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KINGDOM

O

SAUDI R BI

MINISTRY OF COMMUNICATIONS

GENERAL SPECIFICATIONS

FOR

ROAD AND BRIDGE CONSTRUCTION

November 998

PART THREE

AGGREGATE SUBBASE AND BASE COURSES


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ableof Contents

PART THREE

AGGREGATE

SUBB SE

AND BASE COURSES

T BLE OF CONTENTS

PART THREE: AGGREGATE SUBBASE AND BASE COURSESSECTION 3 01 -

PRODUCTION HANDLING AND STOCKPILING AGGREGATES 1

3.01.1 DESCRIPTION .......................................................................................... 1

3.01.2 MATERIALS .................................................................................. .......... 1

3.01.2.1 Sources ........................................................................................... 1

3.01.2.2 Definitions ...........................................................

......................... 1

3.01.3 PRODUCTION REQUIREMENTS ........

............................................... 2

3.01.3.1 Preparation of Site .................................... ... .................................... 2

3.01.3.2 Production

of

Aggregates .................... .......................................... 2

3.01.3.3 Rejected Aggregates .......................... ........................................... 3

3.01.3.4 Surplus Screenings ................................. . ............................... 3

3.01.3.5 Site Cleanup ...................................................... .... .... ...................... 3

3.01.4 QUALITY ASSURANCE PROCEDURES .....................................

.... ....... 3

3.01.4.1 Methods and Procedures ................................................................ 3

3.01.4.2 Preliminary Testing ....................................... .... ............................. 4

3.01.4.3 Production Testing .................................... ... .................................... 4

3.01.4.4 Acceptance Testing ................................ .......................................... 4

3.01.5 STOCKPILING AGGREGATES .............. ..... ....................................... 4

3.01.5.1 Sites ................................................................................... .............. 4

3.01.5.2 Preparation of Stockpile Site ........................................................... 4

3.01.5.3 Construction of Stockpiles ............................................................... 4

3.01.5.4 Removing Aggregate From Stockpiles ...........................

........... 5

3.01.5.5 Site Cleanup ...................................................... .... .... ...................... 5

3.01.6 METHOD OF MEASUREMENT ....................

.......................................... 5

3.01.7 PAYMENT ............................................................................. .................. 5

SECTION 3.02 - AGGREGATE SUBBASES ................................................................ 6

3.02.1 DESCRIPTION .......................................................................................... 6

3.02.2 MATERIALS .............................................................................................. 6

3.02.3 PROPORTIONING AGGREGATE SUBBASE MIXTURES ....................... 7

3.02.3.1 Job Mix Design Proposal ................................................................. 7

3.02.3.2 Acceptance

of

Job Mix Formula ............................................. ....... 8

3.02.3.3 Job Mix Formula Revisions .............. .......................................... 9

3.02.4 EQUIPMENT ................................................................................ ............. 9

3.02.5 CONSTRUCTION ......................................................... ...... ..................... 9

3.02.5.1 Contractor Quality Control Procedures ....................... ..................... 9

3.02.5.2 Surface Preparation ....................................

............................. 10

3.02.5.3 Placing and Spreading ....................... ....... .................................... 10

3.02.5.4 Compacting ....................................................... ............................ 10

3.02.5.5 Finishing ........................................................................................ 12

3.02.5.6 Maintenance and Protection .......................................................... 12

3.02.5.7 Compaction Test Trials ......................... ......................................... 12

3.02.6 QUALITY ASSURANCE PROCEDURES ..................................... ....... 12


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3.02.6.1 Compaction ................................................................................... 13

3.02.6.2 Thickness ...................................................................................... 14

3.02.6.3 Aggregate Gradation Sand Equivalent and Plasticity Index ......... 14

3.02.6.4 California Bearing Ratio and Abrasion ........................................... 15

3.02.6.5 Surface Tolerances ....................................................................... 15

3.02.6.6 Acceptance .................................................................................... 15

3.02.7 METHOD OF MEASUREMENT ...... ....... ....

........................................... 16

3.02.8 PAYMENT ........................................................................ .......

.............. 16

SECTION 3.03 - AGGREGATE BASES .......................... ....

..................................... 17

3.03.1 DESCRIPTION ........................................................................................ 17

3.03.2 MATERIALS ....................................................................... ................. 17

3.03.3 PROPORTIONING AGGREGATE BASE MIXES ............................. 19

3.03.3.1 Job Mix Design Proposal ............................................................... 19

3.03.3.2 Acceptance of Job Mix Formula .............................................. ...... 20

3.03.3.3 Job Mix Formula Revisions ............................................................ 20

3.03.4 EQUIPMENT ...........................................................................................

21

3.03.5 CONSTRUCTION ..................................................

.... ....

......................

21

3.03.5.1 Contractor Quality Control Procedures ...................... ... .............. 21

3.03.5.2 Preparation and Maintenance ............................................. ...... 22

3.03.5.3 Mixing ............................................................... ............................. 22

3.03.5.4 Transporting .................................................... ....

........................ 22

3.03.5.5 Placing and Spreading .............. .................................................. 22

3.03.5.6 Compacting .............................................. ..................................... 23

3.03.5.7 Finishing ....................................................................

.................. 24

3.03.5.8 Maintenance and Protection .......................................................... 24

3.03.5.9 Compaction Test Trials .................................................................. 25

3.03.6 QUALITY ASSURANCE PROCEDURES ............................ .................... 25

3.03.6.1 Compaction ................................................................................... 26

3.03.6.2 Thickness ...................................................................................... 26


3.03.6.4 California Bearing Ratio and Abrasion ........................................... 27


3.03.6.6 Acceptance ......................................................... ......................... 28

3.03.7 METHOD OF MEASUREMENT ...... ........................................................ 29

3.03.8 PAYMENT ...................................................................... ......................... 29

SECTION 3.04 - CEMENT TREATED BASES ....... .................................................. 30

3.04.1 DESCRIPTION ........................................................................................ 30

3.04.2 MATERIALS ...................................................................

....................... 30

3.04.2.1 Portland Cement ....................................

...................................... 30

3.04.2.2 Aggregate .....................................................

......

....................... 30

3.04.2.3 Water ................................................................. ............................

31

3.04.2.4 Flyash and Chemical Admixtures........................................ ...... 31

3.04.2.5 Bituminous Curing Seal ................................................................. 31

3.04.3 MIX DESiGN .................................. ........................................... .... ..... 31

3.04.4 WEATHER LIMITATIONS ........................ ............................................. 32

3.04.5 EQUIPMENT .................................................................

....

................ 32

3.04.6 CONSTRUCTION REQUIREMENTS ...................................................... 32


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3.04.6.1 Surface Preparation ........................

....... ...................................... 32

3.04.6.2 Proportioning and Plant Mixing ........................................ ............ 33

3.04.6.3 Transporting and Spreading .......................................................... 34

3.04.6.4 Compacting and Finishing ........... ................................................ 35

3.04.6.5 Operation Time Requirement ........................................................ 35

3.04.6.6 Construction Joints ........................................................................ 36

3.04.7 CURING ................................................................................................... 36

3.04.8 CONTRACTOR QUALITY CONTROL PROCEDURES .......................... 36

3.04.9 QUALITY ASSURANCE PROCEDURES ............................

................ 36

3.04.9.1 Compaction ................................................................................... 37

3.04.9.2 Thickness ...................................................................................... 37


3.04.9.4 California Bearing Ratio or Compressive Strength ........................ 39


3.04.9.6 Acceptance .................................................. .... .............................. 39

3.04.10 METHOD

OF

MEASUREMENT ............................................................. 40

3.04.11 PAYMENT .............................................................................................. 40

SECTION 3.05 - SHOULDERS AND LAYBYS ...... ................................................. 41

3.05.1 DESCRIPTION ..........................................................

............................ 41

3.05.2 EQUIPMENT ................................................................

......................... 41

3.05.3 CONSTRUCTION REQUIREMENTS ............................................

........ 41

3.05.3.1 General ................................................

....

