milling is required, it shall be done in accordance with the requirements of section 3800. The existing surface of the surfacing shall be swept clean or cleaned by other approved methods to be free from dust, soil, gravel, loose stones or any other undesirable material. A tack coat of 30% anionic stable-grade emulsion shall then be applied at a rate prescribed by the engineer on the site. The bituminous material used for the screed shall be asphalt or coarse slurry as specified in the project specifications. (i) Asphalt

exposed shall be swept clean, watered, and If so instructed, compacted. It shall then be tack coated as specified. The edges shall then be built up with medium continuously-graded asphalt in accordance wlth table 420217. The built-up edges shall be properly compacted and finished in accordance with the required lines and levels.
(f)

Sealing cracks General

(i)

The types of cracks treated will be specified in the project specifications. The engineer will instruct the contractor regarding the type of treatment to be used in the various cases. (ii) Preparation

The asphalt shall consist of a medium or fine-grade continuously graded asphalt, proportioned as specified in table 420217. The actual grade of the mix used shall be in accordance with the instruction of the engineer or as determined by the required thickness of the screed. The asphalt shall be produced, transported, placed and compacted as specified in section 4200, as applicable. The paver shall be so adjusted that the straight-edge blade will screed off high spots on the existing surface and the asphalt will therefore be placed only in depressions. Where high spots have been planed down, the stralghtedge blade shall operate over the planed surface. The screed shall nevertheless comply with the specified standards for evenness. Where the required asphalt thickness exceeds 25 mm at any position, such sections of the screed shall be placed in more than one layer if so instructed by the engineer. Such layerthicknesses shall be in accordance with the instructions of the engineer. Where the surface of the screed breaks up, a slurry-seal treatment shall be applied in accordance with subclause (c) above, or the screed shall be removed and replaced, all at the cost of the contractor. (ii) Coarse slurry

The cracks shall be blown clean with compressed air, and all foreign and loose matter shall be removed from the cracks.

A supply of approved herbicide diluted in accordance with the requirements of the project specifications shall be prepared. The solution shall be sprayed into cracks on the surfaced shoulders of the road or on such extended area as specified in the project specifications by means of rucksack type of sprayers, and allowed to dry.
Twenty-four hours after application of the herblcide, the cracks shall be penetrated with MSPIl or a similar suitable primer. (iii) Cracks smaller than 3 mm

Cracks smaller than 3 mm shall be treated with an emulsion or by means of resealing of the surface. (iv) Cracks of 3 mm and wider

After the primer has been applied, anionic stable-grade emulsion shall be mixed with synthetic modifiers, as specified in the project specifications, and applied by means of pneumatic spraying equipment or other approved equipment at the rate specified in the project specifications. Where the cracks are to be rolled, the contractor, in accordance with the provisions of the project specifications or the prescriptions of the engineer, shall treat the cracks as follows: The surface shall be heated in an approved manner along the full length of the crack and over a width of 250 mm on each side of the crack and then rolled with approved rollers until an even surface has been obtained. Depending on the instructions of the engineer, the cracks shall be treated with cold rubber slurry, hot bitumen rubber, or any other approved sealant. Where, in the opinion of the engineer, the cracks are too wide for this type of treatment, the contractor shall treat the cracks in accordance with the instructions of the engineer.
(1)

The aggregate for coarse slurry shall comply with the requirements for coarse grading in subclause 4302(b). The slurry shall be prepared and applied in accordance with the requirements in the project specifications. (iii) Requirements for evenness

When a completed screed surface is tested, it shall not deviate by more than 6 mm from the bottom edge of a 3 m straight-edge placed in any direction.

(e)

Repairing edge breaks in surfacing

This treatment shall be used for restoring the road edges to the true edge lines of the original road or to such other edge line as may be required. The existing surfacing shall be cut back and the pavement material shall be excavated as specified in clause 3905. Where the surfacing, after having been cut back, requires building up to bring it to the required width, the surface so

Rubber slurry

The rubber slurry mixture shall be proportioned as follows (by volume):

8,O parts of rubber crumbs 2,O parts of crusher dust 4,5 parts of 60% cationic stable grade bitumen emulsion 0,2 parts of ordinary portland cement 1,l part of SBR (net rubber). Water may be added to improve workability. The mixture shall be neatly worked into the cracks by rubber squeegees. Excess slurry shall be removed from the surface as soon as the emulslon has broken. (2) Bitumen rubber

Material removed beyond the specified limits shall be replaced by the contractor at his own cost and to the satisfaction of the engineer. After planlng has been completed, depressions over whlch the planlng machine has moved without touching the surface, and which fall outside the specified smoothness requirements, shall be filled In as specified, or, If so instructed by the engineer, a screed shall be placed as specified in subclause 4804(d). Payment will be made only for filling in depressions which existed In the original surface. Depressions formed as a result of the activities of the contractor shall be filled in at his own cost. Upon completion, the entire treated surface, or where depressions have not been filled in, then the planed surface, shall be tested for levelness, and, unless otherwise specified in the project specifications,the surface shall not deviate by more than 6 mm from the bottom edge of the 3 m straight-edge placed in any direction. (it) Fog spraying of planed surfaces

Bitumen rubber may be used only where the contractor Is able to convince the engineer that he Is able to mix, heat and apply the material satisfactorily. The bitumen rubber shall be mixed on the site or at another approved locality on condition that the contractor is able to propose efficacious methods for controlling both the mixing process and the end product. Approved heating equlpment and mechanical equipment for mixing and applying the mixture shall be used. The rubber content of the mix shall be at least 25% by mass of the total bitumen-rubber mix.
(3)

Other sealants

Other approved sealants shall comply with and be applied In accordance with the requirements of the project specifications. (v) Restrictions

After the planing operation has been compieted, the planed surface or, if so directed by the engineer, the entire levelled surface, shall be sprayed with a 30% spray-grade emulsion which has been further diluted if necessary in accordance with the instructions of the engineer and at a rate of application to be determined by the engineer. The surface shall then be rolled with approved pneumatic rollers until it has dried off sufficiently and, in the opinion of the engineer, can be opened to traffic.

Cracks may be sealed only where the temperature of the road surface exceeds 10C. Crack sealing may not be done wlthin 3 days after rain has fallen on the site, unless otherwise instructed by the engineer. The contractor shall note that a single application of crack sealant is usually insufficient and that the application will have to be repeated.

4805

OPENING TO TFWFFIC

The opening of the road to traffic shall be subject to the requirements of clause 431 1. The road shall be left open to traffic for such period as the engineer may direct before further surface treatment work is carried out.

(g)

Fk&e&ment planing Planing

of me road surfam by means of

4806 JOINTS AND THE PROTECTION OF KERBS
The requirements of subsubclauses 4307(b)(iv) and 4307(b)(v)regarding joints between sprayed strips, and the protection of kerbs, channels, barriers, wails, etc, shall be observed.

(i)

Planing shall be done with an approved planing or milling machine. The work involves the planing down of high spots or ridges In the existing asphalt surfacing in accordance with the specified level requirements. The full width of the road or sections of the road may be planed, depending on the instructions of the engineer.

4807 MEASUREMENT AND PAYMENT

Unit

The planed surface shall be even without any ridges or steps between the longitudinal cuts. Where planing is required over a portion of the road width, the edge of the planed section shall be vertical and straight. The planed surface shall be of such a nature that the road can be opened to traffic immediately if so required by the engineer.

48.01 Trealrnent with diluted b i m i n o u s emulsion (fog spray):

(a) (b) (c)

30% bitumen emulsion 40% bitumen emulsion 50% bitumen emulsion 60% bitumen emulsion

. . . . . . . . . . . . . litre ( I )

.............

litre ( I )

. . . . . . . . . . . . . litre ( I )

Material planed off shall be transported to stockpiles for recycling, or to spoil dumps, whichever is required.

(d)

. . . . . . . . . . . . . .litre ( I )

The unit of measurement for treatment with diluted bituminous emulsion (fog spray) shall be the litre of bituminous emulsion sprayed, measured at spraying temperature.

48.04 Screed of asphall or coarse slurry:

(a) Tack coat using 30% stablegrade bitumen emulsion . . . Continuously-graded asphalt (specify grade)

. . . . . . . . . .litre (I)
ton (1)

The tendered rates shall include full compensation for cleaning and preparing the existing surface, for furnishing the material and applying the fog spray and for all other incidentals necessary for completing the work as specified.

(b)

..............

(c)

Coarse grade slurry . . . . . . . . . cubic metre (m')

Item
48.02 Texturing:
(a) (b) Tack coat (specify binder) Application of slurry seal with double-washed aggregate . . . . . . . . . . .

Unit

...........

litre ( I )

The unit of measurement for the tack coat shail be the litre of emulsion applied. measured at spraying temperature. The unit of measurement for asphalt shall be the ton of asphalt placed according to the specifications. The unit of measurement for coarse grade slurry shail be the cubic metre of aggregate mix used in the slurry.

. . . . . cubic metre (m3)

The unit of measurement for binder application for the tack coat shall be the litre of net bitumen cold as specified in clause 4308. The unit of measl~rement for the slurry seal with double-washed aggregate shall be the cubic metre of aggregate applied, measured loose in the truck and corrected for bulking as described in item 46.05.

The tendered rate for tack coat shall include full compensation for procuring, furnishing and applying the tack coat and demarcating the areas to be sprayed, and for all incidentals necessary for completing the work as soecified. The tendered rate for asphalt shall compensation for procuring. furnishing and materials, for placing the asphalt and for all other incidentals necessary to complete specified. include full mixing all the transport and the work as

The tendered rates shall include full compensation for furnishing all materials, demarcating the areas to be sprayed, spraying the binder and applying the aggregate. rolling, sweeping and all other incidentals necessary for completing the work as specified.

The tendered rate for slurry shall include full compensation for all materials. equipment and labour for producing and applying the slurry, irrespective of the number of applications required to attain the required thickness.

Item

Unil Item
48.05 Repairing edge breaks in surfacing: Unit

(a)

Tack coat using 30% bitumen emulsion (specify type and rate of application) . . . . . . . . . . . . . . litre (1)

(a)

Tack coat (specify type and rate of application) . . . . . . . . . . . . . . . . litre ( I ) Reconstructing edges using medium continuously-graded asphalt . . . ton (1)

(b) (b) (c) Slurry applied by hand . . . . . . cubic metre (m7) Slurry applied by spreader box . . .

cubic metre (m')

The unit of measurement for the tack coat shall be the litre of specified emulsion applied as specified and measured at spraying temperature. The unit of measurement for reconstructing pavement edges shall be the ton of medium continuously-graded asphalt furnished and compacted as specified.

(d) (e)

Slurry applied by hand . . . . . . . . . . . .

ton (tl

Slurry applied by spreader box . . . . . . . . ton (1)

The unit of measurement for tack coat shall be the litre of emulsion measured at spraying temperature and applied as specified. The unit of measurement for slurry shall be the cubic metre of saturated fine aggregate used. measured as described in item 46.05. or the ton of saturated fine aggregate used. as specified.

The tendered rate for reconstructing pavement edges shall include full compensation for compacting the surface on which the new edge is to be constructed and procuring. furnishing and mixing all materials and placing. compacting and trimming the asphalt to the required lines and levels It shall also include full compensation for applying a tack coat of emulsion to the surface to be treated

The tendered rates shail include full compensation for procuring and furnishing all the materials, for mixing and applying the slurry, demarcating all areas to be treated and for all plant, labour and incidentals necessary to complete the work as specified.

The tendered rates shall include full compensation for all transport. handling. labour. material and all incidentals necessary to complete all the work. complete as specified.

Item

Unit

ltem 4.09 Rollingthecradts

Unit

4 8 . 0 6 Cleaning the cracks with

compressed air . . . . . . . . . . . . . . kilometre (km)

. . . . . . . . . . . . . . metre (m)

The unit of measurement shall b e a metre of crack rolled to the satisfaction of the engineer. The unit of measurement for cleaning the cracks with compressed air shall be a kilornetre of road along which all the cracks have been blown clean. The tendered rate shall include full compensation for rolling the cracks complete as specified.

The tendered rate shall include full compensation for providing all equipment. labour, supervision and incidentals for blowing clean the cracks over the full width of the road to the satisfaction of the engineer.

ltem

U n i t

48.10 Planing . . . . . . . . . . . . . . . . . square metre (m2)

The unit of measurement shall b e a net square metre of road surface planed in accordance with the specifications. ltem
48.07 Applying bituminous binders and herbicides for sealing cracks:

Unit The tendered rate shall include full compensation for planing, for obtaining the required surface regularity to a maximum depth of 25 m m . collecting. loading and removing the planed material over a free-haul distance of 1.0 km. for all plant movement over the site as instructed b y the engineer. and for providing planing and other equipment. labour. supervision and incidentals for completing the work in accordance with the specifications. including filling u p irregularities caused b y the contractor. Any planing of deeper than 25 m m will be classified as milling.

(a) (b) (c)

I ) Herbicide . . . . . . . . . . . . . . . . . . . . . . . litre (

MSPI1 or similar primer

. . . . . . . . . . . . litre ( I )

Anionic stable-grade emulsion mixed with synthetic modifiers . . . . . . . . . . . . litre ( I ) Hot bitumen rubber

(d) (e)

. . . . . . . . . . . . . . . litre (1)
ltem
4 . 1 1 Fog spraying o n planed surfaces:

Other specified agents (type indicated) . . . . . . . . . . . . . . . . . . . . . . . litre ( I )

Unit

The unit of measurement shall be a litre of material applied as specified or as instructed b y the engineer.

(a) (b)

Hand spraying . . . . . . . . . . . . . . . . . . . litre ( I ) Spraying with mechanical equipment

..

litre ( I )

The tendered rates shall include full compensation for providing, mixing, heating (where required) and applying all the materials as specified. and for all equipment. labour. supervision and incidentals for completing the work. No additional payment will be made for multiple applications of material, and payment will not distinguish between the various types, widths or lengths of cracks.

The unit of measurement shall be a litre of 30% spraygrade emulsion sprayed on planed surfaces on the instruction of the engineer. The tendered rate shall include full compensation for fog spraying on planed surfaces complete as specified.

ltem Item Unit

unit

48.08 Cold rubber-slurry mix for sealing cracks . . . . . . . . . . . . . cubic metre (m')

4 . 1 2 Rolling planed surfaces . . . . . . square metre of roller passes (m2-pass) The unit of measurement shall be a square metre of rollerpass with an approved pneumatic roller on planed surfaces as may be directed b y the engineer.

The unit of measurement for crack treatment with rubber slurry shall be a cubic metre of fine rubber crumbs csed for preparing the mix.

The tendered rate shall include full compensation for the rolling of planed surfaces complete as specified. The tendered rate shall include full compensation for procuring and providing all the material. including emulsion, synthetic modifiers. cement and water. and for mixing and applying the mixture. and for all equipment. labour, supervision, and incidentals for executing the work in accordance with the specifications.

Item

Unit

48.13 Filling depressions in planed surfaces (asphatt) . . . . . . . . . . . . . . . . . . ton (t) The unit of measurement shall b e a ton of asphalt of the specified composition placed in depressions in planed surfaces. measured in accordance with certified weighbridge tickets.

Payment will not b e made for redundant rubber pellets or redundant mixture or for mixture which. in the opinion of the engineer, has been wasted.

The tendered rate shall include full compensation for the filling of depressions in planed surfaces complete as specified. No extra payment will be made for small quantities of

asphalt.

Where a screed is placed, payment will be made under item 48.04.

SERIES 4000 :ASPHALT PAVEMENTS AND SEALS SECTION 4900 : SAND SEALS
(a) Equipment The following equlpment shall be readily available on the slte: (i) ( 1 1 ) (ill) 4901 Pneumatlc-tyred rollers A rotary broom A drag broom

CONTENTS
4901 4902 4903 4904 4905 SCOPE GRADE OF BINDER TO BE USED SAND CONSTRUCTION MEASUREMENT AND PAYMENT

SCOPE

(iv)

Mechanical aggregate spreaders.

Reparation of surface before appllcalion of seal

This section covers the supply and application of all materials used for constructing sand seals on new pavings. Note: Section 4300 : Seals : Materials and general requirements shall apply to this section.

@)

The surface of the base shall be rolled and swept until a fine texture Is obtained. The base shall then be primed in accordance wlth the provlslons of section 4100 and as instructed by the englneer. The road shall be cleaned of all loose or deleterious materlal before the sand seal is applied.

4 ! J O 2

GRADES OF BINDER TO BE USED

(c) Application of sand seal

The grades of binder specifled in the project specifications or in the schedule of quantities or ordered by the engineer shall be used: Amongst others the following binders may be used: MC-800 cut-back bitumen MC3000 cut-back bitumen Spray-grade emulsion (65% or 70% of net bitumen) 1501200 penetration-grade (84 road grade) bitumen.
4903

The tack coat shall be applied at 1,O f l m 2 net bitumen cold, and, immediately after the coat has been spread, the aggregate shall be distributed thereon at a rate of 0,007 m'/m2 and rolled wlth pneumatic-tyred rollers. Where emulsions are used, the aggregate shall be applied only after the emulsions have broken partially. During the rolling process, any uneven appiication of sand shall be rectified with a light broom drag or other suitable apparatus. Where an emulsion is required to be applied in two applications, the surface can be opened to controlled traffic after the first application of emulsion and sand, as soon as it is convenient to do so. The second application of emulsion and sand may be applied when the first application has cured sufficiently for it to take the traffic without requiring brooming back of the sand. All loose sand and deleterious material shall be removed from the surface and any damaged or defective areas rectified before the second application of binder and sand. While the traffic Is using the road, the sand shall be continuously broomed back onto the road until the binder has cured sufficiently to retain the sand and until traffic does not damage the surface. The sweeping-back process shall be done with a rotary broom or manually and may take as long as two months before the surface finally settles down. Tenders shall be based on brooming back for up to five times. As wet sand is difficult to apply, the preparation of the sand should be done well ahead of the actual construction to allow the sand to be fairly dry when it is applied. If the sand is not cleaned to the engineer's satisfaction by one screening and washing operation, it shall be washed again at no extra payment. Where required by the engineer, the sand shall be precoated with an approved precoating agent, applied at a rate of 7 I l m ' . No precoating will be allowed where

SAND

The grading of the sand may vary to a fair degree, but the conditions of table 490311 shall be met: (a) Grading Table 490311 Sieve size Percentage by mass passing through sieve

0,300 0,150

0 - 15 0-2

The sand shall be screened to ensure the removal of all material exceeding 6,7 mm. Water shall be used to assist the screening process and to clean the sand of dust and foreign matter.

@)

Sand equivalent

The sand equivalent shall be at least 35.

emulsions are used as binders.

(b)

Brooming the sand back onto the paved surface: Mechanically Manually

4905

MEASUREMENT AND PAYMENT

(i) (ii)

.. .. . . . .. ...

square metre (mZ) square metre (m2)

. .... . . . .... ...

49.01 Application of tack coat:

(a) (b) (c)

MC-800 cut-back bitumen MC-3000 cut-back bitumen Spray-grade emulsion (65% net bitumen) . . . Spray-grade emulsion (70% net bitumen) . .

. . . . . . . . . . . . litre . . . . . . . . . . . litre

(1) (L)

The unit of measurement for the application of sand shall be the cubic metre of sand applied to the road as specified, measured in the trucks or in the stockpiles. The unit of measurement for brooming back the sand shall be the square metre of authorized paved surface onto which the sand is broomed back.

. . . . . . . . . . . . . . . litre

(1)

(d)

(e)

1501200 penetrationgrade (84 road grade) bitumen

. . . . . . . . litre ......

(1)

The tendered rate for applying the sand shall include full compensation for supplying the sand, washing, screening and preparing the sand and applying the sand as specified. The tendered rate for brooming the sand back onto the surface shall include full compensation for brooming the sand back onto the paved surface as often as is required. subject to a maximum of 5 times.

(1)

Other (specify type of binder) . .

litre (1)

Hem
The unit of measurement shall be the litre, measured at spraying temperature. The tendered rates shall include full compensation for procuring and furnishing the material and applying the binder, including all preparatory work to the surface prior to application of the binder.
49.03 Recoating the sand with (indicate precoating fluid)

Vnit

....

cubic metre (m')

The unit of measurement shall be the cubic metre of sand precoated as specified, measured in hauling vehicles or in stockpile.

49.02 Sand:

(a)

Applying the sand

.........

cubic metre (m')

The tendered rate shall include full compensation for furnishing the equipment and materials and precoating the sand. complete as specified. including the handling, stockpiling and protecting of the stockpiles against inclement weather.

SERIES 5000 : ANCllLARY ROADWORKS SECTION 5100 : PITCHING, STONEWORK PROTECTK)N AWNST EROSION

AND

(i)

Sand for concrete

Sand for concrete, cement slurry and cement mortar shall comply with the requirements of SABS 1083. (ii) SCOPE MATERIALS STONE PITCHING RiPRAP STONE MASONRY WALLS SEGMENTAL BLOCK PAVING CAST IN SlTU CONCRETE PITCHING MEASUREMENT AND PAYMENT Sand for bedding

Sand for bedding used for paving blocks shall not contain any deleterious impurities and shall comply with the following grading requirements: Sieve size (mm)
% passing through

5101 SCOPE

This section covers the furnishing of materials and the construction of a protective covering in stone pitching, cast in situ concrete pitching, bricks or prefabricated concrete blocks on exposed surfaces such as earth slopes, drains and stream beds, as well as heavier protective layers in the form of riprap and the construction of stone masonry for walls, all as shown on the drawings or ordered b y the engineer.

(iii)

Sand for joints

Sand used for being brushed into the joints between pavement blocks shall ail pass through a 1,18m m sieve, 5 per cent of it shall pass through an and between 10 and 1 0,075m m sieve.

5102 MATERIALS
(d)
(a)

Paving blocks

Stone

(i) Stone for pitching shall be sound, tough and durable, without any stones less than 200 m m in minimum dimension, except that smaller pieces or spalls may be used for filling spaces between the larger stones. The shapes of the rocks or stones shall be so as to form a stable protective layer of the required thickness. Rounded : l boulders shall not be used on slopes steeper than 2 unless grouted.

Paving blocks shall comply with the requirements of SABS 1058 for class 25 paving blocks where paving blocks are made from concrete, and bricks used as paving blocks shali be facebrick units which shall comply with the requirements of SABS 227. Engineering units may also be used instead of facebrick units.

The surface texture and colour of all units shall be uniform. Paving blocks for sidewalks shall be square prefabricated concrete blocks, 450 m m x 450 m m x 50 m m in size and fabricated from class 30 concrete. As to appearance, the blocks shall comply with the requirements of clause 3.3of SABS 927. The upper surface shall have an approved pattern to provide proper skid resistance.

All stone intended for use on a particular pitching job shall be subject to the prior approval of the engineer.
Stone for riprap shall be hard field or quarry stone (ii) not susceptible to disintegration or excessive weathering on exposure to the atmosphere or water. It shall be free from soft material such as sand, clay, shale or organic material and shall not contain an excessive quantity elongated stones. The required size of the stone will depend on the "critical mass" specified. At least 50% by mass of the material comprising the riprap shall consist of stones with a mass heavier than the critical mass, and not more than 10% by mass of the material shall consist of stones with a mass of less than 10% of the critical mass or more than 5 times the critical mass.

Concrete grass blocks shall consist of concrete slabs of the dimensions shown on the drawings, with openings through the slab totalling at least 20% of the surface area.

(e)

C o n -

Concrete work shall be carried out in accordance with the provisions of sections 6200,6300 and 6400.

(f)

Wire

@)

Cement Wire for pitching kept in position by wires shall consist of 4,Om m diameter gaivanised wire which complies with the requirements of SABS 675.

Cement shall be ordinary Portland cement which complies with the requirements of SABS 471.

@)

Permeable material for filter layer

@)

Grouted stone pitching

Permeable material for filter layers shall comply with the requirements specified for permeable material for subsoil drains in subsubclause 2104(a)(ii).

(h)

Syntheticfibre filter fabric

Synthetic-fibre filter fabric shall be of the grade and type specified in the schedule of quantities or project specifications, and shall comply with the requirements of subsubclause 2104(a)(iii).

5103

STONE PITCHING

The work shall be done in accordance with all the requirements specified for plain pitching in subclause 5103(a) above, except that the stones shall be thoroughly cleaned of adhering dirt or clay, moistened and embedded in freshly laid cement mortar composed of one part of cement to every six parts of sand. Any spaces between the stones shall be filled with cement grout of the same composition as the mortar. The mortar and grout shall be placed in a continuous operation for any day's run at any one location. The grout shall be worked into the pitching so as to ensure that all spaces or voids between the stones will be completely filled with grout to the full depth of the stone pitching. Grout spilt onto exposed surfaces of the stones shall be removed while still soft, and the joints between stones shall be neatly finished. The grouted pitching shall be cured with wet sacking or other approved wet cover for a period of not less than four days after grouting, and shall not be subjected to loading until adequate strength has been developed. Where required, weep holes shall be formed in the pitching.

(a)

Plain stone pitching

The area shall be prepared by the excavating, shaping and trimming necessary for pitching, and by thoroughly compacting the area by hand-ramming to prevent subsequent settlement. A trench shall be excavated as directed by the engineer along the toe of any slopes to be pitched or along the unprotected edge of the pitching in the beds of streams. Two pitching methods follow, and the method to be adopted shall be decided on by the engineer.

(c)

Grouted stone pitching on a concrete bed

Method 1
Commencing at the bottom of the trench, the stone shall be laid and firmly bedded into the slope and against adjoining stones. The stones shall be laid with their longitudinal axes at right angles to the slope and with staggered joints. The stones shall be well rammed into the bank or surface to be protected and the spaces between the larger stones shall be filled with spalls of approved pitching stone securely rammed into place.

The area to be pitched shall be prepared as described in subclause 5103(a) and a concrete bed (class 15 concrete) with a thickness of at least 75 m m shall then be placed. The stone pitching shall be of stones with a minimum dimension of 200 mm, which shall be laid while the concrete is still fresh. Openings between stones shall be filled with cement grout as described in subclause 5103(b), and care shall be taken not to spill the grout onto the finally exposed surfaces of the stones. Grout spilt onto the exposed surfaces of the stones shall be removed while still soft, and the joints between stones shall be neatly finished. Curing shall be done as described for grouted stone pitching in subclause 5103(b). The completed pitching shall have an even compacted appearance, and nowhere may the surface deviate by more than 25 m m from the specified lines and grades.

Placing of rock by dumping shall not be allowed.

Method 2
The technique and requirements laid down in method 1 shall also apply to method 2, except in the following aspects: No small stones or spalls shall be used to fill in (i) spaces between larger stones. Simultaneously with the placing of stones, topsoil (ii) shall be introduced between individual stones, and sufficiently rammed so as to provide a firm bonded structure. The topsoil shall be provided to the full depth of the stone pitching at any point. Rooted grass or tufts of grass shall then be planted (iii) in the topsoil between stones, and watered immediately and copiously and thereafter at regular intervals until grass has been established. Whichever of the above two methods is adopted, the finished surface of the pitching shall present an even, tight and neat appearance with no stones varying by more than 25 m m from the specified surface grades or lines. The thickness of the pitching, measured at right angles to the surface, shall not be less than 200 mm.

(a)

General

Riprap shall consist of a course or courses of large rock placed on bank slopes and toes in stream and river beds and at other localities where protection of this type may be required. Two types of riprap are specified here, viz one type where the rocks are individually packed, which is designated as packed riprap, and the other type where the rock is dumped and then spread by machines, which is designated as dumped riprap. The surface of areas to receive riprap shall be neatly trimmed to line and level and all loose material compacted. The perimeters of riprap areas shall be protected by the construction of either rock-filled trenches, walls or other structures as may be required. Perimeter trenches shall normally be backfilled with rock of the same size and quality as that used in the construction of the adjoining

riprap, but any voids shall be filled with smaller stone and the entire backfill shall be well compacted.

@)

Filter bed

The filter bed shall cor~sist of a layer or layers of permeable material placed on the prepared surface to the required thickness and each layer shall be finished to an even surface and thickness. Compaction of pervious material will not be required. Care shall be taken not to mix various grades of filter material neither to disturb material already placed when subsequent layers or riprap are being placed. When the use of synthetic-fibre filter fabric is required, the material shall be placed on the prepared surface or on the filter bed, depending on the instructions. The overlap between adjacent sheets shall be 150 m m unless otherwise specified. Care shall be taken not to damage the filter fabric when subsequent layers are being placed, neither to expose the filter fabric to the sun for periods exceeding three days before it is covered up.

stratified stones shall be laid with the largest dimension in the horizontal plane. Stones shall be packed individually to stagger the joints and to provide a minimum of voids, and shall be firmly bedded against adjoining stones. The spaces between the larger stones shall be filled with spalls securely rammed into place. The larger stones shall not bear on the spalls used for filling the voids. The top and ends of the wall shall be neatly finished with selected coping stones. The appearance of the completed wall shall present an even, tight surface.

(c)

Cement-mortared stone walls

The walling shall be constructed as specified in (b) above, with the exception that the stones shall be wetted and set in a 6:l sand:cement mortar. The exposed parts of the stones on the wall faces shall be cleaned of all mortar by washing or wire-brushing. The mortar shall be flush pointed to the satisfaction of the engineer, who may require a capping and end treatment of the same mortar. Weep holes shall be provided as prescribed and shall be cleaned of mortar or any other clogging material that may have entered during construction. The walling shall be protected from the elements and kept moist for a minimum period of four days after completion.

(c)

Packed riprap

Packed riprap shall be constructed from rocks placed individually to stagger the joints and so as to be firmly bedded in the prepared surface. The spaces between larger stones shall be filled with spalls or smaller stones securely rammed into place. On inclined surfaces the rock shall be laid in long horizontal strips starting from the bottom, and not in strips up the slope. The completed riprap shall present a tight and even surface. Local surface irregularities of the riprap shall not exceed 150 mm.

5106

SEGMENTAL BLOCK PAVING

(a)

General

Dumped riprap shall be constructed by dumping the stone on the prepared surface, spreading it by bulldozer, or other suitable earth-moving equipment, and trimming it to the required lines and levels. The material shall be placed in a manner that will prevent the segregation of the smaller and larger stones and the top layer shall be tight with a minimum of voids.

The underlying layers for surfaces to be pitched shall be constructed as specified or as indicated on the drawings. Where no specified requirements have been set in respect of the underlying layers, the top layer shall be mechanically compacted to at least 90% of modified AASHTO density down to at least 150 m m from the top. During this process the top layer shall be trimmed to the required grades and levels. Where specified or required by the engineer the prepared surface shall be treated with approved environmentally friendly herbicide and ant poison before the layer of sand for bedding is placed.

5105

STONE MASONRY WALLS

@)

Sand for bedding

(a)

General Where required a layer of sand for bedding shall be placed on top of the prepared surface, and, when still loose! accurately floated to an uncompacted thickness of 30 m m (r 5 mm) so as to afford the correct level to the pavement after compaction. Sand for bedding shall be placed immediately before the paving blocks are laid and shall not be compacted before the blocks have been laid.

Stone masonry walls may be plain packed stone walls with dry joints or otherwise mortared stone walls with stones bedded in cement mortar as indicated on the drawings, as specified, or as may be ordered. The minimum mass of each stone used shall be 10 kg and its minimum dimension 75 mm.

(c)

laying the paving blocks

@)

Plain packed stone walls The pattern for laying the paving blocks shall be that as shown on the drawings or approved or prescribed earlier on by the engineer. Unbroken blocks shall first be laid and filler pieces afterwards. Filler pieces shall be neatly sawn or hewn to fit exactly into the space to be filled. Spaces of

Afoundation trench shall be excavated down to rock, or to material with an adequate bearing capacity at a minimum depth of 300 m m below ground level. Large selected stones shall be used for the foundation layer. Flat and

less than 25% of a full-sized block may be filled with 25 MPa concrete. The joints between blocks shall be sized between 2 and 6 mm, and the top faces of blocks shall be flush. After the paving blocks have been laid, and where required, the pavement shall be compacted by two passes of a suitable vibrating-plate compactor operating at a frequency of 65 Hz to 100 Hz and a low amplitude. Its plate surface shall be 0,2 m2 to 0,4 m2 and shall develop a centrifugal force of 7 kN to 16 kN.

The areas where cast in situ concrete pitching is to be constructed shall be compacted, trimmed and prepared as described in clause 5106 for block paving. The areas shall also be treated with vegetation destroyer and ant poison if required. The concrete shall comply with the requirements of series 6000. Prior to placing the concrete, the surface shall be watered and kept damp until the concrete has been placed. Unless otherwise specified, 20 MPa concrete shall be used, and the concrete shall be accurately laid in alternate panels to the lines and levels indicated, after which the remaining panels shall be similarly placed. Accurately set-up guides shall be used to achieve the required line and slope. The concrete shall be thoroughly compacted and finished to a class U2 surface finish. Where indicated, the concrete pitching shall be contained by concrete edge beams being constructed as described in clause 5106(d). The concrete pitching shall be cured for at least seven days and no traffic shall be allowed to move across the pitching before the specified 28-day strength has been reached. The final surface may nowhere deviate by more than 25 m m from the specified levels and planes, and no irregularities exceeding 10 m m may occur during testing with a 3 m straight-edge.

After compaction of the pavement as described above, joint sand shall be spread and brushed into the joints until the joints have been properly filled. Any surplus sand shall then be broomed off and where required the pavement shall then be subjected to two further passes by the plate vibrator.

(d)

Edge beams

Concrete edge beams or any such other edge supports shall be constructed onto the supporting layer in accordance with the details shown on the drawings, and shall be constructed and left to cure before any paving blocks are laid.

(e)

Paving blocks for sidewalks

Paving blocks for sidewalks shall be laid as specified in subclauses 5106(a), (b), (c) and (d), but where so specified, joints shall be filled with a 6 : l sand:cement mortar in stead of with sand only. In this case the width of the joints between the stones shall be strictly in accordance with the dimensions shown on the drawings, and the pavement shall be fully compacted before the joints are filled.

5108

MEASUREMENT AND PAYMENT

51.O1

Stone pitching: Plain pitching: Method 1 Method 2

(f)

Concrete grass blocks (a)

Concrete grass blocks of the size specified or shown on the drawings shall be placed on areas prepared for grassing as specified in section 5800. The holes in the blocks shall be filled with topsoil, and grassed with grass cuttings or hydroseeding as specified in section 5800.

(i) (ii) (b) (c)

. . . . . . . . . . . . . . . square metre (m2)

. . . . . . . . . .. . . . . . . ... ....

square metre (mZ) square metre (m2)

Grouted stone pitching

@)

Finishing requirements

Grouted stone pitching on a concrete bed (total thickness indicated) . . .

square metre (m2)

(i)

Segmental block paving The unit of measurement for pitching shall be the square metre of each type of pitching in place.

The completed paving shall be even and neat, flush with the kerb or edge beam and may not lie below the side of the kerbing. The final surface may nowhere deviate by more than 15 m m from the specified levels and planes, and no irregularities exceeding 10 m m may occur during testing with a 3 m straight-edge.

(ii)

Grass-block pavement

The completed grass-block pavement shall have a neat and even appearance. The final surface of the pavement may nowhere deviate by more than 15 rnrn from the specified levels and planes.

The tendered rate for each type of stone pitching shall include full compensation for furnishing all materials, making all excavations excluding trench and bulk excavations, compacting and trimming the excavated surfaces, forming and cleaning the weepholes, placing stones and grouting, or wiring and grouting where applicable, grassing and watering (applicable to method 2) and for all other work necessary for completing the pitching as specified. The tendered rate for grouted stone pitching on a concrete bed shall also include full compensation for the concrete bed.

Excavations for foundation trenches and concrete edge beams and the construction of the concrete edge beams will be paid for separately.

51.04 Concrete pitching and

Mock paving:
ltem Unit (a) Cast in situ concrete pitching (class of concrete and thickness of pitching indicated) . . . . . . . . . . . . . . square metre (m2) Segmental block paving (type and thickness indicated) . . . . . . . . . . . . . . . square metre (m2) Prefabricated concrete grass blocks . . . . . . . . . . . . square metre (m2) Prefabricated concrete paving blocks for sidewalk pavement (thickness indicated) . . . . . . . . . . . . . . . square metre (m2)

(a)

Packed riprap (critical mass of stone indicated) Dumped riprap (critical mass of stone indicated) Rlter layer (subclauses 2104(a)(ii) and 5104(b) consisting of: Crushed stone

..... .....

cubic metre (m3)

@)

(b)

cubic metre (m3) (c)

(c)

(d) cubic metre (m3)

(i) (ii)

............

Filter sand obtained from borrow pits .

. . . . . . . . . cubic metre (m')

The unit of measurement shall be the square metre of each type constructed. The tendered rates shall Include full compensation for furnishing all materials, all excavation (but excluding bulk excavation and excavation for foundation trenches and edge beams), compacting and trimming all the excavated areas, treating the prepared surface with an approved herbicide and ant-poison, providing a sand bedding (subitems (b) and (d)) laying and compacting the paving blocks (subitems (b) and (d)), laying concrete grass blocks (subitem (c)), topsoiling and grassing, (subitem (c)), constructing concrete pitching, including normal formwork and the shaping of surfaces (subitem (a)), making and cleaning weepholes (subitem (a)) and for all other work necessary for completing the work as specified.

(d)

Synthetic-fibre filter fabric (type, class and grade stated) . . . . . . . . . . . . . . . . . square metre (m2)

The unit of measurement for riprap and filter layer (subitems (a), (b) and (c) above) shall be the cubic metre of riprap or filter layer in place and shall include rock used in trench backfill. The unit of measurement for subitem (d) shall be the square metre of filter fabric laid as specified, including overlaps. The rates tendered for subitems (a), (b) and (c) shall include full compensation for preparing the surfaces, including excavation (but excluding excavation for trenches and bulk excavations) and for the furnishing, transporting, handling and placing of riprap or filter layers. The rate tendered for subitem (d) shall include full compensation for procuring and furnishing the filter fabric and for laying It as specified, including wastage. Collectively the rates shall also include full compensation for all other incidentals necessary for completing the work as specified.

Item

5 1 . 0 5 Concrete edge beams (class

of concrete indicated)

.......

cubic metre (ma)

The unit of measurement shall be the cubic metre of concrete in edge beams constructed as instructed. Item Unil The tendered rate shall include full compensation for furnishing all materials and labour, including formwork as necessary, placing concrete and shaping all surfaces and all excavations required (in all classes of material).

51.03 Stone masonry walls:

(a) Plain packed stone walls . . . . . . . . . . . . . . . . . . . . cubic metre (m3) Cement-mortared stone walls . . . . . . . . . . . . . . . . . . . cubic metre (m3)

(b)

Item

Unit

51.06 Provision of approved herbicide and ant poison:

The unit of measurement for stone masonry walls shall be the cubic metre of actual walling constructed and accepted.

(a) (b)

Provision of materials

........

Prime cost sum

The tendered rate for each type of stone wall shall include full compensation for furnishing all materials, trimming the areas, placing the stones and cement-mortared masonry where necessary, and all other work necessary for completing the walls in accordance with the specifications. Excavation of foundation trenches will be paid for separately.

Contractor's charges and profit added to the prime cost sum . . . . . . . . . . . . . . . . . . . . .per cent (%)

Payment under the prime cost sum for providing ant poison and herbicide and the contractor's costs and profit in this respect shall be made in accordance with the provisions of the general conditions of contract, but, in addition, the contractor's tendered rate for costs and profit

shall include 4 as specified.

compensation for applying the chemicals

material excavated for foundation trenches irrespective of the class or depth of material. The quantity shall be calculated according to the dimensions shown on the drawings or instructed by the engineer. The tendered rate shall include full compensation for the excavation of the foundation trenches, irrespective of the class or depth of material, complete as specified or as shown on the drawings or as instructed by. the engineer.

kern
51.07 Foundation trenches

Unit

. ... . . ..

cubic metre (m')

The unit of measurement shall be the cubic metre of

SERIES 5000 : ANCILIARY ROADWORKS SECTION 5200 : GABIONS

(d)

Galvanizing

All wire used in the making of gabions shall be galvanized in accordance with the provisions of SABS 675 for class A heavy galvanized mild-steel wire.

CONTENTS
5201 5202 5203 5204 5205 SCOPE MATERIALS CONSTRUCTING GABION CAGES CONSTRUCTING GABIONS MEASUREMENT AND PAYMENT
(e)

Wire mesh

Wire mesh shall comply with the requirements of SABS 1580.

(9
5201

Filter fabric below the gabions

SCOPE
Filter fabric shall comply with the requirements of subsubclause 2104(a)(iii) for grade 3 filter fabric.

This section covers the construction of gabion walls and aprons for constructing retaining walls, lining channels, revetments and other anti-erosion structures. Generally gablons shall be flexible galvanized steel-wiremesh cages packed with rock.

5203

CONSTRUCTING GABION CAGES

(a)

General

Gabion cages shall be made from wire mesh of the size and type and selvedge as specified below. The cages shall be subdivided into cells by wire mesh dlaphragms and will be of two types: Boxes which are generally used for the construction (i) of gabion walls. These boxes are subdivided into cells by diaphragms spaced at 1,O m intervals. No diaphragms are required for a box of which the length does not exceed 150 m. Mattresses which are generally used as single-layer (ii) aprons only in revetments, channel linings, etc, and in which the maximum width shall be 2,O m , and the maximum depth 0,5 m. Mattresses shall be subdivided by diaphragms Into cells with a width of 600 m m or 1,O m as specified In the schedule of quantities. The standard sizes of boxes and mattresses are as follows: Boxes Length: 150 200 250 250 Width: Depth: 1, 2, 3 and 4 m 1m 0,3 m, 0,5 m and 1,O m

Rock used as filling for cages shall be clean, hard unweathered boulders or rock fragments. No rock fragment shall exceed the maximum size given in table 520211, and at least 85% of the rocks shall be of a size equal to or above the average least dimension given in table 520211:

Table 520211 Rock size according to the largest dimension of rock Average least dimension (mm) 125 125 125 125 Maximum (mm)

Depth of cage (m)

02 03 0,s 1,o

Diaphragm spacing: 1,O m.

@)

Wire

Mattresses Length: Width: Depth: 6m 2m 0,2 rn, 0,3 rn and 0,5 m.

All wire used for making the gabions and for tying during the construction of the gabions shall comply with the requirements of SABS 675 for mild-steel wire.

(c)

PVCcoated wire
Diaphragm spacing: 600 m m or 1,O m as specified.

The gabions of PVC-coated mesh and binding wire shall be of an acknowledged make which shall be subject to approval by the engineer.

Other gabions may be supplied, provided that the engineer's prior permission has been obtained.

@)

Selvedges

at the joints, and shall be properly fastened to prevent any movement or slipping while the gabions are being placed. (c) Assembly

The cut edges of all mesh used in the construction of gabions, except the bottom edges of diaphragms and end panels, shall be selvedged with wire with a diameter as specified in SABS 1580. Where the selvedge is not woven integrally with the mesh but has to be tied to the cut ends of the mesh, it shall be attached by tying the cut ends of the mesh to the selvedge, so that a force of not less than 8,5 kN applied in the same plane as the mesh at a point on the selvedge of a mesh sample of 1 m in length will be required to separate it from the mesh.

The methods of constructing, stretching, placing in position, wiring and filling the gabions with rock shall generally be in accordance with the manufacturer's instructions subject to the approval of the engineer, but nevertheless sufficient connecting wires shall be tensioned between the vertical sides of all the outer visible cells to prevent the deformation of boxes as they are being filled with stone. It is essential that the corners of gabion cages be securely wired together to provide a uniform surface and ensure that the structure does not resemble a series of blocks or panels. The layout and the tolerances for the layout of the boxes shall be as shown on the drawings or as instructed by the engineer.

(c)

Diaphragms and end-panels

The diaphragms and end-panels shall be selvedged on the top and vertical sides only. The end-panels shall be attached by the cut ends of the mesh wires at the bottom of the panel being twisted around the selvedge on the base of the gabion. Similarly, the diaphragms shall be attached by the cut ends of the mesh being twisted to the twisted joints of the mesh in the base of the gabion. In each case the force required to separate the panels from the base shall be not less than 6 kN/m.

(d)

Rock tilling Boxes in retaining walls

(i)

(d)

Binding and connectinge r w i

Sufficient binding and connecting wire for all the tying to be done during construction of the gabions as specified in clause 5204 below, shall be supplied with the gabion cages. The diameter of the wire shall be 2,2 mm.

Particular care shall be taken in packing the visible faces of gabion boxes, where only selected stone of the specified size shall be used so as to obtain an even-faced finish. The boxes shall be filled in layers to prevent deformation and bulging. Boxes shall be filled to just below the level of the wire braces, after which the braces shall be twisted to provide tension. Care must be taken to ensure that consecutive layers of cages are filled evenly to a level surface ready to receive the next course. (ii) Mattresses used in revetments and aprons

(e)

Tolerances The 0,2 m, 0,3 m and 0,5 m gabions forming aprons and revetments shall be filled by random stones being packed in the first layer and by selected stones being used for the top layer so as to resemble normal stone pitching.

The tolerance on the specified diameter of all wire shall be + 2,5%. The length of the cages shall be subject to a tolerance of lo%, the width of the cages shall be subject to a tolerance of 5% and the depth of the cages shall be subject to a tolerance of 5%.

5205

MEASUREMENT AND PAYMENT

5204

CONSTRUCTING GABIONS Unit

(a)

Preparing the foundation and surface

52.01 Foundation trench excavation and ba*lling:

The surface on which the gabion cages are to be laid prior to their being filled with rock shall be levelled to the depth shown on the drawings or as directed by the engineer so as to present an even surface. If necessary, cavities between rock protrusions shall be filled with material similar to that specified in subclause 5202(a). Where required, a foundation trench along the toe of the revetment or wall shall be excavated to the dimensions shown on the drawings or indicated by the engineer.

(a)

In solid rock (material which requires blasting) In all other classes of material . . . . .

. . . . . cubic metre (m3)

(b)

. . . . . . . . . . cubic metre (m')

The unit of measurement shall be the cubic metre of each class of excavation made in accordance with the authorized dimensions. The tendered rates shall include full compensation for excavating in each class of material, including unavoidable overbreak, the trimming of trenches and compacting the trench inverts! backfilling and compacting the backfill: and the disposing of surplus excavated material, including a free-haul of 1,O km.

@)

Filter fabric

One layer of grade 3 filter fabric shall be placed where indicated on the drawings or ordered by the engineer. The material shall be placed, in accordance with the instructions, in strips with a minimum overlap of 300 m m

Item
52.02 Surface preparation

Unit

(d)

for bedding the gabions

....

square metre (mZ)

PVC-coated gabion mattresses (dimensions of mattress, mesh size, nominal diameter of mesh wire and diaphragm spacing indicated) . . . . . . . . . . . . . . . . cubic metre (m3)

The unit of measurement for levelling and preparing surfaces for receiving the gabions shall be the square metre to the neat dimensions of revetments, aprons or wall foundations. The tendered rate shall include full compensation for excavating, filling any cavities with rock, and levelling the ground surface so as to be ready for receiving the gabion cages for retaining walls, aprons and revetments.

The unit of measurement shall be the cubic metre of the rock-filled cages and the quantity shall be calculated from the dimensions of the gabions indicated on the drawings or prescribed b y the engineer, irrespective of any deformation or bulging of the completed gabions.

Item
52.03 Gabions:

Unit

The tendered rates shall include full compensation for supplying all the materials, including rock fill, wire-mesh cages, galvanizing, PVC-coating, tying and connecting wires, loading, transporting and off-loading, the assembling and filling of the cages, and any other work necessary for constructing the gabions.

(a)

Galvanized gabion boxes (dimensions of box, nominal diameter of mesh wire and mesh size indicated) . . . . . . . . . . . . . cubic metre (m3) PVC-coated gabion boxes (dimensions of box, nominal diameter of mesh wire and mesh size indicated) . . . . . . . . . . . . . cubic metre (m3) Galvanized gabion mattresses (dimensions of mattress, mesh size, nominal diameter of mesh wire and diaphragm spacing indicated) . . . . . . . . . . . . . . . . cubic metre (m3)
52.04 Filter fabric (type and grade indicated)

(b)

......

square metre (m2)

The unit of measurement shall be the square metre of area covered with filter fabric placed in position.

(c)

The tendered rate shall include full compensation for supplying the filter fabric, cutting, waste, placing, joining, overlapping, and securing the material in position.

SERIES 5000 : ANClllARY ROADWORKS SECTION 5300 : GUIDE BLOCKS

The recess near the top of the block shall be painted with the reflective paint specified, while the remainder of the top half of the block shall be painted with white road-marking paint.

CONTENTS
5304

SPACING THE GUIDE BLOCKS

5301 5302 5303 5304 5305 5306

SCOPE MATERIALS FABRICATING SPACING THE GUIDE BLOCKS ERECTING MEASUREMENT AND PAYMENT

The guide blocks shall be spaced as shown on the drawings or as directed by the engineer,

5305 ERECTING
5301

SCOPE
Guide blocks shall be erected after the seal has been completed.

This section covers the supply and erection of guide blocks in positions and in accordance with the dimensions shown on the drawings or as directed by the engineer.

Holes shall be excavated in the shoulder and the blocks placed vertically and square to the road centre line. Backfilling shall be compacted in thin layers right from the bottom of the hole. Surplus excavated material shall be disposed of as directed. The blocks shall be painted immediately after having been placed. Guide blocks shall be maintained and protected during the entire construction period and any guide blocks damaged or broken before the seal has been completed, the road markings have been painted or the certificate of completion has been issued, shall be repaired or replaced, as may be required, at the contractor's cost.

5302

MATERIALS

(a)

Concrete

Concrete work shall be carried out in accordance with the provisions of sections 6200, 6300 and 6400.

@)

Paint

Paint for guide blocks shall be non-reflectorised roadmarking paint as specified in section 5700. Paint for the recess in the block shall be Codit or a similar approved retro-reflective paint.

5306

MEASUREMENT AND PAYMENT

5303

FABRICATING

Item
53.01 Guide blocks. .

Unit

. . . . . . . . . . . . . . . number (No)

Guide blocks shall be fabricated to the dimensions shown on the drawings. A mixture of four parts of concrete sand to one part of Portland cement shall be used. The forms shall be smooth and shall have accurate dimensions. The mixture shall be placed in the forms and vibrated on a vibrating table or by other approved means. The blocks shall be reinforced as shown on the drawings and shall have an F3 surface finish.

The unit of measurement shall be the number of blocks supplied and erected in accordance with the specifications. The tendered rate shall include full compensation for supplying all materials and labour, making and transporting the guide blocks, setting out, excavating and backfilling all the holes and disposing of surplus excavated material, including a free-haul of 1,O km, placing and painting the guide blocks and all the equipment. the tools and incidentals necessary for completing and maintaining the works described in this section.

The blocks shall be true to shape, smooth, and without any honeycombing or other blemishes.

SERIES 5000 : ANCILIARY ROADWORKS SECTION 5400 : GUARDFLAILS

washers and spacer blocks for fixing. Timber posts and spacer blocks shall be treated in accordance with SABS 05 with a creosote that complies with SABS 538 or SABS 539, or if it is approved by the engineer it shall be treated with a copper-chrome-arsenic compound for timber preservation, which complies with SABS 673. The preservative specified in the project specifications shall be used. After the posts have been treated, they shall not be sawn, drilled or shaped. Where, however, the cutting of posts is unavoidable after having been treated, the engineer may permit the required length to be cut off from the bottom of a post, provided that the exposed area is subsequently thoroughly treated with creosote. Timber posts shall not exhibit excessive cracking at the ends, particularly cracks aligned at an angle to the guardrail exceeding 45". Posts which, in the opinion of the engineer, exhibit a degree of cracking that would render them unfit for service during a much shorter than normal life shall not be used. (ii) Steel posts

CONTENTS 5401 5402 5403 5404 5405 5406 SCOPE MATERIALS CONSTRUCTION REQUIREMENTS REMOVING, RENOVATINGAND RE-ERECTING THE EXISTING GUARDRAILS MEASUREMENT AND PAYMENT

5401

SCOPE

This section covers the supplying, installing and maintaining of metal guardrails at locations and in accordance with the details, dimensions and design shown on the drawings or as directed by the engineer.

5402

MATERIALS Normally only timber posts shall be used for supporting the guardrails, but under certain circumstances, eg where guardrails are placed on concrete retaining walls, steel posts may be used. Steel posts shall be of the type and size shown on the drawings or described in the project specifications. (iii) Steel base plates for timber posts

(a)

Guardrails

Guardrails shall comply with the requirements of SABS 1350. The dimensions of guardrails and end treatments such as end wings, bull noses and bridge adaptors shall be in accordance with the details shown on the drawings. Guardrails shall be supplied together with all the bolts, nuts, washers and fixing materials required. (i) Galvanizing

Where it is necessary to install timber guard rail posts on top of a culvert structure, and where the total thickness of the fill and pavement layers over such structure is less than 1,O m, the timber posts shall be fastened to the structure by means of steel base plates as shown on the drawings.

Unless specified in the project specifications, all guardrails shall be galvanized with a hot-dip (galvanized) zinc coating which complies with the requirements of SABS 763 for the coating of type A1 articles. All bolts, nuts and washers shall have a hot-dip (galvanized) zinc coating which complies with the requirements of SABS 763 for the coating of type C1 articles. Galvanized guardrails shall not be nested when stacked for storage.

(c)

Reflective plates

V-shaped reflective plates shall be manufactured from 1,5 mm thick mild steel plate to the dimensions shown on the drawings. When supplied with galvanized guardrails, they shall also be galvanized, and when supplied with painted guardrails, they shall be finished in white baked enamel. The outer surfaces shall be coated with engineering-grade retro-reflective material which complies with the provisions of SABS 1519 in the colours shown on the drawings. Holes for fixing shall be drilled before the reflective plates may be galvanized or painted.

@)
(i)

Guardrail posts
Timber posts 5403 CONSTRUCTION

Timber posts shall be supplied in lengths as shown on the drawings and shall comply with the requirements of SABS 457 and shall carry the SABS mark. Posts shall have a top diameter of not less than 150 mm. Posts with a top diameter up to 230 m m will be acceptable, provided that posts with widely varying diameters shall not be used together in the same length of guardrail. Posts shall be drilled and shaped as shown on the drawings and provided with the necessary bolts, nuts,

(a)

Erection

The holes for the timber posts shall be of sufficient size to permit the proper setting of the posts and to allow sufficient room for backfilling the hole and tamping the filling. At least 1 m of a post shall be embedded in the ground. The holes for the timber posts shall be spaced to suit the standard length of the guardrail supplied. Where shown on the drawings or directed by the engineer, posts shall be set

at half the normal spacings. The posts, spacer blocks (if applicable) and guardrails shall be completely erected and set true to line and level, so that the guardrails will be at the requlred height above the level of the completed road shoulder. Where jointed, the end of the guardrails which overlaps on the side of the traffic shall point in the direction of the traffic movement. The guardrail shall be suitably braced to prevent any movement, and all bolts shall be tightened prior to any holes being backfilled. After the engineer has signified his approval of the guardrails so erected, the holes shall be backfilled with an approved sandy soil. The material shall be mixed with the correct quantity of water to ensure that the mixture will be placed while at or near the optimum moisture content. The mixture shall then be placed and thoroughly rammed in layers not exceeding 100 m m of compacted thickness. End treatments shall be constructed as shown on the drawings. When the backfilling has been completed and the bracing removed, the posts shall be rigid and vertical, and the guardrail shall be true to line and level and firmly fixed to the posts. Excess excavated material shall be disposed of as directed by the engineer. Steel posts shall be erected and fixed as shown on the drawings. All guardrails shall be so erected as to have no projecting ends whlch might Interfere with or endanger traffic. The edges and the centre of the guardrails shall touch either the spacer block or the post where no spacer blocks are used. Guardrails, if specified, shall be provided with end units as shown on the drawings. All splices of guardrails shall be at posts, and guardrails shall make contact over the entire area of the splice.

5404

REQUIREMENTS

The completed guardrail shall have a neat appearance, and shall not show any visible deviations from line and grade. The posts shall be straight and vertical. The guardrails shall not be warped but shall be in a vertical plane parallel to the road centre line except at flared terminal sections. The painted or galvanized surface on the guardrail shall be smooth and continuous and free from abrasions or scratches. Any damage to the surface shall be repaired at the contractor's expense. Guardrails which do not comply with the prescribed requirements shall be replaced or otherwise repaired.

5405

REMOVING, RENOVATING AND RE-ERECTING EXISTING GUARDRAILS

Where existing guardrails have to be removed, or removed and re-erected, or removed, renovated and re-erected, the three processes of removal, renovation and re-erection shall be carried out as follows:

(a)

Removing the guardrails

All guardrails, reflective plates and end units shall be loosened. Posts shall be carefully dug out and the holes shall be filled and compacted in 150 m m layers. Items used for fixing, such as bolts, nuts and washers, together with the reflective plates, shall be placed into bags, after which all the material shall be transported to a store approved by the engineer and all stored in groups by type.

Reflective plates shall be fixed in accordance with the details shown on the drawings. The reflective surfaces shall be arranged with the colours as shown on the drawings.

Where material is intended for re-use, it shall first be unpacked for inspection by the engineer for deciding which material will be suitable for re-use. Suitable material shall then be stored separately from material which is unsuitable for re-use. The contractor shall dispose of material that is unsuitable for re-use.

@)

Renovating the guardrails

The following instructions shall apply where guardrails are to be painted:

If so directed by the engineer, guardrails and end treatments suitable for re-use shall be taken to the workshop for cleaning and painting. Rust and existing paint shall be completely removed and minor indentations hammered out. The guardrails shall then receive surface treatment and be painted as described in clause 8408. Timber posts suitable for re-use shall be cleaned and treated with a timber preservative as described in subclause 5402(b)(i). Bolts, nuts and washers to be reused shall be cleaned and all rust removed, and shall then be oiled.

Before being fixed, the guardrails shall be cleaned, primed and painted as specified in clause 8408. After erection, all abraded or damaged surfaces shall be repainted as specified in clause 8408. Galvanized guardrails shall not be painted.

When existing guardrails are required to be repainted, they shall be dismantled prior to repainting. They shall then be thoroughly cleaned with wire brushes and descaled with suitable tools to remove all rust and loose and oxidised paint. Thereafter they shall be washed down and all exposed steel surfaces shall be glven a coat of zinc chromatic primer. The entire prepared surface shall then be given a full coat of zinc chromatic primer and two coats of palnt as specified In clause 8408.

(c)

Reerection

The guardrails shall be erected in the positions as indicated, and all the removed material suitable for re-use and as much supplementary new material as may be necessary shall be used. Re-erection shall be as specified for new guardrails, including fixing the retro-reflective plates.

54CE

MEASUREMENT AND PAYMENT

Item 54.04 End treatments: Unit (a) End wings. Bull noses

Unit

. . . . . . . . . . . . . . . . . . number

(No) (No)

54.01 Guardrails on timber posts: (a) (b) Galvanized Painted

(b) (m) (m) (c) (d)

. . . . . . . . . . . . . . . . . . . number

..................... metre

Bridge adaptors

..............

number (No)

........................ metre

The unit of measurement shall be the metre of guardrail as erected, excluding end treatments. (e) The tendered rates shall include full compensation for furnishing all materials and labour and for erecting and painting and galvanizing the guardrails, complete with posts, spacer blocks, bolts, nuts, washers and reinforcing plates, and excavating holes in all classes of material and backfilling the post holes and removing any surplus excavated material. Drilling and blasting will be paid for separately under item 54.12.

End treatments in accordance with the drawings where single guardrail sections are used . . . End treatments in accordance with the drawings where double guardrail sections are used . .

...

number (No)

...

number (No)

The unit of measurement shall be the number of end treatments of each type installed. The tendered rates shall include full compensation for all labour, constructional plant and materials required for installing the end treatments as shown on the drawings, including posts and fittings and the bending of turneddown sections, excavations in all classes of material, concrete, backfilling and the removal of surplus backfilling.

Item
54.02 Guardrails on steel posts: (a) (b) Galvanized Painted

Unit Item 54.05 Addiional guardrail posts: (m) (a) Timber Steel Unit

. . . . . . . . . . . . . . . . . . . . metre .

. . . . . . . . . . . . . . . . . . . . . number

(No) (No)

. . . . . . . . . . . . . . . . . . . . . . . .metre

(m) (b)

. . . . . . . . . . . . . . . . . . . . . . . number

The unit of measurement shall be the metre of guardrail erected, excluding end units.

The tendered rates shall include full compensation for furnishing all materials and labour and erecting and painting and galvanizing the guardrail, complete with posts, spacer blocks, bolts, nuts, washers and reinforcing plates and excavating holes in all classes of material and backfilling the post holes, including concrete backfill, and removing any surplus excavated material.

The unit of measurement for additional guardrail posts shall be the number erected over and above those erected in accordance with the normal spacing shown on the drawings. The tendered rates shall include full compensation for supplying and installing additional posts complete as specified, excavating the necessary holes, erecting the posts, and backfilling the holes.

hem Drilling and blasting will be paid for separately under item 54.12.
54.06 Reflective plates

Unit

..............

number (No)

Item

Unit

The unit of measurement shall be the number of reflective plates installed. The tendered rate shall include full compensation for supplying all materials and labour required for manufacturing, painting and fixing the reflective plates as specified and as shown on the drawings.

5 4 . 0 3 Extra over items 54.01.

54.02 and 54.1 1 for horizontally cunred guardrails factory bent to a radius of less than 45 rn .

. . . . . . . . . metre (m)
Item 54.07 Removing existing guardrails . . . . . . Unit

The unit of measurement shall be the metre of curved guardrail erected and measured in place.

metre (m)

The tendered rate extra over the rates tendered for items 54.01, 54.02 and 54.1 1 shall include full compensation for incidentals in respect of supplying and erecting curved guardrails.

The unit of measurement shall be the metre of guardrail removed, and the quantity shall be measured between the terminal points of the sections removed, including the end

treatments, but excluding the anchor blocks and anchor cables, if any, projecting beyond the end treatments. The tendered rate shall include full compensation for the work as described in subclause 5405(a), including loading, transporting to any point on the site, and off-loading and stacking the material, and disposing of material unsuitable for re-use.

(c) (d)

Bridge adaptors

. . . . . . . . . . . . . . number

(No)

End treatments with single guardrails . . . . . . . . . . . . . . number (No) End treatments with double guardrails . . . . . . . . . . . . . number (No)

(e)

Item
54.08 R e n o v a n i tg material:

Unit guardrail

The unit of measurement shall be the number of end treatments installed with recovered and, in part, new rnaterial. The tendered rates shall include full compensation for installing the end treatments and for providing all anchors, fixing materials and anchor blocks. Apart from anchors, anchor blocks and fixing materials, payment will be made separately for all new materials. End treatments made completely from new materials shall be paid for in accordance with the appropriate rates for new end treatments.

(a)

Guardrails and end treatments Posts

. . . . . . . . . . . . . . . . . metre . (m)
(No)

(b)

. . . . . . . . . . . . . . . . . . . . . . number

The unit of measurement for subitem (a) shall be the metre of single guardrail, whether straight or bent, or end treatments renovated as specified, the length of which shall be measured in accordance with the measurements of the guardrail after dismantling. The unit of measurement for subitem (b) shall be the number of treated posts. The tendered rates shall include full compensation for the work as specified in subclause 5405(b), including the loading. transporting to and from the workshops, offloading and storing of the material.

Item
54.11 New material required for the reerection of guardrails with recovered materials:

Unit

(a) (b) (c)

Guardrails

......................

metre (m)

Timber posts . . . . . . . . . . . . . . . . . number (No) Steel posts . . . . . . . . . . . . . . . . . . number (No) Reflective plates Spacer blocks

Item
54.09 Reerection of guardrails with recwered andlor new material:

Unit

(d) (e) (f)

. . . . . . . . . . . . . . number

(No)

. . . . . . . . . . . . . . . . number (No)

Splice bolt complete with nut and washer . . . . . . . . . . . . . . . number (No) Post bolt complete with nut and washer . . . . . . Reinforcing plates

(a) (b)

Single guardrail Double guardrail

. . . . . . . . . . . . . . . . . .metre

(m) (g)

................. metre (m)

(h)

.........

number (No) number (No)

The unit of measurement shall be the metre of single or double guardrail re-erected with used and/or new material and measured between the points where they are joined to the end units. The tendered rates shall include full compensation for reerecting the guardrails as specified in subclause 5405(c), including the loading, transporting between any two points on the site and off-loading the material, and providing new fixing material. Payment shall be made separately for any new material required, including spacer blocks, but not for other fixing materials. Where sections are made entirely from new material, payment therefor shall be made under the appropriate items for new guardrails.

.............

The unit of measurement for subitem (a) shall be the metre of guardrail provided, measured in accordance with the measurements of the loose guardrail. The unit of measurement for subitems (b), (c), (d), (e), (f), (g) and (h) shall be the number of new timber posts, steel posts, reflective plates, spacer blocks, splice bolts, post bolts and reinforcing plates provided, respectively. The tendered rates shall include full compensation for supplying the material as specified. ltem 54.03 shall also apply to horizontally curved guardrails factory bent to a radius of less than 45 m.

Item
54.10 Reerection of end freatments with recovered rnaterial:

Unit ltem
54.12 Extra over items 54.01 and 54.02 for drilling and blasting holes for guardrail posts . . . . . . . . . . .

Unit

(a)

End wings . . . . . . . . . . . . . . . . . . . number (No)

..

number (No)

(b)

Bull noses . . . . . . . . . . . . . . . . . . . number (No)

The unit of measurement shall be the number of holes drilled and blasted with explosives in hard material which

cannot be removed by auger. The tendered rate shall include full compensation for additional work including amongst others all drilling, explosives, materials, labour and equipment and all incidentals required for making holes in hard materials by means of drilling and blasting.

The unit of measurement is the number of steel base plates installed complete as shown on the drawings or directed by the engineer.

Item
54.13 Steel base plates for timber guardrail posts on structures

Unit

. ....

number (No)

The tendered rate shall include full compensation for supplying all labour, materials, equipment and transport required for manufacturing, galvanising and installing the base plates complete with cement mortar pad, for cutting the guardrail post to the required length, drilling an additional hole, treating the hole and butt face with creosote and fixing the post all as specified on the drawings.

SERIES 5000 : ANCILLARY ROADWORKS SECTION 5500 : FENCING

Rolled steel sections shall be provided with a protective coating of tar or other approved material.

@)

Bolts for stays

CONTENTS
SCOPE MATERIALS TYPES OF FENCING PROTECTING LIVESTOCK CLEARING THE FENCE LINE ERECTING STRAINING POSTS AND STANDARDS ERECTING FENCE WIRES ERECTING DIAMOND MESH OR WIRE NETTING CLOSING OPENINGS UNDER FENCES EXISTING FENCES ERECTING GATES TEMPORARY FENCING AND GATES GENERAL REQUIREMENTS MEASUREMENT AND PAYMENT Bolts shall be galvanized steel bolts of the required length and a diameter which shall not be less than 12 mm. All the necessary bolts, nuts and washers, shall be supplied with each post.

(c)

Wire

(i)

Barbed wire

Barbed wire shall comply with the requirements of SABS 675 and shall be one or more of the following types: High-tensile-grade steel single-strand 3,15 rnrn x 2,50 rnm oval-shaped zinc-coated wire, with a 2,82 m m equivalent diameter. High-tensile-grade steel single-strand 2,80 m m x 1.90 m m oval-shaped zinc-coated wire, with a 2,31 m m equivalent diameter. This wire shall not be used less than 500 m m above ground where there is danger of veld fires. Mild-steel-grade zinc-coated double-strand uni-directionaltwist wire, each strand 2,50 m m in diameter, for use at any height above ground. Barbs shall be manufactured from 2.0 m m zinc-coated mild steel wire and shall be spaced at not more than 150 mm. (ii) Smooth wire

5501

SCOPE

This section covers the moving of existing fences where necessary and erecting new fences along the boundaries of the road reserve and where elsewhere indicated on the drawings or as directed by the engineer. It shall also include the erection and later removal of temporary fences. Except when the engineer allows otherwise, new and temporary fences shall be erected before construction on a particular section of the road is commenced with, or before temporary bypasses are opened to traffic. This section also covers the dismantling of existing fences and the stacking of the fencing material.

Smooth wire shall comply with the requirements of SABS 675 and shall be of the types specified below: Straining wire shall be 4,00 m m diameter zinc-coated hightensile-grade steel wire. Fencing wire shall be high-tensile-grade steel 2.24 rnm diameter zinc-coated wire. Tying wire shall be 2,50 m m diameter mild-steel zinccoated wire for tying fencing wire to standards and droppers and 1,6 m m mild-steel zinc-coated wire for tying netting and mesh wire to the fencing wire.

5502

MATERIALS

(a)

Straining posts, stays, standards and droppers

Straining posts, stays, standards and droppers shall be of the type and size indicated on the drawings. Steel sections shall comply with the requirements of CKS 82 and timber posts with the requirements of SABS 457. Timber posts shall be treated with a preservative in accordance with the requirements of subclause 5402(b)(i).

(d)

Diamond mesh

Unless otherwise specified or shown on the drawings, rolled steel posts shall be 15 or 22 kg/m rails as shown on the drawings. Standards shall be 2,50 kglm Y-sections. Droppers shall be 0 5 6 kg/m ridgeback-pattern droppers.

Diamond mesh (chain-link fencing material) shall comply with the requirements of SABS 1373. The width shall be shown on the drawings and the edge finish shall be both sides clinched or barbed. The nominal diameter of the wire shall be 2.5 rnm and the mesh size shall be 64 m m x 64 mm.

Tubular straining posts and stays shall be galvanized in accordance with SABS 763 for class B1 articles, or shall be painted as specified in section 8400 as may be required on the drawings, and shall have a wall thickness of at least 2,95 mrn. Unless otherwise shown on the drawings, all tubular posts shall be provided with a 230 m m x 230 m m footplate and a pressed-steel or cast-iron cap. Tubular stays shall have a nominal bore of at least 60 mm.

The wire shall be fully galvanized.

(e)

Wire netting

Wire netting shall be fully galvanized mild-steel wire with a minimum diameter of 1,8 mm, with 75 rnrn hexagonal

The width shall be as shown on the drawings

erected, they shall be erected either to the same design as the original, but with such modifications as may be required by the engineer, or they shall be erected up to one of the standards specified above, all as ordered by the engineer.

(f)

Barbed-tape concertina wire

Barbed-tape concertina wire shall comply with the requirements of CKS 592 type A. The high-tensile steel wire shall be heavily galvanized (class A), and the barbed tape and concertina clamps shall also be heavily galvanized (class 2600). The diameter of the roll shall be 950 m m or 700 mm according to requirements.

5504

PROTECTING LIVESTOCK

@)

Gates

Gates shall be manufactured to the dimensions and details shown on the drawings. Gates shall be complete in every respect, including hinges, washers, bolts and locking chains attached to the gate. Gates shall be zinc-coated as specified in SABS 763 for class B1 articles, or painted as specified in section 8400, as required on the drawings and in subclause 5502(a).

From the time of the site being handed over to him up to the date of the final maintenance certificate being issued to the contractor, he shall take all measures necessary for preventing the ingress of vermin, and for protecting and controlling livestock, etc, on the sections of the properties affected by his operations. He shall provide gates at the positions in existing fences cut by him for gaining access and shall ensure that all gates are kept closed except when they are opened for admitting his traffic. No fences shall be cut without the approval of the engineer, and consultation with the owner of the fence.

(h)

Timber posts for wire mats

Timber posts for holding down wire mats where the fence crosses streams shall comply with the requirements of SABS 457 and shall be in accordance with the requirements of subclause 5402(b)(i).

Where alternative arrangements cannot be made, the engineer may direct the contractor to erect temporary fencing where necessary to protect livestock that may be lost or are exposed to vermin through his operations. Such fencing shall be of an adequate standard and shall be erected ahead of construction operations. The fencing shall be maintained in a good order during construction operations and, on completion of the work, it shall be removed from the site and all surfaces shall be restored. The engineer may order that any permanent fencing which is required erected up ahead of construction operations, where practicable, in lieu of erecting temporary fencing.

(i)

Manufacturing tolerances for wire Payment for the protection of livestock, excluding the erection of temporary fences, shall be included in the amounts tendered for the contractor's establishment on the site, as specified in section 1300.

The actual diameter of wire supplied shall equal the specified diameter subject to the appropriate tolerance given in SABS 675.

0)

Hinge joint mesh

5505 CLEARING THE FENCE UNE

Hinge joint mesh (Veldspan Tension Fence or approved equivalent) shall be zinc-coated in accordance with SABS 675. It shall consist of 3,00 m m diameter edge wires, 2,2 m m diameter line wires and 2,5 m m diameter vertical stay wires. The grade of steel, the height of the fence, the spacing of the vertical wires, and the number and spacing of the horizontal wires shall be as specified on the drawings and in the project specifications.

5503

TYPES OF FENCING

The fence line shall be cleared over a width of at least 1 m on each side of the centre line of the fence and surface irregularities shall be graded so that the fence will follow the general contour of the ground. Clearing the line shall include the removal of all trees, scrub, stumps, isolated boulders or stones and other obstructions which will interfere with the construction of the fence. Stumps within the cleared space shall be grubbed as described in section 1700. The bottom of the fence shall be located at a uniform distance above the ground line in accordance with the requirements shown on the drawings. All material removed shall be burnt or disposed of in disused borrow pits. Any areas outside the road reserve where clearing is not permitted by the owner or is impracticable shall not be cleared if so directed by the engineer.

The following types of fences shall be erected in accordance with the dimensions shown on the drawings: (a) (b) (c) (d) Stock-proof fences Vermin-proof fences

5506

ERECTING STRAlNlNG POSTS AND STANDARDS

Pedestrian fences Security fences straining posts shall be erected at all terminal points, gates, low points (as required), corners and bends in the fencing and at all junctions with other fences. Straining

Where existing fences have to be dismantled and re-

posts shall not be spaced further apart than shown on the drawings. The length of posts above ground shall be such that the correct clearance between the lowest wire and the ground can be obtained. Straining posts shall be accurately set in holes and shall be provided with concrete bases to the dimensions shown on the drawings. Holes shall be dug to the full specified depth. Where, on account of the presence of rock, the holes cannot be excavated by hand or by pneumatic tools and the contractor has to resort to the use of explosives, he will be paid separately for the drilling and blasting operations required. All straining posts shall be braced by means of stays or anchors as shown on the drawings or as directed by the engineer. Tubular stays shall be bolted to the posts. Standards shall be firmly planted into the ground at the spacings shown on the drawings or as directed by the engineer. The spacing of standards between any two successive straining posts shall be uniform and not greater than that shown on the drawings. In rock or hard material standards shall be either driven or set in holes drilled into the rock. The size of drilled holes shall provide a tight fit to the standards. Care shall be taken when driving standards to prevent their buckling or being damaged. All straining posts and standards shall be accurately aligned and set plumb. Where verandah-type of security fencing is used, the posts shall be planted with the overhang on the road side and perpendicular to the direction of the fence. After the straining posts and standards have been firmly set in accordance with the foregoing requirements, fence wires shall be attached thereto at the spacings shown on the drawings.

fencing wire and the first twist. Splices in the fencing wire shall be permitted if made in the following manner with a splicing tool. The end of each wire at the splice shall be taken at least 75 m m past the splicing tool and wrapped snugly around the other wire by not less than six complete turns with the two separate wire ends being turned in opposite directions. After the splicing tool has been removed, the space left by it in the spliced wire shall be closed by pulling the wire ends together. Unused wire ends shall be cut close so as to leave a neat splice. The gaps between gate posts and the adjacent straining posts shall be fenced off with short lengths of fencing wires. Droppers shall be tied to each fence wire with soft tying wire in the required position as specified for standards to prevent slippage in a vertical direction. The spacing of droppers between any two straining posts shall be uniform. Anchoring to structures shall be done as shown on the drawings. Barbed-tape concertina wire shall be attached to the fence as shown on the drawings at maximum spaces of 1,O metre between tying points. Barbed-tape concertina wire rolls shall be spliced by overlapping for one full circle and tied at four evenly spaced points along the circumference. Spliced ends shall coincide with the positions of the standards.

5508

ERECTING DIAMOND MESH OR WIRE NEllING

5507

ERECTING FENCE WIRES

All fencing wire shall be tied to the sides of standards or posts to prevent the wires from being displaced or becoming loose. The wire shall be carefully tensioned without sagging, and true to line, care being exercised not to tension the wire to such an extent that it will break, or that end, corner, straining or gate posts will be pulled out, or that it will be easily damaged during veld fires. Each strand of fencing wire shall be securely tied in the correct position hard up to each standard with soft galvanised tying wire. The tying wire for each strand shall pass through a hole or notch in the standard, while the ends of the tying wire shall be wound at least four times around the fencing wire to prevent it from moving in a vertical direction. At all straining posts at terminal points, gates, corners, bends and other specified positions, the fencing wire shall be securely wrapped twice around the post and secured against slipping by tying the end tightly around the wire by means of at least six snug tight twists. Where high-tensile wire is used, two long twists may first be made followed by the six tight, snug twists around the post to prevent the wire from breaking at the first twist. When smooth wire is used, the loose end shall preferably be bent over and hooked into the notch between the

Where vermin-proof, pedestrian or security fences are erected, or where instructed by the engineer, wire netting or diamond mesh shall be stretched against the fence and properly tied to the fencing wire as shown on the drawings. The diamond mesh or wire netting shall be secured by soft tying wire at 1,2 m centres along the top and bottom wires and at 3 m centres along each of the other fencing wires. unless otherwise shown on the drawings. In the case of vermin-proof fencing, vermin shall be prevented from creeping under the fence by either one of the two methods described below as ordered by the engineer: By folding back the bottom 130 m m of the wire (a) netting so that it lies flat on the ground and by tightly packing stones (having a minimum dimension of 200 mm) end to end on this flap to secure it in position. By embedding the lower 130 m m of the wire netting (b) in the ground and thoroughly compacting the earth around it on both sides, to secure the netting.

5509

CLOSING OPENINGS UNDER FENCES

At ditches, streams, drainage channels or other depressions where the fence cannot be erected so as to follow the general ground contour, the contractor shall close the opening under the fence with horizontal barbed wires at 150 m m distances, stretched between additional posts or straining posts as shown on the drawings or directed by the engineer. In the case of pedestrian, vermin-

proof and security fences the opening shall be covered with strips of wire netting or diamond mesh 1 000 m m wide, fixed to the barbed wires. In the case of larger streams where damming of debris against the fence would constitute a hazard, the opening below the bottom fencing wire shall be closed with loosehanging wire nets. For this purpose additional straining posts shall be planted on both sides of the stream with a cable consisting of at least five strands of smooth fencing wire stretched between them. Onto this cable vertical strips of diamond mesh hanging down to ground level shall be fixed. The edges of the various strips of diamond mesh shall be tied to each other so that the entire mat will be raised by water flowing underneath to leave a free stream area. These mats at streams shall be erected only on instructions by the engineer. If it should be necessary to keep the bottoms of the mats on the ground, the engineer may order that timber posts or pipes be fixed horizontally to the bottom ends of the diamond-mesh strips.

specifications or the engineer's instructions. The material and erection shall be in accordance with the provisions of this section, but the material need not necessarily be new. Where used materials are offered, they shall nevertheless be in a good condition and approved in advance by the engineer. When no longer required, the temporary fencing and gates shall be dismantled and removed.

5513

GENERAL REQUIREMENTS

The completed fence shall be plumb, taut, true to line and ground contour, with all posts, standards and stays firmly set. The height of the lower fencing wire above the ground at posts and standards shall not deviate by more than 25 m m from that shown on the drawings. Other fencing wires shall not deviate by more than 10 m m from their prescribed vertical positions. The contractor shall, on completion of each section of fence, remove all cut-offs and other loose wire or netting so as not to create a hazard to grazing animals or a nuisance to the owners of the ground.

5510

EXISTING FENCES

Where a new fence joins an existing fence whether in line or at an angle, the new fence shall be erected with a new straining post positioned at the terminal of the existing fence. Existing fences that require to be taken down or moved to a new location shall be dismantled. Material not required for re-erection or unsuitable for re-use shall be neatly stacked at approved locations in accordance with the engineer's instructions. Fencing wire and wire netting shall be stacked clear of the ground. Payment will be made only for fences removed in accordance with the written instruction of the engineer. Where fences require moving, the contractor shall re-use all the material, declared to be suitable for this purpose by the engineer, plus such new material as may be required to put up the fence again to the standard specified for new fences. The engineer shall not be responsible for any delays or costs arising from the breaking of re-used wire during straining.

5514

MEASUREMENT AND PAYMENT

Item
55.01 Clearing the fence line, 2 m wide strip . . . . . .

Unit

. . . . . . . . .kilometre (km)

The unit of measurement for clearing the fence line shall be the kilometre of fence line measured along each fence line. The tendered rate shall be in full compensation for clearing the fence line complete as specified in clause 5505, including amongst others the removal of trees, stones, and other obstructions and the disposal of all waste material resulting from clearing operations, as may be directed. The removal of trees and stumps with a girth exceeding 1 m shall be paid for as specified in section 1700.

5511

ERECTING GATES

Gates shall be erected at the positions indicated by the engineer. The gates shall be hung on gate fittings in accordance with the requirements shown on the drawings. Gates shall be so erected as to swing in a horizontal plane at right angles to the gate posts, clear of the ground in all positions. In pedestrian and security fences the double swing gates shall leave a gap not exceeding 25 m m between them when closed and other gates shall not be further than 25 m m from the gate post when closed. The clearance below the gates shall not exceed 75 m m with the gates closed.

Item
55.02 Supply and erect new fencing

Unit

material for new fences and for supplementing material in existing fences which are being repaired or removed: (a) Zinc-coated barbed wire (grade, and size indicated) . . . . . . . . . Zinc-coated smooth wire (grade and size indicated) . . . . . . . . . . Diamond mesh

. . kilometre (km)
.
kilometre (km)

(b)

5512

TEMWRARl FENCING AND GATES

(c) (d)

. . . . . . . . . . . square metre (mZ)

Wire netting . . . . . . . . . . . . . square metre (mz) Barbed-tape concertina

If required, the contractor shall erect temporary fencing and gates in accordance with the drawings, project

(e)

wire (1) (g)

. . . . . . . . . . . . . . . . . . . . . . kilometre (km)

Fencing wire (subitems (a) and (b)) The unit of measurement shall be the kilometre of each type of fencing wire measured between end posts. Tying wire and wire used for anchoring the posts shall not be measured for payment. Diamond mesh, wire netting and hinge joint mesh (subitems (c), (d) and (1)) The unit of measurement shall be the square metre of diamond mesh, wire netting or hinge joint mesh, the quantity of which shall be calculated according to the prescribed width and the length between straining posts or gate posts, or the length of strips used for covering openings under fences, or the length used for covering the gates. Barbed-tape concertina wire (subitem
(9))

Hinge joint mesh

..........

square metre (m2)

Standards (length and type indicated) . . . . . . . . . . . . . . . number (No) Droppers (length and type indicated) . . . . . . . . . . . . . . . number (No) Straining posts, stays and anchors: Vertical Steel straining posts (type, size and length and whether galvanized or painted indicated) . . . . . . . . . . . number (No) Timber straining posts (diameter indicated) . . . . . . . . . . . number (No) Inclined: Steel stays and anchors (diameter and wall thickness indicated) . . . . . . . . . . . number (No) Timber stays and anchors (diameter indicated) . . . . . . . . . . . number (No) Wire stays and anchors (diameter and type indicated) . . . . . . . . . . . . . . . . . . . number (No) Horizontal: Steel stays and anchors (diameter and wall thickness indicated) . . . . Timber stays and anchors (diameter indicated) . . . .

(h)

(i) (i) (1)

(2)

(ii) (1)

The unit of measurement shall be the kilometre of fence provided with barbed-tape concertina wire of which each concertina is opened to the maximum effective open concertina length as specified in CKS 592. Stays and anchors (subitem (i)) The unit of measurement shall be the number of stays and anchors of each type installed. The tendered rate for each straining post, standard, dropper, each kilometre of fencing wire and barbed-tape concertina wire, and each square metre of diamond mesh, wire netting or hinge joint mesh, and for each anchor or stay shall include full compensation for providing all the materials, including all concrete, tying wire, straining wire, bolts, washers and nuts, for excavating or drilling holes for standards, for erecting the posts, standards and droppers and the complete putting up of the fence as specified and as shown on the drawings. No separate payment will be made in respect of stone packing and/or trenching in the case of wire netting. In the case of hinge joint mesh no separate payment will be made in respect of droppers.
Item

(2)

(3)

(iii)
(1)

. . number (No) . . number (No)

(2)

(3)

Wire stays and anchors (diameter and type indicated) . . . . . . . . . . . . . . . . . . . number (No)

Unit

The quantity of material used shall be determined b y measuring the quantities of individual items of material used in the completed fence. The linear measurement of the completed fence shall not apply. The appropriate units of measurement are as follows: Straining posts (subitem (i)) The unit of measurement shall be the number of posts, as follows: All straining posts erected in accordance with the maximum specified spacing or such lesser spacing as authorised by the engineer, all corner posts and posts at bends authorized by the engineer, and all end posts. Standards and droppers (subitems (g) and (h))

55.03 New gates (size and type indicated) . . . . . . . . . . . . . . . . . . . number (No)

The unit of measurement shall be the number of new gates erected. The tendered rates shall include full compensation for procuring and furnishing all material, including gates, zinccoating, painting, hinges and bolts, and for installing the gates complete as specified and as shown on the drawings. It shall not include compensation for any fencing wire or mesh fitted onto the gate. Gate posts will be paid for under subitem 55.02(i).
Item
55.04 Moving exisling fences and gates:

Unit

The unit of measurement shall be the number of standards and droppers erected to the maximum specified spacing or such lesser spacing as authorized by the engineer.

