SERIES 200 CIVIL WORKS SPECIFICATIONS

SERIES 200
CIVIL WORKS SPECIFICATIONS

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 SERIES 200 CIVIL WORKS SPECIFICATIONS

CONTENTS
Contents................................................................................................................................. 42
TABLES..................................................................................................................................43
Abbreviations & Acronyms................................................................................................. 44
201 Site Preparation And Eartworks...................................................................................... 45
201.01. General............................................................................................................................................ 45
201.02. Materialst................................................................................................................<........................46
201.03. Construction.................................................................................................................................... 46
201.04. Quality Assurance........................................................................................................................... 51

202 Crushed Rock Pavement Courses.................................................................................. 53

202.01. General............................................................................................................................................ 53
202.02. Materials.......................................................................................................................................... 53
202.03. Construction.....................................................................................................................................54
202.04. Quality Assurance............................................................................................................................54
203 Concrete Pavement......................................................................................................... 57
203.01. General............................................................................................................................................ 57
203.02. Materials.......................................................................................................................................... 57
203.03. Construction.....................................................................................................................................59
203.04. Quality Assurance............................................................................................................................65
204 Concrete for Siteworks.................................................................................................... 67
204.01. General............................................................................................................................................ 67
204.02. Materials.......................................................................................................................................... 67
204.03. Construction.....................................................................................................................................68
204.04. Quality Assurance............................................................................................................................70

205 Stormwater Drainage.................................................................................................... 71

205.01. General............................................................................................................................................71
205.02. Materials..........................................................................................................................................71
205.03. Construction.................................................................................................................................... 71
205.04. Quality Assurance............................................................................................................................73
206 Signage & Painting.......................................................................................................... 74
206.01. Signage............................................................................................................................................74
206.02. Painting............................................................................................................................................74

207 Pavement Marking...........................................................................................................75

207.01. General............................................................................................................................................ 75
207.02. Pavement Markings......................................................................................................................... 75
207.03. Materials.......................................................................................................................................... 76

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 SERIES 200 CIVIL WORKS SPECIFICATIONS

TABLES
Table 1 Compaction Requirements 49

t t

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ABBREVIATIONS & ACRONYMS
SMDDR Specified Minimum Dry Density Ratio
DB Deformed bar
RB Plain round mild steel bar
ASTM American Society for Testing and Materials
LL Liquid Limit
c c c c c

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 201 Site Preparation And Eartworks

201 SITE PREPARATION AND EARTWORKS

201.01. General
201.01.01. Scope
This Section specifies requirements for excavation, filling, and the preparation of the subgrade on which
pavements or buildings are to be constructed.

201.01.02. Referenced Documents

The following document, which is referenced in this Section, forms part of this Specification only to the extent
that it is referred to herein.
• ASTM (American Society for Testing and Materials).

201.01.03. Definitions
Spoil comprises any surplus materials or any materials, which cannot be used in the works for any reason.

Subgrade Level is the prepared surface of the in-situ material after the completion of all stripping and
excavation and prior to any filling.

Formation Level is the level of completed earthworks including excavation, filling, compaction, trimming and
a like, to the finished earthworks design levels and profiles as shown on the drawings.

Engineering Services includes drains, power cables, control cables, sewers, water pipes, gas pipes, ducts
or any other pipe, cable, associated structure or similar objects.

Batter is the uniform side slope of a cut or fill.

Optimum Moisture Content is the moisture content of a soil at which a specified amount and type of
compactive effort will produce the maximum dry density.

Dry Density Ratio based on Modified Compactive Effort is defined as the ratio expressed in a percentage,
of the material in its in-situ condition to the dry density of the same material when compacted at optimum
moisture content as determined by the laboratory compaction test described and defined by ASTM D1557

Dry Density Ratio based on Standard Compactive Effort is defined as the ratio expressed in a percentage,
of the material in its in-situ condition to the dry density of the same material when compacted at optimum
moisture content as determined by the laboratory compaction test described and defined by ASTM D698

201.01.04. Plant and Equipment

The plant and equipment used in the Works shall be appropriate for the execution of the tasks and shall be
maintained in satisfactory working condition at all times while operating.

201.01.05. Geotechnical Information

If a geotechnical report is provided for the Works by the Principal, the Contractor shall be responsible for
interpretation of the information given in the geotechnical report, and if the Contractor considers the information
is lacking or inadequate, shall be deemed to have carried out further investigations as considered necessary
to adequately assess subsurface conditions

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 201 Site Preparation And Eartworks

201.02. Materials
201.02.01. Select Fill
Select Fill shall be imported from an approved source. The material shall be stable and well graded, free from
organic or deleterious matter and shall meet the following requirements.

Particle Size after compaction - maximum 75mm

Percentage passing 19m (sieve % in) - maximum 80
Percentage passing 0.075mm (sieve no. 200) - maximum 50
c c V C

Material retained on a 2.00mm (sieve no. 10) Sieve shall consist of hard durable particles of rock and/or gravel.

Material passing a 0.425mm (sieve no. 40) Sieve shall have the following physical properties:

Liquid Limit (LL) - maximum 50

Plasticity Index - 6 to 30
Product of LL and percent passing 0.425 Sieve - maximum 1600

Where the Engineer considers that any Select Fill material delivered for use in the works differs from that of
the approved sample, further compliance testing may be ordered at the Contractor’s expense.

Fill material supplied which is not approved as Select Fill shall be immediately removed from the Site to a place
of legal disposal or used as a General Fill or Landscape Fill.

201.02.02. General Fill

Material for general fill shall be approved stable, well graded earth fill material excavated from the site, free
from organic matter, clay lumps or stones greater than 75mm in size or other material deleterious to compactive
effort.

201.02.03. Topsoil
Topsoil shall be free from unwanted matter such as weeds, rubbish, petrol, oil, lime, rocks, asphalt, bricks,
concrete, clay lumps, tree roots, sticks or other deleterious matter and shall have a pH range of 6.0 - 7.0.

201.03. Construction
201.03.01. Site Preparation
The Contractor shall remove all obstructions including abandoned engineering services, divert all drainage,
relocate existing engineering services which are to be retained and, where appropriate, install new engineering
services and drainage prior to the commencement of excavation or filling in any area.

201.03.02. Setting Out

The Contractor shall be responsible for the setting out of the Works in accordance with the survey details and
dimensions shown on the Drawings. Where the Contractor believes that necessary dimensions are not shown
on the Drawings, he shall request the engineer to provide these dimensions. He shall make adequate
provision, in time, for the engineer to determine such dimensions without causing delay to the works.
The Contractor shall be responsible for the protection of all survey marks on the site.

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 201 Site Preparation And Eartworks

Prior to commencing earthworks over any section of the Site, the Contractor shall place marks as may be
required for setting out and provide the engineer with a schedule and plan of such marks, showing their location
and level.

The Contractor shall be responsible for the maintenance of all survey mars and recovery pegs throughout the
duration of the Contract.

201.03.03. Access Roads

The Contractor shall provide and maintain all necessary temporary access roads. The proposed alignments
and levels of temporary access roads shall be submitted to the engineer for approval prior to their construction.

201.03.04. Protection of Services, Structure and Other Property

The Contractor shall make all reasonable enquiries to identify and confirm the location, depth and size of
existing services and structures that may be encountered in the performance of the works and shall take all
reasonable and necessary precautions to protect these services and structures from damage.

In the event of any injury to any such structure, service or property, the owner and the engineer must be
immediately informed of the injury. If the engineer determines that repairs shall be made by the Contractor, such
repairs will be ordered or arranged as provided for under the General Conditions of Contract.

201.03.05. Drainage
During earthworks, the Contractor shall provide drainage such that all excavation and filling will be free draining
to low points clear of the works at all times. Water shall be drained or pumped from low points to prevent
damage to the Works due to inundation, flooding, ponding or other causes. The Contractor shall do all things
necessary to divert any water, which interferes with progress of the Works, and to keep areas free from water
during excavation and filling. The Contractor shall provide sufficient pumps, well-points or other equipment for
keeping trenches and excavations dewatered during the Works at no additional cost to the principal.

Existing drainage lines and structures may be utilised by the Contractor in draining the site. Before breaking
into any lines or structures, the Contractor shall obtain prior approval from the Engineer in writing. Should such
approval be given, restitution of the structure to a condition at least equivalent to that before the breaking
occurred shall be undertaken by the Contractor at his expense.