........................... 41

3.05.3.2 Earth Shoulders and Laybys ..............................................

....... 42

3.05.3.3 Aggregate Shoulders and Laybys .......................................

...... 42

3.05.3.4 Bituminous Base Shoulders and Laybys ................

...

................ 42

3.05.3.5 Bituminous Wearing for Shoulders and Laybys ............................. 42

3.05.4 SHOULDERING AND DELINEATION ...................................... ........... 42

3.05.5 COMPACTION REQUiREMENTS ........................................................... 42

3.05.6 METHOD OF MEASUREMENT .......... ...

............................................... 43

3.05.7 PAYMENT .......................................................................

...................... 43


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oeGeneral Specifications November 1998

Table of ontents

PART

THREE:

AGGREGATE

SUBBASE

AND

BASE

COURSES

SECTION 3.01 - PRODUCTION, HANDLING

AND

STOCKPILING

AGGREGATES

3.01.1 DESCRIPTION. This work consists

of

producing, handling and stockpiling

crushed and screened aggregates including pit run aggregates

of

the kind, quality and

grading specified for all types

of

materials to be used

in

road and bridge and related

construction.

Requirements set forth herein shall apply whether the source be ledge rock, talus ,

gravel , sand, or a combination thereof.

3.01.2 MATERIALS.

3.01.2.1 Sources. Materials sources may be shown

on

the plans, described

in

the

special specifications, or established by the Contractor after approval by the Engineer.

The Contractor shall furnish the Engineer, not less than thirty 30) days prior to the

scheduled date for beginning crushing operations, information

on

the source of

aggregates, the method of production to be employed, types and capacity of equipment

to be used and a schedule showing rates of production for the several types of

aggregate to be produced.

Whether or not the materials sources are shown

on

the plans, specified

in

the

special specifications, or established by the Contractor after approval by the Engineer,

the Contractor shall determine for himself the types and numbers

of

equipment and

extent of work needed to remove overburden and produce the volumes of aggregates

required for the work within the contract time, and produce aggregates having the

fracture, gradation and quality conforming to the specifications.

The Engineer may require procurement

of

aggregate from any portion

of

a source

and may reject portions

of

the source as being unacceptable.

3.01.2.2 Definitions.

1. Coarse aggregate consists of particles retained on the 4.75 mm No.4) sieve.

2.

Fine aggregate consists

of

particles passing the 4.75 mm No.4) sieve.

3.

Crushed stone consists

of

rock and stone fragments

or

gravel having one 1)

or more mechanically fractured faces. Every fractured face shall have a minimum

dimension from edge to edge across the fractured face which is not less than one-third

1

/3) the minimum dimension of the aggregate particle.

4. Gravel consists of uncrushed aggregate particles passing a seventy-five 75)

millimeter 3-inch) sieve and retained on a 4.75 mm No.4) sieve.


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5

Sand consists of aggregate particles passing a 4.75 millimeter No.4) sieve and

retained

on

a 0.075 millimeter (No. 200) sieve and may be naturally occurring,

manufactured or combinations thereof.

6 Material passing a 0.075 mm (No. 200) sieve may be referred to as silt or clay

or

dust depending on other characteristics.

3.01.3 PRODUCTION REQUIREMENTS.

3.01.3.1 Preparation

of

Site. The portion of the quarry or pit site to be used shall

be cleared and grubbed as specified

in

Section 2.01, Clearing and Grubbing

in

these

General Specifications.

When clearing and grubbing is completed, all surface materials which are

unsatisfactory for the kind of aggregate to be produced shall be stripped and removed.

Materials from clearing, grubbing and stripping which are removed as unsatisfactory

for producing specified aggregates shall be disposed of at locations not visible from the

roadway,

in

a manner that precludes erosion by wind

or

water and the form and

contours

of

the finished disposal area blends with adjacent terrain.

The costs involved

in

preparing the site, clearing , grubbing, stripping and removing

overburden and other operations shall be incidental to the production of aggregate and

shall be included by the Contractor in the contract unit price for the specific aggregate

produced.

3.01.3.2

Production of

Aggregates. The Contractor shall , as a minimum, utilize

all stone, rock fragments or boulders occurring

in

the source, up to and including those

measuring four hundred and fifty (450) millimeters in greatest dimension,

in

the

manufacture of crushed aggregates. The Contractor, at his option, may use stone and

boulders larger than four hundred and fifty (450) millimeters

in

greatest dimension.

When the percent fracture and other requirements cannot be obtained by using the

natural material, portions of the material may be rejected to the extent necessary to

produce aggregates conforming to the requirements of the specifications.

Failure to include an aggregate scalping and rejection requirement in the

specifications for any type of aggregate shall not relieve the Contractor of the

responsibility for scalping and rejection of portions of the materials

if

such become

necessary to produce aggregates conforming to the requirements of the specifications.

When scalping over a screen of specified size is required

in

the special

specifications, the scalping screen shall be of such size and capacity that enough of the

fine material will be removed to produce aggregates conforming to the requirements

of

the specifications.

Rejected materials may be used

in

other portions of the work and locations when it

conforms to the specified requirements for said other portions and locations.


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Table of ontents

Surplus screenings accumulated during crushing and screening

of

specified

aggregates shall be kept separate from materials rejected during scalping operations.

Washing of coarse and fine aggregates shall be performed as specified in the

special specifications or as may be necessary to produce aggregates free from clay,

loam, alkali , vegetable and other deleterious material.

Washing and reclaiming

of

rejected material and subsequent addition to any finished

aggregate shall not be allowed unless authorized

in

writing by the Engineer.

When producing screened gravel or sand materials, the Contractor shall remove all

oversize material by screening at the source. Operations at the source shall be such

that the grading of aggregates in each hauling unit is reasonably uniform within

tolerances that are specified for individual materials. The Contractor shall use the most

suitable materials available at the source. He shall move his loading equipment as

many times as may be necessary to fulfill these requirements.

3.01.3.3 Rejected Aggregates All rejected materials unsatisfactory for use

in

other portions

of

the work and locations, shall

e

disposed

of

as specified

in

Paragraph

3.01.3.1 , Preparation of Site in these General Specifications.

3.01.3.4 Surplus

Screenings

Surplus screenings accumulated during the

production

of

the specified aggregates at material sources established by the

Contractor shall remain the property of the Contractor.

Surplus screenings accumulated during the production

of

the specified aggregates

at materials sources shown on the plans or described in the special specifications and

furnished by the Ministry shall be stockpiled at the source and become the property

of

the Ministry.

The stockpile area shall be prepared and constructed as specified

in

Subsection

3.01.5, Stockpiling Aggregates

in

these General Specifications. All costs incurred

in

producing, hauling and stockpiling the surplus screenings shall be incidental to the

production

of

the specified aggregates and shall be included by the Contractor

in

the

contract unit prices for said aggregates.

3.01.3.5 Site Cleanup Upon completion of the Contractor's operations at any

source, the quarry or pit shall be cleared of rubbish, equipment, temporary structures

and other items brought to the site by the Contractor. The site shall be left

in

a neat

and presentable condition. When the special specifications require that aggregate

sources e reclaimed

in

accordance with an approved reclamation plan, the Contractor

shall comply with such approved reclamation plan.

3.01.4

QUALITY

ASSURANCE PROCEDURES

3.01.4.1 Methods and Procedures All aggregate testing shall be performed in

accordance with methods and procedures described in the specifications and Materials

Manual publications issued by the Ministry of Communications, Materials and Research

Department.


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Table of ontents

3.01.4.2 Preliminary

Testing

The Contractor shall submit to the Engineer all

results

of

testing as may be necessary to confirm that the source

of

materials ,

equipment and production methods to be employed by the Contractor will produce

aggregates conforming to the requirements of the specifications. No installation of

equipment or production shall start at any materials source until the Engineer has

approved the source, and the dimensions

of

the area to be excavated. The equipment

and methods proposed by the Contractor shall also be approved by the Engineer.