(a) (i)

Fences: Stock-proof fences

. . . . . . . . . . . kilometre (km)

(ii) (iii) (iv) (b)

Vermin-proof fences Pedestrian fences Security fences Gates

. . . . . . . . . . kilometre (km)

(c)

Pedestrian fence

. . . . . . . . . . . . . kilometre (km)

. . . . . . . . . . . . kilometre (km)
(km) (No)

. . . . . . . . . . . . . . kilometre

The unit of measurement shall be the kilometre of each type of temporary fencing erected on the instructions of the engineer. The tendered rates shall include full compensation for providing all labour, new or suitable second-hand material, putting up the temporary fence and when no longer required, dismantling and removing it from the site to any new locality where it is required, and for neatly restoring the ground surface. (d) Temporary gates (type and size indicated) . . .

. . . . . . . . . . . . . . . . . . . . . . number

The unit of measurement for moving existing fences shall be the kilometre of fence, the quantity of which shall be taken as the length of fence which has been put up permanently with material obtained from fences which have been dismantled elsewhere. Additional new material used during the re-erection of existing fences shall be measured under item 55.02. The unit of measurement for moving gates shall be the number of gates moved. The tendered rate for each kilometre of existing fence moved or for each existing gate moved shall include full compensation for dismantling the old fence, coiling and stacking the material unsuitable for re-use, moving all material, including posts and wire and again putting up the fence or gate at the new position and the provision of binding, tying and straining wire. New material used for reerection of old fences shall be paid for under item 55.02. The tendered rate for each gate moved shall include full compensation for taking down the gate and re-erecting it where required, including all new bolts, nuts and other accessories required but excluding new gate posts.

.........

number (No)

The unit of measurement shall be the number of temporary gates provided by the contractor. The tendered rate shall include full compensation for procuring, supplying and erecting new or second-hand gates, their later removal, and replacing the fence.

General Where new or second-hand material is used which has been provided by the employer, eg material obtained from taking down existing fences, such material obtained from taking down the temporary fences or gates shall remain the property of the employer.

Item
55.05 Dismantling existing fences:

Unit Material provided by the contractor for temporary fences will similarly become the contractor's property after the temporary fences have been dismantled.

(a) (i) (ii) (iii) (iv) (b)

Fences: Item Stock-proof fences Vermin-proof fences Pedestrian fences Security fences Gates Unit

. . . . . . . . . . . kilometre (km)

..........

kilometre (km)

55.07 Rngbolts for anchoring fencing to siructures . .

number (No)

. . . . . . . . . . . . kilometre (km)
.............
kilometre (km) (No)

The unit of measurement shall be the number of ringbolts supplied and fixed to the structure.

. . . . . . . . . . . . . . . . . . . . . . number

The unit of measurement for the dismantling of existing fences shall be the kilometre of each type taken down and dismantled on the instruction of the engineer. The unit of measurement for the dismantling of gates shall be the number of gates dismantled on the instruction of the engineer. The tendered rates shall include full compensation for taking down existing fences and gates, coiling wires, rolling netting into rolls, transporting the material to designated sites and stacking the material.

The tendered rate shall include full compensation for supplying and fixing ringbolts of the type shown on the drawings to the structure, including, where necessary, drilling holes, anchorage, grouting ringbolts in with epoxy resin. and for all incidentals.

Item
55.08 Drilling and blasting

Unit

holes for posts and anchors

. . . . . number (No)

Item 55.06 Providing temporary fences and gates: (a) (b) Stock-proof fence Vermin-proof fence

Unit

The unit of measurement shall be the number of holes for posts and anchors made by drilling and/or blasting where excavation by hand or by pneumatic tools cannot be done economically.

............

kilometre (km) (km)

. . . . . . . . . . . kilometre

The tendered rate shall include full compensation for drilling and blasting the holes and for all other expenses in connection with providing, storing, transporting and using explosives.

(b)

Mild steel pipes (diameter and wall thickness indicated) . . . . . . . . . . metre (m)

55.09 Posts fixed horizontally to the bottom of wire mesh for the dosing of openings under fences:

The unit of measurement shall be the metre of post of each type installed. The tendered rate shall include full compensation for procuring, furnishing and fixing the posts, complete as specified and as shown on the drawings.

(a)

Timber posts (diameter indicated)

...

metre (m)

SERIES 5000 : ANClllARY ROADWORKS SECTION 5600 : ROAD SIGNS

from or coated with a material that will not cause corrosion through electrolytic action. Hardened blind or aluminium rivets shall be used for attaching aluminium sections.

CONTENTS SCOPE MATERIALS MANUFACTURING OF ROAD SlGN BOARDS AND SUPPORTS ROAD SlGN FACES AND PAINTING STORAGE AND HANDLING ERECTING ROAD SIGNS PROTECTION AND MAINTENANCE DISMANTLING, STORING AND RE-ERECTING EXISTING ROAD SIGNS MEASUREMENT AND PAYMENT

(c)

Steel plate and steel profiles Steel plate

(i)

Steel plate for road signs shall be 1,40 m m thick prepainted galvanized steel plate (Iscor G275 Chromadek or approved equivalent), which has been treated on both sides with an epoxy primer followed by a silicon polyester top coat. The total dry thickness of the treatment shall be at least 25 p m . The reverse side of a STOP sign R1 and all its derivatives shall be painted white. The reverse side of all other signs shall be dark grey. Where a reflectorised road sign is required, its reverse side shall be painted with a dull grey prime coat and the face with only the specified top coat. (ii) Steel profiles

SCOPE

This section covers the supply of permanent and temporary road signs and the erection of permanent road traffic signs alongside and over the carriageway, ramps and cross roads at intersections and interchanges and at the locations indicated on the drawings or as directed by the engineer. The signs shall be of the standard regulatory, warning, guidance and information signs as detailed on the drawings and shall be fabricated in accordance with the South African Road Traffic Signs Manual, except where otherwise indicated on the drawings or in the project specifications, or as directed by the engineer.

Standard sign profiles shall be 200 m m sections with a thickness of 1,O mm, manufactured from prepainted galvanized mild steel substrate (lscor (3275 Chromadek or approved equivalent), and shall comply with the details on the drawings.

(d)

Other plate material

Temporary roadworks delineators signs TW401 and TW402 shall be manufactured from a flexible material and shall comply with the requirements of SABS 1555. Other plate material shall be as specified in the project specifications.

(a)

Structural steel (e) Aluminium

Structural steel shall comply with the requirements of BS 4360 for the type of steel specified or shown on the drawings. Unless otherwise specified, channels, square tubes, angle irons and other steel members on the reverse side of the sign boards and steel tubes for sign supports shall be coated in accordance with subclause 5603(a). Where specified, all structural steel, including tubes shall be galvanised in accordance with the requirements of SABS 763 for type A1 or 82 articles, as may be applicable. Steel tubes shall comply with the requirements of SABS 657.

Aluminium sections shall be of the sizes detailed on the drawings, shall be manufactured from grade 6063.T.5 alloy and shall comply with the requirements of BS 1474. Aluminium plate shall be manufactured from grade 5251.H.3 alloy and shall comply with the requirements of BS 1470 and shall be 2.0 rnm in thickness.

(0

Paint

All paints used shall comply with the requirements of CKS 193. and also with the standards mentioned therein.

@)

Bolts, nuts and rivets Except where reflecting surfaces are specified, the surface of painted road signs shall be semi-matt. The 60" specular gloss measured in accordance with SABS method 134 shall not exceed 50. No thinners shall be added to the paint. The reference numbers of the colours to be used are 849 Golden Yellow, A l l Signal Red, G I 3 Dark Grey, F04 National Flag Blue, E08 Flag Green, 803 Dark Brown and G80 Cloud White as shown in SABS 1091. In the case of prepainted steel plate, the contractor shall

Steel bolts and nuts shall comply with SABS 135 or SABS 1143. Aluminium bolts and nuts shall be manufactured from alloy B51S or D65S. All steel bolts, nuts and washers shall have a hot-dip (galvanized) zinc coating which complies with the requirements of SABS 763 for coatings on type C2 articles. Blind rivets used for fixing road sign boards to squaretubing framework shall be 4,65 m m rivets manufactured

ensure that the colours and shades thereof match with those shown in SABS 1091.

5603

MANUFACTURING OF ROAD SIGN BOARDS AND SUPPORTS

(g)

Retr~dective material

Retro-reflective material shall be supplied in the following grades and shall comply with the requirements of SABS 1519 and the adhesion requirements of CKS 191: Class I material - 7 year warranty grade Class II material - 10 year warranty grade Class Ill material

The road sign face refers to the semi-matt or fully retroreflective painted background plus the text that includes all letters, symbols, numbers, arrows, emblems and borders. The road sign board refers to the assembled sign consisting of the road sign face on the specified plate or profiles, the supporting framework, cross bracing, struts and connecting mechanisms for mounting onto the sign support structure. The sign support structure refers to the steel or timber supports on which the road sign board is erected and includes the foundations. No additional payment will be made for steel members, such as amongst others hanging channels and U-bolts, that are required to complete and erect the total sign structure according to the specifications and the drawings.

- 10 year warranty grade

The specific commercial product used under class Ill shall be subject to the approval of the engineer.

No materials from different manufacturers shall be overlaid without specific approval of the engineer and subject to such conditions as the engineer may impose.

(a)

Road sign boards

The material shall be supplied with a pressure sensitive or heat applied adhesive backing protected by a removable lining.

Road sign boards shall be manufactured by a recognised manufacturer of road signs. Road sign boards shall be manufactured strictly in accordance with the details on the drawings. They shall be manufactured from either steel plate or steel profiles, or aluminium plate or aluminium sections according to what is specified on the drawings. Retro-reflective material shall be affixed to the sign face strictly in accordance with the specifications of the manufacturer of the retro-reflective material. Prefabricated road sign faces are unacceptable. In so far as is possible, road sign boards shall be manufactured as one unit. Where road signs are manufactured in more than one unit, the completed units shall be assembled in the workshop prior to delivery to ensure that all sections and legends fit together properly. Joints in road sign boards shall be provided only at locations and to details as shown on the drawings. (i) Steel plate road sign boards

(h)

Timber posts for road sign supports

Timber posts for road sign supports shall conform to the requirements of SABS 754, shall be equal to or better than strength group B timber posts and shall be stamped with the SABS mark. The posts shall be treated as specified in subclause 5402(b)(i). The exposed surface of the cut shall be given two coats of the specified preservative. Any holes drilled in the timber posts after treatment with the preservative shall be re-treated.

(i)

Corrosionprotectiontape

Corrosion-protection tape used between aluminium and steel shall be a black PVC tape not less than 0,25 m m in thickness, shall be resistant to ultra-violet rays, and shall have an adhesive backing. The breaking strength of the material shall be not less than 3,5 kN/m.

Except where specified for temporary silkscreening shall not be acceptable.

road signs

All road signs exceeding 600 m m in length (ie horizontally measured) shall be stiffened by a supporting framework as shown on the drawings. On all rectangular signs the supporting framework shall be positioned so that the distance to the edge of th sign plate shall not exceed 5 mm. When road sign boards are made up in sections the sections shall be joined with 10 m m galvanised bolts and nuts through 12 m m holes drilled in both adjoining members of the supporting framework sections with a maximum horizontal spacing of 500 m m and a maximum vertical spacing of 250 mm. All such drilling shall be done prior to painting. The framework panels for a particular road sign board shall be equal in size, so that the sign will have a balanced and symmetrical appearance when viewed from the rear. All such panels shall be placed on the rear of the road sign

All permissible silkscreening shall be done strictly in accordance with the requirements of the manufacturer of the retro-reflective material utilising only such inks or press colours as recommended by him.

(k)

Black vinyl

Black vinyl of a seven year outdoor warranty grade may be used. This material shall comply with the chromaticity and luminance factor requirements for black non-reflective sheeting in SABS 1519 and comply with the adhesion requirements of CKS 191.

be joined longitudinally, unless otherwise shown on the drawings. The steel plate shall be riveted to the framework wherever the plate is supported by the framework, and not on the edges only. The rivets shall have a maximum spacing of 150 m m on condition that even the shortest reinforcement will not have fewer than three rivets (ie one at each end and one in the middle). The colour of the rivets shall be the colour of the background on which they are fixed. Fastening clamps and/or erection brackets shall be manufactured, positioned and fastened to the framework in accordance with the details on the drawings. Care shall be taken by the contractor to ensure that the erection brackets are positioned in such a way that the road sign will be vertically and horizontally true to line when mounted. Each sign that does not require a supporting framework shall have two mounting holes of 12 m m diameter each located 25 mm from the sign edges so that the sign may be erected on a vertical post. The surface of structural steel for the framework of road signs shall be prepared by it being cleaned with a wire brush and it shall either be powder coated in accordance with SABS 1274 for Type 6 coatings, or painted in accordance with CKS 193. The colour of the framework shall be Dark Grey (reference number G13, as shown in SABS 1091). Direct contact between aluminium and any supporting steel framework shall be avoided by adhering corrosionprotection tape to the parts of the board in contact with the steel frame. (ii) Steel profile road sign boards Where aluminium sections are to be faced with retroreflective background material, it shall be applied in advance to individual sections before assembly, with the material taken around the face edges of each section for at least 10 mm. Retro-reflective material shall be heated to facilitate adhesion around the edges and to prevent damage being done to the material. During the heating process the temperature shall not exceed the manufacturers recommendations. Where possible, letters across the joint between two sections should be avoided. If it cannot be avoided, the letters concerned shall be bisected on the joint and the edges properly pressed home.

(e)

Gatvanizing

Where the galvanizing of structural-steel frames and signboard supporting structures is specified, it shall be done as far as is practicable after welding. Where, however, this is not practicable, the steel sections shall be galvanized before assembly and then welded. All welds shall be thoroughly cleaned, loose material removed, and dressed, after which the welds shall be coated with two coats of an approved zinc-rich paint.

Unless otherwise specified in the schedule of quantities or the project specifications, galvanized steel will not require painting.

(f)

Road sign supports

Steel profile road sign boards shall be manufactured in accordance with the details on the drawings. The sign faces of all steel profile road sign boards shall comply mutatis mutandis with the requirements of subclause 5603(d). Steel profile road sign boards shall not be joined longitudinally unless the length of the sign exceeds 6,O m. In such a case the sign shall be manufactured in sections of equal length and joined in accordance with the details on the drawings.

Road sign supports shall be constructed in accordance with the details shown on the drawings.

@)

General

Where details for the construction of road sign boards, the framework of the road sign boards and their attachment to the supporting steel framework are not shown on the drawings, the contractor himself shall design them and submit the details to the engineer for approval before manufacture.

@)

Welding

5604

ROAD SIGN FACES AND PAINTING

All welding of steelwork shall be carried out in accordance with the standards laid down in BS 5135. All welding shall be done before painting.

(a)

Colouts, symbols and legends

(c)

Structural steel

Paint colours, symbols, legends and borders used on road signs shall comply with the applicable statutory provisions, and also with the requirements of the South African Road Traffic Signs Manual.

The relevant provisions of section 6700, Structural Steelwork, shall apply to all steel supporting structures for road signs.

The colours and shades shall conform to the colours and shades specified in SABS 1519 and SABS 1091.

(d)

Aluminium sections The templates for all letters, numerals, arrows, borders, symbols, etc or the actual legend itself shall be cut by a method acceptable to the engineer.

Aluminium sections for road sign boards shall be jointed together by blind aluminium rivets or bolts. They shall not

@)

Preparing surfaces and applying paint and retroreflective sheeting

permitted. When required, existing or newly erected road signs shall be fully or partially covered with burlap or other approved adequately ventilated material to obscure destinations that are temporarily inapplicable or irrelevant. The covers shall be neatly applied and firmly fixed in position so that they will be able to withstand strong gusts of wind or eddies caused by passing traffic. The fixing shall be done in a way that will not cause any damage to the road sign face.

The preparation of surfaces and the painting shall be carried out as specified in section 8400. The surface of structural steel for the frames and supports of road signs shall be prepared by it being cleaned with a wire brush and shall then be coated as specified in clause 8407. Unless otherwise specified, aluminium roadsigns, with the exception of painted road sign boards, will not require painting. Galvanized frameworks will not require painting. Road sign boards with a semi-matt finish manufactured from prepainted plate (Chromadek or approved equivalent) shall not require pre-treatment or painting. No re-painting of these boards shall be accepted. Care shall be taken to treat all holes and cutting edges in accordance with CKS 193. The preparation of surfaces and application of retroreflective sheeting shall be done in strict accordance with the recommendations of the sheeting manufacturer. The preparation of the surface shall receive particular attention; as will the surface of a fully retro-reflective sign background prior to the application of the legend thereon.

5606

ERECTING ROAD SIGNS

(a)

Position

Road signs shall be erected in the positions shown on the drawings or indicated by the engineer.

@)

Excavation and backfilling

Excavations for the erection of road signs shall be made according to the dimensions shown on the drawings. Where the excavations are to be backfilled with soil, a 1:12 cement:soil mixture shall be made if so required by the engineer. The soil or soil-cement mixture shall then be placed at optimum moisture content in 100 mm thick layers in the excavation and shall be compacted to a minimum of 90% of modified AASHTO density. Where posts or structures are to be fixed in concrete, or where concrete footings are to be cast, the concrete, formwork and reinforcement shall comply with the requirements of sections 6200, 6300 and 6400. The holes shall be completely filled with concrete up to the level shown on the drawings or indicated by the engineer. The upper surface of the concrete shall be neatly finished with sufficient fall to ensure proper drainage. This subclause shall apply to ground-mounted signs only. Excavating and backfilling for the foundations of overhead steel structures are specified and measured in section 6 100. For the purposes of this subclause, excavation in rock shall correspond with the classification described in clause 2105. When material from the excavations is not suitable for backfilling or for the preparation of soilcrete, suitable material shall be obtained as instructed by the engineer.

(c)

Time of manufacture

The faces and backs of road sign boards and the legend shall not be painted more than six months prior to their erection. The manufacturer shall paint an identification code on the reverse side of every completed road sign board in the lower corner nearest to the road surface in a position where the code will not be obscured by the framework or the erection posts. The code shall be in the form X-MM-JJ where X is the letter used by the manufacturer to identify the manufacturer and MM-JJ indicates the month and year of the manufacture. These letters shall be painted in white (black on STOP signs) and shall not be larger than 50 m m in height.

(d)

Advertisements

No advertisements may be displayed on or attached to any part or any side of a road sign board or a road sign support.

[c)

Erection

5605

STOWIGE AND HANDUNG

All road signs or parts of road signs shall be so transported and so handled and so stored in a weather-proof storeroom as to prevent any damage and deformation. Sign boards shall be stored on blocks in the vertical position so that the signs are not in contact with the ground. There shall be sufficient space between the finished road sign boards to permit free air circulation and moisture evaporation. Contact of road sign boards with treated timber and diesel, or storage where road sign boards come into contact with dirt or water will not be

Road sign boards must be inspected by the engineer and approved in writing before the boards are taken from the manufacturer to the site for erection. The contractor shall notify the engineer at least one (1) week before the said inspections are required. Road signs shall be erected strictly in accordance with the details and instructions on the drawings and as directed by the engineer. During erection the structural steelwork shall be firmly bolted and protected to prevent buckling or damage from being caused during erection, or by the equipment used for erection.

Posts to which road signs are to be fixed shall be vertical and the undersides of road signs shall be horizontal after having been erected. Where timber posts are used for erecting the signs, all holes that are drilled in the timber shall be retreated with the approved preservative. A road sign identification number (as indicated on the layout drawings) shall be painted with white enamel paint on the reverse side of the road sign board, above the month and year of manufacture, in 50 m m high letters and numbers on the side closest to the road surface, Identification numbers on overhead signs shall be painted in a position that is visible from the road shoulder as directed by the engineer.

Where required by the engineer, the signs shall be repainted or repaired and new materials shall be used for part or all of the supporting structure.

5609

MEASUREMENT AND PAYMENT Unit

56.01 Road sign boards with painted or coloured semimatt background. Symbols, lettering and borders in semimatt black or i n Class Iretroreflective material, where the sign board is constructed from:

(d)

Field welding

(a) (i) (ii)

Aluminium sheet (2,O m m thick): Area not exceeding 2 m2 . . . . square metre (mz) Area exceeding 2 m2 but not 10 m Z . . . . . . . . . . . . square metre (m2) Area exceeding 10 m2 Aluminium sections (type indicated) all sizes

All welding done during erection shall comply with the requirements for welding during manufacture.

(e)

On-site painting (iii)

.....
....

square metre (m2)

All painting done after the road signs have been erected shall comply with the requirements for painting during manufacture. All places where the paintwork has been damaged during erection shall be repaired by the contractor at his own cost to the satisfaction of the engineer.

(b)

square metre (mz)

(c)

Prepainted galvanized steel plate (chromadek or approved equivalent): Area not exceeding 2 m2 . Area exceeding 2 m 2 but not 10 ni2 . . . . . .

(i)

(9

...

square metre (m2)

Time of erection (ii)

Road signs shall be erected immediately prior to the road being opened to public traffic, unless otherwise decided by the engineer.

......

square metre (mZ) square metre (m2)

(iii) (d)

Area exceeding 10 m 2 .

.....

@)

General

Prepainted galvanized steel profiles (200 m m high chromadek or approved equivalent): Area not exceeding 2 mz

All destinations and route numbers shown on the drawings shall be subject to amendment, and confirmation of the details shall be obtained from the engineer before any particular signs may be made. Such particulars may be available only at a late stage, for which allowance shall be made by the contractor in his programme.

(i) (ii)

....

square metre (mZ)

Area exceeding 2 m 2 but not 10 mZ . . . . . . . . . . . . . . . . . Area exceeding 10 m2 Other material (details indicated): Area not exceeding 2 m2 . Area exceeding 2 m2 but not 10 m 2 . . . .

. square metre (m2)

square metre (m2)

(iii)
5607

......

PROTECTION AND MAINTENANCE

(e)

The contractor shall protect the completed road signs against damage until they have been finally accepted by the employer, and he shall maintain the road signs until the maintenance certificate has been issued. Damage or defects caused by negligence or faulty workmanship shall be rectified by the contractor at his own cost to the satisfaction of the engineer.

(i) (ii)

. . . square metre (m2)

. . . . . . . square metre (mZ)

The unit of measurement shall be the square metre of completed road sign board. The tendered rate shall include full compensation for procuring and furnishing all the materials, and for manufacturing and supplying the completed road sign board, including amongst others the supporting framework, reinforcement, cross bracing, struts, fixing brackets, angleirons, channel profiles, galvanizing (if specified), painting, retro-reflective or semi-matt black lettering, symbols. numbers, arrows, emblems and borders, for attaching the road sign board to a road sign support structure, or to an

5608

DISMANTLING. STORING AND WSTING ROAD SIGNS

RE-ERECTING

Where ordered by the engineer, the contractor shall dismantle existing road signs, store them, and re-erect them at new positions indicated. This work shall be done with as little damage as possible to the signs.

overhead road sign structure, or to an overbridge, and for all materials, equipment, labour, supervision, nuts, bolts, transport, handling, etc necessary for the manufacture, completion, delivery and installation of the road sign board complete as specified. Payment shall distinguish between road sign boards made from the various materials specified.

The tendered rates shall also include full compensation for tidying up, clearing, trimming, disposing of material at approved dumping sites provided by the contractor, and finishing the area around each sign footing. Overhead road sign supporting structures shall not be measured and paid for under this item, but under the appropriate items of series 6000, Structures.

Item
56.02 Extra over item 56.01 for using:

Unit

Item

Unit

56.04 Kilometre posts (type indicated) . . . . . . . . . . . . . . . . . . . number (No)

(a)

Background of retroreflective material: Class I Class II

(i) (ii) (iii) (b)

. . . . . . . . . . . . . . . . . square metre

(m2) (m2) (m2)

The unit of measurement shall be the number of kilometre posts provided and erected in accordance with the drawings. The tendered rate shall include full compensation for all the labour and material, painting, lettering, posts, excavation, backfilling with soil or concrete, etc, as may be necessary for completing the work in accordance with the details shown on the drawings.

. . . . . . . . . . . . . . . . . square metre

Class Ill .

. . . . . . . . . . . . . . . . square metre

Lettering, symbols, numbers, arrows, emblems and borders of retro-reflective material: Class II Class Ill

Item (i) (ii)

Unit

. . . . . . . . . . . . . . . . . square metre

(m2) (m2)
56.05 Excavation and backfilling for road sign supports (not applicable to kilometre posts)

. . . . . . . . . . . . . . . . . square metre

. cubic metre (m3)

The area measured for payment shall be the full area of the road sign face as measured in item 56.01. The tendered rates paid extra over subitems 56.01(a), (b), (c) and (d) shall include full compensation for the additional cost of providing retro-reflective background, svmbols, lettering, - numbers, arrows, emblems and borders of the type specified in each case.

The unit of measurement shall be the cubic metre of excavation measured in place according to the neat dimensions of the footings or excavations as shown on the drawings or directed by the engineer. In the case of timber posts not in concrete, the plan area of the excavated hole shall be taken as 0,15 m2, irrespective of the actual size of the excavated hole. The tendered rate shall include full compensation for excavating, backfilling and compacting the backfill material, for the disposal of all surplus excavated material. and for providing the backfill material.

Item
56.03 Road sign supports (overhead road sign structures exduded):

Unit

Item (a) Steel tubing (diameter and wall thickness indicated) . . . . . . . . . . . . . ton (t) Timber (diameter and type indicated) . . . . .
56.06 Extra over item 56.05 for cement-treated soil bacMill . . . . . . . . . . .

Unit

(b)

. . . . . . . . . . . . metre . (m)

.......

cubic metre (m3)

The unit of measurement of supporting structures (a) manufactured from steel tubing shall be the ton of steel tubing used. Bolts and other accessories shall not be measured. The unit of measurement for timber supporting (b) structures shall be the metre of each diameter post used. Bolts and other accessories shall not be measured. Only the actual length of completed posts shall be measured. Cut-off sections shall not be measured. The tendered rates for subitems (a) and (b) shall include full compensation for manufacturing and erecting the road sign supports, including all bolts, screws, rivets, welding and accessories, together with the painting and galvanizing required, treatment of timber supports and the provision and treatment of breakaway holes in timber supports.

The unit of measurement shall be the cubic metre of excavation backfilled with cement-treated soil, measured as specified for item 56.05. The tendered rate shall include full compensation for the additional cost of providing and mixing in cement in the backfill material.

Item
56.07 Extra over item 56.05 for rock excavation . .

Unit

.......

cubic metre (ma)

The unit of measurement shall be the in situ cubic metre of rock excavated within the excavation limits specified in item 56.05.

The tendered rate shall include full compensation for the additional cost of excavating in rock.
56.09 Dismantling and storing

Unit

Item
56.08 Dismantling, storing and re-erecting road signs with a surface area of:

Unit (a) (b)

road signs with a surface area of: Up to 2 m 2

.................. ..............

number (No)

Exceeding 2 m 2 but not 10 m 2 . .

number (No)

(a) (b)

Up to 2 m2

. . . . . . . . . . . . . . . . . . number
..............

(No)

(c)

Exceeding 10 m Z . . . . . . . . . . . . . . number (No)

Exceeding 2 m2 but not 10 m2 . .

number (No) number (No)

The unit of measurement shall be the number in each size group dismantled and stored. The tendered rates shall include full compensation for carefully dismantling and disassembling the road signs, loading, transporting, off-loading and carefully stacking all the materials as required by the engineer. It shall also include compensation for restoring the site where the road signs have been dismantled. The tendered rates shall also include full compensation for demolishing the concrete footings of existing signs to at least 200 m m below the adjacent ground level, disposing of the resulting debris at approved dumping sites provided by the contractor, and cutting timber or steel support structures at not less than 200 m m below the adjacent ground level. Note: Concrete, formwork and reinforcing steel for road sign footings shall be measured and paid for in accordance with the provisions of sections 6200, 6300 and 6400, but such payment items shall appear under this section in the schedule of quantities.

(c)

Exceeding 10 mZ .

.............

The unit of measurement shall be the number of signs dismantled, stored and re-erected in each size group.

The tendered rates shall include full compensation for dismantling and storing the road signs and supporting structures, transporting the material to a new location, reerecting the road signs, and restoring the location where they were dismantled.

Payment for excavations, and the new material and concrete required for re-erecting the road signs shall be made under the appropriate item, and any repairs and painting which may be necessary, shall be paid for as "extra work". No separate payment shall be made for new bolts and nuts required for such re-erection, the cost of which shall be included in the rates tendered above.

SERIES 5000 : ANCILLARY ROADWORKS SECTION R O O : ROAD MARKINGS

mixing in 20% by mass Class A glass beads in accordance with BS 6088. (iv) Colour

CONTENTS
SCOPE MATERIALS WEATHER LIMITATIONS MECHANICAL EQUIPMENT FOR PAINTING SURFACE PREPARATION SETTING OUT THE ROAD MARKINGS APPLYING THE PAINT APPLYING THE RETRO-REFLECTIVE BEADS ROADSTUDS TOLERANCES GENERAL FAULTY WORKMANSHIP OR MATERIALS PROTECTION MEASUREMENT AND PAYMENT

The colours to be used shall be bright white, yellow or red. The colour of the yellow and red paint shall be as specified in SABS 731-1.

@)

Roadstuds

Permanent roadstuds shall comply with the requirements of SABS 1442. Permanent and temporary roadstuds shall be of the size and type indicated on the drawings or specified in the project specifications. The contractor shall, prior to delivery, submit to the engineer samples of the type of roadstuds he proposes to supply for approval. All studs subsequently used shall be of an equal quality or better.

5701

SCOPE
Road-marking paint shall not be applied to a damp surface or at temperatures lower than 10C, or when, in the opinion of the engineer, the wind strength is such that it may adversely affect the painting operations.

This section covers the marking of the road surface with painted lines and symbols and the supply and fixing of retro-reflective roadstuds as indicated on the drawings or required by the engineer. This section also covers the removal of existing road studs, and the supply and fixing of temporary road studs as ordered by the engineer, and the removal of existing road markings. All road markings shall be of the standard regulatory, warning and guidance markings as detailed on the drawings and in accordance with the South African Road Traffic Signs Manual.

5704

MECHANICAL EQUIPMENT FOR PAINTING

(a)
(i)

Paint
Road-marking paint

Road-marking paint shall comply with the requirements of SABS 731-1 for type 1, type 2 or type 4 paint as specified in the project specifications. The no-pick-up time of road marking paint shall comply with the class 1 requirement in SABS 731-1. The paint shall be delivered at the site in sealed containers marked in accordance with SABS 731-1. The viscosity of the paint shall be such that it can be applied without being thinned down. (ii) Retro-reflective road-marking paint

The equipment shall consist of an apparatus for cleaning the surfaces, a mechanical road-painting machine and all additional hand-operated equipment necessary for completing the work. The mechanical road-marking machine shall be capable of painting at least three lines simultaneously and shall apply the paint to a uniform film thickness at the rates of application specified hereinafter. The machine shall be so designed that it will be capable of painting the road markings everywhere to a uniform width with sides within the tolerances specified hereinafter, without the paint running or splashing or spattering. The machine shall further be capable of painting lines of different widths by adjusting the spray jets on the machine or by means of additional equipment attached to the machine. The machine shall be capable of spraying at a speed of not less than 5.0 kmlh, and shall be provided with clearly visible amber warning flashing lights which shall always be in operation when the machine is on the road.

5705

SURFACE PREPAR4TION

Retro-reflective road-marking paint shall comply with the requirements of subsubclause 5702 (a)(i) and CKS 192. (iii) Plastic road-marking material

Where specified in the project specifications, hot-melt plastic road-marking material shall comply with the requirements of BS 3262. The binder shall be a plasticized synthetic resin and the material shall be reflectorized by

Road markings shall be applied to bituminous surfaces only after sufficient time has elapsed to ensure that damage will not be caused to the painted surface by volatiles evaporating from the seal. After completion of the seal, no less than 2 weeks or such longer period as may be directed by the engineer shall elapse before any road markings shall be applied. However, the engineer may. in certain cases, require road markings to be painted without waiting for the seal to harden, in which case it shall be done as soon as possible after the instruction had been given.

Before the paint is applied, the surface shall be clean and dry and completely free from any soil, grease, oil, acid or any other material which will be detrimental to the bond between the paint and the surface. The surface where the paint is to be applied shall be properly cleaned by means of watering, brooming or compressed air if required. Where road markings are to be applied to a concrete pavement, all laitance and loose curing compound shall be removed. Particular care shall be taken to ensure that the surface shall be clean, fresh concrete on all areas where roadstuds are to be fixed.

Where two or three lines are required next to each other, the lines shall be applied simultaneously by the same machine. The paint shall be stirred before application In accordance with the manufacturer's instructions. Paint shall be applied without the addition of thinners. Where, under special circumstances, painting is done by hand, it shall be applied in two layers, and the second layer shall not be applied before the first layer has dried out sufficiently. As most road-marking paint reacts with the bitumen surface of the road, the paint shall be applied with one stroke only of the brush or roller. Ordinary road-marking paint shall be applied at a nominal rate of 0,42 l l m Z or as directed by the engineer and proprietary brand paints or plastic road marking materials shall be applied at the rates specified in the project specifications. Unless otherwise prescribed by the engineer, the road marking shall be completed before a particular section of the road is opened to traffic. Each layer of paint shall be continuous over the entire area being painted.

5706

SEITING OUT THE ROAD MARKINGS

The dimensions and positions of road markings shall be as shown on the drawings or as specified in the appropriate statutory provisions and the South African Road Traffic Signs Manual. The lines, symbols, figures or marks shall be premarked by means of paint spots of the same colour as that of the final lines and marks. These paint spots shall be at such intervals as will ensure that the traffic markings can be accurately applied, and in no case shall they be more than 1,5 m apart. Normally spots of approximately 10 m m in diameter should be sufficient. After spotting, the positions of the proposed road markings such as broken lines and the starting and finishing points of barrier lines shall be indicated on the road. These premarkings shall be approved by the engineer prior to any painting operations being commenced. The positions and outlines of special markings shall be produced on the finished road in chalk and shall be approved by the engineer before they are painted. Approved templates may be used on condition that the positioning of the marking is approved by the engineer before painting is commenced. The position of roedstuds shall be marked out on the road and shall be approved by the engineer before they are fixed in position.

5708

APPLYING THE RETRO-REFLECTEB B A D S

Where retro-reflective paint is required, the retro-reflective beads shall be applied by means of a suitable machine in one continuous operation, immediately after the paint has been applied. The rate of application of the beads shall be 0,8k g l l of paint or such other rate as may be directed by the engineer. Machines which apply the beads by means of gravity only shall not be used. The beads shall be sprayed onto the paint layer by means of a pressure sprayer. Additional surface reflectorization of plastic road markings shall be applied at the rate and by means of the methods specified in the project specifications.

5709

ROADSTUDS

5707

APPLYING THE PAlM

Roadstuds shall be of the type indicated on the drawings and shall be fixed in the positions indicated and approved by the engineer. The roadstuds shall be fixed by means of an approved epoxy resin in accordance with the manufacturer's instructions, subject to such amendments to the method as may be required by the engineer. The studs shall be protected against impact until the adhesive has hardened. Before fixing the roadstuds, the surface shall be thoroughly cleaned as specified in clause 5705. Permanent roadstuds shall be fixed after the painting of the road lines. Prior to the application of the surface treatment, all existing roadstuds shall be adequately protected. Painting over roadstuds is strictly prohibited. During laying of aggregate chips, rolling and brooming care shall be taken to protect all existing roadstuds against damage or breakage. The contractor shall replace at his own cost any roadstuds that have been damaged by constructional activities or that have been stained and cannot be cleaned entirely. Where ordered by the engineer, the contractor shall remove the existing road = studs prior to the application of the surfacing seal.

The figures, letters, signs, symbols, broken or unbroken lines or other marks shall be painted as shown on the drawings or as directed by the engineer. Where the paint is applied by machine, it shall be applied in one layer. Before the road-marking machine is used on the permanent works, the satisfactory operation of the machine shall be demonstrated on a suitable site which is not part of the permanent works. Adjustments to the machine shall be followed by further testing. Only when the machine has been correctly adjusted and its use has been approved by the engineer after testing, may the machine be used on the permanent work. The operator shall be experienced in the use of the machine.

After the machine has been satisfactorily adjusted, the rate of application shall be checked and adjusted if necessary before application on a large scale is commenced.

Where ordered by the engineer, temporary roadstuds shall be installed. The contractor shall maintain the temporary roadstuds in position until the permanent road markings have been completed.

5712

FAULTY WORKMANSHIP OR MATERIALS

5710

TOLERANCES

Road markings shall be constructed to an accuracy within the tolerances given below:

If any material which does not comply with the requirements is delivered to the site, or is used in the works, or if any work of an unacceptable quality is carried out, such material or work shall be removed, replaced or repaired as required by the engineer at the contractor's own cost. Rejected road markings and paint which has been splashed or dripped onto the pavement, kerbs, structures or other such surfaces, shall be removed by the contractor at his own cost, in an approved manner so that the markings or spilt paint will not show up at all.

(a)

Width
5713

The width of lines and other markings shall not be less than the specified width, nor shall it exceed the specified width by more than 10 mm.

PROTECTION

@)

Position

The position of lines, letters, figures, arrows, retro-reflective roadstuds and other markings shall not deviate from the true position by more than 100 m m in the longitudinal and 20 mm in the transverse direction.

After the paint has been applied, the road markings shall be protected against damage by traffic or other causes. The contractor shall be responsible for erecting, placing and removing all warning boards, flags, cones, barricades and other protective measures which may be necessary in terms of any statutory provisions and/or as may be recommended in the South African Road Traffic Signs Manual.

(c)

Alignment of markings

5714

MEASUREMENT AND PAYMENT

The alignment of the edges of longitudinal lines shall not deviate from the true alignment by more than 10 m m in 15 m.
57.01 Roadmarking paint:

(d)

Broken lines (a) White lines (broken or unbroken) (width of line indicated) . . . . . . . . . . . . . . . . . kilometre (km) Yellow lines (broken or unbroken) (width of line indicated) . . . . . . . . . . . . Red lines (broken or unbroken) (width of line indicated) . . . . . . . . . . . . White lettering and symbols . . . . . . . . Yellow lettering and symbols . . . . . . . .

The length of segments of broken longitudinal lines shall not deviate by more than 150 m m from the specified length. (b)
5711

GENERAL (c)

. . . . . .kilometre (km)

In broken lines the length of segments and the gap between segments shall be as indicated on the drawings. If these lengths are altered by the engineer, the ratio of the lengths of the painted section to the length of the gap between painted sections shall remain the same. Lines shall not be painted more than 3 months prior to the road being opened to public traffic. Lines on curves. whether broken or unbroken, shall not consist of chords but shall follow the correct radius.

. . . . . . kilometre (km)

(d)

. . . . . . . . square metre (m2) . . . . . . . . square metre (m2)

(e)

(1)

Transverse lines, painted island and arrestor bed markings (any colour) . . . . . . . . . . . . . square metre (m2) Kerb markings (any colour) . . . . . . . . .

Where plastic road-marking material is used, the manufacturer shall produce an approved guarantee as specified in the project specifications.

(g)

. . . . . . . . square metre (m2)

Unit

Where indicated by the engineer, the contractor shall remove existing painted markings from the existing surfaces by means of sand blasting or as ordered by the engineer. Suitable precautions shall be taken to avoid damage to nearby vehicles or other property during the sand blasting process. The use of black paint or chemical paint remover to obliterate existing markings will not be permitted, except where it is ordered by the engineer as a temporary measure.

Item
57.02 Retro-reflective roadmarking paint:

(a)

White lines (broken or unbroken) (width of line indicated) . . . . . . . . . . . . . . . . . . kilometre (krn)

(b)

Yellow lines (broken or unbroken) (width of line indicated) . . . . . . . . . . . .

. . . . . . kilometre

(km)

57.04 Variations i n rate of application:

(c)

Red lines (broken or unbroken)(width of line indicated) . . . . . . . . . . . . . . . . . . kilometre (km) White lettering and symbols . . . . . . .

(a) (b)

White paint . . . . . . . . . . . . . . . . . . . . . . .litre ( I ) Yellow paint

. . . . . . . . . . . . . . . . . . . . . .litre (1)
litre ( I )

(d)

. . . . . . . . . square metre (m')

(d) Retro-reflective beads Plastic road-marking paints (specify) . . . .

(e)

Yellow lettering and symbols . . . . . . . .

. . . . . . . . . . kilogram

(kg)

. . . . . . . . square metre (ni2)

(e)

(1)

Transverse lines, painted island and arrestor bed markings {any colour) . .

. . . . . . . . . . . . . . . litre .

(I)

. . . . square metre (m2)

The unit of measurement for variations in the rate of application of the paint and retro-reflective beads shall be a litre and a kilogram respectively. Payment for variations shall be made as specified in clause

57.03 Hotmelt plastic road-marking

material (particulars stated): (a) White lines (broken or unbroken) (width of line indicated) . . . . . . . . . . . .

1213.

Item

Unit

. . . . . . kilometre

(km)

57.05 Roadstuds (type stated)

.....

number (No)

(b)

Yellow lines (broken or unbroken) (width of line indicated) . . . . . . . . . . . . . . . . . . kilometre (km) Red lines (broken or unbroken)(width of line indicated) . . . . . . . . . . White lettering and symbols . . . . . . .

The unit of measurement for roadstuds shall be the actual number of approved roadstuds placed. The tendered rate shall include full compensation for procuring and furnishing all the necessary material, labour and equipment, and for fixing and maintenance as specified. Distinction shall be made between various types of roadstuds.

(c)

. . . . . . . . kilometre

(km)

(d)

.........

square metre (rn2) Item Unit

(e)

Yellow lettering and symbols . . . . . . . .

. . . . . . . . square metre (mZ)

(f)

Transverse lines, painted island and arrestor bed markings (any colour) . . . . . . . . . . . . . square metre (mz)

57.06 Setting out and premarking the lines (excluding traftio island markings, lettering and symbols)

..........

kilometre (km)

The unit of measurement for painting the lines shall be a kilometre of each specified width of line and the quantity paid for shall be the actual length of line painted in accordance with the instructions of the engineer, excluding the length of gaps in broken lines. The unit of measurement for painting the lettering, symbols, transverse lines or painted island and arrestor bed markings shall be a square metre, and the quantity to be paid for shall be the actual surface area of lettering, symbols or transverse lines, painted island and arrestor bed markings completed in accordance with the instructions of the engineer.

The unit of measurement for setting out lines shall be the kilometre of lines set out and marked. Where two or three lines are to be painted next to each other! and where the centre to centre distance between adjacent lines does not exceed 500 mm, the setting-out of lines shall be measured only once. The tendered rate shall include full compensation for setting out and premarking the lines as specified, including all materials.

Item
57.07 Reestablishing the

Unit

The tendered rate per kilometre or per square metre as the case may be for painting the road markings shall include full compensation for procuring and furnishing all material, including the retro-reflective beads in the case of retroreflective paint, and the necessary equipment, and for painting, protecting and maintenance as specified, including the setting-out of lettering, symbols and transverse lines, painted island and arrestor bed markings, but excluding setting out and premarking the lines.

painting unit at the end of the maintenance period

.........

lump sum

The tendered lump sum shall include full compensation for the re-establishment on the site and for later removing all special equipment, personnel, etc, as may be required for repainting the road-traffic markings at the end of the maintenance period. The contractor will be paid at tender rates for repainting the road markings.

The re-establishment during the construction period shall not be paid for specially, and allowance therefor shall be made by the contractor in his programme arid his rates for painting.

The tendered rate shall include full compensation for the necessary equipment, labour and materials, for any specific protection measures, accommodation of traffic, and the cleaning of the area of all dust, all as specified.

Hem

Unit
57.09 Removal of existing roadstuds .

Unit

57.08 Remwal of existing, temporary or permanent road markings by:

(a) (b) Sandblasting

...

number (No)

..... . . . .

... .

square metre (mZ)

The unit of measurement shall be the actual number of roadstuds removed. The tendered rate shall include full compensation for furnishing all equipment, labour and material to remove the existing roadstuds as specified and to repair the road surface in case of any damage, as well as the disposal of tlie roadstuds.

Overpainting as temporary measure

. . . . . . . . square metre (mZ)

The unit of measurement shall be the square metre of road marking removed or obliterated.

SERIES 5000 : ANCILLARY ROADWORKS SECTION 5800 : LANDSCAPING AND PLANTING PLANTS

seeds in the seed mixture shall be as specified in the project specifications. Mixing the various types of grass seeds for obtaining the prescribed grass-seed mixture shall be done on the site in the presence of the engineer. At any time during the planting process the engineer has the right to take samples in order to test the quality of materials and workmanship. Storing and identifying the grass seeds and the grass-seed mixtures on the site shall be the responsibility of the contractor.

CONTENTS SCOPE AND DEFINITION MATERIALS LANDSCAPING THE AREAS PREPARING AREAS FOR PLANTS GRASSING PLANTING AND MAINTAINING THE PLANTS TREES AND SHRUBS GENERAL MEASUREMENT AND PAYMENT

(d)

Trees and shrubs

Plants shall be of the variety and size shown on the drawings or in the project specifications and/or the schedule of quantities. The contractor shall supply the required number of plants as shown on the drawings or in the project specifications and/or the schedule of quantities. Plants must be healthy, shapely, well rooted and disease-free. Plants shall not show any evidence of having been restricted or deformed at any time. Plants shall be grown specifically to be able to cope with the adverse conditions as experienced in the road reserve. The plants must be hardened off and be exposed to direct sunlight for at least six months prior to planting in the road reserve. A minimum amount of waterlfertiliser should be administered in order to acclimatize the plants for their future environment all to the satisfaction of the engineer. Each tree shall be supplied in a plastic plant container of at least 8,O 1 capacity, and shall have a height of at least 1 500 mm. Each shrub shall be supplied in a plastic plant container of at least 4,5 1 capacity and shall have a height of at least 500 mm. Each plant shall be handled and packed in the approved manner for that species or variety, and all the necessary precautions shall be taken to ensure that the plants will arrive at the site of the works in an undamaged and healthy condition for successful growth. Trucks used for transporting plants shall be equipped with covers to protect the plants from windburn. Containers shall be in an undamaged condition. The contractor shall ensure that the plants are in a good condition and free from pests and diseases and he shall accept full responsibility for maintaining the plants in a good condition throughout the contract and the maintenance periods. The plants shall be fully maintained and watered during this period and any losses of plants on account of the lack of care, also where they are diseased, during the contract and maintenance periods, shall be replaced at the contractor's own cost.

5801

SCOPE AND DEFINITION

This section covers the landscaping of designated areas, the planting of plants for functional and aesthetic purposes on cut and fill slopes, landscaped areas and such other areas where it may be required.

@)

Definition

WEEDS Any proclaimed weeds or alien invader plants (as listed in bulletin 413 issued by the Department of Agriculture, Directorate of Agricultural Information), as well as any tree, shrub, herb, water plant or any other plant which, in the opinion of the engineer, may pose any problems in specified areas (such as the road reserve, haul roads, borrow pits, camp sites, stockpile sites, etc) at certain times, and is therefore regarded as being undesirable.

5802 MATERIALS

(a)

Fertiliser/soilimprovement material

The type of fertiliser/soil-improvement material to be used shall be one or more of the following types and any other type of fertiliser/soil-improvement material specified in the project specifications or prescribed by the engineer. Soil-improvement materials such as dolomitic lime, (i) basic slag, gypsum, superphosphate and agricultural lime. (ii) Fertilisers such as limestone ammonium nitrate,

2:3:2(22) and 3:2:1 (25).

I

@)

Grass cuttings (e) Grass sods

Grass cuttings shall be fresh cuttings of an approved type of grass with sufficient root material to ensure good growth.

(c)

Grass seeds

Only fresh certified seed shall be used and the types of

Grass sods shall be either nursery-grown or veld sods as described below. Both types shall be harvested, delivered, planted and watered within 36 hours unless otherwise authorised by the engineer. The grass sods shall be free from noxious weeds and diseases. Sods delivered to the site shall be moist and shall have at least 30 m m soil thickness for nursery-grown sods and 50 m m soil thickness

for veldsods, at the points of planting or placement. Sods shall also measure a minimum of 400 m m in width and 500 m m in length and shall retain the minimum dimensions until they are placed. (i) Nursery-grown sods

(h)

Manure

These sods shall be of the variety of grass specified in the project specifications, unless the use of an alternative has been approved by the engineer. The grass shall have been grown specifically for sod purposes, mown regularly and cared for to provide an approved uniformity to the satisfaction of the engineer. It shall be harvested by special machines manufactured for this purpose to ensure an even depth of cut with sufficient root material and soil. (ii) Veld sods

Manure shall, unless another type has been approved by the engineer, be old, sweated, pure kraal manure free from soil, noxious weed seeds or other undesirable material. It shall not contain any particles that will not pass through a 50 m m screen and shall be approved by the engineer before being delivered to the site.

(i)

Compost

Compost shall be well decayed, friable and free from noxious weed seeds or any other undesirable materials. It shall not contain any particles that will not pass through a 50 m m screen and shall be approved by the engineer prior to delivery on the site.

These sods may be obtained from areas approved by the engineer within or near the site where a suitable type and density of grass and type of soil are found. These areas shall also be mown regularly and cared for to provide suitable sods to the satisfaction of the engineer.

5803

LANDSCAPING THE AREAS

(a)

Shaping

(f)

Antierosion compounds

Anti-erosion compounds shall consist of an organic or inorganic material to bind soil particles together and shall be a proven product able to suppress dust and form an encrustation. The application rate shall conform to the manufacturer's recommendations. The materials used shall be of such a quality that grass seeds may germinate and penetrate the crust.

Areas within the road reserve but outside the road prism which require shaping by means of bulk earthworks such as contoured areas at interchanges and intersections and rest areas which require earthworks shall be excavated, filled and compacted when required, and shaped to the correct contours to within a tolerance of plus or minus 150 rnrn. Such work shall be regarded as being earthworks and measurement and payment therefor shall be made under section 3300, except that quantities may be measured by means of a grid system of levels taken at 10 m intervals before and after shaping or else it may be determined by levelled cross-sections.

@)

Topsoil

Topsoil shall preferably consist of selected fertile loamy soil, obtained from areas with a good soil coverage of natural vegetation, preferably grasses. It shall be free from deleterious matter such as large roots, stones, refuse, stiff or heavy clays and the seeds of noxious weeds, which will adversely affect its suitability for grass being planted. Topsoil stripped from areas infested with weeds shall be stockpiled separately. Topsoil shall be obtained from wherever suitable material occurs either in the road reserve from areas where cuts and fills are to be constructed or from borrow areas to be cleared as described in subclause 1702(c). The engineer shall communicate his requirements to the contractor regarding the quantity of topsoil which is necessary and the areas from which it shall be selected and removed by the contractor. Unless otherwise specified, topsoil shall be taken from not deeper than 400 m m from the surface. If the contractor fails to conserve the topsoil as instructed, he shall obtain suitable substitute material from other sources at no extra cost to the employer. Where so specified, the contractor shall procure and furnish topsoil from his own sources outside the site, after such sources have been approved by the engineer. Topsoil shall be stockpiled in separate loose heaps as tipped from the trucks and shall not be stockpiled in heaps exceeding 2,Om in height, unless otherwise specified by the engineer. Care shall be taken to prevent the compaction of the topsoil in any way, especially by trucks being driven over such material.

(b)

Trimming

Trimming shall consist of trimming the existing o: previously shaped ground to an even surface with the final levels generally following the original surface. and it is a requirement that the drainage remains effective. Trimming shall normally be done by grader, or in more confined or steep areas by bulldozer. Where machine operations are not practicable, because of confined spaces or steep slopes, trimming shall be done with hand tools. When trimming is done on slopes, the ridges shall be made parallel to the contour. Such ridges shall be approximately 100 rnm wide, and the centres between the ridges approximately 400 rnm. Trimming shall be done where instructed by the engineer to areas inside the road reserve but outside the road prism, ie normally outside the tops of cuts or the toes of fills, but trimming of rock outcrops and koppies will not be required. Trimmed surfaces shall be left slightly rough to facilitate a better binding with topsoil or the natural establishing of vegetation. When subsequent grassing is required or when it is ordered by the engineer, areas previously shaped shall be trimmed as described above to within a tolerance of plus or minus 100 m m with all undulations following a smooth curve. The above tolerance shall apply only to areas where the final contours are given on the drawings. During trimming, all stones in excess of 50 rnm in size and all excess material shall be removed. Areas which require

grassing shall be trimmed in such a way that, after cultivation and the application of topsoil, the finished surface of the area shall be at least 30 mm below the top of adjacent kerbing, channelling or pavement in the event of sodding with nursery grown sods, and at least 50 mm below in the event of veld sods being placed.

by the contractor. The engineer shall be furnished with the soil-analysis and subsequent fertilizer recommendations. Only after approval by the engineer of the nature and quantity of the fertilizer, may the application proceed. Soil-Improvementmaterials (such as lime, superphosphate, etc) shall be evenly applied over all surfaces where grass is to be planted, and shall then be thoroughly mixed with the soil to a depth of 150 mm either mechanically or manually. Where hydroseeding is to be performed, the fertilizer may be mixed with the anti-erosion compound and water used in the hydroseeding.

(c)

Plant rates

The engineer shall be entitled to pay for shaping and trimming as described above on the basis of hourly plant rates. The motor grader and bulldozer to be provided shall each have a flywheel power of not less than 93 kW. All machines shall be in a good condition. Any labour or other plant required shall be paid for as a variation as specified in clause 40 of the general conditions of contract.

(e)

Verdyol Complex or similar

5W)4

PREPAMNG THE AREAS FOR PLANTS

In certain limited and unique cases, where topsoil is not available or can not be retained on a steep slope, Verdyol Complex or similar may be used at an approved application rate, at the discretion of the engineer.

(a)

Soil ripping

(f)

General

Where soil is too hard to be scarified with a light tractor, the soil shall be ripped up to a depth of 300 mm before it is loosened by a scarifier to a depth of 150 mm.

After an area has been prepared for grassing, the grassing shall be completed before crustificationtakes place. Where a crust has been formed before grassing is done, the contractor shall, at his own cost, loosen the crust by scarifying to a depth of 150 mm.

@)

Areas which do not require topsoil

5805

Where the areas to be grassed consist of organically suitable material, the topsoil shall be loosened by scarifying to a minimum depth of 150 mm. All loose stones exceeding 50 mm in size on areas to be mowed by machine and falling withln the road reserve and all stones exceeding 150 mm in size in other areas shall be removed. Fertilizing may still be required as specified in subclause 5804(d).

GRASSING

The method of establishing grass shall depend on the circumstances relating to each case, and the engineer shall decide which method is to be used.

(a)

Planting grass cuttings

(c)

Areas which require topsoil

Where areas to be grassed consist of organically unsuitable material, the surface shall be scarified to a minimum depth of 150 mm before topsoil is placed to ensure a proper bond between the topsoil and the subsoil. If required, the area shall be scarified as described in subparagraphs (a) or (b) above. Topsoil shall be placed on the prepared surfaces and trimmed to the uniform thickness required. The topsoil shall be scarified by means of handraking or light rotavators and all stones removed as specified for areas not requiring topsoil in subparagraph (b) above. Areas inaccessible for topsoil being placed mechanically after the construction works have been completed shall be covered with topsoil and protected against erosion as construction works progress.

The areas to be grassed by means of grass cuttings shall, unless already moist, be thoroughly watered before the cuttings are planted to ensure that the soil will be uniformly moist to a depth of at least 150 mm when the planting is done. This method shall only be used on flat areas, such as medians.

An approved variety of grass cuttings shall be evenly planted by hand or mechanically at a rate of at least 600 kg of cuttings per hectare and shall be covered with 30 mm of approved soil. Fresh cuttings only shall be used but not any grass cuttings that have been allowed to dry out. Immediately after having been planted, the grass cuttings shall be given a copious watering, and, when sufficiently dry, shall be rolled with a light agricultural roller.

@)

Sodding

(d)

Fertilizing

For all areas to be planted the contractor shall have the top 150 mm of the prepared surface analysed to determine the quantity and type of fertilizer which may be required for establishing proper growth conditions for the grass. The locations of soil samples taken shall be indicated on plans

Areas to be grassed by sodding shall be given a layer of topsoil of at least 50 mm In thickness unless, where suitable soil is present, the engineer orders the topsoil to be omitted. The areas to be sodded shall be thoroughly watered beforehand so that it will be moist to a depth of at least 150 mm during sodding. The surface shall be roughened slightly to ensure a good penetration of roots into the soil. Sods shall be protected against drying out and kept moist from the time of harvesting until they are finally placed. The handling of the sods shall not result in

the sods losing their prescribed soil thickness. The first row of sods shall, where possible, be laid in a straight line, and if on a slope, laying the sods shall start at the bottom of the slope. The sods shall be butted tightly against each other, and care shall be taken not to stretch or overlap the sods. Where a good fit cannot be obtained, any intervening spaces shall be filled with topsoil. The next row shall be similarly placed tightly against the bottom row with staggered joints, and so on until the entire area has been covered with sods. Sods shall be laid in such a way that unnecessary trampling over areas previously laid is prevented. To this end, a diagonal method of laying sods is preferred, moving up the slope and behind previously laid sods. On steep slopes the sods shall be held in position by a sufficient number of wooden stakes approximately 300 mm long by 20 mm in thickness and these stakes shall be knocked in to a depth of 100 mm into the subsoil. Sods laid adjacent to concrete side drains shall be laid in such a manner that the sodding will be 20 mm higher than the concrete. The top surface of sods laid adjacent to the road pavement shall be 50 mm lower than the road surface. When stripsodding is required, the sods shall be laid in such a manner that the sods are proud of the surrounding ground level. During stripsodding the areas in between shall be hydroseeded as specified in subclause 5805(c). Stripsodding shall at all times be staked as specified above.

(d)

Topsoiling only

Where, in the opinion of the engineer, the planting of grass or hydroseeding can be dispensed with on account of favourable climatic and other conditions, the contractor may attempt to establish grass by topsoiling only. Topsoil shall be selected for the presence of natural grass and seeds and shall be removed and placed whenever possible at a time that would favour the establishing of grass. These areas shall be treated with an anti-erosion compound, if so instructed by the engineer. Fertilizing shall be done as specified in subclause 5804(d). After the topsoil has been placed, it shall be lightly rolled and well watered, and afterwards watered and mown whenever instructed by the engineer. The contractor will not be held responsible for establishing an acceptable grass cover as defined in subclause 5806@) when this procedure is followed, but will be responsible for the consequences of any omission to water or mow or weed the grass as instructed by the engineer. No payment for grassing shall be made other than for placing topsoil, providing and applying fertilizers and for watering, mowing and weeding the grass, which will be paid for at the tendered rates. For any replanting of grass on bare patches, repairs caused by erosion, and similar work, the contractor will be paid for as a variation in terms of clause 40 of the general conditions of contract.

As sodding is completed each section shall be lightly rolled or firmly pressed to ensure a proper bond with the underlying material, and thoroughly watered afterwards.

(e)

Grassing wiih an appmved grass planbr

Where it is specified that hydroseeding is to be carried out on topsoil, the thickness of the topsoil layer shall be as specified In the project specifications or as directed by the engineer. The types and mixtures of seeds to be used shall be as specified in the project specifications or, if not so specified therein, shall be agreed on by the engineer and the contractor before any seed he may wish to use is ordered by the contractor. The contractor shall be solely responsiblefor establishing an acceptable grass cover, and any approval by the engineer of seed or seed mixtures intended for use by the contractor shall not relieve him of this responsibility.

Grassing shall be done with an approved grass planter which plants the seeds in rows spaced not more than 250 mm apart. The planter shall plant the seeds approximately 6 mm deep and shall lightly compact the soil. The prescribed fertiliser may be distributed simultaneously with the grass planting.

(f)

Sarving by hand

If approved by the engineer, sowing may be done by hand on areas inaccessible to machines. The seed shall be spread uniformly over the surfaces and then lightly raked Into the soil.

(g)

Whenever speMed in the project specifications, other methods of grassing may be employed. The grassing of b o r n pits, tempwary devietions, . camp sites, access roads and stockpile sites

A mulch shall be added to the hydroseeding mix at an approved rate.

(h)

Hydroseeding shall then be carried out with an approved hydroseeding machine at a rate of application of not less than 38 kg of seed mixture per hectare, unless otherwise specified in the project specifications.

Prior to any grassing that may be required on such areas, the finishing-off of borrow pits as described under clause 3105, obliterating the temporary deviations and access roads as described in clauses 1516 and 5903 respectively, and the clearing of camp sites as described In section 1300, shall have been carried out as specified in the relevant sections.

When the use of anti-erosion compounds is required and such compound is to be applied simultaneously with the hydroseeding, it shall be mixed with the hydroseeding mixture before application. Should Verdyol Complex or approved equivalent be used, the quantities of the fertilizers shall be adjusted accordingly, subject to the engineer's approval.

Note:

With regard to subclauses 5805(e) and (1). the areas to be grassed shall be prepared as desaibed In clause 5804 and the areas shall be thoroughly watered after campMon the operation. Also,I f deemed necessary, an anti+roefon

of

campound shall be applied.

5807

TREES AND SHRUBS

5806

PLANTING AND MAINTAINING THE PLANTS

(a)

Positions o f trees and shrubs

(a)

Watering, weeding, mowing and replanting

The localities where trees and shrubs are to be planted are as follows: Trees and shrubs shall be planted at locations (i) shown on the drawings. Plants in the median shall be planted in a line 1,5 (ii) m from the centre line of the median or as directed by the engineer. When the carriageways are at different levels, the (iii) plants in the median shall be planted 3 m from the edge of the pavement on the high side of the median or as directed by the engineer. Where the road curves, the plants In the median (iv) shall be planted on the inside of the median centre line. Where the carriageways are at different levels as (v) well as on a curve, the plants in the median shall be planted on the high side, provided they do not impede on sight distance, or as directed by the engineer. At freeway crossings over roads or rivers, shrubs (vi) shall be planted in the positions shown on the drawings. At the headwalls of culverts or similar structures, (vii) trees and/or shrubs shall be planted to indicate the positions of these structures. The locations for planting the plants shall be as shown on the drawings or as directed by the engineer. (viii) Care shall be taken not to obscure traffic signs by plants. Trees shall not be planted closer than 10 m from (ix) the yellow line on the outside shoulder, or as directed by the engineer.

All sodded and grassed areas shall be adequately watered at regular and frequent intervals to ensure the proper germination of seeds and growth of grass until the grass has established an acceptable cover and thereafter until the beginning of the maintenance period of the grass. The quantity of water and the frequency of watering shall be subject to the engineer's approval. With hydroseeding the commencement of watering may be postponed until a favourable time of the year, but watering shall in any case commence and continue as soon as the seeds have germinated and growth has started.

The contractor shall further mow the grass on all areas where grass has been established whenever so instructed by the engineer, until the end of the maintenance period. All grass cuttings shall be collected and disposed of if so directed by the engineer. All weeds shall be eradicated and disposed of by approved means and provision for payment for such operations shall be made under item 58.04. Weeds shall be eradicated before they have a chance to flower. Any bare patches where the grass has not taken or where it has been damaged or has dried out shall be recultivated, planted, sodded or hydroseeded at the contractor's own expense.

All grassed areas shall have an acceptable cover as defined below at both the beginning and the end of the maintenance period.

@)

Acceptable cover

An acceptable grass cover shall mean that not less than 75% of the area grassed or hydroseeded shall be covered with grass and that no bare patches exceeding 0,25 mZin any area of 1 m x 1 m shall occur. In the case of sodding, acceptable cover shall mean that the entire area shall be covered with live grass at the end of any period not less than three months after sodding.

@)

Reparing plant holes

Unless otherwise directed by the engineer, holes shall be spaced and prepared as follows: (i) All holes shall be square in plan.

(c)

Maintenance period Holes for shrubs shall be at least 500 mm square by (ii) 600 mm deep at intervals of at least 1,5 m centre to centre. Alternatively a 500 mm wide trench 600 mm deep may be dug, subject to the engineer's approval. Holes for trees shall be at least 700 mm square by (iii) 800 mm deep. The holes for plants shall be refilled with selected (iv) and approved topsoil thoroughly mixed beforehand with manure or compost (one 5 1 bucket full for every shrub hole and one 10 1 bucket full for every tree hole) and: depending on soil-analysis, the required quantity and type' of fertilizer. The fill material shall contain an approved water retaining admixture. The holes shall be thoroughly watered before plants (v) are planted. Where the soil is poorly drained, 150 mm of

The maintenance period in respect of grass shall commence when an acceptable grass cover as defined in (b) above has been established and shall be one year. This means that the maintenance period in respect of grass can commence earlier or later than the maintenance period for other parts of the contract.

If the maintenance period in respect of grass expires

before the end of the maintenance period for the other roadworks, the contractor shall further mow the grass on such areas as instructed by the engineer up to the end of the maintenance period for the other roadworks. For mowing that is executed after the maintenance period in respect of grass has expired, the contractor will be paid under item 58.07.

crushed stone shall be placed at the bottom of the hole before it is filled with soil.

@)

Traffic on grassed areas

(c)

Planting

Before trees and shrubs are removed from their containers for planting purposes, they shall be watered to the point of saturation. Directly after having been planted, each plant shall be well watered with a view to settling the soil. After the soil has settled, additional topsoil mixture shall be added where necessary to bring the replaced soil in the hole to within 150 m m of the ground surface, so as to ensure that sufficient water can be retained in the hole around the plant. All trees shall be tied by means of treated sisal rope to two creosote-treated timber stakes planted firmly in the ground on both sides of the tree directly opposite each other. The distance between the stakes shall be 1,O rn. The stakes shall have a minimum diameter of 50 mrn and shall be at least 300 m m longer than the planted tree, but its length shall not exceed 1,5 m above ground level. After planting, the ground surface around the shrubs shall be covered with straw or grass or any other type of mulch to minimise evaporation and/or weed competition. The ground surface around each tree shall be covered with a plastic membrane with a surface area of 1.0 m Z and a thickness of 150 micron. Thereafter rocks or stones measuring 150 m m to 250 m m in diameter shall be placed in a riprap fashion following the contours of the plant hole. The contractor shall water the trees and shrubs until they are established. He will be paid for watering under item 58.06.

The contractor shall not plant any grass until all operations which may require road-building equipment to be taken over grassed areas have been completed. No road-building equipment, trucks or water carts shall be allowed onto areas which have been grassed and only equipment required for the preparations of areas, application of fertiliser and spreading of topsoil will be allowed to operate on areas to be grassed. All damaged areas shall be reinstated by the contractor at his own expense.

(c)

Erosion prevention

During construction the contractor shall protect all areas susceptible to erosion by installing all the necessary temporary and permanent drainage works as soon as possible and by taking such other measures as may be necessary to prevent the surface water from being concentrated in streams and from scouring the slopes, banks or other areas. Any runnels or erosion channels developing during the construction period or during the maintenance period shall be backfilled and compacted, and the areas restored to a proper condition. The contractor shall not allow erosion to develop on a large scale before effecting repairs and all erosion damage shall be repaired as soon as possible and in any case not later than three months before the termination of the maintenance period. All topsoil or other material accumulated in side drains shall be removed at the same time. Topsoil washed away shall be replaced.

(d)

Proprietary brand materials used for erosion prevention

(d)

Maintenance

During the period of maintenance, which shall be twelve months after acceptance of established trees and shrubs. the contractor shall be responsible for watering the trees and shrubs when necessary and keeping the plants free from weeds and pests. The plants shall be watered in accordance with an agreement concluded between the engineer and the contractor prior to the beginning of the maintenance period. The watering of plants will be paid for under item 58.06. Every tree or shrub, which is not healthy or shows unsatisfactory growth, shall be replaced by the contractor at his own expense, within one month of having been notified by the engineer, in writing. Such notification as set out in the latter sentence, may be given quarterly during the maintenance period.

Certain proprietary brands of materials which may be necessary for erosion prevention to enable natural grass to become established, shall, if required, be specified in the project specifications. The method according to which the material is to be applied, the surface preparation required, the type of material to be provided and the method of payment shall be as specified in the project specifications.

(e)

Responsibility for establishing an acceptable cover

5808

GENERAL

(a)

Time for planting

Grass, trees and shrubs shall be planted as far as is practicable during periods of the year most likely to produce best growing results. The contractor shall make every effort to programme his operations in such a manner that grass, trees and shrubs shall, as far as is possible, be planted during this period.

Notwithstanding the fact that the engineer will determine the method of grassing and that the type of seed or grass used and the rate of application of the seed may be specified or agreed on by the engineer, and that the frequency of mowing will be as ordered by him, the contractor shall be solely responsible for establishing an acceptable grass cover and for the cost of replanting grass or rehydroseeding where no acceptable cover has been established. Where however, in the opinion of the contractor, it is doubtful from the outset if it will be possible to establish an acceptable cover he may inform the engineer of his reasons therefor, and the engineer may. if he agrees. either adopt another method of grassing or agree to accept whatever cover can be obtained, provided that all reasonable efforts shall be made to establish a good grass cover by the proposed method. Any such agreement shall be valid only if given in writing by the engineer beforehand. In the case of grassing by topsoiling only the contractor will not be held directly responsible for establishing an

acceptable grass cover but will be held responsible for the consequences of supplying workmanship which does not conform to the specifications, or for lack of proper care.

58.03 Preparing the areas

for grassing:
(f)

Refertilizing

(a) (b)

Ripping

. . . . . . . . . . . . . . . . . . . . . .hectare (ha)
. . . . . . . . . .hectare (ha)

Should it become necessary, the engineer may instruct the contractor to undertake a refertilizing programme on grassed areas during the twelve month maintenance period. Payment for refertilization will be made under subitem 58.03(e).

Scarifying for loosening topsoil . . . . . . . . . . . .

(c)

Topsoiling within the road reserve, where the following materials are used: Topsoil obtained from within the road reserve or borrow areas (free-haul 1,O km) .

(i)

5809 MEASUREMENT AND PAYMENT

(ii) Item
58.01 Trimming:

cubic metre (m3)

Unit

Topsoil obtained from other sources by the contractor (including all haul) . . . . . . . . . cubic metre (m3) Topsoiling of borrow pits by using topsoil obtained from borrow areas or from the road reserve (free-haul 1,O km) . . . . . . . . . . . . . . . . . . cubic metre (m3) Providing and applying chemical fertilisers and/or soil-improvement material: Lime

(d) (a) (b) Machine trimming Hand trimming

.........

square metre (m2) square metre (m2)

...........

Note:
All bulk earth-moving operations as described under shaping in subclause 5803(a) shall be measured and paid for under section 3300. The unit of measurement for trimming shall be the square metre of area trimmed on the instruction of the engineer, including areas trimmed after having been shaped. No trimming within the road prism shall be measured for payment. The tendered rates shall include full compensation for trimming the areas to the specified finishing requirements, including the moving of a small quantity of material which would be inherent in this process and the removal of surplus material and stones. Payment shall distinguish between machine trimming which can reasonably be done by bulldozer or motor grader, and hand trimming which cannot be done by machine on account of confined space, steep slopes or difficult shapes.

(e)

(i) (ii) (iii) (iv) (v) (vi)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . ton

(1) (t)

Superphosphate

. . . . . . . . . . . . . . . . . . . ton
.........

Limestone ammonium nitrate 2:3:2(22) 3 2 : l(25)

ton (1) (1)

. . . . . . . . . . . . . . . . . . . . . . . . . ton

. . . . . . . . . . . . . . . . . . . . . . . . .ton (t)

Other fertilisers and/ or soil-improvement materials if required (type stated) . . . . . Stockpiling topsoil (free-haul 1,O km)

. . . . . . . . . ton (1)

(f)

. . . . . . . . . . cubic metre (m3)

(a) Item
58.02 Using machines for trimming or shaping (alternative to subitem 58.01(a)):

Ripping

Unit The unit of measurement for ripping shall be the hectare of soil ripped. Only areas ripped on the written instructions of the engineer shall be measured for payment. The tendered rate shall include full compensation for ripping, complete as specified in clause 5804. Loosening the soil by scarifying will be paid for under subitem 58.03(b).

(a) (b)

Bulldozer

. . . . . . . . . . . . . . . . . . . . . . . hour
. . . . . . . . . . . . . . . . . . . . . hour

(h) (h)

Motor grader

The unit of measurement shall be the hour actually worked by each machine in trimming or shaping areas. Standing time will not be measured. The tendered rates shall include full compensation for furnishing and using the machines, including the cost of fuel, operators, maintenance, transporting the machine to and from the point where it is to be used, and for all other incidentals necessary for carrying out the work.

(b)

Loosening the topsoil by scarifying

The unit of measurement for loosening the topsoil by scarifying shall be the hectare of soil loosened and prepared in accordance with the specifications. Only areas loosened by scarifying on the written instructions of the engineer shall be measured for payment.

The tendered rate shall include full compensation for loosening the topsoil by scarifying, removing stones, and levelling and trimming the surface.

payments to private owners for the use of stockpile areas.

Unit
(c) and (d) Placing the topsoil The unit of measurement shall be the cubic metre of topsoil applied at the specified thickness or as directed by the engineer, measured in situ after the topsoil has been placed. The quantity shall be calculated from the net area of the topsoiled surface multiplied by the average thickness of the topsoil but before the grass sods are placed. Any topsoil placed in excess of the average thickness specified or prescribed will not be measured for payment. Payment shall distinguish between topsoil obtained from designated areas within the road reserve or borrow areas and topsoil obtained by the contractor from outside sources when sufficient topsoil is not available from the designated areas mentioned above. Payment shall further distinguish between topsoil applied to slopes, at interchanges and at other areas within the road reserve and topsoil applied at borrow areas. The tendered rates shall include full compensation for excavating and loading the topsoil, any royalties or compensation that may be payable in the case of topsoil under subsubitem 58.03(c)(ii),transport (except overhaul), off-loading, placing and spreading it to the required thickness, levelling it off to a smooth surface, for removing any stones as specified and for roughening the surface to be topsoiled. The free-haul distance of topsoil obtained from the road reserve or borrow areas shall be 1,Okm. The tendered rate for topsoil under subsubitem 58.03(c)(ii) shall also include full compensation for transporting the topsoil to the point of eventual use.
58.04 Grassing:

(a)

The planting of grass cuttings (type of grass indicated) . . . . . . . . . Sodding by using the following types of sods: Nursery sods (type of grass specified) . . . . Veld sods

. . . . . . . . . . . hectare

(ha)

(b)

(i)

.......

square metre (m2)

(ii) (c) (i)

. . . . . . . . . . . . . . . square metre (mZ)

Hydroseeding: Providing an approved seed mixture for hydroseeding Providing an approved mulch

...

kilogram (kg) kilogram (kg)

(ii) (iii) (d)

....

Hydroseeding . . . . . . . . . . . . . . . . . hectare (ha) Planting grass seed with an approved grass-planting machine . . . . . . . . . . . . Hand sowing

. . . . . . hectare

(ha)

(e) (f)

. . . . . . . . . . . . . square metre (mZ)

Other methods (specify)

(a)-

Planting grass cuttings

(e)

Providing and applying fertiliser improvement material

and/or

soil-

The unit of measurement for planting grass cuttings shall be the hectare of established grass with an acceptable grass cover.

The unit of measurement for fertiliser shall be the ton of each type of fertiliser and/or soil-improvement material ordered and applied. The tendered rates shall include full compensation for furnishing the fertiliser and/or soil-improvement material, transporting it to the point of use, spreading and mixing it into the scarified soil or topsoil, irrespective of the method of application.

The tendered rate shall include full compensation for furnishing and planting the cuttings, watering, weeding, and replanting if necessary, and all other incidentals which may be necessary for establishing an acceptable cover and maintaining the grass, except mowing.

(b)

Sodding

(1)

Stockpiling the topsoil

The unit of measurement for sodding shall be the square metre covered with sods, which has an acceptable cover.

The unit of measurement shall be the cubic metre of topsoil stockpiled on the written instructions of the engineer where this operation is unavoidable despite proper advance planning. Only material actually loaded, transported to and stockpiled on sites designated for stockpiling will be measured, but not any material merely pushed or bladed into heaps next to the area from which it is taken, unless it was done with the prior approval of the engineer, and the material was stockpiled in an approved area. The tendered rate shall include full compensation for loading the topsoil, placing it in stockpile and for any

The tendered rates shall include full compensation for procuring, excavating, loading, transporting, off-loading, placing and watering the sods, for replanting dead areas, for watering and weeding the grass, for supplying and placing timber stakes and for all other incidentals, except for mowing, which may be necessary for establishing an acceptable cover, and maintaining the grass. Payment shall distinguish between nursery-grown sods and veld sods obtained from within the road reserve or borrow areas. In the case of veld sods the tendered price shall include levelling-off and trimming areas from which the sods are taken.

(c)

Hydroseeding

The unit of measurement for providing seed shall (i) be the kilogram of seed of the specified seed mixture. The tendered rate shall include full compensation for procuring, furnishing, mixing and storing the seeds. The unit of measurementfor providing an approved (ii) mulch shall be the kilogram of mulch. The tendered rate shall include full compensation for procuring and furnishing the mulch and applying it as specified, or as directed by the engineer. The unit of measurementfor hydroseeding shall be (iii) the hectare of grass established by hydroseeding, which has an acceptable cover. The tendered rate shall include full compensation for furnishing mulch and mixing it with seed and water and with any anti-erosion compound if required, applying the mixture, watering, weeding, re-hydroseeding bare patches, and for any other work, except mowing, which may be necessary for establishing an acceptable cover and maintaining the grass.

the grassing or hydroseeding has been done, and the remainder will become due when satisfactory cover has been established.

58.05 Watering the grass when established by topsoiling only

. . . . . . . . . . . . . . . .kilolitre ( k l )

The unit of measurement for waterlng areas which have been topsoiled on the instruction of the engineer but which have not been hydroseeded or planted with grass, shall be the kilolitre of water applied on the instructions of the engineer and calculated from the number of tank loads applied, multiplied by the capacity of the tank used in each case. The tendered rate shall include full compensation for procuring, transporting and applying the water as specified.

Unit
58.06 Watering the already planted grass, trees and s h ~ b s during periods of dmught experienced during the growing season

The unit of measurement for planting any grass (d) seeds by using an approved planter shall be the hectare of grass with an acceptable cover, where the seed has been planted with an approved planter. The tendered rate shall include full compensation for all labour, material, equipment, weeding, and all incidentals which may be necessary for planting the grass seeds and establishing an acceptable grass cover. The tendered rate shall also include full compensation for watering the planted areas until an acceptable grass cover has been established. Payment for the grass seed will be separate under subsubitem 58.04(c)(i).

. . . . . :.

kilolitre (kl)

The unit of measurement for watering the grass, trees and shrubs shall be the kilolitre of water used. The tendered rate shall include full compensation for obtaining, transporting and applying the water. The contractor shall keep a careful record of the quantity of water used by him for watering the grass, trees and shrubs planted and shall submit such information to the engineer on a daily basis. When there are times during the normal growing season, as specified in the project specifications, when the monthly rainfall figure is less than 75% of the monthly average, the contractor will be compensated under this item for the same percentage of the quantity of water used for watering as that for the monthly rainfall that fell short of the average rainfall.

(e)

Hand-sowing

The unit of measurement for hand-sowingthe grass seeds shall be the square metre of grass with an acceptable covering on surfaces instructed by the engineer to be hand-sown. The tendered rate shall include full compensation for all labour, materials, equipment, weeding, and ail incidentals which may be necessary for planting the grass seeds and establishing an acceptable grass covering. The tendered rate shall also include full compensation for watering the planted areas until an acceptable grass covering has been established. Payment for the grass seeds shall be separate under subsubitem 58.04(c)(i).

Note:
The rainfall figures and minimum and maximum temperatures for the contract area are set out in the project specifications.

Item 58.07 Mowing the grass

Unit

..............

hectare (ha)

(f)

Other methods

Whenever other methods of grassing are specified in the project specifications, measurement and payment shall be as specified.

The unit of measurement shall be the hectare measured each time when the grass has been cut on the instructions of the engineer.

General Half the payments under item 58.04 will become due when

The tendered rate shall include full compensation for all plant, equipment and labour, required for every cutting of the grass and disposing of the grass cuttings, ie payment will be made every time the grass has been cut on the instructions of the engineer.

58.08 hti+roslon compound (specify) . . . . . . . . . . . . . . . . . . . . kilogram (kg) The unit of measurement shall be the kilogram net mass of anti-erosion compound used with the approval of the engineer. The tendered rate for each kilogram of anti-erosion compound applied with the hydroseeding or by itself shall include full compensation for furnishing the material and mixing and applying it during hydroseeding or by itself.

The tendered rate for planting and establishing trees shall also include full compensation for furnishing and placing the membrane and riprap stone pitching at every plant hole, complete as specified. Any chemical fertiliser and/or soil-Improvement material required will be measured and paid for under subitem 58.03(e). General: Seventy-five percent of the payments under item 58.09 will become due when the planting has been done, and the remainder will become due when satisfactory growth has been obtained.

58.09 Trees and shrubs: (a) Providing the trees and shrubs (types indicated)

........

58.10 E l r a work for landscaping number (No)

....

provisional sum

The unit of measurement shall be the number of each variety of tree or shrub furnished and established.

The tendered rate shall include full compensation for furnishing the plants at the point of final use, including substitutes for plants whlch may become diseased or die. (b) (i) ([I) Planting and establishing: Trees Shrubs

The provisional sum allowed shall be expended at the discretion of the engineer to cover the cost of work in addition to the scheduled items which may be required in respect of shaping and trimming areas where plant is used at hourly rates, eg the cost of loading and transporting surplus material, establishing grass by topsoiling only, repairing erosion damage after topsoil has been applied, or any other items of work required for whlch no pay items have been provided. Payment shall be made as specified in clause 48 of the general conditions of contract.

......................

number (No)

. . . . . . . . . . . . . . . . . . . . . number (No)
58.1 1 Weeding all grass-seeded areas and the grass when established by topsoiling only . . . . . . . . . . . . . . .

The unit of measurement shall be the number of each type planted and established.

. . . . . . . . .hectare (ha)

The tendered rates shall include full compensation for excavating the holes to the specified' dimensions, furnishing topsoil, wooden stakes, manure and compost and mlxlng them together with any fertilizer and water retaining admixture required for planting and refilling each hole with the topsoil mixture and other soil, for watering the plants until the end of the maintenance period, for weeding and keeplng the plants free from pests and diseases during the maintenance period, furnishing and planting substitutes for plants that have died and for maintaining the plants as specified until the end of the maintenance period, including any other incidentals which may be necessary for properly executing the work.

The unit of measurement for weeding all grass-seeded areas and areas that have been topsoiled on the instruction of the engineer (but have not been hydroseeded or planted with grass), shall be the hectare. The tendered rate shall include full compensation for weeding the prescribed areas in accordance with the specifications. Note: Measurement and payment for overhaul shall be as specified in item 16.02, but no overhaul shall apply to topsoll paid for under subsubitem 58.03(c)(ii).

SERIES 5000 : ANCILLARY ROADWORKS

SECTION 5900 : FINISHING THE ROAD AND ROAD RESERVE AND TREATING OLD ROADS

5W3 TREATING OLD ROADS

All old roads, temporary deviations, haul roads and construction roads shall, in so far as is practicable, be levelled with the original ground. Surfaces shall be scarified and broken up to a depth of 150 m m for promoting plant growth.

5901 5902 5903 5904

SCOPE FINISHING THE ROAD AND ROAD RESERVE TREATING OLD ROADS MEASUREMENT AND PAYMENT

Where required by the engineer, in order to prevent soil erosion, banks, dykes or ditches shall be constructed over the old road to dimensions ordered by the engineer.

!i901 SCOPE

This section covers the final finishing and cleaning up of the road and road reserve after construction, and scarifying and treating old roads and temporary deviations. The contractor shall note that this section does not cover the finishing which has to be done under section 1700 : Clearing and Grubbing, section 3100 : Borrow Materials, section 3300 : Mass Earthworks and section 5800 : Landscaping and planting plants.

All roads and temporary deviations treated as above, shall be left in a neat and tidy state.

