Standard Specs - Subbase, Road Base and Gravel

Standard Technical Specification - 2002
Series 5000: Subbase Road Base And Gravel Wearing Course Table of Content
SERIES 5000: SUBBASE ROAD BASE AND GRAVEL WEARING COURSE

TABLE OF CONTENT
TABLES AND FIGURES................................................................................................................. 6 DIVISION 5100: SUB-BASES ....................................................................................................... 7 5101 Scope..................................................................................................................................7 5102 Materials.............................................................................................................................7 5103 Material Sources for Sub-Bases.........................................................................................7 5104 Material Requirements For Gravel Sub-Base ..................................................................7 (a) General......................................................................................................................7 (b) Grading Limits..........................................................................................................7 (c) Grading Modulus......................................................................................................8 (d) Plasticity Index .........................................................................................................8 (e) Californian Bearing Ratio (CBR) .............................................................................8 (f) Compaction requirements.........................................................................................8 (g) Los Angeles Abrasion ..............................................................................................9 5105 Material Requirements For Crushed Stone Sub-Base........................................................9 (a) General......................................................................................................................9 (b) Grading Limits..........................................................................................................9 (c) Grading Modulus....................................................................................................10 (d) Plasticity Index (PI) ................................................................................................10 (e) Compaction Requirements .....................................................................................10 (f) Los Angeles Abrasion ............................................................................................10 (g) Particle shape; Flakiness Index ..............................................................................10 5106 Construction Requirements For Sub-Bases Using Recycled Material ............................10 (a) General....................................................................................................................10 (b) Milling/Scarifying ..................................................................................................10 (c) Placing, Spreading and Compacting.......................................................................11 5107 Construction Requirements..............................................................................................11 (a) General....................................................................................................................11 (b) Stabilization............................................................................................................11 (c) Trial Areas ..............................................................................................................11 (d) Traffic on Sub-base ................................................................................................11 5108 Protection and Maintenance.............................................................................................12 5109 Sub-Base as a Filter or Separating Layer.........................................................................12 5110 Classification of Layers for Payment Purposes ...............................................................12 5111 Construction Tolerances ..................................................................................................12 (a) Levels .....................................................................................................................12 (b) Width ......................................................................................................................13 (c) Thickness ................................................................................................................13
Ethiopian Roads Authority
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Standard Technical Specification -2002
(d) Cross Section.......................................................................................................... 13 5112 Testing ............................................................................................................................. 13 (a) Process Control ...................................................................................................... 13 (b) Routine Inspection and Testing.............................................................................. 13 5113 Measurement And Payment ............................................................................................ 14 Item 51.01 Sub-base layer constructed from gravel or Crushed stone:.......................... 14 Item 51.02 Extra over Pay item 51.01 for excavation of material in: ............................ 15 Item 51.03 Sub-base layer constructed from gravel or crushed stone obtained from existing pavement layers:....................................................................................... 15 Item 51.04 In situ reconstruction of existing Sub-base layer as:.................................... 16 Item 51.05 Sub-base layer constructed Extra over Pay item 51.03 (a),(b),(c)&(d) and Pay item 51.04 (a),(b)&(c) from recovered pavement material mixed with existing bituminous surfacing material................................................................................ 17 Item 51.06 Extra over Pay item 51.04 for adding extra material ................................... 17 Item 51.07 Extra over Pay item 51.04 for blading the material to windrow.................. 18 Item 51.08 Extra over Pay item 51.03 for excavating material in existing pavement layers in restricted areas ......................................................................................... 18 Item 51.09 Compacting the floors of pavement excavations ......................................... 18 Item 51.10 Watering the pavement excavation floor ..................................................... 19 Item 51.11 Variations in the number of roller passes applicable to pay item 51.09 ...... 19 Item 51.12 Extra over Pay item 51.09 for compacting pavement excavation floor in restricted areas........................................................................................................ 19 DIVISION 5200: ROAD BASES ...................................................................................................20 5201 Scope ............................................................................................................................... 20 5202 Dimensions ...................................................................................................................... 20 5203 Materials .......................................................................................................................... 20 (a) Sources of Material ................................................................................................ 20 (b) Road Base Material Types ..................................................................................... 20 5204 Material Requirements For Crushed Rock Or Stone....................................................... 20 (a) General ................................................................................................................... 20 (b) Grading................................................................................................................... 20 (c) Plasticity Index....................................................................................................... 21 (d) Californian Bearing Ratio (CBR) .......................................................................... 21 (e) Aggregate Crushing Value (ACV)......................................................................... 21 (f) Mechanical Strength Requirements(TFVT)........................................................... 21 (g) Flakiness Index ...................................................................................................... 22 5205 Material Requirements for Naturally Occurring Granular Materials .............................. 22 (a) General ................................................................................................................... 22 (b) Grading................................................................................................................... 22 (c) Plasticity Index....................................................................................................... 23 (d) Californian Bearing Ratio (CBR) .......................................................................... 23 (e) Aggregate Crushing Value (ACV)......................................................................... 23 (f) Abrasion ................................................................................................................. 23 (g) Flakiness Index ...................................................................................................... 23 (h) Crushed Ratio......................................................................................................... 24 (i) Grading Modulus ................................................................................................... 24 5206 Material Requirements for Dense Bitumen Macadam .................................................... 24 (a) Coarse Aggregates ................................................................................................. 24
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(b) Fine Aggregate .......................................................................................................25 (c) Filler .......................................................................................................................25 (d) Binder .....................................................................................................................25 5207 Material Requirements For Mixed Bitumen Macadam ...................................................25 (a) Combined Aggregate Grading................................................................................25 (b) Mix Design Parameters for Dense Bitumen Macadam ..........................................26 5208 Construction Requirements For Crushed Rock And Crushed Boulder Road Bases........27 (a) Equipment...............................................................................................................27 (b) Placing and Compaction.........................................................................................27 (c) Stabilization............................................................................................................28 (d) Trial Sections..........................................................................................................28 (e) Traffic on Road base...............................................................................................28 5209 Construction Requirements For Crushed Gravel Road Base...........................................29 (a) Equipment...............................................................................................................29 (b) Placing and Compaction.........................................................................................29 (c) Stabilization............................................................................................................30 (d) Trial Sections..........................................................................................................30 (e) Traffic on Road Base..............................................................................................30 5210 Construction Requirements For Dense Bitumen Macadam Road Base ..........................30 (a) Equipment...............................................................................................................30 (b) Placing and Compaction.........................................................................................31 (c) Trial Sections..........................................................................................................32 (d) Traffic on Road Base..............................................................................................32 (e) Weather Limitations ...............................................................................................33 5211 Construction Tolerances ..................................................................................................33 (a) Level and Grade......................................................................................................33 (b) Width ......................................................................................................................33 (c) Thickness ................................................................................................................33 (d) Cross Section ..........................................................................................................34 5212 Measurement And Payment .............................................................................................34 Item 52.01 Base layer construction.................................................................................34 Item 52.02 Extra over Pay Item 52.1 for excavation of material....................................35 Item 52.03 Base layer constructed from from existing pavement layers........................35 Item 52.04 In situ reconstruction of existing base layer ................................................37 Item 52.05 Extra over Pay item 52.04 for adding extra material....................................38 Item 52.06 Extra over Pay item 52.04 for t blading the material to windrow ................39 Item 52.07 Extra over Pay item 52.03 for excavating material in existing pavement layers in restricted areas: ........................................................................................39 Item 52.08 Compacting the floors of pavement excavations..........................................39 Item 52.09 Watering the pavement excavation floor......................................................40 Item 52.10 Variations in the number of roller passes applicable to pay item 52.08.......40 Item 52.11 Extra over Pay item 52.08 for compacting pavement excavation floor in restricted areas ........................................................................................................40 Item 52.12 Trial Sections..............................................................................................40 Note on additional Pay Items....................................................................................................41 DIVISION 5300: BREAKING UP EXISTING PAVEMENT LAYERS ............................................... 42 5301 Scope................................................................................................................................42 5302 Selecting The Material .....................................................................................................42
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5303 Classifying The Material ................................................................................................. 42 (a) Existing bituminous material ................................................................................. 42 (b) Non-cemented material .......................................................................................... 42 (c) Cemented material ................................................................................................. 42 5304 Plant And Equipment ...................................................................................................... 42 (a) General ................................................................................................................... 42 (b) Milling equipment.................................................................................................. 43 5305 Construction .................................................................................................................... 43 (a) General ................................................................................................................... 43 (b) Milling.................................................................................................................... 44 5306 Storing Recovered Pavement Material ............................................................................ 45 5307 Measurement And Payment ............................................................................................ 46 General ............................................................................................................................ 46 Item 53.01 Excavating and removing existing bituminous material.............................. 47 Item 53.02 Milling out existing bituminous material..................................................... 47 Item 53.03 Excavating and spoiling material from an existing pavement and/or the underlying fill......................................................................................................... 48 Item 53.04 Sawing or cutting asphalt or cemented pavement layers ............................. 48 Item 53.05 Removing the remaining asphalt from the underlying layer........................ 48 Item 53.06 Preparing stockpile sites............................................................................... 49 DIVISION 5400: GRAVEL WEARING COURSE AND GRAVEL SHOULDERS ................................50 5401 Scope ............................................................................................................................... 50 5402 Sources of Material.......................................................................................................... 50 5403 Material Requirements for Gravel Wearing Course........................................................ 50 (a) General ................................................................................................................... 50 (b) Grading................................................................................................................... 50 (c) Gravel Wearing Course Material Specification ..................................................... 51 5404 Construction Requirements For Gravel Wearing Course................................................ 52 (a) Equipment .............................................................................................................. 52 (b) Crushing and Screening ......................................................................................... 52 (c) Transport, Placing and Spreading .......................................................................... 53 (d) Compaction ............................................................................................................ 53 (e) Trial Areas.............................................................................................................. 53 5405 Construction Tolerances .................................................................................................. 53 5406 Testing ............................................................................................................................. 54 5407 Measurement And Payment ............................................................................................ 55 Item 54.01 Gravel Wearing course and Shoulder .......................................................... 55 Item 54.02 Extra over Pay item 54.01 for excavation of material in ............................. 55 Item 54.03 Gravel Wearing course and Shoulder constructed from gravel obtained from existing pavement layers ........................................................................................ 56 Item 54.04 In situ reconstruction of existing gravel wearing course and shoulder....... 57 Item 54.05 Extra over Pay item 54.04 for adding extra material .................................. 57 Item 54.06 Extra over Pay item 54.04 for blading the material to windrow.................. 58 Item 54.07 Extra over Pay item 54.03 for excavating material in existing pavement layers in restricted areas ......................................................................................... 58 Item 54.08 Compacting the floors of pavement excavations ......................................... 58 Item 54.09 Watering the pavement excavation floor ..................................................... 59 Item 54.10 Variations in the number of roller passes applicable to pay item 54.08 ...... 59
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Item 54.11 Extra over Pay item 54.08 for compacting pavement excavation floor in restricted areas ........................................................................................................59
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Series 5000: Subbase Road Base And Gravel Wearing Course List of Tables and Figures
LIST OF TABLES AND FIGURES
Table 5104/1 Grading Requirements for Sub-base Material: ................................................... 8 Table 5105/1 Grading Requirements for Crushed Stone Sub-base Material............................ 9 Table 5112/1 Testing Frequency............................................................................................. 13 Table 5112/2 Density requirements: ....................................................................................... 14 Table 5200/1 Grading Limits for Graded Crushed Stone Base Course Materials (GB1)....... 21 Table 5200/2 Mechanical Strength Requirements for the Aggregate Fraction of Crushed Stone Base Course Materials (GB1) as Defined by the Ten Percent Fines Test 22 Table 5203/3 Recommended Particle Size Distributions for Mechanically Stable Natural Gravels and Weathered Rocks for Use as Base Course Material (GB2, GB3) . 23 Table 5200/4 Combined Aggregate Grading Limits for Dense Bitumen Macadam .............. 26 Table 5200/5 Mix Design Parameters for Dense Bitumen Macadam .................................... 26 Table 5403/1 Grading Requirements for Gravel Wearing Course and Gravel Shoulder ....... 51 Table 5404/1 Longitudinal grade tolerance ............................................................................ 54 Table 5405/2 Density requirements: ....................................................................................... 55
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Series 5000: Subbase Road Base And Gravel Wearing Course Division 5100: Sub-Bases
DIVISION 5100: SUB-BASES

5101 SCOPE
This Division covers the specification of materials for, and the construction of, sub-base pavement layers including the in-situ recycling of existing pavements.
5102 MATERIALS
Sub-base material shall be obtained from sources located by the Contractor and approved by the Engineer or from existing pavement layers. The Contractor is required to obtain suitable sources, which are closest to the area where subbase is being placed.
5103 MATERIAL SOURCES FOR SUB-BASES

The materials used for the construction of sub-base layers shall be either: 1. Natural Gravel; 2. Scoria (Cinder Gravel); 3. Weathered Rock; 4. Crushed Gravel; 5. Crushed Rock or crushed Boulders; 6. Recycled Pavement Material. Any other granular material complying with the requirements of this clause.
5104 MATERIAL REQUIREMENTS FOR GRAVEL SUB-BASE