The approval

of

the Engineer shall not be construed as final acceptance

of

the

aggregate to be produced.

Representative samples of materials may be obtained by the Contractor and , when

requested, duplicate samples shall be furnished to the Engineer for testing and future

reference.

Testing may be accomplished

in

the Contractor's laboratory or a commercial

laboratory. The testing shall be the responsibility

of

the Contractor and performed at

his expense.

3.01.4.3 Production Testing The Contractor shall arrange all testing necessary

to control specified aggregate fracture , gradation and quality during production as

specified

in

Paragraphs 3.02.5.1, 3.03.5.1 and 3.04.8 all entitled Contractor Quality

Control Procedures in these General Specifications. The results of such testing shall

be promptly delivered to the Engineer. Such test results are intended to be used to

guide the Contractor operations and shall not be used to infer that the aggregates being

produced are acceptable and

in

conformance to the specifications.

3.01.4.4 Acceptance Testing The Engineer shall sample or supervise the

sampling testing and evaluation of aggregates furnished to the work as specified in

Subsections 3.02.6, 3.03.6 and 3.04.9 all entitled Quality Assurance Procedures

in

these General Specifications.

3.01.5 STOCKPILING

AGGREGATES

3.01.5.1 Sites. The site for constructing stockpiles shall be approved by the

Engineer and located in a manner that the stockpiled materials will not e contaminated

with other aggregates or altered by dust, dune sand or other natural or processed

material. Stockpiling

on

private property shall be permitted with the written consent

of

the owner or lessee. The Engineer shall be afforded access to the stockpiled materials

at all times.

3.01.5.2

Preparation of Stockpile

Site. Before placing aggregates on the

stockpile site, the site shall be cleared

of

vegetation, rocks and debris and the ground

leveled to a smooth, firm uniform surface.

3.01.5.3 Construction of Stockpiles The stockpiles shall be constructed

on

the

prepared site, shall be neat and regular

in

shape and not more than eight (8) meters

in

height.


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Table of ontents

Stockpiles

n

excess of two hundred 200) cubic meters shall be built up n layers not

more than one and one-half 1.5) meters

n

depth using methods and equipment

approved by the Engineer. Pushing aggregate into a stockpile using dozers will not be

permitted. Each layer shall be completed over the entire area of the pile before

depositing aggregate n the succeeding layer. Any method of placing aggregate n a

stockpile which,

n

the opinion

of

the Engineer, results

n

segregation, breaks, degrades

or otherwise damages the aggregate will not be permitted.

Stockpiles

of

different kinds or sizes

of

aggregate shall be separated by space or

suitable walls or partitions to prevent mixing. Aggregate shall not be stockpiled where

vehicles will run over or through the piles and cause foreign material to become mixed

with the stockpiled aggregate.

3.01.5.4 Removing Aggregate From Stockpiles Aggregate shall be removed

from the stockpiles using equipment and methods approved by the Engineer and n a

manner that precludes segregation

of

particle sizes or adulteration with underlying or

adjacent soil or foreign material.

When removing aggregate from stockpiles, the removal equipment shall be operated

n such a manner as to face-load from the floor to the top of the stockpile to obtain

maximum uniformity of aggregate.

The Contractor shall remove only such aggregate quantities as are necessary to

complete work under the contract.

3.01.5.5

Site Cleanup

If a surplus remains

n

the stockpile , the Contractor shall

leave said surplus

n

neat, regular shaped piles, free

of

foreign matter and equipment.

3.01.6 METHOD OF MEASUREMENT. No measurement will be made for any work

or

aggregate produced under this section.

3.01.7 PAYMENT. Full compensation for performing all

of

the work specified

n

this

section shall be considered as subsidiary to other items

of

work appearing

n

the Bill

of

Quantities unless otherwise provided for

n

the Special Specifications and listed

n

the

Bill of Quantities.


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oe

General Specifications November

1998

able of Contents

SECTION 3.02 -

AGGREGATE

SUBBASES

3.02.1 DESCRIPTION. This work shall consist of furnishing, spreading and

compacting aggregate subbases to the lines and elevations shown on the plans as

specified in these General Specifications and the Special Specifications.

Aggregate subbases will be designated as Aggregate Subbase Course

or

Aggregate

Subbase Course, Grading

_

The grading s)

of

aggregate subbase to be furnished

shall be according to the item s) shown

in

the Plans or Special Specifications and listed

in

the Bill

of

Quantities. If the grading

of

aggregate subbase is not specified, aggregate

subbase course shall be furnished meeting one

of

the gradations listed

in

Table 3.02-1

as designated by the Engineer. The designation of the appropriate Grading shall be

such that the maximum size of aggregate will not exceed two thirds 2/3) of the

thickness of the subbase course layer to be constructed.

ITEMS IN BILL OF QUANTITIES:

Aggregate Subbase Course

Aggregate Subbase Course,

rad ing_

3.02.2 MATERIALS. Aggregate used for aggregate subbase shall be free from

vegetation matter and other deleterious substances and, when compacted under

watering and rolling, form a firm, stable subbase. Coarse aggregate shall be crushed

stone, crushed slag,

or

crushed gravel. Fine aggregate, material passing the 4.75 mm

No. 14) sieve, shall consist of natural

or

crushed sand and fine material particles.

The Contractor shall furnish , produce, stockpile, blend and mix all necessary

materials using such equipment and procedures as will produce specified aggregate

subbase. Aggregate shall conform to one of the following grading and quality

requirements on the road bed after all blending and mixing and spreading and before

compacting:

TABLE 3.02-1

AGGREGATE SUBBASES GRADATION REQUIREMENTS - MTDTM 204

Sieve Sizes Grading I Grading II

62.5 mm

2

inch) 100

50 mm 2

in

ch) 90-100 100

37.5 mm 1 inch)

-

90-100

25 mm 1 inch)

-

55-85

19 mm 3/4 inch)

-

50-80

9.5 mm inch)

-

40-70

4.75 mm

No.4)

35-70 30-60

2.54 mm No.1 0)

-

20-50

0.425 mm No. 40)

-

10-30

0.075 mm No. 200) 0-15 0-15


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Table of ontents

QUALITY

REQUIREMENTS

Sand Equivalent (MRDTM 313) 25 Min.

Plasticity Index (MRDTM 208) 6 Max.

Abrasion Loss (MRDTM

309) 50 Max.

California Bearing Ratio (CBR) 50 Min.

(MRDTM 213)

Aggregate for Grading

III

aggregate subbase shall conform to the requirements

specified

in

the Special Specifications.

3.02.3 PROPORTIONING AGGREGATE

SUBBASE

MIXTURES.

3.02.3.1 Job Mix Design Proposal. A proposed Job Mix Formula (JMF) shall be

formulated by the Contractor and submitted to the Engineer for approval. The JMF

shall be prepared by the Contractor in precise compliance with procedures and

requirements set forth

in

the Materials and Research Department Manual of Materials

and Tests and all current letters issued by the Ministry

of

Communications.

The Contractor shall select his sources of aggregate and , after sufficient quantities

have been stockpiled or are available for use obtain representative samples of the

materials and test to determine if they conform to the requirements of these

specifications. At least thirty (30) days before producing aggregate subbase mixtures,

the Contractor shall submit

in

writing to the Engineer detailed information for each mix

which he proposes to furnish. The information shall include, but not be limited to the

following:

1 The source and gradation of the aggregate for each mix to be furnished. If the

aggregate (coarse, fine, supplemental fine)

is

separated into two (2) or more sizes , the

information provided shall consist of gradations for all individual sizes, the proportions

of each individual size to be used, and the mathematically combined gradation for each

mix to be furnished. Such combined gradation shall meet the applicable grading

requirements shown

in

Subsection 3.03.2, Materials

in

these General Specifications

and show the percentage passing each

of

the specified sieve sizes.

