RS: ROAD SURFACING

RS : ROAD SURFACING

1. SCOPE

This specification covers the preparation and priming of a base, a one or two coat bituminous surface
treatment a bituminous emulsion slurry and a bituminous concrete which is a continuously graded hot
mix asphalt.

2. MATERIALS

2.1 Prime

A prime shall be one or more of the following:-

a) Bitumen prime will be medium curing cutback bitermen grade MC30 conforming to the latest
CAS No. 145.
b) Tar prime will be refined tar having an equiviscous temperature of between 5 degrees C and 9
degrees C and conforming to the latest CAS No. 105

2.2 Surface treatment binder material

Bitumen used will generally be either

a) bitumen penetration grade 150/200 conforming to C.A.S. No. 144
b) cut-back bitumen grade M.C. 3000 conforming C.A.S. No. 145

2.3 Emulsion slurry binder material:

The binder shall be stable slow breaking Class 3 Bitumen Emulsion containing a minimum of 60%
bitumen and complying with the latest issue of BS434.

2.4 Bituminous Concrete Binder material:

a) The Bitumen used shall be a 80/100 penetration grade conforming to CAS 144

b) The tar used shall be a Road Tar Types with an E.V.T. value ranging from 53 degrees C to 57
degrees C and shall comply with C.A.S. 105

c) Where specified the tack coat shall consist of an approved bitumen emulsion complying with
the latest issue of BS 434.

2.5 Surface treatment Aggregate

Aggregate will be stone from approved sources complying with the latest CAS No. 232

a) for the tack coat

i) -19 mm + 13,2 mm
ii) -13,2 mm + 6,7 mm

b) for the grit seal

i) -6,7 mm + 1,18 mm
ii) coarse clean river sand approved by the Engineer may be used instead of -
6,7mm + 1,18 mm stone aggregate,

2.6 Emulsion Slurry Aggregate

2.6.1 Aggregate will be from approved sources and complying with the latest C.A.S. No. 232
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2.6.2 The aggregate shall be free of organic matter, clay or other material which will adversely affect the
slurry coat.

2.6.3 The aggregate shall be crusher dust with the following grading

BS PERCENTAGE POURING
Sieve mm
Coarse Grading Fine Grading

6,7 100 100 - -

4,75 70 100 100 100
2,36 45 90 80 100
1,18 30 70 55 95
0,60 20 50 35 70
0,30 12 30 20 50
0,15 7 20 10 30
0,075 5 15 5 15

2.6.4 Neither pit sand nor river sand shall be added to the crusher dust to improve the grading.

2.7 Emulsion Slurry Filter

The filter shall consist of 1 per cent to 2 per cent by mass of the aggregate of Portland Cement.

2.8 Bituminous Concrete Aggregates

2.8.1 The aggregates shall be free from organic or deleterious material which could prevent thorough
coating by the binder or adversely affect the strength or durability of the bituminous concrete.

2.8.2 The aggregate shall not be excessively absorbent nor include any soft weathered or decomposed
material which would be likely to breakdown under traffic.

2.8.3 The aggregates shall be stored separately by grading and source and in such a way as to remain
clean and unsegregated. No stockpile is to exceed 1,5 m in height.

2.8.5 Coarse aggregate, defined as that material retained on the 4,75 mm sieve shall consist of hard clean
durable angular crushed rock with the following properties:

a) 10 percent, Fine Aggregate Crushing Test (10% F.A.C.T.) - not less than 10 tonne
b) Flakiness Index - not more than 30 per cent
c) Polished stone value - not less than 50

2.8.6 Fine aggregate, defined as that fraction passing the 4,75 mm sieve, shall consist of approved quarry
dust

2.9 Bituminous Concrete Filler

2.9.1 Filler is defined as that portion of the total aggregate mineral matter passing the 75 m sieve, and
may include, natural dust in the aggregate, approved inert mineral dust and cement.

2.9.2 Unless otherwise directed by the Engineer 2 per cent, by mass of the total aggregate will consist of
Portland Cement and will be added to the mix separately as part of the filler.

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2.9.3 Filler shall be thoroughly dry and free from lumps.

2.9.4 At least 60 per cent of the filler shall be added separately to the bituminous concrete mix.

3.0 PLANT AND EQUIPMENT

3.1 General

All plant and equipment shall be of adequate rated capacity and in good working condition and
shall be operated by properly qualified and experienced operators. All plant and equipment that
are operated on the road during construction of the surface treatment shall be free from any binder,
fuel or oil leaks. No refuelling or servicing of any equipment shall take place while such
equipment is on the road.