(a) General Gravel material to be used for sub-base shall be obtained from approved sources in borrow areas, cuts or existing pavement layers. The complete sub-base shall contain no material having a maximum dimension exceeding two-thirds of the completed layer thickness. Gravel Sub-base material shall, unless otherwise stated, conform to the following requirements. (b) Grading Limits The sub-base material shall comply with one of the gradings shown in Table 5104/1 as described in the Contract. The material shall have a smooth continuous grading within the limits for grading A, B or C given below.
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Table 5104/1 Grading Requirements for Sub-base Material: Sieve Size (mm) 63.0 50.0 37.5 25.0 20 9.5 5 4.75 2.0 1.18 0.425 0.3 0.075 A 100 90 - 100 51 - 80 35 - 70 5 - 15 Mass Percent Passing B C 100 100 80-100 55 - 85 60-100 40 - 70 30-100 30 - 60 20 - 51 17-75 10 - 30 9-50 5 - 15 5-25
D 100 51 - 85 35 - 65 25 - 51 15 - 30 5 - 15
The complete sub-base shall contain no material having a maximum dimension exceeding two-thirds of the compacted layer thickness. Sub-base material shall, unless otherwise authorized, conform to the following requirements when finally placed: (c) Grading Modulus The minimum Grading Modulus shall be 1.5 except where a material, having a lower Grading Modulus but not less than 1.2, is approved for use by the Engineer. (d) Plasticity Index All sub-base materials shall have a maximum Plasticity Index of 6 or 12, as described in the Contract, and when determined in accordance with AASHTO T-90. The plasticity product (PP = PI x percentage passing the 0.075mm sieve) shall not be greater than 75. (e) Californian Bearing Ratio (CBR) The minimum soaked Californian Bearing Ratio (CBR) shall be 30% when determined in accordance with the requirements of AASHTO T-193. The Californian Bearing Ratio (CBR) shall be determined at a density of 95% of the maximum dry density when determined in accordance with the requirements of AASHTO T-180 method D. (f) Compaction requirements The minimum in- situ dry density of sub-base material shall be as specified hereinafter for the layers in terms of a percentage of modified AASHTO density. (i) (ii) 95% or 97% as required for material not chemically stabilized. 95% or 96 % as required for chemically stabilized material.
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(g) Los Angeles Abrasion The Los Angeles abrasion value shall not exceed 51% when determined in accordance with the requirements of AASHTO T-96.
5105 MATERIAL REQUIREMENTS FOR CRUSHED STONE SUB-BASE

(a) General The aggregate used for crushed stone sub-base shall be derived from a parent rock that is hard, sound, durable, and unweathered. It shall be obtained from sound rock from an approved quarry or clean sound boulders. It shall contain no deleterious material such as decomposed rock, clay, shale, or mica. The crushed aggregate shall comply with the following requirements: (b) Grading Limits The grading of the crushed stone sub-base shall comply with one of the gradings shown in Table 5105/1 as described in the Contract, or as approved or directed by the Engineer. The grading shall follow a smooth curve without any marked gaps or excessive quantities at a particular size, unless specified otherwise. Table 5105/1 Grading Requirements for Crushed Stone Sub-base Material. Sieve Size (mm) Percentage Passing by weight A B C Nominal size Nominal size Nominal size 37.5 mm 28 mm 20 mm 100 95-100 100 100 60-80 70-85 90-100 40-60 50-65 60-75 25-40 35-55 40-60 15-30 25-40 30-45 7-19 12-24 13-27 5 - 12 5 - 12 5-12
50.0 37.5 28 20 10 5 2.36 0.425 0.075
Tests to determine whether the crushed stone material complies with the specified grading requirements shall be conducted after the material has been mixed on the road and spread out. The aggregate shall be produced entirely by the crushing of rock or boulders. Single stage crushing will not be allowed and the crusher installation shall be capable of producing material complying with the specified requirements. If, however, the nature of the parent rock is such that despite every effort made the material remains deficient in the finer fractions, the Engineer may allow the addition of approved soil fines, crusher fines or sand in controlled quantities not exceeding 15% by mass of the aggregate. Fines shall be introduced at the crushing plant.
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(c) Grading Modulus The minimum Grading Modulus shall be 1.5 except where a material, having a lower Grading Modulus but not less than 1.2, is approved for use by the Engineer. (d) Plasticity Index (PI) The Plasticity Index shall not exceed 6. (e) Compaction Requirements The minimum dry density to which the material shall be compacted shall be 95% unless specified otherwise, shown on the drawings or ordered by the Engineer, of the maximum dry density as determined by AASHTO T 180. Field dry densities shall be determined by the sand replacement method as specified in AASHTO T 191 or nuclear method as specified in AASHTO T 238. (f) Los Angeles Abrasion The Los Angeles abrasion value shall not exceed 45% when determined in accordance with the requirements of AASHTO T-96. (g) Particle shape; Flakiness Index The flakiness index, determined by testing in accordance with BS812, Part 105 or ASTM D 3398, shall not exceed 35. The crushed aggregate portion, which is retained on the 5 mm sieve, shall have at least 75 percent by weight of particles with at least two fractured faces and 100 percent with at least one fractured face. The area of each face shall be equal to at least 75 percent of the smallest midsection area of the piece. When two fractured faces are contiguous, the angle between the planes of fractures shall be at least 30 degrees to count as two fractured faces.
5106 CONSTRUCTION REQUIREMENTS FOR SUB-BASES USING RECYCLED (INSITU) PAVEMENT MATERIAL
(a) General Construction of sub-bases using recycled (in-situ) existing pavement materials shall comply with the requirements of Clause 5105 and with the requirements of this Clause. (b) Milling/Scarifying (i) Before scarification or milling is commenced, the surface of the existing pavement shall be clean and free from soil and other deleterious matter. (ii) The existing pavement shall be broken up to the depth described in the Contract either by scarifying or by the use of an approved milling machine.
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(c) Placing, Spreading and Compacting Any material which is required to be added, to either supplement or modify the scarified milled material, shall be evenly spread and thoroughly mixed into the scarified/milled material to form a homogeneous material prior to compaction. The material shall be placed, spread and compacted in accordance with the requirements of Clause 5105.
5107 CONSTRUCTION REQUIREMENTS

(a) General. Sub-base material shall be spread on the approved sub-grade by mechanical means without segregation. The material shall be loosely spread in layers to give a compacted thickness not exceeding 200mm and not less than 100mm. The final compacted layer shall be free from concentrations of coarse or fine materials. 1. The surface of each completed layer shall be moistened prior to the construction of the succeeding layer. Determine the optimum moisture content according to AASHTO T 180 method D. Mix the aggregate and adjust the moisture content to obtain a uniform mixture with moisture content within 2 percent of the optimum moisture content. Spread and shape the mixture on the prepared surface in a uniform layer. 2. The material shall be compacted by the use of approved rollers progressing gradually from the outside towards the centre of the layer, except on superelevated curves, where the rolling shall begin at the low side and progress to the high side. Compact each layer full width. Roll from the sides to the center, parallel to the centerline of the road. Along curbs, headers, walls, and all places not accessible to the roller, compact the material with approved tampers or compactors. Each succeeding pass shall overlap the previous pass by at least one third of the roller width. Rolling shall continue until the entire thickness of each layer is thoroughly and uniformly compacted to the specified density. Compact each layer to at least 95 percent of maximum density. Determine the in place density and moisture content according to AASHTO T 238 and AASHTO T 239 or other approved test procedures. (b) Stabilization When specified in the contract or required by the engineer, sub-base layers shall be stabilized as specified in Division 4600. (c) Trial Areas Prior to the commencement of normal working the Contractor shall construct a trial area of not less than 1000 square metres using the materials and equipment proposed for the work to demonstrate compliance with the requirements of this Clause. (d) Traffic on Sub-base The completed sub-base layer may be used by construction and public traffic subject to the approval of the Engineer. Any such approval shall not relieve the Contractor of his responsibility to maintain and repair any damage caused to the layer.
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5108 PROTECTION AND MAINTENANCE

The Contractor shall protect and maintain the completed sub-base at his own expense. Maintenance shall include immediate repairs of any damage or defects, which may occur and shall be repeated as often as is necessary to keep the subbase continuously intact. Repairs shall be made in a manner that will ensure restoration to an even and uniform surface.
5109 SUB-BASE AS A FILTER OR SEPARATING LAYER

This may be required to protect a drainage layer from blockage by a finer material or to prevent migration of fines and the mixing of two layers. The two functions are similar except that for use as a filter the material needs to be capable of allowing drainage to take place and therefore the amount of material passing the 0.075 mm sieve must be restricted. The following criteria should be used to evaluate a sub-base as a separating or filter layer: a) The ratio D15(coarse layer) should be less than 5 D85(fine layer)
where D15 is the sieve size through which 15% by weight of the material passes and D85 is the sieve size through which 85% passes. b) The ratio D50(coarse layer) should be less than 25 D50(fine layer) The ratio D15(coarse layer) should lie between 5 and 40 D15(fine layer)
For a filter to possess the required drainage characteristics a further requirement is: c)
These criteria shall be applied to the materials at both the base course/sub-base and the subbase/subgrade interfaces.
5110 CLASSIFICATION OF LAYERS FOR PAYMENT PURPOSES

Payment for sub-base layers constructed from gravel material shall distinguish between layers constructed with material from borrow pits, cuts or existing pavement layers, and in-situ recompacted layers with or without the use of additional material. Sub-base layers constructed from crushed-stone material recovered from existing crushedstone pavement layers shall be placed and paid for as gravel material, unless otherwise determined by the Engineer. Where the Engineer determines, in writing, which the material shall be processed and placed as crushed stone.
5111 CONSTRUCTION TOLERANCES

The completed subbase shall conform to the dimensional tolerances stated below: (a) Levels The lot shall be deemed to comply with the requirements specified for surface levels if, before any repair work is undertaken, at least 90% of the level measurements are within + 25 mm of the specified levels. Isolated spots , where the surface levels deviate by more than 33 mm of the specified levels shall be repaired to bring the deviation to within the + 25 mm tolerance.
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(b) Width The average width of the sub-base shall not be less than the specified width and nowhere shall the outer edge of the sub-base be more than 75 mm inside the lines shown on the Drawings. (c) Thickness The lot will be considered to comply with the requirements for layer thicknesses if: At least 90 % of all the thickness measurements taken before any thickness repairs are made is equal to or greater than the specified thickness minus 27 mm; and The mean layer thickness of the lot is not less than the specified thickness minus 5 mm Isolated spots where the actual thickness is less than the specified thickness less 35 mm shall be repaired so as to fall within the 27 mm tolerance. (d) Cross Section At any transverse section the difference in level between any two points shall not vary by more than 20 mm from their difference in level as computed from the cross sections as shown on the Drawings.
5112 TESTING
(a) Process Control The minimum testing frequency that will be required from the Contractor in terms of Clause 1202, for the purpose of process control, shall be as shown on Table 5112/1 below. Table 5112/1 Testing Frequency Test Materials Field density and OMC Atterberg limits and gradings Construction Tolerances Surface levels Thickness Width Cross section Testing Frequency One test Minimum number of tests per lot every 2 510 m2 2 510 m2 20 m 20 m 20 m 20 m 4 4 (3 points per cross section) (3 points per cross section) -
(b) Routine Inspection and Testing. Routine inspection and testing will be carried out by the Engineer to test the quality of materials and workmanship for compliance with the requirements of this Division.
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The density requirements specified in Clause 5105 for compaction of subbase shall be deemed to have been complied with if the minimum dry densities as shown in Table 5112/2 are equaled or exceeded. In calculating the mean, density values differing by more than 5 percentage points from the mean shall be disregarded and a new mean calculated. Any material or workmanship that does not comply with the specified requirements shall be removed and replaced with materials and workmanship complying with the specified requirements, or if the Engineer permits, be repaired as specified in Clause 1208 so that after being repaired it will comply with the specified requirements. Table 5112/2 Density requirements Specified density (% of Number of tests AASHTO T 180 MDD) per lot Minimum mean density (% of AASHTO T 180 MDD) 95. 6 95. 8 95. 9 Minimum density for any single test (% of AASHTO T 180 MDD) 92. 0 91. 8 91. 6
95 (unstabilized)
3&4 5 6
Note: The determination of field dry density expressed as a percentage of AASHTO T 180 MDD implies an AASHTO T 180 density determination for each field density. Where material is homogeneous, this ratio can be decreased to one laboratory determination for up to four field densities.
5113 MEASUREMENT AND PAYMENT