201.03.06. Batter Slope and Shape

Unless otherwise specified, temporary batter slopes shall be not steeper than 1 vertical to 2 horizontals. The
batter face shall be finished by trimming to produce a uniform shape. Permanent batter slopes shall be as
shown on the drawings.

201.03.07. Demolition and Grubbing

Unrequired/ obsolete materials or structures shall be demolished and cleared from the site to a depth of 150mm
below either the existing ground surface, or earthworks subgrade level, whichever is the lower.

Holes remaining after the demolition and clearing shall be backfilled to the level of the existing ground surface
or the subgrade level whichever is the lower with Select Fill compacted in layers not greater than 150mm loose
thickness to a dry density ratio of 95% using Standard Compactive Effort.

201.03.08. Stripping of Ground Surface

All areas within the limit of the works shall be topsoil stripped to a depth of at least 200mm and any greater
depth required such that all vegetation, grass roots, organic soil and humus is removed.

Such stripping shall extend for a distance of 1m beyond the limits of the earthworks as shown on the drawings
and, in each area, shall be completed prior to commencing earthworks.

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 201 Site Preparation And Eartworks

201.03.09. Excavation
The Contractor shall excavate every type of material encountered within the limit of earthworks to the lines and
levels shown or indicated on the Drawings.

Excavation shall not proceed closer than 100mm to the proposed earthworks subgrade level if it is raining or
if rain is imminent.

The final excavation and trimming of areas on which it is proposed to construct the pavements shall be
undertaken as specified in Clause 201.03.12, 'Finishing Subgrade Surfaces'.

Areas of pver-excavation shall be restored to the require^ levels in accordance vyith Clause 201.03.14,
“Subgrade Replacement', at the Contractor's expense.

201.03.10. Utilisation of Stripped and Excavated Material

All materials recovered from stripping or excavations shall be assessed by the Contractor for re-use in the
Works as topsoil, general fill, or as spoil. The Contractor shall advise the engineer of this assessment prior to
re-using any stripped or excavated materials in the Works. The engineer may order the Contractor to re-assess
the materials until an acceptable classification is obtained for all materials, which are to be re-used in the
Works.

Stripped or excavated materials in excess of that required in the Works, or which due to unsuitability for any
other reason cannot be used in the Works shall be classified as spoil and shall be disposed of in accordance
with the requirements of the Clause 201.03.11, 'Spoil'.

If the stripped or excavated materials which have been approved for re-use in the Works cannot be
incorporated into the Works at the time of stripping or excavation, respectively, then the materials shall be
stockpiled at locations outside the limits of the earthworks area as approved by the engineer. Stockpiled
materials which have been approved for re-use in the Works shall be moved to their final position in the Works
by the Contractor as and when appropriate for the correct and expeditious completion of the Works. All work
associated with moving materials to and from stockpiles shall be at the Contractor's expense.

Excavated materials approved for re-use as topsoil shall be used to resurface areas which are disturbed in the
course of the Works.

201.03.11. Spoil
Spoil, including material defined as topsoil, general fill, landscape fill or material excavated for subgrade
replacement, which is in excess of that required in the Works shall be disposed off site at a legal point of
disposal by the Contractor at no additional cost to the principal.

201.03.12. Finishing Subgrade Surfaces

Finishing of subgrade surfaces shall include final excavation to earthworks subgrade level and proof rolling of
the subgrade surface.

Final excavation shall comprise the removal of material, which is within a depth of 100mm of the earthworks
subgrade level and shall be undertaken so as to minimise disturbance of the subgrade surface.

Within 24 hours of completion of the final excavation of the subgrade, the first layer of fill shall be placed and
compacted.

The Contractor shall trim the subgrade to provide a reasonably smooth surface, free from all loose excavated
material that shall conform to the shape required at that section. The degree of finish shall be that ordinarily
obtainable with a grader blade. Cobbles and boulders, which protrude above the surface, shall be removed
and the surface in such areas shall be restored to the required levels with Select Fill in accordance with Clause
201.03.14, 'Subgrade Replacement'.

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 201 Site Preparation And Eartworks

The surface of the subgrade in areas of cut shall not be above the Earthworks Formation Level at any point.

201.03.13. Subgrade Preparation

Proof rolling of the subgrade shall be undertaken as directed by the Engineer using a static roller loaded to at
least 4 kN per 100mm width of roller. The roller shall be operated for a maximum of two coverages where one
coverage is defined as one application of the roller to each point on the subgrade surface.

The subgrade shall be assessed visually by observing the deflection and recovery of the surface of the
subgrade behind the roller tyres.

The assessment shall be carried out by walking behind and to the side of the roller outer wheels and
continuously observing the response of the subgrade surface to the rolling wheel.

Subgrade that is unstable or of inferior materials shall be defined as the condition when:

• The roller becomes bogged under normal rolling conditions

• The surface of the subgrade ruts excessively, yields or shows signs of distress
• The surface of the subgrade exhibits excessive elastic deflection, which is clearly visible from a
standing position.

Proof rolling of the subgrade shall be a designated Witness Point.

201.03.14. Subgrade Replacement

Unstable areas of subgrade shall be excavated to the full extent and depth of the instability and replaced with
Select Fill, which shall be placed and compacted in accordance with the requirements of Clause 1.23.

201.03.15. Fill
Fill shall be constructed within the limits of earthworks at the locations and to the lines and levels shown on
the Drawings.

Fill shall be placed in layers essentially parallel to the finished surface with each layer not less than 75mm or
greater than 200mm in thickness and compacted to a dry density ratio of not less than the following:

Table 1 Compaction Requirements

Fill Material Specified Minimum Dry Compactive Effort
Density Ratio (SMDDR)
Select Fill 98% Modified

General Fill 95% Standard

The fill material shall be placed in the Works in layers of uniform thickness such that:

(i) the moisture content of the materials throughout the full depth of the layer is maintained during placing,
compaction and finishing within 1% of the moisture content at which maximum field compaction is
attainable for the material and the equipment being used

(ii) Where a compacted course 200mm or less in nominal thickness is required, the material shall be
placed and compacted in a single layer; when a nominal compacted course thickness in excess of
200mm is required, the material shall be placed and compacted in layers of approximately equal
thickness, but no layer shall be in excess of 200mm nominal thickness

(iii) the underlying layers are not disturbed during placing, compacting and trimming

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 201 Site Preparation And Eartworks

(iv) the least possible surface disturbance is necessary to obtain the design shape, grade and levels within
the tolerances specified

(v) segregation and contamination of the materials does not occur

(vi) the layer is at the finished level or it can be trimmed to level, shaped and smoothed by cutting off
excessive material and

(vii) the completed layer meets the specified density, thickness, surface level and surface shape
requirements for that layer.

Mixing and placing procedures or associated equipment used shall be adjusted, as necessary, to obtain the
finished surface levels within the allowable tolerances, to prevent segregation and degradation, and to reduce
or accelerate loss or gain of water.

Before each section is placed, any material at the end of the preceding section or at the edge of an abutting
area which, is segregated or contaminated shall be rejected and removed and disposed of in accordance with
the requirements of the Specification.

The edges of previously placed materials shall be watered to maintain the moisture content specified herein
for compaction prior to placement of adjoining material. The surface of the fill shall be watered as necessary
to maintain the required moisture content until completion of the compaction. Such watering shall not result in
the removal of the fines from the surface of the layer.

Fill layers shall not be constructed when the weather conditions are such that the moisture content cannot be
maintained within the specified limits during spreading and compaction. Any areas that are damaged by rainfall
or other weather conditions shall be reinstated to conform with the requirements of the Specification.

Where fill is to be placed against an existing slope steeper than one vertical to six horizontal, whether natural
or man-made, the existing slope shall be first stripped of topsoil to the minimum depth shown on the Drawings
or directed by the Engineer and then benched out as the fill proceeds at vertical intervals of not less than
200mm nor more than 500mm.

Filling in areas on which pavements or buildings or structures are to be constructed shall not commence until
the completion of proof rolling of the subgrade surface in accordance with Clause 201.03.13, ‘Subgrade
Preparation’.

Compaction of fill within one metre of footings, walls, slabs or other structures shall be by hand-held motorised
compaction equipment. Where fill is to be placed against both sides of footings, walls or other structures the
Contractor shall raise the fill on opposite sides of the structures equally and compact the fill simultaneously
with similar equipment. Where fill is to be placed against one side only of footings, walls or other structures the
Contractor shall support such structures to prevent overloading.

