ROAD & FLEXIBLE PAVEMENT

SECTION 5
Page 1 of 16

ROAD & FLEXIBLE PAVEMENT

PREPARATION OF SUBGRADE TO RECEIVE ROAD PAVEMENT

The preparation of subgrade shall be carried out only after completion of all subgrade drainage,
piped drains, services and ducts or any other drainage work that might affect the works, unless
otherwise agreed by the Engineer, and such preparation shall be carried out immediately prior to
the laying of the base course.

The surface of the subgrade shall be substantially uniform in density throughout its entire width
and shall conform to the density requirements for compactions. Compaction shall be out by
approved rollers until the subgrade is uniformly compacted to a density not less than 95% of the
maximum dry density obtained by testing in accordance with Test No. 13 of B.S. 1377 (modified
AASHTO). It shall be trimmed to conform to the lines, camber, grades and typical cross sections
shown on the Drawings, or as directed by the Engineer. Where ruts or other objectionable
irregularities occur as a result of construction traffic or other causes, the Contractor shall re-shape
and re-compact the subgrade to the required density.

CONTROL DENSITY TESTS

Arrangement will be made by the Engineer for the following tests to be carried out, and the
Contractor would be required to provide all necessary equipment and attendance, and taking of
samples for these tests. These tests shall be carried out as follows:-

(a) Where Density Tests Are Applicable

The dry density of the material after compaction shall be determined in accordance with Test
No. 15 of B.S. 1377 except that a pouring cone of approved pattern shall be used and the test
holes shall be approximately 6” diameter and shall extend at their full diameter to the full
depth of the layer being tested.

Tests shall be taken at random areas as directed by the Engineer. Work shall be phased and
executed in such manner as to allow the density tests to be taken at least one day ahead of any
further work on the area concerned.

(b) Where Density Tests are not Applicable

Control density tests as specified above are not applicable when 40% or more of the material
is retained on a ¾” B.S. sieve. The maximum compaction for such material would be
considered to have been achieved when the material has been rolled at or near its optimum
moisture content, and when the Engineer is satisfied that no further compaction is required.
Where directed by the Engineer, the material shall be sprinkled with water and scarified
before rolling.

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EARTH FORMATION

Where soft spots and unsuitable material occurs, they shall be removed and backfilled with
approved stable material and compacted by not less than 4 passes of a smooth weighing not less
than 10 tons or an equivalent vibrating roller.

The subgrade shall then be checked and the final trimmed surface shall be rolled by one pass of a
smooth-wheeled roller of not less than 5 tons or an equivalent vibratory roller prior to the laying
of the base.

The subgrade shall be so constructed to drain surface water to the side ditches or other drainage
system. If the Contractor allows the moisture content of the completed formation to reach a value
above the permitted maximum for the compacted material, the Contractor shall allow the material
to revert to an acceptable moisture content and, if directed by Engineer, make good at his own
expenses the surface by recompaction before laying the base.

PAVEMENT THICKNESS

The thickness of the various layers of the road pavement shall be as shown on the Drawings.

SUB-BASE MATERIAL

The crusher run sub-base to be placed on top of the subgrade shall be dry bound macadam
consisting of crusher run metal laid in layers as specified to give the specified total compacted
thicknessess and the width, correct line and levels shown on the Drawing or as directed by the
Engineer.

The material shall be crushed rock of hard durable particles or fragments of rock crushed to the
correct size, well graded and lie within the following grading limits shown in Table 1. The
grading of crushed rock shall be approved by the Engineer.

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Table 1

GRADING LIMITS FOR CRUSHER RUN

___________________________________________________________________
B.S. Sieve Percentage by Weight
Size Passing
___________________________________________________________________

3” 100
1-1/2” 85-100
3/8” 40-70
3/16” 25-45
No. 25 8-22
No. 200 0-10
____________________________________________________________________

Notes :-

1. The particle size shall be determined in accordance with the requirements of B.S.
1377.
2. The material passing the No. 36 B.S. Sieve when tested in accordance with B.S. 1377
shall be non-plastic.

LAYING AND COMPACTION OF CRUSHER RUN

All work on the portion of the subgrade on which the sub-base is to be laid shall be properly
shaped and compacted in accordance with the requirements of this Specification before the
placing of the sub-base material on that portion. The preparation of the subgrade shall be
completed at least 200 yards ahead of the placing of the sub-base material. The sub-base shall be
constructed to the full compacted thickness as shown on the Drawing.

Prior to laying the crusher run sub-base, a layer of sand or quarry waste blanket of described
thickness and to the full width of the pavement shall be placed on the subgrade.