Items 51.08, 51.09 and 51.012 are applicable solely to work that has to be executed in a restricted area of which the width is less than 3.0 m or the length is less than 150.0 m. Item 51.01 Sub-base layer constructed from gravel or Crushed stone: a) Gravel sub-base (unstabilized gravel) compacted to: (i) (ii) b) 95% of modified AASHTO density 97% of modified AASHTO density (specify compacted layer thickness) ....................................................cubic metre (m3) (specify compacted layer thickness) ...................................................cubic metre (m3) Gravel sub-base (chemically stabilized material) compacted to: (i) (ii) 95% of modified AASHTO density 96% of modified AASHTO density (specify compacted layer thickness) ....................................................cubic metre (m3) (specify compacted layer thickness) ...................................................cubic metre (m3) (c) Crushed stone Sub-base 95% of modified AASHTO density (specify compacted layer thickness) .................................................................................................cubic metre (m3)
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The unit of measurement shall be the cubic metre of compacted pavement layer, and the quantity shall be calculated from the authorized dimensions of the completed layer. The tendered rates shall include full compensation for procuring, crushing or soft excavation or pits, breaking down, placing and compacting the material, including transporting the material for a distance of 1.0 km and its removal, disposal and transporting for a distance of 1.0 km, of up to 5% by volume of oversize material, and the protection and maintenance of the layer and the conducting of control tests, all as specified. Item 51.02 Extra over Pay item 51.01 for excavation of material in: (a) (b) Intermediate excavation ..................................................................... cubic metre (m3) Hard excavation................................................................................... cubic metre (m3)
The unit of measurement shall be the cubic metre of material obtained from intermediate or hard excavation. The tendered rates shall include full compensation for the additional costs involved for taking material from classes of material harder than soft excavation and for the additional costs, if any, for processing such material in the pavement layers. Item 51.03 Sub-base layer constructed from gravel or crushed stone obtained from existing pavement layers: (a) Gravel sub-base (unstabilized gravel) compacted to 95% of modified AASHTO density, using: (i) (ii) Non-cemented material (specify compacted layer thickness) ... cubic metre (m3) Cemented material (specify compacted layer thickness)........... cubic metre (m3)
(b) Gravel sub-base (unstabilized gravel) compacted to 97% of modified AASHTO density using: (i) (ii) Non-cemented material (specify compacted layer thickness) ... cubic metre (m3) Cemented material (specify compacted layer thickness)........... cubic metre (m3)
(c) Gravel sub-base (chemically stabilized material) compacted to 95% of modified AASHTO density, using: (i) (ii) Non-cemented material (specify compacted layer thickness) ... cubic metre (m3) Cemented material (specify compacted layer thickness)........... cubic metre (m3)
(d) Gravel sub-base (chemically stabilized material) compacted to 96% of modified AASHTO density, using: (i) (ii) Non-cemented material (specify compacted layer thickness) ... cubic metre (m3) Cemented material (specify compacted layer thickness)........... cubic metre (m3)
(e) Crushed Stone sub-base (unstabilized) compacted to 95% of modified AASHTO density using: (i) Non-cemented material (specify compacted layer thickness) ... cubic metre (m3)
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(ii)
Cemented material (specify compacted layer thickness) ...........cubic metre (m3)
(f) Crushed Stone sub-base (chemically stabilized material) compacted to 95% of modified AASHTO density, using: (i) (ii) Non-cemented material (specify compacted layer thickness)....cubic metre (m3) Cemented material (specify compacted layer thickness) ...........cubic metre (m3)
The unit of measurement shall be the cubic metre of compacted pavement layer, the quantity of which shall be calculated in accordance with the authorized dimensions of the completed layer if the underlying layer has also been reconstructed or reworked. Where the underlying layer has not been reconstructed or reworked but only rolled, or where no work has been done on it, quantities shall be calculated with the aid of cross-sections taken of the layer before and after construction. Where the material consist of recovered pavement material in part and imported material in part the quantity of imported material obtained from cut or borrow shall be paid for under pay item 51.01, calculated in accordance with the volume relation of the respective materials. The tendered rate shall include full compensation for breaking up the existing pavement layer, excavating the material in the existing pavement, procuring, breaking down, placing and compacting the material, including haul for a free-haul distance of 1.0 km, and for the protection and maintenance of the layer as well as for the performance of control tests, all as specified. Where excavation is executed over sections of the road payment shall also include compensation for the proper measuring and marking-off of the excavation, and the protection of the adjacent existing pavement and its repair should it be damaged. The tendered rate for cemented material shall include full compensation of breaking down the material to comply with the specified grading requirements. Item 51.04 In situ reconstruction of existing Sub-base layer as: (a) Gravel sub-base (unstabilized gravel) compacted to 95% of modified AASHTO density, using: (i) (ii) Non-cemented material (specify compacted layer thickness)....cubic metre (m3) Cemented material (specify compacted layer thickness) ...........cubic metre (m3)
(b) Gravel sub-base (chemically stabilized material) compacted to 95% of modified AASHTO density using: (i) (ii) Non-cemented material (specify compacted layer thickness)....cubic metre (m3) Cemented material (specify compacted layer thickness) ...........cubic metre (m3)
(c) Gravel sub-base (chemically stabilized material) compacted to 96% of modified AASHTO density, using: (i) (ii) Non-cemented material (specify compacted layer thickness)....cubic metre (m3) Cemented material (specify compacted layer thickness) ..........cubic metre (m3)
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(d) Crushed stone Sub-base (unstabilized) compacted to 95% of modified AASHTO density, using: (i) (ii) Non-cemented material (specify compacted layer thickness) ... cubic metre (m3) Cemented material (specify compacted layer thickness) ......... cubic metre (m3)
(e) Crushed stone Sub-base (chemically stabilized) compacted to 95% of modified AASHTO density using: (i) (ii) Non-cemented material (specify compacted layer thickness) ... cubic metre (m3) Cemented material (specify compacted layer thickness)........... cubic metre (m3)
The unit of measurement shall be the cubic metre of compacted pavement layer reworked in situ, the quantity of which shall be calculated in accordance with the authorized dimensions of the completed layer. The tendered rate shall include full compensation for breaking up the existing pavement layer to the specified depth, breaking down and preparing the material, placing and compacting the material as well as the protection and maintenance of the layer, conducting control tests, measuring and demarcating the work where layers are reprocessed partly, protecting the adjacent pavement and its repair should it be damaged. The tendered rate shall also include full compensation for spreading and mixing in any additional material should the existing layer thickness be inadequate and it be specified or instructed by the engineer that the thickness be increased. Material which is temporarily bladed to windrow for the removal of an underlying layer and then bladed back and compacted, will be classed as in situ reconstruction and paid for under this item. The temporary blading of the material to windrow will be paid for under Pay item 51.07. The tendered rate for cemented material shall include full compensation for breaking down the material to comply with the specified grading requirements. Item 51.05 Sub-base layer constructed Extra over Pay item 51.03 (a),(b),(c)&(d) and Pay item 51.04 (a),(b)&(c) from recovered pavement material mixed with existing bituminous surfacing material The unit of measurement shall be in cubic metre (m3). The tendered extra-over rate for constructing the pavement layers from material recovered from existing pavements and mixed with existing bituminous surfacing material shall include full compensation for breaking down the surfacing material into fragments not exceeding 37.5 mm in size, uniformly mixing it with the other material, manually removing any over-sized fragments, and for any other incidentals. Item 51.06 Extra over Pay item 51.04 for adding extra material as specified below: (a) (b) Gravel sub-base ................................................................................... cubic metre (m3) Crushed stone Sub-base....................................................................... cubic metre (m3)
Where the thickness of any existing pavement layer requires to be supplemented and the thickness of the added material after compaction will be less than 100 mm, the existing layer shall be scarified to a depth that will give a layer thickness of at least 100 mm after
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compacting together the loosened existing and added material. In the case of gravel or crushed-stone sub-bases the engineer may direct the existing layer to be broken down to its full depth. The composite layer shall be watered mixed and compacted as determined in the clause for placing and compaction. Payment for adding the material will be made as per this pay item. The unit of measurement shall be a cubic metre of material added on the instruction of the engineer, which quantity shall be taken as 70% of the loose volume measured in trucks, unless instructed by the engineer that the quantity be determined by way of cross-sections. The tendered rate shall include full compensation for procuring and adding the material to the in situ broken- down pavement layer and for haul over a free-haul distance of 1.0 km. Item 51.07 Extra over Pay item 51.04 for temporarily blading the material to windrow The unit of measurement shall be a cubic metre (m3) of material from an existing pavement layer, temporarily bladed to windrow and measured in its original position before removal. The tendered rate shall include full compensation for all additional costs involved in temporarily blading the material to windrow and later blading back and also for all clearingup work which may be necessary after the material has been bladed back. Only material bladed to windrow on the instruction of the engineer in order to expose the underlying layer shall be measured and paid for. Material bladed or cut from restricted areas to windrow, and material temporarily stockpiled, will not be paid for under this item. Item 51.08 Extra over Pay item 51.03 for excavating material in existing pavement layers in restricted areas: (a) (b) Non-cemented material........................................................................cubic metre (m3) Cemented material ...............................................................................cubic metre (m3)
The unit of measurement shall be a cubic metre of material excavated in a restricted area, the quantity of which shall be calculated in accordance with the area and the average thickness of the layers excavated. The tendered rate shall include full compensation for all additional costs for excavating the material in restricted areas. Item 51.09 Compacting the floors of pavement excavations (5 roller passes) with: (a) (b) (c) (d) (e) Vibratory rollers ................................................................................. square metre (m2) Oscillatory rollers .............................................................................. square metre (m2) Grid rollers ......................................................................................... square metre (m2) Flat-wheeled rollers ........................................................................... square metre (m2) Pneumatic-tyred rollers...................................................................... square metre (m2)
The unit of measurement shall be a square metre of floor of pavement excavations compacted by 5 roller passes. Payment will differentiate between the above types of rollers. The tendered rate shall include full compensation for supplying the roller, applying 5 roller passes, and removing the roller after completion of the compacting process. The engineer may
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increase or decrease the number of roller passes, in which case payment will be adjusted in accordance with pay item 51.11. Item 51.10 Watering the pavement excavation floor. The unit of measurement shall be kilolitre (kl) of water applied to the floor of the excavation to be compacted on the instruction of the engineer. The tendered rate shall include full compensation for procuring and applying the water, including all hauls. Item 51.11 Variations in the number of roller passes applicable to pay item 51.09: (a) (b) (c) (d) (e) Vibratory rollers ............................................................. square metre- pass (m2 -pass) Oscillatory rollers ............................................................ square metre- pass (m2 -pass) Grid rollers ...................................................................... square metre- pass (m2 -pass) Flat-wheeled rollers......................................................... square metre- pass (m2 -pass) Pneumatic-tyred rollers ................................................... square metre- pass (m2 -pass)
Item 51.12 Extra over Pay item 51.09 for compacting pavement excavation floor in restricted areas The unit of measurement shall be a square metre (m2) of pavement excavation floor compacted in restricted areas. The tendered rate shall include full compensation for all additional costs for compacting the pavement excavation floor in a restricted area irrespective of the compaction plant used.
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Series 5000: Subbase Road Base And Gravel Wearing Course Division 5200: Road Bases
DIVISION 5200: ROAD BASES

5201 SCOPE
This Division covers the specifications of materials for, and the construction of road base pavement layers from approved base materials. It includes the use of crushed, screened or crushed and screened stones or gravels, natural gravels, and stabilized base materials.
5202 DIMENSIONS
The road base layer shall be constructed to the dimensions and cross sectional profiles shown in the Contract.
5203 MATERIALS
(a) Sources of Material Road base material shall be obtained from sources located by the Contractor and approved by the Engineer. (b) Road Base Material Types The materials used for the construction of road base layers shall be one of the following as described in the Contract: Crushed Rock or Stone; Naturally occurring Granular Materials, Boulders, Weathered Rock; Dense Bitumen Macadam.
5204 MATERIAL REQUIREMENTS FOR CRUSHED ROCK OR STONE

(a) General Graded crushed stone (GB1): This material is produced by crushing fresh, quarried rock (GB1) and may be an all-in product, usually termed a 'crusher-run', or alternatively the material may be separated by screening and recombined to produce a desired particle size distribution, as per the specifications. The material shall be clean and free from organic matter, lumps of clay or other deleterious substances. The material shall be of such a nature that it can be readily transported, spread and compacted without segregation. (b) Grading The combined grading of the material shall be a smooth continuous curve falling within the grading limits shown in Table 5200/1 when determined in accordance with the requirements of AASHTO T-27. The mass of material passing the 0.075mm sieve shall be determined in accordance with the requirements of AASHTO T-11.
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Table 5200/1: Grading Limits for Graded Crushed Stone Base Course Materials (GB1) Test sieve (mm) Percentage by mass of total aggregate passing test sieve Nominal maximum particle size 37.5 mm 28 mm 20 mm 100 95 100 100 100 60 80 70 - 85 90 100 40 60 50 - 65 60 75 25 - 40 35 - 55 40 60 15 30 25 - 40 30 45 7 19 12 - 24 13 27 5 12 5 - 12 5 12
50 37.5 28 20 10 5 2.36 0.425 0.075(1)
Note 1. For paver-laid materials a lower fine content may be accepted. (c) Plasticity Index The fine fraction of a GB1 material shall be non-plastic or shall have a maximum Plasticity Index of 6 when determined in accordance with AASHTO T-90. (d) Californian Bearing Ratio (CBR) The in- situ dry density of the placed material should be a minimum of 98% of the maximum dry density obtained in the ASTM Test Method D 1557 (Heavy Compaction). The compacted thickness of each layer should not exceed 200 mm. Crushed stone base courses constructed with proper care with GB1 materials described above should have CBR values in excess of 100 per cent. (e) Aggregate Crushing Value (ACV) Requirements expressed in terms of the results of the Aggregate Crushing Value (ACV) (British Standard 812, Part 110) may be used: the ACV should preferably be less than 25 and in any case less than 29. Other simpler tests e.g. the Aggregate Impact Test (British Standard 812, Part 112, 1990) may be used in quality control testing provided a relationship between the results of the chosen test and the Ten percent Fines Value (TFV) has been determined. (f) Mechanical Strength Requirements (TFVT) To ensure that the materials are sufficiently durable, they should satisfy the criteria given in Table 5200/2. These are a minimum Ten Per Cent Fines Value (TFV) (British Standard 812, Part 111) and limits on the maximum loss in strength following a period of 24 hours of soaking in water. The likely moisture conditions in the pavement are taken into account in broad terms based on annual rainfall.
Page 5000-21
Table 5200/2: Mechanical Strength Requirements for the Aggregate Fraction of Crushed Stone Base Course Materials (GB1) as Defined by the Ten Percent Fines Test Typical Annual Rainfall (mm) >500 <500 (g) Flakiness Index The flakiness index shall not exceed 30% when determined in accordance with BS 812 Part 105-1990. Minimum 10% Fines Values (kN) 110 110 Minimum Ratio Wet/Dry Test (%) 75 60
5205 MATERIAL REQUIREMENTS FOR NATURALLY OCCURRING GRANULAR MATERIALS, BOULDERS, WEATHERED ROCK
(a) General Graded Natural Gravel (GB2, GB3): A wide range of materials including lateritic, calcareous and quartzitic gravels, river gravels, boulders and other transported gravels, or granular materials resulting from the weathering of rocks can be used successfully as base course materials. The material shall be of such a nature that it can be readily transported, spread and compacted without segregation. (b) Grading The particle size distribution should be approximately parallel with the grading envelope, to ensure that the material has maximum mechanical stability, in the grading limits shown in Table 5203/3 when determined in accordance with the requirements of AASHTO T-27. The mass of material passing the 0.075mm sieve shall be determined in accordance with the requirements of AASHTO T-11. Table 5200/3 contains two recommended particle size distributions for suitable materials corresponding to maximum nominal sizes of 37.5 mm and 20 mm.
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Table 5200/3: Recommended Particle Size Distributions for Mechanically Stable Natural Gravels and Weathered Rocks for Use as Base Course Material (GB2, GB3) Test sieve (mm) Percentage by mass of total aggregate passing test sieve Nominal maximum particle size 37.5 mm 20 mm 100 80 100 100 60 80 80 100 45 65 55 80 30 50 40 60 20 40 30 50 10 25 12 27 5 15 5 15
50 37.5 20 10 5 2.36 0.425 0.075
(c) Plasticity Index The fine fraction of a GB1 material shall be non-plastic or shall have a maximum Plasticity Index of 6 when determined in accordance with AASHTO T-90. If the PI approaches the upper limit of 6, it is desirable that the fines content be restricted to the lower end of the range. To ensure this, a maximum PP of 60 is recommended or alternatively a maximum Plasticity Modulus (PM) of 90 where: PM = PI x (percentage passing the 0.425 mm sieve) If difficulties are encountered in meeting the plasticity criteria, consideration should be given to modifying the material by the addition of a low percentage of hydrated lime or cement. (d) Californian Bearing Ratio (CBR) When used as a base course, the material should be compacted to a density equal to or greater than 98 per cent of the maximum dry density achieved in the ASTM Test Method D 1557 (Heavy Compaction). When compacted to this density in the laboratory, the material should have a minimum CBR of 80% after four days immersion in water (ASTM D 1883). (e) Aggregate Crushing Value (ACV) Minimum soaked Ten percent Fines Value (TFV) Value (BS 812, Part 111) shall be 50 KN. (f) Abrasion The Los Angeles Abrasion value, determined by testing in accordance with AASHTO T96 shall not exceed 45 at 500 revolutions unless otherwise specified in the Project Specifications. (g) Flakiness Index The flakiness index shall not exceed 30% when determined in accordance with BS 812 Part 105-1990.
Page 5000-23
(h) Crushed Ratio The crushed ratio shall be a minimum of 60%. (i) Grading Modulus The minimum Grading Modulus for material once placed and compacted on the road shall be: For natural material. . . . . . . . . . . . . . . . . . . . 2.00 For material to be chemically stabilized. . . . . . . . . . 1.75
5206 MATERIAL REQUIREMENTS FOR DENSE BITUMEN MACADAM