2 Pertinent test data and a written certification that the aggregates to be furnished

conform to all quality requirements shown

in


in

these


3

The type

of

plant to be used for mixing each mix to be furnished.

4. The beginning date for producing aggregate subbase mixtures.


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The Engineer shall be provided access to the materials sampling and testing

operations at all times. The combined aggregate, including mineral additives, shall

conform to the approved JMF grading within the following tolerances:

9.75 mm (3/8 ) and larger sieves,

4.75 mm

No.4)

sieve,

2.36 mm

No.8)

sieve,

0.300 mm (No. 50) sieve,

0.075 mm (No. 200) sieve ,

percentage points

10 percentage points

9 percentage points

8 percentage points

8 percentage points

At the same time the above information is provided, the Contractor shall supply to

the Engineer fifty (50) kilogram samples of each individual aggregate size, when used,

ten (10) kilogram samples

of

mineral filler and chemical admixture, all representing the

materials which the Contractor proposes to furnish.

3.02.3.2

Acceptance

of

Job

Mix Formula. The Engineer shall review the JMF to

determine that it contains all required information. If it does not contain all required

information, it shall be returned within seven (7) days to the Contractor for further action

and resubmission by the Contractor.

If the proposed JMF contains all required information but fails to meet all the

requirements specified, it shall not be accepted by the Engineer and will be returned to

the Contractor within fourteen (14) days. The Contractor shall prepare and submit to

the Engineer a new JMF conforming to the requirements specified and propose a new

date for beginning production.

When the Engineer is satisfied that the JMF proposed by the Contractor conforms

to all the requirements of the specifications, he shall order the Contractor to construct

a minimum two hundred (200) meter long field control strip. The Engineer shall

evaluate the control strip as to its constructability and compactability and conformance

to the laboratory tested JMF. Split samples of the aggregate subbase mix for and

components raw material along with the field laboratory test results are to be sent to the

Materials and Research Departments Central Laboratory for a one (1) point check and

documentation. If the Engineer is not satisfied with the results of the control strip, he

shall state his objections

in

writing and request a revised JMF and a new control strip.

When the Engineer is satisfied that the JMF proposed by the Contractor conforms

to all requirements

of

the specifications and the control strip results are acceptable, he

will issue written acceptance to the Contractor to begin producing the mixes proposed.

Production

of

aggregate subbase mixes shall not begin until the Engineer has given

written acceptance of the Job Mix Formula.

Acceptance of the JMF by the Engineer does not relieve the Contractor of his

obligation to produce aggregate subbase mixes conforming to all specified

requirements.


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Table of ontents

3.02.3.3 Job Mix

Formula

Revisions The Contractor shall not alter his methods

of

crushing, screening, blending , or stockpiling from that used to produce materials for

the approved JMF. Changes to the JMF will not be permitted without retesting and

resubmission of a proposed (revised) JMF in accordance with all the steps in Paragraph

3.02.3.1, Job Mix Design Proposal in these General Specifications. Significant

changes may include, but not be limited to, changes

in

the amount or type

of

materials

rejected or wasted, changes

in

the amount

of

materials crushed, reductions

in

the

amount

of

crushed fines, changes

in

the amount and type

of

mineral filler.

Should the Contractor change his source

of

aggregate, he shall furnish a new job

mix design proposal and samples

of

materials, as described

in

Paragraph 3.02.3.1 , Job

Mix Design Proposal in these General Specifications, as determined by the Engineer

to be necessary, at least twenty-one (21) days before their intended use.

At any time after the JMF is approved the Contractor may submit a new JMF for

approval by the Engineer. If the revised JMF is approved it shall become the approved

JMF.

3.02.4 EQUIPMENT. The Contractor shall furnish all necessary equipment for

production, stockpiling and hauling aggregate, preparing the subgrade and placing,

compacting, finishing and maintaining the aggregate subbase according to the minimum

type and number outlined in the contractor's detailed Program

of

Work as approved by

the Engineer.

Blending and mixing aggregates and adjusting the moisture content as required for

compaction shall be performed

in

a central mixing plant or on the grade by means that

insure uniformity.

The blended and mixed aggregates shall be placed and spread to the width and

thickness specified.

3.02.5 CONSTRUCTION.

3.02.5.1

Contractor

Quality

Control Procedures

Testing to control the quality

of aggregate furnished for subbase shall be the responsibility of the Contractor. Copies

of all test results shall be forwarded to the Engineer at the end of each working day.

The Engineer shall have access to the Contractor's testing laboratory at all times and

reserves the right to obtain samples

of

the materials at any point during construction.

When requested by the Engineer, the Contractor shall obtain aggregate subbase

materials and prepare duplicate samples by quartering . One (1) sample shall be

delivered to the Engineer and the duplicate sample shall be tested by the Contractor.

The Contractor shall perform the following minimum types and number

of

tests:

1

Gradation, sand equivalent and plasticity index - One (1) test each per two

thousand (2000) cubic meters of aggregates produced but no less than one (1) test per

production day.


14/48


Table of ontents

2

Abrasion Loss - One (1) test for the first, second and third five hundred (500)

cubic meters

of

aggregate produced and one (1) test for each twenty-five hundred

(2500) cubic meters thereafter.

3 CBR Value - One (1) test for each five thousand (5,000) cubic meters placed.

When test data indicate that the aggregate subbase does not conform to specified

requirements, the Contractor shall take effective action to correct his production

methods to assure that subbase aggregate will conform to all specified requirements.

Such action shall include halting production, changing the source

of

aggregate supply,

altering amount

of

aggregated scalped and rejected , increasing degree

of

crushing, and

revising blending and handling methods. Such material if already placed, shall be

removed and modified or replaced to produce material conforming to the specified

requirements.

3.02.5.2

Surface Preparation

The surface to receive aggregate subbase,

immediately prior to spreading aggregate subbase, shall conform to specified

compaction and elevation tolerances and shall be free

of

loose or extraneous material.

The Contractor shall correct, at his own expense, any deviation from specified

elevation and compaction in the surface to receive aggregate subbase.

When surfaces to receive aggregate subbase are lower than specified , the low areas

may be filled with aggregate subbase. The volume

of

aggregate subbase so placed

shall not be measured for payment under any item listed

in

the Bill

of

Quantities.

3.02.5.3

Placing

and

Spreading

Aggregate for subbase, immediately prior to

spreading, shall be uniform mixtures free from pockets and streaks of coarse or fine

material and shall be deposited on the subgrade in uniform layers or windrows using

approved equipment.

The layers or windrows

of

aggregate subbase shall be shaped to such thickness

that, after watering and compacting, the completed subbase layer shall conform to the

required width, grade and thickness within the tolerances specified

in

Paragraph

3.02.4.5, Finishing in these General Specifications.

The material shall be handled so as to avoid segregation . Segregated materials

shall be remixed until uniform. The water can either be added

in

the borrow pit or on

a mixing platform or

on

the grade.

Where the subbase thickness is twenty (20) centimeters or less, the aggregate

subbase may be spread and compacted

in

one (1) layer. Where the required thickness

is more than twenty (20) cm, the aggregate subbase shall be spread

in

two (2) or more

layers of approximately equal thickness.

3.02.5.4 Compacting Each layer of subbase material, after being shaped to the

required lines and cross section, shall be compacted to a uniform density with no

individual test being less than ninety-five percent (95%)

of

the maximum dry unit weight

determined from MRDTM 212. Each

of

lot

of

subbase material as described

in

1


15/48


Table of ontents

Subsection 3.02.6 Quality Assurance Procedures

n

these General Specifications shall

have a percent relative compaction

o

no less than ninety-nine percent (99%)

o

the

maximum dry unit weight determined from MRDTM 212. The subbase shall be watered

or

dried as may be necessary to obtain a moisture content suitable for compaction.

Material which has dried prior to final compaction or which has dried and decompacted

subsequent to final compaction shall be watered and recompacted using equipment

and procedures approved by the Engineer. Should the Contractor be unable to return

the material to its original or specified condition with respect to compaction, thickness,

and surface tolerances , the Contractor shall remove the material and reconstruct the

course on a reapproved subgrade.

