tje-c-sp-002

DOCUMENT NO. TJE-C-SP-002

0 29 08 11 JK ISSUED FOR COMMENTS AF RDC

Rev. Date Prep. By.

Description Review By. Approved By.

DESIGN AND CONSTRUCTION OF PLANT ROADS

STANDARD SPECIFICATIONCIVIL ENGINEERING

This document contains information proprietary to PT. TJE. And shall not be reproduced or transferred to other documents or disclosed to others or used for any purpose other than that for which it is furnished without prior written permission of PT. TJE.

PT. TRI JAYA ENERGY Revision : 1 Date : 26/08/2011 Page : 2 of 18

TABLE OF CONTENT

1 SCOPE

2 APPLICABLE PUBLICATION

3 GENERAL REQUIREMENTS

3.1. Responsibilities 3.2. Standard Verification 3.3. Compaction Requirements 3.4. Drainage

4 DESIGN CRITERIA

5 CONSTRUCTION METHODS

5.1. Subgrade 5.2. Sub-Base Course Main 5.3. Base Course Main 5.4. Surfacing 5.5. Base Course Maintenance



1. SCOPE This standard outlines recommended construction practices for Tri Jaya Energi

Company for the subgrade, sub-base, base, and surfacing for plant roads, parking

areas and other areas that are to be surfaced. The procedures outlined should be

followed prior to the application of flexible surface courses for the above

described areas.

2. APPLICABLE STANDARDS The following standards (latest edition) shall form a part of this specification:

ASTM: ASTM D-698 Tests for Moisture Density Relations of Soils. ASTM D-1557 Tests for Moisture Density Relations of Soils (may be applied

instead of D-698 in the text).

ASTM D-2049 Relative Density of Cohensionless Soils.

AASHTO: T 99 Moisture Density Relationship T 89 Liquid Limit

T 90 Plastic Limit

T 97 Plasticity Index

T 96 L.A Abrasion Test

T 104 Soundness Level

T 88 Liquid Limit

T 193 C B R

T 27 Sieve Analysis

M 82 Cutback Bitumen

T 85 Specific Gravity of Coarse and Fine Aggregates

T 176 Sand Equivalent

Company Standards: TJE-C-SP-001 Site Preparation, Grading and Fencing for Production Facilities



3. GENERAL REQUIREMENTS 3.1. Responsibilities

It is Contractor's responsibility to the Company to ensure that whoever

performs the work follows all the provisions set out herein. In the event

that any of these provisions are impractical, it is the Contractor's

responsibility to immediately bring this to the Company's notice, in which

case, the Contractor should not proceed until written instruction are

received from the Company.

3.2. Standard Verification Meeting of all standards specified herein will be verified at the

Contractor's expense by written documentation from an independent third

party testing service selected by the Company.

3.3. Compaction Requirements Prior to the placement of surfacing material, the subgrade, sub-base and

base shall be so constructed that they will be compacted to the density

specified and will be uniform throughout the entire width. The subgrade

shall include the area for a distance of not less than 300 mm outside the

limits of the course immediately above. All construction shall conform to

the line, grade, and cross sections shown on the plan and/or as

established, based on the design criteria item 4.0 and approved by the

Company.

3.4. Drainage Drainage work related to the road construction work is included in

specification TJE-C-SP-007. Drainage system shall be fully operative

before work is begun on the construction of subgrade, subbase, or

shoulders.



4. DESIGN CRITERIA Unless otherwise specified, the following is the design criteria to be used as

basis in plant site road design.

Pavement Type for Main : Crushed rock base and sub-base with surface dressing.

Width of Paved Surface : 6.0 m main/4.0 m maintenance Pavement Type for Maintenance : Laterite (local Material) base only Pavement Slope : 2 percent Width of shoulders (each side) : 1.5 m Shoulder Slope : 4 percent Design Axle Loads (single) : 18,000 lbs. (8200 kg) Cycle Frequency : 5 per hour Service Life (base and sub-base) : 20 years



5. CONSTRUCTION METHOD 5.1. Subgrade

5.2.1. Description The subgrade shall be that part of the work that is prepared for the support of the sub-base or, if there is no sub-base, the base of the pavement structures. It shall extend to the full width of roadbed including the shoulders as shown on the drawings or as specified herein. Subgrade is considered in the following situations that are the subjects or separate headings in Construction hereinafter:

5.2.2. Templates and Straightedges The contractor shall provide and use straightedges to check

the accuracy of the work. Prior Works

No work shall be started on the preparation of the subgrade before the Company has approved the prior works herein described.

