LTJ-PGAS-0000-CN-PR-004 - Construction Procedure For Road and Pavement (REV.1) PDF

Contract No. Document No.
CONSTRUCTION PROCEDURE FOR LTJ-PGAS-0000-CN-PR-004

ROAD AND PAVEMENT Revision: 1 Status: IFC
Revision Date: 15/08/2019
Doc Type: Procedure Discipline: Construction
Page 1 of 13
PEKERJAAN PEMBANGUNAN
FASILITAS LNG TERMINAL
JAWA TIMUR
This document has been generated by an Electronic Document Management System. When it its printed, it shall be considered as “For information only copy”.
The controlled copy is the screen version, and thus, it is the holder’s responsibility to make sure that he/she holds the latest valid version.
CONSTRUCTION PROCEDURE FOR ROAD AND PAVEMENT
1 15/08/2019 IFC Re-Issued for Construction FDN ANS EFC FAP
Issued Checked Approved Acknowledge

Rev Date Status Description
PGAS SOLUTION PGN LNG
This document is the property of PGN-LNG and it shall not be disclosed to third parties or reproduced without permission of the COMPANY.
Page 2 of 13
REVISION HISTORICAL SHEET
Rev. Date Page Description
1 15/08/2019 - Re-Issued For Construction
Page 3 of 13
TABLE OF CONTENT
TABLE OF CONTENT ...........................................................................................................................3

1. INTRODUCTION ............................................................................................................................4
2. DEFINITION AND ABBREVIATION ...............................................................................................4
2.1. Definition ....................................................................................................................................4
2.2. Abbreviations ..............................................................................................................................4
3. CODE AND STANDARD ................................................................................................................4
4. SUB GRADE ..................................................................................................................................5
4.1. Material.......................................................................................................................................5
4.2. Sub Grade Preparation ...............................................................................................................6
5. SUB BASE .....................................................................................................................................6
5.1. Material.......................................................................................................................................6
5.2. Sub Base Preparation .................................................................................................................7
6. BASE COURSE..............................................................................................................................7
6.1. Material.......................................................................................................................................7
6.2. Base Course Preparation: ...........................................................................................................8
7. ROAD AND PAVEMENT WORKS .................................................................................................8
7.1. Material.......................................................................................................................................8
7.2. Construction ...............................................................................................................................9
8. TEST AND INSPECTION ............................................................................................................. 11
8.1. Subgrade and Base Course ...................................................................................................... 11
8.2. Concrete ................................................................................................................................... 11
Page 4 of 13
1. INTRODUCTION
This procedure covers the minimum requirement of road and pavement for Pekerjaan
Pembangunan Fasilitas LNG Terminal Jawa Timur Project Project owned by PT PGN LNG
Indonesia.
2. DEFINITION AND ABBREVIATION

2.1. Definition
PROJECT NAME “Pekerjaan Pembangunan Fasilitas LNG Terminal Jawa Timur”
PROJECT SITE LOCATION Teluk Lamong, Surabaya, East Java, Indonesia
CLIENT/OWNER PT PGN LNG Indonesia
CONTRACTOR PT PGAS Solution
SUB-CONTRACTOR The party(ies) that carry(ies) out all or part of the design,
procurement, installation and testing of the system(s) as
specified by the CONTRACTOR
VENDOR/SUPPLIER Refers to the company selected by CONTRACTOR, which is
responsible for the purchase agreement or purchase order of
the goods/services specified in this document
2.2. Abbreviations
AASHTO American Association of State Highway and Transportation
Official
ACI American Concrete Institute
AISC American Institute of Steel construction
ASCE American Society of Civil Engineers
ASTM American Society of Testing and Material
JIS Japan Industrial Standard
SNI Standar Nasional Indonesia
3. CODE AND STANDARD