!SO4

MEASUREMENT AND PAYMENT

59.01 Finishing the road and

road reserve:
5902

FINISHING THE ROAD AND ROAD RESERVE

(a) (b)

Dual carriageway road

......... .... ..

kilometre (km)

After completing the seal or surfacing, or gravel surface on gravel roads, the road and road reserve shall be cleared of all excess earth, stones, boulders, debris, litter, garbage and other waste material resulting from the construction of the works or the use of the road. All finishing and clearing not previously done or completed as specified in the sections of the specifications set out in clause 5901 above shall be completed. This specification, however, does not intend the finishing, clearing and maintenance which must be done as provided for in other sections of these specifications, to be postponed until the final finishing operations provided for in this section. Culvert inlets and outlets, culvert barrels, and open drains shall be cleared of all debris, soil, silt and other material.

Single carriageway road . . . . . . . . . . . . . . .

kilometre (km)

The unit of measurement shall be the kilometre of road measured along the centre line. No separate measurement will be made of ramps at interchanges.

The tendered rates shall include full compensation for clearing, trimming, disposing of material, tidying and ail other work to be done for finishing off the road and road reserve as specified.

59.02 Treatment of old roads

The surfacing shall be cleared of all dirt, mud and foreign objects. Dragging, pushlng or scraping material across the finished surfacing shall not be permitted. All junctions, intersections, islands, kerbing and other elements making up the completed works shall be neatly finished off. The contractor shall ensure that all declared noxious weeds have been removed from the road-reserve and borrow-pit areas. All materials resulting from the finishing operations shall be disposed of at approved locations not visible from the road, such as disused borrow pits and dongas. The contractor himself shall make his own arrangements with the owners of properties on which such materials are to be deposited. Disposal shall be carried out in a neat and uniform manner.

and temporary deviations

......

kilometre (km)

The unit of measurement shall be the kilometre of old road or temporary deviation treated.

The construction of banks, dykes or open drains shall be measured and paid for under section 2100.

The tendered rate shall include full compensation for levelling and scarifying any surfaces and tidying old roads and temporary deviations as specified.

No payment will be made in regard to treating haul roads and construction roads, for which the contractor shall make allowance in his rates for constructing the relevant items of work for which such roads are necessary.

SERIES 6000 : STRUCTURES SECTION 6100 : FOUNDATIONS FOR STRUCTURES

(d)

Granular fill

Granular material used for constructing the compacted granular fill shall be approved granular material of at least gravel subbase quality.

CONTENTS
SCOPE MATERIALS GENERAL ACCESS AND DRAINAGE EXCAVATION FOUNDING UTILIZATION OF EXCAVATED MATERIAL BACKFILL AND FlLL NEAR STRUCTURES FOUNDATION FlLL GROUTING OF ROCK FISSURES FOUNDATION DOWELS FOUNDATION LINING FOUNDATION PILING CAISSONS MEASUREMENT AND PAYMENT (e) Sand fill

Sand used for filling the caissons shall be clean, hard sand free from lumps of clay or organic or other deleterious matter.

(9

!3ructural steel

Steel in the steel piles shall comply with the requirements of SABS 1431 or BS 4360, BS EN 10113 and BS EN 10155 for the grade of steel specified on the drawings. I and H sections shall comply with the requirements of BS 4 : Part 1. Fabricated sections shall comply with the details shown on the drawings and the requirements of section 6700.

6101

SCOPE

This section covers foundation and foundation related work which, for the purposes of these specifications, shall comprise amongst others those elements of construction below the level of the bottom surface of the footings, the pile-capping slabs or the caisson cover slabs, collectively hereinafter referred to as base or bases, and it covers all the associated permanent and temporary works. Foundations for prefabricated culverts are not included but are specified in section 2200.

(g)

Permanent pile casings

Permanent pile casings shall be sufficiently rigid so as not to deform permanently or damage during handling and construction. The casings shall be sufficiently dense to prevent the fluid components of the concrete from leaking during the placing of the concrete or thereafter. Where steel casings contribute to the strength of the pile, the casings shall have a minimum wall thickness of 4,5 m m and shall comply with the requirements of ASTM A 252-68. Welded joints shall comply with the requirements of section 6700.

(a)

General

( h )

Driven pile casings

Material used in the permanent foundation work shall comply with the requirements specified for the particular material in series 6000 of these specifications.

Driven pile casings shall have sufficient strength to permit their being driven and not being distorted by the driving of adjacent piles, and they shall be sufficiently watertight to prevent water leaking through the casing walls during the placing of concrete.

@)

Rock (for rock fill)

Stones shall be hard, angular, veld or quarry stones of such quality that they will not disintegrate on exposure to water or weathering. The stones shall be free from soil, shale or organic material. Neither the breadth nor thickness of a single stone shall be less than one-third its length. Not more than 10% of the total volume of rock fill shall consist of stones with a mass of less than 0,5 times the specified mass and not more than 10% of the total volume of rock fill shall consist of stones with a mass of more than 5 times the specified mass. At least 50% of the total volume of rock fill shall consist of stones the mass of which exceeds the specified mass.

0)
(i)

Grouting Cement grout

Cement grout shall meet the appropriate requirements of subclause 6503(g). (ii) Proprietary-brand grout

Proprietary-brand grout shall be prepared and used strictly in accordance with the instructions of the manufacturer.

6103
(c)

GENERAL

Crushed stone
(a) Subsurface data The provisions of clause 1216 shall apply in regard to any information supplied regarding any subsurface conditions

Crushed stone used for the construction of crushed-stone fill shall originate from sound unweathered rock approved by the engineer.

likely to be encountered. If it is found during the course of excavating, founding-pile or caisson work that the soil or founding conditions differ greatly from those shown on the drawings, the contractor shall immediately notify the engineer. The engineer shall, as often as he may deem necessary during the course of excavation, be entitled to call on the contractor to conduct additional foundation investigations and/or tests at or below the respective founding levels in view of establishing safe bearing pressures and founding depths.

engineer, which show details of the cofferdams and the method of construction.

(c)

Drainage

The contractor shall apply suitable, effective drainage methods for preventing the ingress of water into excavations and to keep them dry. The drainage measures, with the exception of pumping, shall be maintained until the backfilling has been completed. Between the various construction stages pumping may be interrupted in consultation with the engineer. Any draining or pumping of water shall be done in a manner as will preclude the concrete or materials or any part thereof from being carried away.

@)

Channel preservation

The flow of the stream and the conservation of marine and freshwater life shall be maintained at all times. Access to cofferdams, artificial islands and piling platforms shall be effected without unnecessarily disrupting the flow of the stream at the point of crossing, unless otherwise specified. On completion of the work, surplus excavated materials, including materials excavated from caisson compartments and holes for piles, materials used in cofferdams and other temporary works, as well as in situ material, shall be removed and disposed of by the contractor to the level of the original bed or such elevation as agreed to by the engineer or required for stream channelisation.

6105

EXCAVATION

(a)

General

This work shall include excavations not provided for elsewhere in these specifications, which are required for founding the structures as well as for the excavating required in respect of the demolition, extension or modification of existing bridges and culverts. Excavation required for diverting, channelling or widening streams within 5,O m of concrete structures shall be measured and paid for under item 61.02. Excavations beyond the 5,O m limit shall be measured and paid for under the appropriate items of sections 2100 and 3300.

6104

ACCESS AND DMNAGE

(a)

General

This clause covers the provision of access, including the construction of cofferdams, and draining the excavations. Where it is unnecessary to provide access in terms of subclause 6104(b), the contractor shall be paid separately for draining the excavations. After completion of the permanent works, all temporary works shall be completely removed, the ground levelled and the site left neat. Where this is impracticable, such portions as have not been removed, shall be dealt with in accordance with the engineer's instructions.

@)

Surface levels agreed on for excavations

Prior to commencing with any excavation, the contractor shall notify the engineer in good time to ensure that levels be taken of the undisturbed ground surface for determining a ground surface from where the excavation can be measured, and this ground surface shall be agreed on by the engineer and the contractor.

(c)

Excavation

Where temporary banks or artificial islands are constructed in view of affording access to the location where structural members, piles or caissons are to be constructed, the banks or islands shall be adequately compacted in view of supporting any plant and material without any undue settling, which may have a harmful effect on the end product. The contractor may use any material deemed by him to be suitable for constructing the islands, but he shall note that no separate payment will be made in terms of items 61.02(b), 61.21, 61.22, 61.23 and 61.47(b) for any obstructions or hard material occurring in the material used for constructing temporary banks or artificial islands. Designing and constructing any cofferdams shall comply with the requirements of BS 8004. Before starting with construction, the contractor shall submit drawings to the

Where, in the opinion of the engineer, the casting of concrete against the excavated earth faces is not permissible, or where formwork has to be provided, the extremities of the excavation, for purposes of measurement and payment, shall be deemed to be the vertical planes parallel to and 0,5 m outside the perimeter of the member for which formwork is to be provided. Where suitable stable material is encountered during excavating, that part of the trench or foundation pit shall be excavated to the neat dimensions of the base unless otherwise directed by the engineer. Over-excavation (overbreak) in hard material shall be backfilled with the same class of concrete as that in the base or with mass concrete fill as specified or as directed by the engineer. Where blasting is required, the contractor shall complete the entire foundation excavation before he commences with the construction of any permanent concrete work,

unless otherwise approved by the engineer. Boulders, logs or any other unsuitable material excavated shall be spoiled.

Precautionary measures taken by the contractor shall comply with the appropriate legal provisions.

)
When hard material suitable for founding is encountered at the founding level, it shall be cut and trimmed to a firm surface, either level, stepped or serrated, as may be required. Where, in the opinion of the engineer, unsuitable material is encountered at founding level, such material shall be removed and replaced with foundation fill in accordance with clause 6109 and as directed by the engineer.

Inspection

No concrete shall be placed before the excavation has been properly cleaned by the contractor and inspected and approved by the engineer.

(i)

Excavation by hand

(d)

Classification of excavated material

For payment purposes distinction shall be made between excavation in hard and soft material. All excavation for the foundations of structures shall be classified in accordance with the following classification: (i) Hard material

Where circumstances prevent the use of mechanical excavators and material can be removed only by hand implements, the engineer shall authorise the supplementary payment to the contractor for such work at the tendered rates for excavation by hand should he be satisfied that the contractor had been unable to prevent the necessity for excavation by hand by proper planning and precautionary measures. The supplementary rate for excavation by hand shall not apply to minor finishing or clearing jobs in excavations which are otherwise being done by mass excavation plant.

Boulders with a volume of 0,l m3 or more;

6106

FOUNDING

material which cannot be excavated except by drilling and blasting or by using pneumatic tools or mechanical breakers shall be classified as hard material. (ii) Soft material

In consequence of possible variations of the anticipated founding conditions, the dimensions and founding levels specified or shown on the drawings may possibly have to be varied during construction. The engineer has full and absolute power in terms of this contract to order such variations and to specify the actual founding level for each foundation fill, base or caisson during construction. The contractor shall not be entitled to any additional payment in consequence of any such variation in the dimensions or founding depths over and above that 115,'irrespective of the stage of provided for in clause 6 construction at which the instruction to alter the dimensions or founding depths is given. However, if in consequence of such order to alter the contractor is compelled to substitute other machines and equipment for machines and equipment for successfully completing the work, the engineer may reimburse the contractor at a fair price for incidentals incurred, provided that the original machines and equipment had been suitable for the work required prior to the order to alter having been issued. No bases, caissons or piles shall be founded unless authorised by the engineer. Each founding level shall be accurately measured and recorded and agreed on. The term "founding level" used in these specifications shall be deemed to have the following meanings in respect of:

All material not classified as hard material shall be classified as soft material.

(e)

Blasting

Where blasting is permitted, it shall be carried out in accordance with the requirements of clause 1222.

(f)

Deterioration of foundation excavations

Where soft material, or hard material which quickly deteriorates when exposed, is found at foundation level. the excavation shall be excavated to the final slope and level immediately before the screed is placed. Where the bottoms or sides of excavations, in which bases are to be cast, are softened on account of negligence on the part of the contractor in allowing storm or other water to enter the excavations, the softened material shall be removed and replaced with foundation fill as directed by the engineer, at the contractor's expense.

@)

The safety of excavations (a) Foundation fill

The contractor shall take the necessary precautions to safeguard the stability and safety of the excavations and adjacent structures.

The surface of the in situ material that has been prepared to receive foundation fill.

The personal safety of no person shall be jeopardised neither shall any situation be allowed to arise which may result in damage of whatsoever nature.

The underside of the base.

(c)

Piles

The underside of the underream, bulbous base or rock socket; the tip of the pile shoe or lower pile end, as may be relevant.

(d)

Caissons

The underside of the cutting edge.

approved material in horizontal layers not exceeding 150 m m in thickness after compaction, to the level of the original ground surface. Each layer shall be moistened or dried to the optimum moisture content for the material and then compacted to a density of not less than 90% of modified AASHTO density for soils and gravels, and not less than 100% of modified AASHTO density for cohesionless sands, or the density of the surrounding soil, whichever shall be the less, except that, in the road prism, the material shall be compacted to a density of not less than 93% of modified AASHTO density.

6107

WIUZATION OF EXCAVATED MATERIAL (c)

Fill

Excavated material and material recovered from temporary works shall, if suitable, be utilised for backfill. Material unsuitable for use as backfill or in excess of the required quantity, shall be spoiled or utilised as directed by the engineer. Excavated material not used for backfill or not taken to spoil but used in the construction of embankments or other parts of the work, as directed by the engineer, will be paid for under foundation excavation as well as under the relevant item for the purpose for which it is used. The free-haul distance on excavated material and imported material for backfill shall be 1,Okm.

Before the space between the structure and the approach fill, or between the structure and the faces of the surrounding excavation is backfilled, the slope of the approach fill, or the faces of the excavation shall be shaped by benching or serrations to prevent wedge action from occurring between the structure and the approach fill or the excavation faces. The distance between the exposed face of the structure and the toe of the approach fill or the excavation face shall not under any circumstances be less than the height of the exposed face of the structure.

(d) Excavated and stockpiled material shall be so dumped as not to endanger the uncompleted structure either by direct pressure or indirectly by overloading the fills contiguous to the structure, or in any other way.

Fill within restricted area

That part of the fill within a horizontal distance of 3,O m from the vertical and inclined concrete faces of the structure and that part between the pillars of the spillthrough abutments or that part shown on the drawings, shall be termed "fill within restricted area". Fill within the restricted area shall comply with the requirements of section 3300, except that it shall be compacted to a density of not less than 93% of modified AASHTO density. In order to achieve the specified density, the contractor shall, where necessary, import material of suitable quality. Unless otherwise directed by the engineer, only mechanical compaction equipment that is pushed 3r drawn by hand shall be used to achieve the required density within a horizontal distance of 3,Om from any concrete structure. Fill in spaces below concrete soffits that are inaccessible for mechanical compaction equipment shall be constructed by methods specified or approved by the engineer. Payment in accordance with item 61.05for the construction of fill within restricted areas shall be made only when specifically provided for in the schedule of quantities.

6108

BACKFILL AND FILL NEAR STRUCTURES

(a)

General the following

When backfill and fill are placed, precautionary measures shall be taken:

The material shall be placed simultaneously. in so (i) far as is possible, to approximately the same elevation on both sides of an abutment, pier, or wall where appropriate. If conditions require the backfill or fill to be placed appreciably higher on one side than on the other, the additional material on the higher side shall not be placed until authorised by the engineer, and preferably not until the concrete has been in place for 14 days, or until tests show that the concrete has attained sufficient strength to safely withstand any pressure extended by the backfill or fill or by the method of construction. The material behind abutments directly restrained (ii) at the top by the superstructure, eg portal type of structures, shall be placed as shown on the drawings or as directed by the engineer. (iii) The materia! behind the portal walls of portal structures shall not be placed until the top slab has been placed and cured, unless otherwise authorised by the engineer.

6109

FOUNDATION FILL

@)

Backfill

If it is found during the course of excavation that the material at the indicated founding depth does not have the required bearing capacity as specified on the drawings, the excavations shall be extended at the discretion of the engineer until satisfactory founding material is encountered. The engineer reserves to himself the right to order the contractor to make up the difference in levels with foundation fill. Where the foundation fill consists of rock or crushed stone,

Excavated areas around structures shall be backfilled with

it shall be constructed in accordance with the requirements of the project specifications or as directed by the engineer. Foundation fill consisting of granular material shall be constructed in layers not exceeding 150 m m in thickness after compaction. Each layer shall be moistened or dried to the optimum moisture content for the material and compacted to a density of not less than 95% of modified AASHTO density for soils and gravels, and not less than 100% of modified AASHTO density for cohesionless sands. Mass concrete fill to be used shall be of the class or mix of concrete fill as specified or directed by the engineer. Unless otherwise specified or directed by the engineer, the foundation fill constructed from rock, crushed stone or compacted granular material shall be defined by a prism with vertical sides. The base of the prism lies in the founding plane and coincides with the base of a prismoid with trapezium-shaped inclined sides which extend downwards and outwards at an angle of 60" with the horizontal from each outer edge of the underside of the footing down to the founding level. The upper plane of the prism lies in the plane of the underside of the footing. A concrete blinding which complies with the requirements shown on the drawings shall be placed underneath all bases except where mass concrete fill is used or where authorised by the engineer that this need not be done. Where mass concrete fill is constructed under a base it shall be constructed accurately to the final levels of the underside of the base.

cleared and prewetted, they shall be filled with grout. Within 15 minutes of having been filled with grout, the dowels shall be carefully driven into the holes. The cement and water in the grout shall be mixed in the ratio of 50 kg of cement to 20 P of water, and an approved expanding additive which complies with the requirements of subclause 6402(e) shall be added. The dowels shall comply with the requirements of clause 6305.

6112

FOUNDATION UNlNG

Where specified or directed by the engineer, foundation linings shall be installed as described hereafter. The engineer shall have the right to order the use of linings against the sides of excavations and the undersides of bases and slabs in lieu of formwork and concrete blinding. All surfaces to be lined shall be covered with an approved sheeting to provide a clean impervious layer. The material shall be of sufficient strength to provide a durable working surface and to support the concrete and reinforcement without tearing. The joints of the material between strips shall have a 150 m m overlap and the lining shall be held firmly in position by nails, pegs, etc.

Polyethylene sheeting with a thickness of 0,150 mm is generally considered to be adequate for use below bridge approach slabs and bases.

6110

GROUTING OF ROCK FISSURES

6113

FOUNDATION PlUNG

Where specified, fissures in the rock below and around the bases shall be sealed by pressure grouting with a neat cement or sand-cement grout or with a proprietary brand grout as specified. The water:cement ratio of the grout shall be approved in advance by the engineer. The extent of the fissuring shall be established by means of water testing under pressure. Holes of at least 40 m m in diameter shall be drilled at places indicated by the engineer and grout shall then be pumped into these holes under suitable pressures. Grouting shall be done in 3 m stages to the maximum depth ordered. Care shall be taken to avoid further fracturing of the rock strata by excessive grouting pressures. Grouting the rock fissures shall be done by specialised operators with adequate experience in this class of work.

CONTENTS (a) (b) (c) (d) (e) (1) (g) (h) (i) General Piling layout Alternative designs for piling and piling layouts Details to be furnished by the contractor Pile-installation frames and equipment Piling platforms Setting out Ground surface for foundation piling Cast in situ concrete piles Precast concrete piles Steel piles Driving the piles Augering and boring Rock sockets Obstructions Determining pile lengths Piling data

(j)
(k) (I)

6111

FOUNDATION DOWELS (m) (n) (0) (p) (q)

Where required, foundation dowels of specified material, diameter and length shall be installed at the positions and to the dimensions shown on the drawings or as directed by the engineer. After exposing, clearing and trimming the rock formation, holes with specified diameters and depths shall be drilled in the rock. After the holes have been

(r) (s) (t) (u) (v) (w) (x)

Stripping the pile heads Construction of pile-capping slab Core drilling Load test Defective piles Standing time in respect of pile-installation frames Nuclear integrity testing

For alternative designs submitted the contractor shall submit with his tender a detailed description of the method of analysis used in the design of the piles and the pilegroup layouts. The average length of pile and/or of the piles per group on which the quantities in the schedule of quantities for the alternative designs are based shall be stated in each case. The type of pile offered shall be defined in terms of size, materials, working and breaking load. The contractor shall be responsible for and shall bear the cost for redesigning, drafting and submitting the detail drawings for any structural element affected by the alternative pile design. Any economy or incidental caused by constructing such element as compared to the original design shall be for the account of the contractor. The contractor shall, as specified in clause 1212 for alternative designs, submit to the engineer at least three months prior to work being commenced, drawings detailing the piling-group layout and piles, incorporating such amendments to his original design as may be required by the engineer, and drawings detailing the amendments required to the pile-capping slab dimensions and reinforcement as a result of the layout of the piles, all as applicable. No work of whatsoever nature shall be commenced on the piling until the drawings have been submitted to and have been approved by the engineer, in writing. After approval of the drawings, no departure therefrom shall be made without authorization by the engineer. Final working drawings shall comply with the provisions of clause 1221. Where the alternative piles fail in regard to the load test specified in subclause 6113(u) of these specifications, the contractor shall be responsible for the cost of the work required for improving the piles and pile layout so as to comply with the design requirements. (iii) Basis of payment

(a)

General

This section covers the construction of bearing piles of concrete or steel or a combination of these materials.

@)

Piling layout

The piling layout, the minimum pile size and/or bearing capacity and type together with the steel reinforcement and class of concrete required shall be as detailed and specified on the drawings unless otherwise specified in the project specifications.

(c)

Nternative designs for piling and piling layouts Submission

(i)

The priced schedule of quantities submitted for alternative designs shall be compiled strictly in accordance with the relevant measurement and payment clauses of these specifications.

Where pay items defined in these specifications have been omitted, it shall mean either that the items do not apply, or that where the engineer requires work falling under such items to be done, it shall be done without any cost to the employer. The inclusion of "rate-only" items will not be permitted. Where pay items not defined in these specifications are used, the measurement and payment requirements for such items shall be specified in detail by the contractor. In the absence of such definitions, or in the case of any ambiguity, the interpretation of the engineer shall be final and binding. Except in piling-only contracts or where otherwise provided in the project specifications, the contractor shall price the schedule of quantities for the original design irrespective of whether or not an alternative design is offered. (ii) Design

Where the quantities in the schedule of quantities referred to in subsubclause 61 13(c)(i),on the one part, differ from the number of piles and the average pile length given in the submission for the alternative pile design, on the other part, the engineer shall accept the sum in the said schedule of quantities, correct the quantities, and adjust the rates for the applicable pay items accordingly. In addition to these corrections, the employer shall be justified in using one of the following methods for paying for piles constructed in accordance with the alternative design: (1) Method 1

The critical design-load combinations acting upon the underside and the centre of gravity of the pile-capping slab, the maximum permissible set of the pile-capping slab, and the technical data required for designing alternative piles and/or piling layouts will be indicated on the drawings. Alternative designs shall comply with the provisions of clause 1212 and the prescriptions set out below.

The employer may check the alternative designs, calculate the quantities and adjust the rates as set out in the first paragraph of subsubclause 6113(c)(iii).The employer will then pay for the work in accordance with the actually measured quantities. (2) Method 2

The employer may use the following formulae for calculating the quantities under items 61.16 to 61.34 for

payment: Np = Nd Lp = Nd . Ld Lp = Nd . Ld

(iii) (iv)

The mass of the hammer; The set during the last ten blows;

+ Nb(Lb-Ld)K for Nd 2 + Nd(Lb-Ld)K for Nd 5

for Ld
2

Nb and Nb

The expected size of the bulbous base, underream, (v) rock socket, etc, if any; (vi) How concrete or grout is to be placed and compacted in the case of cast in situ piles; How reinforcing steel is to be placed and held in (vii) place during placing and compacting the concrete in cast in situ piles; (viii) Details of permanent casing, if any;

K=Ld

Lb and

K = -Ld Lb
where:

for ~d

~b

p = paid, d = designed and b

built.

The term "units" means items of work measured and paid for in the respective pay items such as piles, raking piles, casings, underreams, concrete, etc. Np = number of "units" measured and finally paid for in a particular pile group. Nd = number of "units" provided for in the tender for the alternative design in the same pile group.

(ix) The mix design for the concrete together with an adequate quantity of cement and aggregate to enable the engineer to conduct the necessary tests.

(e)

Pile-installation frames and equipment

The pile-installation frames and equipment used for driving the piles or forming the holes or for other methods of sinking the piles shall be in a good working condition and to the prior approval of the engineer and shall comply with the relevant legal provisions. The contractor shall supply the necessary equipment, gear and instruments required for the prescribed investigations and inspections. The installation frames shall be so designed as to ensure that piles can be installed in their proper positions and true to line and slope.

Nb = number of approved and accepted "units" finally installed in the same pile group.
Lp = the length of the "units" measured and paid for or the length to be used in calculating quantities which are a direct function of the length of the "units" for the same pile group. Ld = the average length of the "units" provided for in the tender for the alternative design in the same pile group. Lb = the average length of the Nb "units" actually installed in the same pile group.
Note: See the example on page 6100-24 for the application of the formula.

(9

Piling platforms

Piling platforms shall include the prepared in situ material or artificial islands or any structure (excluding the piling equipment) constructed for gaining access to the position where the pile is to be installed and for carrying out the piling operations. Structural piling platforms shall be rigid, and floating barges used for piling operations shall afford sufficient stability to enable piles to be properly installed. On completion of the piling, the contractor shall remove all the artificial, constructed platforms and reinstate the site to the satisfaction of the engineer.

The values Nd and Ld for each pile group for which an alternative design has been offered shall be supplied with his tender by the contractor for the respective "units". The values of Nd, Nb, Ld and Lb for each pile group for which to be used in the formulae for determining the quantity for a particular pay item shall relate only to the piles the item measured.

(d)

Details to be furnished by the contractor

(g)

Setting out

In all cases where the choice of the type of pile to be used is left to the contractor, full particulars, specifications, calculations and drawings of the piles proposed for use by the contractor shall be submitted with the tender. The contractor shall submit the following information to the engineer, 2 weeks before any piles are driven or holes are formed: How the piles and casings will be installed or the (i) holes will be formed; How the piles and casings will be installed or the (ii) holes will be made through identified obstructions;

The contractor shall set out the pile positions and shall stake these positions with a durable marker. Where the level from which the piling is undertaken is above the underside of the pile-capping slab, due allowance shall be made for the offset of raking piles so that the pile at the underside of the pile-capping slab will be in the correct position.

(h)

Ground surface for foundation piling

Before starting any piling work, the contractor shall notify the engineer in good time to ensure that levels of the ground surface be taken in order that an average ground

surface from which the piling is to be measured can be established and agreed on by the engineer and the contractor. Where foundation piling at a site is preceded by excavation or the construction of fill, the surface from which the piling is to be done shall be formed as near as possible to the underside of the pile-capping slab as directed by the engineer.

approved means. Extraction of the temporary casing during placement of the concrete shall be such that no damage is caused to the pile and the advancing concrete level is at all times kept considerably above the temporary casing's trailing edge. Concrete shall generally be placed in the dry, but where this is impracticable, it shall be placed by tremie. The requirements of subclause 6407(c) together with the following requirements shall apply when concrete is placed under water by tremie: The cement content shall be not less than 400 kg (1) per m' and the slump shall be such that the concrete of the specified strength and desired density can be obtained.

( i )
(i)

Cast in situ concrete piles Reinforcement

Reinforcement shall not be placed in the pile holes until immediately before concreting. Before the reinforcement is placed in position, all mud, water, and any loose or soft material shall be removed from the hole. Steel reinforcing shall be accurately maintained in position without damage being done to the sides of the hole or the reinforcing itself. Spacers shall be used to keep the reinforcing steel at the required distance from the inside face of the pile casing and wall of the pile hole but shall not cause zones through which aggressive ground water may penetrate to the reinforcement. Pile reinforcement will not be shown in the bending schedules. Only the number, diameter and type of bars and their arrangement will be shown on the drawings. The contractor may replace the bars shown on the drawings with bars with different diameters and spacing and of different types, on a basis of equivalent strength. The reinforcement shall be assembled in cages, which shall be sufficiently robust to prevent their perrnane~t deformation during handling. In the case of cast in situ piles, the inner sides of the cages shall be kept open in view of the unrestricted placing of concrete therein. The longitudinal bars shall project above !he cut-off point by the distance shown on the drawings, or by 40 times the bar diameter if no dimension has been given. Splicing the reinforcing may be ordered, and the contractor shall k e e ~ available on the site sufficient steel reinforcina so that an additional length of pile reinforcing can be assembled whenever necessary. The assembly of this additional reinforcing shall be carried out expeditiously and before any concreting of any specific pile commences. If splices have to be provided, the longitudinal bars shall overlap for a distance of 40 bar diameters, or as required by the engineer. (ii) The concreting of piles

(2) The hopper and trernie shall be a closed unit which cannot be penetrated by water.
The trernie shall be at least 150 m m in diameter for (3) 19,O mrn aggregate and larger for larger aggregates. The concrete shall be so placed as to prevent the (4) mixing of water and concrete. The tremie shall at all times penetrate into the concrete. Placing the concrete in that part of the pile below (5) the water level in the casing shall be done in one operation, and the same method of placing the concrete shall be maintained throughout. All tremies shall be thoroughly cleaned before and (6) after use. (7) Before placing the concrete in the water, the contractor shall ensure that no silt or other materials have collected at the bottom of the hole, and where drilling mud is used, the contractor shall ensure that no drilling mud suspension with a relative density exceeding 1,3 has collected at the bottom of the hole. Whenever practicable, concrete shall be placed in a manner that will prevent segregation.

(j)

Precast concrete piles

The piles shall be of reinforced or prestressed concrete and shall be manufactured, handled, stored and installed in accordance with BS 8004, unless otherwise specified in these specifications. (i) Manufacture

The concreting of the piles shall not be commenced before the engineer has given his permission therefor. Except in self-supporting pile holes, a temporary or permanent casing shall be installed for the full depth of the hole to prevent lumps of material from falling from the sides of the hole into the concrete. Where concrete is to be placed under the drilling mud, the temporary casing may be omitted, except at the top end of the hole. The concrete shall be so proportioned as to be of sufficient strength, but shall be sufficiently workable to enable it being properly placed, and, where self-compacting concrete is not used, it shall be thoroughly compacted by

The piles may be manufactured in a factory or a casting yard on the site of the works. The contractor shall ensure that the factory or casting yard will at all reasonable times be accessible for inspection by the engineer. The relevant requirements of section 6400 shall apply to the concrete work. Transverse reinforcement requirements of BS 8004. shall comply with the

The piles shall be cast on a rigid horizontal platform in approved moulds. Particular care shall the reinforcement, coupler sockets and pile shoes accurately in position. Adequate provision shall be made for lifting the piles.

Each pile shall be clearly marked with the date of casting, a reference number, and from the tip of the pile at metre intervals, with distance marks. Piles shall be cured for a period sufficient to develop the strength required to withstand, without damage to the pile, the stresses caused by handling, transporting, storing and driving. The piles shall not be driven before the concrete in the pile has attained the specified strength. (ii) Handling, transport and storage

ensure adequate support for the pile or pile casing during installation, Inclined leaders shall be used for installing raking piles. The heads of precast concrete piles shall be protected with packing of resilient material, care being t a k to ~ ensure shall be that it is evenly spread and held in place. A helr~iet placed over the packing, and a dolly of hardwood or other material not thicker than the diameter of the pile shall be placed on top. (ii) Water jetting

Care shall be taken at all stages of lifting, handling and transporting to ensure that the piles are not damaged or cracked. Piles shall be stored on firm ground which will not settle unequally under the weight of the stack of piles. The piles shall be placed on timber supports which are truly level and spaced so as to avoid undue bending in the piles. The supports in the stack shall be located vertically above one another. (iii) Lengthening of precast piles

The contractor may employ water jetting to install piles in granular material. Jetting shall be discontinued before the leading end of the pile reaches a depth of 80 per cent of the anticipated final depth or a depth as agreed on with the engineer. After jetting, piles or their casings shall be driven to the required depth, level or set. (iii) Installation sequence

Piles shall be lengthened where required by such means and methods as approved by the engineer. Care shall be taken to ensure that the additional length of pile joined is truly axially in line with the original pile within the tolerance requirements for straightness set out in subclause 6803(a). Driving shall not be resumed until the pile extension and any bonding agent used has attained the required strength.

Unless otherwise specified or ordered, the sequence for installing the piles shall be left to the contractor. However, the sequence for driving the piles in a group shall be programmed to minimize the creation of consolidated blocks of ground into which piles cannot be driven or which cause fictitious penetration values. Piling shall generally commence at the centre of the group and be progressively extended to the perimeter piles unless otherwise agreed on b y the engineer. The installation of piles shall be undertaken in such a manner that structural damage, distortion or positioning defects will not be caused to previously installed piles or casings. (iv) Heaving of piles

(k)

Steel piles

Hollow steel piles may be filled with cast in situ concrete and, provided that adequate connections are provided between the steel and the concrete with a view to transferring the load, the concrete may be deemed to assist in carrying the load. Wherever steel piles are used, they shall be given a protective coating of bitumen, coal-tar pitch or synthetic resins to the satisfaction of the engineer or as specified. The cross-sectional area of the steel shall be adapted to the aggressiveness of the subsurface conditions to compensate for possible reduction in the pile wall thickness caused by abrasion and corrosion during the service life of the pile. Steel piles shall be used only where permitted by the engineer.

In soils in which the installation of piles may cause previously installed piles to heave, accurate level marks shall be placed on each pile immediately after installation and all piles that have heaved shall be redriven to the required resistance, unless redriving tests on neighbouring piles have shown this to be unnecessary. Piles shall not be concreted neither shall any pile-capping slab be constructed until the piles within a heave-influence zone have been redriven as required. (v) Bulbous bases

(I)
(i)

Driving the piles

Pile-installation frames

Where required, bulbous (enlarged) bases shall be formed after the driven casing has reached the required depth. The base shall be formed by progressively displacing the surrounding subsoil with concrete placed by the repeated action of a gravity hammer. The size of the base will depend on the compressibility of the surrounding subsoil but shall in no case have a diameter of less than 1,5 times the diameter of the pile. (vi) Piling alignment

Piles and pile casings shall be driven with a gravity hammer, a rapid-action power hammer or b y other approved means. Prestressed-concrete piles shall be driven with a hammer with a mass of at least equal to that of the pile. Other piles shall preferably be driven by a hammer with similar mass characteristics. The hammer shall not, during driving operations, damage any permanent component of the pile. Pile driving leaders shall be constructed in such a manner as to afford freedom of movement of the hammer and shall be held in position to

Where the inclination of a precast concrete pile deviates from the correct slope during installation, the pile shall not be forced into the correct position, and the slope of the guiding frame shall be adjusted so as to coincide with the actual inclination of the pile to preclude the bending of the pile. Where the verticality or the inclination of the installed pile falls outside the specified tolerances, the pile will be classified as being defective.

(m)
(i)

Augering and boring Auger and bore pile holes

quality and thickness for transmitting the specified load.

(0) The augering and boring of pile holes shall be carried out as expeditiously as local conditions permit taking due account of services or other restrictions on the site. Holes shall be cleaned after augering and boring to obtain a clean and level surface. Where indicated by the engineer, suitable casing shall be installed in those parts of the augered holes where the sides are in danger of caving in before the concreting has been completed. During extraction of the casing, care shall be taken to avoid lifting the concrete and damaging the pile. The use of water for augering and boring holes shall not be permitted unless approved by the engineer. Surface water shall not be allowed to enter the hole. (ii) Underreaming (i) (1)

Obstructions Definitions ldentified obstructions

Identified obstructions shall mean any obstruction described on the drawings or in the project specifications and for which provision for payment has been made in the schedule of quantities in respect of penetrating the obstructions.

(2)

Unidentified obstructions

Where required, the holes shall be enlarged or belled out to form an underream. The earth excavated shall be removed in a manner which will not damage the walls of the hole. The shape of the underream shall be a truncated cone of which the base diameter depends on the bearing capacity of the founding material, but it shall be not less than twice the shaft diameter. The base angle of the cone between the inclined face and horizontal plane shall be not less than 60". Full safety measures shall be enforced to protect workmen working at the bottom of the pile hole. (iii) Bulbous bases

Where provision has been made in the schedule of quantities in terms of item 61.21 for penetrating identified obstructions and obstructions not described are encountered, such obstructions shall be classified as unidentified obstructions and the penetration of such obstructions shall be paid for under item 61.22 subject to the condition that the rate of penetration drops to below that achieved for identified obstructions when the same method and effort are used, or subject to additional methods and effort over and above those required for identified obstructions being required for penetrating the obstruction.

Where no provision has been made in the schedule of quantities for penetrating identified obstructions and obstructions are encountered and, after resorting to the methods specified in the submission in terms of subclause 61 13(d), it is found to be impossible to form the holes in the proper positions and at the proper inclinations and depths, and the contractor has to resort to additional methods for forming the pile holes successfully, such obstructions shall be classified as unidentified obstructions. (ii) Classification of materials

Bulbous bases shall comply with the requirements of subclause 61 13(l)(v). (iv) Inspecting preformed holes

For piling only the following classification of materials shall apply to the identification and description of obstructions.

Equipment for inspecting the pile shafts shall be provided and operated in accordance with the latest amendment or edition of the Code of Practice Relating to the Safety of Men Working in Small Diameter Vertical and Near Vertical Shafts for Civil Engineering Purposes, obtainable from the South African Institution of Civil Engineers. Immediately before the reinforcement is to be installed or the concrete placed, the engineer shall be informed thereof with a view to inspecting the pile holes. When piles are to be underreamed, the excavation shall be inspected twice by the engineer, firstly to ascertain that suitable founding material has been obtained before underreaming may start, and, secondly, after the underreaming has been completed for approval to be given by the engineer for casting the pile.

(1)

Matrix

The matrix shall comprise that part of the material which will pass through a sieve with 50 m m x 50 m m openings. (2) Coarse gravel

Coarse gravel shall comprise that part of the material (stones, pebbles, cobbles, etc) which will pass through a 200 m m x 200 m m opening, but will not pass through a 50 m m x 50 m m opening. The gravel shall be obtained from material with at least a class R2 hardness.

(3)

Boulders

(n)

Rock sockets

Where required, rock sockets to the required dimensions shall be formed in rock formations of adequate strength,

Boulders shall mean any rock mass with a hardness of at least class R2 which will pass through a square opening with dimensions equal to the maximum size boulder specified in the schedule of quantities but will not pass through a 200 lmm x 200 m m opening.

(4)

Rock formation

A rock formation shall be any rock mass with a hardness of at least class R2 which will not pass through a square opening with dimensions equal to the maximum size boulder specified in the schedule of quantities. Where a boulder Is cut through and part of it is left imbedded in the wall of the hole, such boulder obstruction shall be classified as rock formation. For the identiflcatlon of rock in terms of this clause, the classification in table 61 1311 shall apply. (ill) Driven displacement and prefabricated piles

engineer shall be informed immediately.lf the contractor Is not satisfied that the piles will be capable of carrying the specified loads at the depth determined b y the engineer he may, in consultation with the engineer, lengthen the piles to reach a suitable founding depth. Where the engineer and the contractor cannot agree on the founding depth, the engineer may require the contractor to (i) undertake additional foundation Investigations and/or core drilling in accordance with subclauses 6103(a) and 61 13(t) respectively, andlor Install one or more test piles and conduct a load (ii) test in accordance with subclause 61 13(u). The engineer will prescribe the posltions for each test pile. Test plles shall comply with the specified requirements for piling.

Where obstructions make it difficult to Install driven displacement and prefabricated piles in the positions and at the inclinations shown and to the proper lengths b y the methods specified in the submission in terms of subclause 6113(d), the contractor shall resort to additional methods which are suitable for the type of plle. If the successful installation of a pile proves to be impossible after such methods have been tried, the engineer may order an additional pile or piles to be installed. All such work and additional piles shall be paid for in accordance with the tendered rates where applicable, or where they do not apply, under item 61.23. (iv) Auger and bore plle holes

(q)

Filing data

The following data on each plle installed shall be recorded in a form prescribed by the englneer: (i) The effort used for driving the pile and the resistance to penetration at founding level. A description of subsurface material, the presence (ii) of ground water and the quality of material on which the pile Is founded. The quality of the materials used in the construction (iii) or manufacture of the pile, as well as of the permanent casing if used. The method of placing and compacting the concrete in cast in situ piles. The method of founding of the piles eg bulbous (iv) bases, underreams, rock sockets, etc, and their dimenslons. (v) The maximum working load of the pile.

Where Identified or unidentified obstructions are encountered when shaping holes for piles, payment for penetrating the obstructions shall be made against the approprlate pay items. @)

Determining pile lengths

The design of the piles and pile groups, and the quantities in the schedule of quantitles are based on the subsurface data shown on the drawings. The engineer will determine the depth of piles as work proceeds. Where variations in the subsurface conditions occur as regards the material and height of the water table, the

(vi) The length of the pile and the accuracy of installation in respect of position and inclinatlon. (vii) Nomlnal dimensions and type of pile.

(viii) Length and details of any temporaryand permanent casings used.

Table 61 1311 ROCK CLASSIFICATION Description of hardness Class R2 R3 Description Soft rock Medium hard rock Hard rock
'

Field indicator tests Can just be scraped and peeled with a knife, firm blows of the pick point leave indentations 2 m m to 4 mrn in specimens. Cannot be scraped or peeled with a knife; hand-held specimen can be broken with the hammer end of a geological pick with a single firm blow. Point load tests shall be conducted for distinguishing between these categories. These results may be verified by means of uniaxial compressive-strength tests.

Unconfined compressive strength (MPa) 3 to 10 10 to 25

R4 R5

25 to 70

Very Hard rock

70 to 200

Classification after Core Logging Committee, South African Section, Association of Engineering Geologists: "A guide to Core Logging for Rock Engineering" Bulletin of the Association of Engineering Geologists, Vol. XV, No. 3, 1978.

6100-11

(r)

Stripping the pile heads

testing shall cease. No working pile shall be used as an anchor pile. Where anchor piles or earth anchors are required for providing reaction, they shall be so placed as to have a minimal effect on the test results. The contractor shall provide the complete testing assembly, the necessary plant, equipment, instrumentsand labour for carrying out the test and for determining accurately the settlement of the piles under each increase or decrease of the load. The test assembly, plant, equipment and instruments used shall be subject to the approval of the engineer. Within two days of having completed the tests, the contractor shall supply the engineer with the test results and neatly plotted load against settlement, load against time, and settlement against time graphs. (ii) Loading

Precast piles shall be installed to a level of at least 1,O m above the cut-off level, and cast in situ piles shall be cast to a level of at least 150 m m above the cut-off level. The excess concrete shall be so stripped off that only sound concrete will project into the pile-capping slab. Before a pile head is stripped, the cut-off plane shall be marked by cutting a 20 m m deep groove with a grindingmachine along the full circumference of the pile. Heavy concrete demolishing equipment may not be used for the stripping of pile heads. All loose aggregate shall be removed from the cut-off plane. The concrete shall be so stripped off that the pile below the cut-off level will not be damaged, or, should defective concrete be found in the completed pile, the damaged or defective concrete shall be cut away by the contractor at his own cost and replaced with new concrete well bonded to the old concrete, or the pile shall be replaced as directed by the engineer. The main reinforcement of the piles shall extend at least 40 times the diameters of the reinforcing bar beyond the cutoff level into the pile-capping slab. This reinforcement shall be left straight unless otherwise directed by the engineer. The cut-off level for piles shall be the level shown on the drawings.

The maximum test load applied shall be equal to twice the specified working load or the ultimate test load, whichever shall be the smaller. The maximum working load shall be half of the maximum test load or the test load which corresponds with the allowable settlement, whichever shall be the smaller. The allowabie settlement shall be as specified on the drawings.

(s)

Construction of pilecapping slab (iii) Ultimate test load

The contractor shall not construct the pile capping slab before the engineer has confirmed, in writing, that all the relevant load tests have been completed and the piles have been accepted.

The ultimate test load in the compression-load test shall be the load where settlement suddenly increases disproportionately to the load applied. The ultimate test load in the tension-load test shall be the load where the upward movement suddenly increases disproportionately to the load applied or the load producing a permanent rise of 10 m m at the top of the pile, whichever is the smaller.

(1)

Core drilling

The engineer may instruct core drilling to be done with a view to obtaining cores of the founding formation and/or of the concrete in the completed structural member. In the case of piling, the core drilling may precede the piling or may be done through the completed pile, as specified, or as instructed by the engineer. The contractor shall supply the necessary construction plant on the site for drilling under the above conditions. The plant and techniques used shall be suitable for ensuring 100% core recovery. The diameters, depths and lengths of the cores shall agree with the specifications or the instructions of the engineer. The contractor shall keep accurate records of the drilling, which, together with the cores, shall be handed over to the engineer. The cores shall be placed in the correct sequence in a clearly identified wooden core box with a lid.

(v)

Defective piles

The test pile and the piles represented by the test pile shall be classified as defective if shown in terms of subclause 61 13(u) to have a maximum working load of less than the specified working load, or to exhibit excessive settlement. Defective piles shall also include piles damaged beyond repair, piles with structural defects, or piles which do not comply with the tolerance requirements of subclause 6803(a). If required, the defective piles shall be corrected by the contractor at his own cost, by applying one of the following methods approved by the engineer: (i) Extracting the pile and replacing it with a new pile Installing a new pile adjacent to the defective pile

(u)
(i)

Load test (ii) General (iii) Lengthening the pile to the correct length if defective in length only Altering the design to fit in with the new conditions (iv) caused by the defective pile(s).

The engineer may order certain selected piles to be load tested. The procedure for loading tests shall comply with the requirements of subclause 8112(c). During the period of testing, driving of other piles which may affect the

(w)

Standing t i m e in respect of pileinstallation frames

@)

Conslruction and sinking

Standing time shall only be paid for pile-installation frames standing during normal working hours as laid down in the general conditions of contract for such periods during which the pile-installation work has come to a standstill following an action by the employer.

A firm horizontal base shall be prepared on which the cutting edge of the caisson shall be laid truly horizontally. The level of the base shall be determined and shall be agreed on by the engineer and the contractor and shall serve as the ground surface from which the excavation inside the caisson will be measured.
Successive stages of the caisson shall be of convenient height, or as directed by the engineer, and shall be lined up accurately with the preceding stages.

As soon as the pile-installation frames have come to a standstill, the contractor shall inform the engineer, in writing, that he intends to claim standing time, and shall also furnish full particulars of the action which gave rise to the (i) claim a list of pile-installation frames in respect of which (ii) standing time will be claimed, complete with date and time. The period In respect of which a claim is lodged shall become operative from the moment when the notice has been handed over to the engineer and shall continue until the restriction has been removed and normal procedure may be resumed.

All precast elements shall have properly constructed jolnts in accordance with the drawings to ensure that they fit snugly together.
For in situ phase construction, all construction joints in the walls shall be reinforced and the joints shall be made as specified in clause 6408. The lowest element of every caisson, which contains the cutting edges, shall be cured for at least 4 days or shall have reached a strength of at least 50% of the specified strength before sinking is commenced. Subsequent elements shall be cast in sufficient good time to ensure adequate strength for safely resisting the applied forces. During constructing and sinking, the caissons shall be maintained truly vertically and kept in their correct positions. The position and inclination of each caisson shall be determined accurately by measurement after every 2 m of sinking, or after sinking through the depth of one element, whichever distance is the smalier. With a view to eliminating excess friction, the contractor may use bentonite or a similar lubricant, or a water-jet system. Excavation inside caisson compartments shall, unless otherwise specified herein, comply wlth the provisions of clause 6: 05. In multi-compartmented caissons, the excavation in any one compartment shall not be taken deeper than 0,6 m below that in any other compartment, except where necessary for correcting deviations. Cutting edges shall be frequently inspected or probed to locate obstacles, which shall be removed immediately. The contractor shall supply all grabs, pumps, diving gear and other plant required for sinking and founding all caissons and shall allow the engineer to use the diving suit and equipment for inspection purposes. The contractor shall employ a competent diver to carry out work under water and shall make provision in the rates tendered for the respective items for this cost. Where the caisson strikes a hard inclined layer !nd work has to be carried out below the cutting edge, such work shall be measured and paid for under the relevant items of clause 61 15, and, where no applicable items exist, such work shall be paid for as extra work. Should the contractor wish to apply the pneumatic caisson method (with a compressed air chamber) for construction,

(x)

kh~dear integrity testing

Integrity tests using both the nuclear and neutron method shall be performed on all bored piles. The purpose of these tests is to prove that the technique used in constructing the piles is satisfactory b y checking for necking of concrete in the pile shafts, checking concrete cover to reinforcement and by checking for honeycombing, grout loss and segregation of aggregates. Before piling for the substructure is commenced, the contractor shall construct a 5,O m long calibration pile of the same diameter, concrete mix and reinforcing and by the same method of construction as the piles in the bridge. The location of the calibration pile will be selected in agreement with the engineer.

Results from integrity tests on the piles for each pile cap must be submitted to the engineer for approval before any work on the pile cap may commence. Tests on the calibration pile must be done at the same time or before tests on the first pile are undertaken.

(a)

General

Caissons shall, for the purposes of these specifications, be hollow concrete vessels which are wholly or partly constructed at a higher level and lowered by internal excavation or kentledge to the desired founding level to form structural bearing members. Caissons may be of circular, rectangular or any other shape and may contain one or more excavation compartments, all as detailed on the drawings.

Unless otherwise specified hereafter, the provisions of

85 8004 shall apply in regard to the construction of

caissons.

he shall furnish the engineer with full details of the plant. equipment and method for approval.

(c)

Founding

period of at least 7 days after which the caisson shall be dewatered by pumping for inspection. If more water is still leaking into the caisson, the process of sealing as specified herein shall be continued until the water level within the caisson does not rise at a rate exceeding 10 m m per hour.

The material at the founding level, if sloping and/or irregular, shall in so far as is possible be cut to as nearly level a surface as possible until the entire cutting edge is evenly and firmly supported on the material. Subject to the approval of the engineer, blasting may be used for this purpose. If blasting should be resorted to, only light charges may be used and the caisson shall be protected against damage by suitable cushioning being provided. Should the sloping surface be of hard rock which cannot be cut or broken by any safe and feasible means, the foundation shall be built up by means of a solid wedge of concrete which fills the entire space between the bedrock surface and the horizontal plane through the cutting edge. This concrete shall be of the same class as that specified on the drawings or in the schedule of quantities for the concrete seal. The rock or hard material on which the structure is to be founded shall be completely uncovered. The founding surface shall be cleared of all loose material before inspection by the engineer immediately prior to casting the concrete seal. No concrete shall be placed in the wedge or the seal before the engineer has inspected and approved the foundation. For this purpose the contractor shall adequately dewater the caisson to enable the engineer to conduct the inspection. In the event of a caisson not being vertical or in its correct position when it has reached the required depth, or in the event of a caisson being cracked during the sinking process, the contractor shall at his own cost carry out the necessary remedial work to the satisfaction of the engineer.

The relevant requirements of subclauses 6407(c) and 61 13(i)(ii) shall apply for placing the concrete under water. For concrete placed under water by methods other than by tremie, the cement content shall be 20% more than the quantity required for ordinary concrete of the same mix but shall be not less than 450 kg per m3 of concrete.

(ii)

Filling

Subsequent to inspection of the caisson compartments above the concrete seal, the compartments shall be fiiled with sand. The sand shall be sufficiently wetted to obviate bulking.

The first 2,O m of filling above the concrete seal shall be lowered gently into position. The sand may then be poured from the top and compacted sufficiently to prevent settlement while the cover slab concrete is being placed.

The top of the sand fill within the caisson shall be finished off to the level specified below the underside of the caisson cover slab.

Where the walls of the calsson have been overbuilt, the concrete shall be stripped to the required level without damage being done to the concrete below the cut-off level. The longitudinal reinforcement of the caisson shall project above the cut-off level by a distance of at least 40 times the bar diameter.

(g) The contractor shall provide the engineer with a complete record of the types of material excavated during sinking, together with the level at which each type of the material was found. In addition, a log showing the rate of sinking shall be kept by the contractor and furnished to the engineer.

Concrete screed below the caisson cover slabs

A concrete screed of the specified thickness and class of concrete shall be provided to the level shown on the drawings over the area covered by the cover slab, including the area within the caissons on top of the sand filling, except where the underside of the cover slab is being formed with formwork.

(e) (i)

Filling the caissons 6115 Concrete seal Unit

61.01 Additional foundation investigations . . . . .

MEASUREMENT AND PAYMEM

The seal shall be constructed of mass concrete of the class specified and shall be placed in accordance with the dimensions and levels shown on the drawings or as prescribed by the engineer. If this seal cannot be placed in the dry and has to be placed under water, the method of placing this concrete shall be approved by the engineer. The contractor shall cease placing the concrete under water when sufficient concrete has been placed to seal the foundation effectively. After the concrete has been placed, the concrete seal and the head of water over it shall remain undisturbed for a

. . ... ....

provisional sum

A provisional sum is provided in the schedule of quantities to cover the cost of this work.

The work authorised by the engineer shall be paid for in accordance with the provisions of the general conditions of contract.

In no case shall any of the following excavations be included in the measurement for payment:
61.02 Excavation:

(a)

Excavating soft material situated within the following successive depth ranges: 0 m up to 2 m

The volume of excavation in excess of the above(i) mentioned limits. The volume included within the excavated road (ii) prism, contiguous channels, ditches, etc, for which payment is provided elsewhere in the specifications. The tendered rates shall include full compensation for excavation in each class of material, the spoiling or stockpiling of material, the hauling of excavated material for the free-haul distance of 1,O km, any additional excavation the contractor may require for additional working space outside the authorised limits, trimming and cleaning the bottoms and sides of excavations, and strutting, shoring and safeguarding the excavations. If, after a foundation excavation has been completed, cleaned and trimmed ready for concrete screeding, the engineer orders further excavations to be made on account of changed dimensions and/or founding conditions, an extra over payment (subitem 61.02(c)) on the additional excavation measured for payment shall be payable in full compensation for any incidentals to the contractor over and above the normal excavation costs.

(i) (ii)

. . . . . . . . . . . . cubic metre (ma)

. . . . . . . cubic
metre (m3)

Exceeding 2 m and up to 4 m . . . . . . . . . . . Etc in increments of 2m ...........

(iii)

. . . . . . . . . cubic metre

(m3)

(b)

Extra over subitem 61.02(a) for excavation in hard material irrespective of depth . . . . . . . . . . . . . . . . . . . cubic metre (m3) Extra over subitem 61.02(a) for additional excavation required by the engineer after the excavation has been completed . . . . . . . . . . . cubic metre (m3) Extra over subitem 61.02(a) for excavation by hand . . . . . . cubic metre (m3)

(c)

(d)

Hem The limits for the successive depth ranges shall be measured down from the surface levels agreed on (subclause 6105(b)) to the founding level (clause 6106) agreed on. In the case of excavations that are required for diverting, channelling or widening streams, the successive depth ranges for those portions of the excavations that are within 5,O m of a concrete structure shall be measured from the surface levels agreed on to the invert level of the channel or stream. The unit of measurement shall be the cubic metre of material, measured in the original position before excavation. The quantity of excavation for each depth range shall be calculated from the neat outlines of the base or floor and the depth of excavation completed within each range. Irrespective of the total depth of the excavation, the quantity of material within each depth range shall be measured and paid for separately. Supplementary payment for excavation by hand as specified in subclause 6105(i), shall be the full compensation for incidentals for hand-excavating the materials instead of with mass-excavating equipment. At the concrete faces for which formwork has to be provided, additional excavation shall be measured to 0,5 m outside the concrete perimeter to make provision for a working space.
61.03 Access and drainage:

Unit

(a)

Access

. . . . . . . . . . . . . . . . . . . . . . . lump sum

The tendered lump sum shall include full compensation for providing access, which, inter alia, shall include constructing temporary banks, artificial islands and/or cofferdams, their protection, safeguarding and maintenance, draining and keeping dry the working areas and draining the excavations within the access, and any incidentals in respect of work to be done below standing water. 75% of the lump sum will be paid when the access has been constructed. The remaining 25% will be paid after the access has been removed. (b) Drainage where no access has been provided

.........

lump sum

Payment will be made for this work by way of a lump sum for each structure or series of structures appearing separately in the schedule of quantities. The lump sum shall be paid on a pro rata basis as the work progresses. The tendered lump sum shall include full compensation for draining by pumping or in any other way and for any other work necessary for keeping the excavation dry or for working in the dry.

Hem Where foundation fill is constructed in an excavation, the quantity of excavated material measured for payment shall be the material excavated between the average ground level, as described in subclause 6105(b), and the founding level, from a prism with vertical sides, as described in clause 6109 or as prescribed by the engineer.
61.04 BacMill to excavations utilising:

Unit

(a) (b)

Material from the excavation

. . cubic metre (m3)

Imported material . . . . . . . . . . cubic metre (rn3)

(c)

Soil cement

. . . . . . . . . . . . . . . cubic metre (m3)

Item
61.08 Foundation fill consisting of:

Unit

The unit of measurement shall be the cubic metre of backfill material measured in the excavation. The quantity measured shall be calculated from within the neat outlines defined for the excavation under item 61.02 and the height to which the backfilling is constructed. The volume occupied by the structure shall be subtracted when calculating the volume of backfilling. The height shall be determined by the upper surface of the road prism or the reference ground surface (subclause 6105(b)), whichever is the lower. The tendered rates shall include full compensation for furnishing and placing all materials within the entire excavation, transporting the material within the free-haul distance of 1,O km, and preparing, processing, shaping, watering, mixing and compacting the material to the specified densities.

(a) (b) (c)

Rock fill

. . . . . . . . . . . . . . . . . cubic metre

(rn3)

Crushed-stone fill

. . . . . . . . . . cubic metre (m3)

Compacted granular material . . . . . . . . . . . . . . . . . cubic metre (m3) Mass concrete (class indicated) . . . . . . . .

(d)

. . . . . . . . cubic metre (m3)

(e)

Concrete screed (thickness and class of concrete indicated) . . . . . . . . . . . . . . . . cubic metre (m3)

The unit of measurement shall be the cubic metre of approved material placed and compacted below the bases as specified or where directed by the engineer. The quantity of foundation fill to be measured for payment shall be the material contained within the prism specified in clause 6109 or shall otherwise be the quantity to the outlines shown on the drawings or as directed by the engineer.

Item
61.05 Fill within a restricted area (extra over item 33.01)

Unit

. . cubic metre (m3)

The unit of measurement shali be the cubic metre and the quantity shall be taken as the total volume of material within the restricted area as defined in subclause 6108(d). The quantity shall not include the volume of backfill which is measured and paid for under item 61.04 above. The tendered rate shall include full compensation for all additional work necessitated by working in the restricted area and for the increased density required in the restricted area.

The tendered rates shall include full compensation for procuring, furnishing, transporting, placing and compacting the material.

Item
61.09 Establishment on the site for the drilling of holes (type of drilling indicated) . .

Unit

Item

Unit

.............

lump sum

61.06 Overhaul i n excess of 1.0 k m on excavated material and on material imported for backfill, foundation fill and fill for caissons . . . . . . . . . cubic metre-kilometre (m3-km)

The tendered lump sum shall include full compensation for establishment on the site and the subsequent removal of all special plant for drilling the holes and additional plant for carrying out operations, the cost of which does not vary with the actual amount of work to be done.

Overhaul shall be measured and paid for as specified in clause 1603 and shall apply only to that portion of the material qualifying for payment under items 61.02, 61.04(b), 61.OB(a) and (c), and 61.47. Overhaul shall not apply to concrete used in the foundation fill.

This work will be paid for by way of a lump sum, 75% of which will become payable when all the equipment is on the site and the first hole has been drilled. The remaining 25% will become payable after all the holes have been drilled and the equipment has been removed from the site.

Item Item
61.07 Overbreak in excavation in hard material . . . . . . .

Unit

Unit
61.10 Moving to and setting u p the equipment at each hole to be drilled . . . . . . .

. . . . square metre (rn2)

.......

number (No)

The unit of measurement shall be the square metre of surface area of the vertical outer faces of the base.

The unit of measurement shall be the number of positions to which the equipment has to be moved and set up in position. The number to be measured shall equal the number of holes to be drilled as instructed by the engineer.

The tendered rate shall inciude full compensation for the overbreak material removed from the excavation, for the concrete fill in accordance with subclause 6105(c), and any additional screeding concrete required.

The tendered rate shall include full compensation for all the costs involved in moving and setting up the equipment.

Item

Unit

61.1 1 Drilling of holes (diameter and type of drilling indicated) . . . . . . . . . . . . . . . .metre (m) The unit of measurement shall be the metre of hole drilled. The tendered rate shall include full compensation for drilling and clearing the holes as specified. Where no provision has been made for payment in the schedule of quantities under items 61.09 and 61.10, the tendered rate shall also include full compensation for work falling under these items.

and all special constructional plant and equipment for foundation piling and for carrying out operations, the cost of which does not vary with the actual amount of piling done. This work will be paid for by way of a lump sum, 50% of which will become payable when all equipment is on the site and the first pile has been installed. The second instalment of 25% of the lump sum will be payable after half the total number of piles have been installed, and the final instalment of 25% after all the piles have been completed and the equipment has been removed from the site.

Item ltem 61.12 Grouting (type of grout and for which purpose it is required indicated) . . Unit 61.16

Unit Moving to, and setting u p the equipment at each position for installing the piles . . . . . . . . . . . . . . . . . . . . number (No)

. . . . . . . . kilogram

(kg)

The unit measurement for grouting shall be the kilogram of cement or proprietary mark of grout as may be applicable used in the grouting operation. The tendered rate shall include full compensation for providing the equipment and all the material, and mixing and pumping the grout into the prepared holes in accordance with the instructions of the engineer, and also for the water-pressure tests.

The unit of measurement shall be the number of positions to which the installation equipment has to be moved and set up in position. The quantity measured shall be the number of piles installed plus the number of piles redriven on the instruction of the engineer, plus any piles provided in addition for load tests, which do not form part of a specific pile group. The tendered rate shall include full compensation for all costs involved in moving and setting up any equipment.

Item 61.13

Unit Item Dowel bars (type, diameter and length of dowel bars, together with type of grout, indicated) . . . . . kilogram (kg) 61.17 Augered or bored holes for piles with a diameter of (diameter indicated) through material situated within the following successive depth ranges: (a) (i) Augered holes: 0 m up to 10 m Unit

The unit of measurement for the dowel bars shall be the kilogram of bars provided and secured in position. The tendered rate shall include full compensation for supplying all the material and positioning and grouting the dowel bars as specified.

. . . . . . . . . . . . . . . . . .metre

(m)

Item 61.14 Foundation lining (type of material and thickness indicated)

Unit

(ii) (iii)

Exceeding 10 m and up to 15 m Etc in increments of 5 m depths Bored holes: OrnuptolOm

. . . . . metre (m)
. . . . . metre (m)

.......

square metre (m2)

(b) (i) (ii)

The unit of measurement for foundation lining shall be the square metre of concrete surface lined. The tendered rate shall include full compensation for procuring, furnishing and placing all material and for all labour and incidentals required for completing the work as specified.

. . . . . . . . . . . . . . . . . .metre(m)
. . . . metre
(m)

Exceeding 10 m and up to 15 m Etc in increments of 5 m depths

(iii)

. . . . . metre (m)

Item 61.15 Establishment on the site for piling . . . . . .

Unit

The limits for the successive depth ranges shall be measured down from the average ground surface (subclause 61 13(h)) to the agreed founding level (clause 6106). The unit of measurement shall be the metre of hole, including the depth of the bulbous base formed, as may be applicable. The depth of the bulbous base shall be deemed to be equal to the diameter of a sphere, the volume of which shall be equal to the quantity of compacted concrete in the bulbous base.

. . . . . . . . . . . . . lump sum

The tendered lump sum shall include full compensation for generally levelling the piling site, establishing on the site and subsequently removing all structural platforms, rafts,

lrrespective of the total depth of the hole, the quantity within each depth range shall be measured and paid for separately. The tendered rates for forming augered holes shall include full compensation for augering and disposing of surplus material resulting from the hole having been formed. The tendered rates for forming bored holes shall include full compensation for boring, supplying, installing and extracting the driven temporary casing as well as for disposing of surplus material resulting from the hole having been formed.

61.20 Installation of prefabricated piles (type and size indicated) through material situated within the following successive depth ranges: (a) (b) (c) 0 m up to 10 m

. . . . . . . . . . . . . . . . .metre (m)
. . . . metre (m)

Exceeding 10 m and up to 15 m Etc in increments of 5 m depths

. . . . . metre (m)

Item 61.18 Wiving the temporary casing for driven displacement piling systems for forming holes for piles with a diameter of (diameter indicated) through material situated within the following successive depth ranges: (a) (b) (c) 0 m up to 10 m

Unit

The limits for the successive depth ranges shall be measured down from the average ground surface (subclause 6113(h)) to the founding depth agreed on (clause 6106). The unit of measurement shall be the metre of prefabricated pile installed. That part of the prefabricated pile projecting above the average ground surface shall not be measured and paid for. lrrespective of the total length of pile installed, the quantity installed within each depth range shall be measured and paid for separately. The tendered rates shall include full compensation for hoisting and driving the pile.

. . . . . . . . . . . . . . . . .metre (m)
. . . . . metre (m)

Exceeding 10 m and up to 15 m Etc in increments of 5 m depths

. . . . . metre (m)
Item Unit 61.21 Extraoveritem61.17, irrespective of the depth, to form augered and bored pile holes through identified obstructions consisting of: (a) Coarse gravel with a matrix content of less than (maximum percentage indicated) . . . . . . . Boulders (description of and maximum size indicated) Rock formation (description and class of rock indicated) .

The limits for the successive depth ranges shall be measured down from the average ground surface (subclause 6113(h)) to the agreed founding level (clause 6106). The unit of measurement shall be the metre of hole plus the depth of bulbous base formed, as may be applicable. The depth of the bulbous base shall be deemed to be equal to the diameter of a sphere, the volume of which shall be equal to the quantity of compacted concrete in the bulbous base. lrrespective of the total depth of the hole, the quantity within each depth range shall be measured and paid for separately. The tendered rates shall include full compensation for supplying, driving and subsequently extracting the temporary casing.

. . . . . . metre (m)

(b)

. . . . . . . metre (m)

(c)

. . . . . . . . metre (m)

Item 61.19 Manufacturing, supplying and delivering prefabricated piles (type and size indicated)

Unit

The unit of measurement shall be the metre of pile hole formed through the identified obstruction, measured from the depth at which the identified obstruction is encountered to the depth at which normal auger drilling or boring can be resumed or another type of identified obstruction is encountered. The tendered rates shall include full compensation for all additional work and incidentals required for forming the pile hole through the identified obstruction. Notes: (1) Subitem 61.21(a): The matrix content indicated shall be the percentage by volume of matrix in material containing coarse gravel. Where the maximum percentage indicated is exceeded, payment for forming holes through such material shall be made under item 61.17. Unless otherwise specified, the maximum percentage of matrix shall be accepted to be 60%.

. . . . . . . metre (m)

The unit of measurement shall be the metre of accepted prefabricated pile delivered on the site in accordance with the engineer's written instructions.

The tendered rate shall include full compensation for supplying all the materials, manufacturing, transporting and delivering to the point of use and handling the prefabricated piles.

(2) Where obstructions other than those provided for in item 61.21can be identified, they shall be described on the drawings and/or in the project specifications. Provision therefor shall be made in the schedule of quantities under extensions to item 61.21.

Item
61.26 Forming the bulbous bases for piles of (diameter indicated)

Unit

...........

number (No)

Item

Unit

The unit of measurement shall be the number of bulbous bases formed. The tendered rate shall include full compensation for all work to be done in forming the bulbous bases but shall exclude the concrete work.

61.22 Forming augered and bored pile holes through unidentified obstructions . . . . . . . . . . provisional sum

A provisional sum is allowed in the schedule of quantities for covering the cost of this work. Item Payment for the work authorised by the engineer shall be in accordance with the provisions of the general conditions of contract. Unit

61.27 Socketing piles into rock formation (class of rock and length of socket indicated) . . . . . . . . . . . . . . number (No)

Item

Unit The unit of measurement shall be the number of sockets, the length of which shall be not less than the specified length, formed in rock, the hardness of which shall be not less than that of the specified class of rock. The tendered rate shall include full compensation for all work to be done for socketing into the rock formation.

61.23 Driving temporary casings for driven displacement piling systems or installing prefabricated piles through identified or unidentified obstructions . . . . . . . . . . . . . . . provisional sum A provisional sum is allowed in the schedule of quantities for covering the cost of this work.

Item
61.28 Installing and removing temporary casings i n augered holes for piles of (diameter indicated) . . . . . . . . . . . . .

Unit

The method of payment for the work authorised by the engineer shall be in accordance with the provisions of the general conditions of contract.

. . . . . . . metre . (rn)

Item
61.24 Extra over items 61.17, 61.18 and 61.20 for raking piles:

Unit

The unit of measurement shall be the metre of temporary casing installed as directed by the engineer or shown on the drawings. Only the installed temporary casing below the average ground surface (subclause 61 13(h)) shall be measured for payment. The tendered rate shall include full compensation for supplying, installing and removing the temporary casings.

(a)

Holes for piles of (diameter and rake indicated) . . . . . . . . . . . . . . .metre (rn) Temporary casing for driven displacement pile systems (diameter and rake indicated) Prefabricated piles (type, size and rate indicated) .

(b)

Item

Unit

. . . . . . . metre (m)
61.29 Installing permanent pile casing for piles of (diameter indicated)

(c)

. . . . . . . . . . .metre (m)

. . . . . . . . . . . .metre

(m)

The tendered rates shall include full compensation for all additional work and incidentals for forming the pile holes or for driving and later extracting the temporary casing, or for installing prefabricated piles to the rake shown.

The unit of measurement shall be the metre of permanent casing installed as instructed by the engineer or shown on the drawings.

Item
61.25 Forming underreams for piles of (diameter indicated)

Unit

The tendered rate shall include full compensation for supplying and installing permanent pile casing.

.....

number (No) Item Unit

The unit of measurement shall be the number of pile holes underreamed. The tendered rate shall include full compensation for all work to be done in forming the underreams.

61.30 Steel reinforcement in cast in situ piles:

(a)

Mild-steel bars . . . . . . . . . . . . . . . . . . . . ton (t)

(b)

High-yield-stress-steel bars (type indicated) . . . . . . . . . . . . . . . . ton (t)

ttem
61.34 Strippinglcutting the pile heads (type and diameterlsize of pile indicated) . . . . . . . . . .

Unit

The unit of measurement for steel bars shall be the ton of reinforcement in place in accordance with the drawings or as authorised. Ties and other steel used for keeping the reinforcing steel in position shall be measured as steel reinforcing under the appropriate subitem. The tendered rates shall include full compensation for supplying, delivering, cutting, bending, welding, trial welds, placing and fixing the steel reinforcing, including all tying wires, spacers and waste.

. . . . number (No)

The unit of measurement shall be the number of heads of each type and diameterlsize of pile strippedlcut. The tendered rate shall include full compensation for providing all tools and strippinglcutting the pile heads.

Item

Unit

ttem
61.31 Cast i n situ concrete in piles, underreams, bulbous bases and sockets (class of concrete indicated) .

Unit

61.35 Establishment on the site for the load testing of piles . . . . . . . . . . . . . . . . . lump sum

........

cubic metre (m3)

The tendered lump sum shall include full compensation for the establishment on the site and subsequently removing all the special plant and equipment required for conducting the load tests on piles. This cost does not vary with the number of load tests to be conducted. Payment for this work shall be made by way of a lump sum, 100% of which will be paid after the testing assembly has been completely assembled and the first load test has been started.

The unit of measurement shall be the cubic metre of concrete placed in the cast in situ piles, underreams, bulbous bases and sockets. The quantity shall be calculated from the nominal pile diameter and length of pile from the founding level to the specified cutting-off level, plus the additional quantity of concrete in the underream and bulbous base as may be relevant. The tendered rate shall include full compensation for supplying and storing all material, providing all plant, mixing, transporting, placing and compacting the concrete, curing the concrete and repairing defective concrete. Payment shall distinguish between the different classes of concrete.

Unit
61.36 Load tests on piles (compression/tension test, diameter1 size, specified working load indicated) . .

.......

number (No)

The unit of measurement shall be the number of load tests conducted on the instruction of the engineer, for each specified working load. Test piles, but not anchor piles and anchors, shall be measured as specified above for permanent piles. Anchor piles and anchors shall be deemed to form part of the testing equipment under this item.

Unit
61.32 Extra over item 61.31 for concrete cast under water . . . . . . . . . . . .

. . . . . . .cubic metre (m3)

The unit of measurement shall be the cubic metre of concrete cast under water, the quantity being calculated as for item 61 3 1 . The tendered rate shall include full compensation for all additional work, incidentals and extra cement required for placing the concrete under water.

The tendered rate shall include full compensation for installing the anchor piles and anchors where necessary; conducting load tests, and processing and submitting the results.

Item Item
61.33 Splicinglcoupling prefabricated piles for lengthening (size of pile indicated) . . . . . . . . . . . .

Unit

Unit

61.37 Establishment on the site for core drilling .

. . . . . . . . . . . . . lump sum

. . . . number

(No)

The unit of measurement shall be the number of splices1 couplings in prefabricated piles for each size of pile.

The tendered lump sum shall include full compensation for the establishment on the site and subsequently removing all the equipment required for conducting the core drilling. This cost does not vary with the quantity of work to be done.

The tendered rate shall include full compensation for all work required for splicinglcoupling the piles in accordance with the specifications.

This work will be paid for by way of a lump sum, 100% of which will become payable when the equipment has been set up at the first location and drilling has started.

completed and the equipment has been removed from the site.
61.38 Moving the equipment to and assembling it at each location where cores are to be drilled

..........

Item number (No)

Unit

The unit of measurement shall be the number of locations to which the core-drilling equipment is to be moved and at which it has to be assembled. The tendered rate shall include full compensation for the cost of moving and assembling the equipment.

61.42 Formwork for caissons (class of finish indicated) . . . . . . . . . . . . . . square metre (m2)

Item
61.39 Drilling the cores (diameter indicated) in:

Unit

The unit of measurement shall be the square metre of formwork, and only the area of formwork in contact with the finished face of the concrete shall be measured. Formwork for construction joints shall be measured for payment under class F1 surface finish but shall be measured only for construction joints shown on the drawings or as prescribed by the engineer. The tendered rate shall include full compensation for supplying all the materials, erecting the falsework and formwork, constructing the forms, forming the grooves, fillets, chamfers, stopends for construction joints, treating the forms, all accessories, and stripping and removing the formwork after completion of the work. Payment for formwork shall be made only after the formwork has been stripped and the surface finish approved.

(a) (b) (i) (ii)

Concrete

. . . . . . . . . . . . . . . . . . . . . . .metre (m)

Founding formation: Irrespective of hardness

. . . . . . . . . . . .metre

(m)

With a hardness of (hardness indicated) . . . . . . . . . . . . . .

. . . . . . . metre . (m)
Item Unit
61.43 Steel reinforcement for caissons:

The unit of measurement shall be the metre of hole drilled, The tendered rate shall include full compensation for drilling, recovering and packing the cores, keeping the drilling records, providing core boxes, providing and installing the casings, and backfilling the holes with grout.

(a)

Mild-steel bars

....................

ton (t)

(b)
Item
61.40 Standing time for pile-installation frame

High-yield-stress-steel bars (type indicated) .

. . . . . . . . . . . . . . . ton

(t)

Unit The unit of measurement for steel bars shall be the ton of reinforcement in place in accordance with the drawings or as may have been authorised. Ties and other steel used for positioning the reinforcing steel shall be measured as steel reinforcing under the appropriate subitem. The tendered rates shall include full compensation for supplying, delivering, cutting, bending, welding, trial welding joints, placing and fixing the steel, including all tying wire, spacers and waste.

hour (h)

The unit of measurement for the standing time of a pileinstallation frame shall be the hour during which the pileinstallation frame is standing in terms of subclause 61 13(w). The tendered rate shall include full compensation for all fixed costs for the pile-installation frame, which is not connected with its operation and the quantity of work done.

Item
61.41 Establishment on the site for constructing the caissons . . . . . . . . . . . .

Unit

Item
61.44 Cast in situ concrete in caissons and concrete seals (class of concrete indicated)

Unit

. . . . . . . . . . lump

sum

..

cubic metre (m3)

The tendered lump sum shall include full compensation for the establishment on the site and later removing all special plant and equipment necessary for constructing the caissons. This cost shall not vary in accordance with the number of caissons constructed. This work will be paid for by way of a lump sum, 50% of which will be paid when all the equipment is on the site and the first caisson has been constructed. The second payment of 25% of the lump sum will be paid after half the number of caissons have been completed, and the final instalment of 25% after all the caissons have been

The unit of measurement for cast in situ concrete shall be the cubic metre of concrete in place. Concrete quantities in the caissons shall be calculated from the dimensions shown on the drawings or authorised by the engineer, and the length of the caisson from the founding level to the specified cut-off level. The quantity of concrete in the concrete seal shall be calculated in accordance with the dimensions shown on the drawings or authorised by the engineer. The tendered rate shall include full compensation for procuring and furnishing all the materials, storing the

material, providing all plant, mixing, transporting, placing and compacting the concrete, all sealing, curing the concrete and repairing defective concrete. Payment shall distinguish between the different classes of concrete.

(b)

Extra over subitem 61.47(a) for excavation in hard material irrespective of depth . . . . . . . cubic metre (m3)

Item
61.45 Cutting edge for (diameter1 size indicated) caissons . .

Unit

The limits for the successive depth ranges shall be measured down from the firm horizontal base (subclause 6114(b)) to the excavated level inside the caisson. The unit of measurement shall be the cubic metre of material, measured in the original position before excavation. The quantity of excavation for each depth range shall be calculated from the gross area of the caisson in plan and the depth of excavation completed within each depth range. Irrespective of the total depth of excavation, the quantity of material within each depth range shall be measured and paid for separately. The tendered rates shall include full compensation for excavation in the classified material, spoiling or stockpiling the material, hauling the excavated material for the freehaul distance of 1,O km, trimming the bottom of the excavation, dewatering, pumping and removing the material leaking into the caisson before sealing.

. . . . . . number (No)

The unit of measurement shall be the number of caissons provided with cutting edges, irrespective of the material they have been constructed of.

The tendered rate shall include full compensation for manufacturing, supplying, delivering and installing the complete cutting edge as well as for joining the cutting edge to the caisson unit. Where the cutting edge is of concrete and forms part of the bottom element, the tendered rate shall include full compensation for all additional work required for completing the element.

Item
61.46 Sinking (diameterlsize indicated) caissons through material situated within the following successive depth ranges:

Unit Item
61.48 Filling the caissons

Unit

.........

cubic metre (m3)

(a) (b) (c)

0 m up to 5 m

. . . . . . . . . . . . . . . . . .metre (m)

The unit of measurement shall be the cubic metre of sand placed above the concrete seal in the caisson compartments. The tendered rate shall include full compensation for supplying and placing the sand, transporting the material within a free-haul distance of 1.0 km, and compacting the material as specified.

Exceeding 5 m and up to 10 m

. . . . . metre (m)

Etc in increments of 5 m depths . . . . . metre (m)

The limits of the successive depth ranges shall be measured down from the firm horizontal base (subclause 61 14(b)) to the agreed founding level (clause 6106). The unit of measurement shall be the metre of caisson sunk. Irrespective of the length of caisson sunk, the quantity for each depth range shall be measured and paid for separately. The tendered rates shall include full compensation for locating and holding in position, dewatering, pumping, kentledge and lubricating the sides of the caisson, and for all work in connection with the sinking of the caisson which is not paid for elsewhere.

kern

Unit

61.49 Stripping the (size of caisson indicated) caisson heads . . . . . . . . number (No)

The unit of measurement shall be the number of caissons of each size stripped.

The tendered rate shall include full compensation for cutting away, trimming and disposing of the concrete removed.

kern Item
61.47 Excavation for caissons: (a)

Unit

Unit

61.50 Nuclear integrity testing on bored piles:

(a)

Excavating soft material situated within the following successive depth ranges: 0 m up to 2 m

Constructing 5,O m long calibration piles of (indicate diameter) . . . . . . . . . . . . . . . . . . . number (No) Installing 65 m m internal diameter steel ducts in the piles . . . . . . . . . . . metre (m) Performing integrity tests using: The nuclear method

(i) (ii) (iii)

. . . . . . . . . . . . . cubic metre (m3)

cubic metre (m3)

(b)

Exceeding 2 m and up to 4 m

(c) (i)

Etc in increments of 2 m depths cubic metre (m3)

...........

number (No)

(ii)

The neutron method

. .. . . . . .. . .

number (No)

integrity tests performed by each method. The tendered rates shall include full compensation for procuring and furnishing all materials, constructional plant, equipment, labour and incidentals for forming the bored holes, constructing the calibration piles, installing the steel ducts, and performing the prescribed integrity tests, complete as specified.

The unit of measurement for subitem (a) shall be the number of calibration piles constructed. The unit of measurement for subitem (b) shall be the metre of 65 m m internal diameter steel duct installed. The unit of measurement for subitem (c) shall be the number of

MEASUREMENT FOR PAYMENT FOR ALTERNATIVE PILES IN ACCORDANCE WITH SUBCLAUSE 61 13(c)

CRITERIA Nd r Nb

~b K = Ld for Ld r Lb

Nd 5 Nb

Np = Nd Ld < Lb K = Lbfor~d Lp = Nd.Ld

Np = Nd

+ Nb(Lb - Ld)K
EXAMPLE

Lp = Nd.Ld

+ Nd (Lb - Ld)K

Nd > Nb

Nd = Nb

Nd < Nb

Nb = 25 Lb = 10 Ld > Lb Lp = 360

Nb = 25 Lb = 10 10

Nb = 25 Lb = 10 10

+ 25(-2)E
No 30 25 30 360 250 318

= 318

Lp = 300

+ 25(-2) 1 2
No 25 25 25

= 258

Lp = 240

+ 20(-2) 1 2
No 20 25 20

10

= 207

Length Offered Built Paid

Length 300 250 258 Offered Built Paid

Length 240 250 207

Offered Built Paid

Nb = 25 Lb = 10 Ld = Lb Lp = 300 No Offered Built Paid 30 25 30 Length 300 250 300

Nb = 25 Lb = 10 Lp = 250 No Offered Built Paid 25 25 25 Length 250 250 250

Nb = 25 Lb = 10 Lp = 200 No Offered Built Paid 20 25 20 Length 200 250 200

Nb = 25 Lb = 10 Ld < Lb Lp = 240

Nb = 25 Lb = 10 8

Nb = 25 Lb = 10 8

+ 25(2) 10
No 30 25 30

= 280

Lp = 200

+ 25(2) 10
No 25 25 25

= 240

Lp = 160

+ 20(2)%
No 20 25 20

= 192

Length 240 250 280 Offered Built Paid

Length 200 250 240 Offered Built Paid

Length 160 250 192

Offered Built Paid

SERIES 6000 : STRUCTURES SECTION 6200 : FALSEWORK, FORMWORK AND CONCRETE FINISH

The surfaces of forms which are to be in contact with the concrete shall be clean, free from deposits or adhering matter, ridges or spatter which will impart irregularities and blemishes to the concrete surface, and shall also be free from indentations and warps. (iii) Void formers

CONTENTS
SCOPE MATERIALS GENERAL DESIGN CONSTRUCTION REMOVING THE FALSEWORK AND FORMWORK FORMED SURFACES : CLASSES OF FINISH REMEDIAL TREATMENT OF FORMED SURFACES UNFORMED SURFACES : CLASSES OF FINISH MEASUREMENT AND PAYMENT

Void formers used in permanent work shall be subject to the approval of the engineer. Where void formers of a special design are required, details thereof will be specified. Void formers shall be manufactured from material which will not leak, tear or be damaged during the course of construction and shall be of such tight construction as to prevent undue loss of the mortar component of the concrete through leakage. The units shall be sufficiently rigid so as not to deform during handling or under the pressure of the wet concrete. For mild-steel spiral-lock-formed void formers, the metal thickness shall be as follows, unless otherwise specified:
(1)

6201

SCOPE

This section covers the design, supply and erection of all falsework and formwork used in the construction of permanent work. This section also describes the classes of surface finishes on formed and unformed concrete surfaces.

Unbraced void formers

0,6 m m for diameters of up to 600 m m 0,8 m m for diameters exceeding 600 m m and up to 800 m m

6202

MATERIALS
1,O m m for diameters exceeding 800 m m and up to 1 000 mm.

(a)

General (2) Braced void formers

The materials used in the construction of falsework and formwork shall be suitable for the purpose for which they are required and be of such quality as to produce the specified standard of work. The type, grade and condition of the material shall be subject to the engineer's approval.

