4.

Grading shall be one of the following classes when tested in

accordance with BS 1377: Part 2: Method 9.2. Selected class
shall be as directed by the Engineer

Table 4-4. Gradation of Granular Sub Base
% By Weight Passing
Sieve Size / No.
Class A Class B Class C
3" 100 100 100
2" 90 - 100 90-100 90-100
No. 4 35 - 70 40-90 50-100
No. 200 0 - 20 0-20 0-30


5. Materials shall conform with the following requirements:

Table 4-5. Requirements of Granular Sub Base
Test Standard Limit
Liquid Limit BS 1377: Part 2 : Method 4.5 max 30%
Plasticity Index BS 1377 : Part 2 : Method 5 max 8%
% water absorption after 24 hours
submerged in water
Local codes max 10%
Clay lumps and friable particles in
aggregates
Local codes-T 113 max 10%
Los Angeles Abrasion ASTM C131/C535 max 50%
Compaction Test (MDD) BS 1377: Part 4: Method 3.6 2.1 Mg/m Min
In-situ Density Test BS 1377: Part 9: Method 2.2 min 98%
CBR at 98% MDD (96 hour soaked) BS 1377: Part 4 Method 7 min 25%
Swelling of soaked C.B.R. moulds No swelling


6. Minimum Test Frequency
4-15
One sample every 1000m shall be tested for
complete analysis unless otherwise approved by
the Engineer.
Three in-situ density tests shall be made every
1000m of granular sub base laid, unless
otherwise approved by the Engineer.
One in-situ density shall be carried out for every
150 linear meter of shoulder or footpath, unless
otherwise approved the Engineer.


4.6.7 Aggregate Road Base

1. Hard, durable crushed gravel or crushed stone. The amount of
crushing shall be such that at least 80% (by weight) of the
pieces retained on 4.75mm sieve shall have at least one
mechanically fractured face. Material shall consist of uniform
mixtures of gravel and or crushed gravel with sand, silt and
clay conforming to the following gradation limits.
2. Free of organic matter or other deleterious substances.
3. Grading shall be one of the following classes when tested in
accordance with BS 1377: Part 2: Method 9.2. Selected class
shall be as directed by the Engineer

Table 4-6. Gradation of Aggregate Road Base
% by Weight Passing Sieve Size
/No. Class A Class B Class C
2" 100
1.5" 70 -100 100
1" 55 - 85 70-100 100
3/4" 50 - 80 60-90 70-100
3/8" 40 - 70 45-75 50-80
No.4 30 - 60 30-60 35-65
4-16
No.10 20 - 50 20-50 25-50
No.40 10 - 30 10-30 15-30
N0.200 5 - 15 5-15 5-15

4. Material shall conform with the following requirements:

Table 4-7. Requirements of Aggregate Road Base
Test Standard Limit
Liquid Limit BS 1377: Part 2: Method 4.5 max 30%
Plasticity Index BS 1377: Part 2: Method 5 max 8%
Linear shrinkage BS 1377: Part 2: Method 6.5 Max 7%
Organic Impurities BS 1377: Part 3: Method 3 Max 0.2%
% absorption submerged in water for 24
hours.
Local codes max 10%
Clay lumps and friable particles Local codes T-113 max 5%
Los Angeles Abrasion ASTM C131/C535 max 50%
Thin and Elongated particles Local codes Max 10%
Compaction Test (MDD) BS 1377: Part 4: Method 3.6 min 2.2
Mg/m
In-situ Density Test BS 1377: Part 9: Method 2.2 100%
CBR at 100% MDD (96 hr. soaked) BS 1377: Part 4: Method 7 min 80%
Swelling of soaked C.B.R. moulds No swelling

5. Minimum Test Frequency
One sample every 1000 m
3
shall be tested.
Two in-situ density tests shall be made every 500 m
2
of
aggregate road base laid.