(a) Coarse Aggregates The material shall consist of hard durable particles produced by crushing rock or boulders and shall be clean and free from organic matter, lumps of clay or other deleterious substances and complying with the requirements of AASHTO M-80. Crushed rock or crushed boulders shall be produced from one or more of the following rock types; Basalt; Gabbro; Granite; Gritstone; Hornfels; Limestone; Porphyry or Quartzite. Aggregate Crushing Value The aggregate crushing value of the coarse aggregate shall not exceed 25 when determined in accordance with BS 812 Part 3. (i) Los Angeles Abrasion
The Los Angeles Abrasion value shall not exceed 35% when determined in accordance with the requirements of AASHTO T-96. (ii) Soundness
The loss of soundness of the coarse aggregate shall not be greater than 12% when tested in accordance with AASHTO T-104. (iii) Flakiness index
The flakiness index, shall not exceed 45% when determined in accordance with the requirements of BS 812 Part 105-1990. (iv) Crushed Ratio
The crushed ratio shall be a minimum of 100%.
Page5000-24
(v)
Water Absorption
The water absorption shall not exceed 2% when determined in accordance with the requirements of AASHTO T-85. (vi) Coating of Chippings
The coating of chippings with binder shall not be less than 60% when determined in accordance with the requirements of prEN 12697-11:1998E for compatibility between aggregate and bitumen. (b) Fine Aggregate Fine aggregate shall comply with the requirements of AASHTO M-6 and shall consist of one of the following: (i) (ii) Crushed rock or crushed boulders; Natural sand;
(iii) A blend of (i) and (ii) above. (c) Filler Where necessary to improve the combined grading or other properties of the mix, a filler of either hydrated lime, cement or crushed rock or crushed boulder dust may be added. Filler shall be material passing the 0.075mm sieve. If used as an anti-stripping agent, the quantity of hydrated lime shall be at least 1.5% by weight of total aggregates and in no case shall the quantity exceed 3% by weight of total aggregates. (d) Binder The binder shall be 60/70 penetration grade bitumen complying with the requirements of AASHTO M-20.
5207 MATERIAL REQUIREMENTS FOR MIXED BITUMEN MACADAM

(a) Combined Aggregate Grading The combined grading of the aggregates shall be a smooth continuous curve falling within the grading limits shown in Table 5200/4 when determined in accordance with AASHTO T-27. The mass of material passing the 0.075mm sieve shall be determined in accordance with AASHTO T-11.
Page 5000-25
Table 5200/4 Combined Aggregate Grading Limits for Dense Bitumen Macadam Test sieve (mm) 28 20 14 10 6.3 3.35 1.18 0.3 0.075 (1) Notes: 1. When gravel other than limestone is used, the anti-stripping properties shall be improved by including 2% Portland cement or hydrated lime in the material passing the 0.075 mm sieve. 2. Limestone and gravel shall not be used for wearing courses where high skidding resistance is required. (b) Mix Design Parameters for Dense Bitumen Macadam The parameters for dense bitumen macadam shall comply with the requirements as shown in Table 5200/5. Table 5200/5 Mix Design Parameters for Dense Bitumen Macadam Property Bitumen content (1) (per cent by mass of total mix) Bitumen grade (2) Minimum Marshal Stability (Depending on Design traffic) Unit % pen kN Value 5.0 0.6 60/70 or 80/100 3.5-9 Percentage by mass of total aggregate passing test sieve 100 95 100 65 85 52 72 39 55 32 46 7 21 28
Flow mm 2-4 Air Voids % 4.0 - 8.0 Voids in Mineral Aggregate % 16.0 - 22.0 Voids Filled with Bitumen % 65.0 - 85.0 Filler/Bitumen Ratio* % 1.0 - 1.6 Compaction Level Number of blows 2x50, 2x75 - To refusal (Depending on Design traffic) Note : 1. For aggregate with fine microtexture e.g. limestone, the bitumen content should be reduced by 0.1 to 0.3%. 2. 60/70 grade bitumen is preferred.
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The mix proportions for each type of mixture to be used in the Works shall be determined initially in accordance with the requirements of the Asphalt Institute Mix Design Manual (MS2) using at least five binder contents. The Marshall specimens shall be compacted using 75 blows on each face. Trial mixes shall be carried out using various combined aggregate gradings within the limits stipulated within Table 5200/4 in order to determine the optimum design within the stipulated parameters in Table 5200/5 for the materials being used. Prior to final approval of the proposed job mix formula, mixes shall be compacted to refusal using the extended Marshall compaction method (in accordance with the requirements of BS 598 Part 104 (1989)) and the resulting air voids in the mix shall not be less than 3%.
5208 CONSTRUCTION REQUIREMENTS FOR CRUSHED ROCK AND CRUSHED BOULDER ROAD BASES
(a) Equipment The material shall be laid either by a self-propelled paving machine or by means of a grader, as described in the Contract. It shall be so designed and operated as to produce a mixture of laid material complying with the requirements of this Specification. The equipment used shall be of adequate rated capacity, in good working order, and subject to the approval of the Engineer. Obsolete or worn out equipment will not be permitted on the Site. The mixing plant shall be either a batch or a continuous type, as approved by the Engineer, and shall be equipped with satisfactory means of accurately controlling the proportions of all constituent materials. The crushing and screening plant shall be capable of crushing and screening the aggregates, to be used for crushed rock or crushed boulder road base material, into at least four different sized fractions. Compaction shall be carried out using self-propelled 8 10 tonnes deadweight smooth wheeled rollers having a width of roll not less than 450mm, or by multi-wheeled pneumatic tyred rollers of equivalent mass, or by vibratory rollers of equivalent compactive performance, or a combination of these. Rollers shall be equipped with adjustable scrapers for cleaning the drums and an efficient means of moistening the drums to prevent adhesion of asphalt. The rollers shall be fitted with a quick and smooth acting reversing mechanism. (b) Placing and Compaction The surface on which the crushed rock and crushed boulder road base is to be laid shall be free from loose or deleterious material. The crushed material shall be screened into at least four different aggregate fractions. The aggregate shall be recombined in a mixing plant in the proportions necessary to produce a smooth continuous combined grading curve complying with the requirements of Table 5200/1. The mixing plant shall be an approved type and shall be equipped with satisfactory means of controlling the mix proportions and the addition of the required quantity of water to achieve the optimum, which is required for compaction purposes.
Page 5000-27
The mixed material shall be transported at the required moisture content and in such a way, that no segregation occurs. Unless otherwise described in the Contract, the material shall be laid by a self-propelled paving machine approved by the Engineer. The rate of travel of the paver and its method of operation shall be adjusted to produce an even and uniform flow of material across the full laying width free from dragging and without segregation. The material shall be spread in layers not exceeding 200mm and not less than 100mm compacted thickness. The material shall be compacted by the use of approved rollers progressing gradually from the outside towards the centre of the layer, except on superelevated curves, where the rolling shall begin at the low side and progress to the high side. Each succeeding pass shall overlap the previous pass by at least one third of the roller width. Rolling shall continue until the entire thickness of each layer is thoroughly and uniformly compacted to the specified density. Any area, which is inaccessible to rolling equipment, shall be compacted by means of mechanical tampers or other equipment approved by the Engineer. Upon completion of compaction, the surface of the completed layer shall be tightly bound, free from movement under the compaction plant, and free from laminations, ridges, cracks or loose or segregated material. The in-situ density of the completed layer shall not be less than 98% of the maximum dry density determined in accordance with the requirements of AASHTO T-180 method D. The in-situ density of the completed layer shall be determined in accordance with the requirements of AASHTO T-191. Alternatively, if approved by the Engineer, the dry density may be determined by use of a nuclear densometer in direct transmission mode in accordance with AASHTO T238-86 Method B or ASTM D 2992-96. The nuclear densometer shall be accurately calibrated before use, and at interval thereafter, and correlated against results obtained in accordance with AASHTO T-191. (c) Stabilization When specified in the contract or required by the engineer, base layers shall be stabilized as specified in Division 4600. (d) Trial Sections Prior to the commencement of normal working the Contractor shall construct a trial section of not less than 1000 square metres using the materials and equipment proposed for the work to demonstrate compliance with the requirements of this Clause. (e) Traffic on Road base The completed road base layer shall not be used by construction or public traffic prior to the application of the prime coat in accordance with the requirements of Division 6100 of these specifications and without the prior written approval of the Engineer. The approval by the Engineer shall not relieve the Contractor of his obligations to maintain the road base in a satisfactory condition and to undertake any repairs as instructed by the Engineer.
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5209 CONSTRUCTION REQUIREMENTS FOR CRUSHED GRAVEL ROAD BASE

(a) Equipment The material shall be laid either by a self-propelled paving machine or by means of a grader, as described in the Contract. It shall be so designed and operated as to produce a mixture of laid material complying with the requirements this Specification. The equipment used shall be of adequate rated capacity in good working order and subject to the approval of the Engineer. Obsolete or worn out equipment will not be permitted on the Site. Compaction shall be carried out using self-propelled 8 10 tonnes deadweight smooth wheeled rollers having a width of roll not less than 450mm, or by multi-wheeled pneumatic tyred rollers of equivalent mass, or by vibratory rollers of equivalent compactive performance, or a combination of these. Rollers shall be equipped with adjustable scrapers for cleaning the drums and an efficient means of moistening the drums to prevent adhesion of asphalt. The rollers shall be fitted with a quick and smooth acting reversing mechanism. (b) Placing and Compaction The surface on which the crushed gravel road base is to be laid shall be free from loose and deleterious material. Crushed gravel road base shall be spread on the sub-base material by mechanical means without segregation. The material shall be loosely spread in layers to give a compacted thickness not exceeding 200mm and not less than 100mm. The final compacted layer shall be free from concentrations of coarse or fine materials. The surface of each completed layer shall be moistened prior to the construction of the succeeding layer. Prior to compaction, the moisture content of the spread material shall be adjusted as necessary either by the uniform application of water or drying out, to achieve within -1% to +2% of the optimum moisture content when determined in accordance with AASHTO T-180. The material shall be compacted by the use of approved rollers progressing gradually from the outside towards the centre of the layer, except on superelevated curves, where the rolling shall begin at the low side and progress to the high side. Each succeeding pass shall overlap the previous pass by at least one third of the roller width. Rolling shall continue until the entire thickness of each layer is thoroughly and uniformly compacted to the specified density. Any area, which is inaccessible to rolling equipment, shall be compacted by means of mechanical tampers or other equipment approved by the Engineer. Upon completion of compaction, the surface of the completed layer shall be tightly bound, free from movement under the compaction plant, and free from laminations, ridges, cracks or loose or segregated material. The in-situ density of the completed layer shall not be less than 98% of the maximum dry density determined in accordance with the requirements of AASHTO T-180 method D.
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The in-situ density of the completed layer shall be determined in accordance with the requirements of AASHTO T-191. Alternatively, if approved by the Engineer, the dry density may be determined by use of a nuclear densometer in direct transmission mode in accordance with AASHTO T238-86 Method B or ASTM D 2992-96. The nuclear densometer shall be accurately calibrated before use, and at interval thereafter, and correlated against results obtained in accordance with AASHTO T-191. (c) Stabilization When specified in the contract or required by the engineer, base layers shall be stabilized as specified in Division 4600. (d) Trial Sections Prior to the commencement of normal working the Contractor shall construct a trial section of not less than 1000 square metres using the materials and equipment proposed for the work to demonstrate compliance with the requirements of this Clause. (e) Traffic on Road Base The completed road base layer shall not be used by construction or public traffic prior to the application of the prime coat in accordance with the requirements of Division 6100 of these specifications and without the prior written approval of the Engineer. Such approval shall not relieve the Contractor of his obligations to maintain the road base in a satisfactory condition and to undertake any repairs as instructed by the Engineer.
5210 CONSTRUCTION REQUIREMENTS FOR DENSE BITUMEN MACADAM ROAD BASE

