(JKR/SPJ/1988)

5.3

PRODUCTION OF CONCRETE

5.3.1

Concrete
Concrete shall be of the grade shown on the Drawings and shall comply with the
relevant requirements of Section 9 of this Specification.

5.3.2

Equipment
All equipment used, such as batching plant and mixers shall comply with the relevant
requirements of Section 9 of this Specification.

5.4

CONSTRUCTION

5.4.1

Preparation of Subgrade or Subbase

Prior to placing concrete pavement, the underlying subgrade or subbase shall have
been shaped and compacted in accordance with the provisions of Sub-Section 2.2.7
or 4.1.2 as appropriate and the waterproof membrane laid as required in the
Drawings. Notwithstanding any earlier approval of finished subgrade or subbase,
any damage to or deterioration of the subgrade or subbase shall be made good to the
satisfaction of the S.O. before the waterproof membrane is laid and the concrete
pavement constructed.

5.4.2

Construction by Machine
The concrete slab shall be constructed either by fixed form or by slip form paving
plant in a continuous process in either one or two layers, as approved by the S.O.
Prior to the placing of concrete, all of the required joint assemblies such as dowel
bars, tie bars etc., shall be installed in accordance with the requirements of SubSections 5.5. In one-layer construction, the slab reinforcement shall also be installed
and fixed in accordance with the relevant requirements of Section 9.
In two-layer construction, the thickness of the top layer shall be not less than 50 mm
or twice the maximum size of the coarse aggregate, whichever is the greater, and
shall be at least 15 mm thicker than the depth of the groove former, is used.
Placement of reinforcement and concreting of the top layer shall be done
immediately, and in any case not more than 30 minutes, after the completion of the
bottom layer.

5.4.2.1

Fixed Forms, Rails and Guide Wires For Machine Construction

(a)

Fixed Forms and Rails

All forms and rails shall be made of steel and be sufficiently robust and rigid to
support the weight and pressure caused by the paving equipment. Side forms for use
with wheeled paving machines shall incorporate metal rails firmly fixed at a constant
height below the top of the forms.
The forms shall be secured by using not less than three pins for each 3 m length,
having one pin fixed at each side of every joint. Forms shall be tightly joined
together by a locked joint, free from play or movement in any direction.
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(JKR/SPJ/1988)

For the measurement of the volume that has settled below the original level of
the foundation of the embankment, the measured settlement of each marker
shall be used for volume computation following the method shown on the
Drawings.

2.2.7

Subgrade
Material for the top 300 mm of subgrade shall have a minimum California
Bearing Ration (CBR) as shown on the Drawings when compacted to 95% of
the maximum dry density determined in the B.S. 1377 Compaction Test (4.5 kg
rammer method) under 4 days soaked condition.
Throughout the top 300 mm of subgrade, the material shall be compacted to not
less than 95% (for cohesive material) or 100% (for cohesionless material) of the
maximum dry density determined in the B.S 1377 Compaction Test (4.5 kg
rammer method).
In cut area, the top 300 mm of the subgrade shall be sacrified and recompacted
to 95% (for cohesive material) or 100% (for cohesionless material) of the
maximum dry density determined in the B.S. 1377 Compaction Test (4.5 kg
rammer method). If the S.O. is fully satisfied that the subgrade in its natural
state possesses a density exceeding the requirements, then the surface of the
subgrade shall be trimmed and rolled to obtain a smooth finish.
Where the material in cut area is found to be unsuitable for use in the top 300
mm of subgrade it shall be removed and replaced with suitable material which
shall be compacted as indicated above.
The subgrade shall be finished in a neat and workmanlike manner, and the
widths of embankments and cuts shall be everywhere at least those specified or
shown on the Drawings on both sides of the centreline. The top surface of the
subgrade shall have the required shape, superelevation, levels and grades and
shall be finished everywhere to within + 10 mm and minus 30 mm of the
required level.

i)

Where rock surface extends over the whole width of the formation:The rock surface shall be trimmed to a free draining profile, at or below
formation levels. No high spot shall protrude above the formation levels.
Any voids or cavities more than 0.5 metre below the formation level shall
be filled up with approved lean concrete having 7-day cube strength
greater than 7 N/sq.mm. The rock surface shall then be brought up to the
formation levels with approved crushed rock or gravel, regulated and
blinded.

ii)

Where rock outcrop occurs over part of the formation only :The rock outcrop shall be cut down to a level not less than 300 mm below
the formation level. The surface shall then be brought up to level with
suitable subgrade material.

