Pavement Construction (MS-701)

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BESRAYA EASTERN EXTENSION

METHOD STATEMENT

FOR

PAVEMENT CONSTRUCTION

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LIST OF CONTENT

_______________________________________________________________________ _ LIST OF CONTENT AMENDMENT RECORDS 1.0 INTRODUCTION 2.0 SCOPE 3.0 REFERENCES 4.0 FORMS TO BE USED

5.0 MACHINERY & EQUIPMENT 6.0 MATERIAL

7.0 CONSTRUCTION PROCEDURE 8.0 SAFETY

9.0 ENVIRONMENT 10.0 ANNEXES

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AMENDMENT RECORDS

Pages Revision Details of Amendment Revision Date

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1.0 INTRODUCTION

Pavement construction involves the construction of lower sub-base, sub-base, road base, dense bituminous macadam upper road base, asphaltic concrete binder & wearing course.

2.0 SCOPE

This method statement shall apply for all pavement construction works in the Besraya Eastern Extension Project. The intention of this method statement is to give a general guideline for the pavement construction. Details of the procedures contained herein may be modified based upon actual ground condition and site requirements. The Engineer will be informed about proposed modifications to the Method Statement in writing for his approval.

3.0 REFERENCES

• JKR/SPJ/1988 Specifications Sections 4 • Addendum/Additional Specification Section 4

● M308-ITP-501 Pavement Construction ● M308-WMS-601 Roadway Excavation ● Engineer’s Drawings & Specifications

4.0 FORMS TO BE USED

● M308-OPR-FM-501A Bored Piling Record

● M308-OPR-FM-501B Soil Boring & Rock Coring Record ● M308-OPR-FM-501C Record of Bored Piles

● M308-OPR-FM-501D Bored Piles Concreting Details ● M308-OPR-FM-501E Bored Pile Concreting Graph ● M308-OPR-FM-501F Bentonite Tests Record ● M308-OPR-FM-601C Concrete Pour Record

● M308-OPR-FM-601D Concrete Pour Summary Record

5.0 MACHINERY & EQUIPMENT • Paver

• Motor Grader • Back Pusher

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• Pneumatic Tyre Roller • Power Brooms

• Air Compressor

• Pressure Distributor for Bituminous Material • Tipper Lorries

6.0 MATERIAL

• Crusher Run / Granular Material • Crushed Aggregate

• Dense Bituminous Macadam • Asphaltic Concrete ACB 25 • Asphaltic Concrete ACW 20 • Bituminous Prime Coat • Bituminous Tack Coat

7.0 CONSTRUCTION PROCEDURE 7.1 General

7.1.1 Pavement construction works shall only be allowed to commence on site upon the approval & acceptance of the sub-grade layer. 7.1.2 The Surveyor shall counter check again the alignment & all

dipping pegs and confirm with the Engineer before pavement construction commence.

7.1.3 The pavement construction are divided as follows:-i) Construction of Lower Granular Sub-base ii) Construction of Granular Sub-base Type B

iii) Construction of Crushed Aggregate Lower Road Base iv) Construction of Dense Bituminous Macadam Upper Road

Base

v) Construction of Asphaltic Concrete ACB 28 binder course vi) Construction of Asphaltic Concrete ACW 20 wearing

course

7.1.4 Section Head / Project Engineer will prepare a programme containing schedules and works sequence.

7.2 Lower Granular Sub-base

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7.2.1 The materials will be delivered to the site by tipper lorries and spread and leveled by means of a motor-grader for the full width of the pavement and shoulder. The material shall be filled & compacted to the required thickness as specified in the drawing. 7.2.2 Compaction of the lower granular sub-base layer shall be carried

out by using vibratory roller to achieve relative dry density as per Drawing Specifications.

7.2.3 Periodic testing for grading and field densities will be carried out in accordance to the Specification.

7.2.4 Alignment, level and surface regularity will be checked in accordance to Technical Specification.

7.2.5 The final surface of the lower granular sub-base layer shall be regulated and trimmed by motor grader to the required level and cross fall within the specified vertical tolerances.

7.3 Granular Sub- base Type B

7.3.1 The materials will be delivered to the site by tipper lorries and spread and leveled by means of a motor-grader for the full width of the pavement and shoulder. The material shall be filled & compacted to the required thickness as specified in the drawing. 7.3.2 Compaction of the granular sub-base layer shall be carried out by

using vibratory roller to achieve relative dry density as per Drawing Specifications.

7.3.5 The final surface of the granular sub-base layer shall be regulated and trimmed by motor grader to the required level and cross fall within the specified vertical tolerances.

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7.4.1 The materials will be delivered to the site by tipper lorries and spread and leveled by means of a motor-grader for the full width of the pavement and shoulder. The material shall be filled & compacted in two layers until to the required thickness as specified in the drawing.