201.03.16. Surface Finishing

Upon the completion of all compaction, the surface of the fill shall be finished by lightly watering, and where
the surface is excessively high, by cutting down to the required level, and rolling with a pneumatic-tyred roller
ballasted such that the load is equally distributed to all wheels to achieve a wheel load of not less than two (2)
tonnes with the same tyre pressure in each tyre of not less than 750kPa.

Material cut from the surface of the fill shall be removed and stockpiled in a surplus stockpile.

The surface shall not be raised to the required level by the addition of thin layers of material. Areas below the
specified level shall be corrected prior to the subsequent layer being placed by removing material from the
surface where necessary and placing new material in layers having a compacted thickness of at least 100 mm.
When additional material is added it shall be placed, spread, compacted and finished in accordance with the
requirements of the Specification.

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 201 Site Preparation And Eartworks

201.03.17. Protection of Fill Surface

The surface of the fill and any underlying layers shall only be trafficked by vehicles and equipment essential
for the construction, repair and maintenance of the fill, and shall be kept to the minimum necessary. Any area
of fill that is damaged in any way by traffic shall be reinstated to conform with the requirements of the
Specification.

Finished Surface Level Tolerances

The completed earthwork formation shall be excavated or filled within the following tolerances above (plus) or
below (minus) the theoretical dimensions and or levels shown on the Drawings.

Horizontal Dimensions - plus 150mm, minus 0mm

(lengths, breadths, etc.)

Levels:
Fills - plus 0mm, minus 30mm
Excavation - plus 0mm, minus 50mm

Slopes and batters shall be neatly cut and trimmed to the respective slopes indicated and shall be carried
around curves in a uniform manner.

201.03.18. Topsoil placement

Topsoil shall be spread and compacted with a light roller or other approved method to the finished levels shown
on the Drawing. The roller’s weight shall nor exceed 100kg per metre width and topsoil shall be rolled in two
directions.

201.04. Quality Assurance

201.04.01. Pre-Commencement Phase
Supply of Information on Materials Sources
The following information shall be supplied for the Select Fill material:
• Location of source from which the material will be obtained
• Source rock type and petrographic description
• Atterberg limits and Grading.

A summary of the results of recent tests on samples of the material from the designated source indicating that
the material complies with all the requirements specified herein and endorsed by a laboratory registered for
the performance of such tests.

201.04.02. Production
Compaction
At the completion of compaction of each Lot of fill, the Contractor shall determine the in-situ moisture content
and the dry density ratio at random locations throughout the Lot.

A Lot of Fill is defined as a section in which all of the material has been obtained from the same source with
uniform properties, using the same production techniques and which has all been subjected to the same
handling, placing and compaction processes.

The rate of in-situ moisture content and field dry density testing shall be not less than one for each 1000m2 of
surface area of each layer.

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 201 Site Preparation And Eartworks

Each Lot to be tested shall be divided into subsections of approximately equal area. The number of subsections
shall be the same as the number of dry density determinations it is proposed to undertake. The location for each
dry density determination shall be determined randomly within each subsection.

The in-situ dry density shall be determined in accordance with the requirements of ASTM D4556 or some other
method accepted in writing by the Engineer.

Modified maximum dry density or Standard Maximum Dry Density determinations shall be made at a rate of
not less than one for each sixteen (16) field density determinations, in accordance with the requirements of
ASTM D1557 and ASTM D698, respectively.

Conformance of the Lot with the specified compaction requirements shall be assessed as follows:

If the average of the dry density ratio determinations for any Lot:

(a) equals or exceeds the specified minimum dry density ratio (SMDDR) and no individual density result
is less than SMDDR - 1%, then the Lot shall be considered as complying with the dry density
requirements

(b) equals or exceeds the specified minimum dry density ratio less 1% (i.e. SMDDR - 1%) and any
individual density result is less than SMDDR - 4%, then the Lot shall be further tested and the results
interpreted as in (d) below

(c) equals or is less than the specified minimum dry density ratio less 3% (i.e. SMDDR - 3%) then the Lot
shall be considered as not complying with the dry density requirements and shall be rejected

(d) is between the limits given in the preceding paragraphs (i.e. between 1 and 3% below the specified
minimum dry density ratio), then an additional four randomly located dry density determinations shall
be made in the lot in accordance with the requirements of the Specification. If the average of all the
dry density ratio determinations for that Lot:

(i) equals or exceeds the limit given in the preceding paragraph (a), then the Lot shall be
considered as complying with the dry density requirements

(ii) is less than the limit given in the preceding paragraph (a), then the Lot shall be considered as
not complying with the dry density requirements and shall be rejected.
Witness Point
The following Witness Point shall be incorporated into the Contractors Construction Program:

• Proof rolling of the prepared subgrade.

201.04.03. Post-Construction Phase

Finished Surface
The finished surface of the Fill shall conform to the grades and levels shown on the drawings within the
tolerances specified above.
Non-Conforming Materials and Work
All non-conforming materials and work shall be repaired or replaced so that the Works meet all the
requirements of this Specification.

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 202 Crushed Rock Pavement Courses

202 CRUSHED ROCK PAVEMENT COURSES

202.01. General
202.01.01. Scope
This Section specifies requirements for the supply of materials, spreading, compaction, trimming and finishing
of crushed rock pavement courses.

202.02. Materials
202.02.01. Laterite (Sub-Base) Material
The Laterite hardfill shall be laterite or other approved granular graded material free of any organic matter, silts
and clays or any other deleterious matter, which will cause it to weave when wet.

The maximum aggregate size shall be 80mm with a similar qradinq to that of the Basecourse material specified
in Section 202.02.02.

The CBR is to be greater than 30%. The material is' to be approved by the Engineer prior to construction.

202.02.02. Crushed Rock Basecourse Material

Basecourse material is to consist of a graded granular crushed rock aqqreqate with a crushinq resistance of
not less than 130 kN.

The grading limits shall be as follows:

Test sieve aperture Percentage Passing
37.5 mm 100
19 mm 66-81
9 mm 43-57
4.75 mm 28-43
2.36 mm 19-33
1.18 mm 12-35
600 pm 7-19
300 pm 3-14
150 pm 10 max
75 pm 7 max

The CBR for the basecourse material shall be greater than 80%. The basecourse material shall be tested for
size and CBR for approval by the Engineer.

After the subbase has been prepared and approved, place and compact basecourse to areas specified in the
drawings. The full depth of the basecourse layer is to be compacted to achieve not less than 95% of the
maximum dry density as determined by AASHTO test methods.

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 202 Crushed Rock Pavement Courses

202.03. Construction
202.03.01. Spreading
The first layer of pavement material shall be spread and compacted within 24 hours of final trimming and
compaction of the Formation.

The pavement material shall be spread in even and equal layers not more than 200mm in compacted
thickness. Each layer shall be spread and compacted before the next layer is spread.

Pavement material shall be spread by means which minimise segregation into fine and coarse components.
Where segregation does occur, the material shall be remixed and respread.

202.03.02. Compaction
Compaction shall commence immediately after the material is spread. Where necessary the Contractor shall
lightly water the material to maintain the moisture content within plus 0.5% and minus 1.0% of the optimum
moisture content. Material shall be compacted sufficiently to provide a dense surface by the time work ceases
at the end of each day. Material from unstable areas shall be removed, remixed and reconstituted to comply
with the material specification and then be replaced and recompacted before further layers are added.

During compaction the Contractor shall keep the surface shaped to the required profile free from ruts,
depressions, waves and isolated hard spots by use of power graders.

Each layer of sub-base and base course shall be compacted to a dry density ratio of not less than 98% using
Modified Compactive Effort.

202.03.03. Finishing
Crushed rock pavement courses consisting of one or more layers of the same material shall be finished to a
reasonably smooth and uniform surface and shall conform to the lines, grades, thicknesses and cross-sections
shown.

202.04. Quality Assurance

202.04.01. Pre-Commencement Phase
Supply of Information on Materials Sources
The following information shall be supplied for the base and sub-base materials:
• supplier and source of crushed rock
• source rock type and petrographic description
• proposed method of processing and transportation.

A summary of the results of recent tests on samples of the material from the designated source indicating that
the material complies with all the requirements specified herein and endorsed by a laboratory registered for
the performance of such tests.

202.04.02. Production and Process Control Phase

Layer Thickness
The Contractor shall measure the thickness of the compacted base and sub-base courses upon completion of
compaction and surface finishing by direct measurement or some other method acceptable to the
Superintendent. The frequency of thickness measurements shall be as for the dry density ratio determinations.

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 202 Crushed Rock Pavement Courses

Field dry density and thickness determinations may be performed at the same locations.