3.2 Binder distributor

Each binder distributor shall be capable of maintaining a bituminous binder at any prescribed
temperature within the ranges specified, and of spraying the bituminous binder evenly over the
surface to be sprayed. It shall incorporate sufficient devices for controlling the rate of application
within the applicable tolerances. Each binder distributor shall have a valid calibration certificate,
issued by an approved authority, on which the date of expiry is stated.

Distributors must comply with the latest BS 1707 for mobile tank spraying units.

3.3 Chip Spreaders

Each chip spreader, whether self-propelled or truck-mounted shall be capable of

a) spreading the stone chips uniformly over any width in the range 1,5 m to at least 3,5 m
b) adjustment to permit variation in the rate of application
c) stopping and starting without forming a joint line, and
d) keeping pace with the binder distributor

3.4 Rollers

3.4.1 General

Sufficient rollers of each type shall be available on site to maintain the required tempo of work.

3.4.2 Pneumatic - Tyred Rollers

Each pneumatic-tyred roller shall be of the self-propelled type equipped with smooth pneumatic
tyres of uniform size and diameter. The compaction width shall be at least 1,5 m and the
minimum contact pressure 275 kN/m2.
The rollers shall be such that tyre pressures of up to 600 kPa are possible. Wheels shall be so
positioned that the tracks of the back wheels overlap the tracks of the front wheels.

3.4.3 Flat Steel - Tyred Rollers

Each flat steel-tyred roller, for use only on the first coat of a double seal surface, shall be self-
propelled, of mass between 6 c and 8 c, and equipped with suitable devices for cleaning the
wheels.

3.4.4 Vibratory Rollers

Vibratory rollers may not be used without prior approval of the Engineer. This will be dependent
upon the lift thickness and roller characteristics.
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3.5 Brooms

3.5.1 Drag Broom

Each drag broom shall be of a size, type and mass that will enable the stone chips to be distributed
evenly over the surface without dislodging stone chips from the binder.

3.5.2 Rotary Broom

Each rotary broom shall be of an approved type and shall be available on the Site at all times
during surfacing work.

3.6 Slurry Seal Mixer and Spreader

The equipment shall be an approved self propelled machine, capable of delivering the required
materials accurately in predetermined proportions, of mixing the materials thoroughly into a
slurry, and of spreading the slurry at the specified rate on the road surface in a continuous flow.

3.7 Asphalt Mixing Plant

3.7.1 The mixing plant shall be of an approved type capable of producing designed mixes at the rate
which shal be specified.

3.7.2 All weighing or other measuring devices used to proportion the various constituents of the mix
shall be checked daily by the Contractor and shall be accurate of +- 2 per cent.

3.7.3 The plant shall be capable of measuring the binder by mass for each batch, or by accurate metering
pump.

3.7.4 The plant shall have provision for adding all or part of the filler separately, and efficient means of
showing the temperature of the aggregate in the hot bins.

3.8 Spreading Machines

3.8.1 Spreading machines shall be mechanical self-powered pavers of approved type capable of
spreading the mix accurately to line, level and grade.

3.8.2 The paver shall lay the mix without segregation, dragging, burning or other surface defects.

3.9 Bitumen Heaters

3.9.1 Bitumen heaters shall be of an approved type efficiently insulated and capable of heating the
binder uniformly throughout the tank without overheating and damaging the binder.

3.9.2 The heaters shall be fitted with accurate thermometers positioned to show the maximum
temperature of the binder.

3.9.3 Sufficient binder shall be stored on site to keep the mixing plant supplied with binder at the correct
temperature and operating at full capacity for 10 hours.

3.10 Miscellaneous Equipment

Sufficient equipment for loading, handling, and hauling aggregate and binder shall be provided by
the Contractor to ensure prompt and continuous covering of bituminous material as specified. The
Contractor shall have available on the Site all the necessary ancillary equipment and hand tools,
thermometers, etc. to carry out the work efficiently.

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4. CONSTRUCTION

4.1 General Requirements for all surfacing types

4.1.1 Preparation of Base

The base shall be thoroughly swept with mechanically driven brooms until all loose soil binder
and foreign materials have been removed and the top surface of the stones exposed. Any
superficial film of soil binder that may have formed on the surface during watering and rolling
shall be removed completely.
Where the bituminous surfacing is to abut against kerbs, channels, or manhole frames, the vertical
face of each such kerb, channel, and frame shall be cleaned.

4.1.2 Demarcation of the Work Area

The Contractor shall demarcate the area to be sprayed.