All material shall be placed and spread evenly to the full width of the road bed. The maximum
compacted thickness of any one layer shall not exceed 6 inches, the base shall be constructed in
two or more layers of approximately equal thickness. Each layer shall be compacted to the
required density before the next layer is placed. Care shall be taken to prevent segregation of the
material into the coarse and fine fractions. Segregated surface areas of a base constructed or base
material contaminated to such and extent that it no longer complies with the required
Specification shall be removed and replaced with well-graded and satisfactory material at the
expense of the Contractor.

The material shall be spread by a motor grader or any other approved mechanical plant.

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When a sub-base is spread adjacent to concrete kerbs or roadside drains, extreme care shall be
exercised so as not to damage the kerbs or drains. Any damaged kerbs or drains shall be removed
and reinstated to proper condition at the Contractor’s own expense.

Compaction shall be completed as soon as possible after each layer has been spread and shaped
satisfactorily. Each layer shall be thoroughly compacted with suitable compaction equipment to
the requirement specified in Table 2 on page S/41 – “Compaction Requirements for Granular
Sub-base Materials”.

Rolling operation shall begin along the edges and progress towards the centre gradually in a
longitudinal direction. On super elevated curves, the rolling shall begin at the low side and
progress towards the high side. The rolling operation for each layer shall continue until all rolling
marks, ridges or cracks are eliminated. Any irregularities, segregation or loose material which
may develop in the surface during or after construction shall be corrected or removed and the
defective areas made good to the full thickness of layer and recompacted.

Before the laying of each layer of crusher run metal a partial width of the shoulder, not less than
12” wide, shall be constructed to the top of each uncompacted layer of the base to act as a haunch
to support the edges of the crusher run base during rolling.

Sub-base material shall be maintained at the correct moisture content necessary for proper
compaction by sprinkling with water or drying as required. All these shall be carried out at the
Contractor’s own expense.

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The surface of the aggregate sub-base shall be well drained at all times.

Table 2
_______________________________________________________________________
Compaction Requirements for Granular Materials
_______________________________________________________________________
Number of Passes of
Type of Category Not greater Not greater Not greater
Compaction than 4-1/2” than 6” than 9”
Plant layer layer layer
_______________________________________________________________________
Smooth- Load per
wheeled inch width
roller -----------------
151-300 lb 16 Unsuitable Unsuitable
more than 8 16 Unsuitable
300 lb.
_______________________________________________________________________
Wheeled load
-----------------
Ton
Pneumatic 4-6 12 Unsuitable Unsuitable
tyred 6-8 12 Unsuitable Unsuitable
roller 8-12 10 16 Unsuitable
more than 12 8 12 Unsuitable
_______________________________________________________________________
Static load
Vibratory per inch
roller width of
vibratory
roller
--------------
lb.
41-70 16 Unsuitable Unsuitable
71-100 6 16 Unsuitable
101-130 4 6 10
131-160 3 5 9
161-200 3 5 8
201-240 2 4 7
241-280 2 4 6
_______________________________________________________________________
Vibrating- Static pressure
plate under base plate
compactor ib. in2
2-2-1/2 8 Unsuitable Unsuitable
2-1/2-3 3 8 Unsuitable
more than 3 3 6 10
_______________________________________________________________________

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Vibro- Weight
tamper -----------
cwt

1-1-1/4 4 8 Unsuitable
1-1/4-1-1/2 3 6 10
more than 1-1/2 3 4 8
_______________________________________________________________________
Power Weight
rammer or ---------
cwt

dropping 2-10 5 8 Unsuitable

weight more than 10 5 8 12
compactor
_______________________________________________________________________

FINISHED SUB-BASE SURFACE

The finished sub-base surface shall be even, free from hungry patches, irregularities, loose
material or fines and true to cross-section, line and level. Any irregularities on the finished sub-
base surface of more than ½” when measured with a straight edge 10 feet long laid transversely,
shall be corrected by loosening, adding or removing material, reshaping and recompacting.

BITUMINOUS TACK COAT

A bituminous tack coat shall be applied to the top of the completed crusher run base before the
laying of the bituminous macadam binder course. The bituminous material for the tack coat shall
be either a rapid curing cut back given in B.S. 3690 Part 1:1982 – “Specification for Bitumens for
Road Purposes” or a rapid breaking emulsion. Bitumen emulsion shall be of the anionic type
unless the cationic type is explicitly required.

The grade and use of other anionic emulsified bitumen or cationic emulsified bitumen shall
conform to the requirements for the appropriate grade given in B.S. 434 Parts 1 & 2 : 1984 in
respect of general properties.