0,6 m m for diameters of up to 800 m m 0,8 m m for diameters exceeding 800 m m and up to 1 000 m m 1,O m m for diameters exceeding 1 000 m m and up to 1 200 m m 1,2 m m for diameters exceeding 1 200 mm. The thickness specified for braced void formers shall apply to formers internally braced with timber or equivalent braces. The braces shall be at spacings not exceeding 2,O m and not further than 1,O m from the end of each unit. Timber cross braces shall consist of members with crosssectional dimensions of at least 50 m m x 50 mm. All hollow void-former units shall be provided with a 12 m m diameter drainage hole at each end. (iv) Chamfer and recess fillets

(b)

Falsework

The timber, structural steel and scaffolding used shall be free from defects that may prejudice the stability of the falsework. The jacks, devices, clamps and fittings shall all be in a good working order and of adequate design and strength.

(c)

Formwork
Tongue-and-groove boarding

(i)

Tongue-and-groove boarding shall be of suitably dried timber which will not warp, distort or cause discolouration of the concrete. The widths of the boards shall be as specified on the drawings or in the schedule of quantities or as prescribed by the engineer. Boards shall be supplied in lengths not shorter than 3 m.

Timber fillets used for forming chamfers and recesses on exposed surfaces shall be made from new material unless otherwise authorised. (v) Jack rods for sliding formwork

(ii)

Steel forms to exposed surfaces The jack rods, base plates and couplers shall be strong enough to carry the design load under all operating conditions without buckling, distorting or causing damage to the concrete. Jack rods which are to remain permanently embedded in the concrete shall comply with the

For classes F2 and F3 surface finish the individual panels shall be assembled sufficiently rigidly and so clamped as not to deform or kick during handling or under the pressure of the wet concrete.

requlrernents of clauses 6303 and 6305. Under no circumstances shall bent rods be used in the work. The jack rods used shall have a diameter of at least 25 mm.

The engineer may require the contractor to submit to him for consideration and approval the design and drawings of the faisework and formwork for any structure. The contractor shall submit his design criteria and calculations and detail drawings of the falsework and formwork to the engineer at least 14 days before the engineer's approval is required.

6203 GENERAL
@)
Notwithstanding approval given by the engineer for the design and drawings prepared by the contractor for the falsework and formwork, and the acceptance of the falsework and formwork as constructed, the contractor shail be solely responsible for the safety and adequacy of the falsework and formwork and shall indemnify and keep Indemnifiedthe employer and engineer against any losses, claims or damage to persons or property whatsoever which may arise out of or in consequence of the design, construction, use and maintenance of the falsework and formwork and against all claims, demands, proceedings, damages, costs, charges and expenses whatsoever in respect thereof or in relation thereto. For works on, over, under or adjacent to any railway line which is controlled by a statutory authority, the contractor shall comply, inter alia, with the requirements for the preparation and submission of drawings for falsework and formwork, and the submission of certificates for the proper construction thereof, all In accordance with the official specifications of such authority. After having constructed the falsework and formwork, and prior to placing the reinforcing steel and/or the concrete, the contractor shall Inspect the falsework and formwork. Dimensions shail be checked, unevenness of surface shall be corrected, and special attention paid to the adequacy and tightness of all bolts, ties and bracings as well as to the soundness of the foundations.

Falsework

The contractor shall make his own assessment of the allowable bearing pressure on the foundation material and shall design the footings and falsework to prevent overloading, differential settlement and unacceptable overall settlement. In assessing the allowable bearing pressure, due account shall be taken of the effect of wetting on the foundation material. In designing the faisework, cognizance shall also be taken of the redistribution of load which may occur on account of the effect of temperature, wind force, the prestressing of curved and skewed structures, stage construction, flooding and debris. Particular attention shall be given to providing transverse and diagonal bracing as well as rib stiffeners on cross bearers.

(c)

Formwork
General

(i)

Formwork shall be so designed as to be sufficiently rigid to ensure that the specified dimensional tolerances can be achieved under the combined action of self-weight, dead load and imposed loads as well as the additional loads resulting from the rate of concreting, the layer thickness of the concrete cast in one operation and the method of placing and compaction. (ii) Sliding formwork

The contractor shall give the engineer at least 24 hours' notice of his intention to place the concrete to enable the engineer to inspect all aspects of the completed work. However, before notifying the engineer, the contractor shail satisfy himself that the work complies in all respects with the specifications. Concrete sections with dimension of smaller than 200 mm shall not be formed with sliding formwork unless authorised by the engineer. Where no provision has been made In the schedule of quantities for sliding formwork, the contractor may, in a covering letter to the tender, submit a lump sum which reflects a saving in the cost for the use of sliding formwork in lieu of conventional formwork. The tendered lump sum quoted shall be accompanied by rates for pay items 62.07, 62.08, 62.09 and 63.03, all in accordance with clauses 6210 and 6310.

The contractor shall be responsible for the design of the sliding formwork. Prior to fabrication or bringing the sliding formwork and any additional equipment to the site, the contractor shail submit drawings of the complete slidingformwork assembly to the engineer for approval. The drawings shail show full details of the forms, jacking frames, access ladders, hanging platforms, safety rails and curing skirts as well as details of the jacks and jack layouts. The contractor shall be required to submit to the engineer, before slide casting commences, an instruction manual in which the sliding techniques, jacking procedure, methods of keeping the formwork level, the procedure to be adopted to prevent bonding of the concrete to the forms and a method for releasing the forms in the event of bonding, the instrumentation and monitoring of the slide casting and correcting for verticality, twisting and levelness are described in detail. The formwork panels shall be inclined to give a small taper, the forms being slightly wider at the bottom than at the top.

6204 DESIGN

The contractor's design and drawings of the falsework and formwork shall comply amongst others with all statutory requlrernents.

The taper shall be so designed as to produce the specified concrete thickness at the mid-lift level of the form. The spacing of the jacks with their jack rods shall be so

designed that the dead load of the sliding-formwork assembly, the frictional load, and the mass of materials, personnel and equipment will be evenly distributed and within the design capacity of the jacks used.

Where polystyrene or similar material, susceptible to damage is used, it shall be lined with a hard surface on the side to be concreted. The hard material shall be sufficiently resilient to ensure that the required quality of work can be achieved. Where it is specified, all formwork ties shall be provided with recoverable truncated cones between sleeve ends and formwork faces to ensure that sleeve ends are not exposed on concrete surfaces. The cones shall have a minimum depth of 15 mm. (ii) Formwork to exposed surfaces

6205 CONSTRUCTION

(a)

Falsework

Falsework shall be erected in accordance with the approved drawings incorporating such modifications as required by the engineer. The contractor shall take precautions to prevent deterioration of the foundations during the course of construction. The falsework shall incorporate features which will permit adjustment to the alignment of the formwork to neutralise the expected settlement and deflection under load.

The formwork and boards shall be so arranged as to form a uniform and regular pattern in line with and perpendicular to the main axis of the member, unless otherwise approved or directed by the engineer. Joints between contiguous members shall, after caulking, taping or sealing, be treated to prevent blemishes, stains and undue marks from being imparted to the concrete surface. Bolt and tie positions shall be so arranged that they conform to the symmetry of the formwork panels or boards. Bolt and rivet heads which will be in contact with the formed surface shall be of the countersunk type and shall be treated to prevent marks from forming on the concrete surface. The formwork at construction joints shall be braced to prevent steps from forming in the concrete surfaces at the joints between successive stages of construction. Where moulding or recess strips are specified, they shall be neatly butted or mitred. (iii) Formwork for open joints

(i)

General

The formwork for bridge decks shall be erected to levels calculated from the information given on the plans for roadworks and bridges. The levels shall be adapted to make provision for the specified precamber as well as for the expected deflection and settlement of the fully loaded falsework and formwork. The levels shall be set out and not exceeding 2 3 0 m. checked at i n t e ~ a l s For constructing the formwork, the contractor may, subject to the provisions of clause 6202, use any material suitable for and compatible with the class of surface finish and dimensional tolerances specified forthe particular member. Formwork shall be sufficiently rigid to maintain the forms in their correct position, shape and profile and shall be of such tight construction that the concrete can be placed and compacted without undue loss or leakage of the mortar component of the concrete. The joints between contiguous formwork elements shall be of a tight fit and, where necessary, the joints shall be caulked, taped or packed with a sealing gasket, all at no extra payment if undue leakage occurs or can be expected. Paper, cloth or similar material shall not be used for this purpose. The formwork construction shall permit accurate erection and easy stripping without shock, disturbance or damage to the cast concrete. Where necessary, the formwork assembly shall permit the removal or release of side forms independently of the soffit forms. Metal supports, ties, hangers and accessories embedded in the concrete shall be removed to a depth of not less than the cover specified for the reinforcement. No wire ties shall be used.

The requirements for formwork for open joints shall, unless otherwise specified, apply only to cases where the distance between opposite concrete surfaces is equal to or less than 150 mm. Formwork for open joints shall be constructed to produce a class F1 surface finish to concealed surfaces or a class F2 or F3 surface finish corresponding to the in-plane surface finish of the bordering concrete surfaces. The material used and construction of the formwork shall permit its complete removal to form the open joint. No solvent shall be used to remove forrnwork unless approved by the engineer. (iv) Openings and wall chases

Openings and wall chases shall be provided only where indicated on the drawings or as authorised by the engineer. Frames for openings shall be rigid and firmly secured in position to prevent their moving. Temporary holes shall be so formed that they will not create an irregular pattern in relation to the rest of the exposed formed concrete surface. (v) Sliding formwork Plant and equipment

All external corners shall be chamfered by fillet strips being fixed into the corners of the formwork to form 25 m m x 25 m m chamfers. Re-entrant angles need not be chamfered unless specified.

(1)

Unless otherwise specified in the project specifications,

hoisting equipment for sliding formwork, which operates stepwise with upward movements of between 10 m m and 100 m m will be acceptable. However, the use of linked hydraulic or pneumatic jacks is preferable, which are reversible and driven by an electrically operated pump, and which can hoist at a steady rate. The jacks shall have independent controls for regulating verticality and levelness. The jacking system shall ensure that the slidingformwork assembly can be hoisted evenly. The use of hoisting systems which operate without jack rods shall be subject to the approval of the engineer. All equipment shall be thoroughly tested and inspected before installation and shall be maintained in a good working order throughout the entire sliding operation. The contractor shall keep adequate back-up plant, equipment and quantities of materials on the site to ensure that the slide casting can proceed without interruption.
(2)

reinforcement can be correctly placed and the specified concrete cover over the reinforcement maintained. Where the jack rods are to be recovered, adequate precautions shall be taken in respect of their removal without damage being caused to the concrete. Where jack rods occur at openings or wall chases, adequate lateral support shall be provided to prevent their buckling. Equipment and material shall be so distributed on the working platforms that the load will be evenly distributed over the jacks. Guard plates shall be provided at the tops of the forms to the outside walls to prevent the concrete from falling down the outside. The framework, forms and platforms shall be regularly cleared and the accumulation thereon of redundant concrete prevented. The contractor shall take all precautions to prevent contamination of the concrete by leaking oil or other causes. (5) The sliding process

Instrumentation and monitoring

The contractor shall supply and install suitable instrumentation on the sliding platform and foundations and against the sides of the structure for monitoring the height, verticality, levelness and twisting at regular distances. The equipment used, its utilisation and the frequency of recording any readings shall be approved b y the engineer. The contractor shall be responsible for all monitoring work and shall ensure that records of all readings and measurements taken are filed systematically and are at all times available to the engineer and the person in control of the sliding operation. Unless otherwise specified, the verticality of the structure shall be controlled with laser alignment apparatus or optical plummets, and the levelness of the sliding forms with a water-level system with reference control points placed at strategic locations. Height and verticality shall be monitored at intervals not exceeding 4 hours. The readings shall be plotted immediately on graphs. When the structure is more than 10 mm out of vertical, the engineer shall be notified immediately. (3) Supervision

The contractor shall give the engineer 24 hours' notice of his intention to commence with slide casting. Permission to commence with the sliding shall not be given by the engineer before the sliding-formwork assembly is fully operative and the complete stock of all materials required for the slide casting as well as back-up plant and equipment are on the site. The contractor shall ensure that the rate of sliding is such that the concrete at the bottom of the formwork has obtained sufficient strength to support itself and all loads which may be placed on the concrete at the time, and that the concrete does not adhere to the sides of the forms. The slide-casting operation shall be continuous, without any interruptions, until the full height of the structure has been reached, and shall be geared and arganised so as to maintain an average rate of sliding of 350 m m per hour. (6) Interruptions

During the entire period of the sliding operation, a competent person who is fully acquainted with the sliding technique and the contractor's methods of construction shall be in attendance on the sliding platform and in control of the sliding operations. (4) Construction

The jacking frame shall be constructed with adequate clearance between the underside of the cross members and top of the formwork to allow the horizontal reinforcement and embedded items to be correctly installed. A control procedure shall be agreed on by the contractor and the engineer to ensure that all the reinforcement is placed. At all times there shall be horizontal reinforcement above the level of the top of the formwork panel. Guides shall be provided to ensure that the vertical

When the sliding operations are delayed for more than 45 minutes, the contractor shall prevent adhesion of the setting concrete to the formwork panels by easing the forms or moving them slightly every 10 minutes, or alternatively, where reversible jacks are used, by lowering the forms by 10 m m to 25 mm. Wherever interruptions occur, emergency construction joints shall be formed and treated in accordance with clause 6408. Before concreting is restarted, the form shall be adjusted to fit snugly onto the hardened concrete so as to prevent steps from being formed on the exposed concrete surface. When slide casting is recommenced, care shall be taken to prevent the fresh concrete from being lifted off from the old concrete. (vi) Permanent formwork

Void formers shall be secured in position at regular intervals to prevent displacement and distortion during concreting. The void formers shall be supported on precast concrete blocks or rigid welded steel cradles, all subject to

approval by the engineer. The ties securing the void formers shall be attached to the formwork and cross bearers of the falsework. The void formers shall not be tied to or supported on the reinforcement. Fibre-cement plates shall be supported so that the plate spans in the direction parallel to the orientation of the asbestos fibres. (vii) Preparing the formwork

On prestressed-concrete structures the falsework and supporting formwork shall be removed after the full prestressing force relating to the particular stage of construction has been applied, unless otherwise specified or authorised.

6207

FORMED SURFACES : CLASSES OF FINISH

(a)

General

The surfaces of forms which are to be in contact with fresh (wet) concrete shall be treated to ensure non-adhesion of the concrete to the forms and easy release from the concrete during the stripping of the formwork. Release agents shall be applied strictly in accordance with the manufacturer's instructions, and every precaution shall be taken to avoid the contamination of the reinforcement, prestressing tendons and anchorages. In the selection of release agents, due regard shall be given to the necessity for maintaining a uniform colour and appearance throughout on the exposed concrete surfaces. Before the concrete is placed, all dirt and foreign matter shall be removed from the forms and the forms shall be thoroughly wetted with water.

In addition to complying with the tolerances specified in clause 6803, the surface finish on formed concrete surfaces shall also comply with the following requirements.

@)

Class F1 surface finish

After repair work has been done to surface defects in accordance with subclause 6208(b), no further treatment of the as-stripped finish will be required. This finish is required on concealed formed surfaces.

(c)

Class F2 surface finish

6206

REMOVlNG THE FALSEWORK AND FORMWORK

Falsework and formwork shall not be removed before the concrete has attained sufficient strength to support its own mass and any loads which may be imposed on it. This condition shall be assumed to require the formwork to remain in place after the concrete has been placed, for the appropriate minimum period of time given in table 620611, unless the contractor can prove, to the satisfaction of the engineer, that shorter periods are sufficient to fulfil this condition. In such case the formwork may be removed after the shorter periods of time agreed on by the engineer. Falsework and formwork shall be carefully removed without exposing the cast concrete to damage, disturbance or shock. Weather may be regarded as being "normal" when atmospheric temperatures adjacent to the concrete, as measured by a maximum-and- minimum thermometer, do not fall below 15"C, and as "cold" when temperatures, similarly measured, fall below 5C. When the minimum temperatures fall between these values, the length of the period after which the formwork may be removed, shall be determined by interpolation between the periods specified for normal and cold weather.

This finish shall be equivalent to that obtained from the use of square-edged timber panels and boards wrought to the correct thickness, or shutter boards or steel forms arranged in a regular pattern. This finish is intended to be l$ft as struck but surface defects shall be remedied in accordance with subclause 6208(b). Although minor surface blemishes and slight discolourations will be permitted, large blemishes and severe stains and discolouration shall be repaired where so directed by the engineer.

(d)

Class F3 surface finish

This finish shall be that obtained by first producing a class F2 surface finish with joint marks which form an approved regular pattern to fit in with the appearance of the structure. All projections shall then be removed, irregularities repaired and the surface rubbed or treated to form a smooth finish of uniform texture, appearance and colour. This surface finish is required on all exposed formed surfaces unless a class F2 finish is specified.

Unless specified to the contrary, steel forms may be used to form surfaces with a class F3 surface finish.

(e)

Board surface finish

Any period during which the temperature remains below 2C shall be disregarded in calculating the minimum time which shall elapse before the forms are removed.

This finish shall be that obtaihed by using tongue-andgroove timber boarding arrangt$ in an approved regular pattern. The finish is intended to be left as struck but surface defects shall 'be remedied in accordance with subclause 6208(b) and large fins trimmed where directed by the engineer.

On continuously reinforced concrete structures the falsework and supporting formwork shall not be removed before the concrete of the last pour has reached the appropriate minimum age given in table 620611 or the appropriate minimum strength. Where the structure is constructed in stages, the falsework and supporting formwork shall be removed as specified or authorised.

(f)

Protecting the surfaces

The contractor shall ensure that permanently exposed concrete surfaces are protected from rust marks, spillage and stains of all kinds and other damage during construction.

Table 620611 REMOVING FALSEWORK AND FORMWORK : MINIMUM PERIOD IN DAYS Type of cement used Ordinary portland cement and Portland cement 15 Falsework and formwork for Normal weather 1. Beam sides, walls and unloaded columns Soffits of slabs and beams (a) Spans up to 3 m (b) Spans over 3 m and up to 6 m (c) Spans over 6 m and up to 12 m (d) Spans over 12 m 4 10 14 21
7

Rapid-hardening portland cement and Rapid-hardening portland cement 15 Normal weather Cold weather* 1

Cements containing more than 15% of ground granulated blastfurnace slag or fly ash Normal weather 2 Cold weather 4

Cold weather 1,5

03

2.

2 5 10 18

4 10 18 28

6 14 21 28

10 24 28 36

17 24 30

Shorter perlods may be used for sections thlcker than 300 mm, subject to the requirements and the prior approval of the englneer.

8aOB RMEDl4L TFIEATMENT OF FORMED SURFACES

(a)

Gbneral

Agreement shall be reached wlth the engineer regarding any remedial treatment to be given after the surfaces have been Inspected immediately after the formwork has been removed, which treatment shall be carrled out without delay. No surfaces may be treated before inspection by the englneer.

Where the concrete has been damaged by adheslon to the formwork panel, the cracked and loose concrete shall be removed; or where the fresh concrete has lifted off at construction jolnts, the crack shall be scraped out Immediately on both sides of the wall to a depth of at least 50 mm. The cavltles so formed shall then be repalred as described above.

(c)

Fbbbing the surfaces

@)

Rspairs t o surfam defects

Surface defects such as small areas of honeycombing, cavities produced by form ties, large Isolated blow-holes, broken corner edges, etc, shall be repaired with mortar having a cement and sand ratio equal to that of the concrete being repaired,

If the finish of exposed formed surfaces does not comply with the requirements for uniformity of texture, appearance and colour, the contractor shall, when so Instructed by the engineer, rub down the exposed surfaces of the entire structure or of any part of it as specified below. The surface shall be saturated with water for at least one hour. Initial rubbing shall be done with a medlum-coarse carborundum stone, where a small amount of mortar, having a sand and cement ratio equal to that of the concrete being repaired, is used on the surface. Rubbing shall be continued until all form marks, projections and irregularities have been removed and a uniform surface has been obtained. The paste produced by the rubbing shall be left in place. The final rubbing shall be carried out with a fine carborundum stone and water. This rubbing shall continue until the entire surface Is of a smooth, even texture and is uniform in colour. The surface shall then be washed with a brush to remove surplus paste and powder. Where the concrete surfaces formed by sliding formwork require treatment to achieve the surface finish specified for the member, the concrete shall, as soon as the surfaces under the formwork are exposed, be floated with rubberlined floats to the desired finish.

For the repair of large or deep areas of honeycombing and defects, special approved methods and techniques, such as pneurnatlcally applied mortar, pressure grouting, epoxy bonding agents, etc, may be used.

Where, In the opinion of the engineer, the extent of the honeycombing or defects Is of such a degree that doubt exists about the effectiveness of repalr work, the contractor shall at his own cost perform a load test in accordance with subclause 6414(b)(ii) to prove that the structural safety of the repalred member has not been prejudiced, failing which, the structure shall be rebuilt In part or In full at the contractor's cost.

6209

UNFORMED SURFACES : CLASSES OF HNlSH 62.03 Horizontal forrnwork to provide (class of finish indicated as F1, F2, F3 or board) surface finish to (description of member to which applicable) . . . . .

(a)

Class U1 surface finish (rough)

This surface finish is required on those portions of bridge decks or culvert decks which are to receive asphalt or concrete surfacing or which are to be covered by backfilling material. Where the placing and compacting of the concrete have been completed as specified in clause 6407, the top surface shall be screeded off with a template to the required cross-section and tamped with a tamping board to compact the surface thoroughly and to bring mortar to the surface, so as to leave the surface slightly rough but generally at the required elevation.

square metre (m2)

Unit 62.04 Inclined formwork to provide (class of finish indicated as F1, F2, F3 or board) surface finish to (description of member to which applicable) . . . . . . . . . square metre (m2)

@)

Class U2 surface finish (floated)

This surface finish is required on sidewalks; the tops of wing walls and retaining walls; exposed concrete shoulders and unsurfaced areas on bridge decks; the inverts of box culverts; and decks which are to receive surfacings other than asphalt or concrete, The surface shall first be given a class U1 surface finish and after the concrete has hardened sufficiently, it shall be wood-floated to a uniform surface free from trowel marks. For non-skid surfaces such as on sidewalks and bridge decks, the surface shall then be given a broom finish. The corrugations so produced shall be approximately 1 m m deep, uniform of appearance and width and shall be perpendicular to the centre line of the pavement.

The unit of measurement shall be the square metre, and only the actual area of formwork in contact with the finished face of the concrete shall be measured. Formwork for the different classes of finish shall be measured separately. Formwork for construction joints shall be measured for payment under class F1 surface finish, but only formwork for mandatory construction joints shall be measured for payment. The tendered rates shall include full compensation for procuring and furnishing all materials required, erecting the falsework and formwork, constructing the forms, forming the grooves, fillets, chamfers and stop-ends for construction joints, treating and preparing the forms, all bolts, nuts, ties, struts and stays, stripping and removing the formwork after completion of the work, all labour, equipment and incidentals, and rubbing and surface treatment. Payment of 80% of the amount due for formwork will be made when the forrnwork has been removed, and payment of the remaining 20% will be made on approval of the concrete surface finish.

(c)

Class U3 surface finish (smoothly finished)

This surface finish shall be required at bearing areas and the tops of concrete railings. The surface shall first be given a class U1 surface finish, and after the concrete has hardened sufficiently, it shall be floated with a steel float to a smooth surface to within the dimensional tolerances specified in subclause 6803(h). Rubbing with carborundum stone after the concrete has hardened shall be allowed but under no circumstances will plastering of the surface be permitted.

Note: Vertical and horizontal formwork shall be the formwork of which inclination of the finishing surface in relation to the horizontal level shall be larger and smaller than 40" respectively. Inclined formwork shall be the formwork described as such in the schedule of quantities.

Item
6210

Unit

MEASUREMENT AND PAYMENT

62.05 Permanent formwork:

Unit
62.01 Formwork to provide (class of finish indicated as F1, F2, F3 or board) surface finish to (description of member to which applicable) . . . . . .

(a)

To form voids of (diameter1 size of void indicated) in (description of member to which applicable) . . . . . . . Of (description of material and member to which applicable) . . . . . . . . . . .

. . square metre (m2)

. square metre (mz)

Unit

(b)

. . . square metre (mZ)

Item

62.02 Vertical formwork to provide (class of finish indicated as F1, F2, F3 or board) surface finish to (description of member to which applicable) . . . . . . . . . square metre (m2)

The unit of measurement shall be the square metre of concrete area formed with permanent formwork. The tendered rates shall include full compensation for procuring and furnishing all the materials required, installing the formwork, and labour, equipment and

incidentals,

Item
62.06 Formwork to form open joints (description of member to which applicable, and location) . . . .

Unit

the first structural member on the site, and the remaining 25% will become payable after all sliding work has been completed and the said items have been removed from the site.

Item

Unit

. . . . square metre (m2)

62.08 Transporting to and setting up

The unit of measurement shall be the square metre of concrete area formed. Surfaces formed prior to the construction of the final surface for completing the joint, shall be measured under items 62.01, 62.02, 62.03 or 62.04, as may be applicable. The tendered rate shall include full compensation for procuring and furnishing all the materials required, constructing the formwork and subsequently removing all the material within the joint space, as well as labour, equipment and incidentals. Payment for formwork to open joints shall be made only after the forms and filler material have been completely removed and approval of the surface finish has been obtained.

the sliding formwork assembly at (description of each structure) . . . . number (No) The unit of measurement shall be the number of structures to which the complete sliding-formwork assembly has to be transported and set up in position ready to be commissioned. The tendered rate shall include full compensation for all costs involved in dismantling, transporting and erecting of the complete sliding-formwork assembly.

Item
62.09 Forming the concrete by sliding formwork for (description of each structure and class of surface finish to exposed surfaces indicated) . . . . . . . . . . . . . . . metre (m)

Item
62.07 Establishment on the site for sliding formwork operations. . . . . . . . . .

Unit

. . . . . . . . . . . lump sum

The tendered lump sum shall include full compensationfor the establishment on the site and the subsequent removal of the complete sliding-formwork assembly, special plant and equipment, and incidentals for the sliding work, the cost of which does not vary with the actual amount of sliding work done. This work will be paid for by way of a lump sum, 75% of which will become payable when the sliding-formwork assembly, plant and equipment have been fully installed at

The unit of measurement shall be the metre height of each structure formed by sliding formwork. The quantity measured shall be the actual height of each structure formed by the sliding technique.

The tendered rate shall include full compensation for sliding, instrumentation and monitoring, the maintenance of the complete sliding-formwork assembly, plant and equipment, supplying, installing and recovering the jack rods, floating, repairing and treating the concrete surfaces, forming the emergency construction joints, and all labour, equipment and incidentals.

SERIES 6000 : STRUCTURES SECTION 6300 STRUCTURES

200 GPa. REINFORCEMENT FOR The contractor shall submit to the engineer test certificates from a recognised testing authority to confirm that the tensile couplers offered comply with the specified requirements. All mechanical couplers used shall be subject to the approval of the engineer.

: STEEL

CONTENTS SCOPE MATERIALS STORING THE MATERIALS BENDING THE REINFORCING STEEL SURFACE CONDITION PLACING AND FIXING COVER AND SUPPORTS LAPS AND JOINTS WELDING MEASUREMENT AND PAYMENT

6303 STORING THE MATERVVS

Reinforcing steel shall be stacked off the ground and in aggressive environments it shall be stored under cover.

6304 6301

BENDING THE REINFORCING STEEL

SCOPE Reinforcement shall be cut or cut and bent to the dimensions shown on the bending schedules and in accordance with SABS 82. No flame-cutting of high-tensile steel bars shall be permitted except when authorised. Except as described below, all bars shall be bent cold and bending shall be done slowly, a steady, even pressure being exerted without jerking or impact. If approved, the hot bending of bars of at least 32 m m in diameter will be permitted, provided that the bars do not depend on cold working for their strength. When hot bending is approved, the bars shall be heated slowly to a cherry-red heat (not exceeding 840C) and shall be allowed to cool slowly in air after bending. Quenching with water shall not be permitted. Already bent reinforcing bars shall not be rebent at the same spot without authorization.

This section covers the furnishing and placing of reinforcing steel in concrete structures.

(a)

Steel bars

Steel reinforcing bars shall comply with the requirements of SABS 920. For each consignment of steel reinforcement delivered on the site, the contractor shall submit a certificate issued by a recognised testing authority to confirm that the steel complies with the specified requirements. Cold-worked reinforcing bars may not be used. The type of bar required shall be indicated on the drawings by the symbols R, Y or Z in accordance with SABS 82.

6305 SURFACE CONDITION

@)
Welded steel fabric When the concrete is placed around the reinforcing steel, the reinforcing steel shall be clean, free from mud, oil, grease, paint, loose rust, loose mill scale or any other substance which could have an adverse chemical effect on the steel or concrete, or which could reduce the bond.

Welded steel fabric shall comply with the requirements of SABS 1024.

(c)

Mechanical couplers

The tensile properties determined on a test sample with a maximum gauge length of 610 mm, and which consists of reinforcing bars butt-jointed by a mechanical coupler shall comply with the following requirements: (i) When tested in accordance with the relevant requirements of clause 5.3 of SABS 920, the tensile properties of the test sample shall show an improvement of at least 10% on the requirements of clause 3.7 of SABS 920. Where the test sample is subjected to a load equal (ii) to 0,58 of the specified minimum yield force of the bar, the elongation measured on the gauge length shall not exceed the calculated theoretical elongation for a 610 m m length of the bar, based on a stress of 0,58 of the specified minimum yield stress of the bar and a Young's modulus of

6306

PLACING AND FIXING

Reinforcement shall be positioned as shown on the drawings and shall be firmly secured in position within the tolerance given in subclause 6803(f) by being tied with 1,6 m m or 1,25 m m diameter annealed wire or by suitable clips being used, or, where authorised, by tack welding. Any cover and spacer blocks required tr support the reinforcement shall be as small as may be consistent with their use and shall be of an approved material and design. The concrete cover over the projecting ends of ties or clamps shall comply with the specifications for concrete cover over reinforcement.

Where protruding bars are exposed to the elements for an indefinite period, the bars shall be adequately protected against corrosion and damage and shall be properly cleaned before being permanently encased in concrete. In members which are formed with sliding formwork, spacer ladders for placing and fixing the wall reinforcement shall be used at spacings indicated on the drawings or as prescribed by the engineer. The spacer ladders shall consist of two bars 3,7 m in length with ties 4 m m in diameter welded to them to resemble a ladder. The ties shall be spaced at multiples of the horizontal bar spacing in the wall, and shall be used to secure the horizontal reinforcement. The laps in the horizontal reinforcement shall be staggered to ensure that no part of two laps in any four consecutive layers lie in the same vertical plane.

6309 WELDING

Reinforcement shall be welded only where shown on the drawings or as authorised. Flash butt welding shall be done only with the combination of flashing, heating, upsetting and annealing to the satisfaction of the engineer, and only those machines which control this cycle of operations automatically shall be used. Metal-arc welding of reinforcement shall be done in accordance with BS 5135, and with the recommendations of the reinforcement manufacturers, subject to approval by the engineer and the satisfactory performance of trial joints. Hot-rolled high-yield-stress steel shall be preheated to between 240" C and 280" C and low-hydrogen electrodes only may be used. Trial welding joints shall be made on the site in circumstances similar to those which will govern during the making of production welding joints by the person who will be responsible for the production welding joints. Other methods of welding e g resistance welding, may be used subject to approval by the engineer and to their satisfactory performance in trial joints.

6307 COVER AND SUPPORTS

The term "cover" in this context shall mean the minimum thickness of concrete between the surface of the reinforcement and the face of the concrete. The minimum cover shall be as shown on the drawings. Where no cover is indicated, the minimum cover provided shall be at least equal to the appropriate values shown in table 630611. The cover shall be increased by the expected depth of any surface treatment, e g when concrete is bush hammered or when rebates are provided. Additional cover as prescribed by the engineer shall be provided if porous aggregates are used.

Welded joints shall be full-strength welds and their strength shali be assessed by destruction tests on samples selected by the engineer.

6310

MEASUREMENT AND PAYMENT

The cover blocks or spacers required for ensuring that the specified cover is obtained shall be of a material, shape and design acceptable to the engineer. Concrete spacer blocks shall be made with 6,7 mrn maximum sized aggregate and shall be of the same strength and material source as those of the surrounding concrete. The blocks shall be formed in specially manufactured moulds and the concrete compacted on a vibratory table and cured under water for a period of at least 14 days, all to the satisfaction of the engineer. Ties cast into spacer blocks shall not extend deeper into the spacer block than half the depth of the spacer block. (iii) The contractor shall provide stools as shown on the drawings, or, where they are not detailed on the drawings, wherever the engineer requires them to be installed. The stools shall be suitably robust, and fixed securely so that they can not swivel or move. The stools shall have sufficient strength to perform the required functions, taking into account amongst others temporary loads such as the weight of workmen and wet concrete, and forces caused by vibrators and other methods of compacting the concrete. (b)
63.01 Steel reinforcement for:

Unit

(a)

(Description of portion of structure to which applicable): Mild-steel bars

(i) (ii)

. . . . . . . . . . . . . . . . . . . . ton (1)

High-yield-stress-steel bars (type indicated) . Welded steel fabric

. . . . . . . . . . . . . . . ton

(1)

. . . . . . . . . . . . kilogram (kg)

Etc for other structures or parts of structures

The unit of measurement for steel bars shall be the ton of reinforcing steel in place in accordance with the drawings or as authorised. The unit of measurement for welded steel fabric shali be the kilogram of welded steel fabric in place, the quantity of which shall be calculated from the area of the mesh used in accordance with the drawings or as authorised.

6308

LAPS AND JOINTS

Laps, joints, splices and mechanical couplings shall be applied only by the specified methods and at the positions shown on the drawings or as authorised.

Ties, stools and other steel used for positioning the reinforcing steel shall be measured as steel reinforcement under the appropriate subitem.

Table 630611 MINIMUM CONCRETE COVER OVER REINFORCEMENT Min cover (mm) Class of concrete Condition of exposure
1.

Description of memberlsurface to which the cover applies

1.1

20

25

30

40

50

MODERATE

Concrete surfaces above ground level and 1.2 protected against alternately wet and dry conditions caused by water, rain and sea-water 1.3 1.4 spray. 1.5

Surfaces protected by the superstructure, viz the sides of beams and the undersides of slabs and other surfaces not likely to be moistened by condensation Surfaces protected by a waterproof cover or permanent forrnwork not likely to be subjected to weathering or corrosion Enclosed surfaces Structures/members permanently submerged Transnet Limited structures: (i) (ii) Surfaces of precast elements not in contact with soil Surfaces protected by permanent formwork not likely to be subjected to weathering or corrosion Surfaces in contact with ballast All other surfaces

) )

1 1
) )
50 45 40 30 25

1 1 1

NA

NA

NA

30

30

(iii) (iv)

NA NA NA

30 55 50

30 50 40

30 50 40

30 45 35

2.

SEVERE Concrete surfaces exposed to hard rain and alternately wet and dry conditions

2.1 2.2 2.3 2.4 2.5

All exposed surfaces Surfaces on which condensation takes place Surfaces in contact with soil Surfaces permanently under running water Transnet Limited structures: (i) (ii) Surfaces of precast elements not in contact with soil Surfaces protected by permanent formwork not likely to be subjected to weathering or corrosion Surfaces in contact with ballast All other surfaces

1
) NA )
50 45 40 35

NA

NA

NA

30

30

(iii) (iv)
2.6

NA NA NA

30 55 50

30 50 40

30 50 40

30 45 35

Cast in situ piles: (i) Wet cast against casing (ii) Wet cast against soil (iii) Dry cast against soil All exposed surfaces of structures within 30 km from the sea Surfaces in rivers polluted by industries Cast in situ piles, wet cast against casings
50 50 75 50 75 50 75 50 75

) )

75

3.

VERY SEVERE

3.1

1
) NA ) NA

NA NA

NA NA

60 80

50 80

3.2 Concrete surfaces exposed to aggressive 3.3 water, sea-water spray or a saline atmosphere

4.

EXTREME

4.1

4.2 Concrete surfaces exposed to the abrasive action of sea water or very aggressive water

Surfaces in contact with sea water of industrially polluted water Surfaces in contact with marshy conditions

) ) NA )

NA

NA

65

55

The tendered rates shall include full compensation for supplying, delivering, cutting, bending, welding, trial weld joints, placing and fixing the steel reinforcement, including all tying wire, spacers and waste.

ends to be joined, and all tools, equipment and labour required for completing the work.

Item

Unit

63.03 Spacer ladders for

(description of part of structure to which applicable)

63.02 Mechanical couplers

(type of coupler and diameter of bar indicated)

. . . . . . . . . ton (t)

. ..... . .

number (No)

The unit of measurement for spacer ladders shall be the ton of steel in place in accordance with the drawings or as authorised. The tendered rate shall include full compensation for supplying, delivering, cutting, bending, welding, placing and fixing the ladders, including all tying wire, spacers and waste.

The unit of measurement shall be the number of mechanical couplers for each bar diameter installed. The tendered rate shall include full compensation for supplying all the material, preparing and modifying the bar

SERIES 6MX): STRUCTURES SECTION 6400 :CONCRETE FOR STRUCTURES

in writing.

CONTENTS SCOPE MATERIALS STORING THE MATERIALS CONCRETE QUALITY MEASURING THE MATERIALS MIXING PLACING AND COMPACTING CONSTRUCTION JOINTS CURING AND PROTECTING ADVERSE WEATHER CONDITIONS PIPES AND CONDUITS APPLIED LOADING PRECAST CONCRETE QUALITY OF MATERIALS AND WORKMANSHIP DEMOLITION AND REMOVAL OF EXISTING STRUCTURAL CONCRETE MEASUREMENT AND PAYMENT

Both coarse aggregate (stone) and fine aggregate (sand) shall comply with the requirements of SABS 1083, subject to the following: The drying-shrinkage of both the fine and coarse (i) aggregate when tested in accordance with SABS Method 836 shall not exceed the following limits: For use in prestressed concrete, concrete bridge (1) decks and slender columns the shrinkage of both fine and coarse aggregate shall not exceed 130% of that of the reference aggregate. For use in other reinforced concrete members the (2) shrinkage of the fine aggregate shall not exceed 175% and of the coarse aggregate 150% of that of the reference aggregate.

SCOPE

(3) For use in mass concrete substructures and unreinforced concrete head walls and wing walls, the shrinkage of both the fine and coarse aggregate shall not exceed 200% of that of the reference aggregate.
Where there is any doubt about the shrinkage characteristics of aggregates, the contractor shall submit a certificate by an approved laboratory which gives the shrinkage characteristics of the aggregate. The drying shrinkage of concrete samples made from each of the required three concrete mixtures for preparing the compressive-strength and flextural-strength samples in accordance with clause 7104(b) shall not exceed 0,040%. Drying-shrinkage tests shall be conducted in accordance with SABS method 1085. The flakiness index of the stone as determined by (ii) TMH 1 Method 83 shall not exceed 35. (iii) Aggregates shall not contain any deleterious amounts of organic materials such as grass, timber or similar materials. (iv) Where there is any danger of a particular combination of aggregate and cement giving rise to a harmful alkali-aggregate reaction, the particular combination shall be tested in accordance with the testing method as described in subclause 8105(f), and, where the result points to such reaction, either the aggregate or the cement or both shall be replaced so that an acceptable combination may be obtained. The fineness modulus of the fine aggregate shall (v) not vary by more than a 0,2 from the approved modulus.

This section covers the manufacture, transport, placing and testing of concrete used in the works where plain, reinforced or prestressed concrete is specified.

(a)

Cement

Except as specified below for prestressed concrete members or units, the cement used for concrete shall be any of the following: (i) Ordinary portland cement or rapid-hardening portland cement complying with the requirements of SABS 471. Portland blast-furnace cement complying with the (ii) requirements of SABS 626. Ordinary portland cement 15 or rapid-hardening (iii) portland cement 15 which complies with the requirements of SABS 831. A 50150 mixture of ordinary or rapid-hardening (iv) portland cement and ground granulated blast-furnace slag. Granulated blast-furnace slag shall comply with the requirements of SABS 1491 Part 1. Ordinary or rapidhardening portland cement and ground granulated blastfurnace slag may be mixed in the concrete mixer together with the other ingredients of the concrete. Sulphate-resistant cement, but only where shown on (v) the drawings or instructed by the engineer. In prestressed concrete members or units the use (vi) of portland blast-furnace cement will not be permitted. A 50150 mixture of ordinary portland cement and ground granulated blast-furnace slag may be used only if authorized in the project specifications or by the engineer,

(c)

Plums

Plums used in concrete shall comply with the following requirements: (i) (ii) (iii) The plums shall be clean, durable and inert. The aggregate crushing value may not exceed 25%. The mass of each plum shall be between 15 kg and

(iv) No dimension of any plum shall be less than 150 mm or exceed 500 mm.

Cement in bulk shall be stored in waterproof contalners so designed as to prevent any dead spots from forming, and the cement drawn for use shail be measured by mass. Cement shall not be kept in storage for longer than 8 weeks without the engineer's permission, and different brands and/or types of the same brand of cement shall be stored separately.

(d)

Water

Water shall be clean and free from detrimental concentrations of acids, alkalis, salts, sugar and other organic or chemical substances that could impair the durability and strength of the concrete or the inbedded steel. The contractor shall prove the suitability of the water by way of tests conducted by an approved laboratory. The water used for concrete shall comply with the requirements in clause 8116 unless otherwise approved by the engineer. For reinforced and prestressed concrete the chloride content of the mixing water shall not exceed 500 m g l l when tested in accordance with SABS method 202.

Aggregates of different nominal sizes shall be stored separately and in such a manner as to avoid segregation from occurring, Intermixing of different materials and contamination by foreign matter shall be avolded. Aggregates exposed to a marine environment shall be covered to protect them from salt contamination. Where concrete is batched on site, the aggregates shall be stored in bins with a 3,O m wide concrete apron slab constructed around the outer edge of the aggregate stockpile area to prevent contamination during the process of tipping and hoisting the aggregate. The aggregates shall be tipped on the concrete apron slab. The storage bin shall have a concrete floor of 150 mm thickness.

Admixtures shall not be used in concrete without the approval of the engineer, who may require that tests be conducted before the admixtures be used to prove their suitability. Admixtures, if their use is allowed, shall comply with the following requirements: Admixtures shall be used only in liquid form and (i) shall be batched in solution in the mixing water by mechanical batcher capable of dispensing the admixture in quantities accurate to within 5% of the required quantity. All admixtures shall comply with the requirements (ii) of ASTM C494 or AASHTO MI94 and shall be of an approved brand and type. Air entraining agents shall comply with the (iii) requirements of ASTM C260 or AASHTO M154. (iv) Admixtures shall not contain any chlorides.

(c)

*rage

capacity

The storage capacity provided and the quantity of material stored (whether cement, aggregates or water) shall be sufficient to ensure that no interruptions to the progress of the work will be occasioned by any lack of materials.

(d)

Deteriorated material

Deteriorated or contaminated or otherwise damaged material shail not be used in concrete. Such material shall be removed from the site without delay.

W M CONCRETE QUALITY

(a)

General

Curing agents shali be tested in accordance with ASTM C156 and shall comply with the requirements of ASTM C309, except that the loss of water within 72 hours shall not exceed 0,40 kg/m2.Approved curing agents only shall be used.

Concrete shall comply with the requirements for strength concrete or prescribed-mix concrete, as specified in subclauses 6404(b) and (c) below. The total alkaline content (Na,O-equivalent) of concrete shall be limited taking into account the degree of reactivity as specified in subclause 8105(f). The required tests shall normally be carried out for all proposed sources of aggregate which are included in the materials report. The contractor shall arrange to have the required tests carried out by an approved laboratory and shali submit the results together with the information required in terms of subclause 6404(b) before commencing with any concrete work.

Cement stored on the site shall be kept under cover which provides adequate protection against moisture and other factors which may promote deterioration of the cement.

When the cement is supplied in bags, the bags shall be closely and neatly stacked to a height not exceeding 12 bags and arranged so that they will not be in contact with the ground, the floor or the walls, and can be used in the order in which they were delivered to the site.

The contractor shall be responsible for the design of the concrete mix and for the proportions of the constituent materials necessary for producing concretewhich complies

with the requirements specified below for each class of concrete. The class of concrete is indicated by the characteristic 28day cube compressive strength in MPa and the nominal size of coarse aggregate in the mix, e g class 30138 concrete means concrete with a characteristic cube compressive strength of 30 MPa after 28 days and a nominal size coarse aggregate of 38 mm. The aggregate sizes shall be selected in accordance with SABS 1083. The characteristic cube compressive strength of strength concrete shall be of any strength from 15 MPa, in increments of 5 MPa, up to 60 MPa, as indicated on the drawings or in the schedule of quantities or as may be prescribed by the engineer. The strengths preferred are 15, 20.25, 30, 40, 50 and 60 MPa. The cement content for any class of concrete shall not exceed 500 kg per cubic metre of concrete. Where for reasons of durability or other considerations concrete is designated by the prefix "W', eg class W30119, such designations shall denote concrete having a cementitious content not less than and a water:cement ratio not exceeding the limits specified in the project specifications. In such cases, characteristic strength of the mix shall be based on the higher of the following values: (i) the specified 28-day compressive strength, or a characteristic cube corresponding to the water:cement ratio. or characteristic cube

The actual mix proportions used as well as any changes thereto shall be subject to the engineer's approval, but such approval shall not in any way relieve the contractor of his responsibility for producing concrete with the specified properties.

The contractor is cautioned that the quality . . of cement may vary considerably from consignment to consignment so as to necessitate adjustments in the cement content of mixes. In order to ensure a uniform quality of concrete, the contractor shall obtain from the manufacturer the data regarding the relevant cement quality for each consignment with a view to ascertaining the required adjustment in the cement content. This information shall be submitted to the engineer.

(c)

Presaibedmix concrete

The contractor shall submit samples of every constituent of the concrete in accordance with the appropriate provisions of sections 8200 and 8300 and subclause 6404(b) for approval.

The nominal mixes for prescribed-mix concrete for which no strength requirements have been laid down are shown in table 640411. Table 640411 NOMINAL MIXES
-

Mix

(ii)

compressive strength designated maximum

Constituent or property 1:7:7 Cement (kg) Total quantity of aggregate (m3) Max total quantity of water (1) Estimated average 28-day compressive strength (MPa) 50 0,46 62
155

1:4:4 50 0,26 37

50 0,33 46

(iii)

a characteristic cube compressive strength corresponding to the designated cementitious content.

Before starting with any concrete work on the site, the contractor shall submit, for approval, samples of the constituent materials of the concrete and a statement of the mix proportions which he proposes to use for each class of concrete indicated in the schedule of quantities.

10

15

20

Where any change occurs in the material sources, the aggregate sizes, or any other components of the concrete, the above procedure shall be repeated. The samples submitted shall be accompanied by evidence that they comply with the requirements for the various materials specified. The statement regarding the mix proportionsshall be accompanied by evidence establishing that concrete made from the materials in the proposed proportions will have the specified properties. Evidence shall be in the form of

The class of concrete is indicated by the mix and the nominal size of the coarse aggregate in the mix, e g class 1:7:7/38 concrete shall mean concrete with a prescribed mix in a volume ratio of one part of cement : seven parts of sand : seven parts of stone, with a nominal stone size of 38 mm.

(d)

Consistence and workability

The concrete shall be of suitable workability without the excessive use of water so that it can be readily compacted into the corners of the formwork and around the reinforcement, tendons and ducts without the material segregating.

a statement regarding the test results, which shall (i) be furnished by an approved laboratory; or (ii) an authoritative report on previous use of and experience in regard to the material.

Slump measurements obtained in accordance with the test method described in TMHI Method D3 on concrete used in the works shall fall within the ranges specified in table 640412.

Table 640412 SLUMP VALUES

required mass.

(b)
Type of construction Maximum slump (mm)* Minimum slump (mm)* 25

Water

1.
2.

Prestressed concrete Concrete nosings and prefabricated units Mass concrete Reinforced concrete walls, footings, cast in situ piles (except dry-cast piles), slabs, beams and columns

75

The mixing water for each batch shall be measured, either b y mass or by volume, accurate to within 3 per cent of the required quantity. The quantity of water added to the mix shall be adjusted to make allowance for any moisture in the aggregates.

75 100

50 25 All aggregates for strength concrete shall be measured separately by mass, except as otherwise provided in this clause, accurate to within 3 per cent of the required quantity. Aggregates for strength concrete may be volume batched subject to the approval of the engineer, and to the quantity of cement being increased, at the cost of the contractor, by 25 kg per cubic metre of concrete, over and above the quantity which would have been necessary were the aggregate to have been batched by mass. Aggregates for prescribed-mix concrete as specified in subclause 6404(c) may be measured separately by volume. Batching boxes for volume batching shall be filled without in any way tamping, ramming or consolidating the material (other than that occurring naturally during the filling of the container), and shall be screeded off level with their topmost edges. Any adjustment to the volume shall be made by supplementary containers of a suitable size being used. Adjustments to the volume, by the incomplete filling of batching boxes to marks on their inside faces will not be permitted. Fine aggregate shall be tested for bulking at the beginning of and halfway through each concreting shift, and adjustment shall be made to the batch volume to give the true volume required.

3.
4.

125

50

Where high-frequency vibrators are used, the values above shall be reduced by one-third.

(e)

Bleeding

The concrete shall be so proportioned with suitable materials that bleeding is not excessive.

(f)

Sulphate content

The total water soluble sulphate content of the concrete mix, expressed as SO,, shall not exceed 4% (mlm) of the cementitious binder content of the mix. The sulphate content shall be calculated as the total from the various constituents of the mix using the following test methods: Cementitious binder : Aggregates Water SABS 741 SABS 850 SABS 212.

:
:

@)

Pumped concrete The measurement of cement in gauge boxes will not be permitted and volume batching shall be so planned as to use full bags of cement.

Where pumping of the concrete is approved by the engineer, the concrete mix to be pumped shall be so designed that (i) the slump will not exceed 125 mm;

6406
graded aggregate and suitable admixtures be used, (ii) wherever necessary, with a view to improving the pumpability of the mix; and (iii) its shrinkage capacity shall not be excessively higher than that of ordinary concrete mixes.

MWNG

(a)

General

64Q5

MEASURING THE MATERIALS

Mixing the material for concrete shall be canducted by an experienced operator. Unless otherwise a u t W i e d , mixing shall be carried out in a mechanical mass batch-mixer of an approved type which will be capable of producing a uniform distribution of ingredients throughout the batch.

(a)

Cement

@)

Charging the mixer

Where cement is supplied in standard bags, the bags shall be assumed to contain 50 ~ g All . cement taken from bulkstorage containers and from partly used bags shall be batched by mass, accurate to within 3 per cent of the

The sequence of charging the ingredients shall be subject to approval by the engineer, and, unless otherwise instructed, the same sequence of charging the ingredients shall be maintained.

The volume of the mixed material by batch shall not exceed the volume recommended by the manufacturer of the mixer.

Concrete shall not be placed in any part of the works until the engineer's approval has been given. If concreting is not started within 24 hours of approval having been given, approval shall again be obtained from the engineer. Concreting operations shall be carried out only during daylight hours unless proper lighting arrangements have been made and the lights are in working order by noon. Workmen shall not be allowed to work double shifts and the contractor shall provide a fresh team for night shifts. Placing and compacting the concrete shall at all times be under the direct supervision of an experienced concrete supervisor. Once the casting of concrete has begun, it shall be carried out in a continuous process between construction joints. Concrete shall be placed within 60 minutes from the start of mixing. This time may be extended by the engineer where a retarding admixture has been used. All excavations and other contact surfaces of an absorbent nature such as timber formwork shall be damp but no standing water shall be permitted to remain on these surfaces. The formwork shall be clean on the inside.

(c)

Mixing and discharging

The period of mixing shall be measured from the time when all the materials are in the drum until the commencement of discharge. The mixing period for the materials shall be 90 seconds and may be reduced only if the engineer is satisfied that the reduced mixing time will produce concrete with the same strength and uniformity as concrete mixed for 90 seconds. The reduced mixing time, however, shall be not less than 50 seconds or the manufacturer's recommended mixing time, whichever is the longer. A suitable timing device shall be attached to the mixer to ensure that the minimum mixing time for the materials has been complied with. The first batch to be run when starting with a clean mixer, shall contain only 213 of the required quantity of coarse aggregate to make provision for "coating" the mixer drum. Discharge shall be so carried outthat no segregation of the materials will occur in the mix. The mixer shall be emptied completely before it is recharged with fresh materials.

@)

Placing

(d)

Maintaining and cleaning the mixer

If the mixer has stopped running for a period in excess of 30 minutes, it shall be thoroughly cleaned out, particular attention being given to the removal of any build-up of materials in the drum, in the loader, and around the blades or paddles. Before any concrete is mixed, the inner surfaces of the mixer shall be cleaned and all hardened concrete shall be removed. Worn or bent blades and paddles shall be replaced.

Whenever possible, concrete shall be deposited vertically into its final position. Where chutes are used, their length and slope shall be such as not to cause segregation, and suitable spouts and baffles shall be provided at the lower end to minimise segregation. The displacement of concrete by vibration instead of b y direct placing shall be done only when approved by the engineer.

Care shall be taken when casting bridge decks of a substantial thickness to avoid layering of the concrete, and the entire thickness shall be placed in one pass. Fresh concrete shall not be placed against concrete which has been in position for more than 30 minutes unless a construction joint has been formed or unless a retarding additive has been used in the concrete. The pumping of concrete shall be subject to approval by the engineer. Aluminium pipes shall not be used for this purpose. In plain concrete with a thickness of not less than 300 mm, plums may, if approved, be included to displace concrete for up to 20% of the total volume, provided that (i) the plums are spread evenly throughout the concrete: no plum laid shall have a dimension exceeding one (ii) third of the smallest dimension of the concrete in any plane, and each plum is surrounded by at least 75 m m of (iii) concrete.

(e)

Standby mixer

When sections are cast where it is important for the casting to continue without interruption, a standby mixer shall be held in readiness to run on 15 minutes' notice should the stock mixers break down.

(f)

Readymixed concrete

Where ready-mixed concrete is delivered at the site, the requirements of SABS 878 shall have priority over the requirements specified in this section should inconsistencies occur.

6407

PLACING AND COMPACTING (c) Placing under water

(a)

General Placing under water shall be allowed only in exceptional circumstances where it is unfeasible to dewater the location before the concrete is placed. No concrete shall be placed in running water.

Concrete shall be transported and placed in a manner that will prevent segregation or loss of constituent materials or the contamination of the concrete.

Underwater concrete shall be placed by means of tremies or other approved methods. Full details of the method proposed by the contractor shall be submitted in advance for approval. Placing by skip or pipeline will also be considered in certain circumstances. During concreting by tremie, the pipe shall be kept filled with concrete at all times to prevent air and water from entering the tremie. When the tremie is charged, an approved sliding plug shall be used. Once concreting has begun by tremie, the discharge end of the tremie shall be kept well below the surface of the concrete. Should this seal be broken, the tremie shall be lifted and plugged before concreting is recommenced. Distribution of concrete by lateral movement of the tremie will not be permitted. The concrete mix to be placed underwater shall be specially designed and approved for this purpose to ensure good flowability, plasticity and cohesion. Increased sand and cement contents over those of normal mixes will usually be required.

The contractor shall take all the necessary measures to ensure the continuity of operations. All the necessary lighting and standby equipment for mixing, hoisting, placing and compacting shall be provided and all the materials required for completing each structure shall be ready on the site before casting commences. Concrete shall be cast in uniform layers in the formwork so that the level of the top surface of the concrete differs by no more than 250 m m between any two points in the formwork. In addition, the top level of the concrete shall never be so low down in the formwork as will cause structural instability in the formwork. The working platform shall be kept clean and no concrete which has dried out in part may be swept into the formwork. The concrete shall be compacted during and immediately after placing. Care shall be taken not to damage or disturb previously placed concrete. To ensure the proper bonding of successive layers, not more than one hour shall elapse between the placing of successive layers except where an approved admixture has been applied, in which case the delay may be amended in consideration of such circumstances. The slump of concrete may be up to 150 m m should the approved method of sliding so require.

(d)

Compaction

Concrete shall be fully compacted by approved means during and immediately after placing. It shall be thoroughly worked against the formwork, around reinforcement bars, tendons, ducts and embedded fittings and into corners to form a solid mass free from voids. The concrete shall be free from honeycombing and planes of weakness, and successive layers of the same lift shall be thoroughly bonded together. Unless otherwise permitted by the engineer, concrete shall be compacted by means of vibrators, Internal vibrators shall be capable of operating at more than 10 000 cycles per minute and external vibrators at more than 3 000 cycles per minute. Sufficient standby vibrators shall be kept available in case of breakdowns. Vibration shall be applied by experienced workmen, and over-vibration resulting in segregation, surface water and leakage shall be avoided. Contact with reinforcement and formwork shall, in so far as is practicable, be avoided when internal vibrators are used. Concrete shall not be subjected to disturbance by vibration within 4 to 24 hours of it having been compacted. Whenever vibration is applied externally, the design of the formwork and positioning of vibrators shall be such as to ensure efficient compaction and avoidance of surface blemishes. Special attention shall be given to the compaction of concrete in the anchorage zones and behind the anchor plates and in all places where high concentrations of reinforcing steel or cables occur. Where the placing and compaction of concrete is difficult, a mix containing smaller sized aggregate may be used but only with the approval of the engineer and after a mix containing such aggregate has been designed and tested.

6408

CONSTRUCTION JOINTS

(a)

General

Concreting shall be carried out continuously up to the construction joints shown on the working drawings or as approved, except that if, because of an emergency (such as breakdown of the mixing plant or the occurrence of unsuitable weather), concreting has to be interrupted, a construction joint shall be formed at the place of stoppage and in the manner which will least impair the durability, appearance, and proper functioning of the concrete. Unless otherwise shown on the drawings, the exact position of horizontal construction joints shall be marked on the formwork.

Stub columns, stub walls and stays on footings shall be cast integrally with the footings and not afterwards, even where another class of concrete is being used.

@)

Preparing the surfaces

When the concrete has set and while it is still green, the surface film and all loose material shall be removed, without disturbing the aggregate, by means of a water jet assisted by light brushing to expose the aggregate and leave a sound, irregular surface. Where this is not possible, the surface film shall be removed after the concrete has hardened, by mechanical means appropriate to the degree of hardness of the concrete so as to expose the aggregate and leave a sound, irregular surface. The roughened surface shall be washed with clean water to remove all laitance, dirt and loose particles.

(e)

Requirements i n respect of sliding formwork Surface retarding agents may be used only with the approval of the engineer.

Where sliding formwork is used, the following additional requirements shall apply:

(c)

Placing fresh concrete at construction joints

(g)

Steam curing the concrete (precast units).

Where fresh concrete is placed the same day as that on which the construction joint was formed, the fresh concrete shall be cast directly against the face of the construction joint. When concreting recommences a day or more after the construction joint has been formed, the following procedure shall be followed: The construction joint shall be kept constantly wet for a period of at least 6 hours before concreting restarts, but, the surface of the concrete shall be in a saturated, surfacedry condition when concreting has to recommence.

The method of curing adopted shall be subject to the engineer's approval and shall not cause staining, contamination, or marring of the surface of the concrete. The curing period shall be continuous for at least 7 days for concrete made with ordinary portland cement, ordinary portland cement 15, rapid-hardening portland cement or rapid-hardening portland cement 15, and at least 10 days if portland blast-furnace cement or a 50150 mixture of ordinary portland cement and ground granulated blastfurnace slag is used. When the ambient temperature of concrete falls below 5 " C, these minimum curing periods shall be extended by the period during which the temperature of the concrete was below 5C. When sliding formwork is used, the concrete shall be protected against the weather and rapid drying out by means of a 4 m wide skirt attached to the lower perimeter of the formwork and hanging over the working platform. The skirt shall consist of hessian in summer months but of canvas or other suitable material in winter. The skirt shall be weighted at the bottom to prevent it flapping around in windy conditions. The concrete shall be cured by means of a fog spray to keep it wet constantly for the periods stated above or until a curing compound is applied. Wetting the concrete by spraying shall be by means of a fixed spraybar along the full length of the sliding formwork. The spraybar shall be connected to a suitable high-pressure water supply. Wetting shall be discontinued when the ambient air temperature drops below 5"C, and care shall be taken by the contractor to ensure that the water will not erode the surface of the fresh concrete.

Any dirt, excess water and loose particles shall be removed prior to reconcreting being started.
For horizontal construction joints a 25 m m thick concrete layer of the same grade of concrete made richer by reducing the coarse aggregate content by 25% shall be placed on the joint plane immediately before concreting. For vertical construction joints the fresh concrete shall be placed against a surface prepared in accordance with subclause 6408(b), and which is in a saturated, surface-dry condition.

Epoxy resins specially designed for bonding old concrete to new shall be used at construction joints where so specified. The preparation of the construction joint surface and the application of the epoxy resin shall be strictly in accordance with the manufacturer's recommendations and the engineer's instructions. The actual brand and type of resin used shall be subject to the engineer's approval.

6410 ADVERSE WEATHER 6409

CURING AND PROTECTING (a)

Cold weather

Formwork shall be retained in position for the appropriate times given in clause 6206, and, as soon as may be practicable, all exposed concrete surfaces shall be protected from loss of moisture by one or more of the following methods: (a) Retaining formwork in place for the full curing period. Ponding the exposed surfaces with water, except (b) where atmospheric temperatures are low, i e less than 5 " C. (c) Covering it with sand or mats made from a moisture-retaining material, and keeping the covering constantly wet. Constantly spraying the entire area of the exposed (d) surfaces with water (only on surfaces where sand cover or ponding is impossible). Covering with awaterproof or plastic sheeting firmly (e) anchored and sealed at the edges and joints.

Concrete shall not be placed during falling temperatures when the ambient temperature falls below 7 C or during rising temperatures when the ambient temperature is below 3C. When concrete is placed at ambient temperatures below 5 C the concrete temperature shall not be below 1O0C,for which purpose heating of the water andlor the aggregate shall be permitted. The contractor shall make all the necessary arrangements for heating the material. Heated water and aggregate shall first be mixed and the cement shall then be added only while the temperature of the mix is below 30" C. The temperature of placed concrete shall not be allowed to fall below 5C until the concrete has attained a strength of at least 5 MPa, and the contractor shall be responsible for all protective measures necessary to this end. All concrete damaged by frost or by the formation of ice in the concrete shall be removed and replaced by the contractor at this own expense.

@)

Hot weather

Using an approved curing compound applied in (1) accordance with the manufacturer's instructions, except that, where the surface has to be subsequently waterproofed, coated or gunited, this method may not be used.

When the ambient temperature exceeds 30C during concreting, the contractor shall take measures to control the temperature of the concrete ingredients so that the temperature of the placed concrete will not exceed 30C

unless otherwise determined by the engineer. Such measures include spraying aggregate stockpiles with water to promote cooling down by evaporation and, where feasible, shading the stockpiles and the area where concreting is carried out. Curing shall commence immediately after concrete has been placed to prevent an excessive loss of moisture.

The contractor shall take all necessary safety and precautionary measures during the handling and erection of precast members and for ensuring the stability of members as positioned and prior to their being cast in. Where precast concrete members have not been manufactured on the site, the manufacturer shall keep and make available to the engineer complete records of all the concrete mixes and strength tests pertaining to the members cast. The contractor shall notify the engineer in advance of the dates on which member are to be cast to make arrangements for inspecting and testing the precast members. For the purposes of identification, all members shall be marked with paint in neat lettering with the member number shown on the drawings or as agreed on and an identification number relating to the manufacturing records. Letters etc shall be so positioned as not to be visible when the structural member is placed in its final position in the completed structure.

(c)

Precautionary measures for using sliding formwork

During sliding operations in cold weather, the water only, or the water and the aggregate, shall be heated to ensure that the concrete temperature will not drop below 10C until it has attained a strength of 5 MPa. During cold weather the rate of sliding shall be suitably decreased to ensure sufficient strength in the concrete which leaves the bottom of the formwork.

6411

PIPES AND CONDUITS

No pipes and conduits other than those shown on the drawings shall be embedded in the concrete without the engineer's approval. The clear space between such pipes or between such pipes and any reinforcing steel shall be at least 40 mm or the maximum size of the aggregate plus 5 mm, whichever is the greater. The thickness of the concrete cover over pipes and fittings shall be at least 25 mm. The ends of all ferrules used for bracing formwork shall be neatly finished off to the details shown on the drawings. Where no details are given on the drawings, ferrules shall be cut back to a depth of at least the specified cover, and the holes shall be filled in with mortar and finished off flush with the concrete surface.

All precast members which have been chipped, cracked, warped or otherwise damaged to the extent that such damage will, in the opinion of the engineer, prejudice the appearance, function or structural integrity of the members shall be rejected or, where so allowed, repaired to the satisfaction of the engineer.

6414

QUALITY OF MATERLALS AND WORKMANSHIP

(a)

Criteria for compliance with the requirements

6412

APPLIED LOADING

No load shall be applied to any part of a structure until the specified curing period has expired, after which applied loading shall be allowed only when approved by the engineer. The engineer's decision will be based on the type of load to be applied, the age of the concrete, the magnitude of stress induced and the propping of the structure. No structure shall be opened to traffic until test cubes made from the concrete in all parts of the structure have attained the specified minimum 28-day compressive strength.

Routine inspection and quality control will be done by the engineer as specified in sections 8200 and 83M). The criteria for compliance with the requirements specified for 28-day characteristic compressive strength shall be as specified in clauses 8206 and 8305 for full acceptance, and as specified in clauses 8208 and 8307 for conditional acceptance. The resubmission of concrete lots on the basis of cores for full or conditional acceptance shall not be allowed. The contractor's attention is drawn to clauses 8209 and 8308. If the engineer is satisfied that the requirements of the contractor's process control have been met, the engineer may decide at his discretion to use the contractor's test results in the evaluation of the concrete.

@)

Procedure in the event of noncompliance with the requirements

Any lot represented by test cubesfailing to comply with the criteria specified above for the characteristic strength shall be rejected. The engineer may at his discretion allow the following tests to be conducted in order to decide whether the concrete may be left in position at further reduced payment: The engineer may allow the elements or units (i) concerned to be cured for an additional period not exceeding 56 days. Thereafter the contractor shall drill cores in accordance with SABS 865, and the engineer will evaluate these cores in accordance with SABS 0100-Part II. Where the engineer so directs, full-scale load tests (ii) shall be conducted in accordance with SABS 0100-Part II to determine whether any particular structure or member can

6413

PRECAST CONCRETE

This clause applies to all reinforced and prestressed concrete members other than precast concrete piles, culverts and pipes in so far as they are dealt with separately elsewhere in these specifications. All precast members shall be manufactured in accordance with the requirements specified for cast in situ members in so far as these requirements are relevant. In addition, the following shall apply:

be left in position at further reduced payment as decided by the engineer. The cost of such tests shall be for the contractor's account regardless of the outcome of the tests. In all cases where concrete has been supplied which fails to comply with the strength requirements, the contractor shall immediately take the required remedial action by changing the mix proportions to obtain the required strength.

materials, providing all plant, mixing, transporting, placing and compacting the concrete, forming the inserts, construction joints (except mandatory construction joints), and contraction joints, curing and protecting the concrete, repairing defective surfaces, and finishing the concrete surfaces as specified. Payment shall distinguish between the different classes of concrete.

Item
(c)

Unit

Tests ordered b y the engineer

64.02 Manufacturing precast

Where the routine testing of concrete cubes is not conducted on the site by the engineer, he may order the contractor to have the concrete cubes, which have been made by the engineer, tested at an approved testing laboratory, in which case payment will be made for such tests in accordance with the provisions of section 8100.

concrete members (description of member with reference to drawing)

.......

number (No)

The unit of measurement shall be the number of complete members or elements of each type and size in position in the works. The tendered rate for each precast member shall include full compensation for concrete work, formwork, curing and safeguarding, and for reinforcing steel and prestressing as required for manufacturing the member complete, excluding only prestressing in connection with in situ concrete cast subsequent to the placing of the precast members for which prestressing separate payment is provided elsewhere in the schedule of quantities.

6415

DEMOLITION AND REMOVAL OF STRUCTURAL CONCRETE

WSTING

Where partial demolition is required for extension work to existing structures the first three paragraphs of clause 2214 shall apply. In addition the following shall apply: The contractor shall take great care to ensure that (a) the reinforcement required to tie in the extension work is not cut off or damaged in the demolition process. Where reinforcement has been cut off, or where in the opinion of the engineer, the reinforcement has been damaged to such an extent that it will not adequately perform its function, the contractor shall, at his own expense, install dowel bars of the same diameter as the bar cut off or damaged, all to the satisfaction of the engineer. Only hand operated breaking equipment shall be (b) used for the demolition of concrete where extension work is required.

Hem
64.03 Transporting and erecting

Unit

precast concrete members (description of member and approximate mass to be given) . . . . . . . . . . . . . . . .

. . . . . . number

(No)

The unit of measurement shall be the number of precast concrete members of each type and size placed into position. The tendered rate for each precast member shall include full compensation for all work, costs and equipment required for transporting, stacking, erecting and installing the precast concrete member in its final position, complete as specified.

6416

MEASUREMENT AND PAYMENT

Item
64.01 Cast in situ concrete:

Unit Hem
64.04 Epoxy bonding of new

Unit

(a)

(Class of concrete and part of structure or use indicated) . . . . . . . . . . . . . . . . cubic metre (m3) Etc for other classes of concrete and other uses or parts of the structure

concrete surfaces to old

....

square metre (m2)

(b)

The unit of measurement shall be the square metre of new concrete surface bonded to old by means of an approved epoxy bonding agent as set out in the specifications. The tendered rate shall include full compensation for preparing the surfaces and for furnishing and applying the bonding agent, and for chamfering the concrete on visible joints, complete as shown on the drawings.

The unit of measurement for cast in situ concrete shall be the cubic metre of concrete in place. Quantities shall be calculated from the dimensions shown on the drawings or as authorised. No deduction in volume measured for payment shall be made for the volume of any reinforcing steel, inserts and pipes or conduits up to 150 mm in diameter embedded in the concrete. The tendered rate shall include full compensation for procuring and furnishing all the materials, storing the

Hem
64.05 Extra over items 61.08, 61.31 and 64.01 for the use of

Unit

sulphate-resistant cement in concrete . . . . . . . . . . . . . . . cubic metre (m')

The unit of measurement shall be the cubic metre of concrete manufactured with sulphate-resistant cement and placed in accordance with the details on the drawings, or as instructed by the engineer. The tendered rate shall be extra over each of the rates tendered for items 61.08, 61.31 and 64.01, and shall include full compensation for all additional costs for procuring, furnishing and using sulphate-resistant cement in the concrete.

(b) (i)

Reinforced concrete in: (Member indicated)

...... . . .

cubic metre (m3)

The unit of measurement shall be the cubic metre of plain or reinforced concrete demolished for each member or portion thereof scheduled separately in the schedule of quantities.

Unit
64.06 Demolishing existing concrete:

(a) (i)

Plain concrete in: (Member indicated)

.........

cubic metre (m3)

The tendered rate shall include full compensation for all labour, plant and equipment required to demolish the existing concrete and disposal of the product of the demolition to a borrow pit within a free-haul distance of 1 km. The tendered rate shall also include full compensation for any necessary measures to ensure no debris falls into rivers and for any debris that has fallen into rivers to be recovered.

SERIES 6000 : STRUCTURES SECTION 6500 : PRESTRESSING Duct is the void formed to house the tendon(s) and may be formed by coring, or by using sheaths or by way of extractable cores.

CONTENTS SCOPE DEFINITIONS MATERIALS EQUIPMENT TECHNICAL DATA PRESTRESSING SYSTEM DRAWINGS PREPARED BY THE CONTRACTOR PRECASTING PRE-TENSIONING POST-TENSIONING LOSS OF PRESTRESS MEASUREMENT AND PAYMENT
(9)

Prestress

Prestress is the stress induced in concrete by tensioned tendons.

(h)

Prestressed concrete

Prestressed concrete is structural concrete in which effective internal stresses are induced by means of tensioned tendons.

( i ) 6501 SCOPE

Pre-tensioned concrete

Pre-tensioned concrete is prestressed concrete where the tendon is tensioned before the concrete has been cast. This section covers the materials, equipment and work required for prestressing structural concrete members.

0)
6502 DEFINITIONS

Post-tensioned concrete

Post-tensioned concrete is prestressed concrete where the tendon is tensioned after the concrete has hardened.

The following definitions shall apply to these specifications:

(k)
(a) Anchorage

Pullin

Anchorage is the device comprising all the components and materials required for retaining the force in a tensioned tendon and to tiansmit this force to the concrete of the structure.

Pull-in is the elastic shortening of the tendon caused by relative movement between the anchorage or coupler components on account of seating and gripping action during or immediately after transfer.

(I)

Release

@)

Anchorage reinforcement

Release is the specified elastic shortening of the tendon at the anchorage achieved before or during transfer.

Anchorage reinforcement is the spiral and other reinforcement which forms part of the anchorage and is required for strengthening the anchorage and/or assisting in transmitting the tendon force to the concrete.

(m)

Sheath

(c)

Bursting reinforcement

Sheath is the tube or casing enclosing the tendon and which temporarily or permanently allows a relative movement between the tendon and the surrounding concrete.

Bursting reinforcement is the reinforcing steel required in and adjacent to the anchorage zones to resist the tensile stresses induced in the concrete by the anchorage(s). (n) (d) Cable Tendon

Cable is the tendon. together with the anchorage, sheathing and all fittings.

Tendon is the prestressing steel consisting of the bar, wire or strand individually placed, or of bars, wires or strands placed in a duct, all of which are tensioned to impart prestress to a concrete member.

(e)

Characteristic strength (0) Tensioning

Characteristic strength of prestressing steel is the manufacturer's guaranteed tensile strength below which no more than 5 per cent of the test results in a statistical population shall fall.

Tensioning is the action of inducing and regulating the force in a tendon by means of tensioning and measuring equipment.

@)

Transfer Cold-worked high-tensile alloy steel bars for prestressed concrete shall comply at least with the requirements of BS 4486. The type of prestressing steel shall be indicated in accordance with the requirements of clause 4.2 of BS 4486, e g BS 4486-RR-32-1230 for 32 m m diameter ribbed bar with a nominal tensile strength of 1 230 MPa. (iii) Wires and seven-wire steel strand

Transfer in the case of post-tensioned concrete is the action of transferring the tensioning force from the tensioning equipment (jack) to the anchorage. Transfer in the case of pre-tensioned concrete is the action of transferring the force in the tensioned tendon(s) to the concrete.

(q)

Bond breaker

Bond breaker is the coating or sheath placed on a tendon to prevent it from bonding to the surrounding concrete.

Steel wire and seven-wire steel strand for prestressed concrete shall comply at least with the requirements of BS 5896. The type of prestressing steel shall be indicated in accordance with the requirements of clauses 14 and 20 of BS 5896 for wire and strands respectively, e g : (1) BS 589612 wire 1770-7-PE-relax 1 for a 7 m m nominal diameter straightened smooth wire of class 1 relaxation with a nominal tensile strength of 1 770 MPa; and (2) BS 589613 superstrand 1860-12,9-relax 2 for a 12,9 m m nominal diameter seven-wire superstrand of class 2 relaxation with a nominal tensile strength of 1 860 MPa. (iv) Straightness

(r)

Coupler

Coupler is the device comprising all components required to join up two tendons.

Deflector is the device used to deflect a tendon alignment within a structural element.

(1)

Transmission length

Transmission length is the tendon length required to transmit via bond stresses the full force in the tendon to the concrete.

6503

MATERIALS

(a)

General

Prestressing bars delivered at the site shall be straight. Only small adjustments for straightness may be made, which shall be done by hand on the site at a temperature above 5C and under the supervision of the engineer. Where heating of the bars is required, this shall be b y means of steam or hot water. Bars bent in the threaded portion shall not be used. Prestressing wire and strand shall be supplied in coils with a sufficiently large diameter to ensure that the wire and strand will pay off straight. (v) Surface condition

All materials and prestressing systems used in the prestressing of structural concrete members shall be subject to approval.

@)

Prestressing steel General Prestressing steel shall be clean, free from faults or defects, and without any harmful films and matter which may impair adhesion to the grout or concrete. A film of rust is not necessarily harmful and may improve the bond. It may, however, increase the friction between the tendon and duct. The depth of imperfections or pits on the surface of prestressing steel shall not exceed 0,l m m for wire with a diameter up to and including 8 mm, or 0,2 m m for bars or wire with a diameter exceeding 8 mm.

(i)

The type of prestressing steel shall be designated in accordance with the requirements of subclauses 6503(b)(ii) and (iii) respectively. The contractor shall keep proper records of all material analyses and test certificates for the batches of prestressing steel used in the works. Where required b y the engineer, the contractor shall produce certificates from recognised testing authorities certifying compliance of the prestressing steel with the specified requirements.

Where prestressing steel is available in weld-free lengths (production lengths) and lengths containing welds (standard lengths), the batches delivered at the site shall be clearly labelled for identifications purposes.

Tendons may be cleaned wire brushing or by passing through a pressure box co aining carborundum powder. Solvent solutions shall not be used for cleaning without the approval of the engineer.
'

In no circumstances shall prestressing steel after manufacture be subjected to heat treatment other than provided for in these specifications.

Prestressing steel shall be delivered at the site suitably protected against damage and corrosion. Such protection or the use of a corrosion inhibitor where allowed by the engineer, shall not have any deleterious effect on the steel or concrete or impair the bond between the two.

(vi)

Galvanising

Galvanised prestressing steel shall not be used unless specified. In no circumstances shall prestressing steel be subjected to galvanising after manufacture. (vii) Welds

sheath shall be at least 10 mm greater than the diameter of the tendon. For vertical tendons and where tendons are to be drawn into cast-in sheaths, the cross-sectional duct area shall be at least three times the cross-sectional area of the tendon.

(e) Prestressing steel used in structural prestressed concrete shall be weld-free. Where the steel is supplied in standard lengths, the welds shall be cut out and delivered to the engineer.

Cable supports

Supports of reinforcing steel or structural steel suitably braced to prevent buckling under load shall be used to support the cables. The cable saddles shall be rigid and secured in position by welding or by equivalent mechanical means to resist both gravitational and buoyancy forces. Normal web reinforcement shall not be utilised to support cables. Saddles for external cables shall be of special design and material to ensure low friction and to prevent the tendon or parts thereof from grooving the surface. The saddle plates shall be curved to the requisite radius to prevent the tendon or part thereof from bearing on the end of the plate and shall incorporate features to ensure that individual bars, wires and strands are seated separately.

(c)

Anchorages and couplers

Anchorages and couplers to be used in prestressed concrete shall comply with the requirements of BS 4447 and shall be of a proved and approved type, constructed from durable material completely free from imperfections and shall not damage, distort or kink the prestressing steel in a manner as will result in ultimate tensile strength reduction. They shall resist, without failure and/or excessive deformation or relaxation of the force in the tendons, the full ultimate tensile strength of the tendons. The characteristic value for anchorages and couplers, determined in accordance with BS 4447, shall not be less than 90%. The anchorages shall effectively distribute the force in the tendon to the structural member, and the resulting local stresses and strains in the member shall be so limited as to prevent damage. Unless otherwise approved by the engineer, all anchorages and couplers shall be provided with anchorage reinforcement. Wedges and the insides of barrels or cones shall be clean to allow the free movement and seating of the wedges inside the taper. The threads of bars, nuts, anchorages and couplers shall be suitably protected against damage and corrosion. The protection shall be removed at the last moment and the threads properly lubricated before use.

(1)

Tendon spacers

Tendon spacers used inside the ducts to separate individual bars, wires or strands of the tendon shall be of a proved and approved type and manufactured from material which will not induce corrosion of the prestressing steel.

(i)

Materials

In addition to the requirements of subclause 6402(d), water shall not contain more than 500 mg of CI ions per litre of water. Only ordinary portland cement which complies with the requirements of SABS 471 and ordinary portland cement 15 which complies with the requirements of SABS 831 shall be used. The temperature of the cement shall be less than 40" C, and the cement shall be stored in accordance with the requirements of subclause 6403(a).

(dl

Sheaths

Sheaths shall be grout-tight and of such material and configuration that bond forces can be transferred from the grout to the surrounding concrete. The properties of the sheath material shall be such that no corrosion attack of the prestressing steel will be induced. The sheath shall be sufficientlyflexible to accept the required curvature without kinking, and strong enough to retain its cross-section and alignment and to resist damage on account of handling, transporting, tying and contact with vibrators during concreting. Unless otherwise approved by the engineer, the thickness of the metal of steel sheaths shall not be less than 0,4 mm. Metal sheathing shall be delivered at the site suitably protected against damage and corrosion. At the time of incorporation into the structural member, the sheathing shall be free from loose mill scale, loose rust, lubricants and harmful matter. Galvanised sheathing shall not be used unless specified. Unless otherwise specified, the internal diameter of the

Fine aggregate shall consist of siliceous granules, finely ground limestones, trass or very fine sand. The aggregate used shall pass through an 0,600 mm sieve. The use of fine aggregate shall be subject to the approval of the engineer and shall be restricted to grout for ducts with a diameter exceeding 150 mm. The aggregate content in the grout shall not exceed 30% of the mass of the cement.

The use of admixtures shall be subject to tests havlng shown that their use improves the properties of the grout, e g by increasing workability,reducing bleeding, entraining air, or expanding the grout. Admixtures shall be free from any product liable to damage the steel or the grout itself, such as halides, nitrates, sulphides, sulphates, etc. The quantity of admixture to be used shall be in accordance with the manufacturer's instructions.

(ii)

Properties of the grout

6504

EQUIPMENT

The mixed grout shall have the following properties: (a) (1) litre. The CI ions content shall not exceed 750 m g per All equipment used shall be in a good working order and properly maintained. General

The viscosity of the grout measured in accordance (2) with subsubclause 81 12(b)(iv)for horizontal cables shall be 500 to 2 500 cP and fo; "&ical cables 400 to 1 500 cP. The viscosity of the grout, 20 minutes after mixing, shall not exceed 2 500 cP and 1 500 cP for horizontal and vertical cables respectively. Bleeding at 20C measured in accordance with (3) subsubclause 8112(b)(iv) shall not exceed 2% by volume 3 hours after the grout has been mixed, and the maximum bleeding shall not exceed 4%. In addition, the separated (bleed) water must be reabsorbed after 24 hours. The cube compressive strength of 100 m m cubes (4) made of the grout and cured in a moist atmosphere for the first 24 hours and then in water at 20C shall exceed 20 MPa at 7 days.

@)

Tensioning and measuring equipment

Tensioning and measuring equipment shall be such that the tendon force can be established to an accuracy of +. 2% during any stage of the tensioning operation. Unless otherwise authorised b y the engineer, the tensioning equipment shall be power driven and capable of gradually applying a controlled total force without inducing dangerous secondary stresses in the tendon, anchorage or concrete. The force in the tendon during tensioning shall be measured by a direct-reading dynamometer (load cell type) or obtained direct from pressure gauges fitted in the hydraulic system to determine the pressure in the jacks. Pressure gauges shall have concentric scale dials which comply with the requirements of BS 1780. The dials shall not be less than 150 m m in diameter and the gauges shall be used within the range of 50 90% of their full capacity at maximum service pressure.

(h)

Protecting agents for unbonded tendons

The material used for permanent protection of unbonded tendons shall have the following properties:

(i) It shall remain free from cracks and shall not become brittle or fluid within the temperature range of -20C to 70C.

When pressure gauges not using glycerine are used, a snubber or similar device shall be fitted to protect the gauge against any sudden release of pressure. Provision shall also be made for T-connections for the attachment, when required, of supplementary control gauges. Only self-sealing connections shall be used in the hydraulic circuit. Where the pressure input pipe is connected to the jack, a pipe rupture valve shall be installed in the circuit. Tensioning equipment shall be calibrated before the tensioning operation and thereafter at frequent intervals, as directed by the engineer, with a master gauge or proving ring, and the engineer shall be furnished with a calibration chart. The load-measuring devices shall be calibrated to an accuracy of rt 2%. The extension of tendons shall be measured to an accuracy of 2 2% or + 2 mm, whichever is the more accurate, and pull-in and release to an accuracy of 2 2 mm.
(c)

It shall be chemically stable for the entire life of the (ii) structure.

(iii) It shall be non-reactive with the surrounding materials, i e concrete, tendons, wrapping or sheathing.

(iv)

It shall be non-corrosive or corrosion-inhibiting.

(v)

It shall be impervious to moisture.

(vi) It shall be sufficiently tough to withstand the abrasion caused when a tendon, precoated with the material, is drawn into the sheath.

Grouting equipment Mixer

It shall have no appreciable shrinkage or excessive (vii) volume increase. (viii) It shall have a suitable viscosity at ambient temperature or require only moderate preheating to permit injection.

(i)

Mechanically operated mixers only, of a type capable of producing high local turbulences while imparting only a slow motion to the body of the grout shall be used. The mixer shall be equipped with a screen with openings not exceeding 1 mm and shall be capable of consistently producing grout with a colloidal consistency. (ii) Agitator

(i)

Testing

Prestressing steel, anchorages and couplers, and grout shall be tested in accordance with the requirements of subclause 81 12(b). Testing shall be carried out at the frequencies as directed by the engineer.

