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JKR 20407-0001-90 JABATAN KERJA RAYA MALAYSIA GUIDELINES FOR INSPECTION & TESTING OF ROAD WORKS KETUA PENGARAH KERJA RAYA MALAYSIA GUIDELINES FOR INSPECTION AND QUALITY CONTROL TESTING OF ROAD WORKS EXECUTED BY CONTRACT CONTENTS PAGE Introduction 1 PART I - TECHNICAL INSPECTION 3 PART It - QUALITY CONTROL TESTING aL 1 GENERAL a 2 COMPACTION CONTROL OF EARTH MATERIALS AND AGGREGATES 13 3 QUALITY CONTROL OF EARTHWORK AND FLEXIBLE PAVEMENT MATERIALS 15 aut Embankwent, Fill/Backfill and 15 Select Fill/Backfill 3.2 Lower Subbase and Top 300 mm of Subgrade 15 3.3 Earth Shoulders 35 3.4 Gravel Shoulders, Gravel Surfacing, Subbase and Crushed Aggregate Roadbase 15 3.5 Aggregates for Bituminous Surface Dressing and Penetration Macadi (Semi-grout Surfacing) 17 3.6 Aggregates for Asphaltic Concrete and Asphaltic Concrete Mixtures 18 3.7 Aggregates for Bituminous Macadam and Bituminous Macadam Mixtures 20 4 QUALITY CONTROL OF CONCRETE AND STRUCTURES 4. Concrete Aggregates 4.2 Water for Concrete 4.3 Concrete 44 Reinforcing, Prestressing and Structural Steel 4.5 Welding 4.6 Precast Concrete Culvert Pipes 5 QUALITY CONTROL OF ROAD SURFACE REGULARITY AND TEXTURE 5.1 Surface Regularity of Carriageways and Shoulders 5.2 Surface Texture of Concrete Road Surfaces 6 QUALITY CONTROL OF MANUFACTURED MATERIALS INDEX OF TECHNICAL INSPECTION AND QUALITY CONTROL TESTING REQUIREMENTS a1 21 22 22 23 23 23 25 25 25 28 28 ORK: ic’ Introduction It is long established international practice in civil engineering that a contractor must notify the engineer responsible for supervision of construction of his intention to proceed with each and every item of work, and obtain the engineer's approval of his long term and day to day work Programmes before any works are executed. This enables the engineer to ensure that the works are scheduled in accordance with the specifications and established good practice, and to make satisfactory arrangements for their inspection and testing. It is assumed that this system of construction supervision will be applied to all contract road works in Malaysia, through incorporating the necessary provisions in the contract documents. It is not intended herein to discuss the contractual relations of contractor and supervising engineer, or the latter's responsibility for ensuring sound management of the works, or even his function of measuring ‘the works for payment; suffice it to say that for many items of work the measurement function may often be combined satisfactorily with technical inspection. Rather, the purpose of these guidelines is to describe the appropriate levels of technical inspection and quality control testing that should be carried out for each item of work to preclude the incorporation of faulty or substandard materials in the works, and to enable unsatisfactory workmanship to be detected and rectified. Needless to say, to ensure that contract road works are carried out in accordance with specifications and established good practice, the technical inspection and quality control testing should be performed, as appropriate, by suitably experienced engineers, technical assistants, inspectors, clerks of works and technicians well versed in the activities in hand and thoroughly familiar with the relevant standards and correct technical procedures. Of course different activities require different levels of inspection and testing. For example bush clearing and ditch excavation require only nominal inspection of work in progress, a final inspection (and measurement) of the completed work, and no testing whatever. Whereas construction of an asphaltic concrete carriageway surface requires more or less continuous inspection of all phases of the work, comprehensive checking of finished lines and levels, and thorough testing of materials for quality and level of compaction achieved. In cases where both inspection during execution and testing are required for effectual quality control of an item of work, it is important to balance the two functions. Limited testing resources can often be compensated for by increasing the level of inspection, and vice versa. For example, this is particularly true of mixing concrete, and compacting earth or aggregates in road embankments and pavements. Although many inspection and quality control testing functions ‘are normally carried out by sub-professional staff, all inspection and testing work should be directed and supervised by engineers. Engineers should also be responsible for the review, analysis and interpretation of all inspection reports and test results. . These guidelines are set out in two distinct parts, the first covering inspection requirements for the items of work frequently occurring in road works contracts, and the second presenting complementary materials testing programmes. The guidelines are not hard and fast rules,, but represent desirable minimum levels of inspection and testing for road construction, improvement and periodic maintenance performed by contract under normal conditions of work in Malaysia. For ease of reference a tabulated index of the inspection requirements and materials testing programmes for each item of work is appended. ‘For any work not explicitly covered herein, technical inspection and quality control testing requirements can be deduced from those set forth for items of work of similar importance with comparable characteristics and/or materials. In all cases, quality control testing programmes should be appropriate to the specifications for the materials involved. PART I - TECHNICAL INSPECTION For the purposes of these guidelines, 4 categories of inspection personnel have been defined on the basis of JKR's technical staff grades, and comparable staff grades used by consulting engineering firms. ‘These categories are as follows. Class Inspection Personnel A Senior Enginee B Junior Engineer, with support and occasional assistance of a Senior Engineer c Technical Assistant or Inspector or Clerk of Works, with support and occasional assistance of an Engineer, especially during final inspection of items of work D Technician or Laboratory Assistant or Laboratory . Technician, with support and