When there are delays n constructing the remaining pavement structure over a

granular course, the compaction

o

the granular course shall be reverified and deficient

areas corrected or replaced to the satisfaction

o

the Engineer. Such corrections or

replacement shall be at the Contractor's expense.

The Contractor shall plan the work and handle the various operations so that the

least amount

o

water will be lost by evaporation from uncompleted surfaces. If the

Contractor delays placing

or

succeeding layers o material to the extent that additional

water must be applied to prevent raveling or excessive drying , the application

o

such

water shall be at the Contractor's expense and will not be considered as the basis for

a claim for additional compensation.

The material shall be compacted by means

o

approved compaction equipment,

progressing gradually from the outside towards the center, with each succeeding pass

uniformly overlapping the previous pass. Rolling shall continue until the entire thickness

o

each layer is thoroughly and uniformly compacted to the specified density. The final

rolling o the completed course shall be done with a self-propelled roller as approved

by the Engineer. Rolling shall be accompanied by sufficient blading, n a manner

approved by the Engineer, to insure a smooth surface, free from ruts

or

ridges and

having the proper section and crown. When additional water is required, it shall be

added

n

the amount and manner approved by the Engineer. Initial layers

o

material

must be constructed to a uniform grade and cross section and compacted by the

Contractor and approved by the Engineer prior to the delivery

o

materials for a

succeeding layer.

Prior to placing a succeeding layer

o

granular material, the surface

o

the

underlayer shall be made sufficiently moist , to insure bond between the layers. The

edges and edge slopes

o

the base course shall be bladed or otherwise dressed to

conform to the lines and dimensions shown on the plans, and present straight, neat and

workmanlike lines and slopes as free

o

loose material as practicable.

Any areas inaccessible to normal compaction equipment shall be compacted by

means of portable mechanical tampers until satisfactory compaction s obtained. When

the final layer is to be trimmed to final grade by an automatic grading machine , this

layer shall be constructed approximately one (1) to three (3) centimeters above grade ,

so that the grading machine cuts continually. After the final pass

o

the grading

machine , the subbase shall be wetted and rolled.


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Table of ontents

3.02.5.5 Finishing All subbase material shall be placed, trimmed and finished

n

a neat and workmanlike manner

n

compliance with the lines, grades and typical cross

sections shown

on

the plans

or

staked by the Engineer within the tolerances listed n

Paragraph 3.02.6.5, Surface Tolerances n these General Specifications.

3.02.5.6

Maintenance

and

Protection

Following construction

of

the subbase

course, the compacted course shall be maintained by the Contractor at his expense.

The Contractor shall blade, broom, and otherwise maintain the course, keeping it free

from raveling and other defects that result

n

lost density until such time as the next

element

of

the pavement structure

s

placed. Water shall be applied at such times and

n

such quantities as directed by the Engineer, and the Engineer shall have full authority

to require the suspension of all other work on the project to insure the proper

maintenance of previously compacted material.

The Engineer shall determine when the surface

of

the subbase is

n

the proper

condition to permit the placement of aggregate subbase course or the bituminous prime

and/or surfacing to be applied. The Contractor must continue to maintain the surface

of

the base course, including the application

of

necessary water, at his expense until

such time as the bituminous prime or the subsequent layer is applied. Any additional

expense incurred by the Contractor because of delay n placing subsequent layers or

applying the bituminous prime when so permitted by the Engineer will not be considered

as the basis for a claim for additional compensation.

3.02.5.7

Compaction

Test Trials If directed by the Engineer, or requested by the

Contractor, prior to the commencement

of

his subbase compaction operations, the

Contractor shall construct compaction trial lengths, not to exceed one (1) kilometer.

The materials used

n

the trials shall be that approved for use as aggregate subbase

and the equipment used shall be that according to the Contractor's approved detailed

Program of Work.

The object

of

these trials is to determine the adequacy

of

the Contractor's

equipment, the loose depth measurements necessary to result

n

the specified

compacted layer depths, the field moisture content, and the relationship between the

number

of

compaction passes and the resulting density

of

the material.

The Contractor may proceed with aggregate subbase work only after the methods

and procedures established n the compaction trial has been approved by the Engineer.

3.02.6 QUALITY ASSURANCE PROCEDURES. Aggregate subbase shall be

accepted by lot. Unless otherwise stated

n

the Special Specifications, the lot size shall

be ten thousand (10,000) square meters for each layer constructed. The aggregate

subbase shall be sampled, tested and evaluated

n

accordance with Section 1.08

Acceptance

of

Work

n

these General Specifications. The Engineer may, during the

beginning of placement of subbase, at times when test results indicate erratic

characteristics and at any other time, reduce the lot size to sections of subbase with

similar quality characteristics. This should facilitate the isolation and modification or

replacement of low-quality materials with materials of acceptable quality to maintain the

overall strength

of

the pavement structure.

2


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Table of ontents

The Engineer shall perform or supervise the performance

of

all quality assurance

sampling and testing. The location

of

all samples and tests shall be recorded by

roadway, lane and centerline station (kilometer). Quality assurance sampling and

testing for each lot shall include:

1

Compaction

2

Thickness

3

Aggregate Gradation, Sand Equivalent and Plastic Limit

4 California Beating Ratio and Abrasion

5 Surface Tolerances

3.02.6.1

Compaction

The compacted density for each layer

of

aggregate subbase

shall be determined by the sand cone method, MRDTM 215, or by nuclear method,

MRDTM 218 using full depth penetration, at the option

of

the Engineer.

When the sand cone method is used, unless otherwise stated in the Special

Specifications , the tests shall be made at a minimum of five (5) randomly selected

locations

in

each lot.

When the nuclear method is used, unless otherwise stated

in

the Special

Specifications , the tests shall be made at a minimum

of

eight (8) randomly selected

locations

in

each lot. Three nuclear gauge readings shall

be

made at each test location

within a radius

of

two (2) meters. The three (3) readings shall be averaged and the

average considered to be the density for that test location.

Percent relative compaction shall be computed by comparing the average actual in-

place compacted density from the nuclear gauge or sand cone test results with the

maximum density determined by MRDTM 212. MRDTM 212 maximum density shall be

determined from samples

of

aggregate subbase obtained from the roadbed at a

sampling frequency

of

one (1) test per three (3) lots. The maximum density used for

determining percent relative compaction shall be the running average for three (3)

consecutive tests.

Any lot

of

aggregate subbase that has a percent relative compaction below the

minimum percent compaction specified in Paragraph 3.02.5.4, Compacting, in these

General Specifications resulting

in

a reduced pay factor

of

0.75 or higher determined

in

accordance with Subsection 1.08.5, Statistical Evaluation

of

Work for Acceptance

and Determination

of

Pay Factor (Value

of

Work)

in

these General Specifications may

be accepted on the basis

of

a reduced payment

if

requested

in

writing by the

Contractor. Otherwise the lot shall be removed and replaced by the Contractor at his

expense. Lots that have percent relative compaction resulting in a reduced pay factor

less than 0.75 shall be removed and replaced by the contractor at his expense.

3


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Table of ontents

3.02.6.2

Thickness

The thickness

of

each course

of

aggregate subbase complete

as placed and compacted, shall be measured from test holes obtained at a minimum

of five (5) random locations within the lot. The thickness of each hole shall be

determined after determination that the compacted density is acceptable. The average

of the test hole thicknesses shall be reported as the thickness of the lot.

A lot shall be accepted when the average total thickness is not less than the planned

thickness.

Any lot

of

aggregate subbase course with an average thickness less than shown

in

the plans but resulting

in

a reduced pay factor

of

0.75 or higher determined

in

accordance with Subsection 1.08.5, Statistical Evaluation of Work for Acceptance and

Determination of Pay Factor (Value of Work), in these General Specifications may be

accepted

on

the basis of reduced payment if requested in writing by the Contractor,

otherwise additional material shall be provided as specified

in

the preceding paragraph.