These measurements shall be recorded and included in the Quality Assurance records.

No part of the base or sub-base courses at any location shall have a thickness of less than 90% of the specified
thickness.

Compaction
At the completion of compaction of each Lot of the base and sub-base courses, the Contractor shall determine
the in-situ moisture content and the dry density ratio at random locations throughout the Lot. ,

A Lot of base and sub-base courses is defined as a section in which all of the material has been obtained from
the same source with uniform properties, using the same production techniques and which has all been
subjected to the same handling, placing and compaction processes.

The rate of in-situ moisture content and field dry density testing shall be not less than one for each 500m2 of
surface area of each layer.

Each Lot to be tested shall be divided into subsections of approximately equal area. The number of subsections
shall be the same as the number of dry density determinations it is- proposed to undertake. The location for
each dry density determination shall be determined randomly within each subsection.

The in-situ dry density shall be determined in accordance with the requirements of ASTM or some other method
accepted in writing by the Engineer.

Modified maximum dry density determinations shall be made at a rate of not less than one for each sixteen
(16) field density determinations.

The dry density ratio shall be determined in accordance with the requirements of ASTM using the appropriate
field dry density and modified maximum dry density determinations.

The Contractor shall determine the particle size distribution and Plasticity Index of a sample of the material
made by combining an equal representative portion of the material obtained from each Lot of each layer of
base and sub-base courses for the purpose of determining the field dry density in accordance with the
requirements ASTM.

Conformance of the Lot with the specified compaction requirements shall be assessed as follows:

If the average of the dry density ratio determinations for any Lot:

(a) equals or exceeds the specified minimum dry density ratio (SMDDR) and no individual density result is
less than SMDDR -1 %, then the Lot shall be considered as complying with the dry density requirements

(b) equals or exceeds the specified minimum dry density ratio less 1 % (i.e. SMDDR -1 %) and any individual
density result is less than SMDDR - 4%, then the Lot shall be further tested and the results interpreted
as in (d) below

(c) equals or is less than the specified minimum dry density ratio less 3% (i.e. SMDDR - 3%) then the Lot
shall be considered as not complying with the dry density requirements and shall be rejected

(d) is between the limits given in the preceding paragraphs (i.e. between 1 and 3% below the specified
minimum dry density ratio), then an additional four randomly located dry density determinations shall be
made in the lot in accordance with the requirements of the Specification. If the average of all the dry
density ratio determinations for that Lot:

(i) equals or exceeds the limit given in the preceding paragraph (a), then the Lot shall be
considered as complying with the dry density requirements

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 202 Crushed Rock Pavement Courses

(ii) is less than the limit given in the preceding paragraph (a), then the Lot shall be considered as
not complying with the dry density requirements and shall be rejected.

202.04.03. Post-Construction Phase

Surface Smoothness Testing
The surface smoothness of the completed base course shall be checked using a 3m long straight edge.

Surface irregularities that depart from the straight edge by more than 10mm shall constitute a non-conformance
and shall be clearly marked. c t.

Finished Surface Levels

The finished surface of the base and sub-base courses shall conform to the grades and levels specified and
shall not deviate at any point by more than:
• 0mm above or 10mm below for base course
• 10mm above for sub-base course.
from the design surface level shown on the Drawings.

Non-Conforming Materials and Work

All non-conforming materials and work shall be repaired or replaced so that the Works meet all the
requirements of this Specification.

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 203 Concrete Pavement

203 CONCRETE PAVEMENT

203.01. General
203.01.01. Scope
This Section specifies requirements for the supply of materials and construction of Portland cement concrete
pavements.

203.01.02. Standard r
All work shall comply with relevant sections of ACI 318M-89, Building Code Requirements for Reinforced
concrete, Revised 1992.

Reference specifications shall include:

ACI 318M-89 - Building Code Requirements for Reinforced Concrete, Revised 1992
ASTM C94 - Specification for Ready - Mixed Concrete
ASTM C150 - Specification for Portland Cement..
ASTM C33 - Specification for Concrete Aggregates

203.02. Materials
203.02.01. Composition
Concrete shall consist of fine and coarse aggregates, uniformly mixed with Portland cement and water.

203.02.02. Aggregate
Concrete aggregates shall consist of freshly crushed rock fragments and naturally occurring sand particles
meeting all the requirements of this Specification and each aggregate must:

(i) have been produced by crushing approved rock or processing approved sand
(ii) if a crushed aggregate, have been produced by crushing rock which is free from particles whose
minimum dimensions in any direction is less than 100mm, sand, disintegrated material, friable
material, weathered material, lumps or balls or clays, organic matter or other deleterious materials or
coatings,
(iii) contain no more than a total of 1.0% by mass or weathered, discoloured, soft, fractured, friable or
poorly indurated particles,
(iv) comply with the test limits and assessment procedures contained in this Specification.

If during the progress of the work, materials from other sources are proposed for use a written request shall
be submitted sufficiently in advance of the time when the other source is proposed to be used to permit
evaluation of the request.

Maximum aggregate size and grading shall be in accordance with ASTM C33 - “Specification for concrete
Aggregates”.
Coarse Aggregate
Coarse aggregate shall consist of unweathered, dense, sound, clean, hard, strong, durable pieces of crushed
rock free from deleterious coatings and dust and shall comply with all the requirements of ASTM C33 -
"Specification for Concrete Aggregates”.

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Fine Aggregate
Fine aggregate shall consist of clean, hard, strong, durable uncoated particles of natural sand or a combination
of natural and crushed sand free from weathered particles.

The proportion of natural sand combined with crushed sand shall be sufficient to ensure that concrete of
acceptable quality, workability and finish can be produced from the combined fine aggregate.

Particles of the fine aggregate shall be generally spherical or cubical in shape.

The fine aggregate and separate sizes of fine aggregate shall comply with all the requirements of ASTM C33
- “Specification for concrete Aggregates".

203.02.03. Water
Water for mixing and curing concrete shall be clean, fresh and free from injurious amounts of oil, acid, salt,
alkali, organic matter, or other deleterious substances. Water approved by Public Health Authorities for
domestic consumption will be accepted for use without being tested. Water of questionable quality shall be
tested prior to use in the work.

203.02.04. Admixtures
The use of any other admixtures to the concrete shall be subject to the approval of the Engineer.

203.02.05. Curing Materials

Membrane Curing Compounds
Membrane curing compounds shall be a white pigmented type. Wax based compounds shall not be used.
Impermeable Blankets
Impermeable blankets shall be:
(i) cotton or hessian backed white opaque polyethylene sheet, or
(ii) white opaque polyethylene sheeting, or
(iii) other approved waterproof sheeting
which shall be stitched or cemented together to make blankets at least one metre wider than the section being
placed and not less than 9m long.

The blankets shall be uniform in appearance, and free from all visible defects, tears, holes and shall comply
with the requirements of ASTM C.171.

The blankets shall have sufficient strength and weight to meet the required conditions of service.
Hessian Blankets
Hessian (or Burlap) mats shall consist of two or more layers of hessian having a combined weight of 0.5kg or
more per square metre in a dry condition and shall have a width after shrinkage at least 300mm greater than
necessary to cover the entire width and vertical faces of the pavement lane. They shall be new or have only
been used for curing concrete and shall be free from tears.

203.02.06. Reinforcement
Reinforcing shall comply with the following:
a) Deformed bar (DB) of grade SD-40 complying with TIS standard 24-2536
b) Plain round mild steel bar (RB) of grade SR-24 complying with TIS standard 20-2527
cT"

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 203 Concrete Pavement

203.02.07. Dowels
Unless otherwise specified on the drawings, dowels shall be plain steel and shall be one-piece, straight, bars
complying with TIS 20-2527 and of the sizes shown on the drawings. The dowels shall be cut to length at the
shop or mill prior to delivery to the site. The deformation from true shape of dowels shall not exceed 1mm on
the diameter of the dowel and shall not extend more than 1mm from the end of the dowel. Dowel bars which
have been cropped or sheared to length shall not be incorporated in the Works.

Ends of dowels shall be square and free from burrs. Dowels shall be clean and free from mill scale, loose rust
or soil.

203.02.08. Concrete
The concrete used in the work shall be ready-mixed concrete manufactured, supplied and delivered in
accordance with ACI 318M - 89, Clause 5.8.2. Ready-mixed concrete shall be delivered to the site in trucks
of the revolving drum type.

Concrete strength grade shall be as specified on the Drawings.

