G.

PAVEMENT MATERIALS
1. Interlocking Concrete Pavers (ICP)
a. General
Interlocking concrete pavers shall comply with the requirements of specification for Precast Concrete Paving
Blocks (MS 1380:1995) published by the Standards Malaysia. All materials used shall be of the best quality
obtained from sources and suppliers approved by the Engineer and shall comply strictly with the tests prescribed
hereinafter. When tests are not laid down in this Specification, the contractor shall test the pavers at independent
testing laboratory to comply with the requirements of the latest relevant Malaysian Standards or other Standards
as specified by the Engineer. The cost of all tests required by this specification and any other relevant standards
shall be borne by the Contractor.

b. Interlocking Concrete Pavers (ICP)

i. Raw Materials Standards and Specifications

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MS 29:1995 – Specification for aggregates from natural sources for concrete

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BS812-105 : 1 : 1989 – Testing aggregates. Methods for determination of particle shape (Flakiness Index).

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MS EN 196-1 : 2007 – Methods of testing cement.
MS 888:2011 – White Portland Cement, Compositions, Specification, Conformity

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EN 197-1:2000 – Cement; Composition, Specification, & Conformity criteria for common cement.

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BS EN 450:2005 – Fly ash for concrete
BS EN 1008:2002 – Specification for mixing water for concrete
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BS EN 12620:2013 – Aggregates for concrete
MA 20 – Specification for concrete segmental paving units (Aust. Std.)
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MS 1380:1995 – Specification for precast concrete paving blocks

BS 6717:1993 – Precast concrete paving blocks. Specification for paving blocks
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BS EN 1338:2003 – Concrete paving blocks – Requirement and test methods

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BS 7263: Part 1:94 – Precast concrete flags, kerbs, channels, edgings and quadrants.
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BS 6088:1981 – Specification for solid glass beads for use with road marking compounds and
for other industrial uses.
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MS 738:1981 – Specification for terrazzo floor tiles

ASTM C 979 – Pigments for Integrally Colored Concrete.
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ISO 1248-2006 – Iron Oxide Pigment; specification and method of test

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The Precast Concrete Paving and Kerb Association (Interpave)

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a. Uniclass L534:L212
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Guide to the properties, design, construction, reinstatement & maintenance of concrete block pavements.
b. Uniclass L534
Heavy duty pavement: the standard design of heavy duty pavements for ports and other industries.

American Society of Civil Engineers (ASCE)

ASCE 58-10
Structural Design of Interlocking Concrete Pavement for Municipal Streets and Roads ways.
ii. Paver Type & Compliance
Interlocking concrete paver shall be selected from one of these types based on its application and as
approved by the Engineer/Architect:
c. FOR VEHICULAR PAVEMENT, HEAVY DUTY PAVEMENT, AND PEDESTRIAN
Material Specification

1. In compliance with MS 1380:1995; for 80mm and 100mm thick paver with average minimum
compressive strength of 45 MPa.
2. In compliance with MA 20; for 60mm thick paver with average minimum compressive strength of 30
MPa.
3. Anti-fungal (up to 90% resistance to fungal growth)
4. Green Label certification: Yes
5. Dimension: various size and dimension depending on the profile selected
6. The shapes and profiles of the paver shall be selected from the manufacture available product
catalogue and shall be approved by the Engineer/Architect. The finishing surface shall be in natural
colour, Standard colors, Premium colors, Monochromatic toning colors or any other colors as specified
by the Engineer / Architect. The selected paver shall fit for application for vehicular pavement, heavy

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duty pavement (e.g. Ports) and pedestrian pavement.

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and/or

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Material Specification

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1. High-strength 60mm ICP. Average minimum compressive strength of 45 MPa. Tested in accordance to

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MS 1380:1995 specifications and test method.rD
2. Anti-fungal (up to 90% resistance to fungal growth)
3. Green Label certification: Yes
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4. With Twin-Wide Spacer Locking System
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5. Dimension: 200mm x 200mm x 60mm thick

6. The shapes and profiles of the paver shall be selected from the manufacture available product
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catalogue and shall be approved by the Engineer/Architect. The finishing surface shall be in natural
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colour, Standard colors, Premium colors, monochromatic toning colors or any other colors as specified
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by the Engineer / Architect. The selected paver shall fit for application for vehicular pavement, and/or
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pedestrian pavement.
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and/or
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ii. Material Specification:

1. In compliance with MS 1380:1995; for 80mm thick paver with average minimum
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compressive strength of 45 MPa.

2. In compliance with MA 20; for 60mm thick paver with average minimum compressive
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strength of 30 MPa.
3. Anti-fungal (up to 90% resistance to fungal growth)
4. Twin-wide spacer locking system
5. Green Label certification: Yes
6. Dimension: 200mm x 200mm x 80mm (thick) and 200mm x 200m x 60mm (thick)
7. The shapes and profiles of the paver shall be selected from the manufacture
available product catalogue and shall be approved by the Engineer/Architect. The
finishing surface shall be in natural colour, Standard colors, Premium colors,
Monochromatic toning colors or any other colors as specified by the
Engineer/Architect. The selected paver shall fit for application for vehicular
pavement, and/or pedestrian pavement.

2. For vehicular pavement, pedestrian pavement, rainwater harvesting, and storm-water

management
The pavers for this application shall be selected from the manufacturer with permeable type
interlocking concrete paver, having complied with following product specification:
 1. In compliance with MS 1380:1995; for 80mm and 100mm thick paver with average
minimum compressive strength of 45 MPa.
2. In compliance with MA 20; for 60mm thick paver with average minimum compressive
strength of 30 MPa.
3. Permeability Rate:
- Rough finish; 13 – 17 % porosity and/or 300 liters/min/m2
- Fine finish; 9 – 12 % porosity and/or 150 liters/min/m2
4. Green Label certifications: Yes
5. The shapes and profiles of the paver shall be selected from the manufacture available
product catalogue and shall be approved by the Engineer/Architect. The finishing
surface shall be in natural colour, Standard colors, Premium colors, or any other colors as
specified by the Engineer/Architect. The selected paver shall fit for application for
vehicular and pedestrian pavement, rainwater harvesting, and storm-water management.
3. For road line marking, road directional arrows, road humps, pedestrian humps, road
delineation

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The pavers for this application shall be selected from the manufacturer with reflective type

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paver, having complied with following product specification:

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1. In compliance with MS 1380:1995; for 80mm and 100mm thick paver with average

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minimum compressive strength of 45 MPa.

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2. In compliance with MA 20; for 60mm thick paver with average minimum compressive
strength of 30 MPa.
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3. Anti-fungal (up to 90% resistance to fungal growth)
4. Reflectivity Index: minimum 100 mcd/lux (as tested by 3M Malaysia)
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5. Green Label certifications: Yes

6. Reflective Glass Beads shall be in compliance with BS6088:1981
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7. The shapes and profiles of the paver shall be selected from the manufacture
available product catalogue and shall be approved by the Engineer/Architect. The
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finishing surface shall be in yellow or white, or any other colors as specified by the
Engineer/Architect.
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ii. Gross Plan Area

The gross plan area which is the plan area generated by the vertical projection of the outside
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surfaces of a paver shall not be more than 0.09 square meters.

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iii. Wearing Surface Area

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The wearing surface area which is the plan area of the interlocking concrete pavers shall not be
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less than 70% of the gross plan area.

iv. Thickness
The nominal thickness for the paver shall be in accordance to selected paver type. Any selected
paver type shall conform to the tolerance on dimensions at all time.
v. Tolerance on Dimensions
The manufactured dimensions of any interlocking concrete pavers shall be such that any point on
the external vertical surfaces of that paver shall be horizontally within 2mm of the theoretical
position of that point, according to the manufacturer’s stated manufacturing dimensions.
The thickness of any paver unit shall be within + 3mm of the specified nominal thickness. The length
of any paver unit shall be within + 2mm of the specified nominal length. The width of any paver
unit shall be within + 2mm of the specified nominal width. The dimensional tolerance requirement is
not applicable for rumble/cobble type pavers.
vi. Strength Grade
The specified minimum 28-days characteristics compressive strength for the interlocking concrete
pavers shall be in compliance with MS1380:1995 or as specified by the Engineer.
vii. Abrasion Resistance
The specified minimum 28-days Abrasion resistance for the interlocking concrete pavers shall be
Class 3 (except for reflective type pavers and permeable type pavers) when sampled and tested
in accordance with the BS EN 1338:2003 Specification.
viii. Surface Finishes
A paver that described as natural colour shall not contain any pigment. The coloured/pigmented
pavers shall be coloured homogenously on the facing layer of the paver. The minimum thickness of
the coloured facing layer shall be minimum 5mm. The Engineer/Architect shall approve the colour
prior to manufacture. All pigments used shall be in compliance with ISO 1248-2006 and/or any
other standards as specified by the Engineer.