4.1.3 Protection of Kerbs, Channels, etc.

Kerbs, channels, manholes, etc. shall be protected from the spray of slurry application. Any kerbs,
channels, manholes, etc. on which binder or slurry is sprayed or splashed or which are damaged
shall be thoroughly cleaned or replaced (as appropriate) by the Contractor at his own expense and
to the satisfaction of the Engineer.

4.1.4 Transverse Joints between Bituminous Binder Sprays

In order to prevent overlapping at junctions of separate bituminous binder applications, the

previous work shall be covered in an approved manner at the joint and for a distance back from the
joint sufficient to ensure that the sprayer is operating at the required rate before the untreated
surface is reached, and to prevent the application of additional binder to the previously treated
section. The same method shall be used to ensure a neat joint at the end of each run.

4.1.5 Weather Limitations

No bituminous surfacing work shall be done

a) during foggy or rainy weather;

b) when the wind is, in the opinion of the Engineer, blowing sufficiently to interfere with the
spray work;
c) when the temperature of the road surface immediately before the intended time of the
surfacing operations is below, or likely to fall below, the applicable temperatures set out in
Table 1; and
d) in the case of the application of a slurry seal, when the road surface temperature is below 5
degrees C.

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TABLE 1 - MINIMUM ROAD SURFACE TEMPERATURES

1 2

Binder Road surface temperature,

Grade degree C, minimum *

Emulsion, spray type 5

TP7 10

MC-30 10

RT 55C 20

MC-3 000 20

150-200 pen 25

* When a cold wind is blowing the minimum temperatures shall be increased by 3-6 degrees C,
as directed.

e) No Asphalt shall be applied when there is free water present on the road surface, or when the
road surface is below 10 degrees C for asphalt of 35 mm thickness or less, or below 5 degrees
C when the asphalt thickness is greater than 35 mm.

4.1.6 Heating of Bituminous Binders

Bituminous benders for mixing or spraying shall be heated to a temperature between the
appropriate limits in Table 2 below. Binders that have been heated to temperatures higher than
the applicable maximum value given below shall not be used and shall be removed from the
site.
Table 2 Allowable binder temperature ranges
Storage Tem. °C Max Max.
Binder Spraying Mixing Agg.
Type Excess of 24 Up to Temp. Temp. Temp
hours 24 hours Deg C Deg. C 0 Deg

Prime MC- 30 65 30-55

30 TP. 7 40 65 50-70

Surfacing
Treatments
150/200 115 165 150-170
Pen. 100 155 135-155
MC-3000
Emulsions Ambient 60 Ambient - 60
air temp. Air Temp.
Bituminous
Concrete
60/70 Pen. 130 130 140-165 175
80/100 Pen 130 130 135-165 170
RT55c 80 80 90 -100 100

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4.1.7 Rolling
The rollers shall be so ballasted that they bed the aggregate but do not cause excessive crushing
of the aggregate.

4.1.8 Dust Control

Deviations and construction roads shall be watered and kept damp during all surfacing, and all
dust shall be removed from the surface before any binder or surfacing is applied.

4.1.9 Opening to Traffic

The road shall not be opened to traffic until the binder has set sufficiently to retain the
aggregate, or in the case of slurry seals, until the slurry has so set that it will not be picked up
by the wheels of passing traffic.

4.2 Prime Coat

When a prime coat is required in terms of the specifications or drawings

a) the surface of the base shall be cleaned and approval shall be obtained before any
further work is done
b) a light sprinkling of water may be applied to assist penetration of the prime, but care
shall be taken to avoid saturating the base and causing free water to appear on the
surface; and
c) prime of the type and grade specified shall be sprayed by a distributer at a rate of 0,80
litres/square meter. The optimum rate of application is the maximum that the base can
completely absorb within three days.
d) If the prime has not been absorbed within seven days, the Engineer may order the
Contractor to apply sufficient sand to blot up the excess. All loose sand must be
removed before further surfacing is constructed
e) All defects in the prime or depressions must be made good by either hand spraying or
filling with an approved suitably graded and compacted bituminous concrete at the
Contractors own expense.

4.3 Two coat bituminous surface treatment

4.3.1 General

Durable surface treatment shall consist of the application of a bituminous binder coat, the
spreading of a layer of aggregate, a further application of bituminous binder, and the spreading
of a second layer of aggregate. Each coat of bituminous binder shall be sprayed at the ordered
rate of application.
Each layer of aggregate shall be spread at the ordered rate of application.

4.3.2 Cleaning of Surface

The Engineer must approve the clean surface before bituminous material is applied.