4-17
4.6.8 Materials for Asphalt Concrete
1. Mineral aggregates for bituminous paving course shall consist
of coarse aggregates, fine aggregates and filler material all
complying with the following requirements.
2. Prior to the production of aggregates or delivery of aggregates
the Contractor shall notify the Engineer of the source of
aggregates for inspection of the borrow or quarry area. All
sources of aggregates shall be approved by the Engineer prior
to the processing of material.
3. The properties of aggregates specified in this section shall be
for aggregates from individual sources or individual stockpiles.
4. If the grading and other specified properties of the material
delivered to the site does not conform to the same properties of
originally approved samples or does not comply with the
specification, the Engineer reserves the right to reject such
materials at the site of the work. If required by the Engineer
the Contractor shall submit to the Engineer the original
invoices for any delivery of mineral aggregates including filler.
5. Coarse Aggregates (those retained on a 4.75mm sieve)
Shall consist of crushed rock or crushed gravel.
Shall be clean, hard, tough, durable and sound.
Shall be of uniform quality and free from decomposed
stone, shale, clay lumps and other deleterious substances.
Mineralogical tests shall be carried out on the aggregates,
if requested by the Engineer
Crushed gravel. Consists of products obtained by
crushing material that has first been screened in such a
manner that not less than 90% of the material to be
crushed is retained on an ASTM 9.5 mm sieve.
100% (by weight) of each stockpile of aggregate retained
on 2.36mm sieve shall have at least one crushed face.
4-18
At least 85% (by weight) of each separate stockpile of
aggregate retained on 2.36m sieve shall have all faces
crushed, unless otherwise approved by the Engineer.
Coarse aggregate in each individual stock pile shall have
properties which comply with the following values:

Table 4-8. Requirements of Materials for Asphalt Concrete
Test Standard Binder Course Wearing Course
Los Angeles Abrasion ASTM C131/C535 max 40% max 40%
Thin & Elongated particles Local codes max 10% max 10%
Clay lumps and friable particles
Local codes 0%* 0%*
% water absorption Local codes max 5% max 5%
Organic Impurities BS 1377 Max 0.05% Max 0.05%

6. Fine aggregate shall be obtained from 100% crushed gravel or
crushed rock, unless otherwise approved by the Engineer.
If approved by the Engineer, a maximum of 25%
(by weight) of fine aggregate may be uncrushed if it
is separately fed into the plant.
Use of dune sand shall not be permitted.
Fine aggregates shall be Non-Plastic when tested for
Plasticity Index:

7. Filler Material
When the combined grading of the coarse and fine
aggregates is deficient in material passing the
ASTM No. 200 sieve, external mineral filler shall
be added as approved by the Engineer at the
Contractors expense.
Mineral filler shall consist of finely ground non-
plastic particles of limestone or cement.
4-19
Mineral filler shall be thoroughly dry and free from
organic substances and clay.
Test frequency is as directed by the Engineer.

8. Bitumen Binder
Shall be penetration grade 40/50 or 60/70 as
directed by the Engineer.
Bitumen shall be prepared by refining crude
petroleum.
Shall be homogeneous and free from water.
Shall not foam when heated to 175C.
Shall conform to the following requirements, unless
otherwise accepted by the Engineer.
Bitumen heated 100C above the maximum
temperature obtained form viscosity temperature
relationship shall be considered over-heated and
shall be removed from site and disposed of by the
Contractor at his own expense. Bitumen shall be
heated only in approved boilers or bulk storage
containers equipped with adequate and accurate
thermometers.
When filling the bitumen from distributors boilers
or bulk containers, the bitumen shall be passed
through a filter of fine wire gauge.
The Contractor shall take every reasonable pre-
cautions to avoid fire or heath hazards.
A sample of bitumen that the Contractor propose to
use in the work together with a statement as to its
source and properties shall be submitted to and
approved by the Engineer at least 45 days before
Construction begins.
4-20
The properties of bitumen shall be as specified by
the Local code unless otherwise approved by the
Engineer.
Only the bitumen represented by the approved
sample shall be used by the Contractor.
Blending of bitumen from different refineries will
not be permitted.
Test Frequency. One full analysis shall be carried
out on a sample from every 80ton.


4.6.9 Asphalt Concrete
1. When tested according to ASTM C117 and ASTM C136, the combined
aggregates shall conform to the following grading having a smooth curve
to the appropriate limits and shall not vary from the low limit on one sieve
to the high limit on the adjacent or vice-versa.