Maximum slumps shall not exceed the values stated in ASTM C 143.

Concrete shall not be placed or pumped without the Engineer’s prior approval of the mix design and placing
procedures.

All concrete shall be completely discharged within 60 minutes of the introduction the cement to either the
aggregate or the mixer. There shall be no addition of water or any other material to the concrete on the site.

203.03. Construction
203.03.01. Plant and Equipment
The plant and equipment items used in the Works shall be appropriate for the intended purpose and shall be
maintained in good and serviceable condition at all times during which they are operating.

203.03.02. Forms
General
Forms shall be designed and set to withstand handling and construction loads without warping, sagging or
damage, so that when they are stripped, the formed edge of the concrete is truly vertical (ie plumb).
Form Removal
Forms shall remain in place for at least 12 hours after the concrete has been placed. When conditions on the
site are such that the early strength gain of the concrete is delayed, the forms shall remain in place for such
longer period as may be required. Forms shall be removed without injuring the concrete, dowel bars or tie
bars. Bars or heavy tools shall not be used against the concrete in removing the forms. Any concrete damaged
in form removal shall be repaired promptly using a suitable method.

All arrises shall be removed from the top corner of the concrete immediately after form removal.

203.03.03. Reinforcement Fixing

Reinforcement shall be provided in the locations shown and shall be placed and securely held in its correct
position by the use of approved supports during the placing operation and until the concrete has hardened.

Reinforcement shall be terminated 75 to 80mm from dowelled contraction joints. Reinforcement shall terminate
at least 40mm and not more than 80mm from longitudinal construction joints, or pavement edges.

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203.03.04. Placing and Spreading

General
The area in which concrete is proposed to be placed shall be inspected and checked immediately prior to
commencement of placing. Concrete shall be placed within 60 minutes from the time of batching and before
the concrete has obtained its initial set. The temperature of the concrete as deposited in the forms shall be not
less than 10°C, nor more than 30°C.

Concrete shall be placed in such manner as to require a minimum of rehandling and shall be so distributed
that when compacted and finished, the slab thickness, surface shape and levels required by the Drawings will
be obtained. The placing of concrete shall be rapid and continuous between transverse construction joints.
Workmen with soil or foreign material on their footwear shall not be permitted to walk in the concrete during
placing and finishing operations.

During placing, the concrete shall not be allowed to drop freely by more than one metre onto the base of the
paving lane.

Placing and spreading shall not commence until all equipment for placing, spreading, compaction, finishing
and curing are at the paving site.

The concrete shall be placed in a manner so that the face of the placed concrete is generally vertical and
normal to the direction of the placing. Concrete shall be placed uniformly over the width of the slab or section
and in such manner as to minimise segregation. Concrete shall be spread to levels slightly above the required
finished surface so that when properly compacted and finished the surface of the concrete will be at the design
levels. All hand spreading of concrete shall be done with shovels, not rakes.

Placing of concrete against the face of an existing pavement shall not commence until all organic matter, soil
or other deleterious material which is adhering to the face has been removed.
Limitations on Placing Concrete
Placing of concrete shall not be permitted when heat, cold, wind, rain, low humidity, plant and equipment
defects, inadequate labour or any other reason prevent satisfactory placement and finishing of concrete.

203.03.05. Compaction
Compaction of concrete shall commence immediately after placing and shall be followed immediately by the
finishing operations.

All concrete including that adjacent to forms or existing concrete shall be compacted by internal mechanical
vibration.

The vibrators shall be capable of transmitting at least 3,500 cycles per minute when under load, and the
vibration shall be of sufficient amplitude to produce noticeable vibrations at 300mm radius from the vibrator.
The number of vibrators on site in full working order shall be not less than 1 per 7 cubic metres of concrete
placed per hour.

The vibrators shall be inserted into the concrete to such depth as will provide the best compaction, but not
deeper than 50mm above the surface of the base course. The vibrators shall be operated by slowly inserting
and withdrawing them vertically in a non-uniform pattern at a spacing of about 400mm or as directed. The
duration of vibration shall be sufficient to produce satisfactory compaction, but not longer than 30 seconds in
any one location. Vibrators shall not be used for pushing and spreading concrete.

Particular attention shall be paid to the vibration of concrete adjacent to forms and joints. Any honey-combing
in excess of 5% of a slab edge will be grounds for rejection of the placed concrete in that entire slab, and
removal and replacement of the slab.

The effective operation of the vibrators shall be checked frequently.

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203.03.06. Finishing
General
Finishing operations shall comprise scraping straight-edge finishing and broom finishing, in that order, and
shall be started immediately after compaction of the concrete and completed as soon as possible but not later
than 60 minutes from the time of batching and prior to the concrete attaining its initial set.

The finishing equipment and tools shall be maintained in a clean condition.

Scraping Straight-Edge Finishing

While the concrete is still plastic, minor irregularities and score marks in the pavement surface shall be
eliminated by means of hand operated long-handled scraping straight-edges used in conjunction with long
bladed, long handled, hand operated floats. The blades of the scraping straight-edges and floats shall be not
less than 3m long.

The straight-edges and floats shall be operated from the side of the paving section by drawing them across
the surface of the concrete towards and across the forms or slab edge. They shall maintain contact with the
surface at all times and shall be slightly angled so that they can be drawn across the form to avoid a depression
or ridge in the concrete adjacent to the form or slab edge.

When necessary, excess water and laitance shall be removed from the surface. The hand operated float shall
be used to smooth and fill in open textured areas in the pavement surface. The surface shall also be tested
for trueness with a 3m straight-edge held in successive positions parallel and at right angles to the centreline
of the pavement or any other direction and in contact with the surface and the whole area covered as necessary
to detect variations. The straight-edge shall be advanced along the pavement in successive stages of not more
than one-half the length of the straight-edge.

Any depressions found during straight-edge checking shall be filled with freshly mixed concrete, struck-off,
consolidated and refinished. Concrete used for filling depressions shall have all stones larger than nominal
20mm removed. Projections above the required level shall also be struck-off and refinished.

The straight-edge testing and finishing shall continue until the entire surface of the concrete is free from
observable departures from the straight-edge, conforms to the required grade and shape, and, when hardened,
will satisfy the surface requirements specified.

Broom Texturing
When most of the water glaze or sheen has disappeared and before the concrete becomes non-plastic, the
whole surface of the pavement shall be coarsely broomed in a direction at right angles to the direction of the
placing of the concrete. Brooms shall be at least 500mm wide with bristles of bass, nylon or flexible wire. At
least two (2) brooms shall be available at all times. Brooms shall be washed thoroughly and dried at frequent
intervals to prevent accumulation of dried mortar on the bristles. Brooming shall be from the edge of the paving
sectionor preferably from bridges. Brooming shall be undertaken continuously from edge to edge of the paving
lane.

Brooms shall be drawn in straight lines and successive strokes shall overlap about 50mm. The indentations in
the pavement surface shall be uniform in appearance and approximately 2mm in depth without dislodging
coarse aggregate particles.

203.03.07. Curing
General
Concrete shall be cured by protection against loss of moisture and rapid temperature changes for a period of
not less than 7 days from the completion of the finishing operations.

Curing shall comprise initial curing, moist curing and membrane curing.

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Application of curing medium shall commence on the sides of concrete slabs exposed by the removal of forms
as soon as possible and no longer than 30 minutes after removal of forms in order to provide the exposed
surfaces with continuous curing treatment.

Initial Curing
Immediately after the finishing operations have been completed and until the moist curing medium has been
applied, the surface of the concrete shall be kept continuously damp by means of water fog or mist applied
with approved spraying equipment.
Moist Curing
As soon as possible after the finishing operations have been completed and the concrete has set sufficiently
to prevent marring the surface, the forms and entire surface of the newly layed concrete shall be covered with
wetted hessian (burlap) or cotton mats. Cotton mats and hessian (burlap) strips shall have a width, after
shrinkage, at least 300mm greater than necessary to cover the entire width and faces of the pavement lane.
Provision shall be made to securely anchor the mats to ensure the mats remain in place in windy conditions.
The mats shall overlap each other at least 150mm.

The mats shall be saturated before placing and shall be kept continuously saturated and in intimate contact
with the pavement edges and surface for a period of not less than 24 hours and until the curing membrane is
applied.

Membrane Curing
The entire exposed surface of the concrete, including edges, shall be uniformly coated with an approved white
pigmented membrane curing compound. The concrete shall not be allowed to dry out before the application of
the membrane. If any initial drying has occurred, the surface of the concrete shall be moistened with a fog
spray of water.