Degree of Compaction All materials down to a depth of 300 millimeters below the subgrade level shall be compacted to at least 95 percent of the maximum dry density as determined according to AASHTO T 99.

5.2.3. Subgrade in Earth Cut When the subgrade is in earth cut, it shall be

formed to the correct design transverse and longitudinal profiles, but at a grade level higher than the final grade in order to allow for the effect of compaction. The soil shall be compacted with approved rollers and prior to compaction; the moisture content shall be adjusted by watering with approved sprinkler trucks, or by drying out as may be required, in order that the degree of compaction specified may be attained. If the nature of the soil is such as to make it impossible to obtain the minimum CBR required by the project when compacted as specified then the unsuitable material shall be removed. At the subgrade level, the Contractor shall fill the holes caused by the removal of the roots, as consequence of the execution of



Clearing and Grubbing, with suitable material approved by the Company.

5.2.4. Subgrade on Embankment When the sub grade is to be formed on an embankment. The material to be placed in the upper part of the embankment down to a depth of 300 millimeters below the grade level shall meet the compaction requirements of 95 percent of maximum dry density as determined according to AASHTO T 99 at optimum moisture content. Roller of approved size and type, accepted by the Company, shall be used for compaction, and the moisture content shall be properly adjusted in order to obtain the dry density specified. Care shall be taken to use suitable material approved by the Company for the sub grade. If non-suitable material is placed, it shall be removed and replaced with suitable material by the Contractor without additional payment. The Contractor shall be directed by the Company in all the phases of the sub grade preparation and shall repeat any part of the work if necessary to attain the specified degree of compaction.

5.2.5. Sand Fill Material Sand fill material shall be used as directed by the Company to backfill any undercut areas of existing sub grade material. The sand material shall be a well graded fine-to-course sand, and shall conform within the grading quality requirements and shall be compacted to 95 percent of maximum dry density as determined by AASHTO T 99 at optimum moisture content. The sand shall be clean and free from any vegetable matter, lumps or excessive amounts of soil or earth, and any other objectionable or foreign substances.

5.2.6. Protection of Completion Work Any part of the sub grade that has been completed shall be protected against drying out and cracking. Any damage resulting from default of the Contractor shall be repaired as directed by the Company without additional payment.

5.2. Sub-Base Course Main 5.2.1. Description

This work shall consist of furnishing and placing on one or more course of aggregate on a prepared sub grade in accordance with this specification and to surface tolerance of plus 0, minus 20 mm compared with the lines and grades called for on the drawings.



5.2.2. Materials The sub-base course material shall consist of a mixture of crushed rock fragments of uniform specific gravity together with fine material confirming with the following requirements:

Wet Sieve Analysis Percent Passing By Weight 50.0 mm 37.5 mm 25.0 mm 19.0 mm 9.5 mm No. 4 No. 10 No. 40 No.200 - Liquid Limit - Plastic Index - Soundness Loss Magnesium

Sulfate - Abrasion Loss of Particles

Retained on Sieve No. 12 ASTM

- 10% Fine crushing resistance test

100 70 100 55 85 50 80 40 70 30 60 20 50 10 30 0 12 30 Max 10 Max 30% Max 40% Max 10 Ton

The gradations in the table above represent the limits that shall determine suitability of aggregate for use from the source of supply. The final gradations decided on within the limits designated in the table shall be well graded from coarse to fine and shall not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice versa. The amount of the fraction of material passing the No. 200 mesh sieve shall not exceed one half the fractions passing the No. 40 mesh sieve. The final aggregate material shall be free from any vegetable matter, lumps or excessive amounts of soil or earth, and any other objectionable or foreign substances.