Table 4-9. Gradation of aggregate to used in asphalt concrete
Sieve size/No. % By Weight Passing
Binder Course Wearing Course
1" 100 100
3/4" 75-100 80-100
1/2" NA NA
3/8" 45-70 60-80
No 4 30-50 48-65
No 8 20-35 35-50
No 30 5-20 19-36
No 50 3-12 13-23
No 80 2-8 7-15
No 200 0-4 3-8

2. Combined mineral aggregate shall be non-plastic.
4-21
3. Coarse aggregate, shall show no detrimental amount of stripping when
tested in accordance with ASTM D 1664. The area coated shall be
evaluated not only at 25C but also after the aggregate has been soaked
in water at 40C and 60C.
Minimum value of non-stripped area shall be 95%.
If stripping occurs, the aggregate shall be rejected
unless:
a. An approved method of treatment shall be carried out as specified to
change the material from a hydrophilic to a hydrophobic state.
b. Only approved additives shall be used with the bituminous binder.
4. When necessary to change the hydrophilic character of aggregates to
hydrophobic, additives of approved type will be added to the
bituminous material in such percentage as required to obtain
satisfactory results from the test performed in accordance with ASTM
D1664. Approved additive will be used in accordance with Technical
Specifications issued by the manufacturer and approved by the
Engineer after appropriate testing. No extra payment will be made for
required anti-stripping additives.

5. Design Criteria: The following table summarizes the design criteria of
asphalt concrete. However, the exact percentage of bitumen to be used
shall be fixed by the Engineer based on the laboratory mix and full-
scale plant trial mix results.


Table 4-10. Design Criteria of Asphalt Concrete
Properties
Binder
course
Wearing
course
Bitumen Content (% of total mix) Marshall Specimens: 3 - 6 4 - 7.5
Number of Compaction blow at each end of specimen. 75 75
Air voids in total mix (VIM %) 3 - 8 3 - 5
Voids in mineral aggregate (VMA %) Min. 14 Min. 15
Stability (kg) Min. 700 Min. 900
4-22
Flow (mm) 2 - 4 2 - 4


6. Job mix for Bituminous Paving Courses: field trials with the following
recommendations shall be taken into account.
Combined aggregate gradation should be
adjusted within the allowable limits to achieve
maximum stability whilst not going below the
minimum requirement for void content.
Minimum bitumen binder content should be
used according to the results of the Marshall
Method of Mix Design, if it will still satisfy all
the specified requirements.
Final job mix must display all characteristics as
specified for Asphalt Concrete mixes.
After receiving approval of the aggregates and
bitumen from the Engineer, the Contractor shall
make a written request for the approval of the
job-mix formula from the Engineer at least
thirty, (30) days prior to the date he intends to
begin production of plant-mix Bituminous
Paving Course Mixes. Formula will be
prepared by the Contractor under the
supervision of the Engineer in the Laboratory.
The laboratory job mix formula shall define:
a. Percentage of aggregate passing each required sieve size.
b. Percentage of bitumen binder to be added to the aggregate.
c. Temperature at which the mix is to be emptied from the mixer.
d. Temperature at which the mix is to be delivered to the works site.
Before the start of the permanent work, mock-
ups or trial areas having lengths of at least 30
m shall be laid to the specified layer thickness
4-23
a. Materials used in the trials shall be those
approved for use in the bituminous
paving courses.
b. Equipment used shall be that according
to the Contractors approved method
statement and the program of work.
c. The object of these trials is to determine
adequacy of the Contractors equipment,
loose depth measurements necessary to
result in the specified compacted layer
depths, and relationship between the
number of compaction passes and the
resulting density of the material.
d. Additionally at least two samples of non-
compacted material and two cores of
specified diameter shall be taken from
the trial area in accordance with
AASHTO T-168 and analyzed in the
presence of the Engineer to determine
aggregate grading, binder content,
stability, flow, bulk density, and voids.
Results shall be submitted to the
Engineer for approval before further
mixing and laying are carried out.