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ix. Manufacturer

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It is the responsibility of the Contractor to make sure the manufacturer of interlocking concrete
paver meets all the specified material specifications. The Contractor also to make sure that the

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manufacturer is ISO 9001:2008 and ISO 14001:2004 certified. The Engineer or his
representative shall at all reasonable times be permitted access to the place where the pavers are

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manufactured or stored, for the sole purpose of examining and sampling the materials and the
finished interlocking concrete pavers. rD
x. Quality Assurance
a. Paving Sub-contractors Qualifications:
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1. Utilize an installer having successfully completed interlocking concrete paver installation

previously with similar design, material, and extent of current project.
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2. Comply with all the statutory requirements and approvals from relevant authorities.
b. Mock-ups:
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1. Install a 2m x 2m paver area.

2. Use this area to determine surcharge of the bedding sand layer, joint sizes, and lines, laying
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pattern, color and texture of the job.

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3. Evaluate the need for protective pads when compacting the interlocking concrete paver with
architectural finishes.
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4. This area will be used as the standard by which the final work will be judged
5. Subject to acceptance by owner, mock-up may be retained as part of finished work.
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6. If mock-up is not retained; remove and properly dispose of mock-up.

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Notes: A site visit & approval by the owner’s representative during the first day of paving may
substitute for a mock-up.

xi. Certificates & Document Submittal

The Contractor shall furnish the following items for consignment of interlocking concrete pavers
supplied by his manufacturer:

a. Manufacturer’s drawings and details; indicate perimeter conditions, relationship to adjoining

materials and assemblies, expansion and control joints, interlocking concrete paver layout,
patterns, color arrangement, installation and setting details.
b. Interlocking Concrete Paver:
1. Two representative full-size samples of each paver type, thickness, color, finishes that indicate
the range of color variation and texture expected in the finished installation. Color(s) can be
selected by the Architect, Engineer, or Owner from the manufacturer’s available colors.
2. Accepted samples become the standard of acceptance for the work
 3. Test results/reports from an independent testing body (SIRIM/IKRAM) for compliance of
Interlocking Concrete Paver requirements to MS 1380:1995 and/or BS EN 1338:2003 and/or
MA20.
4. Manufacturer’s product catalogue and installation method statement.
5. ISO 9001-2008 and ISO 14001-2008 certificates
6. Green Label certificates
c. Interlocking Concrete Paver Installation Contractor:
1. Job references from projects of a similar nature. Provide Owner/Client/General Contractor
names and contact details.
Notes: Notwithstanding any previous acceptance of the above mentioned certificates, the Engineer
may require further tests to be done by an independent testing laboratory and the results from the
independent testing shall be the basis for final acceptance and rejection of any interlocking
concrete paver. The cost of the entire test conducted at independent laboratory shall be borne by
the Contractor.
xii. Delivery and Storage
a. Refer to manufacturer’s ordering instructions and lead-time requirements to avoid construction

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delays.

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b. Deliver materials in manufacturer’s original, unopened, undamaged containers packaging with

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identification labels intact.
c. Coordinate delivery and paving schedule to minimize interference with normal use of buildings

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adjacent to paving site.

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d. Deliver interlocking concrete pavers to the site in plastic banded and/or plastic wrapped
packaging capable of transfer by fork lift or clamp lift.
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e. Unload pavers at job site in such a manner that no damage occurs to the product.
f. Store materials in place where it is protected from mud, dirt, and other foreign materials.
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xiii. Laying
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Pavers shall be placed on the un-compacted levelled sand bed to the specified laying pattern.
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Pavers can be hand or machine laid. Paver laying shall possibly start at a fixed edge restraint. If
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this edge restraint is unlikely to be adequately straight or at 90° to the intended paver bond, a
string line temporary datum should be set up a short distance from the edge restraint and used to
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align the first “row” of pavers. A second string line at 90° to the first will ensure that the paver
bond does not “wander”. The area between the first string line and edge restraint can then be
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infilled with pavers, cut to fit as necessary. In area where the closure area is smaller than 25% of
the paver unit area, then it advisable to use concrete with minimum grade of 30 to infill the space.
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It is advisable to continue to use string lines or other control methods during laying of the paved
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area. Manufacturing tolerances in the pavers and normal joint/laying tolerances may not aid
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perfectly straight joint lines but using string lines and continuously adjusting pavers as they are laid
will ensure acceptable alignment of the bond and joint spaces - providing that joints do not
exceed the specified joint widths. The pavers shall be laid with joint widths between 2-5 mm, in the
specified bond. The spacer nibs on some pavers are not designed to fix the joint width but rather
to prevent damage to the pavers from face to face contact. For hand laying, the installer should
work from pavers already placed, taking care not to disturb them. In each row full pavers shall be
laid first. Except where it is necessary to correct any minor variations occurring in the laying bond
the pavers shall not be hammered into position. Where adjustment of position is necessary care
shall be taken to avoid any premature compaction of the sand bedding.
Any foot and wheelbarrow traffic over the paved area shall use boards to prevent disturbance of
pavers prior to mechanical compaction. No construction traffic shall be allowed on the paved area
at before mechanical compaction.
xiv. Fall (Gradient)
After an initial period of operation a pavement surface can be regarded as virtually
impermeable in trafficked areas. Therefore proper gradients for drainage of surface water shall
be provided, as for any surfacing material. The formation of gradient shall follow as specified in
the construction drawing or as specified by the Engineer.
 In the event no details provided, the minimum crossfalls of 2.5% (1:40) and longitudinal falls of
1.25% (1:80) are recommended for carriageways. Where proprietary drainage systems are used
the pavement should be laid with a minimum crossfall of 2.5% and the longitudinal fall as
recommended by the drainage manufacturer. For other areas minimum 1% (1:100) longitudinal
falls and 1.25% (1:80) crossfalls are recommended.
To summarise:
 Carriageway Minimum Crossfall 2.5% (1:40)
 Carriageway Minimum Longitudinal Fall 1.25% (1:80)
 Other Areas Minimum Crossfall 1.25% (1:80)
 Other Areas Minimum Longitudinal Fall 1.0% (1:100)
 Carriageways with propriety drainage systems crossfalls 2.5% (1:40)

xv. Compaction
The bedding sand layer and paver shall be compacted using a vibrating plate compactor, as
detailed in the following table. Some pavers may require a rubber or neoprene faced sole-plate
to prevent damage to the block surfaces.

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Site Category and Description Min area Min Vibration Min.
(m2) effective frequency mass

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force/unit (Hz) (kg)
area kN/m2

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IA  Aircraft pavements
 Bus stations
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 Pavements with severely channelized
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traffic
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IB  Industrial pavements
 Loading bays
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II 0.25 75 65 – 100 200

 Adopted highways
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 Roads
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 Petrol station forecourts

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 Pedestrianization schemes with regular

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heavy traffic
 Car parks with some heavy vehicles
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 Footways with frequent vehicle overrun

III  Pedestrianization projects receiving
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only occasional heavy traffic

 car parks receiving no heavy vehicles
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IV 0.2 60 75 – 100 80
 Private driveways
 Areas with only pedestrian traffic
 Footways with occasional vehicle
overrun
The paved area should be fully compacted as soon as possible after both full pavers and cut pavers have been
laid, to achieve finished pavement tolerances of ± 6 mm from the design level after compaction. Adjacent
blocks should not differ in level by more than 2 mm and, when measured with a 3 m straight edge, there should
be no surface irregularity (i.e. depression or high point) greater than 10 mm. Ideally, at the cessation of the
days’ work, compaction should be completed to within 1.0 m of an unrestrained edge.

c. Bedding Sand
i. The minimum thickness of bedding sand shall be at 30mm, and the maximum shall be 50mm.
ii. The bedding sand shall be from naturally occurring sand or manufactured sand which free from
any deleterious or foreign material, clean, and non-plastic.
iii. The following table provides the basic grading requirement for the bedding sand
(ref.: BS EN 12620:2003)
 Sieve size (mm) % Passing
8 100 100
6.3 95 100
4 85 99
0.5 30 70
0.063 0 0.3

The bedding sand shall be spread loose, and screeded in a loose condition to the specified design profile
and levels plus the necessary surcharge to allow for compaction to the recommended thickness of 30mm
(minimum) and 50mm (maximum). The bedding sand shall be carefully maintained in a loose condition and
protected against pre-compaction both prior to and following screeding. Any pre-compacted sand or
screeded sand left overnight shall be loosened before further pavers are placed. Screeded sand must be
fully protected against accidental pre-compaction including compacted/saturated by rain. Any screeded
sand, which is pre-compacted prior to lying of pavers, shall be removed and brought back to profile in a

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loose condition. Any depressions in the screeded sand exceeding 5mm shall be loosened, raked and re-

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screeded before laying the pavers.

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d. Joint Filling Sand
i. Fine and dry sand should be used as joint filling sand. The sand should be brushed into the joint

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between the pavers till it completely fills the gap.

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ii. The sand selected should not contain any deleterious material that may stain the paver surface.
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iii. Additional sand should be added to top-up the joint as necessary after compaction, and also
during the early life of the pavement.
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iv. The following table provides the basic grading requirement for the joint filling sand
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(ref.: BS EN 12620:2003)
Sieve size (mm) % Passing
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2 100 100
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1 85 100
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0.05 55 100
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0.063 0 2
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Before the commencement of the joint filling operation the paved should be checked to ensure that it is in
full compliance with the specification, including levels and tolerances, joint spaces and paver alignment,
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and with any non-conformance corrected. Only after satisfactory corrections (if needed) have been made
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should the jointing operation commence.