This procedure is prepared based on code and standard. Unless otherwise noted, this reference
is made based on the latest code, standard, and specification.
Codes, standards, and specifications that are listed in the basic design consist of:
AASHTO 1993 Standard Guide for Design of Road and Pavement
ASTM A615 Standard Specification for Deformed and Plain Carbon Steel
Bars for Concrete Reinforcement
Page 5 of 13
ASTM C33 Standard Specification for Concrete Aggregate

ASTM C39 Standard Test Method for Compressive Strength of Cylindrical
Concrete Specimens
ASTM C150 Standard Specification for Portland Cement
ASTM C494 Standard Specification for Chemical Admixture for Concrete
ASTM D136 Standard Test Method for Sieve Analysis of Fine and Course
Aggregate.
ASTM D553 Methods of Test for Viscosity and Total Solids Content of Rubber
Cements
ASTM D792 Standard Test Methods for Density and Specific Gravity of
Plastics by Displacement.
ASTM D698 Standard Test Methods for Laboratory Compaction
Characteristics of Soil Using Standard Effort
ASTM D1241 Standard Specification for Materials for Soil-Aggregate Sub base,
Base, and Surface Courses
ASTM D1556 Standard Test Method for Density and Unit Weight of Soil in
Place by the Sand-Cone Method
ASTM D1557 Standard Test Methods for Laboratory Compaction
Characteristics of Soil Using Modified Effort
ASTM D2628 Standard Specification for Preformed Polychloroprene
Elastomeric Joint Seals for Concrete Pavements
ASTM D4492 Test Method for CBR of Soil in Place
JIS G 3112.87 Reinforce Steel Bar
PU Bina Marga 2012 Manual Desain Perkerasan Jalan
SNI 07-2052-2002 Baja Tulangan Beton
SNI 15-2049-2004 Semen Portland
All deviations from the requirements of this specification, its attachments and the referenced
codes and standards shall be stated in the quotation. In the absence of such a statement, full
compliance shall be assumed
4. SUB GRADE
4.1. Material
a. All materials used for subgrade shall be free from organic matter, refuse rubbish, broken
pieces of concrete, and other foreign substances and shall be approved by CLIENT prior to
Page 6 of 13
use. Grubbing and stripping shall be done in 10 cm below ground surface or depend on site
condition until all foreign substance can be removed (Conform to “Construction Procedure for
Site Preparation (Earth Works)” (Doc. LTJ-PGAS-0000-CN-PR-002-A4)
b. Material for subgrade shall not include high plasticity soil, which is classified as A7-6
according to AASHTO M145 and shall not include very expansive soil which classified on
AASHTO T258.
c. SUB-CONTRACTOR shall propose quarry area with laboratory test report for
CONTRACTOR review and CLIENT approval. If SUB-CONTRACTOR changes quarry area,
new quarry laboratory test shall be submitted to CONTRACTOR review and CLIENT
approval.
d. All materials for subgrade shall comply with Construction Procedure for Site Preparation
(Earth Works) (Doc. LTJ-PGAS-0000-CN-PR-002-A4).
4.2. Sub Grade Preparation

a. Soft soil and obstacles encountered in the sub grade shall be removed and replaced with
suitable material as approved by CLIENT.
b. CBR test on finished level of sub grade shall have a minimum value of 10% CBR field test
and minimum 95% dry density by modified proctor, as per ASTM D 1557 Standard Test
Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort.
c. The elevation of top subgrade finish shall refer to engineering drawing. The tolerance of
elevation subgrade shall refer to Section 8.0 of this document.
d. If required, surface of subgrade may be marked and covered by plastic sheet or other
suitable material after final compaction to ensure there are no changes and damages.
5. SUB BASE
5.1. Material
a. The sub-base shall consist of hard durable particles gravel or crushed stone aggregates. All
sub-base material shall be free from organic matter and deleterious substances, and shall
be of such quality that it will bind readily to form a firm stable base. Material shall comply
with requirement of ASTM D1241 class B as shown in Table 1
b. Sub-base material shall be compacted to not less than 95% of maximum dry density at
optimum moisture as determined in accordance with ASTM D1557.
c. Minimum thickness of sub base course shall be 300 mm.
Page 7 of 13
5.2. Sub Base Preparation