When the average thickness

of

a lot

of

aggregate subbase course is less than the

planned thickness by an amount resulting

in

a reduced pay factor below 0.75 the

Contractor, at his own expense, shall place and remix additional aggregate subbase

material with the original aggregate subbase material and recompact before new test

holes are dug.

3.02.6.3 Aggregate Gradation , Sand

Equivalent

and Plasticity Index.

Aggregate subbase gradation , sand equivalent and plasticity index will be sampled ,

tested and evaluated based

on

the average

of

a minimum

of

five (5) test results per lot

in

accordance with the Job Mix Formula Tolerances listed

in

Paragraph 3.02.3.1 Job

Mix Design Proposal , and Subsection 1.08.5, Statistical Evaluation

of

Work for

Acceptance and Determination of Pay Factor (Value of Work) , in these General

Specifications.

Every sample of aggregate subbase shall be taken on a random time basis from

each uncompacted lot during each one-half ( ) day

of

work, or portion thereof. The

initial sample shall be randomly selected from within one and one-half 1 ) meters

either side

of

the centerline

of

and weigh at least twenty-five (25) kilograms. The initial

sample shall be thoroughly mixed and quartered to obtain a test sample weighing at

least six (6) kilograms. The test sample shall be forwarded to the project laboratory and

the aggregate gradation, and sand equivalent and plastic light determined.

When the aggregate gradation, sand equivalent or plasticity index test results for any

lot produce a reduced pay factor of 0.75 or higher determined

in

accordance with above

referenced Subsection 1.08.5, Statistical Evaluation

of

Work for Acceptance and

Determination

of

Pay Factor (Value or Work) in these General Specifications , the lot

may be accepted on the basis

of

a reduced pay factor if requested

in

writing by the

Contractor. Otherwise said lot shall be removed and replaced by Contractor at his

expense.

When the gradation , sand equivalent or plasticity index pay factor determined

in

accordance with above referenced Subsection 1.08.5, Statistical Evaluation

of

Work

for Acceptance and Determination

of

Pay Factor (Value or Work)

in

these General

4


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Table of ontents

Specifications , for any lot whose pay factor is less than 0.75 the aggregate subbase

shall be removed and replaced by the Contractor at his expense.

3.02.6.4 California Bearing Ratio and

Abrasion

Random samples shall be taken

and tested for California Bearing Ratio and Abrasion from the first three (3) lots and

every fifth lot thereafter unless test results indicate failure to conform to the values

specified

in


in


n

such a

case, increased sampling and testing shall be performed .

3.02.6.5

Surface Tolerances

The surface layer

of

the aggregate subbase shall

be evaluated for compliance with the following surface tolerances:

The cross section of the finished subbase surface shall be checked by the

Contractor in the presence of the Engineer at maximum intervals of twenty-five (25)

meters and at intermediate points as directed by the Engineer. The deviation

of

the

elevation

of

the surface above the design elevation shall be not more than twenty (20)

millimeters. Deviations above the design elevation shall not result

in

the diminished

thickness

of

any subsequent pavement course. The deviation

of

the elevation below

the design elevation shall not be more than twenty (20) millimeters. Isolated deviations

below the design elevation shall be compensated by additional thickness of the

subsequent pavement layer. Additional cost and materials resulting from deviations

from the design elevation shall be borne by the Contractor. Contractor shall furnish all

devices necessary to check the surface, such as stringlines , straightedges, etc., and

the labor necessary to handle the task.

3.02.6.6 Acceptance. Aggregate subbase construction including Califomia Bearing

Ratio, abrasion and surface tolerances shall be accepted under Subsection 1.08.4,

Measured

or

Tested Conformance in these General Specifications.

Compaction, thickness, aggregate gradation, sand equivalent and plasticity index

will be accepted under Subsection 1.08.5, Statistical Evaluation

of

Work for

Acceptance and Determination

of

Pay Factor (Value

or

Work) in these General

Specifications

in

two (2) stages as follows: The first stage shall be the selection

of

the

lowest

of

the four

of

pay factors for the quality

of

the aggregate subbase relating to

aggregate gradation, compaction, sand equivalent and plasticity index. The second

stage involves the selection and application of a quantity pay factor based on the

thickness of the aggregate subbase. The reduced thickness pay factor for the lower

course lots

of

multiple layer courses will be applied provisionally based on the results

of the depths of the holes dug in the lower layers. Additional holes will be dug in the

total depth

of

all aggregate subbase layers within the lot represented by lower layer

reduced thickness pay factors. If the total thickness depths show that the increased

upper level layer thickness has resulted

in

total thickness acceptability, the lower level

layer reduced thickness pay factor will be adjusted accordingly. The second stage

thickness quantity pay factor will be applied to all the individual course lots in addition

to the first stage lowest quality pay factor as determined in accordance with Subsection

1.08.5, Statistical Evaluation of Work for Acceptance and Determination of Pay Factor

(Value or Work)

in


5


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able of Contents

3.02.7 METHOD OF MEASUREMENT. Aggregate subbase shall be measured by the

cubic meter after placement and compaction to the required density, using horizontal

dimensions shown on the plans or as directed by the Engineer and thickness

measurements determined as specified in this specification. No allowance for

overdepth shall be permitted except as approved in writing by the Engineer prior to

spreading the aggregate subbase.

3.02.8 PAYMENT. Aggregate subbase shall be paid for at the contract unit price or

adjusted contract unit price per cubic meter for the aggregate subbase item(s) shown

on the plans and listed

in

the Bill

of

Quantities. Such price and payment shall be full

compensation for furnishing all rnaterials, equiprnent, labor, tools and incidentals and

all other items necessary to complete the work as specified in Subsection 1.07.2,

Scope

of

Payment in these General Specifications.

When a lot

of

aggregate subbase course is accepted with a deficiency, the adjusted

contract unit price for said lot shall be the product

of

the contract unit price

of

aggregate

subbase, and the lowest quality and quantity pay factors specified

in

Subsection 3.02.6,

Quality Assurance Procedures,

in


PAYMENT WILL BE MADE UNDER ONE OR MORE OF THE FOLLOWING:

ITEM NO.

P Y

ITEM

P Y

UNIT

30201 Aggregate Subbase Cubic Meter

Course


Course, Grading I


Course, Grading


Course, Grading

6


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able of Contents

SECTION 3.03 -

GGREG TEB SES

3.03.1 DESCRIPTION. This work shall consist of furnishing, spreading and

compacting aggregate bases to the lines, elevations and thicknesses shown on the

plans and as specified

in

these General Specifications and the Special Specifications.

Aggregate bases will be designated as Aggregate Base Course

or

Aggregate Base

Course, Grading

_

The grading(s)

of

aggregate base to be furnished shall be

according to the item(s) shown

in

the Plans

or

Special Specifications and listed

in

the

Bill

of

Quantities. If the aggregate base course grading is not specified aggregate base

course shall be furnished meeting one of the gradations listed in Table 3.03-1 as

designated by the Engineer. The designation of the appropriate Grading shall be such

that the maximum size of aggregate will not exceed two thirds (2/3) of the thickness of

the aggregate base course layer to be constructed.

ITEMS

N BILL

OF QUANTITIES:

Aggregate Base Course

Aggregate Base Course, rad ing_

3.03.2 MATERIALS. Aggregates used for aggregate base shall be hard durable

particles or fragments free from vegetation matter and other deleterious substances

and, when compacted under watering and rolling, form a firm , stable base. Aggregate

shall consist of crushed stone, crushed slag, or crushed gravel.

Crushed stone aggregate shall contain not more than eight (8) percent , by weight,

flat, elongated, soft, or disintegrated pieces. Aggregate retained

on

the 2.36 mm (No.

8) sieve shall consist of stone particles of which at least ninety percent (90 ), by

weight, shall have at least two (2) mechanically fractured faces.