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e. Lean Concrete Base

The lean concrete base shall be prepared in accordance to the design requirement. All the materials used
shall be in compliance to the relevant Malaysia Standards and/or as specified by the Engineer.
f. Sub-Base (Unbound)
The sub-base shall be laid in layers by mechanical plant to a thickness as specified in the construction
drawing or as specified by the Engineer. The compaction shall not be less than 98% modified compaction
as specified in relevant standards, or as specified by the Engineer. The sub-base should extend beneath
all new edge restraint for at least their full width except where the pavement abuts established structures
offering suitable edge restraint.
The finished level of sub-base shall be even, free from irregularities and/or loose material, and shall be as
specified on the drawings. Under no circumstances shall sand bedding material be used as filler to correct
the sub-base level. The Engineer shall make the final inspection on the finished level of sub-base before
proceeding to the next layer.
g. Subgrade
The sub-grade formation shall be well cleaned, free from mud, slurry, properly shaped, and compacted to
a thickness/level as specified in the construction drawing or as specified by the Engineer. The compaction
shall not be less than 95% modified compaction as specified in relevant standards, or as specified by the
Engineer. All roots and organic matter shall be removed and the Engineer shall inspect the sub-grade
during preparation. Soft areas, which may develop during compacting, shall be removed and replaced by
approved materials. Where shown on drawings or as directed by the Engineer all piped and sub-soil
drainage construction located beneath the pavement shall be completed in conjunction with the sub-grade
preparation and before the commencement of base sub-base construction. Once the formation has been
prepared, construction traffic shall not be allowed to run thereon without the permission of the Engineer.
h. Pavement Preloading
As soon as possible after the filling of joints and prior to opening to traffic, the pavement shall be
preloaded by the passage of not less than 6 but not exceeding 10 passes of a 3 ton heavy duty plate
compactor. Pavements which deforms by more than 8mm over 3m length after pre-loading shall be taken
out and reconstructed to the satisfaction of the Engineer.

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i. Edge Restraint

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Where not otherwise retained, provide edge restraints installed around the perimeter of all interlocking
concrete pavement areas including where pavers abuts different flexible materials, such as bituminous

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bound material, according to engineers specifications. In the event no specification provided; contractor to
determine and install the edge restraint as necessary and shall be approved by the Engineer.

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They should be suitable for the relevant application and sufficiently robust to resist displacement if likely to

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be overrun by vehicles. It may be necessary to extend sub-layers to support the edge restraint together
with any base and haunching. All edge restraint shall be constructed with concrete grade of 30MPa
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(minimum) to dimensions and levels as shown on the drawings. Compaction of pavement layers near edge
restraints shall be delayed until any concrete bed and haunching has gained sufficient strength to prevent
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movement of the edge restraint.

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j. Completion of Work
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Before the pavement is handed over, a final inspection shall be carried out in presence of
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Engineer/Architect to ensure that all work is in compliance with the contractual requirements and any non-
compliance should be corrected. Vacuum sweepers should not be used until the joints have silted up to
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avoid sand loss. Alternatively the jointing sand may be stabilised (to prevent sand loss) with a suitable joint
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sealant (if required by the Engineer).

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k. Determination of Compressive Strength

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Principle
A paver unit is placed in a testing machine and subjected to increasing compression until it fails. From the
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maximum load and gross plan area, the compressive strength is calculated.

Apparatus
The following apparatus is required:

A testing machine, which complies, as regards accuracy, with the requirements for Grade A or B machines
as given in AS 2193. The machine shall be fitted with two steel platens having bearing faces of hardness
not less than Rockwell HRC60, one of which, preferably the upper, shall have a spherical seat allowing the
platen to rotate or tilt through small angles in any direction. The bearing faces of both platens shall be at
least as large as, and larger than, the test specimen and shall not depart from a plane by more than
0.05mm. Should the bearing faces of the platens be smaller than a test specimen, steel plates of adequate
size may be placed centrally between them and the test specimen. Bearing faces of such plates shall not
depart from a plane by more than 0.05mm and their thickness shall be equal to at least one-third of the
greatest difference in dimension between the machine platen and the test specimen but not less than 25mm
Sampling Units
Five units, representing the lot, shall be used as test specimens.
Procedure
1. Clean and wipe each test specimen, the bearing surfaces of the platens on the testing machine, and the
packing to be placed between the specimen and the platen.
2. Place the specimen between two pieces of plywood, chipboard or medium-density hardboard of
thickness between 4 and 6 mm, the length and width of which shall exceed the corresponding
dimensions of the specimen by between 15 and 25mm. The specimen shall be aligned with its height in
the vertical direction.
3. Carefully align each piece of capping material with the centre of thrust of the spherical seated platen.
Bring the upper platen to bear on the specimen and, by hand, gently rotate the seated platen so that
uniform seating is obtained.
4. Apply the load without shock and increase it continuously until failure occurs, in accordance with the
following provisions:

 In testing machines of the screw type, the moving head shall travel at a rate of about 2.5
mm/minute when the machine is running idle.
 In hydraulically operated machines, the load shall be applied at a constant rate within a range
equivalent to a stress of 150 to 700kPa/s.

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 During the application of the first half of the anticipated maximum load required to produce

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failure, a higher rate of loading shall be permitted. No adjustment shall be made in the controls of
the testing machine while a specimen is yielding rapidly immediately before failure.

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5. Observe the maximum load (W) carried by the specimen

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Calculation of Results rD
The compressive strength of each specimen shall be calculated from the following expression.
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C = x
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A √A
+ 1.87
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H
C : The compressive strength, in mega pascal
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W : The total load at which the specimen fails in newton

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H : The nominal height of unit in millimetres

A : The nominal gross plan area in square millimetres based on the manufacturing dimensions of the
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paving units. Where the unit is halved for testing the area of the tested half should be measured
and treated as A
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The characteristic compressive strength of the lot shall be calculated from the following expression:
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Ck = C - 1.65S
Where,
Ck is the characteristic compressive strength in mega pascal
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Is the average of the individual compressive strengths of the specimen in mega pascal.
C

C = C1 + C2 + C3 + C4 + C5
5
S is the unbiased standard deviation in mega pascal

S2 = C12 + C22 + C32 + C42 + C52 - 5 ( C ) 2

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 Records
The following information shall be recorded:
- Identification mark - Date of manufacture
- Date of test - The maximum load, in newton, carried by each specimen
- The average compressive strength of the sample - The unbiased standard deviation of the sample
- The compressive strength, in mega pascal of each specimen
- The characteristic compressive strength of the sample
- The nominal gross plan area of each specimen to the nearest 100 square mm as calculated from the
manufacturing dimensions
Report
If a report is prepared it shall include the following information:
 Identification of the lot, lot size and manufacturing
 Age of units in days at the testing date
 Testing Date
 The compressive strength in mega pascal of each specimen of the sample
 The characteristic compressive strength in mega pascal

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l. Determination of Abrasion Resistance

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Principle
The test is carried out by abrading the upper face of a paving block with an abrasive material under

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standard conditions

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Apparatus
1. Abrasive material comprising fused alumina (corundum) with a grit size of F80 in accordance with ISO
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8486-1. It shall not be used more than three times.
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2. Wearing machine made of a wide abrasion wheel, a storage hopper with one or two control valves to
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regulate the output of the abrasive material, a flow guidance hopper, a clamping trolley and a
counterweight.
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3. When two valves are used, one shall be used to regulate the rate of flow and can be permanently set while
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the other is used to turn the flow on and off.

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4. The wide abrasion wheel shall be made of a steel conforming to EN 10083-2 and with a Brinnel hardness
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of between 203HB and 245HB (as defined in EN ISO 6506-1, EN ISO 6506-2 and EN ISO 6506-3). Its
diameter shall be (200 ± 1) mm and its width shall be (70 ± 1) mm. It shall be driven to rotate 75
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revolutions in (60sec ± 3)
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5. A mobile clamping trolley is mounted on bearings and forced to move forwards to the wheel by a
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counterweight.
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6. The storage hopper containing the abrasive material feeds a flow guidance hopper. The flow guidance
hopper may be cylindrical and shall have a slotted outlet. The length of the slot shall be (45 ± 1) mm and
width shall be (4 ± 1) mm. The body of the flow guidance hopper shall be at least 10 mm bigger than the
slot in all directions. In the case of a rectangular hopper with at least one of the sides inclined down to the
length of the slot, these dimensional limitations are not necessary.

7. The distance of the fall between the slot and the axle of the wide abrasion wheel shall be (100 ± 5) mm
and the flow of the abrasive shall be 1 mm to 5 mm behind the leading edge of the wheel

8. The flow of the abrasive material from the flow guidance hopper shall be at least at a minimum rate of 2.5
l/min onto the wide abrasion wheel. The flow of abrasive shall be constant and the minimum level of the
abrasive in the flow guidance hopper shall be 25 mm.