7.4.2 Compaction of the crushed aggregate lower road base layer shall be carried out by using vibratory roller to achieve relative dry density as per Drawing Specifications.

7.4.5 The final surface of the granular sub-base layer shall be regulated and trimmed by motor grader to the required level and cross fall within the specified vertical tolerances.

7.5 Dense Bituminous Macadam Upper Road Base General Description

DBM consists of the following materials:

1) Road base material complying with JKR / SPJ / 1988 Section 4 and the grading shall be as follows:

B.S. Sieve Size Percentage by Weight Passing

50 mm 100 37.5 mm 95 – 100 28 mm 70 – 94 20 mm – 14 mm 56 – 76 10 mm – 6.3 mm 44 – 60 3.35 mm 32 - 46 1.18 mm -300 um 7 - 21 75 um 2 – 8

2) Bitumen - (80 - 100) Penetration Grade

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3) Filler - Portland Cement or Lime filler 4) Binder Content - 3.5 +/- 0.5%

Temperature of Materials

The aggregates shall be surface dry and shall be mixed at an appropriate temperature. The mixed material as delivered to the laying site shall be between 120 degrees Celsius to 160 degrees Celsius.

Laying Procedure

7.5.1 Work shall commence on site upon approval and acceptance of the crushed aggregate lower road base and prime coating. The prime coating shall be sprayed well in advance & leave for 24hrs for curing.

7.5.2 The dense bituminous macadam shall be plant-mixed with binder content of 3.5 +/- 0.5 %.

7.5.3 The approved dense bituminous macadam shall be delivered to site by tipper trucks. To prevent the loss of heat, the mixture shall be covered by tarpaulin.

7.5.4 The dense bituminous macadam shall be laid by a Paver in single layer and in the manner described below

7.5.5 If the laid surface is open-textured, back casting shall be carried out and the bigger sized aggregates removed before rolling.

7.5.6 At the end of the paving operation, the transverse joint shall be feathered down. Lap joint shall be provided for the next operation of paving.

7.5.7 Compaction shall be carried out using the specified / equivalent type of compactors and the rolling pattern shall be as per established during the trial lay.

7.5.8 Rolling shall always commence from the lower to the higher side of the carriageway. The minimum rolling temperature shall be 80 degrees Celsius.

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finished to the line and grade as required by the Drawings. 7.5.10 Upon completion of laying and compaction, joint survey

shall be carried out to check for compliance with the specified requirement.

7.5.11 After all the above works is completed, the supervisor is to ensure that the site is to be tidied up & all excess materials are to be discarded away from the site.

Field Control

Plant Trial Mix and Trial Lay

1) These shall be carried out to assess the suitability of the mixing, laying and compaction plant and to establish the sequence of the laying operation.

2) The approval of the dense bituminous macadam shall be based on the following criteria:

a) Application of the required rolling pattern using the specified equivalent type of compactor as established during the trial lay.

b) Joint survey to check compliance of finished surface with levels and tolerances specified.

Site Records

A senior staff and the Engineer's Representative must be present during the laying of premix. All records shall consists of:

a) Date, Time of laying

b) Source of Dense Bituminous Macadam c) Weather report

d) Temperature

e) Lists of Machineries/Manpower f) Location of work (Chainage) g) Lorry numbers

7.6 Asphaltic Concrete ACB 28 General Description

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ACB 28 consists of the following materials:

1) Binder Course material complying with JKR / SPJ / 1988 Addendum No. 1 and the grading shall be as follows:

37.5 mm 100 28.0 mm 80 – 100 20.0 mm 72 – 93 14.0 mm 58 – 82 10.0 mm 50 – 75 5.0 mm 36 – 58 3.35 mm 30 – 52 1.18 mm 18 – 38 425 um 11 - 25 150 um 5 – 14 75 um 3 – 8

2) Bitumen - (80 - 100) Penetration Grade 3) Filler - Portland Cement or Lime filler 4) Binder Content - 4.0 – 6.0 %

Laying Procedure

7.6.1 Work shall commence on site upon approval and acceptance of the dense bituminous macadam upper road base.

7.6.2 The surface to receive the asphaltic concrete binder course shall be free of all damage, loose materials and standing water by sweeping.

7.6.3 Tack coat of approved bitumen emulsion shall be applied as per Specifications on the prepared surface prior to laying of

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the asphaltic concrete binder course.

7.6.4 The asphaltic concrete binder course shall be plant-mixed with bitumen content as established in the Job Standard Mixture.

7.6.5 The approved asphaltic concrete binder course shall be delivered to site by tipper trucks. To prevent the loss of heat, the mixture shall be covered by tarpaulin.