The specified gradation shall be obtained by crushing , screening and blending

processes, as necessary. The Contractor shall furnish, produce stockpile, blend and

mix all necessary materials using such equipment and procedures as will produce the

specified aggregate base.

If additional fine material, in excess of that already present in the base course

material, is necessary for correcting the gradation properties, for satisfactory bonding

of

the base material, or for adjusting the material characteristics

of

the fraction passing

the 0.425 mm (No. 40) sieve, it shall be uniformly blended and mixed with the crushed

aggregates. Such mixing shall take place at the crusher, at an approved stationary

proportioning and mixing plant

or on

a traveling plant. Reworking

of

the base course

material

in

place to obtain the specified requirements shall not be permitted. The

additional fine material, if any, shall be obtained from crushing stones, gravel, or slag,

and shall be of a gradation as required to accomplish the specified gradation of the final

mixture.

Aggregate shall conform to one

of

the following grading and quality requirements on

the road bed after all blending and mixing and spreading and before compacting:

7


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Table of Contents

TABLE 3.03-1

AGGREGATE

BASES

GRADING

REQUIREMENTS

MRDTM 204

PERCENTAGE

PASSING

SIEVE SIZES Grading I Grading II Grading III

50 mm (2 inch) 100

37.5

mm

1 inch) 100

25 mm

1

inch) 55-85 70-95 100

19 mm ( inch) 50-80 55-85 70-100

4.75

mm

No.4) 30-60 30-60 35-65

0.425

mm

(No.

40)

10-25 10-25 15-25

0.075 mm (No. 200) 3-10 3-10 3-10

The

fraction

passing the

No. 200

sieve shall not

exceed

the

fraction passing

the

0.425 mm (No. 40) sieve.

QUALITY REQUIREMENTS

Sodium Sulphate Soundness MRDTM

311)

, Loss 12 Max.

Abrasion Loss

MRDTM

309)

45

Max.

Sand Equivalent MRDTM 313)

45

Min.

Liquid Limit

MRDTM 209)

25 Max.

Plasticity Index MRDTM 208) 6 Max.

California Bearing Ratio MRDTM 213) Grading I 100 Min.

California Bearing Ratio

MRDTM 213)

Grading

II

80 Min.

California Bearing Ratio (CBR) MRDTM 213) Grading III

65 Min.

18


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Table of ontents

3.03.3 PROPORTIONING

AGGREGATE BASE

MIXES.

3.03.3.1 Job Mix Design Proposal. A proposed Job Mix Formula (JMF) shall be

formulated by the Contractor and submitted to the Engineer for approval. The JMF

shall be prepared by the Contractor

in

precise compliance with procedures and

requirements set forth

in

the Materials and Research Department Manual

of

Materials

and Tests and all current letters issued by the Ministry

of

Communications.

The Contractor shall select his sources

of

aggregate and, after sufficient quantities

have been stockpiled or are available for

use,

obtain representative samples

of

the

materials and test to determine if they conform to the requirements of these

specifications. At least thirty (30) days before producing aggregate base mixtures, the

Contractor shall submit in writing to the Engineer detailed information for each mix

which he proposes to furnish. The information shall include, but not be limited to the

following:

1

The source and gradation

of

the aggregate for each mix to be furnished. If the

aggregate (coarse, fine, supplemental fine) is separated into two (2) or more sizes, the

information provided shall consist of gradations for all individual sizes, the proportions

of each individual size to be used, and the mathematically combined gradation for each

mix to be furnished. Such combined gradation shall meet the applicable grading

requirements shown

in

Subsection 3.03.2 Materials

in

these General Specifications

and show the percentage passing each of the specified sieve sizes.

2

Pertinent test data and a written certification that the aggregates to be furnished

conform to all quality requirements shown

in


in

these


3

The type

of

plant to be used for mixing each mix to be furnished.

4

The beginning date for producing aggregate base mixtures.

The Engineer

shall be provided access to the materials sampling and testing

operations at all times. The combined aggregate, including mineral additives, shall

conform to the approved JMF grading within the following tolerances:

9.75 mm (3/8 ) and larger sieves,

4.75 mm No.4) sieve,

2.36 mm No.8) sieve,

0.300 mm (No. 50 sieve,

0.075 mm (No. 200) sieve ,

9 percentage points

8 percentage points

7 percentage points

6 percentage points

4 percentage points

At the same time the above information is provided, the Contractor shall supply to

the Engineer fifty (50) kilogram samples of each individual aggregate size, when used,

ten (10) kilogram samples of mineral filler and chemical admixture, all representing the

materials which the Contractor proposes to furnish.

9


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Table of ontents

3.03.3.2

Acceptance of Job

Mix Formula. The Engineer shall review the

JMF

to

determine that it contains all required information. If it does not contain all required

information, it shall be returned within seven (7) days to the Contractor for further action

and resubmission by the Contractor.

If the proposed

JMF

contains all required information but fails to meet all the

requirements specified, it shall not be accepted by the Engineer and will be returned to

the Contractor within fourteen (14) days. The Contractor shall prepare and submit to

the Engineer a new

JMF

conforming to the requirements specified and propose a new

date for beginning production.

When the Engineer is satisfied that the

JMF

proposed by the Contractor conforms

to all the requirements of the specifications, he shall order the Contractor to construct

a minimum two hundred (200) meter long field control strip. The Engineer shall

evaluate the control strip as to its constructability and compactability and conformance

to the laboratory tested JMF. Split samples of the aggregate base mix for and

components raw material along with the field laboratory test results are to be sent to

the Materials and Research Departments Central Laboratory for a one (1) point check

and documentation. If the Engineer is not satisfied with the results of the control strip,

he shall state his objections n writing and request a revised

JMF

and a new control

strip.

When the Engineer is satisfied that the

JMF

proposed by the Contractor conforms

to all requirements of the specifications and the control strip results are acceptable , he

will issue written acceptance to the Contractor to begin producing the mixes proposed.

Production

of

aggregate base mixes shall not begin until the Engineer has given

written acceptance of the Job Mix Formula.

Acceptance of the

JMF

by the Engineer does not relieve the Contractor of his

obligation to produce aggregate base mixes conforming to all specified requirements.

3.03.3.3 Job

Mix Formula

Revisions

The Contractor shall not alter his methods

of

crushing, screening, blending , or stockpiling from that used to produce materials for

the approved JMF. Changes to the

JMF

will not be permitted without retesting and

resubmission of a proposed (revised)

JMF

n accordance with all the steps n

Paragraph 3.03.3.1 , Job Mix Design Proposal

n


Significant changes may include, but not be limited to, changes

n

the amount or type

of materials rejected or wasted, changes

n

the amount of materials crushed, reductions

n

the amount of crushed fines, changes

n

the amount and type of mineral filler.

Should the Contractor change his source of aggregate, he shall furnish a new job

mix design proposal and samples

of

materials, as described n Paragraph 3.03.3.1 , Job

Mix Design Proposal n these General Specifications as determined by the Engineer

to be necessary, at least twenty-one (21) days before their intended use.

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At any time after the JMF is approved the Contractor may submit a new JMF for

approval by the Engineer. If the revised JMF is approved it shall become the approved

JMF.

3.03.4 EQUIPMENT. The Contractor shall furnish all necessary equipment for

producing, stockpiling, moisture conditioning, and hauling aggregate, preparing the

surface

on

which the aggregate base will be placed, and placing, spreading,

compacting, finishing and maintaining the aggregate base

in

accordance with the

minimum type and number outlined

in

the Contractor s Program

of

Work as approved

by the Engineer. Blending and mixing aggregates and adjusting the moisture content

as required for compaction shall be performed

in

a central mixing plant.

The blended and mixed aggregates shall be placed and spread to the width and

thickness specified using approved mechanical spreading equipment. Motor graders

shall not be used for spreading.