2.2.8

Protective Vegetation For Erosion Control

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(JKR/SPJ/1988)

The lower subbase shall be finished in a neat and workmanlike manner and
shall have an average thickness over any 100 metre length not less than the
required thickness. The top surface of the lower subbase shall have the
required shape, superelevation, levels and grades, and shall be everywhere
within the tolerances specified in Sub-Section 4.4.
4.1.2

Subbase

4.1.2.1

Description
This work shall consist of furnishing, placing, compaction and shaping subbase
material on a prepared and accepted subgrade or lower subbase in accordance
with this Specification and the lines, levels, grades, dimensions and crosssections shown on the Drawings and/or as required by the S.O.

4.1.2.2

Materials
Subbase material shall be a natural or prepared aggregate comprising crushed
rock, weathered or fragmented rock, gravel or crushed gravel, sand or a
mixture of any of these materials. It shall have a small proportion of plastic or
non-plastic fines and shall be essentially free from vegetative and other organic
matter, expansive clay minerals and lumps of clay. The material shall conform
to the following physical and mechanical quality requirements :i)

the liquid limit shall be not more than 25% ;

ii)

the plasticity index shall be not more than 6 ;

iii)

the aggregate crushing value when tested in accordance with MS 30

shall be not more than 35 ;

iv)

unless otherwise specified on the Drawings or directed by the S.O. the

material shall have a CBR value of 30 or more when compacted to
95% of the maximum dry density determined in the B.S. 1377
Compaction Test (4.5 kg rammer method) and soaked for 4 days under
a surcharge of 4.5 kg ;

v)

the gradation shall conform to one of the envelopes shown in Table 4.1
with the fraction passing the B.S. 75 m sieve not greater than 2/3 of
the fraction passing the B.S. 425 m sieve.

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(JKR/SPJ/1988)

TABLE 4.1 GRADATION LIMITS FOR SUBBASE MATERIAL

B.S. Sieve
Size

50.mm
25.0 mm
9.5 mm
4.75 mm
2.00mm
425 m
75 m

4.1.2.3

% Passing By Weight
A

100
30-65
25-55
15-40
8-20
2-8

100
79-95
40-75
30-60
20-45
15-30
5-20

100
50-85
35-65
25-50
15-30
5-20

100
60-100
50-85
40-70
25-45
5-20

100
50-100
40-100
20-50
6-20

100
70-100
55-100
30-70
8-25

Construction Methods
Prior to placing any subbase material, the underlaying subgrade (particularly
the top 300 mm of the subgrade) or lower subbase shall have been shaped and
compacted in accordance with the provisions of Sub-Section 2.2.7 or SubSection 4.1.1.3 as appropriate. Notwithstanding any earlier approval of
finishes subgrade or lower subbase, any damage to or deterioration of the
subgrade or lower subbase shall be made good to the satisfaction of the S.O.
before subbase is constructed.
Subbase shall be placed with equipment approved by the S.O. over the full
width of the formation to the required thickness as shown on the Drawings or
directed by the S.O. in one layer or more, each layer not exceeding 200 mm
compacted thickness. Where two or more layers are required they shall be of
approximately equal thickness and none shall be less than 100 mm compacted
thickness.
Each layer of subbase shall be processed as necessary to bring its moisture
content to a uniform level throughout the material suitable for compaction, and
shall then be compacted using suitable compaction equipment approved by the
S.O. to not less than 95% of the maximum dry density determined in the B.S.
1377 Compaction Test (4.5 kg rammer method). Compaction shall be carried
out in a longitudinal direction along the carriageway, and shall generally begin
at the outer edge and progress uniformly towards the centre on each side except
on superelevated curves where rolling shall begin at the lower edge and
progress uniformly towards the higher edge. In all cases compaction shall be
carried out in such a manner that each section receives equal compactive effort,
all to the satisfaction of the S.O.
Throughout the placing, adjustment of moisture content and compaction of
subbase material, care shall be taken to maintain a uniform gradation of the
material and prevent its separation into coarse and fine parts, all to the
satisfaction of the S.O.

S4-3