7.6.6 The asphaltic concrete binder course shall be laid by a paver in single layer and in 2 runs.

7.6.8 At the end of the paving operation, the transverse joint shall be feathered down. Vertical joint shall be provided for the next operation of paving.

7.6.9 Compaction shall be carried out using the specified equivalent type of compactors and the rolling pattern shall be as per established during the trial lay.

7.6.11 The surface of the asphaltic concrete binder course shall be finished to the line and grade as required by the Drawings. 7.6.12 Upon completion of laying and compaction, joint survey

Field Control

1) These shall be carried out to assess the suitability of the

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mixing, laying and compaction plant and to establish the sequence of the laying operation.

2) The approval of the asphaltic concrete binder course shall be based on the following criteria:

a) Application of the required rolling pattern to achieve field density of not less than 92 % of the absolute density of the Job Standard Mixture.

Site Records

b) Source of Asphaltic Concrete ACB 28 c) Weather report

d) Temperature

7.7 Asphaltic Concrete ACW 20 General Description

ACW 20 consists of the following materials:

1) Wearing Course material complying with JKR / SPJ / 1988 Addendum No. 1 and the grading shall be as follows:

37.5 mm

-28.0 mm 100

20.0 mm 76 – 100

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10.0 mm 56 – 81 5.0 mm 46 – 71 3.35 mm 32 – 58 1.18 mm 20 – 42 425 um 12 – 28 150 um 6 – 16 75 um 4 – 8

2) Bitumen - (80 - 100) Penetration Grade 3) Filler - Portland Cement or Lime filler 4) Binder Content - 4.5 – 6.5 %

Laying Procedure

7.7.1 Work shall commence on site upon approval and acceptance of the asphaltic concrete binder course.

7.7.2 The surface to receive the asphaltic concrete wearing course shall be free of all damage, loose materials and standing water by sweeping.

7.7.3 Tack coat of approved bitumen emulsion shall be applied as per Specifications on the prepared surface prior to laying of the asphaltic concrete wearing course.

7.7.4 The asphaltic concrete wearing course shall be plant-mixed with bitumen content as established in the Job Standard Mixture.

7.7.5 The approved asphaltic concrete wearing course shall be delivered to site by tipper trucks. To prevent the loss of heat, the mixture shall be covered by tarpaulin.

7.7.6 The asphaltic concrete wearing course shall be laid by a paver in single layer and in 2 runs.

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7.7.8 At the end of the paving operation, the transverse joint shall be feathered down. Vertical joint shall be provided for the next operation of paving.

7.7.9 Compaction shall be carried out using the specified equivalent type of compactors and the rolling pattern shall be as per established during the trial lay.

7.7.11 The surface of the asphaltic concrete wearing course shall be finished to the line and grade as required by the Drawings. 7.7.12 Upon completion of laying and compaction, joint survey

Field Control

1) These shall be carried out to assess the suitability of the mixing, laying and compaction plant and to establish the sequence of the laying operation.

2) The approval of the asphaltic concrete wearing course shall be based on the following criteria:

a) Application of the required rolling pattern to achieve field density of not less than 92 % of the absolute density of the Job Standard Mixture.

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Site Records

b) Source of Asphaltic Concrete ACW 20 c) Weather report

d) Temperature

8.0 SAFETY

8.1 General Safety

The Section Head, will have overall responsibility for safety.

As the construction area will be isolated and fenced, the danger of injury to members of the general public is minimal. All site visitors within the construction area will be accompanied by a member of the Site Team. The following general safety issues will be addressed on site:

● All lifting appliances and lifting gear shall be inspected by a competent person (eg. By Main Contractor Safety Officer or suitably experienced Plant Manager) and certified as having adequate capacity for their intended purpose.

● All lifting gear should be regularly inspected for damage that may effect capacity.

● Lifting appliances shall only operate on a firm base of adequate bearing capacity.

8.2 Personnel and Safety

All new workers and staff will attend the Safety Induction Course before commencing on site work.

All personnel will wear safety helmet and safety boots. Eye protection shall be worn by all welders.

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All workers must attend the weekly toolbox meetings held on site.

Any unsafe acts or conditions to be identified and corrected promptly or referred to the respective supervisor. Any accident or incident to be reported immediately so preventative action can be taken to prevent re-occurrence.

8.3 Training

All staff members will be briefed on the importance of monitoring on site safety by the Safety Manager.

9.0 ENVIRONMENT

The Section Head will have overall responsibility for the environment.

All new workers and staff will attend the Environmental Induction Course before commencing on site.

Typical environmental management measures will be monitored in accordance with the following documents:

● The Project Environmental Plan ● The Project Management Plan 10.0 ANNEXES