Where the capacity of the mixer is insufficient to fill the duct completely with grout, an agitator shall be used.

Mechanical agitators only shall be used, which are capable of maintaining the colloidal condition of the grout fill during the storing and injection processes. The grout shall be delivered at the structure from the agitator, and the system shall make provision for recirculating the grout from the pump back to the agitator.

(e)

Extension

The extension per tendon or group of tendons under the maximum tensioning force, together with the modulus of elasticity (E) on which it has been based. The release to be attained at each live anchorage as well as the pull-in for which provision has been made.

(iii)

Injection equipment The contractor shall show on his drawings the expected extension based on the actual modulus of elasticity of the strand as well as the expected wedge pull-in and any provision for shimming.

The pump shall be of the positive displacement type (piston, screw or similar type), capable of exerting a constant pressure of at least 10 bars on completely grouted cables and shall incorporate a safety device for preventing the build-up of pressure above 20 bars. The pump shall be fitted with a pressure gauge and a valve which can be locked-off without loss of pressure in the cable.

(9

Prestressing losses i n tendons

The losses allowed for in the design from the causes listed below will be given as follows: (i) Friction loss

The pump shall be capable of delivering grout at a speed as will produce a speed of the grout in the cable of between 6 and 12 m per min.

All connections ir) the pipes and between the pipe and the cable shall be airtight. Only bayonet, threaded, or similar types of connectors shall be used.

The formula used for determining the tendonlduct friction loss together with the values adopted for the friction coefficient @) caused by curvature, and the wobble factor (k) caused by unintentional variation from the specified alignment. (ii) Elastic deformation of concrete

6505 TECHNICAL DATA

The following technical data for pre-tensioned and posttensioned structural members required for the contract will be furnished on the drawings:

The elastic factor, which, when multlplled by the compressive stress in the concrete adjacent to the tendon, will give the loss caused by the deformation of the concrete. (iii) Creep of the concrete

(a)

Tendon alignment

The creep factor, which, when multiplied by the compressive stress in the concrete adjacent to the tendon, will give the loss caused by the creep of the concrete. (iv) Shrinkage of the concrete

A diagram showing the alignment of each tendon or group of tendons in both the horizontal and vertical planes, together with the horizontal and vertical coordinates, and curve equations of the centroid of the tendon(s), as may be relevant.

The stress loss in MPa caused by the shrinkage of the concrete. (v) Relaxation of prestressing steel

@)

Tendon system The stress loss in MPa at a stress level of 70% of the characteristic strength of the prestressing steel caused by the relaxation of the prestressing steel.

The design is based on the system shown on the drawings, but the contractor may use any suitable system which will meet all the specified requirements, subject to approval by the engineer.

(g)
(c)

Anchorages

Tensioning the tendons

The positions where loop or fan-type dead-end anchorage may be used.

Full particulars regarding the partial tensioning of the tendons, the stage during which the tendons shall be tensioned, and the sequence of tensioning to be followed.

Bursting reinforcement

(d)

Tensioning force

The bursting reinforcement for the prestressing system on which the design is based.

The maximum tensioning force and the effective force at the live anchorages, after transfer, as well as the corresponding stress level in the prestressing steel, for each tendon or group of tendons. The forces will be given in MN units, and the stress levels will be expressed as a percentage of the characteristic strength.

(i)

Precamber

The precamber at intervals not exceeding 0,25 times the span length.

(j)

Compressive strength of the concrete during lransfer

bursting forces. After approval by the engineer of the drawings and calculations prepared b y the contractor, no departure shall be permitted from the forces, stresses and extensions shown thereon, without authorization by the engineer. The prestressing work shall not be commenced before the relevant drawings have been accepted by the engineer. The contractor shall make full allowance in his tendered rates for all costs in connection with the furnishing of information, making calculations, and preparing and submitting the drawings. However, no allowance need be made for the cost of checking, undertaken by engineer, of drawings and calculations for work which does not qualify as an alternative design. Alternative designs shall comply with the requirements of clause 1212 and the relevant provisions of this section.

The compressive strength to be attained by the concrete in the relevant member before transfer may be effected.

6506

PRESTRESSING SYSTEM

The use of all prestressing systems will be subject to approval by the engineer. Tenderers are advised to obtain approval for the prestressing system they intend using, prior to submitting their tenders. Within one month of the tender having been awarded, or within a period agreed on with the engineer, the contractor shall submit full details regarding the prestressing system(s), materials and equipment he intends using, as well as regarding the methods he proposed to adopt in the prestressing and related operations. The engineer, at his own discretion, may call for further information in the form of detailed drawings, proof of successful previous use, performance certificates from an approved independent testing authority, and calculations substantiating the adequacy of the system. The contractor shall furnish such information within 2 weeks of being called upon to do so or within a period agreed on with the engineer. If, after investigating all the information, the engineer is not satisfied that the prestressing of the structural member can be carried out satisfactorily with the prestressing system offered by the contractor, the engineer reserves to himself the right to order the contractor to use any system which is suited to the work and which is readily available to the contractor. Only minor alterations to the concrete dimensions shown on the drawings will be considered in order to accommodate the prestressing system finally selected. Major alterations occasioned by the prestressing system offered by the contractor and which is at variance with the tendon system specified in subclause 6505(b) shall be treated as alternative designs and shall be dealt with as specified in clause 1212.

(a)

Casting yard on the site

Subject to approval by the engineer, precast work may be done at any location selected by the contractor. Before the casting yard is established, the contractor shall submit plans to the engineer which demarcate the site and detail the layout of the works, together with a flow diagram of the construction stages and storage.

@)

Manufacture off the site

The contractor shall notify the engineer in advance of the dates when tensioning of tendons, casting of members and transfer. will be undertaken. Within 7 days of transfer, the contractor shall submit to the engineer a certificate giving the tendon force(s) and extension(s) attained as well as records of the cube crushing strength and age of concrete at transfer. Test results relating to all aspects of the work shall be sent to the engineer immediately upon their becoming available. Where the engineer requires tests to be conducted on completed members, no member to which the tests relate shall be dispatched to the site until the tests have been satisfactorily completed and the members accepted by the engineer.

6507

DRAWINGS PREPARED BY THE CONTRACTOR

All drawings prepared by the contractor and submitted to the engineer for consideration shall comply with the requirements of clause 1221. The contractor shall submit to the engineer at least 2 months before he intends commencing with the prestressing work, drawings detailing the layout and alignment for the individual tendons, the cable supports, modifications to the bursting and other reinforcement, anchorage recesses, tensioning sequence, tensioning loads and extensions, as well as requirements ior controlling the tensioning operations. For the prestressing system finally selected, the technical data which are at variance with the information given on the drawings shall be shown on the drawings. Each tendon shall be separately numbered for identification. Where required, the contractor shall submit calculations in respect of the variation of the tendon force along the length of the tendon, the expected extension and the

(c)

Manufacture

Before work is commenced, details of the manufacture, curing and phasing of the work shall be submitted to the engineer for approval. After approval no changes shall be made to the methods or systems without approval b y the engineer. The contractor shall ensure that the specified precamber is incorporated in the formwork. The magnitude of the precamber shown on the drawings shall be subject to variation depending on the contractor's construction

programme, and the contractor shall, before manufacture, ascertain in writing from the engineer, the increase or decrease in precamber. This procedure shall also apply to the cases where no precamber has been specified. Lifting and supporting the precast members shall be made only at the points marked and provided on the members.

member and the exposed ends covered with a heavy coat of approved bituminous material or epoxy resin. The cutting of the prestressing steel shall be performed with a high-speed abrasive cutting wheel. Flame cutting will not be permitted.

6510 Precast members which have not been fully tensioned or fully stage-tensioned or which have ungrouted tensioned tendons shall not be handled without authorization by the engineer. Where members with ungrouted tensioned tendons are handled, control shall be exercised to guard against possible slip of the tendon at the anchorage. Prestressed precast concrete members shall also comply with the requirements of clause 6413.

POST-TENSIONING

(a)

Storage, handling and protection

6509 PRE-TENSIONING

During storage, transit, construction and after installation the sheaths, prestressing steel, anchorages and couplers shall be protected against corrosion, damage or permanent deformation. The manner and extent of protection required will depend on the environmental factors and the length of time before permanent corrosion protection is applied, and shall be to the satisfaction of the engineer. Under severe corrosive conditions in coastal, damp and wet areas and under aggressive conditions the materials shall be stored in weatherproof sheds. All materials shall be stored clear of the ground and while in storage shall not be exposed to the weather. When prestressing steel has been stored for a prolonged period and there is evidence of its deterioration, the contractor may be called on to prove by tests that the quality of the steel has not been significantly impaired and that the prestressing steel still complies with the provisions of these specifications. Suitable protection shall be provided to the threaded ends of bars. After fabrication, the cable ends shall be covered with protective wrapping to prevent the ingress of moisture into the duct. When the tendon is to be left untensioned for a prolonged period after installation, precautions shall be taken to protect the tendon against corrosion. Corrosion inhibitors, oils or similar materials used as lubrication or to provide temporary protection shall be such that they can be completely removed before permanent protection is effected.

During the period between tensioning and transfer, the force in the tendon shall be fully maintained by some positive means. At transfer, detensioning shall take place slowly to minimize any shock which could adversely affect the transmission length of the tendon. In the long-line method of pre-tensioning, sufficient locator plates shall be distributed through-out the length of the bed to ensure that the straight tendons are maintained in their proper position during concreting. Where a number of units are manufactured in line, they shall be free to slide in the direction of their length so as to permit transfer of the tendon force to the concrete along the entire line. In the individual-mould system, the moulds shall be sufficiently rigid to provide the reaction to the tendon force without distortion. Where possible, the mechanism for holding down or holding up deflected tendons shall ensure that the part in contact with the tendon will be free to move in the line of the tendon so that friction losses are eliminated. If, however, a system is used which develops a frictional force, this force shall be determined by test and due allowance made therefor. For single tendons, the deflector in contact with the tendon shall have a radius of not less than 5 times the tendon diameter for wire, or 10 times the tendon diameter for a strand, and the total angle of deflection shall not exceed 15". Transfer of the tendon force to the concrete shall be effected in conjunction with the release of hold-down and hold-up forces in accordance with an approved method. Transfer shall not be effected until compressive-strength tests on the concrete show that the concrete of the particular member has attained a compressive strength of at least the compressive strength shown on the drawings. The transmission length is affected by the concrete strength, and the necessary modification for the concrete strength at transfer shall be made in conjunction with the engineer. The tendons shall be cut off flush with the end of the

@)

Fabrication

All cutting of prestressing steel shall be performed with a high-speed abrasive cutting wheel or by a method approved by the engineer. Flame cutting will not be permitted. Care shall be taken to prevent the prestressing steel or anchorages from coming into contact with splashes from flame-cutting or welding processes in the vicinity. Where possible, all bars, wires or strands tensioned in one operation shall be taken from the same parcel of prestressing steel. The tendon or cable shall be labelled to show the tendon or cable number, as well as identify from which parcel the steel has been taken. Where bars, wires or strands in a tendon are not tensioned simultaneously, tendon spacers shall be used in accordance with the recommendations for the prestressing system or, in the absence thereof, as directed by ttie engineer.

Cables shall be fitted at both ends with pipes with a diameter of at least 10 m m for the injection of grout or protection agents. The ends of the injection pipes shall be fitted with a clamp, valve or device capable of withstanding a pressure of at least 15 bars without loss of grout or protection agent. Vent pipes with a diameter of at least 25 m m shall be provided in the duct at every high point, change of sheath cross-section and at such intermediate positions as may be shown on the drawings or required by the engineer. The vent pipes shall extend to at least 500 m m above the concrete and shall comply with the requirements for injection pipes. Connections to, and joints in sheaths shall be made grouttight by using special sheathing couplings and taping. With bonded cables, the length of taping shall not exceed six sheath diameters. Where oversleeves are used, equal overlaps shall be provided over each length of sheathing. Joints in adjacent sheaths shall be spaced at least 300 m m apart.

External tendons shall be installed to the same standards and accuracy specified herein for internal tendons. The tendons shall be temporarily supported at regular intervals along the straight length between saddles. The supports shall consist of rigidly constructed frames secured to the concrete face.

(d)

Concrete strength

Full tensioning of all or some of the tendons shall not commence until the compressive-strength of the concrete is 35 MPa or the strength shown on the drawings, whichever is the greater. The compressive strength of the concrete shall be determined from cubes manufactured and tested in accordance with subclause 8106(a) which have been cured under the same conditions as the structural member which is to be prestressed. The number of concrete cubes required for this purpose shall be as agreed on with the engineer. Where initially all or some of the tendons are to be partially tensioned, tensioning shall not commence before the concrete has attained the compressive strength indicated on the drawings.

(c)

Installation

The installation of tendons shall not commence until the requirements of clause 6507 have been complied with. The cable, sheath or extractable core shall be accurately installed to the specified alignment and securely held in position both vertically and horizontally at intervals appropriate to its rigidity and so as not to be displaced during concreting, either by the weight of the concrete or by buoyancy. The spacing of the cable supports shall furthermore ensure that the tendon can be installed to a smooth alignment without kinks and within the tolerance specified in subclause 6803(g). Cable sheaths shall be supported and held in position by means of separate reinforcing steel supports with a diameter of not less than 16 mm. The transverse bars must be welded to the vertical bars or must rest on lugs welded to the vertical bars. The spacing of the vertical supports shall not exceed 1 m. Extractable cores shall not be coated with release agent unless approved by the engineer. Unless otherwise shown on the drawings, the alignment of the tendon within a distance of 1,O rn from the live anchorage and/or coupler shall be straight. The tendon axis shall be set perpendicular to the bearing surface of its anchorage and firmly secured in position so as not to move during concreting. External anchorages shall be seated on a thin mortar bedding to bear evenly on the concrete bearing surface, and the tendon axis shall be perpendicular to the bearing surface of the anchorage. Unless otherwise shown on the drawings, the minimum concrete cover over the outside surface of the sheath or cable support shall comply with the requirements of clause 6307, except that, for sheaths, the cover shall not be less than 50 mm. The spacing of cables will depend on the size of the cable and shall be such that the concrete can be properly placed and compacted. Immediately before concreting, the contractor shall inspect the sheaths for grout-tightness and shall seal all damaged and suspect sections.

(e) (i)

Tensioning Preparation

Within 2 hours of the concrete having been placed, the contractor shall demonstrate that sheaths are free from obstructions, that extractable cores can be removed and, where the design permits, that all tendons are free to move in the ducts. All water in the ducts shall then be expelled with compressed air and the cables sealed until tensioning takes place. Before tensioning is commenced, the side forms and other restraining elements shall be released or removed to give the structural member the freedom to deform under the induced force. (ii) Tensioning sequence

The sequence of tensioning to be followed shall be as shown on the drawings and/or on drawings prepared by the contractor in terms of clause 6507. The contractor shall make allowance in his tendered rates for all incidentals which he may have to incur as a result of having to tension fully only some of the tendons at any one stage or instant. Where partial tensioning of tendons is required, the work shall be executed in accordance with the details on the drawings or as specified. The contractor shall, in his tendered rates, make provision for all incidentals he may have to incur as a result of having to tension partially only some of or all the tendons at any one stage or instant. (iii) Assembling the equipment, and safety precautions

The tensioning and measuring equipment shall be assembled for tensioning in exactly the same way as they are combined for calibration. The contractor shall take all the necessary safety precautions to prevent accidents caused by the

malfunctioning or failure of any part of the equipment or material and shall accept full responsibility for injury sustained by persons or damage to property resulting therefrom. (iv) Friction

The tendons have been tensioned to the required (1) force.

(2)

The measured extension on individual tendons is within r 6% of the theoretical extensions.

The engineer may require the contractor to perform friction tests on designated tendons and to revise the relevant theoretical extensions to compensate for the discrepancy between the values adopted in the design and the test results. Payment for these tests shall be made under item 81.02. ,Where applicable, allowance shall be made in the tensioning force to compensate for friction loss in the jack and in the anchorage. (v) Tensioning

The average variation between the measured and (3) theoretical extensions of all the tendons in a structural member is less than 2 3%. The release and/or pull-in is within r 2 m m of the (4) theoretical values. Where the above conditions are not met individually and collectively, the contractor shall immediately advise the engineer and obtain a ruling as to the procedure to be followed. In the event of the tendon friction being too high, the contractor may, subject to approval by the engineer, inject an approved lubricant into the sheath after first having detensioned the tendon. The cost of the remedial and corrective measures and of the release and retensioning of tendons, which have been occasioned by failure of the operations to meet the above requirements shall be for the contractor's account. After the tensioning has been accepted by the engineer, the contractor may cut off the tendons behind the anchorage as described in subclause 6510(b).

Tensioning shall be carried out under the supervision of a technician skilled in the use of the prestressing system and equipment and the methods of tensioning to be adopted. Tensioning shall not be commenced before the engineer has been advised of each tensioning operation and has given his approval for the work to be started. The technician and operators shall be supplied with a schedule listing the sequence of tensioning the various tendons and a tensioning record sheet showing the theoretical gauge readings, jacking forces, extensions, release and pull-in for each tensioning operation. The record sheet shall furthermore provide room for entering the corresponding information recorded and observations made during tensioning. A graph of the tensioning force and/or gauge reading versus theoretical extensions shall, where required, be appended to the record sheet and the actual extensions measured for each load increment shall be plotted on the graph. Copies of the completed record sheets and graphs shall be submitted to the engineer within 24 hours of each tensioning operation having been completed. The contractor shall note that the extensions shall be regarded as an indirect measurement of the tensioning force and shall serve as a control on the tensioning force applied. The protruding ends of all bars, wires and strands shall be clearly marked for the accurate measurement of extension, release and pull-in. Before tensioning is commenced on external tendons, a small load shall be applied to each tendon, commencing with the uppermost tendon. The force shall be sufficient to take up all slack and prevent entanglement of the tendons. The jacking force shall be increased to approximately 5 to 10% of the final jacking force to take up the tendon slack and to determine the zero position for measuring the extension and to check the gripping devices and the position and alignment of the jacks. The load shall then be increased gradually to the full specified tensioning force while intermediate gauge readings and extensions are recorded at regular intervals. The final stage of tensioning shall be deemed to have been satisfactorily accomplished when all the following requirements have been complied with:

(9
(i)

Permanent protection and bonding of tendons

General

After tensioning, all tendons shall receive permanent protection against mechanical damage and corrosion. Internal tendons shall be protected and bonded to the structural member by cement grout or, when permitted by the engineer, by sand-cement grout. Where bond is not important, protection may be effected by the use of bitumen, petroleum-based compounds, epoxy resins, plastics and similar products, all complying with the requirements of subclause 6503(h) and subject to approval.

Tendons located outside the structural section (i e external tendons) shall be encased with a dense concrete, dense mortar or material sufficiently stable and hard, all subject to approval. The encasement shall be of the thickness shown on the drawings. Where bonding of the tendon to the structural concrete is required, this shall be achieved by bonding the concrete encasement to the structure with reinforcing steel as detailed on the drawings. Protection and bonding of the tendons shall be effected within 7 days of the final tensioning of the tendons, or as specified on the drawings, but shall not take place without the prior approval of the engineer having been obtained. After the permanent protection or bonding has been completed the anchorages shall be encased in concrete or grout which shall be bonded to the old concrete with epoxy resin designed for this purpose, or shall be completely coated with a corrosion-resistant material. The protection provided shall in all cases prevent the ingress of water or aggressive agents.

(il)

Preparation of ducts

whichever is situated at the lower end of the cable. Grout lnjection shall proceed without any Interruption until the cable has been completely filled and closed off. (2) Protecting agents

Before permanent protection and/or bonding of tendons is effected, the following precautions shall be taken: The cables shall be checked for blockages by water (1) or compressed air, being injected. Unlined ducts which are to be filled with grout shall (2) be flushed with water to wet the concrete. (3) Temporary protection or lubricants which are incompatible with the permanent protection or bonding, shall be removed by flushing the duct with water or an inert solution, or by any suitable approved method. On completion of the above, any excess fluid shall (4) be expelled from the ducts by means of compressed air or shall be displaced by the protecting agent or grout, as may be relevant. Any blockages, leakages or factors which in any way may affect the permanent protection or bonding shall immediately be reported to the engineer. (iii) (1) Mixing Protecting agents

The injection of protecting agents shall be strictly In accordance with the instructions, and with the equipment specified by the manufacturer. (3) Grout

Immediately after mixing, and also during injection, the fluidity of the grout shall be tested at regular intervals In accordance with subclause 6503(i). lnjection shall be continuous at a rate of 6 m to 12 m per minute. As soon as grout with the original consistency flows from the intermediate vent pipes they shall be successively closed. lnjection shall continue until the grout flowing from the vent at the free end is of the same consistency as that of the injected grout. At this stage the vent shall be closed and the final pressure or a pressure of 5 bars, whichever is the greater, shall have been maintained on the grout column for 5 minutes before the valve at the injection end is closed. All vents shall be kept closed and supported vertically until the grout has finally settled. On vertical cables, a riser pipe with funnel shall be fitted to the top anchor to ensure that the separated water migrate upwards and will not remain in the cable.

The mixing of protecting agents shall be strictly in accordance with the manufacturer's instructions. (2) Grout

The aggregate, if used, and the cement shall be measured by mass, and the water by mass or by volume. The water:cement ratio by mass shall be as low as possible within the range between 0,36 to 0,45, and shall be consistent with the fluidity requirements of subsubclause 6503 (g) (ii)

If an expanding agent is used in the grout mix, the air vents shall be re-opened after grouting to release any separated water, and shall then again be closed.
Unless a retarder is used in the grout mix, the grout not used within 60 minutes of mixing shall be discarded. During the course of grouting 100 m m cubes shall be made for testing in accordance with subclause 6503(i). Whilst the grout is being poured into the cube mould, the sides of the mould shall be slightly tapped to permit any entrapped air to escape. Precautions shall be taken not to discharge the escaping grout onto railway lines, public roads or private property. If a blockage occurs during the course of grouting, the grouting shall be stopped before the maximum grouting pressure is reached. The duct shall then be flushed out immediately and the blockage cleared. Grouting shall not be carried out during very cold weather when the ambient air temperature drops below 5" C. Care shall be taken that the ducts are completely free from frost or ice before grouting commences after frosty weather.

Where an admixture is used, it shall be dissolved in a part of the mixing water before it is added to the grout. Mixing shall be commenced by two-thirds of ths cement being added to the greater part of the mixing water, and, if used, an additive predissolved in part of the mixing water, and finally the remainder of the cement. Mixing shall continue for not longer than 4 minutes after which the grout shall be continually agitated at slow speed throughout the injection operation. Where aggregate is used in the grout mix, the word "cement" in the preceding paragraph shall be replaced by the term "cementlaggregate component". (iv)
(1)

lnjection General

The injection of permanent protecting agents or grout shall not commence before approval has been granted that the work may start. Before injection commences all air shall be expelled from the injection equipment and hoses and all connections checked for airtightness. lnjection shall take place from the anchorage or coupler,

a 1 1 LOSS OF PRESTRESS

Any structural member which has lost all or part of its prestress through the failure or malfunctioning of any part of the prestressing component may be rejected by the engineer and shall be removed from the works unless approved remedial measures have been successfully carried out on the member. No payment will be made In

respect of such remedial work or loss suffered by the contractor in this regard.

(b) (c)

Anchorage at dead end Coupler at jacking end Coupler at dead end

..... .....

meganewton (MN) meganewton (MN) meganewton (MN)

6512

MEASUREMENT AND PAYMENl

(d)
Unit

.......

ltem
65.01 Prestressing tendons:

(a)

Longitudinal tendons . . . . . . . . . meganewton-metre (MN-m) Transverse tendons . .

The unit of measurement shall be the meganewton which is calculated as the product of the nominal tensile strength in megapascals of the prestressing steel and the crosssectional area of the tendon in square metres, effectively anchored or coupled. The tendered rates shall include full compensation for supplying, storing, handling, fabricating and protecting the complete anchorage or coupler assembly, anchorage reinforcing, constructing the recesses for the anchorage or coupler, tensioning, anchoring and/or coupling, trimming the tendon ends, using all the equipment, as well as for all work and incidentals required for completing the work as specified. The coupler shall include the complete assembly consisting of the anchorage built into the first-stage construction and the part coupled to it. The tendered rate for loop or fan anchorages shall exclude the cost of the length of tendon forming the loop or fan.

(b)

... ....
...

meganewton-metre (MN-m) meganewton-metre (MN-m)

(c)

Vertical tendons

The unit of measurement shall be the meganewton-metre which is calculated as the product of the nominal tensile strength in megapascals of the prestressing steel, the ;l square metres and the cross-sectionalarea of the tendon i length of the tendon in metres between the faces of the anchorages. In the case of fan and loop anchorages the "length of the tendon" shall include the length of tendon forming the loop or fan. The tendered rates shall include full compensation for preparing and submitting the drawings, supplying, storing, handling and protecting all materials (excluding anchorages and couplers), fabricating, supporting and installing the cables; lubricating, permanently protecting and bonding the tendons, for the using of all the equipment, as well as for all work and incidentals required for completing the work as specified.

Item

Unit

65.03 Extra over item 65.02 for partially tensioning the tendons. . . . . . . . . . . . . meganewton (MN)

The unit of measurement shall be the meganewton, which is calculated as for item 65.02.
Item 65.02 Anchorages and couplers: Unit

(a)

Anchorage at jacking end

...

meganewton (MN)

The tendered rate shall include full compensation for the use of all equipment, as well as for all work and incidentals required for tensioning and anchoring the tendons to the specified partial force.

SERIES 6000: STRUCTURES SECTION 6600 : NOFINES CONCRETE, JOINTS, BEARINGS, BOLT GROUPS FOR ELECTRIFICATION, PARAPETS AND DRAlNAGE FOR STRUCTURES

Class cement

Aggregate per 50 kg

CONTENTS
SCOPE NO-FINES CONCRETE JOINTS IN STRUCTURES BEARINGS FOR STRUCTURES PARAPETS, RAILINGS AND SIDEWALKS DRAINAGE FOR STRUCTURES BOLT GROUPS FORELECTRIFICATIONBRACKETS MEASUREMENT AND PAYMENT

(c)

Batching and mixing

Cement shall be measured by mass or in full pockets of 50 kg each and aggregate shall be measured by volume in approved measuring boxes or barrows.

6601

SCOPE

The aggregate shall be moist or wetted before the cement is added. Where drum mixers are used, about 20% of the water shall be poured into the drum before the aggregate and cement are loaded. The mixing time in the drum shall be about 45 to 50 seconds.

This section covers the manufacture and placing of no-fines concrete (a) used in the works: the supply and installation of all permanent joints (b) which will permit relative movement between contiguous structural members; the construction, supply and installation of bearings (c) for structures; the construction of parapets, railings and sidewalks (d) on structures; (e) the construction and/or installation of drainage works such as weep holes, drainage pipes and gulleys, nofines concrete blocks, filter lining and concrete channelling; and (1) bolt groups for electrification brackets.

The quantity of water added shall be just sufficient to form a smooth grout which will adhere to and completely coat each and every particle of aggregate, and which is just wet enough to ensure that, at points of contact of aggregate, the grout will run together to form a small fillet to bond the aggregate together. The mix shall contain no more than 20 litres of water for every 50 kg of cement.

Mixing shall be done in an approved batch-type mechanical mixer, but small quantities may be hand mixed.

(d)

Placing

No-fines concrete shall be placed in accordance with the procedure approved by the engineer. It shall be placed in its final position within 15 minutes of having been mixed.

66M NO-FINES CONCRETE

The concrete shall be worked sufficiently to ensure that it will completely fill the space to be concreted and that adjacent aggregate particles are in contact with one another. Excessive tamping shall be avoided and the concrete shall not in any circumstances be vibrated.

(a)

Materials
(e)

Cement, aggregate and water shall comply with the requirements of clause 6402. Each size of aggregate shall be a single size aggregate graded in accordance with SABS 1083 : Part II.

Protection

All no-fines concrete shall be protected from the elements and loss of moisture. Protection against loss of moisture shall be accomplished by one or more of the following methods: (i) Retaining formwork in place.

@)

Classes of no-fines concrete

No-fines concrete shall be classified by the prefix NF and the size of aggregate to be used. Class NF 19 means a nofines concrete with a 19 m m nominal size aggregate. The volume of aggregate per 50 kg of cement for each class of concrete shall be as follows:

Covering exposed surfaces with sacking or other (ii) approved material kept continuously wet. (iii) Covering exposed surfaces with plastic sheeting.

No-fines concrete placed during cold weather shall be adequately protected against frost for at least 3 days.

6 6 0 3 JOINTS IN STRUCTURES
Materials General

(iv)

Waterstops

(a)

Waterstops shall be of natural rubber or flexible PVC and of the type specified or shown on the drawings. Natural-rubber waterstops requirements of CKS 388. shall comply with the

(i)

All materials used in forming, constructing and sealing permanent joints as well as all proprietary or custom-built expansion-joint assemblies shall be subject to the approval of the engineer.
When required by the engineer, the contractor shall submit test certificates issued by an approved, independent testing authority to confirm that the respective materials comply with the specified requirements, or a certificate by the patent holder or designer certifying that the manufactured item complies in all respects with relevant product specifications. (ii) Joint filler

Flexible PVC rubber waterstops shall comply with the requirements of CKS 389. (v) (1) Accessory material Primers

Where a primer is to be used in conjunction with the sealant, it shall be of the prescribed proprietary material.
(2)

Bond breakers

Polyethylene tape, coated paper, metal foil or similar material may be used where bond breakers are required. (3) Backup material

Joint filler shall consist of sheets or strips of the following materials complying with the requirements of the relevant specifications listed: Bitumen-impregnated fibreboard and bitumenimpregnated corkboard U S Federal Specification HHF-341F or AASHTO Specification M213.

Backup material shall consist of a compressible material of correct width and shape to ensure that, after installation, it will be in approximately 50% compression and the sealant can be formed to the specified depth. Backup materials shall be compatible with the sealant used. Material containing bitumen or volatiles shall not be used with thermosetting chemically curing sealants. (vi) Cover plates

Resin-impregnated corkboard HH-F-341F.

- U S Federal Specification

Flexible foams of expanded polyethylene, polyurethane, PVC or polypropylene - AASHTO Specification M153. Rigid foams of expanded polyethylene, polyurethane or polystyrene - BS 4840 or BS 3837. Other joint filler materials may be used if approved by the engineer after he has been furnished with full specifications and information by the contractor. (iii) Sealants

Steel cover plates shall be of grade 43A steel which complies with the requirements of BS 4360, or of grade 300W steel which complies with the requirements of SABS 1431. Galvanising shall comply with the requirements of SABS 763. Anchor bolts shall be of stainless steel grade 302 S.21, which complies with the requirements of BS 970 part 4.

Thermoplastic hot-poured sealants shall comply with the requirements of U S Federal Specification SS-S-14019, BS 2499 or AASHTO Specification M173. The sealants shall be of the rubberised bituminous type containing a minimum of 20% natural or synthetic rubber. Thermoplastic cold-applied sealants shall comply with the requirements of U S Federal Specification SS-S-156. The sealant shall be of the rubberised bituminous type containing a minimum of 20% natural or synthetic rubber. Thermosetting chemically curing sealants shall complywith the requirements of ASTM C.920 or BS 4254. The final IRHD (International Rubber Hardness Degree) hardness of the sealant shall be 20 2 5.

@)
(i)

Filled and unfilled joints General

Wherever polystyrene or similar material susceptible to damage is used for forming joints, it shall be lined with a hard surface on the side to be concreted. The hard surface shall be sufficiently resilient to ensure that the joint and surfaces can be formed free from defects. (ii) Filled joints

Filled joints shall be accurately formed to the dimensions shown and with the filler material specified on the drawings. The filler shall be secured in position not to displace during concreting or thereafter if the filler is to remain permanently in the joint. Where the removal of the filler is required, it shall be done prior to the installation of the proprietary joint. (iii) Unfilled joints

Silicone sealants shall comply with the requirements of subsubclause 7102(e)(iii) and clause 7120.

Other sealants may be used if approved by the engineer after he has been furnished with full information and specifications by the contractor.

Unfilled joints shall be accurately formed to the dimensions given on the drawings, and all external corners chamfered

or rounded for at least 5 mm. The concrete face against which the fresh concrete is placed shall be treated in good time with an approved bond breaker.

(e)

Sealing the joints

General

(i)

(c)

Concrete nosings

Sealed joints shall be made watertight over the full length of the joint, including the full height of the kerbing, unless otherwise prescribed in the project specifications. Unless a waterstop is equipped with an effective watertight interlocking system for joining sections, all joints in waterstops shall be bonded or fused to have a tensile strength of at least 50% of that of the unjointed material. At intersections and abrupt changes of direction, waterstops shall be jointed with prefabricated junction pieces. Restrictions on joint width and on the temperature at the time of installing the sealant or seal will be shown on the drawings. In the absence of such restrictions on the drawings, and unless otherwise specified, installation shall be carried out only within the temperature range between 5" C and 30" C. (ii) Preparing the joints

Concrete nosings forming the edges of expansion joints shall be constructed as follows: After the concrete in the structural member has hardened sufficiently, the protruding ends of the reinforcing steel shall be bent flat onto the concrete surface of the formed recess. Before the asphalt surfacing is laid, the recess shall be filled with well-compacted crusher run, sand or weak mortar. The contractor shall ensure that the concrete surfaces of the recess and the reinforcing steel are not contaminated with bituminous agents. The asphalt surfacing shall then be laid continuously over the joint. The asphalt surfacing shall be cut with a diamond saw blade to correspond to the width of the nosing and all material shall be removed from the nosing recess. The concrete surfaces of the recess shall then be roughened to expose the aggregate and leave sound, irregular surfaces. The reinforcing steel shall then be bent, fixed and placed as shown on the drawings. The prepared concrete surfaces of the recesses shall be treated with an approved epoxy-resin adhesive, immediately before the concrete nosings are cast. Opposite concrete nosings, separated by a joint filler strip as specified, shall be cast simultaneously in accordance with subclause 6408(c), and compacted by vibrator. The nosing shall be screeded flush with the asphalt surfacing and be given a class U2 surface finish. Curing shall be in accordance with method (f) of clause 6409. The exposed corners of the nosings shall be ground to a 10 m m chamfer. After the joint has been sealed, the wearing surface of the nosings shall be treated with a bituminous primer to the satisfaction of the engineer.

Where required joints shall be sawn at a suitable time so as to avoid edge spalling or ravelling. After the temporary filler material has been removed or the excess concrete has been broken out, the inside faces of the joint shall be wire-brushed or sand-blasted to remove all laitance and contaminants. The joint shall then be cleaned and blown out with compressed air to remove all traces of dust. Solvents shall not be used for removing contaminants from the concrete and porous surfaces. The contractor shall ensure that primers are applied only to surfaces which are absolutely dry. The primer shall be applied strictly in accordance with the manufacturer's instructions. Unless otherwise specified, the primer shall be applied within the temperature range of 10C and 40C, and the sealant shall be applied after the curing period of the primer and within the period when the primer remains active. (iii) Sealants

Unless otherwise specified, traffic shall not be permitted to pass over the joint before the concrete in the nosing has aged for at least 10 days.

Sealants shall be applied strictly in accordance with the manufacturer's instructions by a person skilled in the use of the particular type of sealant. Trapping of air and the forming of voids in the sealant shall be avoided. The sealant shall be finished to a neat appearance to the specified depth.

Unless otherwise indicated on the drawings, the concrete used in the construction of the nosings shall be class 40113 and shall have a slump of not less than 50 m m and not exceeding 75 mm. Concrete nosings shall be constructed under the direct supewision of experienced and skilled personnel.

Thermoplastic hot-poured sealants shall not be poured into the joints when the temperature of the joint is below 10C. The safe heating temperature shall not exceed the specified pouring temperature by more than 10C. Two-part thermosetting chemically curing sealants shall not be applied after expiry of the specified pot-life period which commences once the base and activator of the sealant have been combined. (iv) Waterstops

(d)

Plug type expansion joint systems

Plug type expansion joint systems, eg Thormajoint @, shall be constructed in accordance with the details on the drawings and the specifications and instructions of the licensees.

Waterstops shall be securely and accurately located in position so that they will not be displaced or deformed during construction.

( 1 )
(i)

Roprietmy expansion Joints

General

The expansion Jointsdelivered at the site shall be suitably marked to show clearly the sequence and position of installation.

The use of any type of expansion joint shall be subject to approval. Tenderers shall obtain approval for the type of expansion joint they intend using prior to submitting their tenders. (ii) Dimensions

@)

Installing the expansion joints

Proprietary expansion joints shall be installed by approved specialist subcontractors only. Installed proprietary expansion joints shall have a 15 year written guarantee. No expansion joint or part thereof shall be installed prior to the construction of the final surfacing, unless otherwise approved. The expansion joint shall form an even surface with the road surface on either side and the deviation across and along the expansion joint shail comply with the requirements of subclause 3405(e) and subsubclause 3405(f)(ii) for surface regularity measured by ordinary straight-edge.

The contractor shall note the overall dimensions of the expansion joints and the limiting dimensions of that portion of the concrete structure which is to accommodate the joints. No alterations to the concrete which will be visible in the final structure or major re-arrangement of the prestressing anchorages, will be permitted in order to accommodate joints of excessive size. All joints to be installed skew shall be accurately dimensioned to ensure compliance with the requirements of subclause 6603(g). Unless otherwise specified, proprietary expansion joints shall include the complete expansion-joint assembly, traversing the entire roadway, kerbs, sidewalks and modian, and shall include the coping and parapet cover plates as well as the drainage system to drain the expansion joint. (iii) Design and manufacture

On completion of the installation of proprietary expansion joints, the contractor shall submit to the engineer a certificate from the manufacturer or supplier of the joints, certifying acceptance of the installation. Notwithstanding the issuing of such certificate, it shall not relieve the contractor of his responsibility under the contract. Payment for the inspection of the joints and the issuing of the certificate by the manufacturer or supplier will be made under item 81 -02.

The expansion jolnt shall be designed to withstand the movements, displacements and rotations specified on the drawings In conjunction with the loads described in the code of practice adopted for the design of the structure wlthout exceeding in any member the requirement for serviceability limit state. Any strengthening of the supporting member required to resist forces imparted by the joint to the structure shall be for the contractor's account. The specified movements, displacements and rotations shall be withstood without the efficacy or riding quality of the joint being impaired. The joint shail be vibration free, resistant to mechanical wear and other forms of abrasion, and shall resist corrosion. R shall have good riding characteristics, shall be highly skid resistant, and silent, also of watertight constructlon or have provision for the disposal of water, debris or grit collecting In the joint, and shall be of a construction as will facilitate easy inspection, maintenance and repair. h a r t from stainless steel, all steel surfaces shall be prepared In accordance with the requirements of subclause 8407(b) and sprayed with a galvanising coat which complies with the requirements of SABS 1391 part 1 for Zn 150 coverage. AIl exposed surfaces sprayed with zinc shall, within 4 hours, be covered with a sealant suitable for use with the zinc and the subsequent layer. Two coats of chlorinated rubber palnt with a combined dry-coat thickness of not less than 150 micrometres shall then be applied. They shall be of two different colours.

6604

BEARINGS FOR STRUCTURES

(a) (i)

Materials
General

When requested by the engineer, the contractor shall submit test certificates from an approved, independent testing authority to show that the respective materials comply with the specified requirements, or a certificate from the patent holder or designer certifying that the manufactured item complies in all respects with relevant product specifications.

Unless otherwise specified, all the materials used for manufacturing the bearings shall comply with the requirements of BS 5400 : part 9.2. (ii) Roofing felt

Roofing felt shall be 3-ply and comply with the requirements of SABS 92 for type 1 roofing felt. (iii) Elastomer

The elastomer used in the manufacture of bearings shall be natural rubber or synthetic rubber. Natural rubber shall comply with the requirements of BS 1154 for specified IRHD hardness.

Prior to manufacture of the joints, the contractor shall submit for approval detail drawings in accordance with the requirements of clause 1221 of each expansion joint.

Synthetic rubber shall comply with the requirements of BS 2752 for specified IRHD hardness.

(iv)

Stainless steel plate

(c)

Roofing felt

The texture of the sliding surface of stainless steel plate used in conjunction with PTFE to form low-friction sliding surfaces shall be equal to or better than 0,20 micrometre Ra in accordance with the requirements of BS 1134. (v) Stainless steel dowels and bolts

Roofing felt used as bearing strips shall consist of at least 3 layers. Where lubricated linings are specified, the roofing felt shall be saturated with used motor oil and then liberally dusted with graphite powder before it is laid on the bearing surface.

Stainless steel used for the manufacture of dowels and anchor bolts shall comply with the requirements of BS 970 : part 4 for steel 316816. (vi) Mortar

(d)

Elastomeric bearings Technical data

(i)

Mortar beddings for seating the bearings shall be composed of an approved sand and either cement or epoxy resin, or may consist of an approved proprietary mortar. The mortar shall comply with the following strength requirements: (1) Sand-cement mortar

The following technical data for the elastomeric bearings will be supplied on the drawings, and shall also be supplied on drawings prepared by the contractor for submission to the engineer: (1) Design loads and deformations

The 7-day compressive strength of 150 m m cubes made from the mortar and cured in a moist atmosphere for the first 24 hours and afterwards in water at 20C shall be not less than 1,5 times the average contact stress under the bearing or 15 MPa, whichever is the greater. (2) Sand-epoxy resin mortar

The critical design-load combinations and co-existing rotations and horizontal displacements for each bearing or each group of identical bearings. (2) Size and construction of bearing

The size and construction of the bearing shall be designated by

The cured compressive cube strength of the mortar shall be not less than 2,O times the average contact stress under the bearing, or 20 MPa, whichever is the greater.
(3)

where
L = length of bearing in the transverse direction, in m m

Proprietary mortar

The strength requirements for proprietary mortars shall be in accordance with either subclause 6604(a)(vi)(l)or (2) as may be relevant.

width of bearing in the span direction, in m m

t = thickness of individual elastomer layers, in m m n

=

number of elastomer layers.

@)

C o n -

hinges The steel plates shall be encased in a 3 m m thick elastomer layer. (3) Hardness and type of elastomer

Concrete hinges shall be constructed in accordance with the details shown on the drawings. Construction joints shall not be formed in the throat area. Where a joint is necessary, it shall be formed as a recess below the throat, level with the top reinforcement mat. The width of the recess shall be slightly greater than that of the throat. Care shall be taken to eliminate the formation of shrinkage cracks within the throat. During construction, adequate bracing and support shall be provided to the satisfaction of the engineer to prevent rotation in the throat from the time of casting to completion of the structure incorporating the hinge. During the course of construction the hinge shall not be subjected to conditions which will induce tensile stresses in the throat area. Upon completion of the structural members incorporating the hinge, the space around the throat shall be filled and sealed with an approved compressible material.

The IRHD hardness and type of elastomer, i e natural or synthetic rubber, from which the specified bearings are to be manufactured. (4) Identification

Each bearing shall be identified by a number (ii) Alternative bearings

Where alternative bearings are offered by the contractor, they shall be designed in accordance with the requirements of BS 5400 part 9.1 for the loadings and deformations shown on the drawings. Where a bearing consisting of a type of rubber is offered, which differs from that which is specified, the bearing shall be redesigned to make provision for the variation in hardness and/or type of rubber.

(iii)

Inspection and testing

On completion of the manufacture of the bearings, the contractor shall submit bearings selected by the engineer, or specially manufactured bearings to serve as samples as authorised by the engineer, to an independent testing authority for testing. The testing facilities of the manufacturer or supplier may be used if so approved and on condition that the tests are conducted in the presence of the engineer. The engineer will determine which tests are to be conducted, and the tests shall comply with the appropriate requirements of subclause 81 12(a).Payment will be made under item 81.02 for these tests, for bearings damaged, and for sample bearings. Copies of test results and certificates for the abovementioned tests shall be submitted by the contractorto the engineer in good time to enable the engineer to assess the information before the bearings are installed. The dimensional tolerances for the bearings shall comply with the requirements of subclause 6803(h). Before the bearings are dispatched to the site of the works, each bearing, with the exception of large bearings as provided for in the project specifications, shall be subjected simultaneously to a vertical load equal to 150% of the maximum design load, and to a shear distortion equal to 150% of the maximum design value. The bearings shall be visually inspected for defects by the engineer or his nominee and shall not at any stage under this test show any cracks visible to the naked eye or any other defects. The cost of this testing shall be included in the rate tendered for item 81.01. The engineer may instruct that 1 bearing of each consignment shall be cut open with a view to a visual assessment of the bonding and the thickness of layers.

Themanufacturer'sspecificationcontainingdetailed (1) information on the design standards, materials, manufacture and technical data.

Drawings complying with the provision in clause (2) 1221 showing the bearing construction and installation details. Friction properties based on actual tests conducted (3) on the relevant materials. (iii) Technical requirements

The following technical requirements will be supplied on the drawings, and shall also be supplied on the drawings prepared by the contractor for submission to the engineer: (1) Design loads and movement

The maximum and minimum vertical loads and co-existing horizontal loads as well as the maximum horizontal load and co-existing vertical load. The maximum values in each direction of the reversible and irreversible movements and the rotation about each axis. (2) ldentification

Identification of each bearing by a number, data on the degree of freedom of movement (fixed, multi-directional or unidirectional bearings) and the type of bearing (spherical, elastomer-pot, etc) shall appear on each bearing. (iv) Design

The bearings shall be designed in accordance with the requirements and recommendations of BS 5400 part 9.1. The following shall also be complied with: The average pressure on the area of the elastomer (1) shall not exceed 25 MPa under the sewiceabilitylimit state, unless otherwise prescribed by the engineer. (2) The maximum average contact stress and maximum edge stress on the concrete or mortar bedding shall not exceed 0,5 and 0,6 times :he 28-day cube characteristic compressive strength under the serviceability limit state respectively, unless otherwise prescribed by the engineer. The bearing pad shall be of dimensions as will fit (3) into the space allowed for its installation. Major alterations to the contiguous members will not be permitted. (v) Construction

(e)

Proprietary bearings General

(i)

This clause covers custom-built bearings and bearings manufactured under licence, except elastomeric bearings. Combined bearings, consisting of an assembly of an elastomeric bearing in conjunction with a low-friction sliding or mechanical component shall fall under this clause. The tenderer may base his tender on any bearing which complieswith the specified requirements, provided that the efficacy of the bearing has been verified by tests and successful previous use. Evidence hereof as well as information on the durability and suitability of the bearings for the specified use shall be submitted to the engineer for consideration. Details of the product guarantee shall be submitted with the tender. (ii) Drawings and approval

Unless otherwise specified, the following shall be complied with: The thickness of the elastomer disc shall be not less (1) than 0,066 times its diameter. Approved lubricants only shall be used on the PTFE (2) sliding surfaces. The bearing shall be provided with tight-fitting seals (3) to prevent the ingress of dust or deleterious matter onto the moving parts. The seals shall be of an approved type and sufficiently durable to last in excess of 50 years.

Prior to manufacturing the bearings, the contractor or his nominee shall submit the following information to the engineer for consideration.

(4) The assembled bearing shall be supplied with welded or bolted lugs or straps, temporarily securing the moving parts firmly in position to ensure that no undesirable relative movement occurs before or during construction.

(9

Dowels and guides

Where dowels and guides are used in conjunction with bearings they shall not complicate or prevent the removal of the bearings.

The bearing shall be recessed into adaptor plates (5) or be of such construction as to facilitate removal of the bearing from the installed position without damage to any part of the bearing or the surrounding material after the relevant structural member has been raised by 15 m m or the distance specified. Anchors and holding-down bolts shall be of the (6) specified material.

(g)

Storage and handling

The bearings shall at all times be stored under cover and clear of the ground, away from sunlight, heat, oils and chemicals deleterious to the bearings. The bearings shall not be stacked in a manner or on a surface which will cause distortion of the bearings. The bearings shall be handled with care to ensure that they are not subjected to impact loads or any other conditions which may be harmful.

(7)

Corrosion protection of all exposed steel surfaces, with the exception of the stainless-steel sliding plate, shall involve the following treatment: Preparing the surfaces by abrasive blasting to a finish equal to the Sa3 finish of Swedish Standard SIS 05 59 00. Spraying the surfaces with zinc to comply with the requirements of SABS 1391 part 1 for type Zn 150 surfacing. Coating the zinc-sprayed surfaces within 4 hours with a sealer compatible with the zinc and the subsequent coats of paint. Applying a coat of chlorinated rubber paint with a minimum of 75 micrometres of dry-film thickness and of a colour which differs from that of the final coat of paint. Applying a final coat of chlorinated rubber paint with a minimum of 75 micrometres of dry-film thickness and of dark grey colour. Surfaces in contact with concrete shall be sprayed with zinc so that it complies with the requirements of SABS 1391 part 1 for type Zn 150 surfacing. (vi) Inspection and testing

(h)

Installation

The concrete surfaces of elements required to receive bearings shall comply with the requirements of subclause 6209(c). Plastering of the surface will not under any circumstances be permitted. Before the mortar bedding is constructed, the concrete surface shall be chipped back to expose the aggregate and leave a sound irregular surface. Bonding of the mortar bedding to the concrete surface shall be in accordance with the manufacturer's recommendations and the engineer's instructions. Unless otherwise shown on the drawings, the bearings shall be installed on a horizontal plane and shall be in full contact with the concrete and bedding surfaces. To accommodate soffit irregularities and camber in the case of precast members, the member shall be lowered onto a mortar layer on top of the bearing. The member shall then be propped until the mortar layer has hardened into a wedge. The bearings shall be accurately installed to the specified level, alignment and orientation, all within the construction tolerances set out in subclause 6803(h) and the details shown on the drawings. Where the bearing has long sliding plates, the latter shall be rigidly supported to prevent their being distorted under the weight of the wet concrete and the construction loads. Before the bearing is incorporated into the structure, it shall be cleaned to remove all deleterious substances and adhering matter, after which it shall be wrapped in polyethylene sheeting and so sealed as to prevent the ingress of mortar and/or slush onto the bearing during the course of construction. After installation, the polyethylene wrapping shall be removed, the bearing and the space around the bearing thoroughly cleaned and the lugs removed as prescribed by the engineer. On completion of installation of proprietary bearings, the contractor shall submit to the engineer a certificate from the manufacturer or supplier of the bearings certifying acceptance of the installation. The issuing of such a certificate shall not relieve the contractor of his

The engineer may require tests to be conducted to verify compliance of the bearing with the specifications and/or its satisfactory performance under the design loads. Payment for this testing will be made under item 81.02.

Test certificates of all the tests conducted shall be submitted to the engineer.

The contractor shall give the engineer at least 7 days' notice prior to final assembly of the bearings to enable the engineer to inspect the bearings at the factory.

Under no circumstances shall bearings be taken apart and reassembled on the site, except where it is an unavoidable feature of the installation procedure, in which case the dismantling, installation and reassembly shall be under the supervision of qualified personnel.

Rehabilitation, modification and repair work to bearings shall be carried out only in the factory or in an approved engineering works.

responsibility under this contract. Payment for the lnspection of the bearings by the manufacturer or supplier and the issuing of the certificate will be made under item 81 -02.

neatly chamfered at 45". All open spaces between the bolt and the sides of the holes in the base plate shall be grout filled. Steelwork which is to be cast or grouted into concrete shall be completely painted to a distance of 75 m m in the concrete or grout, and shall be cleaned of all loose rust, mill scale, oil or other material which may impair the bond between the concrete and steel. All steelwork shall be painted in the shop and on site in accordance with the provisions of section 8400. Surfaces which will be inaccessible after erection of the units shall be painted before erection commsnces. If called for on the drawings or in the schedule of quantities, steelwork shall be galvanised and painted. Galvanising shall be done after fabrication, in accordance with SABS 763 for type A1 articles.

f3HE PARAPETS. RAIUNGS AND SIDEWALKS

(a)

Materials
Concrete

(i)

All concrete work shall be carried out in accordance with the requirements of sections 6200, 6300, 6400 and clause 6603. (il) Structural steel

Structural steel work shall comply with the provislons of subclause 6702(a). (iii) Mortar

(d) (i)

Numbers for structures

Number plates

Mortar shall comply with the requirements of subsubclause 6604(a)(vi).

Number plates shall be fixed in the positions and according to the method of fixing shown on the drawings. (ii) Painted numbers

Concrete parapets shall be either cast in situ or precast or a combination of the two as shown on the drawings. Where possible, precast elements shail be placed with the unformed surface downwards or outwards. Concrete parapets shall be constructed after the removal of the falsework and the completion of the prestressing, but not before the bridge deck has been accurately measured so as to determine the final lines and levels. Service ducts in parapets and end blocks shall be fixed and cast Into posltion in accordance with the requirements of clause 6411 and the details shown on the drawings. The pipes and fittings to be used for the construction of the ducting shall be rigid PVC pipes and fittings with flexible rubber joints which comply with the requirements of SABS 967. Duct ends shall be provided with suitable conlcal wooden stoppers to prevent dirt, concrete, etc, from entering the ducts. Two strands of 2,5 m m diameter galvanized steel wire shall be threaded through each duct. The strands shall extend 2 m beyond each end and be wedged firmly into position with the wooden stoppers. lnspection eyes for the ducts shall be constructed in accordance with the details shown on the drawings. No separate payment will be made for service ducts in parapets and end blocks and the rates tendered for the parapets and end blocks shall include full compensation for the provision and installation of service ducts complete with stoppers, draw wires and Inspections eyes.

The surface onto which the numbers are to be painted shall be prepared in accordance with the requirements of subclause 8409(a). The background shall be of at least two coats of the prescribed paint. The letters and figures shall be in accordance with the details given on the drawings and shall be written at the prescribed positions with a template. (iii) Numbers shaped In concrete

Bridge numbers shall be placed and shaped in accordance with the requirements shown on the drawings. The minimum concrete cover over the steel reinforcement behind the numbers shall not be less than the prescribed cover for the structural member In question.

(e)

Concrete sidewalks

After completion of the prestressing and the removal of the formwork, the sidewalks and kerbing shall be constructed, but not before the bridge deck has been accurately surveyed to establish final lines and levels.

The previously cast bridge deck area shall be prepared as specified in clause 6408 to receive the sidewalk concrete. Forms shail be accurately set to the final lines and levels and shall be firmly held in position during the placing of the concrete. Stops at the ends of sections shall be accurately placed to ensure that joints between adjacent sections will be truly perpendicular to the surface of the concrete and at right angles to the edge of the road or to the skew angle of the deck at the expansion joint. After removal of the forms, the exposed surfaces of the kerbs and copings shall be rubbed and finished in accordance with the requirements of subclauses 6208(a) and (c) and 6209(b). All edges shall be rounded to a radius of 20 m m unless otherwise shown on the drawings.

(c)

Steel tailings

All steelwork shall be manufactured in accordance with the requirements of section 6700.

A mortar bed, not less than 10 m m in thickness, shall be provlded below all steel base plates over the full dimensions of the plate. The sides of the beds shall be

(fJ

Concrete surface finish requirements

All formed concrete surfaces shall have a class F3 surface finlsh as specified in subclause 6207(d) and all unformed concrete surfaces shall have a class U3 surface finish in accordance with subclause 6209(c).

be wrapped in synthetic-fibre geotextile and placed in accordance with the details shown on the drawings or as instructed by the engineer.

6607

BOLT GROUPS FOR ELECTRIRCATlON BRACKETS

(g)

Transib'on blocks

Transition blocks shall be constructed in accordance with the details shown on the drawings.

Nose endings

Nose endings at balustrades shall be constructed in accordance with the details on the drawings.

The contractor shall supply and install bolt groups in bridge decks for the electrification brackets of railway owners. The bolt groups shall consist of stainless-steel sockets complete with stainless-steel bolts and mild-steel plates. The sockets, bolts and plates shall be manufactured in accordance with the details shown on the drawings. The contractor shall install the sockets in bridge decks in the positions and in the manner shown on the drawings. On completion of the deck, the contractor shall ensure that the threads of the bolts and sockets are clean and that the bolts can be secured in the sockets. The railway owner will supply and install the brackets at a later stage.

6Hl6 DRAlNAGE FOR STRUCTURES

(a)

Weep holes, drainage pipes and channelling

MEASUREMENT AND PAYMENT

Weep holes shall not be placed within 40 mm of any reinforcement and shall be carefully cleaned and kept clean. Drainage pipes shall be of the material prescribed on the drawings, and the interior surface shall, on completion, be smooth and clean. Cast In situ concrete channelling shall be provided next to the kerbing if shown on the drawings and according to the details provided. Concrete work shall be carried out in accordance with the provisions of section 6400 and channelling shall be given a class U2 surface finish as specified In subclause 6209(b). The channelling shall be bonded to the bridge deck concrete in accordance with the provisions of clause 6408.

Item
66.01 Cast in sihr nm fines wnwete (class of concrete indicated)

Unit

.......

cubic metre (ma)

The provisions of clause 6416 item 64.01 shall apply mutatis mutandis.

Item
66.02 Precasl nefines concrete units (class of concrete and description of unit)

U n i t

. ........ ...

number (Na)

@)

No-fines wmxete blocks

The unit of measurement shall be the number of complete units of each size and type in position in the works.

Blocks shall be of the class of prescribed no-fines concrete and to the required dimensions and shall be placed in advance of backfilling. No-fines concrete shall comply with the requirements of clause 6602.

The tendered rate for each precast concrete unit shall include full compensation for providing all the materials, labour, plant and formwork required for manufacturing the unit complete as shown on the drawings and for transporting and placing the unit in position.

(c)

!3ynihetiefibre filter fabric Item

66.W Proprietary expansion joints: (a) Prime cost sum allowed for purchasing and taking delivery of expansion joints Percentage on prime cost sum for charges and profit

Synthetic-fibre filter fabric shall be of the type and grade shown on the drawings or specified in the project specifications. Filter fabric shall be placed as shown on the drawings and shall be protected against sunlight and mechanical damage during storage and installation. The fabric shall comply with the requirements of subsubclause 2104(a)(iii).

Unit

. .. .

prime cost sum

(b) (d)
Crushed stone in drainage sbips behind walls

. . . . . . . per cent (%)

The crushed stone used in drainage strips shall comply with the requirements for 19 m m nominal size stone as specified in table 9 of SABS 1083. The crushed stone shall

Payment for purchasing and taking delivery of proprietary expansion joints shall be in accordance with the provisions of the general conditions of contract (see note 2 below).

66.04 Installation of prtb prietary expansion joints:

The tendered rates shall include full compensatlon for supplying and installing the joint filler and all materials not covered under item 66.08, and for all labour and incidentals required for completing the filled joint as prescribed.

(a)

(Description of joint measured per metre) . . . . . . . . . . . . . .metre (m) (Description of joint measured by number

@)

. . . . . . . . . . number (No)

66.07 Unfilled joints:

The unit of measurement shall be either the metre of complete joint of each type installed or the number of complete joints of each type installed. The tendered rates shall include full compensation for supplying all materials not covered unde; item 66.03, transporting, handling and storing, and all labour, equipment, shaping the recesses, and incidentals required for installing the expansion joint complete in accordance with instructions (see notes 1 and 2 below). The tendered rate shall be final and binding, irrespective of the type or make of joint finally installed.

(a)

(Description of joint for for joints measured per square metre) . . . . . . . . . . . . square metre (mz) (Description of joint for joints measured per linear metre) . . . . . . . . . . . . . . . . . . . . . . . . .metre (m)

(b)

The unit of measurement shall be the square metre of unfilled joint, calculated in accordance with the joint area. Where, however, the depth of the joint is 150 mm or less, the unit of measurement shall be the metre of unfilled Joint measured along the joint centre line. Concrete areas formed before the final surface is constructed to complete the unfilled joint, shall be measured under items 62.01, 62.02, 62.03 or 62.04, as may be applicable. The tendered rates shall include full compensation for providing and applying the bond breaker and all materials not paid for under item 66.08, also for the labour and incidentals required for completing the unfilled joint as prescribed.

66.05 Expansion joints:

(a)

(Description of joint measured per metre)

. . . . . . . . . . . . . .metre (m)
. . . . . . . . . . number (No)

(b)

(Description of joint measured by number)

Item
66.08 Sealing joints w i t h

Unit

The unit of measurement shall be the metre of complete expansion joint of each type installed or the number of completed joints of each type installed. The tendered rates shall include full compensation for supplying all the materials, manufacturing the expansion joint, transporting, handling and storing, and all labour, equipment, shaping the recesses, and incidentals required for installing the expansion joint complete in accordance with instructions (see notes 1 and 2 below).

(a)

Sealant (description of joint, sealant and size)

. . . . . . . . . . . metre (m)
. . . . . . . . . metre (m)

(b)

Waterstop (description of joint, waterstop and size)

The unit of measurement shall be the metre of sealant, seal or waterstop of each type installed. The tendered rates shall include full compensation for supplying all materials, forming or cutting the concrete to the required shape and size, all labour, equipment and incidentals required for sealing the joint complete in accordance with the prescriptions, and for all waste materials (see note 2 below).

66.06 Filled joints:

(a) (Description of joint and thickness of joint filler for joints measured per square metre) . . . . . . . . . . . . square metre (m2) (Description of joint and thickness of joint filler for joints measured per metre)

Item
66.09 Proprietary bearings:

Unit

(b)

. . . . . . metre (m)

(a)

Prime cost sum allowed for purchasing and taking delivery of bearings . . . . . . . . . . prime cost sum Percentage on prime cost sum for charges and percentage (%) profit . . . . . . . . . . . . . . . . . . . . . .

The unit of measurement shall be the square metre of filled joint calculated from the surface area of the joint. Where the filled joint is 150 mm or less in depth, the unit of measurement shall be the metre of filled joints measured along the joint centre line. Concrete surfaces formed prior to the construction of the final surface for completing the filled joint shall be measured under item 62.01, 62.02, 62.03 or 62.04, as may be applicable.

(b)

Payment for purchasing and taking delivery of proprietary bearings, complete with anchor bolts and/or dowels, shall be in accordance with the provisions of the general

conditions of contract,

Item

Unit

The tendered rate shall include full compensation for supplying all the materials, transporting, handling and storing, and all labour and incidentals required for installing the bearing strips complete as detailed.

66.10 Installing the proprietary bearings (description of each type, and state class) . . . . . . . . . . number (No) The unit of measurement shall be the number of complete bearings of each type and class installed. The tendered rate shall include full compensation for supplying all the materials not covered under item 66.09, constructing the bedding, transporting, handling and storing, and all labour, equipment and incidentals required for installing the bearings complete as detailed. The tendered rate shall be final and binding, irrespective of the type or make of bearing finally installed.

Item 66.14 Dowelslguides (description of each type)

Unit

..........

number (No)

The unit of measurement shall be the number of dowels/guides of each type installed. The tendered rate shall include full compensation for supplying all materials, including anchor bolts, manufacturing the dowels/guides, transporting, handling and storing, and all labour, equipment and incidentals required .for installing the dowelslguides complete as detailed.

Item 66.11 Bearings (description of each type and class)

Unit

Item 66.15 Concrete parapets

Unit

.........

. . . . . . . . . . . . . . . .metre (m)

number (No) The unit of measurement for concrete parapets shall be the metre of concrete parapet complete in accordance with the drawings. Concrete parapets shall include all work above the top level of the sidewalks or, where not placed on a sidewalk, above the top of the bridge deck concrete, wingwalls or retaining walls and shall also include any kerbing and coping forming an integral part of the concrete parapet. The tendered rate for concrete parapets shall include full compensation for all concrete, formwork, service ducts, drawing wires and accessories. The rates will exclude only the cost of reinforcing steel as this will be measured and paid for under another pay item.

The unit of measurement shall be the number of complete bearings of each type and class installed. The tendered rate shall include full compensation for supplying all the materials, including anchor bolts and/or dowels, constructing the bedding, manufacturing the bearings, transporting, handling and storing, and all labour, equipment and incidentals required for installing the bearings complete as detailed.

Item 66.12 Concrete hinges: (a) (Description of hinge measured per metre)

Unit

Item

Unit

.............. metre (m)

66.16 Steel railings (type described)

.....

metre (m)

(b)

(Description of hinge measured by number)

..........

number (No)

The unit of measurement for steel railings shall be the metre of railing complete in accordance with the drawings. The tendered rate for steel railings shall include full compensation for all steelwork and corrosion protection, including fastenings, anchor bolts, mortar bedding, etc, as may be required, and for erecting the steel railings, complete as specified.

The unit of measurement shall be either the metre of complete hinge of each type manufactured and installed or the number of complete hinges of each type manufactured and installed. The tendered rates shall include full compensation for supplying all materials, including formwork, manufacturing the hinges, transporting, handling and storing, sealing the hinges, and all labour, equipment and incidentals required for installing the hinges complete as detailed.

Item 66.17 End blocks

Unit

. . . . . . . . . . . . . . . . . . number (No)

Item

Unit The unit of measurement of bridge end blocks shall be the number of end blocks constructed complete in accordance with the drawings.

66.13 Bemangstrips (descr~ption of the material and number of Layers) . . . . . . . . . . . . . . . . . square metre (m 2) The unit of measurement shall be the square metre of bearing area lined with the specified material irrespective of the number of layers placed.

The tendered rate shall include full compensation for all materials, labour, plant, and other incidentals required for constructing the end blocks complete as specified. excluding only reinforcing steel.

Item 66.18 Numbers for structures:

Unit

The unit of measurement shall be the square metre of filter fabric installed as specified, including the specified overlap. The tendered rate shall include full compensation for supplying, cutting and installing the filter fabric, and for waste material.
Item Unit

(a) (b) (c)

Number plates

...............

number (No) number (No)

Painted numbers

..............

Numbers formed in concrete

. . . . . number (No)
6 6 . 2 2 Concrete channelling
(size indicated)

The unit of measurement shall be either the number of bridge number plates provided and installed, or the number of complete numbers painted on the structures, or the number of complete numbers formed in concrete. A bridge number may consist of a combination of letters and digits, eg 81533. The tendered rates shall include full compensation for providing and installing either the number plates, or preparing the surface and painting the numbers, or forming the numbers in concrete, and for all material, labour and equipment required in this connection.

. . . . . . . . . . . . . . . . . .metre

(m)

The unit of measurement shall be the metre of completed concrete channelling of each size constructed. The tendered rate shall include full compensation for providing all the material, all labour, equipment and expenses required for completing the work.

Item
66.23 Crushed stone in drainage strips . . . . . . . . . . . . . . .

Unit

. . . . cubic metre

(m3)

Item 66.19 Drainage pipes and weep holes:

Unit

The unit of measurement shall be the cubic metre of crushed stone placed in position as specified, in accordance with the details shown on the drawings or instructed by the engineer. The tendered rate shall include full compensation for procuring, furnishing and placing the crushed stone, and for wrapping it in synthetic-fibre geotextile as specified. The geotextile will be measured for payment under item 66.21.

(a) (i) (ii) (b)

Drainage pipes: (Type and size indicated) (Type and size indicated) Weep holes: (Type and size indicated) (Type and size indicated)

. . . . . . . . . . metre

(m)

.......

number (No)

(i)
(ii)

. . . . . . . . . . metre (m)
.......
Item Unit

number (No)
66.24 Nose endings at balustrades

.....

number (No)

The unit of measurement shall be either the metre of pipelweep hole or the number of pipeslweep holes of each type and size of pipelweep hole completed. The tendered rates shall include full compensation for supplying all the materials, manufacturing and installing the pipes and making weep holes.

The unit of measurement shall be the number of nose endings constructed complete in accordance with the details shown on the drawings.

Item 66.20 Drainage gulleys (description of each type given) . . . . . .

Unit

The tendered rate shall include full compensation for all labour, constructional plant and materials required, for filling the recesses with concrete or nosing material, 20 m m x 20 m m plastijoint seal between the end block and the transition block, steel cover plate complete with anchor bolts, and all incidentals required for constructing the nose endings complete.

. . . . . . . . . . . . number

(No)
Item 66.25 Concrete transition blocks (length indicated) . . . . . . Unit

The unit of measurement shall be the number of drainage gulleys of each type installed.

.......

number (No)

The tendered rate shall include full compensation for providing all the material and manufacturing and installing the drainage inlets.

The unit of measurement shall be the number of each size of concrete transition block constructed complete in accordance with the details shown on the drawings.

Item

Unit

66.21 Synthetic-fibre filter fabric (type indicated and description) . . . . . . . . . . square metre (m 2)

The tendered rate shall include full compensation for all labour, constructional plant, materials and all incidentals required for constructing the transition blocks.

plant and materials required for installing the bolt groups as specified. 66.26 Supplying and installing bolt groups complete for electrification bra&& (a) (b)

Notes: number (No) number (No) The cost of forming the open joint(s) shall not be (1) included in the rates tendered for items 66.04 and 66.05 as payment for this work shall be made under item 62.06. Separate payment shall not be made for supplying (2) and/or installing the seal in proprietary expansion joints or the seal between concrete or synthetic nosings. (3) Measurement of and payment for concrete sidewalks (including kerbing and coping) shall be made in accordance with clauses 6210. 6310 and 6416.

........... Double-bolt groups . . . . . . . . . . . .

Single-bolt groups . .

The unit of measurement shall be the number of each type of bolt group installed complete in position in accordance with the details shown on the drawings. The tendered rates shall include full compensation for procuring and furnishing all materials, manufacturing, transporting and storing, and all labour, constructional

SERIES 6000 : STRUCTURES SECTION 6700: STRUCTURAL STEELWORK

Other approved friction-grip fasteners equal to the above may be used.

CONTENTS
SCOPE MATERIALS CODES OF PRACTICE SHOP DETAILS FABRICATION AND ASSEMBLY ERECTION TESTING MEASUREMENT AND PAYMENT Mild-steel rivets shall comply with the requirements of SABS 435. High-tensile rivets shall be so manufactured that they can be driven and their heads formed satisfactorily without the physical properties of the steel being impaired.

(e)

Welding consurnables

Welding electrodes shall comply with the requirements of SABS 455.

6701

SCOPE
The quality, handling and storage of all consumables shall be so as to achieve the desirable properties of the weld metal. The welding consumables used shall be appropriate to produce weld metal which will yield all the weld-metal test specimens as specified in BS 709 having both minimum yield and minimum tensile strengths not less than those of the parent metal.

This section covers the manufacture, transport and erection of structural steelwork for minor structures, e g overhead road-sign structures. It does not apply to major steel structures such as steel bridges, which will be covered in the project specifications where work of this nature is required.

(q
(a) Structural steel
shall comply with the following

Test certificates

Structural steel requirements: Mild steel:

The contractor shall submit test certificates, as required by the engineer, of thwstructural steel and anchor bolts that will be used.

BS 4360, grade 43A; or SABS 1431, grade 300W. BS 4360, grade 508; or SABS 1431, grade 350W.

6703

CODES OF PRACTICE

High-yield stress steel:

The design, where undertaken by the contractor, of all work shall comply with the requirements of SABS 0162.

The dimensions and properties of rollei steel sections shall comply with the prescriptions given in the structural steel tables issued by the SA Institute of Steel Construction.

6704

SHOP DETAlLS

@)

Steel tubes

Steel tubes shall comply with the requirements of SABS 657, part 1.

Where shop details have not been furnished on the drawings, the contractor shall prepare his own shop details in accordance with the provisions of clause 1221. Shop details shall be approved and signed by the engineer prior to the fabrication of any items.

(c)

Bolts, nuts and washers

6705

FABRICATION AND ASSEMBLY

Ordinary bolts and nuts shall be bolts and nuts used for transferring forces by tensile stress, compressive stress and shear stress without any friction-grip action being considered. Ordinary bolts and nuts shall comply with SABS 135, SABS 136 or SABS 1143.

(a)

General

All structural steel both before and after fabrication shall be within the tolerances specified in subclause 6803Q) and shall be flat, straight (unless required to be formed to another shape) and free from twists.

Washers for ordinary bolts and nuts shall comply with the requirements of SABS 1i49.

@)
Friction-grip fasteners: High-strength friction-grip bolts, nuts and washers shall comply with the requirements of SABS 1282.

Marking the steel

At all stages of fabrication, all structural steel other than grade 300W and grade 43A steel shall be clearly marked by grade by means of a suitable marking system.

Steel shall be cut b y sawing, shearing with shears, cropping, or flame-cutting. Edges shall be free from any defects or distortions and all burrs, notches and similar defects shall be removed.
(d)

(ii) the welder shall hold a valid certificate of competency in accordance with SABS 044 part V for the specified type of welding. All structural welds shall be full-strength joints. ( i ) Bolting The jointed parts shall be firmly drawn together. Where necessary, tapering washers shall be used for each bolt head and nut to transfer the compressive stress over its full surface. Where bolt holes have greater than normal clearance, washers shall be placed under the bolt heads and nuts.

Holes for fasteners

Holes for fasteners shall not be formed by flame cutting. Holes in light members not thicker than 12 m m or the diameter of the hole, whichever is the smaller, may be punched. Holes for fasteners of up to 25 m m in diameter shall not be more than 2 m m larger than the diameter of the fastener and holes for larger fasteners not more than 3 m m larger than the diameter of the fastener. Holes for friction-grip fasteners shall be in accordance with SABS 094. All burrs shall be removed from holes before assembly.

The length of each bolt shall be such that, after tightening, at least one full thread projects through the nut on the outside and at least one full thread (in addition to the thread run-out) remains clear between the nut and the bolt head.

(j)
(e) Joints in compression

Frictiongrip fastening

The abutting surfaces of joints dependent on contact for the transmission of load shall be accurately prepared so that the full area intended for bearing will be in contact as specified in subclause 6803(j).

The use of friction-grip bolts shall be in accordance with SABS 094. Where use is made of equivalent types of friction-grip fasteners, they shall comply with the requirements of SABS 094 for equivalent fasteners and shall be installed in accordance with the appropriate requirements of SABS 094.

(f)

Hollow sections
(k)

n g ie t v R i

Unless protection against corrosion is provided by other means, the interior of any hollow section shall be sealed to prevent the ingress of moisture. Where a sealed hollow member is holed for a fastener or pin, precautionary measures shall be taken to prevent the ingress of water to the interior of the member. Vent holes for galvanising shall be sealed after galvanising has been completed.

Wherever possible, riveting shall be done with pneumatic equipment. Riveted units shall have all parts firmly drawn together and aligned before riveting. Every rivet shall, when driven, completely fill the hole and shall have a well-formed head or, if countersunk, fill the countersink completely.

@)

Alignment of holes All loose, eccentric-headed, badly formed, burnt or otherwise defective rivets shall be cut out and replaced.

All matching holes for fasteners or pins shall be accurately aligned so that the fasteners can be inserted freely through the assembled members in a direction at right angles to the faces in contact. Drifting for aligning the holes shall not distort the metal or enlarge the holes.

(I)

Trimming

(h)

Welding

All fabricated steel work shall be neatly trimmed so as not to show any sharp edges. Acute angles shall be rounded off to a radius of at least 1 mrn.

Welding shall be done in accordance with the requirements of BS 5135. The welding techniques shall be such as to avoid undue distortion and to minimize shrinking stresses. All slag shall be removed. Where required for certain welding (i) the manufacturer shall hold a valid weldingprocedures certificate in accordance with SABS 044 part Ill for grade B welding joints, and the welding shall be done by a welder qualified in accordance with SABS 044 part IV;

(m) (i)

Corrosion prevention Painting

Before removal from the place of manufacture the steelwork shall be painted as specified in section 8400. Where the finishing coats are to be applied on the site, the shop painting shall include the application of an undercoat as specified in section 8400. Galvanised steel shall not be painted unless painting is specifically called for in the specifications.

(ii)

Sprayed metal coatings

(e)

Repairs to painting and site painting

Where the sprayed metal coating of steel surfaces is called for, it shall be done in accordance with the requirements of SABS 1391 part 1. The type of metal used shall be as specified, and, unless otherwise specified, the metal coating shall comply with the requirements of type Al 150 or type Zn 150. (iii) Galvanising

Repairs to painting and site painting shall be effected in accordance with the provisions of clause 8407.

(9

Grouting

Where the galvanising of structural steelwork is required, the members shall be hot-dip galvanised. Structural steel members shall be given an 85 micrometre coating or such other thickness as may be specified, in accordance with SABS 763 and sheet steel and strip a class M coating in accordance with SABS 934. All nuts, bolts, screws and threaded articles shall be hotdipped galvanised in accordance with the appropriate requirements of SABS 763 for type C1 or type C2 articles. Cut ends and small damaged areas shall be repaired by the application of a zinc-rich paint or by zinc spraying.

The grout shall be poured under and around the base plates of columns after the steelwork has been finally checked for alignment and height and after the approval of the engineer has been obtained to proceed with the grouting. The column base plates shall be supported by the top and bottom nuts and by steel wedges. The area under the steel shall be thoroughly cleaned and shall be dust and oil-free, and the concrete shall be thoroughly rinsed with water to leave the surface clean and moist.

(a)

The grout shall be an approved non-shrinking, pourable, cementitious grout. The grout shall be prepared and applied strictly in accordance with the manufacturer's recommendations and the engineer's directives.

ERECTION

Leak-proof formwork shall be used for the pourable grout, and all corners shall be chamfered. The surface finish shall be class F2 and class U2 as applicable.

General 6707

Where specified, details of the method of erection shall be submitted to the engineer for approval. All structural steel shall be stored, transported, handled and erected so as not to subject it to undue stress or damage.

TESTING

(a)

Testing by the engineer

Erection over traffic is not permitted, and a temporary deviation for traffic shall be provided. Provision for traffic accommodation will be paid for in accordance with the appropriate items under section 1500.

The engineer may nominate a testing authority to inspect the works and to conduct such tests as he may deem to be necessary to test compliance with the specifications. Where required, test samples of welds shall be prepared by the contractor, free of charge.

Payment for these tests shall be made under item 81.02.

@)

Safety during erection

During the erection of a structure, the steelwork shall be bolted, braced or otherwise secured so as to make adequate provision for all erection loads.

@)

Process control

(c)

Alignment

Each part of a structure shall be aligned as soon as possible after erection. Members shall not be permanently connected until sufficiently large members of the structure have been aligned, plumbed, levelled, and temporarily secured to prevent their displacement during the erection or alignment of the remainder of the structure.

Welds shall be regularly inspected and tested by the contractor in terms of his obligations in regard to process control, as described in clause 1205. This shall include visual inspection of welds to ensure that no undercutting, uneven lengths, porosity, or evidence of cracking occurs and that full fusion of the metals has been achieved. In doubtful areas, cores containing weld metal and adjacent parent material shall, if so required by the engineer, be cut out, polished and examined and the hole repaired.

(d)

Corrections

Drift pins, jacking equipment and the like shall not be used for bringing improperly fabricated members into place. A moderate degree of cutting and reaming may be done to correct minor misfits if, in the opinion of the engineer, this will not be detrimental to the appearance or strength of the structure. The burning of holes will not be permitted without written approval.

At least 30% of the welds shall be examined by ultrasonic or radiographic means. If more than 5% of the examined welds show unsatisfactory results, additional examinations covering all welds shall be performed. Certificates of the examination confirming that ihe steel plates and welds comply with the requirements of SABS 044 Part Ill shall be submitted to the engineer.

The cost of testing shall be deemed to be included in the rate tendered for item 67.01 Structural steel.

6708 MEASUREMENT AND PAYMENT

The unit of measurement shall be either the kilogram of installed anchor-bolt assemblies or the number of installed anchor-bolt assemblies. Unit The tendered rates shall include full compensation for the materials, fabrication, handling, transporting and installing the anchor-bolt assemblies, including corrosion protection.

Item 67.01 Struchrral steel:

(a) (b) (c)

(Structurelarticle described) (Structurelarticle described) (Structurelarticle described)

...........

ton (t) (m)

. . . . . . . . .metre
......

number (No)
67.03 Corrosion protection:

The unit of measurement shall be either the ton or the metre of erected permanent steel structures or articles, or the number of erected permanent steel structures or articles. Where the unit of measurement is the ton, the mass of the steel waste caused by punching, drilling, sheared edges, milling or planning, or metal cut-outs shall not be deducted, and the mass of rivets, bolts, nuts, washers, welding fillets or temporary bracing shall not be added. In computing the mass of steel, the nominal mass per unit of length or area will be used and tolerances and other permissible deviations will be ignored. The tendered rates shall include full compensation for preparing shop details where not provided on the drawings, the supply of all the required materials, fabrication, process control, loading, transporting to the site, off-loading, and erecting. It shall also include full compensation for all welding, nuts, bolts, washers, rivets, cutting, waste, and any temporary bracing necessary for transporting and erecting. The tendered rate shall also include full compensation for supplying and pouring the specified grout under and around the base plates of steel columns, for procuring and supplying all the necessary labour, constructional plant, tools and materials, as well as waste, formwork for the grout, and finishing to obtain the required surface finish for the grout under and around base plates of steel columns.

(a) (i)

Sprayed-on metal: (Type of metal and thickness or type symbol of coating indicated) . . . . . . . . . . . . . . . . . . ton (t) (Type of metal and thickness or type symbol of coating indicated) . . . . . . . . . . . . . . . .metre (m) (Type of metal and thickness or type symbol of coating indicated) . . . . . . . . . . . . . number (No) Hot-dip galvanizing: (Thickness or type symbol of zinc coat indicated) (Thickness or type symbol of zinc coat indicated) (Thickness or type symbol of zinc coat indicated)

(ii)

(iii)

(b) (i)

.........

ton (t)

(ii)

. . . . . . . metre (m) ....

number (No)

(iii)

Item

Unit

The unit of measurement shall be either a ton or a metre of steel structures or articles protected against corrosion, or the number of steel structures or articles protected against corrosion. The quantities are calculated as specified in item 67.01.

67.02 Anchor bolts:

(a) (Description of each assembly, and gradeltype of steel, diameter and length indicated) . . . . . . . . . . . . . . . . . . . kilogram (kg) (Description of each assembly, and gradeltype of steel, diameter and length indicated) . . . . . . . . . . . . . . . . . . . number (No) The tendered rates shall be extra over the rates for item 67.01 and shall include full compensation for applying the specified corrosion protection, including surface preparation, materials, labour, tools, equipment and all incidentals required.

(b)

Note:
Payment for painting shall be made under item 84.01.

SERIES 6000 : STRUCTURES SECTION 6800 : CONSTRUCTION TOLERANCES FOR STRUCTURES

distance by which the surface tested may deviate from a straight-edge (or template in the case of curved surfaces) held against the surface.

68W

TOLERANCES

CONTENTS 6801 6802 6803 SCOPE DEFINITIONS TOLERANCES The tolerances given below shall be the maximum permissible deviations from the specified dimensions, levels, alignment, positions, etc, shown on the drawings of the structures or structural members.

6801

SCOPE
(a)

Foundations

This section covers the requirements in regard to the construction tolerances applicable to the various structures and structural members.

Piles: Position

. . . . . . . . . . . . . . . . . 0,167 times the diameter

of the pile, or 100 mm, whichever shall be the greater

6802

DEFINITIONS External dimensions:

Except where otherwise specified, the following aspects of construction to which tolerances apply shall have the meanings attributed to them below:

Prefabricated piles Cast in situ piles

..............

+ 25 m m - 5 m m
plus-tolerance not specified, minustolerance 0 m m

...............

(a)

Position

The position of a structure or structural member shall be the horizontal position of its centre line@) and/or centre point(s) in relation to the overall layout of the works as shown on the drawings.

Pile-head level : Average level of trimmedlcut pile head . . . . . . . . . . . . . . . -c 25 m m Verticality or rake Straightness:

. . . . . . . . . . . . . . . . . . . . . . . . . . 1,5"

@)

Alignment For precast piles the permissible maximum deviation from straight is 5 m m for piles up to 3 m in length and 1 m m more for each additional metre of pile length. Caissons: Position of top of caisson

The alignment of a structure or structural member shall be the alignment of its centre line(s) in relation to the overall layout of the works as shown on the drawings. Deviation from true alignment shall be measured in degrees of an arc.

...............

(c)

Leading and cross-sectional dimensions

The leading and cross-sectional dimensions of a structure or structural member shall be the dimensions relating to width, length, height, thickness, etc, which collectively determine its shape, and are shown on the drawings. Dimensional tolerances not relating to leading or crosssectional dimensions shall be shown on the drawings.

10% of the smallest outer dimension of the caisson, measured in plan.

Verticality

...
.................

Dimensions: Wall thickness

+ 25 m m - 5 m m

(d)

Levels

The level of any structure or structural member shall be the level of the upper or lower surface, as may be relevant, with reference to an established datum-level on the site.

Outer dimension of circular, rectangular or square cross-section . . . . . . . . . . . . . . . . . . . Level: Upper level of trimmedlcut caisson head:

. . .. .

a 25 m m

(e)

Surface regularity Maximum deviation of average level . . . . . .

Surface regularity is the shape of a surface with reference to a 3 m straight-edge (or template in the case of cuwed surfaces) placed on the surface. The tolerance for surface regularity is expressed as a

.................. a

25 m m

Maximum deviation of any individual level . . . . . . . . .