The curing compound shall be applied to the finished surfaces by means of an approved mechanical spraying
machine. The curing compound spraying machine shall have a motor driven pump or compressed air unit to
provide displacement of the curing compound to the spray equipment. The machine shall be equipped with
spraying nozzles that can be controlled and operated so as to completely and uniformly cover the pavement
surface with the required amount of curing compound.

The curing compound in the storage drum used for the spraying operation shall be thoroughly and continuously
agitated mechanically throughout the full depth of the drum during the application. Air agitation may be used
only to supplement mechanical agitation.

Spraying pressure shall be sufficient to produce a fine spray and cover the surface thoroughly and completely
with a uniform film. Spraying equipment shall be maintained in first class mechanical condition, and the spray
nozzles shall be provided with an adequate wind guard.

The curing compound shall be applied in two applications at a total coverage of not less than 0.5 litres per
square metre. Each application of curing membrane shall be applied to the pavement in opposing directions
at a rate of not less than 0.25 litres per square metre.

The compound shall form a uniform continuous, cohesive film that will not check, crack or peel, and that will
be free from pin holes and other imperfections. If discontinuities, pin holes, or abrasions exist, an additional
coat shall be applied to the affected areas within 30 minutes. Concrete surfaces that are subjected to heavy
rainfall within 3 hours after the curing compound has been applied shall be resprayed by the method and at
the coverage specified above, at no additional cost to the Corporation.

In the event of mechanical failure of the spraying machine, either moist curing blankets or impermeable blanket
curing shall be used.

Concrete surfaces to which membrane curing compounds have been applied shall be adequately protected
until the end of the curing period. Any damage to the curing membrane due to joint sawing operations, if used;

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 203 Concrete Pavement

or surface tests, or any other cause which reduces the efficiency of the membrane, shall be immediately
repaired by further application of the membrane curing compounds as specified.
Impermeable Blanket Curing
If the concrete is constructed during weather conditions which cause rapid temperature fluctuations in the
curing concrete, impermeable blanket curing shall be used.

203.03.08. Joints
General
All joints shall conform to the details and shall be constructed in the locations shown on the Drawings.
Transverse and longitudinal joints shall be straight and perpendicular to one another, continuous from edge to
edge of the pavement throughout all paving sections that are connected in a single paved area, except where
shown otherwise on the Drawings.

Construction Joints
Wherever concrete placing has stopped, and concrete has taken its initial set, this joint shall be deemed a
construction joint. The location and detail of construction joints shall be as be as required or approved by the
Engineer. Dowels shall be installed in the longitudinal construction joints as required in accordance with the
details shown on the Drawings, and in accordance with the sub-clause “Dowel Bars”...

Before placing new concrete against concrete which has set, the forms shall be tightened and the surface of
the set concrete shall be roughened, cleaned of foreign matter, laitance and loose or porous material. The
surface shall be covered uniformly with a thin coat of cement grout and concreting shall proceed immediately.

Transverse Contraction Joints

Transverse contraction joints shall be sawn where indicated and detailed on the Drawings.

The width of the joint shall be nominally 3mm wide and shall be sawn to a depth as shown on drawings.

Sawing of contraction joints shall be carried out as soon as the concrete has attained sufficient strength to
enable sawing without tearing the surface and prior to the concrete gaining a strength such that uncontrolled
cracking occurs. Delays in sawing the transverse contraction joints will not be allowed. Sufficient sawing
equipment including one complete standby unit shall be maintained on site in working condition at all times.

The suitability of the newly completed concrete for sawing shall be continuously monitored as the anticipated
time for commencement of sawing approaches.

Since time is of the essence, alternate or third joints may be cut initially, or additional sawing equipment may
be used simultaneously, to avoid exceeding the available time for this critical operation.

Sealing of Joints
Sawn joints shall, unless otherwise specified in the Drawings or approved by the Engineer, be sealed with Dow
Corning 888, silicone joint sealant or an approved equivalent.

Dowel Bars
Dowel bars shall be prepared and placed across joints where shown on the Drawings, correctly aligned, and
securely held parallel to the surface of the finished pavement, and at right angles to the joint in plan view during
placing and finishing operations.

Dowel bars shall be placed by the bonded-in-place method, whereby they are embedded in the freshly placed
concrete. Installation by removing and replacing dowel bars in preformed holes, including their withdrawal to
assist in form stripping, will not be permitted.

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The spacing and vertical location of dowel bars shall be as specified on the Drawings. The following tolerances
shall not be exceeded:

Horizontal Location: +6mm

Vertical Location: +6mm

The spacing of dowel bars in longitudinal construction joints shall be as indicated on the Drawings except that
where the planned spacing cannot be maintained because of form length or interference with form braces,
closer spacing with additional dowel bars shall be used. Dowel bars in longitudinal joints shall be omitted when
the centre of the bar would be located within, a horizontal distance from a transverse joint equal to three
quarters of the slab thickness, but not further than 200mm from the transverse joint.

Dowel bars in longitudinal and transverse construction joints shall be held securely in place by means of
approved devices fastened to the forms. The unpainted ends of dowels shall be installed in the initially placed
section.

The method used in holding dowels in position shall develop such accuracy that the error in alignment of any
dowel from its fixed position after the pavement has been finished shall not be greater than 3mm. This method
shall also ensure that any two consecutive dowel bars are parallel with each other within a tolerance of 3mm.
An approved template shall be used for checking the position of the dowels.

The portion of each dowel intended to move in the concrete, including the dowel end, shall be clean and free
from oil, grease, loose rust, and other foreign material and shall be painted with two coats of bituminous
emulsion prior to placing concrete.

The unpainted portion of all dowel bars shall be clean and free from oil, grease, loose rust, and other foreign
material when the concrete is placed to permit maximum bonding with the concrete.

203.03.09. Protection of Plastic and Hardened Concrete Pavement

The pavement shall be protected against all damage during the period that the site is occupied. Traffic shall
be excluded from the pavement by erecting and maintaining barricades and signs until the concrete is at least
7 days old, or for a longer period if necessary to prevent damage. Irrespective of age, trafficking of pavements
by tracked or steel wheeled equipment shall only be permitted if protective matting or timbers are placed under
their wheels or tracks.

As a construction expedient in paving intermediate lanes between newly paved lanes, operation of concrete
transport vehicles will be permitted on the pavement after the concrete has been cured for seven days,
provided:

(a) evidence that the concrete strength is in excess of the stress developed by the construction equipment

(b) the joints have been sealed or otherwise protected and

(c) all foreign matter including aggregates and concrete are progressively and continuously removed from
the area over which traffic is moving.

Upon completion of the new section of concrete and on the same day, the surface of adjacent concrete on
which equipment has operated, shall be cleaned and barricades replaced.

Concrete finishing equipment and similar equipment may be permitted to ride upon the edges of previously
constructed slabs provided the concrete is more than 72 hours old and has attained a minimum compressive
strength of 25MPa, and provided further that adequate means are furnished to prevent damage to the slab
edge, and no damage whatsoever to the completed pavement.

The pavement carrying traffic or equipment shall be kept continuously clean using power brooms or suction
cleaners, and all spillage of materials or concrete shall be cleaned up immediately upon occurrence.

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 203 Concrete Pavement

Membrane curing shall be used on such pavements and any breaks or tears in the membrane shall be repaired
by re-application of the membrane curing compound.

203.03.10. Construction Requirements

Pavement Thickness
The concrete pavement shall not be less than the thickness shown on the drawings.

Finished Surface Levels

The finished surface levels on the concrete shall be within the tolerance of plus 7mm, minus 5mm of the
specified<or interpolated design level, and the surface of the concrete pavement shall not pond water.

Surface Shape
The finished surface of all concrete pavement shall not deviate from the testing edge of a 3m straight edge by
more than 5mm.

203.04. Quality Assurance

203.04.01. Pre-Commencement Phase
Supply of Information on Materials Sources
The following information shall be supplied for the concrete:
• The supplier of the concrete
• Location of the ready mix concrete plant
• A statement providing details of the concrete mix to be used.

203.04.02. Production and Process Control Phase

Slump
Concrete shall be tested for slump in accordance with the requirements of ASTM C 143.

A slump test shall be taken immediately concreting commences and at all other times when compression test
samples are taken, or directed by the Engineer.

Strength of Concrete
Concrete tests shall be carried out in accordance with ASTM C39 -Test Methods for Compressive strength of
Cylindrical Concrete Specimens.