4.3.3 Application of First Coat of Binder and aggregate

Immediately after the application of bituminous material for the tack coat the aggregate for the
tack coat shall be spread, rolled and broomed. All excess tack stone shall be removed to the
satisfaction of the Engineer, leaving a single layer of stone only.

4.3.4 Rolling the Aggregate

4.3.4.1 As soon as the aggregate has been applied, rolling shall commence with a pneumatic-tyred roller
working parallel to the centre-line of the road from the shoulders towards the crown of the road
until the whole surface has been covered at least twice with the wheels of the roller.
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4.3.4.2 If so ordered by the Engineer, after the bituminous binder has set up sufficiently to prevent any
aggregate from being dislodged, the surface shall be slowly dragged with a drag broom in order to
ensure even distribution of the aggregate.

4.3.4.3 Additional material shall be added by hand to areas that are deficient in stone chips, and stone
chips shall be removed from areas having an excess of stone chips, so as to leave a carpet of one
layer of stone chips shoulder to shoulder. Every care shall be taken to avoid an over-application of
stone chips. (The importance of applying only a single layer of stone chips is stressed.)

4.3.4.4 When the spreading of the aggregate has been completed, the surface shall again be rolled with a
pneumatic-tyred roller for 2 to 4 coverages to obtain a surface that is well knit and has a uniform
appearance free of roller tyre marks. Final rolling shall then be done with a flat steel-tyred roller
until the whole surface has been covered at least once by the wheels of the roller.

4.3.5 Second Application of binder and aggregate

The second application of bituminous binder shall be sprayed preferably within 48 hours of the
application of the first coat when bitumen is used for the first coat and at least 5 days after the
application of the first coat when tar is used for the first coat. The binder spray shall be covered
immediately with the second application of aggregate, and rolled as specified in 4.3.4 except that a
flat steel-tyred roller shall not be used

4.3.6 Application Rates of Material

4.3.6.1 The application of bituminous material shall be at the rates specified by the Engineer, the
following table provides an indication of the general requirements:

Binder application rate for Agg. App. Rate

two coat surface treatment in m³/m²
(litres per square metre, hot)
Traffic vehicles per Total Rate
day per lane both layers Tack Coat Seal Coat

19 mm stone 0,013
Under 125 2,89 1,56 1,33
125-500 2,72 1,47 1,25
500- 1 000 2,45 1,32 1,13

13 mm stone
Under 125 1,95 1,05 0,90
125-500 1,66 0,89 0,77 0,009
500-1 000 13mm stone not permitted

Shoulder seal-
6.7 mm stone 0,80 Single Seal 0,80 0,007

4.3.6.2 The seal binder application rate shall normally be the difference between the total specified rate
and the actual tack coat binder rate obtained.

4.3.6.3 The given quantities are those measured at the spraying temperature specified in Table 2 of 4.1.6

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4.4 Emulsion Slurry

4.4.1 General
This shall consist of the application of one or more layers of Emulsion slurry onto a primed
surface, a tack coat or an old bituminous surface requiring a seal.

4.4.2 Preparation of surface for Slurry

The slurry seal shall be applied only after, when relevant, the prime or tack has cured, dried out,
and drained off the tips of the aggregate.
For tack, the surface shall be rolled once with a flat steel-tyred roller early in the morning on the
day of sealing to depress any loose stones that may have been displaced. The surface shall be
cleaned to remove all dust, mud, leaves etc and shall have a close knit appearance with edges
trimmed correctly to the specified width.

4.4.3 Composition of Slurry

The slurry shall consist of a mixture of aggregate complying with the requirements given in Clause
2.6, a stable-mix emulsion, a filter (2.7) and water in the proportions ordered.

4.4.4 Mixing of Slurry

4.4.4.1 The slurry shall be mixed in an approved type of mixer see 3.6. All the constituents of the slurry
shall be accurately proportioned by volume or mass.

4.4.4.2 The composition of the slurry shall be as follows:

Materials Per Cent by Mass

Aggregate 82 - 84
Cement 1 - 2
Emulsion 15 - 16

4.4.4.3 The residual bitumen content shall be between 10,5 and 11,5 per cent by mass of the dry
aggregate.

4.4.4.4 The consistency of the slurry (using the Calas Viscometer) shall be between 6 and 7. For this
approximately 160 litres of water per cubic metre of dry aggregate is required.

4.4.4.5 In the case of batch mixing, approximately 75% of the estimated quantity of water shall be placed
in the mixer followed by the batch of aggregate to which the filler has been added. When the
water has been mixed thoroughly with the aggregate and filler, further water shall be added to
achieve the desired consistency. The emulsion shall then be added and mixed until the materials
in the batch are thoroughly blended.