(a) Equipment All equipment used for the mixing and paving of the Dense Bitumen Macadam Road Base material shall be so designed and operated as to produce a mixture of laid material complying with the requirements this Specification. The equipment used shall be of adequate rated capacity in good working order and subject to the approval of the Engineer. Obsolete or worn out equipment will not be permitted on the Site. The mixing plant shall be either a batch or a continuous type complying with the requirements of AASHTO 156 and approved by the Engineer. It shall be equipped with satisfactory means of accurately controlling the mix proportions of all constituent materials. The crushing and screening plant shall be capable of crushing and screening the aggregates, to be used for Dense Bitumen Macadam Road Base material, into at least four different sized fractions. Vehicle used for transporting the mixed material shall have tipping bodies capable of discharging directly into the paving machine. The bodies of the vehicles shall be capable of containing the mixed material without spillage.
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All vehicles shall be equipped with a canvas or other approved type of cover which shall be used to cover the mixed material upon loading at the mixing plant and shall not be removed until the mixed material is discharged into the paving machine. Dense Bitumen Macadam Road Base material shall be laid by an approved type of selfpropelled spreading/finishing machine capable of laying to the required widths, thicknesses and cross sectional profiles shown in the Contract without causing segregation, dragging or other surface defects. All paving machines shall be fitted with automatic electronic screed control. Paving machines shall be equipped with heated screeds and with 60o or 45o angle, confining side plates. Paving machines shall also be equipped with an infra-red joint heating system. Compaction shall be carried out using self-propelled 8 10 tonnes deadweight smooth, steel wheeled rollers having a width of roll not less than 450mm, or by multi-wheeled pneumatic tyred rollers of equivalent mass, or by vibratory rollers of equivalent compactive performance, or a combination of these. Rollers shall be equipped with adjustable scrapers for cleaning the drums and an efficient means of moistening the drums to prevent adhesion of asphalt. The rollers shall be fitted with a quick and smooth acting reversing mechanism. (b) Placing and Compaction The surface on which the Dense Bitumen Macadam Road Base it to be laid shall be free of loose and deleterious material. The crushed material shall be screened into at least four different aggregate fractions. The aggregate shall be recombined in a mixing plant in the proportions necessary to produce a smooth continuous combined grading curve complying with the requirements of Table 5200/4 and the approved mix design. The maximum temperature of the material during mixing shall not exceed 165o C. On discharge from the mixer the aggregate shall be completely coated with binder and the fine aggregate shall be evenly dispersed throughout the mix. The material shall be transported at the required temperature and in such a way, that no segregation occurs. During transport the material shall be insulated against heat loss and protected from the ingress of moisture by the use of covers as approved and instructed by the Engineer. The interior of the bodies of the transporting vehicles shall periodically be coated as necessary with a material approved by the Engineer to prevent adhesion and facilitate discharge of, the mixed material. The sequence of delivery of the mixed material shall be such that it can be immediately discharged upon arrival and in sufficient quantity to enable continuous forward movement of the paving machine. Manual laying of asphalt will be permitted only in the following circumstances: For laying irregular shapes and varying thicknesses; In confined spaces where it is impracticable for a paving machine to operate; For footways; Adjacent to expansion joints at bridges or other structures.
Ethiopian Roads Authority Page 5000-31
All transverse and longitudinal construction joints shall be made vertical and offset at least 300mm from joints in the underlying layer. Prior to the spreading of the adjacent layer the cold edge of the joint shall be reheated to at least the minimum rolling temperature and primed with cut-back bitumen to the approval of the Engineer. The rate of travel of the paver and its method of operation shall be adjusted to produce an even and uniform flow of material across the full laying width free from dragging and without segregation. The material shall be spread in layers not exceeding 125mm and not less than 55mm compacted thickness. Compaction shall be carried out using rollers stipulated in Clause 5210(a) above. Vibrating rollers, if used, shall be set in a non-vibrating mode. Rolling shall progress gradually from the outside towards the centre of the layer, except on superelevated curves, where the rolling shall begin at the low side and progress to the high side. Each succeeding pass shall overlap the previous pass by at least one third of the roller width. Rolling shall continue until the entire thickness of each layer is thoroughly and uniformly compacted to the specified density. The temperature of the spread material at the time compaction commences shall not be less than 135o C. The compaction shall be completed before the temperature of the laid material falls below 105o C. Upon completion of compaction, the surface of the completed layer shall be tightly bound, free from movement under the compaction plant and free from laminations, ridges, cracks or loose or segregated material. The density of the compacted layer shall be related to the daily Marshall Density, which shall be determined by making four standard Marshall specimens from samples of the mix taken from the mixing plant and the paving machine. The 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, shall be rejected. Marshall tests shall be repeated on a daily basis to establish the daily Marshall Density for each days production. The daily Marshall Density shall not vary from the job mix design density by more than 2%. The density achieved in the completed layer shall be shall not less than 97% of the Marshall Density for each days production. (c) Trial Sections Prior to the commencement of normal working, and the Contractor is satisfied that his plant is capable of producing a consistent mix, the Contractor shall construct a trial sections of not less than 1000 square metres using the materials and equipment proposed for the work to demonstrate compliance with the requirements of this Clause. (d) Traffic on Road Base The completed road base layer shall not be used by construction or public traffic without the prior written approval of the Engineer. Such approval shall not relieve the Contractor of his obligations to maintain the road base in a satisfactory condition and to undertake any repairs as instructed by the Engineer.
Page5000-32
(e) Weather Limitations Dense Bitumen Macadam Road Base layers shall not be constructed in the following adverse weather conditions: During foggy or wet conditions; When rain is imminent; When the surface on which the layer is to be constructed is wet (i.e. more than damp); When the temperature of the surface on which the layer is to be constructed is less than 10oC.

The completed base shall comply with the construction tolerances given below: (a) Level and Grade The lot shall be deemed to comply with the requirements specified for surface levels if, before any repair work is undertaken, at least 90 % of the level measurements are within + 20 mm of the specified levels. Isolated spots, where the surface levels deviate by more than 25 mm of the specified levels shall be repaired to bring the deviation to within the + 20 mm tolerance. Deviation from the specified longitudinal grade due to deviations from level shall not exceed the following: Length of Grade Maximum Variation Measured in meter from Specified Grade (%) 2 5 10 20 30 0.34 0.27 0.21 0.13 0.08
(b) Width The average width of the base shall be at least equal to that shown on the Drawings and nowhere shall the outer edge of the base be more than 50 mm inside the edge lines shown on the Drawings. (c) Thickness The lot will be considered to comply with the requirements for layer thickness if: At least 90 % of all the thickness measurements taken before any thickness repairs are made is equal to or greater than the specified thickness minus 27 mm; and The mean layer thickness of the lot is not less than the specified thickness minus 5 mm.
Page 5000-33
Isolated spots where the actual thickness is less than the specified thickness less 35 mm shall be repaired so as to fall within the 27 mm tolerance. (d) Cross Section When tested with a 3 m straight-edge laid at right angles to the road center line the surface shall not deviate from the bottom of the straight-edge by more than 10 mm. At any transverse section the difference in level between any two points shall not vary from their difference in level computed from the cross sections shown on the Drawings by more than 20 mm.

Pay Items 52.07 and 52.11 are applicable solely to work that has to be executed in a restricted area of which the width is less than 3.00 m or the length is less than 150.00 m. Item 52.01 Base layer construction (a) Gravel base taken from cut or borrow, including free-haul up to 1.0 km: Gravel base (unstabilized gravel) compacted to: (i) (ii) 98% of modified AASHTO density (Specify compacted layer thickness)..........................................cubic metre (m3) 100% of modified AASHTO density (Specify compacted layer thickness)........................................cubic metre (m3) Gravel base (chemically stabilized material) compacted to: (iii) 97% of modified AASHTO density (Specify compacted layer thickness)..........................................cubic metre (m3) (iv) 98% of modified AASHTO density (Specify compacted layer thickness)..........................................cubic metre (m3) (b) Crushed-stone base compacted to : (i) 98% of modified AASHTO density (Layer thickness indicated) ........................................................cubic metre (m3) (ii) 100% of modified AASHTO density (Layer thickness indicated) .......................................................cubic metre (m3) (c) Dense Bitumen Macadam basecompacted to: (i) (ii) 98% of modified AASHTO density (Layer thickness indicated) .......................................... square metre (m2) or ton. 100% of modified AASHTO density (Layer thickness indicated) .......................................... square metre (m2) or ton.
Page5000-34 Ethiopian Roads Authority
The unit of measurement shall be the cubic metre of completed gravel base or crushed-stone base in place as the case may be, and compacted to the specified density. The quantity shall be calculated from the authorized dimensions of the layer as shown on the drawings or prescribed by the engineer. The tendered rates shall include full compensation for procuring, as if from soft excavation or pits, breaking down, placing and compacting the material, including transporting the material for a distance of 1.0 km and its removal, disposal and transporting for a distance of 1.0 km, of up to 5% by volume of oversize material, and the protection and maintenance of the layer and the conducting of control tests, all as specified. The tendered rates shall include full compensation for procuring, furnishing and placing all materials, including the crusher fines or sand (if approved) necessary for correcting the grading of the crushed stone, for crushing and screening, for hauling the material over an unlimited free-haul distance where material is obtained from commercial sources, and over a 1.0 km free-haul distance where material is obtained from approved borrow pits, for rolling, slushing and correcting the layers, and for testing, protecting and maintaining the work as specified. Macadam base course , completed and accepted , will be measured in square metre or in tons as called for in the proposal. The tendered rates shall include full compensation for procuring, furnishing, hauling, mixing, placing and compacting all materials, priming as specified and for all labour, equipment, tools, maintenance and incidentals necessary to complete the work described in this division. Item 52.02 Extra over Pay Item 52.1 for excavation of material (a) (b) Intermediate excavation. ..................................................................... cubic metre (m3) Hard excavation................................................................................... cubic metre (m3)
The unit of measurement shall be the cubic metre of material obtained from intermediate or hard excavation. The tendered rates shall include full compensation for the additional costs involved for taking material from classes of material harder than soft excavation and for the additional costs, if any, for processing such material in the pavement layers. Item 52.03 Base layer constructed from material obtained from existing pavement layers: 1. Gravel base material:
(a) using:
Gravel base (unstabilized gravel) compacted to 98% of modified AASHTO density, (i) (ii) Non-cemented material (Specify compacted layer thickness) ......................................... cubic metre (m3) Cemented material (Specify compacted layer thickness) ......................................... cubic metre (m3)
(b) using:
Gravel base (unstabilized gravel) compacted to 100% of modified AASHTO density (i) Non-cemented material
Page 5000-35
(specify compacted layer thickness)...........................................cubic metre (m3) (ii) Cemented material (specify compacted layer thickness).......................................... cubic metre (m3) (c) Gravel base (chemically stabilized material) compacted to 97% of modified AASHTO density, using: (i) (ii) Non-cemented material Cemented material (specify compacted layer thickness) ....................................................cubic metre (m3) (specify compacted layer thickness) ....................................................cubic metre (m3) (d) Gravel base (chemically stabilized material) compacted to 98% of modified AASHTO density, using: (i) (ii) Non-cemented material Cemented material (specify compacted layer thickness) ....................................................cubic metre (m3) (specify compacted layer thickness) ....................................................cubic metre (m3) 2. Crushed stone base material: (a) Material compacted to 98% of modified AASHTO density: Material from existing uncemented crushed-stone layers: (i) (ii) Unscreened .................................................................................cubic metre (m3) Screened and recombined in a plant.......................................... cubic metre (m3)
(iii) Material from existing cemented crushed-stone layers, not milled but crushed, screened and recombined in a plant .....................................................cubic metre (m3) (iv) Milled-out material.................................................................... cubic metre (m3) (b) Material compacted to 100% of modified AASHTO density: Material from existing uncemented crushed-stone layers: (i) (ii) Unscreened .................................................................................cubic metre (m3) Screened and recombined in a plant.......................................... cubic metre (m3)
(iii) Material from existing cemented crushed-stone layers, not milled but crushed, screened and recombined in a plant .....................................................cubic metre (m3) (iv) Milled-out material.................................................................... cubic metre (m3) The unit of measurement shall be the cubic metre of compacted pavement layer, the quantity of which shall be calculated in accordance with the authorized dimensions of the completed layer if the underlying layer has also been reconstructed or reworked. Where the underlying layer has not been reconstructed or reworked but only rolled, or where no work has been done on it, quantities shall be calculated with the aid of cross-sections taken of the layer before and
after construction. Where the material consist of recovered pavement material in part and imported material in part the quantity of imported material shall be paid for under pay item 52.01, calculated in accordance with the volume relation of the respective materials. The tendered rate shall include full compensation for breaking up the existing pavement layer, excavating the material in the existing pavement, procuring, breaking down, placing and compacting the material, including haul for a free-haul distance of 1.0 km, and for the protection and maintenance of the layer as well as for the performance of control tests, all as specified. Where excavation is executed over sections of the road payment shall also include compensation for the proper measuring and marking-off of the excavation, and the protection of the adjacent existing pavement and its repair should it be damaged. The tendered rate for cemented material shall include full compensation of breaking down the material to comply with the specified grading requirements. The tendered rates for milled-out material shall also include full compensation for loading the material at the stockpile and for hauling it to a screening plant where applicable or to the point of use for a free-haul distance of 1.0 km, and for any additional processing required to bring the material up to the required standards, but shall not include compensation for milling. The tendered rates for material mixed with existing surfacing material shall also include full compensation for breaking down fragments of bituminous material to the specified maximum size and for removing over-sized fragments by hand. Item 52.04 In situ reconstruction of existing base layer as: 1. Gravel base material: (a) using: Gravel base (unstabilized gravel) compacted to 98% of modified AASHTO density, (i) Non-cemented material (specify compacted layer thickness).................................................... cubic metre (m3) (ii) Cemented material (specify compacted layer thickness).................................................... cubic metre (m3) (b) Gravel base (unstabilized gravel chemically stabilized material) compacted to 100% of modified AASHTO density using: (i) Non-cemented material (specify compacted layer thickness) .......................................... cubic metre (m3) (ii) Cemented material (specify compacted layer thickness) .......................................... cubic metre (m3) (c) Gravel base (chemically stabilized material) compacted to 97% of modified AASHTO density, using: (i) Non-cemented material (specify compacted layer thickness) .......................................... cubic metre (m3)
Page 5000-37
(ii)
Cemented material
(specify compacted layer thickness) .................................................. cubic metre (m3) (d) Gravel base (chemically stabilized material) compacted to 98% of modified AASHTO density, using: (i) (ii) Non-cemented material Cemented material (specify compacted layer thickness) ....................................................cubic metre (m3) (specify compacted layer thickness) ....................................................cubic metre (m3) 2. Uncemented Crushed stone base material: (a) (b) Material compacted to 98% of modified AASHTO density................cubic metre (m3) Material compacted to 100% of modified AASHTO density............. cubic metre (m3)
3. Dense Bitumen Macadam base: (a) (b) 98% of modified AASHTO density (layer thickness indicated).................................... .............................................................................................. square metre (m2) or ton. 100% of modified AASHTO density (layer thickness indicated).................................. .............................................................................................. square metre (m2) or ton.
The unit of measurement shall be as shown for the three cases, compacted pavement layer reworked in situ, the quantity of which shall be calculated in accordance with the authorized dimensions of the completed layer. The tendered rate shall include full compensation for breaking up the existing pavement layer to the specified depth, breaking down and preparing the material, placing and compacting the material as well as the protection and maintenance of the layer, conducting control tests, measuring and demarcating the work where layers are reprocessed partly, protecting the adjacent pavement and its repair should it be damaged. The tendered rate shall also include full compensation for spreading and mixing in any additional material should the existing layer thickness be inadequate and it be specified or instructed by the engineer that the thickness be increased. Material which is temporarily bladed to windrow for the removal of an underlying layer and then bladed back and compacted, will be classed as in situ reconstruction and paid for under this item. The temporary blading of the material to windrow will be paid for under Pay item 52.06. The tendered rate for cemented material shall include full compensation for breaking down the material to comply with the specified grading requirements. Item 52.05 Extra over Pay item 52.04 for adding extra material as specified below: (a) (b) Gravel base ........................................................................................ cubic metre (m3) Crusher fines for improving the grading of recovered crushed stone
Page5000-38
(i) (ii) (c)
Material from approved borrow pits ......................................... cubic metre (m3) Material from commercial sources ............................................ cubic metre (m3)
Macadam base materials added.............................................. square meter (m2) or ton
Where the thickness of any existing pavement layer requires to be supplemented and the thickness of the added material after compaction will be less than 100 mm, the existing layer shall be scarified to a depth that will give a layer thickness of at least 100 mm after compacting together the loosened existing and added material. In the case of gravel or crushed-stone bases the engineer may direct the existing layer to be broken down to its full depth. The composite layer shall be watered mixed and compacted as determined in the clause for placing and compaction. Payment for adding the material will be made as per this pay item. The unit of measurement shall be a cubic metre of material added on the instruction of the engineer for gravel and crushed stone bases, which quantity shall be taken as 70% of the loose volume measured in trucks, unless instructed by the engineer that the quantity be determined by way of cross-sections. The tendered rate shall include full compensation for procuring and adding the material to the in situ broken- down pavement layer and for haul over a free-haul distance of 1.0 km. Item 52.06 Extra over Pay item 52.04 for temporarily blading the material to windrow ....................................................................................................Cubic metre (m3) The unit of measurement shall be a cubic metre of material from an existing pavement layer, temporarily bladed to windrow and measured in its original position before removal. The tendered rate shall include full compensation for all additional costs involved in temporarily blading the material to windrow and later blading back and also for all clearingup work which may be necessary after the material has been bladed back. Only material bladed to windrow on the instruction of the engineer in order to expose the underlying layer shall be measured and paid for. Material bladed or cut from restricted areas to windrow, and material temporarily stockpiled, will not be paid for under this item. Item 52.07 Extra over Pay item 52.03 for excavating material in existing pavement layers in restricted areas: (a) (b) Non-cemented material ...................................................................... cubic metre (m3) Cemented material............................................................................... cubic metre (m3)
The unit of measurement shall be a cubic metre of material excavated in a restricted area, the quantity of which shall be calculated in accordance with the area and the average thickness of the layers excavated. The tendered rate shall include full compensation for all additional costs for excavating the material in restricted areas. Item 52.08 Compacting the floors of pavement excavations (5 roller passes) with: (a) (b) Vibratory rollers area ........................................................................ square metre (m2) Oscillatory rollers area ..................................................................... square metre (m2)
Page 5000-39
(c) (d) (e)
Grid rollers area ................................................................................ square metre (m2) Flat-wheeled rollers area ................................................................... square metre (m2) Pneumatic-tyred rollers area ............................................................. square metre (m2)
The unit of measurement shall be a square metre of floor of pavement excavations compacted by 5 roller passes. Payment will differentiate between the above types of rollers. The tendered rate shall include full compensation for supplying the roller, applying 5 roller passes, and removing the roller after completion of the compacting process. The engineer may increase or decrease the number of roller passes, in which case payment will be adjusted in accordance with pay item 52.10. Item 52.09 Watering the pavement excavation floor ........................................ kilolitre (kl) The unit of measurement shall be kilolitre of water applied to the floor of the excavation to be compacted on the instruction of the engineer. The tendered rate shall include full compensation for procuring and applying the water, including all hauls. Item 52.10 Variations in the number of roller passes applicable to pay item 52.08: (a) (b) (c) (d) (e) Vibratory rollers area ........................................................................ square metre (m2) Oscillatory rollers area...................................................................... square metre (m2) Grid rollers area ................................................................................ square metre (m2) Flat-wheeled rollers area ................................................................... square metre (m2) Pneumatic-tyred rollers area ............................................................. square metre (m2)
Item 52.11 Extra over Pay item 52.08 for compacting pavement excavation floor in restricted areas .......................................................................square metre (m2) The unit of measurement shall be a square metre of pavement excavation floor compacted in restricted areas. The tendered rate shall include full compensation for all additional costs for compacting the pavement excavation floor in a restricted area irrespective of the compaction plant used. Item 52.12 Trial Sections (a) Gravel base trial section (thickness indicated) constructed in accordance with the provisions of this division areas....................................................................... square metre (m2) (b) Crushed-stone base trial section (thickness indicated) constructed in accordance with the provisions of this division areas ................................................................. square metre (m2) (c) Dense Bitumen Macadam base trial section (thickness indicated) constructed in accordance with the provisions of this division areas...................................... square metre (m2) The unit of measurement shall be the square metre of completed trial section approved by the engineer. The tendered rate shall include full compensation for constructing the trial section complete as specified.
Page5000-40
Only trial sections in which the base material and the completed layer comply with all the requirements of the specifications shall be paid for.
NOTE ON ADDITIONAL PAY ITEMS