The Contractor shall apply the tack coat on the completed portion of the granular base as soon as
practical. However, he shall not apply the tack coat if the moisture content in the top 2” of the
aggregate sub-base exceeds the higher of either:-

(i) the average of the optimum moisture content as determined by the standard compaction
test, and the absorption of the B.S. 3/16” sieve fraction, or

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(ii) two-thirds of the optimum moisture content as determined by the standard compaction
test. The surface shall be cleaned immediately prior to the application of the tack coat.
The bituminous material shall be applied by means of a distribution at the rates directed
by the Engineer, but not to be less than 0.08 gallons per sq. yard and at the ambient
temperatures as necessary for uniform spraying and satisfactory penetration.

BITUMINOUS MACADAM ROAD PAVEMENT/SERVICE PATH

The bituminous macadam road pavement and/or service paths shall be of the construction shown
and shall laid to the overall finished thickness shown on the Drawings, and complying with the
requirements of B.S. 1621.

COARSE AGGREGATE

The coarse aggregate shall be natural aggregate substantially free from the material passing an 1/8
in. B.S. sieve in accordance to B.S. 410 – Test Sieves. It shall be hard, clean, durable crushed
rock of granite or limestone group or of any other rock group as may be approved by the
Engineer. Only granite shall be used for the wearing course.

FINE AGGREGATE

(a) The fine aggregate shall consist of crushed rock or of clean sand, substantially all of
which shall pass an 1/8” clay shall not exceed 3 percent by weight of the fine aggregate,
determined in accordance with B.S. 812, method A or B. In the event of dispute, method
A (sedimentation method) shall be used.

(b) If added filler is used in the bitumen macadam, it shall consist of crushed rock, hydrated
line, Portland cement, or other material approved by the Engineer. At least 75 percent of
it shall pass a No. 200. sieve.

BINDER

The binder shall be either cut-back or straight run bitumen which shall have a penetration of
between 80 and 100 at 25C.

COMPOSITION OF MIXTURES

The bituminous macadam road pavement shall generally be laid in two layers comprising the
base course and the wearing course. Each layer shall be to the thickness shown on the Drawings
to make up the finished thickness of the pavement.

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The composition of freshly mixed material for the bitumen macadam shall comply on analysis
with the following requirements :-

BASE COURSE
_________________________________________________________________
1-1/2 in. (38mm) Nominal
Passing B.S. Sieve Size Aggregate
_________________________________________________________________
in. % by Weight
_________________________________________________________________
2-1/2 -
2 100
1-1/2 90-100
1 50-80
1/2 10-30
3/4 0-10
_________________________________________________________________
Binder Content as
found by Analysis 3.0 – 3.8
_________________________________________________________________

WEARING COURSE
_________________________________________________________________
3/4 in. (10 mm) Nominal
Passing B.S. Sieve Size Aggregate
_________________________________________________________________

in. % by Weight
_________________________________________________________________

1 100
3/4 95-100
1/2 70-90
3/8 55-75
1/4 40-60
1/8 25-40
No. 14 14-30
No. 200 3-6
_________________________________________________________________

Binder Content as
found by Analysis 4.4 – 5.4
_________________________________________________________________

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MIXING

The aggregate shall be surface dry, and the aggregate and binder separately heated to the
following temperatures on entering the mixer :-

Aggregate 150F - 300F

Binder 200F - 325F

It is particularly important to avoid excessive heating of the binder, and excessively high
temperature of the aggregate at the time of mixing, as these will adversely affect the quality of the
resultant macadam.

The materials, including any added filler, shall be weighed or measured into a mechanical mixer
and thoroughly mixed in such a manner that all particles of the aggregates are completed and
uniformly coated.

TRANSPORT

The bitumen macadam shall be transported from the manufacturing plant to the site of the work
in clean vehicles and shall be protected against adverse weather conditions by means of tarpaulin.
The use of dust, oil or water on the interior of vehicles to facilitate discharge of the bitumen
macadam is permissible, but the amount shall be kept to a minimum and any excess shall be
removed by tipping or brushing.

It is particularly important that bitumen macadam which is to be laid warm shall be protected to
minimise loss of heat during transit so that all material is delivered in a condition suitable for
spreading and compacting.

SAMPLING AND TESTING

Sampling and testing of the aggregates and mixed materials carried out shall be in accordance
with the following British Standards as appropriate:-

B.S. 812 “Testing of Aggregates”

B.S. 598 “Sampling and examination of bituminous mixtures for roads and other
paved areas”.

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LAYING OF BITUMEN MACADAM

(a) The base course and wearing course shall be laid by machine in single
course each and the average compacted thickness of the individual
courses should be within the limits specified below :-

Base course : 1-3/4 in. to 2-1/2 in.