9. Useful tools for measuring the results are: a magnifying glass preferably equipped with a light, a steel ruler
and a digital caliper.
Calibration

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1. The apparatus shall be calibrated after grinding 400 grooves or every two months whichever is the lesser

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and every time there is a new operator, a new batch of abrasive, or a new abrasion wheel.
2. The abrasive flow rate shall be verified by pouring the material from a height of approximately 100 mm

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into a pre-weighed rigid container with a smooth rim, of height (90 ± 10) mm and of known volume when
filled to the top, this shall be approximately 1 l.

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3. As the container fills, the pourer shall be raised to maintain approximately the 100 mm fall. When the
container is filled, the top shall be struck off level and weighed to determine the mass of abrasive for a
known volume i.e. the density.
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4. Abrasive shall be run through the wearing machine for (60 ± 1) s and collected below the abrasion wheel
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in a pre-weighed container of at least 3 l capacity.
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5. The filled container shall be weighed and from the density determined above, the rate ofabrasive flow can
be verified as more than or equal to 2.5 l/min.
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6. The apparatus shall be calibrated against a reference sample of 'Boulonnais Marble' and the counterweight
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adjusted so that after 75 revolutions of the wheel in (60 ± 3) s the length of thegroove produced is (20.0 ±
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0,5) mm.
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7. The counterweight shall be increased or decreased to increase or decrease the groove length respectively.
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8. The clamping trolley/counterweight assembly shall be checked for undue friction.

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9. The groove shall be measured to the nearest 0.1 mm and the three results averaged to give the calibration
value.
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10. The Boulonnais Marble reference is:

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Lunel demi-clair, thickness: > 50 mm, “contre-passe 2 faces”, ground with a diamond grit size
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100/120, roughness: Ra = (1.6 ± 0,4) m, when measured with a rugotest calibrated in accordance with
EN ISO 4288.
11. At every calibration of the apparatus the squareness of the sample supports shall be checked.
12. The groove on the reference sample shall be rectangular with a difference between the measured length of
the groove at either side not exceeding 0.5 mm.
Sampling Of Units
Three pavers, representing the lot, shall be used as test specimens.
Procedure
1. Fill the storage hopper with dry abrasive material, moisture content not exceeding 1,0 %.
2. Move the clamping trolley away from the wide abrasion wheel.
3. Position the specimen on it so that the groove produced shall be at least 15 mm from any edge of the
specimen and fix the specimen on a wedge to let the abrasive flow pass under it.
4. Place the abrasive collector beneath the wide abrasion wheel.
5. Bring the specimen into contact with the wide abrasion wheel, open the control valve and simultaneously
start the motor so that the wide abrasion wheel achieves 75 revolutions in (60sec ± 3).
6. Visually check the regularity of the flow of the abrasive material during the test.
7. After 75 revolutions of the wheel, stop the abrasive flow and the wheel.
 8. Using a ruler and a pencil, with a lead diameter of 0,5 mm and hardness 6H or 7H, draw the external
longitudinal limits (I1 and I2) of the groove.
9. Then draw a line (A B) in the middle of the groove perpendicular to the centreline of the groove.
10. Position a digital caliper square tips on the points A and B to the inside edge of the longitudinal limits (I1
and I2) of the groove and measure and record the dimension to the nearest 0,1 mm.
11. For calibration purposes, repeat the measurement (10 ± 1) mm from the ends of the groove (C D) to give
three readings.
12. Some surface dyes may be removed above the groove by action of the abrasive. This shall be ignored in
producing line l1 which shall be drawn where the sample surface is abraded.

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Calculation of Results
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1. The result is the dimension corrected by a calibration factor and then rounded to the nearest 0.5 mm.
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2. The calibration factor is the arithmetic difference between 20.0 and the recorded calibration value.
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NOTE For example, if the calibration value is 19.6 mm and the dimension is 22.5 mm, the result is 22.5 + (20.0
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- 19.6) = 22.9 mm, rounded to 23.0 mm.

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Records
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The following information shall be recorded:

- Identification mark - Age of pavers , in days , at the date of test
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- Date of test - Production date

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- The abrasion resistance of each specimen - The lengths of the grooves of each specimen
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Report
If a report is prepared it shall include the following information:
 Identification mark
 Age of pavers , in days , at the date of test
 Date of test
 Production date
 The abrasion resistance of each specimen
 The lengths of the grooves of each specimen

2. Burnt Clay Pavers

a. GENERAL
Burnt Clay Pavers shall be manufactured from finest clays, shales or other argillaceous materials,
which may be mixed with additives. They shall be fired to extra high temperature, pressed or
extruded, cut or moulded to the required shape and pattern.
b. DIMENSION AND TOLERANCES

Burnt clay pavers may have a square, bevelled, rounded, or rumbled edge. It may come in
various sizes depending upon the manufacturer’s standard or laying pattern required. Minimum
minimal paver thickness is specified in TABLE 4-2. Usually 50mm thick paver adequate for
pedestrian-only areas and 65mm thickness is required for vehicular traffic. Where pavers have
bevelled or rounded edges the plan width of a bevel or the radius of a rounded edge shall not
exceed 5mm.
TABLE 4-1: MINIMUM TRANSVERSE BREAKING LOAD OF PAVER

Class Type of Minimum Minimum Dimensional Slip/Skid

Traffic Nominal Breaking Tolerance over Resistance
Carried Thickness Load 20 Paver (mm) (BPN)
(mm)

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1 Low Volume 40 2 KN Length +/- 60 50

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Traffic
Width +/- 40

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2 Light Vehicle 50 3 KN Length +/- 50 50

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3 High Volume 50 3 KN Length +/- 50 50
Pedestrian
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Width +/- 40
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4 Road Vehicle 65 5 KN Length +/- 40 60

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Commercial Width +/- 40

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Vehicle
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c. STRENGHT, DURABILITY and EFFLORESCENE

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The minimum transverse breaking load of individual pavers in all classes shall be in accordance
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with AS 1226.1 – 1984 and as shown in TABLE 1. The recommended minimum characteristic
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compressive strength for Class 4 application is 45 MPa. For a paver of 230mm x 114mm x 65mm
this is the equivalent to an unconfined compressive strength of 25MPa. Paver shall have durability
Class of Exposure as defined in AS 1225-1984. The liability of pavers to pitting due to the
expansion of lime particles shall not worse than Moderate as defined by AS 1225-1984. For
Abrasion Resistance the pavers shall comply with BS Standard Test known as SCC Abrasion Test.
Characteristic abrasion loss shall be as shown in TABLE 2. The Water Absorption percentage shall
be +/- 8%. Efflorescence is a phenomenon that soluble salts dissolved in water are carried,
deposited and accumulated on brick surfaces to form an unsightly scum. Nearly all salts that
caused efflorescence come from the sources outside the brick such as ground water, contaminated
atmosphere, mortar ingredients and other materials in contact with the bricks. However, some
bricks that are made from marine clays containing salts such as sulphates are likely to cause
efflorescence. The limit of specification for salt content are defined in Malaysian Standard MS
7.6:1972 where Total Salt Content shall not exceeding 1% by mass for Facing Bricks and
Sulphuric Anhydrie (SO#) Content shall not exceed 0.3% by mass.
 Table 4-3: CHARACTERISTIC ABRASION LOSS

Characteristic Examples of recommended areas of application

Abrasion Loss
Up to 3.5 culm Inner city and major sub-urban pedestrian mall and paths;
pavements with high-volume pedestrian traffic (over 30,000
passes per day) which includes about one third with heel.
Up to 5.5 culm Sub-urban shopping areas pavements; pedestrian areas
around institutional buildings, sporting or recreational venue.
Up to 5.5 culm Paths in public gardens; pavement; pedestrian at school or
campuses; hard landscape areas; common areas of
residential buildings.

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Burnt Clay Pavers are also subjected to test based on the British or Australian Standards. Basic for

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Clay pavers and subject to the following Test;

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TEST METHODS:

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(1) Compressive Strength : Adopted from BS 6717 : Part 1 : 1993 : Annex B

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: Clause B1 & B2
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(2) Transverse Breaking Load : BS 6677 : Part 1 : 1986
(3) Skid Resistance Value : BS 6677 : Part 1 : 1986
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(4) Efflorescence : Adopted from SS 103 : 1974 : Clauses 22
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SPECIFICATION:
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(1) Tranverse Breaking Load : BS 677 : Part 1 : 1986

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TABLE 4-4
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Type Predominant Traffic Typical Applications

of Carried
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Paver
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PA Pedestrians Hard landscape, footpath and pedestrian

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areas not used by vehicle. Car parks,

Motor Cars, light vans driveways to private houses.
PB As for type PA and also As for type PA and also roads in residential
public transport and areas, lorry parks, public transport and factory
commercial road yard areas, docks, petrol station forecourts,
vehicles farm hard – commercial road vehicles standing.
TABLE 4-5 : Transverse Breaking Loads

Type of Minimum mean transverse Minimum individual transverse

Paver breaking load (kN) breaking load (kN)
PA 3.0 2.0
PB 7.0 4.0
 The following conditions shall met:
a) The mean transverse breaking load of ten pavers shall not be less than the value given for the
appropriate type in column 2 of Table 4.
b) The transverse breaking load of each paver shall be not less than the value given for
appropriate type in column 3 of Table 4.
(2) Skid Resistance Value : Part1 : 1986

The mean wet skid resistance value of five pavers intended for use in areas subject to
vehicular traffic shall not be less than 60 of the Mean Wet Skid Resistance Value (BPN). The
mean wet skid resistance value shall be stated by the manufacturer.
a. PAVING OF FOOTPATH

Paving Structure

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The paving footpath pavement should consist of the following elements:

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I. A fully completed sub-base layer of crusher run overlaying the existing ground that had been

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previously evenly flattened to profile and fully compacted.
II. All edges of this profile must be restrained to prevent lateral movement of clay paving

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blocks, which could Result in the widening of joints between individual clay pavers. Restraints
may be in the form of existing Paving, walls, pre-cast concrete kerbs or other design features.
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III. A loose layer of sand must be evenly distributed over the areas to be paved and screened to
a level of 40mm (inclusive of 10mm allowance for compacting) and left undisturbed.
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IV. A course of clay paver blocks.