4.4.4.6 In the case of continuous mixing, the metering and mixing of the constituents shall be such as to
produce a thoroughly blended slurry of acceptable consistency.

4.4.4.7 The mix shall not be allowed to become dry enough to ball. A mixture in which, in the opinion of
the Engineer, the emulsion shows signs of having broken during the mixing shall not be applied to
the road but shall be disposed of as the Engineer may direct.

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4.4.5 Application of Slurry Seal

4.4.5.1 The surface shall be lightly watered immediately ahead of the first application of slurry. No free
water shall be present when slurry sealing commences.

4.4.5.2 The specified rate of application of slurry is expressed as a rate of spread of the dry aggregate.
Where the emulsion slurry is applied in two layers, the specified rate shall be the total or combined
application of the two layers.

Type of Surface Application rate in m³/m²

Prime 0,0065 to 0,0055

Existing bituminous surface 0,005 to 0,0045
-13,2mm + 6,7mm tack 0,0055 to 0,005
-19,0mm + 13,2mm tack 0,007 to 0,0065

4.4.5.3 The slurry shall be applied in one layer for 13,2 mm stone and two layers for 19,0 mm stone by
means of a spreader box or by hand spreading, as approved.
The first layer of slurry shall be so struck off that the tops of the stones in the aggregate layer are
just visible.
The second layer of slurry shall not be applied until the first layer has dried. Before the second
layer of slurry is applied the road shall, where practicable, be opened to traffic for as long as
possible and as directed.
On sections of the road where it is not practicable for the road to be opened to traffic, the surface
shall be well rolled with at least 6 passes of a pneumatic-tyred roller, and the second layer applied
after enough time has been allowed for the first layer to shrink and cure. The Engineer will decide
on the time necessary for proper curing, which shall be at least 24 hours, and not more than 72
hours. The surface shall be thoroughly cleaned of all dust, dirt and foreign materials before the
second layer of slurry is applied.

4.4.5.4 Where the slurry is spread by hand, the squeegees used for spreading shall be at least 450 mm
wide, and the spreading of each batch discharged onto the road shall be completed before the next
is discharged. Where spreading is carried out by means of a spreader box, the slurry shall be
discharged into the spreader box by means of a chute that is so directed that an even supply of
slurry is maintained against the full width of the strike-off blade of the spreader box.
The slurry seal shall be applied in widths of between 2,5 m and 3,8 m, as the Engineer may direct.
Successive strips of slurry seal shall overlap at each transverse joint by not less than 25 mm and
not more than 150 mm.
There shall be no overlapping at any longitudinal joint. Each strip of slurry seal shall be laid
accurately next to the adjacent strip and no areas shall be omitted.
Where an excess of slurry or insufficient slurry has been applied by a spreader box, hand
squeegees shall be used to adjust the quantity in areas concerned immediately after the passage of
the spreader box.

4.4.5.5 Should breaking of the emulsion, segregation of the mix, or formation of lumps during the
application of the slurry occur, the slurry operations shall be discontinued at once and any
defective material removed from the road.

4.4.5.6 The Contractor shall ensure that the road surface is finished to the specified widths and lines. All
stones dislodged in the process of the application of the slurry shall be removed on the day on
which the slurry seal is applied. All spillage of slurry and all excess slurry shall be neatly removed
from the road and disposed of.
Unless the Contractor is otherwise instructed, a moist hessian drag shall be drawn behind the
spreader box to ensure an even-textured finish.
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4.4.5.7 The work shall be so programmed that half road widths of slurry seal are applied on successive
days and that each section of full road width is completed in 2 days.

4.4.5.8 Any damage to the slurry seal caused by rain or traffic before the slurry has cured shall be rectified
by the Contractor at his own expense.

4.5 Bituminous Concrete

4.5.1 Mix Specification

4.5.1.1 General

The Contractor shall so design the asphalt using the appropriate materials specified in 2.8 and 2.9
that it complies with 4.5.1.2 and 4.5.1.3 for continuously graded mixes.