Wearing course : 1-1/4 in. to 1-1/2 in.

(b) The accuracy of finish in the longitudinal direction shall be determined

by measuring the gap under a 10 ft. (3 m) straight edge, placed in any
position on the road surface parallel to the centre line; the gap at any
place between the points at which the straight edge is in contact with the
road should not exceed the following limits :-

Base course : 1/2 in. (13 mm)

Wearing course : 1/4 in. (6.5 mm)

The transverse profile should conform to a similar standard of accuracy,

using a correctly shaped templates instead of a straight edge.

(c) The bitumen macadam shall be laid by machine. Work shall not proceed
under unsuitable weather condition. The machine shall be of a type
preferably self-propelled and capable of laying bitumen macadam
continuously so as to produce automatically an even, smooth and
compact surface to the required widths, thickness and cross-falls without
segregation of the bitumen macadam.

(d) A fully trained and experienced operator shall be in direct charge of the
machine.

(e) The bitumen macadam shall be supplied continuously to the machine.

Material supplied to the machine shall be laid as soon as possible after
delivery.

(f) The machine shall be used only when it is a serviceable

condition. Bituminous material remaining in the hoppers, conveying and
spreading mechanism, tempers and screeds, shall be cleaned off at the
end of each working day. On no account shall cleaning solvent be
allowed to come into contact with any road surfacing material.
Accumulation of material not of the specified quality shall not be
allowed to deposit on the site. The machine shall be operated to avoid, as
far as possible, dragging of the bitumen macadam.

(g) On carriageways, narrow strips remaining alongside machine work shall

be, as far as possible, hand laid and rolled at the same time as the

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machine laid work and allowance should be made for extra compaction
of hand laid strips.

(h) Continuous inspection of the finished surface as it is laid shall be carried

out and any defects immediately rectified before and rolling takes place.

JOINTS

When a transverse construction joint is to be made, the material shall be cut back to a vertical
face of the full depth of the course being laid and painted with bitumen or bitumen emulsion
before any new material is laid.

On longitudinal joints a complete bond of the two strips, after compaction should be ensured. If
this is not possible, the edge shall be cut back and painted as above.

LAYING AROUND MANHOLE COVERS

When laying around manhole covers and similar fittings, those parts against which the bitumen
macadam is to abut should be cleaned and painted with bitumen or bitumen emulsion prior to
laying operations. The bitumen emulsion macadam shall be tamped, so that, after final
compaction, the finished surface is level with, or slightly proud of, such fittings.

COMPACTION

As soon as rolling can be effected without causing undue displacement, the bitumen macadam
shall be uniformly compacted by rolling. Compaction should be carried out with a roller or rollers
of weight not less than 6 tons nor shall it exceed 10 tons, and the width of a roll shall not be less
than 18 inches. The bitumen macadam shall be rolled in a longitudinal direction, working from
the sides to the centre of the carriageway, over-lapping on successive passes by at least one half
of the width of the rear roll. The roller should be fitted with a quick reverse and smooth acting
clutch.

Rollers should not be allowed to stand on newly laid bitumen macadam while there is a risk that
the surface will be deformed thereby.

Traffic should not be allowed to pass over the surface until the bitumen macadam has been
compacted and is adequately set.

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ROAD MARKINGS

Description

This work shall consist of the supply of road marking material and its application to form
continuous or intermittent lines, arrows, symbols or figures. The markings shall be white or
yellow laid to the dimensions and at the locations shown on the Drawings and as specified herein
or as directed by the E.R. The work includes the supply of all labour, tools, equipment, materials,
and warning and traffic guidance sign as necessary for the safe and efficient completion of the
entire work.

Road Marking Materials

The marking material shall be one of the types detailed below as indicated on the Drawings or as
directed by the S.O.

(a) Thermoplastic Material

Thermoplastic material shall comply with the requirements of B.S. 3262 Part 1.
Yellow thermoplastic material shall be of standard colour B.S. 381C No. 356
(Golden Yellow).

(b) Road Marking Paint

Road marking paint shall comply with the requirements of M.S. 164. Yellow paint
shall be of standard colour B.S. 381C No. 356 (Golden Yellow).

Preparation of Site

Thermoplastic material and road marking paint shall be applied only on a surface which is clean
and dry. It shall not be laid over loose detritus, mud or extraneous matter or over old material or
paint marking incompatible with the paint being applied.

A tack coat compatible with the marking material shall be applied in accordance with
manufacturer’s instructions prior to the application of thermoplastic material.