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Sub-Base Layer
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Gravel or crusher run would be sufficient for use as a sub-base material for interlocking clay pavers
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meant for pedestrian walkway or footpath. The required compacted thickness of this sub-base would
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be dependent on the existing soil conditions, including adequate surface water drainage, and factors
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such as traffic (vehicular and human) volume and leading performance. In case of light duty /
pedestrian walkways, an even layer of 90mm crusher run would be ideal, while medium duty /
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driveways for light vehicles would require at least a minimum of 110mm of the same.
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Edge restraints
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Edge restraint are required along the perimeter of all interlocking clay paver crossings. Their main
purpose is to prevent rotation, lateral migration (shunting) widening of joints and any loss of material
from the bedding course. Failure could result in loss of interlocking capabilities and eventually loss of
interlocking clay paving blocks.
Restraint must sufficiently strong to withstand damage or displacement caused by accidental run over
or knocks by vehicles. Existing kerbs, channels and internal driveways form restraint along two edges.
Under such circumstances, pathways constructed continuously with driveway of incite concrete or
interlocking clay pavers; edge restraints need not to be constructed at the site. Side edge restraints
must be profiled and shaped in accordance with the dimensions and specification provided by the
Pengarah Jabatan Pengangkutan Bandar Dewan Bandaraya Kuala Lumpur.
Sand Bedding
The bedding sand shall be well graded, passing 4.75mm sieve and suited for concrete manufacture.
The recommended grading limits are as follows:
 SIEVE SIZE PERCENTAGE
(mm) PASSING
9.52 100
4.75 95-100
2.36 80-100
1.18 50-85
0.60 25-65
0.30 10-30
0.15 5-15

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0.075 0-10

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Clay Paving Blocks

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Clay pavers shall be designed, manufacrtured and tested in accordance with Design Note 13C,
published by the Bricks Development Research Institute Australia. The dimension shall be 203 x 133 x
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50mm.
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b. CONSTRUCTION
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Existing Ground
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The existing ground shall be boxed cut and shaped as closely as possible to the required dimensions
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and levels. Using vibration plate compactor ot 2-ton roller shall carry out compression of the work site.
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Several overlapping passes are required to obtain uniformity of levels.

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Sub-Base
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The Sub-base materials shall be loosely spread in one layer to the required level and if necessary
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water added before compaction to reach the desired moisture content.

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Edge Restraints
The top level of the edge restraints shall slightly lower than the adjacent paving blocks to ensure that
water can dry freely from channels formed by abutting units.
Sand Bedding Layer
At the time of installing the clay pavers, the sand should have uniformity in moisture content. That sand
shall be evenly distributed and screened in loose condition. The loosely screened sand layer must have
a small surcharge to allow for compaction to the recommended thickness of 30mm.
Installation of Clay Paving Blocks
Clay paving blocks shall be placed with 2 – 3mm gaps between adjacent units, maintaining correct joint
alignment but without pre-compaction of the sand bedding layer. It is vital that the joint width between
paving blocks be maintained. Complete rows of full units shall be laid first. Any gaps at the pavement
edge adjacent to the edge restraints must be neatly filled by cutting units to size using a mechanical /
diamond cutter.
 Compaction and Joint Filling
The clay paving blocks must immediately compacted after laying and brought to level by not less than
3 overlapping passes of the vibrating plate compactor. The vibrating plate must have at least sufficient
area to cover 12 units of clay paver. Immediately after compaction, broom sand over and into the joint
fillings. Excess sand must be removed once the joined are filled.
Adjustment of Manhole Covers, Valve Chambers, ETC.
It will be necessary for the contractor, during the course of his works, to re-adjust the levels of existing
manhole covers, valve chambers, etc to proposed new levels of carriage ways and footpaths. Such
adjustments will involve either raising or lowering existing manhole covers, etc, by removing existing
brickwork or concrete or building to new level with concrete or brickwork. The adjustment, in almost all
cases, will be within plus or minus 300mm

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3. Maintenance of Clay Paver and Clay Tile

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a. CLEANING BEFORE EARLY TRAFFICKING

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If the pavement has unbound joints, traffic may use the pavement immediately after the final pass of the

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plate compactor. Do not clean with hoses or powdered vacuum cleaners during the first three months of

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the pavement use; cleaning should be by hand broom only during this period.
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b. COMMON STAINS AND WAYS OF REMOVING THEM
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Efflorescence
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This is a powdery deposit of salts (usually white or yellow), often found on the surface of clay pavers
after rain. The source of this satin could be the pavers, but more often it comes from the surrounding
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materials, for example the soil under the pavement, or from cement (if the soil was stabilised) or from
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both. Efflorescence is usually harmless, and can be removed by dry brushing and hosing. However, it is
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necessary to follow this up with a wash of weak acid or a propriety cleaner (as recommended).
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Dirt and Grime

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Frequent sweeping and hosing will usually ensure a clean pavement. If it is not enough, washing with
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detergent or a propriety cleaner (as recommended) may be required.

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Fresh Mortar Stains

The simplest way to remove wet mortar stains is to lightly cover the pavement before the mortar sets
hard, with clean, but slightly damp, washed sand. Sweep the sand towards the edges of the pavement. If
necessary, repeat this until the surface is almost clean. The most important point to remember is that the
sand MUST be free of clay. Follow this up with further sweep with dry washed sand. Any sticky wet
mortar residue that escaped the set sanding will be removed. Once again the sand MUST be free of
clay. One or two days after the pavement has dried, some mortar residues may still be visible as a faint
white film. Normally this will weather away.
Hardened Mortar Stains
Experiment on a small section of the pavement with degreasing proportions of water mixed with acid,
starting with one part of acid to eight parts of water or with the type of our recommended cleaning
solution, proceed as follows:
 a. Slightly wet the pavement with a fine spray water.
b. Using a stiff brush, apply the acid or recommended cleaning solution, over proximately one
square meter. Vigorously scrub the areas stained with mortar. When scrubbing is not sufficient,
loosen thick mortar patches with a hard implement such as a steel scrapper. Work on the mortar
stain until it is dissolved.
c. Give the area a good hose-down. A pressurised spray unit is most ideal.

Repeat the procedure until the whole area is cleaned. A final rinsing of the pavement with a high-
pressure water jet is beneficial BUT care must be taken not to remove sand from the paver joints.
Fungi, moulds, moss and lichens
To removes these growths, vigorously brush the affected areas when it is dry. High-pressure water may
also be used. Although the surface may now appear to be completely cleaned, it is necessary to sterilise
the area with poison, a strong fungicide or recommended solution, which should be allowed three to four
days to act. The surface should be brushed again after the period.

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CAUTION: When using the above, pay attention to nearby garden plants or lawn, especially

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on the lower side of the paved area being treated.

4. Recommended Proprietary Cleaning and Sealing Solution

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a. PRODUCT DESCRIPTION
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A high gloss protection for unglazed paver tile, and other porous terra cotta surfaces with just two
coats. It is a grease and oil blocker and is the perfect solution for sealing porous tiles. The chemical
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must be environmentally safe and approved by SIRIM or other international standard.

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b. FEATURES
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 High gloss protection with just two coats

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 Resists oil, grease and food stains

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 Holds up gear outdoors

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 Hardens tiles against chipping and abrasion

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 Gives a long lasting, high gloss appearance

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 Protect and beautifies

 Water base-safe, easy cleanup
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 Dust proofs without altering the colouring of the substance

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 Recoatable
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c. PREPARATION
Surface preparation is the MOST important part of applying a clear sealer. All surfaces must be
clean, free of efflorescence, dirt, oil, wax, grease and defective paints or sealer.

d. SPECIFICATIONS
 BASE : Aqueous acrylic co-polymer
 TUKON HARDNESS : 11.0
 FRICTION LEVEL : Excess 6.0
 GLASS TRANSITION POINT : 34C
 DENSITY : 8.69 pounds per gallon
 REFRACTIVE INDEX : Approximately 1.5066
 SOLIDS : Excess 22%
 APPEARANCE : Milky white – Dries Clearer
 e. APPLICATION

Apply solution with a dense sponge, sponge mop, brush or low pressure or airless sprayer. Two coats are
usually adequate but additional coats may needed where food, oil and grease stains will be a problem.
(To verify the sealer’s appearance and protective ability, do a test sample prior to total application).
Allow the sealer at least 4 hours drying time between coats. Do not over apply. Do not allow sealer to
puddle. Surfaces coated with the solution may be used within 24 hours after drying but will continue to
gain strength against stains and abrasion for up to three weeks. CAUTION: It is always advisable to do a
test before beginning job application to verify bond ability on surface, appearance and oil and grease
protection. For previously sealed tiles, the solution may be diluted with water and wait 48 hours before
grouting. DO NOT APPLY IN DIRECT SUNLIGHT, during hot weather or the threat of rain during inclement
weather. Allow new grout 24 hours to dry before applying this solution. Ideal application and temperature
is 50 to 80 degrees Fahrenheit.