a. Sub Base course shall be excavated or filled, as required, and then shall be graded and
compacted to provide a firm foundation of uniform density throughout.
b. CBR test on finished level of complete sub base course shall have a minimum value of 30
% CBR field test (refers to Manual Desain Perkerasan Jalan, Dirjen Bina Marga, 2012).
c. The material used for sub base course should be durable and strong and has a CBR value
of 30% and Plasticity Index (PI) 4 % (usually used crushed stone class A, B, or C, Lapen or
the stability of the aggregates with cement or asphalt).
d. Drainage culvert under the sub base course shall have been constructed before the sub
base course work is carried out.
e. The SUB-CONTRACTOR shall provide temporary drainage as required to facilitate the
work activities during wet/rainy season and keep sub base course material in dry condition.
f. If required, surface of sub base course may be marked and covered by plastic sheet or
other suitable material after final compaction to ensure there are no changes and damages.
6. BASE COURSE
6.1. Material
a. Granular of material shall be used as base course under concrete pavement. Such material
shall consist of sand, sand-gravel, crushed stone, crushed or granulated slag or
combination of this material.
b. Material for sub base shall meet the following requirements:
- Material gradation shall meet with the minimum class B ASTM D 1241 Standard
Specification for Materials for Soil-Aggregate Sub base, Base, and Surface Courses,
as shown on Table 1 and ASTM D 136 Standard Test Method for Sieve Analysis of
Fine and Course Aggregate.
- Material shall free from organic matter, refuse rubbish, broken pieces of concrete, and
other foreign substances.
Table 1 Material Gradation Class B
Sieve Size Weight Percent Passing
2-in. (50-mm) 100
1-in. (25.0-mm) 75 - 95
1-B-in. (9.5-mm) 40 - 75
No. 4 (4.75-mm) 30 - 60
No. 10 (2.00-mm) 20 - 45
No. 40 (425-µm) 15 - 30
No. 200 (75-µm) 5 - 15
Page 8 of 13
6.2. Base Course Preparation:

a. Base course shall be excavated or filled, as required, and then shall be graded and
compacted to provide a firm foundation of uniform density throughout.
b. CBR test on finished level of complete base course shall have a minimum value of 70 %
CBR field test (refers to Manual Desain Perkerasan Jalan, Dirjen Bina Marga, 2012).
c. The material used for base course should be durable and strong and has a CBR value of
70% and Plasticity Index (PI) 4 % (usually used crushed stone class A, B, or C, Lapen or
the stability of the aggregates with cement or asphalt).
d. Drainage culvert under the base course shall have been constructed before the base
course work is carried out.
e. The SUB-CONTRACTOR shall provide temporary drainage as required to facilitate the
work activities during wet/rainy season and keep base course material in dry condition.
f. If required, surface of base course may be marked and covered by plastic sheet or other
suitable material after final compaction to ensure there are no changes and damages.
7. ROAD AND PAVEMENT WORKS

7.1. Material
a. Concrete
The concrete mix proportions shall be designed to conform to the compressive strength or
flexural strength specified on the drawings, or which shall have a minimum compressive
strength, fc’ = 30 MPa at 28 days. The slump shall not exceed 75 mm for paving subject to
normal plant vehicular traffic, and 100 mm for paving subject to zero or occasional traffic.
b. Reinforcement
- The material for concrete reinforcement shall be of welded steel wire fabric conforming
to ASTM A 185, or steel reinforcing bars conforming to ASTM A 615 and SNl-07-2052-
2002 BJTD 40 or SNl-07- 2053-2002 BJTP 24.
- Construction joint bars shall use deformed bar and shall conform to ASTM A 615 grade
60, minimum yield strength is 60000 psi (420 MPa) or equal to SNl-07-2052-2002
BJTS 40.
- Expansion, isolation, and contraction joint dowel shall use plain/round bar conform and
shall conform to AASHTO M-31 or equivalent.
- All reinforcement shall be free from rust, dirt, oil, paint and other materials.
c. Expansion joint filler and sealer
Material for joint sealer shall be polyurethane sealant, non-bituminous/asphalt, and for filler
shall be flexible foam, soft board or equivalent.
Page 9 of 13
d. Polyethylene I plastic sheet or equivalent.