Where the following items of work are required in connection with constructing the base layer, the appropriate payment items shall appear in Division 5200 of the schedule of quantities. 1) Overhaul of material for a distance in exceeding 1.0 km 2) Excess overburden 3) 4) 5) 6) 7) 8) Finishing-off borrow areas Provision of crushing and/or screening plant Re-erection of crushing and/or screening plant Crushing and screening Removal of oversize pavement material Chemical stabilization
9) Chemical stabilizing agent 10) Mechanical modification 11) Provision and application of water for curing 12) Curing by covering with the subsequent layer 13) Bituminous stabilization 14) Bituminous stabilizing agent 15) Additive for bituminous stabilization.
Page 5000-41
Series 5000: Subbase Road Base And Gravel Wearing Course Division 5300: Breaking Up Existing Pavement Layers
DIVISION 5300: BREAKING UP EXISTING PAVEMENT LAYERS

5301 SCOPE
This section covers the breaking up and excavation of existing pavement layers by conventional means or by milling, selecting the material, and the removal thereof to spoil dumps or to stockpiles for later reprocessing or recycling.
5302 SELECTING THE MATERIAL

Material from existing pavements may only be used for purposes approved by the Engineer. The material shall be so excavated that material from the various pavement layers will not be mixed unless so permitted by the Engineer, in writing.
5303 CLASSIFYING THE MATERIAL

Material from existing pavements shall be classified as follows for excavation and processing purposes: (a) Existing bituminous material Existing bituminous material shall be asphalt or other bituminous seal or base material removed separately from the existing layers on the instruction of the Engineer. Where underlying material is broken down or excavated together with bituminous materials, the mixture will not be classified as bituminous material for payment purposes. (b) Non-cemented material Non-cemented material shall be existing pavement material which can be ripped with the teeth of a 140G Caterpillar or similar grader. (c) Cemented material Cemented material shall be existing pavement material, which cannot be ripped with a type 140G caterpillar, or similar grader. Existing stabilized material will not necessarily be classified as cemented material.
5304 PLANT AND EQUIPMENT

(a) General 1) The equipment to be used for the conventional breaking-up and excavation of existing pavement layers will be determined by the size and depth of the pavement section to be processed or excavated, taking into consideration the fact that work may have to be carried out in restricted areas. 2) No additional pavement will be made for restricted areas. 3) Only approved cutting or sawing equipment may be used for cutting or sawing the asphalt layers. The equipment shall be capable of cutting the asphalt layers to the specified
Page5000-42
depth in one operation without fragmenting the material, and in straight lines within the required tolerances. (b) Milling equipment Only approved milling equipment may be used. The equipment shall be so equipped that it will be able to mill out asphalt and/or cemented material to the prescribed depth in one operation over the width specified in the project specifications. The milling depth shall be controlled electronically. The direction and speed of the milling machine and the speed of rotation of the milling drum shall be adjustable so as to obtain the required grading of the milled material. The machine shall be capable of making a neat vertical cut at the outer edges when milling the layer and to leave the floor of the cut level and with a uniform texture. Unless otherwise specified in the Project Specifications, the milling machine shall be equipped with a self-loading conveyor belt, which can be easily removed and installed and adjusted for slope and direction.
5305 CONSTRUCTION
(a) General Where all or a part of the existing surfacing material is to be reprocessed together with the underlying layer, the surfacing shall be properly broken down and mixed through the full depth of the existing base material to the satisfaction of the Engineer. Fragments of bituminous material shall be broken down to sizes not exceeding 37.5 mm. Where specified in the project specifications or ordered by the Engineer, the existing bituminous material shall first be removed before the underlying layers are broken up. Bituminous material may be milled out or otherwise broken up and removed to approved stockpile sites for recycling or to spoil sites, whichever is required. Where the underlying material is to be reprocessed as base, the exposed surface shall be cleaned to the satisfaction of the Engineer after removal of the bituminous material. All remaining fragments of bituminous material shall be removed, and not more than 5% of the surface may be covered with bituminous material. The existing pavement material shall be broken down to the specified depth and removed, or reprocessed in place, whichever may be required. The underlying layers may not be damaged, and material from one layer may not be mixed with that of another layer. Where such mixing occurs or where the material is contaminated in any other way by the actions of the contractor, he shall remove such material and replace it with other approved material, all at his own cost. Where a layer or layers require to be broken down over part of the pavement width only, the limit of the work shall be clearly demarcated, which limit shall not be exceeded by the contractor by more than 100 mm. Pavement layers broken down outside the specified limits shall be repaired by the contractor at his own cost, to the satisfaction of the Engineer. Where so ordered by the Engineer, asphalt and cemented layers shall be cut or sawn through to the specified depth along the measured limit with approved equipment. Payment will be made for sawing only where specified on the drawings or ordered, in writing, by the engineer.
Page 5000-43
Where existing roads have to be widened, the existing pavement layers shall be cut back to a firm, well-compacted or cemented material. Material so broken up, if acceptable, may be used together with imported material in the widening process, expect in the case of crushed stone base. Where existing pavement layers are widened, separate payment will not be made for cutting back into the existing pavement layers unless so specified in the project specifications, irrespective of the type of material in the existing pavement layer. Where pavement layers are broken down over a section of he road width or where pavement layers are widened, the Engineer may order, in writing, that the various pavement layers be excavated in benches in accordance with his instructions. No additional payment will be made for excavating benches. (b) Milling (i) General
The floor of the milled excavation shall be level and with an even texture without any loose patches or patches of unsuitable material occurring. Loose patches and patches with unsuitable material shall be remedied in accordance with the instructions of the engineer. Payment for removing and replacing unsuitable material and remedying loose patches shall be as specified elsewhere in these specifications. Where such remedial work is done in restricted areas, the extra over payment concerned shall be in accordance with the provisions of the appropriate clauses. Where the floor of an excavation is tested in the longitudinal direction with a 3 m straightedge, and in other directions with a 3 m straight-edge or a straight-edge of such shorter length as fits in between the longitudinal sides of the excavation, the surface shall not deviate by more than 7 mm from the bottom edge of the straight-edge. Payment for milling will distinguish between various milling depths. (ii) Preparing the pavement surface
Before milling may be commenced, the pavement surface shall be clean and free from soil or other deleterious material. Where only part of the pavement is to be milled out, the milling area shall be properly demarcated. Milling may not exceed the required width by more than 50 mm. Payment will not be made for milling beyond the required width, which shall be backfilled with approved material in accordance with the provisions for the specified pavement material at the cost of the Contractor. (iii) Trial milling
Where ordered by the Engineer, the contractor shall execute trial milling on the various materials to be milled. During the trial work, the Contractor will be expected to vary the direction and speed of the milling machine, the speed of rotation of the milling drum, and also the milling depth, in order to obtain milled material of the required grade. (iv) Asphalt
Where the asphalt and/or the cemented base must be reused, the asphalt shall be removed separately.
Where the asphalt consists of layers of various mixes or grades, the Engineer may instruct the separate removal of the layers to different stockpiles. Where the milled material is not conveyed directly by conveyor belt and then loaded, and the Engineer so approves, the material shall first be cut to windrow and then loaded. During loading, the floor of the excavation or the underlying material shall not be damaged. The milled material shall be inspected and classified in accordance with the various types of asphalt and its suitability for recycling. Different stockpiles shall be used for the different types of material as ordered by the Engineer. Contamination of the asphalt with underlying material will not be permitted, and the contractor shall adjust the depths of milling in accordance with the thickness of the layer. (v) Cemented material
Unless otherwise specified milled cemented material to be reprocessed on the road shall first be windrowed with a view to inspecting the underlying surface for any patches of poor or unsuitable material. Where unsuitable material is encountered in the floor of the excavation, such material shall first be removed by further milling (where the underlying layer also consists of the cemented material), or by other approved methods, all to the satisfaction of the Engineer. The unsuitable material shall be replaced with approved material of the required type, which shall be placed in accordance with the specifications for the relevant underlying layer. Where in the opinion of the Engineer it may be necessary, he may instruct the Contractor to taper the ends or edges of a milled excavation for which payment will be made, provided that the tapering is not the result of defective work.
5306 STORING RECOVERED PAVEMENT MATERIAL

Excavated pavement material intended for reprocessing but which cannot be reprocessed in place or, in the opinion of the Engineer, cannot be windrowed next to the excavation, nor placed in position directly at any other place, and material intended for recycling or reprocessing in a plant, shall be transported to approved stockpiles with the written permission of the Engineer. The stockpile site shall be cleaned, and all loose stones, vegetation and other materials, which may cause contamination, shall be removed. The site shall be graded smooth with an adequate slope to ensure proper drainage of water. Where so instructed by the Engineer, the surface shall be watered and compacted to a depth of at least 150 mm to a density of 90% of AASHTO T 180 maximum density. The compacted surface shall be firm without any loose patches. Where asphalt is recovered for recycling, the Engineer may order the surface to be chemically stabilized to a depth of 150 mm. upon completion, this surface shall be swept clean. Stockpile sites shall be sufficiently large to allow the placing of stockpiles of different types of material or types of recovered asphalt without the stockpiles overlapping or the limits of the prepared site being exceeded. The enlargement of the stockpile site after the stockpiles have already been placed will not be permitted without the approval of the Engineer.
Page 5000-45
Stockpiles of milled material shall be shaped in a manner, which will limit segregation to a minimum. The stockpiling of asphalt shall be done in a manner that will limit consolidation to a minimum. Adequate approved covers shall be provided for recovered asphalt stockpiles to prevent them from becoming wet, or being contaminated by dust. Upon completion of the work, the stockpile sites shall be broken up in accordance with the instructions of the Engineer. The stockpiling of excavated material will not be paid for directly, but full compensation therefor shall be included in the rates for the various items of work in which the stockpiled material will be used. Separate payment will be made for the preparation of storage sites.