4.5.1.2 Aggregate Grading Specification

Subject to the requirements of 4.5.1.3 and unless otherwise ordered by the Engineer or specified
the grading of the components of the aggregate shall be as specified below:

Consolidated thickness (mm)

B.S. sieve
size 40 - 75 25 -50 20 - 40 10 - 20
(mm)
% Passing % Passing % Passing % Passing

26,5 . . . . . . . 100
19,0 . . . . . . . 80-100 100
13,0 . . . . . . . 70-90 80-100 100
9,5 . . . . . . . 62-82 70-95 80-100 100
4,75 . . . . . . . 48-64 54-73 60-80 83-95
2,36 . . . . . . 36-52 40-56 44-60 66-86
1,18 . . . . . . . 27-39 29-44 31-45 48-68
0,600 20-30 19-31 20-32 30-50
0,300 12-22 12-22 12-22 18-36
0,150 7-16 7-16 7-16 11-25
0,075 4-9 4-9 4-9 5-12

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4.5.1.3 Marshall Design Criteria

75
No.of compaction blows each end of
specifimen Min Max

Stability (kn) 3,0 12,0

Flow (mm) 2,0 4,0
Airvoids (%) 3,0 5,0
Stability Flow (kN/mm) 1,5 3,0
Immersion Index % (min) 75
Film thickness µm (min) 5

The binder content shall be expressed as a percentage of the total dry aggregate.

4.5.1.4 Tender Mix Design

For tender purposes the Contractor shall design the Tender mix to comply with the
specification in 4.5.1.2 and 4.5.1.3

4.5.1.5 Approval of Mix

a) The Contractor shall submit his mix design proposals to the Engineer for approval and
no asphalt shall be placed before written approval of the mix design has been obtained.
b) Notwithstanding the provisions, the responsibility for ensuring that the asphalt complies
with the specification rests with the Contractor.
c) Once the actual grading and bituminous binder content for a particular mix design have
been approved by the Engineer, that mix shall become the working mix for the Works
until such time as an amendment to the mix is ordered by the Engineer. The asphalt
placed at any stage shall, subject to the tolerances specified conform to the current
approved working mix.

4.5.2 Mixing and Transportation

4.5.2.1 Mixing

The bituminous binder shall be heated at the mixing plant to the applicable temperature given
in 4.1.6 The aggregate shall be dried and so heated that at the point of mixing the temperature
is 0 degrees to 10 degrees C lower than the temperature of the binder.
The required amounts of aggregate filler and bituminous binder after being separately measured
shall be mixed until a uniform coating of binder and a thorough distribution of aggregate
throughout the mix are obtained.
The approximate mixing times shall be between 5 and 15 seconds dry mix and between 30 and
60 seconds wet mix.

4.5.2.2 Transportation of the Mixture

The mixture shall be transported from the mixing plant to the work in trucks with metal bodies
previously cleaned of all foreign materials. The inside surface of the body of each truck may
be lightly lubricated with a release agent just before the truck is loaded. The use of excessive
amounts of release agent will not be permitted and no petroleum products shall be used as
release agents.
The temperature of the mixture on arrival at the Site shall be not less than 120 degrees C and
not more than 160 degrees C for bitumen mixtures, m and not less than 70 degrees C and not
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more than 120 degrees C for car mixtures. When so directed, the body of each truck shall be
suitably covered with canvas or other material of sufficient size to protect the mixture from the
weather.

4.5.2.3 Tack Coat

A tack coat (fog spray) may be required on the prime or existing surface immediately prior to
laying bituminous concrete.
This shall be a stable grade bitumen emulsion diluted with water and sprayed to give
approximately 0,2 litre/square metre residual bitumen, or as varied by the Engineer.

4.5.2.4 Laying of Asphalt

Delivery of the mixture to the paver shall be at a uniform rate, in an amount well within the
capacity of the paver and compaction equipment, and such that the paver is continuously on the
move. The adjustment of the screed tamping bars, feed screws, hopper feed, etc., shall be
checked frequently to ensure uniform spreading of the mix. If segregation occurs, the
spreading operations shall immediately be suspended until the cause is determined and
corrected.
No asphalt shall be added or removed behind the paver unless such addition or removal is
specifically approved.
Where practicable, paving shall commence at the bottom of grades and at the lower edges of
super-elevated curves.
To avoid unnecessary stopping of the paver the Contractor shall ensure that there is an adequate
and continuous supply of material to the paver.
On areas that are inaccessible to a paver the asphalt may be placed by hand or by other
acceptable means. Spreading in such areas shall be carried out in a manner that will avoid
segregation and allow positive control of levels.
Hand tools shall be kept clean.

4.5.2.5 Compaction

The techniques of rolling, the sequence of rollers, and the number of rollers used shall be at the
discretion of the Contractor, provided that the specified density is achieved and provided that,
should he be dissatisfied with the sequence or number of rollers used by the Contractor, the
Engineer may specify another sequence of use of rollers and he may order more rollers to be
used. During the rolling of the surfacing, the Contractor shall ensure, by keeping the rolls
sufficiently moist or by other approved means, that material is not picked up on the rolls.
The compacted asphalt shall have a density of at least 96% of the Marshall density (the
briquettes being prepared with 75 blows on each face), and shall comply with the specified
requirements for surface texture.