occasional assistance of an Engineer, especially during final inspection of items of work Note: In Classes B, C and D, support and occasional assistance of a Senior Engineer (Class B), or an Engineer (Classes C and D), means support and assistance provided at the locations of items of work being inspected, as well as in the (Site) office. Inspection personnel of all classes are technical representatives of the JKR Superintending Officer, or the Engineer, responsible for the supervision of the Works, and will normally be employees of either JKR or a consulting engineering firm engaged by JKR for supervision of construction. All inspection personnel should be experienced in the particular types of work to which they are assigned, and should be familiar with the relevant Specifications and correct technical procedures. For each item or part of the Works, the inspection personnel should ensure, as far as is practicable, that: - all materials and workmanship are in accordance with the Specifications and accepted good practice - quality control testing of materials and workmanship is cerried out in accordance with Part II of these guidelines - the work conforms to the lines, levels, grades, dimensions, and cross-sections shown on the Drawings, or otherwise specified in the Contract Documents, and/or required by the JKR Superintending Officer's, or the Engineer's, Representative on Site. This will normally require that “the inspection personnel have with them at the locations of the work copies of: - the Specifications appropriate to the ite! Works being inspected or parts of the ss these Guidelines for Inspection and Quality Control Testing - ' all relevant Drawings. a They will also need simple measuring equipment appropriate to the items or parts of the Works being inspected. Such equipment could include measuring rules and tapes, spirit levels, straight edges, templates, asphalt thermometers, other types of thermometer, etc. ‘The inspection personnel should complete daily inspection reports on standard forms as described in Chapters 5 and 9 of JKR’s Construction Supervision Manual for Contract Road Works. For ease of reference a draft of JKR's standard form for inspection *reports is included herein on Page 10, These reports should be submitted promptly to the JKR Superintending Officer's, or the Engineer’s, Representative on Site. In particuler, all shortcomings in the work being carried out should be noted and reported to the JKR Superintending Officer’s, or the Engineer's, Representative on Site as soon as possible. Such shortcomings should also be brought to the attention of the Contractor, or his Agent‘oh Site, without delay. However the daily inspection reports should not be used for this purpose and should not be shown to the Contractor or his staff. In addition to the daily inspection reports, separate records for pile driving, the in situ construction of bored piles, and pile load tests should be kept on standard forms especially prepared for these purposes. The forms should be the standard JKR forms’ or similar. The details of pile driving, bored pile construction, and pile load tests are important construction records “which should be kept in especially designated files arranged by structure and/or part of structure. In the table commencing on the next page, minimum desirable levels of inspection are set forth for all items of work commonly included , in road construction, improvement and periodic maintenance contracts. Both the amount of inspection required, and the class of inspection personnel to be provided are specified. ,,,It may not always be possible to meet these requirements,,.in full due to staff shortages. In such circumstances; as much inspection as is possible should be undertaken by as high o class of inspection personnel as can be made available. In critical cases, the JKR Superintending Officer's, or the Engineer's, Representative on Site should order the Contractor to suspend some or all of the work operations until satisfactory levels of inspection can be provided. ITEMS OF WORK Clearing, grubbing, bush trimming, etc. Topsoil stripping, stockpiling or spreading Excavation in all types of material (including rippable rock) for roadway cuts, drainage channels, structures, common borrow, select material, etc. Drilling and blasting hard rock, boulders, etc. Spoil disposal Embankment, fill/backfill and select fill/backfill construction (including granular bedding, etc.), and subgrade preparation, including placing and shaping of fill materials, adjusting moisture content, compaction and final shaping INSPECTION REQUIREMENTS Identification of saleable timber’ and other materials and/or property to be salvaged or preserved, spot checks on work in progress, and final inspection - Class D Spot checks on work in progress, and final inspection - Class D Initial inspection and spot checks to verify the type of material being excavated, and final inspection - Class D When selection or separation of different types of material is involved, part-time inspection, 30-40%, should be provided - Class C. During final stages of excavation for foundations of structures, full-time inspection should be provided - Class B. Initial inspection to verify th class of material, spot checks of all phases of the work, and final inspection - Class D Particular attention should be Paid to safety measures by 4 suitably experienced inspector - Class A or C. Spot checks on work in progress, and final inspection - Class D Initial inspection of work area, inspection of materials, part- time inspection, 40-50%, of all phases of the work, and final inspection - Class D For backfill to structur inspection should be full-time. Particular attention should be paid to checking the quality of select fill/backfill materials. = 10 Construction or rehabilitation of unbound pavement courses: = lower subbase - road shoulders (earth or gravel) - drains through shoulders - gravel surfacing - subbase - roadbase Construction or making good of bituminous prime coat Construction, strengthening, or rehabilitation of bituminous pavement course - surface dressing - penetration macadam - bituminous macadam (roadbase, binder course, wearing course, levelling