General (i) Material to be reprocessed
Direct payment will not be made for breaking up and excavating existing pavement material that is reprocessed and re-used, except when: The material is milled out in accordance with the provisions of the project specifications or upon the written instruction of the Engineer. Bituminous surfacing or other bituminous pavement layers are removed separately from the underlying material in accordance with the Project Specifications or the written instructions of the Engineer. Full compensation for excavating existing pavement material, where the excavation thereof is not payable separately, shall be included in the rates tendered for the various pavement layers and items of work in which the material is used, as provided in the relevant specifications. (ii) Removal of bituminous layers (except milled material)
Separate payment will be made for removing existing bituminous material separately from the underlying layer, when it is not milled out in accordance with the project specifications or the instructions of the Engineer, irrespective of whether or not it requires recycling. (iii) Material from existing pavements which is not reprocessed
Existing gravel pavement material, gravel, or existing bituminous material not intended for reprocessing, shall be used for other specified purposes or taken to spoil. Payment for the excavation of such material will be made directly under Pay Item 53.03 unless it is used for other purposes. (iv) Milling
Milling will be paid for directly irrespective of whether or not the material will be re-used. (v) Measurement for excavating existing pavement material and underlying fill
Where payment is made separately for the excavation of existing pavement material and underlying fill, the quantity will be calculated in accordance with the authorized horizontal
Page5000-46
dimensions of the excavated layer and the average depth of excavation. The average depth of excavation will be determined in accordance with the test holes made or cores drilled at intervals not exceeding 10 m, and which are so distributed over the surface that a realistic estimate of the depth can be obtained. Item 53.01 Excavating and removing existing bituminous material (except milled material) (a) Material intended for recycling with the average depth of excavation: (i) (ii) Not exceeding 30 mm ................. .............................................square meter (m2) Exceeding 30 mm but not exceeding 60 mm........................... square meter (m2)
(iii) Exceeding 60 mm ................ ....................................................square meter (m2) (b) Material to be disposed of with the average depth of excavation: (i) (ii) Not exceeding 30 mm .................. ............................................square meter (m2) Exceeding 30 mm but not exceeding 60 mm............................. quare meter (m2)
(iii) Exceeding 60 mm .................. ..................................................square meter (m2) The unit of measurement shall be a square meter layer of bituminous material excavated from existing pavements separately from the underlying material on the instruction of the engineer, and removed to approved stockpile or spoil sites. The tendered rate shall include full compensation for determining the average thickness of the layer of bituminous material to be excavated, including the excavation of holes or the drilling of cores, if so instructed, for breaking down, excavating, loading, and transporting the material to approved stockpiles or spoil sites and for loading and properly placing the material in stockpiles or spoil dumps. The volume used for calculating overhaul shall be taken as 70% of the loose volume of the material measured in the hauling vehicles. Item 53.02 Milling out existing bituminous material with an average milling depth: (a) (b) (c) Not exceeding 30 mm............................ ..............................................cubic meter (m3) Exceeding 30 mm but not exceeding 60 mm ..................................... cubic meter (m3) Exceeding 60 mm............................. ...................................................cubic meter (m3)
The unit of measurement shall be a cubic meter of asphalt milled out and removed to approved stockpiles. The tendered rate shall include full compensation for providing milling equipment and milling out the material to the specified depth and in accordance with the requirements for evenness and for all measurements, labor, supervision and incidentals for executing the work and obtaining milled material which will comply with the specified requirements. The tendered rate shall also include full compensation for loading and transporting the material to approved irrespective of the method of loading, and for unloading the material and placing it in stockpile, also for screening out the oversize material if necessary. Separate payment will be made for preparing the stockpile site.
Page 5000-47
Payment for milling the material will distinguish between the various average depths of excavation, irrespective of the required number of passes by the plant for milling out the material. Item 53.03 Excavating and spoiling material from an existing pavement and/or the underlying fill: (a) (b) Non-cemented material........................................................................cubic meter (m3) Cemented material ...............................................................................cubic meter (m3)
The unit of measurement shall be a cubic meter of material, with or without existing bituminous material, excavated from the existing pavement and/or fill and removed to spoil dumps. The tendered rate shall include full compensation for excavating the material from the existing pavement and/or fill, irrespective of layer thickness, for loading, transporting, offloading, and placing the material in approved spoil dumps. Payment will not distinguish between material with or without existing bituminous material. Item 53.04 Sawing or cutting asphalt or cemented pavement layers (a) (b) (c) Sawing asphalt ................................... ................................................square meter (m2) Cutting asphalt ............................................................................................... meter (m) Sawing cemented material ..................................... ............................square meter (m2)
The unit of measurement for subitems (a) and (c) shall be the square meter of sawcut area calculated in accordance with the authorized length of sawcut and the average saw depth measured after excavation of the material. The unit of measurement for subitem (b) shall be the meter of cut measured in accordance with the authorized saw length. The tendered rate shall include full compensation for all material and sawing or cutting costs and for all incidentals for cutting or sawing the pavement in accordance with the instructions of the engineer. Payment will not distinguish between the various depths of sawing or cutting work, irrespective of the number of separate cuts, which may be required for sawing or cutting the layer to the required depth. Where surfacing of less than 30 mm thickness is sawn together with a cemented pavement, the surfacing section shall be deemed to be cemented material for payment purposes. Item 53.05 Removing the remaining asphalt from the underlying layer The unit of measurement shall be the square meter of excavation floor cleaned on the instruction of the Engineer. The quantity will be calculated in accordance with the authorized dimensions of the surface from which the remaining bituminous material will have to be removed after the existing bituminous layer has been taken off. Only surfaces of existing layers to be reprocessed as base will be paid for and only if so instructed by the Engineer.
Page5000-48
The tendered rate shall include full compensation for the removal of any remaining bituminous material from the excavation floor as specified and the disposal thereof, all to the satisfaction of the Engineer. Item 53.06 Preparing stockpile sites The unit of measurement shall be the square meter of stockpile site prepared on the instruction of the Engineer. The tendered rate shall include full compensation for demarcating, clearing, leveling, watering, compacting, and draining the stockpile site as specified. Payment will not be made for preparing the sites for spoil dumps unless such preparation has been instructed, in writing, by the Engineer.
Page 5000-49
Series 5000: Subbase Road Base And Gravel Wearing Course Division 5400: Gravel Wearing Course and Gravel Shoulders
DIVISION 5400: GRAVEL WEARING COURSE AND GRAVEL SHOULDERS

5401 SCOPE
This Division covers the specification of materials for, and the construction of, gravel wearing course and gravel shoulders from crushed rock, crushed boulders, crushed gravel or as-ripped weathered rock. The gravel wearing course and gravel shoulders shall be constructed to the dimensions and cross sectional profiles shown in the Contract drawings.
5402 SOURCES OF MATERIAL

Gravel wearing course and gravel shoulder materials shall be obtained from approved sources in borrow areas, cuts or existing pavement layers. The materials shall be located by the Contractor and approved by the Engineer.
5403 MATERIAL REQUIREMENTS FOR GRAVEL WEARING COURSE

(a) General The material shall consist of hard durable angular particles produced by crushing rock, crushing gravel or from natural sources and shall be clean and free from organic matter, lumps of clay or other deleterious substances. The material shall be of such a nature that it can be readily laid and compacted without segregation. They should have sufficient cohesion to prevent ravelling and corrugating (especially in dry conditions). The amount of fines (particularly plastic fines) should be limited to avoid a slippery surface under wet conditions. Selected material shall consist of hard durable angular particles of fragments of stone or gravel. The material shall be free from vegetable matter and lumps or balls of clay. (b) Grading The grading of the gravel after placing and compaction shall be a smooth continuous curve within and approximately parallel to the envelopes or the grading limits shown in Table 5403/1 when determined in accordance with the requirements of AASHTO T-27. The mass of material passing the 0.075mm sieve shall be determined in accordance with the requirements of AASHTO T-11.
Page5000-50
Table 5403/1 Grading Requirements for Gravel Wearing Course and Gravel Shoulder Test Sieve Size(mm) Percent (%) by mass of total aggregate passing test sieve Type 1 50 100 37.5 28 80 - 100 20 14 55 - 100 10 40 - 60 5 30 - 50 2.36 2 1 15 - 30 0.425 5 - 15 0.075 12-32 10-40 5-15 10-25 10-25 18 - 45 15-50 10-25 25-45 25-45 25-55 18-60 30 - 65 22-75 20-40 45-70 50-80 45 - 85 35-90 30-50 60 -85 80-100 65 - 100 55 - 100 45-65 80 - 100 100 80-100 65 - 100 95 - 100 85-100 60-80 100 100 95 - 100 100 80-100 Type 2 Type 3 Type 4 100 Type 5 Type 6 -
(c) Gravel Wearing Course Material Specification Unless and otherwise stated Type 1 gravel wearing course shall be used for all roads which have Annual Average Daily Traffic design greater than 50. Type 4 gravel wearing course shall be used in the new construction of roads having Annual Average Daily Traffic design less than 50. The other Types of gravel wearing course materials shall be used as shown in the contract or as directed by the Engineer. (i) Type 1
The grading of this gravel after placing and compaction shall be a smooth curve within and approximately parallel to the envelopes detailed in Table 5403/1. The material shall have a percentage of wear of not more than 50 at 500 revolutions, as determined by AASHTO T96. The material shall be compacted to a minimum in-situ density of 95% of the maximum dry density determined in accordance with the requirements of AASHTO T 180.
Page 5000-51
The plasticity index should be not greater than 15 and not less than 8 for wet climatic zones and should be not greater than 20 and not less than 10 for dry climatic zones. The linear Shrinkage should be in a range of 3-10%. Note that the above gradation and plasticity requirements are only to be used with angular particles and that crushing and screening are likely to be required in many instances for this purpose. The crushed ratio shall be a minimum of 60%. (ii) Type 2 & 3
These materials may be more rounded particles fulfilling the following: The Plasticity Index lies in a range of 5-12% in wet areas, and in any case less than 16% in other areas The materials have the sanction of local experience Use of more rounded particles may allow the use of river gravel. Trials should nevertheless be conducted to verify whether crushing occurs under traffic or whether crushing should be considered prior to use. Subject to trials, a minimum percentage by weight of particles with at least one fractured face of 40% may be considered. This requirement may also be expressed in terms of crushing ratio. The CBR should be in excess of 20% after 4 days of soaking at 95% of maximum dry density under Heavy Compaction. For very low traffic, the requirement may be relaxed to a CBR of 15. (iii) Type 4
This material gradation allows for larger size material and corresponds to the gradation of a base course material. The use of this gradation of materials is subject to the local experience and shall be used with PIs in a range of 10-20. (iv) Type 5 & 6
These materials gradations are recommended for smaller size particles. They may be used if sanctioned by experience with plasticity characteristics as for material Type 1.
5404 CONSTRUCTION REQUIREMENTS FOR GRAVEL WEARING COURSE

(a) Equipment Gravel wearing course and gravel shoulder material shall be spread by means of graders or other equipment approved by the Engineer. Gravel wearing course and gravel shoulder material shall be compacted by means of selfpropelled or towed steel wheeled rollers which are capable of achieving the density requirements stipulated in this Clause. Water shall be applied by means of equipment, which is capable of distributing the applied water uniformly over the surface of the layer. (b) Crushing and Screening The gravel wearing course and gravel shoulder material shall be crushed and/or screened at source to remove all oversize material.
Page5000-52
(c) Transport, Placing and Spreading The material shall be transported in such a way, that no segregation occurs. The material shall be placed, spread, broken down, watered if necessary and mixed in layers not exceeding 200mm and not less than 100mm compacted thickness for Type 1, Type 2, Type 3, Type 5, Type 6 and 150mm compacted thickness for Type 4. (d) Compaction Prior to compaction, the moisture content of the spread material shall be adjusted as necessary either by the uniform application of water or drying out, to achieve within -1% to +2% of the optimum moisture content when determined in accordance with AASHTO T-180. The material shall be compacted by the use of approved rollers progressing gradually from the outside towards the centre of the layer, except on superelevated curves, where the rolling shall begin at the low side and progress to the high side. Each succeeding pass shall overlap the previous pass by at least one third of the roller width. Rolling shall continue until the entire thickness of each layer is thoroughly and uniformly compacted to the specified density. Any area, which is inaccessible to rolling equipment, shall be compacted by means of mechanical tampers or other equipment approved by the Engineer. Upon completion of compaction, the surface of the completed layer shall be tightly bound, free from movement under the compaction plant, and free from laminations, ridges, cracks or loose or segregated material. The in-situ density of the completed layer shall be 95% of the maximum dry density when determined in accordance with the requirements of AASHTO T-180 method D. The dry density shall be determined in accordance with the requirements of AASHTO T-190. Alternatively, if approved by the Engineer, the dry density may be determined by use of a nuclear densometer, which shall be accurately calibrated before use, and at intervals thereafter, against results obtained in accordance with AASHTO T-190. (e) Trial Areas Prior to the commencement of normal working the Contractor shall construct a trial area of not less than 1000 square metres for gravel wearing courses and 250 square metres for gravel shoulder using the materials and equipment proposed for the work to demonstrate compliance with the requirements of this Clause.