. . . . . . . . . . . . . . a 50 m m

Foundation fill: Average level of top of fill

(d)

Bridge and culvert superstructure

...............

+ 25 m m

Position

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 m m
1 minute

@)

Footings, pile capping slabs, caisson cover slabs, etc

Alignment: Superstructure as a whole . . . . . . . . . . . . . . . . Dimensions: Leading dimensions in plan

Position

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . mm

. . . . . . . . . . . . + 25 m m

Alignment: Alignment of individual members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5" Alignment of members as they collectively determine the alignment of the structure as a whole . . . . . . . . . . . . . . . . . . . . 1 minute Dimensions: Leading dimensions in plan . . . . . . . . . . . . . . . . . . . . . . . . Thickness Thickness of slabs, width and depth of beams: plus-tolerance Minus-tolerance: 3% of the specified dimensions within the range of 5 m m to 15 m m Surface regularity (all surfaces other than upper surface of deck) . . . . . . .

. . . . . . . . . . . . .15 m m

+ 25 m m

. . . . . . . . . . . . . . . . . .3. m m

. . . . . . . . . . . . . . . . . . . . .+

Bridge and culvert decks, surface tolerances: 25 m m - 15 m m The tolerances specified in clause 3405 for the base in respect of level, grade, cross-section and surface regularity shall apply. Surface regularity shall be tested by straightedge.

Levels: Average level of slabs, footings, etc . . . . . . . . . . . . .

. . . . . . . . . . . . + 25 m m

(c)

Columns, walls, piers, abutments, etc (e) Precast beams

Position

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . mm
The following tolerances shall apply to precast beams in addition to the requirements stated in subclause 6803(d) for the superstructure.

Alignment: Alignment of walls, piers, abutments and column groups . . . . . . . . . . . . . . . . . . Dimensions: Leading dimensions of walls, piers and abutments . . . . . . Thickness of walls, piers and abutments and cross-sectional dimensions of columns:

. . . . . . . . . . .2 . minutes
The width of the gap between contiguous beams shall not exceed twice the width of the specified nominal gap shown or, the drawings or the width of the nominal gap plus 40 rnm, whichever is the less, and the overall width between the outermost beams of the bridge deck shall be within 40 m m of the specified width. Straightness or bow: The deviation from the prescribed line measured on the overall length of the beam shall not exceed the following: (i) In the horizontal plane:

............

+ 25 rnm

Minus-tolerance: 3% of the specified dimensions within the range of 5 m m to 25 m m Levels: Average level of finished or trimmedlcut columns, piers, walls, abutments, etc . . . . . . . . . . . . . . . . . . . . . . . . . . + 10 rnm Verticality: (i) Using ordinary : 1 in 400.Maximum 25 rnm formwork Using sliding formwork : 1 in 2OO.Maximum 50 m m

0,5 rnrn per metre length of the beam within the tolerance range of 6 m m to 15 rnm. (ii) In the vertical plane:

(1) I-beams: 2 m m per metre length of the beam within the tolerance range of 6 rnrn to 20 mm. Other beams: 1 rnm per metre length of the beam (2) within the tolerance range of 3 rnm to 20 rnrn. Camber: The soffits of adjacent beams when placed side by side on the bridge deck shall not at any place differ by more than 2 rnrn per metre length of the beam within the tolerance range of 6 rnrn to 20 mm. The lengths of precast beams before stressing shall be + 0,1% of the total length within the tolerance range of r 5 m m to r 20 mm. Surface regularity

(ii)

Surface regularity: (i) (ii) Using ordinary formwork Using sliding formwork

. . . . . . . . . . . . . .3 rnm

. . . . . . . . . . . . . . .6 rnrn

. . . . . . . . . . . . . . . . . . . . . . . .6 . mm

(9

Reinforcing steel

( i )
(i)

Miscellaneous Chamfers

Except for the requirements given below, no tolerances are given for the placing and fixing of reinforcing steel. The steel however, shall be neatly and accurately fixed in a manner which is consistent with proper workmanship and the structural integrity of the structural member. Specifically the following requirements shall apply: (i) Tension steel

Fillets used for forming chamfers shall be within a tolerance of 1 m m in cross-sectional dimensions, and the actual chamfer on the concrete shall not vary by more than 3 m m from the specified dimensions. (ii) Kerbs, copings, sidewalks, bridge railings, parapets, etc

The actual position of tension steel shall not deviate from the true position by a distance which would reduce the effective lever arm by more than 2% of the overall depth of the member, or 10 mm, whichever is the greater. (ii) Concrete cover

The members shall be constructed within a tolerance of +. 5 m m for all dimensions. The alignment shall not deviate from the true alignment by more than 10 m m in any place, nor shall the alignment deviate by more than 5 m m from the true alignment over any length of 5 m.

The concrete cover on reinforcing steel shall nowhere be less than the specified cover. (iii) Spacing between bars

(j)
(i)

Fabrication and assembly tolerances for structural steel General

The spacing between closely spaced parallel bars, especially in beams and columns, shall, unless otherwise specified, be not less than the maximum size of the aggregate used in the concrete. (iv) Bending of reinforcement

The fabrication and assembly tolerances on all dimensions for structural steel shall be +. 2 mm. Holes for connections shall be drilledlpunched and aligned as specified in subclauses 6705(d) and (g) respectively. (ii) Cross-section

The requirements of SABS 82 regarding dimensional tolerances for cutting and bending of the reinforcing steel shall apply, with the proviso that the other requirements set out in this clause shall be complied with even if the tolerances in SABS 82 are not exceeded.

The tolerances on cross-sectional dimensions of rolled sections shall be as specified in the Structural Steel Tables, published by the SA Institute of Steel Construction. (iii) Straightness

@)

Prestressing

Sheaths for prestressing tendons shall be placed and maintained in position within the following tolerances: In the direction of the width of the member: For members of up to 200 m m in depth

A structural member before erection shall not deviate from straightness (or the specified shape) by more than the following: For compression members and beams, one-thousandth of the length between points which are laterally restrained. For other members, one five hundredth of the overall length, but not exceeding 25 mm. (iv) Length

....

c 20 m m

For members exceeding 200 m m in depth

. . + 10 m m

In the direction of the depth of the member: For members of up to 200 m m in depth . . . . . . . . . . . . . . . . . . . . . . . For members exceeding 200 m m in depth . . . . . . . . . . . . . . . . . The length of a member shall not deviate from its prescribed length by more than the following:

+ 0,025 x depth

For compression members faced at both ends for bearing, 5 1 mm For other members,

. . . . . + 0,010 x depth
within the tolerance range of + 5 m m to + 25 mm.

+ 0, - 4 m m

For such members as trusses and lattice girders, the above tolerances shall apply to the members as a whole. The lengths of component parts shall be such that the structural member can be properly assembled with the required accuracy. (v) Bearing surfaces

(h)

Beatings

Bearings for structures shall be installed to within 5 m m of the position shown on the drawings and to within 2 m m of the required level.

Dimensional tolerances for elastomeric bearings shall comply with the requirements of BS 5400 part 9.2.

Where two steel surfaces are required to be in contact for transferring compressive forces, the maximum clearance between the bearing surfaces shall not exceed 1 m m when the members in contact are aligned.

(vi)

Accuracy of erection

Leading dimensions (ii)

........... . .... . . . .

.c 5 m m

Steelwork shall not be out of plumb over any vertical distance by more than 5 m m or one thousandth of the distance, whichever is the greater.

Completed walls:

Surface regularity: When tested with a 3 m straight-edge, the deviation shall not exceed 20 mm. No point of the structure shall be out of position horizontally by more than 50 mm.

Fabrimting and construction reinforcedearth structures

tolerances

for

(i)

Individual concrete panels:

Surface regularity: When tested with a 1,5 m straight-edge, the deviation shall not exceed 5 mm. No point of the structure shall be out of position vertically by more than 10 m m per metre height of the structure, with a maximum of 50 mm.

SERIES 7aJO : SUNDW STRUCTURES SECTION 7100 : C O N C R m PAVEMENTS

SABS 831. Ordinary portland cement 15 FA in accordance with SABS 831. A 50150 mix of ordinary portland cement and milled granulated blast-furnace slag which complies with all the requirements of SABS 626, except for its composition, may be used if approved in writing by the engineer. Granulated blast-furnace slag shall be milled to a specific area of at least 3 500 cm21g. The ordinary portland cement and the milled granulated blast-furnace slag may be mixed in the concrete mixer together with the other concrete components.

CONTENTS SCOPE MATERIALS REQUIREMENTS IN RESPECT OF CONCRETE DETERMINING THE MIX PROPORTIONS BATCHING, MIXING AND TRANSPORTING CONCRETE PREPARING THE UNDERLYING LAYERS GENERAL REQUIREMENTS IN RESPECT OF PLACING AND COMPACTING CONCRETE SIDE-FORMS, RAILS AND GUIDE WIRES PLACING, COMPACTING AND FINISHING WlTH SIDE-FORMS PLACING, COMPACTING AND FINISHING WlTH SLIPFORM EQUIPMENT PLACING, COMPACTING AND FINISHING WlTH HAND EQUIPMENT REINFORCED CONCRETE PAVEMENT SURFACE TEXTURE CURING CONSTRUCTION JOINTS WEAKENED-PLANE JOINTS EXPANSION JOINTS THE SAWING OF JOINTS TIE-BARS AND DOWELS JOINT SEALING TRIAL PAVEMENT CONSTRUCTION TOLERANCES PROCESS CONTROL QUALITY CONTROL AND WORKMANSHIP REMEDIAL WORK OPENING TO TRAFFIC MEASUREMENT AND PAYMENT

The use of other cementitious binders may be allowed by the engineer, provided that it can be proved by the contractor that they perform similarly to the cements specified above, and that the cementitious binders and/or extenders comply with the relevant SABS specifications. Where so specified in the project specifications ordinary portland cement or portland rapid-hardening cement in accordance with SABS 471, may be used in pavement repairs and in replacing sections of the concrete pavements. No ground granulated blast-furnace slag shall be used for this purpose.

The requirements of subclause 6402(d) shall apply.

(c)

Aggregates for wnaete

Aggregates shall comply with the requirements of SABS 1083 but subject to the following:
(i) The drying shrinkage of concrete samples made from each of the required three concrete mixtures for preparing the compressive-strength and flextural-strength samples in accordance with clause 7104(b) shall not exceed 0,040%. Drying-shrinkage tests shall be conducted in accordance with SABS method 1085.

7101

SCOPE

This section covers the construction of concrete pavements for roads, and includes, inter alia, the specifications for materials, the placing and compacting of concrete, applying the surface texture, and the constructing of joints. This section also includes requirements for repairing existing pavements, cleaning and resealing existing joints, repairing cracks in existing concrete pavements, and retexturing pavement surfaces. Section 7100 does not apply to the large-scale rehabilitation of concrete pavements. The extent, positions, dimensions and specifications for the work are as shown on the drawings and described in the project specifications.

Where the drying shrinkage exceeds the specified maximum value, either alternative aggregates shall be used, or further investigations shall be made, or evidence shall be produced with a view to confirming the suitability of the aggregates proposed for use. The historical behaviour of the aggregate in concrete may serve as a recommendation in such cases. Coarse aggregate shall comply with the 10% FACT (ii) values specified for aggregate used in concrete subject to abrasion. In addition, the aggregates shall comply with the following requirements:

7102

MATERIALS

(a)

Cement The fine aggregate shall be either a natural or (1) crusher-produced sand or a blend of natural and crusher sands where a mixture is used, and the quantity passing through each of the 0.150 mm and 0,075 m m sieves shall not exceed the relevant interpolated values for the approved blend. Where required by the engineer the fine aggregate shall contain more than 2096 quartz by mass.

Cement used for concrete shall be any one of the following: Ordinary portland cement in accordance with SABS 471 Ordinary portland cement 15 SL in accordance with

The acid insolubility of the sand or the mixes of (2) sand types as determined b y the test described in subclause 8105(b) shall exceed 40%. The fineness modulus of the fine aggregate (or (3) mixtures thereof) shall not deviate from the approved fine aggregate (or mixtures thereof) by more than 0,20. (4) Aggregates shall not contain any deleterious quantities of organic material, particu:arly pieces of timber, which will cause unacceptable surface defects when they float to the top of fresh concrete during vibration. The nominal sizes of coarse aggregate shall be as (5) follows: Slab thickness of 175 m m and over: 37,s mm, plus one or more of the following: 19,O mm, 13,2 m m and 9,5 mm. Slab thickness of 150 m m and over but less than 175 mm:

requirements of SABS 1023. The seals shall be manufactured in accordance with an extrusion process, from an elastomeric material consisting entirely of polychloroprene which is subsequently vulcanised. (ii) Joint filler for expansion joints

Joint filler for expansion joints shall be manufactured from a closed-cell polyethylene and the filler strips shall be provided with tear-off cover strip. The joint filler shall comply with the requirements of AASHTO M 153, and the particular type used shall be subject to the engineer's approval. (iii) Silicone sealant

The silicone sealant shall be a one-component material with low-modulus properties which comply with the following requirements: Tensile stress at 150% expansion determined in accordance with ASTM D 412 (Matrix C) after seven days' curing at 23C ? 2 C . . . . . Extrusion rate, tested with a pneumatic caulking gun with a 3,18 m m nozzle at a pressure of 0,62 MPa Material temperature - 18C . . . . . . . . . . min 75 glmin Material temperature 38C . . . . . . . . . . . max 250 g/min Relative density determined in accordance with ASTM D 794 Method A . . . . . . . . . . . . . . . . . . . . 1,01 to 1,515 Durorneter hardness determined in accordance with ASTM D 2240 at -18"C after 7 days' curing at 23C 2 C and relative humidity 50% ? 5% . . . . . . . . . . . . . Shelf life

. . . . . . . . . 0 3 1 MPa max

Slab thickness of 100 m m and over but less than 150 mm:

* Where recommended by an approved laboratory, smaller sizes of stone (nominal 26,5 m m and 19,O mrn sizes) shall be provided.
The flakiness index of the coarse aggregate, as (6) determined by the TMHl method B3T, shall not exceed 35.
(7) Where there is any danger of a particular combination of aggregate and cement giving rise to a harmful alkali-aggregate reaction, the particular combination shall be tested in accordance with the testing method as described in subclause 8105(f), and, where the result points to such reaction, either the aggregate or the cement or both shall be replaced so that an acceptable combination may be obtained.

. . . . . . . . . .8 - 20 Shore A
after manufacture

. . . . . . . . . . . . . . . . . . . . . at . least 6 months

(d)

Pdrnixtures to concrete
Ozone and UV resistance determined in accordance with ASTM D 793-75 . . . .

No admixtures shall be used without the written permission of the engineer. Any admixtures used shall comply with the requirements of ASTM C 494 (AASHTO M 194) for chemical admixtures, or ASTM C260 (AASHTO M 154) for air-entraining admixtures, and shall be of an approved type and brand. In addition, admixtures shall be subject to such tests as may be prescribed by the engineer, carried out at an approved testing laboratory at the contractor's expense to determine the effect of the admixture on the concrete mix including early strength development. Admixtures containing calcium chloride shall not be used.

. . . . . . . . . . .no pulverisation,
cracking or loss of bond after 5 000 hours

Adhesion to cement-mortar briquettes determined in accordance with clause 8113

. . . . . . . . . . 0 3 4 MPa min

Non-adhesion period determined in accordance with clause 8113 . . . . . . . . . . . . . . . . . . . . . . . .max 90 rnin Deformation capability and adhesion in accordance with clause 8113

(e)

Materials for joints

. . no adhesion or
cohesion after 10 cycles at -18C

(i)

Preformed elastomeric compression seals

Preformed elastomeric compression seals used for sealing sawn and expansion joints shall comply with the

Colour

...

.........

Grey

The contractor shall submit a certificate, less than six months old, from an approved testing laboratory, certifying that the sealant conforms to all the specified requirements. (iv) Additional materials for silicone sealant

The curing compound shall be capable of hardening within 30 minutes of having been applied and of being sprayed onto a wet surface without loss of stability, change in colour or becoming less efficacious. This characteristic shall also be confirmed by the approved testing laboratory.

The sealant shall be supported by a bond breaker backing strip, and, unless otherwise recommended by the manufacturer and approved by the engineer, the faces of the joint groove shall first be treated with a primer. Supporting and priming materials shall be compatible with adiacent materials or surfaces in contact with the materials and shall be in accordance with the recommendations by the manufacturer and subject to approval by the engineer. Any primer used shall form a barrier layer between the silicone and the concrete. (v) Liquid sealant for joints between concrete or asphalt pavement

7103

REQUIREMENTS IN RESPECT OF CONCRETE

(a)

General

The contractor shall be responsible for providing suitable materials, determining the mix proportions, and manufacturing the concrete of the required quality. The specifications contained herein for materials to be used for concrete shall not limit the contractor's responsibility to manufacture concrete which complies with the requirements of these specifications. If the contractor finds it necessary to work to more stringent tolerances than those specified, or that the aggregates have to be processed in any way (eg by washing or sieving) to permit or to facilitate paving operations, all costs resulting therefrom shall be for the contractor's account. However, if the contractor is of the opinion that the requirements of the specifications regarding the materials to be used will prevent him from manufacturing concrete of the required quality, he shall submit the necessary supporting evidence to the engineer. If such evidence is acceptable to the engineer, he may amend certain requirements of the materials specification.

The liquid sealant used in joints between concrete and asphalt pavement shall be of the hot-poured type and shall comply with the requirements of US Federal Specification SS-S-1401. (vi) Lubricant adhesive for compression seals

The lubricant adhesive used for inserting neoprene compression seals shall comply with the requirements of ASTM D 2835. (vii) Materials for cleaning, repairing and resealing existing joints and repairing cracks

@)
Materials used for cleaning existing joints and for repairing and sealing or resealing joints and cracks shall comply with the provisions of the project specifications. Cleaning agents shall be such that they will not stain the concrete or cause the existing bituminous or other material to soak into the concrete.

Maximum water:cernent ratio

The water:cement ratio shall not exceed 0,53.

(c)

Minimum cement content

The cement content of the mix shall be not less than 320 kglm3.
(f)

Reinforcing steel, tie-bars and dowels (d) Specified strength

Reinforcing steel, tie-bars and dowels shall comply with the requirements of clause 6302 and SABS 920. Tie-bars shall be deformed mild-steel bars or deformed high-yield steel, except that any tie-bars bent and later on straightened shall be hot-rolled deformed mild-steel bars.

The specified compressive strength shall be the highest of the following four values: (i) 35 MPa at 28 days; or

Dowel bars shall be mild-steel bars having a smooth, circular section produced on a Kocksblock to Vi DIN tolerance of the DIN 1013 specification.

(ii) 0,85 f c l where f c l is the 28-day compressive strength corresponding to a 28-day flexural strength of 4,5 MPa. (iii) 0,85 fc2, where fc2 is the 28-day compressive strength corresponding to a water:cement ratio of 0,53.

@)

Curing compound (iv) 0,85 fcg, where fc3 is the 28-day compressive strength corresponding to a cement content of 320 kg/mJ. f c l , fc2 and fc3 shall be the 28-day compressive strengths determined from laboratory mixes as set out in clause 7104.

The curing compound used shall be a white-pigmented resin-based curing compound containing no water and which complies with the requirements of ASTM C 309, except that the water loss requirement be substituted with the efficiency-index as determined in accordance with BS 7542. The efficiency-index shall exceed 90% at an application rate of 0,2 l / m 2 . A recent certificate from an approved testing laboratory shall be submitted, certifying that the curing compound complies with the specifications. Further testing shall be conducted at regular intervals.

(e)

Workability of the concrete

The mix proportions and consistence of the concrete mix

shall be such that, with the equipment in use, the concrete can be fully compacted without bleeding or segregation of the components. The concrete consistence shall be suited to the type of paving equipment used, the haul, the weather and the site conditions. Where consistence is measured by way of a slump test in accordance with TMHl method D3, the slump shall not deviate by more than 20 m m from the optimum value for mixes with a target slump of 35 m m or greater. Where the consistence of the concrete is such that the expected slump is less than 35 mm, the consistence of the concrete shall be determined by means of the Vebe test in accordance with BS 1881, part 104.

(c)

Changes in the mix proportions or the materials

If during the progress of the work the requirements (i) set out in clause 7103 are not being met by concrete manufactured from the materials or material mix proportions being used, the contractor shall immediately cease producing such concrete and shall effect such changes to the mix proportions and/or materials as may be necessary, in order to meet those requirements. If during the progress of the work the contractor (ii) wishes to use materials or mix proportions other than those originally approved, or if the materials from the sources originally approved change in regard to properties, he shall before proceeding with further work, submit adequate evidence to the engineer that the new materials or combination of materials will produce concrete which complies with the requirements of clause 7103 and will not bring about detrimental changes in the properties of the concrete. Any such changes made shall be at the contractor's (iii) expense, and no extra payment will be allowed by reason of such changes. Where concrete is placed by hand and vibrated or (iv) finished with hand equipment, the requirements of clause 7103 shall remain applicable irrespective of the size of the concrete panel or concrete patch placed. The mix proportions, however, shall be adjusted to promote hand placing, vibrating and finishing, and only if the contractor has produced written proof to the engineer that the requirements of clause 7103 cannot be complied with under the circumstances, will the engineer change the requirements in accordance with subclause 7104(d) at his own discretion.

(f)

Air content

Where the contractorwishes to use an air-entraining agent, the total air content in the freshly mixed concrete shall be M + 1%, where M is the target value within the limits of 2% to 4%. Tests shall be conducted in accordance with TMHl method D5 (pressure method).

7104 DETERMINING THE MU<PROPORTIONS

(a)

General

The preliminary proportions of cement and aggregate required for producing concrete which complies with the requirements of these specifications, shall be determined by way of laboratory tests on concrete manufactured from the cement, coarse and fine aggregates, admixtures (if any) and water proposed for use in the works.

@)

Preliminary tests

(d)

Changes in requirements

At least sixty days prior to the construction of the trial pavement, as specified in clause 7121, the contractor shall submit to the engineer samples of all the components of the concrete he proposes to use, and a report b y an approved testing laboratory showing the mix proportions proposed for each combination of material sources for the concrete. The report shall also show the following: The results of tests on the specified properties of all (i) components.

The engineer shall have the power, at any time during the progress of the work, to order changes in the requirements set out in clause 7103. In such cases the contractor shall be compensated in accordance with the terms of the contract for the additional cost of materials or additional handling, placing and/or other costs, if any, entailed b y such changes. If such changes result in savings, the engineer shall recover such savings from the contractor.

7105

The relationship between the 28-day compressive (ii) strength and flexural strength of the concrete at each of at least three water:cement ratios namely 0,48; 0,53 and 0,58. (iii) The effect of the particular admixture (if any) proposed b y the contractor in regard to variations in admixtures, air content (if air entraining) and concrete setting and sawing times. The effect of at least three water contents on (iv) concrete consistence.

BATCHING, CONCRETE

MIXING

AND

TRANSPORTING

All concrete for concrete pavements shall be manufactured by the contractor at the site of the works. The contractor will not be allowed to purchase concrete from a commercial supplier.

(a)

Storing the materials

In determining the relationship between compressive and flexural strength, the tests shall be based on not less than six compressive-strength specimens and six flexuralstrength specimens for each water:cement ratio. All strength tests shall be conducted in accordance with TMHl method Dl (cubes) and SABS method 864 (beams).

Aggregates shall be stockpiled and handled in such a manner that the various sizes of aggregate will not be mixed and that the coarse and fine fractions of each size of aggregates will not segregate. Cement shall be stored in a silo or in a dry weatherproof shed with a raised wooden floor, and each consignment shall be stacked separately. Cement shall be used in the

order in which it has been delivered at the site. The various types of admixtures shall be properly marked and stored separately.

It shall be protected against rain, heat, direct sunlight and/or evaporation by means of covers on all open vehicles. No additional water may be added in transit or where delivered.

@)

Roportioningthe components

All components shall be accurately proportioned in approved automatic proportioning devices to within the following tolerances, and supplied separately at the mixing drums. Cement

The time lapse from the moment when the cement and aggregate are intermingled up to the time of placlng and compacting the concrete shall not exceed 60 minutes when concrete is transported in truck agitators, and shall not exceed 45 minutes in mild weather or 30 minutes when the concrete temperature is 30" C or higher when transported in ordinary trucks.

k 2% of the prescribed mass of cement.

7106

PREPARING THE UNDERLYING LAYERS

Aggregate

Each fraction within .c 3% of the prescribed mass of the fraction in question.

(a)

General

Water

+ 2% of the prescribed volume or mass.

:
Admixtures shall be admixed in part of the mixing water after having been carefully measured in an automatic proportioning device capable of proportioning the admixture in quantities which will not deviate by more than 2% from the required quantities, and shall be done so as to spread the agent uniformly throughout the entire concrete mix during the mixing process.

Admixtures

The underlying layers shall be constructed in accordance with the standard specifications and the project specifications up to the level of the underside of the concrete slab.

The contractor shall note the provisions of clause 1220 in regard to the use of construction tolerances for successive pavement layers and shall make provision in hls prices for any additional concrete which may be necessary in respect of irregularities in the layer underlying the concrete pavement.

@)

Applying the prime coat

(c)

Mixing the conBatch mixing

(i)

All concrete shall be mixed in mechanically operated batch mixers. The mixing period shall be at least 90 seconds, but may be reduced to as little as 50 seconds by the engineer if he is satisfied that, on the basis of site tests, the reduced mixing period is adequate. The production capacity of the mixing plant shall be in accordance with the capacity of the paver used. Where the mixing plant is supplied with more than one drum, the same unit shall be used for proportioning the components.

Unless otherwise specified in the project specifications, a bituminous prime coat shall be applied to the completed and approved subbase as specified in section 4100 at a rate of application ordered by the engineer. Before any pavement concrete is placed, the prime coat shall be checked and any areas having deficient or poor prime, or where the prime coat has been damaged, shall be repaired as directed by the engineer. The primed surface shall then be thoroughly cleaned. The prime coat shall be dry before any reinforcing steel, tie bars, dowels or concrete may be placed.

(c)

Wetting the subbase

The drums shall always be kept clean, and all build-up shall be removed. The total period between the time that the cement is placed in the drums until mixing starts shall not exceed 15 minutes. (ii) Transit-mixing

The subbase shall be kept continuously wet for a period of at least one hour before the concrete is placed. Immediately before the concrete is placed, the excess water shall be broomed off the road ahead of the paver so as to ensure that the subbase will still be damp when the concrete is placed, but no puddles of water or deleterious matter shall be left on the road.

The contractor will be permitted to use appropriate truck mixers which agitate previously mixed concrete in transit.

(d)

Preparing the underlying layers for the purpose of rehabiliition work

(d)

Transporting the concrete

Preparing the underlying layers after the existing (i) concrete has been removed during rehabilitation work.

Concrete shall be so transported to its final position that segregation or loss of any of the ingredients, or contamination will be prevented and that the mix is of the required workability at the point and time of placing.

Where the underlying layers do not have to be removed or reworked after the existing concrete pavement has been removed, it shall be prepared as follows:

(1)

Underlying layers of cemented material

in accordance with the provisions of sections 3200 and 3600 for pavement layers of crushed stone. (iv) Reconstructing underlying rehabilitation work layers during

Where the layer consists of cemented material or cemented crushed stone In accordance with the classification of clause 3803, and unless otherwise lnstructed by the engineer, its surface shall be swept clean and all loose, soft or poorly cemented material shall be removed. A primer shall then be applied as specified in section 4100. The type of primer and the rate of application will be prescribed by the engineer. No primer may be spllt onto the existing concrete pavement. After the primer has dried out sufficiently, the surface shall be tested for irregularities In all directions with a 3 m straight-edge. All holes and depressions where the surface deviates by more than 25 mm from the bottom side of the 3 m straight-edge shall be filled in with fine asphalt or coarse slurry as specified in section 4800. The asphalt or slurry shall be thoroughly compacted with compaction plant and finished flush with the surface of the layer. The asphalt and slurry shall comply with the requirements of sections 4200 and 4600 respectively. The engineer will prescribe the grade and composition of the asphalt and slurry. The surface shall then be thoroughly cleaned immediately before the new concrete is placed. (2) Underlying layers of asphalt

Where required, the underlying layers shall be reconstructed with fresh material, and the provisions of sections 3200 and 3400 shall apply to all gravel layers, and the provisions of section 3600 shall apply to pavement layers of crushed stone. The provisions of section 4200 shall apply to asphalt layers. (v) Stabilization during rehabilitation work

Where the stabilization of the underlying pavement layers is required, the stabilizing agent shall be mixed with the pavement material in a plant or concrete mixer suitable for this purpose. The provisions of section 3500 will remain applicable for the rest.

7107

GENERAL REQUIREMENTS IN RESPECT OF PLACING AND COMPACTING CONCRETE

(a)

Compacting

The layer shall be cleaned and all damaged and loose sections removed. A tack coat shall then be applied and all depressions and holes filled with asphalt in accordance with the requirements of subsubclause 7106(d)(i)(l). The surface shall then be tested for irregularities in all dlrections with a 3 m straight-edge, and the surface may not deviate by more than 25 mm from the bottom edge of the straight-edge at any point. Where the surface is too small for a 3 m straight-edge, a shorter straight-edge shall be used. The levels of the layer shall be such that the concrete pavement constructed on it will comply with all the tolerances applicable thereto. Where so lnstructed by the engineer, a tack coat (30% stable-grade bitumen emulsion) shall be applied to the underlying layer immediately before the concrete is placed. The engineer will prescribe the rate of application of the tack coat. (ii) Removal of existing pavement layers during rehabilitation work

The concrete shall be fully compacted by means of approved equipment and shall be free from honeycombing and planes of weakness. The average amount of air voids as measured in concrete cores shall not exceed 3% when measured by the visual assessment method described in the publication: Concrete Society Technical Report No 11 : Concrete Core Testing for Strength. Over-vibration resulting in segregation, surface laitance, or leakage (or any combination of these) will not be acceptable. No paving in the downhill direction will be allowed if tearing of the concrete occurs. The contractor shall take the necessary measures to the satisfaction of the engineer to prevent tearing of the concrete for example by carrying out the paving in the uphill direction.

@)

Time for placing and compacting

Where required, existing pavement layers shall be removed. The provisions of section 3800 shall apply mutatis mutandis to such work, excepting that milling work and the re-use of excavated material shall not be a requirement, except where it is specified in the project specifications. (iii) Recompaction of existing pavement layers during rehabilitation work

The placing, compacting and finishing of the concrete shall be carried out as quickly as possible, and the operations shall be so arranged that in any transverse section of the pavement, the concrete shall be fully compacted and finished within 2,5 hours of having been mixed. This time shall be reduced by half an hour for every 5C by which the concrete temperature is above 20C at the time of placing, unless otherwise permitted by the engineer. Unless adequate lighting facilities, approved by the engineer, are provided beforehand by the contractor, the placing of concrete pavement shall cease in good time so that the finishing operation can still be completed during daylight hours.

Where required, the contractor shall break up and recompact existing pavement layers to the density specified in the project specifications. The provisions of section 3800 shall apply mutatis mutandis to the breaking up of the material. The processing and compacting of the material shall be done

( c )
(i)

Adverse weather
Protection against rain and hail

No concrete shall be placed during rainy weather. For the

concrete to be properly protected against rain and hail before it has sufficiently hardened, the contractor shall have available at all times frame-mounted waterproof covers for protecting the surface of the unhardened concrete. In addition, when slipforms are used, the contractor shall also provide acceptable emergency protection for the slab edges. When rain appears to be imminent, all paving operations shall cease and the contractor shall take the necessary steps to protect the unhardened concrete. The contractor shall be responsible for the repair of any damage to the concrete, the texturing or the curing compound that may occur. (ii) Cold-weather paving

7108

SIDE-FORMS, M L S AND GUIDE WIRES

(a)

Side-forms

All reasonable precautions shall be taken to prevent the temperature of the pavement concrete from falling below 5C during the first 48 hours after casting. When prevailing temperatures are low or when cold weather is forecast and there is a danger that the temperature of the freshly constructed concrete pavement will fall below the prescribed limits the contractor shall either cease all pavement operations, or he may be permitted to proceed, provided that the engineer is satisfied that adequate protective measures are available and will be taken to ensure that the temperature of the pavement will be maintained above 5C for the period stated. (iii) Hot-weather paving

Side-forms and rails shall be so designed, manufactured, set and supported that the completed concrete pavement will comply with all the requirements of clause 7122. Where the forms are tested with a 3 m straight-edge, the top edge shall not deviate by more than 3 m m at any place, neither the sides by more than 6 mm. The sides shall not deviate by more than 3 m m from the vertical. The height of the side-forms shall not be less than the nominal thickness of the concrete slab less 15 mm, and the resulting opening between the side-forms and the layer on which it is supported shall be caulked with a stiff mortar consisting of one part of rapid-hardening cement and 3 parts of sand by volume and finished vertically on the inside, and the mortar shall have hardened before any concrete may be cast against it. The rails, side-forms and running surface shall be kept clean in front of the wheels of all paving equipment.

When paving is done during hot weather and when the temperature of the fresh concrete can be expected to exceed 24"C, the contractor shall implement appropriate precautionary measures to place the concrete at the coolest temperature practicable. Paving operations shall cease when the concrete temperature as discharged at the paver exceeds 32C. (iv) Responsibility for protection

Side-forms shall not be removed before the concrete has hardened sufficiently to prevent damage being done to the sides and loosening of tie-bars or dowels, if any, and not earlier than 6 hours after the completion of the construction of the slab. The side-forms shall also be removed timeously to permit the sawing of transverse joints up to the edges of the concrete slab.

Projecting tie-bars and/or the concrete shall not be damaged during removal of the side-forms. Before any side-forms may be ordered or brought onto the site, particulars regarding the side-forms shall have been approved by the engineer.

The contractor shall be responsible for the quality and strength of the concrete placed and for its protection, and any concrete damaged by adverse weather (eg any combination of high ambient temperature, low humidity, wind, rain and hail) shall be removed and replaced at the contractor's expense.

@)

Rails

The wheels of spreading and finishing machines and frame-mounted covers shall not run directly on the top surface on the side-forms but on rails rigidly attached to the forms, unless the forms are specially made to double as rails.

(d)

Maintaining continuity during placing (c) Electronic control systems

The contractor shall make adequate advance arrangements for preventing delay in delivering and placing the concrete. An i n t e ~ a of l more than thirty minutes between the placing of any two consecutive batches or loads of concrete shall constitute sufficient reason for the engineer to have the paving operations stopped, and the contractor shall, then at his own expense, make a construction joint in the concrete already placed, at the location and of the type directed by the engineer. Paving operations shall be continuous, and the rate of paving shall be adjusted to suit the rate of delivery of the concrete.

Where a slipform paver is used, the alignment levels for placing the concrete, shall be controlled automatically from guide wires by sensors attached at the four corners of the slipform paving machine. The alignment and level of ancillary machines for finishing, texturing and curing shall be automatically controlled relative to the guide wires and to the surface and edges of the slab. Guide wires shall be so designed, manufactured and fixed that the paver will be capable of producing a completed slab which will comply with the requirements of clause 7122.

(e)

Width of placing

The width of concrete pavement strip to be placed in a single uninterrupted operation shall be as shown on the drawings or specified in the project specifications.

Other control methods will also be considered, and should the engineer be satisfied that they will produce satisfactory results, their use will have to be approved in writing.

(d)

Inspection of sideforms, guide wires and rails

Before any concrete may be cast, the engineer shall approve all assembled side-forms, guide wires and rails. For this purpose the engineer shall be given sufficient notice and opportunity. Approval by the engineer will not relieve the contractor of any of his obligations to construct the concrete slab in accordance with the specified dimensions and tolerances.

with a straight-edge of at least 3 m in length. Irregularities indicated by the straight-edge shall be removed with a long-handled hand-operated scraping straight-edge of at least 3 m length. A gangplank shall be used when walking on the concrete.

(d)

Constructing the concrete pavement in more than one contiguous strip

7109

PLACING, COMPACTING AND FINISHING WlrH SIDE-FORMS

The paving train shall consist of several powered machines which spread, compact, finish, texture and cure the concrete in a continuous operation.

(a)

Placing and spreading

Where concrete is placed adjacent to an existing pavement, that part of the paving equipment running on the existing pavement shall have flanged wheels on flatbottom section rails weighing not less than 15 kg/m or by replacing the flanged wheels on that side of the machines by smooth flangeless wheels. Before the paving operation commences the surface regularity of the existing pavement shall comply with clause 7122 (f) and be thoroughly cleaned and brushed to remove all extraneous materials. The wheels shall run at a distance of not less than 300 m m from the edge of the pavement to prevent the pavement edge from spalling or cracking. No equipment shall be run on the existing pavement until the concrete is strong enough to prevent damage from occurring, but in any case not earlier than 14 days after the construction of the slab. Where visible cracks occur or any other damage is done to the pavement, further work involving the paver shall be suspended immediately. The contractor shall repair all damage at his own cost.

The concrete shall be spread uniformly by means of a purpose-made mechanical hopper spreader running on rails, and capable of spreading the concrete uniformly to a specified level and to a uniform uncompacted density over the entire surface of the slab. The machines shall be capable of being rapidly adjusted for changes in slab thickness or crossfall.

@)

Compaction

The concrete shall be fully compacted by vibration or by a combination of mechanical surface vibration, internal vibration and tamping. The power supply to the vibrators shall cut out automatically as soon as the compaction equipment stops moving. Suitable internal vibrators shall be used against the sideforms and at joint assemblies to ensure compaction throughout the pavement layer.

7110

PLACING, COMPACTING AND FINISHING WITH SUPFORM EQUIPMENT

(a)

General

(c)

Final finishing

Slipform paving equipment shall be used for spreading, compacting, floating and finishing the concrete in a continuous operation and in such a manner that a minimum of finishing by hand will be required and a dense and homogeneous concrete to the proper level and grade will be produced.

The surface of the concrete shall be finished smooth and true to grade and level by means of an initial finishing machine equipped with a transverse or oblique oscillating beam. The final finish of the surface of the slab shall be carried out by a machine which incorporates twin oblique oscillating finishing beams. The beams in the case of both machines shall be readily adjustable for both height and tilt. The leading beam shall be vibrated. The beam shall be supported on a carriage with two wheels on either side, at least 3,5 m apart in the longitudinal direction. The oscillating beams shall be of rectangular section, spanning the full width of the slab and each weighing not less than 170 kgim. Hand-finishing of the concrete surface shall be reduced to the absolute minimum and shall be used only to correct minor imperfections and marks on the surface. Before the concrete starts setting, all pavement edges, and the edges of joints shall be rounded off to the prescribed radius. After finishing, the contractor shall test the concrete surface

@)

Placing and spreading the conuete

The concrete shall be deposited without segregation ahead of the paver across its whole width and to a height which at all times is in excess of the required surcharge. The deposited concrete shall be struck off to the necessary average and differential surcharge by means of a strike-off plate or screw auger device extending across the entire width of the slab. The strike-off equipment shall be capable of being rapidly adjusted for changes in slab thickness or crossfall.

(c)

Compacting and finishing

The slipform paver shall compact the concrete over the full paved width by means of internal vibration only or by a combination of internal and surface vibration. The vibration shall be variable with a maximum energy output of at least 2.5 kN per metre width of slab per 300 rnrn depth for a laying speed of up to 1,5 m per minute or pro

rata for higher speeds. The level and grades of the surface shall be automatically controlled within the prescribed tolerances by means of a sensing device running on guide wires as specified. The consistence of the concrete shall be so controlled that the edge slump will not exceed the tolerance specified in subclause 7122(e). If approved by the engineer, metal side-forms of sufficient thickness may be used to maintain the proper shape and line.

(d)

Compacting and finishing

After the concrete has been finished by the finishing devices incorporated in the slipform paving equipment, the surface of the concrete shall be checked by means of a straight-edge of not less than 3,O m in length. High spots indicated by the straight-edge shall be removed by hand floats.

The concrete shall be compacted by means of vibrating finishing beams. In addition, internal poker vibrators shall be used for slabs thicker than 150 mm. Where used, the pokers shall be inserted at points not more than 500 m m apart over the whole area of the slab, and adjacent to sideforms or the edge of a previously constructed slab. The surface shall be regulated and finished to the level of the sideforms or adjacent slabs by using twin vibrating beams. The beams shall be of metal with a contact surface at least 50 m m wide and a vibrating unit having a minimum centrifugal force of 4 kN with a frequency recommended by the manufacturer or an equivalent compactive effort. The vibrating beams shall be moved forward at a steady speed of 0,s m to 1,O m per minute whilst vibrating over the compacted surface, to produce a smooth finish. The surface shall then be further smoothed by at least two passes of a scraping straight-edge with a blade length of not less than 2,4 m. The final surface finish of the concrete shall be effected by means of hand-operated floats. The finishing of the concrete surface shall be to the same standard asspecified in clause 7122.

After the final finishing and texturing of the concrete, but before curing, the pavement edges shall be rounded to the prescribed radius.

(d)

Constructing the concrete pavement in more than one contiguous strip

Except for the wheels, which are in the case of slipform pavers to be replaced with rubber cushioned crawler tracks, the provisions of subclause 7109(d) shall apply when concrete is being placed in more than one contiguous strip.

7 112

REINFORCED CONCRETE PAVEMENT

(a)

General

(e)

Track support

The term "reinforced concrete pavement" in this context shall mean isolated reinforced slabs incorporated in a pavement which is generally unreinforced.

The contractor shall at his own cost ensure that adequate track support is provided to suit the needs of the slipform paver, either by extending the upper pavement layers or by providing alternative support layers.

@)

Reinforcement

7 111

PLACING, COMPACTING AND FINISHING WITH HAND EQUIPMENT

Reinforcement shall be su, 2orted on prefabricated stools or supports or in any other manner approved by the engineer. The supports shall be capable of maintaining the reinforcement in the positions and at the depths shown on the drawings.

(a)

General
7 113

SURFACE TEXTURE

Where the slabs are too small or irregular, or the site is so restricted as to render the use of the methods described in clauses 7109 and 7110 impracticable, concrete shall be placed, compacted and finished by means of hand-guided twin vibratory beams and poker vibrators. If necessary, the consistence of the concrete shall be adjusted so as to be suitable for placing with hand operated equipment.

(a)

General

After the concrete has been placed, spread, compacted, finished and completed and before the curing membrane is applied, the surface of the concrete shall be provided with a surface texture. The direction of texturing shall be at right angles to the longitudinal axis of the pavement. The surface texture shall be applied and completed before the concrete is so hard that the surface will be torn and coarse aggregate unduly loosened during texturing.

@)

Forms

Side forms complying with the requirements of clause 7108 shall be used.

(c)

Placing and spreading the concrete

@)
The concrete shall be placed and spread uniformly to a surcharge of about one-fifth more than the final pavement thickness and shall then be compacted, struck off and finished to the level of the side forms.

Equipment

The required texturing shall be effected by means of a machine which spans the full width of the concrete pavement, and which is guided in regard to both level and

direction by the rails in the case of sideform construction or by the paver guide wires in the case of slipform construction. (i) Burlap drag equipment

The engineer may permit the use of texturing equipment other than the grooving comb, provided that it produces a texture similar to that produced by the metal tines.

(d)

Hand texturing

Unless otherwise authorised by the engineer, the burlap drag shall be attached to the front of the texturing machine or to an additional machine which spans the full width of the concrete pavement and is placed in such a way that the full width of the concrete pavement is covered in one operation and, when not in use, the entire drag can be lifted clear off the pavement. The dimensions of the burlap drag shall be such that at least 1,O m of the material is in contact with the surface of the concrete pavement measured in the direction in which the drag is being moved. The burlap drag shall consist of at least two layers of approximately 340 glrn2 burlap with the bottom layer at least 150 m m longer than the top layer at the dragging end; however, at the discretion of the engineer, the number of layers may be increased to four. The transverse threads of the trailing 150 m m to 300 m m of the burlap drag shall be removed. (ii) Tine grooving device (grooving comb)

Texturing the surface with hand-held brooms or combs shall be allowed only where the pavement is so small or irregular, or the site is so restricted as to make the use of the texturing machine impracticable, or in cases of mechanical breakdown of the texturina machine, in which case it may be used for the required texturing of concrete already placed. The brush or comb to be used then shall be of the same type and width used in the machine.

In order to ensure straight grooves the comb shall be operated against a straight-edge placed at right angles to the pavement centre line. The same requirements regarding groove dimensions or texture depth as for machine-texturing will apply.

7114

CURING

The pavemen: shall be grooved by means of a metal tine grooving device. The tines shall be made from flat spring steel approximately 0,6 m m in thickness and 3 m m in width, 125 m m in length and spaced at between 12 m m and 25 m m in an approved random pattern. The engineer may, however, require a different random pattern or equal spacing of the tines during the course of the work, and provision shall be made to supply different sets of combs as required. No additional payment will be made for the first two changes in the spacing of the tines. The combs for applying the texturing shall be at least

The exposed surfaces, including the sides of the slab, shall be treated immediately after the required texturing of the surface has been effected and after the side formwork has been removed by the application of a white-pigmented curing compound as specified in clause 7102(g) above in accordance with the directions of the manufacturer. The curing compound shall be sprayed onto the surface at a rate of 0,35 i / m z or as directed by the engineer by means of a mechanical distributor capable of producing a fine fog-type of spray which will not damage the surface of the concrete. The curing compound shall be applied in two layers with the distributor moving in opposite directions for the two applications. Coverage shall be uniform over the entire surface and the rate of application of the curing compound shall be carefully controlled. During spraying operations the curing compound shall be continuously stirred mechanically to keep the pigmentation in suspension. The spray nozzles shall be adequately protected against wind. After shutting off the spray nozzles, no dripping of curing compound on the concrete surface may occur. If necessary, the contractor shall provide drip pans suspended below the nozzles to prevent dripping of the curing compound onto the pavement.

3,Om wide. It must also be possible to adjust the combs

to a lower position in order to compensate for wear.

(c)

Burlapdrag-andgrooved texture

This texture shall be obtained by first applying a burlapdrag finish to the concrete surface and then by grooving it with a grooving comb. The first pass of the burlap drag shall be made as soon as construction operations permit and before the wet sheen has disappeared from the surface. Burlap dragging shall be repeated until a gritty and uniform texture having the required depth of texture has been obtained. Every morning the burlap drag shall be wetted and kept moist throughout the day. At the end of each day's pour the burlap mats shall be cleaned or discarded and replaced with new burlap if cleaning is not possible. After the concrete has hardened, all loose particles generated by the cutting of the grooves shall be broomed off the surface with stiff hand brooms or mechanicallyoperated rotary brooms. When measured with a suitable depth gauge, the grooves shall be not less than 2 m m and not more than 4 m m in depth.

The curing membrane shall be maintained intact for at least seven days after the concrete has been placed. Any damage to the curing membrane, caused by the contractor's activities, shall be repaired by hand-spraying the affected areas.

Areas inaccessible to the mechanical distributor such as odd shaped areas, or those with varying widths or shapes, shall be sprayed with curing compound by means of approved handspraying equipment, at the specified rate of application.

7115

CONSTRUCTION JOINTS

after the initial sawing. Joints shall be sealed in accordance with the details shown on the drawings or specified in the project specifications.

Construction joints shall be made only in accordance with the details and in the positions shown on the drawings or determined by the engineer. Where the pavement is constructed in more than one strip, longitudinal construction joints shall be constructed, and where edge slump in excess of 6 m m occurs with slipform paving, the sides of the pavement shall be supported by an approved method. Transverse construction joints shall be formed at the end of a day's work or where necessary on account of any unavoidable suspension of work. The upper edges of the pavement shall be rounded off or chamfered at a construction joint as shown on the drawings. Where sealing of the construction joint is required, the groove may be sawn only after seven days' curing of the concrete.

Where required, dowels shall be installed as specified in clause 7119. Dowelled shrinkage joints shall be exactly at right angles to the longitudinal axis of the pavement.

7117

EXPANSION JOINTS

Expansion joints shall be constructed in accordance with the details shown on the drawings.

7116

WEAKENED-PLANE JOlNTS

The joint filler shall comply with the requirements of subclause 7102(e) and holes for the dowels shall be accurately punched out or drilled. The filler for each joint shall be supplied in a single piece for the full depth and width required for the joint unless otherwise authorized by the engineer. Where the use of more than one piece is authorized for a joint, the abutting ends shall be securely fastened, and held accurately in shape, by stapling or by another suitable method acceptable to the engineer.

Weakened-plane joints shall be formed by sawing a groove in the concrete. The joint filler together with the sealing groove shall completely separate adjacent slabs. Any loose-fitting dowel bars and any spaces between the subbase and the filler shall be caulked with joint-filler material after the joint has been assembled.

(a)

Longitudinal hinge joints

Hinge joints shall be sawn where the pavement is constructed in widths of two or more lanes at a time. Sawing shall be done at an appropriate time to prevent longitudinal cracking from occurring, but not later than 24 hours after concrete placing. The widths and depths of the groove and the joint filler shall be in accordance with the drawings. The width tolerances for hinge joints are set out in clause 7122. Deformed steel tie bars shall be installed where required.

If expansion joints incorporate dowels, the dowels shall be encased at one end in a close-fitting cap. The cap shall be placed on the free half of each dowel which half shall be coated as late as possible before concreting, with a bondbreaking coating or sleeve which complies with the requirements of subclause 71 19(b).

The sealing groove in the upper portion of the expansion joints shall be sealed with a preformed neoprene compression seal.

@)

Transverse contraction joints

7118

Transverse contraction joints shall initially be sawn as specified in clause 7118, and shall not exceed 3 m m in width. The grooves shall be sawn to the depth shown on the drawings. The exact time and sequence of sawing shall be determined by the contractor, bearing in mind the risk of excessive ravelling and spalling with early sawing, and the risk of cracking with delayed sawing, but not later than 24 hours after the concrete has been placed. When the pavement is constructed in more than one strip, the transverse joints opposite those which have opened in the adjacent pavement shall be sawn within the first 24 hours. The contractor may initially omit up to two consecutive planned contraction joints, and shall saw such joints within 48 hours of the concrete having been placed, but before uncontrolled cracking takes place. All transverse joints shall initially be sawn to the full depth as indicated, and not more than 3 m m wide. In sealed joints the top portion of the groove shall be reamed out to the specified final width and depth not sooner than 7 days

THE SAWING OF JOINTS

The contractor shall use the type of blade and equipment best suited to the hardness of the concrete, the type of aggregate and the site conditions.

Sufficient standby power saws shall be held available by the contractor, ready for use, at all times when concrete is being placed in the pavement.

Immediately after sawing, the joint grooves shall be washed out with a jet of clean water to remove all fine material and the joints shall then be sealed temporarily by means of an approved material, flush with the permanent surface. No traffic of any kind shall be allowed on the pavement until all the joints have been permanently sealed.

7119

TIE-BARS AND DOWELS

(a)
(i)

Preformed elastomeric compression seals

Material

(a)

Tiebars
Preformed elastomeric compression seals shall be as specified in subclause 7102(e). The actual configuration of the seal shall be as shown on the drawings, specified in the project specifications, and approved by the engineer. (ii) Installation

Tie-bars shall be placed at right angles to joints. Tie-bars shall be free from paint, grease or other matter which may affect bonding with the concrete. At construction joints the one half of each tie-bar shall be supported on the subbase by means of suitable stools, while the other half shall project into the adjacent lane. Mild steel tie-bars at longitudinal joints may be bent parallel to the edge of the first lane constructed and later on straightened into its final position before the concrete of the adjacent lane is placed, if the method of fixing and supporting the tie-bars is approved by the engineer. Where tie-bars are bent and later straightened, any damage to the concrete shall be made good by the contractor.

Seals may be installed only after all repairs to the joints have been completed. The joint grooves into which the seals are to be inserted shall be cleaned with a power-driven rotary wire brush. The grooves shall be dry and shall be finally cleaned with oil-free compressed air at a pressure of at least 700 kPa immediately before the seals are installed. Before the joints are sealed, all repair work (if any) shall have been completed. The sides of the sealing groove or seal, or both, shall be coated with an approved lubricant adhesive compound which complies with the specifications and with subclause 7102(e), and shall be inserted into the joint by means of suitable equipment which will not damage the seal during its insertion. The seal shall not be stretched for fitting it into the groove. A maximum increase of 10% in the length of the seal after installation will be allowed. Excess adhesive on top of the seal shall be removed to prevent adhesion of the seal under compression. The top of the seal shall be not less than 5 m m nor more than 7 m m below the pavement surface. No traffic of any nature shall be allowed onto the pavement before the joints have been either temporarily or permanently sealed. In the case where preformed compression seals are used for both transverse and longitudinal joints the seals shall be continuous along the longitudinal joints, with the transverse seals butted and fixed to the longitudinal seals with adhesive. The size of the sealing strip used will depend on the width of the groove to be sealed. The contractor shall not order large quantities of preformed seals before the quantities required in the various sizes have been discussed with and approved by the engineer.

At weakened-plane hinge joints the bars shall be firmly supported in position by steel supporting devices fixed to the subbase. If the paver or other paving equipment is equipped with a device for placing tie-bars into the plastic concrete, such device may be used after it has been demonstrated that the tie-bars will be located in their correct positions after the slab has been compacted and finished.

Dowel bars shall be straight and free from irregularities and without any burred ends, and shall have their sliding ends sawn and bevelled. The free or unbonded end of the dowel shall either be coated with a bond-breaking coating or covered with a sheath, as directed by the engineer, to prevent the concrete from adhering to it. The coating or sheath shall cover at least two-thirds of the dowel length. The bond-breaking coating shall be an approved synthetic material applied at a thickness of 0,5 m m in accordance with the manufacturers recommendations. The sheath shall be a tough polyethylene material with an average thickness of 1,O m m 2 0,2 mm.

Dowels shall be fixed rigidly both in horizontal and vertical alignment parallel to the centre line of the road and the surface of the slab, by robust supporting frames or cradles which do not project over the joint, and are left permanently in place. The free end of the dowel shall not be tack-welded to the frame but shall be held in position by soft binding wire. Dowels may be mechanically inserted (in which case no frames will be required for securing the dowels), provided that conclusive evidence is submitted that the proposed method is an accepted method and has already been used successfully.

@)
(i)

Silicone sealant
Materials

Dowel alignment shall be accurate to within the tolerance given in clause 7122.

The silicone sealant and appurtenant materials shall be as specified in subclause 7102(e). The dimensions and positions of the sealant and appurtenant materials shall be as shown on the drawings or as specified in the project specifications, or as approved by the engineer. (ii) Installation

7120

J O I N SEALING

Joints shall be permanently sealed before the pavement is opened to any traffic.

Just prior to sealing the joint grooves shall be reamed to their prescribed final dimensions and shall then be cleaned by means of a high pressure jet of water over the full depth of the joints to remove all fine matter and to produce dustfree joint grooves. Immediately before the supporting

material is supplied, the grooves shall be dried by means of oil-free compressed air at a pressure of 700 kPa. Compressors shall be equipped with an apparatus which removes water and oil from the compressed air. Where a primer is required, it shall be applied before the supporting materials are installed. After the joints have been finally cleaned and the primer (if any) has been applied, a supporting backing cord shall be installed by means of an approved rolling tool in the prescribed positions. Where the joints are dirty, wet or moist, the supporting material shall be removed, the joints cleaned and dried, and fresh material applied. The procedure(s) to be followed by the contractor to prevent the sealant from being spilt onto the concrete pavement shall be subject to approval by the engineer. The silicone sealant shall be pumped continuously directly into the joints with a suitable pneumatically driven pump. Sealing shall be done from the upper surface of the supporting material. Immediately after installation and before a skin appears, the surface of the sealant shall be worked to compact the sealant and to press it against the sides of the joint so as to ensure that the prescribed clearance under the road surface is obtained. As an alternative to separate installation and finishing of the sealant, an approved injection nozzle incorporating a finishing apparatus may be used, in which case only closed-cell polyethylene may be used as supporting material. Further directions supplied by the manufacturer shall be strictly complied with, particularly with regard to temperatures for application, opening to traffic, and safety aspects. No traffic shall be permitted to pass over a sealed joint before the sealant is able to withstand the penetration of foreign matter. The top surface of the sealant shall not be less than 5 m m and not more than 7 m m below the paved surface. All surplus sealant and other foreign matter shall be removed from the concrete pavement surface in accordance with the directions of the manufacturer of the sealant.

the contractor to construct the pavement in accordance with the specifications. The trial section shall be constructed with the same materials, concrete mix, plant and equipment as those intended for use by the contractor for the pavement, and he shall also demonstrate the methods he proposes to use for applying the required surface texture, the construction of joints and the placing of tie-bars, dowels, etc. Before the contractor commences with the construction of the trial section, he shall demonstrate to the engineer that all items of his paving c t i equipment are in a satisfactory working order. An initial trial section of not less than 150 m in length for mechanical construction, and at least 30 m in length for manual construction, shall be constructed in one continuous operation and be submitted for approval.

The engineer shall also be entitled to call for a new trial section to be constructed at any stage of the contract when changes by the contractor in the approved equipment, materials, mix or rate of paving warrant the construction of another trial section.

The contractor will be paid for the actual length of trial pavement constructed as initial trial section and trial sections constructed in consequence of changes in mixes, techniques, materials, etc, effected by the contractor, up to a maximum total length of 300 m for mechanical construction, and 60 m for manual construction. In addition, he will be paid for any trial lengths necessary as a result of similar changes required by the engineer, notwithstanding the fact that the trial section built by the contractor complied with the specified requirements.

@)

Further trial s e o n s and permission to start constructing the pavement

(c)

Liquid sealant for joints between concrete and asphalt pavements

These joints shall be sealed with a hot-poured joint-sealing compound as specified in subclause 7102(e). Prior to application, the joints shall be clean and free from water. Curing compound adhering to joint walls shall be removed by sandblasting or with an abrasive wheel. Dirt, dust and laitance shall be blown out of the joint with oil-free compressed air at a pressure of at least 700 kPa immediately before the sealing operation. The sealant shall be applied in accordance with the manufacturer's instructions, particularly in regard to the temperature of application. which shall be strictly controlled.

The contractor may, unless advised of any deficiencies in the trial section, proceed with the construction of the pavement ten days after the completion of the trial section or such earlier time as the engineer may determine. In the event of deficiencies in the trial section, the engineer may order the contractor to construct a further trial section, which will again be regarded as the initial trial section. The contractor may then proceed with the construction of the pavement ten days after the satisfactory completion of the second or subsequent trial section.

7122

CONSTRUCTION TOLERANCES

The work described in this section shall be constructed to the tolerances given below.

(a)

Level and grade

7121

TRIAL PAVEMENT

The level tolerances referred to in clauses 8205 and 8305 shall be as follows:

(a)

General Deviations from the specified longitudinal grade on account of deviations from the specified levels shall not exceed those given in subclause 3405(c).

When commencing with paving operations, the contractor shall construct a trial section of pavement, in a position approved by the engineer, to demonstrate the capability of

@)

Width of pavement and the position of pavement edges

@)

Dowels

The average width of each pavement shall be at least equal to the specified width, and the edge of the pavement shall not deviate by more than 25 m m from the specified position.

Dowels shall be positioned at the depth specified, measured from the surface level of the slab, within a tolerance of r 10 mm. They shall be aligned parallel to the finished surface of the slab, to the centreline of the carriageway and to each other within the following tolerances: (i) Dowel supported on cradles, prior to construction of the slab: All dowels in a joint shall be within 300 m m length of bar.

(c)

Joints

Joints shall not deviate by more than 10 m m from their specified positions in the pavement or by more than 10 m m from the edge of a 3 m straight-edge placed so as to touch the line of the joint. Neither shall the line of a joint be discontinuous.

(1)

2 m m per

(2)

The tolerance for the groove width of sawn joints shall be as follows: (ii) Longitudinal hinge joints Transverse contraction joints

No individual dowel shall differ in alignment from an adjoining bar by more than 3 m m per 300 m m length of bar in either the horizontal or vertical planes. Dowels supported on cradles or mechanically installed, after construction of the slab. All dowels in a joint shall be within 300 m m length of bar.

(1)

+ 4 m m per

(d)

Thickness

(2)

The thickness tolerances referred to in clauses 8205 and 8305 shall be as follows: D90 Dmax Dave (3)

No individual dowel shall differ in alignment from an adjoining bar by more than 6 m m per 300 m m length of bar in either the horizontal or vertical planes.
All dowels shall be equally positioned about the intended line of the joint within a tolerance of r 25 mm.

The thickness of the slab shall be determined by accurate levelling in the same positions at random selected points before and after construction of the slab, and also by measuring (an average of 4 measurements per core) on cores drilled from the slab.

Random checks of the dowels shall be ordered by the engineer by taking cores at the position of the bar ends. The coring shall be measured and paid under item 71.07.

7123

PROCESS CONTROL

(e)

Cross section

When tested with a 3 m straight-edge placed at right angles to the road centre line, the surface shall not deviate from the bottom of the straight-edge by more than 6 mm.

(9

Surface regularity

When tested with a rolling straight-edge as described in clause 8111(c), the number of surface irregularities in excess of 3 m m shall not exceed any of the following: (i) Average number of surface irregularities per 100 m taken over 300 m 600 m sections . . . . . . . . . (ii) Number of surface irregularities taken over 100 m sections . . . . . . . .

The contractor shall conduct all and a sufficient number of tests necessary for ensuring compliance with the requirements specified in this series, during all phases of the work. Accelerated 20-hour compressive-strength tests as described in subclause 8106(f) shall be conducted regularly with a view to predicting the 28-day compressive strength of the concrete. Test procedures and methods for the prediction of 28-day compressive strength shall be determined in consultation with the engineer. Where the accelerated tests indicate that the required 28-day compressive strengths will not be attained, the contractor shall immediately effect the necessary changes to the materials and/or mix proportions in order to ensure that further work will comply with the requirements.

.....................

7124

QUAUTY CONTROL AND WORKMANSHIP

Routine inspection and testing will be carried out by the engineer to determine whether the quality of materials and workmanship complies with the requirements of this section.

The maximum value of any individual irregularity when measured with the rolling straight-edge or a 3 m straightedge laid parallel to the road centre line shall not exceed 7 mm.

The assessment of test results and measurements shall be done in accordance with the provisions of section 8200.

In additlon to the above, the following shall also apply:

(a)

Compressivesbength control where P dw ds fw

=
=

Compressive-strength control shall be exercised on the basis of the acceptance-control plan as described in clause 8206 for full acceptance and clause 8208 for conditional acceptance. Attention is drawn to the special requirements The relating to concrete for concrete pavements. resubmission of concrete lots on the basis of cores for full acceptance or conditional acceptance shall not be allowed. The contractor's attention is drawn to clause 8209. The engineer may, at his discretion, decide to use the contractor's test results in the judgement plan, if he is satisfied that the contractor has complied with all the process control requirements.

= =

fs

percentage of normal compensation actual average thickness of slab specified average thickness of slab actual 28-day compressive strength of slab (average of 28-day compressive-strength tests) specified 28-day compressive strength of slab (calculated acceptance limit La in accordance with section 8200).

The above shall be subject to the rejection of a pavement with an average thickness of less than 93,1% of the specified thickness or a strength of less than 91,5% of the specified strength, as determined above.

@)

Relationship between the awnpressive and flexural strengths of concrete

Where both thickness and strength are deficient, it will be rejected if P is less than 70%. Where P exceeds loo%, normal compensation only will be payable.

The relationship between the 28-day compressive and the 28-day flexural strengths of the concrete established by the preliminary tests shall be monitored during paving operations by regular tests at the discretion of the engineer. For thls purpose sets of three beams and three cubes shall be manufactured from the same batch of concrete and tested for flexural and compressive strength respectively.

7125

REMEDIAL WORK

H the test results Indicate a relationship which deviates from that established by the preliminary tests, the specified compressive strength, as specified in subclause 7103(d) shall be adjusted accordingly.
(c) Air content of concrete

In addition to the requirements specified in clause 1218, the following shall apply specifically to concrete pavements:

(a)

Removing concrete

H any test for air content shows a value falling outslde the specified limits, the quantity of air-entraining agent added to the concrete mix shall be adjusted, until the air content of the concrete Is within the specified limits.
(d)
Unacceptable work or materials

Where any section of the pavement which does not comply with the specified requirements is to be removed and reconstructed, the entire portion of the slab shall be removed and reconstructed as prescribed by the engineer in writing.

@)

Removing high spots

Any work or materials which do not comply with the specified requirements shall be removed and replaced with work or materials which comply with the requirements or, if the engineer so permits, shall be repaired as specified in clause 7125, so that it shall comply with the specified requirements after having been repaired.

Where the engineer so permits, high spots may be removed by approved power chisels and planers. After the high spots have been removed, the contractor shall, if required, grind the surface up to the nearest longitudinal and transverse joint in order that all the ground areas will be neat rectangular areas with a uniform texture. On all portions of the pavement where the surface texture has been destroyed or reduced in depth by grinding, the surface texture shall be restored by grooves being cut into the concrete surface. The grooves shall be approximately of the same size and spacing as specified in subsubclause 7113(b)(ii).

(e)

llcceptance of concrete of inferior strength or thickness at reduced payment

In lleu of requiring the removal of work that has been rejected on account of Insufficient strength or thickness, the engineer may accept such work at his sole discretion, at reduced payment for the pavement concrete, on the following conditions:

(c)

Repairing joints

Where concrete is deficient In thickness or in strength, the reduced payment shall be calculated in accordance with the following formula:

Joints along which spalls occur that exceed 5 m m in depth at any point measured from the top surface of the pavement, or any other joints which In the opinion of the engineer are unacceptable, shall be repaired with an approved epoxy resin mortar. The method of repairing joints requires the prior approval of the engineer.

(d)

Repairing the cracks

The contractor shall be responsible for constructing a pavement which will not exhibit any cracks. Where cracks occur in the pavement which, in the opinion of the engineer, do not warrant the removal and reconstruction of the particular section of pavement, the contractor shall, if so required by the engineer, repair such cracks, in accordance with a method approved by the engineer.

the concrete in the first panels has sufficiently hardened so that no damage will be done to the first panels during construction activities. All formwork shall remain in position for at least 24 hours.

(iii)

Surface texture

Unless otherwise specified in the project specifications, the contractor shall produce a surface texture on the new concrete panels which shall be the same as that on the existing panels.

(e)

Rehabilitation

of concrete pavements
(iv) Joints, tie bars and dowels

Where concrete pavements have to be widened or where long continuous sections of concrete pavement have to be replaced and, in the opinion of the engineer, the concrete can be placed with pavers, the work shall be regarded as and shall be measured and paid for as new work under the applicable items for new work.

Joints shall be shaped and tie bars and dowels shall be placed where indicated on the drawings and as specified in clauses 7115 up to and including 7120.

(i)

Removal of existing concrete

Where any section of the concrete pavement has to be removed, the whole panel between longitudinal and transverse joints shall be removed, unless it is specified in the project specifications or ordered by the engineer that only part of the panel be removed. In such cases the concrete shall be removed either over the full length or over the full width of the panel between joints. Where the edge of the section to be removed coincides with an existing joint, the edge shall be accurately demarcated in a straight line and sawn with an approved concrete saw to a depth of at least 50 rnm before the removal of the concrete may commence. Existing concrete may be broken up in any approved manner, but strict control shall be exercised to ensure that the adjacent concrete is not damaged in any way. The contractor shall repair any damage to the adjacent concrete at his own cost in accordance with the instructions of the engineer. Such remedial work may involve the partial or complete replacement of the damaged panel should it be deemed necessary by the engineer. Care shall be taken at existing joints to ensure that tie bars or dowels are not damaged or bent so as to render them useless. Broken-up concrete shall be removed to approved spoil dumps. (ii) Placing new concrete

At joints in new concrete, the tie bars and dowels in the existing concrete shall be cleaned, and the tie bars shall be straightened, should any such bars be indicated on the drawings. In regard to bent dowels, the contractor shall follow the instructions of the engineer. Before concrete is placed, all the bars shall be accurately aligned as indicated on the drawings and specified in clause 7119. Where the sliding end of a dowel occurs in existing concrete, the dowel shall be extracted, cleaned and treated in accordance with the specifications and then replaced. Where tie bars or dowels are shown on the drawings at joints between existing and new concrete, but no such bars occur in the existing concrete, holes shall be drilled in the existing concrete and fresh bars placed and fixed as prescribed in the project specifications. In such cases, the dowels shall be placed with their sliding ends in the new concrete. Where no bars are required between the existing and new concrete but such bars do occur in the existing concrete, such bars shall be cut off flush with the concrete edge.

All joints between the existing and new concrete shall be sawn after the new concrete has hardened sufficiently to prevent splintering or other damage from occurring. Sawing the joints may normally be done from two to five days after the placing of the concrete. The width and depth of the sawn grooves shall comply with the requirements set in the project specifications and on the drawings. (v) Repairing joints and cracks in existing concrete pavement

Before concrete is placed, the underlying surface or layer shall be prepared as specified. Except where concrete is placed in continuous lengths exceeding 50 m, placing, compacting and finishing with hand equipment shall be carried out as specified in clause 7111. Where new concrete is placed next to existing concrete, the edge of the existing pavement shall be properly cleaned and all bituminous and other jointing material shall be removed. Where various adjacent panels are constructed, the concrete in every alternate panel shall first be placed. The concrete in the rest of the panels may be placed only after

Repairing the joints and cracks in the existing concrete pavement shall be done in accordance with the requirements set out in the project specifications and on the drawings, and as required by the engineer. (vi) Retexturing

Where in the opinion of the engineer the skid resistance of the concrete pavement surfaces is too low, or the texture is too irregular, and where so specified in the project specifications, such surfaces shall be provided with a fresh texture. The depth of texture and groove spacing shall comply with the requirements of the project specifications. The work shall be done with approved sawing equipment.

7126

OPENING TO TRAFFIC

No vehicle with an axle load exceeding 20 kN shall travel over the completed surface within 14 days after it has been completed, or such longer period as may be directed by the engineer.

In the case of rehabilitation work the tendered rate shall also include full compensation for cleaning existing joints where new concrete has to join up with existing work, for straightening existing dowels and tie bars, and for cutting off existing bars as specified. The tendered rate shall also include full compensation for constructing concrete pavements which cannot be constructed with conventional plant, as envisaged in section 7100.

7127

MEASUREMENT AND PAYMENT

No extra over payment shall apply to work in restricted areas for work carried out in terms of section 7100. The rates tendered for the payment items of section 7100 shall include full compensation for work in restricted areas.

Item 71.03 Extra over item 71.02 for concrete pavement requiring hand placing

Unit

.....

square metre (m Z)

Item 71.O1 Concrete trial pavement: (a) (b) Mechanical construction Manual construction

Unit

....

square metre (m 2) square metre (m 2)

.......

The tendered rate for hand-placed concrete shall be extra over the rate tendered for item 71.02 and shall include full compensation for the more difficult work, and incidentals required for placing the concrete by hand where placing cannot be done by normal slipform or sideform equipment. It shall also include compensation for all the required formwork. Item 71.03 does not apply to rehabilitation work.

The unit of measurement for the trial pavement shall be the square metre of completed trial section. Not more than a total length of 300 m of mechanically constructed trial pavement and not more than 60 m of manually constructed trial pavement will be measured for payment as described in clause 7121. The tendered rate shall include full compensation for constructing the trial pavement complete as specified.

Item 71.04 Texturing and curing the concrete pavement: (a) Burlap-dragged and grooved texture . . . Curing

Unit

. . . . . . . . square metre

(m2) (m2)

Item 71.02 Concrete pavement (thickness indicated) excluding texturing and curing . . . . . . . . . . . . .

Unit

(b)

. . . . . . . . . . . . . . . . . square metre

. . . . . square metre

(m Z)

The unit of measurement shall be the square metre of concrete pavement placed and finished in accordance with the specifications and the project specifications. The quantity shall be calculated from the authorized dimensions of the completed surface, except when the engineer requires or the drawings show local deviations from the specified thickness, such as at bridge approach slabs. The volume of concrete in such cases shall be converted into an equivalent area in square metres based on the specified thickness of the slab. The tendered rate shall include full compensation for procuring and furnishing all the materials, storing the materials, providing all plant, determining the mix proportions, mixing, transporting, placing and finishing the concrete, including formwork, repairs done to defective work, protecting the pavement against damage, construction joints and process control. The tendered rate shall also include full compensation for the provision of any additional width required by the contractor to the earthworks and/or pavement layers to suit the particular requirements of the paving equipment. It shall also include full compensation for the removal of the additional widening which extends beyond the limits of the specified cross-section.

The unit of measurement for texturing and curing shall be the square metre of completed pavement which has received the specified surface texturing, and which was cured as specified. The quantity shall be calculated from the specified horizontal dimensions of the completed concrete surface in the case of texturing and from the specified horizontal dimensions of the completed concrete surface, plus the surface area of the slab sides, in the case of curing. The tendered rate for texturing shall include full compensation for providing the plant and equipment required and for applying the specified surface texture. The tendered rate for curing shall include full compensation for providing the curing compound and its application as specified at the specified nominal rates of application by means of an apprbved pressure distributor. The tendered rate shall also include compensation for spraying the curing compound in unsealed joints after the sawing has been completed.

Item 71.05 Variation in the rate of application of the curing compound .

Unit

. . . . . . . . . . . . . . . . .litre (I)

The unit of measurement in respect of increases or decreases in the rate of application of the curing

compound shall be the litre. Payment for variations shall be made as specified in clause 1213.

construction joint, provided that the requisite number and sizes of tie bars for the hinge joints are installed. Where the hinge joint replaced by the construction joint is a sealed hinged joint, the construction joint shall be sawn and sealed, in which case the contractor will be paid at the tendered rate for sawn and sealed hinge joints. The tendered rates for expansion joints shall include full compensation for forming the joint complete with joint filler, rounding or chamfering the corners (if required) and installing a compression seal. The tendered rates for longitudinal hinge joints shall include full compensation for sawing the joint (if required) and supplying and inserting the seal (if required). The tendered rate for transverse contraction joints shall include full compensation for sawing the joint and installing the specified type of seal, including appurtenant materials, and for temporarily sealing the joint with paper rope. The tendered rates for dowel bars and tie-bars shall include full compensation for supplying, cutting, placing, holding the bars in position, including a supporting framework or cradles where required, and fixing the end caps and bond breaking materials to dowels. The tendered rate for forming and sealing the joints between asphalt and concrete pavements shall include full compensation for supplying all the necessary plant and materials, for forming a joint to the required dimensions in the asphalt seal, cleaning the joint and sealing it as specified in subclause 7120(c).

(a)

Expansion joints complete (excluding dowels) . . . . . . . . . . . . . . . metre (m) Longitudinal hinge joints: Sealed hinge joints (type indicated with reference to drawings) . . . . . . . . . . . . . . . . . . . .metre (m) Unsealed hinge joints (type indicated with reference to drawings) . . . . . . . . . . . . . . . . . . . . metre (m) Hinge joints between existing and new concrete in rehabilitation work . . . . . . . . . . . . . . . metre (m) Sealed transverse contraction joints sawn in two separate operations (widths as shown on the drawings) . . . . . . . . . . . . . . . . . . .metre (m) Dowel bars (mild steel) (diameter and length indicated): Installed in new concrete

@)
)

(ii)

(iii)

(c)

(d)

(i) (ii)

........
....

number (No)
71.07 [killing and testing of cores:

Unit

Installed in existing concrete in rehabilitation work Tie-bars (diameter and length indicated): Installed in new concrete

number (No)

(e)

(a)

100 mm cores drilled from the pavement . . . . . . . . . . . . number (No) 150 mm cores drilled from the pavement and tested for compressive strength . . . . . . . . number (No)

(i) (ii)

....... ....

number (No)

(b)

Installed in existing concrete in rehabilitation work

number (No) The unit of measurement shall be the number of cores drilled or drilled and tested on the instruction of the engineer. Cores drilled by the contractor at his own initiative as part of his process control or for testing cracks sealed at the contractor's own cost, will not be measured for payment. The tendered rates shall include full compensation for drilling the test cores and, where applicable, having them tested by an approved laboratory, and for all labour, transport, testing charges and other incidentals, save only the cost of providing a core-drilling machine on the site, which is paid for separately. It shall also include compensation for restoring the concrete pavement where holes were drilled.

(1) (g)

End caps for dowels at expansion joints . . . . . . . . . . . . . . number (No) Forming and sealing the joints between asphalt and concrete pavements . . . . . . . . . . . metre (m) Cleaning of tie-bars and dowels in existing concrete pavement and straightening tie-bars in existing concrete pavement in rehabilitation work . . . . . . . . . . . . . number (No)

(h)

The unit of measurement for joints in the pavement shall be the metre of completed joint, except that dowel bars and tie-bars across joints shall be measured separately by the numbers of each type installed. Construction joints as such shall not be measured for payment and their cost shall be deemed to be included in the rate tendered for the concrete pavement. However, if the position of a longitudinal construction joint coincides with that of a hlnge joint, the contractor will be paid at the rate tendered for the type of hinge joint replaced by the

Item
71.08 Steel reinforcement in concrete pavement:

Unit

(a)

Mild steel bars

....................

ton (t)

(b) (c)

High tensile steel bars Welded steel fabric

..............

ton (t)
71.11 Removing existing pavement layers i n rehabilitation work:

..........

kilogram (kg)

The unit of measurement for steel bars shall be the ton of reinforcing steel in place in accordance with the drawings or as authorized.

(a) (b) (c)

Uncemented material Cemented material

....... ........
....

cubic metre (m a) cubic metre (m3) cubic metre (m 3)

Cemented crushed stone

The unit of measurement for welded steel fabric shall be the kilogram of welded steel fabric in place in the special panels of concrete paving which require reinforcement, the quantity of which shall be calculated from the area of the mesh used in accordance with the drawings or as authorized. The tendered rates shall include full compensation for supplying, delivering, cutting, bending, welding, placing and fixing the steel reinforcement, including all tying wires, spacers and waste.

The unit of measurement shall be a cubic metre of material excavated and removed. The quantity shall be computed in accordance with the authorized dimensions for the excavation. The classification of the material shall be made in accordance with the provisions of clause 3803.

The tendered rate shall include full compensation for excavating the material and disposing thereof to approved spoil dumps, including transport over a free-haul distance of 1,O km.

Unit
71.09 Removing existing concrete i n rehabilitation work:

Item
71.12 Recompaction of underlying pavement layers of gravel (required density stated) in rehabilitation work . . . . .

Unit

(a)

Concrete without reinforcement . . . . . . . . . . . . . cubic metre (m a) Reinforced concrete

(b)

........

cubic metre (m')

...

cubic metre (m3)

The unit of measurement shall be a cubic metre of concrete broken up and removed to approved spoil dumps as specified. The quantity shall be determined in accordance with the authorized horizontal dimensions and the average depth of the part removed. The tendered rate shall include full compensation for breaking up the concrete, loading, transporting over a freehaul distance of 1,O km, and placing it in approved spoil dumps. The tendered rate shall also include full compensation for the protection of adjacent concrete and its repair should it be damaged. Dowels and tie bars in existing concrete and stays used to keep the bars in position will not be regarded as reinforcing.

The unit of measurement shall be a cubic metre of material reprocessed and compacted. The quantity shall be calculated in accordance with the authorized dimensions of the layer.

The tendered rate shall include full compensation for breaking up the layer, watering, mixing, compacting and finishing, and preparing the layer for placing the concrete.

Item
71.13 Rehabilitation work: Reconstructing underlying pavement layers with:

Unit

ttem
71.10 Sawing existing concrete i n rehabilitation work

Unit

(a) (b)

Gravel material

. . . . . . . . . . . . cubic metre

(ma)

. . . . . . . . . square metre (m )
2

Crushed stone (grade G I or G2 indicated) Asphalt

.............

cubic metre (ma)

The unit of measurement shall be a square metre of sawcut in the existing concrete as approved by the engineer and sawn to the required depth, measured once only irrespective of the number of times the sawing has to be repeated to obtain such depth. The quantity shall be the product of the authorized length and depth of the saw-cut.

(c)

. . . . . . . . . . . . . . . . . .cubic metre

(rn3)

The unit of measurement shall be a cubic metre of underlying pavement layer reconstructed. The quantity shall be computed in accordance with the authorized dimensions.

The tendered rate shall include full compensation for demarcating the saw line, providing and applying water and other material, and for sawing the concrete to the satisfaction of the engineer. This item shall not apply to the sawing of joints.

The tendered rate shall include full compensation for procuring and placing the material, transporting it over a free-haul distance of 1,O km, and preparing the layer for placing the concrete.

ltem

Unit

Separate payment will be made for providing and placlng asphalt and slurry.

71.14 Ejrtraweritem 71.13for stabilization of undertying pavement layers under reconstruction: (a) Chemical stabilization of 3 gravel layers . . . . . . . . . . . . . . cubic metre (m ) Chemical stabilization of crushed-stone layers . . . . . . . . cubic metre (m3) Bituminous stabilization of crushed-stone layers . . . . . . . . cubic metre (m3)

This item shall not apply to reconstructed or reprocessed layers.

Item 71.17 Placing fine asphalt and coarse slurry in preparing the undertying layers as specified in subdause 7106(d): (a)

Unit

@)

(c)

Fine continuously graded asphalt for levelling the surface . . . . . . . . . . . . . . ton (t) Coarse slurry for levelling the surface . . . . . . . . . . . . . . . cubic metre (my)

The tendered rate shall include full compensation for the additional costs for stabilizing the material, including mixing the material and the stabilizing agent in the plant, curing the layer, and providing the water and the curing agent. The provision of the stabilizing agent will be paid for separately under item 71.15.

(b)

The unit of measurement for subitem (a) shall be a ton of asphalt placed in accordance with the instructlons of the engineer.

ttem 71.15 Stabilizing agents applied in rehabilitation work: (a) (b) Ordinary portland cement

Unit The unit of measurement for subitem (b) shall be a cubic metre of slurry placed in accordance with the instructions of the engineer. ton (t) The tendered rates shall include full compensation for procuring, providing, placing, compacting and finishing all the material, and for all transport.

............

Anionic stable grade bitumen emulsion (60% net bitumen)

.........

litre (1)

(c)

Other chemical stabilizing agents (type indicated) . . . . . . . . . . . . . . ton (t) Other bituminous stabilizing agents (type and grade stated)

ttem

Unit

(d)

.......

litre (1)

71.18 Wxturing existing concrete pavement in rehabilitation work . . . . . . . . . . . . . . . . . . . square metre (m2) The unit of measurement shall be a square metre of existing concrete pavement which has been retextured.

The provisions of items 35.02 and 35.08 shall apply mutatis mutandis.

ltem
71.16 Reparing the undertying layers af'ter the concrete has been removed in rehabilitation work: (a) Cemented gravel or crushed-stone layer

Unit The tendered rate shall include full compensation for all equipment, labour and material required for executing the work, complete as specified.

ttem

........

Unit

square metre (m2) 71.19 Repairing joints and cracks in existing concrete pavement in rehabilitation work: (a) (b) Joints Cracks

(b)

Uncemented crushed-stone layer . . . . . . . . . . . . . . . . . . . square metre (m2) Asphalt subbase

(c)

..........

square metre (m2)

........................
.......................

metre (m) metre (m)

The unit of measurement shall be a square metre of existing underlying layer prepared in accordance with the requirements of subclause 7106(d). The quantity will be computed in accordance with the authorized dimensions of the prepared layer. The tendered rate shall include full compensation for preparing the layer in accordance with the specified requirements, testing for level, cleaning the edge of the existing concrete, providing and applying water, and for removing any remaining loose material and waste.

The unit of measurement shall be a metre of joint or crack actually repaired on the instruction of the engineer and in accordance with the requirements of the project specifications. The tendered rate shall include full compensation for procuring, providing and applying all material, and for repairing, complete as specified. Payment shall distinguish between various types and sizes of joints and cracks.

71.20 Drilling and placing dowels

The tendered rate shall include full compensation for cleaning and re-treating the bars as specified and to the satisfaction of the engineer.

and tie bars in existing concrete i n rehabilitation work: Notes: (a) (b) Dowels Tie bars

.....................

number (No) number (No) Where reinforcing steel, except tie bars and dowel (1) bars, are used for reinforced concrete slabs, it shall be listed under this section in accordance with the pay items in section 6300.
(2) Payment will be made under section 8100 for providing a core drill and a rolling straight-edge.

....................

The unit of measurement shall be the number of bars placed in existing concrete at the joints with new concrete. The tendered rate shall include full compensation for providing all materials, cutting the bars, drilling the holes in the existing concrete, placing and fixing the bars with epoxy, and treating the sliding ends of the dowels, complete as specified.

The tendered rates shall include full compensation (3) for the additional costs for executing the work in restricted areas where necessary. The following items of payment shall apply where (4) necessary and shall be listed under this section in the schedule of quantities.

Item
71.21 Re-treating existing dowels:

Unit

(a) (b)

Sliding end in existing concrete Sliding end in new concrete

. . . number (No)
number (No)

.....

ltem 16.02 : Overhaul on material hauled in excess of 1,O krn ltem 41.01 : Prime coat

The unit of measurement shall be the number of bars retreated.

ltem 42.04 : Tack coat of 30% stable-grade emulsion

SERIES 7000 : SUNDRY STRUCTURES SECTION 7200 : REINFORCED EAATH

For temporary walls and sea walls ungalvanized reinforcing strips and tie strips may be used.