At commencement of concreting, six preliminary cylinder tests shall be made for each mix type. Three cylinders
shall be tested at 7 days and three at 28 days.

For each 150m3 of concrete batched (or less), nine cylinder tests shall be taken with three cylinders each
tested at 7 days, 14 days and 28 days.

203.04.03. Post-Construction Phase

Finished Surface Levels
The finished surface of the concrete shall conform to the grades and levels specified within the tolerances
specified in the above sub clause.

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 203 Concrete Pavement

Surface Shape
The finished surface of the concrete shall conform to the specified tolerances in the above sub clause.

Non-Conforming Materials and Work

All non-conforming materials and work shall be repaired or replaced so that the Works meet all the
requirements of this Specification.

t c f I c <

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 204 Concrete for Siteworks

204 CONCRETE FOR SITEWORKS

204.01. General
204.01.01. Scope
This Section specifies requirements for supplying and placing Portland Cement concrete for miscellaneous
sitework structures such as pits, kerbing, minor footings, headwalls or similar.

204.01.02. Standard
All work shall comply with relevant sections of ACI 318M-89, Building Code Requirements for Reinforced
concrete, Revised 1992.

Reference specifications shall include:

ACI 318M-89 - Building Code Requirements for Reinforced Concrete, Revised 1992
ASTM C94 - Specification for Ready - Mixed Concrete
ASTM C150 - Specification for Portland Cement
ASTM C33 - Specification for Concrete Aggregates

204.02. Materials
204.02.01. General
Cement shall be normal Portland Cement complying with ASTM C150.

Maximum aggregate size and grading shall be in accordance with ASTM C33 - “Specification for concrete
Aggregates’’.

Ready Mixed Concrete shall comply with the requirements of ASTM C94.

Reinforcing shall comply with the following:

a) Deformed bar (DB) of grade SD-40 complying with TIS standard 24-2536
b) Plain round mild steel bar (RB) of grade SR-24 complying with TIS standard 20-2527.
and shall be thoroughly cleaned of rust, scale and any other coating which may destroy bond with the concrete.

Cement grout shall consist of cement and water mixed to form a creamy consistency.

204.02.02. Concrete Properties

The concrete used in the work shall be ready-mixed concrete manufactured, supplied and delivered in
accordance with ASTM C94. Ready-mixed concrete shall be delivered to the site in trucks of the revolving
drum type.
The concrete shall comply with the following requirements:
• Slump 100mm (unless otherwise specified)
• Nominal maximum aggregate size 20mm
• Suitable for placement by manual methods
'S
• Subject to production assessment of strength.

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 204 Concrete for Siteworks

All concrete shall be completely discharged within 60 minutes of the introduction of the cement to either the
aggregate or the mixer. There shall be no addition of water or any other material to the concrete on the site.

204.02.03. Water
Water for mixing and curing concrete shall be clean, fresh and free from injurious amounts of oil, acid, salt,
alkali, organic matter, or other deleterious substances. Water approved by Public Health Authorities for
domestic consumption will be accepted for use without being tested. Water of questionable quality shall be
tested prior to use in the work.

204.02.04. Admixtures
The use of any other admixtures to the concrete shall be subject to the approval of the Engineer.

204.03. Construction
204.03.01. General
Concrete work shall be constructed accurately in locations and to the dimensions and details shown.

204.03.02. Formwork
The design, fabrication, erection and strutting of formwork and falsework shall be in accordance with the
requirements of ACI 318M-89, Clause 6.1 and 6.2.

Formwork shall conform to the shape, lines, levels and dimensions required in the finished structure and shall
be constructed of approved timber or metal. Forms shall be clean, substantial and the inside left clean, smooth,
watertight and of sufficient strength to resist springing out of shape during and after the placing of concrete.

Dirt, chips, sawdust, nails or other foreign material shall be completely removed before any concrete is
deposited. Before concrete is placed in forms, inside surfaces of the forms shall be thoroughly coated with oil
or other approved agent which will permit the ready release of the forms and will not discolour or damage the
concrete.

Unless otherwise shown, forms shall be chamfered for re-entrant angles and filleted for corners. The face of
the bevel in each case shall be 20mm. Core holes and embedded items shall be installed where shown.

The formwork for each monolithic section of the work shall be completely constructed before concreting of that
section is commenced.

Immediately before placing concrete, the forms shall be thoroughly wetted with water. Forms shall not be
removed until the concrete has adequately hardened.

204.03.03. Placing of Reinforcement

Reinforcement shall be formed to the dimension and shapes shown in accordance with the requirements of
ACI 318M-89, Clause 5.10. Reinforcement shall be accurately placed in the positions shown and shall be
securely held in position by wiring or blocking from the forms and wired together at alternate intersections with
annealed iron wire of not less than 1.6mm diameter so that it will not be displaced during the placing and
compacting of concrete. Welding, tack welding or heating of reinforcement is prohibited.

Metal supports which extend to the surface of the concrete and wooden supports shall not be used. Placing
bars on layers of fresh concrete as the work progresses and adjusting bars during placing of concrete shall
not be permitted. Where necessary the reinforcement shall be spliced with the following minimum lap:

• Steel reinforcement - 40 times nominal diameter of bar.

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 204 Concrete for Siteworks

Unless otherwise shown on the drawings, the minimum clear cover to reinforcement shall be 1.5 times the
diameter of the bars with a minimum of 30mm.

204.03.04. Placing of Concrete

Concrete shall be transported and placed in accordance with the requirements of ACI 318M-89.

Concrete shall be placed continuously against fresh concrete between approved or specified construction
joints to form a monolithic section. Concrete shall be deposited as nearly as practicable in its final position.
Free dropping of concrete from a height greater than 1 metre or depositing a large quantity to be worked along
the forms for excessive distances shall not be permitted. Concrete shall be placed and compacted in such a
manner as not to displace any reinforcement.

Concrete which has developed its initial set, or which is not placed in the forms and compacted within 20
minutes after discharge from the mixer, or which has been contaminated by foreign materials, shall not be
used.

Placing of concrete shall not be commenced while the ambient air temperature is less than 10°C or higher
than 30°C without prior approval from the Superintendent.

204.03.05. Compaction of Concrete

During and immediately after placing, concrete in formwork shall be compacted with approved high frequency
internal vibrators and tamped. Finished concrete shall fill formwork with a dense homogenous mixture entirely
free of voids.

Sufficient vibrators, including standby vibrators, shall be available on the site prior to the commencement of
concreting. Vibrations shall not be applied directly or through the reinforcement to sections or layers of concrete
which have hardened to the degree that the concrete ceases to be plastic under vibration. Vibration shall be
of sufficient duration and intensity to thoroughly compact the concrete but shall not be continued so as to cause
segregation.

204.03.06. Construction Joints

Construction joints shall conform with ACI 318M-89, Clause 6.4.

Wherever concrete placing has stopped, and concrete has taken its initial set, this joint shall be deemed a
construction joint. The location and detail of construction joints shall be as required or approved by the
Superintendent.

In the event of any emergency necessitating a special construction joint, mixing and concreting shall proceed
until a location for the special construction joint approved by the Superintendent is reached. The placing of
concrete shall proceed continuously from joint to joint.

Before placing new concrete against concrete which has set, the forms shall be tightened and the surface of the
set concrete shall be roughened, cleaned of foreign matter, laitance and loose or porous material. The surface
shall be covered uniformly with a thin coat of cement grout and concreting shall proceed immediately.

204.03.07. Protection and Curing

Exposed faces of freshly placed concrete shall be protected against loss of moisture or damage by rain, by
covering with polythene film, wet hessian or other approved material, immediately following the finishing
operation. The protection shall be maintained in place for a curing period of seven days, unless a shorter
period is authorised by the Superintendent. Concrete surfaces not covered shall be kept moist by flushing or
sprinkling.

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 205 Stormwater Drainage

205 STORMWATER DRAINAGE

205.01. General
205.01.01. Scope
This Section specifies requirements for supply of all materials, excavation, installation of drainage pipes,
construction of pits and other drainage structures and backfilling necessary to construct the stormwater
drainage system.

205.02. Materials
205.02.01. Concrete Pipes
Reinforced concrete pipe shall comply with TIS 128-2528.
Pipes under Landscape areas shall be class 3. Pipes under roads shall be class 2.

205.02.02. Bedding and Backfill Materials

Bedding material shall be a crushed rock complying with the following grading:
Sieve Size (mm) Percent Passing (%)

Backfill material under pavements shall be Crushed Rock in accordance with Section 202.02.02. Backfill
material under landscape zones shall be General Fill that is free from perishable matter.