If a primer or undercoat is necessary to ensure proper adhesion of marking paint to the road
surface without bleeding or other discoloration, the primer or undercoat shall be fully compatible
with the marking paint and the road surface. The rate of application of tack coat, primer or
undercoat shall be in accordance with the manufacturer’s instruction and to the satisfaction of the
E.R.

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Preparation of Material on Site

(a) Thermoplastic Material

Thermoplastic material shall be supplied in block or powder form. If the material is

supplied in block form it shall be broken into pieces, each weighing not more than 4
kg, which shall be melted in a heater fitted with a mechanical stirrer to prevent local
overheating.

A thermometer of sufficient accuracy shall be used during laying to ensure that

overheating of the material does not occur.

Once molten hydrocarbon resins shall be used within 6 hours and wood and gum
resins shall be used within 4 hours. The material shall not be heated beyond the
manufacturer’s specified temperature during application. Excess material shall be
discarded on completion of application.

(b) Road Marking Paint

All paint shall be thoroughly stirred before application to keep the pigments in
uniform suspension. The use of thinners or other additives shall not be permitted
unless otherwise approved by the S.O.

LAYING

Centre lines, lane lines and edge lines shall be marked by approved mechanical means or as
directed by the E.R. Other markings shall be applied by brush, spray, screed, hand-propelled or
self-propelled machine according to the marking configuration and the type of marking material
for each coat shall be that recommended by the manufacturer unless otherwise specified. When
more than one coat is used, the succeeding coat shall not be applied until the previous coat has
fully set.

Road markings of a repetitive nature other than centre lines, lane lines, etc, shall, unless otherwise
decided by the E.R., be set out with stencils which comply with the size and spacing requirements
as shown on the Drawings.

Protection of Markings

All markings shall be protected from traffic until they have dried sufficiently so that no pick-up
by vehicle tyre will occur.

Reflectorisation

Solid glass beads to be incorporated in marking materials prior to application to road surfaces
shall be Class ‘A’ glass beads complying with the requirements of Table 1 of B.S. 6088 (see
Table 6.1).

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Solid glass beads for additional surface reflectorisation shall be Class ‘B’ glass beads complying
with the requirements of Table 2 of B.S. 6088 (see Table 6.2).

Thickness

The determination of thickness shall be in accordance with B.S. 3262 Part 3, Appendices B and
C.

TABLE 6.1 – CLASS ‘A’ GLASS BEADS : PARTICLE SIZE DISTRIBUTION,

ROUNDNESS AND DEFECTS

B.S. Sieve Percentage Min. % Spherical Beads by Max % Defective Beads as

Retained mass as tested in accordance tested in accordance with
with Appendix C Appendix D

1.18 mm 0 to 3

850 um 0 to 10 70 30

425 um 90 to 100
1.18
1.19

TABLE 6.2 – CLASS ‘B’ GLASS BEADS : PARTICLE SIZE DISTRIBUTION,

ROUNDNESS AND DEFECTS

B.S. Sieve Percentage Min. % Spherical Beads by Max % Defective Beads as

(um) Retained mass as tested in accordance tested in accordance with
with Appendix C Appendix D

850 0 to 5

800 5 to 20

300 30 to 75 80 20

180 10 to 30

Below 180 0 to 15
1.20
1.21

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(a) Thermoplastic Material

Thermoplastic material shall be laid to the following thickness :-

(i) for synthetic hydrocarbon resin binder –

- screed lines : not less than 2 mm nor more than 5 mm;

- sprayed lines other than yellow lines : not less than 1.5 mm;

- sprayed yellow edge lines (for ‘no parking’, ‘no waiting’, etc) : not less than
0.8mm.

(ii) for gum or wood resin binders –

- screed lines : not less than 3 mm not more than 5 mm;

- sprayed lines other than yellow lines : not less than 2 mm;

- sprayed yellow edge lines (for ‘no parking’, ‘no waiting’, etc) : not less than 2
mm nor more than 3 mm.

(b) Road Marking Paint

Road marking paint shall be laid to give a wet film thickness of not less than 315
microns and not more than 400 microns.

Tolerance on Width

The tolerance on the specified width of the marking shall be within the range of + 10% and minus
0%.

Defective Materials or Workmanship

Materials which are defective or which have been applied in an unsatisfactory manner or to
incorrect dimensions or in a wrong location, shall be removed by approved chemical or
mechanical means. To the extent necessary, the road pavement shall be made good and the
markings reapplied all at the Contractor’s own expense and to the approval of the S.O.

Where directed by the E.R., existing markings shall be removed in the same manner as above.

Clearing Up

The Contractor shall clean up all spatters, splashes and smirches of marking material completely
to the satisfaction of the S.O.

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