5.2.3. Construction The materials for the sub-base course shall be blended at the crusher lant or be imported pre-blended and shall be placed in a homogeneous mix of all particle sizes. The sub-base course shall be constructed in layers. Any layer shall not be less than 75 mm or no more than 150 mm of compacted thickness. The material, as spread, shall be of uniform gradation with no pockets of fine or coarse materials. The sub-base shall not be spread more than 1500 square meters in advance of the rolling. No sub-base material shall be placed on a soft or muddy underlying course. Where more than one layer is required, the construction procedure described herein shall apply similarly to each layer. During the placing and spreading, sufficient caution shall be exercised to prevent the incorporation of sub grade or other foreign material in the sub-base mixture. After spreading, the sub-base material shall be thoroughly compacted by rolling. Sufficient rollers shall be furnished to adequately handle the rate placing and spreading of the sub-base course. Rolling shall progress gradually from the sides to the center of the lane under construction, or from one side toward previously placed material, by lapping uniformly each preceding track by at least 300 mm. The rolling shall continue until the sub-base material is thoroughly set and stable, and the sub-base material has been compacted to not less than 98 percent of maximum dry density at optimum moisture as determined by modified AASHTO compaction tests. Blading and rolling shall be done alternately, as required or directed, to obtain a smooth, uniformly compacted sub base. When rolling develops irregularities that exceed 10 mm when tested with a 3 meter straight edge, the irregular surface shall be loosened and then refilled with sub-base material and again rolled as required above. When required, the Contractor shall add water in a uniform spray during sub base coursing operations in order to provide close to optimum moisture content. Great care must be taken to ensure excess water is not applied. Any areas having excess moisture shall be suitably dried out before further rolling operations. When complete, the sub-base course shall have a minimum in-situ CBR value, when measured at the surface, of not less than as specified on the drawings. The finished surface shall be of a dense uniform mosaic appearance without any areas of loose stones.



There shall be no deviations of more than 10 mm when measured with a 3 meter long straight edge between points of change of grade.

5.3. Base Course 5.3.1. Description

This work shall consist of furnishing and placing one or more courses of aggregate on a prepared sub-base in accordance with this specification and to a surface tolerance of plus 0, minus 20 mm compared with the lines and grades called for on the Drawings.

5.3.2. Materials The base course material shall consist of a mixture of crushed rock fragments of uniform specific gravity together with sand and fine materials conforming to the following requirements. Wet Sieve Analysis Percent Passing By Weight

Wet Sieve Analysis Percent Passing By Weight 50.0 mm 37.5 mm 25.0 mm 19.0 mm 9.5 mm No. 4 No. 10 No. 40 No.200 - Liquid Limit - Plastic Index - Soundness Loss Magnesium

Sulfate - Abrasion Loss of Particles

Retained on Sieve No. 12 ASTM

- 10% Fine crushing resistance test

100 70 100 55 85 50 80 40 70 30 60 20 50 10 30 0 12 30 Max 10 Max 30% Max 40% Max 10 Ton

The gradations in the table represent the limits that shall determine suitability of aggregate for use from the sources of supply. The final gradations decided on within the limits designated in the table shall be well graded from coarse to fine and not vary from the low limit on one sieve to the high limit on the adjacent sieves or vice versa.



The amount of the fraction of material passing the No. 200 mesh sieve shall not exceed one-half the fraction passing the No. 40 mesh sieve. The base course material shall be free from vegetation, lumps or excessive amounts of soil or earth, and any other objectionable or foreign substances.

5.3.3. Construction Construction of base course layers shall not be carried out during wet or rainy weather. Any deterioration of the sub-base layer shall be made good to restore the layers being constructed over. Placing and spreading of base course material shall commence where designated by Company and shall progress without breaks. The material shall be deposited and spread in lanes in a uniform layer and without segregation of size, to such loose depth that when the layer compacted will have a minimum thickness of 70 mm and maximum thickness of 100 mm. Unless otherwise permitted by the Company, the aggregate shall not be spread more than 1500 square meters in advance of the rolling. Spreader boxes or other approved devices shall spread the aggregate or methods that will spread the aggregate in the required amount to avoid or minimize the need for re-handling the material and to prevent rutting of the underlying coarse. Dumping from vehicles in piles on the underlying coarse shall not be permitted. Hauling over the uncompacted base course shall not be permitted. No material shall be placed on a soft or muddy underlying coarse. Where more than one layer is required, the construction procedure described herein shall apply similarly to each layer. During the placing and spreading, sufficient caution shall be exercised to prevent the incorporation of sub grade, sub-base, or other material in the base coarse mixture. After spreading, the crushed aggregate shall be thoroughly compacted by rolling. The rolling shall progress gradually from the sides to the center of the lane under construction, or from one side towards previously placed material by lapping uniformly each preceding rear-wheel track by one-half the width of such track. Sheep foot toilers shall not be used. The rolling shall continue until the stone is thoroughly set, and creeping of the stone ahead of the roller is no longer visible. Any areas of badly segregated materials shall be removed and replaced with materials of specified grading and re-compacted to specified standards.