The following requirements shall apply to rolling and compacting generally:

a) The material shall not be excessively displaced in a longitudinal or transverse

direction especially when gears are changed or when the rollers are stopped or
scarred
b) Care shall be taken to ensure that no cracks or hair cracks are formed and that the
bond with the underlying layer is not broken
c) The density shall be uniform over the whole area of the layer.
d) Pneumatic-tyred rollers shall be operated at the most effective pressure for the
attainment of maximum density
e) In restricted areas where the specified rollers cannot be used, compaction shall be
carried out with hand-operated mechanical compaction equipment

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4.5.2.6 Joints

Where joints between adjacent sections of the work are to be made the layer against which new
material is to be placed shall be cut back and all loose and incompletely compacted material
shall be removed.
Unless otherwise required
a) a cutting wheel shall be used for cutting at longitudinal joints;
b) joints shall be made at right angles or parallel to the centre-line; and
c) joints in the final layer of the surfacing shall correspond to edges of the traffic lanes.

Joints in lower layers shall be offset at least 200 mm on either side of the edges of the traffic
lanes.
Before a new layer is placed next to an existing layer, the cut edge of the existing layer shall, if
so directed by the Engineer, be painted with a thin coat of bituminous emulsion.
Joints shall be neat and material at joints shall have the same texture and density as the
remainder of the paving.
Where paving is not bounded by kerbs or channelling, or both, the outside edge of the
completed paving shall be trimmed along the shoulder parallel to the centre-line, to give a
finished width as specified on the drawings, within the tolerances specified.
Any fresh asphalt spread accidentally on finished work at a joint shall be carefully removed by
brooming it with stiff brooms or the backs of rakes onto the uncompacted work, so as to avoid
the formation of irregularities at the joint.

5. TOLERANCES

5.1 Prime coat, Surface Treatment and Emulsion Slurry

5.1.1 Rates of Application of Binder and Aggregate

Each rate of application of binder and aggregate shall not vary by more than 5% from that
ordered by the Engineer.

5.1.2 Finished Surface

When a 3m straight edge is laid on the finished surface parallel with the centre-line of the road,
the distance between the straight edge and the surface shall be nowhere greater than 10 mm.

5.2 Bituminous Concrete

5.2.1 Working Mix

The constituents of all bituminous concrete laid shall be within the tolerances below of the
approved mix.
a) Grading

SIEVE SIZE mm PERMISSIBLE VARIATION % PASSING

26,5 - 4,75 +- 6,0

2,36 +- 4,0
0,600 + - 4,0
0,075 + - 2,0
b) Binder content +- 0,6%
c) Air voids content +- 1,0%
d) Filler content weighing +- 2,0%

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5.2.2 Dimensions, Levels, etc.

The Contractor shall carry out checks at the frequency set out below:
Measurement Area or length of road Number of measurements
to which one check is made per area or length
applied min. Tolerance
max.

Surface levels 20m 3 +- 10mm

Thickness 1000 m² 4 -0 + 5mm

Width of Section 50 m 1 - 0mm

Smoothness - Distance 40 m² 1 5mm

between a 3m straight
edge laid parallel to the
centreline and the road
surface.

6. TESTING

6.1 Initial Testing

Before starting construction the Contractor shall test all plant and materials to ensure they
comply with the necessary specifications. The Contractor shall supply the Engineer with
samples of material at least three weeks before he intends using them.

6.2 Process Control Testing Frequency

The Contractor carry out tests at least at the following frequency for the purpose of process
control, and report the results of such testing to the Engineer within 48 hours.

a) Bituminous Binders:
i) One bitumen sample from each consignment to determine penetration.
ii) One tar sample from each consignment to determine density and viscosity
iii) One bitumen emulsion sample from each consignment to determine viscosity and where,
relevant water content.

b) Aggregates:
Tests to determine grading, flakiness index and 10% fines aggregate crushing valve shall be
performed on at least 3 samples from each stockpile or every 300m3 of aggregate.

6.2 Process Control Testing Frequency Contd.

c) Crusher dust for slurry seal:

Tests to determine grading shall be performed on at least 3 samples from each stockpile or
every 200m3 of crusher dust.

d) Application rates:

Spreading and spraying rates shall be determined for each run and recorded on an approved
daily sheet which will be submitted to the Engineer at the end of each day's work. Records of
receipts of bituminous binder and aggregate shall also be submitted to the Engineer.