Polyethylene sheeting or plastic sheeting applied for covering the base shall be capable of
withstanding impact during the placing and consolidation of the concrete without tearing.
Minimum overlap for polyethylene I plastic sheet shall be 100 mm.
e. Curing material
The curing materials shall be of wet burlap, polyethylene sheeting, waterproof paper or a
liquid membrane-forming compound. Burlap containing sugar shall not be used.
7.2. Construction
a. Forms
- The granular base under form shall be compacted and graded so that form, when set,
are uniformly supported for their entire length and are at the correct elevation.
- The form shall be of wood or steel and shall be cleaned and oiled before used. Bent,
twisted or broken forms shall not be used.
- The form shall be so aligned and secure positioned when the concrete is place and
finished.
- The form shall remain in place for 10 hours if the ambient temperature after placing the
concrete is more than 10°C. When the ambient temperature is below 10°C, the forms
shall remain in position until the pavement edges have hardened sufficiently for the
forms to be removed without damage to the pavement.
b. Joints
- Expansion, isolation, construction, and contraction joints shall be provided in concrete
pavements at the locations indicated on the drawing road and pavement.
- The joint filler shall be straight and perpendicular to the pavement.
- The top of the expansion joint shall be sealed with sealing material according to the
specifications. Before the sealing material is installed the joint opening shall be
thoroughly cleaned of all foreign matter. Any excess material spilled over the concrete
surface shall be immediately removed.
c. Reinforcement
- Welded steel wire fabric or steel reinforcing bars shall be installed in the positions and
with the cover of concrete shown on the engineering drawings.
- Lap length for welded steel wire fabric or steel reinforcing bars and The locations and
details of reinforcement for joints shown on the engineering drawings.
Page 10 of 13
d. Placing of Concrete
- Prior to placing concrete, SUB-CONTRACTOR shall be notified to CONTRACTOR at
least 24 hours in advance.
- Concrete shall be mixed & transported according to “Construction Procedure for
Concrete Work” (Doc. No. LTJ-PGAS-0000-CN-PR-003).
- Before the concrete is placed, the granular base shall be moistened. Polyethylene
sheeting shall be laid over the moist granular base. Polyethylene sheeting shall be
overlapped at minimum 10 cm.
- Concrete shall be placed carefully to prevent segregation and displacement of the
reinforcement or form work. After spreading, the concrete shall be thoroughly
consolidated with vibrators or other approved means.
e. Finishing of Concrete
- The concrete shall be tamped and consolidated by mechanical or vibro machine.
- All excess water and laitance shall be removed from the surface of the concrete by
scraping. Bleeding water shall not be mixed into the concrete.
- The surface of the concrete shall be sloped, grooved and carefully finished to prevent
future pounding use suitable tools/equipment.
- Slope of road surface shall refer to engineering drawing for road and pavement section.
f. Curing
- Curing shall commence immediately after the concrete surface is finished. Concrete
surface, including the vertical sides, shall be completely covered with curing material.
- Burlap shall be kept continually moistened during the curing period. Polyethylene
sheeting or waterproof paper shall be overlapped to prevent moisture loss from
concrete. A curing compound may be applied after approval by CLIENT.
- Curing shall be continued for at least 5 days when the temperature is 21°C or higher or
for at least 7 days when the temperature is less than 21°C. If the concrete contains
high early strength Portland cement, the curing period shall be reduced to at least 3
days.
- The finished pavement shall be closed to pedestrian traffic for a minimum of 3 days
and strictly prohibited to vehicular traffic until the concrete has attained its designed
compressive strength.
Page 11 of 13
8. TEST AND INSPECTION