5. Unglazed Homogenous Granite Tile

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a. GENERAL

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The scope of work shall describe the supply of the material, the installation methods and other accessories

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needed to complete the laying of Unglazed Homogenous Granite Tile over cement/sand (1:3) seceding
surface on concrete slabs using Thin Set Mortar additive with Ordinary Portland Cement/fine silica sand

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(1:1) as adhesive Mortar Bed and joint to be filled with fine silica sand/cement (1:1) incorporate Latex
mortar additive conforms to ANSI 118.4 1976. The use if polyvinyl Acetate, natural rubber or resin latex
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emulsion shall not be permitted. All mortar additives shall be non-toxic, non-flammable and non-hazardous
during storage, mixing application and when cured.
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b. MATERIAL and SPECIFICATION

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The Unglazed Homogenous Granite Tile normally comes in 2 sizes namely 95mm x 95mm x 11mm and
97mm x 97mm x 15mm ( other sizes can be accepted ) in various colour conforming to SS 301:1985
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requirement or other standard approved by the Engineer. Other sizes can also be used subject to the
approval of the Engineer and the specification base on the quality & thickness specified. All tile shall used
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also satisfy and conformed to the following test:

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Surface Quality and Dimension Test

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The length and width deviation shall not exceed ± 0.5% while the thickness of each specimen shall not exceed ±10%
from the average thickness of 10 specimens.
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Modulus of Rapture Test

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The Modulus Rupture should satisfy a minimum of 35N/mm.sq. to be in the extra heavy-duty category.
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Water Absorption Test

The water absorption rate shall be less than 0.1% to qualify for extra heavy duty usage requirement.
Moh’s Hardness Test
The test for each tile should not be less than 7 in Moh’s Scale of Hardness Test
Straightness of Sides Test & Rectangularity Test
The deviation from straightness (%) shall not exceed 0.5% of the nominal dimension while the measured deviation
from rectangularity should not exceed 0.5% of the nominal dimension.
Determination of Resistance to Deep Abrasion
The tile should have a resistance to deep abrasion where average volume of material removed should not exceed
130±5 cu.mm to achieve a grade of extra heavy duty tile.
Acid & Alkaline Resistance Test
The Unglazed Homogenous Granite Tile should not reveal any visible change under microscopic surface examination
after immersion in 70% v/v f sulphuric acid solution at 28 degree celsius for 28 days and 20% m/v of potassium
hydroxide solution at 28 deg. C for 28 days to pass the acid & alkaline resistance test.
Colourfastness to Ultra-Violet Light
The Unglazed Homogeneous Granite Tile should have no detectable colour change when exposed to ultraviolet
exposure after 28 days.
British Ceramic Research Association Tortus Test
The surface condition should have a minimum value of 0.6 for coefficient of friction under dry conditions and a
minimum coefficient value of 0.4 under wet conditions in order to achieve satisfactory friction.
c. CONCRETE SURFACE
The concrete surfaces, which form the base for Unglazed Homogeneous Granite Tile, shall be rigid and conform to
secure good structural design and engineering practices. The surface shall also have a minimum deflection of L/360
and should be uniform over the length of the span. No sealers or curing compounds shall be used on concrete slabs,
which are to be covered with tiles, stone, paver etc. Such slab shall be covered and wet cured for a minimum of seven
(7) days. Allow the slab to cure for 28 days at 70 degrees ( 21 degree Celsius ) prior to installation of the materials.
Screeding surface that are to receive finished flooring, installed by the thin bed method, shall have a wood float
finish, be true to within 1/8 in ( 3 mm ) and pitched to drains where required. Areas requiring fill, the contractor shall
prepare patching or levelling. The concrete surface must be stripped cleaned and free of dirt and dust, oil, wax,
grease, sealers, curing compounds, form oil or loose plaster, paint, and all other contamination, which may reduce or
prevent adhesion before the tile is laid.

d. CEMENT MORTAR
Mix mortars and grouts shall comply with requirements of referenced standards and manufacturers for accurate
proportioning of materials, water or additive content, mixing equipment and mixer speeds, mixing containers, mixing
time, pot life, and other procedures needed to produce mortars and grouts of uniform quality with optimum

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performance characteristics. Prepared Latex Portland Cement Bonding Mortar shall use the mixing proportion of

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approximately 80 kg at 1 of cement to 1 part of silica sand to 20 litre of Thin Set Mortar Additive. Adjust quantity

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of latex liquid to obtain proper consistence mixing in accordance to manufacturer’s instructions and requirement.

e. PREPARATION FOR LATEX-PORTLAND CEMENT BONDING MORTARS

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Machine Mix rD
Pour liquid into rotating blade mortal mixer. Start mixer and add mortar / grout powder. Mix only long enough to
wet out the batch. DO NOT OVERMIX. Stop mixer and pour mortal / grout. Clean out mixer promptly with water.
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Hand Mix
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Pour liquid into a clean mixing container or mixing box. Add mortar /grout powder and mix with a slow speed drill
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mixer, trowel, or hoe until it is uniform. Mix only longs enough to wet out batch. DO NOT OVERMIX
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f. INSTALLATION OF UNGLAZED HOMOGENOUS GRANITE TILE

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A specialist shall carry out tiling. Tiles shall be true to shape, free from cracks, crazes and blemishes. Samples shall be
submitted to the Engineer for approval. All installation must be in accordance with American National Standard for
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installation of Ceramic Tile and Tile Council of America Handbook or other standard approved by the Engineer. Cut
and fit tiles nearly around corners, fittings, and all obstructions. Perimeter of tile shall be minimum at half a tile. All
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chipped, cracked, and split and edges tile shall be rejected. The joints shall be made even and uniform width in
accordance with samples, plumb, straight, true, and with adjacent tile to tolerance approximately at 1/16” or 1.5mm
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over 8ft. or 2.4 meter. Install divider strips at junction of the flooring and dissimilar materials.

Thin Bed Method

Apply mortar/adhesive with suitable notched trowel using scraping motion thoroughly over the surface to be tiled.
Spread only as much mortar / adhesive can be covered in 10-15 minutes or while mortar / adhesive surface is still
wet and tacky. When installing tiles, spread mortar / adhesive onto the back of each tile in addition to trowelling
materials over surface to be tiled. Set tiles unit in place and beat each piece into mortar /adhesive with a beating
block or rubber mallet to insure full bedding and flatness. Aligned pieces to show uniform joints and allow installation
to set until firm. Clean excess mortar / adhesive form tile surface with wet cloth or sponge while mortar is fresh.

Thick Bed Method ( Refloat Method )

The trowel use shall be weather resistant. Screed Latex-Portland Cement Bonding Mortar over concrete. Allow surface
to become firm before tile is install using recommended application.
 Thick Bed Method ( Wet Set Method )
Verify that allowance for minimum bed thickness of 25-50 mm has been made. Then place latex-Portland cement
thick bed mortar. Compact mortar by tamping with flat trowel and screed mortar bed level and provide correct
slopes to drains. Spread latex-Portland cement bond coat mortar with flat trowel over surface of “ green” / fresh
mortar bed as a slurry bond coat approximately 1/16 in. / 1.5mm thick. Apply slurry bond coat to back of tile, unit
just prior to placing each piece. Place tile units while slurry bond coats are wet and tacky. Align pieces to show
uniform joints and beat with a wood block or rubber mallet to level/imbed tile work before mortar bed takes initial
set. Clean excess mortar / adhesive from tile surfaces with wet cloth or sponge while mortar / adhesive is fresh

Grout/Pointing Joints
Grout joints shall be free of dirt, debris or tile spacers. Follow manufacturer recommendations for minimum cure time
prior to grouting. Sponge or wipe dust/dirt off tile faces and remove water standing in joints. Use latex-Portland
cement sanded floor grout / joint widths 1/6 in / 1.5mm to 3/8 in/10mm. Pack joints full and free of voids/pits with
rubber grouting float. “ Squeegee” excess grout from tile faces using edge of rubber float and diagonal strokes ( at
45◦ angle to direction of joints). Clearing Portland cement grouts. Pull/drag towel or sponge diagonally across tile

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faces/joints to remove remaining grout film and allow tile work to dry. Hardened grout film or haze should be

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removed within 24 hours.