If the laboratory job mix formula fails to
produce a satisfactory trial, the mix proportions
may be modified by agreement with the
Engineer, within the applicable specification
requirements to produce a mix of satisfactory
workability and acceptable surface finish.
4-24
All mixes produced shall conform to the
properties of Job Standard Mix approved by the
Engineer, within the ranges of tolerance
specified in Table 22.
Should a change in a material be encountered or
should a change in a source of material be made,
a new Job-Standard Mix shall be submitted by
the Contractor and approved by the Engineer
before the mix containing the new materials is
delivered. Job materials will be rejected if they
do not possess the same characteristics of the
approved Job Standard Mix.


Table 4-11. Job Mix Tolerance
Aggregate retained on 4.75 mm sieve or larger + 5%
Aggregate passing 4.75 mm sieve and retained on 0.075
mm sieve
+ 4%
Aggregate passing 0.075 mm sieve + 2%
Bitumen Binder + 0.25%
Temperature for mixing and placing 10C

7. Samples of Bituminous paving course mixes shall be taken from the
mixing plant and/or behind the paver prior to compaction, as decided
by the Engineer, to check compliance with the approved job mix
requirements. Density of the compacted mixes shall be related to the
job standard density or the daily Marshall Density at the option of the
Engineer, which shall be determined by making four Standard
Marshall specimens from samples of the mix taken from the mixing
plant or paver.
Density of each sample shall be determined and
compared with the mean value.
Any individual result, which varies from the
mean by more than 0.015 g/cc, shall be rejected.
4-25
Marshall tests shall be repeated on a daily basis
to establish the daily Marshal Density for that
particular days production.
Daily Marshall Density shall not vary from the
Job Mix Design Density by more than + 1%.

8. Assistance of the Engineer in the preparation of the job standard mix
shall in no way relieve the Contractor of his responsibility for
producing a bituminous mix meeting the requirements of the
Specifications.

9. Preparation of Bitumen Binder
Temperature of the bitumen binder for mixing
and compacting shall be in accordance with
ASTM D1559. The Contractor shall submit a
temperature / viscosity chart for each grade of
bitumen to be used.

10. Preparation of Mineral Aggregate for Bituminous Mix
Coarse and fine aggregate shall be stored at the
asphalt plant in such a manner that separate
stockpiles will not become intermixed.
a. Stockpiles shall be of sufficient size to provide a minimum quantity of one
weeks continuous production of asphalt mix.
b. Aggregates brought to the asphalt plant to supplement stocks should be
tested and approved prior to placing in the existing approved stockpiles.
Cold bins shall be calibrated with the materials
to be used and the settings shall be such as to
produce a combined gradation in accordance
with the job mix formula.
a. Proportioning shall be such that surpluses and shortages
in the hot bins will not occur.
b. Neither the dryer nor the screens shall be overloaded.
4-26
c. All the above shall be as approved by the Engineer.
Materials shall be thoroughly dried and heated
so that their temperature is within 8C of the
temperature needed to satisfy the viscosity
requirements of the asphalt cement.
a. Moisture content of the heated and dried materials shall not exceed 0.5%.
b. Quantity of materials fed through the drier shall in all cases be held to an
amount, which can be thoroughly dried and heated within the limits
specified.
Immediately after heating, the aggregates shall
be screened into at least five sizes and conveyed
into separate bins ready for batching and mixing
with bituminous materials. When the aggregates
supplied are of such size and grading that
separating into five bins is impractical, the
number of required separations may be reduced
to four or to three with the approval of the
Engineer.
Efficiency of the screening operations shall be
sufficient to produce (at plant operating
capacity) gradations (in all sizes of heated and
dried aggregates) which are reasonably uniform
and result in the production of a mix complying
with the limits specified for the aggregate
gradation.