course, overlay) - asphaltic concrete (binder course, wearing course levelling course, overlay) - slurry seal - seal coat or black seal Minor repairs of bituminous pavements: - pothole repairs - edge failure repairs - surface patching, etc. Initial inspection of work area inspection of materials, full- time inspection of all phases of the work, and final inspection (including thickness checks) - Class D When cement or lime stabilization of soils or aggregates is involved, inspections should be Class B. Initial inspection of work area, inspection of equipment and materials, full-time inspection of all phases of the work, and final inspection - Class C Particular attention should be paid to checking and monitoring spray rates. Initial inspection of work area, inspection of equipment and materials, full-time inspection of all phases of the work (including tack coat when appropriate), and final inspection - Class C As appropriate, particular attention should be paid to checking and monitoring spray rates of bituminous materials, and paving thicknesses. When plant mixed materials are involved, inspection of equipment and materials at the plant, and full-time inspection of the mixing process should also be provided - Class C. jaterials, part- time inspection, 50-60%, of all aspects of the work, and final inspection - Class C Inspection of uw 12 13 14 Pile driving (including splicing/ jointing) Construction of bored piles Pile load tests Reinforced (or mass) concrete construction for cast in situ structures, or precast elements, or rigid pavement Inspection of piles and equipment, full-time inspection of driving, and preparation of driving records for each pile - Class C Particular attention should be paid to checking pile types, sizes and lengths, inspecting all splices and joints, and recording the tip elevation and final driving penetration rate for each pile. Inspection of materials and equipment, including casing when required, full-time inspection of drilling, inspection of reinforcement before and after placing in borehole or casing, full-time inspection of concrete mixing and pouring, and preparation of pile records - Class ¢ Pile records should include for each pile details of cross- section, casing, reinforcement, tip elevation, length and weight of concrete poured. Inspection of all testing equipment, full-time inspection of loading and unloading, and preparation of comprehensive load-time-settlement records - Class © Inspection of materials, inspection of reinforcement after fixing or placing, and inspection of formwork before and after erection - Class C Full-time inspection of concrete mixing and pouring - Class C Particular attention should be paid to checking and monitoring the proportions of cement, aggregates and water being mixed. Spot checks during curing, and final inspection after formwork removal - Class B 15 Prestressed concrete construction 16 Placing prefabricated elements in structures, especially beams in bridges Note: Complicated bridges and structures are beyond the scope of these guidelines. 17 Asphaltic damp-proof ing of concrete surfaces 18 Assembly of culvert pipes from precast concrete or steel elements, and box culverts from precast concrete sections, including preparation of foundations and bedding materials 19 Construction of subsoil drains Inspections should be as for reinforced concrete construction with additional inspections as follows. Inspection of prestressing equipment and materials, inspection uf ducts and cables after fixing, and full-time inspection of prestressing operations and duct grouting - Class A Inspection of all equipment and prefabricated sections, inspection of all bearings, supports and fastenings both permanent and temporary, full- time inspection of all phases of the work - Class C Inspection of prepared concrete surfaces and materials, full~ time inspection of the work, and final inspection - Class C Inspection of materials, part time inspection, 40-50%, of all phases of the work, and final inspection - Class C Particular attention should be paid to checking each and every culvert section prior to assembly, and each and every joint after assembly. For steel pipes, each section should be assembled in the correct location and sequence with all joints and fastenings completed all as per the manufacturer's instructions When the bedding material i: concrete, full-time inspection of concrete mixing and pouring should be provided. Inspection of trench and materials, part-time inspection, 40-50%, of the work, and final inspection (before backfilling) - Class ¢ 20 Miscellaneous works: - concrete blinding - brickwork or masonry ~ installation of gabions - construction of grouted or ungrouted stone pitching (or rip-rap) - installation of guardrail and other road furniture > application of road markings 21 Grassin; - sodding - sprigging - seeding 22 Hydroseeding In addition to construction of the Inspection of materials, part- time inspection, 30-40%, of the work, and final inspection - Class D Inspection of materials, spot checks on work in progress, and final inspection - Class D Initial inspection of work area, inspection of equipment and materials, and full-time inspection of spraying - Class Cc Particular attention should be paid to checking and monitoring spray rates. Permanent Works, the inspection personnel are also required to inspect continually the Contractor's maintenance of all roads affected by the Works, and the construction and maintenance of all Temporary Works provided for the use of the travelling public, including: - diversions, temporary roads, temporary road surfaces, temporary bridges, etc. - traffic signs and traffic control systems needed for the passage of the travelling public in and/or around work temporary roads and temporary road safe areas, and on diversions, surfaces. The inspection requirements for road maintenance, and the construction and maintenance of such Temporary Works are described in Chapter 11 of JKR’s Construction Supervision Manual for Contract Road Works, and in Arahan Teknik (Jalan) 2C/85, Manual on Traffic Control Devices, Temporary Signs and Work Zones Control.

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