The completed wearing course shall comply with the construction tolerances given below. The tolerances shall be maximum permissible deviations from the specified dimensions, levels, alignment, positions, etc. as shown on the Drawings or as given below: (i) Level and Grade
The level tolerance shall be + 25 mm. Deviation from the specified longitudinal grade due to deviations from level shall not exceed the following Table 5405/1.
Page 5000-53
Table 5405/1 Longitudinal grade tolerance Length of Grade Measured in meter Maximum Variation from Specified Grade (%)
2 5 10 20 30 (ii) Width
0.34 0.27 0.21 0.13 0.08
The average total width of the wearing course and shoulders shall be at least equal to that shown on the Drawings and nowhere shall the outer edge of the shoulders be more than 75 mm inside the edge lines shown on the Drawings. (iii) Thickness
The thickness tolerance shall be + 30 mm. (iv) Cross Section
When tested with a 3 m straight-edge laid at right angles to the road centerline the surface shall not deviate from the bottom of the straight-edge by more than 10 mm. At any transverse section the difference in level between any two points shall not vary from their difference in level computed from the cross sections shown on the Drawings by more than 20 mm.
5406 TESTING
The minimum testing frequency that will be required from the Contractor in terms of conditions of contract for the purpose of process control, shall be the following: Table 5406/1 Testing Frequency Testing Frequency Test One test every Minimum number of tests per lot
Materials Field density and OMC Indicator tests Construction Tolerances Surface levels Thickness Width Cross section Smoothness 20 m* 20 m* 200 m 20m 40 m2 *3 pts per cross section 2 500 m2 2 500 m2 4 4
Note: The determination of field dry density expressed as a percentage of AASHTO T180 maximum dry density implies a AASHTO T180 determination for each field density. Where material is homogeneous, this ratio can be decreased to one laboratory density determination for up to four field densities.
Page5000-54
The minimum dry densities given in Table 5406/2 shall be equaled or exceeded. Table 5406/2 Density requirements: Specified Number Density (% of of Tests AASHTO per lot T180 MDD) 95 4 5 6 Minimum mean density (% of AASHTO T180 MDD) 95. 6 95. 8 95. 9 Minimum value of any single test (% of AASHTO T180 MDD)
93. 0 92. 8 92. 6
In calculating the mean, density values differing by more than five percentage points from the mean shall be disregarded and a new mean taken. Any materials or workmanship that do not comply with the specified requirements shall be removed and replaced with materials and workmanship complying with the specified requirements, or if the Engineer permits, be repaired as specified in Clause 1208, so that after being repaired they will comply with the specified requirements. (i) Routine Inspection and Testing
Routine inspection and testing will be carried out by the Engineer to test the quality of materials and workmanship for compliance with the requirements of this Division.

Pay Items 54.08, 54.09 and 54.11 are applicable solely to work that has to be executed in a restricted area of which the width is less than 3.0 m or the length is less than 150.0 m. Item 54.01 Gravel Wearing course and Shoulder constructed from gravel taken from cut or borrow, including free-haul up to 1.0 km (a) Gravel wearing course compacted to 95% of modified AASHTO density specify compacted layer thickness)............................................................................... cubic metre (m3) (b) Gravel shoulders wearing course compacted to 95% of modified AASHTO density (specify compacted layer thickness).................................................................. cubic metre (m3) The unit of measurement shall be the cubic metre of compacted pavement layer, and the quantity shall be calculated from the authorized dimensions of the completed layer. The tendered rates shall include full compensation for procuring, as if from soft excavation or pits, breaking down, placing and compacting the material, including transporting the material for a distance of 1.0 km and its removal, disposal and transporting for a distance of 1.0 km, of up to 5% by volume of oversize material, and the protection and maintenance of the layer and the conducting of control tests, all as specified. Item 54.02 Extra over Pay item 54.01 for excavation of material in (a) (b) Intermediate excavation ..................................................................... cubic metre (m3) Hard excavation .................................................................................. cubic metre (m3)
Page 5000-55
The unit of measurement shall be the cubic metre of material obtained from intermediate or hard excavation. The tendered rates shall include full compensation for the additional costs involved for taking material from classes of material harder than soft excavation and for the additional costs, if any, for processing such material in the pavement layers. Item 54.03 Gravel Wearing course and Shoulder constructed from gravel obtained from existing pavement layers: (a) Gravel wearing course compacted to 95% of modified AASHTO density, using: (i) (ii) Non-cemented material (specify compacted layer thickness)...........................................cubic metre (m3) Cemented material (Specify compacted layer thickness)..........................................cubic metre (m3) (b) using: Gravel shoulder wearing course compacted to 95% of modified AASHTO density, (i) (ii) Non-cemented material (specify compacted layer thickness)...........................................cubic metre (m3) Cemented material (Specify compacted layer thickness)..........................................cubic metre (m3) The unit of measurement shall be the cubic metre of compacted layer, the quantity of which shall be calculated in accordance with the authorized dimensions of the completed layer if the underlying layer has also been reconstructed or reworked. Where the underlying layer has not been reconstructed or reworked but only rolled, or where no work has been done on it, quantities shall be calculated with the aid of cross-sections taken of the layer before and after construction. Where the material consists of recovered pavement material in part and imported material in part the quantity of imported material obtained from cut or borrow shall be paid for under pay item 54.01, calculated in accordance with the volume relation of the respective materials. The tendered rate shall include full compensation for breaking up the existing pavement layer, excavating the material in the existing pavement, procuring, breaking down, placing and compacting the material, including haul for a free-haul distance of 1.0 km, and for the protection and maintenance of the layer as well as for the performance of control tests, all as specified. Where excavation is executed over sections of the road payment shall also include compensation for the proper measuring and marking-off of the excavation, and the protection of the adjacent existing pavement and its repair should it be damaged. The tendered rate for cemented material shall include full compensation of breaking down the material to comply with the specified grading requirements.
Page5000-56
Item 54.04 In situ reconstruction of existing gravel wearing course and shoulder layer as (a) Gravel wearing course compacted to 95% of modified AASHTO density, using: (i) (ii) Non-cemented material (specify compacted layer thickness) .......................................... cubic metre (m3) Cemented material (Specify compacted layer thickness) ......................................... cubic metre (m3) (b) using: Gravel shoulder wearing course compacted to 93% of modified AASHTO density, (i) (ii) Non-cemented material (specify compacted layer thickness) .......................................... cubic metre (m3) Cemented material (Specify compacted layer thickness) ......................................... cubic metre (m3) The unit of measurement shall be the cubic metre of compacted pavement layer reworked in situ, the quantity of which shall be calculated in accordance with the authorized dimensions of the completed layer. The tendered rate shall include full compensation for breaking up the existing layer to the specified depth, breaking down and preparing the material, placing and compacting the material as well as the protection and maintenance of the layer, conducting control tests, measuring and demarcating the work where layers are reprocessed partly, protecting the adjacent pavement and its repair should it be damaged. The tendered rate shall also include full compensation for spreading and mixing in any additional material should the existing layer thickness be inadequate and it be specified or instructed by the engineer that the thickness be increased. Material which is temporarily bladed to windrow for the removal of an underlying layer and then bladed back and compacted, will be classed as in situ reconstruction and paid for under this item. The temporary blading of the material to windrow will be paid for under Pay item 54.06. The tendered rate for cemented material shall include full compensation for breaking down the material to comply with the specified grading requirements. Item 54.05 (a) (b) Extra over Pay item 54.04 for adding extra material as specified below:
Gravel wearing course......................................................................... cubic metre (m3) Gravel shoulder wearing course .......................................................... cubic metre (m3)
Where the thickness of any existing pavement layer requires to be supplemented and the thickness of the added material after compaction will be less than 100 mm, the existing layer shall be scarified to a depth that will give a layer thickness of at least 100 mm after compacting together the loosened existing and added material. In the case of gravel or crushed-stone wearing courses the engineer may direct the existing layer to be broken down to its full depth.
Page 5000-57
The composite layer shall be watered mixed and compacted as determined in the clause for placing and compaction. Payment for adding the material will be made as per this pay item. The unit of measurement shall be a cubic metre of material added on the instruction of the engineer, which quantity shall be taken as 70% of the loose volume measured in trucks, unless instructed by the engineer that the quantity be determined by way of cross-sections. The tendered rate shall include full compensation for procuring and adding the material to the in situ broken- down pavement layer and for haul over a free-haul distance of 1.0 km. Item 54.06 Extra over Pay item 54.04 for temporarily blading the material to windrow The unit of measurement shall be a cubic metre (m3) of material from an existing pavement layer, temporarily bladed to windrow and measured in its original position before removal. The tendered rate shall include full compensation for all additional costs involved in temporarily blading the material to windrow and later blading back and also for all clearingup work which may be necessary after the material has been bladed back. Only material bladed to windrow on the instruction of the engineer in order to expose the underlying layer shall be measured and paid for. Material bladed or cut from restricted areas to windrow, and material temporarily stockpiled, will not be paid for under this item. Item 54.07 Extra over Pay item 54.03 for excavating material in existing pavement layers in restricted areas: (a) (b) Non-cemented material ...................................................................... cubic metre (m3) Cemented material ..............................................................................cubic metre (m3)
The unit of measurement shall be a cubic metre of material excavated in a restricted area, the quantity of which shall be calculated in accordance with the area and the average thickness of the layers excavated. The tendered rate shall include full compensation for all additional costs for excavating the material in restricted areas. Item 54.08 compacting the floors of pavement excavations (5 roller passes) with: (a) (b) (c) (d) (e) Vibratory rollers ................................................................................. square metre (m2) Oscillatory rollers ............................................................................. square metre (m2) Grid rollers ....................................................................................... square metre (m2) Flat-wheeled rollers ......................................................................... square metre (m2) Pneumatic-tyred rollers .................................................................... square metre (m2)
The unit of measurement shall be a square metre of floor of pavement excavations compacted by 5 roller passes. Payment will differentiate between the above types of rollers. The tendered rate shall include full compensation for supplying the roller, applying 5 rollers passes, and removing the roller after completion of the compacting process. The engineer may increase or decrease the number of roller passes, in which case payment will be adjusted in accordance with pay item 54.10.
Page5000-58
Item 54.09 Watering the pavement excavation floor The unit of measurement shall be kilolitre (kl) of water applied to the floor of the excavation to be compacted on the instruction of the engineer. The tendered rate shall include full compensation for procuring and applying the water, including all hauls. Item 54.10 Variations in the number of roller passes applicable to pay item 54.08 (a) (b) (c) (d) (e) Vibratory rollers ................................................................................ square metre (m2) Oscillatory rollers .............................................................................. square metre (m2) Grid rollers ....................................................................................... square metre (m2) Flat-wheeled rollers........................................................................... square metre (m2) Pneumatic-tyred rollers ..................................................................... square metre (m2)
Item 54.11 Extra over Pay item 54.08 for compacting pavement excavation floor in restricted areas The unit of measurement shall be a square metre (m2) of pavement excavation floor compacted in restricted areas. The tendered rate shall include full compensation for all additional costs for compacting the pavement excavation floor in a restricted area irrespective of the compaction plant used.
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Standard Specs - Subbase, Road Base and Gravel

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Standard Technical Specification - 2002

SERIES 5000: SUBBASE ROAD BASE AND GRAVEL WEARING COURSE

Ethiopian Roads Authority

Standard Technical Specification -2002

Ethiopian Roads Authority

Standard Technical Specification - 2002

Ethiopian Roads Authority

Standard Technical Specification -2002

Ethiopian Roads Authority

Standard Technical Specification - 2002

Ethiopian Roads Authority

Standard Technical Specification -2002

LIST OF TABLES AND FIGURES

Ethiopian Roads Authority

Standard Technical Specification - 2002

DIVISION 5100: SUB-BASES

5103 MATERIAL SOURCES FOR SUB-BASES

5104 MATERIAL REQUIREMENTS FOR GRAVEL SUB-BASE

Ethiopian Roads Authority

Standard Technical Specification -2002

Ethiopian Roads Authority

Standard Technical Specification - 2002

5105 MATERIAL REQUIREMENTS FOR CRUSHED STONE SUB-BASE

50.0 37.5 28 20 10 5 2.36 0.425 0.075

Ethiopian Roads Authority

Standard Technical Specification -2002

Ethiopian Roads Authority

Standard Technical Specification - 2002

5107 CONSTRUCTION REQUIREMENTS

Ethiopian Roads Authority

Standard Technical Specification -2002

5108 PROTECTION AND MAINTENANCE

5109 SUB-BASE AS A FILTER OR SEPARATING LAYER

5110 CLASSIFICATION OF LAYERS FOR PAYMENT PURPOSES

5111 CONSTRUCTION TOLERANCES

Ethiopian Roads Authority

Standard Technical Specification - 2002

Ethiopian Roads Authority

Standard Technical Specification -2002

5113 MEASUREMENT AND PAYMENT

Ethiopian Roads Authority

Standard Technical Specification - 2002

Ethiopian Roads Authority

Standard Technical Specification -2002

Cemented material (specify compacted layer thickness) ...........cubic metre (m3)

Ethiopian Roads Authority

Standard Technical Specification - 2002

Ethiopian Roads Authority

Standard Technical Specification -2002

Ethiopian Roads Authority

Standard Technical Specification - 2002

Ethiopian Roads Authority

Standard Technical Specification -2002

DIVISION 5200: ROAD BASES

5204 MATERIAL REQUIREMENTS FOR CRUSHED ROCK OR STONE

Ethiopian Roads Authority

Standard Technical Specification - 2002

50 37.5 28 20 10 5 2.36 0.425 0.075(1)

Ethiopian Roads Authority

Standard Technical Specification -2002

Ethiopian Roads Authority

Standard Technical Specification - 2002