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Expansion and control joints

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Provide space, control or expansion joints in width and depth recommended by the manufacturer. Existing joints in

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concrete subfloors must be carried through to surface of tile work and shall conform to architectural details. Expansion
joints shall be installed where tile abuts restraining surfaces such as perimeter walls, curbs, columns, wall corners, etc.,
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and directly over cold joints and control joints in structural surfaces and shall confirm to architectural details. Make
joints through tile work directly over structural joints at least as wide as structural joints. The optimum ratio of joint
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layout, length to width, is 1:1, and shall not be greater than 2:1
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g. CLEANING
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Clean excess mortar from surface with water as work progresses. Perform cleaning while mortar is fresh and before
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it hardens on surfaces. Care should be taken not to contaminate joints while cleaning prior to grouting. Sponge and
wash tile diagonally across joints. Polish with clean dry cloth. Remove grout haze following recommendation of
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mortar additive manufacturer. Do not use acids for cleaning. Upon completion, remove all surplus materials and
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leave premises broom clean. Close new tiled areas to other trades and traffic until tile being installed has set firmly.
Keep traffic off horizontal Portland cement thick bed mortar installations for at least 72 hours at 70◦ F/21◦ C. Use
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kneeling boards, or equivalent, to walk / work on newly tiled floors. Replace or restore work of other trades
damaged or soiled by work under this section.
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6. Non Slip Heavy Duty Homogenous Extruded Split Tile

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a. GENERAL

The scope of work shall describe the supply of the material, the installation methods and other
accessories needed to complete the laying of Non Slip Heavy Duty Homogenous Extruded Split Tile
over cement/sand (1:3) screeding surface on concrete slabs using Thin Set Mortar additive with
Ordinary Portland Cement/fine silica sand (1:1) as adhesive Mortar Bed and joint to be filled with
fine silica sand/cement(1:1) incorporate Latex mortar additive conforms to ANSI 118.4 1976. The use
if polyvinyl Acetate , natural rubber or resin latex emulsion shall not be permitted. All mortar
additives shall be non-toxic, non-flammable and non-hazardous during storage , mixing application
and when cured.
b. Material

The normal Non Slip Heavy Duty Homogenous Extruded Split Tile comes in 2 sizes 145mm x 145mm x
15mm and 145mm x 145mm x 13mm ( other size can be accepted ) in various colour, the tile are
manufactured using natural raw clay which produced as a doubled tile and is split in two after firing.
 DESCRIPTION PHYSICAL PROPERTIES

% of Deviation for Size 2%

% of Deviation for Thickness 10%

% of Deviation for Straightness 1%

% of Deviation for
1.50%
Rectangularity
% of Water Absortion 6% by weight

Modulus of Rupture 23.6N/mm2

Scratch Hardness of Surface Below 7 on MOH Scale

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Abrasion Resistance 2356

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Acid & Alkaline Resistance 70% w/w of Sulphuric at 28 C

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- do - 20 % w/w of Potassium

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c. CONCRETE SURFACE
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The concrete surface, which forms the base for Non Slip Heavy Duty Homogenous Extruded Split Tile,
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shall be rigid and conform to ensure to secure good structural design and engineering practices. The
surface shall also have a maximum deflection of L / 360 and should be uniform over the length of the
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span. No sealers or curing compounds shall be used on concrete slabs, which are to be covered with
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tiles, stone pavers etc. Such slab shall be covered and wet cured for a minimum of seven (7) days.
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Allow the slab to cure for 28 days at 70 degrees Fahrenheit (21 ⁰ C) prior to installation of the
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materials. Screeding surface that are to receive finished flooring, installed by the thin bed method,
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shall have a wood float finish, be true to within 1/8in (3mm) and pitched to drains where required.
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Areas requiring fill, the contractor shall prepare patching or levelling. The concrete surface must be
striped cleaned and free of dirt and dust, oil wax, grease, sealers, curing compounds, form oil or
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loose plaster, paint, and all other contaminated, which may reduce or prevent adhesion before the tile
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is laid.
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d. CEMENT MORTAR
Mix mortars and grouts shall comply with requirements of referenced standards and manufacturers for
accurate proportioning of materials, water or additive content, mixing equipment and mixer speeds,
mixing containers, mixing time, pot life and other procedures needed to produce mortars and grouts
of uniform quality with optimum performance characteristics. Prepared Latex Portland
Portland_Cement Bonding Mortar shall use the mixing proportion of approximately 80kg at 1 of
cement to 1 part of silica sand to 20 Litres of Thin Set Mortar Additive. Adjust quantity of latex liquid
to obtain proper consistence mixing in accordance to manufacturer’s instructions and requirement.
e. PREPARATION FOR LATEX – PORTLAND CEMENT BONDING MORTAR
Machine Mix
Pour liquid into rotating blade mortar mixer. Start mixer and add mortar / grout powder. Mix only
long enough to wet out the batch. DO NOT OVERMIX. Stop mixer and pour mortar /grout. Clean out
mixer promptly with water.
 Hand Mix
Pour liquid into a clean mixing container or mixing box. Add mortar / grout powder and mix with a
slow speed drill mixer, trowel or hoe until it is uniform. Mix only longs enough to wet out batch. DO
NOT REMIX.
f. INSTALLATION OF NON SLIP HEAVY DUTY HOMOGENOUS EXTRUDED SPLIT TILE
A specialist shall carry out tiling. Tiles shall be true to shape, free from cracks, crazes, and blemishes.
Samples shall be submitted to the Engineer for approval. The Engineer must in accordance with
American National Standard for installation of Ceramic Tile and tile Council of America handbook or
other standard approve all installation. Cut and fit tiles nearly around corners, fittings and all
obstructions. Perimeter of tile shall be made even and uniform width in accordance with samples,
plump, straight, true and with adjacent tile tolerance approximately at 1/16” or 1.5mm over 8ft. or
2.4 meter. Install divider strips at junction of the flooring and dissimilar material.

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Thin Bed Method

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Apply mortar / adhesive with suitable notched trowel using scraping motion thoroughly over the

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surface to be tiled. Spread only as much mortar / adhesive can be covered in 10-15 minutes or while
mortar / adhesive surface is still wet and tacky. When installing tiles, spread mortar / adhesive onto

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the back of each tile in addition to trowelling materials over surface to be tiled. Set tiles unit in place

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and beat each piece into mortar / adhesive with a beating block or rubber mallet to insure full
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bedding and flatness. Aligned pieces to show uniform joints and allow installation to set until firm.
Clean excess mortar /adhesive form tile surface with wet cloth or sponge while mortar is fresh.
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Thick Bed Method (Prefloat Method)

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The trowel use shall be weather resistant. Screed Latex-Portland Cement Bonding Mortar over
concrete. Allow surface to become firm before tile is install using recommended application.
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Thick Bed Method (Wet Set method)

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Verify that allowance for minimum bed thickness of 25-50mm has been made. Then place latex-
Portland cement thick bed mortar. Compact mortar by tamping with flat towel and screed mortar bed
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level and provide correct slopes to drains.

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Spread latex-Portland cement bond coat mortar with flat trowel over surface of “green” / fresh
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mortar bed as a slurry bond coat approximately 1.5mm thick. Apply slurry bond coat to back of tile,
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unit just prior to placing each piece. Place tile units while slurry bond coats are wet and tacky. Align
pieces to show uniform joints and beat with a wood block or rubber mallet to level / imbed tile work
before mortar bed take initial set. Clean excess mortar / adhesive from tile surfaces with wet cloth or
sponge while mortar / adhesive is fresh.
Grout /Pointing Joints
Grout joints shall be free of dirt, debris or tile spacers, follow manufacturer recommendations for
minimum cure time prior to grouting. Sponge or wipe dust/dirt off tile faces and remove water
standing in joints. Use latex-Portland cement sanded floor grout / joint width 1/6in / 1.5mm to 3/8in
/ 10mm. Pack joints full and free of voids / pits with rubber grouting float. “Squeegee” excess grout
from tile faces using edge of rubber float and diagonal strokes (45 angle to direction of joints).
Clearing Portland cement grouts. Pull / drag towel or sponge diagonally across tile faces / joints to
remove remaining grout film and allow tile work to dry. Hardened grout film or haze should be
removed within 24 hours.
 Expansion and Control Joints
Provide space, control or expansion joints in width and depth recommended by the manufacturer.
Existing joints in concrete subfloors must be carried through to surface of tile work and shall conform to
architectural details. Expansion joints shall be installed where tile abuts restraining surfaces such as
perimeter walls, cubs, columns, wall corners, etc. and directly over cold joints and control joints in
structural surfaces and shall conform to architectural details. Make joints through tile work directly
over structural joints at least as wide as structural joints, the optimum ratio of joint layout, length to
width, is 1:1, and shall not be greater than 2:1.
g. CLEANING
Clean excess mortar from surface with water as work progress. Perform cleaning while mortar is fresh
and before it hardens on surfaces. Care should be taken not to contaminate joints while cleaning prior
to grouting. Sponge and wash tile diagonally across joints. Polish with clean dry cloth. Remove grout
haze following recommendation of mortar additive manufacturer. Do not used acids for cleaning.

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Upon completion, remove all surplus materials and leave premises broom. Close new tiled areas to

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other trades and traffic until tile being installed has set firmly. Keep traffic off horizontal Portland

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cement thick bed mortar installations for a least 72 hours at 70 F / 21⁰ C. Use Kneeling boards, or
equivalent, to walk / work or newly tiled floors. Replace or restore work of other trades damaged.