11. Preparation of Bituminous Mix
Asphalt concrete shall be prepared in a central
mixing plant conforming to the requirements of
ASTM D995.
a. The plant shall be equipped with an efficient mechanical dust extraction
system and storage silos.
4-27
b. Its design shall be provided for the controlled return of some of the filler to
the mix, when necessary, by means of filler weighing bin discharging in to
the pugmil.
c. The dust collection system shall be powerful enough to keep the mineral
filler contents the in hot sand bin below 2%.
d. The plant settings once established shall not be changed without the
approval of the Engineer.
e. The minimum mixing time shall not be less than that recommended by the
manufacturer. The mixing time may be increased by the Engineer if
additional time is necessary to obtain a homogeneous mix and satisfactory
coating.
f. Bitumen binder shall be introduced into the mix in the proportion specified
by the job-mix formula.
Initial mixing time will be designated by the
Engineer. Mixing time may be increased by the
Engineer if additional time is necessary to obtain
a homogeneous mix and satisfactory coating.
Timing at the batch plant for mixing shall begin
at the start of the introduction of the bitumen
into the pugmill.
Temperature of the aggregate immediately prior
to mixing shall be within + 8 C of the
temperature of the bitumen binder.
a. Temperature of the aggregate and asphalt prior to mixing shall be
approximately that of the completed mix as defined in the job mix formula
approved by the Engineer.
b. Mix temperature shall be within the limits set out in the job mix formula
when emptied from the mixer.
12. Minimum test requirements for bituminous courses
Bitumen material: One sample shall be tested for
penetration and Ring ball test for every 80 tons
or part thereof, unless otherwise agreed by the
Engineer.
4-28
Aggregate: One sample for each stockpile or
every 1,000 m. Perform all the required tests.
Bituminous mix: one sample of mix shall be
obtained from at least every 200 tons. Perform
all the required tests.

4.6.10 Prime and Tack coats
1. Prime coat shall be a medium curing cut back
asphalt (MC-70) .
Sampling shall be in accordance with ASTM D140.
Frequency of the testing shall be as directed by the
Engineer.
2. Tack Coat shall be Rapid Curing cut back asphalt (
RC-250 ).
Sampling shall be in accordance with ASTM D140.
Frequency of the testing shall be as required by the
Engineer.
3. Depending on the possibilities of obtaining
Bituminous materials, the Engineer may modify the
type and gradation of the materials for the prime
coat and tack coat.
4.6.11 Road marking materials
1. Thermoplastic Materials shall comply with
BS3262 hot-applied thermoplastic road
marking materials and shall be suitable for
road surface temperature of up to 80C,
unless otherwise approved by the
Engineer. Proportions, testing
requirements and type of materials used
shall be as mentioned in the Contractors
approved method statement.
2. Road marking paint shall be either
chlorinated rubber, one pack epoxy or
4-29


4.6.12 Traffic signs
1. Permanent traffic signs shall be
reflector and shall comply with the
following requirements except as
modified here under or as directed by
the Engineer.
2. Sign plates shall be manufactured
from sheet aluminum with a
minimum thickness of 3mm, unless
otherwise approved by the Engineer.
3. Information on signs shall be
constructed in extruded aluminum
plank sections, which will either be
self-locking or rear fixing, and the
aluminum shall be BS EN 485, or BS
1490 or other approved equivalent
International Standard.
4. All sign plates shall have clean,
smooth edges cut to the required
shape of the sign and shall be etched
4-30
5. Sign shall be covered with High
Intensity reflective sheeting.
Sheeting must have
the manufacturers
guarantee for a period
of not less than 5
years for Engineering
Grade and 7 years for
High Intensity.
Rear faces shall be
non-reflective grey
and should give a
similar life span to the
sign face.
Reflective sheeting
shall be fixed to the
sign plate either with
a heat activated
adhesive using
vacuum applicator or
with a pressure
sensitive adhesive
using a pressure roller
in accordance with the
sheeting
manufacturers
instructions.
Sign faces shall be
formed from a single
piece of reflective
4-31
Sheeting, after
application to the sign
base, will not come
off at the edges nor
shall it peel off or
warp. Surface shall
be smooth, flat and
free from any bubbles,
pimples, edge
chipping or edge
shattering. Surface
4-32
Corners of all
direction signs shall
be rounded to a radius
of 75 mm.
6. Stiffening and Framing
All stiffening and
framing shall be of hot
dipped galvanized
steel.
Signs constructed of
aluminum sheet shall,
when recommended
by the Traffic Sign
Manual, be framed on
all edges using hot
dipped galvanized
steel angle.
Stiffening to signs
constructed of
aluminum sheet,
having an area
exceeding 0.10 sq.m.
shall be confined to
horizontal lengths at
the top and bottom
edges of the sign
plate.
7. All rivets or other devices fixing sign
plates to their framework shall be of
non-staining steel or other materials
approved by the Engineer and shall
4-33