8.1. Subgrade and Base Course
a. Inspection
- Surface condition with visual inspection.
- Tolerance of level (common practice in inspection for surface):
Allowable deviation : + 20 mm
Frequency of inspection : every 50 m at center and both sides.
b. Testing
Test method to be applied:
- ASTM D 1556, Density of Soil in Place by Sand Cone Method.
- ASTM D 1557, Standard Test Methods for Laboratory Compaction Characteristics of
Soil Using Modified Effort
- ASTM D 1883, CBR Test
Frequency of testing
Item Frequency Test
Pavement Every 1000 m2 on Subgrade Sand Cone + CBR
Every 100 m2 on Subgrade Sand Cone + CBR
Road Every 100 m2 on Subbase Sand Cone + CBR
Every 100 m2 on Base Course Sand Cone + CBR
8.2. Concrete
a. Inspection
- Surface condition with visual inspection.
- Tolerance of inspection (common practice):
Allowable deviation of level : + 10 mm
Frequency of level inspection : every 20 m at center and both sides
Maximum allowance width for crack : + 2 mm
b. Testing
The CONTRACTOR shall employ an independent third party testing laboratory and furnish
all equipment facilities and labor required for field sampling, curing, transporting test
sampling, field and laboratory test, recording of test result and preparing necessary report.
All test report copy shall be sent to Engineer as each is completed, for review and approval.
Page 12 of 13
- Mix Proportion Test

Prior to the commencement of concrete work, SUB-CONTRACTOR shall perform mix
proportion test to determine the kinds and mix proportion of cement, coarse aggregate,
fine aggregate, water and admixtures.
Result of the mix proportion test shall be reported in the prescribed form shown in table
herewith:
- Compressive Strength Test

Compressive strengths of concrete at 28 days monitored by cylinder test, a minimum of
four concrete mix samples shall be taken from each batch of concrete. Speciments
shall be obtained in accordance with ASTM C172. The minimum compressive strength
evaluation of all compressive strength data shall be done in accordance with ACI-214.
- Slump test.
Slump test shall be made in accordance with ASTM C 143 unless otherwise specified.
Frequency of slump test shall be determined based on the weather conditions and on
the operating condition of the mixer, however, the slump tests shall be made at least
once for each set of specimen. Slump range for various types of construction shown in
table herewith (References: ACI 211.1-91 Table 9-6):
Page 13 of 13
- Air content test

Air content test shall be carried out if requested by CONTRACTOR, and in accordance
with the requirements given in ASTM C 138, ASTM C 173, or ASTM C 231.

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Contract No. Document No.

CONSTRUCTION PROCEDURE FOR LTJ-PGAS-0000-CN-PR-004

CONSTRUCTION PROCEDURE FOR ROAD AND PAVEMENT

1 15/08/2019 IFC Re-Issued for Construction FDN ANS EFC FAP

Issued Checked Approved Acknowledge

REVISION HISTORICAL SHEET

Rev. Date Page Description

1 15/08/2019 - Re-Issued For Construction

TABLE OF CONTENT ...........................................................................................................................3

2. DEFINITION AND ABBREVIATION

3. CODE AND STANDARD

ASTM C33 Standard Specification for Concrete Aggregate

4.2. Sub Grade Preparation

5.2. Sub Base Preparation

6.2. Base Course Preparation:

7. ROAD AND PAVEMENT WORKS

d. Polyethylene I plastic sheet or equivalent.

8. TEST AND INSPECTION

Pavement Every 1000 m2 on Subgrade Sand Cone + CBR

Every 100 m2 on Subgrade Sand Cone + CBR

Road Every 100 m2 on Subbase Sand Cone + CBR

Every 100 m2 on Base Course Sand Cone + CBR

- Mix Proportion Test

- Compressive Strength Test

- Air content test

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