Any surface areas of slightly irregular aggregate may be made good by hand spreading and rolling in a well-graded inch down granular filler. When required, the Contractor shall add water in a uniform spray during base coursing operations in order to provide close to optimum moisture content. Great care must be taken to ensure excess water is not applied. Any areas having excess moisture shall be suitably dried out before further rolling operations. The base course shall be constructed to not less than 100 percent of maximum dry density at optimum moisture content by modified AASHTO-99. The finished surface shall be of a dense uniform mosaic appearance without any areas of loose stones and shall be to a tolerance of plus 0, minus 20 mm compared with the lines and levels given on the Drawings. When complete, the base course layer shall have an in-situ CBR value, when measured at the surface, of not less than specified on the drawings. Furthermore, the surface shall be to such regularity that there will be no deviation of more than 10 mm when measured with a three (3) meter long straight edge in between points of change of grade.

5.4. Surfacing 5.4.1. Bituminous Prime Coat

a. Description This work shall consist of furnishing and applying bituminous material to a previously prepared base course surface in accordance with these specifications and to the width shown on the typical cross sections on the drawings.

b. Materials 1. Blotter Materials

Blotter material shall be clean sand or aggregate passing a 4.75 mm sieve, free from any cohesive material, and it shall be approved by the Company. Spread rate shall be approximately 6 kg/m.

2. Bituminous Material Bituminous material shall be cut back bitumen conforming to AASHTO Specification M 82. The grade of the cut back bitumen shall be Medium-Curing-MC70, with spraying temperature range between 40oC up to 80oC and maximum loading temperature 90oC.

c. Construction



1. Weather Limitation Prime coat shall be applied only when the surface to be treated is dry or slightly damp and when the weather is not rainy.

2. Equipment The equipment used by the Contractor shall include a roller, a power broom and/or a power blower, a self-powered pressure bituminous material distributor, and equipment for heating bituminous material. The distribution equipment shall have pneumatic tires of such width and number that the load produced on the road surface shall not exceed 100 kg per cm of tire width. They shall be so designed, equipped, maintained, and operated that bituminous material at even heat may be applied uniformly on variable widths of surface up to 5 m. At readily determined and controlled rates of from 0.2 to 9 kg/sq. with uniform pressure, and with an allowable variation from any specified rate not to exceed 0.1 kg/sq.m. Distributor equipment shall include a tachometer, pressure gages, accurate volume measuring devices as calibrated tank, and a thermometer for measuring temperature of tank contents. Distributors shall be equipped with a separate power unit for the pump and full circulation spray bars that shall be adjustable laterally and vertically. The spray bars on the distributors shall be controlled by a bootman riding at the rear of the distributor in such a position that the operation off sprays is in his full view.

3. Cleaning Surface Immediately before applying the bituminous material, all loose dirt and other objectionable material shall be removed from the surface with a power broom and/ or blower as required. Or the surface shall be lightly bladed and rolled immediately prior to the application of bituminous material, in which case brooming or blowing will not be required. As approved by the Company, a light application of water shall be made just before the application of bituminous material.

4. Application of Bituminous Material Bituminous material shall be applied by means of a distributor at the rates approved by the Company, which will usually be from 0.4 to 1.2 kg/sq. m and at a temperature within the range called for with the particular material being



used. Any prescribed application shall be divided into two applications when necessary to prevent flowing off the surface, and additional bituminous material shall be applied where surface conditions indicate it to be necessary, if the Company so directs. To check the rate of bituminous material actually applied, sheets of building paper 50 cm, previously weighted, shall be laid on the surface to be treated, and weighed again after application of the prime coat. The difference in weight divided by the area of the sheets shall be the spraying rate actually executed. When necessary to provide access for traffic, the prime coats shall be applied in lanes of approximately one-half the width of the completed surface. Unless the extreme width of the surface makes such application impractical, in which case the prime coats shall be applied in more than two lanes as required. When applied in two or more lanes, there shall be a slight overlap of bituminous material along adjoining edges of lanes. The surface of structures and trees adjacent to the areas being treated shall be protected in such a manner as to prevent their being spattered or marred. No bituminous material shall be discharged into a borrow pit or gutter.

5. Maintenance and Opening to Traffic Traffic shall be directed through the project with warning signs and flagmen in a manner that provides maximum safety for the workmen and the least interruption of the work. Traffic shall not be permitted on the primed surface until the bituminous material has penetrated and dried and, in the opinion of the Company, will not pick up under traffic, but in no case sooner than four hours after the application of the bituminous material. Blotter material shall be applied as directed by the Company and traffic shall be permitted to use the lanes so treated. Blotter material shall be spread from trucks in such a manner that no wheel will travel in uncovered wet bituminous material. When applying blotter material to a treated lane that adjoins a lane yet to be treated. A strip at least 200 mm wide along the adjoining edge shall be left uncovered, or if covered shall be uncovered when the



second lane is being prepared for treatment, in order to permit an overlap of bituminous material as required. The Contractor shall maintain the primed surface for a minimum of five days before covering it with the surfacing or next course, unless the Company

Prior to the application of the surfacing or next course, any surface breaks shall be patched and all excessive blotter material, dirt, and other objectionable materials shall be removed by sweeping.