3.03.5 CONSTRUCTION.

3.03.5.1 Contractor Quality Control Procedures Testing to control the quality

of aggregate base furnished shall be the responsibility of the Contractor. Copies of all

test results shall be forwarded to the Engineer at the end of each working day. The

Engineer shall have access to the Contractor s testing laboratory at all times and

reserves the right to obtain samples of the materials at any point during construction.

When requested by the Engineer, the Contractor shall sample aggregate base

materials and prepare duplicate samples, by quartering. One (1) sample shall be

delivered to the Engineer and the duplicate sample shall be tested by the Contractor.

The Contractor shall perform the following minimum types and number of tests:

1

Gradation, sand equivalent and plasticity index - One (1) test each per one

thousand (1000) cubic meters

of

aggregates produced but not less than one (1) per

production day.

2

Abrasion Loss - One (1) test for first, second and third five hundred (500) cubic

meters of aggregate produced and one (1) test for each twenty-five hundred (2500)

cubic meters thereafter.

3

Percent Crushed Faces - One (1) test for each five hundred (500) meters

of

aggregate produced.

4

CBR Value - One (1) test for each five thousand (5000) cubic meters.

When test data indicate that the aggregate base does not conform to specified

requirements, the Contractor shall take effective action to correct his production

methods to assure that the materials produced will conform to all specified

requirements. Such action shall include halting production, changing the source of

aggregate supply, altering amount of aggregate scalped and rejected , increasing

degree

of

crushing, and revising blending and handling methods.

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3.03.5.2

Preparation

and

Maintenance

After the subgrade or subbase surface

has been prepared , the Contractor shall maintain it true to cross section , grade and

density. The surface of the subgrade or subbase, immediately prior to receiving the

aggregate base shall conform to the specified cross section , grade and density and

shall be free of any loose or extraneous material. All subgrade or subbase protection,

maintenance or repair work is considered subsidiary to items

in

the Bill

of

Quantities.

3.03.5.3

Mixing

The aggregate and the water shall be thoroughly mixed

in

a twin

shaft pugmill type mixer, unless another type of mixer is approved. The amount of

water added to the aggregate shall be an amount which will provide the mixture with a

satisfactory moisture content for compaction to the specified in-place density. The rate

of fiow of the water to the pugmill shall be controlled by valves or other devices which

can be easily reset when a change in the rate of fiow is desirable. The water supply

system shall be equipped with a positive cut-off control which will stop the fiow of water

simultaneously with any stoppage

in

the fiow of aggregate into the pugmill.

3.03.5.4 Transporting The plant-mixed material shall be transported

in

such

manner as to deliver the mix to the project without loss or segregation. Each truck load

shall be covered with a heavy canvas sheet to reduce the loss of moisture in transit

whenever the time between loading the work and spreading the moisture exceeds thirty

(30) minutes.

3.03.5.5 Placing and Spreading The mixture shall be placed on the existing

roadway, approved subgrade or approved subbase, as the case may be,

in

a uniform

layer or layers not exceeding fifteen (15) centimeters

in

compacted depth. Where the

required thickness is greater than fifteen (15) centimeters, the material shall be placed

in

layers

of

equal thickness. However, if heavy duty vibratory compaction equipment

approved by the Engineer is used, the maximum compacted layer thickness may be

increased to twenty (20) centimeters provided test trial compaction tests indicate

compliance with these General Specifications including the following:

1

Compaction samples are taken from the entire layer including the lower part

of

the increased thickness.

2 The coarse aggregates on the top of the Aggregate Base layers are not

damaged or crushed.

The increased thickness approval will be rescinded by the Engineer if more than

fifteen percent (15 ) of the subsequent field density tests taken

on

the thicker layer

initially fail, necessitating retesting after additional compaction.

The mixture course shall be placed on the roadbed to the required width and

uncompacted thickness as follows:

1

Through an approved self-propelled spreading machine.

2 In a sized windrow from which a paving machine or travel plant will pickup and

spread the aggregate base.


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3

To protect the underlayer and to allow proper drainage, the spreading

of

the

base course material shall begin along the centerline on stretches with a crowned

section

or

on the high side of stretches with a one-way slope.

The approved spreader shall deliver the mixture in such a condition that the material

will be ready for compaction without further shaping. Unless otherwise permitted by the

Engineer, the aggregate shall be spread not more than two thousand (.2000) square

meters ahead

of

the rollers. Any necessary sprinkling shall be kept within this limit.

The material shall be handled so as to avoid segregation. If the approved spreader

causes segregation

in

the material , or leaves ridges or other objectionable marks

on

the

surface which cannot be eliminated easily or prevented by adjustment to the spreading

operation , the use of such approved spreader shall be discontinued , and it shall be

replaced. All segregated material shall be removed and replaced with well-graded

material. No skin patching shall be permitted. Only minor surface manipulation and

watering to achieve the required surface tolerances shall be permitted during the

compaction process.

No hauling or placement of material will be permitted when, in the judgement of the

Engineer, the weather or road conditions are such that hauling operations will cause

rutting of the road surface or cause contamination of the subbase or base course

material. Before placing the mixture, the subgrade or previous layer shall be wetted to

insure bond between the layers. The mixture shall be placed and shaped by power

equipment to the lines, elevations, cross sections, depths and density specified

in

the

following subsections.

3.03.5.6 Compacting Each layer

of

aggregate base material, after being shaped

to the required lines and cross section, shall be compacted to a uniform density with no

individual test being less than ninety-five percent (95%) of the maximum dry unit weight

determined from MRDTM 212. Each lot

of

base material as described

in

Subsection

3.03.6, Quality Assurance Procedures

in

these General Specifications shall have a

percent relative compaction

of

no less than one hundred percent (100%)

of

the

maximum dry unit weight determined from MRDTM 212. The aggregate base shall be

watered or dried as may be necessary to obtain a moisture content suitable for

compaction. Material which has dried prior to final compaction or which has dried and

decompacted subsequent to final compaction shall be watered and recompacted using

equipment and procedures approved by the Engineer. Should the Contractor be

unable to return the material to its original or specified condition with respect to

compaction, thickness, and surface tolerances, the Contractor shall remove the material

and reconstruct the course

on

a reapproved subgrade.

When there are delays

in

constructing the remaining pavement structure over a

granular course, the compaction

of

the granular course shall be reverified and deficient

areas corrected

or

replaced to the satisfaction of the Engineer. Such corrections or

replacement shall be at the Contractor's expense.

The Contractor shall plan the work and handle the various operations so that the

least amount

of

water will be lost by evaporation from uncompleted surfaces. If the

Contractor delays placing or succeeding layers

of

material to the extent that additional

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water must be applied to prevent raveling or excessive drying , the application of such

water shall be at the Contractor s expense and will not be considered as the basis for

a claim for additional compensation.

The material shall be compacted by means of approved compaction equipment,

progressing gradually from the outside towards the center, with each succeeding pass

uniformly overlapping the previous pass. Rolling shall continue until the entire thickness

of each layer is thoroughly and uniformly compacted to the specified density. The base

course shall not be rolled when the underlayer is soft or yielding or when rolling causes

undulation of the base course. The final rolling of the completed course shall be done

with a self-propelled roller as approved by the Engineer. Rolling shall be accompanied

by sufficient blading , n a manner approved by the Engineer, to insure a smooth

surface, free from ruts or ridges and having the proper section and crown. When

additional water is required, it shall be added n the amount and manner approved by

the Engineer. Initial layers of material must be constructed to a uniform grade and

cross section and compacted by the Contractor and approved by the Engineer prior to

the delivery of materials for a succeeding layer.

Prior to placing a succeeding layer

of

granular material , the surface

of

the underlayer

shall be made sufficiently moist, to insure bond between the layers. The edges and

edge slopes of the base course shall be bladed or otherwise dressed to conform to the

lines and dimensions shown on the plans, and present straight, neat and workmanlike

lines and slopes as free of loose material as practicable.

Any areas inaccessible to normal compaction equipment shall be compacted by

ksa concrete earth

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