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e) Bituminous concrete:
i) The Contractor shall take and test sample from the mixing plant for aggregate grading
bitumen content Marshall stability, air voids and flow

ii) The Contractor shall test density every 1000m2 and texture depth every 500m2 or
atleast every days production. All holes left by the density coring machine shall be
repaired by the Contractor.

6.3 Testing by the Engineer

The Engineer will arrange for acceptance testing to be carried out at regular intervals on materials
from the stockpiles, mixer and road by an approved accredited laboratory.
Should any dispute arise because of discrepancies between results obtained by the Contractor and
the said laboratory, the Engineer will use the results of tests carried out by the laboratory of his
choice on samples of the completed layers taken from the roadway, as the basis for acceptance.
If the costs of tests, for testing by the Engineer, are not itemised in the schedule, the cost of
additional tests ordered by the Engineer and carried out by the Contractor will be dealt with as
daywork, provided that where the tests do not meet the specification the costs shall be borne by the
Contractor.

7. MEASUREMENT AND PAYMENT

7.1 Measurement

7.1.1 Variation in rates of application

The Engineer may instruct the Contractor to vary the rate of application of the binder and or the
aggregate to suit local conditions. The unit of measurement of binder variations shall be the
lighter calculated at 25 degrees C for increases or decreases in the specified percentage or rate of
application.
Compensation will be either payment to the Contractor for an increase or refund by the Contractor
for a decrease in percentage or rate of application.

7.1.2 Rates tendered to cover costs of testing

The rates of all operations set out in 7.2 shall cover the cost of sampling and testing in accordance
with the terms of
Clause 6.

7.1.3 Computation of Quantities

7.1.3.1 Prime coat, surface treatments and emulsion slurry surfacing will be measured by the actual area
covered within the specified widths and lengths.

7.1.3.2 Bituminous concrete will be measured by mass determined from weighbridge tickets. The
weighbridge shall be checked at regular intervals under the supervision of the Engineer. No
payment will be made for excess width, wastage or asphalt laid in excess of the mean rate of
application.
The mean rate of application (tons per square meter) will be calculated from the total thickness
specified or ordered plus 15% for specified thicknesses up to 50 mm and plus 10% for specified
thicknesses over 50 mm and the average Marshall density of material laid. The mean rate of
application will be calculated for each days run.

7.1.3.3 The quantity of mineral filler used will be measured by mass.

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7.2 Payment

7.2.1 Prime Coat ....................................... m2

The type and grade of prime will be stated.

The rate shall cover the cost preparing the base as specified in 4.1.1, sprinkling with water, and
supplying and spraying the prime in terms of 4.2

7.2.2 Two coat surface treatment

a) 19,0 mm tack and 10 mm seal coat (Binder type stated)..m2

b) 13,2 mm tack and 6,7 mm seal coat(Binder type stated)..m2
c) 13,2 mm tack and crusher dust seal coat (Binder type stated)..m2

The rate shall cover the cost of clearing the primed surface, protecting the kerbs, placing guide
lines, controlling dust, supplying all materials, spraying of binder, spreading of aggregate, rolling
as necessary, and all other incidentals necessary for completing the work.

7.2.3 Surface treatment with aggregate and slurry seal

(Size of aggregate stated) ........................ m²

The type and grade of binder will be stated.
The rate shall cover the cost of cleaning the primed surface, protecting the kerbs, placing guide
lines, controlling dust, supplying all materials, spraying of binder, spreading of aggregate, mixing
and spreading of the slurry seal, and rolling.

7.2.4 Tack Coat .................................. m²

The type and grade of emulsion will be stated.

The rate shall cover the cost of brooming the surface if necessary, and supplying diluting as
specified and spraying the emulsion.

7.2.5 Bituminous Concrete nominal thickness indicated ........ mm

The type of Bituminous Concrete and grade of binder will be stated.

The rate shall cover the cost of supplying, hauling, heating and mixing the various ingredients
(including mineral filler where no separate item is scheduled); hauling, placing, and compacting
the bituminous concrete; and control testing, protecting and maintaining the work as specified.

7.2.6 Variations in quantity of prime, curing and tack coats and bituminous binders ................ l
Separate items will be stated for each type of prime, emulsion in tack coat and bituminous binder
stated.
The rates shall cover the cost of additional or reduced amounts of binder, and the rates will be
added or deducted from the rates applicable to 7.2.1, 7.2.2, 7.2.3, 7.2.4 and 7.2.5 as appropriate.

7.2.7 Variations in the quantity of aggregate

(size of aggregate stated) .................... m3

The volume of aggregate will be measured in the truck.
Variation will be paid for as specified in 7.1.1.

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