205.02.03. Concrete
Concrete for other than pipes shall comply with the requirements of Section 0 - Concrete for Siteworks.

Concrete shall have a cylinder strength of f’c = 25 MPa at 28 days.

205.02.04. Reinforcement
Reinforcing other than for pipes shall comply with the following:
a) Deformed bar (DB) of grade SD-40 complying with TIS standard 24-2536
b) Plain round mild steel bar (RB) of grade SR-24 complying with TIS standard 20-2527.

205.03. Construction
205.03.01. Excavation
Excavation for pipe trenches, pits and other drainage structures shall be carried out accurately to the lines,
levels and grades required in whatever materials or conditions are encountered.

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 205 Stormwater Drainage

Pipe trenches shall be excavated to a vertical-sided rectangular cross-section extending at least 600mm above
the barrel of the pipe or to formation level whichever is the lesser.

The minimum width of vertically-sided trenches shall be the outside diameter of the pipe plus 300mm or 600mm
total, whichever is the greater. In no case shall the clear width of vertically-sided trench exceed the above
minimum by more than ten percent.

Where pipes are to be placed in or under fills, the fill shall be constructed to a height of at least 600mm above
the barrel of the pipe or to formation level whichever is the lesser before the pipe trench is excavated.
No trench shall be opened up until sufficient pipe sections are on the site ready for laying.
< C V (. c

205.03.02. Pipe Bedding

Bedding material shall be provided and placed for the full width of the trench. The compacted thickness of
bedding material following any shaping necessary shall be not less than:
100mm where D < 1500mm
200mm where D > 1500mm
where D is the nominal pipe diameter or culvert height.

When the pipe sections are in position, an additional layer of bedding material shall be placed to a height equal
to 30% of the nominal pipe diameter. This material shall be placed between the pipe and the outer limits of the
lower layers of bedding and shall be compacted to a dry density ratio of not less than 95% using Modified
Compactive Effort.

205.03.03. Pipe Laying

Pipe laying shall commence at the downstream end of the work. Pipe sockets and rebates shall point upstream.
All pipes shall be layed separately and the barrel shall bear evenly on a prepared bedding. Where required,
socket holes shall be cut into the bedding of such size and depth as to allow the joints to be properly made.

Pipes shall be layed accurately to the lines, levels and gradients shown on the Drawings and with the top
uppermost where indicated by the manufacturer. Any pipes not layed within 10mm of the design invert level
and 25mm of the correct alignment shall be removed and relaid. The maximum tolerance in relative gradient
or alignment of adjacent pipes shall be 3mm per pipe length.

Holes provided for lifting or handling purposes shall be plugged with concrete plugs and damage done to pipes
in handling shall be made good to the approval of the Superintendent. Any pipes damaged beyond repair shall
be removed from the Works.

On completion of each drainage line, all pipes shall be free from dirt, debris, mortar droppings or other
impediments to the free and uninterrupted flow of water.

To allow for pits, manholes, bends, junctions and other pipes being constructed in the required positions, pipes
shall be cut where necessary. Cut pipes shall be finished to a smooth surface by sawing or by rendering the
chipped surface with render.

Properly fitting stoppers shall be provided and used to close the ends of all uncompleted pipelines. The
stoppers shall be removed only when additional pipes are to be laid and jointed.

205.03.04. Drainage Pits

Cast in place reinforced concrete pits shall be constructed in accordance with the Drawings

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 205 Stormwater Drainage

205.03.05. Backfilling
Under pavements the trench shall be backfilled with Crushed Rock. Under landscape areas the trench shall
be backfilled with general fill material. Backfilling shall be placed, spread and compacted in even layers, not
exceeding 150mm uncompacted thickness. Backfill under pavements shall be compacted to a dry density ratio
of not less than 95% using modified compactive effort. General fill shall be compacted to a dry density ratio of
not less than 98% using standard compactive effort.

During filling, the maximum difference between filling placed on opposite sides of the culvert shall not exceed
one-quarter the height of the culvert or 0.5m, whichever is the lesser.

Filling shall not be placed within 2m of an exposed culvert end where a further section is to be placed.
( ( C (

205.04. Quality Assurance

205.04.01. Production and Process Control Phase
Concrete Pipes
Pipes shall be laid true to the alignments and grades shown within the following tolerances:
± 5mm in level
± 10mm in line
Any defects in the pipes, discrepancies in levels or alignment in excess of the allowable tolerances, and
defective joints shall be corrected.
Bedding and Backfilling
The Contractor shall test the bedding and backfill material at the following minimum frequency:

Compaction
One field density test shall be taken per 300mm depth for each 100m of the trench bedding and backfill placed.

Hold Point
The following Hold Point shall be incorporated into the Contractor’s Construction Program.

• Following completion of laying of the pipe/culvert and prior to any backfilling.

205.04.02. Post-Construction Phase

As-Constructed Details
An as-constructed survey of the stormwater drainage system shall be submitted to the Engineer.
The survey shall detail the following:
• Location and cover level of pits.
• Invert level of pipes.
Non-Conforming Materials and Work
All non-conforming materials and work shall be repaired or replaced so that the Works meet all the
requirements of this Specification.

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 206 Signage & Painting

206 SIGNAGE & PAINTING

206.01. Signage
Supply signage in accordance with the details shown in the drawings (by others).

The method of fixing the signs, in the locations specified, shall be agreed with the Engineer before work
proceeds.

Shop drawings of the signage fixings to any structures shall be submitted to the Engineer.

206.02. Painting
The traffic marking paint on all exposed pavement areas shall be Reflectorised, Thermoplastic paint. The
colour to be confirmed by the Engineer.

On all specified concrete kerbs, barriers and paved areas under the building, the marking paint shall be Gloss
Enamel-in accordance with BS 4800:1989.

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 207 Pavement Marking

207 PAVEMENT MARKING

This work consists of applying paint, markings, and markers on finished pavement.

207.01. General
Where existing and final pavement marking locations are identical, stake the limits of existing pavement
markings before beginning pavement work.
Submit manufacturer’s MSDS and product data sheets at least 7 days before applying pavement markings. A
field demonstration may be required to verify the adequacy of the material.
Ship marking material in suitable containers plainly marked with the following information as appropriate for
the material being furnished:
• Manufacturer’s name and address
• Name of product
• Lot and batch numbers
• Color
• Net mass and volume of contents
• Date of manufacture
• Date of expiration
• Statement of contents (if mixing of components is required)
• Mixing proportions and instructions and
• Safety information.

Establish marking patterns or locations according to plans, or local authority requirements. In curve widening
areas, establish the edge line markings at the limits of the travelled way and the centreline markings equal
distance between the edge lines.
Remove loose particles, dirt, tar, grease, and other deleterious material from the surface to be marked. Where
markings are placed on rigid pavement less than 1-year old, clean the pavement of laitance and curing
compounds.
Obtain approval before applying markings. Apply markings to a clean, dry surface, and according to the
manufacturer’s recommendations. Produce markings that are clean-cut and uniform in appearance by day and
night.
Current state approved pavement marking material may be used, when approved by the Employer. Submit
proof of compliance with specifications.
Apply glass beads immediately following paint or markings application to ensure adhesion.
Protect markings from traffic until dried to a no-tracking condition. Remove tracking marks, spilled marking
material, markings in unauthorized areas, and defective markings.

207.02. Pavement Markings

Thermoplastic Markings. Apply thermoplastic when pavement and air temperatures not lower than 10 °C
and rising. Heat thermoplastic as specified by the manufacturer.
Apply an epoxy resin primer/sealer according to the thermoplastic manufacturer’s recommendations when
placing markings on rigid pavements or asphalt pavements more than 2-years old, oxidized, or having exposed
aggregates.
Allow the primer/sealer to dry.

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 207 Pavement Marking

For edge lines, apply thermoplastic at 1.5 millimetres dry film thickness. For other lines, apply thermoplastic at
2.3 millimetres dry film thickness.
Apply Type 1 glass beads (AASHTO M 247) on the thermoplastic at a rate recommended by the manufacturer.

207.03. Materials
Thermoplastic Markings. Conform to AASHTO M 249.
Glass Beads. Conform to AASHTO M 247 for the type specified. Treat glass beads with an adherence coating
as recommended by manufacturer.
Epoxy Resin Adhesives. Furnish epoxy resin adhesives conforming to AASHTO M 237 for bonding traffic
markers to rigid and asphalt concrete pavements.

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