6. Method of Inspection The contractor, or the supplier as his agent, shall deliver to the Company or his representative for and along with each shipment of bituminous to the project. Two copies of the covering bill of lading upon which (or on a separate card attached thereto) is stamped and fully executed a Certificate of Compliance containing the following essential information: Consignee Destination Project number Date Identification (Truck No., Car No., etc) Type and Grade Specific Gravity at 15.6`C Loading Temperature Net weight Net liters

5.4.2. Bituminous Double Surface Dressing

a. Description 1. General

This work shall consist of one or more application of bituminous materials and spreading of aggregate, constructed on a previously bituminized surface in accordance with these Specifications and to the width shown on the typical cross sections on the drawings.

2. Quantities of Materials per Square Meter The approximate quantities of material per square meter shall be as follows: 1st Dressing Bituminous material 2.0 l/m Cubical Chipping Grading B 20 kg/m 2nd Dressing Bituminous material 1.2 l/m Cubical Chipping Grading E 14 kg/m



The amounts given above are approximate and the Company for each application and spreading shall set the exact amounts. The amounts of bituminous material per square meter may be varied as necessary to fit conditions, but the total amount of aggregate per square meter, after adjustment for specific gravity, shall not change.

b. Materials

1. Chipping Chipping for surface dressing shall be crushed stone, and shall meet the requirement for grading as follows:

Crushed stone shall consist of clean, tough, durable fragments, free from dirt or other objectionable matter, and shall not have a percentage of wear greater than 40 at 500 revolutions as determined by AASHTO T96. When subjected to five alternations of the sodium-sulfate soundness test as determined by AASHTO T104, it shall not have a weighted loss greater than 12 percent. Aggregate shall be free from clay balls and adherent films of clay or other matter. It shall be of such nature that after being coated thoroughly with bituminous material of the type to be used in the work, over 95 percent of the bituminous material will be retained after being subjected to a stripping test in accordance with AASHTO T182. This stripping test



requirement may be waived if the material has a record of satisfactory performance. The aggregate shall be cubical or pyramidical in shape with permissible flakiness index, maximum 35.

2. Bituminous Material Bituminous material shall be cutback bitumen MC 3000, and shall conform to the requirement of AASHTO M.82.

c. Construction 1. Weather Limitations

Surface dressing shall be applied only when the existing surface is dry or slightly damp and when the weather is not rainy.

2. Equipment The equipment used by the Contractor shall include a power broom and/or a power blower, dragging equipment, a pneumatic tired roller, aggregate spreading equipment that can be so adjusted as to spread accurately the given amounts per surface unit, a distributor, and equipment for heating bituminous material. The pressure distributor shall conform to the requirements of Item 5.4.1 (c) (2). Pneumatic-tired rollers shall have a total compacting width of not less than 1.5 m and the gross weight shall be adjustable within the range of 35-65 kg per cm of compacting width. The operating weight shall be as directed by the Company. The Contractor in addition to or in lieu of the specified equipment may use other equipment of proven performance, when approved by the Company.

3. Sequence of Operations Bituminous surface dressing shall be applied using quantities and sequence of operations as outlined in Item 5.4.2 (a) (2). The spreading of aggregate shall immediately be followed by the application of bituminous material, excepting the prime coat.

4. Cleaning Existing Surface Prior to placing the surface dressing, loose dirt and other objectionable materials shall be removed from the existing surface. If so directed by the Company, the surface shall be cleaned with a power broom or power blower.



5.5. Base Course Maintenance 5.5.1. Description

This work shall consist of furnishing and placing one or more courses of aggregate on a prepared subgrade in accordance with this specification and to a surface tolerance of plus 0, minus 20 mm compared with the lines and grades called for on the Drawings.

5.5.2. Materials The base course material shall be laterite fragments available locally. Company shall approve the source of this material. The base course material shall be free from vegetation, lumps or excessive amounts of soil or earth, and any other objectionable or foreign substances.

5.5.3. Construction Construction of base course for maintenance roads and areas shall be in accordance with construction of base course for main roads. See section 5.3.3 of this specification.

tje-c-sp-002

Documents

liquid limit t

plastic limit t

fine aggregates t

soundness level t

cutback bitumen t

abrasion test t

plasticity index t

c b r t