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7. Specifications for Compressed Concrete Paving Slab
a. General
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This specification sets out the requirements for the compressed concrete paving slab made with cement, sand,
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pigments, decorative aggregates, and glass chippings. All materials used shall be of the best quality obtained from
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sources and suppliers approved by the Engineer and shall comply strictly with the tests prescribed hereinafter. When
tests are not laid down in this Specification, the contractor shall test the pavers at independent testing laboratory to
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comply with the requirements of the latest relevant Malaysian Standards or other Standards as specified by the
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Engineer. The cost of all tests required by this specification and any other relevant standards shall be borne by the
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Contractor. The compressed concrete paving slab shall be manufactured in two (2) stage processes. The facing layer
and base layer shall undergo pre-compaction of 600psi, and followed by composite layer compaction at 3000psi.
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The final product shall be air cured for 24 hours (minimum). The Contractor shall make arrangement for the
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Engineer/Architect/Client to visit the manufacturing plant to ensure that the selected compressed concrete paving slab
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manufacturer complies with the above said process.

b. Raw Material Standards and Specifications

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1. MS 29:1995 – Specification for aggregates from natural sources for concrete

2. BS812-105:1:1989 – Testing aggregates. Methods for determination of particle shape
(Flakiness Index).
3. MS EN 196-1:2007 – Methods of testing cement.
4. MS 888:2011 – White Portland Cement – Compositions, spec., & conformity criteria
5. EN 197-1:2000 – Cement; Composition, spec., & conformity criteria for common cements.
6. BS EN 450:2005 – Fly ash for concrete
7. BS EN 1008:2002 – Specification for mixing water for concrete
8. BS EN 12620:2013 – Aggregates for concrete
9. MA 20 – Specification for concrete segmental paving units (Australian Standard)
10. MS 1380:1995 – Specification for precast concrete paving blocks
11. BS 6717:1993 – Precast concrete paving blocks. Specification for paving blocks
12. BS EN 1338:2003 – Concrete paving blocks – Requirement and test methods
13. BS 7263: Part 1:1994 – Precast concrete flags, kerbs, channels, edgings and quadrants.
14. BS 6088:1981 – Specification for solid glass beads for use with road marking
compounds and for other industrial uses.
15. MS 738:1981 – Specification for terrazzo floor tiles
16. ASTM C 979 – Pigments for Integrally Colored Concrete.
17. ISO 1248-2006 – Iron Oxide Pigment; specification and method of test
c. Paving Slab Type and Compliance
1. The Sandstone finish and/or Shot-Blasted finish and/or Blink Finish and/or Broom Finish, shall be in
compliance with the following product specifications:
i. In compliance with MS738:1981; for transverse strength of minimum 3 MPa.
ii. In compliance with MS 1380:1995; average minimum compressive strength of 45 MPa.
iii. Anti-fungal (up to 90% resistance to fungal growth)
iv. Green Label certifications: Yes
v. Dimension: 400mm x 400mm x 40mm (thick) and 400mm x 600m x 40mm (thick)
vi. The manufacturer shall have the facility to accommodate to the requirement of the
Engineer/Specifier for other custom made dimensions (subject to minimum quantity specified by the
manufacturer)
vii. The finishing surface shall be natural colour, standard colour, premium color, monochromatic
toning colours, or any other colour as specified by the Engineer/Architect. The selected paving slab
shall fit for the application for vehicular pavement, and/or pedestrian pavement.
2. The Visually Impaired Slab shall be in compliance with the following product specifications:

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i. In compliance with MS738:1981; for transverse strength of minimum 3 MPa.
ii. In compliance with MS 1380:1995; average minimum compressive strength of 45 MPa.

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iii. Anti-fungal (up to 90% resistance to fungal growth)

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iv. Green Label certification: Yes
v. Type and Dimensions available:

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1. Direction Tile (Ribbed Tile)

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- 300mm x 300m x 28mm thick
- 400mm x 400mm x 40mm thick rD
2. Caution Tile (Dotted Tile / Tack Tile)
- 300mm x 300m x 28mm thick
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- 400mm x 400mm x 40mm thick
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vi. The finishing surface shall be yellow, grey, and/or black, or any other colour as specified by the
Engineer/Architect. The selected paving slab shall fit for the application for vehicular pavement,
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and/or pedestrian pavement.

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3. Rumble (Cobble) Finish shall be in compliance with the following product specifications:
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i. In compliance with MS738:1981; for transverse strength of minimum 3 MPa.

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ii. In compliance with MS 1380:1995; average minimum compressive strength of 45 MPa.

iii. Anti-fungal (up to 90% resistance to fungal growth)
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iv. Green Label certification: Yes

v. The shapes and profiles of the paver shall be selected from the manufactures available
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product catalogue and shall be approved by the Engineer/Architect. The finishing surface shall
be natural colour, standard colour, premium color, monochromatic toning colours, or any other
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colour as specified by the Engineer/Architect. The selected paving slab shall fit for the
application for vehicular pavement, and/or pedestrian pavement.
d. Surface Finishes
A compressed concrete paving slab that described as natural colour shall not contain any pigment. The
coloured/pigmented paving slabs shall be coloured homogenously on the facing layer of the paver. The
minimum thickness of the coloured facing layer shall be 12mm. The Engineer/Architect shall approve the
colour prior to manufacture. All pigments used shall be in compliance with relevant standards.
e. Thickness
The nominal thickness for the paving slab shall be in accordance to the selected paving slab type. Any
selected paving slab type shall conform to the tolerance on dimension set forth by the Engineer and/or as
in drawing.
f. Water Absorption
Facing surface water absorption of the paving slab shall not exceed 0.4g/cm2, and the total water
absorption of the paving slab shall be less than 8%. The test shall be carried out as specified in
MS738:1981.
g. Manufacturer
It is the responsibility of the Contractor to make sure the manufacturer of compressed concrete paving slab
meets all the specified material specifications. The Contractor also to make sure that the manufacturer is
ISO 9001:2008 and ISO 14001:2004 certified. The Engineer or his representative shall at all reasonable
times be permitted access to the place where the pavers are manufactured or stored, for the sole purpose
of examining and sampling the materials and the finished interlocking concrete pavers.
h. Quality Assurance
1. Paving contractors Qualifications:
1. Utilize an installer having successfully completed compressed concrete paving slab installation
previously with similar design, material, and extent of current project.

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2. Comply with all the statutory requirements and approvals from relevant authorities.

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2. Mock-ups:
i. Install a 2m x 2m paver area.

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ii. Use this area to determine the bedding mortar layer, joint sizes, and lines, laying pattern, color and
texture of the job.

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iii. This area will be used as the standard by which the final work will be judged

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iv. Subject to acceptance by owner, mock-up may be retained as part of finished work.
v. If mock-up is not retained; remove and properly dispose of mock-up.
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Notes: A site visit & approval by the owner’s representative during the first day of paving may substitute
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for a mock-up.
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i. Certificates and Document Submittal

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1. Manufacturer’s drawings and details; indicate perimeter conditions, relationship to adjoining

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materials and assemblies, expansion and control joints, Compressed Concrete Paving Slabs layout,
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patterns, color arrangement, installation and setting details.

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2. Compressed Concrete Paving Slab:

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i. Two representative full-size samples of each paving slab type, thickness, color, finishes that
indicate the range of color variation and texture expected in the finished installation. Color(s)
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can be selected by the Architect, Engineer, or Owner from the manufacturer’s available colors.
ii. Accepted samples become the standard of acceptance for the work
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iii. Test results/reports from an independent testing body (SIRIM) for compliance of compressed
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concrete paving slab requirements to MS 1380:1995 and/or MS738:1981

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iv. Manufacturer’s product catalogue and installation method statement.

v. ISO 9001-2008 and ISO 14001-2008 certificates
vi. Green Label certificates
3. Compressed Concrete Paving Slab Installation Contractor:
i. Job references from projects of a similar nature. Provide Owner/Client/General Contractor
names and contact details.

j. Delivery and Storage

1. Refer to manufacturer’s ordering instructions and lead-time requirements to avoid construction delays.
2. Deliver materials in manufacturer’s original, unopened, undamaged containers packaging with
identification labels intact.
3. Coordinate delivery and paving schedule to minimize interference with normal use of buildings
adjacent to paving site.
4. Deliver compressed concrete paving slabs to the site in plastic banded and/or plastic wrapped
packaging capable of transfer by fork lift or clamp lift.
5. Unload pavers at job site in such a manner that no damage occurs to the product.
6. Store materials in place where it is protected from mud, dirt, and other foreign materials.
k. Bedding Mortar and Joint Filling
1. Where the paving slabs to be laid on mortar bedding; provide 30mm thick cement mortar (ratio
1:1:3) to receive the paving slabs.
2. The receiving base of paving slabs shall be well prepared with minimum G25 concrete reinforce with
A6 type BRC. The minimum concrete base thickness shall be 100mm.
3. To make sure the surface of paving slabs are kept clean from any spillage of cement mortar.

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