(d) CONTENTS 7201 7202 7203 7204 7205 7206 SCOPE MATERIALS MANUFACTURING AND HANDLING THE CLADDING PANELS CONSTRUCTION PATENT RIGHTS AND DESIGN MEASUREMENT AND PAYMENT

Bolts and nuts

Bolts and nuts shall comply with the requirements of SABS 136 for M I 0 Grade 8,8 bolts, and M I 2 Grade 10,9 bolts. Nuts shall be Grade 8. Bolts, nuts and washers (where required) shall be hotdipped galvanized in accordance with the requirements of SABS 763 for either type C1 or type C2 articles.

(e)
7201 SCOPE

Dowels

Dowels shall be formed from 20 m m diameter rigid plastic rods. This section covers the construction of structures in accordance with the patented method registered under the trade name of REINFORCED EARTH. In broad terms, this consists of a granular filling which is reinforced with horizontal layers of galvanized reinforcing strips which produce an apparent cohesion in the direction of the strips and permits the fill to function as a homogeneous gravity structure. The vertical or sloping outer face of the fill is clad with cladding panels which are connected to the reinforcing strips.

(f)

Tubes

Tubes shall be formed from 32 m m diameter PVC pipe.

(g)

Joint filler

The horizontal joint filler between the panels shall consist of two 85 m m long hard-rubber pads, and shall have the following properties: (i) A 90 2 5 IRHD hardness. A 295 Pa breaking strength.

(a)

Concrete panels

(ii)

Concrete panels shall be manufactured from materials which comply with the relevant requirements of sections 6200, 6300 and 6400.

Deformation under compressive loads of15 kN and (iii) 40 kN shall not exceed 35% and 50% respectively, and rubber pads may not exhibit any cracks during testing. The vertical and horizontal joints shall be covered on the rear face with 400 m m minimum width strips of unwoven synthetic fibre. (Kaymat U44 or equivalent).

@)

Steel panels

Steel panels shall be made from cold-rolled steel plate which complies with the provisions of BS 4360 for grade 43A steel or which complies with the provisions of SABS 1431 for grade 300W steel, and shall be galvanized in accordance with the requirements of SABS 934 for a class 2600 coating.

(h)

Fill material

All material which is used as fill behind cladding panels in the Reinforced Earth shall comply with the following grading and chemical requirements in addition to all the the requirements of series 3000. A copy of all the results of the tests conducted on the material by the contractor or his supplier shall be submitted to the engineer. Material which does not comply with these specifications shall not be used without the written permission of the engineer.
)

(c)

Reinforcing strips and ties

Reinforcing strips shall be manufactured from hot-rolled steel which complies with the provisions of BS 4360 for grade 50 steel, or other recognised specifications, eg EN 10025 : 1990 Grade Fe 510c. The reinforcing strips shall be deformed in accordance with the patented specifications.

Grading

The tie strips shall be formed to the required shape prior to galvanizing.

The material which is used as fill in Reinforced Earth structures shall fall within the unshaded section of graph 720211, and shall also comply with the requirements of table 720211. Intermediate material may be used only if approved by the engineer and if its plasticity index is less than 30.

All reinforcing strips and tie strips shall be hot-dipped galvanized after fabrication in accordance with SABS 763 to a minimum thickness of 85 p m .

Table 720211 MATERIAL SUITABLE FOR USE IN REINFORCED-EARTH STRUCTURES

The project specifications will determine whether class A or class B requirements shall apply.

7203 MANUFACTURING AND HANDLING THE

CLADDING PANELS
Percentage passing through an 8 0 p m sieve Percentage finer than 20 p m Plasticity index

Type
(a)

Concrete panels

< 12%
Granular 12 tot 35%

< 10%
> 10% PI < 30 Intermediate

Concrete panels shall be manufactured in accordance with the dimensions and details shown on the drawings, and, where necessary, these details shall be adapted to suit joining onto existing structures, inclined foundations, varying heights or other similar conditions.

The concrete panels shall be manufactured in accordance with the provisions of sections 6200, 6300 and 6400, and shall have an off-shutter class F2 surface finish.

> 35%

< 40%
Concrete panels shall be between 140 m m and 180 m m thick, whichever is required, and shall be classified in accordance with the system of the patentee as type 0, 1 or 2 and on the number of reinforcing strips attached to each concrete panel. The date of manufacture and the classification of every panel shall be clearly marked on the back of such panel. The concrete panels may be removed from the mould once the concrete has attained a cube compressive strength of 7 MPa. The concrete panels shall not be stacked more than five panels high during storage. The bottom concrete panels shall be supported off the ground by means of timber blocking, and adjacent concrete panels shall be separated by timber blocks packed between the tie strips to prevent any forces from being transmitted onto the tie strips.

(ii)

Chemical and electro-chemical properties

Except in the case of structures which will come into contact with salt water, in which case the requirements will be set out in the project specifications, fill material shall comply with the following chemical requirements: Class A Resistivity (0hm.mm) PH Chlorides (ppm) Sulphates (ppm) Sulphides (ppm) Class B

r 10 000 5 to 10 < 200 < 1 000 < 300

r 30 000 5 to 10 < 100 c 500 < 100

The resistivity shall be determined in accordance with the method prescribed by the patentee.

Graph 720211 MATERIAL SUITABLE FOR USE IN REINFORCED EARTH STRUCTURES

SIEVE SIZE (rnrn and prn)

@)

Steel panels

Steel panels shall be manufactured in accordance with the details shown on the drawings, from steel plate 2,O mm, 2,5 m m or 3,O m m thick, according to requirements.

be checked. The horizontal joint filler shall be correctly positioned before higher-lying cladding panels are placed. The clamps and wedges shall be removed as the construction progresses and once the cladding panels have been anchored by the reinforcing strips. The fill material behind the cladding panels in the Reinforced Earth shall be constructed and compacted in accordance with the provisions of sections 3200 and 3300 of the specifications to at least 93% of modified AASHTO density, except that the layer thicknesses may vary between 100 m m and 375 m m so as to coincide with the reinforcing strips. Fill material shall not be placed right up to the cladding panels before the underlying reinforcing strips have been covered, for a sufficient length from the centre of the fill, with compacted earth so as to anchor the strips adequately to keep the cladding panel in position. The filling shall therefore be made from the reinforcing strip ends to the cladding panels, and the earth shall always be spread in a direction parallel to the walls. During placing and compacting the fills, no vehicle or heavy compaction equipment shall come closer than within 2 m of the cladding panels. The earth within 2 m of the cladding panels shall be compacted by hand tamper or light hand-operated vibratory roller. Compaction to 90% of modified AASHTO or equivalent modified Proctor density is acceptable in this 2 m region. No machine with steel tracks shall be allowed on the freshly placed reinforcing strips.

(c)

Accessories

The cladding panels shall be complete and shall be equipped with the following: (i) Tie strips for connection to the reinforcing strips.

Dowels and tubes for joining the cladding panels to (ii) one another. Lifting devices for handling the cladding panels (iii) during transport and erection. The minimum inner radius of bends in tie strips shall be 25 mm.

7204

CONSTRUCTION

(a)

Foundation

The foundation plane for the Reinforced Earth structure shall be graded level to the heights shown on the drawings, and compacted to 93% modified AASHTO density in accordance with the requirements of clause 3305. Measurement and payment for this work will be made under the relevant items of section 3300. Aconcrete footing shall be provided in accordance with the details shown on the drawings, or as may be directed by the engineer.

7205

PATENT RIGHTS AND DESIGN

@)

Construction of Reinforced Earth structure

The contractor shall negotiate direct with the licence holder Reinforced Earth (Pty) Ltd in connection with royalties payable for the use of the patented systems for Reinforced Earth structures and in respect of providing technical assistance during construction. All details shown on the drawings shall be submitted to the licence holders for approval and no construction work shall be carried out in accordance with any drawings if the official approval of the licence holder has not been clearly indicated on it. The licence holder shall be responsible for the design, manufacture and supply of the cladding panels, reinforcing strips and accessories and for providing technical assistance during construction.

Concrete panels may be installed once the concrete reaches the cube compressive strength of 18 MPa. Concrete panels shall be handled and erected by crane and may be lifted only by means of lifting devices to be provided for this purpose. Half concrete panels shall be used for the bottom row, and special panels for the top row in the wall. The bottom row of cladding panels shall be placed accurately in position on the concrete footing and properly braced to prevent movement during the placing of the first layers of fill. Initially only half cladding panels of the bottom row shall be placed in position. The distance between the dowel and the tube of two adjacent half cladding panels shall be accurately controlled with a steel spacer plate to ensure that successive cladding panels will fit accurately inbetween the spaces between the half panels. Freshly placed cladding panels shall be clamped in the vertical position to the previously positioned cladding panels, with screw clamps and wooden wedges. Timber blocks shall be placed between the cladding panels and the clamps to protect the concrete. Each cladding panel shall be individually checked after having been placed with a plumb-bob and spirit level, and the distance between the dowel and the tube of the adjacent cladding panels shall

7206

MEASUREMENT AND PAYMENT

unit
72.01 Cladding panels:

(a)

Concrete panels (class of concrete, type of panel and thickness indicated) .

...

square metre (m2)

(b)

Steel panels (thickness of plate indicated) . . . . . . . . . square metre (m 2) Special panels (specify) . . . . . square metre (m2)

(c)

The unit of measurement shall be the square metre of each type of cladding panel supplied. The quantity shall be calculated on the basis of the specified dimensions on the surface which will be visible in the completed structure. The front surface of the panel only shall be measured in respect of special panels (eg corner elements).

Item
72.05 Erection of cladding panels:

Unit

(a) (b)

Concrete panels Steel panels

..........

square metre (m Z)

. . . . . . . . . . . . . square metre (m2) ...........

square metre (m Z)

The tendered rates shall include full compensation for the labour, the supplying of all the materials, including tie strips, dowels and tubes, bolts and nuts, lifting devices and the necessary jointing material, for manufacturing, storing, loading, transporting and off-loading and all appurtenant work which may be necessary for providing the cladding panels on the site, also for all royalties, design costs and technical assistance.

(c)

Special panels

The unit of measurement shall be the square metre of cladding panel erected as measured cn the front surface of the wall. The tendered rates shall include full compensation for the erection of the cladding panels, the installation of jointing material, and the connecting of reinforcing strips to the cladding panels.

ltem
72.02 Reinforcing strips (dimensions indicatedj

Unit

. . . . . . . . . . . . metre

(m)

Item

Unit

The unit of measurement shall be a metre of reinforcing strip of the various sizes installed.

72.06 lnfill concrete and finishing on top of the wall (class of concrete indicated) . . . . . . . . . . . . . . . . cubic metre (m3)

The tendered rate shall include full compensation for supplying all materials, manufacturing the reinforcing strips, transport, handling and storing, and all the labour and accessories required for installation.

The unit of measurement shall be the cubic metre of infill concrete placed on top of the wall. The tendered rate shall include full compensation for all labour, material, formwork and construction equipment necessary for placing infill concrete and for finishing off the top of the wall.

Item

Unit

72.03 Excavation for concrete footings for walls:

(a) (b) In soft material

Item cubic metre (m 3)

72.07 Extra over items (the numbers of the appropriate payment items in series 3000 indicated) for the construction of fills comprising reinforced earth . . . . . . . . . . . . .

Unit

............

Extra over subitem 72.03(a) for excavation in hard material . . . . . . . .

.....

cubic metre (m )

Measurement of and payment for excavation shall be as specified for item 61.02 of these specifications, except that no additional excavation shall be measured where formwork is required.

. . . . . . . cubic metre (m3)

The unit of measurement shall be the cubic metre of fill placed between the reinforcing strips in accordance with the approved dimensions of the reinforced fills bounded by the reinforcing strips. The tendered rate shall include full compensation for the additional costs of constructing the fills containing reinforcing strips, and for any adjustments to normal backfilling methods as may be necessary for placing the backfill material as specified in this section, including the trimming of layer planes for providing intimate contact with the reinforcing strips.

ltem
72.04 Concrete footings for walls (class of concrete indicated)

Unit

.........

cubic metre (m )

The unit of measurement shall be the cubic metre of concrete cast in the concrete footings for walls, calculated in accordance with the net approved dimensions for the concrete footings.

Note: The tendered rate shall include full compensation for supplying and placing the concrete and constructing the concrete footings, including the supplying of any formwork which may be necessary. Pay item 64.02 shall apply to the manufacture of prefabricated concrete coping and pay item 64.03 to its transport and erection. These pay items shall be listed under section 7200 in the scedule of quantities.

SERIES 7000: SUNDRY STRUCTURES SECTION 7300: CONCRETE BLOCK PAVlNGFOR ROADS

channelling shall comply with the requirements of section 2300.

(e)

Herbicide and ant poison

CONTENTS
7301 7302 7303 7304 SCOPE MATERIALS CONSTRUCTION MEASUREMENT AND PAYMENT The herbicide and ant poison shall be environmentally friendly and shall be subject to the engineer's approval.

7303 CONSTRUCTION

7301

SCOPE

(a)

Underlying pavement layen

This section covers the furnishing of materials and the construction of concrete block paving for roads.

7302

MATERIALS

The underlying pavement layers shall be constructed and prepared in accordance with the requirements for the relevant pavement layers in series 3000 of the standard specifications, the project specifications and the drawings. Where specified or required by the engineer the prepared surface shall be treated with approved herbicide and ant poison before the layer of sand for bedding is placed.

(a)

Bedding sand @) Bedding sand

Bedding sand for concrete block paving shall not contain any deleterious impurities.

Bedding sand shall comply with the following grading requirements: Sieve size (mm)
% passing through

A layer of bedding sand shall be placed on top of the prepared surface of the underlying pavement layer. It shall be accurately levelled to an uncompacted thickness of 25 m m ( + 5 mm) or as specified so that the concrete paving blocks will have the correct level after compaction. The bedding sand shall be placed immediately before the concrete paving blocks are laid and shall not be compacted before the blocks have been laid.

(c)

Concrete paving blocks

Bedding sand shall not contain any clay or silt material.

@)

Jointing sand

The blocks shall be laid in the pattern shown on the drawings or as directed by the engineer. Unbroken blocks shall be laid first and the filler pieces afterwards. Filler pieces shall be neatly sawn or hewn to fit exactly into the space to be filled. Any space of which the size is less than 25% of the size of an unbroken block, shall be filled with 35 MPa concrete. The size of the joints between blocks shall be between 2 m m and 4 mm, and the top faces of the blocks shall be flush. After the paving blocks have been laid, the pavement shall be compacted by two passes of a suitable vibrating-plate compactor operating at a frequency of 65 Hz to 100 Hz and a low amplitude. Its plate surface shall be 0,2 m 2 to 0,4 m 2 and it shall develop a centrifugal force of 7 kN to 16 kN. After compaction of the pavement as described above, jointing sand shall be spread and brushed into the joints until the joints have been properly filled. Any surplus sand shall then be broomed off and the pavement shall then be subjected to two further passes by the plate vibrator.

100% of the sand used to fill the joints between the concrete blocks shall pass through a 1,18 m m sieve and between 10% and 15% of it shall pass through a 0,075 m m sieve.

(c)

Concrete paving blocks

Concrete paving blocks shall comply with the requirements of SABS 1058. The block shall be of the class, type and thickness specified in the project specifications, on the drawings, or in the schedule of quantities. The surface texture and colour of all blocks shall be uniform. The blocks shall comply with the Portland Cement Institute's abrasion test.

(d)

M g e beams and intermediate beams

(d)

Concrete

Cast in situ concrete edge beams or intermediate beams shall be constructed in accordance with the provisions of sections 6200, 6300 and 6400. Prefabrlcated kerbing and

Cast in situ or prefabricated concrete edge beams or intermediate beams shall be constructed on the underlying pavement layer in accordance with the details shown on the drawings. No paving blocks shall be laid before the edge and intermediate beams have developed sufficient strength to withstand the construction forces.

(e)

Construction tolerances

necessary to complete the concrete block paving as specified.

The completed concrete block paving shall comply with the following construction tolerances: Unit (i) Line of pattern Maximum deviation from any 3 m straight line Maximum deviation from any 20 m straight line (ii) Vertical deviation from a 3 m straight-edge at the edge beams
73.02 Cast in situ concrete edge and intermediate beams . .

...

cubic metre (m3)

10 m m The unit of measurement shall be the cubic metre of concrete in edge and intermediate beams. The quantity shall be calculated from the dimensions shown on the drawings or authorized by the engineer. The tendered rate shall include full compensation for furnishing all materials, and constructing the edge and intermediate beams complete as specified, including all excavation and backfilling in all classes of material.

20 m m

elsewhere (iii) Maximum difference in the surface levels of adjacent units

+ 10 m m
Unit
73.03 Provision of approved hehicide and ant poison:
(a)

Provision of materials

. . . . . . . . prime cost sum

7304

MEASUREMENT AND PAYMENT (b) Contractor's charges and profit added to the prime cost sum . . . . . . . . . . . . . . . . . . . .

Item
73.01 Concrete block paving (class, type and thickness indicated) . . . . . . . . . . . .

Unit

per cent (%)

...

square metre (m Z)

The unit of measurement shall be the square metre of completed concrete block paving. The quantity shall be calculated from the dimer~sions shown on the drawings or authorized by the engineer. The tendered rate shall include full compensation for furnishing all materials, constructing the sand bedding, laying and compacting the concrete pavement blocks, filling the joints with jointing sand, and for all other work

Payment under the prime cost sum for providing ant poison and herbicide and the contractor's costs and profit in this respect shall be made in accordance with the provisions of the general conditions of contract, but, in addition, the contractor's tendered rate for costs and profit shall include full compensation for applying the chemicals as specified.

Note: All prefabricated concrete kerbing and channelling will be measured and paid for under section 2300.

SERIES 7000 : SUNDRY STRUCTURES

7403

CONSTRUCTION

4 0 0: PATENTED EARTH RETAINING SYSTEMS SECTION 7

(a) CONTENTS 7401 7402 7403 7404 7405 SCOPE MATERIALS CONSTRUCTION PATENT RIGHTS MEASUREMENT AND PAYMENT Excavations

All excavations for the bases of the earth retaining systems shall be done in accordance with the provisions of section 6100. The contractor shall not commence with the construction of the bases before the excavations have been properly cleaned by the contractor and inspected and approved by the engineer.

7401

SCOPE The bases for the earth retaining systems shall be of the type or types shown on the drawings or specified in the project specifications. The provisions of sections 6200,6300 and 6400 shall apply to the construction of concrete bases. The bases shall be constructed in accordance with the dimensions and levels shown on the drawings subject to the provisions of clause 6106. No precast concrete blocks shall be installed until the engineer has inspected and approved in writing the completed bases.

This section covers the construction of retaining structures by means of proprietary or custom-built precast concrete block retaining systems such as Loffelstein, Enviro-wall, Terrace Blok, etc.

7402

MATERIALS

(a)

General

All materials used in constructing the retaining systems, as well as all precast units of proprietary or custom-built retaining systems shall be subject to the approval of the engineer.

(c)

Installing the precast concrete blocks

When requested by the engineer, the contractor shall submit test certificates from an approved independent testing authority to show that the respective materials comply with the specified requirements, or certificatesfrom the patent holders or licensees certifying that the manufactured items comply in all respects with the relevant product specifications.

The precast concrete blocks shall be installed on the completed bases in accordance with the specifications of the patent holders or the licensees and in accordance with the lines, levels and angles of inclination shown on the drawings, or with the variations ordered in writing by the engineer.

7404

PATENT RIGHTS

@)

Concrete bases for earth retaining systems The contractor shall negotiate direct with the patent holders or licensees in connection with royalties payable for the use of the patented systems. The contractor shall arrange for technical assistance by the patent holders or licensees before and during construction.

All materials for concrete bases for earth retaining systems shall comply with the relevant requirements of sections 6200. 6300 and 6400.

(c)

Precast concrete blocks

7405

MEASUREMENT AND PAYMENT

The precast concrete blocks shall be of the type shown on the drawings or specified in the project specifications, or it shall be an approved alternative type. The blocks shall be uniform of colour and durable and shall not react with soil. All materials for precast concrete blocks shall comply with the relevant requirements of sections 6200, 6300 and 6400.

Unit
74.01 Patented earth retaining systems:

(a) (d) Backfill material (b)

Loffelstein precast concrete blocks of type (state type) . . . . . . . . . . . . . . square metre (m 2) Enviro-wall precast concrete blocks of type (state type) . . . . . . . . .

The backfill material shall be approved granular material, unless otherwise specified in the project specifications or on the drawings.

. . . . . square metre (m2)

(c)

Terrace Blok precast concrete blocks of type (state type) . . . . . . . . . . . . . . square metre (m 2) Etc for other patented earth retaining systems and other types of blocks . . . . . .

(b)

Extra over subitem 74.02(a) for excavation in hard material . . . . . . . . . . . . . . . .

cubic metre (m3)

(d)

square metre (m2)

Measurement and payment for excavation shall be as specified for item 61.02 except that no additional excavation shall be measured were formwork is required.

The unit of measurement shall be the square metre of the front vertical face of the earth retaining system placed in position as shown on the drawings. The front vertical face shall be measured from the top of the base to the top of the earth retaining system. The tendered rate shall include full compensation for procuring,furnishing, transporting, handling and placing all materials and precast concrete blocks, including the specified backfill material between the blocks, and any additional costs required for placing the blocks in position complete as specified.

kern
74.03 Concrete bases for earth

Unit

retaining systems (class of concrete indicated) . . . . . . . .

cubic metre (m3)

The unit of measurement shall be the cubic metre of concrete cast in the concrete bases for earth retaining systems, calculated in accordance with the net approved dimensions of the concrete bases.

Item
74.02 Excavation for concrete bases for earth retaining systems:

Unit

(a)

In soft material

.... . ......

cubic metre (m )

The tendered rate shall include full compensation for supplying and placing the concrete and constructing the concrete bases, including any formwork whiqh may be necessary, and for all steel reinforcement, complete as specified.

SERIES 7000 : SUNDRY STRUCTURES SECTION 7500 : GROUND ANCHORS

requirements of acceptance testing. This facility is available during the initial stressing phase but subsequently, if the protruding tendon is cut, further measurement or adjustment is not possible. (ii) Restressable type

CONTENTS SCOPE DEFINITIONS GENERAL REQUIREMENTS MATERIALS AND EQUIPMENT DRILLING MANUFACTURE HOMING AND GROUTING TENSIONING AND TESTING MEASUREMENT AND PAYMENT

An anchorage meeting all the requirements of the normal anchorage and also permitting the tendon, throughout the life of the structure, to be measured by check lifting. It also allows small losses, up to, say 10% of working load, to be recovered by shimming or nut turning. (iii) De-tensionable type

7501

SCOPE

An anchorage meeting all the requirements of the restressable type and in addition permitting the tendon to be de-tensioned in a controlled manner at any time during the life of the anchor. All temporary anchors shall have anchorages of the de-tensionable type.

This section covers the design, supply, installation, stressing and testing of ground anchors.

(e)

Fixed anchor length

7502

DEFINITIONS

The designed length of the anchor over which the tensile load is transmitted by bond to the surrounding ground.

The definitions in clause 6502 together with the following additional definitions shall apply to these specifications:

(f)

Free anchor length

(a)

Ground anchor

The distance between the proximal end of the fixed anchor and the stressing anchorage.

The term "ground anchor" is a generic term covering all types of ground anchors which are generally subdivided in rock anchors and soil anchors. It is an installation which is capable of transmitting an applied tensile load to a loadbearing stratum. The installation consists basically of a stressing anchorage, a tendon and a fixed anchor as shown in figure 750211,

@)

Proximal

Nearest to the stressing anchorage.

(h)

Distal

Furthest from the stressing anchorage.

@)

Temporary anchor
( i ) Tendon

An installation which is often used during the construction phase of a project to withstand forces for a known short period of time, usually less than two years.

The part of the anchor which is capable of transmitting the tensile load from the fixed anchor to the stressing anchorage.

(c)

Permanent anchor

An installation which is required to ensure the stability and satisfactory service performance of the permanent structure being supported.

(j)

Tendon bond length

The length of the tendon which is bonded directly to the grout.

(d)

Stressing anchorage

(k)
The component of a ground anchor which is capable of transmitting the tensile load from the tendon to the surface of the ground or structure requiring support: (i) Normal type
(I)

Capsule bond length

The overall length of the outer perimeter of the capsule which is bonded to the surrounding grout.

Free tendon length

An anchorage designed to permit the load in the tendon to be raised or lowered within the entire range of operating stress levels and measured when necessary to meet the

The length of the tendon which is decoupled from the surrounding ground or grout. During the initial stressing

operation the free tendon length may be extended by the stressing length, depending on the type of stressing system employed.

(v)

Decoupling

The separation of components. A term normally used when tendons are separated from the surrounding ground and/or grout by grease and sheathing.

(m)

Primary grout
(w)

The grout injected before or after tendon homing, and prior to stressing, to secure the fixed anchor to the surrounding ground.

Characteristic strength

The value of cube strength of grout or concrete or the ultimate tensile strength of prestressing steel, below which not more than 5% of the test results fall.

(n)

Secondary grout
7-

The groit injected after stressing to bond and/or protect the free length of the tendon.

GENERAL REQUIREMENTS

(0)

Absolute accuracy

The ground anchors shall be designed to comply (a) with the requirements contained in the following publications: (i) Lateral Support in Surface Excavations : Code of Practice 1989 : SAICE. Recommendations for the Design and Construction of Prestressed Concrete Ground Anchors : FIP (May 1982). Corrosion and Corrosion Protection of Prestressed Ground Anchorages : THOMAS TELFORD : FIP (1986). A ground anchor shall be specified as follows: Permanent or temporary Minimum working load Minimum ultimate tensile strength Class and type of anchor Degree of corrosion protection Minimum free length .Minimum fixed anchor length Minimum drill hole size Rock or ground quality or bore hole logs.

The deviation of a calibrated measuring instrument from the true value, ie where a measuring instrument has been calibrated against dead weight apparatus or loading machines of which the accuracy is known.

(ii)

@)

Relative amracy (iii)

The accuracy of the reading of small differences in quantities to be measured.

(q)

Lifl off load

(b) (i) (ii) (iii)

The minimum load monitored during a restressing or load checking operation which provides a defined clearance (0,l mm 1,O mm) between the anchor head or ring nut and the anchor plate.

(r)

Relaxation

(iv) (v) (vi) (vii)

The decrease of stress with time while the tendon is held under constant strain.

The change in strain of the tendon with time under constant stress.

(viii) (ix)

Skin friction The contractor shall design the anchor system to (c) comply with the above requirements and shall submit his design to the engineer for his approval. The contractor may not commence with the installation of ground anchors until the engineer has approved the contractor's design.

A term commonly used in practice to define the ultimate bond value at the ground/grout interface of the fixed anchor.

(u)

Debonding No ground anchor may be installed at a distance of (d) 1,O m or less from any point on the exterior of a known service, service duct or culvert.

The breakdown of bond at the grout/tendon or ground/grout interface.

7-

MATERLALS AND EQUIPMENT

Position of hole: Depth of hole:

rt

75 m m of specified position

Specified depth

+ 0,3 m - 0 m

All materials used in the ground anchors shall comply with the requirements of clause 6503, and all equipment used in the fabrication, grouting and stressing shall comply with the requirements of clause 6504.

(d)

Water testing

On completion of drilling in rock the hole shall be tested for watertightness. If the loss of water over a period of 10 minutes exceeds 3 Plmin at a pressure of 100 kPa at collar level the hole shall be grouted and redrilled. The water proofing grout shall be cement grout of similar composition to the anchor grouting. The redrilling shall not commence for at least twelve hours after the waterproof grouting has been completed.

(a)

General

Holes shall be drilled to the diameter, depth, position and tolerances as specified. The diameter of the drilling bit shall not be less than the specified diameter. The depth of drilling shall allow for detritus that cannot be removed from the hole. The drilling rig assembly and the working platform shall be rigid to ensure that the specified alignment shall be achieved. Unless otherwise specified or approved by the engineer the noise level of drilling and pneumatic equipment shall not exceed 75 dBA when measured at a distance of 15,O m from the equipment.

7506

MANUFACTURE

The storage, handling and protection of ground anchors shall comply with the requirements of subclause 6510(a), and the fabrication of ground anchors shall comply with the requirements of subclause 6510(b). Anchors composed of plastic sheathed greased strand shall have the exposed strand in the fixed anchorage zone thoroughly cleaned and degreased, using steam or solvents, after onlaying of the strand. Centralisers and cover spacers shall be non-metallic and shall be firmly attached to the tendon at a maximum spacing of 1,5 m to ensure the central location and minimum grout cover of 10 mm.

@)

Drilling methods

The drilling methods shall be rotary, percussive, rotarypercussive or vibratory and shall be chosen to give the minimum disturbance to the surrounding ground. The use of casing in the free length is permitted. The use of drilling fluid is subject to the following conditions: (i) It shall have no deleterious effect on the ground, tendon or grout. It shall not cause swelling or softening of the ground.

7507 HOMING AND GROUTING

(a)

Homing

(ii)

Tendon installation and grouting shall be carried out as soon as possible after the drilling of the fixed anchor length and shall be completed within 2 to 4 days. The homing shall be carried out at a steady controlled rate.

Special care shall be taken when drilling into ground water with artesian pressure and the contractor shall submit his drilling method to the engineer for approval.

@)

Grouting Cementitious grout shall comply requirements of subclause 6510(f). with the

(i)

Should the contractor encounter ground conditions that differ from those on which his design is based, he shall immediately discontinue the installation of the ground anchors, notify the engineer and wait for the engineer's instructions before recommencing with the installation of the ground anchors.

(ii)

Resin grout shall comply with the recommendations of BS 8081.

The grout shall be injected at the distal end of the hole, through a grout tube. This may be done prior to homing or after homing dependant on the type of anchor. Where a tendon is decoupled in the free length the column of grout shall not extend to the structure being anchored.

(c)

Tolerances maximum tendon diameter plus 10 m m

2

Minimum hole diameter:

The hole shall be adequately vented to allow trapped water and airto escape to permit proper filling. After grouting the anchor shall remain undisturbed until the specified transfer strength is obtained, which shall not be

Inclination of hole:

2,5"of specified
inclination

less than 25 MPa. The anchor shall in any case remain undisturbed for a period of at least three days after grouting. After the tensioning and testing as specified in clause 7508 have been completed and approved, the anchorages at the jacking end shall be encased in concrete as detailed on the drawings or as ordered by the engineer.

ltern

Unit

75.03 Drill holes with a

diameter of (diameter indicated) to the specified depths and inclinations ............metre (m) The unit of measurement shall be the metre of hole, including the depth of the bulbous base formed, as may be applicable. The depth of the bulbous base shall be deemed to be equal to the diameter of a sphere, the volume of which shall be equal to the quantity of compacted concrete in the bulbous base. The tendered rate for forming augered holes shall include full compensation for augering and disposing of surplus material resulting from the hole having been formed. The tendered rate for forming bored holes shall include full compensation for boring, supplying, installing and extracting the driven temporary casing as well as for disposing of surplus material resulting from the hole having been formed.

7508 TENSIONING AND TESTING

Tensioning shall comply with the requirements of (a) subclause 6510(e). Testing shall be done in accordance with Chapter 6 (b) paragraph 6.7 of the SAICE Code of Practice : Lateral Support in Surface Excavations (1989). The contractor shall bear the cost of all acceptance (c) tests specified in the contract or prescribed by the engineer and which are not listed in the schedule of quantities.

kern

Unit

7509 MEASUREMENT AND PAYMENT 75.W Water tests

kern Unit

. . . . . . . . . . . . . . . . . . number (No)

The unit of measurement shall be the number of holes tested. The tendered rate shall include full compensation for installing and the subsequent dismantling and removal of the testing equipment, conducting the test and processing and submitting the results.

7 5 . 0 1 Establishment on the
site for drilling

..................

lump sum

The tendered lump sum shall include full compensation for generally levelling the drilling site, establishing on the site and subsequently removing all structural platforms, rafts and all special plant and equipment for drilling and for carrying out operations, the cost of which does not vary with the actual amount of drilling done. This work will be paid for by way of a lump sum, 50% of which will become payable when all equipment is on the site and the first hole has been drilled. The second instalment of 25% of the lump sum will be payable after half the total number of holes and the final instalment of 25% after all the holes have been drilled and the equipment has been removed from the site.

kern

Unit

75.05 Grouting and redrilling

the holes

. . . . . . . . . . . . . . . . . . . . . . metre . (m)

The unit of measurement shall be the metre of hole grouted and redrilled. The tendered rate shall include full compensation for all grouting materials and equipment, the grouting operation, resetting up drilling equipment, the redrilling operation, flushing and cleaning the hole to provide a watertight hole.

ltern

Unit kern Unit

75.02 Moving to,and setting up

the equipment at each position for drilling the holes . . . . . . . . . . . number (No)

75.06 Ground anchor tendons:

(a)

The unit of measurement shall be the number of positions to which the installation equipment has to be moved and set up in position. The quantity measured shall be the number of holes drilled plus the number holes redrilled on the instruction of the engineer, plus any holes provided in addition for load tests, which do not form part of a specific anchor group.

Free length

.............

meganewton-metre (MN-m) meganewton-metre (MN-m)

(b)

Fixed anchor length

......

The tendered rate shall include full compensation for all costs involved in moving and setting up any equipment.

The unit of measurement shall be the meganewton-metre which is calculated as the product of the characteristic s;:ength in megapascals of the prestressing steel, the cross-sectional area of the tendon in square metres and the length of the tendon in metres between the outer faces of

the anchorages. In the case of fan and loop anchorages the "length of the tendon" shall include the length of tendon forming the loop or fan. The tendered rates shall include full compensation for preparing and submitting the drawings, supplying, storing, handling and protecting all materials (excluding anchorages and couplers at the jacking end), fabricating, supporting and installing the cables, lubricating, permanently protecting and bonding the tendons, for the using of all the equipment, as well as for all work and incidentals required for completing the work as specified.

The tendered rates shall include full compensation for supplying, storing, handling, fabricating and protecting the complete anchorage or coupler assembly, anchorage reinforcing, constructing the recesses for the anchorage or coupler, tensioning of the tendons, anchoring and/or coupling, trimming the tendon ends, using all the equipment, as well as for all work and incidentals required for completing the work as specified. It shall also include full compensation for testing the tendons to the specified test force in accordance with the prescribed methods. The coupler shall include the complete assembly consisting of the anchorage built into the first-stage construction and the part coupled to it.

Item

Unit
Item

75.07 Anchorages and couplers:

(a) (b) Anchorage at jacking end Coupler at jacking end

Unit

. . . rneganewton (MN)
meganewton (MN)

.. ...

75.08 Encasing the anchorages at the jacking end in concrete . . . . . . . . number (No) The unit of measurement shall be the number of anchorages encased. The tendered rate shall include full compensation for encasing the anchorages at the jacking end in concrete, complete as specified and detailed on the drawings.

The unit of measurement shall be the meganewton which is calculated as the product of the characteristic strength in megapascals of the prestressing steel and the crosssectional area of the tendon in square metres, effectively anchored or coupled.

SERIES 8000 : SUNDRIES SECTION 8100 WORKMANSHIP

:

TESTING

MATERIALS

AND

(1) The standard methods of testing of the South African Bitumen and Tar Association (SABITA). In addition to the above standard methods of testing, standard specifications or test methods of other bodies may also be referred to in these specifications, or test methods may be described where no acceptable standard methods exist. Note: In all cases the latest amendment or revision current at the closing date of the tender is implied when reference is made to one of the above standards in the specification.

CONTENTS SCOPE TESTING METHODS THE COSTS OF TESTING TAKING AND SUBMITTING SAMPLES TESTING THE AGGREGATES TESTING THE CONCRETE TESTING THE SOILS. GRAVELS AND CRUSHEDSTONE MATERIALS FOR EARTHWORKS AND PAVEMENT LAYERS DETERMINING THE TOTAL APPROXIMATE DRY BULK RELATIVE DENSITY AND THE APPARENT RELATIVE DENSITY TESTING TAR, BITUMEN AND ASPHALT TESTS RELATING TO CHEMICAL STABILIZATION TESTS ON PAVEMENTS STRUCTURAL TESTS TESTS ON SILICONE SEALANTS G E O T E X T I L E AND G E O T E X T I L E - S O I L COMPATIBILITY TESTS CLASSIFYING THE TESTS TESTING OF CONSTRUCTION WATER MEASUREMENT AND PAYMENT

8103

THE COSTS OF TESTING

(a)

Process control

The cost of testing undertaken by the contractor in terms of his obligations under clause 1205 for purposes of process control, including the taking of samples, reinstating where samples have been taken, and all testing equipment, labour, materials, etc, shall be included in the rates tendered for the various items of work supplied and will not be paid for separately.

8101

SCOPE

@)

Producing certificates

During the progress of the work tests shall be conducted on materials and workmanship to ensure compliance with the requirements of the specifications. Certain sampling and testing procedures not covered in the other sections of the specifications by reference to the standard methods mentioned in clause 8102, are given in this section.

8102

TESTING METHODS

Where the properties of materials or manufactured products are required in these specifications to comply with specified specifications published by a standards authority, the contractor shall produce, when called upon to do so, certificates from the manufacturer confirming that the materials or products supplied comply with the relevant specifications. The cost of providing such certificates shall be borne by the contractor. Where it is specified that a product shall comply with an SABS specification, it means that the product shall have been tested and evaluated in accordance with the requirements of the relevant SABS specification. Where an SABS mark is specified, a certificate will be required.

All tests shall be conducted in accordance with the standard methods specified in the following, in order of precedence: (a) Standard methods for testing road construction materials (TMH1 and TMHG) and for calibration (TMH2). compiled by the Committee of State Road Authorities (CSRA) and published by the Department of Transport as part of the series Technical Methods for Highways. South African Bureau of Standards specifications. (b) test methods, codes of practice and co-ordinating specifications (abbreviated as SABS and CKS). (c) British Standards (abbreviated as BS). Institute Specifications

(c)

Testing materials certificates

and products

covered

by

The engineer shall be entitled to take samples of and order tests to be made on products and materials in respect of which certificates of compliance may be required as described in subclause (b) above. The contractor shall be paid at the appropriate rates if the cost of such tests are itemized in the schedule of quantities, and, if no appropriate rates exist, such tests shall be classed as a variation under clause 40 of the general conditions of contract, provided that such tests indicate compliance with the specifications, otherwise the cost shall be borne by the contractor.

(d) The specifications of the American Society for Testing and Materials (abbreviated as ASTM). The specifications of the American Association of (e) State Highway and Transportation Officials (abbreviated as

8104

TAKING AND SUBMITTING SAMPLES

The method of taking samples shall be as specified in the appropriate sampling and testing methods. The sampling methods described in TMH5. SABS method 827, ASTM and

AASHTO shall apply where relevant. If no sampling method is specified, the sampling methods described in TMH5 and in SABS method 827 shall take precedence. In the case of rehabilitation work the definitions given in the project specifications for lot, lot size, random sample and sample size shall apply. Where the contractor is required in these specifications to submit samples of materials or mixtures to the engineer for approval prior to their being used in the works, the use of these materials or mixtures without the engineer's written approval shall constitute default on the part of the contractor, who shall be liable for the consequence of such default. All samples shall be submitted in sufficient time for proper testing.

@)

Determining acid insolubility

A sample of fine aggregate with an approximate mass of 1 kg shall be dried and weighed. The sample shall then be treated with an adequate amount of a 6 N solution of hydrochloric acid to react with all the acid-soluble particles in the sample. When the reaction is complete, the residue shall be removed from the solution by filtration (Whatman No 4 filter paper), washed with water, screened through an 0,075 m m sieve, dried and weighed. The mass of insoluble residue retained on the 0,075 m m sieve, expressed as a percentage of the total sample, shall be reported as the acid-insoluble content.

(c)

Free-water content

The engineer's approval of any materials or mixtures shall in no way relieve the contractor of his obligation to provide materials, mixtures and workmanship which comply with the specifications.

The free-water content of aggregate shall be determined in accordance with SABS method of testing 855. Rapidtesting methods approved by the engineer may also be applied. Suitable adaptions of the above method may be used for determining the free-water content of coarse aggregate.

All samples for testing shall be taken in a random pattern or as prescribed by the engineer. Where specified or required by the engineer, stratified random sampling methods shall be followed. For the testing of layerwork stratified random sampling methods shall be used for obtaining all the sample portions and for determining the locations for in situ tests.

(d)

Bulking the fine aggregates

The bulking of fine aggregates shall be determined in accordance with SABS method of testing 856.

(e)

The engineer shall have full access to the works for the purpose of taking samples. The contractor shall render any assistance necessary for taking the samples and shall be responsible for the reinstatement of pavement layers or other structures at the positions where the samples have been taken. Full compensation for rendering assistance with sampling and for reinstatement where samples have been taken shall be included in the rates tendered for the various items of work tested, and no additional payment will be made in this respect.

Determining the effect of sand on the water demand of a concrete mix

Water demand is defined as the quantity of water per cubic metre of concrete required to give a slump of 75 m m in a concrete with an optimum quantity of stone with a nominal size of 19 rnm. The following materials are required:

Ordinary portland cement Crushed stone with a nominal size of 19 m m Sand or a sand mix to be tested.

Table 810411 provides guidelines in respect of submitting the materials in regard to the time and quantity of material required for testing, approval and the mix design. As the time stated in this table does not make any allowance for possible rejection and the resubmission of alternative materials, the contractor shall submit any materials of uncertain quality at an early stage or together with alternative materials in order to minimize any delays in final approval. The contractor shall note that any samples submitted direct to the engineer's laboratory for approval shall be properly marked and shall be accompanied by a covering letter with all the required information and countersigned by the engineer's representative.

Method: Determine the relative density (Rsa) in accordance (1) with SABS method 844 and the fineness modules (FM) of the sand or sand mix.

(2)

Determine the compacted bulk density (CBD) of the 19 m m aggregate in accordance with SABS method 845. Also determine the relative density of the stone (R St).

Determine the required quantity of stone (S) per (3) 3 cubic metre of mix (in kg/m ) in accordance with formula: S = CBD (0,975 - 0,lFM). (4) Estimate the water demand (W) of the mix (in l l m 3 ) . 220 l / m 3 may be used as a starting point. Determine the required cement content (C) for the (5) mix (in kg/m 3) by using the water content 0 as obtained from (4) and a water:cement ratio of 0,59. Determine the required sand content (SC) of the (6) mix (in kg/m3) in accordance with the formula:

8105

TESTING THE AGGREGATES

(a)

General

Aggregates shall be regularly tested by the contractor as part of his process control as they are being manufactured or brought onto the site and used or taken to stockpile.

Decide on the mix size which will apply to the (7) available equipment and calculate the mix quantities in relation to the calculated quantities per cubic metre. Do . not produce a mix of less than 10 1

(8) Prepare the mix and determine the slump in accordance with SABS method 862. Where the slump does not amount to 75 mm, repeat the test with adjusted quantities of cement, water and sand. A good rule to remember is that a change of 10 1/m 3 in the water content either halves or doubles the slump.

Table 810411 SCHEDULE SHOWING QUANTITIES AND TIMES FOR SUBMITTING THE MATERIALS FOR APPROVAL AND MIX DESIGNS Submission for quality approval only Material submitted Proposed use Minimum quantity to be submitted 50 kg of each size of stone 50 kg of each size of stone 50 kg of each size of stone 50 kg Submission for quality approval and mix design Minimum time to be allowed for testing, approval and mix design 8 weeks for structures and concrete roads 2 weeks

Minimum time to be allowed for testing and approval 2 weeks

Minimum quantity to be submitted 150 kg of each size of stone for each class of concrete 50 kg of each size of stone

Crushed stone

Coarse aggregate for concrete Bituminous seals

2 weeks

Asphalt mixes Crushed-stone base or subbase Crusher dust and/or sand Fine aggregate for concrete

2 weeks

8 weeks

100 kg of each size of stone

3 weeks

8 weeks (stabilization) 10 weeks

200 kg

2 weeks

50 kg of each size of aggregate

150 kg of each type proposed for use for each class of concrete 150 kg of each type proposed for use 50 kg of each type proposed for use 200 kg

Asphalt mixes

2 weeks

15 kg of each size of aggregate 15 kg of each type proposed for use 200 kg of each sample

8 weeks

Slurry or sand seal Gravel Subbase and/or base As specified

2 weeks

6 weeks

4 weeks

8 weeks (stabilization)

Other materials eg paint, cement, additives, etc

As prescribed by the engineer

The water content giving a slump of 75 m m will (9) then be the water demand for the mix. (10) In view of obtaining repeatable results, the following parameters shall be kept constant in so far as is possible:

r 0,25

The alkali reactivity of the aggregate is harmful and the aggregate is expanding rapidly. Interpretation

(iii)

(9
(i)

Material temperature Mixing time Source of cement Source of stone.

For aggregates falling in the slowly expanding group, the alkalinity per m 3 of concrete shall not exceed 2,80 kg of an Na20 equivalent.

Accelerated-test method for determining the potential alkali reactivity of aggregates

The method

For aggregates falling in the rapidly expanding group, the alkalinity per m 3 of concrete shall not exceed a value of 3 2,10 kg of an Na20 equivalent per m , depending on the reactivity.

Three mortar prisms shall be prepared in accordance with the requirements of ASTM C 227-90. The prisms are removed from the mould after 24 hours and immersed in water in a closed container, placed in an oven and kept at a constant temperature of 80C. After 24 hours in the oven, the prisms are taken to a room with a temperature of 23"C, where their lengths are measured with a vertical comparator (an indicator type of deformation meter) accurately to 2 p m before any significant cooling-down takes place. This reading will be taken as the nil reading. After the initial reading has been taken, the prisms are immersed in a 1 N NaOH solution kept at 80C. This solution is kept in a plastic container which seals tightly and is large enough for the prisms to be completely immersed. Plastic is used, as the caustic solution corrodes glass and metal. The prisms are measured every working day for a period of 14 days at a room temperature of 23"C, and their linear expansion is calculated. The average expansion of the three prisms for each day is then calculated. Where none of the values deviate by more than 15% from the average, the repeatability is regarded as being satisfactory. The average expansion after 10 or 12 days is taken to be the reference value for determining the potential alkali reactivity. (ii) Criteria

The dilution and palliative effect of extenders in the cementitious binders, such as slagment (where permitted in structural concrete) and fly ash, shall be taken into account in the interpretation of the results.

8106

TESTING THE CONCRETE

(a)

Determining the compressive strength

The procedure for sampling and manufacturing, storing, curing and testing test cubes shall be in accordance with TMHl method D l , except that the machines referred to in paragraph 2.3 of TMHl method D l shall also comply with all the requirements of BS 1610 and BS 1881. The following deviations from the above procedure shall apply:

Where instructed by the engineer, the compaction of concrete specimens in the moulds by means of a vibrating table shall be obligatory. The method of compaction shall be as follows: (i) Plastic concrete

The criteria proposed provisionally for the accelerated mortar-prism testing method shall be as follows: (1) Percentage of linear expansion after 10 days: The alkali reactivity of the aggregate is not harmful The alkali reactivity of the aggregate is harmful and the aggregate is expanding slowly The alkali reactivity of the aggregate is harmful and the aggregate is expanding rapidly Percentage of linear expansion after 12 days:

Fill the mould halfway and vibrate it and spade it on all four sides with a suitable trowel to remove air bubbles. Stop the vibration as soon as a wet sheen appears on the surface. Fill the mould and repeat the procedure, but stop when again a wet sheen appears on the surface. (ii) Stiff concrete

< 0,08

The same procedure is followed, except that the mould is filled in three to four steps instead of in two. The vibration is stopped for each layer when a wet sheen appears.

2 0,08 but 0,20

-=

@)

Consistency

2 0,20

The test method described in TMHl method D3 shall apply in regard to the slump test, and the method described in BS 881 (Part 104) in regard to the VEBE test.

(2)
i0,lO

(c)

Air content

The alkali reactivity of the aggregate is not harmful The alkali reactivity of the aggregate is harmful and the aggregate is expanding slowly

1 0,lO but i0,25

The air content of the freshly mixed concrete shall be tested by the method given in TMHl method D5. Arcontent tests shall be conducted on the same samples of concrete from which cubes were made for the 28-day compressive-strength tests.

(d)

Drilling and testing the cores

Where sections of concrete which have failed to comply with the specifications are required to be further investigated by extracting and testing concrete cores, 100 m m or 150 m m cores shall be drilled and tested. The sampling and testing procedure to be followed shall be in accordance with SABS 865.

For purposes of the initial work, it is mentioned that research has shown that the strength of the cubes treated and tested as described above will be approximately 0,58 times the 28-day compressive strength for concrete cubes prepared from ordinary portland cement (for strengths between 30 and 65 MPa). For rapid-hardening cement, the corresponding factor is 0,59, and for PBFC it is 0,66.

8107

(e)

Flexural strength test (modulus of rupture)

TESTING THE SOILS, GRAVELS AND CRUSHED STONE MATERIALS FOR EARTHWORKS AND PAVEMENT LAYERS

The procedure for sampling, making tests beams, curing, storing and testing, and the moulds used, shall be in accordance with SABS method 864.

(f)

Curing concrete wbes to attain accelerated strength development (55"CIM hours)

Scope

(i)

Specimens of soils, gravels and crushed-stone materials in earthworks and pavement layers shall be taken in accordance with the methods described in TMHS (unless SABS method 827 is specified), and any tests thereo'n shall be conducted in accordance with the methods described in TMHl (A series), all subject to the following additional provisions:

A method is described for curing concrete cubes at 55C for 20 hours with a view to pre-estimating the 28-day compressive strength for purposes of quality control. The accelerated tests are additional tests and do not replace the 28-day tests. (ii) Apparatus

The following apparatus is required: Apparatus for preparing the concrete cubes in accordance with method D l of TMHl Plastic sheets of 180 m m x 180 m m Hessian sheets for covering the samples A suitable water bath with a thermostat to maintain the 1 "C, with a circulation temperature constantly at 55C system and adequate capacity.

All field-density determinations shall be done in (a) accordance with method C (direct transmission) of method AlO(b). Method AlO(a) may be used where so instructed by the engineer. Unless otherwise directed by the engineer, density testing for layerworks shall be carried out within 24 hours of compaction having been completed. For the determination of the dry density the moisture content shall be determined by means of a gravimetric method. Method AlO(b) will be the reference method, except where in the opinion of the engineer the material is of such a nature that, when the method is applied, disturbances will occur which will affect the results. The apparatus shall be properly calibrated, and a valid calibration certificate by a recognized laboratory shall be submitted to the engineer on demand. The engineer may insist on recalibration at any stage.

(iii)

Method The dry bulk relative density and the apparent @) relative density of crushed-stone material shall be determined as specified in clause 8108.

Prepare the required number of concrete cubes in accordance with method D l in TMHl and completely cover the exposed surface within the cube mould with small plastic sheets and then with wet hessian. Keep it covered for 3 hours 15 minutes.

Place the concrete cubes into their moulds in the hot-water bath at a rate which will not allow the water temperature to drop below 54C. Record the exact time when each cube is placed into the water and leave it in the water at a 15 minutes. temperature of 55C 2 1 " C for 20 hours

(c) In the case of chemically stabilised material, determining the optimum moisture content and the maximum dry density shall be completed within the period given in table 3503(1), and field density shall be determined within 24 hours of compaction having been completed.

Remove the cubes, in their moulds, from the water and then carefully from their moulds. Cool the cubes for 2 hours + 15 minutes in water at 20C 5C.

The moisture content at the specified saturation (d) degree (Sr) shall be determined as follows: (The apparent density (Gs) of the material shall also be determined for this purpose).

Test the compressive strength of the cubes in accordance with method D l of TMH1. (iv) Calculating the compressive strength

where The cube compressive strength is calculated in accordance with method D l of TMH1. For calculating the expected 28day compressive strength, the ratio between the 28-day compressive strength and the strength of rapid-hardening cubes shall be determined for each type of concrete mix by correlation techniques. moisture content of the specified degree of saturation (%) density of water (kglm') 3 dry field density of the material (kglm ) apparent density of the material (kg/m3) specified degree of saturation (%).

(e)

The soundness of mudrock or shale aggregates

(v)

Evaluation

The soundness of mudrock or shale aggregates (i) shall be determined by weathering the aggregate in water by means of the following method (Venter test): (ii) Apparatus

The disintegration pattern of the aggregate fragments shall be visually classified in accordance with the five classes specified in (vi) and illustrated in figure 8107/2. The terms to be used to describe the shape of the fragments are as follows: Plates - plates of fairly uniform thickness. Flakes - fragments of non-uniform thickness, concave-, convex-, or wedge-shaped. Chunks - roughly equidimensional fragments ( > 3 mm). Grains - fragments from about sand size to 3 m m diameter. Silt, mud or clay. (vi) Classification

Sieves, 300 m m diameter and with perforated plate 37,5 m m and 26,5 m m openings, complying with SABS 197. Stainless steel weathering basins, with perforated bottom comprising 3 m m diameter holes, 10 m m centre to centre apart (see figure 8107/l(a)), with dimensions 150 m m (L) x 100mm (W) x 5 0 m m (H). Stainless steel reaction trough holding three of the above perforated basins with dimension of 500 m m (L) x 160 m m (W) with inner resting shoulders (see figure 8107/l (b)). Stainless steel drip tray, holding nine of the perforated weathering basins for drying in the oven with dimensions of 500 m m (L) x 450 m m (W) x 25 m m (H) (see figure 8107/l (c)). Force draught oven, capable of maintaining a temperature between 105C and 110C. Tank with distilled water supply. (iii) Preparation of aggregate

The five classes for rating the aggregate are as follows: Class I

Nil to minimal breakdown with only minor closed cracks and difficult separation along these fracture planes Disintegration into hard fragments with some open cracks. Moderate disintegration with a high percentage of open cracks into less hard fragments. Extensive disintegration into soft fragments with total separation along fracture planes. Slaking into very soft fragments, silt, mud or clay.

Class II

Class Ill For each laboratory sample, obtain six (6) representative aggregate particles passing the 37,5 m m sieve and retained on the 26,5 m m sieve, without any visible cracks or flaws. Place the particles in the weathering basin without touching each other. Class V (iv) Test procedure (start of first cycle)

Class IV

Put the weathering basins containing the particles in the oven and dry overnight for 15 h 2 0,5 h at a temperature between 105C and 110C. Remove from oven and allow to cool to room temperature for at least 30 minutes. Place the weathering basins with aggregate particles in the reaction trough and fill with clean water until the particles are covered by at least 15 m m of water. Keep the aggregate particles immersed in the water at room temperature for 8 h 0,5 h.

(f)

Nuclear device for compaction process control

The nuclear device for compaction process control shall (i) (ii) be operated by a suitably trained technician; comply with all the statutory regulations governing the use of this equipment; be certified to be suitably calibrated.

(iii)

8108

Lift the weathering basins containing the aggregate particles out of the trough and by tilting it through 90 degrees, allow the weathering basins to rest on the inner shoulders of the trough for drip drying. This completes the first cycle. Visually inspect each particle and record the condition of each particle for cracks, flaws, extent of fissures etc, before starting the following cycle.

DETERMINING THE TOTAL APPROXIMATE DRY BUlX R E L A T M DENSITY AND THE APPARENT R E L A T M DENSITY

(a)

Total approximate dry bulk relative density

The total approximate dry bulk relative density of base material shall be determined as follows:

Repeat until five cycles are completed and finally inspect each aggregate particle.

Firstly the -0,075 m m fraction is removed from the sample and then the sample is divided up into + 4,751m m and - 4,75 m m fractions.

Figure 810711

WEATHERING APPARATUS

* , +
0

O T
+

3mn

FRONT ELEVATION

DETAIL B

.......... .......... .............

".
PLAN

DETAIL B

( a ) WEATHERING B A S I N
0

FRONT ELEVATION

-+% I

204 ]
I

503

20

PLAN ( b ) R E A C T I O N THROUGH
m

~"=t
SECTION B- B
F

500

PLAN

( c ] D R I P TRAY

a "I ' 4

HoLE
+

OETAIL A

'

hIYGE3 qAN3LE

,251
7

110

1251

SECTION A-A

A L L CIMENSIONS I N r n n

APPARATUS MUST BE S T A I h i E S S STEEL

PLAN NOT TO SCALE

Figure 810712 FIVE CLASSES FOR VISUAL CLASSIFICATION

CLASS

ILLUSTRATION

CLASSIFICATION

CLASS 1: N I L TO MINIMAL BREAKDOWN WITH ONLY MINOR CLOSED CRACKS AND D I F F I C U L T SEPARATION ALONG THESE FRACTURE PLANES

II FISSILE
CLASS 1 1 : DISINTEGRATION INTO HARD FRAGMENTS WITH SOME OPEN CRACKS

II MASSIVE

I11 FISSILE
CLASS 111: MODERATE DISINTEGRATION WITH A HIGH PERCENTAGE OF OPEN CRACKS INTC LESS HARD FRAGMENTS

I11 MASSIVE

Iv FISSILE
CLASS I V : EXTENSIVE DISINTEGRATION INTO SOFT FRAGMENTS WITH TOTAL SEPARATION ALONG FRACTURE PLANES

Iv MASSIVE

v
CLASS V: SLAKING INTO VERY SOFT FRAGMENTS. S I L T . MUD OR CLAY

. . . . . .. .. .. .. . .

For the +4,75 m m fraction, the dry bulk density and water absorption are determined according to method 814 of TMHl. The apparent relative density only is required for the -4,75 m m fraction. (i) Definitions

Gently pour off the water without spilling any of the sample. Dry the pycnometer with its contents to a constant mass in an oven at 105'C to 110C and weigh it. Clean the pycnometer, fill it with distilled water at 25"C, dry the outside, and weigh it. Record the mass determinations on a suitable data sheet. (iv) (1) Calculations +4,75 m m fraction

The definitions in methods 814 and 815 of TMHl are applicable. (ii) (1) Apparatus +4,75 m m fraction

Calculate the dry bulk relative density to the nearest 0,001 glcm3 from the following formula:

The same apparatus as that required by method 814. (2) -4,75 m m fraction Dry bulk relative density (25C): Gbc = a/(b-c) where a = mass of oven-dry sample in air b = mass of saturated surface-dry sample in air c = mass of saturated surface-dry sample in water at 25C. The test shall be repeated if the duplicate results do not agree within -c 0,005. Report the result to the nearest 3 0,001 g/cm . Calculate the percentage of water absorbed from the following formula: Percentage of water absorption (mass): Pwa = 100 (b - a)/a Report the result to the nearest 0,1%. (2) -4,75 m m fraction

A 2 1 pycnometer. A balance with a capacity of at least 5 kg and accurate to 0-5 g. A vacuum pump capable of maintaining a reduced pressure of 100 m m mercury. Awater bath capable of maintaining a temperature of 25" C 2 1C.

A drying oven, thermostatically controlled and capable of maintaining a temperature of 105C to 110C.
A 25 m l pipette. A 0,075 mm sieve. (iii)
(1)

Method +4,75 mm fraction

The method is the same as method 814

(2)

Calculate the apparent relative density to the nearest 3 0,001 g/cm from the following formula:

-4.75 m m fraction

After riffling, the volume of the sample shall be 40% of that of the pycnometer.

+ 5%

Apparent relative density (25" C): Gaf = (A - E)/[(D - E) - (C - A)] where A = C = mass of oven-dry sample and pycnometer mass of saturated sample and pycnometer filled with water at 25'C mass of pycnometer filled with water only, at 25C mass of clean, dry pycnometer.

Wash the sample thoroughly to remove the -0,075 m m fraction and soak the sample for 24 hours +. 3 hours. After the sample has been soaked, transfer it to a clean pycnometer. Add distilled water to the sample in the pycnometer until the pycnometer is approximately three-quarters full. Remove any entrapped air by subjecting the sample to partial vacuum (air pressure approximately 100 m m mercury) for a few minutes. This can be done by connecting the pycnometer directly to an aspirator or a vacuum pump, or by using a bell jar. Some soils boil violently when subject to reduced air pressure, in which cases the pressure should be increased. Place the pycnometer and contents in the constant-temperature bath at 25C + 1 " C and leave it for approximately 20 minutes until the contents of the pycnometer are at this temperature. With a pipette, fill the pycnometer up to the mark with distilled water at 25C. Dry the pycnometer quickly and thoroughly, and weigh it.

D=

The test shall be repeated if the duplicate results do not 0,005. Report the result to the nearest agree within 0,001 g/cm 3.

Calculate the dry bulk relative density of the -4,75 m m fraction from the following formula: Dry bulk relative density - fines (25C): Gbf = Gaf/(Pwa.Gaf/lOO

+ 1)

Calculate the dry bulk relative density of the total sample less the -0,075 m m fraction, from the following formula:

Dry bulk relative density - total (25C): Gbt = 100/(Pl/Gbf

constant mass. Ensure that the pycnometer is clean and determine its mass together with that of a marked sheet of glass. Place the dried sample into the pycnometer and determine the mass of the pycnometer, glass sheet and sample together. (The sample shall not take up more than half of the pycnometer's volume.) Add clean water at 25C to the pycnometer until it is approximately three quarters full. Add three drops of the 10% Teepol solution to the water, close the pycnometer and shake it thoroughly for one or two minutes. Fill the pycnometer to near the brim with water at 25C and place it in a thermostatically controlled bath at 25C. Leave it for 30 minutes without disturbing or for so long as may be determined by the engineer. Remove the pycnometer without shaking or jarring and place it on a spread-out towel. Fill it with water at 25C and carefully slide the glass sheet over the brim from one side. Make sure that no air bubbles are trapped beneath the glass sheet. Dry the entire pycnometer and glass sheet carefully and determine the mass of the filled pycnometer plus the glass sheet. Remove the contents of the pycnometer, clean and fill it in the same manner with water at 25C. Dry and determine the mass of the pycnometer filled with water together with the glass sheet.

+ P2IGbs)

where P l = percentage passing through the 4,75 m m sieve P2 = percentage retained on the 4,75 m m sieve. (v) General requirements

The standard temperature is taken as 25C. If the test is conducted at any other temperature, this shall be stated, or the relative density shall be adjusted for a temperature of 25C. The relative density of material retained on the 4,75 m m sieve can also be determined by using a pycnometer. The volume of the pycnometer should not be less than 2 1(the volume occupied by the aggregate shall be 40% + 5% of the pycnometer capacity). The pycnometer may be a relative-density flask with a perforated glass stopper, or avolumetric flask, or any other glass container equipped with a suitable means of ensuring that it can be filled to a constant volume. When the particle size of the -4,75 m m grains is widely distributed, the test may not be repeatable and more samples shall be tested. The apparent relative density of the +4,75 m m fraction is not called for, but if required, calculate it from the following formula: Apparent relative density (25" C): Gac = a/(a - c).

(iii)

Calculation

The apparent relative density of the material is calculated as follows: Mass of pycnometer

@)

Apparent relative density

The apparent relative density of crushed-stone materials shall be determined as follows: (i) Apparatus

Mass of pycnometer glass sheet material

+ glass sheet +

Mass of material only Mass of pycnometer + material + water + glass sheet Mass of pycnometer water + glass sheet

(b - a)

A balance to weigh 5 kg accurately to within 0,5 g.

A pycnometer, eg a preservative jar with a smooth flat rim. A thermostatically controlled bath capable of maintaining a temperature of 25C 1 " C.

A drying oven capable of maintaining the temperature between 105C and 110C. A thermometer marked from 0 100C.
Towels. Teepol (10%) solution. (ii) Method

Apparent relative density of material

Notes:

No chemicals other than the Teepol solution may (1) be added to the water. (2) air. No suction may be applied to the water to remove

Take 3 000 g to 4 000 g of the material as obtained from a density hole in the road. All the material obtained from the hole should preferably be used. If it is too much for one pycnometer, more than one pycnometer shall be used. Dry the material in the oven at 105C

110C to a

The temperature of the water shall be 25C (3) and no other temperature may be used.

+ 1 "C

Where two pycnometers are used, the apparent (4) relative density shall be calculated from the weighted average of the two results. (5) The soaking period will be determined b y the engineer for aggregate, the water absorption of which exceeds 1,0%.

mounted on the interior cylindrical surface of the cylinder, in such a way that a plane centred between the large faces coincides with an axial plane. The shelf shall be 25 m m 1 m m thick and mounted by bolts or other suitable means so that it is firm and rigid. The position of the shelf shall be such that the distance from the shelf to the opening measured along the outside circumference of the cylinder in the direction of rotation, shall not be less than 1 270 mm. The machine shall be driven and counterbalanced to maintain uniform peripheral speed of 30 33 rpm for 300 revolutions.

8109 TESTING TAR. BiTUMEN AND ASPHALT

(a)

Tests described i n the standard specifications for tars, bitumens and bituminous emulsions

The engineer shall be entitled to order the contractor to have materials tested by an approved laboratory for compliance with all or any of the requirements specified, and the results of such tests shall be submitted direct to the engineer by the testing laboratory with copies, if requested, to the contractor. The cost of such tests shall be borne as specified in subclause 8103(c).

If an angle is used as the shelf, the direction of rotation shall be such that the charge is caught on the outside surface of the angle. (ii) Test Procedure

Marshall specimens shall be prepared as described in TMHl - Method C2, but for this test each Marshall specimen shall be compacted with 50 blows only on each side. For each binder content, three specimens shall be made for the abrasion test. The compaction temperature depends on the type of binder to be used. For 820 road-grade (60170 penetrationgrade bitumen) it shall be 115C to 120C and for bitumen-rubber (wet method) it shall be 135C to 140C measured in the mould just prior to compaction. The thickness of the test specimen shall be 63,5 m m 2 1,25 mm. The mass of the specimen in air (PI) to the nearest 0,l g and the average thickness to the nearest 0,l mm, shall be determined. The test specimen shall be placed in the Los Angeles apparatus without the abrasive charge of steel balls and the cover shall be fitted. The machine shall be switched on and allowed to operate for 300 revolutions at a speed between 30 - 33 rpm. After the required number of revolutions, the machine shall be stopped and the specimen removed and the mass determined (P2) to the nearest 0 , l g. The test shall be carried out for each binder content in triplicate. (iii) Calculations

@)

Determining the film thickness

The film thickness of the binder in asphalt mixes shall be determined as described in the publication TRHB.

(c)

Cantabro abrasion test

Where required the resistance of porous asphalt briquettes to abrasion loss shall be determined by means of the Cantabro test. The abrasion loss value for freshly compacted specimens shall not exceed the values specified in table 420311. The details of the test are as follows: (i) Apparatus

The apparatus shall be a Los Angeles Testing Machine as described in ASTM Method C131. The machine shall consist of a hollow steel cylinder, closed at both ends, having an inside diameter of 710 m m 5 mm and an inside length of 510 m m 5 mm.

The cylinder shall be mounted with stub shafts, attached to the end of the cylinder but not entering it, and shall be mounted in such a manner that it may be rotated with the axis in a horizontal position with a tolerance in slope of 1 in 100. An opening in the cylinder shall be provided for introduction of the test sample.
A suitable, dust-tight cover shall be provided for the opening with means for bolting the cover in place.

The percentage abrasion loss for each specimen shall be calculated as follows:

The cover shall be designed to maintain the cylindrical contour of the interior surface unless the shelf is so located that the charge and/or test sample will not fall on the cover, or come in contact with it during the test. A removable steel shelf extending the full length of the cylinder and projecting 90 m m + 2 m m inward shall be

Where:

P l = mass of specimen before testing. P2 = mass of specimen after testing.

The mean of the three specimens at each binder content shall be determined. (iv) Notes:

(d)

Determination of in situ water permeability of bituminous road surfacing or basecourse layers b y using the falling head (MARVIL) apparatus Scope

(i) The determination of the optimum binder content is based on the following factors: a minimum binder content limit to ensure resistance (1) against aggregate loss due to traffic and to enhance durability

(2)

a maximum binder content limit to avoid binder run-off and to ensure good drainage in the mix as a layer on the road.

This method describes the determination of the in situ water permeability of asphalt surfacing and/or basecourse layers and is based on the principle of the falling head permeameter. The permeability of a layer is an indication of the intensity of interconnected voids in the layer which may be detrimental to the material due to oxidation of the binder and/or ingress of water to the lower layers. (ii) Apparatus

I
The minimum binder content to ensure adequate coating thickness shall not be less than 4%. The density of the specimen can also be determined by calculating the volume of the specimen. The voids in the specimen can also be calculated if the maximum theoretical voidless density (Rice) is determined:
% Voids in specimen = 100 (Rice density - Specimen density) / Rice Density.

The apparatus consists of the falling head permeability (MARVIL) apparatus with a circular weight and an acrylic tube with volume markings from 0 m f to 300 m l in 50 m f increments (see figure 8109/1). Other items required are: Adhesive putty (Prestik or similar approved) Water resistant grease (BP LS 3 or wheel bearing grease) Plaster of Paris (commercial grade) optional for granular layers

Figure 810911 MARVIL APPARATUS

D I V I S I O N S AT 50ml SPACING

METRIC THREAD 1. 5rnm P I T C H

RUBBER SEAL

STEEL P L A T E WEIGHT ( M . S ) 270 $ l x 235

p x 40

Stop watch, accurate to 1 second Plastic tanks with sufficient drinking water (40 1 or more) Plastic beakers or aluminium kettles of 5 1 capacity Mechanical power saw with a corundum blade (optional for cutting through thick asphalt layers) (iii) Sundries

Chisels (25 m m and 100 mm width) Hammers (1 kg - 2 kg mass) Paint brushes (25 m m and 100 m m width) Putty knives (50 m m width) Spatula (20 m m width) Hand cleaning cream, paper towels Toluol (at least 5 1 )

As the test is started under a head of 380 m m of water, the two threads must not be too thick because they will prevent the base of the apparatus from coming in close contact with the surface of the test area. Fill the space between the threads of Prestik with grease. The grease shall be applied so that it protrudes below the Prestik (see figure 810912). Place the apparatus lightly on the premarked surface of the road. Lift the apparatus off the surface and apply extra grease over the grease band left on the road and work it into the surface with a spatula or finger. Place the apparatus with the undisturbed adhesive threads, and with additional grease added between the threads, exactly on the pre-marked area. Press firmly until the grease is expelled from underneath the base. Place the circular weight on the upper side of the base. This is to keep the apparatus stable and to prevent the water from lifting it. The expelled grease from underneath the base is worked into the surface to form a band of grease about 20 m m wide around the base of the apparatus to achieve a watertight seal. The apparatus is then ready for filling with water. After testing, carefully lift the apparatus with the aid of a screw driver from the surface. Inspect the condition of the threads and if they are loose, press down again or replace and fill with grease again. (2) Asphalt surfacing with uneven rough surface

(iv)

Test site and apparatus preparation and placing thereof Asphalt and unsurfaced basecourse layers with smooth surfaces

(1)

A test point is randomly chosen or as prescribed in the project specifications. Areas contaminated with foreign matter, such as grease, oil, animal dung, etc, shall be avoided.

Use a brush (100 mm) to clean an area of the surface slightly bigger than the base of the apparatus of all loose aggregate and dust. Place the apparatus in the middle of the clean area and, using the base as template, mark the outside with a marker such as chalk. Clean the bottom of the base of all grease using Toluol (or similar approved organic solvent) and dry with paper towels.

This procedure is for single or double aggregate seals. A test point is obtained as before. In the case of double seals, a groove is cut to a depth of between 3 m m and 5 mm, and 25 m m inside the inner circumference of the pre-marked circle (inner diameter of groove 225 m m 5 mm) using a thin wall barrel and a carborundum bit.

Place a Prestik thread of 5 m m diameter around the inner and outer rims of the base edge and press firmly so that it adheres to the base. The function of the inner thread is to prevent grease from being expelled into the apparatus's test area.

Proceed as before with cleaning the test area, and preparing and placing the apparatus.

Figure 810912 ILLUSTRATION OF GREASE RING

ADHESIVE RING

ADHESIVE RING

FILLED WITH GREASE

(3)

Basecourse layers under existing road surface

Figure 810913 FITTING OF PRESTIK

Mark a circle on the asphalt surfacing, about 25 m m in diameter larger than the base of the apparatus or a square area 300 m m x 300 mm. Remove the surfacing by cutting on the delineated line with a power saw or chisels. Lift the surfacing carefully from the lower layer without causing too much distortion of the surface of the basecourse layer to be tested.

Carefully remove any loose aggregate or surfacing aggregate adhering to the basecourse layer, and, if required, the prime layer and clean the test surface with a brush. Only one thick thread of adhesive putty is placed on the bottom in the middle of the base and formed as shown in figure 810913. Place the apparatus in the centre of the hole and press firmly down. Prepare a liquid slurry mixture of plaster of Paris (see notes in subsubclause (vii)) and water and pour it around and above the base (see figure 810914). Allow the mixture to set to a hard mass (10 - 15 minutes). The apparatus is then ready for filling with water.

ALUMINIUM BASE

PRESTIK TO BE FLATTENED HERE T O FORM PERFECT SEAL

(v)

Test procedure

After testing, the hard plaster of Paris is chipped away and the apparatus carefully lifted from the surface with the aid of a screw driver.

Fill the apparatus from the top with water to the 0 m l mark or just above this mark, depending on the permeability of the layer, in the shortest time possible.

Figure 810914 MAVRIL APPARATUS SHOWING PLASTER OF PARIS

-0
-50

- 100
- 150

- 200 - 250
- 300

PLASTER OF PARIS

BASE COURSE

For the first reading record the time (in minutes and seconds) taken by the water level to drop from the zero mark to one of the graduated marks in a period of 2 to 3 minutes. Repeat the test immediately, by filling the apparatus again to the 0 m l mark, or just above this mark, and record the time taken by the water to drop from 0 m l to the same graduated mark used for the first reading. Not more than three repetitions shall be done at a test point. (vi) Test results and calculations

Table 810911 RECOMMENDED MARK

I

1
Recommended mark to be taken

Time for water to reach 50 m l mark (minutes)

Number or repetitions

The readings of each test at each test point are tabulated and the permeability is calculated as follows:

P = 3,6Vw I Tsec
Where P
=

permeability in l l h , correct to the nearest 0,l llh If it is required to test the bond between the surfacing and the base layer, ten repetitions or more may be required. volume of water in millilitres between the zero mark and the selected volume mark time in seconds taken by the water level to drop from the zero mark to the selected volume mark.

Vw

Tsec

If the bond is not sufficient, an increase in the water flow may be encountered and the surface layer will eventually lift UD from the basecourse. If this does not happen, it is not necessarily an indication of a good bond between the surfacing and the base. In this case the granular base material may be sufficiently permeable for the water to penetrate into the base or even lower layers, rather than follow a horizontal path. The testing for bond strength between the surface and the base, specially in the case of granular materials, should be considered carefully as the unnecessary oversaturation of the layer with water may be detrimental to the road. This procedure is more applicable to research projects. The permeability of a layer will depend on many factors such as: the degree of saturation of the layer, eg, after a spell of rain, or due to built-in moisture content, the degree of density of the layer, the grading, shape and texture of the material, and the degree of saturation of the underlying layer under a thin upper layer. Testing of the surface where it shows signs of intensive cracking should be considered. The plaster of Paris should be mixed to obtain approximately 900 m l of slurry which should be sufficient if the hole is not more than 300 m m in diameter. The procedure is as follows: Add approximately 1100 g of plaster of Paris to approximately 900 m l of water in a mixing bowl or small piastic bucket. Let the powder form a small heap in the middle of the water. Let it stand for a minute or two before mixing. Mix it slowly with the fingers to a watery consistency. Add more water if necessary until a creamy consistency is obtained so that when the slurry is poured around the base of the

The permeability per unit area can also be calculated as follows: Permeability per unit area (llhlm2)

Where A = surface in m 2 underneath the apparatus exposed to the water. The change in flow rate with increasing or decreasing saturation can also be graphically indicated b y plotting the values of permeability or permeability per square metre against the number of test repetitions. The trend of the line may indicate the degree of increasing or decreasing flow. However, in this case more than three repetitions shall be taken. (vli) Notes

Table 810911 indicates the recommended mark to be taken for a reading as indicated by the time for the water level to reach the graduation mark and the number of repetitions (refills) at a test point. When there is a possibility of the water level not reaching the 50 m l mark in 10 minutes, estimate the volume to the nearest 10 m l at 10 minutes, stop the test and calculate the permeability. The times (or flows) may remain fairly constant when taken three times or more, but a decrease in flow indicates that the material is becoming saturated. An increase in flow indicates that the water opens up paths to flow into and if water appears on the surface in the vicinity of the apparatus there has been horizontal flow through the material and this may also give rise to an increase in the flow rate.

apparatus it will fill all the crevices. The slurry must cover the base to a depth of 5 m m to 10 mm. As the air and water temperature may influence the setting of the slurry, the process must be completed before hardening starts. When the surface layer is thinner than the base of the apparatus, the circular weight shall be used to hold the apparatus in the starting position. Less slurry of plaster of Paris will be required.

8111

TESTS O N PAVEMENTS

The following tests shall apply to pavements when specified: texture depth, straight-edge, and rolling straightedge.

(a)

Determining the texture depth

The texture depth shall be determined by way of the sandpatch test as described in test method ST1 of TMH6.

8110

TESTS RELATING TO CHEMICAL STABILIZATION @) Straight-edge test for surface irregularities o n surfaces with a coarse surface texture

(a)

Test for cementitious-binder content Where surface irregularities are measured on surfaces with a coarse surface texture such as grooved concrete pavements, crushed-stone pavement layers, natural gravel base, asphalt with rolled-in chippings, seals and other like surfaces, the following procedure shall be followed:

The test method used for determining the cementitiousbinder content of soils, gravels or crushed stone mixed with a chemical stabilizing agent shall be determined by the engineer and may be any test method currently recognised by the employer as being acceptable. Where the cementitious-binder content is determined, due allowance shall be made for the presence in the unstabilized material of naturally occurring MgO or CaO (eg basalts, calcrete, etc) which affects the result of such tests. If the standard deviation of the natural CaO plus MgO content of the untreated material exceeds 0,35%, any determination of the cementitious-binder content shall be ignored. Sample holes shall be randomly spaced transversely as well as longitudinally over the area to be tested, or as directed by the engineer, and if the material is road-mixed, samples shall be taken from the top and bottom of each hole.

A metal wedge of 100 m m in length and 50 m m in width shall be constructed with a taper of 7,5 horizontal to 1,O vertical and tapering to a feather edge (50 m m wide). Parallel lines spaced at 7,5 m m intervals shall be engraved on the sloping face and numbered to indicate the positions where the wedge is 1,O mm, 2,O mm, etc, thick.

@)

Canvas-patch test for the spreading rate of cementitious binder

Where surface irregularities are measured, the 3,O m straight-edge, which shall have sharp right-angled corners at the bottom, shall be placed on the road and the thin edge of the wedge inserted below the straight-edge from the front at the position where a surface irregularity is to be measured. The size of the irregularity shall be determined in accordance with the mark to which the wedge can be inserted without lifting the straight-edge. The width of the contact plane of the straight edge shall be 18 m m 2 mm, and its height shall be 80 m m ? 10 mm.

The following method shall be used for determining the spreading rate of a chemical stabilizing agent where bulk distributors are used. At least 10 clean canvas patches, each measuring 1 m x 1 m, shall be placed flat on the road in selected positions in relation to the bulk distributor's track. After the stabilizing agent has been spread by the bulk distributor, the canvas patches shall be carefully lifted and all the material on the patches transferred to a container and weighed. The total mass of stabilizing agent on each patch is then recorded and the average rate of application determined. Instead of canvas patches, flat metal trays may be used for collecting the stabilizing agent.

(c)

Using the rolling straightedge for measuring surface irregularities

The apparatus and testing method for this test shall be in accordance with testing method ST3 of TMHG.

8112

STRUCTURAL TESTS

(a) (i)

Tests o n elastomeric bearings General

(c)

Test for mix uniformity i n chemically stabilized layers

Tests on elastomeric bearings shall be conducted in accordance with BS 5400 part 9.2, and the bearings shall comply with the test requirements specified in the said specification.

Where required by the engineer, the contractor shall determine the mix uniformity in chemically stabilized layers by means of unconfined compressive strength tests, using an approved method. The contractor shall timeously make the necessary arrdngements to take samples in accordance with the requirements of the method used.

(ii)

Compression and shear-stiffness tests

When compression and shear-stiffness tests are conducted on sample bearers or on only a limited number of bearers in a consignment, the stiffness values as determined by the tests shall be within 20% of the theoretical values.

@)
(i)

Prestressed concrete : Testing prestressing steel, anchorage assemblies, couplings and grout General

Where so directed by the engineer, the contractor shall make arrangements for samples of the materials he intends to use in the works to be tested b y an independent testing authority. The cost of testing prestressing steel, anchorage assemblies and couplings will be paid for as specified in subclause 8103(c). Control tests on the viscosity and bleeding of grout will be regarded as part of the contractor's obligations under clauses 1205 and 8209 for process control and will not be paid for separately. Material represented by samples which do not comply with the specified requirements shall be removed and replaced with suitable material. (ii) Anchorages and couplers

glass container with an internal diameter of approximately 100 m m and a height of approximately 120 mm. The grout and water levels in the container shall be controlled with a metal bridge into which two adjustable studs A and B are secured. See figure 811212 for details of the apparatus. The procedure for determining the bleeding of grout shall be as follows: Studs A and B in the metal bridge shall be adjusted and locked so that the distance from the lower tips of the studs to the bottom of the container will be approximately 100 m m and 107 m m respectively. The volumes VA and Va for the container at the respective levels of the stud settings shall then be determined to the nearest millilitre.
b 8

Anchorages and couplers shall be tested in accordance with the requirements of subclause 6503(c). The anchorages and couplers shall be assembled in accordance with their practical application on the site where all the components necessary for anchoring shall be used, but excluding the ducts. (iii) Prestressing steel

The container shall be filled with freshly mixed grout to a level where the grout will just touch the tip of stud Awhich points downwards. The bridge shall then be removed and the container tightly sealed to prevent evaporation. The container shall then be stored at 20" C and kept free from vibrations for the entire duration of the test. Three hours after the grout has been mixed, the container shall be opened and the free (bleed) water poured off. The bridge shall be placed over the container with the tip of stud B pointing downwards and water poured onto the grout with a measuring apparatus until the water level touches the tip of stud B. The volume of water added shall be determined to the nearest millilitre and designated as AV. The percentage of bleeding shall be calculated from the formula.

Prestressing steel shall be tested in accordance with the requirements of subclause 6503(b). Should any test piece fail to comply with the requirements specified for the prestressing steel, the material represented by that sample shall not be used without further testing and shall be replaced with materials conforming to the specifications if further testing confirms that they do not comply with the specifications. (iv) Grout

The fluidity of grout shall be measured with a flow cone, immersion apparatus or viscometer. The instrument shall be accurately calibrated in a laboratory so that the specified viscosity of the grout can be controlled satisfactorily. The procedure for conducting the flow-cone test for measuring the fluidity of grout shall be as follows: Unless otherwise approved, the flow cone shall be as shown in figure 81 1211. Immediately after the grout has been mixed, the pre-wetted flow cone, which is held firmly with its top rim in a level position, shall be filled with grout to the level indicated by the pre-set pointer, whilst the bottom orifice is held closed with a finger. As soon as the required volume of grout, ( ? 1 750 m l ) , is reached, the finger shall be released to allow the grout to flow out freely through the bottom orifice. A stop watch shall be used to determine the flow time for emptying the cone, to the nearest second. The readings obtained during grouting shall be compared with the times determined in the laboratory for grouts of the specified viscosities. The bleeding of grout shall be measured in a metal or

(c)

Load test on foundation piles

The head of the test pile shall be exposed for checking position and slope. Where necessary, the head shall be cut further back so as to expose a full bond length of main reinforcing steel, and a suitable pile head slab for applying an axial load to the pile shall be cast. As an alternative, the head may be cut at right angles and the load applied direct to the pile. The test load shall be applied to the top of the pile with a hydraulic jack. Where more than one jack is used for applying the load, all the jacks in the circuit shall be activated by the same pumping unit. The jack(s) shall be placed so as to ensure that the load is applied axially. The applied load shall be calculated in accordance with the hydraulic pressure which is being monitored b y two pressure meters in the circuit. The pressure meter shall be calibrated in divisions not exceeding 2% of the maximum pressure applied, and the range of the meters shall not exceed 150% of the maximum pressure. The jack(s) and meters shall be calibrated b y an approved testing laboratory not more than 4 weeks before the tests will commence. Thedeflection of the pile head shall be measured with two scale rulers and two dial extensometers. The scale rulers shall be fixed to the pile and placed on both sides of the pile on a diameter line, and the dial extensometers shall be

Figure 81 1211 FLOW CONE

Figure 81 1212 METAL OR GLASS CONTAINER

similarly placed but on a diameter line at right angles to that in which the scale rulers have been mounted. Level measurements shall be taken on the scale rulers, and reduced as a level mark to a similar scale ruler placed at a distance from the test pile. All three scale rulers shall be calibrated in millimetres and the level-indicating instrument shall be capable of taking readings to 0,5 mm, and approximate readings of up to 0 , l mm. The dial extensometers shall have a range of 50 mm, and shall be marked in 0.1 m m divisions to enable measurements to 0,05 m m to be taken. The plungers of the extensometer shall rest on a machined metal or glass surface. The extensometers shall be supported by one or more beams kept in the shade. The supports for the beams shall be so placed as to limit the effect of earth movements around the test pile on the deflection readings. The test load shall be applied in increments of 20 per cent of the specified working load to a maximum test load equal to twice the specified working load or the ultimate test load, whichever is the smaller. A load increment may not be applied before the subsidence or heave rate has stabilized at a rate of not more than 0,10 m m in 20 minutes under the load applied. After the loading has been completed, the maximum test load shall be maintained until the movement is less than 0,2 m m within a period of 24 hours. The load shall be removed in decrements of 20 per cent of the specified working load at intewals of not less than 20 minutes. After the load has been removed, the readings on both meters registering the movement of the pile shall be recorded accurately to 0,l mm, at intervals of 5, 10 and 20 minutes, and then every 30 minutes until the load is changed. The final recovery shall be recorded 24 hours after the maximum test load has been removed. During the test, the pile shall be loaded with up to 100 per cent of the specified working load, and the load shall then be removed. It shall then be loaded to the maximum test load after which the test load shall be removed.
8113

material may adhere to the polyethylene while it is nonadhesive.

(c)

Deformability and adhesion

Prepare concrete blocks of 25,4 m m x 25,4 m m x 76,2 m m in accordance with ASTM C-719. A sawn surface is used as the bonding surface. Seal 50,8 m m of the block and leave 12,7 m m at each end of the specimen unsealed. The sealant shall be 9,5 m m thick and 12,7 m m wide. Cure the specimen for 7 days in air at 25C 2 1,7"C, and for 7 days in water at 25C r 1,7"C. Subject the sealant to deformation in accordance with ASTM C-719. The ductility or compressive rate shall be 3,18 m m per hour. One cycle is defined as extension to a width of 25,4 m m and returning to the initial width of 12,7 mm.
8114

GEOTEXTILE AND COMPATlBlUTY TESTS

GEOTEXTILE-SOIL

Where the term geotextile is used, it shall mean syntheticfibre filter fabric.
(a)
Puncture-resistance tests on geotextiles

(i) (1)

Apparatus (see figure 81 1411) Clamping device

The specimen shall be positioned and clamped by means of a suitable clamping device that consists of: A mounting-platenlsupporting-sleeve assembly; An upper and a lower clamping ring provided with the necessary securing bolts, guide pins and V-grooved concentric matching rings for securing the specimen. (2) Mounting device

The specimen shall be positioned in the clamping rings, in a true plane, free from folds and stress, by means of a suitable mounting device that consists of: A metal base plate at least 4 m m thick; A centering device secured to the base plate; A means of preventing the rotation of the upper clamping ring when the first two bolts are tightened (two short sockets welded to the base plate will retain the bolt heads). (3) Cone assembly

TESTS ON SIUCONE SEALANTS

The following tests on silicone sealants will apply as determined in subclause 7102(e)(iii).
(a) Bond to cement mortar

The cone assembly shall consist of: A polished brass cone with the following dimensions: generating angle of cone, 45", radius of point of cone, 0,5 mm, overall diameter, 50 mm, mass of falling assembly, 1 kg; A means of retaining the point of the cone at a height of 500 rnm above the specimen together with a suitable release system. (4) Measuring device

Three briquettes, shaped in accordance with AASHTO T-132 and moisture-cured for at least 28 days, are sawn in half, cleaned and dried to a constant mass in an oven at a temperature of 110C r 5C. After having cooled off, they are bonded with approximately 0,25 m m of silicone sealant and tested with clamps which comply with AASHTO T-132. They are tested under stress at a loading rate of 7,62 mmlmin.

@)

Non-adhesive period

Prepare the specimens in a mould with an area exceeding that of the brass weight described below, and which is 6,35 m m thick. Place a 30 g brass weight with dimensions of 41,28 m m x 25,4 m m x 3,18 m m on a polyethylene strip applied to the sample after the specified curing period. After the weight has been removed,the polyethylene strip is removed by pulling it off at an angle of 90 degrees to the mix and at a rate of 25,4 m m in 5 seconds. No

2 m m lntervaps over a length of 200 m m to measure the diameter of the hole formed in the specimen. The device shall have a polished surface.

A suitable conical measuring device with a mass of 700 g -c 10 g and raduated from zero to 50 m m diameter at

Figure 81 1411

CONE ASSEMBLY AND MEASURING DEVICE

(5)

Marking and cutting stencil

Place the clamping-ring assembly on the supporting cylinder. Release the cone-release system. Carefully remove the cone from the specimen and measure the diameter of the hole formed in the specimen with the measuring device. The device shall be gently lowered vertically, by hand, into the hole formed in the specimen until penetration under its own mass is stopped. The diameter of the hole is taken as the graduation nearest to the line of contact between the device and the geotextile. Note:

The specimens shall be cut by means of a suitable metal stencil with a handhold and studs to secure the stencil on the sample. The stencil shall be capable of accurately locating the position of bolt holes and pin holes on the specimen. The holes in the stencil shall be 13 m m diameter, ie 2 m m larger than the holes to be cut into the specimen.

(6)

Felt pen and punch

The position of the holes on the specimen shall be marked through the stencil with a 3 m m diameter felt-tipped pen.

A punch capable of cutting 11 m m diameter holes in the specimen.

(7)

A suitable cutting device

It is advisable to pack the inside of the supporting cylinder with a resilient material of sufficient thickness to prevent damage to the cone in the event of complete penetration of the specimen. (iv) Calculation and reporting Calculation

(8) (ii) (1)

A torque wrench
Specimens (1) Dimensions of specimens Record the diameter of the hole formed for each specimen and calculate the average diameter of the holes for the sample. Round off the results correct to 2 mm.
(2)

Specimens shall be either 250 mrn x 250 m m square, or circular with a diameter of 282 mm. (2) Number of specimens

At least 10 specimens shall be tested (3) Preparation of specimens

Reporting

Report the value of the hole diameter for each specimen and the average diameter for the sample. (3) Information sheet

With the aid of the stencil, mark on the conditioned sample the positions of the required specimens, together with the positions of the holes for bolts and locating pins. The specimens shall be set out in two rows equally spaced across the width of the sample. The spacing of the specimens shall be as specified, except that the distance between the two rows shall be 150 mm. Where the width of the sample does not allow all the specimens to be set out in two rows, the number of rows shall be increased. Carefully cut each specimen from the sample as specified. Centre the punch over the marked positions and punch out the holes.

An approved information sheet shall be completed in full for each geotextile.

@)
(i)
(1)

Permeability reduction (flow test)

Apparatus Water supply

A supply of water from an overhead tank with constant head of 1 000 m m t 25 m m above the geotextile sample.
Maintain the conditioned specimens in the specified atmosphere. Test the specimens in the testing atmosphere. (iii) (1) Procedure Assembly Permeameter with a suitable means of mounting to ensure that the permeameter remains in a vertical position throughout the test. The permeameter shall consist of the following:

Place the lower clamping ring with bolts in position on the mounting device and carefully position the specimen over the bolts and pins so as to ensure that the specimen is free from stress and is lying flat on the mounting device.Position the upper clamping ring over the bolts and pins and carefully lower the ring onto the spec'men. Secure the ring in position by tightening the nuts to a torque of 30 Nm. (2) Testing

Two Perspex cylinders, 90 m m inner diameter. The bottom cylinder has a recess for the support mesh and a breather hole. Two Perspex end caps with inletloutlet nozzles. The end caps shall be machined as shown in figure 811412 to fit over the cylinders and to allow air bubbles to escape through the inlet nozzle. A bleeding hole shall also be provided. Three brass rods and nuts (wing nuts)

Ensure that the mounting-platen/supporting-sleeve assembly is central with the line of the fall of the cone.

Brass or stainless-steel mesh with 2,67 m m openings (standard soil sieve).

Figure 81 1412 PERMEAMETER FOR PERMEABILITY PRODUCTION TESTS (FLOW TESTS)

+
t ,

WATER INLET FROM CONSTANT HEAD (1000 225mmI

I N L E T NOZZLE FLEEDING HOLE

PEFiSPEX TOP

PERSPEX TUBE

E
0

S O I L SAMPLE ( l k g DRY MASS PLACED AT OPTIMUM MOISTURE CONTENT WITHOUT COMPACTION]

GEOTEXTILE

SUPPORT MESH (2.67mrn OFENINGSJ BREATHER HOLE

o
0

3 x BRASS RODS AND NUTS

OUTLET NOZZLE

OUTLET

(2)

Cutting device

A means of cutting out a circular specimen with a diameter of at least 110 mm.
(3) Miscellaneous equipment

time recorded that it takes to fill the 5 litre container, or the amount of flow that occurs in 30 minutes, whichever occurs first. It is not important that exactly 5 litres or 30 minutes be used, but the time and volume shall be recorded accurately. Record the following with each outflow measurement: Date and time (hours and minutes) Flow volume (1 000 mm 3 = 1 m l ) Calculate flow in mm3/s Flow time (minutes and seconds) Height of the sample (soil + geotextile) in m m Height of the water head above the bottom of the geotextile in m m (ensure that this height remains at 1 000 m m ? 25 mm) The discoloration or otherwise of the water at the outlet. Outflow measurements shall be taken at the beginning of the test (1 minute to 5 minutes after the outlet has been opened) and thereafter at least once a day. The test shall be continued for at least 400 hours (17 days). (iv) Calculations

Containers with capacity of at least 5 litres. A riffler with 25,O m m openings. A soil-test sieve with 13,2 m m openings. A balance to weigh up to 1 kg, accurate to 1 g or better. Stopwatch, silicone grease, pans. (ii) (1) Specimens Number of specimens

Conduct one test for each soil/geotextile combination. (2) Geotextile specimens

Mark and cut the required number of specimens and maintain them in the standard atmosphere until they are tested. (3) Soil samples

Permeability coefficient, k Calculate the permeability coefficient for each outflow measurement, as follows:

Sieve the oven-dried soil through a 13,2 m m sieve and discard the material larger than 13,2 mm. Riffle the remaining soil to obtain specimens of 1 000 g + 5 g. Place the specimens in sample bags and label them. (iii) Procedure

Place the geotextile specimen between the two cylinders on top of the mesh. Apply silicone grease to ensure that water does not leak out between the two cylinders. Mix the amount of water required to bring the soil sample to modified AASHTO optimum moisture content (OMC). With dispersive soils, friable mudstones and heavy clays remoulding often gives an impermeable soil mass. In such cases this step shall be omitted and the soil sample shall be placed dry. Place the soil sample on top of the geotextile. Smooth the surface without compacting the soil. Place the Perspex end caps in position and fasten the rods and nuts. Place the assembled permeameter in its mounting. Close the outlet and the breather hole in the bottorn cylinder and slowly fill the entire cylinder with water from the top. Care must be taken not to disturb the surface of the soil sample. This can be done by using a smalldiameter pipe with a spray nozzle which is inserted through the top inlet to a height just above the soil surface. Fill the permeameter to the top of the inlet nozzle, remove the small-diameter pipe, and connect the hose from the constant-head tank. Remove any entrapped air bubbles through the inlet nozzle and the bleeding hole. Open the outlet nozzle and breather hole in the bottorn cylinder and record the time at the beginning of the test. The first outflow measurement shall be taken between 1 minute and 5 minutes after the beginning of the test. Outflow is measured by way of a container and stopwatch. The container shall be placed under the outflow and the

where Q i

= = = =

outflow (mm3/s) hydraulic gradient water head above geotextile (mm) sample height (mm) cross-section area (mm 2) 6 362 mm 2 for 90 m m diameter

The permeability reduction factor, K400, is determined at the end of the test, as follows:

K400 =

K at 400 hours K at beginning of test

00

If an outflow measurement has not been taken at exactly 400 hours, K at 400 hours may be determined by linear interoolation. The degree of permeability reduction is determined by means of figure 81 1413. (v) Information sheet

An approved information sheet shall be completed in full for each geotextile. Failure to provide the required information may be taken as sufficient motivation for the geotextile to be disqualified.

8115

CLASSIFYING THE TESTS

For the purposes of this section tests are defined as follows: Ordinary tests are tests which are constantly conducted by the contractor on a regular basis in terms of clause 1205

100
-

0 0 T

u
LL

tU

HIGH

c l
U

t3 0
LIJ

10

t-

u >
H

MEDIUM

r
[ I

LOW

10

100

SOIL (PERCENTAGE PASSING 0.075mm)

and section 8100, for which no specified pay items have been provided, and which include the following, inter alia:

Tests for determining the properties of all natural materials such as, inter alia, sand, stone, water, soil and gravel, inter alia, provided by the contractor for use in the works. Tests on processed natural materials such as aggregate for concrete, asphalt and seals, purchased or produced on the site by the contractor. Tests for determining the properties of products such as concrete and asphalt, etc, produced specially for use on the works by the contractor, or purchased from commercial producers or subcontractors. Tests on completed elements of construction such as fills, pavement layers, concrete structures, etc, for establishing compliance with the specified properties.

Any test requested by the engineer purely for purposes of acceptance control. Such tests, however, will not be classified as a special test if the test is requested because the contractor has neglected to conduct sufficient or proper tests in terms of clause 1205 and with a view to submitting the result to the engineer for his approval of ompleted work or materials.

Payment will be made under the pay items of clause 8117 only in regard to special tests. Payment for ordinary tests shall be included in the rates tendered by the contractor for the items of work to which the ordinary tests relate.

8116

TESTING OF CONSTRUCTION WATER

(a)

Compressive strength test

Special tests are tests which have to be conducted by the contractor only at the specific request of the engineer, and include the following:

The average 28 day strength of three mortar cubes made with ordinary portland cement and the water that is to be tested shall be at least 90% of that of three similar cubes made with water of known purity.

Tests on commercial products such as cement, lime, paint, bituminous products, pipes, valves, cranes and bridge bearings. The requirements are specified as a whole or in part by reference being made to the specifications of a standards organisation such as the SABS. Special tests on structures or elements of structures to determine their efficacy, for the payment of which clear provision has been made in the specifications and the schedule of quantities.

Additional tests shall be carried out to ensure that the setting time of the cement is not adversely affected by impurities.

@)

Inorganic impurities criteria

The water used to manufacture concrete shall comply with the criteria in table 81 1611 unless otherwise approved by the engineer.

Table 81 1611 CRITERIA FOR INORGANIC IMPURITIES IN WATER USED TO MANUFACTURE CONCRETE CHARACTERISTIC PH Sulphates 4,5 - 8,5 Reinforced concrete and prestressed concrete : 400 pprn 0 0 pprn Mass concrete : 1 0 500 ppm 330 m Slm Mass concrete : 3 000 ppm Reinforced concrete : 1 500 pprn SABS method 213 CRITERIA TEST METHOD SABS method 113 SABS method 212

Chlorides Conductivity @ 25" C Total dissolved solids (TDS) @ 180C

SABS method 202

Alkali Carbonates and bicarbonates Sugar Organic impurities

SABS method 841 1 000 ppm Negative 300 ppm (applicable if p H < 5) SABS method 837 Chemical oxidation demand

8117

MEASUREMENT AND PAYMENT

81.03 Providing testing equipment:

Item
81.01 Special tests on elastomeric bearings (150% vertical load and 150% shear distortion) as described in subclause 6604(d)

Unit

(a) (b)

Rolling straight-edge

........... .. .

number (No) number (No)

Core drill . . . . . . . . . . . . . . . . .

. . . number (No)

The unit of measurement shall be the number of elastomeric bearings tested as described.

The unit of measurement shall be the number of each item provided. The rolling straight-edge shall comply with the requirements of test method ST3 of TMH6. The core drill shall be of an approved type capable of drilling cores with diameters of 100 m m and 150 m m in concrete and asphalt respectively. It shall be provided with the necessary drilling parts. The tendered rates shall include full compensation for providing the apparatus on the site and making it available and using it on the site for as long as may be necessary. After the work has been completed, and subject to the provisions of clause 22 of the general conditions of contract, the contractor shall remove the apparatus from the site. Note: Providing testing equipment for use by the engineer.

The tendered rate shall include full compensation for having the test conducted by an approved laboratory, also for replacing the bearings which may possibly have been damaged during testing.

Rem
81.02 Other special tests requested by the engineer

Unit

. . . . . provisional sum

The provisional sum provided to cover the cost of special tests as requested by the engineer in terms of clause 81 15 shall be expended in accordance with the provisions of the general conditions of contract. Payment will not be made for any special test should the test indicate that the specifications have not been complied with.

Except for the equipment listed in item 81.03, this specification does not envisage the provision of testing equipment by the contractor for the use of the engineer, but, where necessary, provision shall be made therefor in the project specifications, and the relevant pay items shall be described.

SERIES 8000 : SUNDRIES SECTION 8200 : QUALITY CONTROL (SCHEME 1)

CONTENTS SCOPE JUDGEMENT PLANS : GENERAL DEFINITIONS GENERAL REQUIREMENTS JUDGEMENT PLAN A JUDGEMENT PLAN B CONTROLLING MORE THAN ONE PROPERTY CONDITIONAL ACCEPTANCE PROCESS CONTROL BY THE CONTRACTOR ROUTINE TESTS AND INSPECTION BY THE ENGINEER DETERMINING REJECTION LIMITS I N ACCORDANCE WITH STATISTICAL CRITERIA

Despite acceptance of those properties judged by these statistical methods, the materials or work submitted will be rejected when other properties (which are not controlled by statistical methods) fail to comply with the requirements of the specifications, or where there are other causes for rejection such as obviously defective workmanship or excessively variable properties, visible signs of poor workmanship, and similar considerations which constitute sufficient grounds for rejecting the work without any further testing.

The engineer shall be entitled to assess separately any specified portion of a lot if, in his opinion, it exhibits significant deviations as compared with the remainder of the lot. In order not to change the contractor's or the employer's risks, the statistical judgement plans shall be strictly adhered to in all cases where they are used, and decisions based on these plans shall not be altered. It shall be a condition of this contract that the theoretical validity of the various statistical judgement plans is accepted and that the validity of the decisions made on the basis of these judgement plans cannot be disputed on the grounds of statistical theory or a specified or implied producer's risk, or on the grounds of unjust enrichment.

8201

SCOPE

This section describes one scheme for determining, by means of tests and measurements and by applying statistical judgement plans, whether certain requirements specified in the specifications in regard to the properties of materials and workmanship are being complied with. It also covers the requirements in regard to the control to be exercised by the contractor to monitor the quality of his work and materials and the routine tests and inspection to be carried out by the engineer.

8203

DEFINITIONS

For the purposes of this section the following words and symbols shall have the following meanings:

(a)
8202

Lot

JUDGEMENT PLANS : GENERAL A lot is a sizeable portion of work cr quantity of material which is assessed as a unit for the purposes of quality control, and selected to represent material or work produced by essentially the same process and from essentially the same materials.

Certain requirements and limit values are laid down in the specifications in regard to the properties of materials and workmanship to be supplied. Tests shall be conducted and measurements taken for controlling the relevant properties of the workmanship and materials supplied, and the results of such tests and measurements shall be assessed on the basis of the prescribed criteria for compliance with the specified requirements. Compliance may be judged by two methods being applied. For certain properties statistical judgement plans are prescribed for assessing the test results, and, where no such statistical judgement plan has been prescribed, the specified requirements and limit values shall be fully complied with. In this section two types of statistical judgement plans are used, as follows: Judaement plan A is used for judging measurement of the levels and thicknesses of pavement layers. In accordance with this method the compliance of the individual results only with the specified requirements is determined, and the variability of test results is not computed. Judqement plan B is used for judging measurements of in situ densities, the strengths of concrete, and certain other properties. In this judgement plan the variability of the values of tests is calculated and applied where acceptance limits for sample means are determined.

@)

Random sample

A random sample is a group of "nutest measurements at "nu separate test positions or on "nu sample portions obtained from the lot in an unbiased manner. Random sampling shall mean stratified random sampling, unless inconsistent with the context.

(c)

) , Sample mean ( 1

in is the arithmetic mean of a set of "nu test results constituting the sample.

(d)

Sample standard deviation (Sn)

The sample standard deviation Sn is defined by

where Rn is the sample mean

is the value of an individual sample portion, i e an individual test result or measurement.

(i)

, ) ' Acceptance limits (La and L

ka is used for determining the acceptance limits for singlelimit specifications. n is the sample size, i e the number of individual test results or measurements. kad is used for determining the acceptance limits for double-limit specifications. (ii) Rejection limits (Lr and L'r):

(e)

Specification limit

(b)

This is the limit value of the property of any product outside which not more than a certain specified percentage (cp) of the population of values representing an acceptable product property is allowed to lie. The specification limit may be a single lower limit Ls, or a single upper limit L , . ' or a double limit consisting of a lower limit Ls and an upper limit L , . '

Only when specified in the project specifications that rejection limits shall be determined in accordance with the provisions of clause 821 1. the factors kr and krd shall be used. kr is used for determining the rejection limits in the case of a single-limit specification. krd is used for determining the rejection limits in the case of a double-limit specification. The factors ka, kad, kr and krd shall apply to both a first submission and a resubmission.

(f)

Acceptance limit (La)

This is the limit value of the sample mean within which the lot will be accepted. For a lower-limit specification this acceptance limit is denoted by La. For an upper-limit . ,' For specification this acceptance limit is denoted by L a double limit specification, the lower and upper limits are denoted by La and L , ' respectively.

(g)

Conditional acceptance

This is the acceptance of a lot at reduced payment in lieu of rejection.

cp is the maximum percentage of a statistical population of values of a product property permitted to lie outside the specification limits where the product may still be regarded as being acceptable. Values for cp may be obtained from table 820612.

(m) Conditional acceptance shall be subject to the provisions of clause 8208.

First submission

(h)

Rejection limit

(4)

This is the limit value of the sample mean outside which conditional acceptance cannot be considered. It may be a lower limit Lr or an upper limit L',.

The submission of a lot for approval will be classified as a first submission when actually submitted for the first time or when submitted for a second time on the basis of a second set of test values to be regarded as a first submission in terms of subclause 8204(e), because the properties of the first and the second sets of test values differ significantly.

(n)

Resubmission

(i)

Payment reduction factor ( 1 , ) The submission of a lot for approval for a second time shall be classified as a resubmission should it be regarded as a resubmission in terms of subclause 8204(e), because the properties of the first and second sets of test values do not differ significantly.

This is the factor by which payment at contract rates shall be multiplied for calculating the payment for conditionally accepted work.

(j)

Outliers (0) Definitions pertaining to rehabilitation and repair work

Where, in a sample, one or more test results differ significantly from the other values obtained, this difference could be ascribed to an assignable cause, in which case such test result shall be regarded as an outlier and disregarded when assessing the lot.

In the case of rehabilitation or repair work the definitions for lot, lot size and sample size shall be as specified in the project specifications or as directed by the engineer.

To determine whether or not a test result is an outlier, the procedure given in subclause 8204(d) shall be adopted.

8204

GENERAL REQUIREMENTS

(a)

Determining lot size Road construction layers

(k)

Factors ka, kad, k , and krd (i)

These factors are used for calculating the various judgement limits, as follows:

The lot size shall normally be a section compacted in one

process where essentially the same materials and construction equipment have been used. Where production is on a continuous basis, a lot shall normally mean the product of one day's work and shall not exceed the product of two full days' work. However, a lot of any smaller size may be ordered by the engineer where

and replaced with a fresh test result. Where repeating a test or re-examining a test result is impossible. Method 1 shall be used for identifying outliers for all work, except basecourse and asphalt work. Method 2 shall be used for identifying outliers for basecourse and asphalt work. (i) Method 1

the properties under investigation exhibit abnormal local variation within the normal lot size: an area is obviously of a different quality than the rest, the rate of production is very high.

Calculate the value of To from

For rehabilitation or repair work the lot size shall be as specified in the project specifications, or as determined by the engineer. (ii) Concrete

where i n and Sn are the arithmetic mean and the sample standard deviations respectively, and xo is the value of the test result differing most from the mean. Compare the value of To with the value of T for the applicable value of n, from table 8204(d)l1. If the absolute value of To is greater than T, then xo is an outlier. Table 8204(d)/1

The lot size shall be determined by the engineer, with due regard to the size and the type of structure in which the concrete is placed, the specific portion of the structure and the total quantity of concrete placed in a day. The lot sizes in concrete structures could therefore vary considerably. and, particularly in the case of small structures, it could be necessary to combine samples of the same grade of concrete from different structures, provided that the concrete is obtained from the same concrete plant and is cast in the same period. (iii) Other

Number of obsewations (n) 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Critical value (T) 1.46 1.67 1.82 1.94 2.03 2.1 1 2,18 2.23 2.29 2,33 2.37 2,41 2,44 2,47 2.50 2.53 2,56

In other cases, as for example in material stockpiles where the definition of a lot in accordance with subclause 8203(a) does not apply directly, the engineer will determine lot sizes in accordance with circumstances pertaining to each case.

@)

Random sampling

When any lot is tested, whether a normal sized lot or an isolated section which clearly exhibits an abnormal variation of the property under consideration, all samples shall be taken in a stratified random pattern. For this purpose use shall be made of tables of random numbers, and the instructions in publication TMH5, Sampling for Road Construction Materials, shall be followed.

(c)

Sample sizes

For purposes of acceptance control, the engineer will, in advance, determine sample size "nu. The larger the sample, the more reliable the result will be, and no sample sizes may be smaller than those given in subclause 8205(a) and table 820612. With regard to rehabilitation or repair work the sample sizes specified in the project specifications or prescribed by the engineer shall apply.

Where, incidentally, Sn is very small, it may be the cause for a value being wrongly classified as an outlier. For this purpose a minimum value Sn(min) shall be determined for Sn, as follows:

where ,&g9 ; n - 1 = $0,99 for (n - 1) degrees of freedom as obtained from table 8204(d)12: and

(d)

Outliers
Sn = mean value for Sn for the particular property as determined by records of previous work.

Test results shall be scanned for possible outliers. Where a test result deviates greatly from the remainder in a lot, it shall, if possible, be re-examined by further testing and, if there is reasonable evidence to suggest that the test result is erroneous, it shall be regarded as an outlier, rejected,

Every outlier shall be deleted, and, if possible, be replaced with a new random test value.

Table 8204(d)/2 VALUES OF x20,99 DISTRIBUTION

Table 8204(d)/4 OUTLIER TEST FOR ASPHALT : CRITICAL VALUES C

CRITICAL VALUES C

n
4

For density

For bitumen conlenl

For voids in mix

3.2 3.3
33

0.4 0.5 0.5 0.5

2.3
2.4

5
6 7

2 . 5 2.6

3,6

(ii)

Method2

In the case of basecourse and asphalt work the following procedure shall be used for identifying outliers where it is impossible to repeat a test or to reinvestigate a test result: Calculate the absolute value Co from

Every outlier shall be discarded and replaced by another random test value. The sample mean Rn and the sample standard deviation Sn shall then be recalculated. If an outlier cannot be replaced, the sample mean and standard deviation shall be calculated on the basis of the remaining test results. The final number of test results used in the assessment after the elimination of an outlier shall never be less than four.

(e)

Resubmission

where xo represents the possible outlier. Compare Co with the critical value C
=

Where a lot has been accepted conditionally or has been rejected, the engineer may agree to its resubmission for approval if C O , O ~ ; ~ ~

Where u is the standard deviation of the population derived from historical data. If the absolute value Co > C, the test result xo shall be regarded as an outlier and shall be excluded from the sample. The critical values for different values of n are given in tables 8204(d)/3 and 8204(d)/4 for the different product properties. Table 8204(d)13 OUTLIER TEST FOR BASECOURSE : CRITICAL VALUES
CRITICAL VALUES C For percentage compaction For sieve size (mm) For PI

it has been reworked and the engineer is satisfied that a proper attempt was made to improve the properties which were unacceptable:

where, in his opinion, there are valid technical reasons therefor.

In both cases a fresh sample shall be taken, and a fresh (second) set of test values determined. The first and second sets of test values shall then be compared with each other to determine whether thei~properties differ significantly.

n
4 5 6 7 8 9 10

26.5 19.0 13.2 4,75 2.00 0,425 0.075

Where in the opinion of the engineer a significant difference does occur, the submission of the lot shall be regarded as a first submission and be assessed as such, and only the second set of test values shall then be used for this purpose. Where in the opinion of the engineer no significant difference occurs, the submission of the lot shall be regarded and assessed as a resubmission, which will mean, inter alia, that the first and second sets of test values shall be combined for purposes of assessment. In order to be able to determine theoretically whether there is a significant difference between the two sets of test values (suffixes a and b), the Fisher F-test shall be conducted, and, if necessary, also the 1-test, all as described below.

4 . 1 4.4 4,6 4.7 4 . 8 4.9 4,9

6.1 6.4

8.5 8.5 7.3 5 . 6 9,0 9.0 7.7 5 . 9

3,6 3.9 4.0 4,l 4.2 4 . 3 4.4

3,2 3 . 3 3,5 3,6 3,7 3.7 3,8

2,4 2,6 2,7 2.8 2.8 2.9 2.9

6,7 9.4 9.4 8.0 6.2 6.9 9.7 9.7 8.3 6,3 7 . 1 9.9 9.9 8.5 6,5

0 . 1 8.6 6.6 7,2 10.1 1 7 . 3 10.2 10.2 8.7 6.7

The Fisher F-test is conducted as follows: Calculate the value of F = Sg2/~k2, where Sg = the greater value of Sa and Sb Sk = smaller value of Sa and Sb. The value of F0.05, Vg,?& is obtained from table 8204(e)ll where

8205

JUDGEMENT PLAN A (Surface levels and layer thicknesses)

Surface levels and layer thicknesses shall be judged in accordance with the following procedure: (a) Taking the levels

Vg
?&

= sample size minus one, from the sample with the

larger standard deviation.

= sample size minus one, from the sample with the

Level measurements shall be taken in a random pattern, before and after a layer has been constructed, and levels shall be taken at exactly the same point before and after construction. Layer thicknesses will then be determinable as the difference between the pre- and post-construction levels, but may be supplemented by determinations made by means of holes made in the layer. The number of measurements of layer thicknesses shall be at least 30, and that of surface levels at least 50. Larger sample sizes will give more reliable results. In the case of asphalt layers, the engineer may require that layer thicknesses be determined only by means of measurements taken on drilled cores, in which case the minimum number of cores shall be 20 per lot and not 30. For rehabilitation or repair work the number of measurements shall be as specified in the project specifications or as directed by the engineer.

smaller standard deviation. Where F > F o , ~ , a significant difference occurs theoretically between the two sets of test values, but where F < F0,5. t%, t&,the difference is not necessarily significant, and the t-test shall also be conducted with a view to obtaining a decision. The t-test is conducted as follows: Calculate

tb,

w,

then calculate

@)

Calculating the deviations

Compute the difference between the specified level or thickness and the actual level or thickness. Compute the mean thickness of the layer. where

I Ia - Rb I is the absolute value of the difference between X a and I b and is always positive.
Determine the degrees of liberty

(c)

Identifying outliers

Check this work by remeasuring any results which may possibly be defective.

(d) The value of t0.05, V,is obtained from table 8204(e)/2. Where t > t0.05. V.a significant difference occurs between the two sets of results, and if t < t0.05, V, there is no significant difference. Table 8204(e)/2 VALUES FOR t-DISTRIBUTION (a = 0.05)

Assessing the results

The following criteria will apply when results are assessed: (i) Surface levels

The lot will comply with the requirements specified for surface levels if at least 90% of all surface levels are within the Hgo tolerance specified in each case, before any level corrections are made. Individual spots, where the surface level deviates by more than the Hma, tolerance, specified in each case, shall be repaired to bring them to within the Hgo tolerance. (ii) Layer thickness

The layer will comply with the requirements specified for layer thickness if at least 90% of all thickness measurements taken are equal to or thicker than the specified thickness, minus the Dgo tolerance specified in the relevant section, before any thickness corrections are made, and the mean layer thickness for the lot is not less than the specified layer thickness minus the Dave tolerances specified in each case.

Table 8204(e)il

VALUES OF F DISTRIBUTION (a = 0,05)

Individual spots, where the actual thickness is less than the specified thickness minus the Dmax tolerance specified in each case, shall be locally repaired to bring them within the Dgo tolerance.

Table 820612 MINIMUM SAMPLE SIZES FOR CONCRETE (STRUCTURAL)

8206

JUDGEMENT PLAN B

Size of lot (m3) 0-20 21 - 40 41 - 70 71 - 100 101 - 150 > 150

Min sample size n

The characteristic properties to be controlled in accordance with this judgement scheme are as shown in table 820611.

Table 820611

Structure Gravel pavement layers Crushed-stone base or subbase Asphalt base and surfacing

Characteristic Relative compaction Relative compaction @) Identifying outliers

Outliers shall be identified, not taken into account, and, if possible, replaced with fresh test values, all as prescribed in subclause 8204(d).

Relative compaction Binder content of mix Voids in mix Stabilizing agent content Compressive strength

(c)

Calculating standard deviation and the mean of sample values

Chemically stabilized layers Concrete

Use the sample r7sults for calculating the standard deviation Sn and the mean Rn of the sample values in accordance with definitions in clause 8203. Where it is a resubmission (as defined in clause 8203), the first and second sets of sample results shall be used for standard determining a combined sample mean Rap,. deviation Sat, and sample size nab as determined in formula 820611.

The procedure to be followed when assessing the above properties shall be as follows:

(a)

Taking samples and testing the properties

(d)

Determining the judgement limits

Determine the sample size (n) by taking into consideration the minimum sample sizes given in table 820612, and take the samples in a stratified random pattern as specified in subclause 8204(b). Conduct the appropriate tests. For rehabilitation or repair work the sample size shall be as specified in the project specifications or as directed by the engineer.

All judgement limits shall be computed to three decimal figures. (i) First submission

The acceptance limits La and L , ' are calculated in accordance with the formulas given below in the case of a first submission (as defined in clause 8203).

Formula 820611

nab

na

+ nb

Rab = (naRa

+ nbRb)/(na + nb)
Nb(iab-ib)')/(na +nb-1;

Sab = J { ( n a - 1 ) S Z a

( n b - 1 ) ~ '+ ~ Na(iab-ia)'+

where subscript

a b ab

refers to the first set of test values refers to the second set of test values refers to the combined properties.

For a lower-limit specification

(iii)

Values of constants

Accept the lot if the sample mean Rn is equal to or greater than the acceptance limit La, otherwise reject the lot. For an upper-limit specification

The values of the specification limits Ls and are given in the relevant sections of the specifications and are briefly summarised in table 820613. The minimum sample size "n" and the maximum percentage of defectives (@) in an acceptable product are also given in the table. The values of ka and kad are given in tables 820614 and

820615.
is equal to or less Accept the lot if the sample mean in than the acceptance limit La, otherwise reject the lot. For a double-limit specification calculate Sample size (n)
@ =

Table 820614 VALUES OF ka (SINGLE LIMITS)

ka

5%

@ =

10%

@ =

15%

Accept the lot if the sample mean Rn falls between the lower acceptance limit La and the upper acceptance limit or is equal to either one, otherwise reject the lot. Where a lot has been rejected, it may nevertheless be considered for conditional acceptance in terms of clause

8208.
(ii) Resubmission

Where a lot is resubmitted for approval in terms of subclause 8204(e) the acceptance limits are determined as follows: For a single-limit specification (iv)

4 5 6 7 8 9 10 12 14 1 6 18 20

0,747 0,821 0,878 0.923 0,961 0,993 1,020 1,065 1,101 1,131 1,155 1,177

0,445 0,520 0,576 0,620 0,656 0,687 0,713 0,755 0,789 0,817 0,840 0,860

0,220 0,300 0,358 0,403 0,440 0,470 0,496 0,538 0,571 0,598 0,620 0,640

Requirements for non-structural concrete

Accept the lot if Xab 2 La in the case of a lower-limit specification and if Xab 5 L'a in the case of an upper limit specification, otherwise reject the lot. For a double-limit specification

Where any concrete sections or parts are indicated by the engineer or on the drawings as being non-structural, the statistical judgement scheme shall not apply, and only compliance with the specified characteristic strength will be required. Compliance with the specified characteristic strength means that the mean strength of the sample shall be at least equal to the specified characteristic strength, and no single test result may be lower than the specified characteristic strength minus 5 MPa. Table 8206/5 VALUES OF kad (DOUBLE LIMITS)

Accept the lot if La 5 Rab 5 L'a. If not, reject the lot. The values of ka and kad used in the above cases shall agree with the sample size nab. Where a resubmitted lot is rejected, it may nevertheless be considered for conditional acceptance in terms of clause

8208.
The evaluation of a resubmitted lot shall be final and binding on both employer and contractor. The provisions of this section shall be strictly complied with. Where a resubmitted lot is rejected, the contractor shall be obliged to bear the costs of the additional tests conducted on the resubmitted lot.

Table 820613

, ' AND VALUES OF CONSTANTS n, Ls, L

Material Properties Minimum sample size n 4 6
6

@J

Ls (Lower specification limit)

L's (Upper specification limit)

CP
("'0)

Selected subgrade Subbase Gravel base

Relative compaction Relative compaction Relative compaction

90%, 93% or 95%

95% or 97% 98% and if stabilised, 97% See subclause 3602(a) See note 1 See note 2 See notes 3 and 4 See note 1 See note 2

15 15 15

Crushed stone subbase or base Asphalt base or surfacing

Relative compaction

15

Relative compaction Binder content Voids Cementitious binder content Compressive strength (28 days) Compressive strength (28 days)

6 6 4 10 See table 820613 6

15 15 15 10

Chemically stabilized layers Strength concrete (structural) Pavement concrete

See subclause 7103(d)

(2)
Asphalt base or surfacing : Specification limits for Density Ls = (97 - percentage of voids in approved production mix) % of theoretical maximum density (see clause 4210) Ls =

Specification limits for cementitious-binder content 70% of the specified cementitious-binder content or as ordered by the engineer. Specification limits for compressive strength of concrete

(1) (a)

(3)

(b)

Binder content (conventional and homogeneous modified binders)

Ls = the specified 28-day cube characteristic strength (see clause 6404(b), e g, for class 25138 concrete, Ls = 25 MPa.)

For continuously and semi-gap graded mixes Ls

=

8207

CONTROLLING MORE THAN ONE PROPERTY

specified binder content - 0.30% binder

Ls = specified binder content t 0.30% binder For gap graded mixes, slurry seals and non-homogeneous modified binders Ls = specified binder content - 0,40h binder

Where more than one property of a lot is to be controlled, the lot shall be accepted if all the properties comply with the specified requirements, but the lot shall be rejected if one or more of the properties do not comply with the specified requirements, or the lot may be conditionally accepted subject to the requirements of clause 8208.

8208

CONDITIONAL ACCEPTANCE

L', = specified binder content 0,40% binder

(a)

General

(c) Ls = L',
=

Voids specified values - 1.5 percentage points specified values

+ 1.5 percentage points

Where a lot is rejected under statistical judgement plan B but the test results are such that the lot complies with the requirements for conditional acceptance specified hereafter, the engineer may accept the lot conditionally, that is, the lot may be accepted at reduced payment in lieu of complete rejection, provided that -

(i) conditional acceptance shall be in the sole discretion of the engineer and not an option which may be exercised by the contractor or a right the contractor may claim;

(ii) the lot is approved in respect of all other requirements not judged by a statistical judgement plan;

(2) Crushed stone layers shall not be subject to conditional acceptance, but, where compaction to 88% of apparent density is specified but has not been obtained, the engineer in his sole discretion may accept the layer against payment at the rate for compaction to 86% of apparent density, provided that the layer complies with all the requirements specified for a crushed stone layer compacted to 86% of apparent density.

the contractor shall have the option to remove and (iii) reinstate at his own cost conditionally accepted work with work which complies with the requirements for acceptance at full payment;

The same provisions shall apply mutatis mutandis where a specified compaction of 102% of modified AASHTO density cannot be attained, but 100% of modified AASHTO density can be attained.

(iv) conditional acceptance and the corresponding reduced payment shall apply only in respect of the work and properties listed in subclause 8208(b) below.

(c)

Criiria for conditional acceptance

@)

Roperties to which conditional acceptance applies

Any lot which does not comply with the requirements for acceptance plan B may be conditionally accepted should the value of the sample mean icn lie within the rejection limits given in table 820812. The payment reduction factor shall be calculated in accordance with the following formula:

Conditional acceptance may be applied in respect of the properties listed below in table 820811. Table 820811

For conditional acceptance at a lower limit PROPERTIES IN RESPECT OF WHICH CONDITIONAL ACCEPTANCE MAY BE APPLIED For conditional acceptance at an upper limit Property Relative compaction Structure (i) Asphalt base or surfacing (ii) Chemically stabilized layers (iii) Plant mixed paver laid layers (See note 2) Tar or bitumen binder content Voids in mix Asphalt base or surfacing

See clause 8203 for the meaning of the symbols. Where so required in the project specifications, the rejection limits shall be determined in accordance with the requirements of clause 821 1 instead of table 8208/2.

(d)

Applying the payment-reduction factor

Asphalt base or surfacing

The payment-reduction factor shall be applied to the following payment items as relevant and described in the specifications.

Cementitious binder content or strength requirements 28-day-cube compressive strength

Chemically stabilized layers All strength concrete (concrete pavements not included. See note 1)

Stabilized layers
ltems 34.01, 34.02, 34.03, 34.04, 34.05, 34.09, 35.01, 35.02, 35.05, 35.06, 35.07, 35.08, 35.09, 35.10 and 35.12.

Asphalt base and surfacing

Notes:
See subclause 7124(e) for details regarding reduced (1) payment in the case of inadequate concrete strength or layer thickness in concrete pavements. ltems 64.01, 64.02, 64.03 and 64.05. No reduction will apply to payment items for formwork, reinforcing and prestressing cables.

Table 8208/2 REJECTION LIMITS (L, en L , ') FOR SAMPLE MEAN (in) Property Structure Rejection limits (Lr and L r ) Lr = (La 2.000)% of relative compaction Lr = (La 1.om)% of relative compaction

of process control for monitoring the various properties to be controlled. The specific system used shall be subject to the engineer's approval, and the attention of the contractor is drawn to the systems described in clause 4.4 of TRH5 which is normally regarded as suitable. The contractor shall take immediate steps to rectify any deviation from the specified requirements indicated by his process-control system, and the engineer shall have the right to inspect and be given all details of tests and testing procedures in order to satisfy himself that the contractor is implementing an adequate process-control system.

Relative compaction

(a) Chemically stabilized layers in accordance with sections 3500 or 3700 (b) Asphalt base or surfacing

8210

ROUTINE TESTS AND INSPECTION BY THE ENGINEER

Concrete compressive strength

All strength concrete (excepting that in pavement) Asphalt Lr = (La 0.200)% binder L', = (L', + 0.200)% binder Lr = (La 0.300)% voids L', = (L', 0.300)% voids

Bituminous binder content (%) Voids in mix

(%)

The engineer will inspect and test materials and completed work at regular intervals for compliance with the specified requirements and, where applicable, the various judgement plans specified will be applied. The testing frequencies and sample and lot sizes for routine testing shall be at the engineer's discretion. All sections of completed work shall be submitted to the engineer for routine inspection and testing, and the contractor shall not cover up or construct any work on top of sections of completed work before being advised by the engineer of the outcome of his testing and inspection. The contractor shall make arrangements for the submission of work for testing in a manner which will afford the engineer reasonable opportunity for inspecting and testing the work.

Asphalt

Cementitious binder content

Chemically stabilized layers

8211

DETERMINING REJECTION LIMITS ACCORDANCE WlTH STATISTICAL CRITERIA

IN

Pavement layers mixed in a central mixing plant and placed by paver Items 37.01, 37.02. 37.03. General
.- Where payment items are introduced into the project

Where required in the project specifications that the rejection limits be determined in accordance with statistical criteria such as TRH5, it shall be done as follows: For a single-limit specification First submission

specificatia~ or are changed in the schedule of quantities. the payment reduction factor shall apply to the payment items corresponding to the payment items mentioned above. Where a lot is conditionally accepted in regard to more than one property, the payment-reduction factor for each property shall be computed and the factor which gives the largest reduction shall be applied, except in the case of concrete pavement when the provisions of subclause 7124(e) shall be referred to.

The lot shall be accepted conditionally where iin 2 Lr in the case of a lower-limit specification, or where in IL', in the case of an upper-limit specification. If not, the lot shall be rejected.

For a double-limit specification

8209

PROCESS CONTROL BY THE CONTRACTOR

The requirements of clause 1205 shall apply in respect of the contractor's obligation to institute and implement a quality control system for monitoring the quality of the work and materials during production. For continuous concrete and asphalt-production processes. the engineer may order the contractor to augment the above-mentioned control system by introducing a system

L',

L , '

- Sab.krd

The lot shall be conditionally accepted where i n r Lr and d L',, otherwise reject the lot. The values of kr and krd are given in tables 821 111 and 821 112.

Table 8211/1 VALUES OF kr (SINGLE-LIMIT SPECIFICATION) Sample size (n)

@ = 15%

Table 821 112 VALUES OF krd (DOUBLE-LIMIT SPECIFICATION)

Sample size (n)

@ = 5%

kr
@ = 10%

k rd
@ = 5% @ = 10% @ = 15% @ =20%

4 5 6 7 8 9 10 12 14 16 18 20

0.446 0.547 0.622 0.682 0,732 0,773 0.809 0,867 0,914 0,952 0,985 1,013

0,123 0,238 0.320 0,382 0,432 0,474 0.509 0,567 0,612 0,649 0,680 0,707

-0,148 -0,004 0,089 0,158 0,211 0,255 0,292 0,357 0.397 0,434 0,465 0,491

4 5 6 7 8 9 10 12 14 16 18 20

d,338 0,451 0.534 0.600 0,653 0.698 0.736 0,800 0.850 0.891 0,926 0,956

-0.007 0,132 0,226 0,296 0.352 0,398 0.437 0,500 0,550 0,590 0,624 0,653

-0.324 -0,130 -0,016 0,065 0,126 0,176 0,217 0.283 0,334 0.375 0,409 0,438

-0,708 -0,389 -0,241 -0,144 -0,073 -0,018 0,027 0,098 0,152 0,194 0,229 0,259

SERIES 8000 : SUNDRIES SECTION 8300 : QUAUP/ CONTROL (SCHEME 2)

CONTENTS SCOPE JUDGEMENT PLANS : GENERAL DEFINITIONS GENERAL REQUIREMENTS PROCEDURES CONTROLLING MORE THAN ONE PROPERTY CONDITIONAL ACCEPTANCE PROCESS CONTROL BY THE CONTRACTOR QUALITY OF MATERIALS AND WORKMANSHIP

based on these plans shall not be altered. It shall be a condition of this contract that the theoretical validity of the various statistical judgement plans be accepted and that the validity of the decisions made on the basis of these judgement plans cannot be disputed on the grounds of statistical theory or a specified or implied producer's risk, or unjust on the grounds of enrichment.

For the purposes of this section the following words and symbols shall have the following meanings:

8301 SCOPE

This section describes one scheme used for determining, by means of tests and measurements and by applying statistical judgement plans, whether certain requirements specified in the specifications in regard to the properties of materials and workmanship are being complied with. It also covers the requirements in regard to the control to be exercised by the contractor for monitoring the quality of his work and materials and the routine tests and inspections to be carried out by the engineer.

A lot is a sizeable portion of work or quantity of material which is assessed as a unit for the purposes of quality control, and selected to represent material or work produced by essentially the same process and from essentially the same materials.

@)

Random sample

A random sample is a group of "nu test measurements at "nu separate test positions or on "nu sample portions obtained from the lot In an unbiased manner.
Random sampling shall mean stratified random sampling, unless Inconsistent with the context.

8 3 0 2 JUDGEMENT PLANS : GENERAL

(c) Certain requirements and limit values are laid down In the specifications in regard to the properties of materials and workmanship to be supplied. Tests shall be conducted and measurements taken for controlling the relevant properties of the workmanship and materials supplied, and the results of such tests and measurements shall be assessed on the basis of the prescribed criteria for compliance with the specified requirements. Wherever possible, acceptance criteria shall be determined by way of statistical principles described in this section. Wherever impracticable and where no statistical judgement criteria have been prescribed, the specified requirements and limit values shall be fully complied with. Despite acceptance of those properties judged by these statistical methods, the materials or work submitted will be rejected when other properties (which are not controlled by statistical methods) fail to comply with the requirements of the specifications, or where there are other causes for rejection such as obviously defective workmanship or excessively variable properties, visible signs of poor workmanship, and similar considerations which constitute sufficient grounds for rejecting the work without any further testing. The engineer shall be entitled to assess separately any specified portion of a lot if, in his opinion, it exhibits significant deviations as compared with the remainder of the lot. In order not to change the contractor's or the employer's risks, the statistical judgement plans shall be strictly adhered to in all cases where they are used, and decisions Sample mean (Sn)

Rn is the arithmetic mean of a set of "n" test results constituting the sample.

(d)

Specification limit (Ls)

This is the limit value of the property of any product outside which not more than a specified percentage (Q)) of the population of values representing an acceptable product property is allowed to lie. The specification limit may be a single lower limit Ls, or a single upper limit or a double limit consisting of a lower limit Ls and an upper limit L . ,'

(e)

Acceptance limit for sample mean

This is the limit value of a product property within which the sample mean shall lie for a product to be acceptable.

For a lower-limit specification, this acceptance limit is denoted by La. For an upper-limit specification, this acceptance limit is denoted by Va. For a double-limit specification, the lower and upper limits are denoted by La and L . ,'

(1)

Acceptance limits for individual test values

b)

This is the limit values of a product property within which the sample values representing a product shall lie for the product to be acceptable.

The limit values will depend on the sample sizes "n" and may be a lower limit L,,an upper limit r e , or double limits L, and r e .

the product of two full days' work. However, a lot of any smaller size may be ordered by the engineer where -

the properties under investigation exhibit abnormal local variation within the normal lot size;

(g)

Conditional acceptance

This is the acceptance of a lot at reduced payment in lieu of rejection. Conditional acceptance shall be subject to the provisions of clause 8307.

an area is obviously of a different quality than the rest; the rate of production is very high

(h)
Outliers

Where, in a sample, one or more test results differ significantly from the other values obtained, this difference could be ascribed to an assignable cause, in which case such test result shall be regarded as an outlier and disregarded when assessing the lot. To determine whether or not a test result is an outlier, the method given in subclause 8304(d) shall be adopted.

For rehabilitation or repair work the lot size shall be as specified in the project specifications, or as determined by the engineer. (ii) Concrete

(i)

First submission

The submission of a lot for approval will be classified as a first submission when actually submitted for the first time or when submitted for a second time on the basis of a second set of test values which shall be regarded as a first submission in terms of subclause 8304(e), because the properties of the first and the second sets of test values differ significantly.

The lot size shall be determined by the engineer, with due regard being had to the size and the type of structure in which the concrete is placed, the specific portion of the structure, and the total quantity of concrete placed in a day. The lot sizes in concrete structures could therefore vary considerably, and, particularly in the case of small structures, it could be necessary to combine samples of the same grade of concrete from different structures. provided that the concrete has been obtained from the same concrete plant and has been cast in the same period. (iii) Other

0)

Resubmission

In other cases, as for example in material stockpiles where the definition of a lot in accordance with subclause 8303(a) does not apply directly, the engineer will determine lot sizes in accordance with circumstances pertaining to each case.

The submission of a lot for approval for a second time shall be classified as a resubmission should it be regarded as a resubmission in terms of subclause 8304(e), as the properties of the first and second sets of test values do not differ significantly.

@)

Random sampling

(k)

Payment-reduction factor (fr)

This is the factor by which payment at contract rates shall be multiplied for calculating payment for conditionally accepted work.

When any lot is tested, whether a normally sized lot or an isolated section which clearly exhibits an abnormal variation of the properties under consideration, all samples shall be taken in a stratified random pattern. For this purpose use shall be made of tables of random numbers, and the instructions in publication TMH5, Sampling for Road Construction Materials, shall be followed.

(c)

Sample sizes

(I)

Definitions pertaining the rehabilitation and repair work

In the case of rehabilitation or repair work the definitions for lot, lot size and sample size shall be as specified in the project specifications or as directed by the engineer.

For purposes of acceptance control, the engineer will, in advance, determine sample size "nu. The larger the sample, the more reliable the result will be, and no sample sizes may be smaller than those given in clause 8305. With regard to rehabilitation or repair work the sample sizes specified in the project specifications or prescribed by the engineer shall apply.

8304 GENERAL REQUIREMENTS

(d) (a) (i) Determining the lot size Road-construction layers Test results shall be scanned for possible outliers. Where a test result deviates greatly from the remainder in a lot, it shall, if possible, be re-examined by further testing, and, if there is reasonable evidence to suggest that the test result is erroneous, it shall be regarded as an outlier, rejected, and replaced with a fresh test result. Where repeating a test or re-examining a test result is Outliers

The lot size shall normally be a section compacted in one process where essentially the same materials and construction equipment have been used. Where production is on a continuous basis, a lot shall normally mean the product of one day's work and shall not exceed

impossible, method 1 described below shall be used for identifying outliers for all work except basecourse and asphalt work. Method 2 shall be used for identifying outliers for basecourse and asphalt work. (i) Method 1

If the absolute value Co > C, the test result xo shall be regarded as an outlier and shall be excluded from the sample.

Calculate the value of To from

The critical values for different values of n are given in tables 830412 and 830413 for the different product properties. Table 830412 OUTLIER TEST FOR BASECOURSE : CRITICAL VALUES C

where Rn and Sn are the arithmetic mean and the sample standard deviations respectively, and
For percentage compaction

CRITICAL VALUES C
For sieve size (mm) For PI

xo is the value of the test result differing most from the mean. Compare the value of To with the value of T for the applicable value of "nu, from table 830411. Table 830411 No of observations (n)
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

n
4 5 6 7

26,5 19.0 13,2 4,75 2.00 0,425 0,075

4,l 4,4 4 . 6 4,7 4,8 4,9 4,9

6 . 1

8 . 5

8 . 5

7,3 5,6

3 . 6 3,9 4 . 0 4,l 4,2 4,3 4,4

3,2 3,3 3 . 5 3,6 3,7 3,7 3,8

2,4 2,6 2,7 2,8 2,8 2,s 2 . 9

6,4 9,O 9.0 7,7 5,9 6.7 9.4 9,4 8.0 6,2

6,s 9,7 9.7 8,3 6,3 7,l 9,9 9,9 8,s 6,5

Critical values

8 9

(TI
1,46 1,67 1,82 1,94 2,03 2 . 11 2,18 2,23 2,29 2,33 2,37 2,41 2,44 2,47 2,50 2,53 2,56
10

7,2 10,l 10,l 8,6 6.8 7,3 10,2 10,2 8,7 6.7

Table 830413 OUTLIER TEST FOR ASPHALT : CRITICAL VALUES C

CRITICAL VALUES C
n For density For bitumen content For voids in mix

4 5 6 7

3,2 3-3 33 3 . 6

04
0,s 03 0,s

23 24 23 2,6

If the absolute value of To is greater than T, then xo is an outlier.

Every outlier shall be discarded, and, if possible, be replaced with a new random test value. (ii) Method2 Every outlier shall be discarded and replaced by another random test value. The sample mean Rn and the sample standard deviation Sn shall then be recalculated. If an outlier cannot be replaced, the sample mean and standard deviation shall be calculated on the basis of the remaining test results. The final number of test results used in the assessment after the elimination of an outlier shall never be less than four.

Inthe case of basecourse and asphalt work the following procedure shall be used for identifying outliers where it is impossible to repeat a test or to reinvestigate a test result: Calculate the absolute value Co from

(e)

Resubmission

where xo represents the possible outlier. Compare Co with the critical value C
=

Where a lot has been accepted conditionally or has been rejected, the engineer may agree to its resubmission for approval if

Co,Ol;nu

Where c i s the standard deviation of the population derived from historical data.

it has been reworked and the engineer is satisfied that a proper attempt was made to improve the properties which were unacceptable;

where, in his opinion there are valid technical reasons therefor.

In both cases a fresh sample shall be taken, and a fresh (second) set of test values determined. The first and second sets of test values shall then be compared with each other to determine whether their properties differ significantly. Where in the opinion of the engineer a significant difference does occur, the submission of the lot shall be regarded as a first submission and assessed as such, and only the second set of test values shall then be used for this purpose. Where in the opinion of the engineer no significant difference occurs, the submission of the lot shall be regarded and assessed as a resubmission. Where a lot is resubmitted, it shall be assessed on the same basis as a first submission, except that the original and the second set of sample results shall be combined for purposes of assessment.

before and after construction of the layer in exactly the same position, but may be augmented by thicknesses measurements taken by means of holes made in the layer. In the case of asphalt layers, the engineer may require thickness determinations to be made only by means of measurements on drilled cores, in which case the minimum number of cores per lot shall be 20 instead of 30. Outliers shall be identified, disregarded, and, if possible, replaced. The lot will be considered to comply with the requirements for layer thicknesses if at least 90% of all the thickness measurements (i) taken before any thickness repairs are made is equal to or greater than the specified thickness, minus the Dgo tolerance specified in the appropriate section; and the mean layer thickness of the lot is not less than (ii) the specified thickness, minus the Dmean tolerance. Isolated spots where the actual thickness is less than the specified thickness less the Dmax tolerance shall be repaired so as to fall within the Dgo tolerance.

8305 PROCEDURES

(c)

Relative compaction

of pavement layers

The statistical judgement procedures described below will apply to the corresponding product properties for purposes of acceptance control.

Note:
For rehabilitation or repair work the number of measurements, tests or samples specified in the project specifications or prescribed by the engineer shall be taken for acceptance control in respect of the product properties specified in subclauses (a) to (1) below.

At least 4 relative density determinations shall be taken in the case of selected layers and at least 6 in the case of all other pavement layers in accordance with a random pattern. After outliers have been examined and replaced, compliance with the specified density requirements shall be determined as follows: The sample mean Rn shall be at least equal to or higher than the acceptance limit (La) for the sample mean as given in table 830511, and no single test value shall be for single values. lower than the acceptance limit (k)

(d) (a) Surface levels of fills and pavement layers

Cementitious-binder content of stabilized layers and uniformity of mix

At least 50, but preferably more, level measurements shall be taken according to a stratified random pattern of each lot of completed layer work, and the specified levels shall then be determined. Outliers shall be identified and examined. The lot will be considered to comply with the requirements in respect of surface levels if, before any repair work is undertaken, at least 90% of the level measurements show a deviation from the specified levels which is smaller than the Hgo tolerance specified in the relative sections in regard to each layer. Isolated spots, where the surface levels deviate by more than the appropriate Hmax tolerance of the specified levels shall be repaired to bring the deviation to within the Hgo tolerance.

Take 50 samples according to a random pattern and determine their cementitious-binder content. Examine the results for outliers and replace them if any. As described in subclause 81 10(a), the test results shall be adapted to make provision for the presence of minerals, which may affect the test results, in the material to be stabilized.

The quantity of cementitious binder in the mixed material determined by taking 50 samples per lot and testing them as specified, shall fall within the following limits: The mean cementitious-binder content shall be not (i) less than 91% of the specified binder content. The cementitious binder content in not more than (ii) 12 of the 50 samples may be lower than 70% of the specified binder content.

@)

Layer thicknesses of pavement layers

At least 30, but preferably more, layer thicknesses shall be determined in accordance with a stratified random pattern for each lot of completed layer work. Layer thicknesses may be determined by means of level measurements taken

The requirements for uniformity of the mix shall apply only on condition that the variation of these adjustments fall within the limits specified in subclause 8110(a).

(e)

Binder content of asphalt

(i)

ic 2 Ls

+ AA

where

Take at least 4 specimens of asphalt in a random pattern and determine the binder content. Examine the results and replace any outliers as specified.

R =

a mean value of the 28-day cube compressive strength tests

Determine the sample mean and assess the lot by using the following criteria: The binder content of asphalt mixes shall not deviate from the specified binder content by more than the values given in table 830512. Table 830512 ACCEPTANCE LIMITS FOR BITUMINOUS-BINDER CONTENT Maximum deviation of the sample mean from the specified binder content (% of binder) Continuous, semi-gapSample Gap-graded and graded and opennon-homogeneous size graded conventional (number) modified binder and homogeneous mixes and slurry modified binder mixes seals

Ls =

characteristic strength specified in the concreteclass indication (see clause 6404)

AA

the applicable value given in table 830513

(ii)

No single test value is lower than the value Ls - AB where

AB = the applicable value given in table 830513.

Table 830513 ACCEPTANCE FACTORS FOR STRENGTH CONCRETE Sample size (n)

AA

(MPa)

43

(MPa)

3
4 5 6 7 8

0,51 0,44 0,41 0,38 0,36 035 0,33

037 0,33 0,30 0,28 0,27 0,26 0,25

3 4 5 6 7 8 9 10 11 12 13 14 15

0,s 1,l 1,4 1,7 179 2,1 22 2,3 2,4 2,s 2,6 2,7 2,7

3,9 42 4,5 4,7 4,9 50 52 5,3 5,4 5,5 56 5,7 5,8

Maximum deviation of any single test value from the specified binder content (% of binder) Sample size (number) Gap-graded and semigap-graded mixes Continuous and opengraded mixes

Table 830514 MINIMUM SAMPLE SIZES FOR STRENGTH CONCRETE (STRUCTURAL)

3
4 5 6 7 8

0,76 0,81 0,84 0,87 0,89 0,91 0,92

0,54 0,58 0,60 0,62 0,64 0,65 0,66

Volume of lot (m3)

Minimum sample size

0 - 20 21 - 40 41 - 70 71 - 100 101 - 150 2 150

4 6 9 12 14 16

(1)

Concrete : 28day cube compressive strength

8 3 0 6 CONTROLLING MORE THAN ONE PROPERM

Take at least the minimum number of samples as given in table 830514 according to a random pattern and make test cubes. Test them for cube compressive strength after 28 days. Examine the results for outliers and disregard if any. The results are then assessed according to the criteria set out below. A lot will comply with the requirements for the characteristic strength if it meets the following requirements:

Where more than one property of a lot is being controlled, the lot shall be accepted if all the properties comply with the specified requirements, but if one or more of the properties do not comply with the requirements, the lot shall be rejected, or it may be conditionally accepted subject to the provisions of clause 8307.

8307

CONDITIONAL ACCEPTANCE

(c)

Criteria for conditional acceptance

(a)

General

Where a lot is rejected under a statistical judgement plan described in this section but the test results are such that the lot complies with the requirements for conditional acceptance specified hereafter, the engineer may accept the lot conditionally, that is, the lot may be accepted at reduced payment in lieu of complete rejection, provided that (i) conditional acceptance shall be in the sole discretion of the engineer and is not an option which may be exercised by the contractor or a right he may claim; (ii) the lot is approved in respect of all other requirements not judged by a statistical judgement plan; the contractor shall have the option to remove and (iii) reinstate at his own cost conditionally accepted work with work which complies with the requirementsfor acceptance at full payment; (iv) conditional acceptance and the corresponding reduced payment shall apply only in respect of the work and properties listed in subclause 8307(b) below. Properties to which conditional acceptance applies

In terms of the respective judgement plans relating to the properties to which conditional acceptance applies; two requirements shall always apply, viz one in relation to the sample mean (k,), and one in relation to individual test values xn. A lot may be conditionally accepted when it complies with one of the two requirements for acceptance, but not with the second requirement provided that it complies with the requirements for conditional acceptance in relation to the second requirement. There are therefore always two cases: (i) Case 1

The lot complies with the requirement for sample mean, but not in all cases with the requirement for individual test values. The lot may be accepted conditionally, subject to the following additional conditions:
(1) In regard to the RELATIVE COMPACTION OF PAVEMENT LAYERS, the BITUMINOUS-BINDER CONTENT OF ASPHALT and the CONCRETE CUBE COMPRESSIVE STRENGTH, not more than one test value may not comply with the requirements of individual test values.

@)

In regard to the CEMENTITIOUS-BINDERCONTENT, (2) the binder content may be below 70% of the specified binder content in not more than 13 cases. (ii) Case 2

Conditional acceptance may be applied in respect of the properties of structures listed below in table 830711. Note: Conditional acceptance shall not apply to crushed-stone layers, but, where compaction to 88% of apparent density has been specified but cannot be attained, the engineer may accept the layer at payment at the rate for compaction to 86% of apparent density on condition that the layer complies with the requirements for this compaction standard. The same provisions shall apply mutatis mutandis where a specified density of 102% of modified MSHTO density Table 830711 PROPERTIES TO WHICH CONDITIONAL ACCEPTANCE MAY APPLY Property Relative compaction Structure (i) Asphalt base or surfacing (ii) Chemically stabilized layers (iii) Plant mixed paver laid layers Asphalt base or surfacing

The lot complies with the requirements for individual test values but not with the requirements for sample mean. The lot may be accepted conditionally on condition that the sample mean Cn lies within the rejection limits given in table 830712. Table 830712 REJECTION LIMITS (Lr and L',) FOR THE SAMPLE MEAN (Rn) Rejection limits (Lr and L',) Relative (a) Chemically Lr = (La - 2.000)% stabilized layers in relative compaction accordance with compaction section 3500 or 3700 (b) Asphalt base Lr = (La - 1.000)% or surfacing relative compaction Cube All strengthLr = 0,85 La compressive concrete strength (excluding pavement concrete) Bituminous Asphalt Lr = (La - 0.200)% binder content % binder L', = (L', + 0.200)% binder Cementitiousbinder content Strength Chemically stabilized layers Chemically stabilized layers Lr = 0.80 La Property Structure

Bituminousbinder content Cementitiousbinder content or strenqth requirements 28-day cube compressive strength

Chemically stabilized layers

All structural concrete (excepting concrete pavements)

Lr = 0,85 La

cannot be but 100% of modified AASHTO density has in fact been attained.

(d)

Determining the payment reduction factor or)

(e)

Applying the payment-reduction factor

Where a lot is conditionally accepted, compensation will be reduced by multiplying the tender rates for the items concerned, as set out below, with the payment reduction factor fr. The factor fr is determined as follows in regard to (i) the two cases set out in subclause 8307(c) above. Case 1 The lot complies with the requirements for sample mean, but not in all cases with the requirements for single values. fr is always taken as being equal to 0,85. Case 2 The lot complies with the requirements for single values, but not with the requirements for sample mean (Rn). For conditional acceptance at a lower limit

The payment-reduction factor shall be applied to the following payment items as may apply and be described in the specifications.
Chemically stabilized layers

ltems 34.01, 34.02, 34.03, 34.04, 34.05, 34.09, 35.01, 35.02, 35.05, 35.06, 35.07, 35.08, 35.09, 35.10 and 35.12.
Asphalt base and surfacing

ltems 42.01, 42.02, 42.03, 42.09, 42.10, 42.11, 42.12, 42.13 and 42.16.
Single and double seals (bituminous binder application rates)

ltems 44.01, 44.02, 45.01 and 45.02.

Concrete

ltems 64.01, 64.02, 64.03 and 64.05. No reduction shall apply to payment items for formwork, reinforcing or tendons.
Plantmixed pavement layers placed by paver

For conditional acceptance at an upper limit

ltems 37.01, 37.02 and 37.03.

General

(See clause 8303 for definitions of symbols). Where a lot is conditionally accepted with regard to (ii) bituminous binder application rates, the appropriate payment reduction factor in table 830713 shall be applicable. Table 830713 PAYMENT REDUCTION FACTORS FOR CONDITIONALLY ACCEPTED BITUMINOUS BINDER APPLICATION RATES Conventional and homogeneous modified binders Deviation from the specified rate (net bitumen cold) llm2 Payment reduction factor fr Bitumen-rubber binders

Where payment items are incorporated in the project specifications or have been amended in the schedule of quantities, the payment-reduction factor shall apply to the payment items corresponding to the payment items mentioned above. Where a lot is conditionally accepted in regard to more than one property, the payment-reduction factor for each property shall be calculated, and the factor giving rise to the largest reduction shall be applied, except in the case of concrete pavements when the provisions of clause 7124 shall be referred to.

8308 PROCESS CONTROL BY THE CONTRACTOR

The requirements of clause 1205 shall apply in respect of the contractor's obligation to institute and implement a control system for monitoring the quality of the work and materials supplied. For coritinuous concrete and asphalt-production processes, the engineer may order the contractor to augment the above control system by introducing a process-control system for monitoring the various properties to be controlled. The specific system to be applied shall be subject to the engineer's approval, and the attention of the contractor is drawn to the systems described in clause 4.4 of TRH5, which will normally be regarded as suitable. The contractor shall take immediate steps to rectify any deviation from the specified requirements indicated by his process-control system, and the engineer shall have the right to inspect and be given all details of tests and testing procedures in order to satisfy himself that the contractor is implementing adequate process-control system.

Deviation Payment from the reduction specified rate factor at spraying fr temperature ("/.)

r 0.06

+ 0.07
2 0.08

+ 0,09 + 0,10

1, O O 0,95 0,90 0,85 0,80

+ 5,O + 6,O
2 7,O

+ 8,O

+ 9,O

1, O O 0,97 0,95 0,90 0,85

If the deviation exceeds

If the deviation exceeds

8309 QUALITY OF MATERIALS AND WORKMANSHIP

The engineer will at regular intervals inspect and test materials and completed work for compliance with the specified requirements, and, where applicable, the various specified judgement plans will be applied. The testing frequencies and sample and lot sizes for routine testing shall be at the engineer's discretion.

All sections of completed work shall be submitted to the engineer for routine inspection and testing, and the contractor shall not cover up or construct any work on top of sections of completed work before being advised by the engineer of the outcome of his tests and inspection. The contractor shall arrange the submission of work for testing in a manner as will afford the engineer reasonable opportunity for inspecting and testing.

SERIES 8000 : SUNDRIES

Chloro-rubber paint

. . . . . . . . . . . Project specifications

4 0 0 : PANTING SECTION 8

Bituminous aluminium paint

. . . . . . . . . . . . .SABS 802

CONTENTS SCOPE MATERIAL GENERAL APPLYING THE PAINT PROTECTING THE WORKS DURING PAINTING OPERATIONS PREPARING SURFACES FOR PAINTING PAINTING STRUCTURAL STEEL PAINTING GUARD RAILS PAINTING CONCRETE PAINTING GALVANISED SURFACES MEASURING PAINT THICKNESSES MEASUREMENT AND PAYMENT

(d)

Other

Epoxy-tar paints

. . . . . . . . . . . . . . . . . SABS 801 (type I) ........

CKS 564

Bonding liquid for concrete surfaces Powder coating

. . . . . . . . . . . . . . . . . . . . . .SABS 1274

Bituminous-emulsion paint shall consist of a stable bituminous emulsion with a minimum of 45% of bitumen and about 596 of approved fibre.

8403 GENERAL

8401

SCOPE

This section covers the painting and rehabilitation of structural steel, guard rails, overhead road sign supports and other structures.

No paint shall be applied to surfaces containing (a) physically adhering contaminants such as oil, grease. dirt, marking material, water-soluble salts, wax, paint and temporary protectives, or to surfaces containing chemically bonded contaminants such as rust, mill scale, slag and flux. (b) All surfaces which are painted shall be dry.

8402 MATERIAL

Paints shall comply with the requirements of the following specifications:

All traces of soluble salts and corrosive airborne (c) contaminants shall be thoroughly washed from :he surface prior to painting, and the surface shall be dried and painted immediately afterwards. Where surfaces are to be welded, unless othertvise (d) specified, any paint shall not be applied within 75 m m of the weld position prior to welding. After the welding has been completed, the welds (e) and adjacent parent metal shall be completely deslagged, and the surfaces shall then be inspected and approved. All spatter shall be removed prior to the surfaces being painted. The weld area shall be abrasive-blasted and/or ground and all contaminants such as flux shall be removed prior to the surface being painted. Surfaces which are to rest on concrete or other (f) floors shall receive all the prescribed coats of paint, and the paint shall be dry before the members are erected. Damaged paint areas shall be cleaned, rust spots (g) removed and the surface again be primed so that the patch painting covers the damaged areas and extends over a strip of 20 m m beyond each damaged area. Where the shop coat is allowed to age for a few (h) months before the next layer of paint is applied, light sanding with sandpaper or rubbing with steel wool and scrubbing with clean water with a bristle brush shall be carried out. (i) Steel members embedded in concrete shall be entirely painted to a distance of 75 mm within the concrete measured from the concrete outer surface, and the paint shall be dry before the members are installed.

(a)

Primers

Zinc-chromate primers for steel (or approved alternative)

. . . . . . SABS 679 (type 1

or type 2, grade II)

Wash primer (metal etch primer) Calcium-plumbate primer

. . . . . . . . . . SABS 723

. . . . . . . . . . . . . . . . SABS 912
. . . . . . . . . . SABS 926

Two-pack zinc-rich epoxy primer

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Undercoats

Undercoat

....................

SABS 681 (type II)

(c)

Finishing m a t s

Decorative enamel for interior and exteriw use . . . . . . . . . . . . . . . . . . . . . . . SABS 630 High-gloss paint

. . . . . . . . . . . . . . . . SABS 684 (type A)

Micaceous iron-ore-pigmented paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SABS684 Baking enamels

. . . . . . . . . . . . . . . . . . . . . . .SABS 783

Emulsion paint for exterior use (polyacrylic) . . . . . . . .

SABS 634

(j) The paint manufacturer's instructions shall be strictly adhered to.

Painted steel members shall be stacked so as to be (k) off the ground. Friction-grip surfaces shall not be painted but shall (I) be treated in accordance with the project specifications.

cost to prevent such damage. Any unsightly paint stains shall be removed by the contractor at his own cost. If passing traffic creates sufficient dust to harm or spoil the appearance of painted surfaces, the contractor shall sprinkle the adjacent roads and shoulders with water at his own cost, for a sufficient distance on each side of the location where the painting is being done, to keep the dust away from freshly painted surfaces. The contractor shall, at his own cost, also furnish and post appropriate temporary road signs and take other necessary precautions to prevent dust and dirt from adhering onto freshly painted surfaces.

8404 APPLYING THE PANT

Unless otherwise specified, paint may be applied either by brush, spray or roller method, or by any combination of these three methods, or by powder coating. Where brushes are used, they shall have sufficient body and length of bristle for spreading the paint in a uniform coat. Paint shall be evenly spread and thoroughly brushed out. If brush marks are visible, it will be considered that the paint has been improperly applied, and the paint will not be accepted. On all surfaces which are inaccessible to painting by regular painting equipment, the paint shall be applied by bottle brushes, sheepskin daubers, or by any other acceptable method so as to render the required coating of paint. If spray methods are used, the operator shall be thoroughly experienced.

8406

PREPARING SURFACES FOR PAlNTlNG

Before paint is applied to any surface, the appropriate specified surface preparation shall be carried out in accordance with the relevant sections of SABS Code of Practice 064 or as specified herein.

8407

PAINTING STRUCTURAL STEEL

(a) Runs, sags, thin areas in the paint coat, or where air bubbles have formed or the paint has delaminated, or any skips shall be considered as being unsatisfactory, and the contractor will be required to repaint the surface by brush. A water trap and an air-regulating valve acceptable to the engineer shall be furnished and installed on the equipment used for spray-painting. Mechanical mixers shall be used for mixing paint properly when no ready-mixed paints are used. Prior to application, the paint shall be remixed for a sufficient length of time to mix the pigment and vehicle thoroughly. Paint shall be constantly kept well stirred to keep the pigments in suspension during its application. All skins in the paint shall be removed by screening. If it cannot be removed effectively, the paint and paintwork already completed may be condemned at the discretion of the engineer. Paint shall not be applied when the temperature of the steel is not at least 3C above dew point or when the temperature of the steel is below 5C or above 35"C, unless otherwise prescribed by the engineer. Paint shall not be applied in fog or mist, when it is raining or when rain is expected, or when the relative humidity is above 85%.

General

The surface preparation, priming and application of an undercoat shall be carried out under cover at the fabricator's works. Where possible, all painting shall be done at the fabricator's works but, where this is unfeasible, the engineer may permit the application of the finishing coats on the site, in which case an undercoat shall be applied at the fabricator's works prior to the members being despatched to the works. Unless otherwise specified, the protection described in subclauses 8407(c), (d) and (e) shall be applied to all steel work. Corrosion protection of steel work exposed to aggressive or severe conditions shall comply with the requirements of the project specifications.

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(i)

Surface preparation New structures

8405 PROTECTING THE WORKS DURING PNNTING

OPERATIONS

After all cutting, drilling, welding and punching have been completed, it shall be ascertained that all sharp edges have been uniformly rounded off and smoothed down. AIl physically adhering contaminants shall be removed and the surface shall then be abrasive-blasted to Sa 2% finish in accordance with the Swedish Standard SIS 05/59/00. The profile limit of the surface finish shall be between 30 and 60 p m . The abrasive-blasting profile shall be measured in accordance with SABS method 772 and shall comply with SABS Code of Practice 064. No abrasive-blasting shall be done during rainy weather or when corrosive air conditions prevail. Unless the application of a primer follows within 4 hours of abrasive blasting and before any oxidation of the prepared surface takes place, the abrasive-blasted surface shall immediately after abrasive blasting be given one coat of a wash primer.

The contractor shall protect all parts of the structure against disfigurement by spatters, splashes andlor smirches of paint or of paint materials. The contractor shall be responsible for any damage to or paint on or contamination to vehicles, persons or property, including plants and animals, as a result of his operations, and he will be required to provide protective measures at his own

(ii)

Existing structures

(g)

Back-to-back members and areas not easily accessible

The surface preparation of existing steel structures shall be carried out on site in accordance with clauses 3 and 4.4 of SABS 064.

Back-to-back members and areas not easily accessible shall be fully coated with all the specified coats of paint up to and including the finishing coats before erection.

(c)

Primer

(h)
The prepared surface shall be given two coats of a zincchromate primer in accordance with SABS 679, type 1, grade II. The first coat shall be applied within 12 hours in the case of wash-primed surfaces and within 4 hours, but before any oxidation of the surface takes place, in the case of abrasive-blasted surfaces that have not been washprimed. A fast-drying zinc chromate in accordance with SABS 679, type II, grade II, may be used as primer. In all cases the dry-film thickness shall not be less than 30 p m per coat. When steel has to be welded after the primer has been applied, the steel shall be left unpainted for a distance of 75 mm from the weld joint unless a weldable type of paint has been used. The welds shall be treated in accordance with the instructions of clauses 8403 and 8407.

Damaged areas

Damaged areas shall be treated as follows: Sand down to bright metal and clean. Spot prime with two coats and sand down lightly when hard. Rinse off with water and allow to dry. Apply two finishing coats.

( i )

Sbuctural steel to b e embedded below ground

Those parts of structural-steel members to be embedded in soil and all bases to a height of 500 mm shall be given two coats of an epoxy-tar prime instead of the zincchromate prime specified for other surfaces.

8 4 0 8 PAINTING GUARD W L S
(d) Undercoat
(a)

General

Where the finishing coats are to be applied on the site. the primed surfaces shall be given one coat of a universal undercoat with a suitable colour in the fabricator's shop before despatch. The undercoat shall be applied as soon as the prime coat has dried sufficiently. The dry-film thickness shall not be less than 25 prn.

Guard rails are not painted unless otherwise prescribed.

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Surface preparation and priming

(e)

Finishing coat

Two finishing coats of high-gloss structural paint (SABS 684, type A) of the specified colour shall be applied to leave a dry-film thickness of not less than 25 p m per coat. Where the finishing coats are applied on the site, the undercoat shall be lightly sanded and the members washed and cleaned of all contaminants. The first finishing coat shall be applied as soon as the structural members are dry. Where specified in the project specifications, the second finishing coat shall consist of a micaceous iron-orepigmented structural paint of the specified colour to a dryfilm thickness of not less than 30 p m . In all cases the second finishing coat shall be applied within 48 hours of the application of the first finishing coat. The dry-film thickness of the total paint system shall not be less than 110pm when no undercoat is used and not less than 135 p m when an undercoat is used. Where the second finishing coat is an iron-ore-pigmented paint, these thicknesses shall be increased by 5 p m .

All dirt, loose mill scale and loose corrosion products shall be removed by hand or power tools and all rust and mill scale by pickling, after which the surface shall be rinsed and a neutralising rinse shall be applied, or the surface shall be phosphated.

(c)

Priming

Apply two coats of zinc-chromate primer to a dry-film thickness of not less than 20 p m per coat. After the prime coats have hardened, the guard rails may be transported to the site.

(d)

Storage on the site

fl

Mating surfaces

The primed guard rails shall be stored off the ground under cover and protected against rain and weather until erection. Guard rails shall be stacked individually and not nested so as to prevent corrosion during storage. The finishing coats shall be applied as soon as possible and the primed surfaces shall not be allowed to corrode as a result of prolonged exposure to the weather. Any guard rails showing signs of rust before the application of the finishing coats shall be rubbed down with steel wool or fine sandpaper until all rust is removed, and it shall then be recoated with a zinc-chromate primer.

When mating surfaces are brought together, both surfaces shall already have been covered with all the specified coats of paint, but, where this is impossible, each surface shall be given a copious coating of primer and the surfaces drawn up while the paint is still wet.

(e)

Finishing

Before the first finishing coat is applied, the guard rails shall be thoroughly washed down to remove all traces of

salt and/or other air-borne corrosive materials and all dirt or other contaminants. As soon as the rinsed guard rails are dry, a finishing coat of aluminium paint in accordance with SABS 802 or a white high-gloss enamel in accordance with SABS 684 shall be applied to a dry-film thickness of not less than 25 pm. Within 48 hours this shall be followed by a second coat as described before. The guard rails shall preferably be given both finishing coats before erection, but, where this is impossible, the engineer may permit the finishing coats to be applied after the guard rails have been erected, provided that all mating surfaces and spots which are not easily accessible shall be painted with the finishing coats before the guard rails may be erected. The total dry-film thickness of all coats of the paint shall not be less than 90 p m . All damaged spots shall be treated as specified in subclause 8407(h).

preparation and priming shall be as follows:

(a)

Surface preparation

Freshly galvanised surfaces shall be thoroughly scrubbed down with an approved galvanised-iron cleaner to remove all traces of the resin protective coating. The surface shall be washed down and scrubbed to remove all traces of grease, oil, dirt, etc.

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Priming

Two coats of calcium-plumbate primer shall be applied to a dry-film thickness of at least 25 p m . The undercoat shall follow within one week of the primer.

841 1

MEASURING PAINT THICKNESSES

8 4 0 9 PAINTING CONCRETE
The dry-film thickness of paint shall be determined in accordance with SABS method 141. At least 9046 of all thickness measurements shall comply with the minimum specified requirements. The thickness shall not in any case be less than 70% of the specified thickness. In addition painters shall be supplied with, and instructed to use, wet-film thickness gauges.

(a)

Surface preparation

The surface of the concrete to be painted shall be cleaned of all dust, loose particles, laitance, impurities and other deleterious materials, and then washed and allowed to dry. Unless the surface is to be covered with a bituminous paint, all cracks, holes and cavities shall be filled with grout or an acrylic filler.

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Sealing and priming

8412

MEASUREMENT AND PAYMENT

The surface shall be sealed with an approved clear sealer which complies with CKS 564 and then primed with a primer consisting of an undercoat diluted to 5096.

Hem
84.01 Painting:

Unit

(c)

Undercoat and finishing

(a)

(Describe structure/ article) . . . . . . . . . . . . . . . . . square metre (mZ) (Describe structure/ article) . . . . . . . . . . . . . . . . . . . . . number (No) (Describe structure1 article) . . . . . . . . . . . . . . . . . . . . . . . . metre (m) (Describe structure1 article) . . . . . . . . . . . . . . . . . . . . . . . . . . ton (t)

An undercoat shall be applied after priming, followed by two finishing coats of the prescribed paint.

(b)

(d)

Bituminous paint

(c)

The surface shall be prepared in accordance with the requirements of subclause 8409(a). Before it dries out, a primer shall be applied in accordance with the instructions of the fabricator of the bituminous paint. After the primer has been applied, two coats of bituminous paint shall be applied at the rate of 0,75 I/m2/coat. No paint coat shall be applied unless the previous coat has dried out completely, and no paint shall be applied to the paintwork for so long as any moisture occurs on the surface.

(d)

The unit of measurement shall be the square metre of surface painted. Orily the surface covered by the final finishing coat shall be measured. The unit of measurement may also be the number of structures or articles painted, or a metre length of the structures or articles painted, or a ton of the structures or articles painted, the quantities are calculated as specified in item 67.01. The tendered rates shall include full compensation for surface preparation, applying all the coats of paint, repairing any damaged surfaces, and all materials and construction plant necessary for completing the work.

8410

PAINTING GALVANISED SURFACES

Galvanised surfaces shall be painted as specified in this section for steel surfaces, except that the surface